TM 5-3805-255-14 Ihc Model 100C

*TM 5-3805-255-14
TECHNICAL MANUAL
OPERATOR, FIELD, AND SUSTAINMENT

MAINTENANCE MANUAL
FOR
LOADER, SCOOP TYPE, DED 4 X 4,

ARTICULATED FRAME STEER, 4.5 TO 5 CU. YD. (CCE)
(IHC MODEL H100C)
TYPE I WITH 4.5 CU. YD. BUCKET
(NSN 3805-01-052-9042) (EIC: EFR)
TYPE II WITH 5 CU. YD.
GENERAL PURPOSE BUCKET
(NSN 3805-01-052-9043) (EIC: EFS)
*SUPERSEDURE NOTICE: Supersedes TM 5-3805-255-14&P, 15 July 1980, including all changes.
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY

FEBRUARY 2009
TM 5-3805-255-14
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 - drop 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 show that particles flying
through the air will harm face.
HEAVY OBJECT - human figure stooping over heavy object shows physical injury poten-
tial from improper lifting techniques.
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TM 5-3805-255-14
HEAVY PARTS - hand with heavy object on top shows that heavy parts can crush and
harm.
HEAVY PARTS - heavy object on human figure shows that heavy parts present a danger
to life or limb.
HIGH PRESSURE FLUID - high pressure fluid spraying human hand shows that
fluid escaping under great pressure can cause injury or death.
HOT AREA - hand over object radiating heat shows that part is hot and can burn.
PINCH POINT - object crushing human figure shows that areas between vehicles or
parts present a danger to life or limb.
RADIOACTIVE - identifies a material that emits radioactive energy and can injure human
tissue or organs.
SLICK FLOOR - wavy line on floor with legs prone shows that slick floor presents a
danger from falling.
VAPOR - human figure in a cloud shows that material vapors present a danger to life or
health.
EXPLOSION - rapidly expanding symbol shows that the material may explode if
subjected to high temperatures, sources of ignition or high pressure.
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TM 5-3805-255-14
FOR INFORMATION ON FIRST AID, REFER TO FM 4-25.11.
WARNING
CARBON MONOXIDE (EXHAUST GASES) CAN KILL!

• Carbon monoxide is a colorless, odorless, deadly poison, which, when breathed, deprives the body
of oxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms
of headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain
damage or death can result from severe exposure.
• Carbon monoxide occurs in exhaust fumes of internal combustion engines. Carbon monoxide can
become dangerously concentrated under conditions of inadequate ventilation. Failure to follow this
warning may result in injury or death to personnel.
1. DO NOT operate engine in enclosed areas.
2. DO NOT idle engine without adequate ventilation.
3. BE ALERT for exhaust poisoning symptoms. They are:
• Headache
• Dizziness
• Sleepiness
• Loss of muscular control
4. 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.
5. BE AWARE. The field protective mask for Nuclear, Biological, and Chemical (NBC) protection will not protect
you from carbon monoxide poisoning.
6. CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust and some of its constituents are known to the
State of California to cause cancer, birth defects, and other reproductive harm.
The Best Defense Against Carbon Monoxide Poisoning is Good Ventilation!
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TM 5-3805-255-14
WARNING
BATTERIES
• To avoid injury, eye protection and acid-resistant gloves must be worn when working around
batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around
batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all
jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal,
a direct short will result in instant heating or electric shock, damage to equipment, and injury to
personnel.
• Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes
contact with skin, eyes, or clothing, take immediate action to sop the corrosive burning effects.
Failure to follow these procedures may result in death or 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 householdammonia.
• CALIFORNIA PROPOSITION 65 WARNING: Battery posts, terminals, and related accessories
contain lead and lead components. These chemicals are known to the State of California to cause
cancer and reproductive harm. Wash hands after handling.
WARNING
CLEANING
Improper cleaning methods and use of unauthorized cleaning liquids or solvents can injure
personnel and damage equipment. To prevent this, refer to TM 9-247, Materials Used for
Cleaning, Preserving, Abrading and Cementing Ordnance Materiel and Related Materials
Including Chemicals for further instructions.
WARNING
COMPRESSED AIR
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle
pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when
cleaning components. DO NOT direct compressed air against human skin. 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.
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TM 5-3805-255-14
WARNING
ENGINE/HYDRAULIC OIL
Contact with engine/hydraulic oil can damage skin. Wear gloves when handling engine/hydraulic
oil. If oil contacts skin, wash it off immediately. Failure to follow this warning may cause injury to
personnel.
WARNING
FUEL HANDLING
• DO NOT smoke or permit any open flame in area of H100C 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 or death to personnel or damage to equipment.
• DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire,
flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel.
• Wear fuel-resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash
exposed skin and change fuel-soaked clothing.
• ALWAYS shut down engine before refueling.
WARNING
HAZARDOUS WASTE DISPOSAL

• When servicing this equipment, performing maintenance, or disposing of materials such as engine/
hydraulic oils, coolant, and fuel, consult your unit/local hazardous waste disposal center or safety
office for local regulatory guidance.
• Engine/hydraulic oils, coolant, and fuel can be very slippery. Immediately wipe up any spills. Failure
to follow this warning may result in injury to personnel.
WARNING
HEARING PROTECTION
Hearing protection is required when standing within 50 ft (15.2 m) of H100C while it is operating.
Failure to wear hearing protection may result in hearing loss.
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TM 5-3805-255-14
WARNING
HOT COMPONENTS
Components with metal parts can cause severe burns at operating temperature. Allow
components to cool before performing maintenance on them. Wear insulated gloves, long sleeves,
and eye protection when working with heated parts.
WARNING
LIFTING/HOISTING HEAVY PARTS

• Use extreme caution when lifting heavy parts. Provide adequate support and use assistance during
procedure. Ensure that lifting equipment used is on solid footing, is in good condition, and is of suit-
able lift capacity. Keep clear of heavy parts supported only by lifting equipment. Failure to follow this
warning may result in death or injury to personnel or damage to equipment.
• Death or injury could occur if unauthorized personnel are in the hoisting area. Permit only personnel
engaged in hoisting operation to be near H100C and lifting equipment.
• Hoist H100C slowly and smoothly. Do not swing load from side to side, as this places extra strain on
lifting components. Watch boom angle and overhead clearance when hoisting. Failure to follow this
warning may result in injury or death to personnel or damage to equipment.
WARNING
ETHER
x DO NOT smoke or permit any open flame in area of H100C while you are servicing the Ether
injection system. Failure to follow this warning may result in injury or death to personnel or
damage to equipment.
x DO NOT perform Ether Injection system checks, inspections, or maintenance while smoking or
near fire, flames, or sparks. Ether may ignite, and may result in injury or death to personnel or
x DO NOT spray in direction of body. Ether may be irritating to eyes and skin. Wear gloves and
eye protection when handling ether. If exposed to ether, promptly wash exposed skin and
change ether-soaked clothing.
x If ingested, immediately seek medical attention. DO NOT induce vomiting.
x Observe the precautions printed on the ether container when using or storing ether. When
disposing of ether containers consult your unit/local hazardous waste disposal center or safety
office for local regulatory guidance.
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TM 5-3805-255-14
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 or death to personnel.
• Use a piece of cardboard, newspaper or wood to check for pressurized leaks, to prevent fluid pene-
trating the skin. Failure to follow this warning may cause injury or death to personnel.
WARNING
NBC EXPOSURE
If NBC exposure is suspected, personnel wearing protective equipment must handle all air cleaner
media. Contaminated filters must be handled using adequate precautions and must be disposed of
by trained personnel. Consult your NBC Officer or NBC NCO for appropriate handling or disposal
procedures. Failure to follow this warning 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 PROTEC-
TIVE EQUIPMENT. SEE OPERATOR/
MAINTENANCE MANUAL.
7690-01-114-3702
To order this NBC decal use:

National Stock Number (NSN) - 7690-01-114-3702
Part Number (PN) - 12296626
Commercial and Government Entity Code (CAGEC) - 19207
WARNING
PRESSURIZED COOLING SYSTEM
• DO NOT service cooling system unless engine has cooled. This is a pressurized cooling system and
escaping steam or hot coolant will cause 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 cause serious burns.
• Wear effective eye, hand, and skin protection when handling coolants. Failure to follow this warning
may cause injury to personnel.
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TM 5-3805-255-14
WARNING
SLAVE STARTING ENGINE
When slave starting engine of H100C:
• Use NATO slave cable that does NOT have loose or missing insulation.
• DO NOT proceed if suitable cable is not available.
• DO NOT use civilian-type jumper cables.
• DO NOT allow disabled H100C and booster vehicle to come in contact with each other at any time
during slave starting.
• Failure to follow these warnings may result in injury or death to personnel.
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
H100C OPERATION
Use of seat belt while operating machine is mandatory. Failure to follow this warning may result in
injury or death to personnel in the event of an accident or machine overturn.
WARNING
TIRES
• Operating machine with 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 is flat, DO NOT inflate. Notify Field Maintenance. Failure to follow this warning may cause injury
or death to personnel.
• Use a self-attaching inflation chuck and stand at a distance behind tire when inflating tire. Failure to
follow this warning may cause injury or death to personnel.
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TM 5-3805-255-14
LIST OF EFFECTIVE PAGES/WORK PACKAGES -
NOTE: Zero in the “Change No.” column indicates an original page or work package.
Date of issue for the original manual is:
Original .............. 20 February 2009
TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 26 AND TOTAL NUMBER OF WORK
PACKAGES IS 131, CONSISTING OF THE FOLLOWING:
Page/WP No. Change No. Page/WP No. Change No.
Front Cover . . . . . . . . . . . . . . . . . . . . . . 0 WP 0028 (14 pgs) . . . . . . . . . . . . . . . . . 0

a thru h. . . . . . . . . . . . . . . . . . . . . . . . . . 0 WP 0029 (8 pgs) . . . . . . . . . . . . . . . . . . 0
Chapter 1 Title Page . . . . . . . . . . . . . . . 0
WP 0030 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0001 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0031 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0002 (8 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0032 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0003 (34 pgs) . . . . . . . . . . . . . . . . . 0
WP 0033 (10 pgs) . . . . . . . . . . . . . . . . . 0
Chapter 2 title page . . . . . . . . . . . . . . . . 0
WP 0034 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0004 (12 pgs) . . . . . . . . . . . . . . . . . 0
WP 0035 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0005 (28 pgs) . . . . . . . . . . . . . . . . . 0
WP 0036 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0006 (10 pgs) . . . . . . . . . . . . . . . . . 0
WP 0037 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0007 (8 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0038 (8 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0008 (4 pgs) . . . . . . . . . . . . . . . . . . 0
Chapter 3 Title Page . . . . . . . . . . . . . . . 0 WP 0039 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0009 (2 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0040 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0010 (2 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0041 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0011 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0042 (12 pgs) . . . . . . . . . . . . . . . . . 0
WP 0012 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0044 (10 pgs) . . . . . . . . . . . . . . . . . 0
WP 0013 (50 pgs) . . . . . . . . . . . . . . . . . 0 WP 0045 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0014 (2 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0047 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0015 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0048 (8 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0016 (20 pgs) . . . . . . . . . . . . . . . . . 0 WP 0049 (8 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0050 (14 pgs) . . . . . . . . . . . . . . . . . 0
WP 0017 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0051 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0018 (62 pgs) . . . . . . . . . . . . . . . . . 0
WP 0052 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0053 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0019 (10 pgs) . . . . . . . . . . . . . . . . . 0
WP 0054 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0020 (14 pgs) . . . . . . . . . . . . . . . . . 0
WP 0055 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0021 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0056 (8 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0022 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0057 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0023 (10 pgs) . . . . . . . . . . . . . . . . . 0
WP 0058 (10 pgs) . . . . . . . . . . . . . . . . . 0
WP 0024 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0059 (20 pgs) . . . . . . . . . . . . . . . . . 0
WP 0025 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0060 (14 pgs) . . . . . . . . . . . . . . . . . 0
WP 0026 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0061 (18 pgs) . . . . . . . . . . . . . . . . . 0
WP 0027 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0062 (6 pgs) . . . . . . . . . . . . . . . . . . 0
A
TM 5-3805-255-14
Page/WP No. Change No. Page/WP No. Change No.
WP 0063 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0098 (22 pgs) . . . . . . . . . . . . . . . . . 0

WP 0064 (24 pgs) . . . . . . . . . . . . . . . . . 0 WP 0099 (2 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0065 (16 pgs) . . . . . . . . . . . . . . . . . 0 WP 0100 (14 pgs) . . . . . . . . . . . . . . . . . 0
WP 0066 (2 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0101 (20 pgs) . . . . . . . . . . . . . . . . . 0
WP 0067 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0102 (34 pgs) . . . . . . . . . . . . . . . . . 0
WP 0068 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0103 (46 pgs) . . . . . . . . . . . . . . . . . 0
WP 0069 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0104 (24 pgs) . . . . . . . . . . . . . . . . . 0
WP 0070 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0105 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0071 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0106 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0072 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0107 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0073 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0108 (2 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0074 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0109 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0075 (30 pgs) . . . . . . . . . . . . . . . . . 0 WP 0110 (14 pgs) . . . . . . . . . . . . . . . . . 0
WP 0076 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0111 (30 pgs) . . . . . . . . . . . . . . . . . 0
WP 0077 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0112 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0078 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0113 (14 pgs) . . . . . . . . . . . . . . . . . 0
WP 0079 (2 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0114 (30 pgs) . . . . . . . . . . . . . . . . . 0
WP 0080 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0115 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0081 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0116 (14 pgs) . . . . . . . . . . . . . . . . . 0
WP 0082 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0117 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0083 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0118 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0084 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0119 (14 pgs) . . . . . . . . . . . . . . . . . 0
WP 0085 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0120 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0086 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0121 (26 pgs) . . . . . . . . . . . . . . . . . 0
WP 0087 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0123 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0088 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0124 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0089 (36 pgs) . . . . . . . . . . . . . . . . . 0 WP 0125 (18 pgs) . . . . . . . . . . . . . . . . . 0
WP 0090 (18 pgs) . . . . . . . . . . . . . . . . . 0 Chapter 9 Title Page . . . . . . . . . . . . . . . 0
WP 0091 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0126 (2 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0092 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0127 (4 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0093 (16 pgs) . . . . . . . . . . . . . . . . . 0 WP 0128 (20 pgs) . . . . . . . . . . . . . . . . . 0
WP 0094 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0129 (2 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0095 (24 pgs) . . . . . . . . . . . . . . . . . 0 WP 0130 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0096 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0131 (6 pgs) . . . . . . . . . . . . . . . . . . 0
WP 0097 (18 pgs) . . . . . . . . . . . . . . . . . 0 Index-1 thru Index-6. . . . . . . . . . . . . . . . 0
Back Cover . . . . . . . . . . . . . . . . . . . . . . 0
B
*TM 5-3805-255-14
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington, D.C., 20 February 2009
Technical Manual
OPERATOR, FIELD, AND SUSTAINMENT
MAINTENANCE MANUAL
FOR
LOADER, SCOOP TYPE, DED, 4 X 4,

ARTICULATED FRAME STEER, 4.5 TO 5 CU. YD. (CCE)
(IHC MODEL H100C)
TYPE I WITH 4.5 CU. YD. BUCKET

(NSN 3805-01-052-9042) (EIC: EFR)
TYPE II WITH 5 CU. YD.

GENERAL PURPOSE BUCKET
(NSN 3805-01-052-9043) (EIC: EFS)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this publication. If you find any errors, or if you would like to recommend any
improvements to the procedures in this publication, please let us know. The preferred method is to submit your
DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet, on the Army
Electronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil. The DA Form
2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click
on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better
manage the DA Form 2028 program. You may also mail, E-mail, 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 E-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 793-0726 or
Commercial (309) 782-0726.
*SUPERSEDURE NOTICE: Supersedes TM 5-3805-255-14&P, 15 July 1980, including all changes.
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
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TM 5-3805-255-14
TABLE OF CONTENTS -
WP Sequence No.
Warning Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Chapter 1 - GENERAL INFORMATION, EQUIPMENT
DESCRIPTION, AND THEORY OF OPERATION
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001
Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003
Chapter 2 - OPERATOR INSTRUCTIONS
Description and Use of Operator Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004
Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005
Operation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006
Stowage and Decal, Data Plate, and Stencil Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0007
Preparation for Storage or Shipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0008
Chapter 3 - OPERATOR TROUBLESHOOTING PROCEDURES
Operator Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0009
Operator Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0010
Operator Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0011
Chapter 4 - OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Operator Preventive Maintenance Checks and Services (PMCS) Introduction . . . . . . . . . . . . . . . . . . WP 0012
Operator Preventive Maintenance Checks and Services
(PMCS) Including Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0013
Chapter 5 - FIELD TROUBLESHOOTING PROCEDURES
Field Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0014
Field Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0015
Field Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0016
Chapter 6 - FIELD PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Field Preventive Maintenance
Checks and Services (PMCS) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0017
Field Preventive Maintenance Checks and Services
(PMCS) Including Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0018
Chapter 7 - FIELD MAINTENANCE
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0019
Electrical General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0020
Circuit Breaker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0021
Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0022
Lubricating Oil and Water Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0023
Engine Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0024
Engine Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0025
Intake and Exhaust Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0026
Fuel Injector and Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0027
ii
TM 5-3805-255-14
TABLE OF CONTENTS – CONTINUED -
WP Sequence No.
Fuel Injection Pump Replacement and Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0028

Air Cleaner Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0029
Turbocharger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0030
Fuel Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0031
Governor Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0032
Accelerator Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0033
Emergency Shutdown Control Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0034
Muffler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0035
Radiator and Converter Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0036
Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0037
Fan Drive Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0038
Lubricating Oil Filter Housing and Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0039
Alternator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0040
Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0041
Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0042
Electric Gauge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0043
Sending Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0044
Battery Service and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0045
Transmission Control Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0046
Torque Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0047
Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0048
Propeller Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0049
Transfer Drive Replacement/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0050
Front Axle Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0051
Front Differential Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0052
Front Final Drive/Planetary Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0053
Rear Axle Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0054
Rear Differential Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0055
Rear Final Drive/Planetary Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0056
Parking Brake Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0057
Parking Brake Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0058
Service Brakes Replacement/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0059
Power Cluster Assemblies Replacement/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0060
Treadle Valves Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0061
Air Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0062
Safety Valve and Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0063
Air Compressor Replacement and Repair (Model 500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0064
Air Compressor Replacement and Repair (Model 501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0065
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0066
iii
TM 5-3805-255-14
WP Sequence No.
Steering Wheel and Column Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0067

Steering Gear Replacement/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0068
Steering Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0069
Steering Pump Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0070
Steering Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0071
Steering Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0072
Demand Valve Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0073
Center Hinge Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0074
Cab Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0075
Windshield Wiper Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0076
Main Hydraulic Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0077
Main Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0078
Reservoir Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0079
Hydraulic Control Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0080
Bucket Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0081
Boom Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0082
Hydraulic Tank/Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0083
Pressure Gauge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0084
Bucket Tips Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0085
Bucket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0086
Chapter 8 - SUSTAINMENT MAINTENANCE INSTRUCTIONS
Cylinder Sleeves Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0087
Front and Rear Main Oil Seals Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0088
Cylinder Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0089
Crankshaft and Main Bearings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0090
Flywheel Replacement/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0091
Pistons Inspection/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0092
Connecting Rod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0093
Connecting Rod Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0094
Valves Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0095
Camshaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0096
Timing Gears Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0097
Lubricating Oil and Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0098
Fuel Injector Testing and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0099
Fuel Injection Pump Adapter Housing Replacement/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0100
Fan Drive Assembly Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0101
Torque Converter Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0102
Transmission Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0103
Clutch Pack Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0104
iv
TM 5-3805-255-14
WP Sequence No.
Transmission Forward and Reverse Valve Repair/Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0105

Transmission Charging Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0106
Transmission Main Regulator Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0107
Transmission Neutral Knockdown Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0108
Transmission Range Selector Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0109
Front Axle Assembly Repair/Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0110
Front Differential Repair/Overhaul. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0111
Front Planetary Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0112
Rear Axle Assembly Repair/Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0113
Rear Differential Repair/Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0114
Rear Planetary Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0115
Steering Gear Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0116
Steering Pump Assembly Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0117
Hydraulic Steering Cylinders Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0118
Steering Control Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0119
Main Hydraulic Pump Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0120
Main Control Valve Overhaul. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0121
Bucket Cylinder Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0122
Boom Cylinder Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0123
Hydraulic Tank/Reservoir Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0124
Illustrated List of Manufactured Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0125
Chapter 9 - SUPPORTING INFORMATION
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0126
Maintenance Allocation Chart (MAC) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0127
Maintenance Allocation Chart (MAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0128
Basic Issue Items (BII) List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0129
Expendable and Durable Items List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0130
Torque Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0131
v
TM 5-3805-255-14
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 contains operating instructions, and maintenance procedures, for the H100C Loader.
2. This manual is written in work package format:
a. Chapters divide the manual into major categories of information: Introductory Information, Equipment
Description, and Theory of Operation; Operator Instructions; Operator Troubleshooting Procedures;
Operator Preventive Maintenance Checks and Services (PMCS); Field Troubleshooting Procedures;
Field Preventive Maintenance Checks and Services (PMCS); Field Maintenance; Sustainment
Maintenance Instructions; and Supporting Information.
b. Each chapter is divided into work packages, which are identified by a 4-digit number (e.g., 0001, 0002)
located on the upper right-hand corner of each page. The work package page number (e.g., 0001-1,
0001-2) is located centered at the bottom of each page.
3. Read through this manual to become familiar with its organization and contents before attempting to operate
or maintain the equipment.
CONTENTS OF THIS MANUAL
1. A Warning Summary is located at the beginning of this manual. Become familiar with these warnings before
operating or maintaining the loader.
2. The Table of Contents, located in the front of the manual, lists all chapters and work packages in the publica-
tion. 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.
3. Chapter 1, General Information, Equipment Description, and Theory of Operation provides general informa-
tion about the loader, identifies the major components and systems, and describes how the components and
systems work.
4. Chapter 2, Operator Instructions, identifies operating controls and indicators and explains how to use them.
This chapter covers loader operating procedures under usual and unusual conditions. It also contains the
Stowage and Decal, Data Plate, and Stencil Guide, and Preparation for Storage and Shipment.
5. Chapter 3, Operator Troubleshooting Procedures, describes procedures for locating and correcting
malfunctions of the loader. Included in this chapter is the Operator Troubleshooting Symptom Index. If the
loader malfunctions, this index should always be consulted to locate the appropriate troubleshooting
procedure.
6. Chapter 4, Operator Preventive Maintenance Checks and Services (PMCS), contains operator-level
preventive maintenance and lubrication procedures for the loader.
7. Chapter 5, Field Troubleshooting Procedures, describes field maintenance troubleshooting procedures for
locating and correcting malfunctions of the loader. Included in this chapter is the Field Troubleshooting
Symptom Index. If the loader malfunctions, this index should always be consulted to locate the appropriate
troubleshooting procedure.
8. Chapter 6, Field Preventive Maintenance Checks and Services (PMCS), contains field-level preventive
maintenance and lubrication instructions for the loader.
9. Chapter 7, Field Maintenance, contains work packages with information on field-level maintenance and repair
of the loader.
vi
TM 5-3805-255-14
CONTENTS OF THIS MANUAL – CONTINUED

10. Chapter 8, Sustainment Maintenance Instructions, contains work packages with information on sustainment-
level maintenance and repair of the loader.
11. Chapter 9, Supporting Information, contains the following: References; Maintenance Allocation Chart (MAC)
Introduction; Maintenance Allocation Chart (MAC); Basic Issue Items (BII) List; Expendable and Durable
Items List; and Torque Limits.
FEATURES OF THIS MANUAL
1. This manual contains information on operating and maintaining the H100C loader.
2. WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlighted in BOLD
print as a visual aid.
WARNING
A WARNING indicates a hazard which may result in injury or death to personnel.
CAUTION
A CAUTION is a reminder of safety practices or directs attention to usage practices that may result
in damage to equipment.
NOTE
A NOTE is a statement containing information that will make the procedures easier to perform.
3. Statements and words of particular interest may be printed in CAPITAL LETTERS to create emphasis.
4. Within a procedural step, reference may be made to another chapter or work package in this manual or to
another manual. These references indicate where you should look for more complete information. If you are
instructed to: “Replace air cleaner assembly (WP 0029)”, go to WP 0029 in this manual for instructions on air
cleaner assembly replacement.
5. Illustrations are placed after, and as close as possible to, the procedural steps to which they apply. Callouts
placed on the art are text or numbers.
6. Numbers located at the lower right corner of art (e.g., H100C-0033; H100C-0850) are art control numbers
and are used for tracking purposes only. Disregard these numbers.
7. 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 equipment.
8. Technical instructions include standard units as well as metric units. For your reference, a Metric Conversion
Chart is located on the inside back cover of the manual.
9. Location Terms. The terms left, right, front, or rear are used to describe areas of the equipment. These terms
indicate location as seen when seated in the driver’s seat and facing forward.
10. Torque Values. Whenever a component is “installed” or “tightened,” refer to Torque Limits for the correct
torque specification.
vii/(viii blank)
x
TM 5-3805-255-14
CHAPTER 1
GENERAL INFORMATION, EQUIPMENT
DESCRIPTION, AND THEORY OF OPERATION
4
TM 5-3805-255-14 0001
OPERATOR, FIELD, AND SUSTAINMENT MAINTENANCE -
0 0 0 1 GENERAL INFORMATION
SCOPE 0001
Type of Manual. This manual is for use in operating and performing Operator and Field level maintenance and
troubleshooting and Sustainment level maintenance on the H100C Loader.
Equipment Name and Model Number. Loader, Scoop Type, DED 4X4, Articulated Frame Steer, 4.5 to 5.0 cu. yd.
(CCE) (IHC Model H100C):
a. Type I with 4.5 cubic yard bucket NSN 3805-01-052-9042.
b. Type II with 5.0 cubic yard general purpose bucket NSN 3805-01-052-9043.
Purpose of Equipment. The H100C Loader is used in worldwide earth moving and construction projects by U.S.
Army forces in engineer troop support.
Figure 1. Model H100C Loader. 01
MAINTENANCE FORMS, RECORDS, AND REPORTS 0001
Department of the Army forms and procedures used for the equipment will be those prescribed by DA PAM 750-8,
The Army Maintenance Management System (TAMMS) Users Manual.
0001-1
TM 5-3805-255-14 0001
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRS) 0001
If your loader needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us
what you don’t like about your equipment. Let us know why you don’t like the design or performance. If you have
Internet access, the easiest and fastest way to report problems or suggestions is to go to https://aeps.ria.army.mil/
aespublic.cfm (scroll down and choose “Submit Quality Deficiency Report” bar). The internet form lets you choose
to submit an EIR or a Product Quality Deficiency Report (PDQR). You may also submit your information using an
SF Form 368 (Product Quality Deficiency Report). You can send your SF Form 368 via mail, regular mail, or
facsimile using the addresses/facsimile numbers specified in DA PAM 750-8, TAMMS Users Manual. We will send
you a reply.
CORROSION PREVENTION AND CONTROL 0001
1. CPC of Army materiel is a continuing concern. It is important that any corrosion problems with this item be
reported so that the problem can be corrected and improvements can be made to prevent the problem in future
items.
2. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of
metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of
iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface
residue, and/or cracking.
3. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal energy (heat),
oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common
exposures are excessive heat or light. Damage from these processes will appear as cracking, softening,
swelling, and/or breaking.
4. SF Form 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-
8, TAMMS Users Manual.
DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE 0001
For destruction of Army materiel to prevent enemy use, refer to TM 750-244-3.

PREPARATION FOR STOWAGE OR SHIPMENT 0001
Notify Field Maintenance to perform preparation for storage or shipment procedures.
0001-2
TM 5-3805-255-14 0001
SERIAL NUMBERS 0001
The Loader serial number plate is located in the lower left-hand side of the operator’s compartment. This serial
number is also stamped on the left rear side of the rear frame.
Figure 2. Loader Serial Number Plate. 01
Figure 3. Loader Serial Number Location on Rear Frame. 01
The engine serial number is located on the left side of the engine block near the flywheel housing. It is stamped
into the engine block.
0001-3
TM 5-3805-255-14 0001
SERIAL NUMBERS – CONTINUED
Figure 4. 817 Series C Diesel Engine. 01
Use serial numbers when requesting information or ordering parts. For ready reference, write these serial numbers
in the spaces provided below.
Loader Serial Number: __________________
Engine Serial Number: __________________
OPERATION CONCEPT 0001
The H100C Loader is to be used by engineer construction units equipped with Commercial Construction
Equipment (CCE). The increased loader capability is required for compatibility with the increased haul capability of
the 20 ton on/off highway dump truck and the quarry truck and concrete mobile mixer. This scoop loader will be
used to excavate and load consolidated earth, blast rock, loose or decomposed rock, sand, aggregate, and loose
soil from stockpiles into dump trucks, concrete mobile mixers, hoppers, and aggregate bins.
PERSONNEL AND TRAINING 0001
MOS Requirements.
a. Operator: Rough terrain, forklift, and loader operator, MOS 21E10.
b. Field: Engineer equipment repairman, MOS 62B20.
c. Sustainment: Engineer equipment repairman, MOS 62B30.
LOGISTICS ASSISTANCE (AR 700-4) 0001
When training or additional technical assistance is required for the H100C Loader, contact your local Logistics
Assistance Office (LAO) or refer to AR 700-4, Logistics Assistance.
END OF WORK PACKAGE
0001-4
8
TM 5-3805-255-14 0002
0 0 0 2 EQUIPMENT DESCRIPTION AND DATA
CHARACTERISTICS, CAPABILITIES, AND FEATURES 0002
The H100C Loader is an integral part of the Army’s mission to efficiently build roads, airstrips, and other
engineering assets in a wide a variety of geographic, environmental, and tactical situations. The H100C uses a
4.5 cu. yd. or 5.0 cu. yd. (3.44 cu. m or 3.82 cu. m) bucket, and is equipped with an International Harvester DT-
817C diesel engine.
Figure 1. Model H100C. 02
0002-1
TM 5-3805-255-14 0002
EQUIPMENT DESCRIPTION 0002
1. Overview.
THe H100C is a commercial 4.5 or 5.0 cu. yd. capacity Loader, Scoop Type, DED, 4 x 4, Articulated Frame
Steering: International Harvester Company Model H100C, rubber-tire mounted. When equipped with the
4.5 cu. yd. spade nose rock bucket it is referred to as the Type I Loader (NSN 3805-01-052-9042). When
equipped with a 5.0 cu. yd. general purpose bucket it is referred to as the Type II Loader (NSN 3805-01-052-
9043). The loader will be identified by the CCE Manufacturer's Serial Number and the United States Army
(USA) Number.
The loader is powered by an International Harvester Engine DT-817C which develops 290 Net HP at the fly-
wheel and 320 maximum horse power at 2,100 RPM. The powertrain consists of a single stage, single phase,
three element torque converter, an input charging pump and a power take-off to drive the loader system pump
and the combination power steering-cooling circuit pump. The torque converter drives a full power shift trans-
mission. The transmission has four speeds in both forward and reverse and full power shift in all ranges. Both
axles are full floating, double reduction type. The axles are rigidly attached to their supporting members; the
front main frame is the case for the front axle and an oscillating cradle called a bolster for the rear. By allowing
the rear axle to oscillate, the tractor is assured greater stability in rough terrain. The first gear reduction takes
place in the differential; the second in the planetaries. Each wheel revolves on two tapered roller bearings
mounted on the axle spindle. The axles are full floating. None of the weight is supported by, or transmitted to,
the axle shafts. All weight on the axle is supported by the wheels, bearings, and axle housings. The differential
assemblies are rigidly mounted, one on the forward side of the rear axle housing and one on the rear side of
the front axle housing. The differentials are connected by splined yokes on the propeller shafts from the trans-
mission.
The brake system is a combination of air over hydraulic. An engine driven compressor supplies compressed
air for the system. The compressed air is stored in the air reservoir and the output is regulated by a governor
between the compressor and the reservoir at 90 to 105 psi (620.5 - 723.9 kPa). The hydraulic system is a
closed system with controlled pressure and vacuum relief. The reservoir has a capacity of approximately
54 gal. (204.4 L). The loader has a speed of 21.4 mph (34.4 kph). The fuel tank capacity is 115 gal. (435.3 L),
and the equipment will use approximately 50.4 gallons (190.7 liters) of diesel fuel with the engine operating at
2,100 RPM, for a period of 5 hours. With the engine lubrication oil levels filled as prescribed, lubrication oil
pressure will be maintained on a 30 percent side slope and a 60 percent longitudinal slope.
2. Bucket. The general purpose bucket (Type II) has an SAE nominal heaped rating of 5.0 cu. yd., and eight (8)
bolt-on teeth with replaceable tooth tips. Measured width of bucket is 130.5 in. (331.5 cm). 10 ft 10-1/2 in.
3. Rock Bucket. The spade nose rock bucket (Type I) has an SAE nominal heaped rating of 4.5 cu. yd.
Measured width of bucket 130 in. (330.2 cm). 10 ft 8 in.
4. Steering System. The loader has articulated frame steering with 38 degrees of articulation in each direction.
5. Tires. Standard tire size 26.5 x 25. Optional tire size is 29.5 x 25. Tire ply rating range is 14-22 ply. Sufficient
clearance is provided to mount the L-5 type tires without removal of any components.
6. Electrical System. The loader has a 24VDC electrical starting and lighting system with necessary fuses and
circuit breakers. All control switches are located on the dash within reach of operator. The system has a nega-
tive ground circuit.
7. Alternator. The loader is equipped with an engine-driven alternator and self-contained compatible regulator.
The alternator is 24VDC with 45 amp rating.
0002-2
TM 5-3805-255-14 0002
EQUIPMENT DESCRIPTION – CONTINUED

8. Instruments. The loader is equipped with waterproof gauges and switches. The gauges are illuminated by
rear lighting and identified on the instrument panel. The following instruments are on the panel:
a. Engine Coolant Temperature Gauge
b. Voltmeter
c. Engine Oil Pressure Gauge
d. Transmission Oil Temperature Gauge
e. Air Pressure Gauge
f. Fuel Level Gauge
g. Service Recorder
9. Battery. Either four (4) 6VDC batteries, or two (2) 12VDC batteries are installed in a series to provide 24VDC
for the starting system. Batteries are located on either side of the hydraulic reservoir on the rear frame.
EQUIPMENT DATA 0002
Fluid Capacities
Axles (each) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 qt. (42.5 L)
Crankcase w/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 qt. (30.3 L)
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 gal. (435.3 L)
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 gal. (208.2 L)
Transmission w/Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 qt. (42.5 L)
Intermediate Drive Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 pt (0.47 L)
Engine Specifications 0002
Make and Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . International Harvester, DT 817 Series C

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged, 4-cycle diesel
No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3/8 in. (137 mm)
Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 in. (152.4 mm)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 817 cu. in. (13.3 L)
Net Torque (1,450 RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 891 lb-ft (61 bar)
Engine Speeds:
Full Load Governed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 RPM
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650 to 750 RPM
High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,200 to 3,500 RPM
Operating Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,200 to 1,300 RPM
Rated Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 hp (239 kW)
Valve Clearance:
Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 in. (0.51 mm)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.031 in (0.79 mm)
Belt Tension:
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 to 75 lb (311 to 334 N)
Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 to 100 lb (423 to 445 N)
0002-3
TM 5-3805-255-14 0002
EQUIPMENT DATA – CONTINUED

Electrical System 0002
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24VDC neg ground

Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two 12VDC or Four 6VDC
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 amp
Torque Converter:
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single stage, single phase
Stall Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.08:1
Transmission 0002
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . International Harvester

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-2004
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four speed, constant mesh, full reversing, full power shift
Axles 0002
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . International Harvester

Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FR-150
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planetary
Total Rear Axle Oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Brakes 0002
Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle by axle, air over hydraulic, wedge type internal expanding shoe
Parking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Expanding shoe
Hydraulic System 0002
Steering Circuit:
Pump:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vane
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 gpm (174 L/min.) at full engine gov. speed
Cylinders:
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 in. (114.3 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5 in. (520.7 mm)
Loader Circuit:
Pump:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vane
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 gpm (390 L/min.) at full engine gov. speed
0002-4
TM 5-3805-255-14 0002

Cylinders:
Boom:
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 in. (152.4 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 in. (1270 mm)
Bucket:
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 in. (203.2 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5 in. (546 mm)
Action Time (empty):
Boom Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15 sec.
Boom Lower (float) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 sec.
Bucket Roll Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 sec.
Bucket Dump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 sec.
Tires 0002
Size and Inflation Pressures:

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.5 x 25 - 14 ply (L3) 35 psi (241 kPa)
Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.5 x 25 - 20 ply (L4) 50 psi (345 kPa)
General 0002
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46,688 lb (21,177 kg)

Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2 in. (59.0 cm)
Weight Over Front Axle (Approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21,884 lb (9,926.4 kg)
Weight Over Rear Axle (Approx.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24,959 lb (11,321.2 kg)
Total weight (Approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46,843 lb (21,247.6 kg)
Wheel Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 in. (355.6 cm)
Steering Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40°
Steering Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 in. (711.2 cm)
Bucket (standard)
Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 cu. yd. (3.44 cu.m)
Cutting Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130.5 in. (331.5 cm)
Dump Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees
Clearance Circle Measured to Outside of Tire Tread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517 in. (1,313.2 cm)
Dump Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 in. (314.9 cm) @ 40-degree Dump Angle.
Reach . . . . . . . . . . . . . . . . . . . 65 in. (165.1 cm) @ 40-degree Dump Angle and 124 in. (314.9 cm) Dump Height.
Drawbar Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25,642 lb at 2.1 mph.
0002-5
TM 5-3805-255-14 0002

Dimensions 0002
A. Height to Top of Cab (Shall Not Exceed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 in. (381.0 cm)
B. Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 in. (58.4 cm)
C. Wheel Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 in. (355.5 cm)
D. Length with Bucket on Ground
General Purpose Bucket on Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 in. (833 cm)
Spade Nose Rock Bucket on Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353 in. (896.6 cm)
E. Wheel Tread Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 in. (244 cm)
F. Width at Front and Rear Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 in. (314.9 cm)
Figure 2. Dimension Diagram. 02
0002-6
TM 5-3805-255-14 0002
SYSTEM PRESSURES 0002
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,000 psi (13,789.51 kPa)

Cylinder Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,000 psi (20,684.27 kPa)
Steering Relief Valve:
Main Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,000 psi (13789.51 kPa)
Service Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,500 psi (24131.65 kPa)
Relief Valve Setting:
Main Relief 2,300 psi (15,857.94 kPa) . . . . . . . . . . . . . . . . . plus or minus 50 psi (344.7379 kPa) at full throttle
Cylinder Relief 3,000 psi (20,684.27 kPa) . . . . . . . . . . . . . . . plus or minus 50 psi (344.7379 kPa) at full throttle
END OF WORK PACKAGE
0002-7/(8 blank)
34
TM 5-3805-255-14 0003
0 0 0 3 THEORY OF OPERATION
ENGINE 0003
Description 0003
The 817 Series C diesel engine is a heavy-duty, high-speed, direct-starting, four-cycle, valve-in-head design using
a 24VDC starting system and direct fuel injection.
The crankshaft is fully counterbalanced. It is supported by seven steel-backed, tri-metal type main bearings with
rear bearing, No. 7, absorbing crankshaft end thrust. The connecting rod bearings are also of steel-backed, tri-
metal type.
The camshaft is supported by seven bearings with thrust being taken on front bearing. The bearings are steel
shells, solid or split, with babbit bearing material. The camshaft has two lobes per cylinder, one each for exhaust
and intake valves. The camshaft is driven directly from the crankshaft gear.
The aluminum-alloy, tin-plated, solid-skirt pistons are cam ground, and are fitted with two compression and one oil-
control ring. The full-floating type piston pins are held in place by snap rings at the ends of each pin. The under-
surfaces of the piston crowns are jet-cooled by lubricating oil. Forged steel connecting rods contain a bronze
bushing at the upper end for installation on the piston pin, while the lower end and cap contain the locking type
precision fit bearing inserts.
There are two cylinder heads, each covering three cylinders. There are two intake and two exhaust valves per
cylinder. Each pair of valves is actuated by a rocker arm and guided bridge.
Bridges have an adjustment at one end to ensure even contact with both valves. Positive-type rotators are used on
all intake and exhaust valves. Replaceable valve seat inserts are used on exhaust valves. Positive valve rotators
and valve seat inserts are used on all valves.
The cylinder sleeves are replaceable, wet type. Three O-rings, located in grooves at the lower end of the sleeve,
provide an effective seal between the cylinder sleeve, crankcase, and the water jacket surrounding it.
The full-pressure lubrication system assures positive lubrication to all working parts. A gear-type oil pump is exter-
nally mounted to the left side of the crankcase. Oil is drawn from the oil pan by the pump and is distributed under
pressure though rifle-drilled passages in the crankcase and crankshaft.
Piston cooling jets (located on the right side of crankcase) spray each piston with 1.5 gal. (5.7 L) of oil per minute.
Coolant is circulated through the engine and radiator by a centrifugal water pump mounted on a common shaft with
the lubricating pump. Two thermostats, located in the water outlet header, control coolant temperature in the
system.
The fuel system consists of fuel lines, fuel filters, injection pump, injection nozzles, and lines.
There are three fuel injection nozzles in each cylinder head, one between each pair of intake and exhaust valves.
To insure efficient cooling, nozzles are inserted into a thin-walled copper tube, passing through water space in
cylinder head.
The rocker arm assembly on each head is mounted on four brackets and is located and held down by cylinder
head suds and nuts. There are two rocker levers per cylinder, one for each pair of intake exhaust valves. A valve
bridge connects each pair of intake and exhaust valves which allows both valves to be actuated by one rocker
lever.
Both cylinder heads are basically of uniform construction, however, slight modifications in design prevent them
from being interchangeable. A separate cylinder head gasket with integral gasket rings is provided for each head.
0003-1
TM 5-3805-255-14 0003
ENGINE – CONTINUED
Rotation (Engine and Injection Pump) . . . . . . . . . . . . . . . . . . . . . . . . Counterclockwise (viewed from flywheel end)
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
Compression Ratio:
Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1:1
Injection Pump Timing - Static (Crankshaft Degrees) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 degrees BTDC
Crankshaft 0003
The crankshaft is fully counterbalanced with induction-hardened journals.

The crankshaft supports six connecting rods and pistons along its length. At the front end of the crankshaft, a
timing gear-train supplies drive for camshaft, injection pump, lubricating oil and water pump, fan drive housing, and
hydraulic pump. The flywheel is mounted to the rear end of the crankshaft. Two main seals, one at the front and
one at the rear, prevent leakage of engine lubricating oil around the ends of the crankshaft.
Bearing caps are furnished with crankcase and support the crankshaft in true alignment. Webs integral with the
crankcase provide upper half of main bearing supports and removable bearing caps provide lower support. Seven
bearing caps are held in place with two cap screws each. Bearing caps are not interchangeable, and each has a
number stamped upon them which signifies the correct location in the crankcase. The No. 1 bearing cap is at the
front of the engine.
NOTE
Extreme care must be taken to guarantee cleanliness of crankcase, crankshaft, and
bearings after service has been completed. Whenever possible, crankshaft should be
removed when new bearings are being installed in order to clean crankcase thoroughly.
All bearing surfaces must be free of grit and burrs. Small particles of dust and dirt left
between crankshaft and bearings will cause rapid wear and scoring of crankshaft journal
and bearing insert. Any foreign material left between bearings and crankcase and bearing
caps will cause distortion of bearing and reduction in operating bearing clearance at that
point. Frictional heat thus produced, will in turn, cause bearing material to melt away from
steel back of bearing at that point. Such melted material will create further hot spots until
complete bearing failures take place. Anything that interferes with operating clearance of
any bearing or proper heat dissipation will drastically affect bearing life. Cleanliness
cannot be overstressed.
Bearing inserts are of the precision type. The words “UPPER” and “LOWER” are stamped on the back of bearings
for identification purpose. Bearings are inserted between crankshaft and crankcase and between crankshaft and
bearing caps. Rear main bearing is the thrust bearing and has thrust flanges that determine crankshaft end-play.
0003-2
TM 5-3805-255-14 0003
Connecting Rods 0003
Connecting rods are forged steel and contain a bushing at upper end for installation on piston pins. This bushing is
lubricated by means of a collector cup in top of connecting rod. Oil from piston cooling jets drops into collector cup
and reaches bushing through a drilled passage. Lower end and cap contain locking-type, selective-fit bearing
inserts. Connecting rod and cap are held together using two connecting rod bolts and two nuts.
Figure 1. Exploded View of Connecting Rod Assembly. 03
Pistons and Rings 0003
Pistons are cast aluminum alloy and are cam ground. They are fitted with two compression and one oil control ring.
Pistons receive force of combustion pressure and transmit it to connecting rod and crankshaft. Escape of
combustion pressure past piston is prevented by piston rings. Fit of piston and rings in sleeve must be close
enough to prevent escape of combustion gases, yet be free enough to keep friction to its working minimum.
The oil control ring provides an even circulation of lubricating oil and therefore, an overall lubrication and cooling
action for piston and crankcase sleeve.
Excess oil is wiped by rings, back down to crankcase.
0003-3
TM 5-3805-255-14 0003
Piston Pins 0003
Piston pin is hardened steel and anchors piston to connecting rod. Pin is retained in piston by retainer rings that
lock into grooves of pin bore. Pin floats in its bushing in upper end of rod. Aluminum alloy of piston is an excellent
bearing material and no bushing is required between pin and piston.
Figure 2. Exploded View of Piston Assembly. 03
0003-4
TM 5-3805-255-14 0003
Camshaft 0003
The camshaft is located in the crankcase on the left-hand side of the engine, and is held to the crankcase by a hub
which takes thrust. The camshaft is supported at intervals along its length by seven bushings. These bushings are
removable and are furnished for service reamed to size. Bushings are a press fit in the crankcase.
The camshaft’s main function is operating the intake and exhaust valve mechanism by action of its lobes upon
tappets to push rods during rotation.
It is important to notice that the camshaft gear has twice as many teeth as the crankshaft gear which drives it. The
camshaft, therefore, rotates at one-half of crankshaft speed due to requirement to open and close valves to each
cylinder once for every two revolutions of crankshaft.
The camshaft bearings are pressure-lubricated and have oil holes drilled in them. When bushings are installed, oil
holes must align with ones drilled in crankcase. Slots in two of the journals permit lubricating oil to travel to rocker
arm assemblies.
Figure 3. Camshaft Components. 03
0003-5
TM 5-3805-255-14 0003
Gear Train 0003
The timing gear train is accessible when crankcase front cover is off. All gears are driven by the crankshaft gear.
Gears provide a positive and accurate drive to camshaft, lubricating oil and water pump, injection pump, fan drive,
and hydraulic pump. The only timing marks in gear train are between crankshaft, camshaft, and injection pump
gears. The injection pump is timed to the engine through the injection pump adapter. Refer to WP 0028, Fuel
Injection Pump Replacement and Timing, for detailed information on injection pump timing. Two lubricating oil jets
and an oil slinger provide lubrication for all gears.
Figure 4. Gear Train. 03
0003-6
TM 5-3805-255-14 0003
ELECTRICAL SYSTEM 0003
The electrical circuit employed in the H100C Loader is a 24VDC, negative ground system. Electrical energy stored
in the batteries is available upon demand to the system components. These components, which include the
instruments, are:
1. Headlights, Backup Lights, Stop and Taillights and Cranking Motor. Dependent upon battery energy until
the engine drives the generator at a speed sufficient to carry the electrical load. Above this predetermined
speed, electrical energy produced by the alternator supplies the normal demands of the system. A portion of
this energy is sent to the batteries to keep them in a state of full charge.
2. Regulator. Installed in the system to control the output of the alternator. By using a regulated control, electrical
energy produced by the alternator is supplied to the system components on demand.
3. Batteries. Either two 12VDC batteries or four heavy duty 6VDC batteries, wired in series, produce a 24VDC
system. The batteries are housed in each of the battery boxes located on the left- and right-hand sides of the
rear main frame. Hinged tops on the battery boxes provide easy access for servicing.
The system may be divided into two circuits; the cranking circuit, in use during engine starting, and the charging
circuit, supplying current to the remainder of the system which the engine is operating. In addition, the charging
circuit replaces electrical energy drained from the batteries.
Alternator 0003
The alternator is an electrical energy producing unit designed to meet the increased demand for electrical energy
during low speed operation or at engine idle operation
Diodes 0003
1. The battery and other electrical accessories in the electrical system operate on direct current which flows in
one direction only. For this reason it is necessary to change the AC current to DC current. This function is
performed by rectifying diodes.
2. A diode is an electrical device which changes or rectifies alternating current (AC) to direct current (DC) by
allowing current to pass through it freely in one direction but not in the other. It thus acts much like an electrical
check valve or the commutator on a DC generator.
0003-7
TM 5-3805-255-14 0003
ELECTRICAL SYSTEM – CONTINUED

Regulator 0003
1. To prevent the alternator from producing too much voltage and burning out the accessories and overcharging
the battery, its voltage must be limited. For this function, a regulator is necessary in the charging system.
2. A typical double contact regulator is shown in Figure 5. This regulator has four terminals.
3. The terminals are of the slip-connection type, and a special connector body on the vehicle wiring harness is
keyed to mating slots in the regulator base to insure proper connections. Also, a projection on the connector
body serves to latch the assembly together. This prevents disconnection due to vibration. The assembly can be
disconnected by lifting the latch slightly.
4. A double contact voltage regulator unit and field relay unit make up the regulator assembly. The voltage
regulator unit operates to limit alternator voltage to a pre-set value, whereas the field relay connects alternator
field winding and regulator winding directly to the battery.
Figure 5. Typical Two-Unit Regulator. 03
0003-8
TM 5-3805-255-14 0003

Regulator – Continued
5. This model regulator is designed for use on only one polarity system. Note the marking on the regulator base,
or refer to specifications to determine if polarity of the regulator is negative or positive.
CAUTION
On electrical systems using these regulators, the polarity of the regulator, alternator, and
battery must be the same. When installing any one of these three units, do not make any
connections without first checking polarities. Failure to follow this caution may result in
6. A typical wiring diagram showing internal circuits of the regulator is shown in Figure 6.
7. On some circuits, a condenser may be connected to the No. 4 regulator terminal. If a condenser is not used,
neither is the No. 4 terminal.
NOTE
Do not connect anything to the No. 4 terminal other than a condenser.
8. Following is a brief description of the operating principles of the units in this type of circuit. When the switch is
closed, the field relay winding in the regulator is connected directly to the battery. The magnetism created in
the winding attracts the relay armature toward the core, causing the contacts to close. This connects the
alternator field winding directly to the battery, allowing field current to flow from the battery to the regulator No.
3 terminal, through the field relay contacts and then through the voltage regulator lower or series contacts.
Current continues to flow to the regulator “F” terminal, and then through the alternator field winding to ground.
9. When the alternator begins to operate, AC voltages are generated in the stator windings, and these voltages
are then changed or rectified to a DC voltage which appears at the “BAT” or output terminal on the alternator.
Figure 6. Typical Wiring Diagram Showing Internal Circuits. 03
0003-9
TM 5-3805-255-14 0003

Regulator – Continued
10. As the speed of the alternator increases, the voltage at the “BAT” terminal also increases. This impresses a
higher voltage through the field relay contacts and across the voltage regulator shunt winding. The increased
magnetism created by the higher voltage across the winding causes the lower contacts to separate, and field
current then flows through a resistor resulting in reduced field current. This reduced field current causes the
alternator voltage to decrease, which decreases the magnetic pull of the voltage regulator shunt winding. The
spring causes the contacts to reclose, and the cycle then repeats many times per second to limit the alternator
voltage to a pre-set value. As the alternator speed increases even further, the resistor connected across the
contacts is not of sufficiently high value to maintain voltage control on the series contacts. Therefore, the
voltage increases slightly causing the upper or shorting contacts to close. When this happens, the alternator
field winding is shorted and no current passes through the winding. With no current in the field winding, the
alternator voltage decreases, which also decreases the magnetism in the shunt winding and the upper or
shorting contact points open. With these points open, field current flows through the resistor and the field
winding. As the voltage increases, the contacts re-close. This cycle then repeats many times per second to
limit the alternator voltage to a pre-set value at high alternator speeds. The voltage regulator unit thus operates
to limit the value of alternator voltage throughout its speed range. Consequently the electrical accessories are
protected from too high voltage which would damage them.
Batteries 0003
1. A lead-acid storage battery (Figure 7) of the type used in the electrical system of the loader, does not store
electricity. The hard rubber case stores the chemical ingredients necessary to produce electrical energy. This
energy is produced only when a circuit to which the battery is connected is completed. During periods of
inactivity, when no electrical energy is being supplied, a slow chemical breakdown or discharge is taking place.
If the period of idleness is of sufficient length a condition known as a permanent sulfation will develop. Once
permanently sulfated, a battery cannot be restored to its normal maximum capacity. Routine battery service
greatly extends the useful life of the battery.
2. A storage battery is an electrochemical device for converting chemical energy into electrical energy. The
battery has three major functions:
a. To provide a source of current for cranking the engine.
b. To act as a stabilizer to the voltage in the electrical system.
c. It can, for a limited period, furnish current when the electrical demands of the vehicle exceed the output of
the alternator.
3. The amount of energy that a fully charged battery can produce depends primarily upon the size and number of
the plates.
4. The total energy that a good battery can produce when at full charge is indicated by its reserve capacity rating.
A 120 minute reserve capacity battery has greater capacity for storing energy and doing work than a 100
minute reserve capacity battery because the 120 minute battery has larger plates or a greater number of
plates. The reserve capacity rating of a battery is usually stamped or printed on the battery case.
0003-10
TM 5-3805-255-14 0003

Batteries – Continued 0003
5. A battery should be maintained at not less than 3/4 full charge in normal operation. If it is found that the battery
is less than 3/4 charged, it is almost certain that some condition exists which should be corrected.
Figure 7. Typical 6VDC Storage Battery. 03
0003-11
TM 5-3805-255-14 0003

Common Causes of Battery Failure 0003
1. Check these common causes first:

a. Resistance in the charging circuit.
b. Defective alternator or slipping alternator drive belt.
c. Improper regulator adjustment, or faulty regulator.
d. Overload due to defective starting system, or excessive use of accessories.
e. Dirt and electrolyte on top of battery causing a constant drain.
f. Hardened battery plates, commonly called “sulfation,” due to the battery being in a low state of charge over
a period of time.
g. Physical defects such as shorted cells, loss of active material from the plates, warped plates, broken
terminals, etc.
2. It is important to note that, of the seven common causes of battery failure listed, the first five causes are
outside the battery. Any one of these conditions will result in a battery being at less than normal state of
charge.
3. The sixth cause listed can result from any one of the first five causes. That is, sulfation occurs when any
condition causes the battery to be undercharged for long periods of time. When a battery becomes sulfated, it
will not accept a normal rate of charge and also, its capacity decreases. Sulfation can usually be overcome by
prolonged slow charging or by discharging the battery completely, letting it stand discharged for 6 to 12 hours,
and then recharging it slowly.
4. The causes of battery failure listed last are the defects that can occur in the battery itself. If shorted cells or loss
of active material from the plates occurs when the battery has been in service for less than its guaranteed life,
it is usually a result of overworking or overcharging of the battery. Cracked cases, broken terminals, and
shorted cells can be caused by improper handling of the battery or a faulty battery carrier.
Freezing Points of Electrolyte 0003
The electrolyte of a battery will start to freeze (first ice crystals begin to appear in the electrolyte although it does
not freeze solid until a lower temperature is reached) approximately as indicated below (specific gravity readings
corrected to 80°F).
1.280 sp. gr.................... Freezes at -90°F (-68°C)
1.150 sp. gr.................... Freezes at +15°F (-9°C)
1.100 sp. gr.................... Freezes at +19°F (-7°C)
Effect of Low Temperatures on Battery Performance 0003
Battery capacity is greatly reduced by cold, as cold has a decided numbing effect on the electro-chemical action in
the battery. The following comparison indicates the reduction in cranking power of a fully charged battery when the
temperature of the electrolyte drops from 80°F (27°C) to 32°F (0°C) and to 0°F (-18°C).
80°F (27°C) 100%

32°F (0°C) 65%
0°F (-18°C) 40%
0003-12
TM 5-3805-255-14 0003

Starter 0003
1. A simple description of the cranking motor, commonly referred to as the “starter,” is an electric motor used to
rotate the engine crankshaft during the starting procedure. It is capable of producing high horsepower and
torque. This high output is restricted to very short intervals; 30 seconds or less. During its periods of operation
the motor is actually overloaded and if subjected to long periods of continuous operation will burn itself out.
2. One end of the starter is fitted with a pinion gear to engage the engine flywheel and one of several different
engagement mechanisms. Mounted on top of the motor housing is a heavy duty solenoid used to actuate the
engaging mechanism. The ratio of the drive pinion to the flywheel ring gear is approximately 15 or 20 to 1; that
is 20 teeth on the ring gear for each tooth on the pinion. This allows the starter to operate at high RPM and
exert a considerable amount of torque.
Figure 8. Diesel Engine Starter - Cross-Section. 03
0003-13
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TRANSMISSION 0003
1. The full power shift transmission is designed to increase the useful range of the torque converter. A
countershaft design with hydraulically actuated clutches is employed. First range increases power for starting
and as the demand on the converter diminishes the transmission may be progressively shifted into higher
ranges. The transmission incorporates gearing designed to take extremely wide ranges and types of work
performed in the construction industry.
2. The transmission has four speeds in both forward and reverse and full power shift in all ranges.
Figure 9. Front of Transmission. 03
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TRANSMISSION – CONTINUED
Figure 10. Rear of Transmission. 03
Shift Modulator 0003
1. Change of direction while the loader is in motion is an undesirable operating technique.

2. The shift modulator system was designed to protect the loader from damage resulting from directional shifting
while the loader is in motion.
Torque Converter 0003
1. The converter housing contains a single stage, single phase, three element torque converter, an input charging
pump and a power take-off (PTO) to drive the loader system pump and the combination power steering-cooling
circuit pump.
2. The PTO gear, fixed to the torque converter impeller drives a pair of pump gears mounted to the accessory
drive housing. The loader system pump and the power steering pump are splined to the hubs of the pump
gears.
0003-15
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PROPELLER SHAFT/UNIVERSAL JOINTS 0003
General Information 0003
1. The purpose of the propeller shafts is to transmit power. All the propeller shafts on the loader are similar in
construction. There is a universal joint located at each end of the shaft to permit pivoting in all directions and
accommodate any misalignment. A slip joint is provided to allow the shaft to telescope, to compensate for
changes in the distance between the connected components.
2. During normal operation, the rear axle undergoes considerable axial movement due to surface irregularities
and varying axle loads. Each time these conditions are encountered, a proportional change in the overall
length of the propeller shaft occurs. The slip joint accommodates these variations by telescoping. This
eliminates the forces of tension that would be present in a shaft not so equipped.
Figure 11. Propeller Shafts. 03
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PROPELLER SHAFT/UNIVERSAL JOINTS – CONTINUED

Transfer Drive 0003
The transfer drive transmits power from the transmission to the front differential across the loader articulation point.
The transfer drive consists of a shaft supported by two roller bearing assemblies, held in a lubricant filled housing.
A yoke is attached to each end of the shaft. The parking brake assembly is mounted on the rear of the transfer
drive.
Figure 12. Transfer Drive. 03
0003-17
TM 5-3805-255-14 0003
FRONT AND REAR AXLES 0003
1. The axle assemblies accomplish three main functions: transmit the out-going twisting force (torque) at 90° to
the left and right of its input direction, increase the input torque through reduction gearing, and provide a
means of securing the wheels and at the same time support the loader. To each of these main functions
several secondary requirements are added suggesting a complex piece of machinery. In reality, each axle uses
a minimum of parts to carry out its many functions. Simplicity of design increases reliability and provides easy
servicing.
2. Both axles are full floating, double reduction type. The axles are rigidly attached to their supporting members;
the front main frame in the case of the front axle and an oscillating cradle called a bolster for the rear. By
allowing the rear axle to oscillate, the loader is assured great stability in rough terrain.
3. The first gear reduction takes place in the differential; the second in the planetaries. Each wheel revolves on
two tapered roller bearings mounted on the axle spindle. The axles are full floating in that none of the weight is
supported by, or transmitted to, the axle shafts. All weight on the axle is supported by the wheels, bearings,
and axle housing.
4. The differential assemblies are rigidly mounted; one on the forward side of the rear axle housing and one on
the rear side of the front axle housing. The differentials are connected by splined yokes to the yokes on the
propeller shafts from the transmission.
5. The basic differential consists of a hypoid ring gear, pinion gear, and spider gear assembly. The differential and
spider gear assembly rotate on tapered roller bearings. The pinion is straddle mounted, having two tapered
roller bearings in front of the pinion teeth to take the forward and reverse thrust and a straight roller bearing
behind the pinion teeth to take the forward and reverse thrust and a straight roller bearing behind the pinion
teeth to carry the radial load.
6. Three functions of the differential are transmitting torque from the propeller shaft to the axle shafts, producing
the first torque multiplication in the double reduction axles, and allowing one drive wheel to rotate at a different
speed than the opposite wheel.
Figure 13. Typical Solid Axle. 03
0003-18
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BRAKE SYSTEM 0003
Brake System General Information 0003
The loader brake system is a combination air over hydraulic type. An engine driven compressor supplies com-
pressed air for the system. The compressed air is stored in the air reservoir. Air compressor output is regulated by
a governor which is located between the compressor and the reservoir. Brake operation is controlled by two brake
treadle valves. When a brake treadle is depressed, a flow of compressed air is directed from the reservoir to the
power clusters. The air cylinders in the power clusters then act upon the hydraulic cylinder portions directing a flow
of hydraulic fluid to the wheel cylinders in each brake assembly, applying the wheel brakes.
The late type system includes valving in the left-hand treadle valve to apply the brakes automatically when the
pressure drops to 50 psi (344.7 kPa). A warning buzzer sounds when the pressure drops to 60 psi (413.6 kPa).
Figure 14. Brake System Schematic. 03
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BRAKE SYSTEM – CONTINUED
Figure 15. Brake System Schematic. 03
0003-20
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BRAKE SYSTEM – CONTINUED 0003
Air Control System 0003
The modulator air system consists of a pressure regulator which receives system air pressure from a bottom port
on the right treadle valve and reduces the system pressure from 105 to 70 psi (723.9 to 482.6 kPa), an air solenoid
valve which controls air flow from the pressure regulator, and a double check valve which channels air flow to the
double check valve on the right treadle (for brake application) and to the neutral knockdown valve (for transmission
disconnect). A third air line between the double check valve and a top port on the left treadle allows (upon full
application of either left or right treadle) full system air pressure 105 psi (723.9 kPa) to override the modulator
application 70 psi (482.6 kPa) of the brakes and neutral knockdown valve.
Pressure Regulator Check and Adjustment. The pressure regulator has an air pressure gauge in the body of
the regulator. The gauge should not read over 70 psi (482.6 kPa). If the pressure indicated is not below 70 psi
(482.6 kPa), loosen the locknut and turn the adjusting screw. Apply a brake treadle several times till the air
pressure is below 70 psi (482.6 kPa). Then back off the adjusting screw until compression is released from
pressure spring. Re-adjust pressure by turning adjusting screw clockwise until the 70 psi (482.6 kPa) pressure is
reached. Tighten the locknut.
0003-21
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Figure 16. Air Control System. 03
0003-22
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Pressure Regulator 0003
The pressure regulator limits the pressure of the air flowing to the air solenoid valve from the reservoir.
Air pressure flows through a cartridge assembly and is also applied against the lower side of the diaphragm
opposing the thrust of the control spring, holding the cartridge open. When the air pressure against the diaphragm
exceeds the valve setting, the control spring is overcome and the diaphragm is raised, allowing the compensating
spring to close the cartridge. When the pressure drops, the control spring forces the cartridge open and pressure
again passes through the valve. The regulated pressure is adjusted by the adjusting screw, changing the amount
of compression maintained on the control spring.
Figure 17. Cutaway of Pressure Regulator. 03
0003-23
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Air Solenoid Valve 0003
Air from the pressure regulator enters the valve (Figure 18, Item 1) and into the cavity in back of the spindle
assembly where it is sealed off. Flow also enters the pilot passageway (Figure 18, Item 2) to the diaphragm where
it is sealed off by the plunger (Figure 18, Item 3).
Figure 18. Cutaway of Air Solenoid Valve (Closed). 03
0003-24
TM 5-3805-255-14 0003
When the coil (Figure 19, Item 4) is energized, the plunger moves upward against the stop. The upward movement
allows the air flow from passageway (Figure 19, Item 2) into the passageway (Figure 19, Item 5) to the diaphragm.
The air pressure in the diaphragm cavity overcomes the spring force on the opposite end of the spindle. The spin-
dle movement allows the flow (Figure 19, Item 1) into the spindle cavity and through the outlet port (Figure 19, Item
6) to the transmission and brakes.
Figure 19. Cutaway of Air Solenoid Valve (Opened). 03
0003-25
TM 5-3805-255-14 0003
When the coil (Figure 20, Item 4) is de-energized, the plunger (Figure 20, Item 3) is returned to its seat by the
plunger spring. This movement seals off the air flow from the passageway (Figure 20, Item 2) and opens the
exhaust passageway (Figure 20, Item 7). The force of the spring on the spindle end overcomes the air pressure in
the diaphragm cavity causing the air to flow through the passageway (Figure 20, Item 5), around the plunger
(Figure 20, Item 3), through the exhaust passageway (Figure 20, Item 7), and out the exhaust port (Figure 20,
Item 8).
Figure 20. Cutaway of Air Solenoid Valve (Closed). 03
STEERING SYSTEM 0003
The steering gear is a recirculating ball bearing, worm and nut type.
The recirculating ball type gear consists of a ball nut connected to the steering worm and in mesh with the sector
gear through precision finished helical grooves in the worm. The ball bearings roll within these grooves when the
steering wheel is turned. There are two complete circuits using tubular ball guides to deflect the balls away from
their helical path at one end of the grooves and guide them back to the other end.
0003-26
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FRAME 0003
Chassis 0003
The chassis components are divided into four groups to simplify maintenance and to provide a better
understanding of each group. The groups (Figure 21) are as follows: main frame, sheet cowling, operator’s
compartment, and boom and bucket.
Figure 21. Chassis Components. 03
Main Frame 0003
The forward portion of the articulated frame provides a mount for the operator’s compartment. Seated on the
forward portion, the operator is always in line with the bucket allowing a greater degree of control and operating
accuracy. The rear section of the main frame provides a platform to mount the engine, converter, transmission,
grille, and bulkhead.
In addition to their center hinge pins the frame sections are linked together by a pair of steering cylinders. The
bases of the cylinders are anchored in the forward frame section with the rod ends pinned to the rear section. As
one cylinder extends, the opposite contracts, pivoting the frame sections on the hinge pins and steering the loader.
This type of articulated steering has definite advantages; it eliminates the need for a steering axle with its additional
parts, eliminates the drag link and tie rod and allows the rear wheels to track in the path of the front wheels. This
latter item ensures a much shorter turning radius than that afforded by the more conventional rigid frame and
steering axle type.
The front axle is fastened directly to the forward frame section. The rear axle is connected to a bolster which in turn
is fastened by two pins to the rear frame section. This allows the rear axle to oscillate on uneven terrain.
0003-27
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FRAME – CONTINUED
Each main frame component is composed of many smaller items welded together to form a single rigid assembly,
Bushings are pressed into bores at pivot points and the counterweight is bolted to the rear of the frame section.
The two frame sections are connected at their hinge points by a pin and bearing assembly. The rear axle bolster is
connected to the rear main frame by a pin and bushing arrangement.
The frame locking bar is pinned and locked to the side of the rear frame section in its rest position. The bar and
pins are used to lock the two tractor halves when the loader is serviced or transported.
Figure 22. Main Frame Assembly. 03
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FRAME – CONTINUED
Sheet Cowling 0003
The sheet cowling, as in the case of the main frame, is made primarily by joining various weldments. The support,
assisted by the grille forms a backbone for the sheet cowling. The hood supported by the support and grille
provides the suspension member for the hood side panels. The battery boxes, both left and right, are weldments to
the front support that bolts to the rear main frame weldment. To these boxes the cover assemblies are added.
Figure 23. Sheet Cowling. 03
0003-29
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FRAME – CONTINUED
Operator’s Compartment 0003
The operator’s compartment is composed of the compartment enclosure, the instrument panel and box assembly,
the operator’s seat assembly and the compartment floorboards.
The compartment enclosure is bolted to the front main frame with the operator’s seat assembly mounted on a
raised platform at the rear of the enclosure. The seat height is controlled by the adjustable mounting bracket.
Directional movement of the seat is controlled by a spring loaded ratchet device. A handle to operate the locking
mechanism is provided. A second locking device allows the seat to be tipped forward during periods of inactivity.
This protects the cushions from the heat of the sun and inclement weather.
The loader control levers are mounted to the upright portion of the elevated platform and to the right of the
operator. Just forward of these control levers is the boom kick-out control. The heater is mounted to the upright
portion of the elevated platform and to the right of the operator.
The air horn control valve button is mounted on the floorboard beneath the transmission control levers, to the left of
the operator.
The two brake pedals and accelerator pedal are mounted on the front floorboard and the transmission control
cables, hand throttle linkage, and steering gear shaft pass through it.
Figure 24. Operator’s Compartment. 03
0003-30
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FRAME – CONTINUED
The instrument panel and box are mounted on the front main frame, to the left of the operator’s seat. All wires
leading to the instrument panel pass through a common connector at the base of the instrument box.
The hydraulic control valve is fastened beneath the platform floor in the right rear corner of the enclosure.
Boom and Bucket 0003
The loader linkage and bucket transform the energy produced by the loader hydraulics into a visible working force.
The hydraulic lift cylinders raise and lower the boom and the bucket cylinder actuates the bucket through the
bellcrank and bucket link. The bucket may be moved from the fully retracted to the fully dumped position in a few
seconds.
The boom is of welded steel construction. The bellcrank, joining the boom arms at its pivot point, is a one piece
casting.
Figure 25. Boom and Bucket (4.5 cu. Yard Bucket Shown). 03
0003-31
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FRAME – CONTINUED
The heavy bucket link transfers the stroke of the bucket cylinder rod, multiplied by the bellcrank, to the bucket. The
bucket is heavily ribbed for added strength. Locking pins retain the bucket to the boom and dump link. The 4.5 cu.
yard bucket is equipped with a replaceable, weld on, cutting edge. The 5 cu. yard bucket is equipped with
replaceable teeth.
The automatic boom kick-out control will automatically stop the boom at any preselected height. The control is air
operated and supplied by the right hand brake treadle valve. Pressurized air leaving the treadle valve is piped to
the control valve. The control valve responds to the movement of the cam follower and valve lever.
Figure 26. Boom Kick-Out Control System. 03
0003-32
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HYDRAULIC AND FLUID SYSTEMS 0003
Reservoir 0003
Type: Closed system with controlled pressure and vacuum relief.

Construction: Cylindrical shape with 0.125 in. (3.17 mm) wall thickness, 19.75 in. (501.6 mm) diameter x 34.75 in.
(882.6 mm) high and removable cover.
Vacuum valve setting, 2.3 psi (15.8 kPa)
Pressure relief valve setting, 30 psi (206.8 kPa)
Relief valve spring, correct adjusted length, 3 in. (7.62 cm).
Pressure required to deflect relief valve spring 0.10 in. 6.7 lb.
Filters: Four replaceable, pleated paper, radial fin type elements rated at 5 microns each.
Burst pressure, 100 psi minimum.
Flow rate, inside out, 60 gpm (227.1 L/M) at 15 psi (103.4 kPa) with SAE 10 oil at 100°F (37.7 C).
Strainers #6 square mesh wire cloth.
Capacity, “H” mark on dipstick = 35 gal. (132.4 L), reservoir only.
Pumps 0003
Type:
Main pump: vane, double element, positive displacement.
Steering pump: vane, single element, positive displacement.
Rotation: Counterclockwise as viewed from shaft end.
Pump capacity: (1,200 RPM, 100 psi)
Main pump:
Small element, 21 gpm (79.4 L/M).
Large element, 38 gpm (143.8 L/M).
Steering pump: 25 gpm (94.6 L/M).
Main Control Valve 0003
Type:
Two spool, balanced spool design with integral pilot operated relief valve.
Relief valve setting:
Main relief: 2300 ± 50 psi (15,857.9 ± 344.7 kPa) at full throttle.
Cylinder relief: 3000 ± 50 psi (20,684.2 ± 344.7 kPa) at full throttle.
Rating:
102 gpm (386.1 L/M) at velocity of 22 ft/sec.
Steering Valve 0003
Type:
Plunger operated.
Circuit pressures: Refer to System Pressures.
Demand Valve 0003
Type:
Pressure operated, non-adjustable.
0003-33
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HYDRAULIC AND FLUID SYSTEMS – CONTINUED

Boom Cylinders 0003
Type:
Double acting.
Diameter of bore, 6 in. (15.2 cm).
Stroke (pin C/L to pin C/L), 50 in. (127cm).
Extended length (pin C/L to pin C/L), 120 in. (304.8 cm).
Retracted length (pin C/L to pin C/L), 70 in. (177.8 cm).
Steering Cylinders 0003
Type:
Double acting.
Diameter of bore, 4.5 in. (11.4 cm).
Stroke (pin C/L to pin C/L), 20.5 in. (52 cm).
Extended length (pin C/L to pin C/L), 58 in. (147.3 cm).
Retracted length (pin C/L to pin C/L), 37.5 in. (95.2 cm).
Linkage Rate of Travel 0003
Boom raises, empty, 6.7/7.5 sec.

Boom lowers, empty (float position), 4.8/5.4 sec.
Bucket retracts, empty, 2.5/2.9 sec.
Bucket dumps, empty, 1.9/2.3 sec.
END OF WORK PACKAGE
0003-34
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TM 5-3805-255-14
CHAPTER 2
OPERATOR INSTRUCTIONS
12
TM 5-3805-255-14 0004
OPERATOR MAINTENANCE -
0 0 0 4 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS
0004-1
TM 5-3805-255-14 0004
GENERAL 0004
This work package describes, locates, and illustrates the controls and indicators used on the H100C Loader.
Become familiar with the location and function of all operator controls and indicators described in this work
package before operating or performing operator maintenance on the loader.
OPERATOR CONTROLS 0004
Figure 1. Controls. 04
KEY 04 COMPONENT OR INDICATOR 04 DESCRIPTION 04
1 Transmission Gear Select Range This lever is used to select any one of the transmission
Lever gear ranges.
2 Transmission Direction Lever This lever is used to select loader direction.
3 Engine Shutdown Control The engine shutdown control is located to the left of the
steering column on the underside of the instrument
panel box. Pull the control handle out all the way to shut
the engine down. After the engine has stopped
completely, push the handle back in. The shutdown
control stops the fuel supply to the engine.
0004-2
TM 5-3805-255-14 0004
OPERATOR CONTROLS – CONTINUED
4 Steering Wheel The steering wheel operates the steering valve, which
directs hydraulic fluid into the steering cylinders. When
the steering wheel is turned clockwise, the steering
cylinders articulate the loader so a right turn can be
made. When the steering wheel is turned
counterclockwise, the loader is articulated so a left turn
can be made. The loader continues to articulate as long
as you turn the steering wheel. When you stop turning
the steering wheel, the loader will remain in its current
articulated position.
5 Hand Throttle Control The hand throttle is used to keep the engine running at
a speed higher than low idle without keeping the
accelerator pedal depressed. Turn the handle to the left
or right to unlock it. Pull the control out until the engine
is running at the desired speed. Turn the handle to the
left or right to lock it into this position. Push the control in
before leaving the operator’s compartment.
6 Parking Brake Warning Light This light will be on when the parking brake is applied
and the ignition switch is turned on.
7 Ether Button NOTE

The ether injector should be used only when the
air temperature is below freezing.
The ether injector button injects ether into the engine
when pressed down. The ether aids in starting the
engine during cold weather.
Refer to WP 0005 for operation of the ether injector.
8 Parking Brake Lever CAUTION

The parking brake should always be applied
when the operator is not in the driver’s seat.
To apply the parking brake push the lever up and
forward; to release pull back and down. It is
recommended that the parking brake only be used to
hold the loader after it has come to a stop. However,
should the brake system ever fail, the parking brake
may be used to make an emergency stop.
9 Boom Stop Positioner Control The boom is equipped with an air operated stop
positioner system. The system will automatically stop
the boom to any preselected position of its raising arc.
0004-3
TM 5-3805-255-14 0004
Figure 2. Controls. 04
10 Window Wiper Control Knob Pull the wiper control knob out to turn the window wipers
on. Push the knob in to turn them off. After turning on
the wipers, the speed may be increased by turning the
knob clockwise or decreased by turning the knob
counterclockwise.
11 Boom Control Lever CAUTION

The boom assembly, if raised, can be lowered
any time the lever is moved to float or lower
position whether the engine is running or not.
Always lower the boom to the ground when it is
not in use.
The boom control lever is the far right lever to the right
of the operator’s seat. This lever controls the raising and
lower operation of the booms. Refer to Loading
Mechanism Operation in WP 0005 for additional
information.
0004-4
TM 5-3805-255-14 0004
12 Bucket Control Lever The bucket control lever is the left lever to the right of
the operator’s seat. This lever controls the roll back and
dump operations of the bucket. Refer to Loading
Mechanism Operation in WP 0005 for additional
information.
13 Accelerator Pedal Depress this pedal to increase engine speed; release

the pedal to decrease engine speed.
14 Brake Pedal Depress the brake pedal according to the loader's

speed and the road conditions when slowly release the
pedal as the loader’s speed decreases. When the
loader comes to a complete stop, there should only be
enough pressure to hold it stationary.
15 Brake and Transmission This pedal works in the same manner as the brake
Disconnect Pedal pedal except that it also stops clutch pressure in the
transmission. When this pedal is depressed no power
can be transmitted thorough the transmission and full
engine power can be used to operate the loader hydrau-
lics while braking.
16 Horn Button Horn button is located on floorboard to left of brake and

transmission disconnect pedal. Step on button to sound
horn.
17 Seat For operator’s convenience in reaching the controls and

improved operating visibility, the operator’s seat can be
adjusted to various positions.
CAUTION
Do not adjust the seat position while the loader
is in motion.
The height can be adjusted by removing the two height
adjustment bolts that secure the inner posts to the outer
post and lining up the holes in both posts at a high or
lower setting. Be sure to replace the two bolts with the
heads of the bolts towards the front of the seat.
To adjust the seat forward or backward, pull the slide
release lever under the seat to the left and slide the seat
to the desired position: then release the lever. The
height can be adjusted by removing the two bolts from
both sides of the seat base and lining up the holes at a
higher or lower setting: then reinstalling the bolts. The
seat is hinged to the base and can be tilted all the way
forward. Pull the tilt release chain at the lower front of
the seat to release the latch that is securing the seat.
0004-5
TM 5-3805-255-14 0004
Figure 3. Controls.
KEY COMPONENT OR INDICATOR DESCRIPTION

Seat (Continued) Keep seat belts flat to avoid twisting when not being
used. Do not place heavy or sharp objects on the belts.
The entire seat belt assembly should be inspected
periodically for corrosion, wear, fraying or weak spots.
The seat belt mounting bolts should be periodically
inspected for looseness. Replace if necessary.
18 Instrument Panel The instrument panel contains various gauges you must
check after starting and at frequent intervals during
operation to assure proper care through prompt
detection of irregularities.
0004-6
TM 5-3805-255-14 0004
Figure 4. Instrument Panel. 04
1 Service Recorder The service recorder is geared to the engine, and when
the crankshaft turns a specific number of revolutions in
an hour at average operating speeds on an average job
application, the dial advances one number.
2 Transmission Oil Temperature NOTE

Gauge
Continual high fluid
temperatures should be
corrected before resuming
operations.
This gauge registers the temperature of the fluid in the
torque converter. After the engine has operated suffi-
ciently to reach a stabilized torque converter tempera-
ture, tap the gauge lightly to check the reading.
3 Air Pressure Gauge This gauge registers amount of air pressure in air tank.
Tap gauge lightly when checking the gauge reading.
Unit should not be moved until gauge is registering in
“RUN” (green) segment of gauge.
4 Fuel Level Gauge This gauge is electrically operated and indicates the
available fuel supply in he fuel tank. Tap the gauge
lightly when taking a reading.
0004-7
TM 5-3805-255-14 0004
Figure 5. Instrument Panel. 04
5 Engine Oil Pressure Gauge This gauge shows the pressure at which the lubricating
oil is circulating through the engine. This gauge must
register in the “IDLE” range immediately upon starting.
When engine is operated at full load speed, pointer
must be in (green) “RUN” range. Stop engine
immediately and investigate cause if little or no pressure
is indicated.
6 Starter Switch CAUTION

Never press starter switch
while engine is running. This
will damage starter and engine
flywheel.
Turn the combination switch to ignition position and
press starter switch to crank engine. After engine starts
to run release starter switch.
7 Engine Coolant Temperature This gauge shows temperature of coolant circulating

Gauge through engine. After engine has operated a sufficient
length of time pointer of gauge must be in (green)
“RUN” range.
0004-8
TM 5-3805-255-14 0004
8 Voltmeter Voltmeter indicates the condition of batteries. When

engine is not running or is running at low idle speed,
gauge pointer should be within left green area, which
indicates a good battery charge. If voltage drops below
left green area at low idle speed, batteries should be
checked. With engine operating above low idle speed,
gauge pointer should be within right green area, which
is normal operating range. If voltage drops below right
green area, batteries and/or alternator should be
checked.
9 Light Switch NOTE

Ignition switch must be turned
ON before lights will operate.
Light switch has two positions. When pulled out to first
position front driving lights, tail, and stop lights, and
instrument panel lights will come on. If pulled out to sec-
ond position, rear driving lights will also come on. Push
switch all the way in to turn lights off. If loader is
equipped with low-level lights, they will go on and off the
same time as driving lights.
10 Ignition Switch Ignition switch has two positions: ON and OFF in OFF
position there is no electric current flow to any circuit. In
ON position electric current is allowed to flow to all cir-
cuits. Ignition switch must be in ON position before
engine can be started or cranked.
11 Lock Box Instrument panel is equipped with a lock box over igni-
tion switch and light switch. This box can be locked
closed to prevent unauthorized people from starting
loader or turning electrical components on which could
drain charge in batteries.
0004-9
TM 5-3805-255-14 0004
CONTROLS AND INDICATORS 0004
Figure 6. Air Cleaner Service Indicator. 04
1 Air Cleaner Service Indicator Air cleaner service indicator signals when air filter
element service is required. After servicing element,
press reset button to reset indicator.
0004-10
TM 5-3805-255-14 0004
CONTROLS AND INDICATORS – CONTINUED
Figure 7. Heater and Defroster Control. 04
1 Heater and Defroster Control Heater and defroster are controlled by a two speed
toggle switch.
NOTE
The heater unit is connected to engine by water
hoses. Each hose is connected to a shut-off
valve at engine. Be sure the valves are open
when heater and defroster are being operated.
Turn off valves when heater is not being used
during warm seasons.
This heater unit is also a cab pressurizer. Pressurizer
can be used during warm seasons without heat by
closing the heater hose shut-off valves at engine.
0004-11
TM 5-3805-255-14 0004
CONTROLS AND INDICATORS – CONTINUED
Figure 8. Master Electrical Switch. 04
1 Master Electrical Switch Turn the switch OFF to cut out the electrical system.
Remove the key to lock the switch in the OFF position.
NORMAL GAUGE READINGS 0004
Table 1. Gauge Readings.
I.H.C.
DT-817C
SYSTEM GAUGE
MINIMUM MAXIMUM
Engine Water Temperature 180°F 195°F

(82.2°C) (90.5°C)
Oil Pressure 45 PSI* 60 PSI*
(310.2 kPa) (413.6 kPa)
* At 2,310 + 50 RPM
END OF WORK PACKAGE
0004-12
28
TM 5-3805-255-14 0005
OPERATOR INSTRUCTIONS -
OPERATION UNDER USUAL CONDITIONS

0 0 0 5
General Warnings, Safety Bar and Pins, Loader Precautions, Starting the Engine, Driving the Loader,
Loading Mechanism Operation, Stopping the Loader, Parking the Loader, Stopping the Engine,
Operating Techniques, Access Panel Removal and Installation, Fan Guard Removal and Installation
INITIAL SETUP
References 0
WP 0004 0
GENERAL WARNINGS 0005
Before starting or operating the loader, follow all the warnings listed below. Failure to follow these warnings may
result in injury or death to personnel and damage to equipment.
• Never operate the engine at more than the regular governed speed shown on the serial
number plate. Excessive speeds are harmful and dangerous.
• Use caution in removing radiator cap when the engine is hot.
• Never refuel while the engine is running.
• Do not smoke while refueling.
• PROVIDE PROPER VENTILATION WHEN OPERATING A LOADER IN A CLOSED
BUILDING.
• ONLY ONE PERSON, THE OPERATOR, SHOULD BE PERMITTED TO RIDE ON THE
LOADER WHEN IT IS IN OPERATION.
• Use appropriate cleaning solution for cleaning parts unless otherwise specified.
• Never operate the engine when cleaning or lubricating the loader.
• When it is required to make any checks with the engine running, always use two men; one
man must be in the operator's seat while the other does the checking. As an added
precaution, when making checks with the engine running, place the transmission
directional lever in the neutral (N) position, apply the parking brake, and install safety bar
and pins.
• CLEAR IMMEDIATE AREA OF PERSONNEL OR OBSTRUCTIONS BEFORE STARTING
ENGINE.
• BEFORE DRIVING LOADER FASTEN SEAT BELT.
• AFTER STARTING ENGINE BUT BEFORE MOVING THE LOADER, WARN NEARBY
PERSONNEL WITH THE HORN.
• When leaving the loader unattended, always place the transmission directional lever in
neutral (N) position and apply the parking brake.
0005-1
TM 5-3805-255-14 0005
GENERAL WARNINGS – CONTINUED

• Never leave the loader unattended while the engine is running. When parking the loader,
be sure bucket is lowered completely to prevent damage or injury possibilities. Do not
allow the hydraulic system to support the booms when leaving the loader unattended.
• Carry bucket low for maximum visibility.
• Lower bucket before making hydraulic adjustments. To prevent personal injury, be sure no
personnel are standing in the way of the bucket when it is being lowered.
• Never work beneath bucket without proper blocking.
• Always sit in the operator's seat before operating any controls.
• Never wear a seat belt across the abdomen.
• Federal regulations prohibit repair to ROPS after damage occurs. DO NOT attempt to
repair a protective structure for further service after an accident. Repaired structures do
not provide the original strength and protection. Contact Sustainment Maintenance for
information on ROPS replacement.
SAFETY BAR AND PINS 0005
WARNING
DO NOT SERVICE OR TRANSPORT THE LOADER UNLESS THE SAFETY BAR AND
PINS ARE IN PLACE. Failure to follow this warning may result in injury or death to
personnel.
NOTE
The safety bar (Figure 1, Item 2), pins (Figure 1, Item 1), and cotter pin (Figure 1, Item 3)
are shown in stowed position.
Figure 1. Safety Bars and Pins in Stowed Position. 0005
0005-2
TM 5-3805-255-14 0005
SAFETY BAR AND PINS – CONTINUED

1. To lock the loader halves in straight position, the bar (Figure 2, Item 2), two pins (Figure 2, Item 1), and a cotter
pin (Figure 2, Item 3) are used as shown in Figure 2.
Figure 2. Safety Bar in Straight Lock Position. 0005
2. To lock the loader in a full turn, only one pin (Figure 3, Item 1) is used. Turn the loader to its full turn position
and insert the pin through the holes on the closed side of the loader as shown in Figure 3. Lock pin in place
with cotter pin (Figure 3, Item 3). Always check that the bar (Figure 3, Item 2) and pins have been replaced in
storage position on the left side of the loader before operating. Broken or lost safety bar and pins should be
repaired or replaced immediately to ensure that the safety device is always available for use. Do not attempt to
service or transport the loader if the safety bar or pins are broken or missing.
Figure 3. Safety Pin Installed in Full Turn Lock Position. 0005
0005-3
TM 5-3805-255-14 0005
LOADER PRECAUTIONS 0005
Before starting or operating this loader, read the following general precautions. These are listed here to help you
protect the loader and to remind you of protection for yourself and those around you. Sound judgment and
observance of these rules will help make your job a safer one.
1. Do not place the loader under load without the proper engine oil pressure and operating temperature.
2. To prevent any possible damage to the alternator, the electrical system master switch must be in the ON
position when the engine is running. The switch must be in the OFF position only when the engine is shut down
at the end of each day or when the operator leaves the loader unattended.
3. Never shift the transmission into neutral when going downhill. The loader may go out of control or the
transmission, converter or engine may be damaged when the transmission is again placed in gear.
4. During normal operation, the turbocharger must be free from vibration and unusual noises.
STARTING THE ENGINE 0005
CAUTION
The turbocharger must be primed when the engine has been idle for 30 days or more.
Failure to comply could cause damage to equipment.
1. Set electrical system master switch to ON.
2. Be sure parking brake is applied.
3. Be sure transmission directional lever is in neutral (N).
4. Be sure engine shutdown control is fully pushed in.
5. Depress accelerator pedal to one-half engine speed position at temperatures above +50°F (+10°C) or to full-
speed position at temperatures below +50°F (+10°C).
Figure 4. Starting The Engine. 0005
0005-4
TM 5-3805-255-14 0005
STARTING THE ENGINE – CONTINUED

6. Crank engine as follows:
a. NORMAL START: Turn ignition switch to IGNITION and press starter switch. Release starter switch as
soon as engine starts.
CAUTION
• The ether injector should be used only for starting the engine. Misuse of the ether injector
while the engine is running can result in serious damage to the engine.
• The ether injector should be used only when the air temperature is below freezing.
• To avoid possible damage to the starter release the starter button the instant the engine
starts. Never press the button while the engine is running.
• If the engine does not start with a maximum of two ether injections, determine and correct
the cause before attempting again to start the engine.
• Crank engine for 30 seconds at a time. If engine does not start, allow starter to cool two or
three minutes before cranking again.
• Failure to follow these cautions may result in damage to the engine.
b. COLD WEATHER START USING ETHER INJECTOR: Depress accelerator pedal to full speed position.
While cranking engine simultaneously press ether injector button 2 to 3 seconds. If engine does not start
press ether injector button an additional 1 time (2 to 3 seconds) maximum.
7. If engine will not start or runs roughly, it may be due to one of these causes:
a. Air may be in fuel system. Notify Field Maintenance.
b. Ether injector is not functioning properly. Notify Field Maintenance.
c. Fuel filters may be clogged. Notify Field Maintenance.
8. Immediately after engine starts, release accelerator pedal.
CAUTION
Check the engine oil pressure gauge and if no oil pressure is indicated, immediately stop
the engine. Failure to follow this caution may result in damage to the engine.
9. Check all instruments and controls for proper operation (WP 0004).
END OF TASK
0005-5
TM 5-3805-255-14 0005
DRIVING THE LOADER 0005
NOTE
Before operating, check all instruments and controls for proper operation (WP 0004).
1. Depress brake pedal.
2. Release parking brake.
3. Partially accelerate engine and raise bucket enough to clear ground.
4. Set transmission direction lever in desired position.
NOTE
The backup alarm should sound when the transmission direction lever is placed in reverse
(R).
5. Place transmission gear range lever in 1st gear position.
6. Release brake pedal and gradually depress accelerator pedal. Refer to Shifting Gears in this work package for
transmission shifting instructions.
Figure 5. Driving the Loader. 0005
0005-6
TM 5-3805-255-14 0005
DRIVING THE LOADER – CONTINUED

Shifting Gears 0005
The transmission has four forward gear ranges, four reverse gear ranges, and neutral which are manually selected
with the transmission gear range and direction levers.
“1” (1st gear) and “2” (2nd gear) are the main working ranges. “3” (3rd gear) can be used for roading over rough
terrain or roading with a loaded bucket. “4” (4th gear) is used to road the machine for longer distances at maximum
loader speeds. The direction lever N (neutral) position has a neutral start safety switch incorporated in it. The
direction lever must be in N before the engine can be started. “R” (reverse) also has “1” (1st), “2” (2nd), “3” (3rd)
and “4” (4th) gear ranges.
1. Down-Shifting. Range down-shifts (except in emergency) should never be made at a vehicle ground speed
higher than that possible in the next lower gear range. Down-shifting while in motion (especially to 1st speed
range) should be accomplished in a full engine RPM throttle condition.
2. Up-Shifting. Range up-shifts can be made at any time, or engine RPM, at which the higher gear range will
propel the vehicle efficiently. It is recommended to anticipate the engine RPM dictated by the higher gear range
and decelerate the engine accordingly.
3. Directional-Shifting.
a. Decelerate engine in all direction changes.
b. Use right brake treadle to determine stop or cycle distance.
c. Change directional control lever position in a manner to smoothly coordinate: (a) vehicle stop, (b)
transmission reengagement, and (c) engine acceleration.
Steering 0005
The loader is articulated and steering is accomplished by hydraulic power which pivots the main frames at the
center hinge. Turn the steering wheel until reaching the desired angle of turn. Hydraulic power holds the angle of
turn until the steering wheel is again turned.
END OF TASK
LOADING MECHANISM OPERATION 0005
NOTE
Holding a control lever in any position except HOLD or FLOAT for an extended period of
time after the hydraulic cylinder rod has reached the limit of its travel will produce
excessive heat in the hydraulic system which may affect loader performance.
The hydraulic system provides power for the boom and bucket. When the bucket circuit is being operated, flow to
the boom circuit is cut off.
0005-7
TM 5-3805-255-14 0005
LOADING MECHANISM OPERATION – CONTINUED

Boom Control Lever 0005
The boom control lever is the lever at the far right of the operator's seat. It has four positions: RAISE, HOLD,
LOWER, and FLOAT (Figure 6).
CAUTION
The boom assembly, if raised, can be lowered any time the lever is moved to FLOAT or
LOWER position whether the engine is running or not. Always lower the boom to the
ground when it is not in use. Failure to comply could cause damage to equipment.
1. Raise. To raise booms, pull boom control lever back as far as possible. A detent in valve locks lever in this
position. Return HOLD can be done manually or will be done automatically when boom reaches preset
stopping height of boom stop position. Refer to Boom Stop Positioner in this work package for additional
information.
2. Hold. Boom control lever, when not in a detented position, will automatically return to HOLD when released.
Boom will remain stationary in its present position when lever is placed in HOLD position.
3. Lower. Push boom control lever part way forward to lower boom. Lever will automatically return to HOLD when
released.
4. Float. Push boom control lever fully forward for this position. This position is detented so lever must be pulled
back manually to HOLD position. FLOAT position allows bucket to follow contour of ground.
Figure 6. Boom Control Lever Positions. 0005
0005-8
TM 5-3805-255-14 0005

Bucket Control Lever 0005
The bucket control lever is closer to the operator at the right of the operator’s seat. The lever’s three positions are:
DUMP, HOLD, and ROLL BACK (Figure 7).
1. Roll Back. To roll back bucket, pull bucket control lever back. Lever will return to HOLD automatically when
released and stop roll back motion of bucket.
2. Hold. Bucket will stay in its present position when bucket control lever is in HOLD position.
3. Dump. To dump bucket push bucket control lever forward. When lever is released it will automatically return to
HOLD position.
Figure 7. Bucket Control Lever Positions. 0005
0005-9
TM 5-3805-255-14 0005

Boom Stop Positioner 0005
The boom is equipped with an air operated stop positioner system. The system will automatically stop the boom to
any preselected position of its raising arc.
Figure 8. Boom Stop Positioner. 0005
A rod is connected to the boom arm and the positioner control cam plate. When the boom control lever is pulled all
the way back into the detented RAISE position, the rod moves back and turns the cam plate as the boom raises.
Cam follower(s) on actuating lever follows cam surface. When the follower contacts the cam lobe, the actuating
lever upsets the system control valve. The compressed air from the loader’s air system passes from the brake
treadle valve through the upset air valve and into the boom control spool of the main hydraulic valve. The
compressed air acts against a piston in spool assembly. The air pressure on the piston overcomes the detent
plunger spring pressure and spool centering spring returns the spool and boom control lever to the HOLD position.
Automatic Bucket Positioner 0005
The automatic bucket positioner, which is attached to the bucket cylinder, is factory preset to keep the bucket in a
horizontal or digging position, with the cutting edge of bucket parallel to the ground.
The function of the bucket positioner is to cause the bucket to return to its proper digging position automatically
after its load has been dumped and the loader is returning to the work area. After dumping, move the bucket
control lever into its detented ROLL BACK position. When the bucket reaches its preset position, it automatically
stops, and the bucket control lever moves into its HOLD position.
Adjustment. To adjust positioner for a different bucket altitude, loosen bolt securing activating cam (Figure 9).
Move bucket to desired altitude. Turn cam until cam follower on air valve actuating arm is at point in rise of cam
where air valve is actuated. Tighten bolt to secure cam in place.
END OF TASK
0005-10
TM 5-3805-255-14 0005
STOPPING THE LOADER 0005
1. Fully release accelerator pedal (Figure 9, Item 3).
Figure 9. Stopping the Loader. 0005
CAUTION
• Do not use the brake and transmission disconnect pedal when traveling at a fast speed or
when going downhill.
• Do not fan the brakes by repeatedly depressing and releasing the brake pedal. This can
reduce air pressure too low for braking.
• Failure to comply could cause damage to equipment.
2. Apply brake pedal (Figure 9, Item 4) or brake and transmission disconnect pedal (Figure 9, Item 5) until loader
comes to a complete stop.
3. Move transmission direction lever (Figure 9, Item 1) to neutral position (N).
NOTE
Transmission can remain in gear if loader is brought to a temporary stop and operator
does not leave operator’s compartment.
4. Lower bucket to ground.
5. Apply parking brake (Figure 9, Item 2).
0005-11
TM 5-3805-255-14 0005
STOPPING THE LOADER – CONTINUED

Automatic Brake Apply System 0005
The loader is equipped with an “automatic brake apply system” which has a separate, protected, brake system for
each axle. Under normal operating conditions, both braking systems work together and are controlled by either one
of the two treadle valves in the operator’s compartment.
As the term “automatic brake apply system” implies, the regular service brakes will be applied automatically under
certain emergency conditions. These conditions are described below.
Working in conjunction with the automatic brake apply system is an audible warning device (buzzer). Whenever the
air pressure in the wet air reservoir is 60 psi (414 kPa) or less buzzer will sound warning the operator of low air
pressure in the wet air reservoir (and/or low air pressure in one, or both, of the service air reservoirs). This buzzer
warning will give the operator time to prepare for an involuntary stop.
CAUTION
If the low air pressure warning buzzer sounds, stop the loader immediately, apply the
parking brake, investigate and correct the cause of low air pressure. Failure to comply will
damage equipment.
Air loss, in most cases, would be limited to one of the air brake systems. Should rear axle air system fail, front axle
system will continue to meter air pressure above 50 psi (345 kPa) in the wet reservoir. Each service reservoir is
protected by a check valve between it and the air supply (wet tank).
Should air pressure in the wet air reservoir drop to approximately 50 psi (345 kPa) the brakes will be applied
automatically by the action of the emergency protection unit to stop and hold the loader. The brakes will remain
applied until pressure in the wet reservoir again reaches approximately 60 psi (414 kPa).
Loss of air pressure in both of the service air reservoirs will not activate the “automatic brake apply system” and
the loader will not have any service brakes.
END OF TASK
PARKING THE LOADER 0005
1. Park loader in area free of grease or fuel puddles, which cause tire deterioration.
2. Lower hydraulically supported loader equipment to ground to reduce injury possibilities and to gain loader
stability.
WARNING
Parking on a steep slope is not recommended. Failure to follow this warning could result in
injury to personnel or damage to equipment.
3. Park loader on level ground, if at all possible, to avoid unexpected movement, and to obtain accurate coolant,
lubricant, and fuel level checks.
4. If necessary to park on slope, park at right angle, then secure with blocks (front and rear).
END OF TASK
0005-12
TM 5-3805-255-14 0005
STOPPING THE ENGINE 0005
CAUTION
If the following step is neglected, serious engine damage may result.
1. Operate engine at half throttle (no load) for three to five minutes.
2. Pull out and hold engine shutdown control until engine stops. After engine stops, push handle in.
3. Turn ignition switch to OFF.
NOTE
When loader is shut down at the end of the day or if the loader is to be left unattended, the
electrical system master switch may be locked by removing the key.
4. Turn electrical system master switch to OFF (WP 0004).
Figure 10. Stopping the Engine. 0005
END OF TASK
0005-13
TM 5-3805-255-14 0005
OPERATING TECHNIQUES 0005
General 0005
Terrain, footing conditions, types of materials being worked, and maneuvering space determine the speed at which
the loader can function.
When the bucket is at work, keep the engine speed near full throttle and operate in 1st or 2nd gear transmission
range. Use 2nd and 3rd gear range for traveling purposes.
The techniques for using the loader as indicated in Figure 11 are not intended to be all inclusive. Each work
situation will vary. Loader operation may be altered for each particular application for best efficiency.
When possible, start all jobs from relatively level ground. If necessary, level an area large enough to provide
sufficient working space. This prevents back and forth pitching of the loader and will result in easier operation.
Avoid wheel spin whenever possible; this wastes effort and only converts a relatively smooth working area into ruts
and piles that pitch and tilt the loader. In cold weather, this matter can freeze and cause additional difficulty the
following day.
0005-14
TM 5-3805-255-14 0005
OPERATING TECHNIQUES – CONTINUED
Figure 11. Loading Sequence. 0005
0005-15
TM 5-3805-255-14 0005

Bucket Loading 0005
1. Shift transmission to low, forward and open bucket.

2. To make maximum penetrations into material to be moved, open bucket until it is parallel with ground and lower
it to ground level. In this position, bucket cutting edge will meet with least amount of resistance.
NOTE
• It is necessary to operate the bucket control lever intermittently because the bucket
hydraulic circuit overrides the boom circuit.
• Whenever the bucket circuit is in operation, hydraulic pressure in the boom circuit is cut
off.
3. Once bucket enters material, pull boom control lever up to RAISE and start closing bucket. Operate bucket
control lever intermittently to ROLL BACK so boom will raise at a nearly constant rate. Should bucket penetrate
so deep that boom cannot raise properly, back away slightly.
4. Digging in hard material can be aided by “wiggling” bucket edge immediately after penetration. Operate bucket
control lever alternately between its ROLL BACK and DUMP positions. This action will loosen material and
improve bucket loading. Coordinated operation of two hydraulic control levers as bucket enters material will
yield satisfactory bucket loads.
NOTE
The boom assembly need not be fully raised to load the bucket. Maximum bucket loading
will be obtained before the bucket reaches operator eye level.
5. Shift boom control lever to HOLD once bucket has been filled. Back loader away from loading site and lower
bucket to within two feet of ground level. Carry bucket near ground to provide better transporting stability.
Transporting Loads 0005
Transport loads close to the ground. If it is necessary to carry the bucket raised in transit, the operator should use
increased caution. Perform all steering and shifting as smoothly as possible.
The speed used to transport loads should be relative to the bucket carry position and the type of route used. Safety
should be considered at all times. Carry the bucket low and closed. Travel slowly anytime a load is carried over
rough and/or sloping footing. A loaded bucket should never be transported with the boom fully raised.
Use the lower transmission speed range for bucket loading and the transportation of loads. The higher speed
range may be used for making return trips to the loading sites. Carry the bucket low at high road speeds.
0005-16
TM 5-3805-255-14 0005

Filling a Trench 0005
CAUTION
Keep the loader wheels a safe distance from the opening’s edge while working in the
area. Failure to comply could cause damage to equipment.
Fill trenches or excavations by pushing or unloading material into area to be filled with loader at a 90° angle to line
of fill area (Figure 12). Pile material a little higher than ground level to allow for settling.
Figure 12. Filling a Trench. 0005
Rock Loading 0005
1. Load small, loose rocks first. Dislodge large firmly fixed rocks (Figure 13) by first digging around and
underneath rock with bucket. When enough earth has been removed from around rock, lift boom with center of
bucket under one end of rock. This should loosen rock enough to be removed.
Figure 13. Loading Large Rock. 0005
0005-17
TM 5-3805-255-14 0005

Rock Loading — Continued 0005
2. Put enough loose rock or dirt into truck first to act as cushioning material, before proceeding to load larger
rocks. Place large rocks into center of truck from as low a height as possible (Figure 14).
Figure 14. Dumping Large Rock. 0005
3. Lower loaded or unloaded bucket to ground when waiting for any length of time.
4. Always operate loader at speeds slow enough to insure complete operator control. When traveling, carry
bucket low to obtain maximum visibility (Figure 15).
Figure 15. Transporting a Load. 0005
5. Keep work area as clean and level as possible to ensure more efficient and smoother operation (Figure 16).
H100C-0037
Figure 16. Loader Work Area. 0005
0005-18
TM 5-3805-255-14 0005

Rock Loading — Continued 0005
Figure 17. V-Method of Loading. 0005
Figure 18. Step Loading. 0005
0005-19
TM 5-3805-255-14 0005

Dumping Into a Truck or Hopper 0005
1. When dumping into a truck or bin, raise bucket so that it clears top edge safely, and then move loader forward
so bucket is within dumping area (Figure 19). Apply extreme left brake treadle. Position boom control lever in
HOLD. Push bucket control lever slowly forward. This will cause bucket to spill its load. Dumping load slowly
will ease shock of suddenly adding weight to truck or receptacle.
Figure 19. Loading a Truck. 0005
2. After discharging load, operate bucket control lever to close bucket. Use only enough pressure to activate
control valve. When bucket reaches preset position it will kick out and stop bucket.
3. If hopper or car is higher than maximum reach of loader, build a ramp (Figure 20).
4. Move loader to hopper and raise boom to clear sides. Set boom positioner control at proper height.
Figure 20. Hopper Loading. 0005
5. Load bucket as outlined in this work package. Try to maintain stock pile as close to hopper as possible. With
bucket loaded, approach hopper, raising boom during approach.
6. Boom will raise to proper height and stop. Open bucket to dump into hopper, close bucket while reversing, and
return to stock pile for new load.
0005-20
TM 5-3805-255-14 0005
CAUTION
Never travel forward with the bucket in a complete open position on the ground. Serious
damage to loading mechanism can result.
Dumping Into Truck Body 0005
1. Approach truck with bucket raised to clear truck body.

2. As bucket moves over body, move bucket control lever to DUMP position.
3. Continue dumping bucket and raising boom until bucket is empty.
4. Move bucket control lever to ROLL BACK position until bucket positioner stops bucket. Keep bucket raised
above truck body, and back loader away from truck.
Figure 21. Dumping Into Truck Body. 0005
0005-21
TM 5-3805-255-14 0005

Digging or Excavating 0005
When digging or excavating, keep bucket level with ground. Use boom control lever to force bucket cutting edge
into ground as loader moves forward. If cutting edge does not penetrate ground immediately, use bucket control
lever to incline angle of cutting edge slightly to give better penetration. As cutting edge penetrates, use bucket
control lever to adjust bucket cutting depth to prevent excessive penetration. Manipulate boom and bucket control
levers slightly to maintain as good a grade as possible. When maintaining a grade, drive loader in low gear at about
half throttle to make an accurate cut. When bucket is full, tip bucket back and raise it to clear ground. Carry load to
desired dump area.
Figure 22. Digging or Excavating. 0005
Back Dragging or Leveling 0005
1. When back dragging or leveling, keep bucket cutting edge level with ground as loader is moved backward. Lift
bucket off ground when moving forward to begin a new drag so it will not cut in.
Figure 23. Back Dragging or Leveling. 0005
0005-22
TM 5-3805-255-14 0005

Back Dragging or Leveling — Continued 0005
2. Figure 24 shows recommended method of removing material from an embankment.
Figure 24. Pile Loading Steps. 0005
3. Do not operate too close to an overhang or deep ditch (Figure 25). Use adequate protection and caution when
working on steep slopes.
Figure 25. Avoid Overhangs. 0005
0005-23
TM 5-3805-255-14 0005

Excavating 0005
When digging or excavating in hard material, penetrate with bucket edge. Immediately after penetration, agitate
bucket by moving bucket control lever between ROLL BACK and DUMP positions. This action will loosen material
and allow use of boom control to lift bucket while continuing to loosen material. Fill bucket, roll back, and raise to
transport material to dumping area (Figure 26).
Figure 26. Leaving Excavation. 0005
Removing Small Trees 0005
Small or average sized trees can be removed by centering bucket and raising to eye level. Push tree gently before
applying full power (Figure 27). Push tree over and back loader away. Lower bucket and push tree from area.
Figure 27. Removing Small Trees. 0005
0005-24
TM 5-3805-255-14 0005

Removing Large Trees 0005
1. To remove large trees, make cuts around tree weakening tree roots (Figure 28). After cut is done, fill one side
of cut to allow loader to approach tree. Push tree, with bucket at eye level, until tree starts to fall.
2. Back loader away. Approach root, position bucket under roots, and push tree from area.
Figure 28. Clearing Large Trees. 0005
Moving Railroad Cars 0005
1. Attach cable to car coupler and to welded hook on loader bucket (Figure 29).
2. Station man on car to operate car brakes.
3. Keep loader as close to car as possible and move car.
4. Car will be difficult to place in motion, but much harder to stop.
5. Avoid excessive speed. Allow car to coast ahead of loader to keep both cables tight.
6. Bring car to a smooth stop with loader and brakes.
Figure 29. Moving Railroad Cars. 0005
END OF TASK
0005-25
TM 5-3805-255-14 0005
ACCESS PANEL REMOVAL AND INSTALLATION 0005
Engine Access Panel 0005
NOTE
The procedure for left- and right-side engine access panel removal and installation is the
same.
1. Lift up two latches and remove engine access panel from hood.
2. Install engine access panel on hood and secure two latches.
Body Access Panel 0005
NOTE
The procedure for left- and right-side body access panel removal and installation is the
same.
1. Remove three bolts, lockwashers, and body access panel from frame. Discard lockwashers.
2. Install body access panel, three new lockwashers, and bolts on frame.
Figure 30. Access Panels. 0005
END OF TASK
0005-26
TM 5-3805-255-14 0005
FAN GUARD REMOVAL AND INSTALLATION 0005
NOTE
The procedure for left- and right-side fan guard removal and installation is the same.
1. Remove four bolts, nuts, lockwashers, and fan guard from radiator shroud. Discard lockwashers.
2. Install fan guard, four bolts, new lockwashers, and nuts on radiator shroud.
Figure 31. Fan Guard. 0005
END OF TASK
END OF WORK PACKAGE
0005-27/(28 blank)
10
TM 5-3805-255-14 0006
OPERATION UNDER UNUSUAL CONDITIONS

0 0 0 6
Slave Starting the Loader, Operation in Extreme Cold, Operation in Extreme Heat, Operation in Saltwater
Areas, Operation in Mud or Soft Surfaces, Operation in Sandy or Dusty Conditions, Operation at High
Altitudes, Operation in Snow and Ice
INITIAL SETUP
References 0 References - Continued 0
FM 3-3 0 FM 31-71 0
FM 3-3-1 0 FM 90-3 0
FM 9-20 0 WP 0005 0
FM 21-305 0 WP 0011 0
FM 31-70 0 WP 0013 0
WP 0018 0
INTRODUCTION 0006
1. This work package contains instructions for safely operating the H100C Loader under unusual conditions.
2. In addition to normal preventive maintenance, special care must be taken to keep the loader operational in
extreme temperatures and other environmental conditions.
SLAVE STARTING THE LOADER 0006
WARNING
When slave starting loader:

• Use NATO slave cable that does NOT have loose or missing insulation.
• DO NOT proceed if suitable cable is not available.
• DO NOT use civilian-type jumper cables.
• DO NOT allow “dead” and “live” machines to come in contact with each other at any time
during slave starting.
• Failure to follow these warnings may cause injury or death to personnel, or damage to
equipment.
0006-1
TM 5-3805-255-14 0006
SLAVE STARTING THE LOADER – CONTINUED
CAUTION
Under no circumstances can machine be started by being towed or pushed. Failure to
follow this caution will damage transmission.
NOTE
If machine other than another H100C is used to slave start loader, refer to Operator’s
Manual for that machine for any special slave starting procedures.
1. Ensure battery disconnect switch is in OFF position on “dead” and “live” machines.
2. Ensure transmission on “dead” machine is in N (NEUTRAL).
3. Engage hydraulic lockout control on “dead” machine.
NOTE
NATO slave receptacle is located near the battery on the left side of loader.
4. Remove cover and connect NATO slave cable to receptacle on “dead” machine.
5. Remove cover and connect other end of NATO slave cable to receptacle on “live” machine.
6. Set battery disconnect switch on “dead” machine to ON position.
7. Start engine of “live” machine (WP 0005) and run at a speed just above idle.
8. Allow “live” machine to run for approximately 2 minutes to charge batteries on “dead” machine.
9. Start engine of “dead” machine (WP 0005). If engine on “dead” machine fails to start, notify Field Maintenance.
10. Disconnect NATO slave cable from “live” machine, then from “dead” machine.
11. Install covers.
END OF TASK
OPERATION IN EXTREME COLD 0006
NOTE
Refer to FM 9-207, Operation and Maintenance of Ordnance Materiel in Cold Weather,
FM 31-70, Basic Cold Weather Manual, and FM 31-71, Northern Operations, for additional
information on cold weather operation and maintenance.
1. General. Extreme cold causes many problems:
a. Lubricants thicken or congeal.
b. Batteries may freeze or lose their electrical efficiency.
c. Electrical insulation may crack and cause short circuits.
d. Fuel may not readily atomize for combustion.
e. Various materials become hard, brittle, and easily damaged.
f. Cooling system requires adequate protection from extreme cold.
g. Fuels, lubricants, and antifreeze compounds require special storage, handling, and use.
0006-2
TM 5-3805-255-14 0006
OPERATION IN EXTREME COLD – CONTINUED

2. Cooling System.
WARNING
• DO NOT service cooling system unless engine has cooled. This is a pressurized cooling
system, and escaping steam or hot coolant will cause 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 cause serious burns.
• Wear effective eye, glove, and skin protection when handling coolants. Failure to follow
this warning may cause injury to personnel.
a. Inspect loader for leaks and general condition.
b. Ensure hose clamps are tight.
c. Check coolant level in sight gauge at top of radiator tank. If necessary, add coolant to correct level
(WP 0013).
d. Notify Field Maintenance if system needs service beyond adding coolant.
3. Fuel System.
WARNING
• DO NOT smoke or permit any open flame in area of machine while you are servicing fuel
system. Be sure hose nozzle is grounded against filler tube during refueling to prevent
static electricity.
• Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to
fuel, promptly wash exposed skin and change fuel-soaked clothing.
• ALWAYS stop engine prior to refueling. If equipped with an arctic cold weather starting aid
system, turn arctic heater off.
• Failure to follow these warnings may result in injury or death to personnel or damage to
equipment.
a. Do not allow fuel tank to remain partially empty in extremely cold weather. Fill fuel tank after each work
period to help avoid water condensation in tank (WP 0013).
b. Remove all ice and snow from around fuel filler opening before refueling.
c. Regularly drain water and sediment from fuel/water separator.
4. Electrical System.
a. Inspect battery cables, wiring harnesses, and wiring.
b. Check for breaks or cracks caused by cold weather. Report any problems found to Field Maintenance.
c. Save batteries. Use lights and other electrical equipment as little as possible when engine is not running.
5. Lubrication.
Use correct lubricants as specified (WP 0013) with the temperature range that applies to the lowest expected
ambient temperature.
0006-3
TM 5-3805-255-14 0006
OPERATION IN EXTREME COLD – CONTINUED

6. Engine Operation.
a. Before starting, ensure fuel and oil in engine and transmission are thin enough to flow.
b. If oil drips from engine oil level dipstick, oil is thin enough for engine to be started.
CAUTION
Low idling speeds during extremely cold temperatures can result in incomplete
combustion and heavy deposit formations on valves. These deposits can cause burned
valves, bent pushrods, or other damage to valve components.
c. After engine has started, allow engine time to reach operating temperature. Run engine at reduced speed
only long enough to circulate oil through engine. Then increase engine speed and warm up engine.
d. Cover radiator, if necessary, to bring engine up to operating temperature.
7. Machine Operation.
a. When moving out, be alert that tires may be frozen to ground.
b. Test brakes and machine controls carefully.
c. Move all hydraulic controls slowly to warm hydraulic oil. Cycle each control several times. Normal warmup
period in extreme cold is 30 minutes.
d. Operate under a light load for the first 5 minutes of operation.
e. Start driving very slowly for about 100 yd (91.4 m). If a problem is noted, notify Field Maintenance as
required.
8. Parking Machine.
a. If machine will be parked for a short period, park in a sheltered area out of wind. If shelter is not available,
park machine so that radiator does not face into wind.
b. If machine will be parked for a long shutdown period, try to park on high ground. Keep tires out of snow,
water, ice, and mud, if possible.
c. Clean snow, ice, and mud from engine compartment, hydraulic cylinders, wheels, and work tool as soon as
possible after shutdown.
d. If machine will be parked for a long period of time, notify Field Maintenance to prepare machine for
storage.
e. Ensure tires are properly inflated.
END OF TASK
0006-4
TM 5-3805-255-14 0006
OPERATION IN EXTREME HEAT 0006
CAUTION
During very hot weather, operating procedures may require altering to prevent machine
overheating. Avoid continuous high engine RPM.
NOTE
Refer to FM 90-3, Desert Operations.
1. Driving Machine.
a. Keep a close eye on machine alert indicators and coolant, transmission, and hydraulic temperature
gauges.
b. If alert indicators signal an alert or if a temperature gauge reads unusually high, stop and perform
troubleshooting (WP 0011).
c. If indicators stay on after more than 10 minutes of reduced workload, stop machine and notify Field
Maintenance.
2. Cooling System.
WARNING
system and escaping steam or hot coolant will cause serious burns.
a. Check coolant level at frequent intervals and keep radiator cap tight. Add coolant, if necessary (WP 0013).
b. Be sure radiator is free of bugs, dust, and other foreign matter.
c. Report a damaged or loose belt to Field Maintenance (WP 0018).
3. Lubrication.
a. Use correct lubricants as specified (WP 0013) with the temperature range that applies to the highest
expected ambient temperature.
b. Notify Field Maintenance to shorten differential and final drive oil change interval.
0006-5
TM 5-3805-255-14 0006
OPERATION IN EXTREME HEAT – CONTINUED

4. Air Cleaner.
WARNING
• 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, FM 3-5, NBC
Decontamination, 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.
a. Check air cleaner service indicator frequently (WP 0013).
b. Service air cleaner as necessary (WP 0013).
5. Parking Machine.
a. Park machine under cover, if possible.
b. Ensure all tires are inflated to proper pressure (WP 0013).
c. Check frequently for rust. Clean and lubricate machine to help prevent deterioration (WP 0013).
END OF TASK
OPERATION IN SALTWATER AREAS 0006
1. Keep machine as clean as possible. Wash down with fresh water after use.
2. Inspect wiring connections closely for corrosion.
3. Keep lubrication points clean and well lubricated.
END OF TASK
OPERATION IN MUD OR SOFT SURFACES 0006
1. Before entering mud or other soft surfaces, check conditions. Select appropriate transmission gear range.
Enter soft area at a medium speed for gear range selected.
2. Maintain steady pressure on throttle pedal to keep machine rolling until solid ground is reached. Do not
accelerate to the point where wheels spin, if possible.
3. Notify Field Maintenance to clean and inspect for proper lubrication.
END OF TASK
0006-6
TM 5-3805-255-14 0006
OPERATION IN SANDY OR DUSTY CONDITIONS 0006
NOTE
Refer to FM 90-3, Desert Operations.
1. Maintain steady, even movement with transmission in lower gears. Try to keep machine rolling without
straining engine and powertrain. If machine gets stuck, notify Field Maintenance.
WARNING
• 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, FM 3-5, NBC
Decontamination, 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.
2. Whenever operating in sandy or dusty areas, you should:
a. Service engine air cleaner more frequently.
b. Ensure each tire has a valve cap.
c. If machine overheats, stop and perform troubleshooting procedures (WP 0011).
d. Ensure engine and transmission dipsticks and oil filler caps are cleaned before they are removed to check
fluid levels. Clean accumulations of sand and dirt from around fluid filler locations before checking or
adding fluids.
e. Clean spouts of fuel containers and area around filler cap on fuel tank before adding fuel. Under extremely
sandy or dusty conditions, filter fuel when filling tank.
f. Notify Field Maintenance to clean, inspect, and lubricate more frequently.
g. When operating the machine on soft sand at slow speeds, tire inflation pressure may be decreased for
improved traction. Refer to FM 21-305, Manual for the Wheeled Vehicle Driver.
h. Check hydraulic cylinders frequently. Do not allow dust, dirt, or sand to collect on cylinder rods.
END OF TASK
0006-7
TM 5-3805-255-14 0006
OPERATION AT HIGH ALTITUDES 0006
WARNING
NOTE
Engine operates at less than peak performance at high altitudes.
1. Coolant level and engine indicators must be watched closely.
2. Add coolant, if necessary (WP 0013).
END OF TASK
OPERATION IN SNOW AND ICE 0006
WARNING
• DO NOT smoke or permit any open flame in area of machine while you are servicing fuel
static electricity.
• Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to
fuel, promptly wash exposed skin and change fuel-soaked clothing.
• ALWAYS stop engine prior to refueling. If equipped with an arctic cold weather starting aid
system, turn arctic heater off.
• Failure to follow these warnings may result in injury or death to personnel or damage to
equipment.
1. General.
a. Fuel tank should be kept full. Keep snow and ice away from fuel filler.
b. Clean snow away from windshields and lights.
2. Driving.
a. Accelerate slowly to avoid spinning tires.
b. Drive at slower speeds.
c. Give signals sooner.
d. Apply brakes sooner to give early warning of intention to stop. This will also help to avoid skidding.
e. Maintain double the normal distance from the machine ahead.
f. Keep windshields and lights clean and free of snow and ice.
g. If approaching a difficult stretch of road, stop and inspect road carefully before driving on it.
h. Select transmission gear range that best suits road condition.
0006-8
TM 5-3805-255-14 0006
OPERATION IN SNOW AND ICE – CONTINUED

3. Stopping.
a. Ease up on throttle pedal, leaving machine in gear.
b. Apply service brakes lightly and evenly. DO NOT pump service brake pedals.
c. Always avoid sudden braking.
END OF TASK
END OF WORK PACKAGE
0006-9/(10 blank)
8
TM 5-3805-255-14 0007
0 0 0 7 STOWAGE AND DECAL, DATA PLATE, AND STENCIL GUIDE
INTRODUCTION 0007
This work package shows the typical location of all decals, data plates, and stencils. Some are located inside
access panels or under the hood
DECALS 0007
Figure 1. Control Decals. 0007
0007-1
TM 5-3805-255-14 0007
DECALS – CONTINUED 0007
Figure 2. Instrument Panel Decals. 0007
Figure 3. Interior Decals. 0007
0007-2
TM 5-3805-255-14 0007
Figure 4. Left Side Decals. 0007
0007-3
TM 5-3805-255-14 0007
H100C-1064
Figure 5. Right Side Decals. 0007
0007-4
TM 5-3805-255-14 0007
DATA PLATES 0007
Figure 6. Control Data Plates. 0007
0007-5
TM 5-3805-255-14 0007
DATA PLATES – CONTINUED
Figure 7. Left Side Data Plates. 0007
0007-6
TM 5-3805-255-14 0007
DATA PLATES – CONTINUED
Figure 8. Right Side Data Plates. 0007
STENCILS 0007
No stencils are used on the H100C Loader.
END OF WORK PACKAGE
0007-7/(8 blank)
4
TM 5-3805-255-14 0008
PREPARATION FOR STORAGE OR SHIPMENT

0 0 0 8
Shipping Instructions, Moving a Disabled Loader, Preparation for Storage, One-Month Repetitive Service
Period, Preparation for Operation, Shipment and Storage
INITIAL SETUP
References 0 References - Continued 0
TB 740-97-2 0 WP 0013 0
TM 740-90-1 0 WP 0018 0
WP 0031 0
WP 0045 0
SHIPPING INSTRUCTIONS 0008
CAUTION
• Always install the safety bar before transporting the loader. Failure to do so could damage
equipment.
• When transporting this loader on a high speed carrier, seal the intake and exhaust pipe
openings to prevent turbocharger damage.
NOTE
The electrical system master switch must be in the OFF position.
Truck 0008
When shipping this loader by truck, state and local regulations may vary. Contact state and/or local authorities for
proper shipping and loading regulations.
Railroad Flatcar 0008
Loading rules and specifications published by the Association of American Railroads must be followed when
shipping this loader on open top railroad cars. Check the manual entitled “Rules Governing the Loading of
Commodities on Open Top Cars” at the nearest Railroad Freight Agency.
MOVING A DISABLED LOADER 0008
Towing this loader is not recommended.

PREPARATION FOR STORAGE 0008
When loader is not to be used for a period of time, store it in a dry and protected place. Leaving equipment
outdoors exposed to elements will materially shorten its life.
Follow the procedure below when loader is placed in storage for 30 days or more. Lubricate loader every six
months.
1. Wash or clean loader thoroughly.
2. Lubricate all points of loader (WP 0013).
3. Move the loader to storage location.
4. Service the air cleaner (WP 0013).
0008-1
TM 5-3805-255-14 0008
PREPARATION FOR STORAGE – CONTINUED 0008
5. Drain water from fuel tank and fill with approved diesel fuel (WP 0013).
6. Seal engine air intake, exhaust outlet, electrical components, fuel tank vent line, and breathers on crankcase
and hydraulic reservoir to prevent dirt and moisture from entering.
7. Remove the batteries and store them in a cool dry place 32 to 50°F (0 to 10°C) to minimize self-discharge. Be
sure the batteries are fully charged. Check batteries once a month for water level and specific gravity. Never
allow batteries to run down below 3/4 full charge.
8. Coat all machined, unpainted surfaces with chassis grease to prevent rust.
9. Oil all connections, joints, nuts, pins, shaft, and bushings of control linkage which are not provided with a
lubrication fitting.
10. If bucket is detached for storage, secure the cylinder to loader to avoid damage.
11. If it is desirable to leave tires on loader, jack loader up and place it on blocks leaving tires in suspension.
Deflate and cover the tires.
ONE-MONTH REPETITIVE SERVICE PERIOD 0008
1. Remove the coverings from engine crankcase breather tube, exhaust outlet, electrical components, fuel tank
vent line, and engine air intake. Install air intake cap.
2. Check cooling system for leaks, loose connections, and proper coolant level (WP 0013)
3. Check engine oil level and add appropriate oil as required (WP 0013).
4. Drain the water from the fuel tank (WP 0013).
5. Install fully charged batteries (WP 0045). Notify Field Maintenance.
6. With engine shutdown handle pulled out and electrical system master switch in the ON position, crank engine
until an oil pressure reading is indicated on engine oil pressure gauge.
NOTE
Cranking engine should be limited to 30 second intervals as outlined under Starting the
Engine (WP 0005).
7. Start engine and run at low to medium speed for 20 minutes and then shut down.
8. Remove the air intake cap. Seal the engine crankcase breather tube, exhaust outlet, electrical components,
fuel tank vent line, and engine air intake.
9. If loader has been stored for a period of one year:
a. Fuel system must be completely drained and refilled with approved diesel fuel. Fuel filters must also be
changed.
b. Engine oil must be drained and replaced with recommended lubricating oil. Oil filters must also be
replaced.
0008-2
TM 5-3805-255-14 0008
PREPARATION FOR OPERATION 0008
1. Remove grease from all machined unpainted surfaces.

2. Install fully charged batteries (WP 0045). Notify Field Maintenance.
3. Remove coverings from engine air intake, exhaust outlet, electrical components, fuel tank vent line, and
breathers on the crankcase and hydraulic reservoir.
4. Drain the old fuel from the fuel tank and fill with an approved diesel fuel (WP 0031). Notify Field Maintenance.
5. Check the cooling system for leaks, loose connections, and coolant level (WP 0013).
6. Service the engine as follows:
a. Drain the crankcase oil, change lubricating oil filters, and fill with the specified lubricating oil (WP 0018).
b. Prime the turbocharger. Notify Field Maintenance.
WARNING
• Before starting the engine, be sure the area is adequately ventilated to avoid danger from
exhaust gas. Do not accelerate the engine rapidly or operate it at high speed.
• Do not place the loader under load until normal air pressure and temperature are reached.
• Failure to follow these warnings may result in injury or death to personnel.
c. Start the engine and run at low idle a few minutes to allow thorough distribution of lubricating oil.
d. If the engine is misfiring or loss of power is evident the fuel filter is possibly clogged (WP 0031). Notify
Field Maintenance.
SHIPMENT AND STORAGE 0008
1. Refer to TB 740-97-2, Preservation of USAMECOM Mechanical Equipment for Shipment and Storage, for
procedures covering preservation of equipment for shipment and storage.
2. Refer to TM 740-90-1, Administrative Storage of Equipment, for instructions covering administrative storage of
equipment.
END OF WORK PACKAGE
0008-3/(4 blank)
6
TM 5-3805-255-14
CHAPTER 3
OPERATOR TROUBLESHOOTING
PROCEDURES
2
TM 5-3805-255-14 0009
0 0 0 9 OPERATOR TROUBLESHOOTING INTRODUCTION
GENERAL 0009
1. This chapter provides information for identifying and correcting malfunctions which may develop while
operating the H100C Loader.
2. The Troubleshooting System Index in WP 0010 lists common malfunctions which may occur and refers you to
the proper page in WP 0011 for a troubleshooting procedure.
3. If you are unsure of the location of an item mentioned in troubleshooting, refer to WP 0002, WP 0003,
WP 0004, or WP 0005.
4. Before performing troubleshooting, read and follow all safety instructions found in the warning summary at the
front of this manual.
5. This chapter cannot list all malfunctions that may occur nor all tests, inspections, or corrective actions. If a
malfunction is not listed or is not corrected by the listed corrective actions, notify your supervisor.
6. When troubleshooting a malfunction:
a. Locate the symptom or symptoms in WP 0010 that best describe the malfunction.
b. Turn to the page in WP 0011 where the troubleshooting procedures for the malfunction in question are
described. Headings at the top of each page show how each troubleshooting procedure is organized:
MALFUNCTION, TEST OR INSPECTION (in step number order), and CORRECTIVE ACTION.
c. Perform each step in the order listed until the malfunction is corrected. DO NOT perform any maintenance
task unless the troubleshooting procedures tells you to do so.
EXPLANATION OF COLUMNS 0009
The columns in WP 0011 are defined as follows: 0009
1. MALFUNCTION. A visual or operational indication that something is wrong with the equipment.
2. TEST OR INPECTION. A procedure to isolate the problem in a system or component.
3. CORRECTIVE ACTION. A procedure to correct the problem.
END OF WORK PACKAGE
0009-1/(2 blank)
2
TM 5-3805-255-14 0010
0 0 1 0 OPERATOR TROUBLESHOOTING SYMPTOM INDEX
Malfunction/Symptom Troubleshooting Procedure Page

ENGINE 00010
1. Engine Fails to Crank When Engine Start Switch is Turned to Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-1
2. Engine Cranks But Fails to Start - Operating Temperature Above -25°F (-32°C).. . . . . . . . . . . . . . . . . . . 0011-1
3. Engine Cranks But Fails to Start - Operating Temperature -25°F to -40°F (-32°C to -40°C). . . . . . . . . . . 0011-2
4. Engine Does Not Develop Full Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-2
5. Engine Does Not Idle Properly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-2
6. Engine Starts But Misfires or Runs Rough After Warm-up Period. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-2
7. Excessive Engine Oil Consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-3
8. Excessive Exhaust Smoke (At Normal Operating Speed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-3
9. Excessive Exhaust Smoke (White) During Start-Up.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-3
10. Low Engine Oil Pressure Alert Indicator, Action Light, and Action Alarm Are On. . . . . . . . . . . . . . . . . . . 0011-3
11. Coolant Temperature Gauge Indicates Engine is Overheating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-3
ELECTRICAL 00010
1. Electrical System Alert Indicator Comes On.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-4

2. Backup Alarm Will Not Sound when Loader is Placed in Reverse with Vehicle Running. . . . . . . . . . . . . 0011-4
3. Driving Lights Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-4
4. Horn Will Not Sound When Button is Pressed with Vehicle Running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-4
5. Stop Lights Do Not Operate when Brakes Are Applied with Vehicle Running. . . . . . . . . . . . . . . . . . . . . . 0011-4
6. Taillights Do Not Come On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-4
7. Windshield Washer Not Working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-4
8. Windshield Wiper Not Working with Vehicle Running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-4
TRANSMISSION 00010
1. Slow or Erratic Transmission Engagement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-5

2. Transmission Oil Temperature Gauge Indicates Overheating and Action Light
Comes On (During Normal Operation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-5
3. Transmission Does Not Operate in Any Gear.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-5
4. Transmission Does Not Shift From One Direction to Another. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-5
5. Transmission Does Not Shift From One Gear to Another.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-5
6. Transmission Engages, But Loader Does Not Move - Engine Stops Running. . . . . . . . . . . . . . . . . . . . . . 0011-5
0010-1
TM 5-3805-255-14 0010
BRAKE SYSTEM 00010
1. Brake Oil Pressure Alert Indicator Comes On During Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-6

2. Parking Brake Alert Indicator Does Not Come On When Parking Brake is Engaged. . . . . . . . . . . . . . . . 0011-6
3. Parking Brake Will Not Disengage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-6
4. Parking Brake Will Not Engage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-6
5. Service Brakes Do Not Operate Correctly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-6
6. Service Brakes Do Not Release Correctly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-7
STEERING 00010
1. Loader Slowly Drifts (Either Direction), Wanders, or Pulls To One Side On Level Pavement,
Even When Steering Wheel is in Straight Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013-8
2. Loader Erratic Steering Slow or Intermittent To Respond. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-8
3. Loader Turns Correctly During Normal Driving Conditions But Turns Slowly with a Load. . . . . . . . . . . . . 0011-8
4. Loader Turns Slowly in Either Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-8
5. Turning Steering Wheel is Difficult. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-9
HYDRAULIC SYSTEM 00010
Travel Time of Lift Cylinders is Slow.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-10
END OF WORK PACKAGE
0010-2
10
TM 5-3805-255-14 0011
0 0 1 1 OPERATOR TROUBLESHOOTING PROCEDURES
GENERAL 00011
This work package contains troubleshooting information for the H100C Loader. Each malfunction or symptom
listed is followed by the possible cause(s) and suggested remedy or remedies. This work package should be used
as an aid in the isolation and correction of system problems.
TROUBLESHOOTING PROCEDURES 00011
Table 1. Engine Troubleshooting Procedures for H100C Loader.
MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION
NOTE
A 30-minute cool down time may be required before circuit breaker automatically
resets.
1. Engine Fails to Crank 1. Check position of transmission Place transmission control lever in N
When Engine Start control lever. (NEUTRAL) (WP 0005). If problem
Switch is Turned to still exists, go to step 2.
Start.
2. Check position of battery discon- Turn switch to ON position (WP
nect switch. 0004). If problem still exists, go to
step 3.
3. Check both batteries for dirty, Clean cables if dirty (WP 0013). If
loose, or damaged cables. cable is damaged or loose, notify
Field Maintenance.
2. Engine Cranks But Fails 1. Check fuel tank gauge with If indication is empty, add fuel (WP
to Start - Operating Tem- engine start switch ON. 0013). If indication is OK, go to step 2.
perature Above
-25°F (-32°C).
2. Check air cleaner service If indicator is on, service engine air
indicator. cleaner (WP 0013) and retest. If
problem still exists, go to step 3.
3. Allow circuit breaker Attempt restart; if engine does not
approximately 30 minutes to start, notify Field Maintenance.
automatically reset.
0011-1
TM 5-3805-255-14 0011
Table 1. Engine Troubleshooting Procedures for H100C Loader - Continued.
WARNING
• Do not smoke or permit any open flame in area of H100C 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 or death to personnel or damage to equipment.
• DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or
sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel.
• Wear fuel-resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash
exposed skin and change fuel-soaked clothing.
• ALWAYS shut down engine before fueling.
3. Engine Cranks But Fails 1. Check fuel tank gauge with Turn switch to ON position (WP
to Start - Operating Tem- engine start switch ON. 0004). If indication is OK, go to step 3.
perature -25°F to If indication is empty, add fuel (WP
-40°F (-32°C to -40°C). 0013). If indication is OK, go to step 2.
2. Check air cleaner service If indicator is on, service engine air
indicator. cleaner (WP 0013) and retest. If
3. Check for missing ether starting If ether canister is missing, notify Field
aid bottle. Maintenance.
4. Engine Does Not Check air cleaner service indicator. If indicator is on, service engine air
Develop Full Power. cleaner (WP 0013) and retest. If
problem still exists, notify Field
Maintenance.
5. Engine Does Not Idle Check air cleaner service indicator. If indicator is on, service engine air
Properly. cleaner (WP 0013) and retest. If
problem still exists, notify Field
Maintenance.
6. Engine Starts But After warm-up period, if malfunction Notify Field Maintenance to replace
Misfires or Runs Rough still exist, shut down engine. primary fuel filter. If problem still
After Warm-up Period. exists, notify Field Maintenance.
0011-2
TM 5-3805-255-14 0011
Table 1. Engine Troubleshooting Procedures for H100C Loader - Continued.

7. Excessive Engine Oil Check for loose oil lines and oil leaks. If oil lines are loose or leaks are found
Consumption. or if OK and problem still exists, notify
Field Maintenance.
8. Excessive Exhaust Check air cleaner service indicator. If air cleaner indicator is on, service
Smoke (At Normal engine air cleaner (WP 0013) and
Operating Speed). retest. If problem still exists, notify
Field Maintenance.
9. Excessive Exhaust Check and monitor coolant tempera- Allow engine to warm up to operating
Smoke (White) During ture gauge. temperature and monitor gauge (WP
Start-Up. 0002 and WP 0004). If problem still
exists, notify Field Maintenance.
CAUTION
When action alarm sounds immediately shut down engine to prevent damage.
10. Low Engine Oil Pressure Allow 10 to 15 minutes for oil to drain If engine oil is low, fill to correct level
Alert Indicator, Action back into crankcase, check engine oil (WP 0013). If problem still exists,
Light, and Action Alarm level. notify Field Maintenance.
Are On.
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 will cause serious burns.
• DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Failure to
follow this warning may cause serious burns.
• Wear effective eye, hand, and skin protection when handling coolants. Failure to do so may cause injury.
11. Coolant Temperature 1. Check coolant temperature gauge Reduce load and continue to monitor
Gauge Indicates Engine for an indication in red or orange temperature and gauge (WP 0002
is Overheating. range. and WP 0004). If indicator is still in red
or orange range, go to step 2.
2. Allow engine to idle to cool down. If problem still exists, go to step 3.
3. Check cooling system for leaks. If leaks are found, notify Field Mainte-
nance. If no leaks are found, go to
step 4.
4. Check coolant level. If low, add coolant (WP 0013). If cool-
ant level is OK, notify Field Mainte-
nance.
0011-3
TM 5-3805-255-14 0011
Table 2. Electrical Troubleshooting Procedures for H100C Loader. 011

1. Electrical System Alert Check for loose or broken alternator If loose or broken belt is found, or if
Indicator Comes On. belt. belt is OK and problem still exists,
notify Field Maintenance.
2. Backup Alarm Will Not Check for loose or damage wiring at If loose or damaged wiring is found, or
Sound when Loader is backup alarm. if wiring is OK and problem still exists,
Placed in Reverse with notify Field Maintenance.
Vehicle Running.
3. Driving Lights Inopera- 1. Ensure ignition switch is in the ON Pull light switch out to first position for
tive. position. If switch is ON, go to front lights and second position for
step 2. rear lights (WP 0002).
2. Check work lights for If work light is disconnected,
disconnected or damaged damaged, or if OK and problem still
connector. exists, notify Field Maintenance.
4. Horn Will Not Sound Check horn for damaged or If fittings are found damaged,
When Button is Pressed disconnected fittings. disconnected, or fittings and horn are
with Vehicle Running. OK and problem still exists, notify
Field Maintenance.
5. Stop Lights Do Not Check stop light for disconnected or If stop light connectors are
Operate when Brakes damaged connectors. disconnected, damaged, and
Are Applied with Vehicle connectors are OK and problem still
Running. exists, notify Field Maintenance.
6. Taillights Do Not Come 1. Ensure battery disconnect switch Ensure light switch is pulled out into
On. is in on position. If switch is on, go second position.
to step 2.
2. Check taillight for disconnected or If taillight connectors are
damaged connectors. disconnected, damaged, and
connectors are OK and problem still
7. Windshield Washer Not 1. Check windshield washer fluid If reservoir is empty, fill reservoir (WP
Working. reservoir. If problem still exists, go 0013).
to step 2.
2. Check for disconnected hose at Connect hose if disconnected, if
windshield washer pump. connected and problem still exists,
8. Windshield Wiper Not Check for loose or damaged wiper If wiper motor hoses and fittings are
Working with Vehicle motor hoses and fittings. loose, damaged, or OK and problem
Running. still exists, notify Field Maintenance.
0011-4
TM 5-3805-255-14 0011
Table 3. Transmission Troubleshooting Procedures for H100C Loader. 011
WARNING
BE ALERT for personnel in the area while operating loader. Always check to ensure
area is clear of personnel and obstructions before moving. Failure to follow this
1. Slow or Erratic Check transmission oil level. If transmission oil is low, fill to correct
Transmission level (WP 0013). If problem still exists,
Engagement. notify Field Maintenance.
2. Transmission Oil 1. Ensure proper transmission range Select proper transmission range (WP
Temperature Gauge is selected for loader operation. 0005). If proper range was used, go to
Indicates Overheating step 2.
and Action Light Comes
On (During Normal
Operation).
2. Reduce load and continue to If problem still exists, go to step 3.
monitor transmission oil
temperature gauge (WP 0004).
3. Check transmission oil level. If transmission oil is low, fill to correct
level (WP 0013). If problem still exists,
3. Transmission Does Not Check transmission oil level. If transmission oil is low, fill to correct
Operate in Any Gear. level (WP 0013). If problem still exists,
4. Transmission Does Not 1. Shift transmission to N If problem still exists, go to step 2.
Shift From One Direction (NEUTRAL) and back to
to Another. appropriate direction.
5. Transmission Does Not 1. Ensure transmission direction If problem still exists, go to step 2.
Shift From One Gear to lever is in desired position.
Another.
6. Transmission Engages, Restart engine (WP 0005). If problem still exists, notify Field
But Loader Does Not Maintenance.
Move - Engine Stops
Running.
0011-5
TM 5-3805-255-14 0011
Table 4. Brake System Troubleshooting Procedures for H100C Loader. 011
WARNING
• BE ALERT for personnel in the area while operating loader. Always check to ensure
area is clear of personnel and obstructions before moving. Failure to follow this
• Park loader on level ground, stop engine, and lower bucket to ground. Failure to follow
1. Brake Oil Pressure Alert Stop loader and shut down engine Notify Field Maintenance.
Indicator Comes On Dur- immediately (WP 0005).
ing Operation.
WARNING
Park loader on level ground, stop engine, and lower bucket to ground. Failure to follow
2. Parking Brake Alert Indi- Stop loader and shut down engine Notify Field Maintenance.
cator Does Not Come On immediately (WP 0005).
When Parking Brake is
Engaged.
WARNING
3. Parking Brake Will Not 1. Engage and disengage parking If problem still exists, go to step 2.
Disengage. brake (WP 0005).
2. Shut down engine immediately Notify Field Maintenance.
(WP 0005).
4. Parking Brake Will Not Shut down engine immediately (WP Notify Field Maintenance.
Engage. 0005).
WARNING
• Park loader on level ground, stop engine, and lower bucket to ground. Failure to follow
• If emergency use of parking brake is required due to service brake failure, ensure that
brakes are inspected and repaired, if necessary, before resuming loader operation.
Failure to follow this warning may result in injury or death to personnel or damage to
equipment.
5. Service Brakes Do Not 1. Bring loader to a safe stop and Clean debris from under brake ped-
Operate Correctly. check for debris under brake als. If problem still exists, go to step 2.
pedals.
2. Bring loader to a safe stop and Notify Field Maintenance.
shut down engine immediately
(WP 0005).
0011-6
TM 5-3805-255-14 0011
Table 4. Brake System Troubleshooting Procedures for H100C Loader - Continued. 011
WARNING
6. Service Brakes Do Not 1. Bring loader to a safe stop and Clean debris from under brake
Release Correctly. check for debris under brake pedals. If problem still exists, go to
pedals. step 2.
2. Bring loader to a safe stop and Notify Field Maintenance.
shut down engine immediately
(WP 0005).
0011-7
TM 5-3805-255-14 0011
Table 5. Steering Troubleshooting Procedures for H100C Loader. 011
WARNING
Stand clear of frame articulation area when loader is operating. There is no clearance
of personnel in this area when loader turns. Failure to follow this warning may result in
injury or death to personnel or damage to equipment.
1. Loader Slowly Drifts Check tires for proper inflation pres- Inflate tire to proper pressure (WP
(Either Direction), sure. 0002). If problem still exists, notify
Wanders, or Pulls To Field Maintenance.
One Side On Level
Pavement, Even When
Steering Wheel is in
Straight Position.
2. Loader Erratic Steering 1. Check tires for proper inflation Inflate tire to proper pressure (WP
Slow or Intermittent To pressure. 0002). If problem still exists, notify
Respond. Field Maintenance.
2. Check steering system for oil If any oil leaks are found, notify Field
leaks. Maintenance. If no leaks are found, go
to step 3.
3. Check hydraulic oil level. If hydraulic oil level is low, fill to cor-
rect level (WP 0013). If hydraulic oil
level is OK, notify Field Maintenance.
3. Loader Turns Correctly 1. Check tires for proper inflation Inflate tire to proper pressure (WP
During Normal Driving pressure. 0002). If problem still exists, notify
Conditions But Turns Field Maintenance.
Slowly with a Load.
to step 3.
3. Check hydraulic oil level (WP If hydraulic oil level is low, fill to cor-
0013). rect level. If problem still exists, notify
Field Maintenance.
4. Loader Turns Slowly in 1. Check tires for proper inflation Inflate tire to proper pressure (WP
Either Direction. pressure. 0002). If problem still exists, notify
Field Maintenance.
to step 3.
rect level (WP 0013). If oil level is OK,
0011-8
TM 5-3805-255-14 0011
Table 5. Steering Troubleshooting Procedures for H100C Loader - Continued. 011

5. Turning Steering Wheel 1. Check tires for proper inflation Inflate tire to proper pressure (WP
is Difficult. pressure. 0002). If problem still exists, notify
Field Maintenance.
to step 3.
rect level (WP 0013). If problem still
0011-9
TM 5-3805-255-14 0011
Table 6. Hydraulic System Troubleshooting Procedures for H100C Loader. 011
WARNING
Stand clear of frame articulation area when loader is operating. There is no clearance
for personnel in this area when machine turns. Failure to follow this warning may result
in injury or death to personnel or damage to equipment.
Travel Time of Lift Cylinders 1. Check hydraulic oil level. If hydraulic oil level is low, fill to cor-
is Slow. rect level (WP 0013). If problem still
exists, go to step 2.
2. Check hydraulic lift cylinders for Clean any debris from cylinder(s). If
any buildup of debris. problem still exists, go to step 3.
3. Check loader control levers for If any damage is found, notify Field
damage that would restrict free- Maintenance.
dom of movement.
END OF WORK PACKAGE
0011-10
12
TM 5-3805-255-14
CHAPTER 4
OPERATOR PREVENTIVE MAINTENANCE
CHECKS AND SERVICES (PMCS)
4
TM 5-3805-255-14 0012
0 0 1 2 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL 00012
1. To ensure the H100C Loader is ready for operation at all times, it must be inspected on a regular basis so
defects may be found and corrected before they result in injury, damage, or equipment failure.
2. The PMCS Table in WP 0013 contains systematic instructions on inspections, lubrications, services, tests, and
corrections to be performed by the operator to keep the equipment in good operating condition and ready for
its primary mission.
EXPLANATION OF TABLE ENTRIES 00012
1. Item Number (Item No.) Column. Numbers in this column are for reference. When completing DA Form 2404
or DA Form 5988-E (Equipment Inspection and Maintenance Worksheet), include the item number for the
check/service indicating a fault. Item numbers also appear in the order you must perform checks and services
for the interval listed.
2. Interval Column. This column tells you when you must perform the procedure in the Procedure column.
a. Before procedures must be done immediately before you operate the loader.
b. During procedures must be done while driving the loader.
c. After procedures must be done immediately after you operate the loader.
d. Weekly procedures must be done once each week.
e. Bimonthly procedures must be done twice each month.
3. Location, Item to Check/Service Column. This column provides the location and item to be checked or
serviced.
NOTE
The WARNINGs and CAUTIONs appearing in your PMCS table should always be
observed. WARNINGs and CAUTIONs appear before applicable procedures. You must
observe these WARNINGs to prevent serious injury to yourself and others, and
CAUTIONs to prevent equipment from being damaged.
4. Procedure Column. This column gives you the procedures you must perform to check or service the item
listed in the Item to Check/Service column, to know if the equipment is ready or available for its intended
mission. You must perform the procedures at the time stated in the Interval column.
5. Not Fully Mission Capable If: Column. Information in this column tells you what faults will keep your
equipment from being capable of performing its primary mission. If you perform check/service procedures that
show faults listed in this column, the equipment is not mission-capable. Follow standard operating procedures
for maintaining the equipment or reporting equipment failure.
GENERAL PMCS PROCEDURES 00012
1. Always perform PMCS in the same order so it gets to be a habit. Once you have had some practice, you will
spot anything wrong in a hurry. If the loader does not perform as required, refer to the appropriate trouble-
shooting procedure in Chapter 4.
2. If anything looks wrong and you cannot fix it, write it on your DA Form 2404 or DA Form 5988-E. If you find
something seriously wrong, immediately report it to your supervisor.
0012-1
TM 5-3805-255-14 0012
GENERAL PMCS PROCEDURES – CONTINUED

3. Before performing preventive maintenance, read all checks required for the applicable interval and prepare all
that is needed to make all the checks. You will always need a rag (WP 0120, Item 28) or two.
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant 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 follow this warning may result in injury to personnel.
a. Keep Equipment Clean. Dirt, grease, oil, and debris get in the way and may cover up a serious problem.
Clean as you work and as needed. Use solvent cleaning compound (WP 0120, Item 4) on all metal
surfaces. Use detergent (WP 0120, Item 10) and water when you clean rubber, plastic, and painted
surfaces.
WARNING
When servicing this loader, performing maintenance or disposing of materials such as
engine coolant, hydraulic fluid, lubricants, battery acids or batteries, windshield cleaning
compound, 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. Failure to follow this warning may
result in injury to personnel.
b. Hazardous Waste Disposal. Ensure all spills are cleaned up and disposed of IAW local policy and
ordinances.
c. Rust and Corrosion. Check metal parts for rust and corrosion. If any bare metal or corrosion exists, clean
and apply a light coat of lubricating oil (WP 0120, Items 21, 22, 23, 24, or 25). Report it to your supervisor.
d. Bolts, Nuts, and Screws. Check bolts, nuts, and screws for obvious looseness, missing, bent, or broken
condition. You cannot try them all with a tool, but look for chipped paint, bare metal, or rust around bolt
heads. If you find a bad weld, report it to your supervisor.
e. Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. If you find a bad
weld, report it to your supervisor.
f. Electrical Wires and Connectors. Look for cracked or broken insulation, bare wires, and loose or broken
connectors. Reconnect loose connectors. Ensure that wires are in good condition.
g. Hoses and Fluid Lines. Look for wear, damage, and signs of leaks. Check for loose clamps and fittings.
Wet spots indicate leaks, but a stain around a fitting or connector can also mean a leak. If a leak comes
from a loose fitting or connector, notify your supervisor. If something is broken or worn out, report it to your
supervisor.
h. Fluid Leakage. It is necessary for you to know how fluid leakage affects the status of your loader. The
following are definitions of the types/classes of leakage you need to know to be able to determine the
status of your loader. Learn and be familiar with them, and remember - when in doubt, notify your
supervisor.
0012-2
TM 5-3805-255-14 0012
CAUTION
Operation is allowable with Class I and Class II leakage, EXCEPT for fuel, where NO
leakage is allowed. WHEN IN DOUBT NOTIFY YOUR SUPERVISOR. When operating
with Class I or Class II leaks, check fluid levels more frequently. Class III leaks must be
reported immediately to your supervisor. Failure to do so will result in damage to loader
and/or components.
NOTE
Notify your supervisor of any leaks you cannot fix.
Leakage Definitions for PMCS

Class I - Leakage indicated by wetness or discoloration, but not great enough to form
drops.
Class II - Leakage great enough to form drops, but not enough to cause drops to drip from
the item being checked/inspected.
Class III - Leakage great enough to form drops that fall from the item being checked/
inspected.
END OF WORK PACKAGE
0012-3/(4 blank)
50
TM 5-3805-255-14 0013
0 0 1 3 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(PMCS) INCLUDING LUBRICATION INSTRUCTIONS
INITIAL SETUP
Tools and Special Tools 0 Materials/Parts - Continued 0
Grease gun 0 Rag, Wiping (WP 0130, Item 28) 0
Materials/Parts 0 Personnel Required 0
Antifreeze (WP 0130, Item 2) 0 Two 0
Cleaning Compound, Solvent, Type III (WP

References 0
0130, Item 4) 0
Cleaning Compound, Windshield (WP 0130, DA PAM 750-8 0
Item 5) 0
FM 9-207 0
Detergent, General Purpose, Liquid (WP WP 0002 0
0130, Item 10) 0
Equipment Conditions 0
Fuel, Diesel, DF-1 Grade, Arctic (WP 0130,

Item 12) 0
Machine parked on level ground (WP 0005) 0
Grease, Automotive and Artillery (GAA) (WP Engine OFF (WP 0005) 0
0130, Item 15) 0

Parking brake applied (WP 0005) 0
Oil, Lubricating, OE/HDO-10 (WP 0130, Item Battery disconnect switch in OFF position (WP
22) 0
0004) 0
Oil, Lubricating, OE/HDO-15/40 (WP 0130,

Item 23) 0
Oil, Lubricating, OEA-30 Arctic (WP 0130,

Item 25) 0
0
0
0013-1
TM 5-3805-255-14 0013
Table 1. Preventive Maintenance Checks and Services (PMCS) for H100C. .
LOCATION
ITEM TO
CHECK/ NOT FULLY MISSION
ITEM NO. INTERVAL SERVICE PROCEDURE CAPABLE IF:
LEFT FRONT
1 Before Overall a. Check on ground under loader for Class III oil or coolant leaks
evidence of fluid leakage such as oil, are evident. Any fuel leakage
coolant, or fuel. is evident.
b. Check loader for obvious damage Damage that would impair
that would impair operation. operation is evident.
2 Before Left Front Tire a. Check tire for correct inflation. Tire does not hold pressure.
Refer to WP 0002 for pressure
specifications.
b. Check for missing bolts. Two or more bolts missing.
c. Check tread and sidewall for cuts Damage to tire that would
and foreign material in treads. lead to tire failure is evident.
d. Check backside of wheel for oil Class III oil leaks are evident.
leaks from final drive.
3 Before Air Tanks CAUTION
• Completely lower the bucket to prevent vehicle movement. Be
sure there is an adequate supply of pressure in the air system.
• Do not open the drain valves more than two turns.
• Failure to comply may cause damage to equipment.
NOTE
It is especially important that the air tanks are thoroughly
drained of water in cold weather.
a. Start engine and build up air System does not hold air
pressure in air system. pressure.
b. Shut down engine (WP 0005).
c. Open air tank drain valves.
d. Drain accumulated water from
tanks, then close valves.
0013-2
TM 5-3805-255-14 0013
Table 1. Preventive Maintenance Checks and Services (PMCS) for H100C - Continued. .
LOCATION
ITEM TO
3 Before Air Tanks
(Cont.)
Figure 1. Air Tank Drain Valves. 0013
0013-3
TM 5-3805-255-14 0013
LOCATION
ITEM TO
ARTICULATION
AREA
4 Before Articulation Pivot a. Wipe grease fittings clean with a

Lubrication rag.
b. Apply GAA grease to fittings (two Upper and lower articulation
fittings at each pivot point). Wipe off pin/bearing assemblies are
excess grease from fittings. cracked, have breaks, loose
or missing mounting bolts, or
damaged or missing grease
fittings.
Figure 2. Articulation Pivot Lubrication Points. 0013
LEFT SIDE
5 Before Engine Oil Level a. Park loader on level ground; apply Class III engine oil leak is
parking brake; completely lower evident.
bucket; and stop engine (WP 0005).
b. Allow 10 to 15 minutes for oil to
drain back into crankcase.
0013-4
TM 5-3805-255-14 0013
LOCATION
ITEM TO
5 Before Engine Oil Level c. Loosen “T” handle of oil level
(Cont.) gauge, remove gauge, and wipe
clean.
d. Insert gauge completely, but do
not tighten.
e. Remove gauge and check oil level.
If level is at or below “L” (low) mark,
remove filler cap and add oil through
filler pipe to bring level up to “H” (full)
mark on gauge. See Table 2,
Lubricants, in this work package for
grade and quantity of fluid required.
f. Reinstall and secure oil level
gauge and filler cap.
Figure 3. Checking Engine Oil Level. 0013
6 Before Left Rear Tire a. Check tire for correct inflation. Tire does not hold pressure.
specifications.
0013-5
TM 5-3805-255-14 0013
LOCATION
ITEM TO
RIGHT REAR
7 Before Overall a. Check on ground under loader for Class III oil or coolant leaks
evidence of fluid leakage such as oil, are evident. Any fuel leakage
coolant, or fuel. is evident.
b. Check loader for obvious damage Damage that would impair
that would impair operation. operation is evident.
8 Before Stop Lights To check stop light switch for proper Stop lights are missing,
operation, air pressure gauge must be damaged, or not functioning.
in RUN area. Station a helper at rear
of loader to observe stop lights.
Depress one brake treadle. Stop lights
should go on.
WARNING
• DO NOT smoke or permit any open flame in area of H100C

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 or
death to personnel or damage to equipment.
• DO NOT perform fuel system checks, inspections, or mainte-
nance while smoking or near fire, flames, or sparks. Fuel may
ignite, causing damage to equipment and injury or death to
personnel.
• Wear fuel-resistant gloves and eye protection when handling
fuels. If exposed to fuel, promptly wash exposed skin and
change fuel-soaked clothing.
9 Before Fuel Tank Be sure fuel tank is full. Fill tank at Class I fuel leak from fuel tank
end of each day’s operation to reduce evident.
condensation of moisture.
10 Before Right Rear Tire a. Check tire for correct inflation. Tire does not hold pressure.
specifications.
d. Check back side of wheel for oil Class III oil leaks are evident.
0013-6
TM 5-3805-255-14 0013
LOCATION
ITEM TO
RIGHT SIDE
11 Before Primary Air Filter a. Check for missing air filter. Air filter missing.
Element
NOTE
• The air cleaner primary element must be serviced whenever
indicated by the air cleaner service indicator (WP 0004). The
primary element can be cleaned by either of two methods:
washing or compressed air.
• Washing is the preferred method as it removes more dust and
soot and restores the element to an almost new condition. The
result being better performance and longer intervals between
required element service. It is suggested that a spare element
be available for use while the serviced element is drying. This
will reduce unit down-time to only a few minutes and will allow
sufficient time to service the restricted element properly.
• A filter element must be replaced after six washings.
• Cleaning the element with compressed air is not considered an
entirely satisfactory method. Some dust will remain in the
element causing more frequent servicing of the element. Use
this method only as a temporary measure until sufficient time is
available to clean the element by washing.
b. Stop engine. Remove dust from air Filter missing.
cleaner body and cover.
0013-7
TM 5-3805-255-14 0013
LOCATION
ITEM TO
11 Before Primary Air Filter c. Remove wing nut (and clamp if
(Cont.) Element equipped) and remove cover.
d. Remove wing bolt, seal, and
primary element.
NOTE
Be careful not to dislodge dust from the dirty element onto the
safety element.
e. Check condition of seal. If seal is
damaged or missing, replace.
Figure 4. Air Filter. 0013
0013-8
TM 5-3805-255-14 0013
LOCATION
ITEM TO
11 Before Primary Air Filter f. Carefully tap side or end of Filter missing.
(Cont.) Element element against palm of your hand to
remove loose dust.
WARNING
Particles blown by compressed air are hazardous. DO NOT

exceed 15 psi (103 kPa) nozzle pressure when drying parts
with compressed air. Use a maximum of 30 psi (207 kPa) when
cleaning components. DO NOT direct compressed air against
human skin. Make sure air stream is directed away from user
and other personnel in the area. User must wear protective
goggles or face shield. Failure to follow this warning may result
in injury to personnel.
g. Direct clean, dry compressed air
up and down pleats on clean side
(inside) of element.
h. Inspect filter element for leaks or Filter is clogged or severely
damage by placing a bright light damaged.
inside element. Inspection of element
on outside will disclose any holes
where concentrated light shines
through. Slightest rupture requires
replacement of filter elements.
i. If faulty or damaged gaskets or
surfaces are noted, correct these
conditions immediately.
j. Inspect element for damage.
k. Inspect contact surfaces of
element and air cleaner body.
l. Install open end of primary
element into air cleaner body over
safety element.
m. Install seal and wing bolt.
n. Install cover. Tighten wing nut.
o. Install clamp (if equipped).
0013-9
TM 5-3805-255-14 0013
LOCATION
ITEM TO
12 Air Cleaner Air cleaner service indicator signals
Service Indicator when air filter element service is
required. After servicing element,
press reset button to reset indicator.
Figure 5. Air Cleaner Service Indicator. 0013
13 Before Dust Vacuator Squeeze dust vacuator valve to clear

Valve it of accumulated dust. Be sure valve
lips are not stuck together.
Figure 6. Pre-Cleaner Hood. 0013
0013-10
TM 5-3805-255-14 0013
LOCATION
ITEM TO
14 Before Transmission Oil CAUTION
Level
Do not check the transmission oil level or add oil unless the
loader halves are securely locked with the safety bar and pins
provided. Have a second person at the loader controls while
checking the oil.
NOTE
If transmission oil leakage is suspected or if the loader has
been out of operation for a length of time check transmission
oil level gauge with the loader cold and the engine off. Oil
should appear on the gauge during this condition; if not, add oil
before proceeding to the following steps.
a. Work loader until torque converter a. Loader does not respond
oil temperature gauge registers in to transmission selection.
RUN (green) area. Make use of all b. Class III transmission oil
transmission direction gear ranges. leak.
b. Park loader in a straight position
on level ground.
c. Shift transmission to N (neutral).
Lower bucket to ground and apply
parking brake.
d. Stop engine and install safety bar
(WP 0005).
e. Start engine and let it run at low
idle (WP 0005).
f. Turn cap of transmission oil level
gauge counterclockwise to loosen it.
g. Remove transmission oil level
gauge and wipe it clean.
h. If transmission oil level is low add
clean oil as necessary. Refer to Table
2, Lubricants, in this work package for
grade and quantity of lubricant
required.
0013-11
TM 5-3805-255-14 0013
LOCATION
ITEM TO
14 Before Transmission Oil CAUTION
(Cont.) Level
If transmission oil level is above “H” mark. Notify Field
Maintenance. Too much oil in transmission will cause aeration
of oil. Failure to follow this caution will result in damage to
equipment.
i. Install transmission oil level gauge
and tighten.
Figure 7. Transmission Oil. 0013
ARTICULATION
AREA
15 Before Articulation Pivot a. Wipe grease fittings clean with a

Lubrication rag.
b. Apply GAA grease to fittings (two Upper and lower articulation
fittings at each pivot point). Wipe off pin/bearing assemblies are
excess grease from fittings. cracked, have breaks, loose
or missing mounting bolts, or
damaged or missing grease
fittings.
0013-12
TM 5-3805-255-14 0013
LOCATION
ITEM TO
15 Before Articulation Pivot
(Cont.) Lubrication
Figure 8. Articulation Pivot Lubrication Points. 0013
0013-13
TM 5-3805-255-14 0013
LOCATION
ITEM TO
TOP OF
LOADER
16 Before Engine Coolant CAUTION

Level
Do not operate engine before checking coolant level. Failure to
follow this caution may cause damage to equipment.
a. Correct level is 1 in. (25 mm) Coolant system empty.
above baffle.
b. Do not add cold coolant into Class III coolant leak evident.
radiator of an overheated engine
unless absolutely necessary.
However, if necessary:
1. Remove radiator cap carefully.
2. Coolant must be added to
radiator slowly with engine running at
low idle speed.
Figure 9. Coolant Level. 0013
3. Fill cooling system slowly. This

allows more air to escape and system
to be filled to maximum capacity.
Refer to Table 3, Coolants, in this
work package for type and mixture of
coolant.
0013-14
TM 5-3805-255-14 0013
LOCATION
ITEM TO
16 Before Engine Coolant 4. Start engine and run until
(Cont.) Level normal operating temperature is
reached, adding coolant when
needed to keep proper level of 1 in.
(25 mm) above baffle (WP 0005).
5. After all air is removed and
level remains fixed, install radiator
cap. Check all drains for leakage.
17 Before Hydraulic CAUTION
Reservoir Oil
Level Always lower the bucket to the ground before servicing the
hydraulic system. Loosen the reservoir filler cap slowly to
relieve the pressure in the system. Failure to comply could
cause damage to equipment.
a. While hydraulic oil is at operating a. Hydraulic reservoir empty.
temperature, park machine on level b. Class III oil leak evident.
ground, completely lower bucket,
apply parking brake, and stop engine
(WP 0005).
b. Remove filler cap and hydraulic oil
level gauge and check hydraulic oil
level. Hydraulic oil should be at full
mark, or a little higher, on gauge.
Figure 10. Hydraulic Reservoir. 0013
0013-15
TM 5-3805-255-14 0013
LOCATION
ITEM TO
17 Before Hydraulic c. If hydraulic oil level is low, add
(Cont.) Reservoir Oil clean hydraulic oil as necessary.
Level Refer to Table 2, Lubricants, in this
work package for grade and quantity
of fluid required.
d. Install filler cap and hydraulic oil
level gauge.
RIGHT FRONT
18 Before Right Front Tire a. Check tire for correct inflation. Tire does not hold pressure.
specifications.
CAB INTERIOR
19 During Gauges and During startup and operation, monitor Gauge indicates system
Warning Indicator all gauges and warning indicator lights failure.
Lights for any information that would require
engine or loader shut down (WP
0004).
20 After Cleaning Loader CAUTION
• Remove dirt from engine, transmission, hydraulic cylinders,
axle, and hydraulic connections. If allowed to accumulate, dirt
will find its way into loader components when plugs and covers
are removed. Dirt caked over axle transmission and engine
breathers will cause oil losses.
• Steam is the most effective means of cleaning dirty equipment.
If steam is not available, use a spray of mineral spirits or a
similar solvent. Steam can be harmful to electrical
components. Protect the generator or alternator and cranking
motor openings from the full force of the steam jet. If a solvent
spray is used, it must not be injurious to the hydraulic hoses,
engine fuel lines, or the insulation on electric wires. Apply fresh
grease at all fittings on the loader after cleaning.
0013-16
TM 5-3805-255-14 0013
LOCATION
ITEM TO
21 After Cleaning Remove all bugs and dirt from radiator
Radiator core using air or water under
pressure. Direct flow through core,
opposite normal direction of air flow.
LEFT FRONT
22 Weekly Bucket Link a. Wipe grease fittings clean with a

Lubrication rag.
b. Apply GAA grease to fittings (two

fittings at each pivot point). Wipe off
excess grease from fittings.
Figure 11. Bucket Link Lubrication Points. 0013
0013-17
TM 5-3805-255-14 0013
LOCATION
ITEM TO
23 Weekly Bucket Cylinder a. Wipe grease fittings clean with a
Lubrication rag.
c. Inspect hydraulic hoses for Cracks, splits, bulges, or soft
damage or leaks. spots are evident in hoses, or
Class III leaks are evident.
Figure 12. Bucket Cylinder Front Lubrication Points. 0013
Figure 13. Bucket Cylinder Rear Lubrication Points. 0013
0013-18
TM 5-3805-255-14 0013
LOCATION
ITEM TO
24 Weekly Bucket Pivot a. Wipe grease fitting clean with a
Lubrication rag.
b. Apply GAA grease to fitting. Wipe
off excess grease from fitting.
Figure 14. Bucket Pivot. 0013
0013-19
TM 5-3805-255-14 0013
LOCATION
ITEM TO
25 Weekly Bellcrank Pivot a. Wipe grease fittings clean with a
Lubrication rag.
b. Apply GAA grease to fitting (two
Figure 15. Bellcrank Pivot Lubrication Points. 0013
0013-20
TM 5-3805-255-14 0013
LOCATION
ITEM TO
26 Weekly Boom Pivot a. Wipe grease fittings clean with a
Lubrication rag.
b. Apply GAA grease to fittings (one

fitting in each boom arm). Wipe off
Figure 16. Boom Pivot Lubrication Points. 0013
0013-21
TM 5-3805-255-14 0013
LOCATION
ITEM TO
27 Weekly Boom Cylinder a. Wipe grease fittings clean with a
Lubrication rag.
Figure 17. Boom Cylinder Bottom Lubrication Point. 0013
0013-22
TM 5-3805-255-14 0013
LOCATION
ITEM TO
27 Weekly Boom Cylinder
(Cont.) Lubrication
Figure 18. Boom Cylinder Top Lubrication Point. 0013
0013-23
TM 5-3805-255-14 0013
LOCATION
ITEM TO
ARTICULATION
AREA
28 Weekly Steering a. Wipe grease fittings clean with a

Cylinders rag.
Lubrication
Figure 19. Steering Cylinder Front Lubrication Points. 0013
0013-24
TM 5-3805-255-14 0013
LOCATION
ITEM TO
28 Weekly Steering
(Cont.) Cylinders
Lubrication
Figure 20. Steering Cylinder Rear Lubrication Points. 0013
0013-25
TM 5-3805-255-14 0013
Table 1. Preventive Maintenance Checks and Services (PMCS) for H100C - Continued..
LOCATION
ITEM TO
29 Weekly Drag Links a. Wipe grease fittings clean with a
Lubrication rag.
b. Apply GAA grease to fittings. Wipe
off excess grease from fittings.
Figure 21. Drag Link Front Lubrication Points. 0013
Figure 22. Drag Link Rear Lubrication Points. 0013
0013-26
TM 5-3805-255-14 0013
LOCATION
ITEM TO
LEFT REAR
30 Weekly Axle Cradle a. Wipe grease fittings clean with a

Lubrication rag.
Figure 23. Axle Cradle Lubrication Points. 0013
0013-27
TM 5-3805-255-14 0013
LOCATION
ITEM TO
ARTICULATION
AREA
31 Weekly Steering a. Wipe grease fittings clean with a

Cylinders rag.
Lubrication
Figure 24. Steering Cylinder Front Lubrication Points. 0013
0013-28
TM 5-3805-255-14 0013
LOCATION
ITEM TO
31 Weekly Steering
(Cont.) Cylinders
Lubrication
Figure 25. Steering Cylinder Rear Lubrication Points. 0013
0013-29
TM 5-3805-255-14 0013
LOCATION
ITEM TO
32 Weekly Drag Links a. Wipe grease fittings clean with a
Lubrication rag.
off excess grease from fittings
Figure 26. Drag Link Front Lubrication Points. 0013
Figure 27. Drag Link Rear Lubrication Points. 0013
0013-30
TM 5-3805-255-14 0013
LOCATION
ITEM TO
TOP OF
LOADER
WARNING
Batteries give off highly flammable gas. Never allow sparks or
open flame near the batteries. Avoid spilling any electrolyte on
hand or clothing. Failure to follow this warning may result in
injury or death to personnel.
CAUTION
Excessive tightening can warp or crack battery case.
NOTE
Proper battery maintenance will assure maximum service.
Following are a few simple rules:
• Keep battery cable terminals clean and tight.
• Keep filler cap vent holes unplugged.
• Replace worn, cracked, broken, or corroded cables.
• Keep batteries fastened securely in frame.
33 Weekly Batteries a. Check terminal tightness, and a. Battery leaking electrolyte.
clean batteries. b. Broken and corroded
connections or frayed/burned/
melted cables and clamps are
evident.
b. Check for correct battery liquid
level. Contact Field Maintenance for
service.
c. If the top of a battery is dirty, it may Battery leaking electrolyte.
be cleaned with a brush.
0013-31
TM 5-3805-255-14 0013
LOCATION
ITEM TO
RIGHT FRONT
34 Weekly Bucket Link a. Wipe grease fittings clean with a Class III oil leak from cylinder
Lubrication rag. evident.
Figure 28. Bucket Link Lubrication Points. 0013
0013-32
TM 5-3805-255-14 0013
LOCATION
ITEM TO
35 Weekly Bucket Cylinder a. Wipe grease fittings clean with a
Lubrication rag.
Figure 29. Bucket Cylinder Front Lubrication Points. 0013
Figure 30. Bucket Cylinder Rear Lubrication Points. 0013
0013-33
TM 5-3805-255-14 0013
LOCATION
ITEM TO
36 Weekly Bucket Pivot a. Wipe grease fittings clean with a
Lubrication rag.
Figure 31. Bucket Pivot Lubrication Points. 0013
0013-34
TM 5-3805-255-14 0013
LOCATION
ITEM TO
37 Weekly Bellcrank Pivot a. Wipe grease fittings clean with a Class III oil leak from cylinder
Figure 32. Bellcrank Pivot Lubrication Points. 0013
0013-35
TM 5-3805-255-14 0013
LOCATION
ITEM TO
38 Weekly Boom Pivot a. Wipe grease fittings clean with a Class III oil leak from cylinder
b. Apply GAA grease to fittings (one
fitting at each boom arm). Wipe off
Figure 33. Boom Pivot Lubrication Point. 0013
39 Weekly Boom Cylinder a. Wipe grease fittings clean with a

Lubrication rag.
0013-36
TM 5-3805-255-14 0013
LOCATION
ITEM TO
39 Weekly Boom Cylinder
(Cont.) Lubrication
Figure 34. Boom Cylinder Bottom Lubrication Points. 0013
Figure 35. Boom Cylinder Top Lubrication Points. 0013
0013-37
TM 5-3805-255-14 0013
LOCATION
ITEM TO
CAB INTERIOR
40 Weekly Cab Heater Air NOTE

Filter
The heater air filter cleans air flowing through the heater. When
working in extremely dusty conditions filter should be cleaned
more often.
Figure 36. Cab Air Filter. 0013
0013-38
TM 5-3805-255-14 0013
LOCATION
ITEM TO
40 Weekly Cab Heater Air a. Loosen thumbscrews and/or
(Cont.) Filter release latch securing grille, and lift
grille.
b. Remove filter.
c. Remove loose dirt from filter by
tapping it against palm of your hand.
WARNING
Particles blown by compressed air are hazardous. Use a

maximum of 30 psi (207 kPa) when cleaning components. DO
NOT direct compressed air against human skin. Make sure air
stream is directed away from user and other personnel in the
area. User must wear protective goggles or face shield. Failure
to follow this warning may result in injury to personnel.
d. Blow compressed air, not
exceeding 30 psi (207 kPa), through
the filter to remove embedded dust.
NOTE
Do not dry a wet filter with compressed air.
e. If filter fails to come clean, soak it
in lukewarm water containing a mild
soap, rinse clean and let air dry.
f. Install filter so small mesh screen
is outside. Close grille and secure it
with thumbscrews and/or secure
latch.
0013-39
TM 5-3805-255-14 0013
LOCATION
ITEM TO
LEFT SIDE
41 Bimonthly Air Compressor WARNING

Belt Tension
Check When checking, adjusting or replacing belts be sure the
electrical master switch is in the OFF position. Failure to
comply may cause injury to personnel and damage to
equipment.
Check for loose, worn, or missing belt Belt is loose or missing.
(Figure 37).
Figure 37. Air Compressor Belt Tension Check Point. 0013
0013-40
TM 5-3805-255-14 0013
LOCATION
ITEM TO
RIGHT SIDE
42 Bimonthly Alternator Belt WARNING

Tension Check
When checking, adjusting or replacing belts be sure the
electrical master switch is in the OFF position. Failure to
equipment.
Check for loose, worn, or missing belt. Belt is loose or missing.
Figure 38. Alternator Belt Tension Check Point. 0013
0013-41
TM 5-3805-255-14 0013
LOCATION
ITEM TO
ARTICULATION
AREA
43 Bimonthly Intermediate a. While intermediate drive block oil Class III oil leak evident.
Drive Block Oil is at operating temperature, park
Level loader on level ground, completely
lower bucket, and apply parking brake
(WP 0005).
b. Remove intermediate drive block
oil level gauge and wipe it clean.
c. Insert oil level gauge as far as it
will go.
d. Remove oil level gauge again and
check level. If oil level is below full
mark, add intermediate drive block oil
as necessary. Refer to Table 2,
e. Fill block through oil level gauge
hole. Refer to Table 2, Lubricants, in
this work package for grade and
quantity of fluid required.
0013-42
TM 5-3805-255-14 0013
LOCATION
ITEM TO
43 Bimonthly Intermediate f. Reinstall oil level gauge.
(Cont.) Drive Block Oil
Level
Figure 39. Intermediate Drive Block. 0013
END OF TASK
0013-43
TM 5-3805-255-14 0013
LUBRICATION INSTRUCTIONS 00013
NOTE
• Lubrication instructions contained in this PMCS are MANDATORY.
• The overall view of lubrication points is located at the end of this work package in
Lubrication Instructions. Localized views are located, together with specific lubrication
instructions, in the PMCS table.
• The loader is not enrolled in the Army Oil Analysis Program (AOAP).
• Refer to FM 9-207 for lubrication in arctic operation.
1. Included in this PMCS are lubrication services to be performed by the operator.
2. Lubrication intervals are based on normal operation. Lubricate more during constant use and less during
inactive periods. Use correct grade of lubricant for seasonal temperature expected. Refer to the KEY on the
next page.
3. For equipment under manufacturer’s warranty, hardtime intervals shall be followed. Shorten intervals if
lubricants are known to be contaminated or if operation is under adverse conditions (e.g., longer than usual
operating hours, extended idling periods, extreme dust).
4. Keep all lubricants in a closed container and store in a clean, dry place away from extreme heat. Keep
container covers clean and do not allow dust, dirt, or other foreign materials to mix with lubricants. Keep
lubrication equipment clean and ready for use.
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and

low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves
and goggles. Use in well ventilated areas. Keep away from open flames and other sources
of ignition. Failure to follow this warning may result in injury or death to personnel.
5. Clean area around lubrication points with solvent cleaning compound or equivalent before lubricating
equipment. Keep all external parts not requiring lubrication free of lubricants. After lubrication, wipe off excess
lubricant to prevent accumulation of foreign matter.
6. Maintain a record of lubrication performed and report any problems noted during lubrication. Refer to DA PAM
750-8 for forms and procedures to record and report any findings.
0013-44
TM 5-3805-255-14 0013
LUBRICATION INSTRUCTIONS – CONTINUED
NOTE
Only lubricants authorized for use by the operator are listed in this KEY.
- KEY - 013
EXPECTED TEMPERATURES*
+6°F to +122°F -4°F to +50°F -25°F to

LUBRICANT/ REFILL (-14°C to (-20°C to +32°F
COMPONENT CAPACITY +50°C) +10°C) (-4°C to 0°C) INTERVALS
OE/HDO D - Daily
Lubricating Oil, ICE, W - Weekly
Tactical Service (MIL- M - Monthly
PRF-2104) OC - On
Condition
Engine Crankcase 32 qt See Table 2.
(30.3 L)
45 qt See Table 2.
Transmission
(42.5 L)
55 qt See Table 2.
Hydraulic Tank
(52 L)
GAA
Grease, Automotive
and Artillery
See Table 2.
Grease Fittings As Required
ANTIFREEZE
65 qt See Table 3.
Cooling System
(61.5 L)
* For arctic operation, refer to FM 9-207.
0013-45
TM 5-3805-255-14 0013
Table 2. Lubricants.
Commercial Viscosity
Compartment Lubricant Grade Military Lubricant Temperature Range
Engine I.H. No. 1 SAE-30 MIL-L-2104C or MIL-L-45199B 20°F to 120°F (-7°C to 49°C)
Engine Oil SAE-10W -10°F to 70°F (-23°C to 21°C)
or API CD/ Arctic Grade -30°F to 10°F (-34°C to -12°C)
CC or CD
Transmission I.H. Smooth

Shift Dextron
Hydraulic I.H. No. 1 SAE-10W* MIL-L-45199B or MIL-L-2104B or C 20°F to 120°F (-7°C to 49°C)
Engine Oil or SAE-10W MIL-L-46152 -10°F to 70°F (-23°C to 21°C)
API CD/CC, Arctic Grade -30°F to 10°F (-34°C to -12°C)
CD, CC/SE
Axles I.H. 135H MIL-L-2105C Gear Lubricant

EP Gear
Lubricant or
API-GL-5
Intermediate SAE-85W - 140 20°F to 120°F (-7°C to 49°C)

Drive Block SAE-80W - 90 or -10°F to 70°F (-23°C to 21°C)
SAE-85W - 140
SAE-80W - 90** -30°F to 10°F (-34°C to -12°C)
Service Brake I.H. Super

Power Clusters Heavy Duty
(Each) SAE-J1703E
Brake Fluid
Steering Gear I.H. 135 H SAE-85W - 140 MIL-L-2105B Gear Lubricant 20°F to 120°F (-7°C to 49°C)
Housing EP Gear SAE-80W - 90 or -10°F to 70°F (-23°C to 21°C)
Lubricant or SAE-85W - 140
API GL-5 SAE-80W - 90 ** -30°F to 10°F (-34°C to -12°C)
Grease I.H. Super GAA

Grease or
I.H. 251H EP
*For ambient temperature constantly above 70°F (21°C), SAE 20W-20 may be used.
**Channel point must not exceed -30°F (-34°C) for SAE 80W-90 grade gear lubricants when they are used below -10°F (-23°C).
0013-46
TM 5-3805-255-14 0013
Figure 40. Lubrication Instructions - Checking OE/HDO and Antifreeze. 0013
0013-47
TM 5-3805-255-14 0013
Table 3. Coolants.
Coolant Type Mixture Military Coolant Temperature Range
Engine Coolant I-Ethylene 60/40 A-A-52624 -50°F to 120°F (-46°C to 49°C)

Glycol
II-Propylene
Glycol
Engine Coolant I-Ethylene 50/50 A-A-5264 -30°F to 120°F (-34°C to 49°C)

Glycol
II-Propylene
Glycol
0013-48
TM 5-3805-255-14 0013
Figure 41. Lubrication Instructions - GAA Applications. 0013
END OF TASK
END OF WORK PACKAGE
0013-49/(50 blank)
52
TM 5-3805-255-14
CHAPTER 5
FIELD TROUBLESHOOTING PROCEDURES
2
TM 5-3805-255-14 0014
FIELD MAINTENANCE -
0 0 1 4 FIELD TROUBLESHOOTING INTRODUCTION
GENERAL 00014
1. This chapter provides information for identifying and correcting malfunctions that may develop while operating
the H100C Loader.
2. The Troubleshooting Symptom Index in WP 0015 lists common malfunctions that may occur and refers you to
the proper page in WP 0016 for a troubleshooting procedure.
3. If you are unsure of the location of an item mentioned in troubleshooting, refer to WP 0002, WP 0003,
WP 0004, or WP 0005.
4. Before performing troubleshooting, read and follow all safety instructions found in the warning summary at the
front of this manual.
5. This chapter cannot list all malfunctions that may occur nor all tests, inspections, or corrective actions. If a
malfunction is not listed or is not corrected by the listed corrective actions, notify your supervisor.
6. When troubleshooting a malfunction:
a. Locate the symptom or symptoms in WP 0015 that best describe the malfunction.
b. Turn to the page in WP 0016, where the troubleshooting procedures for the malfunction in question are
described. Headings at the top of each page show how each troubleshooting procedure is organized:
MALFUNCTION, TEST OR INSPECTION (in step number order), and CORRECTIVE ACTION.
7. Perform each step in the order listed until the malfunction is corrected. DO NOT perform any maintenance task
unless the troubleshooting procedure tells you to do so.
The columns in WP 0016 are defined as follows:

1. MALFUNCTION. A visual or operational indication that something is wrong with the equipment.
2. TEST OR INSPECTION. A procedure to isolate the problem in a system or component.
3. CORRECTIVE ACTION. A procedure to correct the problem.
END OF WORK PACKAGE
0014-1/(2 blank)
4
TM 5-3805-255-14 0015
FIELD MAINTENANCE -
0 0 1 5 FIELD TROUBLESHOOTING SYMPTOM INDEX
Malfunction/Symptom Troubleshooting Procedure Page

ENGINE 00015
1. Power Complaint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-1

2. Excessive Fuel Consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-1
3. Excessive Engine Speed (RPM).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-2
4. High Coolant Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-2
5. Low Coolant Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-2
6. Excessive Exhaust Smoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-2
7. Low Fuel Supply Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-3
8. Engine “Misfiring”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-3
ELECTRICAL 00015
1. Discharging Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-4

2. Battery Overheating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-4
3. Alternator Charging Output High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-4
4. Alternator Charging No or Low Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-4
5. Noisy Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-4
6. Voltmeter Shows Less Than 24 VDC with Engine at Idle.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-4
7. High Voltage (Voltmeter Reads above 30 VDC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-4
8. Starter Motor Will Not Operate or Operates Slowly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-5
ELECTRICAL SYSTEM INSTRUMENTS 00015
1. Lights Dim.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-6

2. Electrical Gauge Not Operating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-6
3. Ignition On (No Gauges or Lights Working). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-6
4. All Electrical Gauges Working (No Lights). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-6
TRANSMISSION 00015
1. Converter Stall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-7

2. High Oil Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-7
3. Loss of Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-8
PROPELLER SHAFTS 00015
1. Noise (Propeller Shafts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-9

2. Vibration (Propeller Shafts).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-9
TRANSFER DRIVE 00015
1. Noise (Transfer Drive). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-10

2. Loss of Lubricant (Transfer Drive). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-10
0015-1
TM 5-3805-255-14 0015
FRONT AND REAR AXLES 00015
1. Noise (Axles). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-11

2. Loss of Lubricant (Axles). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-11
BRAKE SYSTEM 00015
1. Brakes Drag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-12

2. Inadequate Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-12
3. Brakes Apply Too Slowly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-13
4. Brakes WIll Not Apply.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-13
5. Brakes Do Not Release or Release Too Slowly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-13
6. Brakes Grab When Applied. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-14
7. Brakes Pull When Applied. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-14
8. Air Pressure Will Not Rise to Normal Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-14
9. Air Pressure Rises to Normal Reading Too Slowly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-15
10. Air Pressure Rises Above Normal Reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-15
11. Air Pressure Drops Too Quickly with Engine Stopped and Brakes Released. . . . . . . . . . . . . . . . . . . . . 0016-15
12. Air Pressure Drops Too Quickly wIth Engine Stopped and Brakes Applied. . . . . . . . . . . . . . . . . . . . . . . 0016-16
13. Noisy Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-16
14. Excessive Water or Oil in System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-16
PARKING BRAKE 00015
1. Lever Will Not Operate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-16

2. Brake Will Not Hold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-16
STEERING GEAR 00015
1. Gear Noise (Rattle or Chuckle). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-17

2. Hard Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-17
HYDRAULIC 00015
General 00015
1. Poor Hydraulic System Performance or Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-17

2. Excessive Oil Foaming.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-17
Main Control Valve 00015
1. Difficult Operation or Sticking of Control Valve Plungers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-18

2. Load Will Not Hold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-18
3. Leaking Seals.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-18
Pump 00015
1. Pump Does Not Deliver Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-18

2. Pump Making Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-18
0015-2
TM 5-3805-255-14 0015
HYDRAULIC – CONTINUED 00015
Steering Control Valve Troubleshooting 00015
1. Hard Steering When Turning Slowly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-19

2. No Effort Required to Turn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-19
3. Momentary Increase in Effort Required When Turning Wheel Quickly.. . . . . . . . . . . . . . . . . . . . . . . . . . 0016-19
4. Excessive Wheel Kickback or Loose Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016-19
END OF WORK PACKAGE
0015-3/(4 blank)
20
TM 5-3805-255-14 0016
FIELD MAINTENANCE -
0 0 1 6 FIELD TROUBLESHOOTING PROCEDURES
GENERAL 00016
This work package contains troubleshooting information for the H100C Loader. Each malfunction or symptom
listed is followed by the possible cause(s) and suggested remedy or remedies. This work package should be used
as an aid in the isolation and correction of system problems.
Table 1. Engine Troubleshooting Procedures for the H100C Loader. 016

1. Power Complaint. 1. Check for external leakage on Inspect, repair, or replace defective
intake or exhaust manifolds at components. If problem still exists, go
gasket, slip-joints, cracks in fuel to step 2.
lines and at fuel line connections,
air compressor-turbocharger
connections, and turbocharger
housing clamps.
2. Check for excessive air cleaner Clean or replace air filters (WP 0018).
restriction. If problem still exists, go to step 3.
3. Check for excessive exhaust back Inspect and replace muffler (WP
pressure after turbocharger. 0035). If problem still exists, go to
step 4.
4. Check for plugged injection Clean or replace nozzles (WP 0027).
nozzles. If problem still exists, go to step 5.
5. Check for plugged or restricted Replace fuel filters (WP 0018). If prob-
fuel filters. lem still exists, go to step 6.
6. Check fuel system for fuel hose Clean, inspect, and repair fuel system
collapse, wrong fuel filter (WP 0018). If problem still exists, go
elements, or foreign material in to step 7.
fuel tank.
7. Check for dirty or restricted Clean or replace element (WP 0018).
crankcase breather element. If problem still exists, go to step 8.
8. Check for defective turbocharger. Inspect, repair, or replace turbo-
charger (WP 0030). If problem still
9. Check for defective or improperly Adjust, repair, or replace fuel injection
adjusted fuel injection pump. pump (WP 0028). If problem still
exists, notify Sustainment Mainte-
nance.
2. Excessive Fuel Check for overfueling of engine Adjust, repair, or replace fuel injection
Consumption. caused by defective or improperly pump (WP 0028). If problem still
adjusted fuel injection pump. exists, notify Sustainment Mainte-
nance.
0016-1
TM 5-3805-255-14 0016
Table 1. Engine Troubleshooting Procedures for the H100C Loader - Continued. 016

3. Excessive Engine Speed Check for defective or improperly Adjust, repair, or replace fuel injection
(RPM). adjusted fuel injection pump. pump (WP 0028). If problem still
nance.
4. High Coolant Tempera- 1. Check for defective gauge. Replace gauge. If problem still exists,
ture. go to step 2.
2. Check for low coolant level. Add correct amount and type of cool-
ant (WP 0018). If problem still exists,
go to step 3.
3. Check for collapsed coolant Replace defective hose (WP 0036). If
hose(s). problem still exists, go to step 4.
4. Check for damaged radiator tubes Clean, repair or replace radiator
or fins. (WP 0036). If problem still exists, go
to step 5.
5. Check for stuck thermostats. Replace thermostats (WP 0037). If
6. Check for defective water pump. Replace water pump (WP 0023). If
7. Check for loose fan belts. Adjust or replace fan belt (WP 0018).
If problem still exists, go to step 8.
8. Check for cylinder head gasket If leakage is present, notify
leakage. Sustainment Maintenance.
5. Low Coolant Tempera- 1. Check for defective gauge Replace gauge. If problem still exists,
ture. (WP TBD) check for defective go to step 2.
sending unit (WP 0043).
2. Check for incorrect or inoperative Replace thermostats (WP 0037). If
thermostats. problem still exists, notify Sustainment
Maintenance.
6. Excessive Exhaust 1. Check for defective turbocharger. Inspect, repair, or replace turbo-
Smoke. charger (WP 0030). If problem still
2. Check for excessive air cleaner Inspect and replace fuel filter
restriction. (WP 0018). If problem still exists, go
to step 3.
3. Check for intake manifold Replace manifold gasket (WP 0026).
pressure leakage. If problem still exists, go to step 4.
4. Check fuel injectors. Replace fuel injectors (WP 0027). If
5. Check for overfueling due to Adjust or replace fuel injector pump
improper adjustment of fuel (WP 0027). If problem still exists,
injection pump. notify Sustainment Maintenance.
0016-2
TM 5-3805-255-14 0016
Table 1. Engine Troubleshooting Procedures for the H100C Loader - Continued. 016

7. Low Fuel Supply Pres- 1. Check for dirty or restricted fuel Replace fuel filters (WP 0018). If
sure. filter element. problem still exists, go to step 2.
2. Check for restricted or leaking low Replace fuel lines. If problem still
pressure fuel lines from fuel tank exists, go to step 3.
to inlet of fuel indicator pump.
3. Check for defective or improperly Adjust, repair, or replace injection
nance.
8. Engine “Misfiring”. 1. Check fuel injectors. Clean or replace fuel injectors
(WP 0027). If problem still exists, go
to step 2.
2. Check valve clearance and Adjust valve clearance and timing
timing. (WP 0018). If problem still exists, go
to step 3.
3. Check for cylinder head gasket If cylinder head gasket leaks, and
leakage. problem still exists, notify Sustainment
Maintenance.
4. Check for defective or improperly Adjust, repair, or replace fuel injection
nance.
5. Check for air in fuel system. Bleed fuel system (WP 0018). If
problem still exists, notify Sustainment
Maintenance.
0016-3
TM 5-3805-255-14 0016
Table 2. Electrical Troubleshooting Procedures for the H100C Loader. 016

1. Discharging Battery. Check for electrical circuits. Repair electrical circuits (WP 0020). If
Maintenance.
2. Battery Overheating. 1. Check for high charging output. Replace alternator (WP 0040). If prob-
lem still exists, notify Sustainment
Maintenance.
2. Check for loose connections and Clean and tighten connections or
frayed or damaged wiring. replace wiring. If problem still exists,
notify Sustainment Maintenance.
3. Alternator Charging Check for defective alternator. Replace alternator (WP 0040). If prob-
Output High. lem still exists, notify Sustainment
Maintenance.
4. Alternator Charging No 1. Check for loose connections and Clean and tighten connections or
or Low Output. frayed or damaged wiring. replace wiring. If problem still exists,
go to step 2.
2. Check for defective batteries. Replace batteries (WP 0045). If prob-
lem still exists, go to step 3.
3. Check for oxidized regulator Repair or replace regulator (WP
contact points. 0040). If problem still exists, go to
step 4.
4. Check for defective alternator. Replace alternator (WP 0040). If prob-
lem still exists, notify Sustainment
Maintenance.
5. Noisy Alternator. 1. Check for loose mountings. Tighten mounting. If problem still
2. Check for loose pulley. Tighten pulley. If problem still exists,
go to step 3.
3. Check for defective alternator. Replace alternator (WP 0040). If
Maintenance.
6. Voltmeter Shows Less 1. Check for defective alternator. Replace alternator (WP 0040). If
Than 24 VDC with problem still exists, go to step 2.
Engine at Idle.
2. Check for loose or dirty Clean and tighten connections or
connections. replace wiring (WP 0020). If problem
still exists, notify Sustainment
Maintenance.
7. High Voltage (Voltmeter Check for defective alternator. Replace alternator (WP 0040). If
Reads above 30 VDC). problem still exists, notify Sustainment
Maintenance.
0016-4
TM 5-3805-255-14 0016
Table 2. Electrical Troubleshooting Procedures for the H100C Loader - Continued. 016

8. Starter Motor Will Not 1. Check for loose, dirty, or defective Clean and tighten connections or
Operate or Operates battery cables or terminals. replace wiring (WP 0020). If problem
Slowly. still exists, go to step 2.
2. Check for faulty batteries. Replace batteries (WP 0045). If prob-
3. Check for defective starting switch Repair or replace switch. If problem
(WP 0042). still exists, go to step 4.
4. Check for defective starter motor. Replace starter motor (WP 0041). If
Maintenance.
0016-5
TM 5-3805-255-14 0016
Table 3. Electrical System Instruments Troubleshooting Procedures for the H100C Loader. 016

1. Lights Dim. 1. Check for low battery voltage. Charge or replace batteries
to step 2.
2. Check ground connection. Clean and tighten connections or
replace wiring (WP 0020). If problem
still exists, go to step 3.
3. Check for loose, dirty, or defective Clean and tighten connections, or
connections. replace wiring (WP 0020). If problem
Maintenance.
2. Electrical Gauge Not 1. Check for loose, dirty, or defective Clean and tighten connections, or
Operating. connection at gauge (WP 0043). replace wiring (WP 0020). If problem
still exists, notify Sustainment Mainte-
nance.
2. Check for defective sending unit Replace sending unit (WP 0044). If
(WP 0044). problem still exists, notify Sustainment
Maintenance.
3. Check for defective gauge. Replace gauge. If problem still exists,
3. Ignition On (No Gauges 1. Check for dead battery. Charge or replace batteries
or Lights Working). (WP 0045). If problem still exists, go
to step 2.
2. Check for loose, dirty, or defective Clean and tighten connections and
connection from battery to ignition replace wiring (WP 0020). If problem
switch. still exists, notify Sustainment Mainte-
nance.
4. All Electrical Gauges 1. Check for defective light switch. Replace switch. If problem still exists,
Working (No Lights). go to step 2.
2. Check for defective bulb. Replace bulb. If problem still exists,
0016-6
TM 5-3805-255-14 0016
Table 4. Transmission Troubleshooting Procedures for the H100C Loader.
NOTE
Before troubleshooting problems with the transmission, perform the following
diagnostic checks:
– Engine output.
– Transmission sump oil level.
– Cleanliness of oil and oil filter.
– Airflow through oil cooler.
– Condition of all oil lines and fittings.
– Condition of all wiring and connections.
– Proper linkage positioning of all valves and levers.
– All drive lines and mounting brackets for tightness.
1. Converter Stall. 1. Check for low transmission oil Add correct amount and type of fluid
level. (WP 0018). If problem still exists, go
to step 2.
2. Check for foaming oil. a. Low oil level. Add oil as
needed (WP 0018).
b. Water in oil. Drain oil
(WP 0018).
c. Oil line suction leak.
d. Improper oil. If problem still
3. Check for plugged or restricted Replace lines (WP 0047). If problem
accessory drive and torque still exists, notify Sustainment
converter housing lines. Maintenance.
2. High Oil Temperature. 1. Check for improper loader a. Operate in correct range.
operation. b. Downshift into lower range.
c. If loader remains in stall too
long or if problem still exists,
go to step 2.
2. Check transmission oil level. Add correct amount and type of fluid
to step 3.
3. Check for foaming oil and air a. Add correct amount and type
leaks in suction lines. of fluid (WP 0018).
b. Repair or replace suction lines.
If problem still exists, go to
step 4.
4. Check for clogged oil cooler. Clean or replace oil cooler (WP 0036).
If problem still exists, notify Sustain-
ment Maintenance.
0016-7
TM 5-3805-255-14 0016
Table 4. Transmission Troubleshooting Procedures for the H100C Loader - Continued.

3. Loss of Power. 1. Check for improper loader Operate in proper range for load and
operation. terrain (WP 0005). If problem still
2. Check for dragging parking brake. Adjust linkage to allow full release
to step 3.
3. Check for foaming oil. a. Correct oil level (WP 0013).
b. Check for air leak in suction
line.
c. If oil used is not meeting spec-
ifications or if problem still
4. Check for dragging loader brakes. Check brake linkages. If problem still
5. Check for out-of-adjustment Adjust linkage. If problem still exists,
linkage. notify Sustainment Maintenance.
0016-8
TM 5-3805-255-14 0016
Table 5. Propeller Shafts Troubleshooting Procedures for the H100C Loader. 016
NOTE
• Drive-line failures are usually indicated by noise or vibrations. The noise or vibration may come and go
as different speeds are reached.
• Inspect the areas of the loader around the propeller shafts for signs of grease that may have been
thrown out by the universal joint or slip joints. If grease is found in the area of the universal joints, replace
the grease seals on the spider and bearing assemblies. If grease is found in the area of the slip joint,
tighten the slip joint seal retainer. If the leakage continues, replace the slip joint grease seal.
• Check the drive yokes on the torque converter, transmission, transfer drive, and differentials for
looseness. If the yokes can be moved back and forth any appreciable amount, disconnect the propeller
shaft at the yoke and tighten the yoke mounting nuts or capscrews. Torque the nuts or capscrews as
directed (WP 0132). Before tightening the yoke, check for backlash. Backlash indicates that the yoke
splines are worn and the yoke should be replaced.
• Check the universal joint spider and bearing assemblies for excessive play. If excessive play is found,
replace the spider and bearing assemblies on the propeller shaft.
1. Noise (Propeller Shafts). 1. Check for lack of lubricant. Check grease seals in slip joints and
universals (WP 0013). If problem still
2. Check for excessive backlash due Replace spider and bearing assem-
to worn universal spider or bly (WP 0049). If problem still exists,
bearings. go to step 3.
3. Check for loose mounting yokes. Tighten yoke mounting nuts or cap-
screws. If problem still exists, go to
step 4.
4. Check for worn splines in Replace propeller shaft (WP 0049). If
propeller shaft slip joints. problem still exists, notify Sustainment
Maintenance.
2. Vibration (Propeller 1. Check for sprung or bent propeller Replace propeller shaft (WP 0049). If
Shafts). shaft. problem still exists, go to step 2.
2. Check for improperly seated Correct or replace bearing and spider
universal joint bearings. (WP 0049). If problem still exists, go
to step 3.
3. Check for loose mounting yokes. Tighten mounting nuts or capscrews.
If problem still exists, notify Sustain-
ment Maintenance.
0016-9
TM 5-3805-255-14 0016
Table 6. Transfer Drive Troubleshooting Procedures for the H100C Loader. 016

1. Noise (Transfer Drive). 1. Check for low lubricant level or Fill to FULL mark on dipstick
incorrect lubricant. (WP 0013). If problem still exists, go
to step 2.
2. Check for scored or damaged Replace bearings (WP 0050). If
bearings. problem still exists, notify Sustainment
Maintenance.
2. Loss of Lubricant 1. Check for high lubricant level. Drain and correct level (WP 0018). If
(Transfer Drive). problem still exists, go to step 2.
2. Check for excessively foaming Drain and fill with correct type of
lubricant. lubricant (WP 0018). If problem still
3. Check for worn or broken seals. Replace seals (WP 0050). If problem
Maintenance.
0016-10
TM 5-3805-255-14 0016
Table 7. Front and Rear Axle Troubleshooting Procedures for the H100C Loader. 016
CAUTION
If a failure should occur in the differential, the loader must not be operated under its
own power. If the loader must be moved, disconnect the propeller shaft at the
transmission, or remove the propeller shaft completely. Drain both planetary hubs of
the noisy axle, remove the planetary covers, and pull the axle shafts to prevent further
damage. When shafts are removed, install planetary covers and fill hubs before
moving loader. The loader may be driven a short distance with one axle if the propeller
shafts and axle shafts are removed from the noisy axle or differential. Failure to comply
will damage equipment.
NOTE
• Noise and vibration originating in the transmission, drive shafts, or tires is often
attributed to an axle. The source of noise should be investigated before deciding that
the cause is in the axle.
• Axle noise may be isolated within the axle by jacking up the loader so the tires clear the
ground. If the noise is in one axle, disconnect the propeller shaft of the opposite axle at
the transmission. Now the noise may be isolated with only the noisy axle turning. Run
the engine at a moderate speed with the transmission in first gear. Both wheels must
be off the ground to prevent damage to the differential.
1. Noise (Axles). Check lubricant level. Add correct amount and type of lubri-
cant (WP 0013). If problem still exists,
2. Loss of Lubricant 1. Check lubricant level. Add correct amount and type of lubri-
(Axles). cant (WP 0013). If problem still exists,
go to step 2.
2. Check for lubricant foaming Drain and add correct amount and
excessively. type of lubricant (WP 0013). If prob-
3. Check for lubricant leaks at If leaks are present or problem still
planetary cover. exists, notify Sustainment Mainte-
nance.
0016-11
TM 5-3805-255-14 0016
Table 8. Brake System Troubleshooting Procedures for the H100C Loader.
WARNING
Ensure wheels are chocked to prevent loader from moving. Failure to follow this
warning may result in death or injury to personnel.
1. Brakes Drag. 1. Check for incorrectly adjusted Adjust brake lining (WP 0059). If
brakes. problem still exists, go to step 2.
2. Check for broken return springs. Replace spring (WP 0059). If problem
3. Check for broken wedge return Replace spring (WP 0059). If problem
spring. still exists, notify Sustainment
Maintenance.
2. Inadequate Braking. 1. Check brake adjustment. Adjust brake linings (WP 0059). If
2. Check for worn brake linings. Replace brake linings (WP 0059). If
3. Check for low fluid level in power Add or replace fluid (WP 0013). If
cluster. problem still exists, go to step 4.
4. Check for defective wheel Repair or replace wheel cylinder
cylinders. (WP 0059). If problem still exists, go
to step 5.
5. Check air system for leaks. Fix air leaks. Repair or replace
components as needed. If problem
6. Check for defective brake treadle Clean, repair, or replace treadle valve
valve delivery pressure. (WP 0061). If problem still exists, go
to step 7.
7. Check for defective power cluster. Repair or replace power cluster
to step 8.
8. Check for restricted air or Repair or replace lines. If problem still
hydraulic lines. exists, notify Sustainment
Maintenance.
0016-12
TM 5-3805-255-14 0016
Table 8. Brake System Troubleshooting Procedures for the H100C Loader - Continued.

3. Brakes Apply Too 1. Check brake adjustment Adjust brake linings (WP 0059). If
Slowly. problem still exists, go to step 2.
2. Check air pressure in brake Inspect for leaks, and repair or
system. replace components as necessary. If
valve. (WP 0061). If problem still exists, go
to step 4.
4. Check for leakage in air system. Inspect for leaks, and repair or
replace components as necessary. If
Maintenance.
4. Brakes WIll Not Apply. 1. Check for no air pressure in brake Inspect, repair, or replace air
system. compressor. If problem still exists, go
to step 2.
valve. (WP 0061). If problem still exists, go
to step 3.
3. Check for low fluid level in power Add correct amount and type of fluid
cluster. (WP 0013). If problem still exists, go
to step 4.
to step 5.
cylinders. (WP 0059). If problem still exists,
5. Brakes Do Not Release 1. Check for broken brake shoe Replace spring (WP 0059). If problem
or Release Too Slowly. return springs. still exists, go to step 2.
to step 3.
3. Check for defective brake treadle Clean, lubricate, or repair treadle
valve. valves (WP 0061). If problem still
to step 5.
Maintenance.
0016-13
TM 5-3805-255-14 0016

6. Brakes Grab When 1. Check for grease on brake lining. Reline brakes (WP 0059). If problem
Applied. still exists, go to step 2.
2. Check for brake drum out of Service or replace drum (WP 0059). If
round. problem still exists, go to step 3.
3. Check for defective brake treadle Clean, lubricate, or repair treadle
exists, notify Sustainment
Maintenance.
7. Brakes Pull When 1. Check brake adjustment. Adjust brake linings (WP 0059). If
Applied. problem still exists, go to step 2.
2. Check for low fluid level in power Add correct amount and type of fluid
clusters. (WP 0013). If problem still exists, go
to step 3.
3. Check brake linings. Replace brake linings (WP 0059). If
to step 5.
5. Check for broken brake return Replace spring (WP 0059). If problem
spring. still exists, go to step 6.
to step 7.
7. Check for brake drum out of Service or replace drum (WP 0059). If
round. problem still exists, notify Sustainment
Maintenance.
8. Air Pressure Will Not 1. Check for defective air pressure Replace gauge (WP 0084). If problem
Rise to Normal Reading. gauge. still exists, go to step 2.
2. Check for excessive leakage in air Inspect for leaks and repair or replace
system. components as necessary. If problem
3. Check for open air reservoir drain. Close air reservoir drain. If problem
4. Check for improper governor Adjust governor (WP 0032). If
adjustment. problem still exists, go to step 5.
5. Check for defective compressor. Repair or replace compressor
(WP 0064 or WP 0065). If problem
Maintenance.
0016-14
TM 5-3805-255-14 0016

9. Air Pressure Rises to 1. Check for excessive leakage in air Inspect for leaks and repair or replace
Normal Reading Too system. components as necessary. If problem
Slowly. still exists, go to step 2.
2. Check for slow engine speed. Adjust engine speed (WP 0028). If
3. Check for leaking compressor Repair or replace compressor
discharge valves. (WP 0064 or WP 0065). If problem
4. Check for defective compressor. Repair or replace compressor
nance.
10. Air Pressure Rises 1. Check for defective air pressure Replace gauge (WP 0084). If problem
Above Normal Reading. gauge. still exists, go to step 2.
2. Check for improper governor Adjust, repair, or replace governor
adjustment. (WP 0032). If problem still exists, go
to step 3.
3. Check for defective governor. Repair or replace governor
to step 4.
4. Check for restricted line from Clean, repair, or replace line. If
governor and compressor problem still exists, go to step 5.
unloading mechanism.
5. Check for defective compressor. Clean, repair or replace compressor
nance.
11. Air Pressure Drops Too 1. Check for leaking brake treadle Clean, lubricate, or repair treadle
Quickly with Engine valve. valves (WP 0061). If problem still
Stopped and Brakes exists, go to step 2.
Released.
2. Check for leaking hoses or lines. Repair or replace lines. If problem still
3. Check for leaking compressor Clean, lubricate, or repair compres-
discharge valve. sor (WP 0064 or WP 0065). If problem
4. Check for leaking governor. Clean, repair, or replace governor
(WP 0032). If problem still exists,
0016-15
TM 5-3805-255-14 0016

12. Air Pressure Drops Too 1. Check for leaking power cluster. Replace power cluster (WP 0060). If
Quickly wIth Engine problem still exists, go to step 2.
Stopped and Brakes
Applied.
2. Check for leaking brake treadle Clean, lubricate, or repair treadle
3. Check for leaking hoses or lines. Repair or replace lines. If problem still
Maintenance.
13. Noisy Compressor. 1. Check for inadequate lubrication. Check oil supply line. If problem still
2. Check for excessively worn Repair or replace compressor
compressor. (WP 0064 or WP 0065). If problem
Maintenance.
14. Excessive Water or Oil in Check for defective compressor. Repair or replace compressor
System. (WP 0064 or WP 0065). If problem
Maintenance.
Table 9. Parking Brake Troubleshooting Procedures for the H100C Loader. 016

1. Lever Will Not Operate. 1. Check for incorrect linkage or Adjust linkage (WP 0057). If problem
lever adjustment. still exists, go to step 2.
2. Check for defective or binding Clean or replace components
lever joints. (WP 0057). If problem still exists, go
to step 3.
3. Check for defective or binding Clean or replace components
brake mechanism. (WP 0059). If problem still exists,
2. Brake Will Not Hold. 1. Check for incorrect linkage or Adjust linkage (WP 0057). If problem
lever adjustment. still exists, go to step 2.
2. Check for broken linkage. Replace linkage (WP 0057). If
3. Check for broken drum. Replace drum (WP 0059). If problem
4. Check for defective brake Replace components (WP 0059). If
mechanism. problem still exists, notify Sustainment
Maintenance.
0016-16
TM 5-3805-255-14 0016
Table 10. Steering Gear Troubleshooting Procedures for the H100C Loader. 016

1. Gear Noise (Rattle or Check for loose gear mounting. Tighten gear mounting (WP 0068). If
Chuckle). problem still exists, notify Sustainment
Maintenance.
2. Hard Steering. 1. Check for lack of lubrication in Lubricate linkage (WP 0013). If
linkage. problem still exists, go to step 2.
2. Check for tires not properly Set tire pressure (WP 0002). If
inflated. problem still exists, notify Sustainment
Maintenance.
Table 11. Hydraulic General Troubleshooting Procedures for the H100C Loader. 016

1. Poor Hydraulic System 1. Check for defective main Clean or replace main hydraulic pump
Performance or Failure. hydraulic pump. (WP 0077). If problem still exists, go
to step 2.
2. Check for defective reservoir Clean or replace reservoir relief valve
relief valve. (WP 0079). If problem still exists, go
to step 3.
3. Check for worn cylinders. Replace worn cylinders (WP 0081
and WP 0082). If problem still exists,
go to step 4.
4. Check main control valve linkage. Adjust linkage (WP 0078). If problem
5. Check reservoir level. Add correct amount and type of fluid
to step 6.
6. Check for clogged system filter Clean or replace filters (WP 0018). If
screen. problem still exists, go to step 7.
7. Check for restrictions in lines. Clean, repair, or replace lines.
2. Excessive Oil Foaming. Check hydraulic fluid level. Add correct amount and type of fluid
0016-17
TM 5-3805-255-14 0016
Table 12. Hydraulic Main Control Valve Troubleshooting Procedures for the H100C Loader. 016

1. Difficult Operation or 1. Check for fittings too tight. Clean or replace valve. If problem still
Sticking of Control Valve exists, go to step 2.
Plungers.
2. Check for binding linkage. Clean, adjust, or replace linkage. If
Maintenance.
2. Load Will Not Hold. Check for leaking valve plunger. Replace main control valve
3. Leaking Seals. Check for scored plunger. Replace main control valve
Table 13. Hydraulic Pump Troubleshooting Procedures for the H100C Loader. 016

1. Pump Does Not Deliver 1. Check for sheared or disengaged Replace hydraulic pump (WP 0077). If
Fluid. shaft. problem still exists, go to step 2.
2. Check for restrictions in lines. Clean, repair or replace lines. If
3. Check hydraulic oil. Add correct amount and type of oil
2. Pump Making Noise. 1. Check hydraulic oil level. Add correct amount and type of oil
to step 2.
2. Check for foaming oil. Drain and add correct amount and
type of fluid (WP 0018). If problem still
3. Check for vortex or spiral in oil Check installation and condition of
circulating in reservoir. filter/screens (WP 0018). If problem
4. Check for sheared or disengaged Replace hydraulic pump (WP 0077). If
shaft. problem still exists, notify Sustainment
Maintenance.
0016-18
TM 5-3805-255-14 0016
Table 14. Hydraulic Steering Control Valve Troubleshooting Procedures for the H100C Loader. 016

1. Hard Steering When 1. Check hydraulic oil level. Add correct amount and type of fluid
Turning Slowly. (WP 0018). If problem still exists, go
to step 2.
2. Check for restrictions in lines. Clean, repair, or replace lines. If
3. Check for leaking steering control Replace control valve (WP 0072). If
valve. problem still exists, notify Sustainment
Maintenance.
2. No Effort Required to Check for loose control valve. Tighten control valve (WP 0072). If
Turn. problem still exists, notify Sustainment
Maintenance.
3. Momentary Increase in Check hydraulic oil level. Add correct amount and type of oil
Effort Required When (WP 0018). If problem still exists,
Turning Wheel Quickly. notify Sustainment Maintenance.
4. Excessive Wheel Kick- Check for foaming oil. Drain and add correct amount and
back or Loose Steering. type of fluid (WP 0018). If problem still
Maintenance.
END OF WORK PACKAGE
0016-19/(20 blank)
22
TM 5-3805-255-14
CHAPTER 6
FIELD PREVENTIVE MAINTENANCE CHECKS
AND SERVICES (PMCS)
4
TM 5-3805-255-14 0017
FIELD MAINTENANCE -
FIELD PREVENTIVE MAINTENANCE

0 0 1 7
CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL 00017
1. To ensure that the H100C is ready for operation at all times, it must be inspected on a regular basis so that
defects may be found and corrected before they result in injury, damage, or equipment failure.
2. The PMCS Table in WP 0018 contains systematic instructions on inspections, lubrications, services, tests, and
corrections to be performed by the operator to keep the equipment in good operating condition and ready for
its primary mission.
EXPLANATION OF TABLE ENTRIES 00017
1. Item No. Column. Numbers in this column are for reference. When completing DA Form 2404 or DA Form
5988-E (Equipment Inspection and Maintenance Worksheet), include the item number for the check/service
indicating a fault. Item numbers also appear in the order that you must perform checks and services for the
interval listed.
2. Interval Column. This column tells you when you must perform the procedure in the Procedure column:
a. Weekly procedures must be done once each week.
b. Bimonthly procedures must be done twice each month.
c. Monthly procedures must be done once each month.
d. Quarterly procedures must be done once every three months.
e. Semiannual procedures must be done once every 6 months.
f. Annual procedures must be done once each year.
g. Biennial procedures must be done once every two years.
h. Initial 100 Hours must be done after the first 100 hours of operation.
i. Periodic procedures must be done as needed.
3. Item to Check/Service Column. This column lists the item to be checked or serviced.
NOTE
The WARNINGs and CAUTIONs appearing in your PMCS table should always be
observed. WARNINGs and CAUTIONs appear before applicable procedures. You must
observe these WARNINGs to prevent injury or death to yourself and others, and
CAUTIONs to prevent your equipment from being damaged.
4. Procedure Column. This column gives the procedure you must perform to check or service the item listed in
the Item to Check/Service column to know if the equipment is ready or available for its intended mission. You
must perform the procedure at the time stated in the Interval column.
5. Not Fully Mission Capable If: Column. Information in this column tells you what faults will keep your
equipment from being capable of performing its primary mission. If you perform check/service procedures that
show faults listed in this column, the equipment is not mission-capable. Follow standard operating procedures
for maintaining the equipment or reporting equipment failure.
0017-1
TM 5-3805-255-14 0017
GENERAL LUBRICATION PROCEDURES 00017
NOTE
Refer to WP 0018 for lubrication chart, key, localized views, and procedural notes.
1. Recommended intervals are based on normal conditions of operation, temperature, and humidity. When
operating under extreme conditions, lubricants should always be changed more frequently. When in doubt,
notify your supervisor.
2. Keep all lubricants in a closed container and store in a clean, dry place away from extreme heat or cold. Keep
container covers clean and do not allow dust, dirt, or other foreign material to mix with lubricants. Keep all
lubrication equipment clean and ready for use.
3. Maintain a good record of all lubrication performed and report any problems noted during lubrication. Refer to
DA PAM 750-8 for maintenance forms and procedures to record and report any findings.
4. Keep all external parts of equipment not requiring lubrication free of lubricants. Before lubrication, wipe
lubrication fittings with a clean rag (WP 0131, Item 28). After lubrication, wipe off excess oil or grease to
prevent accumulation of foreign matter.
5. Refer to FM 9-207 for lubrication instructions in cold weather.
6. Refer to AR 70-12 for use of standardized lubricants.
GENERAL PMCS PROCEDURES 00017
1. Always perform PMCS in the same order so it becomes a habit. Once you have had some practice, you will
spot anything wrong quickly. If the equipment does not perform as required, refer to the appropriate
troubleshooting procedure in Chapter 7.
2. If anything looks wrong, and you cannot fix it, write it on your DA Form 2404 or DA Form 5988-E. If you find
something seriously wrong, IMMEDIATELY report it to your supervisor.
3. Before performing preventive maintenance, read all the checks required for the applicable interval and prepare
all that is needed to make all the checks. You will always need a rag (WP 0131, Item 28) or two.
0017-2
TM 5-3805-255-14 0017
WARNING

and goggles. Use in well-ventilated areas. Keep away from open flames and other
sources of ignition. Failure to follow this warning may result in injury or death.
CAUTION
Be especially careful when cleaning electrical system components including lighting.
Damage or impaired operation could result if this caution is not observed.
a. Keep Equipment Clean. Dirt, grease, oil, and debris get in the way and may cover up a serious problem.
Clean as you work and as needed. Use solvent cleaning compound (WP 0131, Item 4) on all metal
surfaces. Use detergent (WP 0131, Item 10) and water when you clean rubber, plastic, and painted
surfaces. Spot paint as required to prevent corrosion.
b. Bolts, Nuts, and Screws. Ensure that they are not loose, missing, bent, or broken. Report loose, missing,
or damaged bolts, nuts, and screws to your supervisor.
c. Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. Report bad welds to
your supervisor.
d. Electrical Wires and Connectors. Look for cracked or broken insulation, bare wires, and loose or broken
connectors. Report loose connections and faulty wiring to your supervisor.
e. Hoses, Lines, and Fittings. Look for wear and damage. Check for loose clamps and fittings. Report any
worn, damaged, or loose hoses, lines, and fittings to your supervisor.
END OF WORK PACKAGE
0017-3/(4 blank)
62
TM 5-3805-255-14 0018
FIELD MAINTENANCE -
0 0 1 8 FIELD PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(PMCS) INCLUDING LUBRICATION INSTRUCTIONS
INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP Oil, Lubricating, OEA-30 Arctic (WP 0130,
0128, Item 20) 0 Item 25) 0
Rag, Wiping (WP 0130, Item 28) 0
Materials/Parts 0
Antifreeze (WP 0130, Item 2) 0

Personnel Required 0
Cleaning Compound, Solvent, Type III (WP Two 0
0130, Item 4) 0
References 0
Detergent, General Purpose, Liquid (WP

0130, Item 10) 0
DA PAM 750-8 0
Fuel, Diesel, DF-2 Grade (WP 0130, Item 13) 0

FM 9-207 0
Grease, Automotive and Artillery (GAA) (WP TB 750-651 0
0130, Item 15) 0 TM 750-254 0
Oil, Lubricating, OE/HDO-10 (WP 0130, Item WP 0002 0
22) 0
WP 0005 0
Oil, Lubricating, OE/HDO-15/40 (WP 0130, WP 0027 0
Item 23) 0
WP 0057 0
WP 0059 0
WP 0132 0
0018-1
TM 5-3805-255-14 0018
Table 1. Field PMCS for the H100C Loader.
LOCATION
ITEM TO
LEFT FRONT
1 Bimonthly Lug Nuts Check wheel lug nuts for correct Two or more lug nuts missing.
torque (WP 0131).
2 Bimonthly Tire Check tire for correct inflation Tire does not hold pressure.
(WP 0002).
3 Monthly Axle Breather a. Completely lower bucket, apply Class III oil leak is evident.
parking brake, and shut down engine
(WP 0005).
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an

environmentally compliant and low-toxic material. However, it
may be irritating to the eyes and skin. Use protective gloves
and goggles. Use in well-ventilated areas. Keep away from
open flames and other sources of ignition. Failure to do so may
result in injury or death to personnel.
b. Unscrew breather and clean with

cleaning solvent.
c. Dry breather with compressed air

and install.
0018-2
TM 5-3805-255-14 0018
Table 1. Field PMCS for the H100C Loader - (Continued).
LOCATION
ITEM TO
3 Monthly Axle Breather

(Cont.)
Figure 1. Axle Breather. 0018
ARTICULATION
AREA
4 Semiannually Propeller Shaft After every 1,000 hours of loader a. Class III grease leak is
Lubrication operation and after an overhaul, apply evident.
lubricant to all propeller shaft universal
b. Propeller shaft damaged or
joints and slip joints. Refer to Table 6,
missing.
grade and quantity of lubricant
required.
0018-3
TM 5-3805-255-14 0018
LOCATION
ITEM TO
4 Semiannually Torque Converter- NOTE

(Cont.) to-Transmission
Fittings (three total) are located one at each end of the propeller
shaft in the spider, and one in the slip tube.
a. Wipe grease fittings clean with a

rag.

Transmission-to- NOTE
Rear Axle
Fittings (three total) are located one at each end of the propeller
c. Wipe grease fittings clean with a

rag.
d. Apply GAA grease to fittings. Wipe

Transmission-to- NOTE
Intermediate
Block Fittings (three total) are located one at each end of the propeller
e. Wipe grease fittings clean with a

rag.
f. Apply GAA grease to fittings. Wipe

0018-4
TM 5-3805-255-14 0018
LOCATION
ITEM TO
4 Semiannually Intermediate NOTE

(Cont.) Block-to-Front
Axle Fittings (three total) are located one at each end of the propeller
g. Wipe grease fittings clean with a

rag.
h. Apply GAA grease to fittings. Wipe

Figure 2. Propeller Shaft Lubrication. 0018
0018-5
TM 5-3805-255-14 0018
LOCATION
ITEM TO
The following procedure must be done

LEFTSIDE as needed.
ENGINE
5 Periodic Ether Injector

WARNING
x DO NOT smoke or permit any open flame in area of H100C

while you are servicing the Ether injection system. Failure to
follow this warning may result in injury or death to personnel
or damage to equipment.
x DO NOT perform Ether Injection system checks, inspections,
or maintenance while smoking or near fire, flames, or sparks.
Ether may ignite, and may result in injury or death to
personnel or damage to equipment.
x Observe the precautions printed on the ether container when
using or storing ether. When disposing of ether containers
consult your unit/local hazardous waste disposal center or
safety office for local regulatory guidance.
CAUTION
Improper starting fluids can cause valve seizure and severe
damage to the engine.
Make certain ether is available under
pressure. To do so, remove ether container
and check if a good spray is obtained. If
not, replace with a new container. If a
good spray was obtained, reinstall
container and test ether injector as follows:
a. Disconnect ether tube at spray

nozzle in engine manifold. Remove
spray nozzle.
b. Reconnect nozzle to tube.
c. Direct nozzle away from engine
and actuate ether injector.
d. Dribbling or no spray indicates a
blocked spray nozzle or tube. If
necessary, clean or replace spray
nozzle and/or tube.
0018-6
TM 5-3805-255-14 0018
LOCATION
ITEM TO
6 Bimonthly Turbocharger e. As a precaution against dirt getting Class III oil leak is evident.
into engine, frequently inspect flexible
rubber hose connections clamped to
turbocharger compressor housing. If
signs of deterioration are evident,
replace immediately.
f. To eliminate undue strain on rubber

hose connections, ensure pipes are
properly aligned.
7 Monthly Air Compressor a. Loosen fan guard mounting bolts Belt missing.
Belt Adjustment and remove fan guard.
b. Loosen four compressor mounting

nuts.
c. Move compressor out to tighten

belt or in to loosen it.
d. When correct belt tension is

obtained, tighten nuts. Refer to Table 2
and Table 3.
e. Install fan guard.
Figure 3. Air Compressor Belt Adjustment.

0018
0018-7
TM 5-3805-255-14 0018
LOCATION
ITEM TO
7 Monthly Air Compressor

(Cont.) Belt Adjustment
Table 2. Belt Tension Chart.
AIR COMPRESSOR
CONDITION BELT
New Belt Installation 95 to 100 lb

New Machine Upon Delivery 80 to 85 lb
1 Hour After Belt Replacement
After 10 Hours of Operation
At Intervals of 200 Hours
Minimum Permissible Tension 60 lb
Table 3. Belt Tension Chart (Deflection Method).
AIR COMPRESSOR
CONDITION BELT
New Belt Installation 3/4 in. (19 mm)

New Machine Upon Delivery 13/16 in.
1 Hour After Belt Replacement ( 21 mm)
Minimum Permissible Tension 7/8 in. (22 mm)
8 Biennially Starter Starter must be lubricated every Broken motor housing or gear.
Lubrication 5,000 hours under normal starting
conditions, or sooner, should it
become necessary to remove motor in
process of engine servicing.
0018-8
TM 5-3805-255-14 0018
LOCATION
ITEM TO
LEFT REAR
torque (WP 0132).
(WP 0002).
RIGHT REAR
torque (WP 0132).
(WP 0002).
13 Monthly Axle Breather a. Completely lower bucket, apply Class III oil leak is evident.
parking brake, and shut down engine
(WP 0005).
WARNING

b. Unscrew breather and clean with

cleaning solvent.
0018-9
TM 5-3805-255-14 0018
LOCATION
ITEM TO
13 Monthly Axle Breather c. Dry breather with compressed air

(Cont.) and install.
Figure 4. Axle Breather. 0018
0018-10
TM 5-3805-255-14 0018
LOCATION
ITEM TO
RIGHT SIDE WARNING

ENGINE
14 Weekly Fuel Tank

• DO NOT smoke or permit any open flame in area of H100C
while you are servicing fuel system. Be sure hose nozzle is
grounded against filler tube during refueling to prevent static
electricity.
• DO NOT perform fuel system checks, inspections, or mainte-
nance while smoking or near fire, flames, or sparks.
• Wear fuel-resistant gloves and eye protection when handling
fuels. If exposed to fuel, promptly wash exposed skin and
change fuel-soaked clothing.
• Failure to follow these warnings may result in injury or death to
personnel and damage to equipment.
Drain water from fuel tank by removing Class I fuel leak from fuel tank
drain plugs in bottom of tank. Replace evident.
drain plugs when clean fuel begins to
flow.
DRAIN
PLUG
Figure 5. Fuel Tank Drain Plug.
0018-11
TM 5-3805-255-14 0018
LOCATION
ITEM TO
15 Periodic Fuel System The following procedure must be done

as needed.
NOTE
All air must be eliminated from fuel lines before engine will
operate properly. All fuel line connections must be tight to pre-
vent leakage and to prevent air from entering system. System
must be vented when:
• Starting an engine that has not been operated for an
extended period of time.
• An engine, in operation, runs out of fuel.
• Fuel filters have been replaced.
• Fuel piping has been disconnected or loosened.
Vent fuel system as follows: Class III fuel leak is evident.

a. Fill fuel tank.
b. Unlock plunger of hand priming

pump by rotating counterclockwise.
c. Open vent on final filter.
d. Pump fuel into system using pump

plunger until a stream of fuel comes
out of final filter vent.
e. Close vent on final filter.
f. Lock priming pump plunger by

pressing in and rotating clockwise until
tight.
0018-12
TM 5-3805-255-14 0018
LOCATION
ITEM TO
15 Periodic Fuel System CAUTION

(Cont.)
If priming pump plunger is not tight, it will back out due to vibra-
tion during operation and it will literally blow out.
g. Start engine. With engine at low

idle, reopen vent on final filter and
allow fuel to flow until free of air
bubbles.
Figure 6. Priming and Venting the Fuel System. 0018
0018-13
TM 5-3805-255-14 0018
LOCATION
ITEM TO
16 Monthly Engine Oil and

Filter Change WARNING
• When servicing this equipment, performing maintenance, or

disposing of materials such as engine/hydraulic oils, coolant,
and fuel, consult your unit/local hazardous waste disposal cen-
ter or safety office for local regulatory guidance.
• Engine/hydraulic oils, coolant, and fuel can be very slippery.
Immediately wipe up any spills.
• Engine and oil may be hot. Use gloves.
• Failure to follow these warnings may result in injury to
personnel.
a. Park loader on level ground and Class III engine oil leak is evi-
apply parking brake. Run engine until dent.
it reaches normal operating
temperatures, then shut down engine
(WP 0005).
b. Allow 10 minutes for oil to drain

back into crankcase. Place a container
under crankcase drain plug to catch
oil. Remove crankcase drain plug.
c. After oil has drained completely,

reinstall drain plug.
d. Clean outside of filters to prevent

dirt from entering system while
servicing.
e. Remove spin-on filters by turning

them counterclockwise. Discard filters.
f. Apply a little engine oil to seal of

new filters and thread new filters on by
hand. Turn clockwise until filter seal
contacts header, then turn filter by
hand one full turn more. Do not use
tools to tighten filters.
0018-14
TM 5-3805-255-14 0018
LOCATION
ITEM TO
16 Monthly Engine Oil and g. Remove oil filter plug and fill
(Cont.) Filter Change crankcase with fresh oil. Refer to
Table 6, Lubricants, in this work
package for grade and quantity of fluid
required. Install filter plug.
Figure 7. Crankcase Drain Plug. 0018
h. Operate engine at low idle for 5 to

10 minutes (WP 0005). Do not operate
under load until normal oil pressure
and temperature are reached. During
warm-up, check filters and crankcase
drain plug for leakage.
0018-15
TM 5-3805-255-14 0018
LOCATION
ITEM TO
16 Monthly Engine Oil and i. Shut down engine. Allow

(Cont.) Filter Change 10 minutes for oil to drain back into
crankcase. Check engine oil level with
engine oil level gauge.
Figure 8. Engine Lubricating Oil Filters. 0018
0018-16
TM 5-3805-255-14 0018
LOCATION
ITEM TO
16 Monthly Engine Oil and

(Cont.) Filter Change
Figure 9. Crankcase Oil Filler Cap and Level Gauge. 0018
17 Semiannually Transmission Oil

Change
WARNING

• Transmission and oil may be hot. Use gloves.
personnel.
a. After reaching operating Class III transmission oil leak

temperature, park loader on level is evident.
ground. Lower bucket to ground, apply
parking brake, and shut engine down
(WP 0005).
b. Install safety bar (WP 0005).
0018-17
TM 5-3805-255-14 0018
LOCATION
ITEM TO
17 Semiannually Transmission Oil c. Place container under transmission

(Cont.) Change to catch oil.
d. Remove drain plug from

transmission immediately after
operation while lubricant is still warm.
e. Unscrew transmission oil level

gauge and remove. This will vent case
and allow oil to drain faster.
f. Open vent valve on top right side of

transmission and torque converter oil
cooler. Cooler is mounted to rear of
radiator.
g. After lubricant has drained, service

transmission filter element. Refer to
“Transmission Oil Filter Change” in
this work package.
h. Install transmission drain plug.

Close oil cooler vent valve.
Figure 10. Transmission Sump Strainer and Drain Plug. 0018
0018-18
TM 5-3805-255-14 0018
LOCATION
ITEM TO
17 Semiannually Transmission Oil i. Loosen split flange clamp bolts and

(Cont.) Change disconnect hose from sump strainer
and position aside.
j. Loosen bolts and remove strainer

assembly from transmission.
k. Remove gasket from between

strainer and housing. Remove all
gasket material from metal surfaces.
l. Unscrew strainer from valve portion

of strainer assembly.
Figure 11. Sump Strainer Assembly. 0018
m. Look down inside of pipe portion of

valve and inspect spring for breakage.
Figure 12. Transmission Oil Cooler Vent Valve. 0018
0018-19
TM 5-3805-255-14 0018
LOCATION
ITEM TO
17 Semiannually Transmission Oil n. Push down on stem inside of pipe

(Cont.) Change and inspect mating surface of rubber
disc for excessive wear. Replace valve
assembly if necessary.
WARNING
• Solvent cleaning compound MIL-PRF-680 Type III is an envi-

ronmentally compliant and low-toxic material. However, it may
be irritating to the eyes and skin. Use protective gloves and
goggles. Use in well-ventilated areas. Keep away from open
flames and other sources of ignition. Failure to do so may result
in injury or death to personnel.
• Particles blown by compressed air are hazardous. DO NOT
goggles or face shield.
• Failure to follow these warnings may result in injury or damage
to personnel.
o. Wash valve assembly and strainer

in cleaning solvent. Remove all metal
particles from magnetic rods on
strainer. If necessary, rods may be
removed. Dry parts with compressed
air.
p. Assemble strainer onto valve

assembly.
q. Install a new gasket over strainer

and align holes with retaining plate
mounting holes.
r. Install strainer assembly in

transmission and secure in place with
bolts previously removed.
0018-20
TM 5-3805-255-14 0018
LOCATION
ITEM TO
17 Semiannually Transmission Oil s. Attach hose to sump strainer and

(Cont.) Change secure with split flange clamps.
t. Fill transmission with fresh

lubricant through fill-check pipe. Refer
to Table 6, Lubricants, in this work
required. Install transmission level
gauge.
u. Remove safety bar (WP 0005).

Operate loader with no load until
transmission oil reaches a normal
operating temperature (approximately
150° to 200°F ([65° to 90°C]).
v. Install transmission level gauge

and check oil level.
w. Park loader on level ground. Place

transmission in neutral leaving engine
running. Apply parking brake.
x. Install safety bar (WP 0005).
y. Check transmission oil level.
z. Remove safety bar (WP 0005).
0018-21
TM 5-3805-255-14 0018
LOCATION
ITEM TO
18 Quarterly Transmission Oil

Filter Change
WARNING

Immediately wipe up any spills. Failure to follow this warning
may result in injury to personnel.
• Transmission and oil may be hot. Use gloves to prevent injury.
NOTE
Filter is located on left-hand side of loader.
a. Drain transmission oil as described Class III transmission oil leak

under “Transmission Oil Change” in is evident.
this work package.
b. Clean area around filter head.

Remove drain plug. After filter has
drained, install plug.
c. Remove four screws securing body

to head. Separate body from head.
d. Remove element from body.

Remove and discard O-rings and seal
ring.
0018-22
TM 5-3805-255-14 0018
LOCATION
ITEM TO

WARNING

e. Clean body in cleaning solvent and

dry thoroughly.
f. Install new element, O-rings, and

seal ring in body.
g. Install body and four screws on

head.
h. Fill transmission oil as described

under “Transmission Oil Change” in
this work package.
0018-23
TM 5-3805-255-14 0018
LOCATION
ITEM TO

Figure 13. Transmission Oil Filter. 0018
0018-24
TM 5-3805-255-14 0018
LOCATION
ITEM TO
19 Periodic Safety Filter NOTE

Element Replace the safety filter element with every third change of the
Replacement outer element or when plugged as shown by the service
indicator.
a. Remove wing nut (and clamp if

equipped) and remove cover.
b. Remove wing bolt, seal, and

primary element.
NOTE
Be careful not to dislodge dust from the dirty element onto the
safety element.
c. Check condition of seal. If seal is

damaged or missing, replace.
Figure 14. Air Filter.
0018
0018-25
TM 5-3805-255-14 0018
LOCATION
ITEM TO
19 Periodic Safety Filter d. Remove nut, seal, and safety filter

(Cont.) Element element.
Replacement e. Insert open end of safety filter
element into air cleaner body. Install
seal. Secure element with nut.
f. Install open end of primary element

into air cleaner body over safety
element.
g. Install seal and wing bolt.
h. Install cover. Tighten wing nut.
i. Install clamp (if equipped).
0018-26
TM 5-3805-255-14 0018
LOCATION
ITEM TO
20 Monthly Alternator Belt a. Remove fan guard (WP 0005). Belt missing.
Adjustment
b. Loosen brace bolt and mounting

bolt.
Figure 15. Alternator Belt Adjustment. 0018
0018-27
TM 5-3805-255-14 0018
LOCATION
ITEM TO
20 Monthly Alternator Belt c. Move alternator out to tighten belt,

(Cont.) Adjustment or in to loosen belt, until correct
tension is obtained. Refer to Table 4
and Table 5.
CAUTION
Excess belt tension will damage alternator bearings. If a pry bar
is used, DO NOT OVER TENSION.
d. Tighten brace bolt and mounting

bolt.
e. Install fan guard (WP 0005).
Table 4. Belt Tension Chart.
ALTERNATOR BELT
CONDITION
New Belt Installation 70 to 75 lb

New Loader Upon Delivery 60 to 65 lb
1 Hour After Belt Replacement
Minimum Permissible Tension 45 lb
Table 5. Belt Tension Chart (Deflection Method).
ALTERNATOR BELT
CONDITION
New Belt Installation 7/8 in.

(22 mm)
New Loader Upon Delivery 29/32 in.
1 Hour After Belt Replacement (23 mm)
Minimum Permissible Tension 1 in.
(25 mm)
0018-28
TM 5-3805-255-14 0018
LOCATION
ITEM TO
21 Monthly Transmission
Breather
WARNING

ronmentally compliant and low-toxicity material. However, it
personnel.
NOTE
Breather is located at top of transmission in housing.
Unscrew breather to remove and Class III oil leak is evident.

clean it in a cleaning solvent. Dry
breather with compressed air and
install.
0018-29
TM 5-3805-255-14 0018
LOCATION
ITEM TO
21 Monthly Transmission
(Cont.) Breather
Figure 16. Transmission Breather. 0018
22 Quarterly Fan Hub Lubricate fan hub. Fan damaged or missing.

Lubrication
23 Annually Engine Valve

Clearance
Adjustments
Figure 17. Valve Arrangement. 0018
0018-30
TM 5-3805-255-14 0018
LOCATION
ITEM TO
23 Annually Engine Valve

(Cont.) Clearance
Adjustments
WARNING
Before making any adjustments place the battery disconnect
switch in the OFF position. Failure to comply could cause injury
to personnel and damage to equipment.
NOTE
• Following this simplified procedure, all valves can be adjusted
quickly and accurately. Note that the engine need not be
cranked six times to position the piston of each cylinder on
TDC. All valves are adjusted by cranking the engine only twice.
• Valve lash is adjusted with engine cold.
a. Remove cover and gasket from

both cylinder heads (WP 0027). Turn
crankshaft until number one piston is
on compression stroke and timing
pointer on front cover is in line with
TDC mark on vibration damper. Refer
to Figure 17 for numbering sequence
of valves.
Figure 18. Sectional View of Valve Mechanism. 0018
0018-31
TM 5-3805-255-14 0018
LOCATION
ITEM TO
23 Annually Engine Valve NOTE

(Cont.) Clearance
Adjustments Be sure that the number one piston is on the compression
stroke by turning both push rods by hand to determine that both
intake and exhaust valves are closed. Valves are closed when
push rods are loose and can be turned easily.
b. Before adjusting valve clearance,

valve bridge must be adjusted. Adjust
intake valve bridges for cylinders 1, 2,
and 4 and exhaust valve bridges for
cylinders 1, 3, and 5 as follows:
1. Loosen bridge adjusting screw

nut and back out screw several times.
2. Position fingers on bridge

directly above bridge guide and hold
bridge down firmly against cam side
valve. Be sure screw does not contact
valve.
3. Turn screw in until it just

touches valve. Turn screw an
additional 20 degrees to 30 degrees to
ensure uniform contact of bridge on
guide.
4. While holding adjusting screw in

this position, tighten locknut
(WP 0131).
c. With cylinders in this position,

adjust valves under bridges previously
adjusted as follows:
1. Loosen rocker lever nut and

adjusting screw.
2. Insert a feeler gauge 0.375 in.

(9.5 mm) wide or less and of proper
thickness, at point A between bridge
and rocker lever.
3. Tighten adjusting screw until

feeler gauge is snug. While holding
screw in this position tighten rocker
lever nut to 85 lb-ft (115 Nm).
0018-32
TM 5-3805-255-14 0018
LOCATION
ITEM TO
23 Annually Engine Valve d. Rotate camshaft one full revolution

(Cont.) Clearance so No. 6 cylinder is at TDC
Adjustments (compression). In this position, adjust
intake valve bridges and valves for
cylinders 3, 5, and 6, and exhaust
valve bridges and valves for cylinders
2, 4, and 6 in same manner described
in steps b and c.
e. Install new gaskets and valve

covers.
24 Initial 100 Engine Cylinder After initial 100 hours of new cylinder Broken bolts, cylinder head
Hours Head head operation, torque cylinder head gasket leaking.
nuts in sequence shown (Figure 19).
With engine at operating temperature,
loosen one nut at a time (1/4 turn) and
torque in rows as shown to 300 lb-ft
(407 Nm) except for nut #25, which is
to be torqued to 420 lb-ft (543 Nm).
Figure 19. Engine Cylinder Head Torquing Sequence. 0018
0018-33
TM 5-3805-255-14 0018
LOCATION
ITEM TO
ARTICULATION
AREA
25 Bimonthly Intermediate
Drive Block Oil
WARNING
Check

Immediately wipe up any spills. Failure to follow this warning
may result in injury to personnel.
• Intermediate drive block and oil may be hot. Use gloves.
personnel.
a. While lubricant is at operating

temperature park loader on level
ground, completely lower bucket, and
apply parking brake (WP 0005).
b. Remove oil level gauge and wipe it Class III oil leak is evident.
clean.
c. Insert gauge as far as it will go.
d. Remove level gauge and check

lubricant level. If level is below full
mark, add lubricant as necessary.
Refer to Table 6, Lubricants, in this
work package for grade of lubricant
specified.
e. Fill block through level gauge hole.

of fluid required.
f. Install gauge.
0018-34
TM 5-3805-255-14 0018
LOCATION
ITEM TO
26 Semiannually Intermediate a. Place a suitable container under

Drive Block Oil drive block to catch oil.
Change
b. Remove oil level gauge and drain Class III oil leak is evident.
plug.
c. Install drain plug after oil has

completely drained.
d. Fill block through level gauge hole.

of fluid required.
e. Install oil level gauge and check oil

level.
Figure 20. Intermediate Drive Block. 0018
0018-35
TM 5-3805-255-14 0018
LOCATION
ITEM TO
27 Bimonthly Service Brakes

Power Cluster
WARNING

personnel.
CAUTION
Trapped air in hydraulic brake lines between service brake
power cluster and wheel cylinders reduces braking
effectiveness. Bleed the brakes (WP 0059).
NOTE
Procedure is same for all power clusters.
a. Clean area around filler plug and Class III oil or air leak is
remove plug. evident.
b. Check fluid level. Correct level is

3/8 to 1/2 in. (9 to 13 mm) from top of
housing. If necessary, add fluid. Refer
to Table 6, Lubricants, in this work
required.
0018-36
TM 5-3805-255-14 0018
LOCATION
ITEM TO
27 Bimonthly Service Brakes c. Install and tighten filler plug.

(Cont.) Power Cluster
d. Remove breather from power

cluster.
e. Wash breather in cleaning solvent.
f. Dry breather using compressed air

or shake to remove as much solvent
as possible.
g. Install breather in power cluster.
Figure 21. Power Cluster. 0018
h. Bleed brakes (WP 0059).
0018-37
TM 5-3805-255-14 0018
LOCATION
ITEM TO
28 Monthly Steering Gear Oil Check lubricant level by removing top Class III oil leak is evident.
Level Check bolt in steering gear housing. If level is
below bolt hole, add lubricant as nec-
essary. Refer to Table 6, Lubricants, in
this work package for grade and quan-
tity of fluid required.
Figure 22. Steering Gear. 0018
29 Semiannually Parking Brake

Adjustment
WARNING
Install blocking in front of and behind the tires before adjusting
the parking brake. Failure to comply may cause injury to
NOTE
A minor brake adjustment can be made by turning adjustment
knob on parking brake control lever several turns clockwise.
After this method of adjustment has reached its limit, proceed
as follows.
a. Install blocking in front of and

behind wheels. Release parking brake
(WP 0005).
b. Back off parking brake control lever

adjusting knob.
0018-38
TM 5-3805-255-14 0018
LOCATION
ITEM TO
29 Semiannually Parking Brake c. Remove cotter pin and clevis pin

(Cont.) Adjustment securing clevis to brake lever.
d. Loosen jam nut and back it away

from clevis a few turns.
e. Shorten length of brake cable by

rotating clevis onto cable clockwise.
Cable should be shortened enough to
remove all slack from brake arm
without causing contact between
brake lining and drum.
f. Reinstall clevis pin through clevis

and brake arm. Secure clevis pin with
cotter pin.
g. Tighten nut down against clevis.
h. Remove wheel blockings, start

engine, and apply parking brake
(WP 0005).
Figure 23. Parking Brake Linkage. 0018
0018-39
TM 5-3805-255-14 0018
LOCATION
ITEM TO
29 Semiannually Parking Brake WARNING

(Cont.) Adjustment
Be sure area in front of loader is clear of personnel and
obstructions as vehicle may move forward during this test.
Failure to comply may cause injury to personnel and damage to
equipment.
i. Place transmission directional lever

in forward position and transmission
gear range lever in fourth gear range
position. Fully accelerate engine. If
loader moves forward, parking brake
must be readjusted or linings replaced
(WP 0057).
TOP OF
LOADER
30 Semiannually Engine Coolant a. Run engine until it reaches normal Class III coolant leak is
System Service operating temperature, then stop evident.
engine. Lower bucket completely and
apply parking brake (WP 0005).
WARNING
Loosen radiator cap slowly to gradually release any pressure

buildup. Failure to comply may cause injury to personnel and
b. Remove radiator cap.
0018-40
TM 5-3805-255-14 0018
LOCATION
ITEM TO
30 Semiannually Engine Coolant c. Inspect radiator cap gasket.

(Cont.) System Service Replace if damaged.
Figure 24. Coolant Level. 0018
WARNING

personnel.
d. Place suitable container under

radiator drain valve to catch coolant.
0018-41
TM 5-3805-255-14 0018
LOCATION
ITEM TO
30 Semiannually Engine Coolant e. Open radiator drain valve located

(Cont.) System Service at bottom left side of radiator and allow
coolant to drain.
H100C-1122
Figure 25. Radiator Drain Valve Cover Plate. 0018
0018-42
TM 5-3805-255-14 0018
LOCATION
ITEM TO
30 Semiannually Engine Coolant f. Place suitable container under

(Cont.) System Service engine oil cooler drain valve to catch
coolant.
WARNING
Stop engine. Relieve pressure in system by moving loader con-

trols through their full travel several times. Relieve reservoir
pressure by slowly removing filler cap. Escaping hydraulic fluid
can penetrate skin. Failure to follow this warning can result in
injury to personnel.
g. Open oil cooler drain valve and
allow coolant to drain.
Figure 26. Engine Oil Cooler Drain Valve.
0018-43
TM 5-3805-255-14 0018
LOCATION
ITEM TO
30 Semiannually Engine Coolant h. Place suitable container under

(Cont.) System Service engine crankcase drain valve to catch
coolant.
i. Open engine crankcase drain valve

and allow coolant to drain.
Figure 27. Left Engine Crankcase Drain Valve. 0018
j. Open two heater shut-off valves

located on left and right side of engine
and allow coolant to drain.
NOTE
Ensure all valves in steps e, g, i, and j are closed before filling
or flushing.
k. Fill system with clean water. Add a

flushing compound that is compatible
with aluminum. Flush system in
accordance with instructions furnished
with compound. Refer to TB 750-651.
l. Flush, rinse, and completely drain

system (repeat steps d thru j).
0018-44
TM 5-3805-255-14 0018
LOCATION
ITEM TO
30 Semiannually Engine Coolant CAUTION

(Cont.) System Service
Do not add coolant into the radiator of an overheated engine.
Allow engine to cool. Failure to follow this warning may cause
m. Fill cooling system slowly. This Class III coolant leak is
allows more air to escape and system evident.
to be filled to maximum capacity. Refer
to Table 7, Coolants, in this work
package for type and mixture of
coolant.
NOTE
Use only a corrosion inhibitor that is compatible with aluminum.
DO NOT use inhibitors labeled as “acid neutralizers”.
n. Start engine and run until normal
operating temperature is reached,
adding coolant when needed to keep
proper level of 1 in. (25 mm) above
baffle.
o. After all air is removed and level
remains fixed, install radiator cap.
Check all drains for leakage.
31 Semiannually Hydraulic a. Start engine and operate boom, Class III oil leak is evident.
Reservoir Oil bucket, and steering until hydraulic oil
Draining reaches operating temperature
(WP 0005).
b. Park loader on level ground
(WP 0005).
c. Raise bucket completely and roll

bucket back all the way (WP 0005).
WARNING
Do not allow anyone under boom and bucket while in raised
position. Failure to comply may cause injury or death to
d. Shut engine down and apply
parking brake (WP 0005).
0018-45
TM 5-3805-255-14 0018
LOCATION
ITEM TO
31 Semiannually Hydraulic
(Cont.) Reservoir Oil
WARNING
Draining

open flames and other sources of ignition.
personnel.
e. Clean top of reservoir with cleaning

solvent.
WARNING
Always loosen filler cap slowly to relieve pressure build-up in
system. Failure to comply may cause injury to personnel and
f. Slowly loosen and remove

reservoir filler cap.
g. Remove pipe plug in drain valve.
h. Fit a short 3/4 in. (19 mm) threaded

pipe into end of a piece of hose. Screw
pipe into drain valve. Put other end of
hose into a container large enough to
hold all of fluid from reservoir.
0018-46
TM 5-3805-255-14 0018
LOCATION
ITEM TO
31 Semiannually Hydraulic WARNING

(Cont.) Reservoir Oil
Draining Boom may lower when drain valve is opened. Do not allow any-
one under boom. Failure to comply may cause injury to person-
nel and damage to equipment.
i. Open drain valve and allow

reservoir to drain.
j. Close reservoir drain valve.
k. Lower boom slowly. After boom

comes to rest on ground, push bucket
lever forward and let bucket down
slowly. This will force hydraulic oil out
of boom and bucket cylinders and into
reservoir.
l. Open reservoir drain valve.
m. Allow reservoir to drain completely,

then close drain valve. Remove drain
pipe and hose from drain valve. Install
plug.
n. Place suitable container under

drain plug to catch remaining hydraulic
fluid.
o. Remove drain plug from reservoir.

Allow bottom of reservoir to drain then
reinstall plug.
0018-47
TM 5-3805-255-14 0018
LOCATION
ITEM TO
31 Semiannually Hydraulic p. Fill reservoir. Refer to “Hydraulic

(Cont.) Reservoir Oil Reservoir Oil Filling” in this work
Draining package.
Figure 28. Exploded View of Hydraulic Reservoir.
0018
0018-48
TM 5-3805-255-14 0018
LOCATION
ITEM TO
32 Hydraulic
Reservoir Filter
WARNING
Service

ronmentally 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.
and fuel, consult your unit/local hazardous waste disposal
center or safety office for local regulatory guidance.
• Hydraulic oil may be hot. Use gloves to prevent injury.
personnel.
a. Drain reservoir as described under Class III oil leak is evident.

“Hydraulic Reservoir Oil Draining” in
this work package.
b. Loosen retainer bolts and nuts

enough to facilitate removal of cover.
c. Remove cover and seal ring.
d. Remove nuts, plate, and filters.
e. Loosen clamps and remove

screen.
f. Clean screens in cleaning solvent

and dry with compressed air. Install
screens and secure with clamps.
g. Inspect seal ring. If deteriorated or

damaged, replace with new seal ring.
Install seal ring on reservoir rim.
h. Install cover and secure with

retainer band.
0018-49
TM 5-3805-255-14 0018
LOCATION
ITEM TO
32 Hydraulic i. Fill reservoir. Refer to “Hydraulic

(Cont.) Reservoir Filter Reservoir Oil Filling” in this work
Service package.
33 Hydraulic WARNING
Reservoir Oil
Filling Prior to removing reservoir fill cap, operate hydraulic controls
several times to help relieve hydraulic pressure. Failure to
equipment.
a. Remove reservoir filler cap and Class III oil leak is evident.
dipstick.
b. Fill reservoir with clean oil up to “H”

mark on dipstick. Refer to Table 6,
c. Install and tighten reservoir filler

cap.
d. Start engine and operate boom and

bucket several times to fill hydraulic
cylinders with oil.
e. Lower bucket to ground and shut

down engine (WP 0005).
WARNING
Always loosen filler cap slowly to relieve pressure build-up in
system. Failure to comply may cause injury to personnel and
f. Slowly remove reservoir filler cap

and dipstick and check oil level. Fill
reservoir as necessary to bring level
up to “H” mark on dipstick.
g. Install filler cap and tighten. Check

reservoir for leakage.
0018-50
TM 5-3805-255-14 0018
LOCATION
ITEM TO
34 Weekly Batteries and a. Disconnect battery cables from a. Battery leaking electrolyte.
Cables battery.
b. Broken and corroded
b. Check liquid level. connections or frayed/burned/
melted cables and clamps are
evident.
WARNING
• Batteries give off highly flammable gas. Never allow sparks or

open flame near the batteries. Avoid spilling any electrolyte on
skin or clothing. Failure to comply may cause injury to
• Before servicing batteries, ensure battery cables are
disconnected from battery. Failure to follow this warning may
c. Replace worn, cracked, broken, or

corroded cables.
d. Keep batteries fastened securely in
frame.
CAUTION
Do not over tighten battery hold-downs. Excessive tightening
can warp or crack battery case.
e. Maintain correct battery liquid level.
Refer to “Battery Liquid Level” in this
work package.
f. If top of a battery is dirty, it may be Battery leaking electrolyte.
cleaned with a brush. Clean terminal
contact surfaces with steel wool or a
stiff brush.
0018-51
TM 5-3805-255-14 0018
LOCATION
ITEM TO
34 Weekly Batteries and g. Electrolyte in each cell must be at Battery leaking electrolyte.
(Cont.) Cables proper level 1/4 to 1/2 in. (6 to 13 mm)
above plates at all times to prevent
battery failure. Check level of
electrolyte. When electrolyte is below
this level, pure distilled water must be
added. Never use hydrant water or
any water that has been in a metal
container. Under no circumstance add
any special battery “dopes”, solutions,
or powders.
h. Once battery PMCS is complete,

reconnect battery cables to battery
terminal, and check for tightness.
RIGHT FRONT
torque (WP 0131).
(WP 0002).
0018-52
TM 5-3805-255-14 0018
LOCATION
ITEM TO
37 Bimonthly Axle Oil Level

Check WARNING

• Axle oil may be hot. Use gloves.
personnel.
NOTE
Both front and rear axles are checked in same manner.
a. While lubricant is at operating Class III oil leak is evident.

temperature, park loader on level
ground, completely lower bucket, stop
engine and apply parking brake
(WP 0005).
b. Remove filler and level check plug.

If lubricant is below plug hole, add
lubricant as necessary to bring level
up to bottom of hole. Refer to Table 6,
c. Install filler and level check plug.
0018-53
TM 5-3805-255-14 0018
LOCATION
ITEM TO
38 Semiannually Axle Oil Change

WARNING

• Axle oil may be hot. Use gloves.
• Failure to follow this warning may result in injury to personnel.
NOTE
Both front and rear axles are checked in same manner.
a. Operate loader until normal Class III oil leak is evident.

operating temperature is reached.
Park loader on level ground,
completely lower bucket, apply parking
brake, and shut down engine
(WP 0005).
b. Place a suitable container under

axle to catch oil.
c. Remove drain plug and filler and

level check plug.
d. After oil stops draining, install drain

plug.
e. Fill axle up to bottom of filler hole.

of fluid required.
f. Install filler plug.
g. Operate loader for a short period of

time so oil can work into gears
throughout axle and planetaries
(WP 0005).
0018-54
TM 5-3805-255-14 0018
LOCATION
ITEM TO
38 Semiannually Axle Oil Change h. Check oil level and add oil
(Cont.) necessary to bring level up to filler
plug hole.
Figure 29. Axle Drain and Filler Plug. 0018
0018-55
TM 5-3805-255-14 0018
LOCATION
ITEM TO
39 Semiannually Planetary Oil

Change WARNING

• Planetary oil may be hot. Use gloves.
personnel.
NOTE
Move loader only enough to properly locate planetary drain
plug.
a. Operate loader until normal Class III oil leak is evident.

temperature is reached. Park loader
on level ground, completely lower
bucket, apply parking brake, and shut
down engine (WP 0005).
b. Position planetary drain plug at

6 o’clock (Figure 30).
Figure 30. Planetary Drain Plug at 6 O’Clock Position. 0018
0018-56
TM 5-3805-255-14 0018
LOCATION
ITEM TO
39 Semiannually Planetary Oil c. Place suitable container below

(Cont.) Change planetary drain plug to catch oil.
d. Remove planetary drain plug.
e. After oil stops draining, install

planetary drain plug.
f. Repeat steps a through e for

opposite planetary on same axle.
g. Position planetary drain plug at

12 o’clock (Figure 31).
H100C-0111-1
Figure 31. Planetary Drain at 12 O’Clock Position. 0018
h. Fill planetary to bottom of filler hole.

of fluid required.
i. Install filler plug.
j. Operate loader for a short period of

time so oil can work into gears
throughout axle and planetaries
(WP 0005).
k. Check oil level and add oil

necessary to bring level up to filler
plug hole.
0018-57
TM 5-3805-255-14 0018
LOCATION
ITEM TO
CAB INTERIOR
40 Semiannually Control Levers Lubricate pivot points on control

levers.
END OF TASK
NOTE
• Lubrication instructions contained in this PMCS are MANDATORY.
• The overall view of lubrication points is located at the end of this work package. Localized
views are located, together with specific lubrication instructions, in the PMCS table.
• The loader is not enrolled in the Army Oil Analysis Program (AOAP).
• Refer to FM 9-207 for lubrication in arctic operation.
1. Included in this PMCS are lubrication services to be performed by Field Maintenance.
2. Lubrication intervals are based on normal operation. Lubricate more during constant use and less during inac-
tive periods. Use correct grade of lubricant for seasonal temperature expected. Refer to the KEY on next page.
3. For equipment under manufacturer’s warranty, hardtime intervals shall be followed. Shorten intervals if lubri-
cants are known to be contaminated or if operation is under adverse conditions (e.g., longer than usual operat-
ing hours, extended idling periods, extreme dust).
4. Keep all lubricants in a closed container and store in a clean, dry place away from extreme heat. Keep contain-
ers covers clean and do not allow dust, dirt, or other foreign materials to mix with lubricants. Keep lubrication
equipment clean and ready for use.
0018-58
TM 5-3805-255-14 0018
WARNING

an goggles. Use in well ventilated areas. Keep away from open flames and other sources
of ignition. Failure to follow this warning may result in injury or death to personnel.
5. Clean area around lubrication points with solvent cleaning compound (WP 0121, Item 3) or equivalent before
lubricating equipment. Keep all external parts not requiring lubrication free of lubricants. After lubrication, Wipe
excess lubricant to prevent accumulation of foreign matter.
6. Maintain a record of lubrication performed and report any problems noted during lubrication. Refer to DA PAM
750-8 for forms and procedures to record and report any findings.
NOTE
Only lubricants authorized for use by the Field Maintainer are listed in this KEY.
KEY
EXPECTED TEMPERATURES*
+6°F to +122°F -4°F to +50°F -25°F to

LUBRICANT/ REFILL (-14°C to (-20°C to +32°F
COMPONENT CAPACITY +50°C) +10°C) (-4°C to 0°C) INTERVALS
OE/HDO D - Daily
Lubricating Oil, ICE, W - Weekly
Tactical Service Bim -
(MIL-PRF-2104) Bimonthly
M - Monthly
32 qt SA - Semi-
Engine Crankcase See Table 6.
(30.3 L) annually
AN -
45 qt Annually
Transmission See Table 6.
(42.5 L)
55 qt See Table 6.
Hydraulic Tank
(208.2 L)
GAA
Grease, Automotive
and Artillery
See Table 6.
Grease Fittings As Required
ANTIFREEZE
65 qt
Cooling System See Table 7.
(61.5 L)
* For arctic operation, refer to FM 9-207.
0018-59
TM 5-3805-255-14 0018
Table 6. Lubricants.
COMPART- COMMERCIAL VISCOSITY MILITARY LUBRICANT TEMPERATURE RANGE

MENT LUBRICANT GRADE
Engine I.H. No. 1 SAE-30 MIL-L-2104C or MIL-L-45199B 20°F to 120°F (-7°C to 49°C)
Engine Oil SAE-10W -10°F to 70°F (-23°C to 21°C)
or API CD/ Arctic Oil -30°F to 10°F (-34°C to -12°C)
CC or CD
Transmission I.H. Smooth

Shift Dexron
Hydraulic I.H. No. 1 SAE-10W* MIL-L-45199B or MIL-L-2104B or C 20°F to 120°F (-7°C to 49°C)
Engine OIl or SAE-10W MIL-L-46152 -10°F to 70°F (-23°C to 21°C)
API CD/CC, CD, Arctic Oil -30°F to 10°F (-34°C to -12°C)
CC/SE
Axles I.H. 135H MIL-L-2105C Gear Lubricant

EP Gear
Lubricant or
API-GL-5
Intermediate SAE-85W - 140 20°F to 120°F (-7°C to 49°C)

Drive Block SAE-80W - 90 or -10°F to 70°F (-23°C to 21°C)
SAE-85W - 140
SAE-80W - 90** -30°F to 10°F (-34°C to -12°C)
Service Brake I.H. Super

Power Clusters Heavy Duty
(Each) SAE-J1703E
Brake Fluid
Steering Gear I.H. 135 H SAE-85W - 140 MIL-L-2105B Gear Lubricant 20°F to 120°F (-7°C to 49°C)
Housing EP Gear SAE-80W - 90 or -10°F to 70°F (-23°C to 21°C)
Lubricant or SAE-85W - 140
API GL-5 SAE-80W - 90% -30°F to 10°F (-34°C to -12°C)
Grease I.H. Super GAA

Grease or I.H.
251H EP
*For ambient temperatures constantly above 70°F (21°C), SAE 20W-20 may be used.
**Channel point must not exceed -30°F (-34°C) for SAE 80W-90 grade gear lubricants when they are used below -10°F (-23°C).
0018-60
TM 5-3805-255-14 0018
Table 7. Coolants.
COOLANT TYPE MIXTURE MILITARY LUBRICANT TEMPERATURE RANGE
Engine Coolant I-Ethylene 60/40 A-A-52624 -50°F to 120°F (-46°C to
Glycol 49°C)
II-Propylene
Glycol
Engine Coolant I-Ethylene 50/50 A-A-5264 -30°F to 120°F (-34°C to
Glycol 49°C)
II-Propylene
Glycol
Figure 32. Lubrication Instructions - Fluid and Filter Changes. 0018
END OF TASK
END OF WORK PACKAGE
0018-61/(62 blank)
64
TM 5-3805-255-14
CHAPTER 7
FIELD MAINTENANCE
10
TM 5-3805-255-14 0019
FIELD MAINTENANCE -
GENERAL MAINTENANCE INSTRUCTIONS

0 0 1 9
Work Safety, Relieving Hydraulic System Pressure, Relieving Air System Pressure, General Information,
Cleaning Instructions, Inspection Instructions, Repair Instructions, Lubrication Instructions, Standard
Tool Requirements, Applying Torque, Tagging Instructions, Lines and Ports, Fluid Disposal
INITIAL SETUP 0
Tools and Special Tools 0 References 0
Wire Brush 0 TM 43-0139 0
TM 9-214 0
Materials/Parts 0
TM 9-247 0

WP 0013 0
0130, Item 4) 0
WP 0018 0
WP 0131 0
Tag, Marker (WP 0130, Item 37) 0
SCOPE 00019
These general maintenance instructions contain general shop practices and specific methods you must be familiar
with to properly maintain the H100C Loader. You should read and understand these practices and methods before
starting maintenance tasks on the loader.
WORK SAFETY 00019
1. Before starting a task, think about the risks and hazards to your safety as well as that of others. Wear
protective gear such as safety goggles or lenses, safety shoes, rubber apron, and gloves. Protect yourself
against injury.
2. Observe all WARNINGs, CAUTIONs, and NOTEs.
3. When lifting heavy parts, have someone help you. Make sure lifting equipment is working properly, suitable for
the task assigned, of sufficient load capacity, and secured against slipping.
4. Always use power tools carefully.
5. Before beginning a procedure, ensure the following conditions have been observed, unless otherwise
specified:
a. Loader must be parked on level ground with parking brake engaged.
b. Transmission must be in NEUTRAL.
c. Engine must be off.
d. Components which are hot at operating temperatures (i.e., cooling, exhaust, and hydraulic systems) must
cool down before they are removed.
e. Components must, however, be at operating temperature to be tested.
f. Batteries must be disconnected when performing electrical system maintenance.
g. Hydraulic system pressure must be relieved before disconnecting any hydraulic system line or fitting.
Refer to Relieving Hydraulic System Pressure in this work package.
0019-1
TM 5-3805-255-14 0019
RELIEVING HYDRAULIC SYSTEM PRESSURE 00019
WARNING
• DO NOT disconnect or remove any hydraulic system lines 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 removing
any hydraulic fitting. Failure to follow this warning may result in injury to personnel.
• To prevent injury, wear protective eye covering.
• Sudden movement of vehicle can cause injury to persons on or near the machine.
Remove filler cap from hydraulic reservoir.
RELIEVING AIR SYSTEM PRESSURE 00019
1. Open drain valves and let air bleed off.

2. Depress brake pedal.
GENERAL INFORMATION 00019
1. Before beginning a task, find out how much repair, modification, or replacement is needed to fix the equipment
as described in this manual. Sometimes the reason for equipment failure can be seen right away and complete
teardown is not necessary. Disassemble the equipment only as far as necessary to repair or replace damaged
or broken parts.
2. All tags and forms attached to the equipment must be checked to learn the reason for removal from service.
Check all Modification Instructions (MIs) and Technical Bulletins (TBs) for equipment changes and updates.
3. In some cases a part may be damaged by removal. If the part appears to be good, and other parts behind it are
not defective, leave it on and continue the procedure. Here are a few simple rules:
a. Do not remove dowel pins or studs unless loose, bent, broken, or otherwise damaged.
b. Do not pull bearings or bushings unless damaged. If you must get at parts behind them, pull out bearings
or bushings carefully.
c. Replace all gaskets, seals, preformed packings, O-rings, cotter pins, spring pins, self-locking nuts, and
lockwashers.
0019-2
TM 5-3805-255-14 0019
CLEANING INSTRUCTIONS 00019
WARNING
• Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and

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.
• Improper cleaning methods and use of unauthorized cleaning solvents may injure
personnel and damage equipment. Refer to TM 9-247, Materials Used for Cleaning,
Preserving, Abrading, and Cementing Ordnance Materiel and Related Materials Including
Chemicals, for correct information.
• Fire extinguishers should be placed nearby when using solvent cleaning compound.
• Cloths or rags saturated with solvent cleaning compound must be disposed of IAW
authorized facilities’ procedures.
• Eye shields must be worn when cleaning with a wire brush. Flying rust and metal particles
may cause injury.
• Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa)
when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when
drying parts with compressed air. DO NOT direct compressed air against human skin.
Failure to follow this warning may result in injury to personnel. Make sure air stream is
directed away from user and other personnel in the area. To prevent injury, user must
wear protective goggles or face shield.
1. Cleaning instructions are the same for the majority of the parts and components of the H100C.
2. The importance of cleaning must be thoroughly understood by maintenance personnel. Great care and effort
are required in cleaning. Dirt and foreign material are a constant threat to satisfactory maintenance. The
following should apply to all cleaning, inspection, repair, and assembly operations.
a. Clean all parts before inspection, after repair, and before assembly.
b. To prevent contamination, hands should be kept free of any accumulation of grease, which can collect
dust, dirt, or grit.
c. After cleaning, all parts should be covered or wrapped to protect them from dust and dirt. Parts that are
subject to rust should be lightly oiled.
3. External Engine Cleaning.
a. Protect all electrical equipment that could be damaged by steam or moisture before steam cleaning.
b. Cover all openings before steam cleaning.
c. After cleaning, dry and apply a light coat of oil to all parts subject to rust.
d. Clear out all tapped (threaded) holes with compressed air to remove dirt and cleaning fluid.
4. Cleaning Disassembled Parts.
a. Place all disassembled parts in wire baskets for cleaning.
b. Dry and cover all cleaned parts.
c. Place parts on or in “racks” and hold for inspection or repair.
d. All parts subject to rusting must be lightly oiled and wrapped.
e. Keep all related parts and components together. Do not mix parts.
0019-3
TM 5-3805-255-14 0019
CLEANING INSTRUCTIONS – CONTINUED

5. Castings.
a. Clean inner and outer surfaces of castings and all areas subject to grease and oil with solvent cleaning
compound.
b. Use a stiff brush to remove sludge and gum deposits.
c. Clear out all tapped (threaded) holes with compressed air to remove dirt and cleaning solvent.
6. Oil Passages. Particular attention must be given to all oil passages in castings and machined parts. Oil
passages must be clean and free of any obstructions.
a. Clean passages with wire probes to break up any sludge or gum deposits.
b. Wash passages by flushing with solvent cleaning compound.
c. Dry passages with compressed air.
7. Oil Seals and Flexible Hoses.
CAUTION
Washing flexible hoses and oil seals with solvent cleaning compound or mineral spirits will
cause serious damage or destroy the material.
a. Wash flexible hoses with a mild solution of detergent and water and wipe dry.
b. Oil seals are generally damaged during removal; cleaning will not be necessary since new seals will be
used in assembly.
8. Machined Surfaces.
a. Clean machined surfaces with solvent cleaning compound.
b. Dry surfaces with compressed air.
9. Mated Surfaces.
a. Remove old gasket and/or sealing compound using a wire brush and solvent cleaning compound.
b. Lightly coat with oil and wrap all parts subject to rust before storing.
10. Rusted Surfaces. Clean all rusted surfaces using wire brush and abrasive cloth.
11. Oil-Bathed Internal Parts. Wipe oil-bathed internal parts clean with a lint-free cloth.
12. Air-Actuated Internal Parts. Wash air-actuated internal parts and dry with a lint-free cloth.
13. Externally Exposed Parts. Wash externally exposed parts with detergent and water. Rinse thoroughly and air
dry.
14. Hydraulic Cylinders.
a. Care in handling of parts and hydraulic system cleanliness cannot be over-stressed.
b. Use ONLY the oil type and viscosity ranges specified in WP 0013 and WP 0018.
c. Wash all metal parts including cylinder in solvent. Dry all parts with filtered compressed air. Protect
components with a light film of oil. Flush cylinder with oil to remove all traces of solvent and protect cylinder
walls from oxidation.
d. Check cylinder bore and rod surface for scratches and/or abrasions that may have been caused by grit
deposits in the cylinder packings. Carefully remove small rough or sharp surfaces with a fine grained
stone. The closer these surfaces are to a mirror finish, the more efficiently the new packing will operate.
0019-4
TM 5-3805-255-14 0019
INSPECTION INSTRUCTIONS 00019
1. General. All components and parts must be carefully checked to determine if they are serviceable for reuse, if
they can be repaired, or if they must be scrapped.
2. Hydraulic Cylinders.
a. Inspect all surfaces for burrs, scratches, nicks, scores and other abrasions. Stone or lap all burrs. If scoring
is deep enough to produce excessive leakage, replace valve assembly. Stone or use abrasive cloth on
small scores.
b. All parts with sliding fit must move freely in their bores.
c. All grooves and passages must be free of foreign matter.
d. Replace springs if they are broken or distorted.
e. Replace all O-rings, seal rings, and gaskets.
f. Listed below are instructions that must be followed to insure correct installation and effective sealing of
O-rings.
(1) Seal counterbores must be thoroughly cleaned.
(2) O-rings, plungers, and counterbores must be lubricated on assembly.
(3) O-rings must be free of molding defects and handling damage.
(4) O-RINGS MUST NOT BE STRETCHED beyond the yield point.
(5) EXTREME care must be taken to avoid ROLLING the O-ring into the counterbore. (A twisted O-ring is
not likely to straighten itself after installation, and is almost certain to leak.)
(6) Care in handling of parts and hydraulic system cleanliness cannot be over-stressed.
(7) Use ONLY the oil type and viscosity ranges specified in WP 0013 and WP 0018.
3. Drilled and Tapped (Threaded) Holes.
a. Inspect for wear, distortion (stretching), cracks, or any other damage in or around holes.
b. Inspect threaded areas for wear, distortion, or evidence of cross-threading.
c. Mark all damaged areas for repair or replacement.
4. Metal Lines, Flexible Lines (Hoses), and Fittings.
a. Inspect lines for sharp kinks, cracks, bends, or dents.
b. Inspect threaded areas for wear, distortion, or evidence of cross-threading.
c. Check all fittings and connectors for thread damage. Check for hex heads that are worn or rounded by
poorly fitting wrenches.
d. Mark all damaged material for repair or replacement.
5. Castings.
a. Inspect all ferrous and nonferrous castings for cracks using a magnifying glass and strong light.
Particularly check areas around studs, pipe plugs, threaded inserts, and sharp corners. Replace all
cracked castings.
b. Inspect machined surfaces for nicks, burrs, or raised metal. Mark damaged areas for repair or replace-
ment.
c. Inspect all pipe plugs, pipe plug openings, screws, and screw openings for damaged or stripped threads.
d. Check all gasket mating surfaces, flanges on housings, and supports for warpage with a straightedge or
surface plate. Inspect mating flanges for discoloration that may indicate persistent oil leakage.
6. Studs, Bolts, and Screws. Replace if threads are damaged, bent, loose, or stretched.
0019-5
TM 5-3805-255-14 0019
INSPECTION INSTRUCTIONS – CONTINUED

7. Gears.
NOTE
When gear teeth wear limits are not established, good judgement is required to determine
if gear replacement is necessary.
a. Inspect all gears for cracks using a magnifying glass and strong light. No cracks are permissible.
b. Inspect gear teeth for wear, sharp fins, burrs, and galled or pitted surfaces.
c. Check keyway slots for wear or damage. If keyways are worn, damaged, or elongated, replace gear.
8. Bushing and Bushing Type Bearings.
a. Check all bushings and bushing type bearings for secure fit, evidence of overheating, wear, burrs, nicks,
and out-of-round condition. Replace as necessary.
b. Check for dirt in lubrication holes or grooves. Holes and grooves must be clean and free from damage.
9. Oil Seals. Oil seals are mandatory replacement items.
10. Core Hole Expansion Plugs. Inspect for leakage. Replace plugs when leakage is present.
11. Machine-Tooled Parts. Inspect for cracks, breaks, elongated holes, wear, and chips. Replace any damaged
parts.
12. Machined Surfaces. Inspect for cracks, evidence of wear, galled, or pitted surface, burrs, nicks, and
scratches.
13. Mating Surfaces. Inspect for remains of old gasket, seal, secure fit, pitting, and evidence of leakage.
14. Rusted Surfaces. Inspect for pitting, holes, and severe damage.
15. Oil-Bathed Internal Parts. Inspect for cracks, nicks, burrs, evidence of overheating, and wear.
16. Internal Parts. Inspect for cracks, nicks, burrs, evidence of overheating, and wear.
17. Externally Exposed Parts. Inspect for breaks, cracks, rust damage, and wear.
18. Springs. Inspect for broken, collapsed, and twisted coils.
REPAIR INSTRUCTIONS 00019
1. General.
a. Any repair procedure peculiar to a specific part or component is covered in the work package relating to
that item.
CAUTION
Repaired items must be thoroughly cleaned to remove metal chips and abrasives, to
prevent them from entering working parts of the machine. Failure to comply could cause
b. After repair, clean all parts thoroughly to prevent dirt, metal chips, or other foreign material from entering
any working parts.
2. Castings.
a. Only minor repairs to machined surfaces, flanges, and gasket mating surfaces are permitted. Remove
minor nicks, burrs and scratches with:
(1) Fine-mill file.
(2) Abrasive cloth dipped in solvent cleaning compound.
(3) Lapping across a surface plate.
0019-6
TM 5-3805-255-14 0019
REPAIR INSTRUCTIONS – CONTINUED

b. Remachining of machined surfaces to repair damage, warpage, or uneven surfaces is not permitted.
Replace castings.
c. Repair damaged threaded pipe plug or screw threads with a tap or die. Repair oversized holes with
threaded inserts.
3. Studs.
a. Repair minor thread damage with a thread die.
b. Replace studs having stripped or damaged threads as described below:
(1) Remove using a stud remover. Back studs out slowly to avoid heat buildup and seizure that can cause
stud to break off.
(2) If studs break off too short to use a stud remover, use a stud extractor to remove or use “welding
method”: weld bar stock or a nut to stud and remove with a wrench.
(3) Install replacement stud slowly to prevent heat buildup and break-off.
4. Gears.
a. Remove gears using pullers.
b. Only minor repairs to gears are permitted. Remove minor nicks, burrs, or scratches on gear teeth with:
(1) Fine-mill file.
(2) Abrasive cloth dipped in solvent cleaning compound.
5. Bushings and Bushing Type Bearings.
a. When bushings and bushing type bearings seize to a shaft and spin in the bore, associated parts must
also be replaced.
b. It may be necessary to heat bearings to aid in installation.
6. Oil Seals.
a. Remove oil seals by pressing or prying out, being careful not to damage casting or adapter bore.
b. Always install new seal in bore using proper seal installation tool.
7. Painting. Upon installation, restored parts must be painted in accordance with TM 43-0139.
Refer to Field Maintenance PMCS (WP 0017 and WP 0018) for detailed, illustrated instructions on proper lubrica-
tion. The following are some general practices to remember:
a. Use correct lubricant.
b. Keep lubricants clean.
c. Clean all fittings and area around fill and drain points before lubrication.
d. Lubricate clean disassembled and new parts to prevent rust.
STANDARD TOOL REQUIREMENTS 00019
1. The following are general practices regarding the use of tools:

a. Always use proper tool kit and tools for procedure being performed.
b. Ensure tools are clean and lubricated to reduce wear and to prevent rust.
c. Keep track of tools. Do not be careless with them.
d. Return tools to toolbox when finished with repair or maintenance.
e. Return toolboxes and tools to tool storage when not in use.
f. Inventory tools before and after each use.
0019-7
TM 5-3805-255-14 0019
STANDARD TOOL REQUIREMENTS – CONTINUED 00019
2. Some maintenance tasks may require special or fabricated tools. The “Initial Setup” of the procedure will
specify any special or fabricated tools needed to perform that procedure. Use these special tools only for the
maintenance procedures for which they are designed or called out. If you are unfamiliar with a required tool,
see your supervisor.
APPLYING TORQUE 00019
1. When tightening fasteners, use torque value as specified in Torque Limits (WP 0131).
2. If a unique torque value is required, it will be provided in a procedural step in the task.
TAGGING INSTRUCTIONS 00019
1. Use marker tags to identify all electrical wires, fuel, oil, coolant, and hydraulic lines, and any other parts which
may be hard to identify or replace later. Fasten tags to parts during removal by wrapping wire fasteners around
or through parts and twisting ends together. Position tags to be out of the way during cleaning, inspection, and
repair. Mark tags with a pencil, pen, or marker.
2. Whenever possible, identify electrical wires with the number of the terminal or wire to which they connect. If no
markings can be found, tag both wires or wire and terminal, and use the same identifying mark for both. If you
cannot tag a wire because it must fit through a small hole or you cannot reach it, write down description of the
wire and the point to which it connects, or draw a simple diagram on paper. Be sure to write down enough infor-
mation for you to properly connect the wires during assembly. If you need to identify a loose wire, look for an
identifying number near the end of the wire, stamped on a permanent metal tag. Compare the number to wire
numbers on the appropriate electrical schematic.
3. Identify fuel, oil, coolant, and hydraulic lines when you are taking off more than one line at the same time. Mark
tags with points to which lines and hoses must be connected. If it is not obvious which end of a line goes
where, tag each end of the line.
4. Identify and tag other parts by name and installed location as required.
LINES AND PORTS 00019
To keep dirt from contaminating fluid systems when removing and installing fuel, oil, coolant, and hydraulic lines,
perform these steps:
a. Clean fittings and surrounding area before disconnecting lines.
b. Cover, cap, plug, or tape lines and ports after disconnecting lines. When these specialized covers are not
available, use plastic bags and rubber bands, clean rags, duct tape, or other similar materials to prevent
dirt from entering system.
c. Ensure new and used parts are clean before installing.
d. Replace all removed tiedown straps.
e. Wait to remove covers, caps, plugs, or tape from lines and ports until just before installing lines.
0019-8
TM 5-3805-255-14 0019
FLUID DISPOSAL 00019
WARNING
• When servicing equipment, 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.
• To prevent injury to personnel, wear protective eye covering.
Dispose of contaminated drained fluids in accordance with the Standard Operating Procedures (SOP) of your unit.
END OF WORK PACKAGE
0019-9/(10 blank)
14
TM 5-3805-255-14 0020
FIELD MAINTENANCE -
0 ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS

0 2 0
Multiple-Pin Connector Identification Diagrams, Connector Repair, Sealed Connector Repair, Receptacle
Connector Repair, Waterproof Connector Repair, Military Connector Repair, Ring Terminal Repair,
Splicing Wires, Electrical Ground Points, Multimeter Usage, Relay Inspection and Test
INITIAL SETUP
Tools and Special Tools 0 Equipment Condition 0
Tool Kit, General Mechanic’s, Automotive (WP Machine parked on level ground (WP 0005) 0
0128, Item 20) 0

Multimeter (WP 0128, Item 12) 0

Engine OFF (WP 0005) 0
Materials/Parts 0
Battery disconnect switch in OFF position (WP
0004) 0
NOTE
Use electrically conductive grease on unprotected (exposed to weather) electrical
connectors before connections are made.
0020-1
TM 5-3805-255-14 0020
MULTIPLE-PIN CONNECTOR IDENTIFICATION DIAGRAMS 00020
NOTE
The following diagrams (Figure 1) illustrate typical multiple-pin connectors and identify pin
numbers as viewed from wire side of connector.
Figure 1. Multiple-Pin Connector Identification. 0020
CONNECTOR REPAIR 00020
NOTE
• Perform the following steps for each wire of connector.
• Tag wires for installation.
1. Using pin removal tool, position tool over pin (Figure 2, Item 1) and push inward to retract two barbs of pin.
0020-2
TM 5-3805-255-14 0020
CONNECTOR REPAIR – CONTINUED
Figure 2. Connector Repair. 0020
2. Remove wire (Figure 3, Item 1), with pin (Figure 3, Item 5) attached, from rear of connector.
3. If defective, remove pin (Figure 3, Item 5) from wire (Figure 3, Item 1) by cutting through wire just behind pin.
4. Using wire stripping tool, strip insulation off wire (Figure 3, Item 1) to expose proper length of metal strands
(Figure 3, Item 4).
5. Using crimping tool, securely crimp tabs (Figure 3, Item 3) of pin (Figure 3, Item 5) over metal strands (Figure
3, Item 4) of wire (Figure 3, Item 1).
NOTE
The other two tabs of pin may need to be crimped slightly in order to enter connector.
6. Using crimping tool, crimp tabs (Figure 3, Item 2) at rear of pin (Figure 3, Item 5) over insulation of wire (Figure
3, Item 1).
Figure 3. Connector Repair 0020
7. Push pin (Figure 2, Item 1) into rear of connector (Figure 2, Item 2) until fully seated.
0020-3
TM 5-3805-255-14 0020
SEALED CONNECTOR REPAIR 00020
1. Open hinged cover (Figure 4, Item 8) of connector (Figure 4, Item 7) for access to rear of connector.
NOTE
• Perform steps 2 through 9 for each wire of connector.
2. Using pin removal tool, position tool over pin (Figure 4, Item 6) and push inward to retract two barbs of pin.
3. Remove wire (Figure 4, Item 1), with pin (Figure 4, Item 6) and seal (Figure 4, Item 3) attached, from rear of
connector (Figure 4, Item 7).
4. If defective, remove pin (Figure 4, Item 6) and seal (Figure 4, Item 3) from wire (Figure 4, Item 1) by cutting
through wire just behind seal.
5. Position new seal (Figure 4, Item 3) on wire (Figure 4, Item 1).
6. Using wire stripping tool, strip insulation off wire (Figure 4, Item 1) to expose 1/8-in. (3-mm) length of metal
strands (Figure 4, Item 2).
7. Using crimping tool, securely crimp tabs (Figure 4, Item 5) of pin (Figure 4, Item 6) over metal strands (Figure
4, Item 2) of wire (Figure 4, Item 1).
8. Slide seal (Figure 4, Item 3) next to pin (Figure 4, Item 6) and crimp tabs (Figure 4, Item 4) of pin over end of
seal.
10. Close hinged cover (Figure 4, Item 8) of connector (Figure 4, Item 7).
Figure 4. Sealed Connector Repair. 0020
0020-4
TM 5-3805-255-14 0020
RECEPTACLE CONNECTOR REPAIR 00020
1. Using removal tool, insert tool into front of connector (Figure 5, Item 1) and depress locking tab of receptacle
(Figure 5, Item 6).
2. Push wire (Figure 5, Item 2), with receptacle (Figure 5, Item 6) attached, through front of connector (Figure 5,
Item 1).
3. If defective, remove receptacle (Figure 5, Item 6) from wire (Figure 5, Item 2) by cutting through wire just
behind receptacle.
4. Slide connector (Figure 5, Item 1) back on wire (Figure 5, Item 2).
5. Using wire stripping tool, strip insulation off wire (Figure 5, Item 2) to expose 1/4 in. (6 mm) length of metal
6. Using crimping tool, securely crimp tabs (Figure 5, Item 5) of receptacle (Figure 5, Item 6) over metal strands
(Figure 5, Item 3).
7. Using crimping tool, crimp tabs (Figure 5, Item 4) of receptacle (Figure 5, Item 6) over insulation of wire (Figure
5, Item 2).
8. Slide connector (Figure 5, Item 1) forward over receptacle (Figure 5, Item 6) until locking tab of receptacle
snaps into place.
Figure 5. Receptacle Connector Repair. 0020
0020-5
TM 5-3805-255-14 0020
WATERPROOF CONNECTOR REPAIR 00020
1. Remove end cover (Figure 6, Item 7) and gasket (Figure 6, Item 6) from front of connector (Figure 6, Item 5).
2. Remove seal (Figure 6, Item 1) from rear of connector (Figure 6, Item 5) and slide seal back on wire (Figure 6,
Item 2).
NOTE
• Perform steps 3 through 9 for each wire of connector.
3. Using pin removal tool, insert tool into front of connector (Figure 6, Item 5) and depress locking tab of connec-
tor.
4. Remove wire (Figure 6, Item 2) with pin (Figure 6, Item 4) from rear of connector (Figure 6, Item 5).
5. If defective, remove pin (Figure 6, Item 4) from wire (Figure 6, Item 2) by cutting through wire just behind pin.
6. Using wire stripping tool, strip insulation off wire (Figure 6, Item 2) to expose 1/4 in. (6 mm) length of metal
7. Insert metal strands (Figure 6, Item 3) of wire (Figure 6, Item 2) fully into rear of pin (Figure 6, Item 4).
8. Using crimping tool, securely crimp pin (Figure 6, Item 4) to metal strands (Figure 6, Item 3) of wire (Figure 6,
Item 2).
10. Install seal (Figure 6, Item 1) on rear of connector (Figure 6, Item 5).
11. Install gasket (Figure 6, Item 6) and end cover (Figure 6, Item 7) on front of connector (Figure 6, Item 5).
Figure 6. Waterproof Connector Repair. 0020
0020-6
TM 5-3805-255-14 0020
MILITARY CONNECTOR REPAIR 00020
1. Slide shell (Figure 7, Item 1) back on wire (Figure 7, Item 2) to expose sleeve (Figure 7, Item 5).
2. Remove sleeve (Figure 7, Item 5) from terminal (Figure 7, Item 4) by pulling sleeve forward.
3. If defective, remove terminal (Figure 7, Item 4) from wire (Figure 7, Item 2) by cutting through wire just behind
terminal.
4. Using wire stripping tool, strip insulation off wire (Figure 7, Item 2) to expose length of metal strands (Figure 7,
Item 3) equal to depth of terminal (Figure 7, Item 4).
5. Using crimping tool, securely crimp terminal (Figure 7, Item 4) to metal strands (Figure 7, Item 3) of wire (Fig-
ure 7, Item 2).
6. Install sleeve (Figure 7, Item 5) on terminal (Figure 7, Item 4) by pushing sleeve over front of terminal until fully
seated.
7. Slide shell (Figure 7, Item 1) up wire (Figure 7, Item 2) and over sleeve (Figure 7, Item 5).
Figure 7. Military Connector Repair. 0020
0020-7
TM 5-3805-255-14 0020
RING TERMINAL REPAIR 00020
1. Remove ring terminal (Figure 8, Item 6) from wire (Figure 8, Item 2) by cutting through wire just behind heat
shrink tubing (Figure 8, Item 1).
2. Cut heat shrink tubing (Figure 8, Item 1) to length sufficient to cover tabs (Figure 8, Items 4 and 5) of ring
terminal (Figure 8, Item 6) and 1/4 in. (6 mm) of wire (Figure 8, Item 2).
3. Slide heat shrink tubing (Figure 8, Item 1) back on wire (Figure 8, Item 2).
4. Using wire stripping tool, strip insulation off wire (Figure 8, Item 2) to expose proper length of metal strands
(Figure 8, Item 3).
5. Using crimping tool, securely crimp tabs (Figure 8, Item 5) of ring terminal (Figure 8, Item 6) over metal strands
(Figure 8, Item 3).
6. Using crimping tool, crimp tabs (Figure 8, Item 4) of ring terminal (Figure 8, Item 6) over insulation of wire
(Figure 8, Item 2).
7. Slide heat shrink tubing (Figure 8, Item 1) over tabs (Figure 8, Items 4 and 5) of ring terminal (Figure 8, Item 6).
8. Using heater gun, apply heat to heat shrink tubing (Figure 8, Item 1) until tubing snugly conforms to ring
terminal (Figure 8, Item 6) and insulation of wire (Figure 8, Item 2).
Figure 8. Ring Terminal Repair. 0020
SPLICING WIRES 00020
NOTE
The selection of crimping tool and type of splice connectors is optional. High quality splice
connectors can be expected to last the life of the vehicle.
1. Inspect each end of wire (Figure 9, Item 1). Trim insulation and metal strands (Figure 9, Item 2) of wire back, as
necessary, to ensure integrity of wire.
2. Using wire stripping tool, strip each end of wire (Figure 9, Item 1) to expose length of metal strands (Figure 9,
Item 2) to suit type of splice connector (Figure 9, Item 3) used.
NOTE
Perform steps 3 and 4 at each end of splice connector.
3. Insert metal strands (Figure 9, Item 2) of wire (Figure 9, Item 1) fully into splice connector (Figure 9, Item 3).
4. Using crimping tool, securely crimp splice connector (Figure 9, Item 3) to metal strands (Figure 9, Item 4) of
wire (Figure 9, Item 5).
Figure 9. Splicing Wires. 0020
0020-8
TM 5-3805-255-14 0020
ELECTRICAL GROUND POINTS 00020
Many electrical problems are the result of poor ground connections. Ensure ground connections are good by per-
forming the following steps.
WARNING
Although batteries must be connected to test electrical circuit voltage, disconnect batteries
before performing resistance tests or replacing parts. Failure to follow this warning may
a. Remove screw, lockwasher, nut, etc., connecting ground wire terminal to vehicle ground point.
b. If necessary, clean mounting hardware, wire terminal, and ground point with detergent and a scrub brush.
c. Remove any rust or corrosion from ground point with a wire brush and abrasive cloth.
d. Replace defective mounting hardware and wire terminal as necessary.
e. Install wire terminal to ground point with screw, lockwasher, nut, etc., and tighten securely.
MULTIMETER USAGE 00020
1. General. The multimeter used to troubleshoot the electrical system of the vehicle. The multimeter’s Ohms
scale is used to test for continuity, shorts, and resistance and the voltmeter scale is used to test voltage levels
at any point in the electrical system.
2. Continuity Tests. Continuity tests are performed to check for breaks in a circuit (such as a fuse, switch, light
bulb, or electrical cable).
0020-9
TM 5-3805-255-14 0020
MULTIMETER USAGE – CONTINUED
NOTE
If digital readout will not zero properly, replace batteries and repeat zeroing procedure. If
digital readout will not zero after batteries have been replaced, notify your supervisor.
a. Zero the Multimeter.
(1) Set multimeter ON/OFF switch (Figure 10, Item 3) to ON position.
(2) Press OHMS FUNCTION switch (Figure 10, Item 2).
(3) Press LOWEST VOLTAGE/OHMS selector switch (Figure 10, Item 4).
(4) Touch black and red probes (Figure 10, Items 5 and 6) together and check for a zero reading on digital
readout (Figure 10, Item 1).
Figure 10. Multimeter Usage. 0020
CAUTION
Before performing a continuity test, always disconnect batteries and circuit to be tested.
Failure to follow this caution may damage multimeter.
b. Testing for Continuity.
(1) Zero multimeter.
(2) Connect black and red probes (Figure 10, Items 5 and 6) from both terminals to circuit being tested.
(3) Read digital readout (Figure 10, Item 1) and interpret results as follows:
(a) If digital readout indicates 0L, circuit has continuity.
(b) If digital readout indicates resistance, circuit is open.
0020-10
TM 5-3805-255-14 0020
CAUTION
Before performing a continuity test (Figure 11), always disconnect batteries and circuit to
be tested. Failure to follow this caution may damage multimeter.
Figure 11. Testing Continuity. 0020
c. Testing for Shorts. A short (or short circuit) occurs when two circuits that should not be connected have
metal-to-metal contact with each other. A short also occurs when a circuit that should not touch ground has
metal-to-metal contact with ground.
0020-11
TM 5-3805-255-14 0020

(2) Connect black probe (Figure 12, Item 2) to one circuit (Figure 12, Item 3) and red probe (Figure 12,
Item 1) to either a ground or another circuit (Figure 12, Item 4).
(3) Read digital readout (Figure 12, Item 5) and interpret results as follows:
(a) If digital readout indicates 0L, circuits are shorted or circuit is grounded if testing to ground.
(b) If digital readout does not indicate 0L, circuits are not shorted.
(c) If digital readout jumps or flickers, circuits are shorted or grounded intermittently.
Figure 12. Testing For Shorts. 0020
CAUTION
Before performing a continuity test, always disconnect batteries and circuit to be tested.
Failure to follow this caution may damage multimeter.
d. Testing for Resistance. Allowable resistance readings depend on circuit being tested. Refer to the partic-
ular section dealing with that circuit or component for allowable readings.
(2) Press OHMS FUNCTION switch (Figure 13, Item 3).
(3) Press LOWEST VOLTAGE/OHMS selector switch (Figure 13, Item 7). If test calls for ohms range other
than RX1, set RANGE SELECTOR switch (Figure 13, Item 6) to required range.
(4) Connect black and red probes (Figure 13, Items 8 and 9) across circuit to be tested.
(5) Read digital readout (Figure 13, Item 1) and interpret results as circuit resistance.
0020-12
TM 5-3805-255-14 0020

3. Measuring DC Voltage.
a. Set multimeter ON/OFF switch (Figure 13, Item 5) to ON position.
b. Press VOLTS FUNCTION switch (Figure 13, Item 2).
c. Set AC/DC selector switch (Figure 13, Item 4) to DC.
d. Select and press LOWEST VOLTAGE/OHMS selector switch (Figure 13, Item 7) for voltage range higher
than volts to be measured.
e. Connect red probe (Figure 13, Item 9) to positive (+) side of circuit and black probe (Figure 13, Item 8) to
negative (-) side of circuit.
f. Read digital readout (Figure 13, Item 1) and interpret results as DC voltage in circuit being tested.
Figure 13. Multimeter Usage. 0020
RELAY INSPECTION AND TEST 00020
1. Inspecting Relays.
a. Check for bent or damaged pins.
b. Check for burned or damaged relay case.
2. Testing Relays.
NOTE
When testing relays, always refer to the circuit diagram printed or stamped on relay case.
a. Using a multimeter, check for continuity across relay coil.
b. Using a multimeter, check open or closed contacts within relay.
END OF WORK PACKAGE
0020-13/(14 blank)
4
TM 5-3805-255-14 0021
FIELD MAINTENANCE -
0 0 2 1 CIRCUIT BREAKER REPLACEMENT

Circuit Breakers Replacement
INITIAL SETUP
Tools and Special Tools 0 Equipment Condition - Continued 0
Tool Kit, General Mechanic’s, Automotive (WP Parking brake applied (WP 0005) 0
0128, Item 20) 0

Equipment Condition 0
0004) 0
CIRCUIT BREAKERS REPLACEMENT 00021
A 15 amp and 25 amp circuit breaker are located on the underside of instrument panel.
REMOVAL 00021
Remove gauge face plate (Figure 1, Item 1) from instrument panel (Figure 1, Item 2).
Figure 1. Gauge Cluster. 0021
0021-1
TM 5-3805-255-14 0021
REMOVAL – CONTINUED
3. Remove nuts (Figure 2, Items 1 and 3), lockwashers (Figure 2, Items 2 and 4), and wire (Figure 2, Item 5) from
circuit breaker (Figure 2, Item 6). Discard lockwashers.
4. Remove circuit breaker (Figure 2, Item 6) from dash panel (Figure 2, Item 7).
Figure 2. Circuit Breaker. 0021
END OF TASK
INSTALLATION 00021
1. Install circuit breaker (Figure 2, Item 6) on dash panel (Figure 2, Item 7).
2. Install wire (Figure 2, Item 5), new lockwashers (Figure 2, Items 2 and 4), and nuts (Figure 2, Items 1 and 3) on
circuit breaker (Figure 2, Item 6).
0021-2
TM 5-3805-255-14 0021
INSTALLATION – CONTINUED
Install gauge face plate (Figure 3, Item 1) on instrument panel (Figure 3, Item 2).
END OF TASK
END OF WORK PACKAGE
0021-3/(4 blank)
6
TM 5-3805-255-14 0022
FIELD MAINTENANCE -
0 0 2 2 ENGINE REPLACEMENT
Removal, Installation
INITIAL SETUP
Tools and Special Tools 0 References - Continued 0
Shop Equipment, Automotive Maintenance WP 0044 0
and Repair: Organizational Maintenance WP 0048 0
Common #1 (WP 0128, Item 14) 0

WP 0063 0
Compression Test Adapter (WP 0128, Item 2) 0
WP 0064 0
Materials/Parts 0
WP 0122 0
Cap Set, Protective Dust and Moisture Seal Equipment Condition 0
(WP 0130, Item 3) 0
Personnel Required 0 Engine access panels removed (WP 0005) 0
Two 0
Coolant drained (WP 0016) 0

References 0
0004) 0
WP 0016 0
Battery cables removed from batteries (WP
WP 0034 0 0044) 0
WP 0035 0 Hydraulic reservoir drained (WP 0016) 0
WP 0036 0 Engine oil drained (WP 0016) 0
WP 0037 0
WP 0043 0
REMOVAL 00022
1. Remove clamps that secure muffler to turbocharger exhaust elbow and remove muffler (WP 0035)
2. Remove air cleaner hood and extension shaft from air cleaner housing.
3. Remove hardware securing hood to grille and front hood support and remove hood.
NOTE
Tag and identify all electrical wires, hoses and lines to aid in installation.
4. Disconnect electrical wires at rear lamps, stop lamps, and back-up alarm.
5. Remove radiator grille and oil cooler assembly (WP 0036).
0022-1
TM 5-3805-255-14 0022
NOTE
Tag and identify all wires and hoses to aid in installation.
6. Disconnect battery cables from starter, beginning with ground cable (WP 0041). Pull battery cables out of
engine compartment.
NOTE
• Tag and identify all hoses prior to removal to aid in installation.
• Plug all hoses and open ports to prevent contamination and leaks.
7. Disconnect ether supply line (Figure 1, Item 1) at thermal shut-off valve (Figure 1, Item 2) at rear of water
manifold (Figure 1, Item 3).
Figure 1. Ether Supply Line. 022
0022-2
TM 5-3805-255-14 0022
NOTE
Relieve brake air pressure by pressing brake pedal until air pressure gauge reads
zero psi.
8. Disconnect air compressor outlet line. Disconnect air compressor governor line at air compressor (WP 0063
and WP 0064).
9. Remove U-bolt and disconnect oil drain hose from fuel tank.
NOTE
Place a suitable drain pan under fuel line connections at fuel tank.
10. Disconnect fuel lines from fuel tank (WP 0031).
11. Disconnect accelerator cable from injector actuating arm (WP 0028).
12. Disconnect emergency shutdown control linkage from fuel injection pump (WP 0028).
13. Remove two electrical wires from oil pressure sending unit (WP 0044).
14. Remove electrical wire from coolant temperature sending unit (WP 0044).
NOTE
Place a suitable drain pan under heater hose shut off valves.
15. Close heater hose shut-off valves (Figure 2, Item 1).
16. Remove two clamps (Figure 2, Item 2) and heater hoses (Figure 2, Item 3) from engine (Figure 2, Item 4).
Figure 2. Heater Hoses. 022
0022-3
TM 5-3805-255-14 0022
NOTE
Place a suitable drain pan under hydraulic reservoir-to-pump inlet line.
17. Remove clamps and disconnect hydraulic reservoir-to-pump inlet line. Tag, identify, disconnect, and plug all
reservoir, pump and hose lines and open ports to keep dirt from entering hydraulic system.
18. Tag, disconnect and plug or cap all lines at torque converter, main hydraulic pump and converter charging
pump.
19. Disconnect and remove transmission-to-torque converter propeller shaft (WP 0048).
20. Attach suitable lifting device to engine.
NOTE
Do not remove mounting brackets from engine.
21. Remove bolts and nuts that secure front and rear engine mounting brackets to frame.
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use
assistance during procedure. Ensure that any lifting equipment is in good condition and of
suitable load capacity. Keep clear of heavy parts supported by lifting equipment. Failure to
follow this warning may result in injury or death to personnel.
22. Carefully lift engine out of loader, checking for any wires, hoses or connections that may have been over-
looked.
23. Set engine in an engine stand and remove lifting device from engine.
24. Attach suitable lifting device to torque converter.
25. Remove bolts and torque converter from engine.
26. Set torque converter in a properly supported position.
END OF TASK
CLEANING AND INSPECTION 00022
Clean debris from engine compartment and check for wear or damage to wires, hoses or tubes. Repair or replace
as necessary.
END OF TASK
0022-4
TM 5-3805-255-14 0022
INSTALLATION 00022
WARNING
1. Attach suitable lifting device to torque converter. Install torque converter and bolts to engine. Remove lifting
device from torque converter.
2. Using a suitable lifting device, raise engine from its stand and position it over engine compartment. Slowly
lower engine into compartment, positioning engine mounting brackets onto support brackets on frame. Use a
drift to line up mounting holes. Install mounting bolts and washers. Use new nuts on all mounting bolts. Refer to
WP 0122 for special torques when tightening bolts. Remove lifting device from engine.
3. Position and install transmission-to-torque converter propeller shaft (WP 0048).
NOTE
Install hoses, tubes and lines as noted during removal.
4. Remove plugs and caps from hoses, tubes and converter and pump ports. Connect all tagged lines to their
proper ports. Use new O-rings. Be sure all split flange clamps are properly seated before tightening cap-
screws.
5. Connect all tagged lines to hydraulic reservoir. Be certain that all plugs and/or caps are removed before mak-
ing connections. Check reservoir drain valve to be sure it is closed, and drain plugs are in place and tightened.
Tighten all clamps.
6. Install two heater hoses and clamps to engine. Open two heater shut-off valves.
7. Install electrical wire to coolant temperature sending unit (WP 0044).
8. Install two electrical wires to oil pressure sending unit (WP 0044).
9. Connect emergency shutdown control linkage to fuel injection pump (WP 0034).
10. Connect accelerator cable to injector actuating arm (WP 0028).
11. Connect fuel lines to fuel tank (WP 0031).
12. Connect oil drain hose to fuel tank. Install U-bolt.
13. Connect fuel supply line to fuel pump.
14. Connect air compressor outlet line. Connect air compressor governor line to air compressor (WP 0064 and
WP 0065).
15. Feed battery cables into battery box, but do not connect to battery.
16. Connect ether supply line to bottom port of thermal shut-off valve at rear of water manifold.
17. Feed battery cables into engine compartment. Connect battery cables to starter (WP 0043).
0022-5
TM 5-3805-255-14 0022
INSTALLATION – CONTINUED 00022
WARNING
18. Using suitable lifting device, raise grille-oil cooler-radiator unit into position on loader frame.
19. Work carefully to avoid damage to fan blades or radiator fan housing. Install grille mounting bolts, washers and
nuts. Tighten securely. Remove lifting device.
20. Install lower radiator mounting capscrews into brackets and tighten nuts.
21. Connect electrical wires at rear lamps, stop lamps, and back-up alarm.
22. Connect previously tagged lines to oil cooler. Connect both upper and lower radiator hoses to radiator.
WARNING
23. Using a suitable lifting device, raise and install hood on grille and front bulkhead. Line up mounting holes and
install bolts, washers and nuts. Remove lifting device.
24. Install hose between air cleaner and engine air inlet pipe. Tighten hose clamps securely.
25. Connect air compressor air inlet hose to air cleaner.
26. Install extension shaft and air cleaner on air cleaner housing.
27. Install exhaust stack, through hood, on exhaust of turbocharger. Tighten stack clamp securely.
28. Fill radiator with coolant (WP 0018).
29. Fill hydraulic reservoir with fluid (WP 0018).
30. Fill and check engine crankcase oil level (WP 0018).
31. Connect cables to batteries (WP 0045).
32. Start engine and check for leaks at radiator and torque converter connections.
33. With engine idling, check transmission fluid level (WP 0018). Add fluid as needed.
34. Check engine for proper operation (WP 0005).
35. Install engine access panels (WP 0005).
END OF TASK
END OF WORK PACKAGE
0022-6
10
TM 5-3805-255-14 0023
FIELD MAINTENANCE -
0 0 2 3 LUBRICATING OIL AND WATER PUMP REPLACEMENT

INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP Gasket 0
0128, Item 20) 0

O-ring (4) 0
Shop Equipment, Automotive Maintenance

and Repair: Organizational Maintenance Equipment Condition 0
Common #1 (WP 0128, Item 14) 0 Machine parked on level ground (WP 0005) 0
Materials/Parts 0

Battery disconnect switch in OFF position
Item 23) 0
(WP 0004) 0
Engine access panels removed (WP 0005) 0
Ferule 0
Coolant system drained (WP 0018) 0
0023-1
TM 5-3805-255-14 0023
REMOVAL 00023
1. Remove four clamps (Figure 1, Item 3) from two hoses (Figure 1, Item 4).
2. Remove two clamps (Figure 1, Item 7) from hose (Figure 1, Item 5).
3. Remove radiator tube (Figure 1, Item 2) from radiator (Figure 1, Item 6), by-pass tube (Figure 1, Item 1), and
water pump.
4. Remove two hoses (Figure 1, Item 4) and hose (Figure 1, Item 5) from radiator tube (Figure 1, Item 2).
Figure 1. Radiator Hoses. 0023
0023-2
TM 5-3805-255-14 0023
5. Remove clamp (Figure 2, Item 9) and hose (Figure 2, Item 8) from water pump (Figure 2, Item 7).
6. Disconnect fitting (Figure 2, Item 1) and line (Figure 2, Item 3) from water pump (Figure 2, Item 7). Remove
and discard ferule (Figure 2, Item 2).
7. Remove two clamps (Figure 2, Item 5) from hose (Figure 2, Item 6) on water pump (Figure 2, Item 7) and oil
cooler (Figure 2, Item 4).
Figure 2. Hoses and Clamps. 0023
0023-3
TM 5-3805-255-14 0023
8. Remove bolt (Figure 3, Item 1) and lockwasher (Figure 3, Item 2) from lubricating oil pump (Figure 3, Item 3).
Discard lockwasher.
9. Remove two bolts (Figure 3, Item 5), washers (Figure 3, Item 6), and manifold (Figure 3, Item 7) from engine
(Figure 3, Item 8).
10. Remove four O-rings (Figure 3, Item 4) from manifold (Figure 3, Item 7). Discard O-rings.
Figure 3. Oil Pump Manifold. 0023
0023-4
TM 5-3805-255-14 0023
11. Remove hose (Figure 4, Item 2) from lubricating oil pump (Figure 4, Item 4). Remove O-ring (Figure 4, Item 1)
from hose. Discard O-ring.
12. Remove six bolts (Figure 4, Item 7), nuts (Figure 4, Item 5), lockwashers (Figure 4, Item 6), and lubricating oil
pump (Figure 3, Item 4) and water pump (Figure 3, Item 3) assembly from timing cover (Figure 4, Item 9).
13. Remove gasket (Figure 4, Item 8) from lubricating oil pump (Figure 4, Item 4). Discard gasket.
Figure 4. Oil and Water Pump. 0023
END OF TASK
0023-5
TM 5-3805-255-14 0023
INSTALLATION 00023
1. Install new gasket (Figure 5, Item 8) on lubricating oil pump (Figure 5, Item 4).
2. Install lubricating oil pump (Figure 4, Item 4) and water pump (Figure 5, Item 3) assembly, six bolts (Figure 5,
Item 7), new lockwashers (Figure 5, Item 6), and nuts (Figure 5, Item 5) on timing cover (Figure 5, Item 9).
3. Install new O-ring (Figure 5, Item 1) on hose (Figure 5, Item 2). Install hose on lubricating oil pump (Figure 5,
Item 4).
Figure 5. Oil and Water Pump. 0023
0023-6
TM 5-3805-255-14 0023
NOTE
Lubricate O-rings with clean engine oil (WP 0008).
4. Install four new O-rings (Figure 6, Item 4) on manifold (Figure 6, Item 7).
5. Install manifold (Figure 6, Item 7), two washers (Figure 6, Item 6), and bolts (Figure 6, Item 5) on engine
(Figure 6, Item 8).
6. Install new lockwasher (Figure 6, Item 2) and bolt (Figure 6, Item 1) on lubricating oil pump (Figure 6, Item 3).
Figure 6. Oil Pump Manifold. 0023
0023-7
TM 5-3805-255-14 0023
7. Install two clamps (Figure 7, Item 5) on hose (Figure 7, Item 6) on water pump (Figure 7, Item 7) and oil cooler
(Figure 7, Item 4).
8. Install new ferule (Figure 7, Item 2) on line (Figure 7, Item 3) and connect line to water pump (Figure 7, Item 7).
Tighten fitting (Figure 7, Item 1).
9. Install hose (Figure 7, Item 8) and clamp (Figure 7, Item 9) on water pump (Figure 7, Item 7).
Figure 7. Hoses and Clamps. 0023
0023-8
TM 5-3805-255-14 0023
10. Install two hoses (Figure 8, Item 4) and hose (Figure 8, Item 5) on radiator tube (Figure 8, Item 2).
11. Install radiator tube (Figure 8, Item 2) on radiator (Figure 8, Item 6), by-pass tube (Figure 8, Item 1), and water
pump.
12. Install two clamps (Figure 8, Item 7) on hose (Figure 8, Item 5).
13. Install four clamps (Figure 8, Item 3) on two hoses (Figure 8, Item 4).
Figure 8. Radiator Hoses. 0023
14. Fill cooling system (WP 0018). Start engine and check for leaks.
END OF TASK
END OF WORK PACKAGE
0023-9/(10 blank)
6
TM 5-3805-255-14 0024
FIELD MAINTENANCE -
ENGINE OIL COOLER REPLACEMENT

0 0 2 4
Removal, Cleaning and Inspection, Leakage Tests, Installation
INITIAL SETUP
0128, Item 20) 0

Plate, Oil Cooler Leak Test (WP 0125, Item 11 Engine OFF (WP 0005) 0
and 11a) 0

Materials/Parts 0
(WP 0004) 0

0130, Item 4) 0
Gasket (4) 0
O-ring (2) 0
0024-1
TM 5-3805-255-14 0024
REMOVAL 00024
WARNING
Wear gloves when handling engine oil. If oil contacts skin, wash it off immediately. Failure
to follow this warning may cause injury to personnel.
1. Remove two clamps (Figure 1, Item 2) and hose (Figure 1, Item 1) from engine oil cooler (Figure 1, Item 8).
2. Loosen nut (Figure 1, Item 6) and disconnect hose (Figure 1, Item 5) from engine oil cooler (Figure 1, Item 8).
Remove O-ring (Figure 1, Item 7) from hose. Discard O-ring.
3. Remove four clamps (Figure 1, Item 10), two hoses (Figure 1, Item 9), and hose (Figure 1, Item 11) from
engine oil cooler (Figure 1, Item 8) and engine (Figure 1, Item 17).
4. Loosen nut (Figure 1, Item 13) and disconnect pipe (Figure 1, Item 12) from engine oil cooler (Figure 1,
Item 8). Remove O-ring (Figure 1, Item 14) from pipe. Discard O-ring.
5. Remove two bolts (Figure 1, Item 3) and washers (Figure 1, Item 4) from engine oil cooler (Figure 1, Item 8).
6. Remove two bolts (Figure 1, Item 15), washers (Figure 1, Item 16), and engine oil cooler (Figure 1, Item 8)
from engine (Figure 1, Item 17).
Figure 1. Engine Oil Cooler. 0024
END OF TASK
0024-2
TM 5-3805-255-14 0024
WARNING

low-toxicity 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
1. Immerse coolers in solvent cleaning compound to loosen any sludge or foreign matter.
CAUTION
Do not use wire brushes or steel scrapers for removing deposits. Failure to follow these
instructions may cause damage to components.
2. Drain and blow out any solvent and foreign matter inside of coolers, being certain that all passages are clean
and clear before installation.
END OF TASK
0024-3
TM 5-3805-255-14 0024
LEAKAGE TESTS
WARNING
• Use adequate safety precautions, including eye protection, when performing Air Pressure Test.
• Do not exceed air pressure in oil cooler. Excessive pressure may damage oil cooler.
Failure to follow this caution may cause injury to personnel or damage to equipment.
Air Pressure Test
NOTE
Use a one-inch pipe plug on engine oil coolers as indicated in Figure 2, Plate "B".
Fasten gaskets or O-rings and cover plates (as shown in Figure 2) to engine oil cooler and immerse assembly in a
container of 120°F (49°C) water. Apply 80 psi (550 kPa) of air while immersed in water. Check for leaks.
H100C-0817
Figure 2. Cover Plates and Coupling Installed.
END OF TASK
TM 5-3805-255-14 0024
INSTALLATION 00024
1. Install engine oil cooler (Figure 3, Item 8), two washers (Figure 3, Item 16), and bolts (Figure 3, Item 15) on
engine (Figure 3, Item 17).
2. Install two washers (Figure 3, Item 4) and bolts (Figure 3, Item 3) on engine oil cooler (Figure 3, Item 8).
3. Install new O-ring (Figure 3, Item 14) on pipe (Figure 3, Item 12). Connect pipe to engine oil cooler (Figure 3,
Item 8). Tighten nut (Figure 3, Item 13).
4. Install hose (Figure 3, Item 11), two hoses (Figure 3, Item 9), and four clamps (Figure 3, Item 10) on engine oil
cooler (Figure 3, Item 8) and engine (Figure 3, Item 17).
5. Install new O-ring (Figure 3, Item 7) on hose (Figure 3, Item 5). Install hose on engine oil cooler (Figure 3, Item
8).
6. Install hose (Figure 3, Item 1) and two clamps (Figure 3, Item 2) on engine oil cooler (Figure 3, Item 8).
Figure 3. Engine Oil Cooler. 0024
7. Fill cooling system and lubricating oil system (WP 0018).

8. Start engine (WP 0005) and check all connections for leaks.
END OF TASK
END OF WORK PACKAGE
0024-5/(6 blank)
4
TM 5-3805-255-14 0025
FIELD MAINTENANCE -
ENGINE BREATHER REPLACEMENT

0 0 2 5
Removal, Cleaning and Inspection, Installation
INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP WP 0019 0
0128, Item 20) 0
Materials/Parts 0

Gasket 0

(WP 0004) 0
REMOVAL 00025
1. Remove bolt (Figure 1, Item 1), flat washer (Figure 1, Item 2), and clamp (Figure 1, Item 3) from engine
breather tube (Figure 1, Item 4).
Figure 1. Clamp. 0025
0025-1
TM 5-3805-255-14 0025
2. Remove bolt (Figure 2, Item 1) and flat washer (Figure 2, Item 2) from filter support bracket (Figure 2, Item 6).
3. Remove bolt (Figure 2, Item 7), flat washer (Figure 2, Item 8), and clamp (Figure 2, Item 9) from filter support
bracket (Figure 2, Item 6).
4. Remove bolt (Figure 2, Item 11) and flat washer (Figure 2, Item 10) from filter support bracket (Figure 2,
Item 6).
5. Remove bolt (Figure 2, Item 5) and flat washer (Figure 2, Item 12) from engine breather (Figure 2, Item 4)
housing.
6. Remove engine breather (Figure 2, Item 4) from engine.
7. Remove gasket (Figure 2, Item 3) from engine breather (Figure 2, Item 4). Discard gasket.
Figure 2. Engine Breather. 0025
END OF TASK
0025-2
TM 5-3805-255-14 0025
CLEANING AND INSPECTION

Clean and inspect all parts IAW General Maintenance Instructions (WP 0019).
END OF TASK
INSTALLATION 00025
1. Install engine breather (Figure 2, Item 4) on engine.

2. Install new gasket (Figure 2, Item 3) on engine breather (Figure 2, Item 4). Install engine breather on engine.
3. Install flat washer (Figure 2, Item 12) and bolt (Figure 2, Item 5) on engine breather (Figure 2, Item 4) housing.
4. Install flat washer (Figure 2, Item 10) and bolt (Figure 2, Item 11) on filter support bracket (Figure 2, Item 6).
5. Install clamp (Figure 2, Item 9), flat washer (Figure 2, Item 8), and bolt (Figure 2, Item 7) on filter support
6. Install flat washer (Figure 2, Item 2) and bolt (Figure 2, Item 1) on filter support bracket (Figure 2, Item 6).
7. Install clamp (Figure 3, Item 3), flat washer (Figure 3, Item 2), and bolt (Figure 3, Item 1) on engine breather
tube (Figure 3, Item 4).
Figure 3. Clamp. 0025
8. Turn battery disconnect switch to ON position (WP 0005).

9. Start engine and check for leaks (WP 0005).
END OF TASK
END OF WORK PACKAGE
0025-3/(4 blank)
6
TM 5-3805-255-14 0026
FIELD MAINTENANCE -
0 0 2 6 INTAKE AND EXHAUST MANIFOLD REPLACEMENT

INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0

Gasket, Exhaust Manifold (4) 0

Gasket, Intake Manifold (3) 0

Gasket, Oil Drain Tube 0 0004) 0
Gasket, Oil Inlet Tube 0 Exhaust pipe and muffler removed (WP 0035) 0
Two 0
0026-1
TM 5-3805-255-14 0026
REMOVAL 00026
WARNING
Manifolds may be hot. Allow engine to cool before removing manifolds. Failure to follow
this warning may result in injury to personnel.
NOTE
Exhaust sleeve is loosely held between exhaust elbow and turbine housing. Sleeve must
be held as elbow is removed, to prevent sleeve from dropping.
1. Remove two nuts (Figure 1, Item 11), four washers (Figure 1, Item 12), four bolts (Figure 1, Item 13),
turbocharger exhaust elbow (Figure 1, Item 8), and sleeve (Figure 1, Item 7) from exhaust manifold (Figure 1,
Item 27).
2. Remove two bolts (Figure 1, Item 4), washers (Figure 1, Item 5), oil inlet tube (Figure 1, Item 3), and gasket
(Figure 1, Item 6) from turbocharger (Figure 1, Item 1). Discard gasket.
3. Remove clamp (Figure 1, Item 30) and inlet hose (Figure 1, Item 29) from turbocharger (Figure 1, Item 1).
4. Remove two bolts (Figure 1, Item 16), washers (Figure 1, Item 17), drain tube (Figure 1, Item 19), and gasket
(Figure 1, Item 18) from turbocharger (Figure 1, Item 1). Discard gasket.
5. Disconnect two clamps (Figure 1, Item 2) and hose (Figure 1, Item 28) from turbocharger (Figure 1, Item 1)
and air discharge elbow (Figure 1, Item 23).
6. Remove four bolts (Figure 1, Item 21), washers (Figure 1, Item 22), air hose bracket (Figure 1, Item 20), and
air discharge elbow (Figure 1, Item 23) from intake manifold (Figure 1, Item 26).
7. Disconnect exhaust pick-up tube fitting (Figure 1, Item 15) from exhaust manifold (Figure 1, Item 27).
8. Remove four nuts (Figure 1, Item 9), washers (Figure 1, Item 10), and turbocharger (Figure 1, Item 1) from
exhaust manifold (Figure 1, Item 27).
9. Remove 10 nuts (Figure 1, Item 24), washers (Figure 1, Item 25), exhaust manifold (Figure 1, Item 27), and
four gaskets (Figure 1, Item 14) from cylinder head. Discard gaskets.
0026-2
TM 5-3805-255-14 0026
REMOVAL – CONTINUED 00026
H100C-0871
Figure 1. Turbocharger Connections and Manifold. 0026
0026-3
TM 5-3805-255-14 0026
10. Remove upper pick-up tube (Figure 2, Item 8) and lower pick-up tube (Figure 2, Item 9) from intake manifold
(Figure 2, Item 1).
11. Remove four bolts (Figure 2, Item 7) and washers (Figure 2, Item 6) from intake manifold (Figure 2, Item 1).
12. Remove two bolts (Figure 2, Item 10) and washers (Figure 2, Item 11) from intake manifold (Figure 2, Item 1).
13. Remove two nuts (Figure 2, Item 3), washers (Figure 2, Item 4), intake manifold (Figure 2, Item 1), and three
gaskets (Figure 2, Item 2) from cylinder head (Figure 2, Item 5). Discard gaskets.
Figure 2. Intake Manifold. 0026
END OF TASK
0026-4
TM 5-3805-255-14 0026
1. Clean and inspect all parts IAW General Maintenance Instructions (WP 0019).
2. Inspect intake manifold, exhaust manifold, and flanges for cracks and distortions. Replace if necessary.
CAUTION
When cleaning parts, ensure debris does not enter internal components. Failure to follow
this caution may result in damage to equipment.
3. Clean intake gasket, exhaust manifold gasket, and clean cylinder head gasket surfaces thoroughly.
END OF TASK
INSTALLATION 00026
1. Install three new gaskets (Figure 3, Item 2), intake manifold (Figure 3, Item 1), two washers (Figure 3, Item 4),
nuts (Figure 3, Item 3), washers (Figure 3, Item 11), bolts (Figure 3, Item 10), four washers (Figure 3, Item 6),
and bolts (Figure 3, Item 7) on cylinder head (Figure 3, Item 5).
2. Torque intake manifold bolts (Figure 3, Items 7 and 10) and nuts (Figure 3, Item 3) to 75 lb-ft (102 Nm).
3. Attach upper pick-up tube (Figure 3, Item 8) and lower pick-up tube (Figure 3, Item 9) to intake manifold
(Figure 3, Item 1).
H100C-0870
Figure 3. Intake Manifold. 0026
0026-5
TM 5-3805-255-14 0026
4. Install four new gaskets (Figure 4, Item 14), exhaust manifold (Figure 4, Item 27), 10 washers (Figure 4, Item
25), and nuts (Figure 4, Item 24) on cylinder head (Figure 4, Item 15).
5. Torque nuts (Figure 4, Item 24) to 75 lb-ft (102 Nm).
6. Install exhaust pick-up tube fitting (Figure 4, Item 15) on exhaust manifold (Figure 4, Item 27).
7. Install turbocharger (Figure 4, Item 1), four washers (Figure 4, Item 10) and nuts (Figure 4, Item 9) on exhaust
manifold (Figure 4, Item 27).
8. Install air discharge elbow (Figure 4, Item 23) in hose (Figure 4, Item 28).
9. Install four washers (Figure 4, Item 22), bolts (Figure 4, Item 21), and air hose bracket (Figure 4, Item 20) on
intake manifold (Figure 4, Item 26).
10. Install two hose clamps (Figure 4, Item 2) on hose (Figure 4, Item 28).
11. Install new gasket (Figure 4, Item 18), two washers (Figure 4, Item 17), bolts (Figure 4, Item 16), and drain
tube (Figure 4, Item 19) on turbocharger (Figure 4, Item 1).
12. Install clamp (Figure 4, Item 30) and inlet hose (Figure 4, Item 29) on turbocharger (Figure 4, Item 1).
13. Install new gasket (Figure 4, Item 6), oil inlet tube (Figure 4, Item 3), two washers (Figure 4, Item 5), and bolts
(Figure 4, Item 4) on turbocharger (Figure 4, Item 1).
NOTE
Exhaust sleeve is held loosely between exhaust elbow and turbine housing. Sleeve must
be held as exhaust elbow is installed to prevent sleeve from dropping.
14. Install exhaust sleeve (Figure 4, Item 7), turbocharger exhaust elbow (Figure 4, Item 8), four bolts (Figure 4,
Item 13), four washers (Figure 4, Item 12), and two nuts (Figure 4, Item 11) on exhaust manifold (Figure 4, Item
27).
H100C-0871
Figure 4. Turbocharger Connections and Manifold. 0026
15. Install exhaust pipe and muffler (WP 0035).

END OF TASK
END OF WORK PACKAGE
0026-6
6
TM 5-3805-255-14 0027
FIELD MAINTENANCE -
0 0 2 7 FUEL INJECTOR AND LINE REPLACEMENT

INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0
Cap Set, Protective Dust and Moisture Seal Parking brake applied (WP 0005) 0
(WP 0130, Item 3) 0


0004) 0

Engine acess panels removed (WP 0005) 0
REMOVAL 00027
1. Remove two thumbscrews (Figure 1, Item 1), washers (Figure 1, Item 2) and valve cover (Figure 1, Item 3)
from cylinder head (Figure 1, Item 5). Do not remove gasket (Figure 1, Item 4) from valve covers.
Figure 1. Cylinder Head. 0027
0027-1
TM 5-3805-255-14 0027
2. Remove fuel inlet (Figure 2, Item 2) and fuel return lines (Figure 2, Item 1).
Figure 2. Fuel Lines. 0027
3. Remove six bolts (Figure 3, Item 1), washers (Figure 3, Item 2), and injector hold-downs (Figure 3, Item 3).
CAUTION
Handle injectors with care to prevent nozzle damage. Failure to follow this caution may
result in damage to equipment.
4. Remove six injectors (Figure 3, Item 4) from injector sleeves (Figure 3, Item 6). Do not damage nozzles (Figure
3, Item 7).
0027-2
TM 5-3805-255-14 0027
NOTE
Cap and plug injectors and fuel lines to prevent contamination.
5. Cap and plug fuel inlet and return openings (Figure 3, Item 5) on injectors (Figure 3, Item 4).
6. If necessary, test injectors (WP 0090).
Figure 3. Injector Nozzles. 0027
END OF TASK
0027-3
TM 5-3805-255-14 0027
INSTALLATION 00027
1. Remove caps and plugs from fuel inlet and return openings (Figure 4, Item 5) on injectors (Figure 4, Item 4).
CAUTION
Handle injectors with care to prevent nozzle damage. Failure to follow this caution may
result in damage to nozzles or equipment.
2. Install six injectors (Figure 4, Item 4) in injector sleeves (Figure 4, Item 6).
3. Install six injector hold-downs (Figure 4, Item 3), washers (Figure 4, Item 2), and bolts (Figure 4, Item 1).
Tighten bolts to 30 lb-ft (40 Nm).
Figure 4. Injector Nozzles. 0027
0027-4
TM 5-3805-255-14 0027
4. Install fuel inlet (Figure 5, Item 2) and return lines (Figure 5, Item 1).
0027-5
TM 5-3805-255-14 0027
5. Install valve cover (Figure 6, Item 3) with gasket (Figure 6, Item 4), two washers (Figure 6, Item 2), and
thumbscrews (Figure 6, Item 1) on cylinder head (Figure 6, Item 5).
Figure 6. Cylinder Head. 0027
6. Prime fuel system. Refer to Fuel System (WP 0018).

7. Install engine acces panels (WP 0005).
END OF TASK
END OF WORK PACKAGE
0027-6
14
TM 5-3805-255-14 0028
FIELD MAINTENANCE -
0 0 2 8 FUEL INJECTION PUMP REPLACEMENT AND TIMING

Removal, Installation, Adjustment
INITIAL SETUP
Shop Equipment, Automotive Maintenance Machine parked on level ground (WP 0005) 0
and Repair: Organizational Maintenance Parking brake applied (WP 0005) 0

Materials/Parts 0
(WP 0004) 0
References 0
Emergency shutdown cable removed from fuel
WP 0018 0
injection pump (WP 0034) 0
WP 0020 0
Accelerator cable removed from fuel injection
WP 0XX 0
pump (WP 0028) 0
Fan guard removed (WP 0005) 0
0028-1
TM 5-3805-255-14 0028
REMOVAL 00028
1. Close fuel shut-off valve at fuel tank.
WARNING
• DO NOT smoke or permit any open flame in area of H100C while you are servicing fuel
static electricity. Failure to follow this warning may result in injury or death to personnel or
• DO NOT perform fuel system checks, inspections, or maintenance while smoking or near
fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death
to personnel.
• Wear fuel-resistant gloves and eye protection when handling fuels. If exposed to fuel,
promptly wash exposed skin and change fuel-soaked clothing.
2. Rotate engine crankshaft clockwise until No. 1 cylinder is on compression stroke and position engine vibration
damper to 38 degrees Before Top Dead Center (BTDC) with last movement made in direction of engine
rotation. This will take up all slack in gear train.
3. Remove four of five capscrews (Figure 1, Item 3), and loosen fifth, securing injection pump timing cover
(Figure 1, Item 1) to crankcase front cover (Figure 1, Item 2) and rotate cover down as shown in Figure 1.
Figure 1. Injection Pump Timing Port. 0028
0028-2
TM 5-3805-255-14 0028
NOTE
• There are helical gears on pump and pinion shaft, and in order for pump to be removed or
installed, one or both of these gears has to rotate. Capscrews are loosened to permit shaft
to rotate within limits of elongated holes in drive gear.
• If capscrews (Figure 2, Item 1) are secured with a lock plate (Figure 2, Item 7), lock plate
and retainer plate (Figure 2, Item 6) should not be reused. Replace with three washers
(Figure 2, Item 2).
4. Loosen three timing pointer capscrews (Figure 2, Item 1) securing drive gear (Figure 2, Item 3) to hub
(Figure 2, Item 4) on pinion shaft (Figure 2, Item 5).
Figure 2. Exploded View of Injection Pump Adapter. 0028
0028-3
TM 5-3805-255-14 0028
NOTE
• Air cleaner dust unloader is located right above injection pump. Be sure to clean this out
before disconnecting any lines to prevent dirt from unloading into pump openings.
• Cap and tag all openings of pump and lines immediately after disconnecting to prevent
entry of dirt.
• Place a suitable drain pan under fuel injection pump to catch fuel as lines are
disconnected.
5. Remove clamp (Figure 3, Item 2) and disconnect hose (Figure 3, Item 3) from fuel injection pump (Figure 3,
Item 1).
6. Remove nut (Figure 3, Item 6), bolt (Figure 3, Item 4), and washer (Figure 3, Item 5) from fuel injection pump
(Figure 3, Item 1).
Figure 3. Fuel Injection Pump Cables. 0028
0028-4
TM 5-3805-255-14 0028
7. Disconnect six fuel injector supply lines (Figure 4, Item 2) from fuel injection pump (Figure 4, Item 1).
8. Disconnect hose (Figure 4, Item 3) from fuel injection pump (Figure 4, Item 1).
9. Disconnect fuel line (Figure 4, Item 4) from fuel injection pump (Figure 4, Item 1).
10. Disconnect hose (Figure 4, Item 5) from fuel injection pump (Figure 4, Item 1).
11. Disconnect line (Figure 4, Item 9) from fuel injection pump (Figure 4, Item 1).
12. Disconnect line (Figure 4, Item 13) from fuel injection pump (Figure 4, Item 1).
13. Remove four capscrews (Figure 4, Items 6, 7, 10, and 11) and injection pump adapter (Figure 4, Item 8) from
adapter housing (Figure 4, Item 12).
14. Remove fuel injection pump (Figure 4, Item 1) and gasket from adapter housing (Figure 4, Item 12). Discard
gasket.
CAUTION
Do not crank or rotate engine with fuel injection pump removed. Failure to follow this
caution may result in engine damage.
Figure 4. Fuel Injection Lines and Pump. 0028
END OF TASK
0028-5
TM 5-3805-255-14 0028
INSTALLATION 00028
1. Install new gasket on fuel injection pump (Figure 5, Item 1).

2. Install fuel injection pump (Figure 5, Item 1) on engine.
3. Install four capscrews (Figure 5, Items 6, 7, 10, and 11) on injection pump adapter (Figure 6, Item 8).
NOTE
Install lines and hoses as noted during removal.
4. Connect line (Figure 5, Item 13) to fuel injection pump (Figure 5, Item 1).
5. Connect line (Figure 5, Item 9) to fuel injection pump (Figure 5, Item 1).
6. Connect hose (Figure 5, Item 5) to fuel injection pump (Figure 5, Item 1).
7. Connect fuel line (Figure 5, Item 4) to fuel injection pump (Figure 5, Item 1).
8. Connect hose (Figure 5, Item 3) to fuel injection pump (Figure 5, Item 1).
9. Connect six fuel injector supply lines (Figure 5, Item 2) to fuel injection pump (Figure 5, Item 1).
Figure 5. Fuel Injection Lines and Pump 0028
0028-6
TM 5-3805-255-14 0028
10. Install bolt (Figure 6, Item 4), washer (Figure 6, Item 5), and nut (Figure 6, Item 6) on fuel injection pump
(Figure 6, Item 1).
NOTE
Install hose as noted during removal.
11. Connect hose (Figure 6, Item 3) to fuel injection pump (Figure 6, Item 1). Position clamp (Figure 8, Item 2).
Figure 6. Fuel Injection Pump Cables. 0028
12. With three capscrews loosely installed, remove pivot bracket capscrew (Figure 7, Item 1). Adjust support
(Figure 7, Item 4) and bracket (Figure 7, Item 2) so that with these parts tightened, pivot capscrew (Figure 7,
Item 3) can be inserted freely through bracket and support. Install pivot capscrew and pivot bracket capscrew.
Figure 7. Injection Pump Adjustable Support with Bracket. 0028
0028-7
TM 5-3805-255-14 0028
NOTE
Remove plug located on top of injection pump adapter housing so that injection pump
gear is visible for timing procedure.
13. Rotate drive gear to bring mark on injection pump gear into alignment with pointer on pump and tighten three
drive gear capscrews evenly.
14. Rotate engine crankshaft counterclockwise (as viewed from fan drive end) to approximately 60 degrees before
top dead center of No. 1 cylinder and bring it back clockwise to 38 degrees BTDC.
15. Check timing pointer to be sure it lines up with mark on gear. If pointer is not aligned, loosen capscrews on
drive gear and align. Tighten capscrews.
16. Install plug on pump adapter housing.
17. Secure injection pump timing cover to crankcase front cover.
18. Connect tube (Figure 8, Item 1) to tee (Figure 8, Item 5). Secure two clips (Figure 8, Item 2) to crankcase with
capscrews (Figure 8, Item 3).
19. Connect tube (Figure 8, Item 4) to tee (Figure 8, Item 5).
Figure 8. Fittings and Clamps. 0028
20. Ensure control linkage is properly adjusted.
NOTE
Fuel system may need priming. If fuel does not flow from lines while cranking engine, refer
to WP 0018.
21. With control lever positioned in half throttle position, crank engine (at 10-second intervals) until fuel flows from
all six loose fuel line nuts. Torque line nuts at pump to 30 lb-ft (40 Nm).
22. Start engine and verify all connections made do not leak.
END OF TASK
0028-8
TM 5-3805-255-14 0028
ADJUSTMENT
High Idle Speed Adjustment
NOTE
Be sure engine is at operating temperature before making high idle speed adjustment.
Check and adjust engine high idle speed as follows:
CAUTION
DO NOT OVERSPEED ENGINE. Failure to follow these instructions may result in
a. Check engine high idle speed with pump control lever (Figure 9, Item 4) against high idle stop screw
(Figure 9, Item 3).
NOTE
Engine high idle speed should be within +20 RPM of maximum idle RPM stamped on
vehicle serial number plate.
b. If out of specified speed, remove seal rivet (Figure 9, Item 5) from boss and plastic seal cap (Figure 9,
Item 1) with a small punch. Be careful not to damage seal rivet boss when removing rivet.
c. Loosen high idle speed stop screw locknut (Figure 9, Item 6) and adjust to specified high idle. Tighten
locknut.
d. Remove and discard seal wires (Figure 9, Item 2).
Figure 9. Seal Wire Locations.
0028-9
TM 5-3805-255-14 0028
ADJUSTMENT – CONTINUED
Bumper Spring Adjustment 00028
NOTE
Check to be sure that external pump control linkage travels 0.125 to 0.375 in. (3 to 9 mm)
beyond pump control lever with pin connecting linkage to pump lever removed, and
accelerator pedal or governor control lever is on its high idle stop screw.
Bumper spring adjustment screw for idle surge control is preset to protrude 0.450 in. (11.4 mm) from locknut to slot-
ted end of adjustment screw. This adjustment is to be changed only if it is necessary to eliminate surging. If neces-
sary, adjust as follows:
a. Remove bumper screw cap.
b. Loosen bumper spring adjustment screw locknut and turn screw in to just contact at speed at which surge
occurs.
c. Tighten locknut and recheck high idle speed. If high idle has increased to more than 20 RPM above
maximum idle speed stamped on vehicle serial number plate, back-out bumper spring adjustment screw
locknut and reset high idle to low side of specified RPM range.
d. Readjust bumper spring to eliminate surge.
NOTE
Engine RPM must not exceed that specified, as it will definitely affect rated load
operations. Low idle speed is automatically adjusted when external pump control linkage
is adjusted correctly.
Low Idle Speed Adjustment 00028
1. Check and adjust low idle speed as follows:

a. Check engine low idle speed (650 RPM ± 25 RPM).
b. If out of specified speed, remove capnut from low idle adjustment screw (located above bumper spring
adjustment screw).
c. Loosen low idle adjustment screw locknut and adjust to specified low idle. Tighten locknut and install cap
nut.
0028-10
TM 5-3805-255-14 0028
Low Idle Speed Adjustment — Continued 00028
NOTE
Check to be sure that external pump control linkage travels 0.125 to 0.375 in. (3 to 9 mm)
beyond pump control lever with pin connecting linkage to pump lever removed, and
accelerator pedal or governor control lever is on its high idle stop screw.
2. Install new seal cap (Figure 10, Item 1) over high idle adjustment screw (Figure 10, Item 5) and secure to boss
with new rivet (Figure 10, Item 5). Use seal pliers (Tool No. PLT-371-4) and seal rivet.
3. Install new seal wires (Figure 10, Item 2) and seal all adjustment points as shown in Figure 10.
Figure 10. Seal Wire Locations.
0028-11
TM 5-3805-255-14 0028
Hydraulic Method of Checking Port Closure (Pump Timing Point) 00028
NOTE
This procedure is to be used to check pump-to-engine timing.
1. Move governor control lever (Figure 11, Item 1) against high speed screw (Figure 11, Item 6) and secure in this
position.
2. Move shut-off lever (Figure 11, Item 2) approximately 0.375 to 1.000 in. (19 to 25 mm) (Figure 11, Item 5)
(measured at outer pin hole in lever) from STOP (Figure 11, Item 5) toward RUN (Figure 11, Item 3) position
and secure in this position.
NOTE
If shut-off lever is in full RUN position, starting spring will move injection pump control rack
to its starting position where pump timing is automatically retarded to 10 to 12 degrees
due to retard notch being lined up with control port on plunger.
3. Disconnect fuel line from supply pump at inlet on injection pump. Connect a test pump capable of providing
250 to 300 psi (1,725 to 2,070 kPa) (7 gal/hr. minimum capacity).
4. Remove return valve and plug opening.
5. Disconnect No. 1 fuel injection tube at injection pump delivery valve and install a drip tube. Make drip tube out
of 1/4 in. O.D. injection tubing bent in a U-shape with free end cut at 45 degrees to centerline of tube.
0028-12
TM 5-3805-255-14 0028
Hydraulic Method of Checking Port Closure (Pump Timing Point) — Continued 00028
6. Crank engine in direction of rotation until number one piston is approaching Top-Dead-Center (TDC) on
compression stroke.
Figure 11. Injection Pump Governor Control Lever and Shut-Off Lever Positions. 0028
NOTE
The large inspection plug on side of injection pump adjacent to number one plunger may
be removed to observe number one tappet on up stroke.
7. Continue cranking engine until a degree mark (approximately 10 to 20 degrees before specified timing degree
mark of 38 degrees) lines up with timing pointer.
8. Hand crank engine slowly while maintaining 250 to 300 psi (1,725 to 2,070 kPa) pressure with test pump. Note
flow of fuel out of drip tube from No. 1 delivery valve.
9. Continue cranking and maintaining pressure until fuel flow diminishes from flow to drops, then stop cranking
engine.
10. Check at what point degree mark on vibration damper lines up with timing pointer. This point should coincide
with specified timing of 38 degrees plus or minus one engine degree. If timing is incorrect it must be re-timed
as outlined in step 11.
0028-13
TM 5-3805-255-14 0028
NOTE
To verify that pump-to-engine timing is correct or incorrect, repeat steps 6 through 10 two
or three times to verify results.
11. Re-time pump-to-engine as follows:
a. Rotate engine crankshaft clockwise (as viewed from front) until No. 1 cylinder is coming up on
compression stroke and position engine vibration damper to 38 degree mark BTDC with last movement
made in direction of engine rotation. This will take up all slack in gear train.
b. Loosen three drive gear retainer plate bolts (Figure 12, Item 1).
c. Remove plug from top of pump adapter housing.
d. Rotate drive shaft to align timing pointer and timing mark on pump gear. Tighten three drive gear retainer
bolts (Figure 12, Item 1), replace cover and plug.
Figure 12. Injection Pump Timing Port in Crankcase Front Cover 0028
e. If drive shaft cannot be rotated to align pointer and mark within confines of three drive gear retainer plate
capscrew slots, injection pump must be removed. See Removal in this work package.
f. Reinstall pump as described in steps 1 through 11 under INSTALLATION in this work package.
g. Repeat hydraulic method of checking port closure as previously outlined.
12. Remove drip tube and connect No. 1 fuel injection tube to delivery valve.
13. Disconnect wires securing governor control and shut-down levers.
14. Disconnect test pump and connect fuel line at pump inlet.
15. If it was necessary to re-time pump-to-engine as outlined in step 11, and timing was corrected; then complete
steps 13 through 22 under Installation in this work package.
END OF TASK
END OF WORK PACKAGE
0028-14
8
TM 5-3805-255-14 0029
FIELD MAINTENANCE -
0 AIR CLEANER ASSEMBLY REPLACEMENT

0 2 9
INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP FM 3-3 0
0128, Item 20) 0

FM 3-3-1 0
Regulator, Air 0
FM 3-5 0
Materials/Parts 0
WP 0013 0
WP 0019 0

0130, Item 10) 0
Filter, Air Primary Element 0
Filter, Air Safety Element 0
Lockwasher (4) 0
Seal Washer (2) 0
0004) 0
0029-1
TM 5-3805-255-14 0029
REMOVAL 00029
WARNING
If NBC exposure is suspected, personnel wearing protective equipment must handle all air
cleaner media. Contaminated filters must be handled using adequate precautions and
must be disposed of by trained personnel. Consult your NBC Officer or NBC NCO for
appropriate handling or disposal procedures. Failure to follow this warning may cause
WARNING
IF NBC EXPOSURE IS SUSPECTED ALL AIR
FILTER MEDIA WILL BE HANDLED BY PER-
SONNEL WEARING FULL NBC PROTEC-
TIVE EQUIPMENT. SEE OPERATOR/
MAINTENANCE MANUAL.
7690-01-114-3702
To order this NBC decal use:

National Stock Number (NSN) - 7690-01-114-3702
Part Number (PN) - 12296626
Commercial and Government Entity Code (CAGEC) - 19207
NOTE
Remove dust from exterior of air cleaner assembly and cover.
0029-2
TM 5-3805-255-14 0029
1. Remove clamp (Figure 1, Item 2) and air inlet hood and tube assembly (Figure 1, Item 1) from air cleaner body
(Figure 1, Item 3).
2. Remove clamp (Figure 1, Item 7) from hose (Figure 1, Item 8).
3. Remove four bolts (Figure 1, Item 6) and lockwashers (Figure 1, Item 5) from two air cleaner mounting clamps
(Figure 1, Item 4). Discard lockwashers.
4. Remove air cleaner assembly (Figure 1, Item 3) from hose (Figure 1, Item 8).
Figure 1. Air Cleaner. 029
END OF TASK
0029-3
TM 5-3805-255-14 0029
DISASSEMBLY 00029
1. Remove wing nut (Figure 2, Item 1) (and clamp if equipped) and cover (Figure 2, Item 2) from air cleaner body
(Figure 29).
2. Remove wing bolt (Figure 2, Item 3), seal washer (Figure 2, Item 4), and primary element (Figure 2, Item 5)
from air cleaner assembly (Figure 2, Item 9).
3. Remove seal washer (Figure 2, Item 4) from primary element (Figure 2, Item 5).
4. Replace seal washer (Figure 2, Item 4) if damaged or missing.
5. Remove stop nut (Figure 2, Item 6), seal washer (Figure 2, Item 7), and safety element (Figure 2, Item 8) from
air cleaner assembly (Figure 2, Item 9).
6. Replace seal washer (Figure 2, Item 7) if damaged or missing.
7. Remove unloader valve (Figure 2, Item 10) from air cleaner body (Figure 2, Item 9) and clean.
Figure 2. Air Cleaner Elements. 029
END OF TASK
0029-4
TM 5-3805-255-14 0029
1. Clean and inspect all components IAW General Maintenance Instructions (WP 0019).
2. Wash filter element IAW Operator Preventive Maintenance Checks and Services (PMCS) Including Lubrication
Instructions (WP 0013).
CAUTION
• Do not clean safety element, replace if damaged or dirty.
• Only primary element may be cleaned.
• Primary filter element must be replaced after six washings.
• Do not wash element in fuel oil, gas, or solvent.
• Do not oil element.
• Use only warm water and general purpose liquid detergent to wash primary element.
• Do not attempt to take elements apart.
• Tapping against a hard surface will damage element.
• If safety element is ruptured, no matter how slight, replace.
• Failure to follow these instructions may cause damage to equipment.
NOTE
• After cleaning, if an element is stored for later use, place in a plastic bag and store in an
element shipping container to protect against dirt and damage.
• Clean primary element by washing in a warm water and general purpose liquid detergent
solution.
• Rinse element carefully in clear water. Shake gently to remove excess water. Lay element
on side and allow to air dry before reinstalling. Overnight drying is usually sufficient. When
drying element, protect from dirt and freezing.
• Keep spare elements available for use while serviced element is drying. This reduces unit
down time and allows time to properly service primary element.
• Clean with regulated compressed air only as a temporary measure until time is available
to clean element by washing.
3. Cleaning filter element using compressed air.
a. Element may be cleaned with regulated compressed air, not to exceed 30 PSI at nozzle, and at a
reasonable distance from element.
b. Direct clean dry compressed air up and down pleats on the clean side (inside) of element.
4. Cleaning dual element unloading valve and air cleaner assembly.
a. Wipe inside of air cleaner assembly with clean damp cloth.
b. Squeeze rubber lips of unloading valve to remove any residual dust or dirt. Be certain valve is not blocked
or inoperative.
0029-5
TM 5-3805-255-14 0029
CLEANING AND INSPECTION – CONTINUED

5. Inspect surface where element contacts air cleaner body. If faulty or damaged or surfaces are noted, replace
air cleaner assembly.
END OF TASK
ASSEMBLY 00029
1. Install unloader valve (Figure 3, Item , Item 10) in air cleaner assembly (Figure 3, Item , Item 9).
2. Install open end of safety element (Figure 3, Item , Item 8) into air cleaner assembly (Figure 3, Item , Item 9).
3. Install seal washer (Figure 3, Item , Item 7) and nut (Figure 3, Item , Item 6) on air cleaner assembly (Figure 3,
Item , Item 9).
4. Install open end of primary element (Figure 3, Item , Item 5) over safety element (Figure 3, Item , Item 8).
5. Install seal washer (Figure 3, Item , Item 4) and wing bolt (Figure 3, Item , Item 3) on air cleaner assembly
(Figure 3, Item , Item 9).
6. Install cover (Figure 3, Item , Item 2) and wing nut (Figure 3, Item , Item 1) (and clamp if equipped) on air
cleaner assembly (Figure 3, Item , Item 9).
Figure 3. Air Cleaner Elements. 029
END OF TASK
0029-6
TM 5-3805-255-14 0029
INSTALLATION 00029
1. Install clamp (Figure 4, Item 7) and air cleaner assembly (Figure 4, Item 3) on hose (Figure 4, Item 8).
2. Install four new lockwashers (Figure 4, Item 5) and bolts (Figure 4, Item 6) on two mounting clamps (Figure 4,
Item 4).
3. Install air inlet hood tube assembly (Figure 4, Item 1) and clamp (Figure 4, Item 2) on air cleaner assembly
(Figure 4, Item 3).
Figure 4. Air Cleaner. 029
END OF TASK
END OF WORK PACKAGE
0029-7/(8 blank)
4
TM 5-3805-255-14 0030
FIELD MAINTENANCE -
TURBOCHARGER REPLACEMENT
0 0 3 0
INITIAL SETUP
0128, Item 20) 0

WP 0026 0
Materials/Parts 0
Compound, Antiseize (WP 0130, Item 7) 0

Oil, Lubricating, OE/HDO-10 (WP 0130, Item Parking brake applied (WP 0005) 0
22) 0

Gasket, Turbocharger 0
0004) 0
Muffler removed (WP 0035) 0
0030-1
TM 5-3805-255-14 0030
REMOVAL 00030
1. Disconnect oil inlet tube (Figure 1, Item 4) from turbocharger (Figure 1, Item 3).
2. Disconnect oil drain tube (Figure 1, Item 10) from turbocharger (Figure 1, Item 3).
3. Loosen clamp (Figure 1, Item 5) from air discharge hose (Figure 1, Item 6).
4. Remove clamp (Figure 1, Item 7) from air inlet hose (Figure 1, Item 8).
NOTE
Exhaust sleeve is loosely held between exhaust elbow and turbocharger. Sleeve must be
held as turbocharger is removed, to prevent sleeve from dropping.
5. Remove four bolts (Figure 1, Item 16), two nuts (Figure 1, Item 17), and four washers (Figure 1, Item 15) from
exhaust manifold (Figure 1, Item 9).
6. Remove exhaust elbow (Figure 1, Item 1) from exhaust manifold (Figure 1, Item 9) and from turbocharger
(Figure 1, Item 3).
7. Remove four nuts (Figure 1, Item 11) from exhaust manifold (Figure 1, Item 9).
8. Remove turbocharger (Figure 1, Item 3) and gasket (Figure 1, Item 12) from exhaust manifold (Figure 1,
Item 9). Discard gasket.
9. Remove exhaust sleeve (Figure 1, Item 2), seal (Figure 1, Item 14), and seal ring (Figure 1, Item 13) from
exhaust elbow (Figure 1, Item 1).
Figure 1. Turbocharger. 030
END OF TASK
0030-2
TM 5-3805-255-14 0030
2. Inspect air intake system for loose bolts, nuts, or any foreign material.
3. Inspect exhaust manifold for debris or damage. Clean or replace exhaust manifold (WP 0026).
4. Inspect oil drain tube and clean or replace if necessary.
5. Inspect oil inlet tube for dirt, clogging, or deterioration.
6. Inspect exhaust manifold for flatness.
END OF TASK
INSTALLATION 00030
NOTE
Apply antiseize compound to exhaust manifold studs.
1. Install new gasket (Figure 1, Item 12), turbocharger (Figure 1, Item 3), and four nuts (Figure 1, Item 11) on
exhaust manifold (Figure 1, Item 9). Torque nuts to 35 lb-ft (47 Nm).
2. Install seal (Figure 1, Item 14) and seal ring (Figure 1, Item 13) into exhaust sleeve (Figure 1, Item 2).
3. Insert exhaust elbow (Figure 1, Item 1) into exhaust sleeve (Figure 1, Item 2) and turbocharger (Figure 1,
Item 4).
4. Connect oil outlet tube (Figure 1, Item 10) to turbocharger (Figure 1, Item 3).
5. Add four to five ounces of oil (WP 0016) into oil inlet tube (Figure 1, Item 4) opening on top of turbocharger
(Figure 1, Item 3).
6. Connect oil inlet tube (Figure 1, Item 4) to turbocharger (Figure 1, Item 3).
7. Connect air discharge hose (Figure 1, Item 6) to turbocharger (Figure 1, Item 3) and secure with clamp (Figure
1, Item 5).
8. Connect air inlet hose (Figure 1, Item 8) to turbocharger (Figure 1, Item 3) and secure with clamp (Figure 1,
Item 7).
9. Install exhaust elbow (Figure 1, Item 1), four washers (Figure 1, Item 15), bolts (Figure 1, Item 16), and two
nuts (Figure 1, Item 17) on exhaust manifold (Figure 1, Item 9). Torque nuts to 35 lb-ft (47 Nm).
10. Install muffler (WP 0035).
END OF TASK
END OF WORK PACKAGE
0030-3/(4 blank)
6
TM 5-3805-255-14 0031
FIELD MAINTENANCE -
FUEL TANK REPLACEMENT

0 0 3 1
INITIAL SETUP
0128, Item 20) 0

WP 0013 0
Materials/Parts 0
WP 0019 0
(WP 0130, Item 3) 0


Gasket, Fuel Sender 0
0004) 0
Two 0
0031-1
TM 5-3805-255-14 0031
REMOVAL 00031
WARNING
Use suitable container when draining fuel. Fuel may explode if subject to sources of
ignition. Failure to follow this warning may result in injury or death to personnel. In event of
exposure or injury cleanse affected area with soap and water. For eyes flush eyes with
water. Seek medical attention.
NOTE
Tag and identify all hose flanges for ease of installation. Cap all hose flanges to prevent
contamination and leaks.
1. Remove two drain plugs (Figure 1, Item 12) from front bottom portion of fuel tank (Figure 1, Item 17).
2. Drain fuel tank (Figure 1, Item 17) into suitable container.
3. Remove electrical lead (Figure 1, Item 5) from fuel level sender (Figure 1, Item 1).
4. Disconnect fuel supply hose (Figure 1, Item 10) from front top of fuel tank (Figure 1, Item 17).
5. Disconnect fuel return hose (Figure 1, Item 11) from front top of fuel tank (Figure 1, Item 17).
6. Remove two nuts (Figure 1, Item 9), washers (Figure 1, Item 8), and U-bolt (Figure 1, Item 7) from front of fuel
tank (Figure 1, Item 17).
7. Secure oil drain hose (Figure 1, Item 6) to engine.
8. Position lifting device tightly under center of fuel tank (Figure 1, Item 17).
WARNING
Use extreme caution when handling heavy components. 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 by lifting
equipment. Failure to follow this warning may result in injury or death to personnel.
9. With assistance, inside engine compartment, remove six nuts (Figure 1, Item 16), washers (Figure 1, Item 15),
bolts (Figure 1, Item 13), and washers (Figure 1, Item 14) from frame mounting brackets.
10. Gently lower fuel tank (Figure 1, Item 17) onto flat surface.
11. Remove four bolts (Figure 1, Item 4), cover (Figure 1, Item 3), gasket (Figure 1, Item 2), and fuel level sender
(Figure 1, Item 1) from fuel tank (Figure 1, Item 17). Discard gasket.
0031-2
TM 5-3805-255-14 0031
H100C-0873
Figure 1. Fuel Tank and Related Parts. 031
END OF TASK
0031-3
TM 5-3805-255-14 0031
Clean and inspect all components IAW General Maintenance Instructions (WP 0019).
END OF TASK
INSTALLATION 00031
WARNING
Fuel may explode if subject to sources of ignition. Failure to follow this warning may result
in injury or death to personnel. In event of exposure or injury cleanse affected area with
soap and water. For eyes flush eyes with water. Seek medical attention.
1. Install fuel level sender (Figure 2, Item 1), new gasket (Figure 2, Item 2), cover (Figure 2, Item 3), and four
bolts (Figure 2, Item 4) into fuel tank (Figure 2, Item 17).
WARNING
2. Using lifting device, install fuel tank (Figure 2, Item 17) on frame.
3. Align fuel tank (Figure 2, Item 17) with frame mounting brackets.
4. With assistance, inside engine compartment, install six washers (Figure 2, Item 14) and bolts (Figure 2, Item
13) through frame mounting brackets. Outside engine compartment, install six washers (Figure 2, Item 15) and
nuts (Figure 2, Item 16) on bolts.
5. Install U-bolt (Figure 2, Item 7), two washers (Figure 2, Item 8), and nuts (Figure 2, Item 9) to secure oil drain
hose (Figure 2, Item 6) to front of fuel tank (Figure 2, Item 17).
6. Attach fuel supply hose (Figure 2, Item 10) to fuel tank (Figure 2, Item 17).
7. Attach fuel return hose (Figure 2, Item 11) to fuel tank (Figure 2, Item 17).
8. Connect electrical lead (Figure 2, Item 5) to fuel level sender (Figure 2, Item 1).
9. Install two drain plugs (Figure 2, Item 12) in front bottom of fuel tank (Figure 2, Item 17).
WARNING
Fuel may explode if subject to sources of ignition. Failure to follow this warning may result
in injury or death to personnel. In event of exposure/injury cleanse affected area with soap
and water. For eyes flush eyes with water. Seek medical attention.
NOTE
Vent fuel system IAW Field Preventive Maintenance Checks and Services (PMCS)
Including Lubrication Instructions (WP 0008). Start engine and check for and correct fuel
leaks.
10. Refill fuel tank (Figure 2, Item 17) with clean fuel and start engine (WP 0013).
0031-4
TM 5-3805-255-14 0031
H100C-0873
END OF TASK
END OF WORK PACKAGE
0031-5/(6 blank)
4
TM 5-3805-255-14 0032
FIELD MAINTENANCE -
GOVERNOR REPLACEMENT AND ADJUSTMENT

0 0 3 2
Removal, Cleaning and Inspection, Installation, Adjustment
INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP Loader parked on level ground (WP 0005) 0
0128, Item 20) 0

Materials/Part 0

0004) 0
0130, Item 4) 0
Wheels chocked 0
References 0
WP 0019 0
0032-1
TM 5-3805-255-14 0032
REMOVAL 00032
WARNING
Chock wheels to prevent loader from moving. Failure to follow this warning may result in
injury or death to personnel and damage to equipment.
1. Open drain valve on air reservoir and drain air from system (WP 0005).
2. Disconnect tube (Figure 1, Item 5) and line (Figure 1, Item 1) from governor (Figure 1, Item 2).
3. Remove two bolts (Figure 1, Item 3), nuts (Figure 1, Item 4) and governor (Figure 1, Item 2) from frame.
Figure 1. Governor. 0032
END OF TASK
2. Check governor body for cracks or other damage. If necessary, replace governor.
END OF TASK
0032-2
TM 5-3805-255-14 0032
INSTALLATION 00032
1. Install governor (Figure 1, Item 2), two bolts (Figure 1, Item 3), and nuts (Figure 1, Item 4) to frame.
2. Connect tube (Figure 1, Item 5) and line (Figure 1, Item 1) to governor (Figure 1, Item 2).
3. Close drain valves, start engine, and check air pressure (WP 0005).
4. If necessary, adjust governor pressure.
END OF TASK
ADJUSTMENT 00032
1. Start engine and build up air system pressure. Note pressure at which governor cuts out. This pressure range
should be 90 to 105 psi (620.5 to 724.0 kPa).
2. If cutout pressure is incorrect, remove governor cover, loosen locknut, and turn adjusting screw clockwise to
lower pressure, or counterclockwise to raise pressure.
3. When proper pressure is obtained, tighten locknut.
END OF TASK
END OF WORK PACKAGE
0032-3/(4 blank)
10
TM 5-3805-255-14 0033
FIELD MAINTENANCE -
ACCELERATOR LINKAGE REPLACEMENT

0 0 3 3
INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0

Cotter Pin (2) 0

Lockwasher (10) 0
0004) 0
Two 0
REMOVAL 00033
Foot Throttle 00033
1. Remove spring (Figure 1, Item 4) from clips (Figure 1, Items 2 and 6).
2. Loosen nut (Figure 1, Item 3) and remove connector (Figure 1, Item 1) and clip (Figure 1, Item 2) from cable
(Figure 1, Item 9).
3. Remove nut (Figure 1, Item 5) and lockwasher (Figure 1, Item 10) from cable (Figure 1, Item 9). Discard
lockwasher.
4. Remove cable (Figure 1, Item 9) from bracket (Figure 1, Item 7).
5. Remove lockwasher (Figure 1, Item 11), nut (Figure 1, Item 3), and nut (Figure 1, Item 8) from cable (Figure 1,
Item 9). Discard lockwasher.
Figure 1. Foot Throttle (Engine End). 0033
0033-1
TM 5-3805-255-14 0033
Foot Throttle — Continued
6. Remove nut (Figure 2, Item 1), lockwasher (Figure 2, Item 2), and ball joint (Figure 2, Item 4) from bellcrank
(Figure 2, Item 3). Discard lockwasher.
7. Remove ball joint (Figure 2, Item 4) and top nut (Figure 2, Item 5) from cable (Figure 2, Item 6).
8. Remove nut (Figure 2, Item 7) and lockwasher (Figure 2, Item 8) from cable (Figure 2, Item 6). Discard
lockwasher.
9. Remove cable (Figure 2, Item 6) from bracket (Figure 2, Item 11). Remove nut (Figure 2, Item 9) and
lockwasher (Figure 2, Item 10) from cable. Discard lockwasher.
Figure 2. Foot Throttle (Pedal End). 0033
10. Remove nut (Figure 3, Item 2), lockwasher (Figure 3, Item 3), and ball joint (Figure 3, Item 4) from accelerator
pedal (Figure 3, Item 1). Discard lockwasher.
11. Remove ball joint (Figure 3, Item 4) and top nut (Figure 3, Item 5) from rod (Figure 3, Item 6).
12. Remove nut (Figure 3, Item 2), lockwasher (Figure 3, Item 3), and ball joint (Figure 3, Item 7) from bellcrank
13. Remove rod (Figure 3, Item 6) from floor board plate.
14. Remove ball joint (Figure 3, Item 7) and bottom nut (Figure 3, Item 5) from rod (Figure 3, Item 6).
15. Remove bolt (Figure 3, Item 9), nut (Figure 3, Item 12), lockwasher (Figure 3, Item 10), and brackets (Figure 3,
Item 11) from bellcrank (Figure 3, Item 8). Discard lockwasher.
0033-2
TM 5-3805-255-14 0033
16. Remove bellcrank (Figure 3, Item 8) from angle bracket.
17. Remove cotter pin (Figure 3, Item 15), pin (Figure 3, Item 13), and accelerator pedal (Figure 3, Item 1) from
hinge (Figure 3, Item 14). Discard cotter pin.
Figure 3. Accelerator Pedal. 0033
0033-3
TM 5-3805-255-14 0033
Hand Throttle 00033
1. Remove cable clamp (Figure 4, Item 5) from cable (Figure 4, Item 3).
2. Remove cotter pin (Figure 4, Item 13), from cable fitting (Figure 4, Item 4). Discard cotter pin.
3. Disconnect cable fitting (Figure 4, Item 4) and lever (Figure 4, Item 9) from cable (Figure 4, Item 3).
4. Remove bolt (Figure 4, Item 8), nut (Figure 4, Item 12), lockwasher (Figure 4, Item 7), and two washers (Figure
4, Items 6 and 11), from lever (Figure 4, Item 9). Discard lockwasher.
5. Remove lever (Figure 4, Item 9) and sleeve (Figure 4, Item 10) from hinge (Figure 4, Item 14).
6. Remove nut (Figure 4, Item 1) and lockwasher (Figure 4, Item 2) from cable (Figure 4, Item 3) and cable from
bracket on dash. Discard lockwasher.
Figure 4. Hand Throttle. 0033
END OF TASK
0033-4
TM 5-3805-255-14 0033
2. Check cables for smooth operation. If cables bind or drag, replace cables.
END OF TASK
INSTALLATION 00033
Hand Throttle 00033
1. Install cable (Figure 4, Item 3), new lockwasher (Figure 4, Item 2), and nut (Figure 4, Item 1) on bracket.
2. Install sleeve (Figure 4, Item 10), lever (Figure 4, Item 9), new lockwasher (Figure 4, Item 7), two washers
(Figure 4, Items 6 and 11), bolt (Figure 4, Item 8), and nut (Figure 4, Item 12) on hinge (Figure 4, Item 14).
3. Install cable fitting (Figure 4, Item 4) on cable (Figure 4, Item 3).
4. Install cable clamp (Figure 4, Item 5) on cable (Figure 4, Item 3).
5. Install cable fitting (Figure 4, Item 4) on lever (Figure 4, Item 9) and new cotter pin (Figure 4, Item 13) on cable
fitting (Figure 4, Item 4).
0033-5
TM 5-3805-255-14 0033
Foot Throttle 00033
1. Install accelerator pedal (Figure 5, Item 1), pin (Figure 5, Item 13), and new cotter pin (Figure 5, Item 15) on
hinge (Figure 5, Item 14).
2. Install bellcrank (Figure 5, Item 8) on angle brackets.
3. Install two brackets (Figure 5, Item 11), new lockwasher (Figure 5, Item 10), bolts (Figure 5, Item 9), and nuts
(Figure 5, Item 12) on bellcrank (Figure 5, Item 8).
0033-6
TM 5-3805-255-14 0033
4. Install bottom nut (Figure 5, Item 5) and ball joint (Figure 5, Item 7) on rod (Figure 5, Item 6).
5. Install rod (Figure 5, Item 6) through floorboard plate.
NOTE
• Be sure end of lever is above arm of bellcrank (refer to Hand Throttle Installation in this
work package).
• Bellcrank arm should be horizontal, parallel to floor.
6. Install ball joint (Figure 5, Item 7), new lockwasher (Figure 5, Item 3), and nut (Figure 5, Item 2), on bellcrank
(Figure 5, Item 8).
7. Install lockwasher (Figure 5, Item 10), nut (Figure 5, Item 9) and ball joint (Figure 5, Item 4) on rod (Figure 5,
Item 6).
8. Install ball joint (Figure 5, Item 4), new lockwasher (Figure 5, Item 3), and nut (Figure 5, Item 2) on accelerator
pedal (Figure 5, Item 1).
9. Install lockwasher (Figure 6, Item 10), nut (Figure 6, Item 9) on cable (Figure 6, Item 6).
10. Install cable (Figure 6, Item 6) on bracket (Figure 6, Item 11).
11. Install lockwasher (Figure 6, Item 7), nut (Figure 6, Item 8) on cable (Figure 6, Item 6).
12. Install nut (Figure 6, Item 5) and ball joint (Figure 6, Item 4) on cable (Figure 6, Item 6).
13. Install ball joint (Figure 6, Item 4) lockwasher (Figure 6, Item 2), and nut (Figure 6, Item 1) on bellcrank (Figure
6, Item 3).
Figure 6. Foot Throttle (Pedal End). 0033
0033-7
TM 5-3805-255-14 0033
14. Install nut (Figure 7, Item 8) on cable (Figure 7, Item 9).
15. Install cable (Figure 7, Item 9) on bracket (Figure 7, Item 7).
16. Install clip (Figure 7, Item 6) and nut (Figure 7, Item 5) on cable (Figure 7, Item 9).
17. Install nut (Figure 7, Item 3) on cable (Figure 7, Item 9).
18. Install clip (Figure 7, Item 2) and connector (Figure 7, Item 1) on cable (Figure 7, Item 9).
19. Install spring (Figure 7, Item 4) on two clips (Figure 7, Items 2 and 6).
20. Adjust accelerator linkage. Refer to Adjustment in this work package.
Figure 7. Foot Throttle (Engine End). 0033
END OF TASK
ADJUSTMENT 00033
Foot Throttle 00033
1. Disconnect ball joint from accelerator pedal before adjusting foot throttle linkage. Refer to Foot Throttle
Removal in this work package.
2. Disconnect hand throttle cable from bellcrank before adjusting foot throttle linkage. Refer to Hand Throttle
Removal in this work package.
3. Bellcrank arm should be horizontal, parallel to floor. If not horizontal, loosen jam nuts and adjust ball joints, or
cable connections on brackets until bellcrank arm is in a horizontal position.
4. Connect ball joint (Figure 8, Item 4), new lockwasher (Figure 8, Item 3), and nut (Figure 8, Item 2) to
accelerator pedal (Figure 8, Item 1).
5. Start engine and check low idle speed. Correct idle speed is 650 to 750 RPM.
6. Fully depress accelerator pedal. Make sure injection pump lever travels a full stroke.
7. Check engine high idle speed. Correct high idle speed is 2,200 to 3,500 RPM.
8. Shut engine OFF.
9. If necessary, adjust engine idle speeds.
0033-8
TM 5-3805-255-14 0033
ADJUSTMENT – CONTINUED 00033
Foot Throttle — Continued 00033
10. Start engine and check idle speeds. If necessary, adjust engine idle speeds. Shut engine OFF.
0033-9
TM 5-3805-255-14 0033
Hand Throttle 00033
NOTE
Adjust foot throttle linkage before adjusting hand throttle linkage.
1. Install cable fitting (Figure 9, Item 3) on cable (Figure 9, Item 2).
2. Install cable clamp (Figure 9, Item 4) on cable (Figure 9, Item 2).
3. Connect fitting (Figure 9, Item 3) to lever (Figure 9, Item 5).
4. Adjust to allow slight clearance between lever (Figure 9, Item 5) and bellcrank arm (Figure 9, Item 6).
5. Adjust hand throttle cable (Figure 9, Item 1) so fuel injection pump lever travels to low idle position with throttle
pushed in; with the throttle pulled all the way out, engine must maintain a minimum speed of 1200 RPM (no
load). The throttle should lock in position by turning handle one quarter turn.
6. Install cable fitting (Figure 9, Item 3) and new cotter pin (Figure 9, Item 7).
Figure 9. Hand Throttle. 0033
END OF TASK
END OF WORK PACKAGE
0033-10
4
TM 5-3805-255-14 0034
FIELD MAINTENANCE -
0 0 3 4 EMERGENCY SHUTDOWN CONTROL LINKAGE REPLACEMENT

INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

Cotter Pin
(WP 0004) 0
Locknut
Lockwasher (2)
REMOVAL 00034
1. Remove cotter pin (Figure 1, Item 2) from ferrule (Figure 1, Item 5). Discard cotter pin.
2. Remove washer (Figure 1, Item 7) and ferrule (Figure 1, Item 5) from injector pump shut-off lever (Figure 1,
Item 1).
3. Remove locknut (Figure 1, Item 3), washer (Figure 1, Item 4), and ferrule (Figure 1, Item 5) from emergency
shutdown control cable (Figure 1, Item 6). Discard locknut.
Figure 1. Emergency Shutdown Control Cable. 0034
0034-1
TM 5-3805-255-14 0034
4. Remove emergency shutdown control cable (Figure 2, Item 2) from bracket (Figure 2, Item 1).
Figure 2. Bracket. 0034
5. Remove emergency shutdown control handle (Figure 3, Item 1) from emergency shutdown control cable
(Figure 3, Item 3).
6. Remove nut (Figure 3, Item 4) and lockwasher (Figure 3, Item 5) from emergency shutdown control cable
7. Remove emergency shutdown control cable (Figure 3, Item 3) from bracket (Figure 3, Item 2).
8. Remove nut (Figure 3, Item 7) and lockwasher (Figure 3, Item 6) from emergency shutdown control cable
Figure 3. Emergency Shutdown Control Handle. 0034
END OF TASK
0034-2
TM 5-3805-255-14 0034
INSTALLATION 00034
1. Install new lockwasher (Figure 3, Item 5) and nut (Figure 3, Item 4) on emergency shutdown control cable
(Figure 3, Item 3).
2. Install emergency shutdown control cable (Figure 3, Item 3), new lockwasher (Figure 3, Item 6), and nut
(Figure 3, Item 7) on bracket (Figure 3, Item 2).
3. Install emergency shutdown control handle (Figure 3, Item 1) on emergency shutdown control cable (Figure 3,
Item 3).
4. Install emergency shutdown control cable (Figure 2, Item 2) on bracket (Figure 2, Item 1).
5. Install ferrule (Figure 4, Item 5), washer (Figure 4, Item 4), and new locknut (Figure 4, Item 3) on emergency
shutdown control cable (Figure 4, Item 6).
6. Install ferrule (Figure 4, Item 5) and washer (Figure 4, Item 7) on injector pump shut-off lever (Figure 4, Item 1).
7. Install new cotter pin (Figure 4, Item 2) on ferrule (Figure 4, Item 5).
Figure 4. Emergency Shutdown Control Cable. 0034
8. Check emergency shutdown control handle for proper operation.

END OF TASK
END OF WORK PACKAGE
0034-3/(4 blank)
4
TM 5-3805-255-14 0035
FIELD MAINTENANCE -
0 0 3 5 MUFFLER REPLACEMENT
INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

0004) 0
0035-1
TM 5-3805-255-14 0035
REMOVAL 00035
WARNING
assistance during procedure. Ensure that any lifting equipment used is in good condition
and of suitable load capacity. Keep clear of heavy parts supported by lifting equipment.
Failure to follow this warning may result in death or injury to personnel.
1. Install suitable lifting device on muffler (Figure 1, Item 3).
2. Remove two bolts (Figure 1, Item 5), nuts (Figure 1, Item 6), and clamp (Figure 1, Item 4) from muffler
(Figure 1, Item 3).
3. Lift muffler (Figure 1, Item 3) off pipe (Figure 1, Item 7) and lower to ground. Remove lifting device.
4. Remove nut (Figure 1, Item 8), bolt (Figure 1, Item 2), washer (Figure 1, Item 9), and weather cap (Figure 1,
Item 1) from muffler (Figure 1, Item 3).
END OF TASK
INSTALLATION 00035
1. Install weather cap (Figure 1, Item 1), washer (Figure 1, Item 9), bolt (Figure 1, Item 2), and nut (Figure 1, Item
8) on muffler (Figure 1, Item 3).
WARNING
2. Install suitable lifting device on muffler (Figure 1, Item 3).
3. Position muffler (Figure 1, Item 3) on pipe (Figure 1, Item 7).
4. Install clamp (Figure 1, Item 4), two bolts (Figure 1, Item 5), and nuts (Figure 1, Item 6) on muffler (Figure 1,
Item 3).
5. Remove lifting device from muffler (Figure 1, Item 3).
6. Turn battery disconnect switch to ON position and start engine (WP 0005).
7. Check for exhaust leaks at muffler.
0035-2
TM 5-3805-255-14 0035
Figure 1. Muffler. 0035
END OF TASK
END OF WORK PACKAGE
0035-3/(4 blank)
6
TM 5-3805-255-14 0036
FIELD MAINTENANCE -
0 0 3 6 RADIATOR AND CONVERTER OIL COOLER REPLACEMENT

INITIAL SETUP
0128, Item 20) 0

WP 0019 0
Materials/Parts 0
WP 0032 0
WP 0035 0
Fluid, Brake, Silicone, BFS (WP 0130, Item Equipment Condition 0
11) 0
Loader parked on level ground (WP 0005) 0
0004) 0
Two 0
Hydraulic reservoir tank drained (WP 0018) 0
0036-1
TM 5-3805-255-14 0036
REMOVAL 00036
WARNING
• When disposing of antifreeze and transmission fluid, consult your unit/local hazardous
waste disposal center or safety office for local regulatory guidance.
• Antifreeze and transmission fluid used in the performance of maintenance can be very
slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury
to personnel.
NOTE
The radiator and oil cooler are connected to the grille and are removed as a unit from the
frame.
1. Remove 10 bolts (Figure 1, Item 3), nuts (Figure 1, Item 5), washers (Figure 1, Item 4), and two fan guards
(Figure 1, Item 6) from radiator (Figure 1, Item 9).
NOTE
Tag and identify all hoses for ease of installation. Plug all hoses to prevent contamination.
2. Remove four clamps (Figure 1, Items 1 and 7) and two radiator hoses (Figure 1, Items 2 and 8) from radiator
(Figure 1, Item 9).
NOTE
Tag and identify wires for ease of installation.
3. Place a suitable drain pan under oil cooler and disconnect hydraulic hoses from oil cooler. Drain hydraulic fluid
from oil cooler.
4. Disconnect wires from the rear driving lights, stop lights, and backup alarm.
5. Remove muffler (WP 0035).
6. Remove air cleaner extension pipe (WP 0029).
7. Remove retaining bolts, nuts, and flat washers, and disconnect hood from grille. Remove hood.
0036-2
TM 5-3805-255-14 0036
Figure 1. Radiator. 036
0036-3
TM 5-3805-255-14 0036
WARNING
Lifting cables, chains, hooks, and slings used for lifting must be in good condition and of
suitable capacity. Failure to follow this warning may cause injury or death to personnel and
8. Attach a suitable lifting device to grille and radiator unit. Remove bolts, nuts, and washers from lower radiator
mounting brackets and grille.
9. Slowly raise grille and radiator unit and move it back until fan housing clears fan blades. Lower grille and
radiator unit to floor. Place in properly supported position.
WARNING
Radiator and oil cooler are heavy. Properly support radiator and oil cooler before
separating from grille. Failure to follow this warning may cause injury or death to
10. Support radiator and oil cooler in properly supported position. Remove lifting device from grille.
11. Remove hardware, upper radiator mounting brackets, radiator, and oil cooler from grille.
END OF TASK
2. Inspect radiator for cracks, holes, or leaks. Inspect interior for scale, rust, or deterioration. Repair or replace if
damaged.
END OF TASK
INSTALLATION 00036
1. Install upper radiator mounting brackets, hardware, and radiator and oil cooler on grille.
WARNING
Lifting cables, chains, hooks, and slings used for lifting must be in good condition and of
suitable capacity. Failure to follow this warning may cause injury or death to personnel and
2. Attach a suitable lifting device to grille and raise entire unit into position. Carefully work unit forward into its
proper mounting position with radiator fan shroud around fan blade.
3. Line up lower radiator mounting brackets with frame brackets and install flat washers, bolts, and nuts. Install
grille mounting hardware. Remove lifting device.
4. Connect hood to grille, and secure with flat washers, bolts, and nuts.
5. Install wires on rear driving lights, stop lights, and backup alarm.
6. Install muffler (WP 0035).
7. Install air cleaner extension pipe (WP 0029).
8. Connect transmission hoses to oil cooler.
0036-4
TM 5-3805-255-14 0036
9. Connect upper and lower radiator hoses (Figure 2, Items 2 and 8) and four clamps (Figure 2, Items 1 and 7) to
radiator (Figure 2, Item 9).
10. Install two fan guards (Figure 2, Item 6), 10 bolts (Figure 2, Item 3), washers (Figure 2, Item 4), and nuts
(Figure 2, Item 5) to loader.
Figure 2. Radiator. 036
0036-5
TM 5-3805-255-14 0036
11. Close drain valve. Fill radiator with coolant (WP 0018). Install radiator cap.
12. Check and fill transmission with fluid (WP 0018).
13. Start engine and check for leaks. Check and adjust transmission and coolant levels as required (WP 0010).
END OF TASK
END OF WORK PACKAGE
0036-6
4
TM 5-3805-255-14 0037
FIELD MAINTENANCE -
THERMOSTAT REPLACEMENT
0 0 3 7
Removal, Cleaning, Inspection, Installation
INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

0004) 0
Gasket 0
Lockwasher (5) 0
Cooling system drained (WP 0018) 0
Seal (2) 0
References 0
WP 0019 0
0037-1
TM 5-3805-255-14 0037
REMOVAL 00037
WARNING
• When disposing of antifreeze, consult your unit/local hazardous waste disposal center or
safety office for local regulatory guidance.
• Antifreeze can be very slippery. Immediately wipe up any spills. Failure to follow this
warning may result in injury to personnel.
1. Remove clamp (Figure 1, Item 11) and lower hose (Figure 1, Item 10) from thermostat housing (Figure 1, Item
14).
2. Remove clamp (Figure 1, Item 4) and upper hose (Figure 1, Item 3) from thermostat housing.
3. Remove three bolts (Figure 1, Item 13), and lockwashers (Figure 1, Item 12) from thermostat housing. Discard
lockwashers.
4. Remove two bolts (Figure 1, Item 1), lockwashers (Figure 1, Item 2), nuts (Figure 1, Item 8) and thermostat
housing (Figure 1, Item 14) from manifold assembly (Figure 1, Item 9).
5. Remove two thermostats (Figure 1, Item 6) and seals (Figure 1, Item 5) from thermostat housing (Figure 1,
Item 14). Discard seals.
6. Remove gasket (Figure 1, Item 7) from thermostat housing (Figure 1, Item 14). Discard gasket.
Figure 1. Thermostat. 0037
END OF TASK
0037-2
TM 5-3805-255-14 0037
CLEANING, INSPECTION 00037
2. Inspect thermostats for deterioration, damage, and cracks and burrs, and replace if necessary.
END OF TASK
INSTALLATION 00037
1. Install two new seals (Figure 1, Item 5) in thermostat housing (Figure 1, Item 14) with lip of seals facing down.
Surface of seal must be flush with housing inner surface and parallel with housing gasket surface.
2. Install two thermostats (Figure 1, Item 6) in thermostat housing (Figure 1, Item 14).
3. Install new gasket (Figure 1, Item 7) on thermostat housing (Figure 1, Item 14).
4. Install thermostat housing (Figure 1, Item 14), two lockwashers (Figure 1, Item 2), nuts (Figure 1, Item 8), and
bolts (Figure 1, Item 1) on manifold assembly (Figure 1, Item 9).
5. Install bolt (Figure 1, Item 13) and washer (Figure 1, Item 12) on thermostat housing (Figure 1, Item 14).
6. Install three new lockwashers (Figure 1, Item 12), bolts (Figure 1, Item 13), and nuts (Figure 1, Item 8) on
thermostat housing (Figure 1, Item 14) and manifold assembly (Figure 1, Item 9).
7. Install lower hose (Figure 1, Item 10) and clamp (Figure 1, Item 11) on thermostat housing (Figure 1, Item 14).
8. Install upper hose (Figure 1, Item 3) and clamp (Figure 1, Item 4) on thermostat housing (Figure 1, Item 14).
9. Fill cooling system with antifreeze (WP 0018).
END OF TASK
END OF WORK PACKAGE
0037-3/(4 blank)
8
TM 5-3805-255-14 0038
FIELD MAINTENANCE -
FAN DRIVE ASSEMBLY REPLACEMENT

0 0 3 8
Removal, Cleaning and Inspection, Installation, Testing
INITIAL SETUP
0128, Item 20) 0

Torque Adapter (WP 0125, Item 14) 0

Materials/Parts 0
(WP 0004) 0
Radiator removed (WP 0036) 0
Gasket, Fan Drive 0
Wheels blocked to prevent loader from rolling

Washer Key Locks (3) 0
(WP 0005) 0
References 0
Air compressor and alternator belt removed
(WP 0018) 0
WP 0019 0
0038-1
TM 5-3805-255-14 0038
REMOVAL
1. Remove fan in accordance with Testing, step 1, in this work package.
2. Use two 3/8 x 3-3/8 in. UNC grade 8 bolts and nuts to install prefabricated torque adapter (WP 0125) on fan
mounting assembly.
3. Remove three bolts (Figure 1, Item 5), washer key locks (Figure 1, Item 6), and hub retainer plate (Figure 1,
Item 4) from fan drive assembly (Figure 1, Item 1). Discard washer key locks.
4. Remove ten bolts (Figure 1, Item 2), washers (Figure 1, Item 3), and fan drive assembly (Figure 1, Item 1) from
front cover (Figure 1, Item 7).
5. Remove gasket (Figure 1, Item 8) from front cover (Figure 1, Item 7). Discard gasket.
Figure 1. Fan Drive Assembly Removal. 0038
END OF TASK
2. Check fan blades for looseness and bends; replace if necessary.
END OF TASK
0038-2
TM 5-3805-255-14 0038
INSTALLATION 00038
CAUTION
Drive gear and rear face of housing assembly must be clear of obstructions before
installation to prevent damage to internal engine parts. Failure to follow caution may result
in damage to engine.
NOTE
Raised boss (Figure 2, Item 7) must be in six o’clock position.
1. Install fan drive assembly (Figure 2, Item 1) and new gasket (Figure 2, Item 9) on front cover (Figure 2, Item 8).
2. Install remaining eight bolts (Figure 2, Item 2), washers (Figure 2, Item 3), and fan drive assembly (Figure 2,
Item 1) on front cover (Figure 2, Item 8).
3. Install hub retainer plate (Figure 2, Item 4), three new washer key locks (Figure 2, Item 6), and bolts (Figure 2,
Item 5) on front cover (Figure 2, Item 8).
Figure 2. Raised Boss on Fan Housing. 0038
0038-3
TM 5-3805-255-14 0038
4. Install air compressor, alternator (Figure 3, Item 5), and belts on engine. Adjust belts (WP 0016).
NOTE
• Ensure there is no interference between fan spacer and fan mounting assembly. If there is
interference, replace fan spacer. Be sure the word “front” stamped on one fan blade is
facing towards the front of the loader.
• There are two possible fan installations. The blower fan uses eight bolts, the reversible fan
uses 16 bolts.
5. With pilot towards front, install eight bolts (Figure 3, Item 8), washers (Figure 3, Item 7), fan (Figure 3, Item 1),
fan spacer (Figure 3, Item 6), eight washers (Figure 3, Item 3), and nuts (Figure 3, Item 4) on fan mounting
assembly (Figure 3, Item 2).
0038-4
TM 5-3805-255-14 0038
H100C-1015
Figure 3. Install Fan, Generator, Air Compressor, and Belts. 0038
END OF TASK
0038-5
TM 5-3805-255-14 0038
TESTING 00038
NOTE
Excessive fan slippage can cause problems in the cooling system such as the engine
overheating. Use this procedure to check fan slip clutch torque on the engine.
Checking Fan Clutch Slip Torque on Engine 00038
NOTE
Use torque adaptor for proper testing.
1. Remove eight nuts (Figure 4, Item 5), 16 washers (Figure 4, Item 4), eight bolts (Figure 4, Item 7), and fan
Figure 4, Item 1) from fan mounting assembly (Figure 4, Item 3).
2. Use two 3/8 x 3-3/8 in. UNC grade 8 bolts (Figure 4, Item 7) and nuts (Figure 4, Item 5) to install pre-fabricated
torque adapter (WP 0125) on fan mounting assembly (Figure 4, Item 3).
CAUTION
Make sure torque adapter bolts DO NOT touch pulley after mounting. Failure to follow this
caution may result in damage to equipment.
3. Hold 1-3/4 in. nut on crankshaft pulley (Figure 4, Item 6) to keep stationary.
CAUTION
Rotate torque adaptor in clockwise direction only. Failure to follow caution may result in
NOTE
Break clutch loose five times to seat friction plates before recording torque value. Torque
should be 160 to 300 lb-ft (712 to 1,334 Nm). If clutch torque is not within specification,
4. Prevent crankshaft pulley (Figure 4, Item 6) from rotating while checking fan mounting assembly (Figure 4,
Item 3) clutch slippage. Use a torque wrench on torque adaptor (Figure 4, Item 2) and rotate fan mounting
assembly (Figure 4, Item 3) clockwise. Note torque value when fan mounting assembly clutch slips or breaks
away. Torque should be 160 to 300 lb-ft (712 to 1,334 Nm).
0038-6
TM 5-3805-255-14 0038
TESTING – CONTINUED
5. Remove two bolts (Figure 4, Item 7), nuts (Figure 4, Item 5), and torque adaptor (Figure 4, Item 2) from fan
mounting assembly (Figure 4, Item 3).
6. Install fan (Figure 4, Item 1), 16 washers (Figure 4, Item 4), eight bolts (Figure 4, Item 7), and nuts (Figure 4,
Item 5) on fan mounting assembly (Figure 4, Item 3).
Figure 4. Torque Adaptor and Mounting Assembly. 0038
END OF TASK
END OF WORK PACKAGE
0038-7/(8 blank)
6
TM 5-3805-255-14 0039
FIELD MAINTENANCE -
0 0 3 9 LUBRICATING OIL FILTER HOUSING AND VALVE REPLACEMENT

INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

0004) 0
Item 23) 0
Accelerator linkage removed (WP 0033) 0
Gasket 0
Oil filter removed (WP 0018) 0
References 0
WP 0013 0
WP 0019 0
0039-1
TM 5-3805-255-14 0039
REMOVAL 00039
1. Remove nut (Figure 1, Item 1), gasket (Figure 1, Item 2), spring (Figure 1, Item 3), and by-pass valve (Figure 1,
Item 4) from filter head (Figure 1, Item 5). Discard gasket.
Figure 1. By-Pass Valve. 0039
2. Remove nut (Figure 2, Item 4), spring (Figure 2, Item 3), and pressure regulating valve (Figure 2, Item 2) from
pressure regulating valve housing (Figure 2, Item 1).
Figure 2. Pressure Regulating Valve. 0039
0039-2
TM 5-3805-255-14 0039
3. Loosen nuts from both ends of oil outlet pipe (Figure 3, Item 5) and oil inlet pipe (Figure 3, Item 6).
4. Disconnect turbocharger oil supply line (Figure 3, Item 3) from filter head (Figure 3, Item 4).
NOTE
It will be necessary to push the oil inlet and outlet pipes up into the filter head as far as
possible to enable the head to be removed from under the water manifold.
5. Remove three capscrews (Figure 3, Item 2) and filter head (Figure 3, Item 4) from cylinder head (Figure 3,
Item 1).
Figure 3. Oil Filter Head. 0039
END OF TASK
1. Clean filter head and all other parts IAW General Maintenance Instructions (WP 0019).
2. Flush out oil inlet and outlet pipes and clean pressure regulating valve housing.
3. Check pressure regulating valve spring for proper length, action, and condition. A spring outside of these
standards must be replaced.
a. Free length - 2.565 in. (65.15 mm).
b. Test length - 1.711 in. (43.41 mm).
c. Test load - 17.5 lb (78 N).
4. Check pressure regulating valve.
a. Outside diameter - 0.747 to 0.748 in. (18.97 to 19.00 mm).
b. Valve bore - 0.750 to 0.752 in. (19.05 to 19.10 mm).
c. Running clearance - 0.002 to 0.005 in. (0.05 to 0.13 mm).
0039-3
TM 5-3805-255-14 0039
CLEANING AND INSPECTION – CONTINUED 00039
5. Check by-pass valve spring for proper length, action, and condition. A spring outside of these standards must
be replaced.
a. Free length - 2.068 in. (52.53 mm).
b. Test length - 1.224 in. (31.09 mm).
c. Test load - 6.92 lb (31 N.)
6. Check by-pass valve.
a. Outside diameter - 0.622 in. (15.80 to 15.82 mm).
b. Valve bore - 0.624 to 0.625 in. (15.85 to 15.88 mm).
c. Running clearance - 0.001 to 0.003 in. (0.0254 to 0.0752 mm).
7. Check valve condition. Valves should slide freely, and valve seats in housing and filter head should not be worn
or damaged. Replace if damaged.
8. Check seal rings on oil outlet and inlet pipes for damage. Replace if damaged.
END OF TASK
INSTALLATION 00039
1. Install filter head (Figure 4, Item 4) and three capscrews (Figure 4, Item 2) on cylinder head (Figure 4, Item 1).
2. Connect turbocharger oil supply line (Figure 4, Item 3) to filter head (Figure 4, Item 4).
3. Install oil outlet pipe (Figure 4, Item 5) and oil inlet pipe (Figure 4, Item 6) and tighten nuts on each end of
pipes.
Figure 4. Oil Filter Head. 0039
0039-4
TM 5-3805-255-14 0039
4. Install pressure regulating valve (Figure 5, Item 2), spring (Figure 5, Item 3), and nut (Figure 5, Item 4) on
pressure regulating valve housing (Figure 5, Item 1).
Figure 5. Pressure Regulating Valve. 0039
5. Install by-pass valve (Figure 6, Item 4), spring (Figure 6, Item 3), new gasket (Figure 6, Item 2), and nut (Figure
6, Item 1) on filter head (Figure 6, Item 5).
6. Install oil filters (WP 0016).
Figure 6. By-Pass Valve. 0039
7. Install accelerator linkage (WP 0033).

8. Check engine oil level and fill with correct amount and type of oil (WP 0018).
END OF TASK
END OF WORK PACKAGE
0039-5/(6 blank)
6
TM 5-3805-255-14 0040
FIELD MAINTENANCE -
ALTERNATOR REPLACEMENT
0 0 4 0
INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

0004) 0
Lockwasher 0
Alternator belt removed (WP 0018) 0
References 0 Fan guard removed (WP 0038) 0
WP 0019 0
0040-1
TM 5-3805-255-14 0040
REMOVAL 00040
WARNING
Ensure battery disconnect switch is in OFF position. Be careful not to touch tool used to
disconnect or connect wire on alternator to any part of the loader, as sparks may occur.
Failure to follow this warning may result in injury to personnel or damage to equipment.
NOTE
Tag and identify all wires prior to removal for ease of installation.
1. Remove nut (Figure 1, Item 2), lockwasher (Figure 1, Item 1), and wire (Figure 1, Item 3) from alternator
Figure 1. Alternator Wiring. 0040
0040-2
TM 5-3805-255-14 0040
2. Remove bolt (Figure 2, Item 1) and washer (Figure 2, Item 2) from upper bracket (Figure 2, Item 3).
3. Remove bolt (Figure 2, Item 5), nut (Figure 2, Item 6), two washers (Figure 2, Item 7), and alternator (Figure 2,
Item 4) from lower bracket (Figure 2, Item 8).
4. If necessary, remove nut (Figure 2, Item 9), washer (Figure 2, Item 10), and pulley (Figure 2, Item 11) from
alternator (Figure 2, Item 4).
Figure 2. Alternator Mounting. 0040
END OF TASK
Clean and Inspect all parts IAW General Maintenance Instructions (WP 0019).
END OF TASK
0040-3
TM 5-3805-255-14 0040
INSTALLATION 00040
1. If removed, install pulley (Figure 3, Item 11), washer (Figure 3, Item 10), and nut (Figure 3, Item 9) on alternator
(Figure 3, Item 4).
2. Install alternator (Figure 3, Item 4), two washers (Figure 3, Item 7), bolt (Figure 3, Item 5), and nut (Figure 3,
Item 6) on lower bracket (Figure 3, Item 8). Do not tighten bolt.
3. Install washer (Figure 3, Item 2) and bolt (Figure 3, Item 1) on upper brace (Figure 3, Item 3) and alternator
(Figure 3, Item 4). Do not tighten bolt.
Figure 3. Alternator Mounting. 0040
0040-4
TM 5-3805-255-14 0040
4. Install wire (Figure 4, Item 3), new lockwasher (Figure 4, Item 1), and nut (Figure 4, Item 2) on alternator
(Figure 4, Item 4).
5. Install and adjust alternator belt (WP 0018).
6. Install fan guard (WP 0038).
Figure 4. Alternator Wiring. 0040
END OF TASK
END OF WORK PACKAGE
0040-5/(6 blank)
4
TM 5-3805-255-14 0041
FIELD MAINTENANCE -
STARTER REPLACEMENT
0 0 4 1
INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0


Gasket 0
Lockwasher (7) 0 0004) 0
Two 0
0041-1
TM 5-3805-255-14 0041
REMOVAL 00041
NOTE
Tag all wires and cables prior to removal for ease of installation.
1. Remove nut (Figure 1, Item 2), lockwasher (Figure 1, Item 3), and two cables (Figure 1, Item 4) from starter
2. Remove nut (Figure 1, Item 15), lockwasher (Figure 1, Item 16), and cable (Figure 1, Item 14) from starter
3. Remove nut (Figure 1, Item 5), lockwasher (Figure 1, Item 6), and two wires (Figure 1, Item 7) from starter
4. Remove nut (Figure 1, Item 8), lockwasher (Figure 1, Item 9), and wire (Figure 1, Item 10) from starter (Figure
1, Item 1). Discard lockwasher.
WARNING
• Use extreme caution when lifting heavy parts. Provide adequate support and use
assistance during procedure. Ensure lifting equipment used is on solid footing, is in good
condition, and has suitable lifting capacity. Keep clear of heavy parts supported only by
lifting equipment.
• Failure to follow this warning may result in injury or death to personnel or damage to
equipment.
5. Remove three bolts (Figure 1, Item 12), lockwashers (Figure 1, Item 13), and starter (Figure 1, Item 1) from
engine. Discard lockwashers.
6. Remove gasket (Figure 1, Item 11) from starter (Figure 1, Item 1). Discard gasket.
Figure 1. Starter Removal and Installation. 0041
END OF TASK
0041-2
TM 5-3805-255-14 0041
END OF TASK
INSTALLATION 00041
1. Install new gasket (Figure 1, Item 11) on starter (Figure 1, Item 1).
2. Install starter (Figure 1, Item 1), three new lockwashers (Figure 1, Item 13), and bolts (Figure 1, Item 12) on
engine. Torque bolts to 105 to 120 lb-ft (142 to 163 Nm).
3. Install wire (Figure 1, Item 10), new lockwasher (Figure 1, Item 9), and nut (Figure 1, Item 8) on starter (Figure
1, Item 1).
4. Install two wires (Figure 1, Item 7), new lockwasher (Figure 1, Item 6), and nut (Figure 1, Item 5) on starter
(Figure 1, Item 1).
5. Install cable (Figure 1, Item 14), lockwasher (Figure 1, Item 16), and nut (Figure 1, Item 15) on starter (Figure
1, Item 1).
6. Install two cables (Figure 1, Item 4), new lockwasher (Figure 1, Item 3), and nut (Figure 1, Item 2) on starter
(Figure 1, Item 1).
END OF TASK
END OF WORK PACKAGE
0041-3/(4 blank)
12
TM 5-3805-255-14 0042
FIELD MAINTENANCE -
0 0 4 2 SWITCH REPLACEMENT
INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

(WP 0004) 0
Lockwasher (3) 0
REMOVAL 00042
Remove gauge panel (Figure 1, Item 1) from instrument panel (Figure 1, Item 2).
0042-1
TM 5-3805-255-14 0042
ON/OFF Switch 00042
NOTE
Tag and identify all wires for ease of installation.
1. Remove nut (Figure 2, Item 10) and six wires (Figure 2, Items 1, 2, 3, 7, 8, and 9) from ON/OFF switch
(Figure 2, Item 5).
2. Remove nut (Figure 2, Item 6) and wire (Figure 2, Item 4) from ON/OFF switch (Figure 2, Item 5).
Figure 2. ON/OFF Switch Wiring. 0042
0042-2
TM 5-3805-255-14 0042
ON/OFF Switch — Continued
3. Remove screw (Figure 3, Item 2) and ON/OFF switch selector (Figure 3, Item 1) from ON/OFF switch
(Figure 3, Item 4).
4. Remove nut (Figure 3, Item 6), lockwasher (Figure 3, Item 5), and ON/OFF switch (Figure 3, Item 4) from dash
panel (Figure 3, Item 3). Discard lockwasher.
Figure 3. ON/OFF Switch. 0042
0042-3
TM 5-3805-255-14 0042
Headlamp Switch 00042
NOTE
1. Remove screw (Figure 4, Item 9) and two wires (Figure 4, Items 1 and 10) from headlamp switch (Figure 4,
Item 8).
2. Remove screw (Figure 4, Item 3) and two wires (Figure 4, Items 2 and 4) from headlamp switch
(Figure 4, Item 8).
3. Remove nut (Figure 4, Item 7), lockwasher (Figure 4, Item 6), and wire (Figure 4, Item 5) from headlamp
switch (Figure 4, Item 8). Discard lockwasher.
Figure 4. Headlamp Switch Wiring. 0042
0042-4
TM 5-3805-255-14 0042
Headlamp Switch — Continued
4. Loosen headlamp switch knob screw (Figure 5, Item 2) and remove headlamp switch knob (Figure 5, Item 1)
from headlamp switch (Figure 5, Item 3).
5. Remove headlamp switch retaining nut (Figure 5, Item 4) from headlamp switch (Figure 5, Item 3).
6. Remove headlamp switch (Figure 5, Item 3) from rear of dash panel (Figure 5, Item 5).
Figure 5. Headlamp Switch. 0042
0042-5
TM 5-3805-255-14 0042
Starter Button 00042
NOTE
1. Remove nut (Figure 6, Item 3) and wire (Figure 6, Item 4) from starter button switch (Figure 6, Item 7).
2. Remove nut (Figure 6, Item 6) and wire (Figure 6, Item 2) from starter button switch (Figure 6, Item 7).
3. Loosen locknut (Figure 6, Item 1) on starter button switch (Figure 6, Item 7).
Figure 6. Starter Button Switch Wiring. 0042
0042-6
TM 5-3805-255-14 0042
Starter Button — Continued
4. Remove starter button (Figure 7, Item 1) and lockwasher (Figure 7, Item 2) from dash panel (Figure 7, Item 4).
Discard lockwasher.
5. Remove starter button switch (Figure 7, Item 3) from rear of dash panel (Figure 7, Item 4).
Figure 7. Starter Button. 0042
END OF TASK
INSTALLATION 00042
Starter Button 00042
1. Install starter button switch (Figure 7, Item 3) in rear of dash panel (Figure 7, Item 4).
2. Install new lockwasher (Figure 7, Item 2) and starter button (Figure 7, Item 1) on dash panel (Figure 7, Item 4).
3. Tighten locknut (Figure 6, Item 1) on starter button switch (Figure 6, Item 7).
NOTE
Install wires as noted during removal.
4. Install wire (Figure 6, Item 2) and nut (Figure 6, Item 6) on starter button switch (Figure 6, Item 7).
5. Install wire (Figure 6, Item 4) and nut (Figure 6, Item 3) on starter button switch (Figure 6, Item 7).
0042-7
TM 5-3805-255-14 0042
Headlamp Switch 00042
1. Install headlamp switch (Figure 8, Item 3) in rear of dash panel (Figure 8, Item 5).
2. Install headlamp switch retaining nut (Figure 8, Item 4) on headlamp switch (Figure 8, Item 3).
3. Install headlamp switch knob (Figure 8, Item 1) on headlamp switch (Figure 8, Item 3). Tighten headlamp
switch knob screw (Figure 8, Item 2).
Figure 8. Headlamp Switch. 0042
0042-8
TM 5-3805-255-14 0042
Headlamp Switch — Continued
NOTE
4. Install wire (Figure 9, Item 5), new lockwasher (Figure 9, Item 6), and nut (Figure 9, Item 7) on headlamp
switch (Figure 9, Item 8).
5. Install two wires (Figure 9, Items 2 and 4) and screw (Figure 9, Item 3) on headlamp switch (Figure 9,
Item 8).
6. Install two wires (Figure 9, Items 1 and 10) and screw (Figure 9, Item 9) on headlamp switch (Figure 9,
Item 8).
Figure 9. Headlamp Switch Wiring. 0042
0042-9
TM 5-3805-255-14 0042
ON/OFF Switch 00042
1. Install ON/OFF switch (Figure 10, Item 4), new lockwasher (Figure 10, Item 5), and nut (Figure 10, Item 6) in
dash panel (Figure 10, Item 3).
2. Install ON/OFF switch selector (Figure 10, Item 1) and screw (Figure 10, Item 2) on ON/OFF switch (Figure 10,
Item 4).
Figure 10. ON/OFF Switch. 0042
0042-10
TM 5-3805-255-14 0042
ON/OFF Switch — Continued
NOTE
3. Install wire (Figure 11, Item 4), and nut (Figure 11, Item 6) on ON/OFF switch (Figure 11, Item 5).
4. Install six wires (Figure 11, Items 1, 2, 3, 7, 8, and 9) and nut (Figure 11, Item 10) on ON/OFF switch (Figure
11, Item 5).
Figure 11. ON/OFF Switch Wiring. 0042
5. Install gauge panel (Figure 12, Item 1) on instrument panel (Figure 12, Item 2).
END OF TASK
END OF WORK PACKAGE
0042-11/(12 blank)
4
TM 5-3805-255-14 0043
FIELD MAINTENANCE -
ELECTRIC GAUGE REPLACEMENT

0 0 4 3
INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0



(WP 0004) 0
REMOVAL 00043
NOTE
The following procedure is for the fuel gauge. All other electrical gauges are removed in a
similar manner.
1. Remove gauge face plate (Figure 1, Item 1) from instrument panel (Figure 1, Item 2).
0043-1
TM 5-3805-255-14 0043
NOTE
Tag and identify all wires and connectors for aid in assembly.
2. Remove lamp (Figure 2, Item 2) from gauge (Figure 2, Item 1).
3. Remove nut (Figure 2, Item 6) and two wires (Figure 2, Items 5 and 7) from gauge (Figure 2, Item 1).
4. Remove nut (Figure 2, Item 8) and wire (Figure 2, Item 9) from gauge (Figure 2, Item 1).
5. Remove nut (Figure 2, Item 11) and wire (Figure 2, Item 10) from gauge Figure 2, Item 1).
6. Remove two nuts (Figure 2, Items 3 and 12) and bracket (Figure 2, Item 4) from gauge (Figure 2, Item 1).
7. Remove gauge (Figure 2, Item 1) from front of gauge panel (Figure 2, Item 13).
Figure 2. Gauge Removal. 0043
END OF TASK 00043
END OF TASK
INSTALLATION 00043
1. Install gauge (Figure 2, Item 1) in front of gauge panel (Figure 2, Item 13).
2. Install bracket (Figure 2, Item 4) and two nuts (Figure 2, Items 3 and 12) on gauge (Figure 2, Item 1).
3. Install wire (Figure 2, Item 10) and nut (Figure 2, Item 11) on gauge Figure 2, Item 1).
4. Install wire (Figure 2, Item 9) and nut (Figure 2, Item 8) on gauge (Figure 2, Item 1).
5. Install two wires (Figure 2, Items 5 and 7) and nut (Figure 2, Item 6) on gauge (Figure 2, Item 1).
0043-2
TM 5-3805-255-14 0043
6. Install lamp (Figure 2, Item 2) in gauge (Figure 2, Item 1).

7. Install gauge face plate (Figure 3, Item 1) on instrument panel (Figure 3, Item 2).
Figure 3. Gauge Cluster 0043
8. Turn battery disconnect switch to ON position.

9. Start engine and check operation of gauges.
END OF TASK
END OF WORK PACKAGE
0043-3/(4 blank)
10
TM 5-3805-255-14 0044
FIELD MAINTENANCE -
SENDING UNIT REPLACEMENT

0 0 4 4
INITIAL SETUP
0128, Item 20) 0

WP 0018 0
Materials/Parts 0
WP 0019 0
(WP 0130, Item 3) 0

Gasket 0

0004) 0
0044-1
TM 5-3805-255-14 0044
REMOVAL
Fuel Level Sending Unit
WARNING
water.
NOTE
1. Remove two drain plugs (Figure 1, Item 12) from front bottom portion of fuel tank (Figure 1, Item 17).
2. Drain fuel tank (Figure 1, Item 17) into suitable container.
3. Remove wire (Figure 1, Item 5) from fuel level sender (Figure 1, Item 1).
4. Disconnect fuel supply hose (Figure 1, Item 10) from fuel tank (Figure 1, Item 17). Disconnect fuel return hose
(Figure 1, Item 11) from fuel tank (Figure 1, Item 17).
5. Remove two nuts (Figure 1, Item 9), washers (Figure 1, Item 8), and U-bolt (Figure 1, Item 7) from front of fuel
tank (Figure 1, Item 17).
6. Position suitable lifting device tightly under center of fuel tank (Figure 1, Item 17).
WARNING
7. Remove six nuts (Figure 1, Item 16), washers (Figure 1, Item 15), bolts (Figure 1, Item 13), and washers
(Figure 1, Item 14) from frame mounting brackets.
8. Remove fuel tank (Figure 1, Item 17) from loader.
9. Remove four bolts (Figure 1, Item 4), cover (Figure 1, Item 3), gasket (Figure 1, Item 2), and fuel level sender
(Figure 1, Item 1) from fuel tank (Figure 1, Item 17). Discard gasket.
0044-2
TM 5-3805-255-14 0044
Fuel Level Sending Unit — Continued
0044-3
TM 5-3805-255-14 0044
Water Temperature Sending Unit 00044
NOTE
• Allow engine to cool before performing this procedure
• Relieve cooling system pressure by removing radiator cap before beginning.
• Place suitable container under engine to catch coolant as sending unit is removed.
1. Remove nut (Figure 2, Item 2), washer (Figure 2, Item 3), and wire eyelet (Figure 2, Item 4) from water
temperature sending unit (Figure 2, Item 1).
2. Remove water temperature sending unit (Figure 2, Item 1) from water manifold (Figure 2, Item 5).
Figure 2. Water Temperature Sending Unit. 044
0044-4
TM 5-3805-255-14 0044
Oil Pressure Sending Unit 00044
NOTE
• There are two oil pressure sending units, one for high oil pressure and one for low oil
pressure.
• Tag and identify all wires to aid in installation.
1. Place suitable container under engine to catch oil as sending units are removed.
2. Remove screw (Figure 3, Item 2) and wire eyelet (Figure 3, Item 3) from oil pressure sending unit (Figure 3,
Item 1).
3. Remove oil pressure sending unit (Figure 3, Item 1) from fitting (Figure 3, Item 7).
4. Remove nut (Figure 3, Item 5) and wire eyelet (Figure 3, Item 6) from oil pressure sending unit (Figure 3,
Item 4).
5. Remove oil pressure sending unit (Figure 3, Item 4) from fitting (Figure 3, Item 7).
Figure 3. Oil Pressure Sending Unit. 044
END OF TASK
END OF TASK
0044-5
TM 5-3805-255-14 0044
INSTALLATION 0044
Oil Pressure Sending Unit 00044
1. Install oil pressure sending unit (Figure 4, Item 4) in fitting (Figure 4, Item 7).
2. Install wire eyelet (Figure 4, Item 6) and nut (Figure 4, Item 5) on oil pressure sending unit (Figure 4, Item 4).
3. Install oil pressure sending unit (Figure 4, Item 1) in fitting (Figure 4, Item 7).
4. Install wire eyelet (Figure 4, Item 3) and screw (Figure 4, Item 2) on oil pressure sending unit (Figure 4, Item 1).
Figure 4. Oil Pressure Sending Unit. 044
5. Check and fill engine oil level (WP 0018).

7. Check oil pressure sending unit connections and check oil pressure gauge for proper operation (WP 0005).
0044-6
TM 5-3805-255-14 0044
Water Temperature Sending Unit 00044
1. Install water temperature sending unit (Figure 5, Item 1) in water manifold (Figure 5, Item 5).
2. Install wire eyelet (Figure 5, Item 4), washer (Figure 5, Item 3), and nut (Figure 5, Item 2) on water temperature
sending unit (Figure 5, Item 1).
Figure 5. Water Temperature Sending Unit. 044
3. Check and fill engine coolant as necessary (WP 0018).

5. Check water temperature gauge for proper operation (WP 0005).
0044-7
TM 5-3805-255-14 0044
Fuel Level Sending Unit
WARNING
water.
1. Install fuel level sender (Figure 6, Item 1), new gasket (Figure 6, Item 2), cover (Figure 6, Item 3), and four
bolts (Figure 6, Item 4) in fuel tank (Figure 6, Item 17).
WARNING
2. Using a suitable lifting device, align fuel tank (Figure 6, Item 17) with frame mounting brackets.
3. Install 12 washers (Figure 6, Items 14 and 15), six bolts (Figure 6, Item 13), and nuts (Figure 6, Item 16)
through frame mounting brackets.
4. Install U-bolt (Figure 6, Item 7), two washers (Figure 6, Item 8), nuts (Figure 6, Item 9), and oil drain hose (Fig-
ure 6, Item 6) on fuel tank (Figure 6, Item 17).
5. Attach fuel supply hose (Figure 6, Item 10) and return hose (Figure 6, Item 11) to fuel tank (Figure 6, Item 17).
6. Connect wire (Figure 6, Item 5) to fuel level sender (Figure 6, Item 1).
7. Install two drain plugs (Figure 6, Item 12) in fuel tank (Figure 6, Item 17).
0044-8
TM 5-3805-255-14 0044
0044-9
TM 5-3805-255-14 0044
INSTALLATION – Continued 0044
8. Refill fuel tank (WP 0013).

9. Vent fuel system IAW Field Preventive Maintenance Checks and Services (PMCS), Including Lubrication
Instructions (WP 0018).
10. Start engine (WP 0005). Check for leaks.
12. Check fuel gauge for proper operation (WP 0005).
END OF TASK
END OF WORK PACKAGE
0044-10
6
TM 5-3805-255-14 0045
FIELD MAINTENANCE -
0 0 4 5 BATTERY SERVICE AND REPLACEMENT

Inspection, Removal, Installation
INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

(WP 0004) 0
Cotter Pin (2) 0
SCOPE 00045
This work package contains instructions for inspection, removal, and installation of two types of batteries: 12 VDC
and 6 VDC.
WARNING
• To avoid injury, eye protection and acid-resistant gloves must be worn when working
around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition
sources around batteries. If a battery is giving off gases, it can explode and cause injury.
Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool
contacts a battery terminal, a direct short will cause instant heating, damage to
equipment, and injury to personnel.
• 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.
• Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or
electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the
corrosive burning effects. Failure to follow these procedures may result in injury or death
to personnel.
– Eyes. Flush with cold water for no less than 15 minutes and seek medical
attention immediately.
– Skin. Flush with large amounts of cold water until all acid is removed. Seek
medical attention as required.
– Internal. If corrosion or electrolyte is ingested, drink large amounts of water or
milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical
attention immediately.
– Clothing/Equipment. Wash area with large amounts of cold water. Neutralize
acid with baking soda or household ammonia.
• Use extreme caution when handling heavy parts. Provide adequate support and use
assistance during procedure. Ensure any lifting equipment used is in good condition and
of suitable load capacity. Keep clear of heavy parts supported only by lifting equipment.
Failure to follow this warning may result in injury or death to personnel.
• Be careful not to touch tool used to disconnect or connect cable clamp to any part of
machine. Sparks may occur resulting in injury to personnel or damage to equipment.
0045-1
TM 5-3805-255-14 0045
INSPECTION 00045
NOTE
The battery should always be very carefully inspected before any actual testing is done.
Many undesirable conditions can be seen and corrected before they result in battery
trouble. Other visible indications are very important when analyzing the hydrometer
readings.
1. Inspect battery case for cracks and leaks.
2. Inspect battery posts, clamps, and cables for breakage, loose connections, corrosion, and other faults.
3. Note whether top of battery is clean and dry. Dirt and electrolyte on top of battery causes excessive self-
discharge.
4. Be sure cell vents are open.
5. Be sure battery carrier is solidly mounted and in good condition and that battery hold-down is properly
tightened. A loose battery carrier or battery hold-down will allow battery to be damaged by vibration and jarring.
An excessively tightened battery hold-down may buckle or crack battery case.
6. Inspect battery for raised cell covers or warped case, which may indicate that the battery has been overheated
or overcharged at some time. This may be important when analyzing results of electrical tests.
7. Note reserve capacity rating of battery (usually stamped on case). If not indicated, refer to manufacturer's
specifications for battery capacity.
END OF TASK
0045-2
TM 5-3805-255-14 0045
REMOVAL 00045
12VDC Batteries 00045
1. Open battery cover.

2. Remove two nuts (Figure 1, Item 2), washers (Figure 1, Item 3), battery hold-down (Figure 1, Item 13), and two
angle bolts (Figure 1, Item 1) from vehicle.
3. Remove nut (Figure 1, Item 5), bolt (Figure 1, Item 6), negative cable (Figure 1, Item 7) and terminal (Figure 1,
Item 4) from battery terminal.
4. Remove nut (Figure 1, Item 8), bolt (Figure 1, Item 9), positive cable (Figure 1, Item 10) and terminal (Figure 1,
Item 11) from battery terminal.
5. Remove battery (Figure 1, Item 12) from vehicle.
6. Repeat steps 1 through 5 for battery on opposite side of loader.
Figure 1. 12VDC Battery. 0045
0045-3
TM 5-3805-255-14 0045
1. Open battery cover.
NOTE
Tag and identify battery cables to aid in installation.
2. Remove nut (Figure 2, Item 9), bolt (Figure 2, Item 10), two positive cables (Figure 2, Item 7), and cable end
(Figure 2, Item 8) from positive battery terminal.
3. Remove nut (Figure 2, Item 14), bolt (Figure 2, Item 15), two negative cables (Figure 2, Item 13), and cable
end (Figure 2, Item 16) from negative battery terminal.
4. Remove two nuts (Figure 2, Items 18 and 11), bolts (Figure 2, Items 19 and 20), and intermediate cable (Figure
1, Item 12) from battery terminals.
5. Remove two cotter pins (Figure 2, Item 6) from angle bolts (Figure 2, Item 5). Discard cotter pins.
6. Remove two nuts (Figure 2, Item 1), washers (Figure 2, Item 2), lockwashers (Figure 2, Item 3), battery hold-
downs (Figure 2, Item 4), and angle bolts (Figure 2, Item 5).
7. Remove two batteries (Figure 2, Item 17) from loader.
8. Repeat steps 1 through 7 for batteries on the opposite side of loader.
Figure 2. 6VDC Batteries. 0045
END OF TASK
0045-4
TM 5-3805-255-14 0045
INSTALLATION 00045
1. Install two batteries (Figure 2, Item 17) on loader.

2. Install two angle bolts (Figure 2, Item 5), battery hold-downs (Figure 2, Item 4), new lockwashers (Figure 2,
Item 3), washers (Figure 2, Item 2), and nuts (Figure 2, Item 1) on batteries (Figure 2, Item 17).
3. Install two new cotter pins (Figure 2, Item 6) on angle bolts (Figure 2, Item 5).
NOTE
Connect battery cables as noted during removal.
4. Install intermediate cable (Figure 2, Item 12) on battery terminals. Install two bolts (Figure 2, Items 19 and 20)
and nuts (Figure 2, Items 18 and 11) on cable ends.
5. Install cable end (Figure 2, Item 16), bolt (Figure 2, Item 15), nut (Figure 2, Item 14), and two negative cables
(Figure 2, Item 13) on negative battery terminal.
6. Install cable end (Figure 2, Item 8), bolt (Figure 2, Item 10), nut (Figure 2, Item 9), and two positive cables
(Figure 2, Item 7) on positive battery terminal.
7. Close battery cover.
8. Repeat steps 1 through 7 for batteries on opposite side of loader.
0045-5
TM 5-3805-255-14 0045
1. Install battery (Figure 3, Item 12) in vehicle.

2. Install positive cable (Figure 3, Item 10), terminal (Figure 3, Item 11), bolt (Figure 3, Item 9), and nut (Figure 3,
Item 8) on battery terminal.
3. Install negative cable (Figure 3, Item 7), terminal (Figure 3, Item 4), bolt (Figure 3, Item 6), and nut (Figure 3,
Item 5) on battery terminal.
4. Install two angle bolts (Figure 3, Item 1), battery hold-down (Figure 4, Item 13), two washers (Figure 3, Item 3),
and nuts (Figure 3, Item 2) on loader.
5. Close battery cover.
6. Repeat steps 1 through 5 for battery on opposite side of loader.
Figure 3. 12VDC Battery. 0045
END OF TASK
END OF WORK PACKAGE
0045-6
6
TM 5-3805-255-14 0046
FIELD MAINTENANCE -
TRANSMISSION CONTROL LINKAGE REPLACEMENT

0 0 4 6
INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0
Grease, Automotive and Artillery (GAA) (WP Parking brake applied (WP 0005) 0
0130, Item 15) 0


Lockwasher (12) (WP 0004) 0
Nut, Self-Locking (3)

O-Ring (5)
Pin, Cotter (4)
0046-1
TM 5-3805-255-14 0046
REMOVAL 00046
1. Remove cotter pin (Figure 1, Item 41), clevis pin (Figure 1, Item 45), and two control cables (Figure 1, Item 6)
from levers (Figure 1, Items 3 and 4). Discard cotter pin.
2. Remove two cable ends (Figure 1, Items 42 and 46) and nuts (Figure 1, Items 40 and 44) from control cables
(Figure 1, Item 6).
3. Remove two nuts (Figure 1, Item 43) and lockwashers (Figure 1, Item 38) from control cables (Figure 1, Item
6). Discard lockwashers.
4. Remove two control cables (Figure 1, Item 6) from control housing (Figure 1, Item 39).
5. Remove two nuts (Figure 1, Item 43) and lockwashers (Figure 1, Item 38) from control cables (Figure 1,
Item 6). Discard lockwashers.
6. Remove two control cables (Figure 1, Item 6) from floorboard (Figure 1, Item 37).
7. Remove cotter pin (Figure 1, Item 21) from clevis pin (Figure 1, Item 14) at transmission bellcrank (Figure 1,
Item 26). Discard cotter pin.
8. Remove clevis pin (Figure 1, Item 14) from cable end (Figure 1, Item 15).
9. Remove cable end (Figure 1, Item 15) and nut (Figure 1, Item 20) from control cable (Figure 1, Item 6).
10. Remove nut (Figure 1, Item 17) and lockwasher (Figure 1, Item 19) from control cable (Figure 1, Item 6) and
remove control cable from mounting bracket (Figure 1, Item 16). Discard lockwasher.
11. Remove two nuts (Figure 1, Item 25), lockwashers (Figure 1, Item 24), bolts (Figure 1, Item 22), and P-clamps
(Figure 1, Item 23) from control cables (Figure 1, Item 6). Discard lockwashers.
12. Remove nut (Figure 1, Item 17) and lockwasher (Figure 1, Item 19) from control cable (Figure 1, Item 6).
Discard lockwasher.
13. Remove control cable (Figure 1, Item 6) from loader.
14. Remove nut (Figure 1, Item 13), lockwasher (Figure 1, Item 12), and ball joint (Figure 1, Item 10) from
bellcrank (Figure 1, Item 11). Discard lockwasher.
15. Remove ball joint (Figure 1, Item 10) and nut (Figure 1, Item 9) from control cable (Figure 1, Item 6).
16. Remove locknut (Figure 1, Item 7) and lockwasher (Figure 1, Item 18) from control cable (Figure 1, Item 6).
Discard lockwasher and locknut.
17. Remove control cable (Figure 1, Item 6) from support bracket (Figure 1, Item 8).
18. Remove locknut (Figure 1, Item 7) and lockwasher (Figure 1, Item 18) from control cable (Figure 1, Item 6).
Discard lockwasher and locknut.
0046-2
TM 5-3805-255-14 0046
19. Remove self-locking nut (Figure 1, Item 2), pivot pin (Figure 1, Item 1), two control levers (Figure 1, Items 3
and 4), and three O-rings (Figure 1, Item 5) from control housing (Figure 1, Item 39). Discard self-locking nut
and O-rings.
20. Remove three bolts (Figure 1, Item 28) and washers (Figure 1, Item 29) from support shaft (Figure 1, Item 27).
21. Remove cotter pin (Figure 1, Item 36), washer (Figure 1, Item 35), clevis pin (Figure 1, Item 33), two O-rings
(Figure 1, Item 30), support shaft (Figure 1, Item 27), bellcrank (Figure 1, Item 26), and three bushings (Figure
1, Item 31) from two links (Figure 1, Item 32) and transmission (Figure 1, Item 34). Discard cotter pin and two
O-rings.
Figure 1. Transmission Control Linkage. 0046
END OF TASK
0046-3
TM 5-3805-255-14 0046
2. Examine cables for signs of deterioration, unbraiding, and excessive wear. Replace cables if worn.
3. Check cable ends, clevises, and ball joint. Ensure that bores of clevises, bellcrank arms, and connecting links
are not worn. Replace any worn parts.
END OF TASK
INSTALLATION 00046
1. Apply lubricant to bushing of bellcrank (Figure 2, Item 26) and install bellcrank, support shaft (Figure 2,
Item 27), two new O-rings (Figure 2, Item 30), clevis pin (Figure 2, Item 33), washer (Figure 2, Item 35), new
cotter pin (Figure 2, Item 36), and three bushings (Figure 2, Item 31) on two links (Figure 2, Item 32) and
transmission (Figure 2, Item 34).
2. Install three washers (Figure 2, Item 29) and bolts (Figure 2, Item 28) on support shaft (Figure 2, Item 27).
3. Apply lubricant to bushings of two control levers (Figure 2, Items 3 and 4) and install three new O-rings
(Figure 2, Item 5) and pivot pin (Figure 2, Item 1) on control housing (Figure 2, Item 37). Install new self-locking
nut (Figure 2, Item 2) on pivot pin.
4. Install new lockwasher (Figure 2, Item 18) and nut (Figure 2, Item 7) on control cable (Figure 2, Item 6). Install
control cable on support bracket (Figure 2, Item 8). Install new lockwasher and nut on control cable. Tighten
two nuts.
5. Install nut (Figure 2, Item 9) and ball joint (Figure 2, Item 10) on control cable (Figure 2, Item 6). Tighten nut.
6. Install ball joint (Figure 2, Item 10), new lockwasher (Figure 2, Item 12), and nut (Figure 2, Item 13) on
bellcrank (Figure 2, Item 11).
7. Install new lockwasher (Figure 2, Item 19) and nut (Figure 2, Item 17) on control cable (Figure 2, Item 6).
8. Route control cable (Figure 2, Item 6) through mounting bracket (Figure 2, Item 16).
9. Install new lockwasher (Figure 2, Item 19) and nut (Figure 2, Item 17) on control cable (Figure 2, Item 6).
10. lnstall two P-clamps (Figure 2, Item 23), bolts (Figure 2, Item 22), new lockwashers (Figure 2, Item 24), and
nuts (Figure 2, Item 25) on control cables (Figure 2, Item 6).
11. Install cable nut (Figure 2, Item 20) and cable end (Figure 2, Item 15) on control cable (Figure 2, Item 6).
12. Install clevis pin (Figure 2, Item 14) through cable end (Figure 2, Item 15) and transmission bellcrank (Figure 2,
Item 26). Install new cotter pin (Figure 2, Item 21) on clevis pin.
13. Route two control cables (Figure 2, Item 6) through floorboard (Figure 2, Item 37).
14. Install two new lockwashers (Figure 2, Item 17) and nuts (Figure 2, Item 7) on control cables (Figure 2, Item 6).
15. Route two control cables (Figure 2, Item 6) through control housing (Figure 2, Item 33).
16. Install two new lockwashers (Figure 2, Item 38) and nuts (Figure 2, Item 43) on control cables (Figure 2,
Item 6).
17. Install two nuts (Figure 2, Item 44) and cable ends (Figure 2, Items 42 and 46) on control cables (Figure 2,
Item 6).
18. Install two control cables (Figure 2, Item 6), clevis pin (Figure 2, Item 45), and new cotter pin (Figure 2,
Item 41) on two control levers (Figure 2, Items 3 and 4).
0046-4
TM 5-3805-255-14 0046
Figure 2. Transmission Control Linkage. 0046
END OF TASK 00046
0046-5
TM 5-3805-255-14 0046
ADJUSTMENT 00046
1. Remove nut (Figure 3, Item 7) and lockwasher (Figure 3, Item 6) from ball joint (Figure 3, Item 4) on end of
range control lever control cable (Figure 3, Item 2). Discard lockwasher.
2. Remove ball joint (Figure 3, Item 4) from range bellcrank (Figure 3, Item 5).
3. Remove cotter pin (Figure 3, Item 11) and clevis pin (Figure 3, Item 8) from directional control cable clevis
(Figure 3, Item 9). Discard cotter pin.
4. Remove cable clevis (Figure 3, Item 9) from directional bellcrank (Figure 3, Item 10).
5. Position directional control lever (Figure 3, Item 14) in “NEUTRAL” and range control lever (Figure 3, Item 13)
in “1”. Block or otherwise immobilize both levers in these positions until adjustments are completed.
6. Position range bellcrank (Figure 3, Item 5) in its uppermost position.
7. Loosen locknut (Figure 3, Item 3), adjust ball joint (Figure 3, Item 4) so it freely fits bore of range bellcrank
(Figure 3, Item 5), and install new lockwasher (Figure 3, Item 6) and nut (Figure 3, Item 7).
8. Position directional bellcrank (Figure 3, Item 10) in center position. Adjust cable clevis (Figure 3, Item 9) so that
clevis bore aligns with bore of bellcrank arm.
9. Install clevis pin (Figure 3, Item 8) on cable clevis (Figure 3, Item 9).
10. Install new cotter pin (Figure 3, Item 11) on clevis pin (Figure 3, Item 8).
11. Remove lever blocking and start engine. Operate loader throughout full range of speeds in both forward and
reverse. Check for positive action of levers and correct positioning of transmission spools.
12. When adjustments are satisfactorily completed, shut off engine, tighten all locknuts (Figure 3, Items 3, 12,
and 7), and bend over cotter pin (Figure 3, Item 11).
Figure 3. Transmission Control Linkage Adjustment. 0046
END OF TASK
END OF WORK PACKAGE
0046-6
6
TM 5-3805-255-14 0047
FIELD MAINTENANCE -
0 0 4 7 TORQUE CONVERTER REPLACEMENT

INITIAL SETUP
0128, Item 20) 0

WP 0049 0
Materials/Parts 0
Cap Set, Protective Dust and Moisture Seal Machine parked on level ground (WP 0005) 0
(WP 0130, Item 3) 0
Cleaning Compound, Solvent, Type III (WP Engine OFF (WP 0005) 0
0130, Item 4) 0

(WP 0004) 0
Body access panels removed (WP 0005) 0
Lockwasher (12) 0
Bulkhead removed 0
O-Ring 0
Wheels blocked (WP 0005) 0
Hydraulic reservoir removed (WP 0083) 0
Two 0
Steering pump removed (WP 0070) 0
Main hydraulic pump removed (WP 0077) 0
Hood removed 0
0047-1
TM 5-3805-255-14 0047
REMOVAL 00047
CAUTION
Tag and identify all hoses, lines, and ports for ease of installation. Cap all hose flanges to
prevent contamination and leaks. Open valve and pump ports should be plugged. Do not
use rag to plug ports. Failure to follow this caution may result in damage to equipment.
1. Remove hose clamp (Figure 1. Item 7) and hose (Figure 1. Item 6) from converter housing (Figure 1. Item 8).
2. Disconnect breather tube (Figure 1. Item 1) from elbow on top of converter housing (Figure 1. Item 8).
3. Disconnect lines (Figure 1, Items 2, 3, 4, and 5) from converter housing (Figure 1. Item 8).
Figure 1. Cooler Lines and Tube Removal. 0047
NOTE
Mark the converter drive ring and rotating housing for ease of assembly.
4. Remove propshaft from converter housing (WP 0049).
5. Attach suitable lifting device to converter housing (Figure 2, Item 3).
6. Remove 12 bolts (Figure 2, Item 2) and 12 lockwashers (Figure 2, Item 1) from converter housing (Figure 2,
0047-2
TM 5-3805-255-14 0047
WARNING
Use extreme caution when lifting heavy parts. Provide adequate support and use
assistance during procedure. Ensure that lifting equipment used is on solid footing, is in
good condition, and is of suitable lift capacity. Keep clear of heavy parts supported only by
lifting equipment. Failure to follow this warning may result in death or injury to personnel or
7. Using suitable lifting device, carefully remove converter housing (Figure 2, Item 3) from engine flywheel
housing.
Figure 2. Propshaft and Converter.

END OF TASK
0047-3
TM 5-3805-255-14 0047
INSTALLATION
WARNING
assistance during procedure. Ensure that lifting equipment used is on solid footing, is in good
condition, and is of suitable lift capacity. Keep clear of heavy parts supported only by lifting
equipment. Failure to follow this warning may result in death or injury to personnel or damage to
equipment.
1. Attach suitable lifting device to converter housing (Figure 3, Item 3). Remove slack from lifting device.
2. Line up punch marks and carefully install converter housing (Figure 3, Item 3) on engine flywheel housing.
3. Apply thread sealant to bolts (Figure 3, Item 2).
4. Install 12 new lockwashers (Figure 3, Item 1) and bolts (Figure 3, Item 3) on converter housing (Figure 3, Item
3) and engine flywheel housing. Torque bolts to 50 to 60 lb-ft (67.79 to 81.34 Nm).
5. Install propshaft on converter housing (WP 0049).
Figure 3. Propshaft and Converter.
0047-4
TM 5-3805-255-14 0047
6. Connect lines (Figure 4, Items 2, 3, 4, and 5) to their ports on converter housing (Figure 4, Item 8). Tighten
fittings.
7. Install breather tube (Figure 4, Item 1) on elbow on top of converter housing (Figure 4, Item 8).
8. Install hose (Figure 4, Item 6) and hose clamp (Figure 4, Item 7) on converter housing (Figure 4, Item 8).
Figure 4. Cooler Line Hoses and Tube. 0047
9. Install steering pump (WP 0070).

10. Install main hydraulic pump (WP 0077).
11. Install bulkhead.
12. Install hood.
13. Install hydraulic reservoir (WP 0083).
14. Start engine and check for leaks. Check operator’s compartment controls for proper operation (WP 0005).
15. Check fluid level (WP 0018).
END OF TASK
END OF WORK PACKAGE
0047-5/(6 blank)
8
TM 5-3805-255-14 0048
FIELD MAINTENANCE -
0 0 4 8 TRANSMISSION REPLACEMENT
INITIAL SETUP
Tools and Special Tools 0 Personnel Required 0
Tool Kit, General Mechanic’s, Automotive (WP Two 0
0128, Item 20) 0

and Repair: Organizational Maintenance Machine parked on level ground (WP 0005)0
Common #1 (WP 0128, Item 14) 0 Parking brake applied (WP 0005) 0
Transmission Lifting Eye (WP 0125, Item 1) 0 Engine OFF (WP 0005) 0

Materials/Parts 0
(WP 0004) 0
Cap Set, Protective Dust and Moisture Seal Battery cables disconnected (WP 0045) 0
(WP 0130, Item 3) 0
Transmission oil drained (WP 0018) 0
Oil, Lubricating, OE/HDO-10 (WP 0130, Item

Cab removed (WP 0075) 0
22) 0
Propeller shafts removed (WP 0049) 0
Transmission control linkage removed (WP

0046) 0
Locknut (37) 0
Hydraulic reservoir drained (WP 0018) 0
Pin, Cotter (3) 0
Safety bar installed (WP 0005) 0
Seal, O-Ring (5) 0
0048-1
TM 5-3805-255-14 0048
REMOVAL 00048
1. Disconnect sump hose (Figure 1, Item 2) and strainer hose (Figure 1, Item 3) from transmission (Figure 1,
Item 1).
INSERT ART H100C-0226
Figure 1. Rear Axle Propeller Shaft. 0048
0048-2
TM 5-3805-255-14 0048
NOTE
Tag and identify all hose flanges for ease of installation. Cap all hoses to prevent
2. Remove 12 bolts (Figure 2, Item 7), six split flanges (Figure 2, Item 6), three hoses (Figure 2, Item 4), and
O-rings (Figure 2, Item 8) from demand valve (Figure 2, Item 5). Discard O-rings.
3. Remove four bolts (Figure 2, Item 3), nuts (Figure 2, Item 1), split flanges (Figure 2, Item 10), two hoses
(Figure 2, Item 9), and O-rings (Figure 2, Item 11) from hose bracket (Figure 2, Item 2). Discard O-rings.
Figure 2. Demand Valve Hoses. 0048
0048-3
TM 5-3805-255-14 0048
4. Remove three bolts (Figure 3, Item 3), nuts (Figure 3, Item 4), and demand valve (Figure 3, Item 2) from
5. Remove two bolts (Figure 3, Item 5) and hose bracket (Figure 3, Item 1) from transmission (Figure 3, Item 6).
Figure 3. Hose Bracket and Demand Valve. 0048
6. Install suitable lifting device in holes on top of transmission. Attach suitable lifting device to lifting eyes and take
up slack.
0048-4
TM 5-3805-255-14 0048
WARNING
• Death or injury could occur if unauthorized personnel are in the hoisting area. Permit only
personnel engaged in hoisting operation to be near H100C and lifting equipment.
• When lifting components do not swing load from side to side, as this places extra strain on
lifting components. Watch boom angle and overhead clearance when hoisting. Failure to
follow this warning may result in injury or death to personnel or damage to equipment.
NOTE
Remove bolts from transmission mounts to frame (not mounts to transmission).
7. Remove six bolts (Figure 4, Item 2) and locknuts (Figure 4, Item 3) from transmission mounts (Figure 4, Item 1)
to frame. Discard locknuts.
8. Remove transmission (Figure 4, Item 4) from loader.

Figure 4. Transmission Mounts. 0048
END OF TASK
0048-5
TM 5-3805-255-14 0048
INSTALLATION 00048
WARNING
• Death or injury could occur if unauthorized personnel are in the hoisting area. Permit only
personnel engaged in hoisting operation to be near H100C and lifting equipment.
• Hoist components slowly and smoothly. Do not swing load from side to side, as this places
extra strain on lifting components. Watch boom angle and overhead clearance when
hoisting. Failure to follow this warning may result in injury or death to personnel or damage
to equipment.
1. Install transmission mounts on transmission (Figure 5, Item 4). Torque mount-to-transmission bolts to 155 to
165 lb-ft (210 to 224 Nm).
2. Install suitable lifting device in holes on top of transmission. Attach suitable lifting device to lifting eyes and take
up slack.
3. Lift transmission (Figure 5, Item 4) into loader.
4. Through access holes under lock bars on loader, align transmission mounts (Figure 5, Item 1) with frame.
5. Install six bolts (Figure 5, Item 2) and nuts (Figure 5, Item 3) through transmission mounts (Figure 5, Item 1).
Torque mounting bracket-to-frame bolts to 300 to 330 lb-ft (406 to 447 Nm).

Figure 5. Transmission Mounts. 0048
0048-6
TM 5-3805-255-14 0048
6. Install hose bracket (Figure 6, Item 1) and two bolts (Figure 6, Item 5) on transmission (Figure 6, Item 6).
7. Install demand valve (Figure 6, Item 2), three bolts (Figure 6, Item 3), and nuts (Figure 6, Item 4) on
Figure 6. Hose Bracket and Demand Valve. 0048
8. Install three new O-rings (Figure 7, Item 8), hoses (Figure 7, Item 4), six split flanges (Figure 7, Item 6), and 12
machine bolts (Figure 7, Item 7) on demand valve (Figure 7, Item 5).
9. Install two new O-rings (Figure 7, Item 11), hoses (Figure 7, Item 9), four split flanges (Figure 7, Item 10), bolts
(Figure 7, Item 3), and nuts (Figure 7, Item 1) on hose bracket (Figure 7, Item 2).
Figure 7. Demand Valve Hoses and Bracket. 0048
0048-7
TM 5-3805-255-14 0048
NOTE
Some propeller shafts have bolts threaded into universal joint caps.
10. Install strainer hose (Figure 8, Item 3) and sump hose (Figure 8, Item 2) on transmission (Figure 8, Item 1).
Figure 8. Rear Axle Propeller Shaft. 0048
11. Install cab (WP 0075).

12. Install propeller shafts (WP 0049).
13. Install transmission control linkage (WP 0046).
14. Stow safety bar (WP 0005).
15. Fill hydraulic reservoir (WP 0018).
16. Add required fluid to transmission-converter system (WP 0018).
17. Start engine, check controls for proper operation (WP 0005).
END OF TASK
END OF WORK PACKAGE
0048-8
8
TM 5-3805-255-14 0049
FIELD MAINTENANCE -
PROPELLER SHAFT REPLACEMENT

0 0 4 9
Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0
Grease, Automotive and Artillery (GAA) (WP Parking brake assembly removed (WP 0057) 0
0130, Item 15) 0

0004) 0
Locknut (8) 0
Mechanic’s Wire 0
WARNING
Chock tires to prevent loader from moving. Failure to follow this warning may result in
injury to personnel and damage to equipment.
0049-1
TM 5-3805-255-14 0049
NOTE
All propeller shafts on the loader are similar, and are serviced in the same manner. Mark
propeller shaft-to-yoke and spider bearing assembly for ease of installation.
REMOVAL 00049
1. Remove eight capscrews (Figure 1, Item 1) and locknuts (Figure 1, Item 2) from propeller shaft (Figure 1,
Item 4). Discard locknuts (Figure 1, Item 2).
WARNING
Propeller shafts may be heavy. Use suitable supporting device when handling propeller
shafts. Failure to follow this warning may result in injury to personnel and damage to
equipment.
2. Apply leverage to telescope slip yoke (Figure 1, Item 3) inward and remove propeller shaft (Figure 1, Item 4)
from loader.
Figure 1. Propeller Shaft Removal. 0049
END OF TASK
0049-2
TM 5-3805-255-14 0049
DISASSEMBLY 00049
1. Remove four bolts (Figure 2, Item 6), nuts (Figure 2, Item 5), and spider and bearing assembly (Figure 2,
Item 4) from yoke (Figure 2, Item 2) of propeller shaft (Figure 2, Item 1).
2. Bearing caps (Figure 2, Item 3) may stick in grooves in yoke. Carefully tap them at an angle to remove.
Figure 2. Propeller Shaft Disassembly. 0049
3. Mark slip yoke (Figure 3, Item 5) and splined shaft (Figure 3, Item 2).
4. Unscrew dust cap (Figure 3, Item 1) and slide it back on splined shaft (Figure 3, Item 2).
5. Remove slip yoke (Figure 3, Item 5), two packing retainer washers (Figure 3, Item 3), and packing (Figure 3,
Item 4). Discard packing.
Figure 3. Propeller Shaft Disassembly. 0049
END OF TASK
0049-3
TM 5-3805-255-14 0049
1. Clean all parts IAW General Maintenance Instructions (WP 0019). Remove all burrs and rough spots from yoke
flanges and from slip joint splines. Use a fine tooth file or an India stone. Do not disassemble bearing
assemblies. Clean with a brush and dry with compressed air.
2. Inspect propeller shaft for signs of torsional fractures or other indications of impending failure.
3. Parts that are to be assembled immediately should be coated with light oil to prevent corrosion. If parts are to
be stored, coat with a good grade rust preventive, and wrap in paper treated to prevent corrosion.
4. Replace all seals and packings.
5. Place bearing assemblies on spider and check for wear. If they are worn, replace complete spider.
END OF TASK
ASSEMBLY 00049
1. Install packing retainer washer (Figure 4, Item 1), new packing (Figure 4, Item 3), packing retainer washer
(Figure 4, Item 1) on splined shaft (Figure 4, Item 4). Coat splined shaft with grease.
2. Slide slip yoke (Figure 4, Item 5) onto splined shaft (Figure 4, Item 4). Align marks made during disassembly.
Screw slip yoke onto splined shaft and tighten enough to avoid leakage when shaft is greased.
Figure 4. Propeller Shaft Assembly. 0049
0049-4
TM 5-3805-255-14 0049
ASSEMBLY – CONTINUED 00049
3. Install two opposite bearing caps (Figure 5, Item 1) onto spider (Figure 5, Item 2).
4. Insert bearing cap (Figure 5, Item 1) into groove in yoke (Figure 5, Item 3) and install spider (Figure 5, Item 2)
in yoke (Figure 5, Item 3). Tap opposite bearing cap at an angle to seat spider and bearing assembly.
Figure 5. Spider Installation. 0049
0049-5
TM 5-3805-255-14 0049
5. Install four capscrews (Figure 6, Item 1) and four new locknuts (Figure 6, Item 3) in bearing caps (Figure 6,
Item 2). Torque capscrews and locknuts to 40 to 50 lb-ft (54 to 68 Nm) on torque-converter-to-transmission
propeller shaft (Figure 6, Item 4). For all other propeller shafts, torque hardware to 90 to 100 lb-ft (122 to 136
Nm).
Figure 6. Spider Fastener Installation. 0049
6. Install remaining two bearings (Figure 7, Item 1) on spider (Figure 7, Item 4). Use mechanic’s wire (Figure 7,
Item 3) to secure spider to propeller shaft.
Figure 7. Bearing Cap Wire Installation. 0049
END OF TASK
0049-6
TM 5-3805-255-14 0049
INSTALLATION 00049
NOTE
Align index marks on propeller shaft with yoke and spider bearing assembly for ease of
assembly. Use new locknuts when assembling propeller shaft.
1. Install propeller shaft (Figure 8, Item 4) in loader.
2. Align slip joint end of shaft (Figure 8, Item 3) with marks made at removal. Fit bearing caps securely in grooves
in mounting yokes.
3. Install two capscrews (Figure 8, Item 1) and new locknuts (Figure 8, Item 2) in bearing cap holes that are not
wired.
4. Remove mechanic’s wire from remaining two holes and install two capscrews (Figure 8, Item 1) and new
locknuts (Figure 8, Item 2). Discard mechanic’s wire.
5. Torque four capscrews (Figure 8, Item 1) and locknuts (Figure 8, Item 2) to 40 to 50 lb-ft (54 to 68 Nm) on
torque-converter-to-transmission propeller shaft, and 90 to 100 lb-ft (122 to 136 Nm) for all other propeller
shafts.
6. Remove pipe plug from slip yoke and apply grease (WP 0013). Install pipe plug. Apply grease to universal joint
fittings at each end of shaft.
Figure 8. Propeller Shaft Installation. 0049
END OF TASK
END OF WORK PACKAGE
0049-7/(8 blank)
14
TM 5-3805-255-14 0050
FIELD MAINTENANCE -
TRANSFER DRIVE REPLACEMENT/REPAIR

0 0 5 0
INITIAL SETUP
0128, Item 20) 0

WP 0019 0
Materials/Parts 0
Compound, Sealing, RTV-732 (WP 0130, Item Machine parked on level ground (WP 0005) 0
9) 0
Oil, Lubricating, Gear, GO 80/90 (WP 0130, Battery disconnect switch in OFF position
Item 20) 0
(WP 0004) 0

Safety pins installed to lock loader halves in a
full-turn position (WP 0005) 0
Gasket 0
Locknut (2) 0 (WP 0005) 0
Lockwasher (6) 0 Parking brake linkage disconnected

O-Ring 0
(WP 0057) 0
Oil Seal (2) 0

Parking brake assembly removed (WP 0058) 0
Seal Washer 0
Transmission-to-transfer drive propeller shaft
removed (WP 0049) 0
Two 0
0050-1
TM 5-3805-255-14 0050
REMOVAL 00050
NOTE
Place suitable container below transfer drive housing to catch lubricating oil.
1. Remove dipstick (Figure 1, Item 1), drain plug (Figure 1, Item 2), and gasket (Figure 1, Item 3) from transfer
drive housing (Figure 1, Item 4). Discard gasket.
H100C-0338
Figure 1. Dipstick and Drain Plug Removal. 0050
0050-2
TM 5-3805-255-14 0050
NOTE
Prior to removing bolts, support transfer drive.
2. Remove six bolts (Figure 2, Item 3), lockwashers (Figure 2, Item 4), and transfer drive (Figure 2, Item 1) from
crossmember (Figure 2, Item 2). Discard lockwashers.
Figure 2. Transfer Drive Removal. 0050
END OF TASK
0050-3
TM 5-3805-255-14 0050
DISASSEMBLY 00050
NOTE
Tag and identify shims in order of removal.
1. Remove locknut (Figure 3, Item 3), retainer (Figure 3, Item 4), shim pack (Figure 3, Item 5), and output yoke
(Figure 3, Item 1) from shaft (Figure 3, Item 2) and transfer drive (Figure 3, Item 6). Discard locknut.
Figure 3. Output Yoke Removal. 0050
2. Remove eight bolts (Figure 4, Item 1), cover (Figure 4, Item 2), and O-ring (Figure 4, Item 3) from transfer drive
housing (Figure 4, Item 4). Discard O-ring.
Figure 4. Transfer Drive Cover Removal. 0050
0050-4
TM 5-3805-255-14 0050
DISASSEMBLY – CONTINUED 00050
3. Remove oil seal (Figure 5, Item 2) from cover (Figure 5, Item 1). Discard oil seal.
Figure 5. Cover Oil Seal Removal. 0050
4. Remove shaft (Figure 6, Item 1) from transfer drive housing (Figure 6, Item 2).
Figure 6. Transfer Drive Shaft Removal. 0050
0050-5
TM 5-3805-255-14 0050
5. Remove bearing cone (Figure 7, Item 1) from shaft (Figure 7, Item 2).
Figure 7. Bearing Removal. 0050
6. Remove oil seal (Figure 8, Item 1), bearing cone (Figure 8, Item 2), and bearing cup (Figure 8, Item 3) from
housing output end (Figure 8, Item 4). Discard oil seal.
Figure 8. Output Bearing and Seal Removal. 0050
END OF TASK
0050-6
TM 5-3805-255-14 0050
NOTE
Parts that are to be assembled immediately should be dipped in light oil to prevent
corrosion. If any parts are to be stored for any length of time, they should be coated with a
good grade rust preventive and wrapped in paper treated to prevent corrosion.
a. Inspect transfer drive shaft for signs of wear or ridging. Replace if necessary.
b. Inspect transfer drive housing for wear or damage. Replace if necessary.
END OF TASK
ASSEMBLY 00050
NOTE
Ensure cups are seated securely against housing shoulders.
1. Install output bearing cup (Figure 9, Item 2) and input bearing cup (Figure 9, Item 1) in housing (Figure 9, Item
3).
Figure 9. Bearing Cups Installation. 0050
0050-7
TM 5-3805-255-14 0050
ASSEMBLY – CONTINUED
NOTE
For ease in handling, use of output yoke is recommended when pressing bearing on shaft.
2. Position transfer drive shaft (Figure 10, Item 4) in an arbor press, input side up. Position bearing (Figure 10,
Item 3) on shaft. Install output yoke (Figure 10, Item 2).
3. Use a suitable sleeve (Figure 10, Item 1) to press bearing (Figure 10, Item 3) on shaft. Continue press
pressure until yoke (Figure 10, Item 2) bottoms on end of splines. Bearing is now correctly positioned on shaft.
Remove yoke from shaft.
Figure 10. Bearing Installation. 0050
0050-8
TM 5-3805-255-14 0050
4. Install shaft and bearing assembly (Figure 11, Item 2) in drive housing (Figure 11, Item 1).
0050
Figure 11. Shaft and Bearing Installation. 0050
NOTE
Spring-loaded lip of seal must face in toward center of housing. Press until seal is flush
with face of cover.
5. Coat outside diameter of new oil seal (Figure 12, Item 2) with sealant and press seal into outside face of cover
(Figure 12, Item 1).
Figure 12. Oil Seal Installation. 0050
0050-9
TM 5-3805-255-14 0050
6. Place new cover O-ring (Figure 13, Item 3) in groove in transfer drive housing (Figure 13, Item 4). Install cover
(Figure 13, Item 2) on housing with eight capscrews (Figure 13, Item 1). Tighten capcrews in an alternating
pattern to 33 to 37 lb-ft (45 to 50 Nm).
Figure 13. Cover Installation. 0050
0050-10
TM 5-3805-255-14 0050
7. Install parking brake backing plate, parking brake shoes and springs, and parking brake drum assembly on
transfer drive (WP 0058).
NOTE
Coat new lubricating seal lip and seal contact surface of yoke with clean, new transfer
drive lubricant.
8. Place yoke (Figure 14, Item 5) on shaft (Figure 14, Item 1).
9. Place new seal washer (Figure 14, Item 2) (where used) on shaft (Figure 14, Item 1).
10. Install retainer (Figure 14, Item 3) and new locknut (Figure 14, Item 4). Tighten locknut to 200 lb-ft (271 Nm).
Figure 14. Yoke and Drum Installation. 0050
0050-11
TM 5-3805-255-14 0050
11. Position transfer drive assembly, input yoke down, in arbor press. Use a suitable spacer (Figure 15, Item 4)
between yoke retainer and new locknut. Press pressure should be on spacer not yoke ears.
12. Position bearing (Figure 15, Item 3) on shaft (Figure 15, Item 6) and slide output yoke (Figure 15, Item 7) onto
shaft splines. Position a suitable adapter (Figure 15, Item 1) on yoke and carefully, using yoke as a driver,
press bearing cone into cup.
13. Pressure on yoke (Figure 15, Item 7) must be applied slowly and carefully. Rotate housing (Figure 15, Item 5)
while pressing bearing into position. As soon as bearings bind slightly during rotation, stop press pressure.
0050-12
TM 5-3805-255-14 0050
14. Dimension A is thickness of required shim pack (Figure 16, Item 2). Add to this pack sufficient shims to pro-
duce recommended shaft end play of 0.002 to 0.004 in. (0.050 to 0.101 mm).
15. Install shim pack (Figure 16, Item 2), yoke retainer (Figure 16, Item 3), and new locknut (Figure 16, Item 4) on
transfer drive shaft (Figure 16, Item 1). Tighten locknut to 200 lb-ft (271 Nm).
Figure 16. Shim Pack and Locknut Installation. 0050
16. Install new gasket (Figure 17, Item 2) on drain plug (Figure 17, Item 3) and install drain plug in housing
(Figure 17, Item 1). Tighten drain plug securely.
Figure 17. Drain Plug Installation. 0050
END OF TASK
0050-13
TM 5-3805-255-14 0050
INSTALLATION 00050
1. Install transfer drive (Figure 18, Item 1) in loader frame crossmember (Figure 18, Item 2).
2. Install six new lockwashers (Figure 18, Item 4) and capscrews (Figure 18, Item 3) through crossmember
(Figure 18, Item 2) and into transfer drive housing (Figure 18, Item 1). Tighten capscrews to 80 to 90 lb-ft
(108 to 122 Nm).
Figure 18. Transfer Drive Installation. 0050
3. Install transfer drive-to-front differential propeller shaft (WP 0049).

4. Fill transfer drive housing to full mark on dipstick with 1 pt (0.473 L) of gear lubricant (WP 0018).
5. Install transmission-to-transfer drive propeller shaft (WP 0049).
6. Install parking brake assembly (WP 0058).
7. Connect parking brake linkage (WP 0057).
8. Remove safety pins from lockbar and reposition lockbar in stowed position (WP 0005).
10. Start engine and check transfer drive operation (WP 0005).
END OF TASK
END OF WORK PACKAGE
0050-14
4
TM 5-3805-255-14 0051
FIELD MAINTENANCE -
0 FRONT AXLE ASSEMBLY REPLACEMENT

0 5 1
Disassembly, Cleaning and Inspection, Assembly
INITIAL SETUP
0128, Item 20) 0
Torque Wrench, 2,500 lb-ft (WP 0128,

Item 21) 0
Materials/Parts 0

0004) 0
Safety pins installed to lock loader halves in

Two 0
straight-ahead position (WP 0005) 0
Rear wheels chocked 0
0051-1
TM 5-3805-255-14 0051
WARNING
• Align frame halves and install safety bar with wheels in straight-ahead position. Failure to
install safety bar could lead to serious injury or death.
• Ensure wheels are chocked to prevent loader from moving.
REMOVAL 00051
1. Raise vehicle until front wheels are free of floor. Support vehicle using appropriate support stands placed under
main frame.
2. Remove two wheels from axle.
3. Remove propeller shaft from axle (WP 0049).
4. Disconnect two brake lines from axle (WP 0059).
5. Support front axle at each end with a suitable support stand. Position suitable lifting device under differential
bowl of axle.
WARNING
6. Remove eight bolts (Figure 1, Item 4), nuts (Figure 1, Item 1), and sixteen washers (Figure 1, Item 2) from axle
(Figure 1, Item 3).
Figure 1. Front Axle. 0051
0051-2
TM 5-3805-255-14 0051
7. Remove support stands from either end of axle. Lower axle on suitable lifting device until it clears frame.
8. Remove axle from loader.
END OF TASK
Clean and inspect axle IAW General Maintenance Instructions (WP 0019).
WARNING
assistance during the procedure. Ensure that any lifting equipment used is in good
equipment. Failure to follow this warning may result in death or injury to personnel.
END OF TASK
INSTALLATION 00051
1. Use a suitable sling and lifting device to position axle on a support stand placed under differential bowl.
2. With an assistant, move front axle under loader until it is in original mounting position. Support axle with a
suitable support stand placed under each end.
3. Tighten nuts to 3,500 lb-ft (4,745 Nm).
4. Install axle (Figure 1, Item 3), eight bolts (Figure 1, Item 4), nuts (Figure 1, Item 1) and sixteen washers
(Figure 1, Item 2).
5. Install two brake lines on axle assembly (WP 0059).
6. Install propeller shaft on axle (WP 0049).
7. Install two wheel assemblies on axle.
8. Adjust front brakes (WP 0059).
END OF TASK
END OF WORK PACKAGE
0051-3/(4 blank)
4
TM 5-3805-255-14 0052
FIELD MAINTENANCE -
FRONT DIFFERENTIAL REPLACEMENT

0 0 5 2
INITIAL SETUP
0128, Item 20) 0
Torch, Acetylene 0
Materials/Parts 0
Oil, Lubricating, Gear, GO 80/90 (WP 0130, Engine OFF (WP 0005) 0
Item 20) 0

0004) 0
Lockwasher (12) 0
Front axle removed (WP 0051) 0
O-Ring 0
Front axle drained (WP 0016) 0
Plastic Gasket 0
Rear wheels chocked 0
Two 0
0052-1
TM 5-3805-255-14 0052
WARNING
REMOVAL 00052
NOTE
Both axle shafts must be removed before differential assembly can be pulled from
housing. In some cases it may be necessary to pry heated differential and axle housing
units apart.
1. Position front axle (Figure 1, Item 1) so that input yoke (Figure 1, Item 4) is facing up.
2. Remove two planetaries (WP 0052) and two axle shafts from front axle (WP 0051).
3. Remove 12 bolts (Figure 1, Item 2) and lockwashers (Figure 1, Item 3) from front axle (Figure 1, Item 1).
Discard lockwashers.
4. Attach suitable lifting device to differential assembly (Figure 1, Item 5), and remove differential assembly from
axle housing (Figure 1, Item 1).
Figure 1. Front Axle Differential. 052
END OF TASK
1. Clean and Inspect differential assembly IAW General Maintenance Instructions (WP 0019).
2. Replace any worn, pitted, or damaged parts.
END OF TASK
0052-2
TM 5-3805-255-14 0052
INSTALLATION 00052
NOTE
Follow manufacturer’s instructions for application and curing time for Loctite Plastic
Gasket.
1. Coat differential mounting face of axle housing (Figure 1, Item 7) with Loctite Plastic Gasket. Apply a light
coating of plastic gasket to threads of 12 bolts (Figure 1, Item 2).
WARNING
follow this warning may result in injury or death to personnel. In event of injury, seek
medical attention.
2. With axle housing (Figure 1, Item 1) blocked securely, lift differential (Figure 1, Item 5) into position on axle
housing, making sure holes are correctly aligned.
3. Install 12 new lockwashers (Figure 1, Item 3) and bolts (Figure 1, Item 2). Tighten capscrews gradually and
evenly around circumference of carrier flange to 150 to 175 lb-ft (203 to 237 Nm).
4. Install two planetaries (WP 0052) and axle shafts on front axle (WP 0051).
5. With drain plug hole in axle housing facing up, fill front axle with gear lubricant.
6. Install new O-ring on drain plug (Figure 1, Item 6) and install drain plug on axle housing (Figure 1, Item 7).
Tighten plug securely.
7. Install front axle (WP 0051).
END OF TASK
END OF WORK PACKAGE
0052-3/(4 blank)
6
TM 5-3805-255-14 0053
FIELD MAINTENANCE -
0 0 5 3 FRONT FINAL DRIVE/PLANETARY ASSEMBLY REPLACEMENT

INITIAL SETUP
0128, Item 20) 0
Axle Removal, Installation Tool (WP 0125,

Item 4) 0
Materials/Parts 0

Gasket 0
0004) 0
O-Ring 0
Planetary oil drained (WP 0018) 0
Stud, 1/2-13 N.C. 2 0

Front tire removed 0
Tubing, Steel, 36 in. Long, 0.50 in. I.D. 0

Wheels chocked 0
Washer, Sealing (8) 0
Two 0
REMOVAL 00053
WARNING
1. Clean exterior of front final drive/planetary assembly IAW General Maintenance Instructions (WP 0019).
2. Remove eight bolts (Figure 1, Item 1), planetary cover (Figure 1, Item 3), and gasket (Figure 1, Item 4) from
carrier assembly (Figure 1, Item 2). Discard gasket.
Figure 1. Planetary Cover Removal. 0053
0053-1
TM 5-3805-255-14 0053
3. Fabricate axle tool as shown in Figure 2.
Figure 2. Axle Tool. 0053
4. Thread axle removal tool into tapped pilot hole in axle shaft (Figure 3, Item 2). Remove axle shaft from axle
housing (Figure 3, Item 1).
Figure 3. Axle Removal. 0053
0053-2
TM 5-3805-255-14 0053
5. Remove four capscrews (Figure 4, Item 2) and planetary carrier (Figure 4, Item 3) from wheel hub (Figure 4,
Item 1).
Figure 4. Planetary Fastener Removal. 0053
WARNING
6. Use a suitable lifting device to remove planetary carrier assembly (Figure 5, Item 1) from front axle (Figure 5,
Item 2).
Figure 5. Planetary Carrier Removal. 0053
END OF TASK
0053-3
TM 5-3805-255-14 0053
INSTALLATION 00053
WARNING
1. Use a suitable lifting device to position planetary carrier assembly (Figure 6, Item 1) on front axle (Figure 6,
Item 2). As carrier is installed, planet gear teeth must mesh with ring gear teeth; large cut-out in carrier must be
aligned with cut-out in wheel hub.
2. Install planetary carrier (Figure 6, Item 3) and install four flat head capscrews (Figure 6, Item 2) on wheel hub
(Figure 6, Item 1). Torque capscrews to 80 to 90 lb-ft (108 to 122 Nm).
Figure 6. Planetary Fastener Installation. 0053
0053-4
TM 5-3805-255-14 0053
3. Thread axle tool into tapped pilot hole in axle shaft (Figure 7, Item 2). Install axle shaft in axle housing (Figure
7, Item 1).
Figure 7. Axle Installation. 0053
4. Carefully inspect thrust button (Figure 8, Item 1) in planetary cover (Figure 8, Item 2) for excessive wear.
Replace cover if required.
Figure 8. Thrust Button Inspection. 0053
0053-5
TM 5-3805-255-14 0053
5. Position new gasket (Figure 9, Item 4) on planetary cover (Figure 9, Item 3) being careful to align bolt holes.
6. Position cover (Figure 9, Item 3) and gasket (Figure 9, Item 4) assembly on carrier assembly (Figure 9, Item 2);
align bolt holes and install eight bolts (Figure 9, Item 1). Tighten bolts to 105 to 115 lb-ft (142 to 156 Nm).
Figure 9. Planetary Cover Installation. 0053
7. Fill planetary hub with recommended lubricant (WP 0018).

8. Install new O-ring (Figure 10, Item 3) on drain plug (Figure 10, Item 2) and install drain plug in hole. Tighten
drain plug to 35 lb-ft (47 Nm).
9. Check front axle fluid level and add gear lubricant as necessary (WP 0018).
10. Install front tire.
END OF TASK
END OF WORK PACKAGE
0053-6
4
TM 5-3805-255-14 0054
FIELD MAINTENANCE -
0REAR AXLE ASSEMBLY REPLACEMENT

0 5 4
INITIAL SETUP
0128, Item 20) 0

WP 0058 0
Torque Wrench, 2,500 lb-ft (WP 0128,

Item 21) 0
Materials/Parts 0
0004) 0
Two 0
Safety pins installed to lock loader halves in

References 0 straight-ahead position (WP 0005) 0
WP 0019 0
Front wheels chocked (WP 0005) 0
WARNING
0054-1
TM 5-3805-255-14 0054
REMOVAL 00054
1. Jack up vehicle under rear differential until wheels are free of floor. Support vehicle using suitable support
stands placed under main frame.
2. Remove two wheels from rear axle.
3. Remove propeller shaft from rear axle (WP 0049).
4. Disconnect two brake lines from rear axle (WP 0058).
5. Support rear axle at each end with a suitable support stand. Position suitable lifting device under differential
bowl of axle.
6. Remove eight bolts (Figure 1, Item 4), nuts (Figure 1, Item 1) and sixteen washers (Figure 1, Item 2) from axle
(Figure 1, Item 3) and bolster plate.
WARNING
equipment. Failure to follow this Warning may result in death or injury to personnel. In
event of injury, seek medical assistance.
7. Remove support stands from either end of rear axle. With assistance, lower rear axle on lifting device until it
clears underside of loader.
8. Remove rear axle from under loader.
Figure 1. Rear Axle. 0054
END OF TASK
0054-2
TM 5-3805-255-14 0054

Clean and inspect axle IAW General Maintenance Instructions (WP 0019).
END OF TASK
INSTALLATION
WARNING
equipment. Failure to follow this Warning may result in death or injury to personnel. In
event of injury, seek medical assistance.
1. Use a suitable lifting device to position axle on a suitable support stand placed under differential bowl.
2. With assistance, move rear axle under loader until it is in original mounting position. Support rear axle with a
suitable support stand placed under each end.
3. Install axle (Figure 1, Item 3), eight bolts (Figure 1, Item 4), sixteen washers (Figure 1, Item 2), and eight nuts
(Figure 1, Item 1) to bolster plate.
4. Remove lifting device and support stands. Tighten nuts to 3,500 lb-ft (4,745 Nm).
5. Install two brake lines on axle assembly (WP 0058).
6. Install propeller shaft on axle (WP 0049).
7. Install two wheel assemblies on axle.
8. Adjust brakes (WP 0058).
END OF TASK
END OF WORK PACKAGE
0054-3/(4 blank)
4
TM 5-3805-255-14 0055
FIELD MAINTENANCE -
REAR DIFFERENTIAL REPLACEMENT

0 0 5 5
INITIAL SETUP
0128, Item 20) 0

WP 0104 0
Torch, Acetylene 0
Materials/Parts 0
Oil, Lubricating, Gear, GO 80/90 (WP 0130, Parking brake applied (WP 0005) 0
Item 20) 0

Plastic Gasket 0
0004) 0
Lockwasher (12) 0
Rear axle removed (WP 0054) 0
O-Ring 0
Rear axle drained (WP 0018) 0
Two 0
WARNING
Failure to follow this Warning may result in death or injury to personnel.
0055-1
TM 5-3805-255-14 0055
REMOVAL 00055
1. Position rear axle (Figure 1, Item 1) so that input yoke (Figure 1, Item 4) is facing up.
2. Remove two planetaries (WP 0052) and axle shafts from rear axle (WP 00054).
3. Remove 12 bolts (Figure 1, Item 2) and lockwashers (Figure 1, Item 3) from rear axle (Figure 1, Item 1).
4. Attach suitable lifting device to differential assembly (Figure 1, Item 5), and remove differential assembly
(Figure 1, Item 5) from axle housing (Figure 1, Item 7). Refer to WP 0104 for rear differential overhaul.
Figure 1. Rear Differential Removal. 0055
END OF TASK
1. Clean and inspect rear differential assembly IAW General Maintenance Instructions (WP 0019).
2. Replace any worn, pitted, or damaged parts.
END OF TASK
0055-2
TM 5-3805-255-14 0055
INSTALLATION 00055
1. Be sure mating surfaces of differential carrier (Figure 1, Item 5) and axle housing (Figure 1, Item 7) are
absolutely clean and free of nicks or burrs.
NOTE
Follow manufacturer’s instructions for application and curing time for plastic gasket.
2. Coat differential mounting face of axle housing (Figure 1, Item 7) with plastic gasket. Apply a light coating of
plastic gasket to threads of 12 bolts (Figure 1, Item 2).
WARNING
medical attention.
3. With axle housing (Figure 1, Item 1) blocked securely, lift differential assembly (Figure 1, Item 5) into position
on axle housing making sure holes are correctly aligned.
4. Install 12 new lockwashers (Figure 1, Item 3) and bolts (Figure 1, Item 2) and tighten capscrews gradually and
evenly around circumference of carrier flange to 150 to 175 lb-ft (203 to 237 Nm).
5. Install two planetaries and axle shafts on rear axle (WP 0054).
6. With drain plug hole in axle housing facing up, fill rear axle with recommended amount of gear lubricant (WP
0016).
7. Install new O-ring on drain plug (Figure 1, Item 6) and install drain plug in axle housing (Figure 1, Item 1).
Tighten plug securely.
8. Install rear axle (WP 0054).
END OF TASK
END OF WORK PACKAGE
0055-3/(4 blank)
8
TM 5-3805-255-14 0056
FIELD MAINTENANCE -
0 0 5 6 REAR FINAL DRIVE/PLANETARY ASSEMBLY REPLACEMENT

INITIAL SETUP
0128, Item 20) 0

WP 0115 0
Axle Removal/Installation Tool (WP 0125,

Item 4) 0
Materials/Parts 0
Gasket 0

O-Ring 0
0004) 0
Stud, 1/2-13 N.C.2 0

Planetary oil drained (WP 0016) 0
Tubing, steel, 36 in. Long, 0-50 in. I.D. 0

Rear tire removed 0

Wheels chocked 0
Two 0
REMOVAL 00056
WARNING
1. Clean exterior of rear final drive/planetary assembly IAW General Maintenance Instructions (WP 0019).
2. Rotate planetary hub (Figure 1, Item 1) until drain filler plug (Figure 1, Item 2) is at bottom. Remove plug
(Figure 12) and drain lubricant into a suitable container. Remove O-ring (Figure 1, Item 3) from drain plug.
Discard O-ring.
Figure 1. Drain Plug Removal. 0056
0056-1
TM 5-3805-255-14 0056
3. Remove eight bolts (Figure 2, Item 1), planetary cover (Figure 2, Item 3), and gasket (Figure 2, Item 4) from
carrier assembly (Figure 2, Item 2). Discard gasket.
Figure 2. Planetary Cover Removal. 0056
4. Fabricate axle tool as shown in Figure 3.
Figure 3. Axle Tool. 0056
0056-2
TM 5-3805-255-14 0056
5. Thread axle tool into tapped pilot hole in axle shaft (Figure 4, Item 2). Remove axle shaft from axle housing
(Figure 4, Item 1).
Figure 4. Axle Removal. 0056
6. Remove four capscrews (Figure 5, Item 2) and planetary carrier (Figure 5, Item 3) from wheel hub (Figure 5,
Item 1).
Figure 5. Planetary Fastener Removal. 0056
0056-3
TM 5-3805-255-14 0056
WARNING
7. Use a suitable lifting device to remove planetary carrier assembly (Figure 6, Item 1) from rear axle (Figure 6,
Item 2).
Figure 6. Planetary Carrier Removal. 0056
8. For final drive/planetary assembly overhaul, refer to WP 0115.
END OF TASK
0056-4
TM 5-3805-255-14 0056
INSTALLATION 00056
WARNING
1. Use a suitable lifting device to position planetary carrier assembly (Figure 6, Item 1) on rear axle (Figure 6,
Item 2). As carrier is installed, planet gear teeth must mesh with ring gear teeth; large cut-out in carrier must be
in alignment with cut-out in wheel hub.
2. Install planetary carrier (Figure 7, Item 3) and install four capscrews (Figure 7, Item 2) on wheel hub (Figure 7,
Item 1). Torque capscrews to 80 to 90 lb-ft (108 to 122 Nm).
Figure 7. Planetary Fastener Installation. 0056
0056-5
TM 5-3805-255-14 0056
3. Thread axle tool into tapped pilot hole in axle shaft (Figure 8, Item 2). Install axle shaft in axle housing (Figure
8, Item 1).
Figure 8. Axle Installation. 0056
4. Carefully inspect thrust button (Figure 9, Item 1) in planetary cover (Figure 9, Item 2) for excessive wear.
Replace cover if required.
Figure 9. Thrust Button Inspection. 0056
5. Position new gasket (Figure 10, Item 4) on planetary cover (Figure 10, Item 3), being careful to align bolt holes.
6. Position cover (Figure 10, Item 3) and gasket (Figure 10, Item 4) assembly on carrier assembly (Figure 10,
Item 2); align bolt holes and install eight bolts (Figure 10, Item 1). Tighten bolts to 105 to 115 lb-ft (142 to
156 Nm).
0056-6
TM 5-3805-255-14 0056
Figure 10. Planetary Cover Installation. 0056
7. Fill planetary hub with recommended lubricant (WP 0018).

8. Install new O-ring (Figure 11, Item 3) on drain plug (Figure 11, Item 2) and install drain plug in hole. Tighten
drain plug to 35 lb-ft (47 Nm).
9. Check rear axle fluid level and add gear lubricant as necessary (WP 0018).
10. Install rear tire.
END OF TASK
END OF WORK PACKAGE
0056-7/(8 blank)
6
TM 5-3805-255-14 0057
FIELD MAINTENANCE -
PARKING BRAKE LINKAGE REPLACEMENT

0 0 5 7
INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

0004) 0
0130, Item 4) 0
Safety pins installed in full-turn lock position

(WP 0005) 0
Pin, Cotter (2) 0
Wheels chocked 0
References 0
WP 0019 0
0057-1
TM 5-3805-255-14 0057
REMOVAL 00057
WARNING
1. Remove cotter pin (Figure 1, Item 7) from clevis pin (Figure 1, Item 8). Discard cotter pin.
2. Remove clevis pin (Figure 1, Item 8) and cable end (Figure 1, Item 6) from brake actuating arm (Figure 1,
Item 9).
3. Remove control cable end (Figure 1, Item 6) and clevis nut (Figure 1, Item 5) from cable (Figure 1, Item 1).
4. Remove cable nut (Figure 1, Item 4) from cable (Figure 1, Item 1).
5. Remove cable (Figure 1, Item 1) from support bracket (Figure 1, Item 2).
6. Remove nut (Figure 1, Item 3) from cable (Figure 1, Item 1).
Figure 1. Parking Brake Linkage (Lower). 0057
0057-2
TM 5-3805-255-14 0057
7. Remove cotter pin (Figure 2, Item 6) and flat washer (Figure 2, Item 7) from pin (Figure 2, Item 8). Discard
cotter pin.
8. Remove pin (Figure 2, Item 8) and cable end (Figure 2, Item 9) from actuating arm (Figure 2, Item 5).
9. Remove two bolts (Figure 2, Item 1), washers (Figure 2, Item 2), and parking brake handle assembly (Figure 2,
Item 4) from sidewall of operator’s compartment (Figure 2, Item 3).
10. Remove nut (Figure 2, Item 17), plate (Figure 2, Item 10) and nut (Figure 2, Item 16) from cable (Figure 2,
Item 15).
11. Remove cable nut (Figure 2, Item 14) and cable (Figure 2, Item 15) through bracket (Figure 2, Item 13).
12. Remove nut (Figure 2, Item 11) and cable (Figure 2, Item 15) through floorboard (Figure 2, Item 12).
Figure 2. Parking Brake Linkage (Upper). 0057
END OF TASK
END OF TASK
0057-3
TM 5-3805-255-14 0057
INSTALLATION 00057
1. Install cable (Figure 3, Item 15) through floorboard (Figure 3, Item 12) and install nut (Figure 3, Item 11) on
cable. Install cable through bracket (Figure 3, Item 13) and install cable nut (Figure 3, Item 14).
2. Install nut (Figure 3, Item 16) and switch actuating plate (Figure 3, Item 10) on cable (Figure 3, Item 15).
3. Install clevis nut (Figure 3, Item 16) and cable end (Figure 3, Item 9) on cable (Figure 3, Item 14).
4. Install cable end (Figure 3, Item 9) on actuating arm (Figure 3, Item 5) and insert pin (Figure 3, Item 8).
5. Install flat washer (Figure 3, Item 7), and new cotter pin (Figure 3, Item 6) on pin (Figure 3, Item 8).
6. Install parking brake assembly (Figure 3, Item 4), two washers (Figure 3, Item 2), and bolts (Figure 3, Item 1)
on sidewall of operator’s compartment (Figure 3, Item 3).
7. Adjust top of brake handle counterclockwise to loosen cable prior to installation.
0057-4
TM 5-3805-255-14 0057
8. Install cable nut (Figure 4, Item 3) on cable (Figure 4, Item 1). Install cable (Figure 4, Item 1) through support
9. Install cable nut (Figure 4, Item 4) on cable (Figure 4, Item 1). Tighten two cable nuts.
10. Install clevis nut (Figure 4, Item 5) and cable end (Figure 4, Item 6) on cable (Figure 4, Item 1). Tighten clevis
nut.
11. Attach cable end (Figure 4, Item 6) to brake actuating arm (Figure 4, Item 9), aligning hole in arm with holes in
cable end. Install clevis pin (Figure 4, Item 8) through cable end and brake actuating arm.
12. Install new cotter pin (Figure 4, Item 7) on clevis pin (Figure 4, Item 8).
Figure 4. Parking Brake Linkage (Lower). 0057
END OF TASK
0057-5
TM 5-3805-255-14 0057
ADJUSTMENT 00057
1. Turn adjustable top of brake handle (Figure 5, Item 4) counterclockwise to loosen; clockwise to tighten brake
shoes.
2. Adjust nuts (Figure 5, Items 16 and 17) so actuating plate (Figure 5, Item 10) is not in contact with warning
lamp switch. Ensure plate is in contact with warning lamp switch when handle is in down position.
3. Tighten all nuts after adjustment is complete.
END OF TASK
END OF WORK PACKAGE
0057-6
10
TM 5-3805-255-14 0058
FIELD MAINTENANCE -
PARKING BRAKE ASSEMBLY REPLACEMENT

0 0 5 8
INITIAL SETUP
0128, Item 20) 0

WP 0048 0
Materials/Parts 0
Cleaning Compound, Solvent, Type III (WP Loader parked on level ground (WP 0005) 0
0130, Item 4) 0
0130, Item 15) 0

0004) 0
Locknut (5) 0
Safety pins installed in full-turn lock position

Lockwasher (4) 0
(WP 0005) 0
Parking brake linkage disconnected (WP

0057) 0
Wheels chocked 0
REMOVAL 00058
WARNING
Remove transmission-to-transfer drive propeller shaft (WP 0049).
END OF TASK
0058-1
TM 5-3805-255-14 0058
DISASSEMBLY 00058
1. Remove locknut (Figure 1, Item 5), retainer (Figure 1, Item 4), shim (Figure 1, Item 3), and yoke (Figure 1,
Item 2) from transfer drive shaft (Figure 1, Item 1). Discard locknut.
Figure 1. Yoke and Drum Assembly. 0058
2. Remove four bolts (Figure 2, Item 1), lockwashers (Figure 2, Item 2), and drum (Figure 2, Item 3) from yoke
(Figure 2, Item 4). Discard lockwashers.
Figure 2. Yoke and Drum Separation. 0058
0058-2
TM 5-3805-255-14 0058
DISASSEMBLY – CONTINUED
3. Remove brake springs (Figure 3, Item 1) from brake shoes (Figure 3, Item 2).
4. Remove brake shoes (Figure 3, Item 2) from backing plate (Figure 3, Item 3).
Figure 3. Brake Shoe. 0058
0058-3
TM 5-3805-255-14 0058
5. Remove operating cam lever (Figure 4, Item 3) and roller (Figure 4, Item 2) from pawls (Figure 4, Items 1
and 4).
Figure 4. Cam Lever. 0058
0058-4
TM 5-3805-255-14 0058
6. Remove four bolts (Figure 5, Item 4), lockwashers (Figure 5, Item 3), and backing plate (Figure 5, Item 2) from
transfer drive housing (Figure 5, Item 1). Discard lockwashers.
Figure 5. Backing Plate. 0058
END OF TASK
2. Inspect brake shoes for wear. Replace if worn.
3. Inspect drum for wear. Replace if worn.
4. Lubricate actuating parts of brake (operating cam lever, roller, pawls).
END OF TASK
0058-5
TM 5-3805-255-14 0058
ASSEMBLY 00058
1. Install backing plate (Figure 6, Item 2) on transfer drive housing (Figure 6, Item 1) and secure with four new
lockwashers (Figure 6, Item 3) and bolts (Figure 6, Item 4). Tighten bolts to 53 to 60 lb-ft (71.8 to 81.3 Nm).
Figure 6. Backing Plate. 0058
2. Install roller (Figure 7, Item 2). Install operating cam lever (Figure 7, Item 3) on pawls (Figure 7, Items 1 and 4).
Figure 7. Cam Lever. 0058
0058-6
TM 5-3805-255-14 0058
3. Install brake shoes (Figure 8, Item 2) on backing plate (Figure 8, Item 3).
4. Install brake springs (Figure 8, Item 1) on brake shoes (Figure 8, Item 2). Be sure springs are installed in rear
holes of brake shoes.
Figure 8. Brake Shoe. 0058
5. Install yoke (Figure 9, Item 4) in drum (Figure 9, Item 3) and install four bolts (Figure 9, Item 1) and new
lockwashers (Figure 9, Item 2). Tighten bolts to 36 lb-ft (48.8 Nm).
Figure 9. Drum Assembly. 0058
0058-7
TM 5-3805-255-14 0058
6. Install yoke and drum assembly (Figure 10, Item 2) on transfer drive propeller shaft (Figure 10, Item 1). Install
shim (Figure 10, Item 3), retainer (Figure 10, Item 4), and new locknut (Figure 10, Item 5) on shaft. Tighten
locknut to 200 lb-ft (271.2 Nm).
Figure 10. Yoke and Drum Assembly. 0058
END OF TASK
0058-8
TM 5-3805-255-14 0058
INSTALLATION 00058
1. Connect transmission-to-transfer drive propeller shaft (Figure 11, Item 1) to transfer drive yoke (Figure 11,
Item 3). Install bolts (Figure 11, Item 2) and tighten to 177 lb-ft (240 Nm)
NOTE
Ensure adjustable top of brake handle is fully counterclockwise prior to connecting
linkage.
2. Connect parking brake linkage (WP 0057).
3. Adjust parking brake linkage (WP 0057).
Figure 11. Transmission to Transfer Drive. 0058
END OF TASK
END OF WORK PACKAGE
0058-9/(10 blank)
20
TM 5-3805-255-14 0059
FIELD MAINTENANCE -
SERVICE BRAKES REPLACEMENT/REPAIR

0 0 5 9
Removal, Disassembly, Cleaning and Inspection, Brake Relining, Brake Line Removal, Brake Line
Installation, Assembly, Installation, Adjustment, Bleeding Hydraulic Brake Circuit
INITIAL SETUP
0128, Item 20) 0
References 0
Materials/Parts 0
WP 0013 0
Fluid, Brake, Silicone, BFS (WP 0130, Item WP 0019 0
11) 0
Grease, Automotive and Artillery (GAA) (WP Equipment Condition 0
0130, Item 15) 0 Wheel removed (WP 0066) 0
Rag, Wiping (WP 0130, Item 28) 0 Planetary hub assembly removed (WP 0053
Lining (4) 0
or WP 0056) 0
Lockwasher (15) 0
Safety bar installed and wheels chocked
O-Ring 0
(WP 0005) 0
Plug 0
Retaining Ring 0
NOTE
This work package describes procedures and materials/parts for one wheel. Other wheels
are identical
0059-1
TM 5-3805-255-14 0059
REMOVAL 00059
1. Disconnect hydraulic line (Figure 1, Item 4) from wheel cylinder (Figure 1, Item 2).
NOTE
Identify orientation of bolts for ease of installation.
2. Remove 15 bolts (Figure 1, Item 7), locknuts (Figure 1, Item 5), washers (Figure 1, Item 6), and spider
(Figure 1, Item 8) from axle.
Figure 1. Spider Assembly. 0059
END OF TASK
DISASSEMBLY 00059
1. Remove bleeder screw (Figure 1, Item 3) from wheel cylinder (Figure 1, Item 2).
2. Remove lockplug (Figure 1, Item 1) from wheel cylinder (Figure 1, Item 2).
3. Unscrew wheel cylinder (Figure 1, Item 2) from spider (Figure 1, Item 8).
0059-2
TM 5-3805-255-14 0059
4. Remove piston (Figure 2, Item 5) from cylinder (Figure 2, Item 1).
5. Remove cup (Figure 2, Item 4), plug (Figure 2, Item 3), and spring (Figure 2, Item 2) from cylinder (Figure 2,
Item 1).
6. Remove O-ring (Figure 2, Item 6) from piston (Figure 2, Item 5). Discard O-ring.
Figure 2. Wheel Cylinder. 0059
7. Remove wedge and roller assembly (Figure 3, Item 2) from brake spider (Figure 3, Item 1).
Figure 3. Wedge and Roller Removal. 0059
0059-3
TM 5-3805-255-14 0059
8. Compress spring (Figure 4, Item 4) and remove retaining ring (Figure 4, Item 6) and flat washer (Figure 4,
Item 5).
9. Slide spring (Figure 4, Item 4) and washer (Figure 4, Item 3) off cage (Figure 4, Item 2).
10. Remove rollers (Figure 4, Item 7) from cage (Figure 4, Item 2) and slide wedge (Figure 4, Item 1) out of cage.
Figure 4. Wedge and Roller Disassembly. 0059
0059-4
TM 5-3805-255-14 0059
11. Remove brake shoe return spring (Figure 5, Item 1) from shoes (Figure 5, Item 7).
12. Remove retaining springs (Figure 5, Item 2) from anchor pins (Figure 5, Item 5).
13. Remove felt retainer (Figure 5, Item 3) and felt (Figure 5, Item 4) from two anchor pins (Figure 5, Item 5).
14. Slide anchor pins (Figure 5, Item 5) out of spider (Figure 5, Item 6) and shoes (Figure 5, Item 7). Remove
shoes from spider.
Figure 5. Brake Shoe Disassembly. 0059
0059-5
TM 5-3805-255-14 0059
15. Bend back lock (Figure 6, Item 2) and remove bolt (Figure 6, Item 1).
16. Remove lock (Figure 6, Item 2) and detent (Figure 6, Item 3).
17. Remove adjustment bolt (Figure 6, Item 7) from plunger (Figure 6, Item 5).
18. Remove seal (Figure 6, Item 6) and plunger (Figure 6, Item 5) from plunger housing (Figure 6, Item 4).
Figure 6. Plunger Disassembly. 0059
END OF TASK
2. Inspect wheel cylinder cup and plug for signs of wear or cracking. Replace if necessary.
3. Inspect wheel cylinder for scoring or damage. Replace if necessary.
4. Inspect parts of wedge and roller assembly and plunger assembly for signs of wear or damage. Replace if
necessary.
5. Inspect plunger seal. Replace if necessary.
6. Inspect anchor pins for wear or misalignment. Inspect brake shoes for wear at anchor pin holes. Replace if
necessary.
END OF TASK
0059-6
TM 5-3805-255-14 0059
BRAKE RELINING 00059
1. Remove rivets (Figure 7, Item 1) and linings (Figure 7, Item 2) from shoes (Figure 7, Item 3). Discard rivets.
NOTE
Lining and shoe contact faces should be clean before assembling. Rivets of the correct
size and shape must be used.
2. Clamp new lining (Figure 7, Item 2) to shoes (Figure 7, Item 3) so rivet holes in both pieces are aligned.
Figure 7. Brake Relining. 0059
3. Install rivets in sequence shown in Figure 8.
Figure 8. Rivet Installation Sequence. 0059
4. Check lining installation with a 0.002-in. feeler gauge to assure proper lining and shoe contact.
END OF TASK
0059-7
TM 5-3805-255-14 0059
BRAKE LINE REMOVAL 00059
Front 00059
NOTE
• This procedure covers one front brake line. Brake line on opposite side of loader is
serviced in similar manner.
• Place a suitable drain pan under the component before disconnecting brake line.
1. Loosen fitting (Figure 9, Item 1) and disconnect brake line (Figure 9, Item 2) from wheel cylinder (Figure 9,
Item 3).
Figure 9. Brake Line at Wheel Cylinder. 0059
0059-8
TM 5-3805-255-14 0059
BRAKE LINE REMOVAL – CONTINUED

Front - Continued 00059
2. Locate opposite end of brake line being removed at power cluster (Figure 10, Item 1). Loosen fitting
(Figure 10, Item 2) and disconnect brake line (Figure 10, Item 3) at power cluster.
3. Remove brake line (Figure 10, Item 3) from loader.
Figure 10. Brake Line at Power Cluster. 0059
0059-9
TM 5-3805-255-14 0059

Rear 00059
NOTE
• This procedure covers one rear brake line. Brake line on opposite side of loader is
serviced in similar manner.
• Place a suitable drain pan under the component before disconnecting brake line.
1. Loosen fitting (Figure 11, Item 1) and disconnect brake line (Figure 11, Item 2) from wheel cylinder (Figure 11,
Item 3).
Figure 11. Brake Line at Wheel Cylinder. 0059
0059-10
TM 5-3805-255-14 0059

Rear – Continued 00059
2. Locate opposite end of brake line being removed at T-fitting (Figure 12, Item 2). Loosen fitting (Figure 12,
Item 1) and disconnect brake line (Figure 12, Item 3) from T-fitting.
Figure 12. Brake Line at T-Fitting. 0059
END OF TASK
0059-11
TM 5-3805-255-14 0059
BRAKE LINE INSTALLATION 00059
Front 00059
1. Install brake line (Figure 13, Item 3) in loader.

2. Connect brake line (Figure 13, Item 3) to power cluster (Figure 13, Item 1). Tighten fitting (Figure 13, Item 2).
Figure 13. Brake Line at Power Cluster.

3. Connect brake line (Figure 14, Item 2) to wheel cylinder (Figure 14, Item 3). Tighten fitting (Figure 14, Item 1).
Figure 14. Brake Line at Wheel Cylinder.
0059-12
TM 5-3805-255-14 0059
BRAKE LINE INSTALLATION – CONTINUED

Rear 00059
1. Connect brake line (Figure 15, Item 3) to T-fitting (Figure 15, Item 2). Tighten fitting (Figure 15, Item 1).
Figure 15. Brake Line at T-Fitting. 0059
2. Connect brake line (Figure 14, Item 2) to wheel cylinder (Figure 14, Item 3). Tighten fitting (Figure 14, Item 1).
3. Bleed brakes. See Bleeding Hydraulic Brake Circuit in this work package.
END OF TASK
0059-13
TM 5-3805-255-14 0059
ASSEMBLY 00059
NOTE
Lubricate internal actuating parts of brake assembly (wedge assembly, guide screws,
plunger, and actuator cavity) with GAA before assembly.
1. Install seal (Figure 16, Item 6) on plunger (Figure 16, Item 5) until seal lip enters groove in plunger. Slide
plunger into housing (Figure 16, Item 4), aligning groove in plunger with guide screw hole in housing. Seat seal
on housing.
2. Place detent (Figure 16, Item 3), lock (Figure 16, Item 2), and bolt (Figure 16, Item 1) on housing (Figure 16,
Item 4).
3. Tighten bolt (Figure 16, Item 1) and bend lock (Figure 16, Item 2) against bolt.
4. Screw adjustment bolt (Figure 16, Item 7) into plunger (Figure 16, Item 5).
Figure 16. Plunger Assembly. 0059
0059-14
TM 5-3805-255-14 0059
5. Install felt (Figure 17, Item 4) and felt retainer (Figure 17, Item 3) on anchor pins (Figure 17, Item 5).
6. Install shoes (Figure 17, Item 7) and anchor pins (Figure 17, Item 5) on spider (Figure 17, Item 6).
7. Install retaining springs (Figure 17, Item 2) on anchor pins (Figure 17, Item 5).
8. Install brake shoe return spring (Figure 17, Item 1) on shoes (Figure 17, Item 7).
Figure 17. Brake Shoe Assembly. 0059
0059-15
TM 5-3805-255-14 0059
9. Insert wedge (Figure 18, Item 1) into cage (Figure 18, Item 2) and install rollers (Figure 18, Item 7) in cage.
10. Install washer (Figure 18, Item 3), spring (Figure 18, Item 4), and flat washer (Figure 18, Item 5) on cage
11. Install spring (Figure 18, Item 4) and retaining ring (Figure 18, Item 6) on wedge (Figure 18, Item 1).
Figure 18. Wedge and Roller Assembly. 0059
12. Install wedge and roller assembly (Figure 19, Item 2) in brake spider (Figure 19, Item 1). Be certain that rollers
enter slots in plunger (Figure 16, Item 5).
Figure 19. Wedge and Roller Installation. 0059
0059-16
TM 5-3805-255-14 0059
13. Install new O-ring (Figure 20, Item 6) on piston (Figure 20, Item 5).
NOTE
Dip wheel cylinder cup, piston, and piston seal ring in brake fluid before assembly.
14. Install cup (Figure 20, Item 4) on piston (Figure 20, Item 5).
15. Slide spring (Figure 20, Item 2), plug (Figure 20, Item 3), cup (Figure 20, Item 4), and piston (Figure 20, Item 5)
into cylinder (Figure 20, Item 1).
Figure 20. Wheel Cylinder Assembly. 0059
0059-17
TM 5-3805-255-14 0059
CAUTION
Do not over-tighten cylinder housing. Failure to comply may result in damage to
equipment.
NOTE
If bleeder and brake line holes are not in desired position, unscrew cylinder to align as
desired. This will require less than one full turn.
16. Install wheel cylinder (Figure 21, Item 2) in spider (Figure 21, Item 8).
17. Install lockplug (Figure 21, Item 1) and torque to 175 to 200 lb-in. (19.8 to 22.6 Nm). Loosen lockplug and
torque to 50 lb-in. (5.6 Nm).
18. Install bleeder screw (Figure 21, Item 3) and connect hydraulic line (Figure 21, Item 4) to wheel cylinder
END OF TASK
0059-18
TM 5-3805-255-14 0059
INSTALLATION 00059
1. Install spider (Figure 21, Item 8), 15 washers (Figure 21, Item 6), bolts (Figure 21, Item 7), and new locknuts
(Figure 21, Item 5) on axle.
Figure 21. Spider Assembly. 0059
2. Install planetary hub assembly (WP 0053 or WP 0056).

3. Install wheel (WP 0066).
4. Adjust brake lining to drum clearance.
5. Bleed hydraulic brake circuit. See Bleeding Hydraulic Brake Circuit in this work package.
END OF TASK
ADJUSTMENT 00059
WARNING
Align frame halves and install safety bar with wheels in straight-ahead position. Failure to
follow this warning may result in serious injury or death to personnel.
1. Use a suitable lifting device to raise loader until wheel is clear of ground. Use a suitable supporting device to
support loader.
2. While rotating wheel, rotate star wheel until brake lining drags on drum or rotate star wheel in opposite direc-
tion until drag is relieved.
3. Lift loader, remove supporting device, lower loader to ground. Remove lifting device.
END OF TASK
0059-19
TM 5-3805-255-14 0059
BLEEDING HYDRAULIC BRAKE CIRCUIT
WARNING
Ensure wheels are chocked to prevent loader from moving. Failure to follow this warning
may result in death or injury to personnel.
NOTE
The hydraulic portion of each power cluster and wheel brake assembly must be bled when
it is suspected that air is present in brake fluid.
Manually bleed hydraulic lines of a power cluster as described below:
a. Start engine to charge compressed air portion of brake system. Shut down engine (WP 0005).
WARNING
Contact with engine/hydraulic oil can damage skin. Wear gloves when handling engine/hydraulic oil.
If oil contacts skin, wash it off immediately. Failure to follow this warning may cause injury to
personnel.
b. Remove hydraulic cylinder fill cap and fill power cluster reservoir (WP 0013) with brake fluid. Ensure
reservoir remains full during entire bleeding operation.
c. Attach a bleeder hose to bleeder screw at power cluster. Submerge opposite end of hose in a suitable
container partially filled with brake fluid.
NOTE
If a bleeder hose is not used, close bleeder screw each time before releasing treadle
valve.
d. Open bleeder screw one turn and slowly apply treadle valve. Make additional treadle applications until no
bubbles escape from bleeder hose.
e. Close bleeder screw and remove bleeder hose from bleeder screw.
f. Attach a bleeder hose to bleeder screw at wheel cylinder. Submerge opposite end of hose in a suitable
container partially filled with brake fluid.
NOTE
If a bleeder hose is not used, close bleeder screw each time before releasing treadle
valve.
g. Open bleeder screw one turn and slowly apply treadle valve. Make additional treadle applications until no
bubbles escape from bleeder hose.
h. Bleed hydraulic cylinders on each wheel until brake pedal is firm.
i. Fill cylinder reservoir to within 0.50 in. to 0.375 in. (12.7 to 9.5 mm) of fill hole.
j. Install hydraulic cylinder fill cap.
END OF TASK
END OF WORK PACKAGE
0059-20
14
TM 5-3805-255-14 0060
FIELD MAINTENANCE -
POWER CLUSTER ASSEMBLIES REPLACEMENT/REPAIR

0 0 6 0
INITIAL SETUP
0128, Item 20) 0

WP 0021 0
Materials/Parts 0
WP 0059 0
(WP 0130, Item 3) 0
Cleaning Compound, Solvent, Type III (WP Parking brake applied (WP 0005) 0
0130, Item 4) 0
Fluid, Brake, Silicone, BFS (WP 0130, Item

11) 0
0004) 0
Isopropyl Alcohol, USP (WP 0130, Item 16) 0
Wheels chocked 0
Air reservoir drained (WP 0010) 0
Lockwasher (12) 0
0060-1
TM 5-3805-255-14 0060
REMOVAL 00060
WARNING
CAUTION
Cap air and hydraulic tubes to prevent contamination. Failure to follow this caution may
1. Disconnect air tube (Figure 1, Item 1) and hydraulic tube (Figure 1, Item 7) from power cluster (Figure 1,
Item 2).
2. Remove two nuts (Figure 1, Item 3), lockwashers (Figure 1, Item 4), and power cluster (Figure 1, Item 2) from
frame (Figure 1, Item 8). Discard lockwashers.
3. If left power cluster (Figure 1, Item 2) is being removed, remove stop light switch wires (Figure 1, Item 5) from
stop light switch (Figure 1, Item 6).
Figure 1. Power Cluster Lines. 060
END OF TASK
0060-2
TM 5-3805-255-14 0060
DISASSEMBLY 00060
1. Clean exterior of power cluster (Figure 2, Item 2).
WARNING
• When servicing this equipment, performing maintenance, or disposing of materials such

as engine/hydraulic oils, coolant, and fuel, consult your unit/local hazardous waste
disposal center or safety office for local regulatory guidance.
• Engine/hydraulic oils, coolant, and fuel can be very slippery. Immediately wipe up any
spills. Failure to follow this warning may result in injury to personnel.
NOTE
Place a suitable container under hydraulic cylinder.
2. Remove hydraulic cylinder filler cap (Figure 2, Item 1) and drain brake fluid.
0060-3
TM 5-3805-255-14 0060
3. Remove hydraulic cylinder (Figure 3, Item 1) from bracket (Figure 3, Item 2).
Figure 3. Hydraulic Cylinder. 060
NOTE
Late model units are equipped with an indicator rod which is installed in place of the lower
right-hand bolt. Also, an external breather replaces the filter screen just below the lower
left-hand bolt.
4. Remove four bolts (Figure 4, Item 1), lockwashers (Figure 4, Item 2), and bracket (Figure 4, Item 4) from air
cylinder (Figure 4, Item 3). Discard lockwashers.
0060-4
TM 5-3805-255-14 0060
5. Remove six bolts (Figure 5, Item 5), lockwashers (Figure 5, Item 4), air cylinder shell (Figure 5, Item 1), and
piston return spring (Figure 5, Item 2) from head (Figure 5, Item 3). Discard lockwashers.
6. Remove indicator rod and return spring, and unscrew breather from face of head, if equipped.
Figure 5. Return Spring. 060
7. Remove piston and rod assembly (Figure 6, Item 2) from air cylinder shell (Figure 6, Item 1).
Figure 6. Air Cylinder. 060
0060-5
TM 5-3805-255-14 0060
8. Remove air cylinder piston cup (Figure 7, Item 2) and wiper (Figure 7, Item 3) from piston (Figure 7, Item 1).
Figure 7. Piston Cup. 060
9. Separate piston rod boot (Figure 7, Item 2) from hydraulic cylinder (Figure 7, Item 1).
Figure 8. Rod Boot. 060
0060-6
TM 5-3805-255-14 0060
10. Remove snap ring (Figure 9, Item 7) from hydraulic cylinder (Figure 9, Item 1).
11. Slide piston stop plate (Figure 9, Item 6), piston (Figure 9, Item 5), primary cup (Figure 9, Item 4), and piston
return spring (Figure 9, Item 3) out of hydraulic cylinder (Figure 9, Item 1).
12. Remove check valve (Figure 9, Item 2) from return spring (Figure 9, Item 3).
Figure 9. Hydraulic Cylinder Disassembly. 060
13. Remove secondary cup (Figure 10, Item 1) from piston (Figure 10, Item 2).
Figure 10. Piston. 060
0060-7
TM 5-3805-255-14 0060
14. Separate check valve and seat (Figure 11, Item 1) and spring (Figure 11, Item 2) from valve retainer (Figure 11,
Item 3).
Figure 11. Check Valve. 060
END OF TASK
2. Inspect air cylinder piston cup and felt for wear or deterioration. Replace worn parts as necessary.
3. Inspect hydraulic cylinder bore for scratches or wear. Replace if necessary. Clean compensating port (smaller
hole in bottom of reservoir).
4. Check filler cap gasket for wear and replace if necessary.
END OF TASK
ASSEMBLY 00060
NOTE
Before assembling hydraulic cylinder parts, coat with hydraulic brake fluid (WP 0018).
1. Install spring (Figure 11, Item 2) and check valve and seat (Figure 11, Item 1) in valve retainer (Figure 11,
Item 3).
0060-8
TM 5-3805-255-14 0060
2. Attach secondary cup (Figure 12, Item 1) to piston (Figure 12, Item 2).
3. Install check valve (Figure 13, Item 2) on return spring (Figure 13, Item 3).
4. Install primary cup (Figure 13, Item 4), piston (Figure 13, Item 5), and piston stop plate (Figure 13, Item 6) in
hydraulic cylinder (Figure 13, Item 1).
5. Install snap ring (Figure 13, Item 7) on hydraulic cylinder (Figure 13, Item 1).
Figure 13. Hydraulic Cylinder Assembly. 060
0060-9
TM 5-3805-255-14 0060
6. Install piston rod boot (Figure 14, Item 2) on hydraulic cylinder (Figure 14, Item 1).
Figure 14. Rod Boot. 060
7. Lubricate air cylinder piston cup (Figure 15, Item 2) and wiper (Figure 15, Item 3) with brake fluid and install on
piston (Figure 15, Item 1).
Figure 15. Piston Cup. 060
0060-10
TM 5-3805-255-14 0060
8. Install piston and rod assembly (Figure 16, Item 2) in air cylinder shell (Figure 16, Item 1).
Figure 16. Air Cylinder. 060
9. Install piston return spring (Figure 17, Item 2) and head (Figure 17, Item 3) in air cylinder shell (Figure 17,
Item 1).
10. Install six new lockwashers (Figure 17, Item 4) and bolts (Figure 17, Item 5) on air cylinder shell (Figure 17,
Item 1).
Figure 17. Return Spring. 060
0060-11
TM 5-3805-255-14 0060
NOTE
Late model units are equipped with an indicator rod which is installed in place of the lower
right-hand bolt. Also, an external breather replaces the filter screen just below the lower
left-hand bolt.
11. Install bracket (Figure 18, Item 4), four new lockwashers (Figure 18, Item 2), and bolts (Figure 18, Item 1) on
air cylinder (Figure 18, Item 3).
12. Install hydraulic cylinder (Figure 19, Item 1) on bracket (Figure 19, Item 2). Be certain plunger on air cylinder
fits in metal grommet in boot on hydraulic cylinder.
Figure 19. Hydraulic Cylinder. 060
0060-12
TM 5-3805-255-14 0060
13. Install hydraulic cylinder filler cap (Figure 20, Item 1) on power cluster (Figure 20, Item 2).
END OF TASK
INSTALLATION 00060
1. Install power cluster (Figure 21, Item 2), two new lockwashers (Figure 21, Item 4), and nuts (Figure 21, Item 3)
on frame (Figure 21, Item 8).
2. Connect air tube (Figure 21, Item 1) and hydraulic tube (Figure 21, Item 7) to power cluster (Figure 21, Item 2).
3. If left power cluster (Figure 21, Item 2) was removed, install stop light switch wires (Figure 21, Item 5) on stop
light switch (Figure 21, Item 6).
4. Fill power cluster reservoir with brake fluid and bleed hydraulic circuit (WP 0059).
Figure 21. Power Cluster Lines. 060
END OF TASK
END OF WORK PACKAGE
0060-13/(14 blank)
18
TM 5-3805-255-14 0061
FIELD MAINTENANCE -
TREADLE VALVES REPAIR

0 0 6 1
INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0
0130, Item 4) 0
Lubriplate Lubricating Fluid (WP 0130, Item Battery disconnect switch in OFF position
17) 0
(WP 0004) 0
Wheels chocked 0
Cotter Pin (2) 0
Lockwasher (10) 0
O-Ring (6) 0
Packing 0
Seal (5) 0
0061-1
TM 5-3805-255-14 0061
REMOVAL 00061
WARNING
NOTE
The following instructions are applicable for both left and right treadle valves.
1. Remove cotter pin (Figure 1, Item 1) from pin (Figure 1, Item 3). Discard cotter pin.
2. Remove pin (Figure 1, Item 3) and treadle (Figure 1, Item 2) from mounting plate (Figure 1, Item 4) and treadle
valve (Figure 1, Item 5).
Figure 1. Treadle. 0061
0061-2
TM 5-3805-255-14 0061
3. Remove cotter pin (Figure 2, Item 1) from roller pin (Figure 2, Item 4). Discard cotter pin.
4. Remove roller pin (Figure 2, Item 4) and roller (Figure 2, Item 2) from treadle (Figure 2, Item 3).
Figure 2. Roller.
0061-3
TM 5-3805-255-14 0061
NOTE
Left treadle valve is not repairable and must be replaced if worn or damaged. Right treadle
valve is repairable. Tag and identify all hoses and tubes for ease of installation.
Left Treadle Valve 00061
1. Disconnect hoses (Figure 3, Items 1 and 3) from left check valve (Figure 3, Item 2).
2. Remove left check valve (Figure 3, Item 2) from elbow (Figure 3, Item 18).
3. Disconnect tube (Figure 3, Item 4) from elbow (Figure 3, Item 5).
4. Disconnect tubes (Figure 3, Items 10 and 11) from tees (Figure 3, Items 13 and 12).
5. Disconnect hoses (Figure 3, Items 14 and 15) from tees (Figure 3, Items 12 and 13)
8. Remove elbows (Figure 3, Items 5, 17, 18, and 19) from treadle valve (Figure 3, Item 9).
9. Remove tees (Figure 3, Items 12 and 13) from treadle valve (Figure 3, Item 9).
10. Remove three bolts (Figure 3, Item 6), nuts (Figure 3, Item 7), lockwashers (Figure 3, Item 8), and treadle
valve (Figure 3, Item 9) from floorboard (Figure 3, Item 21). Discard lockwashers.
Figure 3. Left Treadle Valve. 0061
0061-4
TM 5-3805-255-14 0061
Right Treadle Valve 00061
1. Disconnect hoses (Figure 4, Items 2 and 3) from check valve (Figure 16, Item 1).
2. Remove right check valve (Figure 4, Item 1) from fitting (Figure 16, Item 14).
4. Disconnect hoses (Figure 4, Items 8 and 10) from elbows (Figure 16, Items 9 and 11).
5. Disconnect hose (Figure 4, Item 7) from elbow (Figure 16, Item 6).
6. Disconnect tube (Figure 4, Item 13) from fitting (Figure 16, Item 12).
7. Remove elbows (Figure 4, Items 5, 6, and 9) from treadle valve (Figure 16, Item 15).
8. Remove fittings (Figure 4, Items 12 and 14) from treadle valve (Figure 16, Item 15).
9. Remove three bolts (Figure 4, Item 16), nuts (Figure 4, Item 17), lockwashers (Figure 4, Item 18), and treadle
valve (Figure 4, Item 15) from floorboard (Figure 4, Item 19). Discard lockwashers.
H100C-0902
Figure 4. Right Treadle Valve. 0061
END OF TASK
0061-5
TM 5-3805-255-14 0061
DISASSEMBLY 00061
1. Remove rubber boot (Figure 5, Item 1) from plunger (Figure 5, Item 7) and mounting plate (Figure 5, Item 4).
2. Remove treadle stop nut (Figure 5, Item 2) and set screw (Figure 5, Item 3) from mounting plate (Figure 5,
Item 4).
3. Remove plunger (Figure 5, Item 7) from mounting plate (Figure 5, Item 4).
NOTE
Place an alignment mark on mounting plate and body for ease of assembly.
4. Remove three screws (Figure 5, Item 6) and mounting plate (Figure 5, Item 4) from body (Figure 5, Item 5).
Figure 5. Plunger. 0061
0061-6
TM 5-3805-255-14 0061
5. Depress primary piston assembly (Figure 6, Item 3) and remove retaining ring (Figure 6, Item 4). Remove
piston assembly and spring (Figure 6, Item 2) from upper body (Figure 6, Item 1).
6. Remove retaining ring (Figure 7, Item 5), spring retainer (Figure 7, Item 4), and spring (Figure 7, Item 3) from
7. Remove O-ring (Figure 7, Item 2) from piston (Figure 7, Item 1). Discard O-ring.
Figure 7. Piston Spring. 0061
0061-7
TM 5-3805-255-14 0061
NOTE
Place an alignment mark on upper and lower body for ease of assembly.
8. Remove four bolts (Figure 8, Item 1), lockwashers (Figure 8, Item 2), and upper valve body (Figure 8, Item 4)
from cover (Figure 8, Item 3) and lower valve body (Figure 8, Item 7). Discard lockwashers.
9. Remove push rod (Figure 8, Item 5) and push rod guide (Figure 8, Item 6) from upper valve body (Figure 8,
Item 4).
Figure 8. Push Rod. 0061
10. Remove primary inlet valve guide (Figure 9, Item 6) from upper valve body (Figure 9, Item 1). Remove seals
(Figure 9, Items 5 and 7) from valve guide. Discard seals.
11. Separate primary inlet spring (Figure 9, Item 4) and valve (Figure 9, Item 2). Remove seal, (Figure 9, Item 3)
from valve. Discard seal.
Figure 9. Valves. 0061
0061-8
TM 5-3805-255-14 0061
NOTE
Place an alignment mark on valve body and cover for ease of assembly.
12. Remove cover (Figure 10, Item 1) from lower valve body (Figure 10, Item 7). Remove seal (Figure 10, Item 2)
from cover (Figure 10, Item 1). Discard seal.
13. Remove secondary piston (Figure 10, Item 5) from lower valve body (Figure 10, Item 7). Remove O-rings
(Figure 10, Items 4 and 3) from piston. Remove spring (Figure 10, Item 6) from lower valve body. Discard
O-rings.
14. Remove retaining ring (Figure 10, Item 10), exhaust shield (Figure 10, Item 9), and inlet and exhaust valve
assembly (Figure 10, Item 8) from lower valve body (Figure 10, Item 7).
Figure 10. Cover. 0061
0061-9
TM 5-3805-255-14 0061
15. Remove inlet valve (Figure 11, Item 6), spring (Figure 11, Item 5), valve guide (Figure 11, Item 4), and seal
(Figure 11, Item 3) from shield retainer (Figure 11, Item 1). Discard seal.
16. Remove packing (Figure 11, Item 2) from retainer (Figure 11, Item 1). Discard packing.
Figure 11. Packing.
END OF TASK
0061-10
TM 5-3805-255-14 0061
2. Inspect right treadle valve seats for nicks and burrs; replace if worn.
3. Check right treadle valve springs for cracks or distortion; replace if worn.
4. Check right treadle valve exhaust valve diaphragm; replace if worn or deteriorated.
END OF TASK
ASSEMBLY 00061
NOTE
Lightly lubricate piston, valve bores, and O-rings with lubricant.
1. Install new packing (Figure 12, Item 2) on shield retainer (Figure 12, Item 1).
2. Install inlet valve (Figure 12, Item 6), spring (Figure 12, Item 5), valve guide (Figure 12, Item 4), and new seal
(Figure 12, Item 3) on shield retainer (Figure 12, Item 1).
3. Install new seal (Figure 12, Item 2) on cover (Figure 12, Item 1). Install cover on lower valve body. (Figure 12,
Item 7).
4. Install new O-rings (Figure 12, Items 4 and 3) on secondary piston (Figure 12, Item 5).
5. Install spring (Figure 12, Item 6) and secondary piston (Figure 12, Item 5) in lower valve body (Figure 12,
Item 7).
6. Install inlet and exhaust valve assembly (Figure 12, Item 8), exhaust shield (Figure 12, Item 9), and retaining
ring (Figure 12, Item 10) on lower valve body (Figure 12, Item 7).
Figure 12. Cover. 0061
0061-11
TM 5-3805-255-14 0061
7. Install new seal (Figure 13, Item 3) on valve (Figure 13, Item 2). Install primary inlet spring (Figure 13, Item 4)
on valve.
8. Install new seals (Figure 13, Items 5 and 7) on primary inlet valve guide (Figure 13, Item 6). Install primary inlet
valve guide in upper valve body (Figure 13, Item 1).
Figure 13. Valves. 0061
9. Install push rod guide (Figure 14, Item 6) and push rod (Figure 14, Item 5) in upper valve body (Figure 14,
Item 4).
10. Align previously made marks and install lower valve body (Figure 14, Item 7) on cover (Figure 14, Item 3) and
upper valve body (Figure 14, Item 4). Install four new lockwashers Figure 14, Item 2) and bolts (Figure 14,
Item 1).
Figure 14. Push Rod. 0061
11. Install new O-ring (Figure 15, Item 2) on piston (Figure 15, Item 1).
12. Install spring (Figure 15, Item 3), retainer (Figure 15, Item 4), and retaining ring (Figure 15, Item 5) in piston
0061-12
TM 5-3805-255-14 0061
Figure 15. Piston Spring. 0061
13. Install spring (Figure 15, Item 2) and piston assembly (Figure 15, Item 3) in upper valve body (Figure 15,
Item 1).
14. Install retaining ring (Figure 15, Item 4) in upper valve body (Figure 15, Item 1).
END OF TASK
0061-13
TM 5-3805-255-14 0061
INSTALLATION 00061
1. Install right treadle valve (Figure 17, Item 15), three bolts (Figure 17, Item 16), new lockwashers (Figure 17,
Item 18), and nuts (Figure 17, Item 17) on floorboard (Figure 17, Item 19).
2. Install fittings (Figure 17, Items 12 and 14) on right treadle valve (Figure 17, Item 15).
3. Install elbows (Figure 17, Items 5, 6, and 9) on right treadle valve (Figure 17, Item 15).
4. Install right check valve (Figure 17, Item 1) on fitting (Figure 17, Item 14).
5. Connect tube (Figure 17, Item 13) to fitting (Figure 17, Item 12).
6. Connect hose (Figure 17, Item 7) to elbow (Figure 17, Item 6).
7. Connect hoses (Figure 17, Items 8 and 10) to elbows (Figure 17, Items 9 and 11).
8. Connect tube (Figure 17, Item 4) to elbow (Figure 17, Item 5).
9. Connect hoses (Figure 17, Items 2 and 3) to right check valve (Figure 17, Item 1).
Figure 17. Right Treadle Valve. 0061
0061-14
TM 5-3805-255-14 0061
NOTE
Align marks on section and body during assembly.
10. Install mounting plate (Figure 18, Item 4) and three screws (Figure 18, Item 6) on body (Figure 18, Item 5).
11. Install plunger (Figure 18, Item 7) on mounting plate (Figure 18, Item 4).
12. Install set screw (Figure 18, Item 3) and stop nut (Figure 18, Item 2) on mounting plate (Figure 18, Item 4).
13. Install rubber boot (Figure 18, Item 1) on plunger (Figure 18, Item 7) and mounting plate (Figure 18, Item 4).
Figure 18. Plunger. 0061
0061-15
TM 5-3805-255-14 0061
Left Treadle Valve 00061
1. Install left treadle valve (Figure 19, Item 9), three bolts (Figure 19, Item 6), new lockwashers (Figure 19,
Item 8), and nuts (Figure 19, Item 7) on floorboard (Figure 19, Item 21).
2. Install tee fittings (Figure 19, Items 2 and 13) on left treadle valve (Figure 19, Item 9).
3. Install elbow fittings (Figure 19, Items 5, 17, 18, and 19) on left treadle valve (Figure 19, Item 9).
4. Install left check valve (Figure 19, Item 2) or elbow (Figure 19, Item 18).
7. Connect hoses (Figure 19, Items 14 and 15) to tees (Figure 19, Items 12 and 13).
8. Connect tubes (Figure 19, Items 10 and 11) to tees (Figure 19, Items 13 and 12).
10. Connect hoses (Figure 19, Items 1 and 3) to left check valve (Figure 19, Item 2).
Figure 19. Left Treadle Valve. 0061
0061-16
TM 5-3805-255-14 0061
Treadle 00061
1. Place roller (Figure 20, Item 2) in treadle (Figure 20, Item 3). Insert roller pin (Figure 20, Item 4) through treadle
and roller.
2. Install new cotter pin (Figure 20, Item 1) in roller pin (Figure 20, Item 4).
Figure 20. Roller. 0061
3. Install treadle (Figure 21, Item 2) and pin (Figure 21, Item 3) on mounting plate (Figure 21, Item 4) of treadle
valve Figure 21, Item 5).
4. Install new cotter pin (Figure 21, Item 1) in pin (Figure 21, Item 3).
Figure 21. Treadle. 0061
0061-17
TM 5-3805-255-14 0061
5. Close drain valve, start engine, and check air pressure (WP 0005).
6. Install body access panels (WP 0005).
END OF TASK
END OF WORK PACKAGE
0061-18
6
TM 5-3805-255-14 0062
FIELD MAINTENANCE -
AIR RESERVOIR REPLACEMENT

0 0 6 2
INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0
(WP 0130, Item 3) 0
Cleaning Compound, Solvent, Type III (WP Battery disconnected switch in OFF position
0130, Item 4) 0
(WP 0004) 0

Wheels chocked 0
Two 0
0062-1
TM 5-3805-255-14 0062
REMOVAL 00062
WARNING
NOTE
• Tag and identify all tubes for ease of installation.
• Plug all hoses and open ports to prevent contamination.
1. Disconnect air tubes (Figure 1, Items 1, 3, and 4) from left side of reservoir (Figure 1, Item 2).
Figure 1. Reservoir (Left Side). 062
0062-2
TM 5-3805-255-14 0062
2. Disconnect air tubes (Figure 2, Items 6 and 7) from right side of reservoir (Figure 2, Item 5).
3. Disconnect air drain tubes (Figure 2, Item 8 and 9) from bottom of reservoir (Figure 2, Item 5).
4. Disconnect air tubes (Figure 2, Items 1 and 2) from reservoir (Figure 2, Item 5).
5. Remove four nuts (Figure 2, Item 4), two U-bolts (Figure 2, Item 3), and reservoir (Figure 2, Item 5) from frame
Figure 2. Reservoir (Right Side). 062
END OF TASK
0062-3
TM 5-3805-255-14 0062
2. Clean exterior and interior of reservoir with hot water and steam. Inspect exterior of reservoir for damage or
corrosion. Replace damaged reservoir. Keep exterior of reservoir painted to retard corrosion.
END OF TASK
INSTALLATION 00062
1. Install reservoir (Figure 3, Item 5), two U-bolts (Figure 3, Item 3), and four nuts (Figure 3, Item 4) on frame
2. Connect air tubes (Figure 3, Items 1 and 2) to reservoir (Figure 3, Item 5).
3. Connect air drain tubes (Figure 3, Items 8 and 9) to bottom of reservoir (Figure 3, Item 5).
4. Connect air tubes (Figure 3, Items 6 and 7) to right side of reservoir (Figure 3, Item 5).
Figure 3. Reservoir (Right Side). 062
0062-4
TM 5-3805-255-14 0062
5. Connect air tubes (Figure 4, Items 1, 3, and 4), to left side of reservoir (Figure 4, Item 2).
Figure 4. Reservoir (Left Side). 062
END OF TASK
END OF WORK PACKAGE
0062-5/(6 blank)
4
TM 5-3805-255-14 0063
FIELD MAINTENANCE -
0 0 6 3 SAFETY VALVE AND CHECK VALVE REPLACEMENT

Safety Valve: Removal, Installation
Check Valve: Removal, Installation
INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

0004) 0
0130, Item 4) 0
Wheels chocked 0
References 0
WP 0019 0
0063-1
TM 5-3805-255-14 0063
SAFETY VALVE REMOVAL 00063
WARNING
1. Remove safety valve (Figure 1, Item 1) from tee (Figure 1, Item 2).
Figure 1. Safety Valve. 0063
END OF TASK
SAFETY VALVE INSTALLATION 00063
Install safety valve (Figure 1, Item 1) on tee (Figure 1, Item 2).
END OF TASK
CHECK VALVE REMOVAL 00063
Remove check valve (WP 0063).
END OF TASK
CHECK VALVE CLEANING AND INSPECTION 00063
2. Inspect check valve body and cap, and replace if worn or damaged.
END OF TASK
0063-2
TM 5-3805-255-14 0063
CHECK VALVE INSTALLATION 00063
1. Install check valve (WP 0060).

END OF TASK
END OF WORK PACKAGE
0063-3/(4 blank)
24
TM 5-3805-255-14 0064
FIELD MAINTENANCE -
AIR COMPRESSOR REPLACEMENT AND REPAIR (MODEL 500)

0 0 6 4
INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP Pin, Cotter 0
0128, Item 20) 0

Seal (3) 0
Shop Equipment, Automotive Maintenance Personnel Required 0
and Repair: Organizational Maintenance Two 0
Shop Equipment, Machine Shop, Field References 0
Maintenance, Heavy, Supplemental No. 1, WP 0019 0
Less Power (WP 0128, Item 16) 0
Materials/Parts 0
(WP 0130, Item 3) 0

0130, Item 4) 0
0004) 0

0130, Item 10) 0
Wheels chocked 0
Gasket (8) 0
Lockwasher (28) 0
0064-1
TM 5-3805-255-14 0064
REMOVAL 00064
WARNING
NOTE
• Tag and identify all hoses prior to removal, for ease of installation.
• Plug all hoses to prevent contamination and leaks.
1. Disconnect seven hoses (Figure 1, Items 1, 2, 3, 4, 13, 14, and 18), from compressor (Figure 1, Item 19).
2. Loosen four nuts (Figure 1, Item 15) and move compressor (Figure 1, Item 19) toward engine to remove
compressor belt (Figure 1, Item 5) from pulley (Figure 1, Item 6).
3. Remove four nuts (Figure 1, Item 15), lockwashers (Figure 1, Item 16), washers (Figure 1, Item 17), and
compressor (Figure 1, Item 19) from mounting plate (Figure 1, Item 12). Discard lockwashers.
END OF TASK
DISASSEMBLY 00064
1. Clean compressor exterior.

2. Remove cotter pin (Figure 1, Item 7), nut (Figure 1, Item 8), and washer (Figure 1, Item 9) from crankshaft
3. Remove pulley (Figure 1, Item 6) from crankshaft (Figure 1, Item 10).
4. Remove woodruff key (Figure 1, Item 11) from crankshaft (Figure 1, Item 10).
0064-2
TM 5-3805-255-14 0064
Figure 1. Air Compressor Mounting. 0064
0064-3
TM 5-3805-255-14 0064
5. Remove ten bolts (Figure 2, Item 1) and cylinder head (Figure 2, Item 2) from cylinder block (Figure 2, Item 4).
6. Remove cylinder head gasket (Figure 2, Item 3) from cylinder head (Figure 2, Item 2) and cylinder block
(Figure 2, Item 4). Discard gasket.
7. Remove two inlet valve springs (Figure 2, Item 15) from cylinder head (Figure 2, Item 2).
8. Remove two inlet valves (Figure 2, Item 13) and inlet valve guides (Figure 2, Item 14) from inlet valve seats
(Figure 2, Item 12) on cylinder block (Figure 2, Item 4).
9. Remove unloader spring seat (Figure 2, Item 11), unloader spring (Figure 2, Item 10), and spring saddle
(Figure 2, Item 9) from cylinder block (Figure 2, Item 4).
NOTE
If necessary, carefully apply air pressure at governor port of cylinder block to remove
unloader pistons.
10. Remove two unloader pistons (Figure 2, Item 8) from cylinder block (Figure 2, Item 4).
11. Remove grommets (Figure 2, Item 6), bushings (Figure 2, Item 5), and rings (Figure 2, Item 7) from cylinder
block (Figure 2, Item 4).
Figure 2. Air Compressor Cylinder Head. 0064
0064-4
TM 5-3805-255-14 0064
12. Remove two discharge valve caps (Figure 3, Item 1), discharge valve springs (Figure 3, Item 2), discharge
valves (Figure 3, Item 3) and discharge valve seats (Figure 3, Item 4) from cylinder head (Figure 3, Item 12).
13. Remove two nuts (Figure 3, Item 11), lockwashers (Figure 3, Item 10), and discharge fitting (Figure 3, Item 9)
from cylinder head (Figure 3, Item 12). Discard lockwashers.
14. Remove gasket (Figure 3, Item 6) and two studs (Figure 3, Item 5) from cylinder head (Figure 3, Item 12).
Discard gasket.
15. Remove compression nut (Figure 3, Item 7) and compression sleeve (Figure 3, Item 8) from discharge fitting
(Figure 3, Item 9).
Figure 3. Air Discharge. 0064
0064-5
TM 5-3805-255-14 0064
16. Remove six bolts (Figure 4, Item 5), nuts (Figure 4, Item 1), lockwashers (Figure 4, Item 2), washers (Figure 4,
Item 3), and base plate (Figure 4, Item 7) from compressor (Figure 4, Item 4). Discard lockwashers.
17. Remove gasket (Figure 4, Item 8) from base plate (Figure 4, Item 7) and compressor (Figure 4, Item 4).
Discard gasket.
18. Remove four studs (Figure 4, Item 6) from base plate (Figure 4, Item 7).
Figure 4. Base Plate. 0064
0064-6
TM 5-3805-255-14 0064
19. Remove six bolts (Figure 5, Item 1), lockwashers (Figure 5, Item 2), and cylinder block (Figure 5, Item 3) from
crankcase (Figure 5, Item 10). Discard lockwashers.
20. Remove gasket (Figure 5, Item 9) from cylinder block (Figure 5, Item 3) and crankcase (Figure 5, Item 10).
Discard gasket.
21. Remove two bolts (Figure 5, Item 6), lockwashers (Figure 5, Item 7), flange (Figure 5, Item 5), strainer plate
(Figure 5, Item 8), and two gaskets (Figure 5, Item 4) from cylinder block (Figure 5, Item 3). Discard
lockwashers and gaskets.
22. Remove plugs (Figure 5, Items 11 and 12) from cylinder block (Figure 5, Item 3).
Figure 5. Cylinder Block. 0064
0064-7
TM 5-3805-255-14 0064
CAUTION
Each connecting rod is matched to its own bearing cap. Do not interchange. Before
separating, mark each rod and cap for proper fit and ease of installation. Failure to follow
NOTE
Disassembly of one piston is shown. Repeat steps 23 through 29 for other piston.
23. Remove two bolts (Figure 6, Item 5), washer key (Figure 6, Item 6), and bearing cap from connecting rod
(Figure 6, Item 4).
24. Remove piston (Figure 6, Item 3) and connecting rod (Figure 6, Item 4) from cylinder block (Figure 6, Item 1).
25. Replace bearing cap on connecting rod (Figure 6, Item 4).
26. Remove piston rings (Figure 6, Item 2) from piston (Figure 6, Item 3).
27. Remove wrist pin lock (Figure 6, Item 9) and press wrist pin (Figure 6, Item 10) from piston (Figure 6, Item 3)
and connecting rod (Figure 6, Item 4).
28. Remove bearing sleeve (Figure 6, Item 7) from bearing cap and connecting rod (Figure 6, Item 4).
29. Remove wrist pin bushing (Figure 6, Item 8) from connecting rod (Figure 6, Item 4).
0064-8
TM 5-3805-255-14 0064
30. Remove four bolts (Figure 7, Item 1), lockwashers (Figure 7, Item 2), and front cover (Figure 7, Item 11) from
31. Remove gasket (Figure 7, Item 10) and oil seal ring (Figure 7, Item 12) from front cover (Figure 7, Item 11).
Discard seal ring and gasket.
32. Remove four bolts (Figure 7, Item 1), lockwashers (Figure 7, Item 2), and rear cover (Figure 7, Item 7) from
33. Remove gasket (Figure 7, Item 6) and oil seal ring (Figure 7, Item 8) from rear cover (Figure 7, Item 7). Discard
seal ring and gasket.
34. Press crankshaft (Figure 7, Item 4) with ball bearings (Figure 7, Items 3 and 9) out of crankcase (Figure 7,
Item 5) from drive end of compressor.
35. Press ball bearings (Figure 7, Items 3 and 9) off crankshaft (Figure 7, Item 4).
Figure 7. Crankshaft. 0064
END OF TASK
2. Inspect cylinder head for cracks or wear and replace if necessary.
3. Use air pressure to test water jacket of cylinder head and cylinder block for leakage. Replace unit if leaking.
4. Check crankcase, cylinder block, and end covers for cracks and broken lugs. Replace lugs if damaged.
5. Inspect ball bearings for wear or flat spots. Replace bearings if worn. Check ball bearing fit in crankcase.
Bearings must be a finger-press fit. If crankcase bearing bores are worn or damaged, replace crankcase.
0064-9
TM 5-3805-255-14 0064

6. Inspect inlet valves, springs, and inlet valve seats for nicks, scratches, or cracks, and replace if necessary.
7. Inspect discharge valves, springs, and discharge valve seats for nicks, scratches, or cracks, and replace if
necessary.
8. Inspect discharge valve for leakage by applying 100 lb (45.36 kg) of air pressure through discharge port of
cylinder head and apply soap suds to discharge valve openings in floor of cylinder head. Leakage should not
exceed a 1-in. soap bubble within five seconds.
9. If excessive leakage is found, leave air pressure applied, and tap discharge valves off their seats several times
to improve seal between valves and their seats. If valves and seats have been reconditioned properly, this will
reduce leakage.
Figure 8. Seating Discharge Valve with Dowel. 0064
0064-10
TM 5-3805-255-14 0064

10. Inspect discharge valve caps for leaks by applying soap suds around the discharge valve caps with air
pressure applied as previously outlined. Leakage at valve caps is not permissible.
11. Check cylinder bores for evidence of excessive wear, out-of-round, or scoring. Replace parts as necessary.
12. Inspect pistons for scores, cracks, or wear, and replace if worn.
13. Inspect piston and cylinder bore clearance between pistons (Figure 9, Item 1) and cylinder bores (Figure 9,
Item 2) with feeler gauge stock. Clearance should be between 0.002 in. (0.101 mm) minimum and 0.004 in.
(0.101 mm) maximum.
Figure 9. Checking Piston and Cylinder Bore Clearance. 0064
0064-11
TM 5-3805-255-14 0064

14. Inspect piston ring groove clearance (Figure 10, Item 1) for correct clearance between rings (Figure 10, Item 2)
and ring grooves (Figure 10, Item 3). Refer to Figure 12 for tolerances.
Figure 10. Checking Piston Ring Groove Clearance. 0064
15. Check piston ring gap with rings installed in cylinder bores (Figure 11, Item 1). Refer to Figure 12 for
tolerances.
Figure 11. Checking Piston Ring Gap. 0064
0064-12
TM 5-3805-255-14 0064
Figure 12. Position and Clearance of Piston Rings. 0064
16. Check fit of wrist pins in pistons and connecting rods. Wrist pins must be a light press fit in pistons. If wrist pin
is a loose fit, replace if necessary.
17. Check fit of wrist pin in connecting rod bushing by rocking piston. Clearance of wrist pin-to-connecting rod
bushing should not exceed 0.0015 in. (0.038 mm). If excessive clearance is apparent, replace wrist pin
bushings in connecting rods.
0064-13
TM 5-3805-255-14 0064

18. When pressing new bushings into place, be sure oil hole in bushing lines up with oil hole in connecting rod.
Bushings must then be reamed, honed, or bored to provide between 0.0001 in. (0.0025 mm) and 0.0006 in.
(0.0152 mm) clearance between bushing and wrist pin.
19. Inspect connecting rod bearings for proper fit on crankshaft journals. Check connecting rod bearings for wear.
If worn or cracked, replace rod bearings. Connecting rod caps are not interchangeable. Position caps so two
insert locking slots are adjacent to same capscrew.
20. Inspect crankshaft journals for out-of-round, and replace if necessary.
21. Inspect oil seal ring grooves for wear, and replace crankshaft if necessary.
END OF TASK
ASSEMBLY 00064
1. Press ball bearings (Figure 13, Items 3 and 9) onto crankshaft.

2. Position crankshaft (Figure 13, Item 4) and ball bearings (Figure 13, Items 3 and 9) into crankcase (Figure 13,
Item 5), making sure drive end of crankshaft is positioned as marked during removal. Front bearing (Figure 13,
Item 3) should bottom against front cover (Figure 13, Item 11).
3. Press crankshaft (Figure 13, Item 4) and ball bearings (Figure 14, Items 3 and 9) in crankcase (Figure 13,
Item 5).
4. Install new oil seal ring (Figure 13, Item 8) on rear cover (Figure 13, Item 7). Install new gasket (Figure 13,
Item 6), rear cover, four new lockwashers (Figure 13, Item 2), and bolts (Figure 13, Item 1) on crankcase
(Figure 13, Item 5). Note rear cover alignment marks.
5. Install new oil seal ring (Figure 13, Item 12) on front cover (Figure 13, Item 11).
6. Install new gasket (Figure 13, Item 10), front cover (Figure 13, Item 11), four new lockwashers (Figure 13,
Item 2), and bolts (Figure 13, Item 1) on crankcase (Figure 13, Item 5). Note front cover alignment marks.
0064-14
TM 5-3805-255-14 0064
NOTE
• Procedure describes one cylinder assembly; repeat for other cylinder.
• Lubricate pistons, piston bores, piston rings, wrist pin bushings, and connecting rod
bearings with clean oil prior to assembly.
7. Align oil hole in wrist pin bushing with oil hole in connecting rod. Press wrist pin bushing (Figure 14, Item 8) in
connecting rod (Figure 14, Item 4).
8. Install sleeves (Figure 14, Item 7) in bearing cap and connecting rod (Figure 14, Item 4).
9. Position connecting rod (Figure 14, Item 4) in piston (Figure 14, Item 3) and press wrist pin (Figure 14, Item 10)
into piston (Figure 14, Item 3) with lock holes in pin aligned with lock holes in piston.
0064-15
TM 5-3805-255-14 0064
10. Install new wrist pin lock (Figure 15, Item 1) in wrist pin (Figure 15, Item 2) and piston (Figure 15, Item 3). Snap
short end of lock into lock hole near bottom of piston skirt.
Figure 15. Method of Installing Wrist Pin Lockwire. 0064
0064-16
TM 5-3805-255-14 0064
11. Install piston rings (Figure 16, Item 2) in proper piston groove, with pip marks or bevel up. Stagger piston ring
gaps so they are not in line.
12. Turn crankshaft to position one crankshaft journal downward. Remove bearing cap from connecting rod
(Figure 16, Item 4), leaving connecting rod bolts (Figure 16, Item 5) in rod.
13. Use a ring compressor to install connecting rod (Figure 16, Item 4) and piston (Figure 16, Item 3) through top
of cylinder (Figure 16, Item 1). Push piston down until connecting rod bearing contacts crankshaft journal.
14. Align marks and install connecting rod bearing cap on rod end (Figure 16, Item 4). If cap and rod are not
marked, position cap on rod so two locking slots in bearing inserts, rod, and cap are both located adjacent to
same connecting rod bolt. Secure cap to rod with two bolts (Figure 16, Item 5) and washer key nuts (Figure 16,
Item 6).
0064-17
TM 5-3805-255-14 0064
15. Install plugs (Figure 17, Items 11 and 12) on cylinder block (Figure 17, Item 3).
16. Install two new gaskets (Figure 17, Item 4), strainer plate (Figure 17, Item 8), new gasket (Figure 17, Item 4),
flange (Figure 17, Item 5), two new lockwashers (Figure 17, Item 7), and bolts (Figure 17, Item 6) on cylinder
block (Figure 17, Item 3).
17. Install new gasket (Figure 17, Item 9), cylinder block (Figure 17, Item 3), six new lockwashers (Figure 17,
Item 2), and bolts (Figure 17, Item 1) on crankcase (Figure 17, Item 10).
Figure 17. Cylinder Block. 0064
0064-18
TM 5-3805-255-14 0064
18. Install four studs (Figure 18, Item 6) on base plate (Figure 18, Item 7).
19. Install new gasket (Figure 18, Item 8), base plate (Figure 18, Item 7), six bolts (Figure 18, Item 5), washers
(Figure 18, Item 3), new lockwashers (Figure 18, Item 2), and nuts (Figure 18, Item 1) on compressor (Figure
18, Item 4).
0064-19
TM 5-3805-255-14 0064
20. Install compression sleeve (Figure 19, Item 8) and compression nut (Figure 19, Item 7) on discharge fitting
21. Install two studs (Figure 19, Item 5) on cylinder head (Figure 19, Item 12).
22. Install new gasket (Figure 19, Item 6), discharge fitting (Figure 19, Item 9), two new lockwashers (Figure 19,
Item 10), and nuts (Figure 19, Item 11) on cylinder head (Figure 19, Item 12).
23. Install discharge valve seats (Figure 19, Item 4), discharge valves (Figure 19, Item 3), discharge valve springs
(Figure 19, Item 2), and discharge valve cap nuts (Figure 19, Item 1) on cylinder head (Figure 19, Item 12).
Figure 19. Air Discharge. 0064
0064-20
TM 5-3805-255-14 0064
24. Install ring (Figure 20, Item 7), bushing (Figure 20, Item 5), and grommet (Figure 20, Item 6) on cylinder block
25. Install unloader pistons (Figure 20, Item 8) in cylinder block (Figure 20, Item 4).
26. Install spring saddle (Figure 20, Item 9), unloader spring (Figure 20, Item 10), and unloader seat (Figure 20,
Item 11) on cylinder block (Figure 20, Item 4).
NOTE
The dimension from top of the cylinder block to the inlet valve seat should not exceed
0.118 in. (2.99 mm) or be less than 0.101 in. (2.56 mm). If inlet valves cannot be reclaimed
by lapping with crocus cloth, replace inlet valves.
27. Install two inlet valve seats (Figure 20, Item 12), valve guides (Figure 20, Item 14), inlet valves (Figure 20,
Item 13), and valve springs (Figure 20, Item 15) on cylinder block (Figure 20, Item 4).
28. Align cylinder head inlet valve springs (Figure 20, Item 15) with inlet valve guides (Figure 20, Item 14) in
cylinder block (Figure 20, Item 4). Install new cylinder head gasket (Figure 20, Item 3), cylinder head
(Figure 20, Item 2), and ten bolts (Figure 20, Item 1) on cylinder block.
Figure 20. Air Compressor. 0064
0064-21
TM 5-3805-255-14 0064
29. Install woodruff key (Figure 21, Item 11) on crankshaft (Figure 21, Item 10).
30. Install pulley (Figure 21, Item 6), washer (Figure 21, Item 9), and nut (Figure 21, Item 8) on crankshaft
(Figure 21, Item 10). Install new cotter pin (Figure 21, Item 7).
END OF TASK
0064-22
TM 5-3805-255-14 0064
INSTALLATION 00064
1. Install compressor (Figure 21, Item 19), four washers (Figure 21, Item 17), new lockwashers (Figure 21,
Item 16), and nuts (Figure 21, Item 15) on mounting plate (Figure 21, Item 12). Do not tighten nuts.
2. Connect seven hoses (Figure 21, Items 1, 2, 3, 4, 13, 14, and 18) to compressor (Figure 21, Item 19).
3. Install compressor belt (Figure 21, Item 5) on pulley (Figure 21, Item 6) and adjust belt tension. Tighten four
nuts (Figure 21, Item 15).
4. Fill system with coolant (WP 0005).
5. Close drain valve on air reservoir (WP 0005).
6. Start engine and check air pressure. Check for oil or coolant leaks.
END OF TASK
END OF WORK PACKAGE
0064-23/(24 blank)
16
TM 5-3805-255-14 0065
FIELD MAINTENANCE -
AIR COMPRESSOR REPLACEMENT AND REPAIR (MODEL 501)

0 0 6 5
INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP Lockwasher (14) 0
0128, Item 20) 0

Pin, Cotter 0
Shop Equipment, Automotive Maintenance Seal 0
and Repair: Organizational Maintenance

Shop Equipment, Machine Shop, Field Two 0
Maintenance, Heavy, Supplemental No. 1,

References 0
WP 0019 0
Materials/Parts 0

Cap Set, Protective Dust and Moisture Seal Loader parked on level ground (WP 0005) 0
(WP 0130, Item 3) 0 Parking brake applied (WP 0005) 0
Cleaning Compound, Solvent, Type III (WP Engine OFF (WP 0005) 0
0130, Item 4) 0
Detergent, General Purpose, Liquid (WP 0004) 0
0130, Item 10) 0


Wheels chocked 0

Gasket (5) 0
0065-1
TM 5-3805-255-14 0065
REMOVAL 00065
WARNING
NOTE
• Tag and identify all hoses prior to removal, for ease of installation.
• Plug all hoses to prevent contamination and leaks.
1. Disconnect seven hoses (Figure 1, Items 1, 2, 3, 4, 13, 14, and 18), from compressor (Figure 1, Item 19).
2. Loosen four nuts (Figure 1, Item 15) and move compressor (Figure 1, Item 19) toward engine and remove
compressor belt (Figure 1, Item 5) from pulley (Figure 1, Item 6).
3. Remove four nuts (Figure 1, Item 15), lockwashers (Figure 1, Item 16), washers (Figure 1, Item 17), and
compressor (Figure 1, Item 19) from mounting plate (Figure 1, Item 12). Discard lockwashers.
4. Remove cotter pin (Figure 1, Item 7), nut (Figure 1, Item 8), and washer (Figure 1, Item 9) from crankshaft
5. Use a puller to remove pulley (Figure 1, Item 6) from crankshaft (Figure 1, Item 10).
6. Remove woodruff key (Figure 1, Item 11) from crankshaft (Figure 1, Item 10).
0065-2
TM 5-3805-255-14 0065
END OF TASK
0065-3
TM 5-3805-255-14 0065
DISASSEMBLY 00065
1. Clean compressor exterior.

2. Remove six bolts (Figure 2, Item 1) and cylinder head (Figure 2, Item 3) from crankcase (Figure 2, Item 8).
3. Remove cylinder head gasket (Figure 2, Item 7) from cylinder head (Figure 2, Item 3) and crankcase (Figure 2,
4. Remove two inlet valve springs (Figure 2, Item 14) from cylinder head (Figure 2, Item 3).
5. Remove two inlet valves (Figure 2, Item 13), inlet valve guides (Figure 2, Item 12), and inlet valve seats (Figure
2, Item 11) from crankcase (Figure 2, Item 8).
6. Unscrew discharge valve seats (Figure 2, Item 6) and remove discharge valves (Figure 2, Item 5) and
discharge valve springs (Figure 2, Item 4) from cylinder head (Figure 2, Item 8).
7. Remove discharge valve stops from bottom of head.
8. Remove sleeves (Figure 2, Item 10) and plungers (Figure 2, Item 9) from crankcase (Figure 2, Item 8).
9. Remove plugs (Figure 2, Item 2) from cylinder head (Figure 2, Item 3).
0065-4
TM 5-3805-255-14 0065
10. Remove six bolts (Figure 3, Item 5), nuts (Figure 3, Item 1), lockwashers (Figure 3, Item 2), washers (Figure 3,
Item 3) and base plate (Figure 3, Item 7) from compressor (Figure 3, Item 4). Discard lockwashers.
11. Remove gasket (Figure 3, Item 8) from base plate (Figure 3, Item 7) and compressor (Figure 3, Item 4).
Discard gasket.
12. Remove four studs (Figure 3, Item 6) from base plate (Figure 3, Item 7).
0065-5
TM 5-3805-255-14 0065
CAUTION
Each connecting rod is matched to its own bearing cap. Do not interchange. Before
separating, mark each rod and cap for proper fit and ease of installation. Failure to follow
NOTE
One piston is shown; repeat steps 13 through19 for other piston.
13. Remove two bolts (Figure 4, Item 9), locking plate (Figure 4, Item 10), and bearing cap (Figure 4, Item 6) from
connecting rod (Figure 4, Item 5) and crankshaft (Figure 4, Item 8).
14. Remove piston (Figure 4, Item 11) and connecting rod (Figure 4, Item 5) from crankcase (Figure 4, Item 7).
15. Replace bearing cap (Figure 4, Item 5) on connecting rod (Figure 4, Item 5).
16. Remove piston rings (Figure 4, Item 1) from piston (Figure 4, Item 11).
17. Remove wrist pin securing buttons (Figure 4, Item 3) and press wrist pin (Figure 4, Item 2) from piston (Figure
4, Item 11) and connecting rod (Figure 4, Item 5).
18. Remove bearing sleeve (Figure 4, Item 6) from bearing cap and connecting rod (Figure 4, Item 5).
19. Remove wrist pin bushing (Figure 4, Item 4) from connecting rod (Figure 4, Item 5).
0065-6
TM 5-3805-255-14 0065
20. Remove four bolts (Figure 5, Item 1) and front cover (Figure 5, Item 14) from crankcase (Figure 5, Item 11).
21. Remove gasket (Figure 5, Item 13) and oil seal ring (Figure 5, Item 16) from front cover (Figure 5, Item 14).
Discard seal and gasket.
22. Remove four bolts (Figure 5, Item 4), lockwashers (Figure 5, Item 3), and rear cover (Figure 5, Item 5) from
23. Remove gasket (Figure 5, Item 7) from rear cover (Figure 5, Item 5). Discard gasket.
24. Press crankshaft (Figure 5, Item 12) with ball bearings (Figure 5, Items 6 and 15) out of crankcase (Figure 5,
Item 11) from drive end of compressor.
25. Press ball bearings (Figure 5, Items 6 and 15) off crankshaft (Figure 5, Item 12).
26. Remove plug (Figure 5, Item 8) from crankcase (Figure 5, Item 11).
27. Remove plug (Figure 5, Item 2) from crankcase (Figure 5, Item 11).
28. Remove plug (Figure 5, Item 9) and gasket (Figure 5, Item 10) from crankcase (Figure 5, Item 11). Discard
gasket.
END OF TASK
0065-7
TM 5-3805-255-14 0065
2. Inspect cylinder head for cracks or wear and replace if necessary.
3. Use air pressure to test water jacket of cylinder block for leaks. Replace if necessary.
4. Inspect end covers for cracks or damage and replace as necessary.
5. Inspect ball bearings for wear or flat spots. Replace bearings if worn. Check ball bearing fit in crankcase.
Bearings must be a finger-press fit. If crankcase bearing bores are worn or damaged, replace crankcase.
6. The dimension from top of cylinder block to inlet valve seat should not exceed 0.113 in. (2.87 mm) and not be
less than 0.101 in. (2.56 mm).
7. Inspect crankshaft threads, keyways, tapered ends, and all machined surfaces for wear, scores, or damage.
Replace if necessary.
8. Inspect pistons for scores, cracks, or enlarged ring grooves and replace if necessary. Measure each piston
with a micrometer in relation to the cylinder bore diameter to be sure the diametrical clearance is between
0.002 in. (0.050 mm) minimum and 0.004 in. (0.101 mm) maximum.
9. Check fit of wrist pin to piston and connecting rod. Wrist pin should be a light press fit in the piston. If loose,
replace piston and pin. Check wrist pin in connecting rod. The clearance should not exceed 0.0007 in.
(0.0177 mm); replace if excessive. Wrist pin bushings should be reamed to between 0.5314 in. (13.49 mm)
and 0.5317 in. (13.50 mm) after being pressed into connecting rods.
10. Check the fit of the piston rings in the piston ring grooves. Check the ring gap with the rings installed in the
cylinder bores. Refer to Figure 6 for correct gap and groove clearances.
Figure 6. Correct Piston Ring Groove Clearance. 0065
11. Inspect connecting rod bearing inserts, connecting rod, and wrist pin bushing for wear or damage. Replace as
necessary.
12. Inspect discharge valves for leakage by applying 100 lb (45.36 kg) of air pressure through discharge port of
cylinder head and applying soap solution to discharge valves and seats. A slight leakage in the form of soap
bubbles is permissible. If excessive leakage is found, leave air pressure applied and, using a fiber or hardwood
dowel and a hammer, tap the discharge valves off their seats several times. This will help seat the valves and
should reduce leaking on properly reconditioned valves. No leaking is allowed at the discharge valve stops
exposed on the top of the cylinder head casting.
13. Inspect cylinder bore clearance between pistons and cylinder bores. Clearance should be between 0.002 in.
(0.101 mm) minimum and 0.004 in. (0.101mm) maximum.
END OF TASK
0065-8
TM 5-3805-255-14 0065
ASSEMBLY 00065
1. Install new gasket (Figure 7, Item 10) and plug (Figure 7, Item 9) on crankcase (Figure 7, Item 11).
2. Install plug (Figure 7, Item 2) on crankcase (Figure 7, Item 11).
3. Install plug (Figure 7, Item 8) on crankcase (Figure 7, Item 11).
4. Press ball bearings (Figure 7, Items 6 and 15) on crankshaft (Figure 7, Item 12).
5. Press crankshaft (Figure 7, Item 12) with ball bearings (Figure 7, Items 6 and 15) in crankcase (Figure 7, Item
11) from drive end of compressor.
6. Install new gasket (Figure 7, Item 7) on rear cover (Figure 7, Item 5).
7. Install four new lockwashers (Figure 7, Item 3), bolts (Figure 7, Item 4), and rear cover (Figure 7, Item 5) on
crankcase (Figure 7, Item 11).
8. Install new gasket (Figure 7, Item 13) and oil seal ring (Figure 7, Item 16) on front cover (Figure 7, Item 14).
9. Install front cover (Figure 7, Item 14) and four bolts (Figure 7, Item 1) on crankcase (Figure 7, Item 11).
0065-9
TM 5-3805-255-14 0065
NOTE
• Procedure describes one cylinder assembly; repeat for other cylinder.
• Lubricate pistons, piston bores, piston rings, wrist pin bushings, and connecting rod
bearings with clean oil prior to assembly.
10. Align oil hole in wrist pin bushing (Figure 8, Item 4) bushing with oil hole in connecting rod (Figure 8, Item 5).
Press wrist pin bushing (Figure 8, Item 4) in connecting rod.
11. Install piston (Figure 8, Item 11) on connecting rod (Figure 8, Item 5).
NOTE
Ream or hone new wrist pin bushings to provide clearance of 0.0001 in. (0.00254 mm) to
0.0006 in. (0.01524 mm) on the wrist pin.
12. Press wrist pin (Figure 8, Item 2) through piston (Figure 8, Item 11) and connecting rod (Figure 8, Item 5).
13. Install wrist pin securing buttons (Figure 8, Item 3) on wrist pin (Figure 8, Item 2).
14. Install sleeve (Figure 8, Item 6) in bearing cap (Figure 8, Item 5) and connecting rod (Figure 8, Item 5).
15. Install piston rings (Figure 8, Item 1) in proper piston groove, with pip marks or bevel up. Stagger piston ring
gaps so they are not in line.
16. Turn crankshaft to position one crankshaft journal downward. Remove two bolts (Figure 8, Item 9) and bearing
cap from connecting rod (Figure 8, Item 5).
17. Use a ring compressor to install connecting rod (Figure 8, Item 5) and piston (Figure 8, Item 11) through top of
crankcase (Figure 8, Item 7). Push piston down until connecting rod bearing contacts the crankshaft journal
(Figure 8, Item 8).
18. Align marks and install connecting rod bearing cap on rod end (Figure 8, Item 5). If cap and rod are not
marked, position cap on the rod so two locking slots in bearing inserts rod and cap are both located adjacent to
same connecting rod bolt. Secure cap to rod with locking plate (Figure 8, Item 10) and two bolts (Figure 8,
Item 9). Clearance between connecting journal and connecting rod bearing must not be less than 0.0003 in.
(0.007 mm) or more than 0.0021 in. (0.053 mm) after rebuilding.
0065-10
TM 5-3805-255-14 0065
0065-11
TM 5-3805-255-14 0065
19. Install plug (Figure 9, Item 2) in cylinder head (Figure 9, Item 3).
20. Install sleeves (Figure 9, Item 10) and plungers (Figure 9, Item 9) on crankcase (Figure 9, Item 8). Install
unloader pistons in their bores. Position unloader plungers in their guides and slip them in and over the piston
tops. Install unloader spring seat in the crankcase inlet cavity. Position the saddle between the unloader guide
piston guides so forks are centered on guides. Install unloader spring, making sure it seats both in crankcase
and on saddle.
21. If removed, install discharge valve seats (Figure 9, Item 6), discharge valves (Figure 9, Item 5), and discharge
valve springs (Figure 9, Item 4) on cylinder head (Figure 9, Item 3). After installing new discharge valves,
springs, and seats, the discharge valve travel should be between 0.041 and 0.057 in. (1.04 to 1.44 mm).
NOTE
The dimension from top of the cylinder block to the inlet valve seat should not exceed
0.113 in. (2.87 mm) or be less than 0.101 in. (2.56 mm). If inlet valves cannot be reclaimed
by lapping with crocus cloth, replace inlet valves.
22. Install two inlet valve seats (Figure 9, Item 11), inlet valve guides (Figure 9, Item 12), and inlet valves (Figure 9,
Item 13) in crankcase (Figure 9, Item 8).
23. Install two inlet valve springs (Figure 9, Item 14) on cylinder head (Figure 9, Item 3). Apply a turning motion to
the spring after it is in cylinder head. If spring does not stay, apply a small amount of grease to hold spring in
position.
24. Install new cylinder head gasket (Figure 9, Item 7) on cylinder head (Figure 9, Item 3).
25. Install cylinder head (Figure 9, Item 3) and six bolts (Figure 9, Item 1) on crankcase (Figure 9, Item 8). Torque
bolts to 25 to 30 lb-ft (34 to 41 Nm).
0065-12
TM 5-3805-255-14 0065
0065-13
TM 5-3805-255-14 0065
26. Install four studs (Figure 10, Item 6) on base plate (Figure 10, Item 7).
27. Install new gasket (Figure 10, Item 8), base plate (Figure 10, Item 7), six bolts (Figure 10, Item 5), washers
(Figure 10, Item 3), new lockwashers (Figure 10, Item 2), and nuts (Figure 10, Item 1) on compressor (Figure
10, Item 4).
END OF TASK
0065-14
TM 5-3805-255-14 0065
INSTALLATION 00065
1. Install woodruff key (Figure 11, Item 11) on crankshaft (Figure 11, Item 10).
2. Install pulley (Figure 11, Item 6), washer (Figure 11, Item 9), and nut (Figure 11, Item 8) on crankshaft (Figure
11, Item 10). Install new cotter pin (Figure 11, Item 7).
3. Install compressor (Figure 11, Item 19), four washers (Figure 11, Item 17), new lockwashers (Figure 11, Item
16), and nuts (Figure 11, Item 15) on mounting plate (Figure 11, Item 12). Do not tighten nuts.
4. Connect seven hoses (Figure 11, Items 1, 2, 3, 4, 13, 14, and 18) on compressor (Figure 11, Item 19).
5. Install compressor belt (Figure 11, Item 5) on pulley (Figure 11, Item 6) and adjust belt tension. Tighten four
nuts (Figure 11, Item 15).
6. Fill system with antifreeze (WP 0005).
7. Close drain valve on air reservoir (WP 0005).
8. Start engine and check air pressure. Check for oil or coolant leaks.
END OF TASK
END OF WORK PACKAGE
0065-15/(16 blank)
2
TM 5-3805-255-14 0066
FIELD MAINTENANCE -
0 0 6 6 WHEEL REPLACEMENT
INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

(WP 0004) 0
References 0
WP 0002 0
REMOVAL 00066
WARNING
1. Using a suitable lifting device, lift loader until tire clears ground. Install suitable support under loader.
2. Install suitable lifting device on wheel (Figure 1, Item 3).
3. Remove 21 nuts (Figure 1, Item 1), washers (Figure 1, Item 2), and wheel (Figure 1, Item 3) from loader. Place
wheel on ground in a properly supported position. Remove lifting device from wheel.
Figure 1. Wheel Assembly. 066
END OF TASK
0066-1
TM 5-3805-255-14 0066
INSTALLATION 00066
WARNING
Failure to follow this Warning may result in death or injury to personnel.
1. Install suitable lifting device on wheel (Figure 2, Item 3).
2. Install 21 washers (Figure 2, Item 2), nuts (Figure 2, Item 1), and wheel (Figure 2, Item 3) on loader. Torque
nuts.
3. Using suitable lifting device, raise loader and remove support from under loader.
4. Lower loader to ground and remove lifting device.
5. Check tires for proper inflation pressure (WP 0002).
Figure 2. Wheel Assembly. 066
END OF TASK
END OF WORK PACKAGE
0066-2
10
TM 5-3805-255-14 0067
FIELD MAINTENANCE -
0 0 6 7 STEERING WHEEL AND COLUMN REPLACEMENT

Removal, Assembly, Installation
INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

0004) 0
Lockwasher (2) 0
Wheels chocked 0
References 0
WP 0019 0
0067-1
TM 5-3805-255-14 0067
REMOVAL 00067
1. Remove button plug (Figure 1, Item 1) from steering wheel (Figure 1, Item 4).
2. Remove nut (Figure 1, Item 2) and washer (Figure 1, Item 3) from steering column (Figure 1, Item 6).
3. Remove steering wheel (Figure 1, Item 4) and spring (Figure 1, Item 5) from steering column (Figure 1,
Item 6).
Figure 1. Steering Wheel Replacement. 067
4. Remove two nuts (Figure 2, Item 7), lockwashers (Figure 2, Item 8) and pull steering column flange (Figure 2,
Item 9) from flange on steering gear. Discard lockwashers.
5. Remove two nuts (Figure 2, Item 1), flatwashers (Figure 2, Item 2), and U-bolt (Figure 2, Item 6) and remove
steering column assembly from bracket (Figure 2, Item 3). Retain support (Figure 2, Item 5) and shim
(Figure 2, Item 4) as column is removed.
0067-2
TM 5-3805-255-14 0067
Figure 2. Steering Column Removal. 067
0067-3
TM 5-3805-255-14 0067
DISASSEMBLY 00067
1. Remove nut (Figure 3, Item 1), washer (Figure 3, Item 2), spring (Figure 3, Item 3), seat (Figure 3, Item 4), and
bearing (Figure 3, Item 5) from column jacket (Figure 3, Item 6).
Figure 3. Steering Column Disassembly. 067
2. Slide shaft (Figure 4, Item 1) from column jacket (Figure 4, Item 2).
Figure 4. Shaft Removal. 067
0067-4
TM 5-3805-255-14 0067
3. Remove retainer (Figure 5, Item 1) and seal (Figure 5, Item 2) from column jacket (Figure 5, Item 4). Use a
suitable puller to pull old bushing (Figure 5, Item 3) from column jacket.
Figure 5. Seal and Bushing Removal. 067
END OF TASK
1. Thoroughly clean and inspect all metal parts IAW General Maintenance Instructions (WP 0019) in clean
solvent and dry with compressed air.
2. Inspect column upper bearing and lower bushing. Replace if necessary.
END OF TASK
0067-5
TM 5-3805-255-14 0067
ASSEMBLY 00067
1. Press bushing (Figure 6, Item 3) in column jacket (Figure 6, Item 4).

2. Install seal (Figure 6, Item 2) and retainer (Figure 6, Item 1) on column jacket (Figure 6, Item 4).
Figure 6. Seal and Bushing Installation. 067
CAUTION
Use care not to damage bushing when installing shaft to column jacket.
3. Slide shaft (Figure 7, Item 1) in column jacket (Figure 7, Item 2).
Figure 7. Shaft Installation. 067
0067-6
TM 5-3805-255-14 0067
4. Install bearing (Figure 8, Item 5) in column jacket (Figure 8, Item 6) using a suitable driver to bear on outer race
of bearing.
5. Install seat (Figure 8, Item 4), spring (Figure 8, Item 3), washer (Figure 8, Item 2), and nut (Figure 8, Item 1) on
steering shaft.
Figure 8. Steering Column Disassembly. 067
END OF TASK
0067-7
TM 5-3805-255-14 0067
INSTALLATION 00067
NOTE
Steering column flange on bottom must be aligned with steering gear flange when
installing column to loader.
1. Install steering column to bracket (Figure 9, Item 3) placing shim (Figure 9, Item 4) and support (Figure 9,
Item 5) between column and bracket.
2. lnstall U-bolt (Figure 9, Item 6) around column and through holes in bracket (Figure 9, Item 3).
3. Install two flatwashers (Figure 9, Item 2) and nuts (Figure 9, Item 1).
4. Install two new lockwashers (Figure 9, Item 8) and nuts (Figure 9, Item 7) on steering column flange (Figure 9,
Item 9).
0067-8
TM 5-3805-255-14 0067
Figure 9. Steering Column Installation. 067
0067-9
TM 5-3805-255-14 0067
5. Install spring (Figure 10, Item 5) and steering wheel (Figure 10, Item 4) on steering column (Figure 10, Item 6).
6. Install washer (Figure 10, Item 3) and nut (Figure 10, Item 2) on steering column (Figure 10, Item 6).
7. Install button plug (Figure 10, Item 1) on steering wheel (Figure 10, Item 4).
Figure 10. Steering Wheel Replacement. 067
END OF TASK
END OF WORK PACKAGE
0067-10
4
TM 5-3805-255-14 0068
FIELD MAINTENANCE -
0 0 6 8 STEERING GEAR REPLACEMENT/ADJUSTMENT

INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

0004) 0
Lockwasher 0
Drag link removed from pitman arm (WP

0069) 0
Wheels chocked 0
REMOVAL 00068
1. Remove pitman arm retaining nut (Figure 1, Item 1), lockwasher (Figure 1, Item 2), and pitman arm (Figure 1,
Item 3) from steering gear (Figure 1, Item 4). Discard lockwasher.
Figure 1. Steering Gear Disconnection. 068
0068-1
TM 5-3805-255-14 0068
2. Remove three bolts (Figure 2, Item 1) and steering gear (Figure 2, Item 2) from loader.
END OF TASK
INSTALLATION 00068
1. Install steering gear (Figure 2, Item 2) and three bolts (Figure 2, Item 1) on loader.
2. Align keyway in pitman arm (Figure 3, Item 3) with key in steering gear (Figure 3, Item 4) shaft and install
pitman arm on steering gear. Install new lockwasher (Figure 3, Item 2) and nut (Figure 3, Item 1). Tighten nut to
100 to 125 lb-ft (136 to 169 Nm).
Figure 3. Steering Gear Installation. 068
END OF TASK
0068-2
TM 5-3805-255-14 0068
ADJUSTMENT 00068
1. Loosen locknut (Figure 4, Item 2) and turn lash adjuster screw (Figure 4, Item 1) all the way in (clockwise),
then out (counterclockwise) three turns. This will remove load imposed on worm bearings by close meshing of
rack and sector teeth.
NOTE
Do not turn hard against stops as damage to ball guides may result.
2. Using a socket on steering gear worm shaft (Figure 4, Item 3), turn shaft from one stop all the way to the other
carefully counting total number of turns.
3. Turn the steering gear worm shaft back half the total number back half the total number of turns to center
position and using a lb-in. torque wrench, measure pull required to keep worm shaft in motion through center
position. This should be 1.5 to 5.5 lb-in. (0.169 to 0.621 Nm).
Figure 4. Adjustment. 068
0068-3
TM 5-3805-255-14 0068
4. If indicated pull does not lie between given limits, make the following adjustments:
a. Loosen locknut (Figure 5, Item 2).
b. Turn adjuster (Figure 5, Item 1) until required resistance to pull (1.5 to 5.5 lb-in. [0.169 to 0.621 Nm)] is
reached.
c. Tighten locknut (Figure 5, Item 2) to 18 to 27 lb-ft (24 to 37 Nm) torque and recheck pull. Pull resistance
must lie between limits specified after locknut is tightened.
d. Turn lash adjuster screw (Figure 5, Item 1) clockwise to remove lash from ball nut (Figure 5, Item 4) gear
teeth and pitman shaft (Figure 5, Item 3) gear teeth. Tighten locknut (Figure 5, Item 2).
e. Check pull with socket and lb-in. torque wrench as before, taking highest reading of scare as shaft is
turned through center position. This should be 3.0 to 7.0 lb-in. (0.339 to 0.790 Nm) over bearing adjust-
ment but not to exceed a total of 11.0 lb-in. (1.24 Nm).
f. Readjust lash adjuster screw (Figure 5, Item 1) if necessary to obtain proper pull. Tighten locknut (Figure
5, Item 2) to 18 to 27 lb-ft (24 to 37 Nm) torque and recheck pull. Pull resistance must lie between specified
limits after locknut is tightened.
6. Install drag link to pitman arm (WP 0072).
Figure 5. Gear Lash Final Adjustment. 068
END OF TASK
END OF WORK PACKAGE
0068-4
10
TM 5-3805-255-14 0069
FIELD MAINTENANCE -
STEERING LINKAGE REPLACEMENT

0 0 6 9
Removal, Disassembly, Cleaning and Inspection, Assembly, Installation, Adjustment
INITIAL SETUP
0128, Item 20) 0

WP 0019 0
Puller, Gear 0
Materials/Parts 0
0130, Item 15) 0

Cotter Pin (2) 0
(WP 0004) 0
Lockwasher (4) 0
Nut, Self-Locking (4) 0

Personnel 0
Two 0
REMOVAL 00069
WARNING
Keep personnel clear of articulation area when moving. Align frame halves and install
safety bar with wheels in straight-ahead position. Failure to install safety bar could lead to
serious injury or death.
0069-1
TM 5-3805-255-14 0069
1. Remove locknut (Figure 1, Item 2) and washer (Figure 1, Item 3) from drag link (Figure 1, Item 5) on lever arm
(Figure 1, Item 4). Discard locknut.
2. Remove cotter pin (Figure 1, Item 10) from tie-rod end (Figure 1, Item 13). Discard cotter pin.
3. Loosen plug (Figure 1, Item 11) until ball-stud (Figure 1, Item 12) on steering gear (Figure 1, Item 9) clears
large opening in tie-rod end (Figure 1, Item 13). Remove drag link (Figure 1, Item 17) from loader.
4. Remove locknut (Figure 1, Item 6), bolt (Figure 1, Item 8), bushing (Figure 1, Item 20), and steering rod
(Figure 17) from lever arm (Figure 1, Item 4). Discard locknut.
5. Remove bolt (Figure 1, Item 16), locknut (Figure 1, Item 14), and steering rod (Figure 1, Item 7) from steering
front end (Figure 1, Item 15). Discard locknut.
6. Remove nut (Figure 1, Item 18) flat washer (Figure 1, Item 19), and lever arm (Figure 1, Item 4) from pivot
plate (Figure 1, Item 1).
7. Remove three bolts (Figure 1, Item 22), lockwashers (Figure 1, Item 23), and washers (Figure 1, Item 24) from
pivot plate (Figure 1, Item1). Discard lockwashers.
8. Remove bearing (Figure 1, Item 21) from lever arm (Figure 1, Item 4).
0069-2
TM 5-3805-255-14 0069
Figure 1. Steering Linkage. 0069
0069-3
TM 5-3805-255-14 0069
NOTE
Before removing pitman arm from steering gear, mark pitman arm and sector shaft to align
for assembly.
9. Remove nut (Figure 2, Item 1) and lockwasher (Figure 2, Item 2) from pitman arm (Figure 2, Item 3). Discard
lockwasher.
10. Remove pitman arm (Figure 2, Item 3) from steering gear (Figure 2, Item 4).
Figure 2. Pitman Arm. 0069
END OF TASK
0069-4
TM 5-3805-255-14 0069
DISASSEMBLY 00069
1. Loosen nut (Figure 3, Item 10) on clamp assembly (Figure 3, Item 2) and remove tie-rod end (Figure 3, Item 3)
from drag link (Figure 3, Item 1).
2. Remove grease fitting (Figure 3, Item 8) from plug (Figure 3, Item 9).
3. Remove plug (Figure 3, Item 9) from tie-rod end (Figure 3, Item 3).
4. Remove two ball-stud seats (Figure 3, Item 7), spring (Figure 3, Item 6), safety plug (Figure 3, Item 5), and
seat (Figure 3, Item 4) from tie-rod end (Figure 3, Item 3).
Figure 3. Tie-Rod End. 0069
END OF TASK
END OF TASK
0069-5
TM 5-3805-255-14 0069
ASSEMBLY 00069
NOTE
Assembly is for both tie-rod ends.
1. Install seat (Figure 4, Item 4), safety plug (Figure 4, Item 5), spring (Figure 4, Item 6), two ball-stud seats
(Figure 4, Item 7), and plug (Figure 4, Item 9) into tie-rod end (Figure 4, Item 3).
2. Grease ball-stud seats (Figure 4, Item 7).
NOTE
DO NOT compress spring.
3. Tighten plug (Figure 4, Item 9) one to two turns.
4. Install grease fitting (Figure 4, Item 8) in plug (Figure 4, Item 9).
5. Install tie-rod end (Figure 4, Item 3) in drag link (Figure 4, Item 1).
6. Do not tighten nut (Figure 4, Item 10) on clamp assembly (Figure 4, Item 2) at this time.
H100C-0446
Figure 4. Tie-Rod End. 0069
END OF TASK
0069-6
TM 5-3805-255-14 0069
INSTALLATION 00069
NOTE
Installation covers both tie-rod ends. Line up marks on pitman arm with sector shaft to
install. If new pitman arm is being installed, center steering gear. Center steering gear by
turning steering wheel gently to stop as far as it will go in one direction. Count turns it
takes to turn steering wheel to opposite stop. Turn wheel back half of total turns to center
steering gear. Install pitman arm 90 degrees to floor on steering gear.
1. Install pitman arm (Figure 5, Item 3), new lockwasher (Figure 5, Item 2), and nut (Figure 5, Item 1) on steering
gear (Figure 5, Item 4).
Figure 5. Pitman Arm. 0069
0069-7
TM 5-3805-255-14 0069
2. Install bearing (Figure 6, Item 21) in lever arm (Figure 6, Item 4).
3. Install lever arm (Figure 6, Item 4) on pivot plate (Figure 6, Item 1).
4. Install three washers (Figure 6, Item 24), new lockwashers (Figure 6, Item 23), and bolts (Figure 6, Item 22) on
pivot plate (Figure 6, Item 1).
5. Install flat washer (Figure 6, Item 19) and nut (Figure 6, Item 18) on pivot plate (Figure 6, Item 1).
6. Install steering rod (Figure 6, Item 7) on loader.
7. Install steering rod (Figure 6, Item 7), bolt (Figure 6, Item 16), and new locknut (Figure 6, Item 14) on steering
rod end (Figure 6, Item 15).
NOTE
Loosen locknut on steering rod end to demand valve. Turn steering rod end in or out of
demand valve to line up holes with steering rod with lever arm centered.
8. Install steering rod (Figure 6, Item 7), bolt (Figure 6, Item 8), and new locknut (Figure 6, Item 6) on lever arm
(Figure 6, Item 4).
NOTE
Ball-stud on steering gear must be positioned between the two ball-stud seats within the
tie-rod end.
9. Align ball-stud (Figure 6, Item 12) on steering gear (Figure 6, Item 9) with large opening in tie-rod end
(Figure 6, Item 13), and install drag link (Figure 6, Item 17) on loader.
10. Tighten plug (Figure 6, Item 11) until no free play exists. DO NOT compress spring. Tighten plug an additional
half-turn to compress spring.
11. Line up slot in plug (Figure 6, Item 11) with cotter pin holes in tie-rod end (Figure 6, Item 13). If not aligned,
tighten plug until new cotter pin (Figure 6, Item 10) slides in. Bend cotter pin.
NOTE
Tighten down clamps on tie-rod ends after drag link is installed.
12. Install washer (Figure 6, Item 3) and new locknut (Figure 6, Item 2) on drag link stud (Figure 6, Item 17) on
lever arm (Figure 6, Item 5).
0069-8
TM 5-3805-255-14 0069
Figure 6. Steering Linkage.
13. Grease tie-rod ends (WP 0013).

14. Remove safety bar (WP 0005).
END OF TASK
ADJUSTMENT
WARNING
Keep personnel clear of articulation area when moving. Failure to follow this warning
may result in injury or death to personnel.
1. Start engine. Turn loader to right so frame closes. Lock frame halves together with frame locking safety pin.
Turn engine off.
0069-9
TM 5-3805-255-14 0069
2. Adjust lock stop bolt (Figure 7, Item 1) until snug against pitman arm (Figure 7, Item 6) on steering gear
(Figure 7, Item 3).
3. Tighten nut (Figure 7, Item 2) to lock stop bolt (Figure 7, Item 1).
WARNING
Keep personnel clear of articulation area when moving. Failure to follow this warning may
4. Remove frame locking safety pin. Start engine and turn loader to left. Install frame locking safety pin. Turn
engine off.
5. Adjust stop bolt (Figure 7, Item 5) until snug against pitman arm (Figure 7, Item 6) on steering gear (Figure 7,
Item 3).
6. Tighten nut (Figure 7, Item 4) to lock stop bolt (Figure 7, Item 5).
Figure 7. Steering Gear Lock Stop Bolt.
7. Remove safety bar from loader (WP 0005).

END OF TASK
END OF WORK PACKAGE
0069-10
4
TM 5-3805-255-14 0070
FIELD MAINTENANCE -
0 0 7 0 STEERING PUMP ASSEMBLY REPLACEMENT

INITIAL SETUP
0128, Item 20) 0

and Repair: Organizational Maintenance Machine parked on level ground (WP 0005) 0
Materials/Parts 0

Cap Set, Protective Dust and Moisture Seal 0004) 0
(WP 0130, Item 3) 0

22) 0
Wheels chocked 0
Lockwasher (2) 0
O-Ring (2) 0
Personnel 0
Two 0
0070-1
TM 5-3805-255-14 0070
REMOVAL 00070
NOTE
1. Remove hydraulic line (Figure 1, Item 1) from hydraulic reservoir (WP 0079).
2. Remove four bolts (Figure 1, Item 2), two split flanges (Figure 1, Item 3), hydraulic line (Figure 1, Item 1) and
O-ring (Figure 1, Item 4) from steering pump (Figure 1, Item 9). Discard O-ring.
O-ring (Figure 1, Item 8) from steering pump (Figure 1, Item 9). Discard O-ring.
4. Remove two bolts (Figure 1, Item 10) and lockwashers (Figure 1, Item 11) from steering pump (Figure 1, Item
9). Discard lockwashers.
CAUTION
Ensure splined shafts are not damaged when removing from converter. Failure to follow
5. Remove steering pump (Figure 1, Item 9) from converter.
Figure 1. Steering Pump. 0070
END OF TASK
0070-2
TM 5-3805-255-14 0070
INSTALLATION 00070
CAUTION
Ensure splined shafts are not damaged when removing from converter. Failure to follow
1. Install steering pump (Figure 1, Item 9) on converter.
2. Install two new lockwashers (Figure 1, Item 11) and bolts (Figure 1, Item 10) on converter.
3. Install new O-ring (Figure 1, Item 8), hydraulic line (Figure 1, Item 6), two split flanges (Figure 1, Item 7), and
four bolts (Figure 1, Item 5) on steering pump (Figure 1, Item 9).
four bolts (Figure 1, Item 2) on steering pump (Figure 1, Item 9).
END OF TASK
END OF WORK PACKAGE
0070-3/(4 blank)
6
TM 5-3805-255-14 0071
FIELD MAINTENANCE -
0 0 7 1 STEERING CYLINDER REPLACEMENT

INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0
(WP 0130, Item 3) 0

22) 0
0004) 0
Wheels chocked 0
REMOVAL 00071
WARNING
• DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut
down and hydraulic system pressure has been relieved.
• Escaping hydraulic fluid under pressure can penetrate the skin, causing injury to
personnel.
• When disposing of hydraulic fluid, consult your unit/local hazardous waste disposal center
or safety office for local regulatory guidance.
• Lubricating/hydraulic oils can be very slippery. Immediately wipe up any spills.
• Failure to follow these warnings may result in injury to personnel.
NOTE
This work package describes procedure and materials/parts for one cylinder. Tag and
identify cylinder prior to removal. Do not damage pivot bushings and pinlocks during
removal. Tag and identify all hose flanges for ease of installation and to protect and
identify for assembly. Cap all hose flanges to prevent contamination and leaks.
0071-1
TM 5-3805-255-14 0071
1. Remove hoses (Figure 1, Items 1 and 4) from steering cylinder (Figure 1, Item 5).
2. Remove bolt (Figure 1, Item 2) and flat washer (Figure 1, Item 3) from pinlock (Figure 1, Item 6).
3. Remove pinlock (Figure 1, Item 6) and weather seal clamps (Figure 1, Item 7) from steering cylinder (Figure 1,
Item 5). Do not damage pivot bushing (Figure 1, Item 8) during pinlock removal.
Figure 1. Steering Cylinder (Front). 0071
0071-2
TM 5-3805-255-14 0071
4. Remove hose (Figure 2, Item 6) from steering cylinder (Figure 2, Item 1).
5. Remove bolt (Figure 2, Item 2) and washer (Figure 2, Item 3) from pinlock (Figure 2, Item 4).
6. Remove pinlock (Figure 2, Item 4) and weather seal clamps (Figure 2, Item 5) from steering cylinder (Figure 2,
Item 1).
7. Remove steering cylinder (Figure 2, Item 1) from loader.
Figure 2. Steering Cylinder (Rear). 0071
END OF TASK
0071-3
TM 5-3805-255-14 0071
INSTALLATION 00071
NOTE
Make sure all hoses are tight and leak-free after installation.
1. With assistance, mount steering cylinder (Figure 3, Item 1) and two weather seal clamps (Figure 3, Item 5) in
original position on loader.
2. Install pinlock (Figure 3, Item 4) through steering cylinder (Figure 3, Item 1).
3. Install bolt (Figure 3, Item 2) and flat washer (Figure 3, Item 3) to secure pinlock (Figure 3, Item 4).
4. Install hose (Figure 3, Item 6) on steering cylinder (Figure 3, Item 1).
Figure 3. Steering Cylinder (Rear). 0071
0071-4
TM 5-3805-255-14 0071
5. Do not damage pivot bushing (Figure 4, Item 8) in pinlock (Figure 4, Item 6) during installation.
6. Install pinlock (Figure 4, Item 6) through weather seal clamps (Figure 4, Item 7) and steering cylinder (Figure 4,
Item 5).
7. Install bolt (Figure 4, Item 2) and flat washer (Figure 4, Item 3) to secure pinlock (Figure 4, Item 6) to frame.
8. Install hoses (Figure 4, Items 1 and 4) on steering cylinder (Figure 4, Item 5).
Figure 4. Steering Cylinder (Front). 0071
END OF TASK
END OF WORK PACKAGE
0071-5/(6 blank)
6
TM 5-3805-255-14 0072
FIELD MAINTENANCE -
STEERING CONTROL VALVE REPLACEMENT

0 0 7 2
Removal, Cleaning and Inspection, Installation, System Pressure Adjustment
INITIAL SETUP
0128, Item 20) 0

WP 0019 0
Gauge, High Pressure (5,000 psi) 0
Materials/Parts 0
(WP 0130, Item 3) 0
24) 0
0004) 0
O-Ring (4) 0
Hydraulic system drained (WP 0016) 0
Personnel 0
Wheels chocked 0
Two 0
WARNING
personnel.
NOTE
Tag and identify all hydraulic lines for ease of installation and to protect and identify for
assembly. Cap all hydraulic lines to prevent contamination and leaks.
0072-1
TM 5-3805-255-14 0072
REMOVAL 00072
1. Remove twelve bolts (Figure 1, Item 1), six split flanges (Figure 1, Item 2), three hydraulic lines (Figure 1,
Items 4, 5 and 6) and three O-rings (Figure 1, Item 3), from steering control valve (Figure 1, Item 11). Discard
O-rings.
2. Remove bolt (Figure 1, Item 7), nut (Figure 1, Item 8), washer (Figure 1, Item 9) and steering rod (Figure 1,
Item 10) from steering control valve (Figure 1, Item 11).
Figure 1. Steering Control Valve, Left Side. 0072
0072-2
TM 5-3805-255-14 0072
3. Loosen fitting (Figure 2, Item 2), and disconnect hydraulic line (Figure 2, Item 1) from steering control valve
(Figure 2, Item 9).
O-ring (Figure 2, Item 4) from steering control valve (Figure 2, Item 9). Discard O-ring.
5. Remove three bolts (Figure 2, Item 10), nuts (Figure 2, Item 7), six washers (Figure 2, Item 11), and steering
control valve (Figure 2, Item 9) from frame (Figure 2, Item 8).
Figure 2. Steering Control Valve, Right Side. 0072
END OF TASK
END OF TASK
0072-3
TM 5-3805-255-14 0072
INSTALLATION 00072
NOTE
• Remove caps and plugs from lines and ports before installation.
• Connect tagged lines to correct ports as noted in removal.
1. Install steering control valve (Figure 3, Item 9), six washers (Figure 3, Item 11), three bolts (Figure 3, Item 10),
and nuts (Figure 3, Item 7) on frame (Figure 3, Item 8).
2. Install new O-ring (Figure 3, Item 4), hydraulic line (Figure 3, Item 3), two split flanges (Figure 3, Item 5) and
four bolts (Figure 3, Item 6) on steering control valve (Figure 3, Item 9).
3. Connect hydraulic line (Figure 3, Item 1) to steering control valve (Figure 3, Item 9) and tighten fitting (Figure 3,
Item 2).
Figure 3. Steering Control Valve, Right Side. 0072
0072-4
TM 5-3805-255-14 0072
4. Connect steering rod (Figure 4, Item 10), bolt (Figure 4, Item 7), washer (Figure 4, Item 9) and nut (Figure 4,
Item 8) on steering control valve (Figure 3, Item 11).
5. Install three new O-rings (Figure 4, Item 3), three hydraulic lines (Figure 4, Items 4, 5, and 6), six split flanges
(Figure 4, Item 2) and twelve bolts (Figure 4, Item 1), on steering control valve (Figure 4, Item 11).
6. Fill hydraulic reservoir (WP 0018).
7. Remove safety bar (WP 0005).
8. Turn battery disconnect switch to ON position and start engine (WP 0005). Check for leaks and proper steering
operation.
Figure 4. Steering Control Valve, Left Side. 0072
END OF TASK
0072-5
TM 5-3805-255-14 0072
ADJUSTMENT 00072
WARNING
Before attempting to adjust pressure relief valve, align frame halves and install loader
safety bar in straight ahead position. Failure to follow warning may result in injury or death
to personnel.
1. Remove pipe plug from tee at front end of left-hand steering cylinder and install a test gauge (5,000 psi
capacity).
2. Hold capnut (Figure 5, Item 4) and remove nut (Figure 5, Item 1) from steering control valve (Figure 5, Item 5).
3. Hold adjusting screw (Figure 5, Item 2) and loosen capnut (Figure 5, Item 4) on steering control valve (Figure
5, Item 5).
4. Start engine and allow it to run at low speed until hydraulic fluid reaches operating temperature.
5. Turn steering wheel to left until all slack is taken up. Accelerate engine to full throttle and read pressure
indicated on test gauge. Idle the engine. If indicated pressure is not within recommended limits, adjustment is
necessary. Refer to System Pressures (WP 0002) for recommended setting.
6. To adjust pressure, hold capnut (Figure 5, Item 4) and rotate adjusting screw (Figure 5, Item 2) clockwise to
increase and counterclockwise to decrease pressure. Recheck indicated pressure.
NOTE
Must set preload on adjusting screw. Always turn clockwise one half-turn to set spring
preload.
7. When correct pressure is obtained, hold adjusting screw (Figure 5, Item 2) and tighten capnut (Figure 5,
Item 4) on steering control valve (Figure 5, Item 5).
8. Install washer (Figure 5, Item 3), and nut (Figure 5, Item 1) on steering control valve (Figure 5, Item 5).
9. Stop the engine. Remove test gauge and replace pipe plug. Remove safety bar.
Figure 5. Steering Control Valve Adjustment. 0072
END OF TASK
END OF WORK PACKAGE
0072-6
10
TM 5-3805-255-14 0073
FIELD MAINTENANCE -
DEMAND VALVE REPLACEMENT AND REPAIR

0 0 7 3
INITIAL SETUP
Tools and Special Tools 0 Personnel 0
0128, Item 20) 0
References 0
Materials/Parts 0
WP 0019 0
Adhesive, Thread (WP 0130, Item 1) 0
Cap Set, Protective Dust and Moisture Seal

(WP 0130, Item 3) 0
22) 0 Engine OFF (WP 0005) 0
Rag, Wiping (WP 0130, Item 28) 0 Battery disconnect switch in OFF position (WP
0004) 0
Gasket 0
O-Ring (7) 0
Hydraulic system drained (WP 0016) 0
Wheels chocked 0
WARNING
personnel.
NOTE
Tag and identify all hose flanges for ease of installation and to protect and identify for
assembly. Cap all hose flanges to prevent contamination and leaks.
0073-1
TM 5-3805-255-14 0073
REMOVAL 00073
1. Remove four machine bolts (Figure 1, Item 3), two split flanges (Figure 1, Item 14), hydraulic line (Figure 1,
Item 5) and O-ring (Figure 1, Item 2) from demand valve (Figure 1, Item 7). Discard O-ring.
2. Remove four machine bolts (Figure 1, Item 8), two split flanges (Figure 1, Item 4), hydraulic line (Figure 1, Item
1), and O-ring (Figure 1, Item 6) from demand valve (Figure 1, Item 7). Discard O-ring.
4. Remove bolt (Figure 1, Item 10) from demand valve (Figure 1, Item 7).
Figure 1. Demand Valve, Passenger Side. 0073
0073-2
TM 5-3805-255-14 0073
6. Remove two bolts (Figure 2, Item 1) and nuts (Figure 2, Item 2) from demand valve. Remove demand valve
(Figure 2, Item 3) from frame.
Figure 2. Demand Valve, Driver Side. 0073
END OF TASK
0073-3
TM 5-3805-255-14 0073
DISASSEMBLY 00073
1. Remove cap (Figure 3, Item 1) and O-ring (Figure 3, Item 2) from valve body (Figure 3, Item 5). Discard O-ring.
2. Remove retaining ring (Figure 3, Item 3) and orifice plug (Figure 3, Item 4) from valve body (Figure 3, Item 5).
3. Remove cap (Figure 3, Item 19), O-ring (Figure 3, Item 20), spring (Figure 3, Item 21), and check valve (Figure
3, Item 22) from valve body (Figure 3, Item 5). Discard O-ring.
4. Remove two bolts (Figure 3, Item 23), plate (Figure 3, Item 24), and gasket (Figure 3, Item 25) from valve body
5. Remove cap (Figure 3, Item 14), O-ring (Figure 3, Item 15), and spring (Figure 3, Item 16) from valve body
(Figure 3, Item 5). Discard O-ring.
6. Remove retaining ring (Figure 3, Item 17) and valve assembly (Figure 3, Item 18) from valve body (Figure 3,
Item 5).
7. Remove retaining ring (Figure 3, Item 13), from valve assembly (Figure 3, Item 18).
8. Remove plug (Figure 3, Item 12), seat (Figure 3, Item 11), and check (Figure 3, Item 10) from valve assembly
9. Remove spring (Figure 3, Item 9), cap (Figure 3, Item 8), spring (Figure 3, Item 7), and check (Figure 3, Item 6)
from valve assembly (Figure 3, Item 18).
0073-4
TM 5-3805-255-14 0073
Figure 3. Demand Valve. 0073
END OF TASK
00073
0073-5
TM 5-3805-255-14 0073
2. Inspect all surfaces for burrs, scratches, nicks, scores, and other abrasions. Replace worn or damaged valves.
3. All parts with sliding fit must move freely in their bores. All grooves and passages must be free of foreign
matter.
4. Replace springs if broken or distorted.
5. For effective sealing of O-rings.
a. Seal counter bores must be thoroughly cleaned.
b. Coat O-rings, plungers, and counter bores with lubricant before assembly.
c. O-rings must be free of molding defects and handling damage.
d. O-rings must not be stretched beyond yield point.
END OF TASK
ASSEMBLY 00073
NOTE
Apply thread adhesive to caps before assembly.
1. Install check (Figure 4, Item 6), spring (Figure 4, Item 7), cap (Figure 4, Item 8), and spring (Figure 4, Item 9)
on valve assembly (Figure 4, Item 18).
2. Install check (Figure 4, Item 10), seat (Figure 4, Item 11), and plug (Figure 4, Item 12) on valve assembly
3. Install retaining ring (Figure 4, Item 13) on valve assembly (Figure 4, Item 18).
4. Install valve assembly (Figure 4, Item 18) and retaining ring (Figure 4, Item 17) on valve body (Figure 4,
Item 5).
5. Install spring (Figure 4, Item 16), new O-ring (Figure 4, Item 15), and cap (Figure 4, Item 14) on valve body
(Figure 3, Item 5).
6. Install gasket (Figure 4, Item 25), plate (Figure 4, Item 24), and two bolts (Figure 4, Item 23) on valve body
(Figure 3, Item 5).
7. Install check valve (Figure 4, Item 22), spring (Figure 4, Item 21), new O-ring (Figure 4, Item 20), and cap
(Figure 4, Item 19) on valve body (Figure 4, Item 5).
8. Install orifice plug (Figure 4, Item 4) and retaining ring (Figure 4, Item 3) on valve body (Figure 4, Item 5).
9. Install new O-ring (Figure 4, Item 2) and cap (Figure 4, Item 1) on valve body (Figure 4, Item 5).
0073-6
TM 5-3805-255-14 0073
Figure 4. Demand Valve. 0073
00073
0073-7
TM 5-3805-255-14 0073
INSTALLATION 00073
1. Install demand valve (Figure 5, Item 6), two bolts (Figure 5, Item 1), and nuts (Figure 5, Item 6) on frame.
NOTE
Connect previously tagged lines to their proper ports as identified on removal. Use new
O-rings at all split flange connections. Be sure all connections are tight and leak-free.
four machine bolts (Figure 5, Item 4) on demand valve.
Figure 5. Demand Valve, Driver Side. 0073
0073-8
TM 5-3805-255-14 0073
3. Install bolt (Figure 6, Item 10) on demand valve (Figure 6, Item 7).
four machine bolts (Figure 6, Item 11) on demand valve (Figure 6, Item 7).
7. Check and refill hydraulic reservoir to correct level (WP 0016).
8. Turn battery disconnect switch to ON position and start engine.
9. Operate hydraulic equipment and check demand valve and lines for leaks.
Figure 6. Demand Valve, Passenger Side. 0073
END OF TASK
END OF WORK PACKAGE
0073-9/(10 blank)
4
TM 5-3805-255-14 0074
FIELD MAINTENANCE -
CENTER HINGE ADJUSTMENT

0 0 7 4
Locking Frame, Center Hinge Adjustment
INITIAL SETUP
0128, Item 20) 0
Dial Indicator 0
Materials/Parts 0


(WP 0004) 0
LOCKING FRAME 00074
WARNING
Align frame halves and install safety bar with wheels in straight-ahead position. Failure to
To lock loader halves in straight position, remove rear cotter pin (Figure 1, Item 2) and locking pin (Figure 1, Item
1), swing bar (Figure 1, Item 3) forward, and align with hole in forward section, and replace pins.
Figure 1. Safety Bar and Pin in Straight Lock Position. 0074
END OF TASK
0074-1
TM 5-3805-255-14 0074
CENTER HINGE ADJUSTMENT 00074
1. Place boom and bucket control lever in FLOAT position (WP 0005).
2. Adjust hinge spacing so frame tongues (Figure 2, Items 4 and 7) are centered between rear frame ears
(Figure 2, Items 3, 5, 6 and 8), such that A dimensions as shown in Figure 2 are the same. (A dimension may
not be the same as B dimension.)
Figure 2. Tongue Spacing. 0074
WARNING
Do not loosen bottom nut more than 30°. Failure to follow this warning may result in injury
or death to personnel.
3. Loosen bottom nut (Figure 3, Item 10) before any adjustment.
4. If front frame tongues are too high, loosen top nut (Figure 3, Item 1) until tongues are centered.
5. Install retainer plate (Figure 3, Item 2). Note that two retainer plate positions are available by turning plate over.
6. Once adjustment has been made, tighten bottom nut (Figure 3, Item 10) to 225 to 250 lb-ft (305 to 339 Nm) to
seat mating parts in hinge assembly. Loosen bottom nut.
7. Tighten bottom nut (Figure 3, Item 10) using retainer plate (Figure 3, Item 9) as a wrench. Hinge should be just
snug at this point. DO NOT OVER-TIGHTEN.
8. If holes in retainer plate (Figure 3, Item 9) line up with tapped holes in frame, install plate. Note that two
positions are available by turning retainer plate over.
9. If holes in retainer plate (Figure 3, Item 9) do not line up with tapped holes in frame (in either retainer plate
position), loosen bottom nut (Figure 3, Item 10) until plate holes line up with frame holes. (Because two retainer
plate positions are available, the amount of nut loosening required will always be less than 30°.)
10. Install retainer plate (Figure 3, Item 9).
11. Lubricate upper and lower hinges (WP 0018).
0074-2
TM 5-3805-255-14 0074
CENTER HINGE ADJUSTMENT – CONTINUED
Figure 3. Center Hinge Bushing. 0074
0074-3
TM 5-3805-255-14 0074
CENTER HINGE ADJUSTMENT – CONTINUED

12. To adjust pin lock, bring pin lockplate (Figure 4 and Figure 5, Item 3) into contact with block (Figure 4 and
Figure 5, Item 4).
13. Rotate cam (Figure 4 and Figure 5, Item 2) clockwise to contact pin lockplate (Figure 4 and Figure 5, Item 3).
14. Tighten cam capscrew (Figure 4 and Figure 5, Item 1).
15. Repeat steps 11 through 13 for other hinge.
16. Position a dial indicator with its base on front frame and indicator needle on rear frame. Start engine and power
boom down until front tires clear the ground. Read and record indicator dial reading.
17. Raise boom to maximum height and read and record indicator dial reading. Total vertical movement shown by
dial indicator (difference between both readings) should not exceed 0.010 in. (0.254 mm).
18. If movement is excessive, repeat hinge adjustment procedure and re-check with dial indicator.
Figure 4. Upper Hinge Detail. 0074
Figure 5. Lower Hinge Detail. 0074
END OF TASK
END OF WORK PACKAGE
0074-4
30
TM 5-3805-255-14 0075
FIELD MAINTENANCE -
CAB REPLACEMENT
0 0 7 5
INITIAL SETUP
0128, Item 20) 0

WP 0041 0
Materials/Parts 0


Gasket 0
Batteries disconnected (WP 0005) 0
Locknut (8) 0
Lockwasher (56) 0
Cooling system drained (WP 0018) 0
Accelerator pedal removed (WP 0033) 0
Boom and bucket control levers removed

Two 0
(WP 0080) 0
Washer reservoir removed 0
REMOVAL 00075
1. Disconnect power wire (Figure 1, Item 1) from heater (Figure 1, Item 2).
Figure 1. Power Wire. 0075
0075-1
TM 5-3805-255-14 0075
WARNING
down. Loosen cap to first stop and let any pressure out of cooling system, them remove
cap.
• Failure to follow these warnings may cause injury or serious burns to personnel.
NOTE
Note and identify routing of heater hoses through machine. New heater hoses will be
installed in the same locations.
2. Disconnect hoses (Figure 2, Item 1) from under right side of cab (Figure 2, Item 2).
0075-2
TM 5-3805-255-14 0075
NOTE
• Tag and identify all air lines to aid in installation.
• Note and identify routing of air lines prior to removal from loader to aid in installation.
3. Remove four bolts (Figure 3, Item 4), lockwashers (Figure 3, Item 5), and cover (Figure 3, Item 1) from boom
stop control bracket (Figure 3, Item 8). Discard lockwashers.
4. Disconnect three air lines (Figure 3, Item 6) from wiper control valve (Figure 3, Item 7).
5. Remove knob (Figure 3, Item 2), nut (Figure 3, Item 3), and wiper control valve (Figure 3, Item 7) from cover
(Figure 3, Item 1).
Figure 3. Wiper Control Valve. 0075
0075-3
TM 5-3805-255-14 0075
NOTE
• Note and identify routing of air lines prior to removal from loader to aid in installation
6. Remove two nuts (Figure 4, Item 5), washers (Figure 4, Item 6), and wiper arm assembly (Figure 4, Item 4)
from cab (Figure 4, Item 7).
7. Disconnect two air lines (Figure 4, Item 3) from wiper motor (Figure 4, Item 1).
8. Remove nut (Figure 4, Item 11) and lockwasher (Figure 4, Item 12) from wiper motor shaft (Figure 4, Item 13).
Discard lockwasher.
9. Remove two screws (Figure 4, Item 9), washers (Figure 4, Item 10), spacer assembly (Figure 4, Item 8), wiper
motor (Figure 4, Item 1) and gasket (Figure 4, Item 2) from front of cab (Figure 4, Item 7). Discard gasket.
Figure 4. Wiper Motor and Arms. 0075
0075-4
TM 5-3805-255-14 0075
10. Remove two pins Figure 5, Item 2) and control rod (Figure 5, Item 4) from boom stop positioner control
Figure 5, Item 3) and boom (Figure 5, Item 1).
Figure 5. Control Rod. 0075
NOTE
• Note and identify routing of air lines prior to removal from loader to aid in installation
11. Disconnect three air lines Figure 6, Item 7) from boom stop positioner control (Figure 6, Item 1).
12. Remove two nuts (Figure 6, Item 6), lockwashers (Figure 6, Item 5), bolts (Figure 6, Item 4), washers (Figure 6
Item 3), and boom stop positioner control (Figure 6, Item 1) from side wall of cab (Figure 6, Item 2). Discard
lockwashers.
Figure 6. Boom Stop Positioner Control. 0075
0075-5
TM 5-3805-255-14 0075
13. Tilt seat (Figure 7, Item 1) forward.
14. Remove four nuts (Figure 7, Item 2), lockwashers (Figure 7, Item 3), bolts (Figure 7, Item 5), washers
(Figure 7, Item 4), and seat assembly (Figure 7, Item 1) from cab ((Figure 7, Item , Item 6). Discard lockwash-
ers.
Figure 7. Seat Assembly. 0075
0075-6
TM 5-3805-255-14 0075
NOTE
Tag and identify all wires and harnesses to aid in installation.
15. Disconnect red wire (Figure 8, Item 1) from start button (WP 0041).
16. Under left side of cab, pull red wire (Figure 8, Item 1) through floor support plate (Figure 8, Item 2) and remove
from cab.
17. Disconnect air line (Figure 8, Item 3) from floor support plate (Figure 8, Item 2).
Figure 8. Floor Wiring. 0075
0075-7
TM 5-3805-255-14 0075
18. Remove two bolts (Figure 9, Item 3), lockwashers (Figure 9, Item 4), and control box cover (Figure 9, Item 2)
from control box (Figure 9, Item 11). Discard lockwashers.
19. Remove eight locknuts (Figure 9, Item 10), washers (Figure 9, Item 9), bolts (Figure 9, Item 7), and washers
(Figure 9, Item 8) from control box (Figure 9, Item 11) and connector plate (Figure 9, Item 6). Discard locknuts.
20. Disconnect two electrical connectors (Figure 9, Item 5) and feed connector plate (Figure 9, Item 6) through
hole in cab floor (Figure 9, Item 1).
21. Remove control box (Figure 9, Item 11) and control box cover (Figure 9, Item 2) from loader.
H100C-1106
Figure 9. Control Box and Cover. 0075
0075-8
TM 5-3805-255-14 0075
NOTE
Ladder and hand rail weighs 95 lb (43 kg).
22. Remove six bolts (Figure 10, Item 2), self-supporting nuts (Figure 10, Item 3), handrail (Figure 10, Item 1), and
ladder (Figure 10, Item 4) from loader.
Figure 10. Ladder and Handrail. 0075
0075-9
TM 5-3805-255-14 0075
WARNING
assistance during procedure. Ensure any lifting device used is in good condition and of
suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to
23. Attach suitable lifting device to four lifting links (Figure 11, Item 1) on cab (Figure 11, Item 2) with equal tension
on all four links.
Figure 11. Cab. 0075
24. Remove nine nuts (Figure 12, Item 4), lockwashers (Figure 12, Item 3), bolts (Figure 12, Item 1), and washers
(Figure 12, Item 2) from right, left, and rear edges of cab floor (Figure 12, Item 5). Discard lockwashers.
Figure 12. Cab Bottom Fasteners. 0075
0075-10
TM 5-3805-255-14 0075
WARNING
suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure
to follow this warning may cause injury or death to personnel.
25. Remove four nuts (Figure 13, Item 4), lockwashers (Figure 13, Item 3), bolts (Figure 13, Item 1), and washers
(Figure 13, Item 2) from left and right sides of cab (Figure 13, Item 9). Discard lockwashers.
(Figure 13, Item 5) from left and right sides of cab (Figure 13, Item 9). Discard lockwashers.
Figure 13. Cab Side Fasteners. 0075
0075-11
TM 5-3805-255-14 0075
WARNING
27. Using a suitable lifting device, remove cab (Figure 14, Item 9) from loader and lower onto wood blocks on a flat
surface.
28. Remove lifting device and sling from cab.
29. Remove two nuts (Figure 14, Item 5), lockwashers (Figure 14, Item 4), bolts (Figure 14, Item 2), washers
(Figure 14, Item 3), and bracket (Figure 14, Item 1) from cab floor (Figure 14, Item 6). Discard lockwashers.
0075-12
TM 5-3805-255-14 0075
30. Remove six nuts (Figure 15, Item 4), lockwashers (Figure 15, Item 3), bolts (Figure 15, Item 1), and washers
(Figure 15, Item 2) from left edge of floor plate (Figure 15, Item 5). Discard lockwashers.
(Figure 15, Item 7) from lower edge of upper floor plate (Figure 15, Item 10). Discard lockwashers.
32. Attach suitable lifting device to upper floor plate (Figure 15, Item 10).
WARNING
33. Using suitable lifting device, remove upper floor plate (Figure 15, Item 10) from loader and lower onto flat
surface.
34. Remove lifting device from upper floor plate.
Figure 15. Upper Floor Plates. 0075
0075-13
TM 5-3805-255-14 0075
(Figure 16, Item 2) from left floor plate (Figure 16, Item 5). Discard lockwashers.
WARNING
equipment.
36. With assistance, remove left floor plate (Figure 16, Item 5) from loader.
(Figure 16, Item 8) from right floor plate (Figure 16, Item 6). Discard lockwashers.
38. With assistance, remove right floor plate (Figure 16, Item 6) from loader.
Figure 16. Lower Floor Plates.
0075-14
TM 5-3805-255-14 0075
WARNING
39. Attach suitable lifting device to left bracket (Figure 17, Item 5).
40. Remove three nuts (Figure 17, Item 4), lockwashers (Figure 17, Item 3), bolts (Figure 17, Item 1), and washers
(Figure 17, Item 2) from left bracket (Figure 17, Item 5). Discard lockwashers.
41. Using suitable lifting device, remove left bracket (Figure 17, Item 5) from loader and lower onto flat surface.
42. Remove lifting device from left bracket.
43. Attach suitable lifting device to right bracket (Figure 17, Item 6).
44. Remove three nuts (Figure 17, Item 10), lockwashers (Figure 17, Item 9), bolts (Figure 17, Item 7), and
washers (Figure 17, Item 8) from right bracket (Figure 17, Item 6). Discard lockwashers.
45. Using suitable lifting device, remove right bracket (Figure 17, Item 6) from loader and lower onto flat surface.
46. Remove lifting device from right bracket.
Figure 17. Brackets. 0075
END OF TASK
END OF TASK
0075-15
TM 5-3805-255-14 0075
INSTALLATION 00075
WARNING
1. Attach suitable lifting device to right bracket (Figure 18, Item 6).
2. Using suitable lifting device, install right bracket (Figure 18, Item 6) on loader.
3. Install three washers (Figure 18, Item 8), new lockwashers (Figure 18, Item 9), bolts (Figure 18, Item 7), and
nuts (Figure 17, Item 10) on right bracket (Figure 18, Item 6).
4. Attach suitable lifting device to left bracket (Figure 18, Item 5).
5. Using suitable lifting device, install left bracket (Figure 18, Item 5) on loader.
6. Install three washers (Figure 18, Item 2), new lockwashers (Figure 18, Item 3), bolts (Figure 18, Item 1), and
nuts (Figure 18, Item 4) on left bracket (Figure 18, Item 5).
7. With assistance, install right floor plate (Figure 18, Item 6) on loader.
8. Install four washers (Figure 18, Item 8), new lockwashers (Figure 18, Item 9), bolts (Figure 18, Item 7), and
nuts (Figure 18, Item 10) on right floor plate (Figure 18, Item 6).
9. With assistance, install left floor plate (Figure 18, Item 5) on loader.
nuts (Figure 18, Item 4) on left floor plate (Figure 18, Item 5).
Figure 18. Lower Floor Plates. 0075
0075-16
TM 5-3805-255-14 0075
WARNING
11. Install lifting device on upper floor plate (Figure 19, Item 10).
12. Using suitable lifting device, install upper floor plate (Figure 19, Item 10) on loader.
nuts (Figure 19, Item 9) on lower edge of upper floor plate (Figure 19, Item 10).
14. Install six washers (Figure 19, Item 5), new lockwashers (Figure 19, Item 3), bolts (Figure 19, Item 1), and nuts
(Figure 19, Item 4) on left edge of floor plate (Figure 19, Item 5).
Figure 19. Upper Floor Plate. 0075
0075-17
TM 5-3805-255-14 0075
WARNING
15. Attach suitable lifting device to four lifting links (Figure 20, Item 1) on cab (Figure 20,
Item 2) with equal tension on all four links.
16. Using a suitable lifting device, install cab (Figure 20, Item 2) on loader.
17. Remove lifting device from cab (Figure 20, Item 2)
Figure 20. Cab. 0075
0075-18
TM 5-3805-255-14 0075
18. Install bracket (Figure 21, Item 1), two washers (Figure 21, Item 3), new lockwashers (Figure 21, Item 4), bolts
(Figure 21, Item 2), and nuts (Figure 21, Item 5) on cab floor (Figure 21, Item 6).
0075-19
TM 5-3805-255-14 0075
WARNING
nuts (Figure 22, Item 8) on left and right sides of cab (Figure 22, Item 9).
nuts (Figure 22, Item 4) on left and right sides of cab (Figure 22, Item 9).
Figure 22. Cab Side Fasteners. 0075
0075-20
TM 5-3805-255-14 0075
21. Install nine washers (Figure 23, Item 2), new lockwashers (Figure 23, Item 3), bolts (Figure 23, Item 1), and
nuts (Figure 23, Item 4) on right, left, and rear edges of cab floor (Figure 23, Item 5).
Figure 23. Cab Bottom Fasteners. 0075
0075-21
TM 5-3805-255-14 0075
NOTE
Ladder and hand rail weighs 95 lbs (43 kg).
22. Install handrail (Figure 24, Item 1), ladder (Figure 24, Item 4), six bolts (Figure 24, Item 2), and self-supporting
nuts (Figure 24, Item 3) on loader.
Figure 24. Ladder and Handrail. 0075
0075-22
TM 5-3805-255-14 0075
23. Install control box (Figure 25, Item 11) and control box cover (Figure 25, Item 2) on loader.
24. Feed connector plate (Figure 25, Item 6) through hole in cab floor (Figure 25, Item 1) and connect two
electrical connectors (Figure 25, Item 5).
25. Install eight washers (Figure 25, Item 8), bolts (Figure 25, Item 7), and new locknuts (Figure 25, Item 10) on
control box (Figure 25, Item 11) and connector plate (Figure 25, Item 6).
26. Install control box cover (Figure 25, Item 2), two new lockwashers (Figure 25, Item 4), and bolts (Figure 25,
Item 3) on control box (Figure 25, Item 11).
Figure 25. Control Box and Cover. 0075
0075-23
TM 5-3805-255-14 0075
NOTE
Connect all wires and harnesses as noted during removal.
27. Connect red wire (Figure 26, Item 1) to start button (WP 0041).
28. Connect air line (Figure 26, Item 3) to fitting on floor support plate (Figure 26, Item 2).
Figure 26. Floor Wiring. 0075
29. Install seat assembly (Figure 27, Item 1), four washers (Figure 27, Item 4), new lockwashers (Figure 27,
Item 3), bolts (Figure 27, Item 5), and nuts (Figure 27, Item 2) on cab floor (Figure 27, Item 6).
Figure 27. Seat Assembly. 0075
0075-24
TM 5-3805-255-14 0075
30. Install boom stop positioner control (Figure 28, Item 1), two washers (Figure 28, Item 3), new lockwashers
(Figure 28, Item 5), bolts (Figure 28, Item 4), and nuts (Figure 28, Item 6) on side wall of cab (Figure 28,
Item 2).
NOTE
Install and route air lines as noted during removal.
31. Connect three air lines (Figure 28, Item 7) to boom stop positioner control (Figure 28, Item 1).
Figure 28. Boom Stop Positioner Control. 0075
32. Install control rod (Figure 29, Item 4) and two pins (Figure 29, Item 2) on boom stop positioner control
(Figure 29, Item 3) and boom (Figure 29, Item 1).
H100C-1102
Figure 29. Control Rod. 0075
0075-25
TM 5-3805-255-14 0075
NOTE
Install and route all air lines as noted during removal.
33. Install new gasket (Figure 30, Item 2), wiper motor (Figure 30, Item 1), spacer assembly (Figure 30, Item 8),
two washers (Figure 30, Item 10), and screws (Figure 30, Item 9) on front of cab (Figure 30, Item 7).
34. Install new lockwasher (Figure 30, Item 12) and nut (Figure 30, Item 11) on wiper motor shaft
35. Connect two air lines (Figure 30, Item 3) to wiper motor (Figure 30, Item 1).
36. Install wiper arm assembly (Figure 30, Item 4), two washers (Figure 30, Item 6), and nuts (Figure 30, Item 5) on
cab (Figure 30, Item 7).
Figure 30. Wiper Motor and Arms. 0075
0075-26
TM 5-3805-255-14 0075
NOTE
Install and route all air lines as noted during removal.
37. Install wiper control valve (Figure 31, Item 7), nut (Figure 31, Item 3), and knob (Figure 31, Item 2) on cover
38. Connect three air lines (Figure 31, Item 6) to wiper control valve (Figure 31, Item 7).
39. Install cover (Figure 31, Item 1), four new lockwashers (Figure 31, Item 5), and bolts (Figure 31, Item 4) on
boom stop control bracket (Figure 31, Item 8).
Figure 31. Wiper Control Valve. 0075
0075-27
TM 5-3805-255-14 0075
NOTE
Install and route heater hoses through machine as noted on removal.
40. Route heater hoses on loader. Connect hoses to sources.
41. Connect heater hose quick-disconnects (Figure 32, Item 1) under right side of cab (Figure 32, Item 2).
0075-28
TM 5-3805-255-14 0075
42. Connect power wire (Figure 33, Item 1) to heater (Figure 33, Item 2).
Figure 33. Power Wire. 0075
43. Connect batteries (WP 0005).

44. Check and fill cooling system (WP 0018).
45. Install accelerator pedal (WP 0033).
46. Install boom and bucket control levers (WP 0080).
47. Install washer reservoir (WP 0062). Fill washer reservoir.
48. Start engine and check all cab controls for proper operation (WP 0005).
END OF TASK
END OF WORK PACKAGE
0075-29/(30 blank)
10
TM 5-3805-255-14 0076
FIELD MAINTENANCE -
0 0 7 6 WINDSHIELD WIPER MOTOR REPLACEMENT

INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0

Gasket, rear wiper motor spacer 0

Lockwasher (2) 0
Tiedown strap (4) 0 0004) 0
REMOVAL 00076
Front Windshield Wiper Motor 00076
NOTE
Mark position of wiper arms on spindles for aid in installation.
1. Remove two capnuts (Figure 1, Items 3 and 5), lockwasher (Figure 1, Item 6), windshield wiper arm (Figure 1,
Item 2), front windshield wiper guide arm (Figure 1, Item 1) and cup (Figure 1, Item 7) from spacer (Figure 1,
Item 4). Discard lockwasher.
Figure 1. Front Windshield Wiper Arms. 0076
0076-1
TM 5-3805-255-14 0076
Front Windshield Wiper Motor – Continued 00076
2. Remove two tiedown straps (Figure 2, Item 8) from windshield wiper motor (Figure 2, Item 9).
3. Disconnect windshield washer hose (Figure 2, Item 1) from windshield wiper motor (Figure 2, Item 9).
4. Loosen two fittings (Figure 2, Items 2 and 3) and disconnect two airlines (Figure 2, Items 4 and 5) from wind-
shield wiper motor (Figure 2, Item 9).
5. Remove two nuts (Figure 2, Item 7), washers (Figure 2, Item 6), and windshield wiper motor Figure 2, Item 9)
from loader.
Figure 2. Front Windshield Wiper Motor. 0076
Rear Windshield Wiper Motor 00076
1. Remove cap nut (Figure 3, Item 3), lockwasher (Figure 3, Item 4), rear windshield wiper arm (Figure 3, Item 1),
cap (Figure 3, Item 2), and nut (Figure 3, Item 5) from spacer (Figure 3, Item 6). Discard lockwasher.
Figure 3. Rear Wiper Arm. 0076
0076-2
TM 5-3805-255-14 0076
Rear Windshield Wiper Motor – Continued 00076
2. Remove two tiedown straps (Figure 4, Item 3) from wiper motor (Figure 4, Item 8). Discard tiedown straps.
3. Disconnect washer hose (Figure 4, Item 7) from wiper motor (Figure 4, Item 8).
4. Loosen two fittings (Figure 4, Items 2 and 9) and disconnect two air lines (Figure 4, Items 1 and 10) from wiper
motor (Figure 4, Item 8).
5. Remove two nuts (Figure 4, item 5), washers (Figure 4, Item 6), and wiper motor (Figure 4, Item 8) from
mounting bracket (Figure 4, Item 4).
Figure 4. Rear Windshield Wiper Motor. 0076
0076-3
TM 5-3805-255-14 0076
6. Remove nut (Figure 5, Item 4), lockwasher (Figure 5, Item 5), and mounting bracket (Figure 5, Item 3). Discard
lockwasher.
7. Remove two screws (Figure 5, Item 1), washers (Figure 5, Item 2), spacer (Figure 5, Item 8), gasket (Figure 5,
Item 7), and wiper mounting plate (Figure 5, item 6). Discard gasket.
Figure 5. Rear Wiper Motor Bracket. 0076
END OF TASK
0076-4
TM 5-3805-255-14 0076
INSTALLATION 00076
Rear Windshield Wiper Motor 00076
1. Install wiper mounting plate (Figure 6, Item 6), new gasket (Figure 6, Item 7), spacer (Figure 6, Item 8), two
washers (Figure 6, Item 2), and screws (Figure 6, Item 1) on exterior of cab.
2. Install mounting bracket (Figure 6, Item 3), new lockwasher (Figure 6, Item 5), and nut (Figure 6, Item 4) inside
cab.
Figure 6. Rear Wiper Motor Bracket. 0076
0076-5
TM 5-3805-255-14 0076
3. Install wiper motor Figure 7, Item 8), two nuts (Figure 7, Item 5), and washers (Figure 7, Item 6) on mounting
4. Connect two air lines (Figure 7, Items 1 and 10) to wiper motor (Figure 7, Item 8). Tighten two fittings (Figure 7,
Items 2 and 9).
5. Connect washer hose (Figure 7, Item 7) to wiper motor (Figure 7, Item 8).
6. Install two new tiedown straps (Figure 7, Item 3) on wiper motor (Figure 7, Item 8).
Figure 7. Rear Windshield Wiper Motor. 0076
0076-6
TM 5-3805-255-14 0076
NOTE
Install wiper arm as marked during removal.
7. Install nut (Figure 8, Item 5), weatherseal cap (Figure 8, Item 2), rear windshield wiper arm (Figure 8, Item 1),
new lockwasher (Figure 8, Item 4), and cap nut (Figure 8, Item 3) on spacer (Figure 8, Item 6).
Figure 8. Rear Wiper Arm. 0076
0076-7
TM 5-3805-255-14 0076
Front Windshield Wiper Motor 00076
8. Install windshield wiper motor (Figure 9, Item 9), two washers (Figure 9, Item 6), and nuts (Figure 9, Item 7) on
loader.
9. Connect two air lines (Figure 9, Items 4 and 5) to windshield wiper motor (Figure 9, Item 9). Tighten two fittings
(Figure 9, Items 2 and 3).
10. Connect windshield washer hose (Figure 9, Item 1) to windshield wiper motor (Figure 9, Item 9).
11. Install two new tiedown straps (Figure 9, Item 8) on windshield wiper motor (Figure 9, Item 9).
Figure 9. Front Windshield Wiper Motor. 0076
0076-8
TM 5-3805-255-14 0076
NOTE
Install wiper arms on spindles as marked during removal.
12. Install windshield wiper guide arm (Figure 10, Item 1), cap (Figure 10, Item 7), windshield wiper arm (Figure
10, Item 2), new lockwasher (Figure 10, Item 6), and two capnuts (Figure 10, Items 3 and 5), on spacer (Figure
10, Item 4).
Figure 10. Front Windshield Wiper Arms. 0076
14. Check and fill windshield washer reservoir as necessary (WP 0016).
15. Check front and rear wipers and washers for proper operation (WP 0005).
END OF TASK
END OF WORK PACKAGE
0076-9/(10 blank)
4
TM 5-3805-255-14 0077
FIELD MAINTENANCE -
0 0 7 7 MAIN HYDRAULIC PUMP REPLACEMENT

INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0
(WP 0130, Item 3) 0

22) 0
0004) 0
O-Ring (2) 0
Wheels chocked 0
Lockwasher (2) 0
Personnel 0
Two 0
WARNING
personnel.
NOTE
Tag and identify all hose flanges for ease of installation and to protect and identify for
assembly. Cap all hose flanges to prevent contamination and leaks.
0077-1
TM 5-3805-255-14 0077
REMOVAL 00077
1. Disconnect line from hydraulic tank (WP 0083).

2. Remove eight bolts (Figure 1, Item 2) and four split flanges (Figure 1, Item 3) from main hydraulic pump
(Figure 1, Item 5).
3. Remove two hydraulic lines (Figure 1, Item 1) and O-rings (Figure 1, Item 4) from main hydraulic pump (Figure
1, Item 5). Discard O-rings.
4. Remove two bolts (Figure 1, Item 6) and lockwashers (Figure 1, Item 7) from main hydraulic pump (Figure 1,
NOTE
Be sure splined shaft is not damaged when removing from converter. Cap main hydraulic
pump ports before cleaning exterior.
5. Remove main hydraulic pump (Figure 1, Item 5) from converter.
Figure 1. Main Hydraulic Pump. 0077
END OF TASK
0077-2
TM 5-3805-255-14 0077
INSTALLATION 00077
1. Carefully align splined shaft with splined drive in torque converter.

2. Install main hydraulic pump (Figure 1, Item 5) on converter.
3. Install two new lockwashers (Figure 1, Item 7) and bolts (Figure 1, Item 6) through main hydraulic pump (Fig-
ure 1, Item 5) and converter.
4. Install two new O-rings (Figure 1, Item 4), hydraulic lines (Figure 1, Item 1), four split flanges (Figure 1, Item 3),
and eight bolts (Figure 1, Item 2) on main hydraulic pump (Figure 1, Item 5).
5. Connect line to hydraulic tank (WP 0083).
6. Check and refill hydraulic oil in reservoir (WP 0016).
END OF TASK
END OF WORK PACKAGE
0077-3/(4 blank)
12
TM 5-3805-255-14 0078
FIELD MAINTENANCE -
MAIN CONTROL VALVE REPLACEMENT

0 0 7 8
INITIAL SETUP
0128, Item 20) 0
References 0
Gauge, Pressure (5,000 psi) 0
Tee (2) 0
WP 0013 0
WP 0019 0
Materials/Parts 0
WP 0021 0

(WP 0130, Item 3) 0
Oil, Lubricating, OE/HDO-10 (WP 0130, Item Machine parked on level ground (WP 0005) 0
22) 0 Parking brake applied (WP 0005) 0
Rag, Wiping (WP 0130, Item 28) 0 Engine OFF (WP 0005) 0
Tag, Marker (WP 0130, Item 37) 0 Battery disconnect switch in OFF position
Pin, Cotter (2) 0
(WP 0004) 0
Seal, O-Ring (5) 0

0078-1
TM 5-3805-255-14 0078
REMOVAL 00078
1. Loosen two fittings (Figure 1, Items 1 and 3) and remove two lines (Figure 1, Items 2 and 5) from main control
valve (Figure 1, Item 4).
Figure 1. Gauge Lines. 0078
2. Remove four machine bolts (Figure 2, Item 2), two split flanges (Figure 2, Item 1), and O-ring (Figure 2, Item 3)
from front hydraulic line (Figure 2, Item 4). Discard O-ring.
3. Remove front hydraulic line (Figure 2, Item 4) from main control valve (Figure 2, Item 5).
Figure 2. Front Hydraulic Line. 0078
0078-2
TM 5-3805-255-14 0078
4. Remove eight machine bolts (Figure 3, Items 1 and 8), four split flanges (Figure 3, Items 4 and 6), and two
O-rings (Figure 3, Items 3 and 7) from side hydraulic lines (Figure 3, Items 2 and 5).
5. Remove two side hydraulic lines (Figure 3, Items 2 and 5) from main control valve (Figure 3, Item 9).
Figure 3. Side Hydraulic Line.
0078-3
TM 5-3805-255-14 0078
6. Remove two cotter pins (Figure 4, Item 2), clevis pins (Figure 4, Item 3), and main control valve linkages
(Figure 4, Item 4) from main control valve (Figure 4, Item 1). Discard cotter pins.
7. Remove eight machine bolts (Figure 4, Item 6), four split flanges (Figure 4, Item 7), and two O-rings
(Figure 4, Item 9) from bottom hydraulic lines (Figure 4, Item 8). Discard O-rings.
8. Remove two hose flanges (Figure 4, Item 5) from main control valve (Figure 4, Item 1).
9. Remove four bolts (Figure 4, Item 6), nuts (Figure 4, Item 10), and main control valve (Figure 4, Item 1) from
loader.
Figure 4. Main Control Valve. 0078
END OF TASK
END OF TASK
0078-4
TM 5-3805-255-14 0078
INSTALLATION 00078
1. Install main control valve (Figure 4, Item 1), four bolts (Figure 4, Item 6), and nuts (Figure 4, Item 10) on loader.
2. Install two bottom hydraulic line hose flanges (Figure 4, Item 5) on main control valve (Figure 4, Item 1).
3. Install two new O-rings (Figure 4, Item 9), four split flanges (Figure 4, Item 7), and eight machine bolts
(Figure 4, Item 6) on bottom hydraulic lines (Figure 4, Item 8).
4. Install main control valve linkages (Figure 4, Item 4), two clevis pins (Figure 4, Item 3), and two new cotter pins
(Figure 4, Item 2) on main control valve (Figure 4, Item 1).
5. Install two side hydraulic line hose flanges (Figure 5, Items 2 and 5) on main control valve (Figure 5, Item 9)
6. Install two new O-rings (Figure 5, Items 3 and 7), four split flanges (Figure 5, Items 4 and 6), and eight machine
bolts (Figure 5, Items 1 and 8), on side hydraulic lines (Figure 5, Items 2 and 5).
Figure 5. Side Hydraulic Lines. 0078
0078-5
TM 5-3805-255-14 0078
7. Install front hydraulic line (Figure 6, Item 4) on main control valve (Figure 6, Item 5).
8. Install new O-ring (Figure 6, Item 3), two split flanges (Figure 6, Item 1) and four machine bolts (Figure 6,
Item 2) on front hydraulic line (Figure 6, Item 4).
Figure 6. Side Hydraulic Lines. 0078
9. Install two lines (Figure 7, Items 2 and 5) on main control valve (Figure 7, Item 4). Tighten two fittings (Figure 7,
Items 1 and 3).
Figure 7. Gauge Lines. 0078
10. Fill reservoir with hydraulic oil (WP 0018).

11. Start engine and operate boom and bucket through several cycles to purge air from system. Adjust relief
valves. Refer to Adjustment in this work package.
END OF TASK
0078-6
TM 5-3805-255-14 0078
ADJUSTMENT 00078
Main Relief Valve 00078
WARNING
• Before attempting to adjust pressure relief valve, align frame halves and install loader
safety bar in straight-ahead position. Do not move steering wheel while adjusting
hydraulic system main relief valve.
• Failure to install safety bar could lead to serious injury or death. In event of injury seek
medical attention.
causing injury to personnel. Failure to follow warning may result in injury or death to
personnel.
NOTE
• In addition to regular periodic system pressure checks and checks to detect system
problems, main relief valve must be pressure checked and adjusted if it has been
completely disassembled or if repairs have been made to hydraulic system. Pilot section
of relief valve may be removed without disturbing valve setting. Refer to System
Pressures (WP 0002).
• Remove pipe plug from main control valve and install 5,000 psi (34,474 kPa) capacity
pressure gauge.
0078-7
TM 5-3805-255-14 0078
1. Start engine and check for leaks around relief valve (Figure 8, Item 6) and plug (Figure 8, Item 5) at either end
of relief valve.
a. Accelerate engine to full throttle and hold bucket control lever in ROLLED BACK (retracted) position. Note
indicated pressure on gauge.
b. System pressure at full throttle for main relief valve is 2,300 psi (15,858 kPa) plus or minus 50 psi
(345 kPa).
c. Idle engine. If indicated pressure was not within recommended limits, adjustment is necessary.
d. System pressure at idle is 2,000 psi (13,790 kPa).
e. Always turn adjusting screw clockwise at least one-half turn to set preload.
2. Hold jamnut (Figure 8, Item 4) to remove acorn nut (Figure 8, Item 1) and copper washer (Figure 8, Item 3).
3. Hold adjusting screw (Figure 8, Item 2) and loosen jamnut (Figure 8, Item 4).
4. To adjust pressure, hold jamnut (Figure 8, Item 4) and rotate adjusting screw (Figure 8, Item 2) clockwise to
increase pressure and counterclockwise to decrease pressure.
5. Recheck indicated pressure. When correct pressure is obtained, hold adjusting screw (Figure 8, Item 2) and
tighten jamnut (Figure 8, Item 4).
NOTE
Make sure copper washer is in good condition.
6. Install copper washer (Figure 8, Item 3) and acorn nut (Figure 8, Item 1) on relief valve (Figure 8, Item 6).
WARNING
causing injury to personnel.
• Failure to follow warning may result in injury or death to personnel.
7. Stop engine.
8. Relieve pressure in system by moving loader controls through their full travel several times.
9. Relieve reservoir pressure by slowly removing filler cap.
0078-8
TM 5-3805-255-14 0078
10. Remove test gauge and replace pipe plug.
Figure 8. Main Control Valve Relief Valve. 0078
0078-9
TM 5-3805-255-14 0078
Bucket Circuit Relief Valves 00078
CAUTION
Bucket circuit relief valves are preset. Valve seldom requires adjustment. Valves are
designed to protect bucket during closed circuit operation, while back-dragging or leveling
when bucket control lever is in HOLD position. Resistance developed at cutting edge is
transferred to loader linkage. Unless protected by circuit relief valves, excessive
pressures could inflict serious damage on loader linkage.
1. Prepare to adjust bucket circuit relief valves:
a. Place bucket on ground and all controls in HOLD or NEUTRAL. Apply parking brake.
WARNING
DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut
causing injury to personnel. Failure to follow warning may result in injury or death to
personnel.
Before attempting to adjust circuit relief valve, align frame halves and install loader safety
bar in straight ahead position. Do not move steering wheel while adjusting hydraulic
system circuit relief valve. Failure to install safety bar could lead to serious injury or death.
b. Stop engine. Relieve pressure in system by moving loader controls through their full travel several times.
Relieve reservoir pressure by slowly removing filler cap.
c. Insert a tee connection in hydraulic lines on high pressure side of each relief valve.
d. Insert a hose connected to a 5,000 psi (34,474 kPa) gauge in stem of each tee. Gauge hoses must be long
enough to reach operator’s compartment.
e. Check oil level in hydraulic reservoir and add oil if necessary (WP 0018).
f. Replace and tighten reservoir filler cap.
g. Start engine. Raise boom slightly and retract bucket three-quarters of its travel. Release bucket control
lever as soon as bucket reaches desired position.
h. Release parking brake and move loader forward, allowing underside of bucket cutting edge to contact an
immovable object. Contact must be along full length of edge.
i. By depressing accelerator, increase pressure on cutting edge. Note pressure at which valve discharges.
This pressure should equal recommended maximum. If pressure exceeds maximum, adjustment is
necessary (3,000 psi (20,684 kPa) plus or minus 50 psi (345 kPa) at full throttle).
2. Hold jamnut (Figure 9, Item 4) and remove acorn nut (Figure 9, Item 1) from relief valve (Figure 9, Item 5).
3. Hold adjusting screw (Figure 9, Item 2) and loosen jamnut (Figure 9, Item 4).
4. Hold jamnut (Figure 9, Item 4) and rotate adjusting screw (Figure 9, Item 2). Turn clockwise direction to
increase pressure and counterclockwise to decrease pressure.
0078-10
TM 5-3805-255-14 0078
5. Check valve discharge pressure. Continue to test and adjust relief valve pressure until recommended setting is
obtained. Always turn adjusting screw clockwise at least one-half turn to set preload.
6. When correct adjustment is obtained, hold adjusting screw (Figure 9, Item 2) and tighten locknut (Figure 9,
Item 4).
7. Install copper washer (Figure 9, Item 3), if in good condition, and acorn nut (Figure 9, Item 1) on relief valve
(Figure 9, Item 5).
H100C-0521
Figure 9. Bucket Circuit Relief Valve. 0078
0078-11
TM 5-3805-255-14 0078
8. To test opposite valve, place bucket cutting edge under a very heavy object and slowly raise boom while
bucket remains in HOLD position. Note pressure at which valve discharges. This pressure should equal
recommended pressure (step i).
WARNING
DO NOT disconnect or remove pressure gauges, tees, hydraulic system line, or fittings
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. Failure to follow warning may result in
9. Stop engine.
10. Relieve pressure in system by moving loader controls through their full travel several times.
11. Relieve reservoir pressure by slowly removing filler cap.
12. Remove 5,000 psi (34,474 kPa) gauges and tees and reconnect loader hydraulic lines.
13. Check level of hydraulic reservoir and add fluid as required (WP 0018).
14. Disconnect safety bar.
END OF TASK
END OF WORK PACKAGE
0078-12
2
TM 5-3805-255-14 0079
FIELD MAINTENANCE -
0 0 7 9 RESERVOIR RELIEF VALVE REPLACEMENT

INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

0004) 0
22) 0
Wheels chocked 0
Plug and Cap Kit 0
0079-1
TM 5-3805-255-14 0079
REMOVAL 00079
WARNING
• DO NOT disconnect or remove any hydraulic system line, cap, or fitting unless engine is
shut down and hydraulic system pressure has been relieved. Failure to follow this warning
may result in damage to equipment.
personnel.
NOTE
Cap all hydraulic lines to prevent contamination.
Remove relief valve (Figure 1, Item 1) from reservoir cover (Figure 1, Item 2).
Figure 1. Reservoir Relief Valve. 0079
END OF TASK
INSTALLATION 00079
Install relief valve (Figure 1, Item 1) on reservoir cover (Figure 1, Item 2).
END OF TASK
END OF WORK PACKAGE
0079-2
12
TM 5-3805-255-14 0080
FIELD MAINTENANCE -
HYDRAULIC CONTROL LINKAGE REPLACEMENT

0 0 8 0
Removal, Disassembly, Cleaning and Inspection, Assembly, Installation, Adjustment
INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0
0130, Item 15) 0


Lockwasher (4) 0
0004) 0
O-Ring (6) 0
Pin, Cotter (8) 0

Main control valve linkage disconnected (WP

0078) 0
0080-1
TM 5-3805-255-14 0080
REMOVAL 00080
NOTE
This procedure removes both control rods and linkages.
1. Remove two cotter pins (Figure 1, Item 2) from clevis pins (Figure 1, Item 3). Discard cotter pins.
2. Remove two clevis pins (Figure 1, Item 3) and control rods (Figure 1, Item 1) from bellcrank (Figure 1, Item 7).
4. Remove two clevis pins (Figure 1, Item 4) and linkage (Figure 1, Item 6) from bellcrank (Figure 1, Item 7).
Figure 1. Hydraulic Control Linkage at Bellcrank. 0080
0080-2
TM 5-3805-255-14 0080
6. Remove two clevis pins (Figure 2, Item 2) and control rods (Figure 2, Item 3) from control levers (Figure 2,
Item 1).
7. Remove two control rods (Figure 2, Item 3) from loader.
Figure 2. Control Rods to Control Levers. 0080
END OF TASK
0080-3
TM 5-3805-255-14 0080
DISASSEMBLY 00080
1. Remove nut (Figure 3 , Item 6), two washers (Figure 3 , Item 5), and bolt (Figure 3 , Item 4) from bellcrank
lever pin (Figure 3 , Item 7).
2. Remove bellcrank lever pin (Figure 3 , Item 7), three O-rings (Figure 3 , Item 1), and two bellcrank levers
(Figure 3 , Item 3) from frame mounting brackets. Discard O-rings.
3. Remove four bushings (Figure 3 , Item 2) from two bellcrank levers (Figure 3 , Item 3).
H100C-0879
Figure 3. Bellcrank Assembly. 0080
0080-4
TM 5-3805-255-14 0080
5. Remove two clevis pins (Figure 4, Item 12) and cable ends (Figure 4, Item 13) from control levers (Figure 4,
Items 3 and 5).
6. Remove nut (Figure 4, Item 10), flat washer (Figure 4, Item 9), and six spacer washers (Figure 4, Item 6) from
control lever pin (Figure 4, Item 2).
7. Remove nut (Figure 4, Item 16), lockwasher (Figure 4, Item 17), and bolt (Figure 4, Item 1) from each end of
control lever pin (Figure 4, Item 2). Discard lockwasher.
8. Remove control lever pin (Figure 4, Item 2), two control levers (Figure 4, Items 3 and 5), and seven bushings
(Figure 4, Items 7, 8, 11, and 15) from mounting brackets.
Figure 4. Control Levers. 0080
END OF TASK
0080-5
TM 5-3805-255-14 0080
2. Carefully inspect all components for signs of excessive wear, cracks, or damage. Replace if necessary.
3. Inspect control lever and bellcrank bushings for wear or damage. Replace if necessary.
END OF TASK
ASSEMBLY 00080
CAUTION
Do not install grease fittings. Pressure lubrication may cause serious damage to bushings.
1. Install seven bushings (Figure 5, Items 7, 8, 11, and 15) in two control levers (Figure 5, Items 3 and 5). Hand
pack bushings with grease.
2. In cab, install control lever pin (Figure 5, Item 2), and two control levers (Figure 5, Items 3 and 5) on mounting
brackets.
3. Install six spacer washers (Figure 5, Item 6), flat washer (Figure 5, Item 9), and nut (Figure 5, Item 10) on
control lever pin (Figure 5, Item 2).
4. Install two bolts (Figure 5, Item 1), new lockwashers (Figure 5, Item 17), and nuts (Figure 5, Item 16) on each
end of control lever pin (Figure 5, Item 2).
5. Install two cable ends (Figure 5, Item 13) on control levers (Figure 5, Items 3 and 5). Install two clevis pins
(Figure 5, Item 12) on cable ends (Figure 5, Item 13). Install two new cotter pins (Figure 5, Item 14) on clevis
pins.
0080-6
TM 5-3805-255-14 0080
Figure 5. Control Levers. 0080
0080-7
TM 5-3805-255-14 0080
CAUTION
DO NOT replace hub plugs with grease fittings on bellcrank and control levers. Pressure
lubrication may cause serious damage to bushings.
6. Install four bushings (Figure 6, Item 2) in two bellcrank levers (Figure 6, Item 3). Press in new bushings. Hand
pack bushings with grease.
7. Install bellcrank lever pin (Figure 6, Item 7), three new O-rings (Figure 6, Item 1), and two bellcrank levers
(Figure 6, Item 3) on mounting brackets.
8. Install bolt (Figure 6, Item 4), two new lockwashers (Figure 6, Item 5), and nut (Figure 6, Item 6) on each end of
bellcrank lever pin (Figure 6, Item 7).
H100C-0879
Figure 6. Bellcrank Assembly. 0080
END OF TASK
0080-8
TM 5-3805-255-14 0080
INSTALLATION 00080
1. Install two control rods (Figure 7, Item 3) and clevis pins (Figure 7, Item 2) on control levers (Figure 7, Item 1).
2. Install two new cotter pins (Figure 7, Item 4) in clevis pins (Figure 7, Item 2).
Figure 7. Control Rods. 0080
0080-9
TM 5-3805-255-14 0080
NOTE
Welded ends of control rods go to bellcrank. Be sure control lever end of rods have bend
angling down from clevis pins.
3. Install two control rods (Figure 8, Item 1) and clevis pins (Figure 8, Item 3) on bellcrank (Figure 8, Item 7).
5. Install two clevis pins (Figure 8, Item 4) and linkage (Figure 8, Item 6) on bellcrank (Figure 8, Item 7).
Figure 8. Hydraulic Control Linkage at Bellcrank. 0080
END OF TASK
0080-10
TM 5-3805-255-14 0080
ADJUSTMENT 00080
NOTE
Position both valve spools in their center positions.
1. Loosen two jam nuts (Figure 9, Item 4) on clevises (Figure 9, Item 3) at threaded ends of control rods (Figure
9, Item 5).
2. With two control levers (Figure 9, Item 1) in vertical position, adjust clevises (Figure 9, Item 3) so control rod
(Figure 9, Item 5) bores align with bores of control levers.
3. Install clevis pins (Figure 9, Item 2) and new cotter pins (Figure 9, Item 6) on control rods (Figure 9, Item 5) and
control levers (Figure 9, Item 1).
4. Hold clevises (Figure 9, Item 3) in a horizontal position while tightening jam nuts (Figure 9, Item 4).
Figure 9. Hydraulic Control Linkage Adjustment. 0080
5. Start engine and after warm-up, operate hydraulic control levers through several cycles to check for proper
adjustment (WP 0005).
7. Stow safety bar (WP 0005).
END OF TASK
END OF WORK PACKAGE
0080-11/(12 blank)
6
TM 5-3805-255-14 0081
FIELD MAINTENANCE -
0 0 8 1 BUCKET CYLINDER REPLACEMENT

INITIAL SETUP
0128, Item 20) 0
Drain Pan 0
Materials/Parts 0
Cap Set, Protective Dust and Moisture Seal Engine OFF (WP 0005) 0
(WP 0130, Item 3) 0

0004) 0

Hydraulic system pressure relieved (WP
O-Ring (2) 0 0124) 0
Two 0
WARNING
NOTE
Tag and identify hydraulic lines for ease of installation. Cap all lines to prevent
0081-1
TM 5-3805-255-14 0081
REMOVAL 00081
1. Loosen fitting (Figure 1, Item 1) and disconnect air line (Figure 1, Item 3) from bucket cylinder (Figure 1,
Item 5).
2. Loosen fitting (Figure 1, Item 2) and disconnect air line (Figure 1, Item 4) from bucket cylinder (Figure 1,
Item 5).
Figure 1. Air Lines. 0081
0081-2
TM 5-3805-255-14 0081
3. Position suitable drain pan under cylinder to catch draining fluid.

4. Remove eight flange bolts (Figure 2, Item 11), four split-flange collars (Figure 2, Item 14), two separator plates
(Figure 2, Item 12), and hydraulic lines (Figure 2, Items 5 and 7) from bucket cylinder (Figure 2, Item 13).
Remove two O-rings (Figure 2, Items 6 and 8) from lines. Drain cylinder. Discard O-rings.
5. Remove four flange bolts (Figure 2, Item 9) and manifold pipe (Figure 2, Item 10) from bucket cylinder (Figure
2, Item 13).
6. Remove four nuts (Figure 2, Item 2), washers (Figure 2, Item 3), two U-bolts (Figure 2, Item 4), and gauge tube
(Figure 2, Item 1) from bucket cylinder (Figure 2, Item 13).
Figure 2. Hydraulic Lines. 0081
0081-3
TM 5-3805-255-14 0081
WARNING
assistance during procedure. Ensure that nay lifting equipment is in good condition and of
follow this warning may result in inuury or death to personnel.
CAUTION
Do not damage pivot bushings or port flanges during removal. Failure to follow this caution
may result in damage to the equipment.
7. Attach suitable lifting device to bucket cylinder (Figure 3, Item 4).
8. Remove two weather seal clamps (Figure 3, Item 6) from each end of bucket cylinder (Figure 3, Item 4).
9. With assistance, remove two bolts (Figure 3, Items 1 and 8), washers (Figure 3, Items 2 and 7), pins (Figure 3,
Items 3 and 5), and bucket cylinder (Figure 3, Item 4) from loader.
Figure 3. Bucket Cylinder. 0081
END OF TASK
0081-4
TM 5-3805-255-14 0081
INSTALLATION 0081
WARNING
1. Install bucket cylinder (Figure 3, Item 4) on loader. Install two weather seal clamps (Figure 3, Item 6) on each
end of cylinder.
2. Install two pins (Figure 3, Items 3 and 5), washers (Figure 3, Items 2 and 7), and bolts (Figure 3, Items 1 and 8)
on loader. Torque bolts to 170 lb-ft (230 Nm).
3. Install gauge tube (Figure 4, Item 1), two U-bolts (Figure 4, Item 4), four washers (Figure 4, Item 3), and nuts
(Figure 4, Item 2) on bucket cylinder (Figure 4, Item 13).
4. Install manifold pipe (Figure 4, Item 10) and four flange bolts (Figure 4, Item 9) on bucket cylinder (Figure 4,
Item 13).
5. Install two new O-rings (Figure 4, Items 6 and 8) in hydraulic lines (Figure 4, Items 5 and 7). Install two
separator plates (Figure 4, Item 12), hydraulic lines, four split-flange collars (Figure 4, Item 14), and eight
flange bolts (Figure 4, Item 11) on bucket cylinder (Figure 4, Item 13).
0081-5
TM 5-3805-255-14 0081
6. Start engine and allow hydraulic oil to reach operating temperature. Cycle bucket cylinder several times.
Retorque bolts (Figure 4, Items 1 and 8) to 85 lb-ft (115 Nm) with bucket cylinder under pressure.
7. Check hydraulic fluid level in reservoir and top off as necessary (WP 0018).
8. Connect air line (Figure 5, Item 4) to bucket cylinder (Figure 5, Item 5). Tighten fitting (Figure 5, Item 2).
9. Connect air line (Figure 5, Item 3) to bucket cylinder (Figure 5, Item 5). Tighten fitting (Figure 5, Item 1).
Figure 5. Air Lines. 0081
END OF TASK
END OF WORK PACKAGE
0081-6
8
TM 5-3805-255-14 0082
FIELD MAINTENANCE -
0 0 8 2 BOOM CYLINDER REPLACEMENT

INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

Cap Set, Protective Dust and Moisture Seal 0004) 0
(WP 0130, Item 3) 0
Hydraulic system pressure relieved (WP

0124) 0
Locknut (2) 0
O-Ring (2) 0
0082-1
TM 5-3805-255-14 0082
WARNING
NOTE
• This procedure covers one boom cylinder. Remaining boom cylinder is serviced in a
similar manner.
• Tag and identify hydraulic lines for ease of installation.
• Cap all lines and ports to prevent contamination and leaks.
REMOVAL 0082
1. Remove two locknuts (Figure 1, Item 5), bolts (Figure 1, Item 1), four washers (Figure 1, Items 2 and 4), and
two weatherseal clamps (Figure 1, Item 3) from end of boom cylinder (Figure 1, Item 6).
Figure 1. Weatherseal Clamps. 0082
0082-2
TM 5-3805-255-14 0082
NOTE
Position suitable drain pan under cylinder to catch draining fluid.
2. Remove two locknuts (Figure 2, Item 13), washers (Figure 2, Item 14), bolts (Figure 2, Item 15), washers (Fig-
ure 2, Item 16), and weatherseal clamps (Figure 2, Item 10) from boom cylinder (Figure 2, Item 7). Discard
locknuts.
3. Remove eight flange bolts (Figure 2, Item 17), four split-flange collars (Figure 2, Item 9), and two hydraulic
lines (Figure 2, Items 1 and 3) from boom cylinder (Figure 2, Item 7). Remove two O-rings (Figure 2, Items 2
and 4) from lines. Drain cylinder being removed as much as possible. Discard O-rings.
4. Remove nut (Figure 2, Item 12) and bolt (Figure 2, Item 11) from boom cylinder (Figure 2, Item 7).
5. Remove four bolts (Figure 2, Item 5), flange (Figure 2, Item 6), and return pipe (Figure 2, Item 8) from boom
cylinder (Figure 2, Item 7).
0082-3
TM 5-3805-255-14 0082
CAUTION
Do not damage pivot bushings or port flanges during removal. Failure to follow this caution
6. Remove bolt (Figure 3, Item 4), washer (Figure 3, Item 3), and pin plate (Figure 3, Item 1) from boom arm
(Figure 3, Item 6).
WARNING
7. Remove pin (Figure 3, Item 2) from boom cylinder (Figure 3, Item 5).
8. Attach suitable lifting device to boom cylinder (Figure 3, Item 5).
9. With assistance, remove boom cylinder (Figure 3, Item 5) from loader.
10. Remove lifting device from boom cylinder.
Figure 3. Boom Cylinder. 0082
END OF TASK
0082-4
TM 5-3805-255-14 0082
INSTALLATION 0082
WARNING
NOTE
Do not damage cylinder bushings during installation
1. Install suitable lifting device on boom cylinder (Figure 3, Item 5). With assistance, install boom cylinder on
loader.
2. Install pin (Figure 3, Item 2) in boom cylinder (Figure 3, Item 5).
NOTE
Do not damage pivot bushings or port flanges during installation.
3. Install pin plate (Figure 3, Item 1), washer (Figure 3, Item 3), and bolt (Figure 3, Item 4) on boom arm (Figure
3, Item 6).
0082-5
TM 5-3805-255-14 0082
4. Install return pipe (Figure 4, Item 8), flange (Figure 4, Item 6), and four bolts (Figure 4, Item 5) on boom
cylinder (Figure 4, Item 7).
5. Install bolt (Figure 4, Item 11) and nut (Figure 4, Item 12) on boom cylinder (Figure 4, Item 7).
6. Install two new O-rings (Figure 4, Items 2 and 4) in two hydraulic lines (Figure 4, Items 1 and 3).
7. Install two hydraulic lines (Figure 4, Items 1 and 3), four split-flange collars (Figure 4, Item 9), and eight flange
bolts (Figure 4, Item 17) on boom cylinder (Figure 4, Item 7).
8. Install two weatherseal clamps (Figure 4, Item 10), washers (Figure 4, Item 16), bolts (Figure 4, Item 15),
washers (Figure 4, Item 14), and new locknuts (Figure 4, Item 13) on boom cylinder (Figure 4, Item 7).
0082-6
TM 5-3805-255-14 0082
9. Install two weatherseal clamps (Figure 5, Item 3), bolts (Figure 5, Item 2), four washers (Figure 5, Items 2
and 4), and new locknuts (Figure 5, Item 5) on end of boom cylinder.
Figure 5. Weatherseal Clamps. 0082
END OF TASK
END OF WORK PACKAGE
0082-7/(8 blank)
6
TM 5-3805-255-14 0083
FIELD MAINTENANCE -
0 0 8 3 HYDRAULIC TANK/RESERVOIR REPLACEMENT

INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP Seal (4) 0
0128, Item 20) 0

Lockwasher (4) 0

and Repair: Organizational Maintenance Personnel 0
Common #1 (WP 0128, Item 14) 0 Two 0
Materials/Parts 0 Equipment Condition 0
(WP 0130, Item 3) 0

Parking/emergency brake applied (WP 0005) 0
Oil, Lubricating, OE/HDO-10 (WP 0130, Item Engine OFF (WP 0005) 0
22) 0
0004) 0

O-Ring 0
Wheels chocked 0
REMOVAL 00083
WARNING
personnel.
0083-1
TM 5-3805-255-14 0083
1. Loosen fitting (Figure 1, Item 5) and disconnect line (Figure 1, Item 6) from air filter indicator (Figure 1, Item 2).
2. Remove bolt (Figure 1, Item 1) and nut (Figure 1, Item 3) from air filter indicator (Figure 1, Item 2).
3. Remove air filter indicator (Figure 1, Item 2) and spacer (Figure 1, Item 4) from battery box (Figure 1, Item 7).
Figure 1. Air Filter Indicator. 0083
CAUTION
Cap and tag each line to prevent entry of dirt and provide identification for proper
assembly. Cover all open ports. Failure to follow these instructions may result in damage
to equipment.
4. Remove four bolts (Figure 2, Item 9), two split flanges (Figure 2, Item 10), hose flange (Figure 2, Item 8), and
O-ring (Figure 2, Item 2) from reservoir (Figure 2, Item 1). Discard O-ring.
5. Remove four hose clamps (Figure 2, Item 3), two sleeves (Figure 2, Item 6), four seals (Figure 2, Items 5 and
7), and four washers (Figure 2, Item 4) from reservoir (Figure 2, Item 1). Discard seals.
WARNING
Reservoir tank is heavy. Use suitable lifting device. Failure to follow this warning may
6. Remove four bolts (Figure 2, Item 11), lockwashers (Figure 2, Item 12), washers (Figure 2, Item 13), nuts
(Figure 2, Item 14) and reservoir (Figure 2, Item 1) from frame. Discard lockwashers.
7. Attach suitable lifting device to reservoir (Figure 2, Item 1).
0083-2
TM 5-3805-255-14 0083
Figure 2. Hydraulic Reservoir/Tank.
0083-3
TM 5-3805-255-14 0083
INSTALLATION 00083
WARNING
Reservoir tank is heavy. Use suitable lifting device to remove or install to prevent injury.
Failure to follow this warning may result in injury to personnel.
1. Using suitable lifting device, install reservoir (Figure 3, Item 1) on loader.
2. Install four washers (Figure 3, Item 13), bolts (Figure 3, Item 11), new lockwashers (Figure 3, Item 12), and
nuts (Figure 3, Item 14) on reservoir (Figure 3, Item 1).
3. Install four seals (Figure 3, Items 5 and 7), four washers (Figure 3, Item 4), two sleeves (Figure 3, Item 6), and
four hose clamps (Figure 3, Item 3) on reservoir (Figure 3, Item 1).
4. Install new O-ring (Figure 3, Item 2), hose flange (Figure 3, Item 8), two split flanges (Figure 3, Item 10), and
four bolts (Figure 3, Item 9) on reservoir (Figure 3, Item 1).
Figure 3. Hydraulic Reservoir/Tank. 0083
0083-4
TM 5-3805-255-14 0083
5. Install spacer (Figure 4, Item 4) and air filter indicator (Figure 4, Item 2) to battery box (Figure 4, Item 7).
6. Install bolt (Figure 4, Item 1) and nut (Figure 4, Item 3) to air filter indicator (Figure 4, Item 2).
7. Connect line (Figure 4, Item 6) to air filter indicator (Figure 4, Item 2). Tighten fitting (Figure 4, Item 5).
Figure 4. Air Filter Indicator. 0083
8. Fill hydraulic reservoir using oil filtered through a fine mesh screen (WP 0018).
9. Add oil through dipstick opening in reservoir and fill to full mark on dipstick (WP 0018).
10. Start and run engine to reduced speed while operating controls to circulate oil throughout various circuits and
to purge air from system.
11. Check reservoir oil level frequently, adding oil as necessary to full mark on dipstick.
12. Check all lines and fittings for leaks.
13. Stop engine and lower bucket to ground. Recheck oil level.
14. Tighten reservoir filler cap.
END OF TASK
END OF WORK PACKAGE
0083-5/(6 blank)
4
TM 5-3805-255-14 0084
FIELD MAINTENANCE -
PRESSURE GAUGE REPLACEMENT

0 0 8 4
INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

0005) 0
References 0
WP 0019 0
REMOVAL 00084
NOTE
The following procedure shows the air pressure gauge. All other pressure gauges are
removed in a similar manner.
1. Remove gauge face plate (Figure 1, Item 1) from instrument panel (Figure 1, Item 2).
0084-1
TM 5-3805-255-14 0084
NOTE
Tag and identify all hoses, lines, and wires for aid in assembly.
2. Remove lamp (Figure 2, Item 4) from gauge (Figure 2, Item 3).
3. Loosen fitting (Figure 2, Item 10) and disconnect line (Figure 2, Item 11) from gauge (Figure 2, Item 3).
4. Remove wire (Figure 2, Item 6) from sending unit (Figure 2, Item 7).
5. Remove sending unit (Figure 2, Item 7) from fitting (Figure 2, Item 9).
6. Remove fitting (Figure 2, Item 9) from gauge (Figure 2, Item 3).
7. Remove two nuts (Figure 2, Items 1 and 5) and bracket (Figure 2, Item 8) from gauge (Figure 2, Item 3).
8. Remove gauge (Figure 2, Item 3) from front of gauge panel (Figure 2, Item 2).
Figure 2. Gauge. 0084
0084-2
TM 5-3805-255-14 0084

END OF TASK
INSTALLATION 00084
1. Install gauge (Figure 2, Item 3) in front of gauge panel (Figure 2, Item 2).
2. Install bracket (Figure 2, Item 8) and two nuts (Figure 2, Items 1 and 5) on gauge (Figure 2, Item 3).
3. Install fitting (Figure 2, Item 9) in gauge (Figure 2, Item 3).
4. Install sending unit (Figure 2, Item 7) in fitting (Figure 2, Item 9).
5. Connect wire (Figure 2, Item 6) to sending unit (Figure 2, Item 7).
6. Connect line (Figure 2, Item 11) to gauge (Figure 2, Item 3). Tighten fitting (Figure 2, Item 10).
7. Install lamp (Figure 2, Item 4) in gauge (Figure 2, Item 3).
8. Install gauge face plate (Figure 3, Item 1) on instrument panel (Figure 3, Item 2).

10. Start engine and check operation of gauges (WP 0005).
END OF TASK
END OF WORK PACKAGE
0084-3/(4 blank)
10
TM 5-3805-255-14 0085
FIELD MAINTENANCE -
BUCKET TIPS REPLACEMENT

0 0 8 5
Cutting Edge Removal, Cutting Edge Installation, Bucket Teeth Removal, Bucket Teeth Installation
INITIAL SETUP
0128, Item 20) 0

Shop Equipment, Welding (WP 0128, Item 17) 0 Engine OFF (WP 0005) 0

Materials/Parts 0
0004) 0
Clip, Locking (7) 0
0085-1
TM 5-3805-255-14 0085
CUTTING EDGE REMOVAL 00085
WARNING
NOTE
• Type I teeth are used with edge P/N X311567.
• Type II teeth are used with edge P/N 923885C1.
General Purpose Cutting Edge Removal 00085
NOTE
Replace cutting edge tip before it wears back to weld joining tip and its backing plate. Use
a carbon-graphite electrode to remove weld at rear of tip. Attach replacement tip to
backing plate using a dry, low-hydrogen E-7018 (AWS) electrode.
1. Remove bucket from loader (WP 0086). Position bucket (Figure 1, Item 1) so that cutting edge tip (Figure 1,
Item 2) is accessible.
2. Prior to removing worn cutting edge tip (Figure 1, Item 2), straighten any existing bow in cutting edge (Figure 1,
Item 3).
WARNING
Wear tinted protective goggles and insulated gloves when working with acetylene torch
and/or welders and heated parts. Failure to do so could cause blindness from flame of
torch or serious injury due to burns.
3. Tack weld a brace (Figure 1, Item 1) in center of bucket (Figure 1, Item 4) to hold cutting edge (Figure 1,
Item 3).
Figure 1. Cutting Edge Replacement. 0085
0085-2
TM 5-3805-255-14 0085
CUTTING EDGE REMOVAL – CONTINUED 00085
4. Clamp a straightedge piece of stock (Figure 2, Item 2) along weld joining cutting edge tip (Figure 2, Item 3) and
backing plate (Figure 2, Item 1).
Figure 2. Tip Removal. 0085
CAUTION
Keep heat penetration (heat build-up) in cutting edge tip and backing plate to a minimum.
Failure to follow this caution may cause parts to warp.
5. Remove weld at rear of cutting edge tip (Figure 3, Item 1) and on bottom of backing plate (Figure 3, Item 2).
Figure 3. Weld Removal. 0085
0085-3
TM 5-3805-255-14 0085
CUTTING EDGE REMOVAL – CONTINUED 00085
CAUTION
Wear suitable eye protection and gloves while operating grinder. Failure to follow these
instructions may result in injury to personnel.
6. Grind surface backing plate (Figure 4, Item 1) smooth along forward face (Figure 4, Item 2) and lower surface
(Figure 4, Item 3) where replacement tip contacts plate.
Figure 4. Backing Plate Preparation. 0085
Spade Nose Cutting Edge Removal 00085
NOTE
The spade nose cutting edge removal procedure is similar to the general purpose cutting
edge procedure, except the spade nose has two cutting edges instead of one. Refer to
Figure 5 and General Purpose Cutting Edge Removal in this work package to remove
both cutting edges.
Figure 5. Spade Nose Cutting Edges. 0085
END OF TASK
0085-4
TM 5-3805-255-14 0085
CUTTING EDGE INSTALLATION 00085
General Purpose Cutting Edge Installation 00085
1. Position new cutting edge tip (Figure 6, Item 4) on backing plate (Figure 6, Item 1).
2. Tack weld cutting edge tip (Figure 6, Item 4) to backing plate (Figure 6, Item 1) at front of plate and along back
of tip as shown (Figure 6, Item 2). Start tacks at center of tip as shown (Figure 6, Item 3) and work alternately
between front edge of plate and rear of tip toward both ends.
3. Fix tip ends with firm welds.
Figure 6. Cutting Edge Tip Attachment. 0085
CAUTION
Keep heat penetration (heat build-up) in cutting edge tip and backing plate to a minimum
to control parts warpage.
4. Best results will be obtained by preheating tip (Figure 7, Item 4) and backing plate (Figure 7, Item 2) to 200°F
to 300°F.
5. Use a 0.312 in. (7.93 mm) fillet weld to join rear of tip (Figure 7, Item 4) to bottom of backing plate (Figure 7,
Item 1). Start a weld 6 in. on either side of tip center and work alternately toward center. Skip 6 in. from
previous welds and work back.
6. Continue to backstep welds alternately on either side of tip center until weld is completed at bucket side plates.
7. Join front tip (Figure 7, Item 3) to front of backing plate (Figure 7, Item 2) in same manner.
Figure 7. Fillet Welds. 0085
8. Remove tack welded brace.

9. Install bucket on loader (WP 0086).
0085-5
TM 5-3805-255-14 0085
CUTTING EDGE INSTALLATION – CONTINUED 00085
Spade Nose Cutting Edge Installation 00085
NOTE
The spade nose cutting edge installation procedure is similar to the general purpose
cutting edge procedure, except the spade nose has two cutting edges instead of one.
Refer to Figure 5 and General Purpose Cutting Edge Installation in this work package.
END OF TASK
BUCKET TEETH REMOVAL 00085
WARNING
NOTE
Bucket does not have to be removed from loader for teeth replacement. The following
steps explain removal of one tooth.
Type I teeth are used with edge P/N X311567.
Type II teeth are used with edge P/N 923885C1.
0085-6
TM 5-3805-255-14 0085
BUCKET TEETH REMOVAL – CONTINUED 00085
Type 1 Teeth Removal 00085
1. Position bucket (Figure 8, Item 1) so that teeth to be replaced are accessible.

2. Remove two nuts (Figure 8, Item 6), bolts (Figure 8, Item 5), tooth (Figure 8, Item 2), and tip (Figure 8, Item 4)
from bucket (Figure 8, Item 1).
3. Turn tooth (Figure 8, Item 2) and tip (Figure 8, Item 4) over so bottom side faces up. Remove locking clip
(Figure 8, Item 3) from slot in tooth. Discard locking clip.
Figure 8. Bucket Teeth. 0085
0085-7
TM 5-3805-255-14 0085
BUCKET TEETH REMOVAL – CONTINUED 00085
Type 2 Teeth Removal 00085
1. Position bucket (Figure 9, Item 8) so that teeth to be replaced are accessible.

2. Remove two nuts (Figure 9, Item 5), bolts (Figure 9, Item 7), spacers (Figure 9, Item 6), tooth (Figure 9,
Item 4), and tip (Figure 9, Item 1) from bucket (Figure 9, Item 8).
3. Remove pin locks (Figure 9, Items 2 and 3) and separate tooth (Figure 9, Item 4) and tip (Figure 9, Item 1).
Figure 9. Type 2 Bucket Teeth. 0085
Spade Nose Teeth Removal 00085
NOTE
The spade nose teeth removal procedure is similar to the type 2 teeth removal procedure.
Refer to Figure 9 and Type 2 Teeth Removal in this work package.
END OF TASK
0085-8
TM 5-3805-255-14 0085
BUCKET TEETH INSTALLATION 00085
Type 1 Teeth Installation 00085
1. Install tooth (Figure 10, Item 2) in tip (Figure 10, Item 4) by rotating clockwise until it stops.
2. Install new locking clip (Figure 10, Item 3) in slot.
3. Turn assembled tooth (Figure 10, Item 2) and tip (Figure 10, Item 4) over and position on bucket (Figure 10,
Item 1).
4. Install two bolts (Figure 10, Item 5) and nuts (Figure 10, Item 6).
Figure 10. Type 1 Bucket Teeth Assembly. 0085
0085-9
TM 5-3805-255-14 0085
BUCKET TEETH INSTALLATION – CONTINUED 00085
Type 2 Teeth Installation 00085
1. Install pin locks (Figure 11, Items 2 and 3) on tooth (Figure 11, Item 4) and tip (Figure 11, Item 1).
2. Position tooth (Figure 11, Item 4) and tip (Figure 11, Item 1) on bucket (Figure 11, Item 8) and install two
spacers (Figure 11, Item 6), nuts (Figure 11, Item 5), and bolts (Figure 11, Item 7).
Figure 11. Type 2 Bucket Teeth Assembly. 0085
Spade Nose Bucket Teeth Installation 00085
NOTE
The spade nose teeth installation procedure is similar to the type 2 teeth installation
procedure. Refer to Figure 11 and Type 2 Teeth Installation in this work package.
END OF TASK
END OF WORK PACKAGE
0085-10
6
TM 5-3805-255-14 0086
FIELD MAINTENANCE -
BUCKET REPLACEMENT
0 0 8 6
INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0

Wire, Mechanic’s 0
Lockwasher (2) 0
WARNING
REMOVAL 00086
1. Place bucket (Figure 1, Item 1) on ground as shown.
Figure 1. Rolling Bucket. 0086
0086-1
TM 5-3805-255-14 0086
2. Place boom and bucket control lever in neutral (HOLD) position.
3. Using a suitable support device, securely block rear of bucket to prevent it from rolling back when bucket is
separated from linkage assembly.
WARNING
Ensure bucket is attached to suitable lifting device to provide support during bucket
removal. Be sure chain hoist is securely fastened to part and that all slack in chain is taken
up. Failure to do so could cause serious injury due to part falling on you. Failure to follow
these instructions may result in death or injury to personnel.
4. Attach suitable lifting device to bucket to support during removal.
CAUTION
Support bucket links during pin removal. After removing pins, carefully lower links to
ground. Failure to follow these instructions may result in damage to equipment.
NOTE
After bucket removal, to prevent loss of parts, reinstall four pins in their respective bucket
bores, looping cord rings over pins as they are installed. Thread two locking capscrews
with two lockwashers and flat washers through pinlock and into respective bores. Coat all
pin shanks with grease (WP 0018) to prevent rusting.
5. Remove two pin-locking capscrews (Figure 2, Item 4), lockwashers (Figure 2, Item 5), and flat washers (Figure
2, Item 6). Remove four pins (Figure 2, Item 2) and cord rings (Figure 2, Item 3) from bucket (Figure 2, Item 1).
6. Place boom and bucket control lever in FLOAT position, allowing boom arms (Figure 2, Item 7) to drop away
from bucket (Figure 2, Item 1).
Figure 2. Typical Bucket Removal. 0086
0086-2
TM 5-3805-255-14 0086
7. Back loader away from bucket.
CAUTION
In step 8, do not allow links to strike polished surface of tilt cylinder assembly rods. To do
so may cause damage to cylinder assemblies resulting in hydraulic oil leakage and
requiring replacement and repair of cylinder assemblies. Failure to follow this caution may
result in damage to the equipment.
8. Swing links up and over bellcrank assemblies and secure in position so that they cannot move. Make sure that
links don’t strike and damage polished surface of tilt cylinder assembly rods.
9. Use a heavy gauge wire (Figure 3, Item 2) to wire bucket links (Figure 3, Items 1 and 3) to top of bellcrank.
Figure 3. Bucket Links Wired Up. 0086
END OF TASK 00086
0086-3
TM 5-3805-255-14 0086
INSTALLATION 00086
1. Position bucket (Figure 4, Item 3) on ground so it rests on cutting edge (Figure 4, Item 2) and spill guard
(Figure 4, Item 4).
2. Remove wire holding boom arms (Figure 4, Item 1) to loader. Discard wire.
3. Start engine. With engine running, raise and position boom arms (Figure 4, Item 1) so holes in arms are directly
in line with holes in bucket (Figure 4, Item 3).
Figure 4. Bucket Placement. 0086
4. Install four pins (Figure 5, Item 2), cord rings (Figure 5, Item 3), two locking capscrews (Figure 5, Item 4), new
lockwashers (Figure 5, Item 5), and flat washers (Figure 5, Item 6) on bucket (Figure 5, Item 1).
Figure 5. Bucket Installation. 0086
5. Test bucket operation (WP 0005).
END OF TASK
0086-4
TM 5-3805-255-14 0086
ADJUSTMENT 00086
NOTE
Boom kick-out control will automatically stop boom at any preselected height.
1. Loosen adjusting knob (Figure 6, Item 1) and move cam plate (Figure 6, Item 2) to desired position.
2. Tighten knob (Figure 6, Item 1).
Figure 6. Boom Kick-Out Control System. 0086
END OF TASK
END OF WORK PACKAGE
0086-5/(6 blank)
8
TM 5-3805-255-14
CHAPTER 8
SUSTAINMENT MAINTENANCE INSTRUCTIONS
12
TM 5-3805-255-14 0087
SUSTAINMENT MAINTENANCE -
CYLINDER SLEEVES REPLACEMENT

0 0 8 7
Cylinder Sleeves Removal; Cleaning, Inspection, and Repair; Cylinder Sleeves Installation
INITIAL SETUP
0128, Item 20) 0
Reference 0
Shop Equipment, Machine Shop, Field Main-

tenance, Heavy, Supplemental No. 1, Less WP 0019 0
Power (WP 0128, Item 16) 0
Cylinder Sleeve Puller (WP 0128, Item 6) 0
Adapter, 1 020 554 R91 0
Depth Gauge, 1 020 560 R91 0
Driver, 1 020 553 R91 0

Extension, 1 020 563 R1 0
0004) 0
Holder, 1 020 557 R1 0
Engine removed (WP 0022) 0
Materials/Parts 0 Cylinder heads removed (WP 0089) 0
Petrolatum, Technical (WP 0130, Item 27) 0

Connecting rods removed (WP 0093) 0

Pistons removed (WP 0092) 0
Retaining Compound, Loctite 638 (WP 0130,

Item 29) 0
Sealant, Loctite 270 (WP 0130, Item 32) 0
0087-1
TM 5-3805-255-14 0087
CYLINDER SLEEVES REMOVAL 00087
The cylinder sleeves (Figure 1, Item 1) are the wet type. The bottom of the sleeve is sealed in the crankcase by
three O-rings (Figure 1, Item 2). A flange (Figure 1, Item 3) at the top of each sleeve fits into a counterbore in the
top of the crankcase and serves to position the sleeve correctly. In some engines, shims may be used between the
sleeve flange and crankcase counterbore to provide the correct cylinder sleeve protrusion. The wet type sleeve is
water cooled over its entire length.
Figure 1. Cylinder Sleeve. 0087
NOTE
• Whenever cylinder heads are removed, new head gaskets must be installed.
• Wrap a clean, oil-soaked cloth around crankshaft connecting rod bearing journals. Wrap
piston and connecting rod assemblies in clean cloth.
• Tag and identify all components for ease of installation.
1. Use Sleeve Puller Set, PLT-502-3 as shown in Figure 2 to remove cylinder sleeves (Figure 2, Item 1) from
crankcase (Figure 2, Item 3).
2. Remove shims (Figure 2, Item 2) (if equipped) from counterbore in top of crankcase.
0087-2
TM 5-3805-255-14 0087
CYLINDER SLEEVES REMOVAL – CONTINUED 00087
Figure 2. Removing Cylinder Sleeve. 0087
END OF TASK
0087-3
TM 5-3805-255-14 0087
CLEANING, INSPECTION, AND REPAIR 00087
Cylinder Sleeves 00087
CAUTION
• Do not clean or reuse O-rings.
• Do not use abrasive material to clean cylinder sleeves. Failure to follow these instructions
may result in damage to the equipment.
2. Remove O-ring (Figure 3, Item 3), shim(s) (Figure 3, Item 2) (if equipped), and two black packing O-rings
(Figure 3, Item 4) from cylinder sleeve (Figure 3, Item 1). Discard O-rings.
3. Measure inside diameter of sleeve (Figure 3, Item 1) with an inside micrometer or bore gauge from top to
bottom of sleeve where it is subject to piston and ring travel. Take measurements at right angles to determine if
sleeve is out-of-round or excessively tapered. See Table 1 for maximum allowable sleeve wear. If sleeve does
not meet specifications it must be discarded and a new piston sleeve (and piston) installed.
Figure 3. Cylinder Sleeve with Packing Rings and Shims. 0087
0087-4
TM 5-3805-255-14 0087
CLEANING, INSPECTION, AND REPAIR – CONTINUED 00087
Table 1. Cylinder Sleeve Specifications.
0ITEM SPECIFICATION
0
Sleeve inside diameter 5.3756 to 5.3766 in. (136.540 to 136.566 mm) 0
Sleeve length 12.47 in. (316.7 mm) 0
Maximum permissible diameter sleeve wear (at top of 0
ring travel) before replacement is necessary 0.008 in. (0.20 mm) 0
Top surface of sleeve flange extends above top surface 0
of crankcase 0.002 to 0.004 in. (0.050 to 0.100 mm) 0
4. Inspect sleeve for scuffing or scoring and replace sleeve (and piston) if necessary.
5. Check counterbore, making sure there are no burrs or fractures, replace if necessary.
Refacing Cylinder Sleeve Counterbore in Crankcase 00087
NOTE
Refer to instructions furnished with counter-boring tool for tool assemblies and counter-
boring procedures.
1. Check cylinder sleeve counterbore depth with a depth gauge, 1 020 560 R91, at several points around
counterbore (Figure 4, Item 1). Maximum variation between points of measurement must not exceed 0.002 in.
(0.05 mm) The counterbore must be refaced if it exceeds 0.002 in. (0.05 mm) variation.
2. Use the following counterbore tools: Driver, 1 020 553 R91, Adapter, 1 020 554 R91, Holder, 1 020 557 R1,
and Extension, 1 020 563 R1.
Figure 4. Checking Crankcase Counterbore Depth. 0087
0087-5
TM 5-3805-255-14 0087
Wear Sleeve Insert (Lower) Installation 00087
NOTE
When erosion of crankcase at lower cylinder sleeve sealing area takes place, lower bore
must be machined and an insert installed.
1. Refer to Figure 5 for rework dimensions for crankcase. Surface finish to be 125 micro-in. (3.18 micrometers).
2. Apply Loctite 638 Retaining Compound to crankcase and install sleeve with chamfer on outside diameter
towards bottom and chamfer on inside diameter towards top.
3. Remove any excess retaining compound.
Wear Sleeve Insert (Upper) Installation 00087
Level crankcase so that machine spindle is perpendicular to crankcase top deck. Locate spindle at center of crank-
case lower pilot bore and machine new counterbore for insert as specified in Figure 5.
Figure 5. Rework for Crankcase Lower Sleeve Insert. 0087
(1) Bores (Figure 5, Items 1 and 4) must be concentric within 0.001 in. (0.03 mm) total indicator reading.
(2) Bores (Figure 6, Items 1 and 5) must be concentric within 0.002 in. (0.05 mm) total indicator reading
and their center lines must be square with crankshaft bearing bores within 0.003 in. (0.08 mm) in 12 in.
(305 mm).
(3) Care must be taken to hold counterbore seat parallel with top deck as specified. Failure to follow these
instructions may result in damage to equipment.
0087-6
TM 5-3805-255-14 0087
1. Freeze insert before installing. Apply a thin coat of Loctite 270 retaining compound to crankcase counterbore
seat and approximately two-thirds (2/3) up bore.
2. Install crankcase cylinder sleeve counterbore insert into counterbore.
3. Allow insert to return to room temperature.
4. Machine counterbore of installed insert as specified in Figure 6.
CAUTION
Extreme care must be taken to hold insert counterbore seat parallel with crankcase top
deck as specified. Failure to follow these instructions may result in damage to equipment.
5. Machine insert pilot bore as specified in Figure 6.
H100C-0715
Figure 6. Modification of Crankcase. 0087
0087-7
TM 5-3805-255-14 0087
6. Machine top of insert to be flush to 0.002 in. (0.051 mm) above crankcase top deck without removing any metal
from crankcase top deck.
7. Record cylinder sleeve protrusion measurements from crankcase top deck and not insert. The amount of clear-
ance between deck of crankcase and top surface of sleeve flange must not exceed 0.002 to 0.004 in. (0.050 to
0.100 mm).
END OF TASK
CYLINDER SLEEVES INSTALLATION 00087
CAUTION
• Whenever cylinder heads are removed, new head gaskets must be used. The pressure
contact surfaces of integral gasket rings are grooved to provide a better seal. This surface
flattens out when heads are torqued and may destroy sealing effect if reused. Check
cylinder sleeve flange protrusion as described in this procedure. After sleeve flange
protrusion has been determined, adjust cylinder to obtain correct total height (shims)
required for proper combustion sealing. Failure to follow these instructions may result in
• When shimming of sleeve is necessary to obtain proper protrusion, it is best to use no
more than two shims, and only one if possible, per sleeve. If more shims are used, they
may set or extrude from their position. If necessary, resurface counterbore and use a
thicker shim rather than using more shims of a smaller size. The total thickness of all
shims used per sleeve cannot exceed 0.064 in. (1.63 mm). Failure to follow these
1. Follow instructions that pertain to existing condition of your engine.
2. Construct Cylinder Sleeve Holding Adapter using locally obtained materials as shown in Figure 7.
Figure 7. Cylinder Sleeve Holding Adapter. 0087
0087-8
TM 5-3805-255-14 0087
CYLINDER SLEEVES INSTALLATION – CONTINUED
NOTE
Each cylinder may be adjusted independently. It is acceptable to use shims of one
thickness in one cylinder, and shims of another thickness in a different cylinder to arrive at
correct total cylinder sleeve height for proper combustion seating.
3. Install cylinder sleeve (Figure 8, Item 6), without O-rings, into crankcase (Figure 8, Item 7). Clamp sleeve down
by placing a sleeve holding adapter over three cylinder studs (Figure 8, Items 1 and 4).
NOTE
All pipes must be square and flat on both sides.
4. Place three pipes (Figure 8, Items 3 and 5) with a maximum ID of 1.00 in. (25 mm) over same three studs
(Figure 8, Items 1 and 4). For long studs (Figure 8, Item 1) use 8.500 in. (215 mm) long pipe (Figure 8, Item 3)
and 4.500 in. (115 mm) pipe for short stud.
5. Place regular cylinder head nuts (Figure 8, Item 2) on three studs (Figure 8, Items 1 and 4). Torque nuts
(Figure 8, Item 2) to 150 lb-ft in three stages of 50 lb-ft (68 Nm), 100 lb-ft (135 Nm) and 150 lb-ft (155 Nm).
Figure 8. Cylinder Sleeve Clamping. 0087
0087-9
TM 5-3805-255-14 0087

6. Use a dial indicator (Figure 9, Item 2) to determine cylinder sleeve (Figure 9, Items 1 and 4) protruded height.
as follows:
a. Place dial indicator, with block, across cylinder sleeve flange (Figure 9, Item 3). Top of sleeve must be
clean and free of carbon.
b. With dial indicator pointer on cylinder sleeve flange, set dial indicator pointer at zero. Move indicator block
until pointer drops to crankcase deck (Figure 9, Item 6) and take a micrometer reading.
c. If cylinder sleeve flange is below crankcase deck, rest indicator pointer on crankcase deck and set
indicator at zero. Move indicator block until pointer drops to sleeve flange and take reading.
d. This check must be made at four points around cylinder and average reading used to determine which
shim (Figure 9, Item 4) is needed.
CAUTION
• If a variation greater than 0.002 in. (0.05 mm) exists between these readings, sleeve must
be removed and crankcase counterbore depth checked at several points around
counterbore using depth gauge, 1 020 560 R91. See Crankcase Counterbore Refacing in
this work package.
• Maximum variation between points of measurement cannot exceed 0.002 in. (0.05 mm).
Mark each sleeve before removing so that it can be reinstalled in same position as it was
while making protrusion check.
• If engine has been run with a blown gasket ring or evidence of water leakage is present,
check all sleeve counterbores to determine if resurfacing is necessary prior to installing
shims.
• Shims are available in the following thicknesses: 0.002 in. (0.05 mm), 0.004 in. (0.1016
mm), 0.010 in. (0.254 mm), 0.020 in. (0.508 mm), and 0.032 in. (0.8128 mm).
• This must be done even if sleeve protrusion checked out to be within 0.002 in. (0.05 mm)
specification.
• Make sure that sleeve counterbore and sleeve flange are clean and free of foreign
material.
• Failure to follow these instructions may result in damage to equipment.
Figure 9. Cross-Section of Engine Crankcase. 0087
0087-10
TM 5-3805-255-14 0087

Crankcase Counterbore Refacing 00087
1. If sleeve flange protrusion was found to be more than 0.003 in. (0.08 mm) below crankcase deck (Figure 10,
Item 1), crankcase counterbore (Figure 10, Item 2) must be refaced.
NOTE
When shimming of cylinder sleeve is necessary to obtain proper protrusion, it is best to
use no more than two shims (and only one if possible) per sleeve. If more shims are used,
they may set or extrude from their position. If necessary, resurface counterbore and use a
thicker shim rather than using more shims of a smaller size. Total thickness of all shims
used per sleeve cannot exceed 0.064 in. (1.63 mm).
2. After counterboring, place necessary shims under sleeve flange to raise it up to 0.002 to 0.004 in. (0.05 to
0.010 mm) above crankcase deck.
Figure 10. Checking Crankcase Counterbore Depth. 0087
0087-11
TM 5-3805-255-14 0087

3. Install sleeve as follows:
a. Carefully clean top deck of crankcase and cylinder sleeve counterbore.
b. Ensure sealing ring grooves and cylinder sleeve counterbore (in crankcase) are clean and dry.
c. Coating sealing O-rings with Petrolatum, Technical and install them into grooves in sleeve. Coat sealing
ring contacting surface in crankcase with Petrolatum, Technical. Coat lower end of sleeve (approximately
three inches) with Petrolatum, Technical.
d. Position shims (if equipped) in sleeve counterbore in top of crankcase. Install sleeve carefully into crank-
case and press into place by hand.
e. After sleeve has been installed, recheck to see that sealing O-rings are not pulled or damaged in any way.
This can be done visually and by feeling around outside of sleeve at bottom.
CAUTION
After installing a cylinder sleeve in crankcase, check amount of clearance between deck of
crankcase and top surface of sleeve flange. This amount must not exceed 0.002 to 0.004
in. (0.050 to 0.100 mm). If sleeve protrusion is not at or less than specification, refer to
Cleaning, Inspection and Repair in this work package. Failure to follow these instructions
f. Install pistons (WP 0092) and connecting rods (WP 0093).
g. Install cylinder heads (WP 0089).
END OF TASK
END OF WORK PACKAGE
0087-12
10
TM 5-3805-255-14 0088
FRONT AND REAR MAIN OIL SEALS REPLACEMENT

0 0 8 8
Front Main Oil Seal Replacement, Rear Main Oil Seal Replacement, Engine Run-In
INITIAL SETUP
0128, Item 20) 0

WP 0064 0
Centering Tool, 1 020 471 R1 (PLT 513-7) 0

WP 0065 0
Driver, PLT-542 0
WP 0081 0
Oil Leak Detector, SE-1632 0

WP 0083 0
Materials/Parts 0
WP 0084 0
WP 0089 0
Compound, Sealing, RTV-732 (WP 0130, Item

9) 0
WP 0092 0
Grease, Automotive and Artillery (GAA) (WP WP 0093 0
0130, Item 15) 0

Item 23) 0

Personnel Required 0 0004) 0
Two 0
Flywheel removed from engine (WP 0091) 0
References 0
Timing gear cover removed from engine (WP

WP 0016 0
0097) 0
WP 0026 0
WP 0040 0
0088-1
TM 5-3805-255-14 0088
REAR MAIN OIL SEAL REPLACEMENT 00088
CAUTION
• Care should be taken not to damage bore while filing chamfer edge. Failure to follow these
• Prior to installing seal and wear sleeve, clean bore and crankshaft of all foreign material.
Failure to follow these instructions may result in damage to equipment.
NOTE
• When rear main oil seal in flywheel or adapter housing is changed oil seal bore should be
checked for a chamfer. If no chamfer is found use a file to break edge of bore. This should
be done to prevent possible damage to oil seal casing during installation.
• If rear oil seal is being installed as part of crankshaft installation disregard steps 1 through
4 inclusive as they were performed as part of crankshaft removal procedure.
1. Remove eight capscrews securing oil seal retainer to flywheel housing.
2. Remove seal retainer (if equipped) and gasket from flywheel housing. Remove oil seal unit from crankshaft.
Remove seal from seal retainer. Remove wear sleeve from crankshaft flange.
3. Inspect flywheel housing surface in area to which seal face plate or retainer is installed. Remove any burrs with
a stone and be sure entire surface is clean. Touch up outside diameter of crankshaft flange chamfer with a
stone to remove roughness or nicks.
4. Determine three evenly spaced tapped holes in crankshaft flange that will be used for driver tool bolts to install
seal and wear sleeve. One tapped hole in flange is offset 0.125 in. (3.1 mm) from equal spacing and must not
be used for installing seal and wear sleeve.
5. Install a new crankshaft seal and wear sleeve as follows:
a. If oil seal (Figure 1, Item 1) and wear sleeve (Figure 1, Item 2) are not unitized (preassembled), assemble
seal to sleeve before installing onto crankshaft as follows:
b. Seal must be clean and lubricated. Coat single lip seal with clean engine oil (WP 0131). Double lip seal
must have cavity between lips filled with grease (WP 0131).
c. Assemble seal onto sleeve as shown in Figure 1 by pushing seal in direction of arrow.
0088-2
TM 5-3805-255-14 0088
REAR MAIN OIL SEAL REPLACEMENT – CONTINUED 00088
CAUTION
Seal must be installed onto side of sleeve with chamfer on outside diameter (Figure 1) to
avoid damage to seal lip.
d. If unit is equipped with a crankshaft rear oil seal retainer, assemble retainer to flywheel housing making
sure it is centered to crankshaft by using centering tool, 1 020 471 R1 (part of old installing tool PLT-513-7)
and bolt to flywheel housing.
e. Torque Nylok capscrews to 20 lb-ft (27 Nm).
Figure 1. Assembling Seal to Sleeve. 0088
Table 1. Unitized Oil Seal and Wear Sleeve Dimension Chart.
SEAL AND SLEEVE DIM. “A” SLEEVE DIM. “B” SEAL

LOCATION INSTALLED INSTALLED
Single or Double Lip 0.486 in. (12.34 mm) 0.680 in. (17.27 mm)
in Housing or Retainer
on Crankshaft
6. If removed, install flywheel housing (WP 0091).
0088-3
TM 5-3805-255-14 0088
NOTE
Seal bore in retainer must be concentric with crankshaft within 0.010 in. (0.0025 mm) full
indicator measure as shaft is rotated 360 degrees.
7. Coat inside diameter of wear sleeve and outside diameter of seal with a thin film of sealing compound, RTV-
732. Care should be taken not to get any of this liquid on seal lip or outside diameter of wear sleeve.
NOTE
Do not remove seal from sleeve during assembly.
8. Bolt crankshaft attaching adapter plate to crankshaft.
9. Place utilized seal assembly installing adapter plate. Radius on outside diameter if wear sleeve is to be located
toward rear.
NOTE
• Two spacers are included with this tool are to be used when installing double lip seal
assemblies in retainer on PTO gear along with two longer capscrews.
• Seal face must be parallel with rear of crankshaft within 0.010 in. (0.25 mm).
10. Place hydraulic cam (OTC-Y-15A or equivalent) on adapter plate and secure with washer and nut. Install seal
and sleeve onto shaft into housing or retainer as one assembly to dimensions “A” and “B” per Figure 2.
0088-4
TM 5-3805-255-14 0088
Figure 2. Oil Seal and Wear Sleeve Installation Program. 0088
11. Install flywheel (WP 0091).
0088-5
TM 5-3805-255-14 0088
CAUTION
Be sure that timing marks on camshaft gear and crankshaft gear are lined up before
installing crankcase front cover. Failure to follow this caution will cause damage to
equipment.
12. Install crankcase front cover (WP 0090).
13. Install new oil suction pipe gasket on crankcase.
14. Install crankcase oil pan and scavenging oil pump manifold. Be sure that manifold O-rings are in place.
15. Install and torque oil pan drain plugs to 35 lb-ft (47 Nm).
16. Install oil pan on engine.
17. Install flywheel on engine (WP 0091).
18. Install engine (WP 0022).
19. Fill crankcase with lubricating oil (WP 0018).
20. Prime lubricating oil pump.
21. Check coolant level in cooling system (WP 0018).
22. Start engine and check for leaks.
END OF TASK
0088-6
TM 5-3805-255-14 0088
FRONT MAIN OIL SEAL REPLACEMENT 00088
NOTE
Do not cut completely through sleeve.
1. Remove wear sleeve (Figure 3, Item 2) from vibration damper hub (Figure 3, Item 3).
2. Remove any nicks or scratches from wear sleeve surface of hub with an emery cloth.
3. Install a new wear sleeve (Figure 3, Item 2) as follows:
a. Apply a light coat of sealing compound, RTV-732 onto wear sleeve surface of damper hub (Figure 3,
Item 3).
b. Use driver PLT-542 (Figure 3, Item 1) to press new wear sleeve (Figure 3, Item 2) onto hub (Figure 3,
Item 3) until drive bottoms on hub face.
Figure 3. Vibration Damper Hub with a Wear Sleeve and Driver. 0088
0088-7
TM 5-3805-255-14 0088
FRONT MAIN OIL SEAL REPLACEMENT – CONTINUED 00088
4. Remove oil seal from front cover. Thoroughly clean seal bore in housing and remove any nicks and scratches.
5. Install new oil seal. Use a tool of sufficient diameter to press on outside diameter of seal.
6. Inspect viscous vibration damper for following:
a. Dents. Even small dents can cause inner space member, which floats in silicone fluid, to contact outer
housing. Such contact can cause damper malfunction. Replace dented dampers.
b. Leaks. Clean damper thoroughly and inspect for silicone fluid leaks. Such leaks can occur at cracks or
seam openings in housing. Replace damper if any leaks are found.
NOTE
Viscous dampers are designed to operate for as many hours or miles as other major
engine components. Therefore, except for those cases mentioned above, dampers do not
need to be replaced except at major overhauls.
7. If crankcase front plate was removed, reinstall as follows:
a. Install a new gasket on front of crankcase and install front plate with hydraulic pump attached. Secure front
plate with capscrews and locks.
b. If equipped with hydraulic pump, connect oil line manifold to pump.
c. Install adapter housing with injection pump attached. Secure adapter housing to crankcase front plate.
Secure injection pump to mounting block. Connect all lines to injection pump.
d. Install lubricating oil and water pump assembly (WP 0098).
8. Install crankshaft gear key on crankshaft.
9. Heat crankshaft gear (Figure 4, Item 1) to 475°F (245°C). Using suitable heat-resistant gloves, install gear on
crankshaft with timing mark facing out.
Figure 4. Installing Crankshaft Gear. 0088
0088-8
TM 5-3805-255-14 0088
FRONT MAIN OIL SEAL REPLACEMENT – CONTINUED 00088
NOTE
Be sure to check clearance between all timing gears as outlined in WP 0088 before
installing engine front cover. Failure to follow these instructions may result in damage to
equipment.
10. Install timing gear cover (WP 0097).
11. Install oil pan.
14. Prime oil pump (WP 0098).
15. Check coolant level in cooling system (WP 0018).
END OF TASK
ENGINE RUN-IN 00088
Engine Run-In Schedule 00088
After installation of new sleeve and piston sets or piston rings, engine must be run-in according to the following
conditioning schedule, before operating at normal load and speed.
1. Check and fill cooling system.
3. If engine was placed on its side during any inspection, repair, or replacement procedure, lubricating oil pump
must be primed as described in Priming Lubrication System in this work package.
NOTE
Do not run engine at low idle speeds for long periods after installing new rings or sleeves,
as rings will not seat during idle operation.
Dynamometer Run-In Procedure 00088
1. Install necessary diagnostic instruments.

2. Operate engine at no load at 550 to 600 RPM and check for leaks in water, lube oil, fuel, and air induction
systems; time required: 5 minutes.
3. Operate engine at 3/4 rated speed and 1/2 rated load (approximate) for that speed, time required: 5 to
10 minutes.
4. Operate engine at Rated Horsepower and Rated Speed (RPM), time required: 35 to 40 minutes.
5. Recheck for oil, air, and water leaks, retighten cylinder head bolts and adjust valve lash (WP 0018).
6. Inspect and replace oil filters if necessary.
7. It is not necessary to change oil filter after above run-in schedule. The same oil may be used until next regular
change period.
0088-9
TM 5-3805-255-14 0088
ENGINE RUN-IN – CONTINUED 00088
In Vehicle Run-In Procedure 00088
1. Install necessary diagnostic instruments.

2. Operate engine at No Load at 550 to 600 RPM to check for leaks in water, lube oil, fuel, and air induction
systems; time required: 5 minutes maximum.
3. Operate vehicle at 3/4 rated speed (RPM) and 1/2 load for that speed; time required: 5 to 10 minutes
maximum.
4. Operate vehicle at full load and rated speed while maintaining normal operating temperature of engine and
torque converter; time required: 35 to 40 minutes.
5. Recheck for oil, air, and water leaks, retighten cylinder head stud nuts, and adjust valve lash (WP 0018).
Inspect and replace oil filter elements if necessary.
6. Continue to operate engine for a period of 30 minutes to complete a total of one hour and 15 minutes.
NOTE
Do not exceed 15 minutes per each stall check.
7. It is not necessary to change oil after above run-in schedule. The same oil may be used until next regular
change period.
Priming Lubricating System 00088
WARNING
Diesel engine must not be rotated when priming with oil, otherwise they are likely to start
running. Failure to follow these instructions may result in injury to personnel or damage to
equipment.
CAUTION
Failure to prime engine will cause damage to engine components.
When assembling overhauled engine, it is necessary to thoroughly lubricate running parts with engine oil to assure
lubrication when engine is started. To make certain that complete initial lubrication is available, engine lubricating
system should be pressure primed or charged with oil using Oil Leak Detector SE-1632. New or overhauled
engines that have been in storage over an extended period should also be primed in a similar manner.
When priming procedure is used, make certain that oil level is correct before the engine is put into service.
END OF TASK
END OF WORK PACKAGE
0088-10
36
TM 5-3805-255-14 0089
CYLINDER HEAD REPLACEMENT

0 0 8 9
Removal; Disassembly; Cleaning, Inspection, and Repair; Assembly; Installation
INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP Filter, Fuel 0
0128, Item 20) 0

Gasket (8) 0
Shop Equipment, Automotive Maintenance Lockwashers (24) 0
and Repair: Organizational Maintenance

Shop Equipment, Machine Shop, Field Main- Two 0
tenance, Heavy, Supplemental No. 1, Less

References 0
Tool Kit, Machinist’s (WP 0128, Item 21) 0

WP 0019 0
Adapter for Pressure Testing Valve Housing to WP 0023 0
Injection Nozzle Lines (WP 0128, Item 1) 0 WP 0027 0
Cylinder Head Water Test Kit (WP 0128, Item WP 0035 0
5) 0
WP 0036 0
Cylinder Sleeve Puller (WP 0128, Item 6) 0

WP 0039 0
Injector Rolling Sleeve (WP 0128, Item 8) 0

WP 0098 0
Injector Sleeve Bottoming Tool (WP 0128, WP 0099 0
Item 9) 0
Injector Sleeve Puller (WP 0128, Item 10) 0

Injector Sleeve Reamer and Guide Bushing Machine parked on level ground (WP 0005) 0
(WP 0128, Item 11) 0 Parking brake applied (WP 0005) 0
Spring Load Tester Valve and Clutch Spring Engine OFF (WP 0005) 0
Tester (WP 0128, Item 18) 0

0004) 0
Materials/Parts 0
Air cleaner assembly removed (WP 0029) 0

Muffler removed (WP 0035) 0
(WP 0130, Item 3) 0
Compound, Prussian Blue Marking (WP 0130,

Item 8) 0
Intake and exhaust manifold removed (WP
0026) 0
Turbocharger oil inlet tube removed (WP

0030) 0
0089-1
TM 5-3805-255-14 0089
DESCRIPTION 00089
Each cylinder head contains six intake and six exhaust valves (two of each per cylinder). Positive valve rotators
and valve seat inserts are used on all valves.
There are three fuel injection nozzles in each cylinder head, one between each pair of intake and exhaust valves.
To insure efficient cooling, nozzles are inserted into a thin-walled copper tube, passing through water space in
cylinder head.
The rocker arm assembly on each head is mounted on four brackets and is located and held down by cylinder
head studs and nuts. There are two rocker levers per cylinder, one for each pair of intake exhaust valves. A valve
bridge connects each pair of intake and exhaust valves which allows both valves to be actuated by one rocker
lever.
Both cylinder heads are basically of uniform construction, however, slight modifications in design prevent them
from being interchangeable. A separate cylinder head gasket with integral gasket rings is provided for each head.
REMOVAL 00089
1. Remove water transfer tube (Figure 1, Item 4), inverted nut tube (Figure 1, Item 3), and straight pipe adapter
(Figure 1, Item 2) from cylinder head (Figure 1, Item 1).
Figure 1. Water Transfer Tube. 0089
0089-2
TM 5-3805-255-14 0089
CAUTION
Tag and identify all hose flanges for ease of installation. Cap all hoses to prevent
contamination and leaks. Failure to follow caution may result in failure of equipment.
2. Disconnect injection pump hose (Figure 2, Item 1) and pump supply tube (Figure 2, Item 5) from final fuel filter
header (Figure 2, Item 3).
3. Remove two bolts (Figure 2, Item 6) and lockwashers (Figure 2, Item 7) from final fuel filter header (Figure 2,
Item 3) and final fuel filter support (Figure 2, Item 2). Discard lockwashers.
4. Remove final fuel filter (Figure 2, Item 4) and final fuel filter header (Figure 2, Item 3) from engine as an
assembly.
Figure 2. Final Fuel Filter and Connections. 0089
0089-3
TM 5-3805-255-14 0089
5. Disconnect fuel injection lines (Figure 3, Item 2) from fuel injection pump (Figure 3, Item 3).
6. Disconnect fuel injection lines (Figure 3, Item 2) from fuel injection pipes (Figure 3, Item 4).
NOTE
Do not remove fuel lines from injection pipe clamps and support brackets. Leave as an
assembly connected to brackets.
7. Remove two bolts (Figure 3, Item 6) and lockwashers (Figure 3, Item 7) from fuel line brackets (Figure 3,
8. Remove fuel lines (Figure 3, Item 2) and brackets (Figure 3, Item 5) as fuel line assembly (Figure 3, Item 1).
9. Cap opening at injection pump, valve housings, and open ends of fuel lines.
Figure 3. Injection Pump Fuel Lines. 0089
0089-4
TM 5-3805-255-14 0089
10. Remove two clamps (Figure 4, Item 3) on hose (Figure 4, Item 8) from front coolant manifold (Figure 4, Item 1)
and rear water manifold (Figure 4, Item 5).
11. Remove four bolts (Figure 4, Item 6), lockwashers (Figure 4, Item 7), rear coolant manifold (Figure 4, Item 5),
and two manifold gaskets (Figure 4, Item 4) from cylinder head. Discard lockwashers and gaskets.
12. Disconnect two hose clamps (Figure 4, Item 11), water outlet hose (Figure 4, Item 14), and by-pass hose
(Figure 4, Item 12) from thermostat housing (Figure 4, Item 13).
NOTE
Remove air compressor water inlet hose from thermostat housing (if equipped). Where
necessary, remove alternator brace bolt and washer from thermostat housing.
13. Remove six bolts (Figure 4, Item 9), lockwashers (Figure 4, Item 10), front coolant manifold (Figure 4, Item 1),
and two manifold gaskets (Figure 4, Item 2) from cylinder head. Discard lockwashers and gaskets.
14. Remove thermostat housing from front coolant manifold (WP 0037).
Figure 4. Coolant Manifolds. 0089
0089-5
TM 5-3805-255-14 0089
15. Remove lubricating oil filter assembly (WP 0039).
16. Disconnect fuel return tubes (Figure 5, Item 1) from two valve housings (Figure 5, Item 2).
Figure 5. Fuel Return Lines. 0089
0089-6
TM 5-3805-255-14 0089
17. Remove two valve covers and gaskets (WP 0027).
18. Remove fuel return and supply tubes (WP 0027).
19. Remove six bolts (Figure 6, Item 2) and flat washers (Figure 6, Item 3) from valve cover housing (Figure 6,
Item 1).
20. Remove 10 bolts (Figure 6, Item 4), lockwashers (Figure 6, Item 5), and valve housing clamps (Figure 6,
Item 6) from valve cover housing (Figure 6, Item 1). Discard lockwashers.
21. Remove valve cover housing (Figure 6, Item 1) and cylinder gasket (Figure 6, Item 7) from cylinder head.
Discard gasket.
Figure 6. Valve Housing Cover and Gasket. 0089
0089-7
TM 5-3805-255-14 0089
22. Remove bolts (Figure 7, Item 1) from intermediate valve lever brackets (Figure 7, Item 2).
23. Remove six cylinder head stud nuts (Figure 7, Item 3) and flat washers (Figure 7, Item 4) from valve lever
24. Remove valve lever assembly (Figure 7, Item 5) from cylinder head.
25. Remove valve push rods (Figure 7, Item 6) from cylinder head.
Figure 7. Valve Lever Assembly. 0089
26. Remove fuel injectors (WP 0030).
0089-8
TM 5-3805-255-14 0089
WARNING
assistance during procedure. Ensure that any lifting device is in good condition and of
27. Use suitable lifting device to remove cylinder head (Figure 8, Item 1) from engine.
28. Remove cylinder head gasket (Figure 8, Item 2) from engine. Discard gasket.
Figure 8. Cylinder Head and Gasket. 0089
29. Repeat steps 17 through 28 for remaining cylinder head.
END OF TASK
0089-9
TM 5-3805-255-14 0089
DISASSEMBLY 00089
Valve Lever and Shaft Assembly 00089
1. Remove six valve lever adjusting screws (Figure 9, Item 5) and nuts (Figure 9, Item 6) from rocker levers
(Figure 9, Item 3).
2. Remove five roll pins (Figure 9, Item 2) from brackets (Figure 9, Items 1, 8, and 9) and slide end brackets off of
shaft (Figure 9, Item 4).
3. Remove brackets (Figure 9, Item 9), six rocker levers (Figure 9, Item 3), and three bushings (Figure 9, Item 7)
from shaft (Figure 9, Item 5).
4. Repeat steps 1 through 3 to disassemble valve lever assembly on other cylinder head.
0089-10
TM 5-3805-255-14 0089
CAUTION
Place each valve and associated hardware in a numbered rack. Valve assemblies must
be reassembled in their original positions. Failure to follow this caution may result in
premature wear or failure to cylinder head.
5. Compress valve springs (Figure 10, Item 3) in cylinder head (Figure 10, Item 1) and remove valve seat keys
(Figure 10, Item 5) from valve (Figure 10, Item 6).
6. Release spring compressor and remove valve (Figure 10, Item 6), valve rotator (Figure 10, Item 4), valve
spring (Figure 10, Item 3), and valve seat (Figure 10, Item 2) from cylinder head (Figure 10, Item 1).
7. Repeat steps 5 and 6 to remove remaining valves (Figure 10, Item 6).
Figure 10. Removing Valves and Hardware. 0089
END OF TASK
0089-11
TM 5-3805-255-14 0089
Cylinder Head 00089
1. Clean cylinder head (Figure 11, Item 2) and crankcase deck thoroughly. Carbon must be removed from bottom
face of cylinder head, out of valve ports, and flush out water passages to remove any accumulation of salt,
lime, or sludge.
2. Check cylinder head for flatness. Use a feeler gauge and a straightedge long enough to span length and width
of cylinder head. If more than a 0.003 in. (0.08 mm) feeler gauge can be inserted under straightedge, resurface
cylinder head to a maximum of 0.030 in. (0.08 mm) if necessary. After resurfacing head, surface must have a
smoothness of 0.001 in. (0.003 mm) or less with a wave pattern or no more than 3 in. (76 mm).
NOTE
Crankcase deck cannot be resurfaced.
3. Check cylinder head height before resurfacing. Cylinder head height should be 4.998 to 5.002 in. (126.95 to
127.05 mm) with a minimum allowable reconditioned height of 4.968 in. (126.19 mm). If height is at minimum
allowable reconditioned height, further resurfacing cannot be done and it will be necessary to replace cylinder
head.
4. If cylinder head needs to be resurfaced, protrusion of valves (Figure 11, Item 1) must be maintained. Allowable
valve protrusion from cylinder head (Figure 11, Item 2) face is 0.020 to 0.032 in. (0.50 to 0.81 mm), and
minimum allowable protrusion is 0.010 in. (0.25 mm).
Figure 11. Valve Protrusion from Cylinder Head. 0089
0089-12
TM 5-3805-255-14 0089
CLEANING, INSPECTION, AND REPAIR – CONTINUED

Cylinder Head Studs 00089
1. Inspect cylinder head studs (Figure 12, Items 1, 2, and 3) for proper height. Refer to Figure 12.
2. If necessary, torque studs (Figure 12, Items 1, 2, and 3) to 75 to 265 lb-ft (102 to 360 Nm) to achieve proper
stud height above crankcase (Figure 12, Item 4).
Figure 12. Cylinder Head Stud Height. 0089
Table 1. Stud Height.
ITEM DESCRIPTION
1 Long Studs
2 Center Stud
3 Short Studs
A 10.8125 in. (275 mm)
B Without Crab: 6.500 in. (165 mm)

With Crab: 7.800 in. (198 mm)
C 6.500 in. (165 mm)
0089-13
TM 5-3805-255-14 0089

Cylinder Head Pressure Check 00089
With injection nozzles installed and valves removed, pressure check cylinder heads (Figure 14) as follows:
a. Install rubber stoppers (Figure 13, Item 1) and special adapter (Figure 13, Item 3), from test kit PLT-508 or
use fabricated plates like those shown in (Figure 14, Figure 15, and Figure 16).
NOTE
• Fabricate pressure plate (Figure 14) from 0.500 in. (13 mm) plywood, side plates from
0.250 in. (6 mm) steel, and a gasket for each plate from 0.125 in. (3 mm) rubber.
• A kit consisting of thicker cylinder head gasket grommet inserts is available for use when
cylinder head or crankcase is eroded in water passage areas. Remove existing grommets
from new cylinder head gaskets and replace with grommets furnished in kit.
b. Fill cylinder head (Figure 13, Item 2) with hot water. Apply 10 to 12 psi (69 to 83 kPa) air pressure and
check for leaks.
Figure 13. Cylinder Head Pressure Check. 0089
0089-14
TM 5-3805-255-14 0089
Figure 14. Cylinder Head Pressure Plate. 0089
0089-15
TM 5-3805-255-14 0089
Figure 15. Side Plate with Quick Disconnect. 0089
Figure 16. Side Plate with Drain Plug. 0089
0089-16
TM 5-3805-255-14 0089

Injector Nozzle Sleeves 00089
1. If an injector nozzle sleeve (Figure 17, Item 2) is to be replaced proceed as follows:
NOTE
Never remove a nozzle sleeve with a chisel and punch as scoring and grooving of
machined seating surfaces will result. Even if these surfaces are dressed with a stone,
only surface burrs are removed; but grooves remain, leaving potential leaks of coolant into
lubricating oil or combustion chamber.
a. Remove valve bridge guides to allow for installation of sleeve puller.
NOTE
Puller PL T-507-3 is a pre-cup puller used on all pre-cup type diesel engines and is used
in the same manner.
b. Install Puller No. PLT-507-3 and remove defective sleeve(s).
c. Clean sleeve seating surfaces in cylinder head (Figure 17, Item 1) thoroughly.
Figure 17. Removing Injector Sleeve. 0089
0089-17
TM 5-3805-255-14 0089

d. Place new sleeve (Figure 18, Item 1) into sleeve bore in cylinder head (Figure 18, Item 2). Tap sleeve with
a plastic or rawhide hammer until it bottoms.
e. Install Sleeve Bottoming Tool No. PLT-507-4 (Figure 18, Item 3). Tighten hex head nut against spacer of
tool until sleeve comes in firm contact with seat in cylinder head. Top of nozzle sleeve can be slightly below
finished surface of cylinder head but must not protrude above it more than 0.030 in. (0.76 mm).
Figure 18. Injector Nozzle Sleeve Bottoming Tool. 0089
0089-18
TM 5-3805-255-14 0089

f. Seal sleeve (Figure 19, Item 1) at top with Expanding Roller Tool No. PLT-507-1. As roller is turned,
tension is increased against rollers by center tapered mandrel. Turn tool until mandrel bottoms and no
rolling resistance is felt. At that point, copper sleeve will be seated tightly into cylinder head (Figure 19,
Item 2).
Figure 19. Sealing Injector Sleeve with Rolling Tool. 0089
0089-19
TM 5-3805-255-14 0089
NOTE
Be extremely careful not to ream seat beyond this point or nozzle tip will protrude too far
from face of cylinder head. Allowable nozzle tip protrusion (above finished cylinder head
surface) is 0.030 to 0.150 in. (0.08 to 0.38 mm).
g. Ream injector copper sleeve (Figure 20, Item 2) with Injector Sleeve Bottoming Tool No. PLT-507-4 (Figure
20, Item 1). Place cylinder head (Figure 20, Item 3) on a flat surface and turn bottoming tool until pilot on
bottom of reamer comes in contact with flat surface.
h. Perform Cylinder Head Pressure Check in this work package.
i. Install valve bridge guides.
Figure 20. Injector Sleeve Bottoming Tool. 0089
0089-20
TM 5-3805-255-14 0089

Valve Lever and Lever Shaft Assembly 00089
1. Wash all parts in a cleaning solvent and dry thoroughly with compressed air. Be sure drilled oil passages in
lever shaft (Figure 21, Item 3), intermediate brackets (Figure 21, Item 1), and lever bushings (Figure 21,
Item 2) are open. Also clean out oil passages in push rods.
2. Check outside diameter of valve lever shaft (Figure 21, Item 3) with a micrometer. Check inside diameter of
valve lever bushings (Figure 21, Item 2) with telescoping gauge. Difference between these two readings is
running clearance. If clearance is greater than 0.001 to 0.003 in. (0.03 to 0.08 mm) with a maximum allowable
clearance of 0.006 in. (0.15 mm), replace worn parts.
3. When replacing lever bushings (Figure 21, Item 2), be certain that oil hole in bushing aligns with oil hole in
lever. Bore or hone bushings to 1.4220 to 1.4235 in. (36.119 to 35.157 mm).
4. Inspect valve stem contact pad surface of valve levers and replace if wear is severe.
5. Remove and recondition valves (WP 0086).
Figure 21. Checking Valve Lever Bushing and Shaft for Wear. 0089
Injector Nozzle Lines 00089
Blow compressed air through injector nozzle supply and return lines to be sure they are clean.
END OF TASK
0089-21
TM 5-3805-255-14 0089
ASSEMBLY 00089
Cylinder Head 00089
1. Install valve (Figure 22, Item 6), valve seat (Figure 22, Item 2), valve spring (Figure 22, Item 3) and valve
rotator (Figure 22, Item 4) in cylinder head (Figure 22, Item 1).
2. Compress valve springs (Figure 22, Item 7) in cylinder head (Figure 22, Item 1).
3. Install valve seat keys (Figure 22, Item 5) into valve rotator (Figure 22, Item 4) at end of valve (Figure 22,
Item 6). Release spring compressor.
4. Install all valves (Figure 22, Item 6) in same manner.
Figure 22. Cylinder Head Valves. 0089
0089-22
TM 5-3805-255-14 0089
1. Install three bushings (Figure 23, Item 7), six rocker levers (Figure 23, Item 3) and brackets (Figure 23, Item 9)
on shaft (Figure 23, Item 4).
2. Slide end brackets (Figure 23, Items 1 and 8) onto shaft (Figure 23, Item 4) and install five roll pins (Figure 23,
Item 2) on brackets (Figure 23, Items 1, 8, and 9).
3. Position six nuts (Figure 23, Item 6) and valve lever adjusting screws (Figure 23, Item 5) on rocker levers
4. Make sure valve lever adjusting screws (Figure 23, Item 5) are loose.
END OF TASK
0089-23
TM 5-3805-255-14 0089
INSTALLATION 00089
Cylinder Head 00089
CAUTION
Clean injection nozzle copper sleeves with a clean cloth. DO NOT use a screwdriver or
sharp metal object. Failure to follow this caution will result in damage to sleeves.
1. Install new cylinder head gasket (Figure 24, Item 2) on engine. Line up on dowel pins.
WARNING
2. Using suitable lifting device, install cylinder head (Figure 24, Item 1).
Figure 24. Cylinder Head and Gasket. 0089
0089-24
TM 5-3805-255-14 0089
NOTE
With the following procedure, it is essential that thread lubricant be used where specified.
3. Apply thread lubricant at nut end of cylinder head studs (Figure 25, Item 2), both sides of flat washers
(Figure 25, Item 4), and nuts (Figure 25, Item 3) on all short cylinder head studs. DO NOT torque hardware.
4. Center stud (Figure 25, Item 1) may be equipped with special crab.
Figure 25. Torquing Injector Nozzle Crab Bolt. 0089
5. Install injector nozzles (WP 0027).

6. Connect fuel return and supply tubes (WP 0027).
0089-25
TM 5-3805-255-14 0089
NOTE
Care must be taken when fitting the nozzle supply tubes. Binding cannot exist when lines
are tightened. The supply tube locknut must be left loose until the fuel tubes are
positioned and connected to the valve housing, and then tightened down.
7. Install valve push rods (Figure 26, Item 6) in cylinder head.
NOTE
Be sure that all rocker levers install into push rod sockets to tighten down valve lever
assembly, but do not torque nuts.
8. Install valve lever assembly (Figure 26, Item 5) on cylinder head.
9. Install six flat washers (Figure 26, Item 4) and cylinder head stud nuts (Figure 26, Item 3) on valve lever
10. Install bolts (Figure 26, Item 1) on intermediate valve lever brackets (Figure 26, Item 2).
11. Install valve bridges and adjust them as follows:

a. Loosen bridge adjusting screw nut and back out screw (two) several turns making sure it is not in contact
with valve stem.
b. Firmly press straight down on rocker arm just above point of contact with bridge.
c. Turn adjusting screw down until contact is made with valve stem (opposite cam side). Turn screw an addi-
tional 20 to 30 degrees (1/3 flat on nut). Release pressure on rocker arm and torque nut to 35 lb-ft (47 Nm)
while holding screw in position.
12. Repeat step 11 to adjust remaining valve bridges.
0089-26
TM 5-3805-255-14 0089
13. Tighten valve lever shaft set screws and locknut in intermediate valve lever brackets. Install two capscrews
and flat washers securing intermediate valve lever brackets to cylinder head.
14. Install straight pipe adapter (Figure 27, Item 2), inverted nut tube (Figure 27, Item 3), and water transfer tube
(Figure 27, Item 4), on cylinder head (Figure 27, Item 1).
Figure 27. Water Transfer Tube. 0089
15. Install intake and exhaust manifolds (WP 0026).

16. Do not install turbocharger or intercooler at this time (if equipped).
17. Torque cylinder head nuts in sequence. Do not tighten to full torque immediately. The nuts must be torqued in
seven steps:
a. 130 lb-ft (175 Nm).
b. 200 lb-ft (270 Nm).
c. 250 lb-ft (340 Nm).
d. Loosen one nut at a time1/4 turn and torque to 300 lb-ft (407 Nm) in sequence shown (Figure 28).
e. If stud No. 25 is equipped with a crab assembly, loosen nut No. 25 1/4 turn and torque to
420 lb-ft (570 Nm).
f. After engine is run under load and operating temperature is obtained, loosen one nut at a time
1/4 turn and torque to 300 lb-ft (407 Nm) in sequence shown (Figure 28).
0089-27
TM 5-3805-255-14 0089
NOTE
If stud No. 25 is equipped with a crab assembly, loosen nut No. 25 (1/4 turn) and torque to
420 lb-ft (570 Nm).
g. A second retorque must be done after the engine has acquired 50 hours. Torque by row and not by
sequence, marking relation of socket to cylinder head, back off 1/4 turn and bring to final torque or back to
original position, whichever is higher.
Figure 28. Sequence for Tightening Cylinder Head Nut. 0089
0089-28
TM 5-3805-255-14 0089
18. Install new valve housing gasket (Figure 29, Item 7) and valve cover housing (Figure 29, Item 1) on cylinder
head.
19. Install six flat washers (Figure 29, Item 3) and bolts (Figure 29, Item 2) on valve cover housing (Figure 29,
Item 1).
20. Install ten valve housing clamps (Figure 29, Item 6), new lockwashers (Figure 29, Item 5), and bolts (Figure 29,
Item 4) on valve cover housing (Figure 29, Item 1).
21. Torque valve housing cover bolts (Figure 29, Item 2) to 55 lb-ft (75 Nm).
22. Torque bolts (Figure 29, Item 4) to 20 lb-ft (27 Nm) for aluminum clamps or 35 lb-ft (47 Nm) for gray iron.
Figure 29. Valve Housing Cover. 0089
23. Install fuel return and supply tubes (WP 0030).
0089-29
TM 5-3805-255-14 0089
NOTE
Care must be taken when fitting nozzle supply tubes. Binding must not exist when lines
are tightened down. Supply tube lock nut must be left loose until fuel tubes are positioned
and connected to valve housing and then tighten down.
24. Install fuel lines (Figure 30, Item 2) and brackets (Figure 30, Item 5) as fuel line assembly (Figure 30, Item 1)
on fuel injection pipes (Figure 30, Item 4). Leave bracket loose until all lines are installed.
25. Install fuel injection lines (Figure 30, Item 2) on fuel injection pump (Figure 30, Item 3).
26. Install two new lockwashers (Figure 30, Item 7) and bolts (Figure 30, Item 6) on fuel line brackets (Figure 30,
Item 5).
27. Install turbocharger and intercooler (WP 0030).
NOTE
If they were removed, install air compressor coolant inlet hose and alternator brace on
thermostat housing and install intercooler coolant inlet hose on rear water manifold.
28. Install thermostat housing on front coolant manifold (WP 0037).
29. Install two new manifold gaskets (Figure 31, Item 2) and front coolant manifold (Figure 31, Item 1) on cylinder
head with six new lockwashers (Figure 31, Item 10) and bolts (Figure 31, Item 9).
30. Install two hose clamps (Figure 31, Item 11), coolant outlet hose (Figure 31, Item 14), and by-pass hose
(Figure 31, Item 12) on thermostat housing (Figure 31, Item 13).
31. Install two clamps (Figure 31, Item 3) and hose (Figure 31, Item 8) on front coolant manifold (Figure 31, Item 1)
and rear coolant manifold (Figure 31, Item 5).
0089-30
TM 5-3805-255-14 0089
32. Install two new manifold gaskets (Figure 31, Item 4) and rear coolant manifold (Figure 31, Item 5) on cylinder
head with four new lockwashers (Figure 31, Item 7) and bolts (Figure 31, Item 6).
NOTE
Where necessary, install alternator brace bolt and washer from thermostat housing.
Figure 31. Coolant Manifolds. 0089
0089-31
TM 5-3805-255-14 0089
33. Install final fuel filter (Figure 32, Item 4) and final fuel filter header (Figure 32, Item 3) on engine as an
assembly.
34. Install two new lockwashers (Figure 32, Item 7) and bolts (Figure 32, Item 6) on final fuel filter header (Figure
32, Item 3) and final fuel filter support (Figure 32, Item 2).
35. Install injection pump hose (Figure 32, Item 1) and pump supply tube (Figure 32, Item 5) on final fuel filter
header (Figure 32, Item 3).
Figure 32. Final Fuel Filter and Connections. 0089
0089-32
TM 5-3805-255-14 0089
36. Install lubricating oil filter assembly (WP 0039).
37. Lubricate threads of fuel line nuts with lubricant. Connect fuel lines to injection pump and valve housings.
Torque nuts at pump to 30 lb-ft (40 Nm) and nuts at valve housings to 40 lb-ft (55 Nm).
38. Fill complete cooling system (WP 0018). Be certain that radiator and cylinder block drain valves are closed.
Also close vent valve on water manifold after venting system.
39. Check oil level in crankcase (WP 0018).
40. Adjust valve lash to cold setting as follows.
41. Pressure test valve housing-to-injection nozzle lines. Connect a test pump to injector nozzle pipe inlet elbow
outside of valve housing. Be sure engine timing pointer (Figure 33, Item 1) is set at “I-6” mark on vibration
damper (Figure 33, Item 2) for cylinder and injector to be tested.
42. Build up 3,000 psi. (20,685 kPa) pressure on test pump gauge and look for leaks at the following points:
a. Connector nut at housing fitting.
b. Fittings at each end of injector lines.
c. Connector nut at injector nozzle inlet elbow.
Figure 33. Timing Mark. 0089
43. If leaks are found and further tightening does not stop leaks, replace defective parts.
44. Pressure test return lines. Connect test pump to return line tee or elbow. Apply 25 psi. (172 kPa) pressure and
look for leaks at all connector nuts and return lines.
45. If pressure cannot be maintained, look for leakage around injector nozzle fittings. Defective fittings must be
replaced.
46. Hand prime fuel system (WP 0018).
0089-33
TM 5-3805-255-14 0089
Valve Lash Adjustment 00089
Whenever cylinder heads have been replaced or cylinder head bolts re-torqued, adjust valve lash before starting
engine.
NOTE
Before adjusting valve lash, be sure valve bridges have been adjusted.
All valves can be adjusted quickly and accurately. Do not crank engine six times to position piston of each cylinder
on TDC. All valves are adjusted by cranking engine only twice.
1. Remove cover and gasket from both cylinder heads.
NOTE
Be sure that No. 1 piston is on compression stroke by turning both push rods by hand to
determine that both intake and exhaust valves are closed. Valves are closed when push
rods are loose and can be turned easily.
2. Turn crankshaft until No. 1 piston is on compression stroke and timing pointer (Figure 33, Item 1) on front cover
is in line with TDC mark on vibration damper (Figure 33, Item 2). Figure 34 shows the numbering sequence of
valves.
Figure 34. Valve Arrangement. 0089
0089-34
TM 5-3805-255-14 0089
3. In this position, adjust intake valves (as described in step 4) for cylinders 1, 2, and 4; and exhaust valves for
cylinders 1, 3, and 5.
4. Rotate crankshaft one full revolution until No. 6 cylinder is at TDC (compression). In this position, adjust intake
valves for cylinders 3, 5, and 6; and exhaust valves for cylinders 2, 4, and 6.
5. Loosen rocker lever nut (Figure 35, Item 3) and screw (Figure 35, Item 2).
NOTE
Feeler gauge must not be more than 0.375 in. (9.5 mm) wide to ensure a free fit between
ears of bridge.
6. Insert feeler gauge between rocker lever and valve bridge (Point A). Turn adjusting screw (Figure 35, Item 2)
until bridge (Figure 35, Item 1) just touches feeler gauge. Hold adjusting screw (Figure 35, Item 2) in position
and torque jamnut (Figure 35, Item 3) to 85 lb-ft (115 Nm).
Figure 35. Valve Lash Adjustment. 0089
7. Install two new gaskets and valve covers (WP 0027).
END OF TASK
END OF WORK PACKAGE
0089-35/(36 blank)
18
TM 5-3805-255-14 0090
CRANKSHAFT AND MAIN BEARINGS REPLACEMENT

0 0 9 0
Removal; Cleaning, Inspection, and Repair; Crankshaft Bearings Caps; Installation
INITIAL SETUP
0128, Item 20) 0

WP 0021 0
WP 0027 0
Shop Equipment, Machine Shop, Field

WP 0085 0

WP 0088 0
Crankshaft Gear Nut Torque Wrench Adapter Equipment Condition 0
(WP 0128, Item 4) 0
Rear Crankshaft Oil Seal (WP 0128, Item 13)0
Rockwell Hardness Tester 0
Hydraulic Cam OTC Y-15A 0

Materials/Parts 0
0004) 0
Plastigage (WP 0130, Item 26) 0

Cylinder head removed from engine (WP
0089) 0
Grease, Grade 251 H-EP 0
Crankcase oil pan removed from engine 0
Pin, Cotter 0
Seal, Front Main Oil 0
Seal, Rear Main Oil 0
0090-1
TM 5-3805-255-14 0090
REMOVAL 00090
Crankshaft Bearings 00090
1. Remove oil suction pipe from engine.

2. Remove piston cooling jets from right side of crankcase.
3. Loosen gear oil jet tube nut (Figure 1, Item 5) and remove gear oil jet tube (Figure 1, Item 4) from crankcase
(Figure 1, Item 6).
4. Remove 14 capscrews (Figure 1, Item 1) securing seven crankshaft bearing caps (Figure 1, Item 2).
Figure 1. Removing Gear Oil Jet Tube. 0090
0090-2
TM 5-3805-255-14 0090
NOTE
If bearings are to be reused, be certain that they are identified as to their original positions.
5. Remove seven lower crankshaft bearings (Figure 2, Item 1) from seven crankshaft bearing caps (Figure 2,
Item 2). Lubricate parts lightly with engine oil (WP 0131). Wrap pieces in a clean cloth and store until
Assembly.
Figure 2. Removing Lower Bearings. 0090
0090-3
TM 5-3805-255-14 0090
NOTE
• If crankshaft is to be removed, disregard step 6.
• An alternate method of removing upper halves of bearings is to hammer closed end of a
small cotter pin to form a T and then insert prongs of cotter pin in oil hole of crankshaft
journal with flattened head just protruding. Rotate crankshaft, and cotter pin head will
push bearing from position.
6. Use a thin piece of flexible soft metal to remove seven upper bearing halves (Figure 3, Item 1) from between
crankshaft (Figure 3, Item 3) and crankcase (Figure 3, Item 4). This will push against end of bearing farthest
from nib (Figure 3, Item 2) holding bearing in crankcase support and at same time turning crankshaft in direc-
tion of rotation. Bearing will slide easily from position.
Figure 3. Removing Upper Half of Crankshaft Bearing. 0090
0090-4
TM 5-3805-255-14 0090
Crankshaft 00090
1. Remove flywheel (WP 0026).
NOTE
It is not necessary to remove flywheel housing if replacing crankshaft rear oil seal. Refer
to WP 0088 for rear oil seal replacement.
2. Remove flywheel housing from crankcase (WP 0091).
3. Remove crankcase front cover assembly (WP 0097).
4. Remove six connecting rod bearing caps (WP 0093).
5. Push piston and rod assemblies to top of their travel.
WARNING
6. Use a suitable lifting device to lift crankshaft (Figure 4, Item 1) out of crankcase (Figure 4, Item 2).
Figure 4. Removing Crankshaft. 0090
0090-5
TM 5-3805-255-14 0090
7. Remove seven upper main bearing halves (Figure 5, Item 1) from crankcase (Figure 5, Item 2).
Figure 5. Removing Upper Main Bearing Halves. 0090
8. Remove rear oil seal retainer and rubber lip type seal from flywheel housing. Remove rubber lip oil seal from
retainer. Discard rear oil seal.
END OF TASK
0090-6
TM 5-3805-255-14 0090
NOTE
Crankshaft must not be straightened
2. Hardness must be checked on every journal which incurred a bearing failure, shows evidence of overheating
or before grinding crankshaft. Using a Rockwell Hardness Tester, check in at least three locations as close to
fillet as possible. Also, check rod journals at top, bottom, and one other location (top and bottom determined
with journal at TDC). Minimum hardness for non-fillet hardened shafts is 30 Rc. These shafts have an identifi-
cation number, 277 100 R1 or R2, forged into center cheek. Fillet hardened shafts, forged number 670 331 C1,
must have a minimum hardness of 45 Rc. If any reading is below this, shaft must be scrapped.
3. Inspect crankshaft journals for scoring and measure diameter of each journal, using a micrometer. Check
dimensions obtained against those specified in following table:
Table 1. Crankshaft Specifications.
ITEM 090 SPECIFICATION 090
Crankshaft Pin Diameter 3.4965 to 3.4975 in. (88.811 to 88.837 mm)
Main Journal Diameter 4.4990 to 4.5000 in. (114.275 to 114.300 mm)
Maximum Permissible Journal Out-of-Round- 0.004 in. (0.10 mm)

ness, Before Reconditioning
Number of Main Bearings 7
Main Bearing Running Clearance 0.0026 to 0.0060 in. (0.066 to 0.152 mm)
Maximum Permissible Bearing Running Clear- 0.0086 in. (0.218 mm)

ance
End-Play Clearance 0.005 to 0.011 in. (0.13 to 0.28 mm)
Maximum Permissible End-Play Clearance, 0.024 in. (0.61 mm)

Before Reconditioning
Counterbalanced Crankshaft Yes
Main Bearing Bore in Crankcase (Line- 4.844 to 4.845 in. (123.04 to 123.06 mm)
Reamed with caps assembled)
0090-7
TM 5-3805-255-14 0090

4. Measure each journal (Figure 6, Item 1) at two points, one at right angles to other, in order to show any
tendency of out-of-round. Move micrometer over entire width of journal.
5. Inspect crankshaft gear teeth for wear and chipping, replace if necessary.
Figure 6. Measuring Crankshaft Journal. 0090
0090-8
TM 5-3805-255-14 0090

6. Clean all crankshaft internal oil passages (Figure 7, Item 2) of any dirt or sludge that may have accumulated.
With six plugs (Figure 7, Item 4) removed from crankshaft (Figure 7, Item 5), run a stiff wire brush (seven in. or
longer) through oil passages to loosen deposits. Then wash passages and external surfaces of crankshaft
(Figure 7, Item 3) thoroughly with solvent. Blow passages and external surfaces dry with compressed air. A
visual inspection of drilled holes in main (Figure 7, Item 1) and connecting rod journals must be made to assure
all passages are open. Install plugs securely in crankshaft.
Figure 7. Cleaning Crankshaft Oil Passages. 0090
0090-9
TM 5-3805-255-14 0090
NOTE
Crankshaft must be hardness checked before regrinding.
7. If crankshaft, bearings and crankcase are in good condition, measurement taken should fall within specified
clearances. Should clearance obtained be more or less than specified amount, replace with new bearings.
Should clearance obtained be more or less than specified amount, replace with new bearings. Should clear-
ance remain excessive, grind crankshaft and install undersize bearings for ground crankshaft. Bearings are
available in 0.010 in. (0.25 mm) and 0.030 in. (0.76 mm) undersize. Figure 8 shows dimensions to which
crankshaft journals may be ground. Do not grind beyond maximum limit shown.
Figure 8. Dimensions to Which Crankshaft May be Ground. 0090
CONN. ROD REAR MAIN ALL CRANKPIN

MAIN BEARING BEARING BEARING BEARINGS ALL MAIN
DIAMETER DIAMETER WIDTH DIAMETER BEARINGS
A 090 B 090 C 090 D 090 E 090
BEARING SIZE 090 in. (mm) 090 in. (mm) 090 in. (mm) 090 in. (mm) 090 in. (mm) 090
(114.274 to (88.811 to (66.90 to 4.70 to 4.06 to

114.300 mm) 88.837 mm) 66.98 mm) 5.08 in. 4.44 in.
Standard
4.4990 to 3.4965 to 2.634 to (0.185 to (0.160 to
4.5000 in. 3.4975 in. 2.637 in. 0.200 mm) 0.175 mm)
(114.020 to (88.557 to (66.90 to 4.70 to 4.06 to
0.010 in.
114.046 mm) 88.583 mm) 66.98 mm) 5.08 in. 4.44 in.
(0.25 mm)
4.4890 to 3.4865 to 2.634 to (0.185 to (0.160 to
undersize 4.4900 in. 3.4875 in. 2.637 in. 0.200 mm) 0.175 mm)
(113.512 to (88.049 to (67.21 to 4.70 to 4.06 to
0.030 in.
113.538 mm) 88.075 mm) 67.29 mm) 5.08 in. 4.44 in.
(0.76 mm)
4.4690 to 3.4665 to 2.646 to (0.185 to (0.160 to
undersize 4.4700 in. 3.4675 in. 2.649 in. 0.200 mm) 0.175 mm)
*Grind an equal amount of material off at each thrust face to maintain proper crankshaft end-play.
0090-10
TM 5-3805-255-14 0090

8. Inspect crankcase for sludge deposits, especially in corners. Crankcase must be thoroughly cleaned and
inspected. Remove oil gallery plugs and flush out passages in crankcase with fuel oil. Install plugs.
9. Replace front and rear main oil seals. Refer to Installation in this work package for rear main oil seal
replacement details. For front main oil seal replacement refer to WP 0088. Discard front and rear main oil seal.
10. Remove and clean crankcase breather element. Element is located in mounting flange of breather pipe which
is secured to right hand (rear) side of crankcase.
11. Inspect oil pan and clean thoroughly.
END OF TASK
CRANKSHAFT BEARING CAPS 00090
Crankshaft main bearing caps are rough machined and line reamed while fitted to crankcase. Each cap is fitted for
its respective position.
Dimensions of Main Bearing Bore in Crankcase 00090
Line-Ream Final To . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.844 to 4.845 in. (123.04 to 123.06 mm)
END OF TASK
INSTALLATION 00090
1. Wipe seven crankcase bearing supports (Figure 9, Item 1) free of oil with a lint-free clean cloth. Crankcase
(Figure 9, Item 4) must be bottom side up and supported level with blocks.
2. Install seven main bearing upper halves (Figure 9, Item 2) (bearings with oil hole in center) on crankcase
bearing supports (Figure 9, Item 1). If original bearings are being reinstalled, be sure that they go to positions
from which they came. Nibs of bearings must fit in notches (Figure 9, Item 3) on crankcase bearing supports.
Lubricate main bearing upper halves with clean engine oil (WP 0018).
Figure 9. Installing Upper Halves of Main Bearings. 0090
0090-11
TM 5-3805-255-14 0090
NOTE
When installing a new crankshaft, remove protective coating from exterior and all drilled oil
passages.
3. Install crankshaft (Figure 10, Item 3) in place.
NOTE
• Number that is stamped on each main bearing cap (to identify its location) must be toward
camshaft side of crankcase when installed.
• Coat all main bearings with clean engine oil (WP 0131) after installation.
4. Install lower main bearings (Figure 10, Item 5) and bearing caps (Figure 10, Item 4). Lubricate main bearing
cap bolts (Figure 10, Item 1) with clean engine oil and torque in steps, first to 175 lb-ft (238 Nm), then to
235 lb-ft (320 Nm).
5. Pull six connecting rods (Figure 10, Item 2) down on crankshaft (Figure 10, Item 3). Be sure that bearings
(Figure 10, Item 11) are in place. Coat threads of connecting rod bolts (Figure 10, Item 9) with clean engine oil
(WP 0021).
6. Install six connecting rod bearings (Figure 10, Item 11) and bearing caps (Figure 10, Item 10), being sure that
correct cap is located on its rod and that identifying numbers are on same side. Torque connecting rod bolt
nuts (Figure 10, Item 8) in steps, first to 112 lb-ft (152 Nm) then to 150 lb-ft (203 Nm).
7. Install gear oil jet tube (Figure 10, Item 6) on crankcase. Tighten gear oil jet tube nut (Figure 10, Item 7)
securely.
Figure 10. Main Bearing and Connecting Rod Cap Installation. 0090
0090-12
TM 5-3805-255-14 0090
Fitting Main Bearings 00090
1. Fit main bearings as follows:
NOTE
Do not turn crankshaft while following procedure is being performed.
a. Remove center main bearing cap (Figure 11, Item 2) and lower main bearing (Figure 11, Item 1).
b. If virgin lead wire is to be used to check bearing clearance, wipe clean and oil crankshaft journal (Figure
11, Item 3). If Plastigage is to be used, wipe bearing surface and exposed half of crankshaft journal free of
oil as plastic material is soluble in oil.
c. Place a suitable length of 0.010 in. (0.25 mm) virgin lead wire or a piece of Plastigage (Figure 11, Item 4)
across bearing surface (Figure 11, Item 1) and install bearing and cap. Tighten capscrews to 235 lb-ft
(320 Nm). Remove bearing cap. If virgin lead was used carefully remove wire, which will have been
crushed to amount of clearance present. Measure wire, using a micrometer. If Plastigage was used,
flattened plastic material will be found adhering to either bearing or crankshaft. DO NOT REMOVE
PLASTIGAGE. To determine bearing clearance, compare width of flattened plastic material at its widest
point with graduations on envelope.
Figure 11. Checking Main Bearing Running Clearance. 0090
0090-13
TM 5-3805-255-14 0090
d. If results obtained were within specified amount of 0.0026 to 0.0060 in. (0.066 to 0.152 mm), remove
Plastigage, coat bearing with clean engine oil (WP 0131) and install center main bearing cap. Torque two
capscrews to 235 lb-ft (320 Nm).
e. Continue checking other main bearings in same manner. Check rear main bearing next, followed by front
main bearing and then intermediate bearings.
f. Check end-play present in crankshaft by inserting a feeler gauge equal to desired clearance of 0.005 to
0.011 in. (0.13 to 0.28 mm) (Figure 12). Should end-play clearance present be less that amount specified,
remove rear main bearing and grind off material equally from flange surface. Should clearance be more
than specified, replace rear main bearing with a new one.
g. Recheck connecting rod end play as outlined in WP 0093 and WP 0094.
Figure 12. Checking Crankshaft End Clearance. 0090
CAUTION
When rear main oil seal in flywheel housing is changed, oil seal bore should be checked
for a chamfer. If no chamfer is found use a file to break edge of bore in housing. Take care
not to damage bore while filing chamfer edge. This should be done to prevent possible
damage to rear main oil seal casing during installation.
2. Install a new crankshaft rear oil seal as follows:
a. Determine three evenly spaced tapped holes in crankshaft flange that will be used for driver tool bolts to
install seal and wear sleeve. One of tapped holes in flange is off-set 0.125 in. (3.175 mm) from equal
spacing and must not be used for installing seal and wear sleeve.
b. If oil seal and wear sleeve are not unitized (pre-assembled), assemble seal to sleeve before installing on
crankshaft as follows:
c. Seal must be clean and lubricated. Coat single lip seal with clean engine oil (WP 0131). Double-lip seal
must have cavity between lips filled with Grade 251H-EP grease.
0090-14
TM 5-3805-255-14 0090
NOTE
Seal must be installed on side of sleeve with chamfer on outside diameter to avoid
damage to seal lip.
3. Install seal (Figure 13, Item 1) on sleeve (Figure 13, Item 2).
Figure 13. Assembling Seal to Sleeve. 0090
4. If loader is equipped with a crankshaft rear oil seal retainer, assemble retainer to flywheel housing making sure
it is centered to crankshaft by using centering tool, 1 020 471 R1 (part of old installing tool PLT-513-7) and bolt
to flywheel housing. Tighten Nylok capscrews to 20 lb-ft (27 Nm).
NOTE
Seal bore in retainer must be concentric with crankshaft within 0.010 in. (0.025 mm).
5. If removed, install flywheel housing.
CAUTION
Care should be taken not to get any of this RTV on seal lip or outside diameter of wear
sleeve. Failure to follow this Caution may result in damage to equipment.
NOTE
At no time should seal be removed from sleeve during assembly.
6. Coat inside diameter of wear sleeve and outside diameter of rear main oil seal with RTV.
7. Bolt crankshaft attaching adapter plate to crankshaft.
8. Place unitized seal assembly (Figure 13, Item 1) on adapter plate. Position radius on outside diameter of wear
sleeve (Figure 13, Item 2) toward rear.
0090-15
TM 5-3805-255-14 0090
NOTE
Two spacers are included with this tool and are to be used when installing double-lip seal
assemblies in retainer on PTO gear along with two longer capscrews.
9. Place unitized seal assembly installing adapter on crankshaft adapter plate. Place hydraulic cam (OTC Y-15A
or equivalent) on adapter plate and secure with washer and nut. Install seal and sleeve on shaft in housing or
retainer as one assembly to dimension A and B per Oil Seal and Wear Sleeve Dimension Chart that follows:
Figure 14. Oil Seal and Wear Sleeve Installation Diagram. 0090
0090-16
TM 5-3805-255-14 0090
Table 2. Oil Seal and Wear Sleeve Dimension Chart.
Seal and Sleeve Location 090 Dimension A – Sleeve Installed 090 Dimension B – Seal Installed 090
Single or double Lip In Housing or 0.486 in. 0.680 in.

Retainer on Crankshaft (12.34 mm) (17.27 mm)
10. Install flywheel on crankshaft (WP 0091).

11. If removed, install crankcase front cover assembly (WP 0097).
12. Install piston cooling jets on right side of crankcase.
13. Install oil suction pipe and oil pan on engine.
14. Install cylinder head on engine (WP 0089).
15. Install engine on loader (WP 0022).
16. Check and fill all fluid levels (WP 0018).
END OF TASK
END OF WORK PACKAGE
0090-17/(18 blank)
6
TM 5-3805-255-14 0091
FLYWHEEL REPLACEMENT/REPAIR
0 0 9 1
Removal; Cleaning, Inspection, and Repair
INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

Cleaning Compound, Solvent, Type III (WP 0004) 0
0130, Item 4) 0
Torque converter removed (WP 0047) 0
Two 0
NOTE
• The flywheel is secured to the end of crankshaft with hardened bolts and hardened
washers. Dowels are provided to pilot the flywheel to the crankshaft flange.
• The cranking motor drive ring gear is a shrink fit to the flywheel and is replaceable.
0091-1
TM 5-3805-255-14 0091
REMOVAL 00091
1. Remove six flywheel bolts (Figure 1, Item 2) and washers (Figure 1, Item 3).
2. Insert two jack screws (Figure 1, Item 1) into tapped puller holes in flywheel (Figure 1, Item 5). Also install two
guide pins (Figure 1, Item 4) on flywheel.
3. Tighten jack screws (Figure 1, Item 1) evenly until flywheel is pulled free of dowel pins on crankshaft.
WARNING
4. Attach a suitable lifting device to flywheel (Figure 1, Item 5). Lift flywheel and slide it off guide pins.
Figure 1. Flywheel Removal. 0091
END OF TASK
0091-2
TM 5-3805-255-14 0091
1. Clean and inspect flywheel and ring gear IAW General Maintenance Instructions (WP 0019).
NOTE
• When heat check score marks or grooving is considered excessive, flywheel must be re-
faced. Maximum allowable stock that can be removed during life of flywheel is 0.060 in.
(1.52 mm).
• Removal of more surface material than specified above may weaken flywheel or result in
interference of driven disc hub with clutch pilot bearing on crankshaft bolt heads.
2. Inspect clutch driven disc friction face on flywheel for heat checks and scoring. If it is not in serviceable
condition, replace flywheel.
3. Inspect starter gear for broken or milled teeth, and replace if necessary.
4. Inspect ring gear for broken or milled teeth and replace if necessary.
5. Inspect pilot bearing for wear or damage, replace if necessary.
NOTE
Before installing flywheel, flywheel housing should be checked as follows.
Checking Flywheel Housing Face Run-Out 00091
To check run-out of flywheel housing (Figure 2, Item 1), attach a dial indicator to crankshaft flange (Figure 2, Item
2) placing indicator pointer against flywheel housing flange (Figure 2, Item 3). Remove crankshaft end-play and
note reading. Check at four points 90 degrees apart for total face variation. Keep crankshaft end-play at zero in
same direction for all readings. Allowable housing face run-out tolerance is 0.008 in. (0.20 mm).
Figure 2. Checking Run-Out of Flywheel Housing Face. 0091
0091-3
TM 5-3805-255-14 0091

Checking Flywheel Housing Bore Eccentricity 00091
To check eccentricity of flywheel bore (Figure 3, Item 1) relative to crankshaft axis, attach a dial indicator to
crankshaft (Figure 3, Item 2) placing indicator pointer against flywheel housing bore as shown in Figure 3. Rotate
crankshaft slowly and note total indicator reading variation. Allowable housing bore eccentricity tolerance is 0.008
in. (0.20 mm).
Figure 3. Checking Eccentricity of Flywheel Housing Bore. 0091
END OF TASK
0091-4
TM 5-3805-255-14 0091
INSTALLATION
WARNING
equipment.
1. Place flywheel (Figure 4, Item 5) in position on guide pins (Figure 4, Item 4) so bolt and dowel pin holes line up.
2. Install four flywheel bolts (Figure 4, Item 2) and washers (Figure 4, Item 3) on flywheel (Figure 4, Item 5) to
draw crankshaft flange evenly.
3. Remove guide pins (Figure 4, Item 4). Install remaining two washers (Figure 4, Item 3) and flywheel bolts
(Figure 4, Item 1). Torque bolts to 225 lb-ft (305 Nm) using an alternating pattern.
Figure 4. Flywheel Installation.
4. Install torque converter (WP 0047).

6. Check and fill all fluids to their recommended levels (WP 0018).
END OF TASK
END OF WORK PACKAGE
0091-5/(6 blank)
12
TM 5-3805-255-14 0092
PISTONS INSPECTION/REPLACEMENT
0 0 9 2
Removal, Cleaning and Inspection, Assembly, Installation
INITIAL SETUP
0128, Item 20) 0

WP 0080 0
WP 0094 0
Materials/Parts 0
Molykote, Dry Lubricant (WP 0130, Item 18) 0
References 0 Battery disconnect switch in OFF position (WP

WP 0019 0
0004) 0
WP 0021 0
REMOVAL 00092
1. Remove six piston and connecting rod assemblies from engine (WP 0093).
2. Remove six piston pins from pistons and remove six connecting rods (WP 0093).
END OF TASK
0092-1
TM 5-3805-255-14 0092
Piston and Piston Pin 00092
1. Clean and inspect pistons, piston rings, and pins IAW General Maintenance Instructions (WP 0019).
2. Clean all carbon from piston ring grooves using ring groove cleaner or a broken piston ring as shown in Figure
1. Be sure that all oil holes in piston (Figure 1, Item 1) are open.
Figure 1. Cleaning Piston Ring Grooves. 0092
3. Inspect pistons for scuffed or scored skirts and cracked or worn piston ring lands, replace if necessary.
4. Inspect piston pins for wear, replace if necessary.
NOTE
This fit is common on both sides of piston.
5. To check piston pin fit, pins and pistons must be at room temperature 70°F (21°C). Pin should be a palm-push
fit under these conditions. Refer to Table 1 for clearance specifications.
Table 1. Piston Pin Specifications.
SPECIFICATION
ITEM 092 in. (mm) 092
Pin Diameter 2.2493 to 2.495 in. (57.132 to 57.137 mm)
Pin Length 4.385 to 4.395 in. (111.38 to 111.63 mm)
Clearance (Between End of Pin and Retainer 0.020 to 0.030 in. (0.051 to 0.076 mm)
Ring)
Clearance (Pin to Connecting Rod Bushing) 0.0011 to 0.0015 in. (0.028 to 0.038 mm)
Maximum Permissible Clearance in Rod 0.004 in. (0.10 mm)

(Before Replacing)
Clearance (Pin to Piston) 0.0006 to 0.0010 in. (0.015 to 0.025 mm)
Maximum Permissible Clearance in Piston 0.0025 in. (0.064 mm)

(Before Replacing)
0092-2
TM 5-3805-255-14 0092

6. Check piston clearance in sleeves as follows:
a. Measure inside diameter of six cylinder sleeves (Figure 2, Item 1) with a dial bore gauge. Take
measurements at right angles.
Figure 2. Checking Sleeve ID. 0092
NOTE
Piston is cam ground, therefore it has two different diameters. Diameter across piston pin
bosses is less than diameter across thrust face. In order to check piston to sleeve
clearance, it is necessary to measure skirt at 90 degrees to pin centerline.
b. Measure outside diameter of piston (Figure 3, Item 1) at bottom of skirt.
Figure 3. Checking Piston Outside Diameter. 0092
0092-3
TM 5-3805-255-14 0092

c. Subtract outside diameter of piston from inside diameter of sleeve to obtain existing clearance. Refer to
Table 2 for clearance specifications.
Table 2. Piston Specifications.
SPECIFICATION
ITEM 092 in. (mm) 092
Overall Length 6.778 in. (172.16 mm)
Skirt Clearance (Measured 90 degrees from 0.0061 to 0.0081 in. (0.155 to 0.206 mm)
Oil Hole)
Connecting Rods 00092
1. Clean connecting rod thoroughly and visually inspect for defects IAW General Maintenance Instructions (WP
0019). Be sure collector cup at top of connecting rod is clean and open. Inspect connecting rods for
straightness. Rods must be free of twist and be parallel to pistons.
2. Check fit of piston pin in connecting rod bushing for proper clearance. If greater than maximum allowable
clearance of 0.0061 to 0.0081 in. (0.155 to 0.206 mm), replace bushing (refer to Piston Pin Bushing
Replacement in this work package).
3. Clean connecting rod bolts and nuts.
NOTE
Apply lubricant to bolts and nuts. Hand thread all nuts prior to torquing.
Piston Rings 00092
NOTE
Apply all piston rings when installing pistons.
0092-4
TM 5-3805-255-14 0092

1. Inspect new rings for any sign of damage before installation.
NOTE
Ensure gap on rings does not extend to end gap.
2. Prior to installing rings on pistons, each ring must be checked for proper ring gap. Push ring (Figure 4, Item 1)
down into cylinder sleeve (Figure 4, Item 2) with a piston. This will position ring squarely in sleeve. Extreme
caution must be used during this operation. Check space or gap between ends of ring with a feeler gauge
(Figure 4). Refer to Table 3 for acceptable ring gap specifications. Replace ring if not as specified.
Table 3. Piston Ring Specifications (Compression).
SPECIFICATION
ITEM 092 in. (mm) 092
Ring Gap (Top Ring) 0.020 to 0.030 in. (0.51 to 0.76 mm)
Ring Gap (Intermediate Ring) 0.018 to 0.028 in. (0.46 to 0.71 mm)
Maximum Permissible Ring Gap (Before 0.070 in. (1.78 mm)

Replacing)
Figure 4. Checking Piston Ring Gap. 0092
0092-5
TM 5-3805-255-14 0092

3. Check oil control ring as follows:
a. Inspect windows of oil control ring (Figure 5, Item 1) and piston (Figure 5, Item 2) for blocked oil-ways.
Failure to keep oil-ways clear will result in uneven lubrication and hot-spots on piston and cylinder sleeve.
b. With a feeler gauge, check side clearance of oil control ring (Figure 5, Item 1) in its groove. See Table 4 for
specifications.
Table 4. Oil Control Ring Specifications.
SPECIFICATION
ITEM 092 in. (mm) 092
Ring Side Clearance in Groove (New) 0.0019 to 0.0035 in. (0.048 to 0.089 mm)
Ring Side Clearance in Groove (Max) 0.0045 in. (0.114 mm)
Ring Gap 0.017 to 0.032 in. (0.43 to 0.81 mm)
Maximum Permissible Ring Gap (Before Replacing) 0.060 in. (1.52 mm)
Figure 5. Checking Oil Control Ring Side Clearance. 0092
0092-6
TM 5-3805-255-14 0092
NOTE
On a used piston, side clearances tend to increase toward top of piston due to greater
operating temperature prevalent at this point.
4. Check compression rings as follows:
a. Check compression ring grooves using a new keystone ring to correctly establish piston groove wear.
b. Obtain a Perfect Circle piston ring gauge No. 1 (1/8 in. by 15 degrees) (Figure 6, Item 1) and insert it in ring
groove (Figure 6, Item 2). If one or both shoulders on gauge touch ring groove land (Figure 6, Item 2),
piston (Figure 6, Item 3) must be replaced. A groove worn this much would not support ring in operating
position. Install a new piston and rings.
Figure 6. Checking Piston Compression Ring Grooves. 0092
0092-7
TM 5-3805-255-14 0092
NOTE
The following checks are made to ensure top compression ring fit is correct and not
carrying piston load.
c. Install correct compression ring in top piston groove and be sure it is seated into groove.
d. Position a dial indicator gauge on special service tool PLT-501 (Figure 7).
e. Position piston (Figure 7, Item 2) on tool with piston ring in clearance slot (Figure 7, Item 3) of tool, and
locate piston land directly above ring under indicator pointer (Figure 7, Item 4).
NOTE
IMPORTANT: Be sure that piston ring is seated in its groove.
f. Set pointer at zero and slide piston forward (toward gauge) until pointer rests on ring. Note dial reading. It
must read 0.002 to 0.015 in. (0.05 to 0.38 mm) below piston land with pointer resting on top ring.
g. Repeat step (f) at four positions 90 degrees apart and be sure that all readings are within specifications.
Figure 7. Checking Piston Ring Drop. 0092
NOTE
When new rings are being installed on a used piston for operation in a used sleeve, wear
on sleeve may have left a ridge where piston reaches top of its stroke. This ridge will
cause noisy engine operation and breakage of top ring. Remedy this by removing ridge
with a ridge grinder before installing piston and ring.
0092-8
TM 5-3805-255-14 0092

5. Thick wall cooling jets (3/8 in. OD tube) are accurately aligned when manufactured to provide correct spray
angle. Stiffer construction ensures that they will retain this angle through normal handling. If a jet tube is
obviously abused and damaged, it must be replaced.
END OF TASK
ASSEMBLY 00092
1. Generously coat piston pin (Figure 8, Item 3) with Molykote dry lubricant.
2. Position connecting rod (Figure 8, Item 2) inside piston (Figure 8, Item 1). Align bushing in rod with piston pin
holes in piston and push piston pin (Figure 8, Item 4) completely into position.
3. Squeeze pronged ends of piston pin retainer rings (Figure 8, Item 3), and install one ring in groove on each
side of piston (Figure 8, Item 1) to secure piston pin (Figure 8, Item 4).
4. Check fit of piston pin in piston for proper end clearance as follows:
a. Push one end of piston pin (Figure 8, Item 4) until it reaches a definite stop against retainer ring (Figure 8,
Item 3) on opposite side of piston (Figure 8, Item 1).
b. Position a feeler gauge between end of pin (Figure 12, Item 4) that was pushed in and retainer ring (Figure
8, Item 3) to check for end clearance. Clearance must be 0.002 to 0.030 in. (0.051 to 0.076 mm).
Figure 8. Checking Piston Pin End Clearance. 0092
0092-9
TM 5-3805-255-14 0092
NOTE
Position piston rings so that gaps are 90 degrees from thrust side of piston (in line with
piston pin bore) and 180 degrees from one gap to another.
5. Using a piston ring expander, install piston rings (Figure 9, Items 1, 2, 3, and 4) into grooves of six pistons
(Figure 9, Item 5). Install oil ring coil spring expander (Figure 9, Item 4) in groove before chrome oil control ring
(Figure 13, Item 3) is installed. Also, coil spring joint must be approximately 180 degrees from oil control ring
gap.
6. Install chrome tapered face keystone compression ring (Figure 9, Item 2) in middle ring groove with side
marked UP-2 facing up.
7. Install top barrel-chrome keystone compression ring (Figure 9, Item 1) in top ring groove with the side marked
TOP facing up.
Figure 9. Piston Rings Correctly Installed on Piston. 0092
END OF TASK
INSTALLATION 00092
NOTE
When installing a piston and connecting rod assembly which was formerly used in the
engine, install the assembly in the same cylinder from which it was removed. When a new
piston or a new piston and connecting rod assembly is being installed, install a matched
set of pistons and sleeves.
1. Install six piston and connecting rod assemblies in engine (WP 0093).
2. Piston and connecting rod assemblies (Figure 10, Item 3) must be installed through top of crankcase (Figure
10, Item 4).
3. Coat a piston (Figure 10, Item 3) and piston ring compressor (Figure 10, Item 2) with clean lubricating oil (WP
0021).
4. Install piston and rod assembly (Figure 10, Item 3) into piston ring compressor (Figure 10, Item 2).
0092-10
TM 5-3805-255-14 0092
5. Coat cylinder sleeve (Figure 10, Item 1) with a generous amount of clean lubricating oil (WP 0131). Install
compressor (Figure 10, Item 2), with piston and rod assembly (Figure 10, Item 3), into cylinder sleeve with
cylinder number stamped on connecting rod facing camshaft side of engine. Push down on piston carefully
until it is in cylinder sleeve.
Figure 10. Installing Connecting Rod and Piston. 0092
6. Coat connecting rod journal and connecting rod bearings with clean lubricating oil (WP 0131). Install upper half
of bearing in connecting rod and put rod down onto journal. Coat threads of connecting rod studs with engine
oil. Install connecting rod bearing cap on connecting rod. Match cap and rod with marks previously made for
removal and tighten to 150 lb-ft (203 Nm).
NOTE
Connecting rod bearings must be fitted, bearing clearance checked, and connecting rod
end play checked as outlined in WP 0094 before continuing assembly of engine.
7. Repeat steps 1 through 6 to install remaining connecting rods and pistons.
0092-11
TM 5-3805-255-14 0092
8. Install piston cooling jets on right side of crankcase (WP 0093).
9. Install oil suction pipe on crankcase. Use new gasket where pipe attaches to front cover. Install crankcase oil
pan with new gasket and scavenging pump manifolds (if equipped). Be sure that scavenging oil pump
manifold O-rings are in place.
10. Install cylinder heads (WP 0089).
11. Install oil suction pipe and oil pan on engine. Install and torque oil pan drain plug to 35 lb-ft (47 Nm).
12. Install engine in loader (WP 0022).
13. Check and fill all fluid levels (WP 0018).
NOTE
After installation of new piston sets or new piston rings, engine must be run-in before
operating at normal load and speed.
END OF TASK
END OF WORK PACKAGE
0092-12
16
TM 5-3805-255-14 0093
CONNECTING ROD REPLACEMENT

0 0 9 3
INITIAL SETUP
0128, Item 20) 0
Connecting Rod Bushing Removal and

Installation Tool (WP 0128, Item 3) 0
Materials/Parts 0

Gasket 0
0004) 0
Lockwasher (3) 0
Nut, Plastic Lock Safety (12) 0 0089) 0
Retaining Ring, Piston Pin (12) 0 Engine removed from loader (WP 0022) 0
0093-1
TM 5-3805-255-14 0093
REMOVAL 00093
NOTE
This procedure explains removal process for one cylinder. Repeat process for other
cylinders.
1. Refer to Piston Inspection (WP 0092) for general information on this procedure.
2. Remove oil pickup tube from engine.
3. Remove piston cooling jet (Figure 1, Item 2) from right side of crankcase as follows:
CAUTION
DO NOT turn jet counterclockwise or jet tube will strike piston skirt. Failure to follow this
a. Remove capscrew (Figure 1, Item 1) from jet (Figure 1, Item 2).
Figure 1. Removing Piston Cooling Jet. 0093
0093-2
TM 5-3805-255-14 0093
b. Turn jet (Figure 2, Item 1) 1/4 turn clockwise so that end of flange with capscrew hole is pointing up (1/4
turn is necessary to clear skirt of pistons that are at bottom of stroke).
CAUTION
Jet cooler tubes are set at a 92 degree angle so that oil is directed to a particular spot on
underside of piston. Careful handling of this assembly is extremely important. NEVER
remove a piston without first removing piston cooling jet. Failure to follow this caution may
c. When cooling jet (Figure 2, Item 1) is properly positioned, pull cooling jet straight out, maintaining its
position. If cooling jet binds, use pry bars to pull it loose from crankcase.
d. Repeat procedure until cooling jet is removed from each cylinder from which a piston is to be removed.
Figure 2. Correct Position for Removing Cooling Jet. 0093
0093-3
TM 5-3805-255-14 0093
4. Crank engine until connecting rod to be removed (Figure 3, Item 1) is at its lowest position.
NOTE
Mark pistons, connecting rods and connecting rod bearing caps so that they can be
installed in same cylinders from which they were removed, and in same position.
5. Remove two elastic stop safety nuts (Figure 3, Item 3) and bearing cap (Figure 3, Item 4) from crankshaft
(Figure 3, Item 6). Tap cap lightly with a mallet if necessary to aid removal. Lower bearing insert (Figure 3, Item
5) is removed with bearing cap (Figure 3, Item 4). Upper half of bearing (Figure 3, Item 2) will remain on
connecting rod (Figure 3, Item 1). Discard two elastic stop safety nuts.
Figure 3. Connecting Rod Cap Removal. 0093
0093-4
TM 5-3805-255-14 0093
CAUTION
• If a ridge exists on cylinder sleeve at upper end of ring travel, ridge must be removed by
using a ridge grinder before piston is removed. This prevents damage to piston ring lands
during removal of pistons, and prevents damage to new top piston rings after installation
of new rings. If necessary, refer to Engine Repair (WP 0080).
• Pistons must be handled with care to avoid damage and knocking out-of-round or
alignment. When removing a piston from crankcase, do not allow skirt of piston to strike
crankcase or connecting rod. Failure to follow this caution may result in damage to
equipment.
6. Push up on connecting rod (Figure 4, Item 1) until piston (Figure 4, Item 3) is clear of sleeve (Figure 4, Item 2)
and lift assembly out of top of sleeve.
Figure 4. Removing Piston and Connecting Rod. 0093
0093-5
TM 5-3805-255-14 0093
NOTE
Precautions must be taken to see that parts are marked so they may be reinstalled in their
respective cylinders if they are to be reused.
7. Use a piston ring expander to remove three piston rings (Figure 5, Item 1) from piston (Figure 5, Item 4),
removing top ring first and remaining rings in order.
8. Remove two piston pin retainer rings (Figure 5, Item 2), one from each side of piston (Figure 5, Item 4), and
remove piston pin (Figure 5, Item 3) from piston. If piston pin cannot be removed by hand, it is recommended
to heat piston in water to 160° to 180°F (71° to -82°C). Heating of piston makes it unnecessary to use force in
removing piston pin. Discard two piston pin retainer rings.
9. After piston pin (Figure 5, Item 3) is removed from piston (Figure 5, Item 4), separate piston from connecting
rod (Figure 5, Item 5).
Figure 5. Piston Disassembly. 0093
END OF TASK
0093-6
TM 5-3805-255-14 0093
Piston Pin Bushing Replacement 00093
1. Replace connecting rod bushings using bushing removal and installing tool, PLT-544-1 which consists of Items
1, 3, 4, 5, 6, and 7 shown in Figure 8.
2. A center line is scribed on block (Figure 6, Item 4) and sleeves (Figure 6, Item 7) to ensure locating correct
position of bushing (Figure 6, Item 6) on connecting rod (Figure 6, Item 2).
Figure 6. Connecting Rod Bushing Removal and Installation Tools. 0093
0093-7
TM 5-3805-255-14 0093
NOTE
For clarity, these items are numbered the same in Figures 8, 9, 10, and 11:
1 Mandrel
2 Connecting Rod
3 Guide Sleeve
4 Block
5 Removing Sleeve
6 Bushing
7 Sleeve
3. Remove old bushing as follows:
a. Using a suitable arbor press, position connecting rod (Figure 7, Item 2) on block (Figure 7, Item 4).
b. Assemble removing sleeve (Figure 7, Item 5) on mandrel (Figure 7, Item 1). Place assembled tool on
connecting rod (Figure 7, Item 2), indexing center line mark on removing sleeve with center line mark on
block (Figure 7, Item 4). Place guide sleeve (Figure 7, Item 3) on lower end of mandrel in block to act as a
guide. This will also center connecting rod bushing with hole in block.
c. Press bushing until halfway removed.
Figure 7. Removing Bushing (First Step). 0093
0093-8
TM 5-3805-255-14 0093
d. Remove tool and reassemble guide sleeve (Figure 8, Item 3) on mandrel (Figure 8, Item 1) between man-
drel head and removing sleeve (Figure 8, Item 5) to provide increased tool travel.
e. Reinstall tool into connecting rod (Figure 8, Item 2) and press bushing out.
Figure 8. Removing Bushing (Second Step). 0093
0093-9
TM 5-3805-255-14 0093
4. Install new bushing as follows:

a. On mandrel (Figure 9, Item 1) assemble sleeve (Figure 9, Item 7), new piston pin bushing (Figure 9, Item
6), removing sleeve (Figure 9, Item 5) and guide sleeve (Figure 9, Item 3).
b. Place connecting rod (Figure 9, Item 2) on block (Figure 9, Item 4) in horizontal position.
c. Assemble mandrel (Figure 9, Item 1) with all components described in step (a) into connecting rod bushing
bore. Make sure scribe mark on sleeve (Figure 9, Item 7) lines up with scribe mark on block (Figure 9, Item
4).
d. Using a suitable arbor, press bushing (Figure 9, Item 6) into bore until sleeve (Figure 9, Item 7) contacts
connecting rod (Figure 9, Item 2).
e. Check bushing (Figure 9, Item 6) to be sure bushing did not rotate during assembly.
f. Burnish and finish ream bushing (Figure 9, Item 6) to 2.2506 to 2.2508 in. (57.166 to 57.170 mm). Break
edges of bushing bore (both sides) to 0.020 in. (0.50 mm).
Figure 9. Connecting Rod Bushing Installation. 0093
0093-10
TM 5-3805-255-14 0093
5. Wash piston cooling jets in an oil solvent and dry thoroughly with compressed air. Be sure that oil passage in
body and tube is open and clean. Discard sealing O-rings if they show any signs of damage.
END OF TASK
INSTALLATION 00093
NOTE
If parts are being reused, precaution must be taken to see that parts are reinstalled in
cylinder from which they were removed.
1. Install connecting rod (Figure 10, Item 5) on piston (Figure 10, Item 4), aligning pin bore in rod with pin bore in
piston.
2. Lubricate piston pin (Figure 10, Item 3) with clean engine oil (WP 0131) and install piston pin through piston
(Figure 10, Item 4), connecting rod (Figure 10, Item 5) and opposite end of piston.
3. Use snap ring pliers to install two new piston pin retaining rings (Figure 10, Item 2), one in bore in each side of
4. Use a piston ring expander to install three piston rings (Figure 10, Item 1) into lands of piston, (Figure 10, Item
4) starting with oil control ring first. Stagger ring end gaps so that they do not line up in same spot on piston.
Figure 10. Piston Installation. 0093
0093-11
TM 5-3805-255-14 0093
CAUTION
Pistons must be handled with care to avoid damage and knocking out-of-round or
alignment. When installing a piston in the crankcase, do not allow skirt of piston to strike
crankcase or connecting rod. Failure to follow this caution may result in damage to
equipment.
NOTE
If parts are being reused, be sure that pistons, connecting rods, and connecting rod
bearing caps are installed in the same cylinders from which they were removed, and in the
same position.
5. Push connecting rod (Figure 11, Item 1) into sleeve (Figure 11, Item 2) and use piston ring compressor to
compress rings so that piston (Figure 11, Item 3) will fit into sleeve (Figure 11, Item 2).
Figure 11. Piston Installation. 0093
0093-12
TM 5-3805-255-14 0093
6. Align rod bolts on either side of crank shaft journal and tap piston until connecting rod (Figure 12, Item 1) and
upper bearing assembly (Figure 12, Item 2) are seated on crankshaft (Figure 12, Item 6).
7. Install lower bearing insert (Figure 12, Item 5) on bearing cap (Figure 12, Item 4).
8. Install bearing cap (Figure 12, Item 4), and two new elastic stop safety nuts (Figure 12, Item 3) on rod bolts.
Torque nuts to 150 lb-ft (204 Nm).
Figure 12. Connecting Rod Cap Installation. 0093
0093-13
TM 5-3805-255-14 0093
CAUTION
Jet cooler tubes are set at a 92 degree angle so that oil is directed to a particular spot on
underside of piston. Careful handling of this assembly is extremely important. Failure to
follow this caution may result in damage to equipment.
9. Position cooling jet (Figure 13, Item 1) at 92 degree angle as shown in Figure 13.
Figure 13. Correct Position for Installing Cooling Jet. 0093
10. Turn cooling jet (Figure 14, Item 2) 45 degrees counterclockwise so that end of flange with capscrew hole
(Figure 14, Item 3) is pointing as shown in Figure 14.
11. Install bolt (Figure 14, Item 1) through cooling jet (Figure 14, Item 2) and into engine. Tighten bolt securely.
Figure 14. Correct Position for Installing Cooling Jet. 0093
0093-14
TM 5-3805-255-14 0093
12. Install new gasket (Figure 15, Item 1), oil pickup tube (Figure 15, Item 2), three new lockwashers (Figure 15,
Items 3 and 6) and bolts (Figure 15, Items 4 and 5) on crankcase. Tighten bolts securely.
Figure 15. Oil Pickup Tube Installation. 0093
13. Install crankcase oil pan.

14. Install cylinder head (WP 0089).
15. Install engine in loader (WP 0022).
END OF TASK
END OF WORK PACKAGE
0093-15/(16 blank)
4
TM 5-3805-255-14 0094
0 0 9 4 CONNECTING ROD BEARING REPLACEMENT
INITIAL SETUP
0128, Item 20) 0

(Shop Equipment, Automotive Maintenance Engine OFF (WP 0005) 0
and Repair: Organizational Maintenance Battery disconnect switch in OFF position (WP
0004) 0
Shop Equipment, Machine Shop, Field Main- Cylinder head removed (WP 0089) 0

Materials/Parts 0
Virgin Lead Wire 0
0094-1
TM 5-3805-255-14 0094
BEARING FITTING PROCEDURE 00094
General 00094
1. Undersize precision-type bearing shells should be installed when, because of wear, bearing-to-crankshaft run-
ning clearances are to be reduced.
NOTE
Bearing caps must not be filed, lapped, or modified in any other manner.
2. Premature bearing failure will result from attempts to reduce journal-to-bearing running clearances by
modifying bearing caps, bearings, or both, because such modification will alter engineered fit of bearing shells
in their bores and destroy specifically desired crush.
3. When installing precision-type connecting rod or main bearings, it is important that bearing shells fit tightly in
rod or case bore. To accomplish this, the bearing manufacturer makes the diameter at right angles to the part-
ing line slightly larger than the actual diameter of the bore into which they are assembled. When the assembly
is drawn up tight, the bearing is compressed, assuring a positive contact between bearing back and bore. This
increased diameter is referred to as bearing crush as shown in Figure 1.
Figure 1. Illustrating Bearing Crush. 094
4. To obtain proper bearing assembly with correct crush, be careful when tightening clamping bolts or nuts to be
sure they are drawn down alternately and evenly, using a torque wrench and tightening as specified.
5. Rods, caps, or blocks must not be filed, lapped, or modified in any other manner in order to reduce clearance.
While such practice will make a tighter fit at top and bottom, it will result in an out-of-round bore and bearing
shell distortion.
6. Main and connecting rod bearings are designed with a spread (width across open ends) slightly larger than the
diameter of the crankcase bore or connecting rod bore into which they are assembled. For example, the width
across a rod bearing not in place is approximately 0.025 in. (0.64 mm) more than when the bearing is in
position. This condition is originally designed into the bearing causing it to spread outward at the parting line
when crush load is applied by tightening nuts or bolts. Some of this snap may be lost in normal use, but the
bearing need not be replaced because of a nominal loss of this condition.
7. This condition causes the bearing to fit snugly in the rod bore and the bearing must be snapped or lightly
forced into its seat as shown in Figure 2.
0094-2
TM 5-3805-255-14 0094
BEARING FITTING PROCEDURE – CONTINUED
Figure 2. Illustrating Bearing Spread. 094
Fitting Connecting Rod Bearings 00094
NOTE
Do not rotate crankshaft during the following procedure.
1. Remove a bearing cap. If lead wire is to be used, wipe clean and oil crankshaft journal (Figure 3, Item 3). If
plastigage is to be used, wipe bearing surface (Figure 3, Item 2) and exposed half of crankshaft journal free of
oil as plastic material is soluble in oil.
2. Place a suitable length of 0.010 in. (0.25 mm) lead wire or a piece of plastigage (Figure 3, Item 1) across bear-
ing (Figure 3, Item 2) and install bearing cap.
Figure 3. Checking Connecting Rod Bearing Running Clearance. 094
0094-3
TM 5-3805-255-14 0094
BEARING FITTING PROCEDURE – CONTINUED

3. Torque two nuts to 150 lb-ft (203 Nm); then remove nuts and bearing cap. If virgin lead wire was used, use a
micrometer to measure wire which will have been crushed down to amount of clearance between crankshaft
journal and connecting rod bearing by torque applied to nuts. If plastigage was used, flattened plastic material
will be found adhering to either bearing shell or crankshaft. DO NOT REMOVE PLASTIGAGE. To determine
bearing clearance, compare width of flattened plastic material at its widest point with graduation on envelope.
Number within graduation on envelope indicates clearance in thousandths of an inch.
4. Measurement should fall between 0.0045 to 0.0075 in. (0.114 to 0.191 mm). Reinstall cap and bearing and
torque to specified amount if reading was as specified. Repeat steps 1 through 3 for all remaining connecting
rods.
5. Should reading not fall within specified limits, remove bearing from connecting rod and replace it with a new
one. However, with precision bearings used, no problem should be encountered providing crankshaft and con-
necting rod are in good order.
6. Check connecting rod end clearance using a feeler gauge as shown in Figure 4. Side clearance should be
between 0.0009 to 0.015 in. (0.23 to 0.38 mm). Excessive clearance may require replacement of rods or
crankshaft. Check must be made to be certain that specified end clearance exists. When checking end
clearance, feeler gauge must cover both connecting rod (Figure 4, Item 2) and cap (Figure 4, Item 1). Lack of
clearance could indicate a damaged rod or perhaps a rod bearing out of position.
Figure 4. Checking Connecting Rod End Clearance. 094
7. Install cylinder head on engine (WP 0089).

8. Install crankcase oil pan on engine.
END OF TASK
END OF WORK PACKAGE
0094-4
24
TM 5-3805-255-14 0095
VALVES REPLACEMENT
0 0 9 5
Removal, Valve Reconditioning, Installation
INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP Detergent, General Purpose, Liquid (WP
0128, Item 20) 0 0130, Item 10) 0
Shop Equipment, Automotive Maintenance Oil, Lubricating, OE/HDO-10 (WP 0130, Item
and Repair: Organizational Maintenance 22) 0

Shop Equipment, Machine Shop, Field Ice, Dry 0

Spring Load Tester Valve and Clutch Spring Two 0
Materials/Parts 0
0130, Item 4) 0
Cloth, Abrasive (WP 0130, Item 6) 0

Compound, Prussian Blue Marking (WP 0130, 0004) 0
Item 8) 0
Cylinder head removed (WP 0089) 0
0095-1
TM 5-3805-255-14 0095
REMOVAL 00095
1. Install valve spring compressor over spring (Figure 1, Item 3) and compress.
2. Remove valve keepers (Figure 1, Item 5) from groove on valve stem (Figure 1, Item 6).
3. Depress valve spring compressor and remove valve rotator (Figure 1, Item 4), spring (Figure 1, Item 3), and
spring seat (Figure 1, Item 2) from cylinder head (Figure 1, Item 1).
4. Remove valve stem (Figure 1, Item 6) from rear of cylinder head (Figure 1, Item 1).
5. Repeat steps 1 through 4 to remove all valve stems (Figure 1, Item 6) from cylinder head (Figure 1, Item 1).
Figure 1. Removing, Valves, Springs, Rotators, Seats, and Keepers. 0095
END OF TASK
0095-2
TM 5-3805-255-14 0095
VALVE RECONDITIONING 00095
Valves Cleaning and Inspection 00095
1. Remove carbon from valve face, head, and stem (Figure 2). Valve stems should be lightly polished with an
extremely fine abrasive cloth. Remove carbon deposits only.
Figure 2. Cleaning Carbon from Valve. 0095
2. Place straightedge across valve head and check for “dishing” (Figure 3). Any valves that are dished must be
discarded. (A narrow margin is common cause of dishing, therefore discard any valve that cannot be
satisfactorily refaced with specified margin (50 percent of a new valve).
Figure 3. Dished Valve Head. 0095
0095-3
TM 5-3805-255-14 0095
VALVE RECONDITIONING – CONTINUED

3. Discard severely burned valves (metal behind burn has lost its original properties). Valves which show
indications of “necking” must also be discarded. Necking is evidenced by a reduced diameter of valve stem
above port end of guide and is result of hot corrosion (Figure 4). Necked valves are susceptible to breakage, a
most expensive type of failure, since engine may be badly damaged when a valve head breaks off.
Figure 4. Necked Valve Stem. 0095
4. Discard valves with badly scuffed stems (Figure 5). Rough stems cause rapid valve guide wear. If there are
only slight indications of scuffing at extremities of guide contact area and there is no appreciable reduction in
stem diameter, valves will continue to give satisfactory service.
5. Inspect for worn keeper grooves and damaged valve tips. If present, discard valve. Worn grooves allow
cocking of spring retainer which tends to tip valve in guide, increasing guide wear and in extreme cases
causing leakage across valve face. Similar results can be expected from use of valves having badly damaged
tips. Refacing machines usually have an attachment for reconditioning valve tip, however, where tip is badly
damaged, grinding may remove all case-hardened metal on tip. Valves with deep notches or grooves in tip
must be replaced.
Figure 5. Scuffed Valve Stem. 0095
0095-4
TM 5-3805-255-14 0095

6. Measure OD of valve stems (Figure 6, Item 1) at various locations along guide bearing area, and at each
location take several readings around circumference. If readings are below minimum permissible stem
diameter dimension, discard valve.
7. Intake and exhaust valve minimum permissible stem diameter dimension is 0.4335 in. (11.011 mm).
Figure 6. Checking Valve Stem OD. 0095
8. Check valve stem (Figure 7, Item 1) straightness. If stem “runout” is more than 0.001 in. (0.03 mm), discard
valve.
9. New valves must also be checked for straight stems and face runout as they may have been damaged in
shipment or by handling.
Figure 7. Checking Valve Stem Straightness and Face Runout. 0095
0095-5
TM 5-3805-255-14 0095

Valve Face Grinding 00095
1. Set valve refacing machine to grind correct valve face angle. Dress grinding stone (Figure 8, Item 2).
2. Valve face angle degrees:
a. Intake valves are 30 degrees -0’ to 29 degrees -45’.
b. Exhaust valves are 45 degrees -0’ to 45 degrees -15’.
3. Insert a valve (Figure 8, Item 1) in chuck. Center and take light cut across face. This determines if valve can be
reconditioned to service standards with correct amount of margin maintained. Warpage not apparent in visual
inspection will be clearly definable.
Figure 8. Locating Valve and Grinding Stone to Specified Angle. 0095
0095-6
TM 5-3805-255-14 0095

4. Avoid taking heavy grinding cuts as this heats valve head excessively, produces an unsatisfactory valve face,
and necessitates dressing grinding wheel frequently. Repeated light grinding cuts are preferred until a true
face of even width is obtained around valve. Avoid passing stone beyond face of valve, as this will cause ridg-
ing and grooving of stone surface and make dressing of stone necessary. Replace valves with distorted heads,
which produce an uneven face, and valves which grind down to thin edge (Figure 9).
5. Maximum amount of material which can be removed from either valve seat or valve face is:
a. 0.01 in. (0.25 mm) for exhaust.
b. 0.012 in. (0.30 mm) for intake.
c. 0.015 in. (0.38 mm) is combined maximum material removed for valve face and seat.
6. Only minimum amount needed to make a good valve seat contact should be removed. If necessary to remove
more than maximums stated above, valves and/or valve seat inserts must be replaced.
7. At times, large amounts of heat scale may be found on exhaust valves. This is rough on grinding stone. Fre-
quent redressing of stone will be necessary to maintain a smooth, even surface, and a uniform set of face
angles.
Figure 9. Maintaining Proper Margin. 0095
0095-7
TM 5-3805-255-14 0095

8. After refacing each valve-inspect stem. If wear is noticeable, but not too severe, reface end of stem with
attachment usually provided with valve grinding equipment (Figure 10). Grind sufficiently to tune-up end of
stem.
9. Check valve face runout and head margin after refacing. Maximum face runout in reference to valve stem must
be less than 0.002 in. (0.05 mm) total variation in dial indicator reading. Head margin must be at least one half
(50 percent) of new valve of same type.
Figure 10. Refacing Valve Stem End. 0095
0095-8
TM 5-3805-255-14 0095

Valve Guides 00095
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally complaint and

low-toxicity 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
NOTE
Guides require very careful cleaning. Carbon left in guide will deflect pilot and result in
inaccurate reconditioning of valve seat.
1. Use a 7/16 in. (11 mm) nylon bristle brush, solvent, and power drill to remove residue in guide bore. Guides
must be washed down with a strong soap solution. As an option use a 3/8 in. (10 mm) spiral brush for cleaning.
Examine bore for signs of burning, blistering, cracking, and excessive wear.
2. Measure ID of valve guide (Figure 11, Item 1) with a small hole gauge at several points around its circumfer-
ence and along its length. If readings are above maximum permissible dimensions, replace guide (see Intake
and Exhaust Valve Specifications in this work package.
3. Press out worn guides from underside of cylinder head (Figure 11, Item 2) from valve port up through top. Use
a mandrel slightly smaller than guide in order to prevent jamming.
Figure 11. Checking Guide ID. 0095
0095-9
TM 5-3805-255-14 0095
NOTE
Valve guides have a 30° chamfer at top of guide, and an internal thread in bottom portion.
Guides must be installed with threaded end downward.
4. Use a mandrel to press new valve guides in from top of cylinder head. Guides must extend specified distance
above top surface of cylinder head (Figure 12) (see Intake and Exhaust Valve Specifications in this work
package).
5. All guides furnished as service parts are reamed to size. However, as they are installed, remove any possible
burrs or slight distortion caused by pressing operation (see Intake and Exhaust Valve Specifications in this
work package)
Figure 12. Measuring Position of Valve Guides. 0095
0095-10
TM 5-3805-255-14 0095

Valve Bridge and Guides 00095
1. Measure ID of bridge guides in same manner as valve guides. Measure OD of valve bridge stems across
greater diameter (not flat sides) with a micrometer. If difference between these two reading is greater than
maximum allowable stem clearance (see Intake and Exhaust Valve Specifications in this work package),
replace bridge stems and guides.
2. All replacement guides now have an outside diameter of 0.6870 to 0.6875 in. (17.488 to 17.501 mm). If not, it
must be enlarged to this dimension by reaming to a depth of 0.720 in. (18.29 mm) and restoring original
chamfer to edge of hole. New guide will then have a press fit of 0.001 to 0.002 in. (0.03 to 0.05 mm). It is
recommended that new guides be installed with a press and a suitable sleeve driver.
Figure 13. Removing Valve Bridge Guides. 0095
0095-11
TM 5-3805-255-14 0095

3. This method is recommended for checking wear on valve lever bridge (Figure 14, Item 1). Other methods can
be used. Using a block of hard wood with one side finished, drill a hole large enough to allow stem of bridge to
fit through. If a surface plate is available, use that with suitable supports instead of block of hard wood.
4. Install indicator into indicator block (Figure 14, Item 2) and place block on hard finished surface. Place indicator
point on bridge at edge of wear groove. Set indicator at zero and move indicator block until indicator point
drops into wear groove. Take a reading. If reading exceeds wear limit, replace valve bridge.
Table 1. Wear Limits.
Valve Lever Bridge and Bridge Guide

Guide Length 2.31 in. (56.7 mm)
Guide Inside Diameter 0.5015 to 0.5025 in. (12.738 to 12.754 mm)
Maximum Permissible Guide Inside Diameter 0.5045 in. (12.81mm)
Bridge Stem Clearance in Guide 0.0015 to 0.0035 in. (0.38 to 0.089 mm)
Maximum Permissible Valve Lever Bridge Wear
Wear at Valve Lever Contact Surface 0.004 in. (0.10 mm)
Figure 14. Checking Valve Bridge for Wear. 0095
Valve Seats and Seat Inserts 00095
1. Inspect intake and exhaust valve faces and seat inserts for cracks and burned condition. Also check valve seat
inserts for looseness.
2. Remove defective valve seat inserts with an insert puller.
3. If new oversize valve seat inserts are installed, ream insert counterbore in cylinder head to dimension shown in
Table 1 to obtain correct fit.
0095-12
TM 5-3805-255-14 0095

Intake and Exhaust Valve Specifications 00095
ITEM SPECIFICATIONS
Intake Valves
Stem Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4350 to 0.4360 in. (11.049 to 11.074 mm)
Minimum Permissible Stem Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4335 in. (11.011 mm)
Port Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 in. (38 mm)
Head Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.700 to 1.710 in. (43.18 to 43.43 mm)
Stem Clearance in Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0015 to 0.0040 in. (0.38 to 0.102 mm)
Maximum Permissible Stem Diameter (Clearance Allowed Before Reconditioning). . . . . 0.0070 in. (0.178 mm)
Valve Face Angle (Degrees) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 degrees - 0’ to 29 degrees-45’
Valve Seat Angle in Cylinder Head (Degrees) . . . . . . . . . . . . . . . . . . . . . 30 degrees - 0’ to 30 degrees-15’
Valve Head Protrusion from Cylinder Head Face (New). . . . . . . . . . . . 0.020 to 0.032 in. (0.50 to 0.81 mm)
Minimum Allowable Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 in. (0.25 mm)
Valve Lash Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 in. (0.50 mm)
Valve Seat Insert Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.778 to 1.779 in. (45.16 to 45.19 mm)
Valve Margin (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50% of a New Valve
Exhaust Valves
Stem Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4350 to 0.4360 in. (11.049 to 11.074 mm)
Minimum Permissible Stem Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4335 in. (11.011 mm)
Port Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 in. (38 mm)
Valve Seat Insert Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.778 to 1.779 in. (45.161 to 45.187 mm)
Head Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.700 to 1.710 in. (43.43 mm)
Stem Clearance in Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0015 to 0.0040 in. (0.038-0.102 mm)
Maximum Permissible Stem
Clearance Allowed Before Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0070 in. (0.178 mm)
Valve Face Angle- Degrees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees - 0’ to 45 degrees-15
Valve Seat Angle in Cylinder Head from Valve Center Line (Degrees) . . . . . . 45 degrees - 0’ to 44degrees-45’
Valve Head Protrusion from Cylinder Head Face (New) . . . . . . . . . . . . . . . 0.020 to 0.032 in. (0.50 to 0.81 mm)
Minimum Allowable Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 in. (0.25 mm)
Valve Lash Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.031 in. (0.79 mm)
Valve Margin (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50% of New Valve
0095-13
TM 5-3805-255-14 0095
Figure 15. Removing Exhaust Valve Seat Insert. 0095
Table 2. Intake and Exhaust Valve Seat Insert.
APPLICATION 095 COUNTERBORE DIAMETER 095
0.002 in. (0.0508 mm) Oversize 1.7800 to 1.7810 in.

(45.212 to 45.2374 mm)
0.015 in. (0.381 mm) Oversize 1.7930 to 1.7940 in.
(45.5422 to 45.5676 mm)
0095-14
TM 5-3805-255-14 0095

Insert Installation 00095
NOTE
Valve seat inserts which are not fitted tight work loose, permitting carbon formations to
collect on outer surface of insert, thus insulating exhaust heat within insert, preventing
proper heat dissipation through cylinder head.
1. To assure maximum valve and insert life, it is essential that valve insert ring be installed to obtain maximum
contact with bottom and sides of ring counterbore as shown in Figure 16. Proper heat dissipation through valve
insert ring can only be accomplished by valve insert ring being a tight fit in cylinder head with bottom of insert
ring squarely seated on bottom of counterbore.
Figure 16. Insert Ring Properly Installed. 0095
0095-15
TM 5-3805-255-14 0095
CAUTION
DO NOT install inserts by hammering or striking insert driver. After installing insert, do not
peen head metal over edge of insert. Failure to follow caution may result in serious
damage to engine.
2. Install valve seat inserts as follows (Figure 17):
a. Chill inserts and driver thoroughly for at least one-half hour before installing.
b. Properly align insert to avoid cocking.
c. Using an arbor press and driver, press insert into cylinder head. An evenly applied 500lb-ft (2,225 Nm) load
is required for proper installation and is to be sustained for a five second period to guarantee proper
installation and seating.
Figure 17. Installing Insert. 0095
0095-16
TM 5-3805-255-14 0095

Refacing Valve Seats and Seat Inserts 00095
1. Remove all carbon, scale, and oil before attempting to reface valve seats. Grinding stone, when placed against
an oily seat, will become fouled and uneven grinding will occur.
2. Use a clean, oiled rag to lubricate pilot shank lightly. Before installing pilot, be certain that valve guides are
perfectly clean. This is important to prevent an eccentric cut to seat.
3. Depress stone to correct angle and install a pilot of correct size in valve guide bore (see Intake and Exhaust
Valve Specifications in this work package) for seat angle and guide ID.
4. Lower grinder head over pilot shank until stone just clears valve seat (Figure 18). Turn on power and very
gently allow stone to contact valve seat. Very little pressure other than normal weight of stone must be used.
Sudden, hard pressures can cause cocking of pilot in guide and result in eccentric grinding. Frequently raise
stone from valve seat in order to prevent overheating and to clear away grinding dust. Grind seat sufficiently to
provide an even, smooth surface.
Figure 18. Grinding Valve Seat. 0095
0095-17
TM 5-3805-255-14 0095

Refacing Valve Seats and Seat Inserts – Continued 00095
CAUTION
Maximum amount of material which can be removed from valve seat is 0.010 in.
(0.25 mm) for exhaust and 0.012 in. (0.30 mm) for intake. However, if both valve face and
seat must be refinished, combined total matter removed from both must not exceed 0.015
in. (0.38 mm). Only minimum amount needed to make a good valve seat contact should
be removed. If necessary to remove more than maximums stated above, valve and/or
valve stated inserts must be replaced. Failure to follow caution may result in damage to
engine.
5. Check seat concentricity with valve guide by using a dial indicator mounted on pilot. Run indicator around seat
surfaces, thereby testing for concentricity. Runout must not exceed a total of 0.002 in. (0.05 mm).
6. Finish left by regular type grinding stone is usually satisfactory for practical purposes. Lapping valves into their
seats is unnecessary if precision equipment is used and extreme care taken. Use Prussian blue to test refaced
valves and seats roundness and concentricity. Spread an extremely thin film of this blue on valve face and
insert valve into its guide.
With pressure on exact center of valve head, make a quarter-turn rotation in seat. Remove valve and inspect
impression made upon seat by transfer of blueing, and upon valve face by removal of blueing. Check several
times to be sure that no error was made.
7. After grinding seats, it may be found that seats are considerably wider than width recommended in Table 3.
Valve seats that are too wide may be narrowed by grinding down top edge of seat with a stone mounted on
grinder head (Figure 20). Stone must be a smaller angle than valve seat (15 degrees preferably).
Figure 19. Valve Seat Width Must Conform to Specifications and Center of Valve Face. 0095
0095-18
TM 5-3805-255-14 0095

Refacing Valve Seats and Seat Inserts – Continued 00095
Figure 20. Narrowing Valve Seat Width. 0095
Valve Springs 00095
1. Check for proper valve spring compression with spring tester No. PLT-100 (Figure 21).
Outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.289 in. (32.74 mm)
Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.302 to 2.382 in. (58.47 to 60.50 mm)
Test length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.350 in. (34.29 mm)
Test load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 to 125 lb (512 to 556 Nm)
Figure 21. Checking Valve Spring Tension. 0095
0095-19
TM 5-3805-255-14 0095

Valve Springs – Continued 00095
2. Springs must be free of corrosion, pitting, scratches, and notches. Spring ends must be flat and square to
prevent lateral loads on valves stems. Check both ends of springs on a flat surface (Figure 22). Any out-of-
square springs must be discarded.
Figure 22. Checking Valve Spring Squareness. 0095
0095-20
TM 5-3805-255-14 0095

Valve Rotator 00095
1. Rotator can be identified by a snap ring on bottom. Rotator can be disassembled for cleaning and inspection
by removing snap ring. Individual parts are not furnished separately and a new rotator assembly must be
installed if any part is worn or damaged.
NOTE
When reassembling rotator, Belleville washer must be installed with concave side toward
snap ring (pitch of washer down against spring).
2. Check valve rotators for operation. A valve rotator in free state (not assembled in engine) may rotate in either
direction, or may not rotate at all and still be satisfactory for use.
3. To properly test a valve rotator for rotation, a valve spring load must be applied to rotator. This can be done in
a spring tester or assembled in an engine.
4. When using a spring tester, place valve spring (Figure 23, Item 1), with rotator, in a tester. Place a bearing ball
between rotor cap and ram of spring tester. By compressing valve spring, valve rotator can be observed as it
turns.
Figure 23. Testing Valve Rotator. 0095
0095-21
TM 5-3805-255-14 0095

Valve Rotator – Continued 00095
NOTE
Wear on outside surface of locks can be caused by overspeeding engine.
5. Clean parts thoroughly in solvent. Check ribs inside of locks to be sure that none are worn enough to cause
looseness. Locks must be fit snugly into valve stem groove. Check locks for wear on outside surface which
might allow valve spring retainer to slide over lock. Replace if in doubt.
Figure 24. Valve Specifications. 0095
0095-22
TM 5-3805-255-14 0095
Table 3. Specifications.
INTAKE AND EXHAUST

SYMBOL KEY TO VALVE CHART VALVE
A Valve Face Angle 45°4 (Exhaust)
60° (Intake)
B Valve Head Diameter 1.700 to 1.710 in.
(43.18 to 43.43 mm)
C Valve Stem Diameter 0.4350 to 0.4360 in.
(11.05 to 11.07 mm)
D Valve Length 7.365 in.
(187.07 mm)
E Valve Port Inside Diameter 1-1/2 in.
(38 mm)
F Valve Seat Outside Diameter 1.647 in.
(41.83 mm)
G Valve Seat Width 0.067 in.
(1.70 mm)
H Distance from Valve Seat 2.604 in.
(66.14 mm)
I Valve Guide Length 3.440 in.
(87.38 mm)
J Valve Guide Inside Diameter 0.437 - 0.439 in.
(11.10 - 11.15 mm)
K Valve Guide Outside Diameter 0.6885 to 0.6790 in.
(17.488 to 17.501 mm)
L Distance from Bottom Face of 1-1/8 in.
Cylinder Head to Stem End of (29 mm)
Valve Guide
M Distance from Bottom Face of 0.075 to 0.078 in.
Cylinder Head to face of Valve (1.91 to 1.98 mm)
Seat or Insert
N Depth of Valve Seat Insert 0.523 to 0.525 in.
Counterbore (13.28 to 13.34 mm)
O Diameter of Valve Seat Insert 1.778 to 1.799 in.
Counterbore (45.16 to 45.19 mm)
END OF TASK
0095-23
TM 5-3805-255-14 0095
INSTALLATION 00095
Valves 00095
1. Coat valve stems (Figure 25, Item 6) with clean SAE-50 oil and insert them from bottom of head. Each valve
and its parts must be returned to position from which it came.
2. Place spring seat (Figure 25, Item 2), spring (Figure 25, Item 3), and positive valve stem (Figure 25, Item 6).
With a valve spring compressor, compress spring far enough to install valve keepers (Figure 25, Item 5) in
groove at top of each valve stem. Install all valves in same manner.
1. Install both intermediate valve lever brackets onto shaft with one set of rocker levers and spacers between
them. Do not tighten intermediate bracket set screws.
2. Place remaining rocker levers on shaft (three on each side of intermediate brackets and two levers and one
spacer on each side). Turn shaft in brackets so that slot at rear of shaft is up. Install rear valve lever bracket so
that roll pin in bracket engages slot in shaft. Install front valve lever bracket.
Figure 25. Valve Assembly Installation. 0095
END OF TASK
END OF WORK PACKAGE
0095-24
14
TM 5-3805-255-14 0096
CAMSHAFT REPLACEMENT
0 0 9 6
INITIAL SETUP
0128, Item 20) 0

Sealer, Non-Hardening 0

and Repair: Organizational Maintenance Personnel Required 0
Shop Equipment, Machine Shop, Field Main-

References 0

WP 0019 0
Crankshaft Gear Nut Torque Wrench Adapter WP 0091 0
(WP 0128, Item 4) 0 WP 0097 0
Fan Drive Pulley Puller (WP 0128, Item 7) 0
Vibration Damper Hub with Wear Sleeve and

Damper (WP 0128, Item 23) 0
Materials/Parts 0

Tag, Marker (WP 0130, Item 37) 0 0004) 0
Cloth, Abrasive 0 Engine removed (WP 0022) 0
Dry Ice 0 Cylinder head removed from engine (WP

Gasket (2) 0
0089) 0
0096-1
TM 5-3805-255-14 0096
REMOVAL 00096
1. Remove both rocker arm assemblies and push rods (WP 0089).
NOTE
Mark tappets as to location in engine block, so that they can be returned to their original
position.
2. Remove two push rod chamber covers on left side of engine. Reach through push rod chamber opening
(Figure 1, Item 1) and remove 16 valve tappets (Figure 1, Item 2).
Figure 1. Removing Valve Tappets. 0096
3. Remove crankcase front cover (Figure 2, Item 1). Refer to Timing Gears Replacement (WP 0097).
4. Remove crankshaft gear retaining nut (Figure 2, Item 2) and oil slinger (Figure 2, Item 3).
Figure 2. Removing Front Cover. 0096
0096-2
TM 5-3805-255-14 0096
NOTE
Before removing camshaft drive gear, check camshaft end-play as shown in Figure 4 to
determine if new parts are required. Camshaft end play should be 0.007 to 0.13 in. (0.18
to 0.33 mm). Maximum allowable end-play is 0.025 in. (0.64 mm).
5. Measure and record camshaft end play (Figure 3).
Figure 3. Measuring Camshaft End-Play. 0096
0096-3
TM 5-3805-255-14 0096
6. Crank engine until timing marks on crankshaft gear (Figure 4, Item 6), camshaft gear (Figure 4, Item 2), and
injection pump drive gear (Figure 4, Item 1) are in line.
NOTE
If equipped with a lockplate, discard plate and replace with new capscrews and
lockwashers.
7. Remove four capscrews (Figure 4, Item 4), lockwashers (Figure 4, Item 5), and camshaft gear (Figure 4, Item
2) from camshaft (Figure 4, Item 3). Discard lockwashers.
Figure 4. Timing Marks Alignment. 0096
0096-4
TM 5-3805-255-14 0096
8. Remove five capscrews, lock, and camshaft thrust bearing hub (Figure 5, Item 2) from camshaft (Figure 5,
Item 1).
Figure 5. Camshaft Thrust Bearing Hub Removal. 0096
0096-5
TM 5-3805-255-14 0096
CAUTION
Support camshaft along its length as it is being removed, to prevent cam lobes from
damaging camshaft bushings.
9. Remove camshaft (Figure 6, Item 1) from engine.
Figure 6. Camshaft Removal. 0096
END OF TASK
0096-6
TM 5-3805-255-14 0096
WARNING
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa)
nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi
(207 kPa) when cleaning components. DO NOT direct compressed air against human
skin. 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.
2. Inspect camshaft journals for wear. Table 1 shows allowable camshaft journal diameter specifications. If
journals are worn beyond limits specified, replace camshaft.
Table 1. Camshaft Journal Diameters. 096
Front Camshaft Journal 2.997 to 2.998 in. (76.12 to 76.15 mm)

Intermediate and Rear Camshaft Journal 2.371 to 2.372 in. (60.22 to 60.25 mm)
3. Replace camshaft if any lobes are scuffed, scored, or cracked.

4. Inspect camshaft lobes for wear. Refer to Table 2 for camshaft lobe lift when new and for maximum allowable
lobe wear.
Table 2. Camshaft Lift and Lobe Specifications.
Camshaft Lobe Lift

Intake Lobes 0.2970 in. (7.544 mm)
Exhaust Lobes 0.2990 in. (7.595 mm)
Maximum Permissible Valve Cam Lobe Wear 0.2990 in. (7.595 mm)
0096-7
TM 5-3805-255-14 0096

5. If lifting areas of cam lobes show excessive wear, replace camshaft. Measure camshaft lobe wear with a
micrometer in the following manner:
a. Take a reading with a micrometer across A-C and across B-D (Figure 7). Subtract B-D reading from A-C
reading. This will give lobe lift specification.
b. If camshaft lobe wear limit has been reached, replace camshaft.
Figure 7. Points of Measurement to Determine Camshaft Lobe Wear. 0096
0096-8
TM 5-3805-255-14 0096

6. Inspect thrust bearing hub (Figure 8, Item 2) and thrust face of camshaft (Figure 8, Item 1) for wear. Replace
parts as necessary.
Figure 8. Camshaft Thrust Hub and Face Inspection. 0096
7. Inspect camshaft bushings for wear, and if replacement is necessary, proceed as follows:
a. Remove flywheel housing and flywheel (WP 0091).
b. Pull or press bushings from position.
c. Inspect bushing bores in crankcase for burrs or damage.
8. Align oil holes in bushings with oil holes in crankcase and install bushings into crankcase.
9. Two bushings in thrust bearing hub must be pressed in from outside of hub bore until outer edges of bushings
are flush with hub. This provides a channel between two bushings for lubricating oil to gear train and front main
bearing.
10. Inspect valve tappets. Replace any valve tappets that are scuffed, scored, or cracked. If one or more valve
tappet faces are badly chipped, install new camshaft.
END OF TASK
0096-9
TM 5-3805-255-14 0096
INSTALLATION 00096
NOTE
Apply lubricant to camshaft and journals thrust bearing and bushings.
1. Install camshaft (Figure 9, Item 1) in engine.
Figure 9. Camshaft Installation. 0096
2. Install thrust bearing hub (Figure 10, Item 2) on camshaft (Figure 10, Item 1). Install five capscrews and locks.
Figure 10. Camshaft Thrust Hub and Face Inspection. 0096
0096-10
TM 5-3805-255-14 0096
3. Install camshaft drive gear (Figure 11, Item 2) so timing marks on crankshaft gear (Figure 11, Item 6), camshaft
drive gear, and injection pump drive gear (Figure 11, Item 1) are aligned.
4. Install four new camshaft drive gear lockwashers (Figure 11, Item 5) and bolts (Figure 11, Item 4) on camshaft
thrust hub (Figure 11, Item 3). Torque bolts to 90 lb-ft (122 Nm).
Figure 11. Camshaft Drive Gear Installation. 0096
0096-11
TM 5-3805-255-14 0096
5. Measure backlash between camshaft drive gear (Figure 12, Item 1) and all mating gears with a dial indicator
and magnetic base as shown. Backlash must be 0.0010 to 0.0055 in. (0.025 to 0.140 mm). Maximum
permissible backlash is 0.008 in. (0.20 mm).
Figure 12. Camshaft Gear Backlash Measurement. 0096
6. Measure camshaft endplay with a dial indicator and magnetic base as shown in Figure 13. Maximum allowable
camshaft endplay is 0.007 to 0.013 in. (0.18 to 0.33 mm). Maximum permissible endplay is 0.025 in. (0.64
mm).
Figure 13. Camshaft Gear Endplay Measurement. 0096
0096-12
TM 5-3805-255-14 0096
7. Install crankshaft oil slinger (Figure 14, Item 3) and crankshaft gear nut (Figure 14, Item 2). Use wrench
adapter and torque crankshaft gear nut to 525 lb-ft (712 Nm). When using wrench adapter, reading on torque
wrench should be 438 lb-ft (594 Nm).
Figure 14. Crank Gear Nut Installation. 0096
8. Install crankcase front cover (Figure 14, Item 1) and vibration damper. Refer to Timing Gears Replacement
(WP 0097).
11. Check and fill all fluids to their recommended levels (WP 0018).
END OF TASK
END OF WORK PACKAGE
0096-13/(14 blank)
18
TM 5-3805-255-14 0097
TIMING GEARS REPLACEMENT

0 0 9 7
INITIAL SETUP
0128, Item 20) 0

WP 0019 0
WP 0040 0
Crankshaft Gear Nut Torque Wrench Adapter

WP 0064 0
(WP 0128, Item 4) 0
WP 0065 0
WP 0100 0
Vibration Damper Hub with Wear Sleeve and

Damper (WP 0128, Item 23) 0
Materials/Parts 0
Cloth, Abrasive (WP 0130, Item 6) 0


Gasket (2) 0
0004) 0
Two 0
0089) 0
Engine removed from loader (WP 0022) 0
0097-1
TM 5-3805-255-14 0097
REMOVAL 00097
WARNING
Be careful when breaking damper free of crankshaft taper. Damper may spring outward
with force due to tension of puller. Failure to follow these instructions may result in injury
to personnel or damage to equipment.
1. Position Service Tool No. PLT-506 on vibration damper (Figure 1, Item 1) with four bolts (Figure 1, Item 2). Turn
puller bolt inward to remove damper from crankshaft.
Figure 1. Removing Vibration Damper. 0097
0097-2
TM 5-3805-255-14 0097
NOTE
The crankcase oil pan must be removed in order to disconnect lube oil suction line from
front cover.
2. Remove oil pan with scavenging pump manifold attached.
3. Remove two bolts (Figure 2, Item 1) and lube oil suction pipe (Figure 2, Item 2) from front cover (Figure 2,
Item 3).
WARNING
4. Remove bolts (Figure 2, Item 4) from front cover (Figure 2, Item 3) and crankcase. Be sure to remove two bolts
and locks located in fan drive housing opening of front cover. Attach a suitable lifting device to front cover and
remove front cover from engine.
5. Remove crankshaft gear nut (Figure 2, Item 1) and oil flinger (if equipped) (Figure 2, Item 2).
Figure 2. Front Cover Removal. 0097
0097-3
TM 5-3805-255-14 0097
NOTE
Check backlash between every set of gears before removal to determine which gears
need service.
6. Record backlash between each pair of gears as shown in Figure 3. Specified backlash between any pair of
gears is 0.003 to 00.007 in. (0.08 to 0.18 mm). Maximum permissible backlash between any pair of gears
before service is necessary is 0.011 in. (0.28 mm).
Figure 3. Measuring Gear Train Backlash. 0097
0097-4
TM 5-3805-255-14 0097
CAUTION
After camshaft gear is removed, DO NOT ROTATE crankshaft without first backing off all
valve lever adjusting screws. This is to relieve valve levers in order to seat all valves and
avoid damage by piston up-strokes. Failure to follow these instructions may result in
7. Crank engine until timing marks on crankshaft gear (Figure 4, Item 6), camshaft gear (Figure 4, Item 2), and
injection pump drive gear (Figure 4, Item 1) are aligned. Remove four bolts (Figure 4, Item 4), washers (or
lockplate) (Figure 4, Item 5), and camshaft gear from camshaft (Figure 4, Item 3).
Figure 4. Removing Camshaft Gear. 0097
0097-5
TM 5-3805-255-14 0097
NOTE
Hydraulic pump idler gear shaft bolt has a left-hand thread.
8. If equipped with hydraulic pump idler gear (Figure 5, Item 1), remove hydraulic pump idler gear shaft bolt
(Figure 510) and bearing retainer (Figure 5, Item 9).
9. Remove gear (Figure 5, Item 1) with bearing outer cone (Figure 5, Item 11) and race (Figure 5, Item 2).
10. Remove bearing spacer (Figure 5, Item 7) and bearing inner cone (Figure 5, Item 3) off shaft (Figure 5, Item 8).
Tag or mark inner and outer bearing cones to retain same wear pattern in cup when reassembled.
11. Remove three bolts (Figure 5, Item 4) and locks (Figure 5, Item 5) from gear shaft (Figure 5, Item 7) and tap
shaft off two dowel pins (Figure 5, Item 6).
Figure 5. Removing Hydraulic Pump Idler Gear. 0097
0097-6
TM 5-3805-255-14 0097
NOTE
• Fan drive idler gear shaft bolt has a left-hand thread.
• If fan drive idler gear shaft is to be removed, mark one locating dowel and shaft casting
next to dowel. This will ensure correct installation of shaft upon assembly.
12. Remove fan drive idler gear shaft bolt and bearing retainer. Remove gear and bearing in same manner as
hydraulic pump idler gear.
13. Remove bolt and fan drive idler gear shaft (Figure 6, Item 1) from crankcase (Figure 6, Item 2) and remove
shaft.
Figure 6. Removing Fan Drive Idler Gear Shaft. 0097
14. Remove crankshaft gear (Figure 7, Item 1) from crankshaft (Figure 7, Item 2).
Figure 7. Removing Crankshaft Gear. 0097
0097-7
TM 5-3805-255-14 0097
15. Remove injection pump drive gear with gear hub attached.
16. Remove nut from shaft and lube oil and water pump drive gear.
17. If crankcase front plate is to be removed proceed as follows:
a. Disconnect all lines to fuel injection pump. Remove two bolts, nuts, and washers securing injection pump
to mounting block. Remove adapter housing with fuel injection pump attached (WP 0100).
b. Remove lube oil and water pump (WP 0023).
c. Remove bolts, lock and front plate (Figure 8, Item 1) from crankcase (Figure 8, Item 2).
Figure 8. Removing Crankcase Front Plate. 0097
END OF TASK
0097-8
TM 5-3805-255-14 0097
NOTE
If any gear is to be replaced because of damaged teeth, all of the gears that mesh with the
damaged gear must also be replaced.
2. Inspect all gears for wear, chipped teeth, or otherwise damaged condition, and replace as necessary.
3. Inspect fan drive and hydraulic pump idler gear bearings for chipped or pitted rollers and damaged cups. If any
part of these bearings is excessively worn, complete bearing must be replaced, as bearing is furnished only as
an assembly.
4. If it is necessary to remove bearing cup (Figure 9, Item 2) from gear (Figure 9, Item 3), remove retaining snap
ring (Figure 9, Item 1) and press cup out of gear.
NOTE
Chill new cup prior to installation.
5. Press cup into gear (Figure 9, Item 3) until it seats on shoulder in gear and install a new retaining snap ring
(Figure 9, Item 1).
Figure 9. Bearing Cup Retaining Snap Ring. 0097
0097-9
TM 5-3805-255-14 0097
Servicing and Adjusting Fan Drive Idler Gear and Hydraulic Pump Idler Gear Roller Bearings 00097
NOTE
The tapered roller bearings and spacer are furnished as a matched unit, so a definite
procedure for adjustment of tapered roller bearings, due to normal wear, must be followed.
1. Assemble complete bearing assembly (Figure 10, Item 2) on a flat surface (surface plate).
2. Place a minimum 20 lb (9 kg) weight (Figure 10, Item 1) on top of bearing assembly (Figure 10, Item 2) as
shown in Figure 10. This will keep rollers in alignment.
NOTE
Be sure to place lower parallel or spacer under bearing, and then rest weight on top of
upper parallel or spacer. This is done to keep weight concentrated on bearing cone. Both
upper parallel or spacer and lower parallel or spacer must be of equal thickness.
3. Rotate cup (Figure 10, Item 3) a minimum of four revolutions in each direction.
4. With spacer (Figure 10, Item 6) in place, set dial indicator at zero. Check at three different points.
5. Slide dial indicator off cone (Figure 10, Item 7) carefully. (Do not upset dial indicator setting.)
6. Remove weight (Figure 10, Item 1), parallels (Figure 10, Items 8 and 5), upper cone (Figure 10, Item 7), and
spacer (Figure 10, Item 6). Then reinstall parallels and weight. Do not reinstall spacer.
7. Repeat rotation of cup (Figure 10, Item 3) and slide dial indicator on cone (Figure 10, Item 7). Record accurate
reading from dial indicator. Check at three different points.
NOTE
A bearing assembly that is heavily pitted or scored must NOT be salvaged.
8. The factory end play specification in a new bearing assembly is 0.009 to 0.012 in (0.23 to 0.30 mm) for idler
shaft bearing or 0.009 to 0.011 in. (0.23 to 0.28 mm) for hydraulic pump idler gear bearing. If reading on dial
indicator shows a greater drop than maximum factory set end plate, grinding or lapping of spacer (Figure 106)
is necessary. The amount to be ground off of spacer is the difference between indicator reading and factory set
end play (0.009 to 0.012 in. [0.23 to 0.30 mm]).
Figure 10. Adjustment of Tapered Roller Bearings. 0097
0097-10
TM 5-3805-255-14 0097

Front Main Oil Seal and Wear Sleeve Replacement 00097
1. Secure vibration damper hub (Figure 11, Item 3) in a soft-jawed vise. Be sure vise jaws grasp only hub casting.
CAUTION
Do not cut completely through sleeve. Failure to follow this caution will damage engine
components.
2. Remove any nicks or scratches from wear sleeve contact surface of hub with an emery cloth.
3. Install a new wear sleeve as follows:
a. Apply RTV onto wear sleeve surface of damper hub.
b. Use driver PLT -542 (Figure 11, Item 1) to install a new wear sleeve (Figure 11, Item 2) onto hub
(Figure 11, Item 3) until seal driver bottoms on hub face.
Figure 11. Vibration Damper Hub with Wear Sleeve and Driver. 0097
4. Remove front main oil seal from front cover. Thoroughly clean seal bore in front cover and remove any nicks or
scratches.
5. Use a tool of sufficient diameter to press on outside diameter of new front main oil seal and press seal into
housing.
6. Inspect vibration damper for dents, leaks, or cracks. Replace if damaged.
END OF TASK
0097-11
TM 5-3805-255-14 0097
INSTALLATION 00097
1. If crankcase front plate was removed, install as follows:

a. Install a new gasket to front on crankcase and install front plate with hydraulic pump attached (if equipped).
Install front plate bolts and locks. Tighten bolts securely.
b. If equipped with hydraulic pump, connect oil line manifold to pump.
c. Install adapter housing with injection pump attached (WP 0100). Connect all lines to injection pump.
d. Install lubricating oil and water pump assembly (WP 0023).
2. Install crankshaft gear key in keyway in crankshaft. Heat crankshaft drive gear (Figure 121) to 475°F (245°C).
WARNING
Use suitable heat-resistant gloves to handle heated crankshaft drive gear. Failure to follow
this caution will result in injury to personnel.
CAUTION
Be sure crankshaft drive gear is aligned on crankshaft. Failure to follow this caution will
result in damage to engine.
3. Position crankshaft drive gear (Figure 12, Item 1) on crankshaft (Figure 12, Item 3) with timing mark (Figure 12,
Item 2) facing out. Drive gear onto crankshaft until it bottoms.
Figure 12. Installing Crankshaft Gear. 0097
0097-12
TM 5-3805-255-14 0097
4. Install injection pump drive gear with hub attached. Install gear retainer nuts and torque to 160 lb-ft (217 Nm).
5. Install lube oil and water pump drive gear. Install gear retaining nut and torque to 140 lb-ft (190 Nm).
6. Place hydraulic pump gear and bearing assembly on pump drive housing and secure with snap ring. Install
drive adapter with snap ring on pump shaft and secure to gear with bolts and locks.
NOTE
Fan idler gear shaft and fan drive housing can be installed in one of two positions (180°
apart) depending on engine application. Refer to Figure 15 for proper installation. Idler
gear shaft and housing must be installed in proper position for fan.
7. Install fan drive idler gear shaft (Figure 13, Item 1) on crankcase (Figure 13, Item 2), aligning marks made on
dowel (Figure 13, Item 3) and casting before removal. Install a lock (Figure 13, Item 5) and bolt (Figure 13,
Item 4). Torque bolt to 150 lb-ft (203 Nm). Bend two lock tabs in to capture hex head.
Figure 13. Fan Idler Gear Shaft in Correct Position. 0097
0097-13
TM 5-3805-255-14 0097
8. Install hydraulic pump idler gear shaft (Figure 14, Item 8), three bolts (Figure 14, Item 4), and locks (Figure 14,
Item 5). Torque bolts to 225 lb-ft (305 Nm). Bend two lock tabs in to capture each hex head.
9. Slide fan drive idler gear bearing cone (Figure 14, Item 3) and spacer (Figure 14, Item 7) onto shaft (Figure 14,
Item 8).
10. Install fan drive idler gear (Figure 14, Item 1), bearing outer cone (Figure 14, Item 11), and bearing race (Figure
14, Item 2) on shaft (Figure 14, Item 8). Install bearing retainer (Figure 14, Item 9) and idler shaft bolt (Figure
14, Item 10) on idler gear shaft. Rotate gear to seat bearing and torque bolt to 150 lb-ft (203 Nm).
Figure 14. Hydraulic Pump Idler Gear Installation. 0097
0097-14
TM 5-3805-255-14 0097
NOTE
One of the camshaft locating dowel pins is off-center, preventing gear from being installed
out-of-time.
11. Install camshaft gear (Figure 15, Item 2) so that timing marks stamped on crankshaft gear (Figure 15, Item 6),
injection pump drive gear (Figure 15, Item 1), and camshaft gear are aligned.
12. Install four new camshaft gear lockwashers (Figure 15, Item 5) and bolts (Figure 15, Item 4). Torque bolts to
90 lb-ft (122 Nm).
Figure 15. Camshaft Gear Installation. 0097
0097-15
TM 5-3805-255-14 0097
13. Measure backlash between every set of gears with a dial indicator and magnetic base as shown in Figure 16.
Specified backlash between any pair of gears is 0.003 to 0.007 in. (0.08 to 0.18 mm). Maximum permissible
backlash between any pair of gears before service is necessary is 0.011 in. (0.28 mm).
Figure 16. Backlash Measurement. 0097
14. Check to be sure that gear train upper oil spray jet (Figure 17, Item 1) and lower lubricating oil spray jet (Figure
17, Item 2) are set at correct angle as shown in Figure 17. These spray angles are the most effective way to
lubricate all gears in gear train.
Figure 17. Gear Train Lubricating Oil Spray Jets. 0097
0097-16
TM 5-3805-255-14 0097
15. Install oil slinger (Figure 18, Item 5) and crankshaft gear nut (Figure 18, Item 4) on crankshaft (Figure 18, Item
3). Use wrench adapter and torque crankshaft gear nut to 525 lb-ft (712 Nm). When using wrench adapter,
reading on torque wrench should be 438 lb-ft (594 Nm).
NOTE
Gasket between suction pipe and front cover must be installed with color-coded side of
gasket against front cover, which is UP side.
16. Apply sealer to gasket surface of front cover (Figure 18, Item 2) and crankcase front plate (Figure 18, Item 1)
and install a new front cover gasket.
Figure 18. Gear Train Front Cover Installation. 0097
0097-17
TM 5-3805-255-14 0097
WARNING
equipment.
17. Install front cover (Figure 19, Item 3), bolts (Figure 19, Item 4), and locks. Be sure to install two bolts and locks
located in fan drive housing opening of front cover.
18. Connect lube oil suction pipe (Figure 19, Item 2) to bottom of front cover (Figure 19, Item 3). Install two bolts
(Figure 19, Item 1) and tighten securely.
Figure 19. Lube Oil Suction Pipe Installation.
19. Install crankcase oil pan and scavenging oil pump manifold (if equipped) (WP 0023). Be sure scavenging oil
pump manifold O-rings are in place. Tighten oil pan drain plug to 35 lb-ft (47 Nm).
20. Install vibration damper and damper hub nut and torque nut to 350 lb-ft (475 Nm).
21. Install fan drive housing on engine front cover (WP 0038).
24. Install air compressor (WP 0064 or WP 0065).
25. Install alternator (WP 0040).
26. If valve lever adjusting screws were backed off during removal, adjust valve clearance (WP 0089).
27. Check and fill all fluid levels to their recommended levels (WP 0018).
END OF TASK
END OF WORK PACKAGE
0097-18
22
TM 5-3805-255-14 0098
LUBRICATING OIL AND WATER PUMP REPAIR

0 0 9 8
INITIAL SETUP
0128, Item 20) 0

Maintenance, Heavy, Supplemental No. 1, Machine parked on level ground (WP 0005) 0
Less Power (WP 0128, Item 16) 0 Parking brake applied (WP 0005) 0
Materials/Parts 0

0004) 0
Gasket (3) 0
Lubricating oil and water pump removed (WP

Lockwasher (8) 0
0023) 0
Seal (2) 0
0098-1
TM 5-3805-255-14 0098
DISASSEMBLY 00098
1. Install dial indicator attached to magnetic base as shown (Figure 1).

2. Measure drive shaft end-play. End-play must be within 0.003 to 0.007 in. (0.08 to 0.18 mm). If end-play is not
within specification, excessive wear of one of the following is the probable cause:
a. Width of oil and water pump drive shaft gear (Figure 1, Item 2).
b. Thrust faces of water pump body (Figure 1, Item 1).
Figure 1. Checking Drive Shaft End-Play. 0098
0098-2
TM 5-3805-255-14 0098
3. Mark inlet elbow-to-water pump housing (Figure 2, Item 7) and oil scavenging pump (if equipped) or water
pump body-to-oil pump body (Figure 2, Item 6).
4. Remove five bolts (Figure 2, Item 2), washers (Figure 2, Item 3), and inlet elbow (Figure 2, Item 1) from water
pump housing (Figure 2, Item 5).
5. Remove gasket (Figure 2, Item 4) from inlet elbow (Figure 2, Item 1). Discard gasket.
Figure 2. Oil and Water Pump Disassembly. 0098
0098-3
TM 5-3805-255-14 0098
6. Use two 0.375 in. tapped holes in face of water pump impeller (Figure 3, Item 2) as puller holes. Remove
impeller from shaft (Figure 3, Item 3).
7. Remove seal seat (Figure 3, Item 4) from impeller. Discard seal seat.
8. Remove eight nuts (Figure 3, Item 5) and lockwashers (Figure 3, Item 6) securing water pump housing (Figure
3, Item 1). Discard lockwashers.
Figure 3. Removing Water Pump Impeller. 0098
0098-4
TM 5-3805-255-14 0098
9. Remove water pump housing (Figure 4, Item 1) and gasket (Figure 4, Item 3) from oil pump housing (Figure 4,
10. Lift coolant seal (Figure 4, Item 2) out of water pump housing (Figure 4, Item 1).
Figure 4. Removing Water Pump Housing. 0098
11. Remove garter type oil seal (Figure 5, Item 1) and oil flinger (Figure 5, Item 2) from oil pump end of water
pump housing (Figure 5, Item 3).
Figure 5. Oil Seal Removal. 0098
0098-5
TM 5-3805-255-14 0098
12. If equipped with oil scavenging pump: Before any further disassembly of oil and water pump, check backlash
between scavenging pump body gear (Figure 6, Item 1) and idler gear (Figure 6, Item 2) using a dial indicator
and magnetic base. Record backlash and proceed to step 13.
Figure 6. Measuring Gear Backlash. 0098
0098-6
TM 5-3805-255-14 0098
13. Use a feeler gauge to measure radial clearance between oil pump drive gear (Figure 7, Item 1) and oil pump
body (Figure 7, Item 2) and radial clearance between oil pump idler gear (Figure 7, Item 3) and oil pump body
( to determine if gears or body need replacement. Clearance must be between 0.0085 to 0.0100 in. (0.22 to
0.25 mm).
Figure 7. Measuring Radial Clearance. 0098
0098-7
TM 5-3805-255-14 0098
NOTE
If equipped with scavenging pump, mark scavenging pump gears as shown (Figure 8,
Item 2).
14. Remove scavenging pump gears (Figure 8, Items 1 and 3) from oil pump housing (Figure 8, Item 4).
Figure 8. Oil Pump Gear Removal. 0098
0098-8
TM 5-3805-255-14 0098
15. If equipped with scavenging pump: Remove scavenging pump body (Figure 9, Item 1) from oil pump body
(Figure 9, Item 2).
Figure 9. Scavenging Oil Pump Body Removal. 0098
0098-9
TM 5-3805-255-14 0098
16. With oil scavenging pump removed (if equipped), check backlash between oil pump body gear and idler gear
(Figure 6). Clearance must be 0.008 to 0.012 in. (0.20 to 0.30 mm).
17. Measure radial clearance between gears and oil pump body (Figure 7) to determine if gears or pump body
need replacement. Clearance must be between 0.0085 to 0.0100 in. (0.22 to 0.25 mm).
18. Mark oil pump body gear and idler gear in same way as scavenging pump gears, as outlined in note prior to
step 14. Remove idler gear from idler shaft.
19. Reposition oil pump (Figure 10, Item 1) in vise and remove drive gear nut (Figure 10, Item 3) from drive shaft
Figure 10. Removing Drive Gear Nut. 0098
0098-10
TM 5-3805-255-14 0098
20. Use a gear puller (Figure 11, Item 1) to remove drive shaft (Figure 11, Item 2) from gear (Figure 11, Item 3).
Remove gear and Woodruff key (Figure 11, Item 4) from body (Figure 11, Item 5).
21. Remove drive shaft (Figure 11, Item 2) with oil pump body gear (Figure 11, Item 3) from body (Figure 11, Item 5).
Figure 11. Pushing Drive Shaft Out of Drive Gear. 0098
0098-11
TM 5-3805-255-14 0098
22. If necessary, drive idler shaft (Figure 12, Item 1) from body (Figure 12, Item 2).
.
Figure 12. Removing Idler Shaft. 0098
END OF TASK
1. Wash all metal parts IAW General Maintenance Instructions (WP 0019).
2. Inspect idler shaft (Figure 13, Item 10) and oil pump body (Figure 13, Items 2 and 4) to ensure oil holes and
drilled passages are clean and open. Check drain holes in water pump body (Figure 13, Items 7 and 8).
Remove dirt or sludge from water pump seal drain hole. Inspect all pipes and hoses for damage and replace if
necessary.
3. Inspect all gears (Figure 13, Items 1, 3, 5, 6, and 9) for wear, scoring, and chipped teeth. Replace if necessary.
0098-12
TM 5-3805-255-14 0098
Figure 13. Cleaning and Inspection. 0098
0098-13
TM 5-3805-255-14 0098

4. Using a micrometer (Figure 14, Item 1), check width of gears (Figure 14, Items 2 and 3). Allowable gear widths
are 2.623 to 2.624 in. (66.62 to 66.65 mm) for water pump body gear and idler gears, and 2.0575 to 2.0585 in.
(52.61 to 52.286 mm) for oil scavenging pump body gear and idler gear. Replace worn or damaged gears.
Figure 14. Measuring Gear Width. 0098
5. Inspect bushings in water pump housing (Figure 15, Item 4) and oil pump housing (Figure 15, Items 1 and 2)
and two bushings in oil pump idler gear (Figure 15, Item 3) for excessive wear or damage. Inside diameter of
bushings must be 0.8645 to 0.8655 in. (21.958 to 21.984 mm) for water pump housing bushing, and 0.990 to
0.991 in. (25.15 to 25.17 mm) for oil pump housing bushing. Oil pump idler gear bushing inside diameter must
be 0.8660 to 0.8670 in. (21.996 to 22.022 mm).
Figure 15. Bushing Measurement. 0098
0098-14
TM 5-3805-255-14 0098

6. Use a hole gauge and a 0 to 1 in. micrometer to measure each bushing (Figure 16, Item 1) as indicated in step
5 for wear and out-of-roundness.
7. If replacement is necessary, water and oil pump housing bushings must be installed until they are flush to
0.015 in. (0.38 mm) below front surface of housing. Idler gear bushings must be installed in each end of gear
until they are approximately 0.125 in. (3.18 mm) below edge of gear.
Figure 16. Bushing Measurement. 0098
8. Use a micrometer to measure diameter of idler shaft (Figure 17, Item1) and drive shaft (Figure 17, Item 2).
Idler shaft diameter must be between 0.8635 to 0.8640 in. (21.993 to 21.946 mm). Drive shaft diameter must
be between 0.9875 to 0.9880 in. (25.083 to 25.095 mm). Replace any shaft not within specification.
Figure 17. Idler Shaft and Drive Shaft Measurement. 0098
0098-15
TM 5-3805-255-14 0098

9. Examine water pump impeller (Figure 18, Item 2) and water pump housing (Figure 18, Items 1 and 3) contact
surfaces for evidence of wear or grooving. Replace if necessary.
10. Inspect four impeller vanes (Figure 18, Item 4) and remove any nicks, burrs, or roughness.
Figure 18. Water Pump Impeller Inspection. 0098
11. Inspect oil scavenging pump manifold (Figure 19, Item 3) (if equipped). Remove two O-rings (Figure 19,
Item 2). Discard O-rings.
12. If oil scavenging pump manifold (Figure 19, Item 3) is removed from engine, remove manifold-to-engine O-
rings (Figure 19, Item 1). Discard O-rings.
13. It is also recommended that oil pan be removed and oil pick-up tube be pressure checked for leaks.
Figure 19. Scavenge Oil Pump Manifold and O-Rings. 0098
END OF TASK
0098-16
TM 5-3805-255-14 0098
ASSEMBLY 00098
1. Position idler shaft (Figure 20, Item 2) in oil pump body (Figure 20, Item 3) so that oil holes (Figure 20, Item 1)
in shaft are in line with oil slot (Figure 20, Item 4) in pump body.
2. Install idler shaft (Figure 20, Item 2) into body (Figure 20, Item 3) until lower oil hole (Figure 20, Item 1) in shaft
is indexed with slot (Figure 20, Item 4) as shown.
Figure 20. Idler Shaft Installation. 0098
3. Install drive shaft with body gear (Figure 21, Item 4) into oil pump body (Figure 21, Item 7).
4. Install Woodruff key (Figure 21, Item 3) on drive shaft (Figure 21, Item 4) and install drive gear (Figure 21, Item
2) onto shaft. Install drive gear nut (Figure 21, Item 1) and torque to 140 lb-ft (190 Nm).
5. Install idler gear with bushings (Figure 21, Item 5) on idler shaft (Figure 21, Item 6) so that marks on two gears
line up.
Figure 21. Oil Pump Assembly. 0098
0098-17
TM 5-3805-255-14 0098
6. If equipped with scavenging pump: Install new gasket (Figure 22, Item 5) and scavenging pump body (Figure
22, Item 1) on oil pump body (Figure 22, Item 4) with scavenging ports (Figure 22, Item 2) facing away from
outlet elbow (Figure 22, Item 3).
Figure 22. Scavenging Oil Pump Housing Installation. 0098
7. If equipped with scavenging pump: Install scavenging pump gears (Figure 23, Items 1 and 2) into scavenging
pump body (Figure 23, Item 3) and line up marks.
Figure 23. Scavenging Oil Pump Gears Installation. 0098
0098-18
TM 5-3805-255-14 0098
CAUTION
Do not press seal down beyond the 1.0625 in. (27mm) dimension or it will block an
internal oil return passage in housing. Failure to follow this caution may result in damage
to components.
8. Install a new garter type oil seal (Figure 24, Item 3) into water pump housing (Figure 24, Item 2).
9. Install seal (Figure 24, Item 3) 1.0625 in. (27mm) below inner machine surface (Figure 24, Item 1) of water
pump housing (Figure 24, Item 2). Measure depth using a scale as indicated.
Figure 24. Garter Oil Seal Installation. 0098
0098-19
TM 5-3805-255-14 0098
10. Install new gasket (Figure 25, Item 2) and water pump housing (Figure 25, Item 3) on oil pump housing (Figure
25, Item 1).
11. Install 10 bolts (Figure 25, Item 9) and oil pump housing (Figure 25, Item 1) on water pump housing (Figure 25,
Item 3). Tighten bolts to 26 lb-ft (36 Nm).
12. Position flinger (Figure 25, Item 5) on drive shaft (Figure 25, Item 10) so small outside diameter of flinger is
facing out from water pump housing (Figure 25, Item 3). Tap flinger into position on the shaft until a
measurement of 3.557 to 3.567 in. (90.35 to 90.60 mm) is obtained from water pump housing rear face to rear
face of flinger.
13. Install new coolant seal assembly (Figure 25, Item 6) over drive shaft (Figure 25, Item 10).
14. Install new seat (Figure 25, Item 7) into groove of impeller (Figure 25, Item 8).
15. Install new seal (Figure 25, Item 4) on water pump housing (Figure 25, Item 3).
Figure 25. Water Pump Housing Installation. 0098
0098-20
TM 5-3805-255-14 0098
16. Install impeller (Figure 26, Item 3) onto drive shaft (Figure 26, Item 2) to a depth of 1.445 to 1.465 in. (36.70 to
37.21 mm). Using a caliper gauge and a straightedge, measure from water pump housing rear face (Figure 26,
Item 5) to machined surface on impeller.
17. Rotate pump drive gear (Figure 26, Item 6). If impeller (Figure 26, Item 3) is rubbing on water pump housing
(Figure 26, Item 5), recheck position of impeller as described in step 15.
Figure 26. Water Pump Impeller-to-Housing Clearance. 0098
18. Install new water pump inlet elbow gasket (Figure 27, Item 2) and water pump inlet elbow (Figure 27, Item 3)
on water pump housing (Figure 27, Item 1).
19. Install six washers (Figure 27, Item 5) and bolts (Figure 27, Item 4) on water pump housing (Figure 27, Item 1).
Tighten bolts to 38 lb-ft (52 Nm).
Figure 27. Water Pump Housing Assembly. 0098
END OF TASK
END OF WORK PACKAGE
0098-21/(22 blank)
2
TM 5-3805-255-14 0099
0 0 9 9 FUEL INJECTOR TESTING AND REPAIR
INITIAL SETUP
0128, Item 20) 0

Adapter for Pressure Testing Valve Housing to Engine OFF (WP 0005) 0
Injection Nozzle Lines (WP 0128, Item 1) 0

Test Set, Diesel Injector (WP 0128, Item 19) 0
0004) 0
Materials/Parts 0
Fuel injectors removed (WP 0027) 0
TESTING 00099
WARNING
Keep hands away from nozzle spray. At opening pressure, velocity of spray could
puncture skin. Failure to follow this warning may result in injury to personnel.
NOTE
• Before testing nozzles, it is advisable to place them in a cold decarbonizing solution for at
least one hour.
• After removing nozzles from solution, wash off exterior of all dirt and carbon.
• Use clean filtered diesel fuel and standard type hand pump (equipped with a pressure
gauge having a capacity of at least 4,000 psi [27,579 kPa]) when testing nozzle
assemblies.
1. Connect nozzle loosely to hand test pump. Pump handle several strokes to flush out fittings; then tighten
nozzle.
2. CHATTER: Operate test pump and observe if nozzle chatters at opening pressure and if all orifices in the
nozzle tip are clear. Fuel should spray in an atomized mist and valve should emit a sharp high-pitched chatter.
If chattering does not occur, flush with test pump using rapid, complete strokes.
3. OPENING PRESSURE: Pump test pump handle a few strokes to clear air from nozzle and then raise pressure
steadily. Observe gauge pressure at which valve opens. Opening pressure should be between 3,500 to 3,600
psi (24,130 to 24,820 kPa). If pressure is below that specified, nozzle must be disassembled and reset by
addition of shims.
4. SEAT LEAKAGE: Wipe nozzle tip dry. Bring pressure up slowly to 500 psi (3,450 kPa) below nozzle opening
pressure and maintain this pressure for 5 seconds. Wetting of nozzle is permissible without formation of a
droplet.
0099-1
TM 5-3805-255-14 0099
TESTING – CONTINUED
NOTE
Do not wipe tip with finger as this will tend to draw fuel present in sac hole through orifices
and falsely indicate a leak and rejection of a good valve. Touch a finger or hold a wiper
lightly against tip of valve. Leakage at seat may be caused by dirt or foreign material,
carbon, or gum deposits at seat area or excessive wear of seat. If seat is worn, it may be
refinished with precision grinding equipment.
5. STEM LEAKAGE: Bring pressure on nozzle to 1,500 psi (10,350 kPa). If there is any leakage from return,
collect it. To conserve time, nozzle may be in inverted position. Maximum allowable leakage is one cc in one
minute at this pressure.
NOTE
Excessive leakage at this point can be caused by scratches or poor sealing at flat surfaces
of nozzle body, intermediate plate or valve body. If this possibility has been already
eliminated, there is excessive clearance between valve stem and body. This condition
necessitates replacement of nozzle valve.
6. Install fuel injectors (WP 0027).
END OF TASK
END OF WORK PACKAGE
0099-2
14
TM 5-3805-255-14 0100
0 1 0 0 FUEL INJECTION PUMP ADAPTER HOUSING REPLACEMENT/REPAIR

Removal; Disassembly; Cleaning, Inspection, and Adjustment; Assembly; Installation
INITIAL SETUP
0128, Item 20) 0

Snap Ring 0

and Repair: Organizational Maintenance References 0
Common #1 (WP 0128, Item 14) 0 WP 0019 0
Injection Pump Hub Holding Tool (1 020 327

R1) 0
Pliers, Seal (PLT-371-4) 0

Materials/Parts 0
Cap Set, Protective Dust and Moisture Seal Battery disconnect switch in OFF position (WP
(WP 0130, Item 3) 0
0004) 0

Fuel injection pump removed (WP 0028) 0
0100-1
TM 5-3805-255-14 0100
NOTE
Removing fuel injection pump adapter housing will require adjusting fuel injection pump
timing and engine idle speeds. Refer to WP 0028 for this information.
REMOVAL 000100
1. Remove tube (Figure 1, Item 1) from tee (Figure 1, Item 5).

2. Remove tube (Figure 1, Item 4) from tee (Figure 1, Item 5).
3. Remove two bolts (Figure 1, Item 3) and clips (Figure 1, Item 2) from crankcase.
4. Rotate engine clockwise until TC mark on vibration damper is in line with timing pointer. At this point No. 1
piston is on top-dead-center (TDC) of compression stroke.
5. Remove front three bolts from push rod chamber cover.
6. Remove bolts, nuts, washers, and adapter housing from crankcase front cover.
Figure 1. Injection Pump Adapter Disconnect Points. 0100
END OF TASK
0100-2
TM 5-3805-255-14 0100
DISASSEMBLY 000100
1. Secure adapter housing (Figure 2, Item 1) in a vise with soft jaws.

2. Remove three bolts (Figure 2, Item 2), washers (Figure 2, Item 3), two plates (Figure 2, Item 6), and gear
(Figure 2, Item 4) from pinion shaft (Figure 2, Item 5).
Figure 2. Removing Drive Gear. 0100
3. Secure injection pump hub holding tool to hub (Figure 3, Item 3) with two bolts (Figure 3, Item 1).
4. Install a suitable drift into hole in adapter housing (Figure 3, Item 4) to anchor holding tool.
5. Remove nut (Figure 3, Item 2) from pinion shaft (Figure 3, Item 3).
6. Remove drift, two bolts (Figure 3, Item 1), and holding tool from pinion shaft (Figure 3, Item 3).
Figure 3. Pinion Shaft Nut Removal. 0100
0100-3
TM 5-3805-255-14 0100
7. Remove hub (Figure 4, Item 1) from pinion shaft (Figure 4, Item 3).
8. Remove key (Figure 4, Item 4) from pinion shaft (Figure 4, Item 3).
9. Remove snap ring (Figure 4, Item 2) from adapter housing (Figure 4, Item 5). Discard snap ring.
Figure 4. Hub Removal. 0100
0100-4
TM 5-3805-255-14 0100
10. Remove adapter housing (Figure 5, Item 1) from vise and position on a press.
11. Remove pinion shaft with bearing (Figure 5, Item 2) from adapter housing (Figure 5, Item 1).
Figure 5. Pinion Shaft and Bearing Removal. 0100
12. Support bearing cone (Figure 6, Item 2) and remove shaft (Figure 6, Item 1) from gear (Figure 6, Item 3).
END OF TASK
0100-5
TM 5-3805-255-14 0100
CLEANING, INSPECTION, AND ADJUSTMENT 000100
2. Inspect bearings (Figure 7, Item 2) for corrosion or wear and replace if necessary.
3. Inspect pinion shaft (Figure 7, Item 3), gear (Figure 7, Item 4), and pinion drive gear (Figure 7, Item 1) for wear
or damage. Replace parts as necessary.
Figure 7. Component Inspection. 0100
Servicing and Adjusting Tapered Roller Bearing 000100
NOTE
Bearings, spacer, and cup assembly are furnished as a matched unit. Perform the
adjustment procedure.
1. Assemble complete bearing assembly (Figure 8, Item 6) on a flat surface (surface plate) (Figure 8, Item 4).
2. Place a minimum weight (Figure 8, Item 2) of 20 lb (9 kg) on top of bearing assembly (Figure 8, Item 6) (this will
keep roller in alignment).
3. Rotate lower bearing cup (Figure 8, Item 3) a minimum of four revolutions in each direction.
4. With spacer (Figure 8, Item 5) in place, set up a dial indicator with magnetic base. Set dial indicator at zero.
Take a measurement at three different points on upper bearing cone (Figure 8, Item 1).
5. Slide dial indicator off upper bearing cone (Figure 8, Item 1). (Do not upset indicator setting.)
6. Remove weight (Figure 8, Item 2), upper bearing cone (Figure 8, Item 1), and spacer (Figure 8, Item 5).
Replace upper bearing cone and weight. Do not replace spacer.
7. Slide dial indicator onto upper bearing cone (Figure 8, Item 1). Repeat rotation of lower bearing cup (Figure 8,
Item 3). Record an accurate reading from dial indicator. Measure at three different points.
8. Factory end-play in a new bearing assembly is 0.0045 to 0.0060 in. (0.114 to 0.152 mm). If reading on dial
indicator shows a greater drop than maximum permissible end-play of 0.009 in. (0.23 mm), grinding or lapping
of spacer (Figure 8, Item 5) is necessary. Amount to be ground off spacer is difference between indicator
reading and factory set end-play.
9. Remove dial indicator.
0100-6
TM 5-3805-255-14 0100
CLEANING, INSPECTION, AND ADJUSTMENT – CONTINUED
Figure 8. Tapered Roller Bearing Measurement. 0100
END OF TASK
ASSEMBLY 000100
1. Support bearing assembly (Figure 9, Item 2) between two flat plates on a hydraulic press. Install pinion shaft
(Figure 9, Item 1) into bearing until shoulder on shaft bottoms on bearing cone.
Figure 9. Pinion Shaft Assembly. 0100
0100-7
TM 5-3805-255-14 0100
2. Support adapter housing (Figure 10, Item 5) on a hydraulic press. Install pinion shaft with bearings installed
(Figure 10, Item 1) into housing (Figure 10, Item 5).
3. Install new snap ring (Figure 10, Item 4) in groove on housing (Figure 10, Item 5).
4. Install hub key (Figure 10, Item 2) in keyway on pinion shaft (Figure 10, Item 1).
5. Align keyway in hub (Figure 10, Item 3) with hub key (Figure 10, Item 2). Install hub onto pinion shaft
(Figure 10, Item 1) until it bottoms on bearing.
Figure 10. Injection Pump Adapter Assembly. 0100
0100-8
TM 5-3805-255-14 0100
6. Install injection pump hub holding tool on hub (Figure 11, Item 2) and two bolts (Figure 11, Item 1).
7. Install a suitable drift into hole in adapter housing (Figure 11, Item 4).
8. Install pinion nut (Figure 11, Item 3) on end of pinion shaft. Torque pinion nut to 160 lb-ft (217 Nm).
9. Remove drift, two 3/8 NF x 1 1/8 in. bolts (Figure 11, Item 1), and holding tool from housing (Figure 11, Item 4).
Figure 11. Torquing Pinion Shaft Nut. 0100
10. Install drive gear (Figure 12, Item 1) on pinion shaft (Figure 12, Item 3). Install three washers (Figure 12,
Item 4) and bolts (Figure 12, Item 5) into hub (Figure 12, Item 2) finger-tight only.
Figure 12. Drive Gear Installation. 0100
END OF TASK
0100-9
TM 5-3805-255-14 0100
INSTALLATION 000100
1. Crank engine until TC mark on vibration damper is in line with timing pointer on crankcase front cover. Make
sure No. 1 piston is on TDC of compression stroke.
2. Rotate pinion shaft (Figure 13, Item 1) until mark (Figure 13, Item 3) on drive gear (Figure 13, Item 2) is at six
o’clock position.
Figure 13. Drive Gear Phasing. 0100
3. Install assembled adapter housing on crankcase front cover, aligning mark on camshaft gear with mark on
drive gear. Secure adapter housing to crankcase front cover.
4. Install and secure front three capscrews in push rod chamber cover.
5. Connect tube (Figure 14, Item 1) to tee (Figure 14, Item 5). Secure two clips (Figure 14, Item 2) to crankcase
with two capscrews (Figure 14, Item 3). Tighten capscrews securely.
6. Connect tube (Figure 14, Item 4) to tee (Figure 14, Item 5).
7. Install a new gasket onto pump mounting flange of adapter housing.
8. Rotate engine crankshaft clockwise (as viewed from fan drive end) to 38 degrees with No. 1 cylinder on
compression stroke.
9. Loosen three bolts on drive gear and rotate pinion shaft so bolts are approximately halfway between center of
elongated holes and clockwise end of drive gear.
NOTE
Pump shaft will not stay in location but will rotate counterclockwise (as viewed from drive
end of pump) approximately 12 degrees to stable stationary position. Allow pump shaft to
remain in this position.
10. Position injection pump camshaft so that pointer aligns with timing mark on gear.
11. Install pump on engine (WP 0028).
0100-10
TM 5-3805-255-14 0100
Figure 14. Lines Attachment. 0100
12. With three bolts loosely installed, remove pivot bracket capscrew (Figure 15, Item 1). Adjust support (Figure
15, Item 4) and bracket (Figure 15, Item 2) so that with these parts tightened, pivot bolt (Figure 15, Item 3) can
be inserted freely through bracket and support. Install pivot bolt. Tighten two bolts (Figure 15, Items 1 and 3)
securely.
Figure 15. Injection Pump Adjustable Support with Bracket. 0100
0100-11
TM 5-3805-255-14 0100
NOTE
Remove plug located on top of injection pump adapter housing so injection pump gear is
visible for timing procedure.
13. Rotate drive gear to bring mark on injection pump gear into alignment with pointer on pump and tighten three
drive gear bolts evenly.
14. Rotate engine crankshaft counterclockwise (as viewed from fan drive end) to about 60 degrees before top
dead center (BTDC) of No. 1 cylinder and bring it back clockwise to 38 degrees BTDC.
15. Check timing pointer to be sure it lines up with mark on gear. If pointer is not aligned, loosen bolts on drive gear
and align. Retighten bolts.
16. Install plug on pump adapter housing.
17. Install new gasket on injection pump timing cover (Figure 16, Item 1). Position timing cover on crankcase front
cover (Figure 16, Item 2). Install five bolts (Figure 16, Item 3) and tighten bolts securely in alternating pattern.
Figure 16. Injection Pump Timing Port. 0100
0100-12
TM 5-3805-255-14 0100
18. Connect all lines and controls to pump. Lubricate injection line nuts with lubricant but do not tighten six
injection lines at this time.
19. Check to be sure control linkage is properly adjusted.
20. With control lever positioned in half throttle position, crank engine (at 10 second intervals) until fuel flows from
loose fuel line nuts. Torque line nuts at pump to 30 lb-ft (40 Nm).
NOTE
Fuel system may need priming. If fuel does not flow from lines, refer to Fuel System
(WP 0018).
21. Start engine and check all connections for leaks.
22. Refer to WP 0028 for fuel injection pump timing and idle speed adjustments.
END OF TASK
END OF WORK PACKAGE
0100-13/(14 blank)
20
TM 5-3805-255-14 0101
0 1 0 1 FAN DRIVE ASSEMBLY REPAIR

Removal, Diagnosis, Fan Mounting Disassembly, Inspection and Repair, Fan Mounting Assembly,
Housing Disassembly, Housing Inspection and Repair, Housing Assembly, Fan Drive Assembly
INITIAL SETUP
Shop Equipment, Automotive Maintenance Friction Disc (2) 0
and Repair: Organizational Maintenance Gasket, Fan Drive 0
Lock, Bolt (3) 0
Nut, Fan Retaining 0
Spring Load Tester Valve and Clutch Spring Snap Ring 0
Torque Wrench, 2,500 lb-ft (WP 0128, Item References 0
21) 0
WP 0019 0
Coupling Flange Support Tool (WP 0125,

Item 8) 0
Belleville Spring Compressing Tool (WP 0125, Machine parked on level ground (WP 0005) 0
Item 9) 0 Parking brake applied (WP 0005) 0
Fan Pulley Torque Fixture (WP 0125, Item 12) 0 Engine OFF (WP 0005) 0
Snap Ring Installation Tool (WP 0125, Battery disconnect switch in OFF position (WP
Item 10) 0 0004) 0
Materials/Parts 0
Radiator removed (WP 0036) 0
Fan drive removed (WP 0038) 0
Friction Bearing 0
0101-1
TM 5-3805-255-14 0101
REMOVAL 000101
1. Support fan housing assembly (Figure 1, Item 3) by clamping fan drive gear (Figure 1, Item 4) in vise. Use soft,
protective vise jaws being careful not to damage fan drive gear.
2. Remove front nut (Figure 1, Item 2) from fan mounting assembly (Figure 1, Item 1).
CAUTION
Do not damage rubber member. Failure to follow caution may result in failure of rubber
member.
3. Attach puller to bottom of fan mounting assembly (Figure 1, Item 1).
4. Remove fan mounting assembly (Figure 1, Item 1) from fan housing assembly (Figure 1, Item 3).
Figure 1. Fan Mounting Assembly Disassembly. 0101
END OF TASK
0101-2
TM 5-3805-255-14 0101
DIAGNOSIS 000101
Service Diagnosis 000101
1. Refer to Table 1 and replace proper item(s) that correspond with problem encountered on engine.
2. Check fan blades for looseness and bends; repair or replace if necessary.
3. If drive gear is reason for replacement of housing assembly, also check fan idler.
Table 1. Service Diagnosis.
PROBLEM REPLACE
Engine overheating due to fan slipping continuously. Check fore and aft play in fan, excessive radial
movement, and knocking gear for damaged teeth.
Repair if necessary.
Improper torque of fan mounting assembly. Fan mounting assembly.
Rubber member separation of fan mounting assembly. Housing assembly.
Shaft wobble. Fan mounting assembly not turning.
Oil leakage. Complete drive assembly.
Fan wobbling. Fan mounting assembly. Fan spacer.
Checking Fan Clutch Slip Torque When Removed from Engine 000101
NOTE
Break clutch loose five lb-ft times to seat friction plates before recording torque value.
Torque should be 160 to 300 lb-ft (215 to 406 Nm). If clutch torque is not within
specification, replace or rebuild fan mounting assembly.
1. Support fan mounting assembly (Figure 2, Item 1) by clamping pulley (Figure 2, Item 2) in a vise. Use soft,
protective vise jaws, being careful not to damage pulley.
2. Bolt torque adapter to fan mounting assembly (Figure 2, Item 1).
3. Use a torque wrench on center 3/4 in. bolt of torque adapter to check torque required to slip fan clutch in fan
mounting assembly (Figure 2, Item 1).
Figure 2. Checking Clutch Slip Torque. 0101
END OF TASK
0101-3
TM 5-3805-255-14 0101
FAN MOUNTING DISASSEMBLY 000101
1. Support fan mounting assembly in a press using coupling flange support tool (WP 0125).
CAUTION
Make sure support tool slips through slots in rear of pulley and supports coupling flange
only. Failure to follow caution may result in damage to equipment.
2. If necessary, fabricate Belleville spring compressing tool (WP 0125).
3. Place Belleville spring compressing tool (Figure 3, Item 1) on top of fan mounting assembly (Figure 3, Item 3).
4. Place a steel bar (Figure 3, Item 2) across top of Belleville spring compressing tool and compress Belleville
spring (Figure 3, Item 4).
5. Remove snap ring (Figure 3, Item 5) from fan mounting assembly (Figure 3, Item 3) using snap ring pliers.
6. Slowly release pressure of press on Belleville spring (Figure 3, Item 4).
7. Remove fan mounting assembly (Figure 3, Item 3) from press.
Figure 3. Snap Ring Removal. 0101
END OF TASK
INSPECTION AND REPAIR 000101
1. Refer to dimensional drawing (Figure 4) and replace any part that does not meet specifications.
2. Check dimensions in more than one area and watch for unusual wear patterns.
NOTE
Dimensional drawing is of latest fan mounting assembly only. It is recommended that parts
be inspected for wear and replaced with new. Check all parts for gouging caused by
spinning against mating part. Replace part if worn beyond specification or gouged.
3. Check snap ring (Figure 4, Item 1), Belleville springs (Figure 4, Item 3), spacer (Figure 4, Item 2), Belleville
spacer (Figure 4, Item 4), mounting flange (Figure 4, Item 7), and pressure plate (Figure 4, Item 5) for bluing or
gouging. Replace if present.
4. Inspect pressure plate (Figure 4, Item 5) tangs and coupling flange/pulley assembly (Figure 4, Item 9) keyways
for pounding and wear. Replace if wear is beyond specifications.
5. Replace friction discs (Figure 4, Item 6) and friction bearing (Figure 4, Item 8) every time fan mounting
assembly (Figure 4, Item 10) is disassembled for service.
0101-4
TM 5-3805-255-14 0101
INSPECTION AND REPAIR – CONTINUED
H100C-0765
Figure 4. Exploded View of Fan Mounting Assembly. 0101
LEGEND
A 5.510 to 5.530 in. (139.95 to 140.46 mm) Dia. I 0.495 to 0.497 in. (12.57 to 12.62 mm)
B 0.195 to 0.200 in. (4.95 to 5.08 mm) J 0.6825 to 0.6875 in. (17.336 to 17.463 mm)
C 0.050 to 0.055 in. (1.2 to 1.40 mm) K 0.059 to 0.065 in. (1.50 to 1.65 mm)
D 0.109 in. (2.77 mm) Ref. L 0.875 in. (22.23 mm)
E 5.510 to 5.540 in. (139.95 to 140.72 mm) Dia. M 0.120 to 0.130 in. (3.05 to 3.30 mm)
F 5.008 to 5.016 in. (127.20 to 127.41 mm) N 5.497 to 5.499 in. (139.62 to 139.67 mm) Dia.
between tangs
G 0.3100 to 0.3125 in. (7.874 to 7.938 mm) O 5.492 to 5.499 in. (139.50 to 139.67 mm) Dia.
H 5.634 to 5.636 in. (143.10 to 143.15 mm) Dia. P 1.1245 to 1.1252 in. (28.562 to 28.580 mm) Dia.
0101-5
TM 5-3805-255-14 0101
INSPECTION AND REPAIR – CONTINUED
NOTE
Bluing of any part of fan mounting assembly is a sign of excessive heat. This heat can
weaken bonding of rubber member. Anytime this happens, strength of bonding must be
checked as follows:
6. Clamp pulley in fabricated holding fixture (WP 0125), install fabricated fan pulley torque fixture (WP 0125) in
keyway of coupling flange and torque to 1,800 to 2,000 lb-ft (2,450 to 2,700 Nm).
7. If any slippage occurs between coupling and pulley, part must be replaced.
8. If necessary, fabricate fan pulley holding fixture (WP 0125).
9. If necessary, fabricate fan pulley torque fixture (WP 0125).
END OF TASK
0101-6
TM 5-3805-255-14 0101
FAN MOUNTING ASSEMBLY 000101
1. Support pulley and coupling assembly (Figure 5, Item 3) in a press using coupling flange support tool.
CAUTION
Make sure support tool slips through slots in rear of pulley and supports coupling flange
only; otherwise, damage will occur to rubber member. Failure to follow caution may result
in damage to equipment.
2. Install friction bearing (Figure 5, Item 1) inside one of friction discs (Figure 5, Item 2) to coupling assembly
(Figure 5, Item 3).
Figure 5. Friction Disc and Friction Bearing Assembly. 0101
0101-7
TM 5-3805-255-14 0101
FAN MOUNTING ASSEMBLY – CONTINUED

3. Slide friction bearing (Figure 6, Item 8) inside friction disc (Figure 6, Item 6) on coupling flange/pulley assembly
(Figure 6, Item 9) until friction bearing is against shoulder.
4. Slide friction disc (Figure 6, Item 6) to shoulder making sure friction bearing (Figure 6, Item 8) stays inside fric-
tion disc.
5. Install fan mounting flange (Figure 6, Item 7) over friction bearing (Figure 6, Item 8) with fan pilot up.
6. Install other friction disc (Figure 6, Item 6) on end of friction bearing (Figure 6, Item 8).
NOTE
If pressure plate tangs do not slide easily through keyways, replace pressure plate.
7. Install pressure plate (Figure 6, Item 5), with tang in keyway, on coupling flange/pulley assembly (Figure 6,
Item 9).
CAUTION
Use only the correct Belleville springs when rebuilding fan mounting assembly. Single
Belleville springs used on early model fan drives have different spring rates and do not
compensate for friction disc wear, causing premature failure. Belleville springs must be
installed opposite each other, otherwise, premature wear and failure of friction discs will
occur. Failure to follow this caution can lead to serious damage or failure of fan clutch.
8. Install Belleville spring (Figure 6, Item 3), concave side up, on coupling flange/pulley assembly (Figure 6,
Item 9).
9. Install Belleville spacer (Figure 6, Item 4) on coupling flange/pulley assembly (Figure 6, Item 9).
CAUTION
Belleville springs must be installed opposite each other, otherwise, premature wear and
failure of friction discs will occur.
10. Install other Belleville spring (Figure 6, Item 3), concave side down, and spacer (Figure 6, Item 2) on coupling
flange/pulley assembly (Figure 6, Item 9).
0101-8
TM 5-3805-255-14 0101
Figure 6. Fan Mounting Assembly. 0101
LEGEND
A 5.510 to 5.530 in. (139.95 to 140.46 mm) Dia. I 0.495 to 0.497 in. (12.57 to 12.62 mm)
B 0.195 to 0.200 in. (4.95 to 5.08 mm) J 0.6825 to 0.6875 in. (17.336 to 17.463 mm)
C 0.050 to 0.055 in. (1.2 to 1.40 mm) K 0.059 to 0.065 in. (1.50 to 1.65 mm)
D 0.109 in. (2.77 mm) Ref. L 0.875 in. (22.23 mm)
E 5.510 to 5.540 in. (139.95 to 140.72 mm) Dia. M 0.120 to 0.130 in. (3.05 to 3.30 mm)
F 5.008 to 5.016 in. (127.20 to 127.41 mm) N 5.497 to 5.499 in. (139.62 to 139.67 mm) Dia.
between tangs
G 0.3100 to 0.3125 in. (7.874 to 7.938 mm) O 5.492 to 5.499 in. (139.50 to 139.67 mm) Dia.
H 5.634 to 5.636 in. (143.10 to 143.15 mm) Dia. P 1.1245 to 1.1252 in. (28.562 to 28.580 mm) Dia.
0101-9
TM 5-3805-255-14 0101

11. Refer to WP 0125 to fabricate snap ring installation tool.
NOTE
Only use new snap ring for fan mounting assembly.
12. Support fan mounting assembly (Figure 7, Item 1) on press.
13. Install snap ring installation tool on fan mounting assembly (Figure 7, Item 1).
Figure 7. Assembling Snap Ring Installation Tool. 0101
14. Place steel bar stock and Belleville spring compressor tool over snap ring installation tool on top of spacer
(Figure 8, Item 1).
15. Compress Belleville springs (Figure 8, Item 2) and install snap ring (Figure 8, Item 3) with snap ring pliers.
16. Check fan mounting assembly (Figure 8, Item 4) slip torque. Refer to Diagnosis in this work package.
Figure 8. Snap Ring Installation. 0101
END OF TASK
0101-10
TM 5-3805-255-14 0101
HOUSING DISASSEMBLY 000101
1. Support housing assembly (Figure 9, Item 1) by clamping gear (Figure 9, Item 3) in a vise. Use soft, protective
vise jaws, being careful not to damage gear.
2. Remove hexagonal jam nut (Figure 9, Item 2) from shaft (Figure 9, Item 4).
Figure 9. Removing Jam Nut. 0101
3. Remove drive gear (Figure 10, Item 1) from shaft (Figure 10, Item 2) with a gear puller.
Figure 10. Removing Drive Gear. 0101
END OF TASK
0101-11
TM 5-3805-255-14 0101
HOUSING INSPECTION AND REPAIR 000101
NOTE
Refer to Figure 11 for dimension drawing of fan housing assembly.
2. Remove four bolts (Figure 11, Item 9), bolt locks (Figure 11, Item 8), and bearing retainer plate (Figure 11,
Item 7) from housing (Figure 11, Item 2). Discard bolt locks.
CAUTION
Do not force or damage will occur to housing, bearings, and shaft. Failure to follow caution
may result in damage to fan drive assembly.
3. Gently tap front of shaft (Figure 11, Item 3) to remove with front and rear bearings (Figure 11, Items 4 and 6)
from rear of housing (Figure 11, Item 2).
4. Remove front oil seal (Figure 11, Item 1) from housing (Figure 11, Item 2). Discard seal.
5. Support front side of inner race of front ball bearing (Figure 11, Item 4) and press shaft (Figure 11, Item 3) out
from rear, removing both bearings (Figure 11, Items 4 and 6) and spacer (Figure 11, Item 5).
CAUTION
Only support bearings by inner race. Do not press through balls or damage will occur to
bearings. Failure to follow caution will result in bearing failure.
NOTE
• Refer to dimensional drawing (Figure 11) and replace any part that does not meet
specifications.
• Always check dimensions in more than one area and watch for unusual wear patterns.
Dimensional drawings are of latest housing assemblies only.
• For earlier models, it is recommended that parts be inspected for wear and replaced with
new.
• Check all parts for gouging caused by spinning against mating part. Replace part if worn
beyond specifications or gouged.
6. Check nut (Figure 11, Item 11) and drive gear (Figure 11, Item 10) for pitting and damaged teeth. Replace if
damaged.
7. Inspect shaft (Figure 11, Item 3) for damage due to front and rear bearings (Figure 11, Items 4 and 6) turning
on shaft. Replace if worn.
8. Inspect housing (Figure 11, Item 2) for damage from front and rear bearings (Figure 11, Items 4 and 6) turning.
Replace if damaged or worn beyond specifications.
9. Inspect bearing retainer plate (Figure 11, Item 7) for bending or wear from rear bearing (Figure 11, Item 6).
Replace if damaged.
10. Oil seal (Figure 11, Item 1) should be replaced every time drive is disassembled.
CAUTION
Anytime unbalance has occurred in fan mounting assembly, ball bearings should be
replaced due to possible damage. Failure to follow caution may result in damage to fan
housing assembly.
0101-12
TM 5-3805-255-14 0101
HOUSING INSPECTION AND REPAIR – CONTINUED

11. Replace front and rear bearings (Figure 11, Items 4 and 6) every time drive is serviced. Front and rear bearing
damage can be hard to detect, causing further damage later.
H100C-0774
Figure 11. Dimensional Drawing of Fan Housing. 0101
LEGEND
A 2.622 to 2.624 in. (66.60 to 66.65 mm) Dia. H 1.3775 to 1.3780 in. (34.989 to 35.001 mm) Dia.
B 0.180 to 0.185 in. (4.57 to 4.70 mm) I 2.83451 to 2.9347 in. (71.986 to 71.999 mm)
C 2.8345 to 2.8351 in. (71.996 to 72.012 mm) Dia. J 1.520 to 1.540 in. (38.61 to 39.12 mm)
D 1.748 to 1.752 in. (44.40 to 44.50 mm) Dia. K 1.1807 to 1.811 in. (29.990 to 30.000 mm) Dia.
E 1.113 to 1.123 in. (28.27 to 28.52 mm) Dia. L 2.8341 to 2.8346 in. (71.986 to 71.999 mm) Dia.
F 1.3779 to 1.3784 in. (34.999 to 35.011 mm) Dia. M 1.1795 to 1.1802 in. (29.959 to 29.977 mm) Dia.
G 1.1810 to 1.814 in. (29.997 to 30.008 mm) Dia.
END OF TASK
0101-13
TM 5-3805-255-14 0101
HOUSING ASSEMBLY 000101
NOTE
• Do not rebuild with any obsolete parts such as keyed shafts, keyed gears, and keyed
mounting assemblies. Keyed shafts and gears were discontinued to prevent failures
through keyways. Use only current part numbers or replace with current assemblies.
• Only use specified ball bearings. Bearings of similar code and size do not necessarily
have equivalent capacities.
1. Support front of shaft (Figure 12, Item 1) and install front bearing (Figure 12, Item 4), spacer (Figure 12,
Item 3), and rear bearing (Figure 12, Item 2) on rear of shaft.
CAUTION
Press only through inner race of ball bearings; otherwise, damage will occur. Failure to
follow caution will fail bearing and may cause damage to fan drive assembly.
2. Install inner race until front bearing (Figure 12, Item 4), spacer (Figure 12, Item 3), and rear bearing (Figure 12,
Item 2) bottoms out on rear of shaft (Figure 12, Item 5).
Figure 12. Pressing Bearings and Spacer to Shaft. 0101
0101-14
TM 5-3805-255-14 0101
HOUSING ASSEMBLY – CONTINUED

3. Support housing (Figure 13, Item 1) on a press.
4. Press oil seal (Figure 13, Item 3) in flush with front face of housing (Figure 13, Item 1).
5. Place an oil seal expanding sleeve over front end of shaft assembly (Figure 13, Item 2).
6. Install shaft assembly (Figure 13, Item 2) in housing (Figure 13, Item 1), centering shaft assembly in bores.
NOTE
Press only through outer race of bearing or damage will occur.
7. Install shaft assembly (Figure 13, Item 2) in housing (Figure 13, Item 1).
Figure 13. Pressing Shaft and Bearing in Housing. 0101
0101-15
TM 5-3805-255-14 0101
HOUSING ASSEMBLY 000101
1. Install bearing retainer plate (Figure 14, Item 3), four new bolt locks (Figure 14, Item 6), and bolts (Figure 14,
Item 7) on housing (Figure 14, Item 4). Torque bolts to 24 lb-ft (33 Nm).
2. Supporting shaft (Figure 14, Item 2) in a press, position gear (Figure 14, Item 1).
3. Install gear (Figure 14, Item 1) onto shaft (Figure 14, Item 2) until it bottoms on rear bearing (Figure 14, Item 5).
Figure 14. Pressing Gear on Shaft. 0101
0101-16
TM 5-3805-255-14 0101
HOUSING ASSEMBLY – CONTINUED
CAUTION
Hexagonal jam nut torque is critical. Nut must be torqued to 600 to 625 lb-ft (815 to
845 Nm) using a torque wrench. Insufficient torque will cause bearing slippage and
excessive torque will cause bearing wear. DO NOT use an ESNA nut. ESNA nut does not
have capacity for higher torque. Failure to follow this caution may result in damage.
4. Support housing assembly (Figure 15, Item 1) by clamping gear (Figure 15, Item 2) in a vise. Use soft,
protective vise jaws being careful not to damage gear).
5. Install hexagonal jam nut (Figure 15, Item 3) on gear (Figure 15, Item 2).
6. Torque jam nut (Figure 15, Item 3) to 600 to 625 lb-ft (815 to 845 Nm).
Figure 15. Installing Jam Nut. 0101
END OF TASK
0101-17
TM 5-3805-255-14 0101
FAN DRIVE ASSEMBLY 000101
CAUTION
Cleanliness of housing oil passageways and gear is important to prevent damage to
internal parts. Two bolts cannot be removed when fan mounting assembly is mounted on
fan housing assembly.
1. Insert two bolts (Figure 16, Item 1) and washers (Figure 16, Item 2) in fan housing assembly (Figure 16,
Item 3) prior to assembly of fan mounting assembly (Figure 16, Item 4) and fan housing assembly as shown.
Figure 16. Bolts Installed in Housing. 0101
0101-18
TM 5-3805-255-14 0101
FAN DRIVE ASSEMBLY – CONTINUED
CAUTION
Shaft and gear must be supported to prevent damage to ball bearings in housing
assembly. Assembly must be installed so pulley is towards housing. Failure to follow
caution may result in failure of fan drive assembly.
2. While supporting shaft (Figure 17, Item 2) and gear (Figure 17, Item 5), press fan mounting assembly (Figure
17, Item 1) through pulley (Figure 17, Item 3) and bottom onto shaft (Figure 17, Item 2).
Figure 17. Pressing on Fan Mounting Assembly. 0101
0101-19
TM 5-3805-255-14 0101
FAN DRIVE ASSEMBLY – CONTINUED

3. Support fan drive assembly (Figure 18, Item 1) by clamping gear (Figure 18, Item 3) in a vise. Use soft,
protective vise jaws being careful not to damage drive gear.
4. Install and torque a new fan hub retaining nut (Figure 18, Item 2) to 275 to 300 lb-ft (373 to 407 Nm).
Figure 18. Fan Hub Retaining Nut. 0101
END OF TASK
END OF WORK PACKAGE
0101-20
34
TM 5-3805-255-14 0102
0 1 0 2 TORQUE CONVERTER REPAIR

INITIAL SETUP
Tools and Special Tools 0 Materials/Parts – Continued 0
0128, Item 20) 0

Seal 0
Shop Equipment, Machine Shop, Field Seal Ring (2) 0
Maintenance, Heavy, Supplemental No. 1, Snap Ring (3) 0
Wrench, Torque, 3/4 in. Drive 100 to 500 lb-ft Personnel Required 0
(WP 0128, Item 25) 0

Two 0
Materials/Parts 0
References 0
Cap Set, Protective Dust and Moisture Seal WP 0019 0
(WP 0130, Item 3) 0
WP 0021 0

0130, Item 4) 0
Rag, Wiping (WP 0130, Item 28) 0 Machine parked on level ground (WP 0005) 0
Sealant, Loctite 496 (WP 0130, Item 33) 0 Parking brake applied (WP 0005) 0
Tag, Marker (WP 0130, Item 37) 0 Engine OFF (WP 0005) 0
Gasket (2) 0 Battery disconnect switch in OFF position (WP

O-ring (3) 0
0004) 0
Lockplate 0
0102-1
TM 5-3805-255-14 0102
DISASSEMBLY 000102
WARNING
suitable load capacity. Keep clear of heavy parts supported by lifting device. Failure to
CAUTION
Use caution when removing parts to prevent damage.
NOTE
• Clean torque converter exterior and surrounding area thoroughly with steam. Prepare a
clean work area. Cleanliness is very important during converter overhaul.
• Tag and identify all components for ease of assembly.
1. Use a suitable lifting device to position converter (Figure 1, Item 1) on a bench with output yoke (Figure 1,
Item 2) facing down. Block housing so yoke will clear bench. Remove lifting device.
Figure 1. Torque Converter Positioning. 0102
0102-2
TM 5-3805-255-14 0102
2. Remove seal ring (Figure 2, Item 1) from housing (Figure 2, Item 2). Discard seal ring.
Figure 2. Seal Ring Removal. 0102
3. Remove six capscrews (Figure 3, Item 5), lockwashers (Figure 3, Item 4), inspection cover (Figure 3, Item 2),
and gasket (Figure 3, Item 3) from housing (Figure 3, Item 1). Discard gasket.
Figure 3. Inspection Cover Removal. 0102
0102-3
TM 5-3805-255-14 0102
4. Remove six capscrews (Figure 4, Item 2), lockwashers (Figure 4, Item 1), hub (Figure 4, Item 3), and shims
(Figure 4, Item 4) from converter assembly (Figure 4, Item 5). Tie input hub shims together to facilitate
assembly. Discard lockwashers.
Figure 4. Hub and Shims Removal. 0102
5. Remove three bolts (Figure 5, Item 1), lockplate (Figure 5, Item 2), retaining washer (Figure 5, Item 3), and
shims (Figure 5, Item 4) (if used) from output shaft (Figure 5, Item 5). Discard lockplate.
Figure 5. Retaining Washer and Shim Removal. 0102
0102-4
TM 5-3805-255-14 0102
WARNING
6. Use a suitable lifting device to remove converter assembly (Figure 6, Item 1) from housing (Figure 6, Item 2).
Figure 6. Converter Removal. 0102
7. Place converter assembly (Figure 7, Item 1) on bench. Block impeller (Figure 7, Item 2) high enough to allow
accessory drive gear (Figure 7, Item 3) to clear bench. Remove lifting device.
Figure 7. Converter Positioning. 0102
0102-5
TM 5-3805-255-14 0102
8. Remove 24 capscrews (Figure 8, Item 2) from converter assembly (Figure 8, Item 1).
Figure 8. Converter Separation. 0102
WARNING
NOTE
Do not drop turbine as it is removed from converter assembly
9. Use a suitable lifting device to lift drive housing (Figure 9, Item 1) and turbine (Figure 9, Item 2) from converter
10. Invert drive housing (Figure 9, Item 1) and turbine (Figure 9, Item 2) and remove turbine from drive housing.
Figure 9. Turbine Removal. 0102
0102-6
TM 5-3805-255-14 0102
11. Remove bearing (Figure 10, Item 1) from drive housing (Figure 10, Item 2).
12. Remove spacer (Figure 11, Item 1) and dowel (Figure 11, Item 2) from stator (Figure 11, Item 3).
13. Remove stator (Figure 11, Item 3) from impeller (Figure 11, Item 4).
Figure 11. Stator Removal 0102
0102-7
TM 5-3805-255-14 0102
14. Remove seven bolts (Figure 12, Item 2) from drive gear (Figure 12, Item 1).
15. Remove bearing (Figure 12, Item 4) and drive gear (Figure 12, Item 1) from impeller (Figure 12, Item 3).
Figure 12. Accessory Drive Gear Removal. 0102
16. Position converter housing (Figure 13, Item 6) with output yoke (Figure 13, Item 1) facing up.
17. Remove three capscrews (Figure 13, Item 2), lockplate (Figure 13, Item 3), retaining washer (Figure 13,
Item 4), and output yoke (Figure 13, Item 1) from output shaft (Figure 13, Item 5). Discard lockplate.
Figure 13. Yoke Removal. 0102
0102-8
TM 5-3805-255-14 0102
18. Remove six bolts (Figure 14, Item 2), lockwashers (Figure 14, Item 1), bearing retainer (Figure 14, Item 4),
retainer gasket (Figure 14, Item 5), and shims (Figure 14, Item 6) from converter housing (Figure 14, Item 8).
Discard gasket and lockwashers.
19. Remove seal (Figure 14, Item 3) from bearing retainer (Figure 14, Item 4). Discard seal
20. Remove yoke spacer (Figure 14, Item 7) from converter housing (Figure 14, Item 8).
Figure 14. Bearing Retainer Removal. 0102
0102-9
TM 5-3805-255-14 0102
21. Invert converter housing (Figure 15, Item 3) with open end up.
22. Use snap ring pliers to remove snap ring (Figure 15, Item 2) from groove in upper end of output shaft (Figure
15, Item 1).
23. Remove output shaft (Figure 15, Item 1) and bearing from housing (Figure 15, Item 3).
Figure 15. Output Shaft and Bearing Removal. 0102
24. Remove seal ring (Figure 16, Item 1) and snap ring (Figure 16, Item 3) from output shaft (Figure 16, Item 2).
Discard seal ring.
Figure 16. Seal and Snap Ring Removal. 0102
0102-10
TM 5-3805-255-14 0102
25. Remove bearing (Figure 17, Item 2) from output shaft (Figure 17, Item 1).
Figure 17. Output Shaft Bearing Removal. 0102
26. Remove retaining nut (Figure 18, Item 1) and input charging bolts (Figure 18, Item 2) from pump shaft (Figure
18, Item 3).
Figure 18. Charging Pump Drive Gear Removal. 0102
0102-11
TM 5-3805-255-14 0102
27. Invert converter housing (Figure 19, Item 1) and remove two bolts (Figure 19, Item 2) and lockwashers (Figure
19, Item 3). Discard lockwashers.
Figure 19. Charging Pump Retainer Removal. 0102
28. Remove charging pump (Figure 20, Item 1) from converter housing (Figure 20, Item 3). Discard O-rings.
29. Remove two O-rings (Figure 20, Item 2) from converter housing (Figure 20, Item 3). Discard O-rings,
Figure 20. O-Rings Removal. 0102
0102-12
TM 5-3805-255-14 0102
30. Remove two pump mount adapter plates (Figure 21, Item 1) from converter housing (Figure 21, Item 5).
31. Using snap ring pliers, remove two snap rings (Figure 21, Item 4) from gear shaft (Figure 21, Item 3). Discard
snap rings.
32. Remove drive seal (Figure 21, Item 2) from adapter plate (Figure 21, Item 1). Remove shafts from converter
Figure 21. Pump Plates Removal. 0102
0102-13
TM 5-3805-255-14 0102
NOTE
Do not remove snap ring.
33. Remove four bearings (Figure 22, Item 1) from converter housing (Figure 22, Item 2).
34. Remove seal ring (Figure 23, Item 4) from hub.
CAUTION
Do not attempt to drive ground sleeve from converter housing as serious damage may
occur to both housing and ground sleeve. Support center of housing. Ensure sleeve does
not contact hub.
35. Remove hub (Figure 23, Item 1) and gasket (Figure 23, Item 2) from housing (Figure 23, Item 3). Discard
gasket.
Figure 23. Ground Sleeve Hub Removal. 0102
END OF TASK
0102-14
TM 5-3805-255-14 0102
Cleaning 000102
Clean all metal parts IAW General Maintenance Instructions (WP 0019) in cleaning solvent and dry with
compressed air. Lubricate all machined surfaces with clean machine oil (WP 0131). During cleaning operation, pay
particular attention to oil passages, bearing assemblies, bearing bores, snap and seal ring grooves, and screw
threads.
Inspection 000102
Inspect all parts for wear or damage. Check converter and rotating housings for cracks. Inspect bearing bores and
mounting faces for wear, grooves, or scratches. Remove burrs and scratches with a crocus cloth. Inspect all
splined parts for worn, twisted, chipped, or burred splines. Remove burrs with a soft stone. Check turbine, impeller,
and guide wheel for cracks or other damage. Replace any parts that are in doubt or cannot be repaired.
END OF TASK
ASSEMBLY 000102
NOTE
• Make sure all components are properly seated during assembly.
• The ground sleeve hub must be chilled for at least 30 minutes prior to assembly.
1. Place converter housing (Figure 24, Item 4) in a press with output side down.
2. Position new gasket in housing.
CAUTION
Ensure oil passages (Figure 24, Item 3) are aligned. Failure to follow procedures may
cause damage to equipment.
3. Install ground sleeve hub (Figure 24, Item 2) and position hub in converter housing (Figure 24, Item 4).
Figure 24. Ground Sleeve Hub Installation. 0102
0102-15
TM 5-3805-255-14 0102
NOTE
• Coat new seal ring lightly with heavy grease before installation.
• Apply pressure to outer bearing races only.
4. Install new seal ring (Figure 25, Item 2) on hub (Figure 25, Item 1).
5. Press inner pump drive gear bearings (Figure 25, Item 4) into housing (Figure 25, Item 3).
Figure 25. Seal Ring and Inner Bearings Installation. 0102
0102-16
TM 5-3805-255-14 0102
NOTE
Apply pressure to outer bearing races only.
6. Invert housing (Figure 26, Item 2) and install outer bearings (Figure 26, Item 1) into housing.
Figure 26. Outer Bearings Installation. 0102
7. Invert converter housing (Figure 27, Item 1) and install accessory driven gears (Figure 27, Item 2) into
bearings until snap ring groove near end of shaft is exposed and gear shoulder is bottomed on inner race of
inner bearing. Install new snap ring (Figure 27, Item 3).
Figure 27. Drive Gears Installation. 0102
0102-17
TM 5-3805-255-14 0102
8. Install new O-ring (Figure 28, Item 2) in housing bore and apply a light coat of heavy grease (WP 0021) to bore
and O-ring.
9. Install new O-ring (Figure 28, Item 1) in groove in input pump cover (Figure 28, Item 4).
NOTE
Care must be taken during pump installation to avoid cutting O-rings.
10. Install pump (Figure 28, Item 4) into bore of housing (Figure 28, Item 3). Install two capscrews (Figure 28,
Item 5) and new lockwashers. Torque capscrews to 26 to 32 lb-ft (35 to 32 Nm).
Figure 28. Pump and O-Rings Installation. 0102
0102-18
TM 5-3805-255-14 0102
11. Install gear (Figure 29, Item 1) and nut (Figure 29, Item 3) on pump shaft (Figure 29, Item 2). Tighten nut to
45 to 55 lb-ft (51 to 75 Nm).
Figure 29. Pump Drive Gear Installation. 0102
NOTE
Support bearing inner race during pressing operation.
12. Install new snap ring (Figure 30, Item 2) in its groove in output shaft (Figure 30, Item 1).
13. Install output shaft (Figure 30, Item 1) into bearing (Figure 30, Item 3).
0102-19
TM 5-3805-255-14 0102
14. Install new seal ring (Figure 31, Item 2) in groove in output shaft (Figure 31, Item 1). Coat seal ring with grease.
Figure 31. Output Shaft Installation Preparation. 0102
15. Invert housing (Figure 32, Item 1) and install output shaft (Figure 32, Item 2) in converter housing.
CAUTION
Extreme care must be exercised to prevent breaking seal ring on shaft
16. Install bearing (Figure 32, Item 3) and output shaft (Figure 32, Item 2) in housing (Figure 32, Item 1).
Figure 32. Output Shaft Installation. 0102
0102-20
TM 5-3805-255-14 0102
17. Coat outside diameter of new output shaft seal (Figure 33, Item 1) with sealant.
NOTE
Large lip of seal should face down toward large flange end of bearing retainer.
18. Install seal (Figure 33, Item 1) in retainer (Figure 33, Item 2).
Figure 33. Output Shaft Seal Installation. 0102
0102-21
TM 5-3805-255-14 0102
19. Be sure output shaft bearing (Figure 34, Item 2) is flush against ground sleeve hub (Figure 34, Item 3). Using a
depth micrometer, measure distance between machined surface of housing (Figure 34, Item 4) and top of
bearing race (Dimension A).
20. Measure height of lip on bearing retainer (Figure 34, Item 1) (Dimension B).
21. Subtract height of lip from depth of bearing (Dimension A minus Dimension B). The remainder, plus measured
thickness of retainer-to-housing gasket, equals thickness of shim pack to be used in step 23.
Figure 34. Shim Pack Thickness Determination. 0102
22. Install yoke spacer (Figure 35, Item 1) on output shaft (Figure 35, Item 2).
Figure 35. Yoke Spacer Installation. 0102
0102-22
TM 5-3805-255-14 0102
23. Install new gasket (Figure 36, Item 4) and shims (Figure 36, Item 3) in converter housing (Figure 36, Item 5).
24. Install six bolts (Figure 36, Item 1) and new lockwashers (Figure 36, Item 2) and torque bolts to 26-32 lb-ft (3 to
43 Nm).
Figure 36. Shim Pack and Bearing Retainer Installation. 0102
25. Place output yoke (Figure 37, Item 3) over splines of output shaft. Install retaining washer (Figure 37, Item 2)
and new lockplate (Figure 37, Item 4) on output shaft and secure with three bolts (Figure 37, Item 1).
26. Torque three bolts (Figure 37, Item 1) to 26 to 32 lb-ft (35 to 43 Nm). Bend up tabs of lockplate (Figure 37, Item
4) to prevent bolts from loosening.
Figure 37. Output Yoke Installation. 0102
0102-23
TM 5-3805-255-14 0102
27. Invert housing (Figure 38, Item 1) to avoid tipping.
Figure 38. Housing Positioning. 0102
28. Use snap ring pliers to install new snap ring (Figure 39, Item 2) in upper groove of output shaft (Figure 39,
Item 1) in housing (Figure 39, Item 3).
Figure 39. Output Shaft Snap Ring Installation. 0102
0102-24
TM 5-3805-255-14 0102
29. Install bearing (Figure 40, Item 1) on impeller (Figure 40, Item 2).
Figure 40. Impeller Bearing Installation. 0102
NOTE
Units may be equipped with either 5/16 or 7/16 in. capscrews. Identify size prior to
installation.
30. Install accessory drive gear (Figure 41, Item 1) in impeller (Figure 41, Item 2).
31. Install seven retaining capscrews (Figure 41, Item 3) and torque 5/16 in. capscrews to 36 to 43 lb-ft (49 to
57 Nm). Tighten 7/16 in. capscrews to 50 to 60 lb-ft (68 to 81 Nm).
Figure 41. Impeller Installation. 0102
0102-25
TM 5-3805-255-14 0102
NOTE
Press on bearing outer race only.
32. Install bearing (Figure 42, Item 2) into drive housing (Figure 42, Item 1).
Figure 42. Turbine Hub Bearing Installation. 0102
33. Install snap ring (Figure 43, Item 3) on bearing (Figure 43, Item 4).
34. Install original shim pack in position (Figure 43, Item 5) on outer race of bearing (Figure 43, Item 4).
35. Place input hub (Figure 43, Item 2) in position over shims (Figure 43, Item 5) and bearing (Figure 43, Item 4).
36. Apply pressure to top of hub and check clearance at “A” between hub and drive housing (Figure 43, Item 1)
flange surfaces.
Figure 43. Clearance Determination. 0102
0102-26
TM 5-3805-255-14 0102
37. Add or subtract impact shims (Figure 44, Item 2) until a 0.005 in. (0.127 mm) clearance is obtained.
38. Remove hub (Figure 44, Item 1) and shims (Figure 44, Item 2) from drive housing (Figure 44, Item 3). Tie shim
pack to hub and set aside.
Figure 44. Clearance Measurement. 0102
39. Invert drive housing (Figure 45, Item 2) on bench with gear teeth facing down.
40. Support outer hub bearing race. Install turbine (Figure 45, Item 1) in drive housing (Figure 45, Item 2).
Figure 45. Turbine Installation. 0102
0102-27
TM 5-3805-255-14 0102
41. Align pin (Figure 46, Item 1) in stator (Figure 46, Item 2) with pin bore (Figure 46, Item 3) in spacer (Figure 46,
Item 4).
Figure 46. Pin Alignment. 0102
NOTE
Spacer must make full contact with bottom of its bore in stator.
42. Install spacer (Figure 47, Item 2) in stator (Figure 47, Item 1).
Figure 47. Spacer Installation. 0102
0102-28
TM 5-3805-255-14 0102
43. Install stator and spacer assembly (Figure 48, Item 1) in turbine (Figure 48, Item 2) with spacer facing down.
Figure 48. Stator and Spacer Installation. 0102
44. Install impeller (Figure 49, Item 1) on drive housing (Figure 49, Item 3) with accessory gear (Figure 49, Item 2)
facing up. Install 24 bolts (Figure 49, Item 4). Torque bolts to 36 to 43 lb-ft (49 to 59 Nm).
Figure 49. Impeller Installation. 0102
0102-29
TM 5-3805-255-14 0102
CAUTION
While lowering converter assembly into housing, check the following:
– Stator and ground sleeve hub must spline together.
– Accessory drive gear must mesh with accessory driven gears and input pump
driven gear.
– Accessory drive gear must also fit over seal ring on ground sleeve hub.
– Output shaft must spline into turbine hub.
Failure to follow this caution may cause damage to equipment.
45. Invert converter assembly (Figure 50, Item 2) and, with accessory drive gear (Figure 50, Item 3) facing down,
attach a suitable lifting device to input drive hub (Figure 50, Item 1) mounting holes. Lower converter assembly
into converter housing (Figure 50, Item 4). Remove lifting device.
Figure 50. Converter Assembly Installation. 0102
0102-30
TM 5-3805-255-14 0102
46. Install retaining shim pack (Figure 51, Item 4) on end of output shaft (Figure 51, Item 5).
47. Install retaining washer (Figure 51, Item 3) with capscrews (Figure 51, Item 1) and new lock plate (Figure 51,
Item 2). Tighten capscrews hand tight.
Figure 51. Shim Pack Installation. 0102
48. Use a feeler gauge to measure clearance between lower surface of retaining washer (Figure 52, Item 1) and
drive housing bearing inner race (Figure 52, Item 2).
0102-31
TM 5-3805-255-14 0102
49. Add or subtract shims beneath retaining washer until clearance between washer and bearing is within
recommended limits of 0.000 to 0.030 in. (0.000 to 0.763 mm) (Figure 53).
Figure 53. Clearance Determination. 0102
50. When proper clearance is obtained, torque three capscrews (Figure 54, Item 1) to 26 to 32 lb-ft (35 to 43 Nm).
Bend up tabs on lockplate (Figure 54, Item 2).
Figure 54. Locking Plate Installation. 0102
0102-32
TM 5-3805-255-14 0102
51. Install input hub shim pack (Figure 55, Item 1) on outer race of drive housing bearing
Figure 55. Drive Housing Shim Pack Installation. 0102
52. Install input hub (Figure 56, Item 1), six capscrews (Figure 56, Item 2), and new lockwashers (Figure 56,
Item 3) on converter (Figure 56, Item 4). Torque capscrews to 26 to 32 lb-ft (35 to 43 Nm).
Figure 56. Input Hub Installation. 0102
0102-33
TM 5-3805-255-14 0102
53. Center new gasket (Figure 57, Item 3) on inspection cover opening (Figure 57, Item 1).
54. Install inspection cover (Figure 57, Item 2), six bolts (Figure 57, Item 5), and new lockwashers (Figure 57,
Item 4). Torque bolts to 26 to 32 lb-ft (35 to 43 Nm).
Figure 57. Inspection Cover Installation. 0102
55. Install new O-ring (Figure 58, Item 1) in groove of converter housing (Figure 58, Item 2).
Figure 58. O-Ring Installation. 0102
END OF TASK
END OF WORK PACKAGE
0102-34
46
TM 5-3805-255-14 0103
0 1 0 3 TRANSMISSION REPAIR
INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP Seal 0
0128, Item 20) 0

Seal Ring (6) 0

and Repair: Organizational Maintenance Personnel Required 0
Transmission Clutch Pack Lifting Tool (WP

References 0
0125, Item 16) 0
WP 0019 0
Materials/Parts 0
WP 0104 0
Molykote, Dry Lubricant (WP 0130, Item 18) 0


Capscrew, Ny-Lok (2) 0

Gasket (12) 0
0004) 0
Locking Plate 0
Transmission removed from vehicle (WP

Lockwasher 0
0048) 0
O-Ring (11) 0
0103-1
TM 5-3805-255-14 0103
DISASSEMBLY 000103
CAUTION
Use caution when removing parts to prevent damage.
1. Remove 10 bolts (Figure 1, Item 5), lockwashers (Figure 1, Item 4), and main regulator valve (Figure 1, Item 1)
from transmission housing (Figure 1, Item 3). Remove gasket (Figure 1, Item 2). Discard gasket.
Figure 1. Main Regulator Valve Removal. 0103
0103-2
TM 5-3805-255-14 0103
2. Bend back tabs of locking plate (Figure 2, Item 4). Remove three bolts (Figure 2, Item 5), locking plate (Figure
2, Item 4), retaining washer (Figure 2, Item 3), and yoke (Figure 2, Item 2) from input shaft (Figure 2, Item 1).
Discard locking plate.
Figure 2. Input Yoke Removal. 0103
3. Remove output locknut (Figure 3, Item 1), washer (Figure 3, Item 2) and O-ring (Figure 3, Item 4) from output
shaft (Figure 3, Item 5). Remove yoke (Figure 3, Item 3) from output shaft (Figure 3, Item 5). Discard O-ring.
Figure 3. Output Yoke Removal. 0103
0103-3
TM 5-3805-255-14 0103
4. Remove eight bolts (Figure 4, Item 3), output shaft retainer (Figure 4, Item 1), and O-ring (Figure 4, Item 2).
Discard O-ring.
Figure 4. Output Shaft Retainer Removal 0103
5. Remove 12 bolts (Figure 5, Item 1), lockwashers (Figure 5, Item 2), and two oil supply covers (Figure 5,
Items 3 and 4) from transmission housing (Figure 5, Item 7).
6. Remove and discard two cover gaskets (Figure 5, Item 6) and four O-ring seals (Figure 5, Item 5).
Figure 5. Oil Supply Covers Removal. 0103
0103-4
TM 5-3805-255-14 0103
7. Remove six bolts (Figure 6, Item 1), lockwashers (Figure 6, Item 2), shaft bearing retainer (Figure 6, Item 3),
and gasket (Figure 6, Item 5) from transmission housing (Figure 6, Item 7). Discard gasket.
8. Remove six bolts (Figure 6, Item 1), lockwashers (Figure 6, Item 2), main idler shaft bearing retainer (Figure 6,
Item 4), and gasket (Figure 6, Item 6) from transmission housing (Figure 6, Item 7). Discard gasket.
Figure 6. Bearing Covers Removal. 0103
9. Remove six bolts (Figure 7, Item 1), lockwashers (Figure 7, Item 2), directional selector valve (Figure 7,
Item 3), and gasket (Figure 7, Item 4) from neutral knock-down valve (Figure 7, Item 5). Discard gasket.
Figure 7. Directional Selector Valve Removal. 0103
0103-5
TM 5-3805-255-14 0103
10. Remove three bolts (Figure 8, Item 1), washers (Figure 8, Item 5), neutral knockdown valve (Figure 8, Item 2),
and gasket (Figure 8, Item 3) from valve mounting pad (Figure 8, Item 4). Discard gasket.
Figure 8. Neutral Knockdown Valve Removal. 0103
11. Remove eight bolts (Figure 9, Item 1), lockwashers (Figure 9, Item 5), range selector valve (Figure 9, Item 2),
and gasket (Figure 9, Item 3) from valve mounting pad (Figure 9, Item 4). Discard gasket and lockwashers.
Figure 9. Range Selector Valve Removal. 0103
0103-6
TM 5-3805-255-14 0103
WARNING
12. Attach suitable lifting device to rear cover (Figure 10, Item 3).
13. Remove 30 bolts (Figure 10, Item 1), lockwashers (Figure 10, Item 2), and rear cover (Figure 10, Item 3) from
transmission housing (Figure 10, Item 5).
14. Remove two dowels (Figure 10, Item 4) from transmission housing (Figure 10, Item 5).
15. Remove gasket (Figure 10, Item 6) from transmission housing (Figure 10, Item 5). Discard gasket.
16. Remove lifting device.
Figure 10. Rear Cover Removal. 0103
0103-7
TM 5-3805-255-14 0103
17. Remove two oil transfer tubes (Figure 11, Item 1) from transmission housing (Figure 11, Item 3). Remove and
discard two O-rings (Figure 11, Item 2) from both ends of tubes. Discard four O-rings.
Figure 11. Oil Transfer Tubes Removal 0103
0103-8
TM 5-3805-255-14 0103
WARNING
medical attention.
18. Install clutch pack lifting tool to forward-reverse clutch pack (Figure 12, Item 2) in oil supply groove. Using a
suitable lifting device, lift clutch pack and reverse idler shaft assembly (Figure 12, Item 1) from transmission
housing (Figure 12, Item 3). For clutch pack overhaul procedure refer to (WP 0104). Remove lifting device.
Figure 12. Clutch Pack and Reverse Idler Shaft Removal. 0103
19. Remove low speed gather gear (Figure 13, Item 2) to remove shaft assembly (Figure 13, Item 1) from trans-
mission housing (Figure 13, Item 3).
Figure 13. Gather Shaft Assembly Removal. 0103
0103-9
TM 5-3805-255-14 0103
20. Attach special lifting tool to 2nd and 4th clutch pack (Figure 14, Item 1) oil supply groove and use suitable lifting
device to remove clutch pack (Figure 14, Item 1) from transmission housing (Figure 14, Item 2). For clutch
pack overhaul procedure refer to WP 0104.
Figure 14. 2nd and 4th Clutch Pack Removal. 0103
21. Attach clutch pack lifting tool to 1st and 3rd clutch pack (Figure 15, Item 1) in oil supply groove and use suitable
lifting device to remove clutch pack from transmission housing (Figure 15, Item 2). For clutch pack overhaul
procedure refer to WP 0104.
Figure 15. 1st and 3rd Clutch Pack Removal. 0103
0103-10
TM 5-3805-255-14 0103
22. Remove main idler shaft (Figure 16, Item 1) from transmission housing (Figure 16, Item 2).
Figure 16. Main Idler Shaft Removal. 0103
23. Remove two bolts (Figure 17, Item 3) and oil baffle (Figure 17, Item 1) from transmission housing (Figure 17,
Item 2).
Figure 17. Oil Baffle Removal. 0103
0103-11
TM 5-3805-255-14 0103
24. Secure transmission housing (Figure 18, Item 5) in a vertical position. Remove stop nut (Figure 18, Item 4),
retainer (Figure 18, Item 3), gasket (Figure 18, Item 1) and yoke (Figure 18, Item 2) from transmission housing
Figure 18. Yoke Removal. 0103
25. Remove six bolts (Figure 19, Item 1) from bearing retainer (Figure 19, Item 3) and housing (Figure 19, Item 2).
Remove retainer (Figure 19, Item 3) and shim pack (Figure 19, Item 4) from transmission housing (Figure 19,
Item 2). Tag and retain shim pack for ease of assembly.
26. Remove output shaft (Figure 19, Item 5) from housing (Figure 19, Item 2).
Figure 19. Bearing Retainer and Output Shaft Removal. 0103
0103-12
TM 5-3805-255-14 0103
27. Remove four bolts (Figure 20, Item 5), washers (Figure 20, Item 2), filter assembly (Figure 20, Item 3), and
gasket (Figure 20, Item 4) from transmission housing (Figure 20, Item 1). Discard gasket.
Figure 20. Filter Assembly Removal 0103
28. Rotate transmission (Figure 21, Item 4) until front cover (Figure 21, Item 1) is facing up.
29. Remove 20 bolts (Figure 21, Item 2), front cover (Figure 21, Item 1), dowels (Figure 21, Item 3), and gaskets
(Figure 21, Item 5). Discard gaskets.
Figure 21. Front Cover Removal. 0103
0103-13
TM 5-3805-255-14 0103
NOTE
• Only remove cover bearings and spacers if worn or damaged or cover is being replaced.
• If cover is to be replaced and bearings reused, tag and identify bearing and spacer sets.
Tie bearing and spacers together. Reused bearings must be matched with their original
shafts during assembly.
30. Remove six bearings (Figure 22, Item 1) and spacers (Figure 22, Item 2) from front cover (Figure 22, Item 3).
31. Remove input shaft seal (Figure 22, Item 4) from front cover (Figure 22, Item 3) bore. Discard seal.
Figure 22. Front Cover Bearings Removal. 0103
0103-14
TM 5-3805-255-14 0103
32. Remove bearing inner race (Figure 23, Item 1), from reverse idler shaft (Figure 23, Item 5).
33. Remove retaining rings (Figure 23, Items 2 and 8) and driven gear (Figure 23, Item 3) from reverse idler shaft
34. Remove drive gear (Figure 23, Item 7) and bearing inner race (Figure 23, Item 9) together from reverse idler
35. Remove retaining rings (Figure 23, Items 4 and 6) from reverse idler shaft (Figure 23, Item 5).
Figure 23. Reverse Idler Shaft Disassembly. 0103
36. Remove bearing inner race (Figure 24, Item 1), spacer (Figure 24, Item 2), and gear (Figure 24, Item 3) as a
unit from gather shaft (Figure 24, Item 5).
37. Remove spacer (Figure 24, Item 4) and retaining ring (Figure 24, Item 8) from gather shaft (Figure 24, Item 5).
38. Remove gear (Figure 24, Item 7) and inner bearing race (Figure 24, Item 9) together from gather shaft (Figure
24, Item 5).
39. Remove retaining ring (Figure 24, Item 6) from gather shaft (Figure 24, Item 5).
Figure 24. Gather Shaft Disassembly. 0103
0103-15
TM 5-3805-255-14 0103
40. Remove main idler gear (Figure 25, Item 3) and bearing inner race (Figure 25, Item 4) from main idler shaft
41. Remove spacer (Figure 25, Item 5) and bearing (Figure 25, Item 1) from shaft (Figure 25, Item 2).
Figure 25. Main Idler Shaft Disassembly. 0103
42. Remove bearings (Figure 26, Items 1 and 3) from output shaft (Figure 26, Item 2).
43. Remove snap ring (Figure 26, Item 5) and gear (Figure 26, Item 4) from output shaft (Figure 26, Item 2).
Figure 26. Output Shaft Bearing Removal. 0103
0103-16
TM 5-3805-255-14 0103
NOTE
Prior to removal, mark location of oil supply cover in rear cover for ease of assembly.
44. Remove supply cover (Figure 27, Item 2) from rear cover. (Figure 27, Item 1).
Figure 27. Oil Supply Cover Removal. 0103
45. Remove three seal rings (Figure 28, Items 1, 3, and 4) from oil supply cover (Figure 28, Item 2) removed in
step 45. Discard seal rings.
0103-17
TM 5-3805-255-14 0103
46. Remove O-ring (Figure 29, Item 1) from inlet port of outside oil supply cover (Figure 29, Item 2). Discard
O-ring.
47. Remove three seal rings (Figure 29, Items 3, 4, and 5) from outside oil supply cover (Figure 29, Item 2). Dis-
card seal rings.
Figure 29. O-Ring Removal. 0103
0103-18
TM 5-3805-255-14 0103
NOTE
• Only remove cover bearings and spacers if worn or damaged or cover is being replaced.
• If cover is to be replaced and bearings reused, tag and identify bearing and spacer sets.
Tie bearing and spacers together. Reused bearings must be matched with their original
shafts during assembly.
48. Remove bearings (Figure 30, Item 2) from rear cover (Figure 30, Item 1).
Figure 30. Rear Cover Bearings Removal. 0103
0103-19
TM 5-3805-255-14 0103
49. Remove four bolts (Figure 31, Item 1), lockwashers (Figure 31, Item 2), flange (Figure 31, Item 3), gasket
(Figure 31, Item 4), check valve (Figure 31, Item 5), and gasket (Figure 31, Item 6) from filter retainer (Figure
31, Item 8). Discard gaskets.
50. Remove four bolts (Figure 31, Item 7), filter retainer (Figure 31, Item 8), filter (Figure 31, Item 9) and gasket
retainer (Figure 31, Item 10) from transmission cover.
Figure 31. Filter Housing Removal. 0103
51. Remove output shaft front seal (Figure 32, Item 2) from bearing retainer (Figure 32, Item 1). Discard output
shaft front seal.
Figure 32. Output Shaft Front Seal Removal. 0103
0103-20
TM 5-3805-255-14 0103
52. Remove output shaft rear seal (Figure 33, Item 2) from bearing retainer (Figure 33, Item 1).
Figure 33. Output Shaft Rear Seal. 0103
END OF TASK
Clean and inspect transmission components IAW General Maintenance Instructions (WP 0019). In preparation for
assembly be sure to include following:
1. Clean all parts thoroughly in solvent or steam. Use compressed air to dry parts. If steam is used to clean parts,
oil immediately thereafter. Carefully inspect all parts for excessive wear, cracks, and breakage.
NOTE
If replacement is required, bearing cup and cone must be replaced as a set.
2. Inspect all bearings for pits and spalled areas and replace if necessary.
3. Replace all seals, hook type seal rings, gaskets, O-rings, and snap rings.
4. Inspect all sealing surfaces for wear and for grooving.
5. Inspect housing for dirt particles, and flush all passageways thoroughly.
6. Inspect splines on all shafts and drive gears for wear.
7. Provisions should be made for heating bearings in oil or an oven.
8. Clean and flush oil supply tubes.
END OF TASK
0103-21
TM 5-3805-255-14 0103
ASSEMBLY 000103
1. Coat outside diameter of a new output shaft seal (Figure 34, Item 2) with sealant. Install seal into output shaft
front bearing retainer (Figure 34, Item 1).
Figure 34. Output Shaft Front Seal Installation. 0103
2. Coat outside diameter of new output shaft seal (Figure 35, Item 2) with sealant and install seal into output shaft
rear bearing retainer (Figure 35, Item 1).
Figure 35. Output Shaft Rear Seal Installation. 0103
0103-22
TM 5-3805-255-14 0103
3. Install gasket retainer (Figure 36, Item 10), filter (Figure 36, Item 9), filter retainer (Figure 36, Item 8), and four
bolts (Figure 36, Item 7) on transmission cover.
NOTE
Check valve should allow fluid flow in only one direction. Install new check valve if fluid
flows in both directions.
4. Install new gasket (Figure 36, Item 6), check valve (Figure 36, Item 5), new gasket (Figure 36, Item 4), flange
(Figure 36, Item 3), four new lockwashers (Figure 36, Item 2), and bolts (Figure 36, Item 1) on transmission
cover.
Figure 36. Filter Assembly. 0103
0103-23
TM 5-3805-255-14 0103
5. Install bearings (Figure 37, Item 2) in rear transmission cover (Figure 37, Item 1).
Figure 37. Rear Cover Bearings Installation. 0103
0103-24
TM 5-3805-255-14 0103
6. Install three new seal rings (Figure 38, Items 3, 4, and 5) and new O-ring (Figure 38, Item 1) on outside oil
supply cover (Figure 38, Item 2), starting from rear of cover as follows:
a. Lip facing rearward (Figure 38, Item 3).
b. Lip facing forward (Figure 38, Item 4).
c. Lip facing rearward (Figure 38, Item 5).
Figure 38. O-Rings Installation. 0103
0103-25
TM 5-3805-255-14 0103
7. Install three new seal rings (Figure 39, Item 1) in inlet ports of inner oil supply cover (Figure 39, Item 2). Retain
seal rings in position with a small amount of grease.
8. Coat lips of three seal rings (Figure 39, Items 1, 3, and 4) with grease. Install three seal rings in inner oil supply
cover (Figure 39, Item 2) starting from rear of cover as follows:
a. Lip facing rearward (Figure 39, Item 1).
b. Lip facing forward (Figure 39, Item 3).
c. Lip facing rearward (Figure 39, Item 4).
Figure 39. Seal Rings Installation. 0103
0103-26
TM 5-3805-255-14 0103
9. Align identification marks (Figure 40, Item 3) on oil supply cover (Figure 40, Item 2) with front cover (Figure 40,
Item 1). Install oil supply cover in base of front cover.
Figure 40. Oil Supply Cover Installation. 0103
NOTE
• Coat shaft with Molykote or equivalent lubricant prior to installation of gear and bearing.
• It may be necessary to heat bearing prior to installation.
10. Install gear (Figure 41, Item 4), snap ring (Figure 41, Item 5), and bearings (Figure 41, Items 1 and 3) on shaft
Figure 41. Output Shaft Assembly. 0103
0103-27
TM 5-3805-255-14 0103
CAUTION
Shaft must be assembled into chamfered side of gear. Incorrect installation will result in
gear and shaft failure.
11. Install spacer (Figure 42, Item 4) and main idler gear (Figure 42, Item 3) on idler shaft (Figure 42, Item 2).
12. Install bearing (Figure 42, Item 1) on shaft (Figure 42, Item 2).
13. Install bearing inner race (Figure 42, Item 5) with shoulder toward gear.
Figure 42. Main Idler Gear Installation. 0103
14. Install spacer (Figure 43, Item 4), transmission output high gear (Figure 43, Item 3), spacer (Figure 43, Item 2)
and bearing inner race (Figure 43, Item 1) on gather shaft (Figure 43, Item 5).
Figure 43. Gather Shaft Assembly. 0103
0103-28
TM 5-3805-255-14 0103
15. Install snap rings (Figure 44, Items 4 and 6) on reverse idler shaft (Figure 44, Item 5).
16. Install reverse transfer driven gear (Figure 44, Item 3), snap ring (Figure 44, Item 2), and smaller diameter
bearing inner race (Figure 44, Item 1) with shoulder toward gear.
17. Install reverse transfer drive gear (Figure 44, Item 7), snap ring (Figure 44, Item 8), and larger diameter
bearing inner race (Figure 44, Item 9) with shoulder toward gear.
Figure 44. Reverse Idler Shaft Assembly. 0103
0103-29
TM 5-3805-255-14 0103
18. Install spacers (Figure 45, Item 2) and bearings (Figure 45, Item 1) in front cover (Figure 45, Item 3).
19. Coat outside diameter of new input shaft seal (Figure 45, Item 4) with sealant. Install seal in front cover (Figure
45, Item 3).
Figure 45. Cover Bearings and Spacers Installation. 0103
20. Install new gasket (Figure 46, Item 5) on transmission housing (Figure 46, Item 4). Install transmission cover
(Figure 46, Item 1) and 20 bolts (Figure 46, Item 2). Be sure cover is positioned on dowels (Figure 46, Item 3).
Figure 46. Front Cover Installation. 0103
0103-30
TM 5-3805-255-14 0103
21. Rotate transmission until output shaft bore (Figure 47, Item 3) is facing down.
22. Install oil baffle (Figure 47, Item 1), and three bolts (Figure 47, Item 2). Torque bolts to 33 to 37 lb-ft (30 to
50 Nm).
Figure 47. Oil Baffle Installation. 0103
23. Install output shaft rear retainer (Figure 48, Item 1) and two bolts (Figure 48, Item 2), 180° apart, on
transmission housing (Figure 48, Item 3). Tighten bolts just enough to hold retainer in place.
Figure 48. Output Shaft Retainer Installation. 0103
0103-31
TM 5-3805-255-14 0103
NOTE
Prior to installation in transmission, lubricate all shaft bearing surfaces and bearings with
oil soluble grease.
24. Install assembled output shaft (Figure 49, Item 1) in its bore in transmission housing (Figure 49, Item 2).
Figure 49. Output Shaft Installation. 0103
25. Position transmission (Figure 50, Item 2) horizontally. Install main idler shaft and gear assembly (Figure 50,
Item 1) on transmission housing.
Figure 50. Main Idler Shaft and Gear Installation. 0103
0103-32
TM 5-3805-255-14 0103
NOTE
Prior to installation in transmission, lubricate all shaft bearing surfaces.
26. Attach special lifting tool in oil supply groove of 1st and 3rd clutch pack (Figure 51, Item 1) (pack with large
input gear) and install assembly in transmission housing (Figure 51, Item 2). Remove lifting tool.
Figure 51. 1st and 3rd Clutch Pack Installation. 0103
NOTE
Do not attempt to lift any of clutch packs by oil supply ports.
27. Attach special lifting tool to oil supply groove in 2nd and 4th clutch pack (Figure 52, Item 1) and install
assembly in transmission housing (Figure 52, Item 2). Remove lifting tool.
Figure 52. 2nd and 4th Clutch Pack Installation. 0103
0103-33
TM 5-3805-255-14 0103
28. Install gear (Figure 53, Item 1) and shaft (Figure 53, Item 2) on transmission housing (Figure 53, Item 3).
Figure 53. Gather Shaft Assembly Installation. 0103
29. Attach lifting tool to directional clutch pack (Figure 54, Item 3) and lower clutch pack into transmission housing
(Figure 54, Item 1) while installing reverse idler shaft assembly (Figure 54, Item 2). Larger gear (Figure 54,
Item 4) on reverse idler shaft is in up position. Remove lifting tool.
Figure 54. Directional Clutch Pack Installation. 0103
0103-34
TM 5-3805-255-14 0103
30. Install two new O-rings (Figure 55, Item 2) on each oil transfer tube (Figure 55, Item 1). Lubricate O-rings and
install transfer tubes in transmission housing (Figure 55, Item 3). Be sure tubes are bottomed in their
respective bores.
Figure 55. Oil Transfer Tubes Installation. 0103
0103-35
TM 5-3805-255-14 0103
NOTE
Before installing cover check the following:
– Be sure directional oil supply seal rings have been properly installed and are
coated with grease.
– Be sure all gears are properly meshed.
– Be sure all bearings are properly seated.
– Transmission housing must be free of all foreign material, tools, etc.
– Be sure O-rings on oil transfer tubes are well greased.
0103-36
TM 5-3805-255-14 0103
31. Install two dowels (Figure 56, Item 4) on transmission housing (Figure 56, Item 5).
32. Install new gasket (Figure 56, Item 6) on transmission housing (Figure 56, Item 5).
33. Install suitable lifting device on rear cover (Figure 56, Item 3).
WARNING
34. Install rear cover (Figure 56, Item 3), 30 new lockwashers (Figure 56, Item 2), and bolts (Figure 56, Item 1) on
transmission housing (Figure 56, Item 5).
Figure 56. Rear Cover Installation. 0103
0103-37
TM 5-3805-255-14 0103
35. Install new gasket (Figure 57, Item 3), range selector valve (Figure 57, Item 2), eight new lockwashers (Figure
57, Item 5), and bolts (Figure 57, Item 1) on valve mounting pad (Figure 57, Item 4). Torque bolts to 19 to
21 lb-ft (26 to 29 Nm).
Figure 57. Range Selector Valve Installation. 0103
NOTE
• Be sure directional oil supply cover is in correct alignment.
• Do not tighten bolts until directional selector valve has been installed.
36. Install new gasket (Figure 58, Item 3), neutral knockdown valve (Figure 58, Item 2), three washers (Figure 58,
Item 5), and bolts (Figure 58, Item 1) on valve mounting pad (Figure 58, Item 4).
Figure 58. Neutral Knockdown Valve Installation. 0103
0103-38
TM 5-3805-255-14 0103
37. Install new gasket (Figure 59, Item 4), directional selector valve (Figure 59, Item 3), six new lockwashers
(Figure 59, Item 2), and bolts (Figure 59, Item 1) on neutral knockdown (Figure 59, Item 5).
38. Torque all bolts (knockdown and selector valve bolts) to 33 to 37 lb-ft (30 to 50 Nm).
Figure 59. Directional Selector Valve Installation. 0103
39. Install new gasket (Figure 60, Item 6), main idler shaft bearing retainer (Figure 60, Item 4), six new
lockwashers (Figure 60, Item 2) and bolts (Figure 60, Item 1) on transmission housing (Figure 60, Item 7).
Torque bolts to 33 to 37 lb-ft (30 to 50 Nm).
40. Install new gasket (Figure 60, Item 5), shaft bearing retainer (Figure 60, Item 3), six new lockwashers (Figure
60, Item 2), and bolts (Figure 60, Item 1) on transmission housing (Figure 60, Item 1). Torque bolts to 33 to
37 lb-ft (30 to 5 Nm).
Figure 60. Shaft Covers Installation. 0103
0103-39
TM 5-3805-255-14 0103
41. Install four new O-rings (Figure 61, Item 5) on two range clutch oil supply covers (Figure 61, Items 3 and 4).
42. Install oil supply covers (Figure 61, Items 3 and 4), 12 new lockwashers (Figure 61, Item 2), and 12 bolts
(Figure 61, Item 1) on transmission housing (Figure 61, Item 7). Torque bolts to 33 to 37 lb-ft (45 to 50 Nm).
Figure 61. Oil Supply Covers Installation. 0103
43. Install new O-ring (Figure 62, Item 2) on output shaft front retainer (Figure 62, Item 1).
44. Install output shaft front retainer (Figure 62, Item 1), eight new lockwashers (Figure 62, Item 4), and bolts
(Figure 62, Item 3) on transmission cover (Figure 62, Item 5). Torque bolts to 33 to 37 lb-ft (40 to 50 Nm).
Figure 62. Output Shaft Front Retainer Installation. 0103
0103-40
TM 5-3805-255-14 0103
45. Secure transmission housing (Figure 63, Item 1) in vertical position. Grasp end of output shaft (Figure 63,
Item 2) where it protrudes from loose retainer (Figure 63, Item 4), “roll” shaft into opposite (tightened) retainer.
Exert a heavy pressure (thrust) in this direction. This “rolling in” procedure is designed to seat bearing (Figure
63, Item 5) squarely and firmly in its retainer.
46. Loosen two bolts (Figure 63, Item 3) installed previously in output shaft retainer (Figure 63, Item 4). Torque
bolts to preliminary torque of 25 to 30 lb-in. (0.18 to 0.21 Nm).
NOTE
Continue to “roll” output shaft while torquing bolts.
47. Rotate output shaft (Figure 63, Item 2) several times. Torque two bolts (Figure 63, Item 3) to secondary torque
of 50 lb-in. (0.35 Nm).
Figure 63. Output Shaft Bearing Seat Procedure. 0103
0103-41
TM 5-3805-255-14 0103
48. Rotate output shaft (Figure 64, Item 2) several times to seat bearings (Figure 64, Item 6).
49. Use a feeler gauge to measure gap between transmission housing (Figure 64, Item 1) and retainer (Figure 64,
Item 5) at each bolt (Figure 64, Item 3). If two readings are not identical, add two readings and divide by two.
50. Add 0.025 in. (0.63 mm) to reading obtained in previous step. Make up a shim pack equal to resulting
thickness. Install shim pack between end cap (Figure 64, Item 4) and transmission housing (Figure 64, Item 1).
51. Install end cap (Figure 64, Item 5), six new lockwashers (Figure 64, Item 4), and six bolts (Figure 64, Item 3).
Torque six bolts in an alternating pattern to final torque of 33 to 37 lb-ft (40 to 50 Nm).
52. Install a dial indicator on transmission (Figure 65, Item 1) as shown. Position tip of dial indicator on end of
output shaft (Figure 65, Item 2). Place a jack under opposite end of output shaft (do not contact shaft). Use a
pry bar to exert pressure on end of shaft and measure reading on dial indicator. This distance should be within
recommended tolerance of 0.005 to 0.009 in. (0.127 to 0.228 mm). If reading is not within recommended
limitations, shim pack thickness should be corrected. Remove dial indicator.
Figure 65. Output Shaft End-Play Measurement. 0103
0103-42
TM 5-3805-255-14 0103
53. Install rear output yoke (Figure 66, Item 3), new gasket (Figure 66, Item 1), washer (Figure 66, Item 2), and
new nut (Figure 66, Item 4) on transmission (Figure 66, Item 5). Torque nut to 200 lb-ft (271 Nm).
Figure 66. Rear Output Yoke Installation. 0103
54. Install front output yoke (Figure 67, Item 3), new O-ring (Figure 67, Item 4), washer (Figure 67, Item 2), and
new locknut (Figure 67, Item 1) on output shaft (Figure 67, Item 5). Torque locknut to 200 lb-ft (271 Nm).
Figure 67. Front Output Yoke Installation. 0103
0103-43
TM 5-3805-255-14 0103
55. Place transmission (Figure 68, Item 6) upright. Lubricate yoke sealing surface (Figure 68, Item 2) and lip of
gasket (Figure 68, Item 7) with grease (WP 0021).
56. Align splines of shaft and yoke and install yoke (Figure 68, Item 2) on input shaft (Figure 68, Item 1). Install
retaining washer (Figure 68, Item 3), new locking plate (Figure 68, Item 4), and three bolts (Figure 68, Item 5).
Torque bolts to 33 to 37 lb-ft (40 to 50 Nm). Lock bolts by bending up tabs on locking plate.
Figure 68. Input Yoke Installation. 0103
0103-44
TM 5-3805-255-14 0103
57. Install new gasket (Figure 69, Item 2), main regulator valve (Figure 69, Item 1), 10 new lockwashers (Figure
69, Item 4), and bolts (Figure 69, Item 5) on transmission (Figure 69, Item 3). Torque bolts to 33 to 37 lb-ft (40
to 50 Nm).
Figure 69. Main Regulator Valve Installation. 0103
58. Install transmission (WP 0048).
END OF TASK
END OF WORK PACKAGE
0103-45/(46 blank)
24
TM 5-3805-255-14 0104
0 1 0 4 CLUTCH PACK ASSEMBLY REPAIR

INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP Seal Ring, Rectangular (2) 0
0128, Item 20) 0

Snap Ring (12) 0

Common #1 (WP 0128, Item 14) 0 WP 0019 0
Snap Ring Groove Filler Tool (WP 0125,

Item 3) 0
Materials/Parts 0
0130, Item 15) 0

0004) 0
O-Ring 0
Transmission removed (WP 0048) 0
Retaining Ring (2) 0

Clutch Packs removed from transmission (WP
Seal Ring, Hook-Type (10) 0 0103) 0
NOTE
Range and directional clutch packs are serviced in the same manner. Differences
between the two assemblies will be noted.
0104-1
TM 5-3805-255-14 0104
DISASSEMBLY 000104
Directional Clutches 000104
1. Remove snap ring (Figure 1, Item 1) and bearing inner race (Figure 1, Item 2) from clutch shaft (Figure 1,
Item 3). Discard snap ring.
CAUTION
Do not push directly on plug on end of shaft. Failure to follow this caution may cause
2. Remove bearing race (Figure 1, Item 4) from opposite clutch shaft (Figure 1, Item 3).
Figure 1. Directional Clutch Bearing Race Removal. 0104
Range Clutches 000104
1. Remove snap ring (Figure 2, Item 1) and bearing inner race (Figure 2, Item 2) from clutch shaft (Figure 2,
Item 5). Discard snap ring.
2. Remove snap ring (Figure 2, Item 3) and inner race (Figure 2, Item 4) from clutch shaft (Figure 2, Item 5).
Discard snap ring.
Figure 2. Range Clutch Bearing Race Removal. 0104
0104-2
TM 5-3805-255-14 0104
Directional and Range Clutches 000104
1. Remove spacer (Figure 3, Item 4), spacer (Figure 3, Item 3), thrust washer (Figure 3, Item 2), and spacer
(Figure 3, Item 1) from clutch shaft (Figure 3, Item 5).
Figure 3. Spacers and Thrust Washer Removal. 0104
CAUTION
Do not attempt to separate drive gear and cup. Failure to follow this caution may cause
2. Remove two gears (Figure 4, Item 4), bearings (Figure 4, Items 2 and 3) and spacers (Figure 4, Item 5) from
clutch shaft (Figure 4, Item 1).
Figure 4. Gear and Bearing Removal. 0104
0104-3
TM 5-3805-255-14 0104
3. Remove spacer (Figure 5, Item 1), thrust washer (Figure 5, Item 2), and spacer (Figure 5, Item 3) from clutch
Figure 5. Spacers and Thrust Washer Removal. 0104
4. Remove two capscrews (Figure 6, Item 2), clutch hub retainers (Figure 6, Item 3), and hub and plate assembly
(Figure 6, Item 4) from clutch shaft (Figure 6, Item 1).
Figure 6. Clutch Hub and Plate Removal. 0104
0104-4
TM 5-3805-255-14 0104
5. Remove retaining ring (Figure 7, Item 1) from hub and plate assembly (Figure 7, Item 2). Discard retaining ring.
Figure 7. Retaining Ring Removal. 0104
6. Remove snap ring (Figure 8, Item 1) from hub and plate assembly (Figure 8, Item 2). Discard snap ring.
Figure 8. Hub and Plate Snap Ring Removal. 0104
0104-5
TM 5-3805-255-14 0104
7. Remove backing plate (Figure 9, Item 1) and dowel pin (Figure 9, Item 2) from hub and plate assembly
(Figure 9, Item 3).
Figure 9. Backing Plate and Dowel Pin Removal. 0104
8. Remove 11 bronze clutch plates (Figure 10, Item 1) and 10 steel clutch plates (Figure 10, Item 2) from clutch
hub assembly (Figure 10, Item 3).
Figure 10. Clutch Plate Removal. 0104
0104-6
TM 5-3805-255-14 0104
9. Remove clutch piston (Figure 11, Item 1) and snap ring (Figure 11, Item 2) from piston housing (Figure 11, Item
3). Discard snap ring.
Figure 11. Snap Ring Removal. 0104
10. Construct a snap ring groove filler tool (WP 0125).

11. Install snap ring groove filler tool (Figure 12, Item 2) with bevel edge down in piston housing (Figure 12, Item 1)
snap ring groove.
Figure 12. Special Tool Insertion. 0104
0104-7
TM 5-3805-255-14 0104
12. Remove clutch piston (Figure 13, Item 1) and rectangular seal ring (Figure 13, Item 2) from piston housing
(Figure 13, Item 4). Discard rectangular seal ring.
13. Remove snap ring groove filler tool (Figure 13, Item 3) from piston housing (Figure 13, Item 4).
Figure 13. Piston Removal. 0104
14. Remove piston housing (Figure 14, Item 1) and O-ring (Figure 14, Item 2) from shaft (Figure 14, Item 3).
Discard O-ring.
Figure 14. Piston Housing and O-Ring Removal. 0104
0104-8
TM 5-3805-255-14 0104
15. Remove hook-type seal rings (Figure 15, Item 1) from clutch shaft assembly (Figure 15, Item 2). Discard seal
rings.
16. Remove accelerating piston retaining snap rings (Figure 16, Item 3). Remove accelerating pistons (Figure 16,
Item 1). Remove hook-type seal rings (Figure 16, Item 2) from pistons. Discard snap rings and hook-type seal
rings.
Figure 16. Accelerating Piston Removal. 0104
0104-9
TM 5-3805-255-14 0104
17. Remove disc valve (Figure 17, Item 1), reinforcing disc (Figure 17, Item 2), hook-type seal ring (Figure 17,
Item 3), and two dowel pins (Figure 17, Item 4) from clutch shaft (Figure 17, Item 5). Discard seal ring.
Figure 17. Clutch Shaft Disassembly. 0104
NOTE
Shaft is serviced as an assembly only. If snap rings, shaft, or separator plate are
damaged, entire assembly must be replaced.
Figure 18. Clutch Shaft Identification. 0104
END OF TASK
0104-10
TM 5-3805-255-14 0104
1. Clean and inspect all parts of clutch assembly IAW General Maintenance Instructions (WP 0019).
2. Inspect splines on all shafts and drive gears for excessive wear or damage. Replace as necessary.
3. Inspect sintered bronze and steel discs for wear, signs of burning, and/or warping. Replace as necessary.
END OF TASK
ASSEMBLY 000104
1. Place shaft (Figure 19, Item 5) horizontally on bench. Install new hook-type seal rings (Figure 19, Items 2
and 3) on grooves of inner shaft.
NOTE
Perform step 2 only if assembling directional clutch.
2. Be sure roll pins (Figure 19, Items 1 and 4) are in place and bores are clean.
Figure 19. Clutch Shaft Assembly. 0104
3. Install two dowel pins (Figure 20, Item 4) in separator plate (Figure 20, Item 3). Install a reinforcing disc
(Figure 20, Item 2) on each side of separator plate.
4. Install a disc valve (Figure 20, Item 1) on each side of separator plate (Figure 20, Item 3). Align reinforcing
discs (Figure 20, Item 2) and disc valves with two dowel pins (Figure 20, Item 4).
Figure 20. Reinforcing Discs and Disc Valves Installation. 0104
0104-11
TM 5-3805-255-14 0104
5. Install a new hook-type seal ring (Figure 21, Item 1) on each accelerating piston (Figure 21, Item 2).
NOTE
Lubricate seal rings and inner bore of accelerating pistons with transmission fluid before
assembling.
6. Install two pistons (Figure 21, Item 2) on shaft (Figure 21, Item 3).
Figure 21. Accelerating Pistons Installation. 0104
7. Install two new snap rings (Figure 22, Items 2 and 3) that retain accelerating pistons (Figure 22, Item 1).
Figure 22. Accelerating Pistons Snap Ring Installation. 0104
0104-12
TM 5-3805-255-14 0104
8. Place shaft (Figure 23, Item 1) in vertical position with reverse oil supply plug facing down. Install new hook-
type seal ring (Figure 23, Item 2) in groove on shaft.
Figure 23. Shaft Seal Ring Installation. 0104
9. Install new rectangular seal ring (Figure 24, Item 1) on clutch piston outer diameter (Figure 24, Item 3). Coat
seal ring on shaft and accelerating piston and inner bore of clutch piston with grease or clean transmission
fluid.
10. Install clutch piston (Figure 24, Item 3) on shaft assembly (Figure 24, Item 2). Be careful not to damage hook-
type seal rings (Figure 24, Item 4).
Figure 24. Clutch Piston Installation. 0104
0104-13
TM 5-3805-255-14 0104
11. Invert shaft (Figure 25, Item 2). Install new hook-type seal ring (Figure 25, Item 3) in groove on shaft.
12. Install new O-ring (Figure 25, Item 1) on outer diameter of separator plate (Figure 25, Item 4). Coat seals with
grease. Coat rectangular seal (Figure 25, Item 5) on clutch piston (Figure 25, Item 4) with grease.
Figure 25. Seal Lubrication. 0104
13. Install special snap ring groove filler tool (Figure 26, Item 2), bevel edge up, in groove of piston housing
(Figure 26, Item 1). Lubricate groove area and mouth of piston housing with heavy grease.
14. Install piston housing (Figure 26, Item 1) on shaft assembly (Figure 26, Item 3).
NOTE
O-ring is larger in diameter than separator plate. This design allows inside diameter of
piston housing to compress O-ring to proper fit.
15. Install new O-ring seal (Figure 26, Item 4) into housing while applying pressure to piston housing (Figure 26,
Item 1). Push piston housing over O-ring seal and groove filler tool (Figure 26, Item 2).
Figure 26. Piston and O-Ring Installation. 0104
0104-14
TM 5-3805-255-14 0104
16. Invert shaft assembly. Depress clutch piston (Figure 27, Item 1) into piston housing (Figure 27, Item 3).
Remove snap ring groove filler tool. Install new snap ring (Figure 27, Item 2).
NOTE
DO NOT exceed 100 psi (689 kPa) air pressure.
17. Apply regulated shop air pressure (maximum 100 psi) to oil port holes (Figure 28, Item 1) to check operation of
clutches. Clutch piston (Figure 28, Item 2) and piston housing assembly (Figure 28, Item 3) should move
freely.
Figure 28. Air Check. 0104
0104-15
TM 5-3805-255-14 0104
NOTE
Steps 18 through 22 apply to both sides of clutch pack
18. Install hub assembly (Figure 29, Item 4), two hub retainers (Figure 29, Item 3), and capscrews (Figure 29,
Item 1) on clutch shaft (Figure 29, Item 2). Torque capscrews to 33 to 37 lb-ft (40 to 50 Nm).
Figure 29. Hub and Hub Retainer Installation. 0104
19. Install spacer (Figure 30, Item 5) and two locking retainer bolts (Figure 30, Item 4) on clutch shaft (Figure 30,
Item 1).
20. Coat bronze thrust washer (Figure 30, Item 3) with grease and install bronze thrust washer and thin spacer
washer (Figure 30, Item 2) on shaft (Figure 30, Item 1).
Figure 30. Shaft Assembly. 0104
0104-16
TM 5-3805-255-14 0104
21. Install 11 bronze clutch plates (Figure 31, Item 4) and 10 steel clutch plates (Figure 31, Item 1) alternately,
starting with a bronze plate, on clutch shaft (Figure 31, Item 2).
22. With all plates (Figure 31, Items 1 and 4) installed, position backing plate (Figure 31, Item 3) on clutch shaft
(Figure 31, Item 2) and install dowel pin (Figure 31, Item 5) on backing plate.
Figure 31. Clutch Plates Installation. 0104
23. Install new external snap ring (Figure 32, Item 1) in hub recess (Figure 32, Item 2).
Figure 32. External Snap Ring Installation. 0104
0104-17
TM 5-3805-255-14 0104
24. Install new retaining ring (Figure 33, Item 1) in backing plate (Figure 33, Item 3). This locks in external snap
ring (Figure 33, Item 2).
Figure 33. Retaining Ring Installation. 0104
NOTE
Heat bearing inner race to 250°F (121°C) prior to installation.
Directional Clutch 000104
1. Install spacer (Figure 34, Item 3), roller bearing (Figure 34, Item 2), and spacer (Figure 34, Item 1) on splined
end of clutch shaft (Figure 34, Item 4). Cover rollers with a coat of heavy grease.
Figure 34. Roller Bearing and Spacers Installation. 0104
0104-18
TM 5-3805-255-14 0104
2. Install drive gear and cup assembly (Figure 35, Item 5) (small diameter, wide gear) on clutch shaft (Figure 35,
Item 1).
3. Install spacer washer (Figure 35, Item 4), bronze thrust washer (Figure 35, Item 3), and spacer washer
(Figure 35, Item 2) on clutch shaft (Figure 35, Item 1).
NOTE
Heat bearing inner race to 250°F (121°C) prior to installation.
4. Install wide spacer (Figure 35, Item 7), with large diameter shoulder toward spacer washer (Figure 35, Item 2),
and heated bearing inner race (Figure 35, Item 6) on clutch shaft (Figure 35, Item 1).
Figure 35. Bearing Race Installation. 0104
0104-19
TM 5-3805-255-14 0104
NOTE
Heat bearing inner race to 250°F (121°C).
5. Install drive gear and cup assembly (Figure 36, Item 7) (large diameter, narrow gear), spacer washer
(Figure 36, Item 6), bronze thrust washer (Figure 36, Item 5), spacer washer (Figure 36, Item 4), spacer
(Figure 36, Item 3), with large diameter shoulder toward spacer washer (Figure 36, Item 4), and heated bearing
inner race (Figure 36, Item 2) on clutch shaft (Figure 36, Item 8).
6. Install new snap ring (Figure 36, Item 1) on clutch shaft (Figure 36, Item 8).
Figure 36. Directional Clutch Shaft Assembly. 0104
0104-20
TM 5-3805-255-14 0104
Range Clutch 000104
1. Install roller bearing (Figure 37, Item 3), spacer (Figure 37, Item 2), and roller bearing (Figure 37, Item 1) on oil
supply port end of clutch shaft (Figure 37, Item 4). Cover rollers with a coat of grease.
Figure 37. Roller Bearings Installation. 0104
NOTE
2. Install drive gear and cup assembly (Figure 38, Item 7) (small diameter, wide gear), spacer washer
(Figure 38, Item 6), bronze thrust washer (Figure 38, Item 5), spacer washer (Figure 38, Item 4), spacer
(Figure 38, Item 3) with large diameter shoulder toward spacer washer, and heated bearing inner race
(Figure 38, Item 2) on clutch shaft (Figure 38, Item 8).
3. Install new snap ring (Figure 38, Item 1) in groove of clutch shaft (Figure 38, Item 8).
Figure 38. Range Clutch Shaft Assembly. 0104
0104-21
TM 5-3805-255-14 0104
4. Install roller bearing (Figure 39, Item 1) on splined end of clutch shaft (Figure 39, Item 2). Cover rollers with a
coat of grease.
Figure 39. Roller Bearing Installation. 0104
5. Install drive gear and cup assembly (Figure 40, Item 4) (large diameter, narrow gear), spacer washer
(Figure 40, Item 3), bronze thrust washer (Figure 40, Item 2), and spacer washer (Figure 40, Item 1) on clutch
Figure 40. Drive Gear Installation. 0104
0104-22
TM 5-3805-255-14 0104
NOTE
6. Install input gear (Figure 41, Item 4), with long boss (Figure 41, Item 3) facing out, and heated bearing inner
race (Figure 41, Item 2) on clutch shaft (Figure 41, Item 5).
7. Install new snap ring (Figure 41, Item 1) on clutch shaft (Figure 41, Item 5).
8. Assemble transmission (WP 0103).

END OF TASK
END OF WORK PACKAGE
0104-23/(24 blank)
4
TM 5-3805-255-14 0105
0 1 0 5 TRANSMISSION FORWARD AND REVERSE VALVE REPAIR/OVERHAUL

INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

0004) 0
Gasket (2) 0
Transmission forward and reverse valve

O-ring 0
removed 0
Seal 0
References 0
WP 0019 0
0105-1
TM 5-3805-255-14 0105
DISASSEMBLY 000105
1. Remove plug (Figure 1, Item 2) and O-ring (Figure 1, Item 3) from valve body (Figure 1, Item 1). Discard O-
ring.
2. Remove plug (Figure 1, Item 7), gasket (Figure 1, Item 6), spring (Figure 1, Item 5), and check ball (Figure 1,
Item 4) from valve body (Figure 1, Item 1). Discard gasket.
3. Remove plugs (Figure 1, Items 8 and 9) from valve body (Figure 1, Item 1).
4. Remove valve spool (Figure 1, Item 11) and seal (Figure 1, Item 10) from valve body (Figure 1, Item 1).
Discard seal.
5. Remove pin (Figure 1, Item 12) from bottom of valve body (Figure 1, Item 1).
6. Remove plug (Figure 1, Item 16), plug gasket (Figure 1, Item 15), spring (Figure 1, Item 14), and check ball
(Figure 1, Item 13) from valve body (Figure 1, Item 1). Discard gasket.
Figure 1. Forward and Reverse Valve. 0105
END OF TASK
2. Replace worn or damaged parts as necessary.
3. Inspect end cap for damage or leaks. Replace if necessary.
END OF TASK
0105-2
TM 5-3805-255-14 0105
ASSEMBLY 000105
1. Install new plug gasket (Figure 1, Item 15) on plug (Figure 1, Item 16).
2. Install check ball (Figure 1, Item 13), spring (Figure 1, Item 14), plug (Figure 1, Item 16), and plug gasket
(Figure 1, Item 15) in valve body (Figure 1, Item 1).
3. Install pin (Figure 1, Item 12) in bottom of valve body (Figure 1, Item 1).
4. Install new seal (Figure 1, Item 10) and valve spool (Figure 1, Item 11) on valve body (Figure 1, Item 1).
5. Install plugs (Figure 1, Items 8 and 9) in valve body (Figure 1, Item 1).
6. Install new seal (Figure 1, Item 6) on plug (Figure 1, Item 7).
7. Install check ball (Figure 1, Item 4), spring (Figure 1, Item 5), and plug (Figure 1, Item 7) in valve body
(Figure 1, Item 1).
8. Install plug (Figure 1, Item 2) and new O-ring (Figure 1, Item 3) in valve body (Figure 1, Item 1).
9. Install transmission forward and reverse valve.
END OF TASK
END OF WORK PACKAGE
0105-3/(4 blank)
4
TM 5-3805-255-14 0106
0 1 0 6 TRANSMISSION CHARGING PUMP REPAIR

INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

Cleaning Compound, Solvent, Type III (WP 0004) 0
0130, Item 4) 0
Fluid, Brake, Silicone, BFS (WP 0130, Item

11) 0
(WP 0005) 0
Lockwasher (10) 0
Pump removed from torque converter (WP

Seal, Pump Cover 0
0102) 0
Seal, Wear Plate (2) 0
Snap Ring 0
0106-1
TM 5-3805-255-14 0106
DISASSEMBLY 000106
Charging Pump 000106
1. Remove six bolts (Figure 1, Item 8) and lockwashers (Figure 1, Item 9) from pump cover (Figure 1, Item 7).
2. Remove seal (Figure 1, Item 6) from pump cover (Figure 1, Item 7). Discard seal.
3. Remove drive gear (Figure 1, Item 11), driven gear (Figure 1, Item 4), two dowel pins (Figure 1, Item 5), and
wear plate (Figure 1, Item 3) from pump body (Figure 1, Item 1).
4. Remove two seals (Figure 1, Item 12) from wear plate (Figure 1, Item 3). Discard seals.
5. Remove two bushings (Figure 1, Item 10) from pump cover (Figure 1, Item 7).
6. Remove two bushings (Figure 1, Item 2) from pump body (Figure 1, Item 1).
Figure 1. Transmission Charging Pump. 0106
END OF TASK
2. Clean all parts thoroughly in mineral spirits or solvent. Inspect pump body, base, cover, and gears for
excessive wear and/or scoring. Inspect needle bearings for wear, discoloration. Replace if necessary.
END OF TASK
0106-2
TM 5-3805-255-14 0106
ASSEMBLY 000106
Charging Pump 000106
CAUTION
Lubricate bushings and gears with hydraulic fluid. Rotate pump driveshaft to be sure
gears and shafts turn freely. Failure to lubricate will cause bearings and gears to fail.
1. Install two bushings (Figure 2, Item 10) into pump cover (Figure 2, Item 7).
2. Install two bushings (Figure 2, Item 2) into pump body (Figure 2, Item 1).
3. Install two new seals (Figure 2, Item 12) on wear plate (Figure 2, Item 3).
4. Install wear plate (Figure 2, Item 3), driven gear (Figure 2, Item 4), drive gear (Figure 2, Item 11), and two
dowel pins (Figure 2, Item 5) in pump body (Figure 2, Item 1).
5. Install new seal (Figure 2, Item 6) on pump cover (Figure 2, Item 7).
6. Install pump cover (Figure 2, Item 7), six new lockwashers (Figure 2, Item 9), and bolts (Figure 2, Item 8) on
pump body (Figure 2, Item 1). Torque bolts to 28 to 32 lb-ft (37.96 to 43.38 Nm).
Figure 2. Transmission Oil Pump (Late Type). 0106
7. Install pump in torque converter (WP 0102).

END OF TASK
END OF WORK PACKAGE
0106-3/(4 blank)
4
TM 5-3805-255-14 0107
0 1 0 7 TRANSMISSION MAIN REGULATOR VALVE REPAIR

INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

0004) 0
Gasket (5) 0
Transmission main regulator valve removed 0
References 0
WP 0019 0
0107-1
TM 5-3805-255-14 0107
DISASSEMBLY 000107
1. Remove plugs (Figure 1, Items 7 and 8) from main regulator valve body (Figure 1, Item 9).
2. Remove four screws (Figure 1, Item 14), washers (Figure 1, Item 13), cover (Figure 1, Item 12), gasket (Figure
1, Item 11), and spring (Figure 1, Item 10) from main regulator valve body (Figure 1, Item 9). Discard gasket.
3. Remove four screws (Figure 1, Item 1), washers (Figure 1, Item 2), cover (Figure 1, Item 3), gasket (Figure 1,
Item 4), and valve (Figure 1, Item 29) from main regulator valve body (Figure 1, Item 9). Discard gasket.
4. Remove plug (Figure 1, Item 5) and lube valve (Figure 1, Item 6) from main regulator valve body (Figure 1,
Item 9).
1, Item 18), spring (Figure 1, Item 19), and washer (Figure 1, Item 20) from main regulator valve (Figure 1, Item
9). Discard gasket.
1, Item 24), and main valve (Figure 1, Item 28) from main regulator valve body (Figure 1, Item 9). Discard
gasket.
7. Remove pin (Figure 1, Item 25), spring (Figure 1, Item 26), and check ball (Figure 1, Item 27) from main valve
(Figure 1, Item 28). Discard pin.
8. Remove four screws (Figure 1, Item 37), washers (Figure 1, Item 36), cover (Figure 1 Item 35), gasket (Figure
1, Item 34), outer spring (Figure 1, Item 33), inner spring (Figure 1, Item 32), and two washers (Figure 1,
Items 30 and 31) from valve (Figure 1, Item 29). Discard gasket.
H100C-0318
Figure 1. Main Regulator Control Valve. 0107
END OF TASK
0107-2
TM 5-3805-255-14 0107
2. Replace damaged or worn parts as necessary.
END OF TASK
ASSEMBLY 000107
1. Install valve (Figure 1, Item 29), two washers (Figure 1, Items 30 and 31), inner spring (Figure 1, Item 32),
outer spring (Figure 1, Item 33), new gasket (Figure 1, Item 34), plate (Figure 1, Item 35), four washers (Figure
1, Item 36), and screws (Figure 1, Item 37) on main regulator valve body (Figure 1, Item 9).
2. Install check ball (Figure 1, Item 27), spring (Figure 1, Item 26), and new pin (Figure 1, Item 25) on main valve
3. Install assembled main valve (Figure 1, Item 28), new gasket (Figure 1, Item 24), cover (Figure 1, Item 23),
four washers (Figure 1, Item 22), and screws (Figure 1, Item 21) on main regulator valve body (Figure 1,
Item 9).
4. Install washer (Figure 1, Item 20), spring (Figure 1, Item 19), new gasket (Figure 1, Item 18), cover (Figure 1,
Item 17), four washers (Figure 1, Item 16), and screws (Figure 1, Item 15) on main regulator valve body
(Figure 1, Item 9).
5. Install lube valve (Figure 1, Item 6) and plug (Figure 1, Item 5) on main regulator valve body (Figure 1, Item 9).
6. Install valve (Figure 1, Item 29), new gasket (Figure 1, Item 4), cover (Figure 1, Item 3), four washers (Figure 1,
Item 2), and screws (Figure 1, Item 1) on main regulator valve body (Figure 1, Item 9).
7. Install spring (Figure 1, Item 10), new gasket (Figure 1, Item 11), cover (Figure 1, Item 12), four washers
(Figure 1, Item 13), and screws (Figure 1, Item 14) on main regulator valve body (Figure 1, Item 9).
8. Install plugs (Figure 1, Items 7 and 8) on main regulator valve body (Figure 1, Item 9).
9. Install main regulator valve.
END OF TASK
END OF WORK PACKAGE
0107-3/(4 blank)
2
TM 5-3805-255-14 0108
0 1 0 8 TRANSMISSION NEUTRAL KNOCKDOWN VALVE REPAIR

INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

0004) 0
O-Ring (2) 0
Transmission neutral knockdown valve

References 0
removed 0
WP 0019 0
DISASSEMBLY 000108
1. Remove plug (Figure 1, Item 1), O-ring (Figure 1, Item 2), seal ring (Figure 1, Item 3), and valve spool (Figure
1, Item 4) from valve (Figure 1, Item 5). Discard O-ring.
2. Remove plug (Figure 1, Item 8), O-ring (Figure 1, Item 7), and spring (Figure 1, Item 6) from valve (Figure 1,
Item 5). Discard O-ring.
Figure 1. Transmission Neutral Knockdown Valve Disassembly. 0108
END OF TASK
0108-1
TM 5-3805-255-14 0108
2. Replace any parts that are worn or damaged.
END OF TASK
ASSEMBLY 000108
1. Install spring (Figure 2, Item 6), new O-ring (Figure 2, Item 7), and plug (Figure 2, Item 8) on valve (Figure 2,
Item 5). Tighten plug securely.
2. Install valve spool (Figure 2, Item 4), new seal (Figure 2, Item 3), new O-ring (Figure 2, Item 2) and plug
(Figure 2, Item 1) on valve (Figure 2, Item 5). Tighten plug securely.
3. Install neutral knock down valve (WP 0093).
Figure 2. Transmission Neutral Knockdown Valve Assembly. 0108
END OF TASK
END OF WORK PACKAGE
0108-2
4
TM 5-3805-255-14 0109
0 1 0 9 TRANSMISSION RANGE SELECTOR VALVE REPAIR

INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive WP 0019 0
(Item 20, WP ) 0
Materials/Parts 0
Rag, Wiping (Item 28, WP ) 0

Gasket (2) 0
Oil Seal 0
Seal Ring 0 0004) 0
Snap Ring (2) 0 Transmission removed (WP 0048) 0
Transmission range selector valve removed 0
0109-1
TM 5-3805-255-14 0109
DISASSEMBLY 000109
1. Remove snap ring (Figure 1, Item 18), woodruff key (Figure 1, Item 19), and snap ring (Figure 1, Item 20) from
range housing (Figure 1, Item 17). Discard two snap rings.
2. Remove eight bolts (Figure 1, Item 1) from range housing (Figure 1, Item 17).
3. Remove seal ring (Figure 1, Item 25) from range housing (Figure 1, Item 17). Discard seal ring.
4. Remove plate (Figure 1, Item 2) and gasket (Figure 1, Item 4) from range housing (Figure 1, Item 17). Discard
gasket.
5. Remove spacer (Figure 1, Item 23) and bearing (Figure 1, Item 24) from range housing (Figure 1, Item 17).
6. Remove two pins (Figure 1, Item 3) from plate (Figure 1, Item 2).
7. Remove shaft (Figure 1, Item 22) from range housing (Figure 1, Item 17).
8. Remove pin (Figure 1, Item 5), oil inlet valve (Figure 1, Item 6), O-ring (Figure 1, Item 7), and spring (Figure 1,
Item 8) from shaft (Figure 1, Item 22). Discard O-ring.
9. Remove check ball (Figure 1, Item 9) and spring (Figure 1, Item 10) from valve (Figure 1, Item 11).
10. Remove valve (Figure 1, Item 11), washer (Figure 1, Item 12), retainer (Figure 1, Item 13), washer (Figure 1,
Item 14), bearing (Figure 1, Item 15), washer (Figure 1, Item 21), and seal (Figure 1, Item 16) from shaft
(Figure 1, Item 22). Discard seal.
Figure 1. Range Control Valve. 0109
END OF TASK
0109-2
TM 5-3805-255-14 0109
2. Replace any damaged or worn parts.
END OF TASK
ASSEMBLY 000109
1. Install valve (Figure 1, Item 11), washer (Figure 1, Item 12), retainer (Figure 1, Item 13), washer (Figure 1, Item
14), bearing (Figure 1, Item 15), washer (Figure 1, Item 21), and new seal (Figure 1, Item 16) on shaft (Figure
1, Item 22).
2. Install spring (Figure 1, Item 10), and check ball (Figure 1, Item 9) on valve (Figure 1, Item 11).
3. Install spring (Figure 1, Item 8), new O-ring (Figure 1, Item 7), and oil inlet valve (Figure 1, Item 6) on shaft
(Figure 1, Item 22). Install pin (Figure 1, Item 5) on shaft (Figure 1, Item 22).
4. Install assembled shaft (Figure 1, Item 22) on range housing (Figure 1, Item 17).
5. Install two pins (Figure 1, Item 3) on plate (Figure 1, Item 6).
6. Install spacer (Figure 1, Item 23), bearing (Figure 1, Item 24), and new seal ring (Figure 1, Item 25) on range
7. Install new gasket (Figure 1, Item 4) and plate (Figure 1, Item 2) on range housing (Figure 1, Item 17).
8. Install eight bolts (Figure 1, Item 1) on range housing (Figure 1, Item 17). Tighten bolts securely.
9. Install new snap ring (Figure 1, Item 20), woodruff key (Figure 1, Item 19), and new snap ring (Figure 1, Item
18) on range housing (Figure 1, Item 17).
10. Install range selector valve on transmission.
END OF TASK
END OF WORK PACKAGE
0109-3/(4 blank)
14
TM 5-3805-255-14 0110
FRONT AXLE ASSEMBLY REPAIR/OVERHAUL

0 1 1 0
INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP Seal Ring (2 0
0128, Item 20) 0

Sealing Washer (16) 0

Maintenance, Heavy, Supplemental No. 1, Personnel Required 0
Less Power (WP 0128, Item 16) 0 Two 0
Wrench, Torque, 3/4 in. Drive 100 to 500 lb-ft

References 0
(WP 0128, Item 25) 0
Axle Remover and Installer (WP 0125, Item 4) 0

WP 0019 0
Wheel Hub and Brake Drum Lifting Tool (WP WP 0059 0
0125, Item 6) 0
Materials/Parts 0 Machine parked on level ground (WP 0005) 0



0004) 0
Gasket 0
Front axle removed (WP 0051) 0
Lockwasher (12) 0
Front differential removed (WP 0052) 0
O-Ring (2) 0
Front planetary removed (WP 0053) 0
Retainer, Axle Seal (2) 0
Seal, Axle (2) 0
0110-1
TM 5-3805-255-14 0110
DISASSEMBLY 000110
NOTE
Tag and identify shims for ease of assembly.
1. Remove seal ring (Figure 1, Item 1) from wheel hub shoulder (Figure 1, Item 4). Discard seal ring.
2. Remove 12 retainer bolts (Figure 1, Item 5), retainer (Figure 1, Item 3), and shim pack (Figure 1, Item 2) from
wheel hub (Figure 1, Item 4).
Figure 1. Shim Pack Removal. 0110
0110-2
TM 5-3805-255-14 0110
WARNING
3. Use a suitable lifting device to remove ring gear and hub assembly (Figure 2, Item 1) from axle housing splines
(Figure 2, Item 2).
CAUTION
Do not damage bearing cage, bearing race, seal surfaces or splines. Failure to follow this
4. Remove ring gear from hub assembly. Pry between wheel hub (Figure 2, Item 1) and ring gear assembly
(Figure 2, Item 3).
Figure 2. Ring Gear and Hub Removal 0110
0110-3
TM 5-3805-255-14 0110
WARNING
suitable load capacity. Keep clear of heavy parts supported by lifting equipment.
• Do not allow brake drum to pull free of hub and fall.
• Failure to follow these warnings may result in injury to personnel and/or damage to
equipment.
5. Use suitable lifting device and hub and drum lifting tool to remove wheel hub and brake drum (Figure 3, Item 1)
from axle spindle (Figure 3, Item 2).
Figure 3. Hub and Drum Removal. 0110
0110-4
TM 5-3805-255-14 0110
6. Remove brake assembly. Refer to (WP 0096) for brake overhaul procedures.
7. Remove axle seal (Figure 4, Item 1) from housing hub (Figure 4, Item 3). Discard axle seal.
8. Remove seal retainer (Figure 4, Item 2) from housing hub (Figure 4, Item 3). Discard seal retainer.
Figure 4. Seal and Retainer Removal. 0110
9. Remove O-ring (Figure 5, Item 1) from seal retainer (Figure 5, Item 2). Discard O-ring.
Figure 5. Seal Retainer. 0110
END OF TASK
0110-5
TM 5-3805-255-14 0110
Cleaning 000110
NOTE
Coat parts to be assembled immediately with lubricant to prevent corrosion.
1. Clean all parts thoroughly IAW General Maintenance Instructions (WP 0019).
2. Flush out axle housing being sure it is completely clean. Be sure all flaked metal deposits and dirt are removed
from corners. Cover differential opening with plastic cover when housing is clean and dry.
3. Check polished surfaces and ring groove of seal retainer for nicks, dents or burrs. Replace seal retainer if
damaged beyond repair.
Inspection 000110
CAUTION
Never dry bearings by spinning with compressed air. Failure to follow this caution may
result in injury to personnel and/or damage to equipment.
1. Inspect all bearings, cups, and cones, including those not removed from axle. If necessary replace worn parts.
2. Inspect all gears and splines for wear or damage. Replace all parts that are scored, pitted, ridged, or worn.
3. Inspect axle shafts for signs of torsional fractures or damage. Replace if necessary.
END OF TASK
0110-6
TM 5-3805-255-14 0110
ASSEMBLY 000110
1. Be sure mating surfaces of differential carrier and axle housing are absolutely clean and free of nicks or burrs.
NOTE
Gasket.
2. Coat differential mounting face of axle housing (Figure 6, Item 1) with Sealant, Loctite 270. Apply a light
coating of plastic gasket to threads of retaining capscrews (Figure 6, Item 3). With axle housing (Figure 6,
Item 6) blocked securely, lift differential (Figure 6, Item 2) into position on axle housing, being sure holes are
correctly aligned.
3. Install 12 new lockwashers (Figure 6, Item 5) and capscrews (Figure 6, Item 4). Tighten capscrews gradually
and evenly around circumference of carrier flange to 150 to 175 lb-ft (203 to 237 Nm) torque.
H100C-0923
Figure 6. Differential Installation. 0110
0110-7
TM 5-3805-255-14 0110
4. Install new O-ring (Figure 7, Item 1) in groove of seal retainer (Figure 7, Item 2).
5. Grease seal surface of axle hub (Figure 8, Item 1) and O-ring (Figure 8, Item 3). Push retainer (Figure 8, Item
2) in position being sure it contacts axle housing flange about its entire circumference.
6. Inspect end surface of axle spindle (Figure 8, Item 4) for nicks, burrs, or other irregularities. If necessary, file
surface until it is flat and smooth. File carefully to prevent a wavy surface. Entire surface must be at 90 degrees
to centerline of axle bore.
7. Coat outside diameter of a new axle seal (Figure 8, Item 5) with Loctite 496 sealant or equivalent sealant and
use a suitable driver to install seal in axle bore. This seal must bottom in its bore.
Figure 8. Oil Seals Installation. 0110
0110-8
TM 5-3805-255-14 0110
8. Install brake assembly (WP 0059).
WARNING
9. Use special lifting tool to position wheel hub/brake drum assembly (Figure 9, Item 1) on axle spindle (Figure 9,
Item 2).
Figure 9. Hub and Drum Positioning. 0110
10. Start ring gear and hub assembly (Figure 10, Item 1) on axle spindle splines (Figure 10, Item 2). Place a 4 x 4
in. wooden block across ring gear and use a sledge or heavy mallet to drive ring gear and hub assembly on
spindle until it bottoms in wheel hub bearing cup (Figure 10, Item 3).
Figure 10. Hub and Drum Installation. 0110
0110-9
TM 5-3805-255-14 0110
11. Position retainer (Figure 11, Item 1) against ring gear hub (Figure 11, Item 2) WITHOUT shims. Secure retainer
with three equally spaced capscrews. Tighten capscrews evenly to 40 lb-ft (54 Nm) torque while rotating wheel
hub.
Figure 11. Retainer Installation. 0110
12. Carefully measure gap (Figure 12). Using a depth micrometer, measure through a bolt hole in retaining ring to
a heavy feeler gauge held across a threaded bolt hole in spindle. Add thickness of feeler gauge to micrometer
reading and subtract measured thickness of retaining ring to determine gap.
13. Measure shims individually to obtain a shim pack thickness equal to measured gap. To this shim pack add
additional 0.005 in. (0.127 mm) shim.
Figure 12. Shim Pack Determination. 0110
0110-10
TM 5-3805-255-14 0110
14. The total shim pack (Figure 13, Item 2) thickness should equal measured gap plus required additional 0.005 in.
(0.127 mm) shims or as close as possible to this dimension on plus side.
15. Remove retainer (Figure 13, Item 3) and install entire shim pack (Figure 13, Item 2). Install retainer and secure
with 12 capscrews (Figure 13, Item 5). Coat threads of each capscrew with Loctite Plastic Gasket before
installation. Tighten capscrews (Figure 13, Item 5) to a preliminary torque of 40 lb-ft (54 Nm) while rotating
16. Tighten 12 retainer capscrews (Figure 13, Item 5) to a final torque of 200 lb-ft (271 Nm).
17. Lubricate new seal ring (Figure 13, Item 1) with grease and install on wheel hub shoulder. Be sure there are no
twists in seal ring.
Figure 13. Final Retainer Installation. 0110
0110-11
TM 5-3805-255-14 0110
18. Install front planetaries to front axle (WP 0053).
19. Install front differential to front axle (WP 0052).
20. Install front axle assembly to loader (WP 0051).
21. Rotate planetary hub (Figure 14, Item 1) until oil level line (Figure 14, Item 4) is horizontal. Remove drain and
fill plug (Figure 14, Item 2) and O-ring (Figure 14, Item 3). Discard O-ring. Fill planetary hub to level of plug hole
with 6.5 pt (3.08 L) of recommended lubricant (WP 0018).
22. Install new O-ring (Figure 14, Item 3) on drain plug (Figure 14, Item 2). Install drain plug on planetary hub
(Figure 14, Item 1). Tighten plug.
Figure 14. Lubricant Installation and Check. 0110
0110-12
TM 5-3805-255-14 0110
23. Rotate axle (Figure 15, Item 1) until differential input is horizontal. Install and tighten drain plug (Figure 15,
Item 2). Fill axle bowl to level of level plug hole (Figure 15, Item 3) with 17 qt (16 L) of lubricant (WP 0016).
24. Install new O-ring (Figure 15, Item 4) on level plug (Figure 15, Item 3) and install plug assembly in housing
(Figure 15, Item 1). Tighten plug securely.
25. After mounting axle in loader with wheels and tires installed, adjust each brake assembly (WP 0059).
END OF TASK
END OF WORK PACKAGE
0110-13/(14 blank)
30
TM 5-3805-255-14 0111
0 1 1 1 FRONT DIFFERENTIAL REPAIR/OVERHAUL

Disassembly; Cleaning, Inspection, and Repair; Assembly; Adjustment
INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP Tag, Marker (WP 0130, Item 37) 0
0128, Item 20) 0

Gasket 0
Shop Equipment, Automotive Maintenance Lockwasher (8) 0
and Repair: Organizational Maintenance Pin, Cotter (4) 0
Seal, Cork 0

Seal, Felt 0

Seal (3) 0
Differential Holding Fixture (WP 0125, Item 5) 0

Mechanic’s Wire 0
Wrench Set, Socket (WP 0128, Item 24) 0

References 0
Wrench, Torque, 3/4 in. Drive 100 to 500 lb-ft WP 0018 0
(WP 0128, Item 25) 0
WP 0125 0
Materials/Parts 0

Item 8) 0
Lubriplate Lubricating Fluid (WP 0130, Item

17) 0
Oil, Lubricating, Gear, GO 80/90 (WP 0130, Battery disconnect switch in OFF position (WP
Item 20) 0
0004) 0

Front differential removed (WP 0052) 0
0111-1
TM 5-3805-255-14 0111
DISASSEMBLY 000111
CAUTION
Drifts or hammers may damage or distort component parts. Failure to follow this caution
may result in damage to components.
1. If necessary, fabricate holding fixture. Refer to WP 0125, Item 5. Place front differential assembly (Figure 1,
Item 1) in a suitable holding fixture.
2. Remove oil pipe plug (Figure 1, Item 4), spring (Figure 1, Item 3), and oil distributor (Figure 1, Item 2) from front
differential assembly (Figure 1, Item 1).
Figure 1. Front Differential Disassembly. 0111
0111-2
TM 5-3805-255-14 0111
3. Mark two bearing caps (Figure 2, Item 5) and carrier housing legs (Figure 2, Item 6).
4. Remove two cotter pins (Figure 2, Item 1) and adjuster locks (Figure 2, Item 2) from bearing caps (Figure 2,
Item 5). Discard cotter pins.
5. Remove lockwire (Figure 2, Item 3) from bearing cap bolts (Figure 2, Item 4). Discard lockwire.
6. Remove four bearing cap bolts (Figure 2, Item 4) from two bearing caps (Figure 2, Item 5).
Figure 2. Marking Bearing Caps. 0111
0111-3
TM 5-3805-255-14 0111
7. Remove two bearing caps (Figure 3, Item 1) from front differential (Figure 3, Item 3).
8. Remove two bearing adjusters (Figure 3, Item 2) from front differential (Figure 3, Item 3)
Figure 3. Bearing Cap Removal. 0111
9. Loosen nut (Figure 4, Item 1).

10. Loosen thrust adjusting screw (Figure 4, Item 2).
Figure 4. Thrust Adjusting Screw Adjustment. 0111
0111-4
TM 5-3805-255-14 0111
WARNING
11. Use a suitable lifting device to remove differential (Figure 5, Item 1) from carrier housing.
12. Remove two carrier bearing cups (Figure 5, Item 2) from differential (Figure 5, Item 1).
Figure 5. Differential Removal. 0111
0111-5
TM 5-3805-255-14 0111
13. Remove nut (Figure 6, Item 5) and lockwasher (Figure 6, Item 4) from adjusting screw (Figure 6, Item 3). Dis-
card lockwasher.
14. Remove thrust block (Figure 6, Item 1) from carrier housing (Figure 6, Item 2).
15. Remove adjusting screw (Figure 6, Item 3) from carrier housing (Figure 6, Item 2).
Figure 6. Thrust Block Removal. 0111
16. Mark differential case halves (Figure 7, Items 3 and 4) to ensure correct alignment during assembly.
17. Remove lockwires (Figure 7, Item 2).
CAUTION
When removing plain half, do not allow side gear to drop. Failure to follow these
instructions may result in damage to components.
18. Remove 12 bolts (Figure 7, Item 1) from differential case halves (Figure 7, Items 3 and 4).
19. Lift plain half (Figure 7, Item 3) from flanged half (Figure 7, Item 4).
Figure 7. Differential Case Halves Separation. 0111
0111-6
TM 5-3805-255-14 0111
20. Remove one thrust washer (Figure 8, Item 4) and side gear (Figure 8, Item 5) from spider (Figure 8, Item 3).
21. Remove spider (Figure 8, Item 3) with four spider gears (Figure 8, Item 2) and thrust washers (Figure 8,
Item 1) from case flange (Figure 8, Item 6).
22. Remove remaining side gear (Figure 8, Item 5) and thrust washer (Figure 8, Item 4) from case flange (Figure
8, Item 6).
Figure 8. Spider Assembly Removal. 0111
23. Remove 12 bolts (Figure 9, Item 2), nuts (Figure 9, Item 3), and ring gear (Figure 9, Item 4) from flange case
(Figure 9, Item 1).
Figure 9. Ring Gear Removal. 0111
0111-7
TM 5-3805-255-14 0111
24. Remove two differential bearings (Figure 10, Item 2) from case half and case flange (Figure 10, Item 1).
Figure 10. Differential Bearings Removal. 0111
25. Rotate differential carrier (Figure 11, Item 1) in repair stand until assembled pinion (Figure 11, Item 4) faces up.
26. Remove six pinion bolts (Figure 11, Item 2), lockwashers (Figure 11, Item 3), and pinion bearing cap assembly
(Figure 11, Item 5) from carrier (Figure 11, Item 1). Discard lockwashers.
Figure 11. Pinion Bearing Cage Retainer Removal. 0111
0111-8
TM 5-3805-255-14 0111
WARNING
Companion flange is heavy. Prevent dropping when removing from differential carrier.
Failure to follow this warning may result in personal injury and/or damage to the
components.
27. Remove assembled pinion (Figure 12, Item 1) from differential carrier (Figure 12, Item 2).
Figure 12. Pinion Removal. 0111
28. Remove shim or shims (Figure 13, Item 5) from assembled pinion (Figure 13, Item 4).
29. Wire shim pack together in order of removal and attach it to pinion (Figure 13, Item 4) for reference.
30. Secure yoke (Figure 13, Item 7) and remove cotter pin (Figure 13, Item 1), nut (Figure 13, Item 2), washer (Fig-
ure 13, Item 3), and pinion shaft (Figure 13, Item 6) from yoke (Figure 13, Item 7).
Figure 13. Pinion Disassembly. 0111
0111-9
TM 5-3805-255-14 0111
31. Remove oil seal retainer (Figure 14, Item 1) from pinion bearing cage assembly (Figure 14, Item 6).
32. Remove washer (Figure 14, Item 2), bearing (Figure 14, Item 3), bearing cup (Figure 14, Item 4), and cork seal
(Figure 14, Item 5) from pinion bearing cage (Figure 14, Item 6). Discard cork seal.
Figure 14. Pinion Bearing Cage Disassembly. 0111
33. Remove felt seal (Figure 15, Item 2) and oil seal (Figure 15, Item 1) from oil seal retainer (Figure 15, Item 3).
Discard seals.
Figure 15. Felt and Oil Seals Removal. 0111
0111-10
TM 5-3805-255-14 0111
34. Remove flat washer (Figure 16, Item 2), spacer (Figure 16, Item 3), and bearing cup (Figure 16, Item 4) from
pinion (Figure 16, Item 1).
Figure 16. Washer and Bearing Removal. 0111
END OF TASK
0111-11
TM 5-3805-255-14 0111
Cleaning 000111
NOTE
2. Parts that have been cleaned, dried, and inspected and are to be assembled immediately should be coated
with light oil to prevent corrosion. If parts are to be stored for any length of time, they should be treated with a
good rust preventive and wrapped in special paper or other material designed to prevent corrosion.
Inspection 000111
1. Inspect all bearing cups and cones, including those not removed, for wear, pitting, or damage. Replace if
necessary.
NOTE
If it becomes necessary to replace ring or pinion gear, both gears must be replaced with a
matched set.
2. Inspect hypoid gears for wear, pitting, scoring, or ridges and replace if necessary.
3. Inspect differential case halves, thrust washers, spider trunnions, and differential gears for pitted, scored, or
worn thrust surfaces. Thrust washers must be replaced in sets.
NOTE
Pinion and side gears must be replaced in sets.
4. Inspect differential pinion gears, thrust washers, side gear teeth, and spider gear for wear or damage. Replace
if worn or damaged.
Repair 000111
1. Remove nicks, mars, and/or burrs from machined or ground surfaces.

2. All threads must be clean and free to obtain accurate adjustment and correct torque.
END OF TASK
0111-12
TM 5-3805-255-14 0111
ASSEMBLY 000111
1. If new bearing cups (Figure 17, Item 1) are to be installed, press cups firmly against pinion bearing cage
shoulders (Figure 17, Item 2).
Figure 17. Bearing Cup Installation. 0111
2. Lubricate bearing cups and cones with light machine oil (WP 0018).
3. Install bearing cone (Figure 18, Item 1) on pinion (Figure 18, Item 2) against gear shoulder (Figure 18, Item 3).
Be sure bearing cone bottoms on gear shoulder.
Figure 18. Bearing Cone Installation. 0111
0111-13
TM 5-3805-255-14 0111
4. Install pilot bearing (Figure 19, Item 1) on stub end of pinion (Figure 19, Item 2); stake pilot bearing to pinion in
at least four places.
Figure 19. Pilot Bearing Installation. 0111
0111-14
TM 5-3805-255-14 0111
5. Lubricate bearing cone (Figure 20, Item 5) with light machine oil (WP 0018).
6. Install bearing cage assembly (Figure 20, Item 7), bearing cone (Figure 20, Item 5), and flat washer (Figure 20,
Item 4) on pinion shaft (Figure 20, Item 6).
7. Install companion flange assembly (Figure 20, Item 3) on pinion shaft (Figure 20, Item 6). Tap flange lightly
until it exposes pinion threads.
8. Install pinion washer (Figure 20, Item 2) and nut (Figure 20, Item 1) on pinion shaft (Figure 20, Item 6). Use nut
to draw down companion flange assembly (Figure 20, Item 3), and torque nut to 500 to 700 lb-ft (678 to
949 Nm).
Figure 20. Pinion Assembly. 0111
0111-15
TM 5-3805-255-14 0111
9. Wrap a soft iron wire around outer circumference of bearing cage assembly (Figure 21, Item 1). Pull on a line
tangent to outside diameter of cage with a pound scale hooked to wire as shown. With flange (Figure 21, Item
2) held stationary, rotate cage with pull of spring scale.
NOTE
Use rotating torque, not starting torque.
10. Read torque required to keep cage moving (starting torque will be higher). Scale should read between 2 and 6
lb (0.746 to 2.240 kg).
11. If torque is not within recommended limitations, install a thinner spacer as installed in step 6 to decrease
preload.
Figure 21. Rotating Torque Measurement. 0111
0111-16
TM 5-3805-255-14 0111
12. Remove pinion nut (Figure 22, Item 2), washer (Figure 22, Item 3), and companion flange assembly (Figure
22, Item 4) from pinion bearing cage (Figure 22, Item 10).
13. Install seal (Figure 22, Item 8) in groove of bearing cage (Figure 26, Item 10) with split at top side of assembly.
14. Coat new oil seal (Figure 22, Item 7), new felt seal (Figure 22, Item 6), and oil seal retainer (Figure 22, Item 5)
with lubricant. Install oil seal in oil seal retainer. Be sure lip of seal is toward bearing cage (Figure 22, Item 10).
15. Position assembled oil sealed retainer (Figure 22, Item 5) on bearing cage (Figure 22, Item 10). Reinstall
companion flange (Figure 22, Item 4), washer (Figure 22, Item 3), and pinion nut (Figure 22, Item 2) on pinion
shaft (Figure 22, Item 9). Tighten pinion nut to 500 to 700 lb-ft (678 to 949 Nm).
NOTE
Do not back off pinion nut to align cotter pin holes
16. Align cotter pin holes in pinion shaft (Figure 22, Item 9) with pinion nut (Figure 22, Item 2). Install new cotter pin
Figure 22. Companion Flange Installation. 0111
0111-17
TM 5-3805-255-14 0111
17. Install shim pack (Figure 23, Item 4) removed during disassembly, between bearing cage (Figure 23, Item 1)
and differential carrier (Figure 23, Item 3).
NOTE
Locate thin shims on outside of pack for best sealing ability.
18. Tap pinion and cage assembly (Figure 23, Item 1) into position with a soft mallet.
19. Install six cage/cover retaining capscrews (Figure 23, Item 2) and tighten to 150 to 175 lb-ft (203 to 237 Nm).
Figure 23. Pinion Assembly Installation. 0111
0111-18
TM 5-3805-255-14 0111
20. Install new lockwasher (Figure 24, Item 4) and nut (Figure 24, Item 5) on adjusting screw (Figure 24, Item 3).
21. Install adjusting screw (Figure 24, Item 3) in carrier housing (Figure 24, Item 2) far enough that thrust block
(Figure 24, Item 1) can be installed from inside differential carrier. Lubricate thrust block with lubricant and
install it on end of adjusting screw.
Figure 24. Adjusting Screw Installation. 0111
22. Install plain half (Figure 25, Item 3) on flanged half (Figure 25, Item 5). Install 12 bolts (Figure 25, Item 1), flat
washers (Figure 25, Item 2), and hex nuts (Figure 25, Item 4). Tighten bolts to a preliminary torque of 40 lb-ft
(54 Nm). Tighten bolts to a final torque of 200 lb-ft (271 Nm).
Figure 25. Ring Gear Installation. 0111
0111-19
TM 5-3805-255-14 0111
23. Lubricate side gear (Figure 26, Item 2) and thrust washer (Figure 26, Item 3) with lubricant (WP 0018).
24. Position thrust washer (Figure 26, Item 3) and side gear (Figure 26, Item 2) in ring and case half assembly
Figure 26. Side Gear Installation. 0111
0111-20
TM 5-3805-255-14 0111
25. Lubricate spider (Figure 27, Item 6), four spider gears (Figure 27, Item 2), and thrust washers (Figure 27, Item
5) with lubricant (WP 0018).
26. Place spider (Figure 27, Item 6), spider gears (Figure 27, Item 2), and thrust washers (Figure 27, Item 5) in
position in case half (Figure 27, Item 1).
27. Install remaining side gear (Figure 27, Item 4) and thrust washer (Figure 27, Item 3) on case half (Figure 27,
Item 1).
28. Align mating marks on case halves (Figure 28, Item 1) and secure assembly (Figure 28, Item 3) with four
equally spaced capscrews and hex nuts.
29. Check assembly for free rotation of differential gears (Figure 28, Item 4). Correct if necessary.
30. If ring gear thrust bearings (Figure 28, Item 2) were removed, press new bearings squarely to each case half
(Figure 28, Item 1). Use a suitable sleeve and press only on bearing inner race.
0111-21
TM 5-3805-255-14 0111
31. Install remaining eight bolts (Figure 29, Item 3) and hex nuts (Figure 29, Item 4). Tighten all 12 bolts and hex
nuts to 190 to 200 lb-ft (257 to 271 Nm).
32. Install lockwire on bolts (Figure 29, Item 3).
33. Lubricate two bearings (Figure 29, Item 2) with lubricant (WP 0018).
34. Place two bearing cups (Figure 29, Item 1) over differential bearing cones (Figure 29, Item 2) and position
differential assembly (Figure 29, Item 5) in carrier (Figure 29, Item 6).
0111-22
TM 5-3805-255-14 0111
35. Install two bearing adjusters (Figure 30, Item 2) on front differential (Figure 30, Item 3).
NOTE
Do not force caps into position.
36. Install two bearing caps (Figure 30, Item 1) on front differential (Figure 30, Item 3).
37. If bearing caps (Figure 30, Item 1) do not position properly, adjusting nuts (Figure 30, Item 2) may be cross-
threaded. Remove caps and reposition adjusting nuts.
Figure 30. Bearing Cap Installation. 0111
0111-23
TM 5-3805-255-14 0111
38. Install four bearing cap bolts (Figure 31, Item 3) and torque to 25 lb-ft (34 Nm).
39. Loosen bearing adjuster (Figure 31, Item 5) on tooth side of ring gear (Figure 31, Item 1) and tighten opposite
bearing adjuster until all backlash is removed between pinion gear (Figure 31, Item 2) and ring gear.
END OF TASK
ADJUSTMENT 000111
1. Measure backlash between ring gear (Figure 31, Item 1) and pinion gear (Figure 31, Item 2) with a dial
indicator as shown.
2. Backlash is adjusted by backing off one adjuster (Figure 31, Item 5) and tightening opposite adjuster (Figure
31, Item 4) an equal amount. When backlash adjustment is within allowable limit of 0.008 to 0.015 in. (0.203 to
0.381 mm), add a light preload by tightening adjuster (Figure 31, Item 5) on tooth side ring gear an additional
1-1/2 to 2 notches.
3. Torque four bearing cap bolts (Figure 31, Item 3) to 150 to 175 lb-ft (203 to 237 Nm).
Figure 31. Backlash Adjustment. 0111
0111-24
TM 5-3805-255-14 0111
4. Apply Prussian Blue Compound (WP 0130, Item 8) to ring gear teeth (Figure 32, Item 1). When gear is rotated,
Prussian Blue Compound is squeezed away by contact of teeth leaving an imprint the exact size, shape, and
location as gear contact.
5. Sharper impressions may be obtained by applying a small amount of resistance to ring gear with a steel bar
and using a wrench to rotate pinion. When making adjustments, check drive side of ring gear teeth (Figure 32,
Item 1). Coating approximately 12 teeth is sufficient to check tooth contact.
Figure 32. Prussian Blue Compound Application. 0111
6. With adjustments properly made, contacts like those shown in Figure 33 will be obtained. Area of contact
should favor toe and is centered between top and bottom of tooth.
7. After a satisfactory tooth contact pattern is obtained, especially in relation to top and bottom of the tooth,
backlash may be altered within recommended limits of 0.008 to 0.015 in. (0.203 to 0.381 mm) to obtain a better
contact position relative to length of tooth. A high backlash setting can be used to keep contact from starting
too close to the toe. A low backlash setting can be used to keep contact from starting too far away from the toe.
8. Hand-rolled pattern shown in Figure 33 will result in a pattern centered in length of tooth when gears are under
load. Loaded patterns will be almost full length and top of pattern will approach top of gear tooth.
Figure 33. Correct Gear Contact Pattern. 0111
0111-25
TM 5-3805-255-14 0111
9. The pattern on the coast side of teeth will appear the same width as drive side; however, overall length will be
centered between toe and heel of gear tooth.
10. Set used gears with tooth contacts to match established wear pattern. Hand-rolled patterns of used gears will
be smaller in area and should be at toe end of wear pattern.
11. A high contact pattern, as shown in Figure 34, indicates pinion is too far out. Set pinion to correct depth by
removing shims under pinion cage. A slight outward movement of ring gear may be necessary to maintain
correct backlash.
Figure 34. High Contact Pattern. 0111
0111-26
TM 5-3805-255-14 0111
12. A low contact pattern, as shown in Figure 35, indicates pinion is too deep. Set pinion to correct depth by adding
shims under pinion cage. Slight inward movement of ring gear may be necessary to maintain correct backlash.
Figure 35. Low Contact Pattern. 0111
13. Recheck pinion gear-to-ring gear clearance for a full rotation of ring gear.
14. After establishing correct tooth contact, install two adjuster locks (Figure 36, Item 2) and new cotter pins (Fig-
ure 36, Item 1).
15. Install lockwire (Figure 36, Item 3) on four bearing cap bolts (Figure 36, Item 4).
Figure 36. Lock Nut Installation. 0111
0111-27
TM 5-3805-255-14 0111
16. Remove carrier (Figure 37, Item 1) from holding fixture. Position assembly with back face of ring gear (Figure
37, Item 5) facing up.
17. Hold jam nut (Figure 37, Item 3) and turn adjusting screw (Figure 37, Item 2) until thrust block (Figure 37, Item
4) is pressed firmly against back face of ring gear (Figure 37, Item 5).
18. Back off adjusting screw (Figure 37, Item 2) until recommended clearance of 0.010 to 0.015 in. (0.254 to 0.381
mm) is obtained.
19. Hold adjusting screw (Figure 37, Item 2) and tighten jam nut (Figure 37, Item 3) securely.
20. Recheck thrust block-to-ring gear clearance for a full rotation of ring gear.
Figure 37. Thrust Block Clearance Adjustment. 0111
0111-28
TM 5-3805-255-14 0111
21. Install oil distributor (Figure 38, Item 2), spring (Figure 38, Item 3), and pipe plug (Figure 38, Item 4) in front
22. Install front differential (WP 0052).
Figure 38. Oil Distributor Installation. 0111
END OF TASK
END OF WORK PACKAGE
0111-29/(30 blank)
6
TM 5-3805-255-14 0112
0 1 1 2 FRONT PLANETARY ASSEMBLY REPAIR

INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

0004) 0
Oil, Lubricating, Gear, GO 80/90 (WP 0130, Planetary assembly removed from front axle
Item 20) 0
(WP 0053) 0
Oil, Lubricating, Gear, GO 85/140 (WP 0130, Brake drum removed (WP 0058) 0
Item 21) 0
O-ring (2) 0
0112-1
TM 5-3805-255-14 0112
NOTE
The disassembly and assembly procedures are for one planetary assembly. Repeat for
other side.
DISASSEMBLY 000112
1. Remove three nuts (Figure 1, Item 11) from pinion shafts (Figure 1, Item 3).
2. Remove three pinion shafts (Figure 1, Item 3), and pins (Figure 1, Item 12) from planetary carrier (Figure 1,
Item 1).
3. Remove three retaining rings (Figure 1, Item 7), six bearings (Figure 1, Items 4 and 10), and three spacers
(Figure 1, Item 6) from three pinion gears (Figure 1, Item 8).
4. Remove six cups (Figure 1, Items 5 and 9) from three pinion gears (Figure 1, Item 8).
5. Remove ring gear (Figure 1, Item 2) and ring gear hub (Figure 1, Item 20) from planetary carrier (Figure 1,
Item 1).
6. Remove eight bolts (Figure 1, Item 18), four lockplates (Figure 1, Item 19), and ring gear hub (Figure 1, Item
20) from ring gear (Figure 1, Item 2).
7. Remove seal (Figure 1, Item 17) and bearing (Figure 1, Item 16) from hub (Figure 1, Item 13).
8. Remove cup (Figure 1, Item 15) from hub (Figure 1, Item 13).
9. Remove O-ring (Figure 1, Item 14) from hub (Figure 1, Item 13). Discard O-ring.
0112-2
TM 5-3805-255-14 0112
H100C-1162
Figure 1. Planetary. 0112
END OF TASK
0112-3
TM 5-3805-255-14 0112
1. Clean and inspect all parts thoroughly IAW General Maintenance Instructions (WP 0019).
2. Inspect pinion gears for wear or damage; replace if necessary.
3. Inspect pinion shafts for wear or ridging; replace if necessary.
END OF TASK
ASSEMBLY 000112
1. Install new O-ring (Figure 2, Item 14) on hub (Figure 2, Item 13).
2. Install cup (Figure 2, Item 15) in hub (Figure 2, Item 13).
3. Install bearing (Figure 2, Item 16) and seal (Figure 2, Item 17) on hub (Figure 2, Item 13).
4. Install ring gear hub (Figure 2, Item 20), four lockplates (Figure 2, Item 19), and eight bolts (Figure 2, Item 18)
on ring gear (Figure 2, Item 2).
5. Install ring gear (Figure 2, Item 2) and ring gear hub (Figure 2, Item 20) on planetary carrier (Figure 2, Item 1).
6. Install six cups (Figure 2, Items 5 and 9) on three pinion gears (Figure 2, Item 8).
7. Install six bearings (Figure 2, Items 4 and 10), three retaining rings (Figure 2, Item 7), and spacers (Figure 2,
Item 6) on pinion gears (Figure 2, Item 8).
NOTE
Install all three pinion gears before installing pinion shafts.
8. Install three pinion gears (Figure 2, Item 8) in planetary carrier (Figure 2, Item 1).
NOTE
Chill pinion shafts for ease of installation.
9. Install three pinion shafts (Figure 2, Item 3) and pins (Figure 2, Item 12) in planetary carrier (Figure 2, Item 1).
NOTE
Position nuts to fit inside ID of gasket on planetary carrier.
10. Install three nuts (Figure 2, Item 11) on pinion shafts (Figure 2, Item 3) and torque to 450 lb-ft (610 Nm).
11. Install brake drum (WP 0058).
12. Install planetary assembly on front axle (WP 0053).
0112-4
TM 5-3805-255-14 0112
H100C-1162
END OF TASK
END OF WORK PACKAGE
0112-5/(6 blank)
14
TM 5-3805-255-14 0113
REAR AXLE ASSEMBLY REPAIR/OVERHAUL

0 1 1 3
INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP O-Ring (2) 0
0128, Item 20) 0

Retainer, Axle Seal (2) 0
Shop Equipment, Automotive Maintenance Seal, Axle (2) 0
and Repair: Organizational Maintenance Seal Ring (2)Sealing Washer (16) 0
Shop Equipment, Machine Shop, Field Personnel Required 0
Maintenance, Heavy, Supplemental No. 1, Two 0
Axle Remover and Installer (WP 0125, Item 4) 0

References 0
Wheel Hub and Brake Drum Lifting Tool (WP WP 0019 0
0125, Item 6) 0 WP 0058 0

(WP 0128, Item 25) 0
Materials/Parts 0


Sealant, Loctite 496 (WP 0130, Item 33) 0 0004) 0
Tag, Marker (WP 0130, Item 37) 0 Rear axle removed (WP 0054) 0
Gasket 0 Rear differential removed (WP 0055) 0
Lockwasher (12) 0 Rear planetary removed (WP 0056) 0
0113-1
TM 5-3805-255-14 0113
DISASSEMBLY 000113
NOTE
Tag and identify shims for ease of assembly.
1. Remove seal ring (Figure 1, Item 1) from wheel hub shoulder (Figure 1, Item 4). Discard seal ring.
2. Remove 12 retainer bolts (Figure 1, Item 5), retainer (Figure 1, Item 3), and shim pack (Figure 1, Item 2) from
Figure 1. Shim Pack Removal. 0113
0113-2
TM 5-3805-255-14 0113
WARNING
3. Use a suitable lifting device to remove ring gear and hub assembly (Figure 2, Item 1) from axle housing splines
(Figure 2, Item 2).
CAUTION
Do not damage bearing cage, bearing race, seal surfaces or splines. Failure to follow this
4. Remove ring gear from hub assembly. Pry between wheel hub (Figure 2, Item 1) and ring gear assembly
(Figure 2, Item 3).
Figure 2. Ring Gear and Hub Removal. 0113
0113-3
TM 5-3805-255-14 0113
WARNING
suitable load capacity. Keep clear of heavy parts supported by lifting equipment.
• Do not allow brake drum to pull free of hub and fall.
• Failure to follow these warnings may result in injury to personnel and/or damage to
equipment.
5. Use suitable lifting device and hub and drum lifting tool to remove wheel hub and brake drum (Figure 3, Item 1)
from axle spindle (Figure 3, Item 2).
Figure 3. Hub and Drum Removal. 0113
0113-4
TM 5-3805-255-14 0113
6. Remove brake assembly. Refer to (WP 0059) for brake overhaul procedures.
7. Remove axle seal (Figure 4, Item 1) from housing hub (Figure 4, Item 3). Discard axle seal.
8. Remove seal retainer (Figure 4, Item 2) from housing hub (Figure 4, Item 3). Discard seal retainer.
Figure 4. Seal and Retainer Removal. 0113
9. Remove O-ring (Figure 5, Item 1) from seal retainer (Figure 5, Item 2). Discard O-ring.
Figure 5. Seal Retainer. 0113
END OF TASK
0113-5
TM 5-3805-255-14 0113
Cleaning 000113
NOTE
1. Clean all parts thoroughly IAW General Maintenance Instructions (WP 0019).
2. Flush out axle housing being sure it is completely clean. Be sure all flaked metal deposits and dirt are removed
from corners. Cover differential opening with plastic cover when housing is clean and dry.
3. Check polished surfaces and ring groove of seal retainer for nicks, dents or burrs. Replace seal retainer if
damaged beyond repair.
Inspection 000113
CAUTION
Never dry bearings by spinning with compressed air. Failure to follow this caution may
result in injury to personnel and/or damage to equipment.
1. Inspect all bearings, cups, and cones, including those not removed from axle. If necessary replace worn parts.
2. Inspect all gears and splines for wear or damage. Replace all parts that are scored, pitted, ridged, or worn.
3. Inspect axle shafts for signs of torsional fractures or damage. Replace if necessary.
END OF TASK
0113-6
TM 5-3805-255-14 0113
ASSEMBLY 000113
1. Be sure mating surfaces of differential carrier and axle housing are absolutely clean and free of nicks or burrs.
NOTE
Gasket.
2. Coat differential mounting face of axle housing (Figure 6, Item 1) with Sealant, Loctite 270. Apply a light
coating of plastic gasket to threads of retaining capscrews (Figure 6, Item 3). With axle housing (Figure 6,
Item 6) blocked securely, lift differential (Figure 6, Item 2) into position on axle housing, being sure holes are
correctly aligned.
3. Install 12 new lockwashers (Figure 6, Item 5) and capscrews (Figure 6, Item 4). Tighten capscrews gradually
and evenly around circumference of carrier flange to 150 to 175 lb-ft (203 to 237 Nm) torque.
H100C-0923
0113-7
TM 5-3805-255-14 0113
4. Install new O-ring (Figure 7, Item 1) in groove of seal retainer (Figure 7, Item 2).
5. Grease seal surface of axle hub (Figure 8, Item 1) and O-ring (Figure 8, Item 3). Push retainer (Figure 8, Item
2) in position being sure it contacts axle housing flange about its entire circumference.
6. Inspect end surface of axle spindle (Figure 8, Item 4) for nicks, burrs, or other irregularities. If necessary, file
surface until it is flat and smooth. File carefully to prevent a wavy surface. Entire surface must be at 90 degrees
to centerline of axle bore.
7. Coat outside diameter of a new axle seal (Figure 8, Item 5) with Loctite 496 sealant or equivalent sealant and
use a suitable driver to install seal in axle bore. This seal must bottom in its bore.
Figure 8. Oil Seals Installation. 0113
0113-8
TM 5-3805-255-14 0113
8. Install brake assembly (WP 0059).
WARNING
9. Use special lifting tool to position wheel hub/brake drum assembly (Figure 9, Item 1) on axle spindle (Figure 9,
Item 2).
Figure 9. Hub and Drum Positioning. 0113
10. Start ring gear and hub assembly (Figure 10, Item 1) on axle spindle splines (Figure 10, Item 2). Place a 4 x 4
in. wooden block across ring gear and use a sledge or heavy mallet to drive ring gear and hub assembly on
spindle until it bottoms in wheel hub bearing cup (Figure 10, Item 3).
Figure 10. Hub and Drum Installation. 0113
0113-9
TM 5-3805-255-14 0113
11. Position retainer (Figure 11, Item 1) against ring gear hub (Figure 11, Item 2) WITHOUT shims. Secure retainer
with three equally spaced capscrews. Tighten capscrews evenly to 40 lb-ft (54 Nm) torque while rotating wheel
hub.
Figure 11. Retainer Installation. 0113
12. Carefully measure gap (Figure 12). Using a depth micrometer, measure through a bolt hole in retaining ring to
a heavy feeler gauge held across a threaded bolt hole in spindle. Add thickness of feeler gauge to micrometer
reading and subtract measured thickness of retaining ring to determine gap.
13. Measure shims individually to obtain a shim pack thickness equal to measured gap. To this shim pack add
additional 0.005 in. (0.127 mm) shim.
Figure 12. Shim Pack Determination. 0113
0113-10
TM 5-3805-255-14 0113
14. The total shim pack (Figure 13, Item 2) thickness should equal measured gap plus required additional 0.005 in.
(0.127 mm) shims or as close as possible to this dimension on plus side.
15. Remove retainer (Figure 13, Item 3) and install entire shim pack (Figure 13, Item 2). Install retainer and secure
with 12 capscrews (Figure 13, Item 5). Coat threads of each capscrew with Loctite Plastic Gasket before
installation. Tighten capscrews to a preliminary torque of 40 lb-ft (54 Nm) while rotating wheel hub (Figure 13,
Item 4).
16. Tighten 12 retainer capscrews (Figure 13, Item 5) to a final torque of 200 lb-ft (271 Nm).
17. Lubricate new seal ring (Figure 13, Item 1) with grease and install on wheel hub shoulder. Be sure there are no
twists in seal ring.
Figure 13. Final Retainer Installation. 0113
0113-11
TM 5-3805-255-14 0113
18. Install rear planetaries to rear axle (WP 0056).
19. Install rear differential to rear axle (WP 0055).
20. Install rear axle assembly to loader (WP 0054).
21. Rotate planetary hub (Figure 14, Item 1) until oil level line (Figure 14, Item 4) is horizontal. Remove drain and
fill plug (Figure 14, Item 2) and O-ring (Figure 14, Item 3). Discard O-ring. Fill planetary hub to level of plug hole
with 6.5 pt (3.08 L) of recommended lubricant (WP 0018).
22. Install new O-ring (Figure 14, Item 3) on drain plug (Figure 14, Item 2). Install drain plug on planetary hub
(Figure 14, Item 1). Tighten plug.
Figure 14. Lubricant Installation and Check. 0113
0113-12
TM 5-3805-255-14 0113
23. Rotate axle (Figure 15, Item 1) until differential input is horizontal. Install and tighten drain plug (Figure 15,
Item 2). Fill axle bowl to level of level plug hole (Figure 15, Item 3) with 17 qt (16 L) of lubricant (WP 0016).
24. Install new O-ring (Figure 15, Item 4) on level plug (Figure 15, Item 3) and install plug assembly in housing
(Figure 15, Item 1). Tighten plug securely.
25. After mounting axle in loader with wheels and tires installed, adjust each brake assembly (WP 0059).
END OF TASK
END OF WORK PACKAGE
0113-13/(14 blank)
30
TM 5-3805-255-14 0114
0 1 1 4 REAR DIFFERENTIAL REPAIR/OVERHAUL

Disassembly; Cleaning, Inspection, and Repair; Assembly; Adjustment
INITIAL SETUP
0128, Item 20) 0

Lockwasher (8) 0
Shop Equipment, Machine Shop, Field Mechanic’s Wire 0
Maintenance, Heavy, Supplemental No. 1, Pin, Cotter (4) 0
Seal, Cork 0
Differential Holding Fixture (WP 0125, Item 5) 0
Seal, Felt 0
Wrench Set, Socket (WP 0128, Item 24) 0
Seal (3) 0

(WP 0128, Item 25) 0 References 0
Materials/Parts 0
WP 0019 0
WP 0125 0

Item 8) 0
Lubriplate Lubricating Fluid (WP 0130, Item Machine parked on level ground (WP 0005) 0
17) 0
Oil, Lubricating, Gear, GO 80/90 (WP 0130,

Item 20) 0

0004) 0
Rear differential removed (WP 0055) 0
0114-1
TM 5-3805-255-14 0114
DISASSEMBLY 000114
CAUTION
Drifts or hammers may damage or distort component parts. Failure to follow this caution
may result in damage to components.
1. If necessary, fabricate holding fixture. Refer to WP 0125, Item 5. Place rear differential assembly (Figure 1,
Item 1) in a suitable holding fixture.
2. Remove oil pipe plug (Figure 1, Item 4), spring (Figure 1, Item 3), and oil distributor (Figure 1, Item 2) from rear
Figure 1. Rear Differential Disassembly. 0114
0114-2
TM 5-3805-255-14 0114
3. Mark two bearing caps (Figure 2, Item 5) and carrier housing legs (Figure 2, Item 6).
4. Remove two cotter pins (Figure 2, Item 1) and adjuster locks (Figure 2, Item 2) from bearing caps (Figure 2,
Item 5). Discard cotter pins.
5. Remove lockwire (Figure 2, Item 3) from bearing cap bolts (Figure 2, Item 4). Discard lockwire.
6. Remove four bearing cap bolts (Figure 2, Item 4) from two bearing caps (Figure 2, Item 5).
Figure 2. Marking Bearing Caps. 0114
0114-3
TM 5-3805-255-14 0114
7. Remove two bearing caps (Figure 3, Item 1) from rear differential (Figure 3, Item 3).
8. Remove two bearing adjusters (Figure 3, Item 2) from rear differential (Figure 3, Item 3)
Figure 3. Bearing Cap Removal. 0114
9. Loosen nut (Figure 4, Item 1).

10. Loosen thrust adjusting screw (Figure 4, Item 2).
Figure 4. Thrust Adjusting Screw Adjustment. 0114
0114-4
TM 5-3805-255-14 0114
WARNING
11. Use a suitable lifting device to remove differential (Figure 5, Item 1) from carrier housing.
12. Remove two carrier bearing cups (Figure 5, Item 2) from differential (Figure 5, Item 1).
Figure 5. Differential Removal. 0114
0114-5
TM 5-3805-255-14 0114
13. Remove nut (Figure 6, Item 5) and lockwasher (Figure 6, Item 4) from adjusting screw (Figure 6, Item 3). Dis-
card lockwasher.
14. Remove thrust block (Figure 6, Item 1) from carrier housing (Figure 6, Item 2).
15. Remove adjusting screw (Figure 6, Item 3) from carrier housing (Figure 6, Item 2).
Figure 6. Thrust Block Removal. 0114
16. Mark differential case halves (Figure 7, Items 3 and 4) to ensure correct alignment during assembly.
17. Remove lockwires (Figure 7, Item 2).
CAUTION
When removing plain half, do not allow side gear to drop. Failure to follow these
instructions may result in damage to components.
18. Remove 12 bolts (Figure 7, Item 1) from differential case halves (Figure 7, Items 3 and 4).
19. Lift plain half (Figure 7, Item 3) from flanged half (Figure 7, Item 4).
Figure 7. Differential Case Halves Separation. 0114
0114-6
TM 5-3805-255-14 0114
20. Remove one thrust washer (Figure 8, Item 4) and side gear (Figure 8, Item 5) from spider (Figure 8, Item 3).
21. Remove spider (Figure 8, Item 3) with four spider gears (Figure 8, Item 2) and thrust washers (Figure 8,
Item 1) from case flange (Figure 8, Item 6).
22. Remove remaining side gear (Figure 8, Item 5) and thrust washer (Figure 8, Item 4) from case flange (Figure
8, Item 6).
Figure 8. Spider Assembly Removal. 0114
23. Remove 12 bolts (Figure 9, Item 2), nuts (Figure 9, Item 3), and ring gear (Figure 9, Item 4) from flange case
(Figure 9, Item 1).
Figure 9. Ring Gear Removal. 0114
0114-7
TM 5-3805-255-14 0114
24. Remove two differential bearings (Figure 10, Item 2) from case half and case flange (Figure 10, Item 1).
Figure 10. Differential Bearings Removal. 0114
25. Rotate differential carrier (Figure 11, Item 1) in repair stand until assembled pinion (Figure 11, Item 4) faces up.
26. Remove six pinion bolts (Figure 11, Item 2), lockwashers (Figure 11, Item 3), and pinion bearing cap assembly
(Figure 11, Item 5) from carrier (Figure 11, Item 1). Discard lockwashers.
Figure 11. Pinion Bearing Cage Retainer Removal. 0114
0114-8
TM 5-3805-255-14 0114
WARNING
Companion flange is heavy. Prevent dropping when removing from differential carrier.
Failure to follow this warning may result in personal injury and/or damage to the
components.
27. Remove assembled pinion (Figure 12, Item 1) from differential carrier (Figure 12, Item 2).
Figure 12. Pinion Removal. 0114
28. Remove shim or shims (Figure 13, Item 5) from assembled pinion (Figure 13, Item 4).
29. Wire shim pack together in order of removal and attach it to pinion (Figure 13, Item 4) for reference.
30. Secure yoke (Figure 13, Item 7) and remove cotter pin (Figure 13, Item 1), nut (Figure 13, Item 2), washer
(Figure 13, Item 3), and pinion shaft (Figure 13, Item 6) from yoke (Figure 13, Item 7).
Figure 13. Pinion Disassembly. 0114
0114-9
TM 5-3805-255-14 0114
31. Remove oil seal retainer (Figure 14, Item 1) from pinion bearing cage assembly (Figure 14, Item 6).
32. Remove washer (Figure 14, Item 2), bearing (Figure 14, Item 3), bearing cup (Figure 14, Item 4), and cork seal
(Figure 14, Item 5) from pinion bearing cage (Figure 14, Item 6). Discard cork seal.
Figure 14. Pinion Bearing Cage Disassembly. 0114
33. Remove felt seal (Figure 15, Item 2) and oil seal (Figure 15, Item 1) from oil seal retainer (Figure 15, Item 3).
Discard seals.
Figure 15. Felt and Oil Seals Removal. 0114
0114-10
TM 5-3805-255-14 0114
34. Remove flat washer (Figure 16, Item 2), spacer (Figure 16, Item 3), and bearing cup (Figure 16, Item 4) from
pinion (Figure 16, Item 1).
Figure 16. Washer and Bearing Removal. 0114
END OF TASK
0114-11
TM 5-3805-255-14 0114
Cleaning 000114
NOTE
2. Parts that have been cleaned, dried, and inspected and are to be assembled immediately should be coated
with light oil to prevent corrosion. If parts are to be stored for any length of time, they should be treated with a
good rust preventive and wrapped in special paper or other material designed to prevent corrosion.
Inspection 000114
1. Inspect all bearing cups and cones, including those not removed, for wear, pitting, or damage. Replace if
necessary.
NOTE
If it becomes necessary to replace ring or pinion gear, both gears must be replaced with a
matched set.
2. Inspect hypoid gears for wear, pitting, scoring, or ridges and replace if necessary.
3. Inspect differential case halves, thrust washers, spider trunnions, and differential gears for pitted, scored, or
worn thrust surfaces. Thrust washers must be replaced in sets.
NOTE
Pinion and side gears must be replaced in sets.
4. Inspect differential pinion gears, thrust washers, side gear teeth, and spider gear for wear or damage. Replace
if worn or damaged.
Repair 000114
1. Remove nicks, mars, and/or burrs from machined or ground surfaces.

2. All threads must be clean and free to obtain accurate adjustment and correct torque.
END OF TASK
0114-12
TM 5-3805-255-14 0114
ASSEMBLY 000114
1. If new bearing cups (Figure 17, Item 1) are to be installed, press cups firmly against pinion bearing cage
shoulders (Figure 17, Item 2).
Figure 17. Bearing Cup Installation. 0114
2. Lubricate bearing cups and cones with light machine oil (WP 0131).
3. Install bearing cone (Figure 18, Item 1) on pinion (Figure 18, Item 2) against gear shoulder (Figure 18, Item 3).
Be sure bearing cone bottoms on gear shoulder.
Figure 18. Bearing Cone Installation. 0114
0114-13
TM 5-3805-255-14 0114
4. Install pilot bearing (Figure 19, Item 1) on stub end of pinion (Figure 19, Item 2); stake pilot bearing to pinion in
at least four places.
Figure 19. Pilot Bearing Installation. 0114
0114-14
TM 5-3805-255-14 0114
5. Lubricate bearing cone (Figure 20, Item 5) with light machine oil (WP 0021).
6. Install bearing cage assembly (Figure 20, Item 7), bearing cone (Figure 20, Item 5), and flat washer (Figure 20,
Item 4) on pinion shaft (Figure 20, Item 6).
7. Install companion flange assembly (Figure 20, Item 3) on pinion shaft (Figure 20, Item 6). Tap flange lightly
until it exposes pinion threads.
8. Install pinion washer (Figure 20, Item 2) and nut (Figure 20, Item 1) on pinion shaft (Figure 20, Item 6). Use nut
to draw down companion flange assembly (Figure 20, Item 3), and torque nut to 500 to 700 lb-ft (678 to
949 Nm).
Figure 20. Pinion Assembly. 0114
0114-15
TM 5-3805-255-14 0114
9. Wrap a soft iron wire around outer circumference of bearing cage assembly (Figure 21, Item 1). Pull on a line
tangent to outside diameter of cage with a pound scale hooked to wire as shown. With flange (Figure 21, Item
2) held stationary, rotate cage with pull of spring scale.
NOTE
Use rotating torque, not starting torque.
10. Read torque required to keep cage moving (starting torque will be higher). Scale should read between 2 and 6
lb (0.746 to 2.240 kg).
11. If torque is not within recommended limitations, install a thinner spacer as installed in step 6 to decrease
preload.
Figure 21. Rotating Torque Measurement. 0114
0114-16
TM 5-3805-255-14 0114
12. Remove pinion nut (Figure 22, Item 2), washer (Figure 22, Item 3), and companion flange assembly (Figure
22, Item 4) from pinion bearing cage (Figure 22, Item 10).
13. Install seal (Figure 22, Item 8) in groove of bearing cage (Figure 22, Item 10) with split at top side of assembly.
14. Coat new oil seal (Figure 22, Item 7), new felt seal (Figure 22, Item 6), and oil seal retainer (Figure 22, Item 5)
with lubricant. Install oil seal in oil seal retainer. Be sure lip of seal is toward bearing cage (Figure 22, Item 10).
15. Position assembled oil sealed retainer (Figure 22, Item 5) on bearing cage (Figure 22, Item 10). Reinstall
companion flange (Figure 22, Item 4), washer (Figure 22, Item 3), and pinion nut (Figure 22, Item 2) on pinion
shaft (Figure 22, Item 9). Tighten pinion nut to 500 to 700 lb-ft (678 to 949 Nm).
NOTE
Do not back off pinion nut to align cotter pin holes
16. Align cotter pin holes in pinion shaft (Figure 22, Item 9) with pinion nut (Figure 22, Item 2). Install new cotter pin
Figure 22. Companion Flange Installation. 0114
0114-17
TM 5-3805-255-14 0114
17. Install shim pack (Figure 23, Item 4) removed during disassembly, between bearing cage (Figure 23, Item 1)
and differential carrier (Figure 23, Item 3).
NOTE
Locate thin shims on outside of pack for best sealing ability.
18. Tap pinion and cage assembly (Figure 23, Item 1) into position with a soft mallet.
19. Install six cage/cover retaining capscrews (Figure 23, Item 2) and tighten to 150 to 175 lb-ft (203 to 237 Nm).
Figure 23. Pinion Assembly Installation. 0114
0114-18
TM 5-3805-255-14 0114
20. Install new lockwasher (Figure 24, Item 4) and nut (Figure 24, Item 5) on adjusting screw (Figure 24, Item 3).
21. Install adjusting screw (Figure 24, Item 3) in carrier housing (Figure 24, Item 2) far enough that thrust block
(Figure 24, Item 1) can be installed from inside differential carrier. Lubricate thrust block with lubricant and
install it on end of adjusting screw.
22. Install plain half (Figure 25, Item 3) on flanged half (Figure 25, Item 5). Install 12 bolts (Figure 25, Item 1), flat
washers (Figure 25, Item 2), and hex nuts (Figure 25, Item 4). Tighten bolts to a preliminary torque of 40 lb-ft
(54 Nm). Tighten bolts to a final torque of 200 lb-ft (271 Nm).
Figure 25. Ring Gear Installation. 0114
0114-19
TM 5-3805-255-14 0114
23. Lubricate side gear (Figure 26, Item 2) and thrust washer (Figure 26, Item 3) with lubricant (WP 0131).
24. Position thrust washer (Figure 26, Item 3) and side gear (Figure 26, Item 2) in ring and case half assembly
Figure 26. Side Gear Installation. 0114
0114-20
TM 5-3805-255-14 0114
25. Lubricate spider (Figure 27, Item 6), four spider gears (Figure 27, Item 2), and thrust washers (Figure 27, Item
5) with lubricant (WP 0021).
26. Place spider (Figure 27, Item 6), spider gears (Figure 27, Item 2), and thrust washers (Figure 27, Item 5) in
position in case half (Figure 27, Item 1).
27. Install remaining side gear (Figure 27, Item 4) and thrust washer (Figure 27, Item 3) on case half (Figure 27,
Item 1).
28. Align mating marks on case halves (Figure 28, Item 1) and secure assembly (Figure 28, Item 3) with four
equally spaced capscrews and hex nuts.
29. Check assembly for free rotation of differential gears (Figure 28, Item 4). Correct if necessary.
30. If ring gear thrust bearings (Figure 28, Item 2) were removed, press new bearings squarely to each case half
(Figure 28, Item 1). Use a suitable sleeve and press only on bearing inner race.
0114-21
TM 5-3805-255-14 0114
31. Install remaining eight bolts (Figure 29, Item 3) and hex nuts (Figure 29, Item 4). Tighten all 12 bolts and hex
nuts to 190 to 200 lb-ft (257 to 271 Nm).
32. Install lockwire on bolts (Figure 29, Item 3).
33. Lubricate two bearings (Figure 29, Item 2) with lubricant (WP 0131).
34. Place two bearing cups (Figure 29, Item 1) over differential bearing cones (Figure 29, Item 2) and position
differential assembly (Figure 29, Item 5) in carrier (Figure 29, Item 6).
0114-22
TM 5-3805-255-14 0114
35. Install two bearing adjusters (Figure 30, Item 2) on rear differential (Figure 30, Item 3).
NOTE
Do not force caps into position.
36. Install two bearing caps (Figure 30, Item 1) on rear differential (Figure 30, Item 3).
37. If bearing caps (Figure 30, Item 1) do not position properly, bearing adjusters (Figure 30, Item 2) may be cross-
threaded. Remove caps and reposition adjusting nuts.
Figure 30. Bearing Cap Installation. 0114
0114-23
TM 5-3805-255-14 0114
38. Install four bearing cap bolts (Figure 31, Item 3) and torque to 25 lb-ft (34 Nm).
39. Loosen bearing adjuster (Figure 31, Item 5) on tooth side of ring gear (Figure 31, Item 1) and tighten opposite
bearing adjuster until all backlash is removed between pinion gear (Figure 31, Item 2) and ring gear.
END OF TASK
ADJUSTMENT 000114
1. Measure backlash between ring gear (Figure 31, Item 1) and pinion gear (Figure 31, Item 2) with a dial
indicator as shown.
2. Backlash is adjusted by backing off one adjuster (Figure 31, Item 5) and tightening opposite adjuster (Figure
31, Item 4) an equal amount. When backlash adjustment is within allowable limit of 0.008 to 0.015 in. (0.203 to
0.381 mm), add a light preload by tightening adjuster (Figure 31, Item 5) on tooth side ring gear an additional
1-1/2 to 2 notches.
3. Torque four bearing cap bolts (Figure 31, Item 3) to 150 to 175 lb-ft (203 to 237 Nm).
Figure 31. Backlash Adjustment. 0114
0114-24
TM 5-3805-255-14 0114
4. Apply Prussian Blue Compound (WP 0131, Item 8) to ring gear teeth (Figure 32, Item 1). When gear is rotated,
Prussian Blue Compound is squeezed away by contact of teeth leaving an imprint the exact size, shape, and
location as gear contact.
5. Sharper impressions may be obtained by applying a small amount of resistance to ring gear with a steel bar
and using a wrench to rotate pinion. When making adjustments, check drive side of ring gear teeth (Figure 32,
Item 1). Coating approximately 12 teeth is sufficient to check tooth contact.
Figure 32. Prussian Blue Compound Application. 0114
6. With adjustments properly made, contacts like those shown in Figure 33 will be obtained. Area of contact
should favor toe and is centered between top and bottom of tooth.
7. After a satisfactory tooth contact pattern is obtained, especially in relation to top and bottom of the tooth,
backlash may be altered within recommended limits of 0.008 to 0.015 in. (0.203 to 0.381 mm) to obtain a better
contact position relative to length of tooth. A high backlash setting can be used to keep contact from starting
too close to the toe. A low backlash setting can be used to keep contact from starting too far away from the toe.
8. Hand-rolled pattern shown in Figure 33 will result in a pattern centered in length of tooth when gears are under
load. Loaded patterns will be almost full length and top of pattern will approach top of gear tooth.
Figure 33. Correct Gear Contact Pattern. 0114
0114-25
TM 5-3805-255-14 0114
9. The pattern on the coast side of teeth will appear the same width as drive side; however, overall length will be
centered between toe and heel of gear tooth.
10. Set used gears with tooth contacts to match established wear pattern. Hand-rolled patterns of used gears will
be smaller in area and should be at toe end of wear pattern.
11. A high contact pattern, as shown in Figure 34, indicates pinion is too far out. Set pinion to correct depth by
removing shims under pinion cage. A slight outward movement of ring gear may be necessary to maintain
correct backlash.
Figure 34. High Contact Pattern. 0114
0114-26
TM 5-3805-255-14 0114
12. A low contact pattern, as shown in Figure 35, indicates pinion is too deep. Set pinion to correct depth by adding
shims under pinion cage. Slight inward movement of ring gear may be necessary to maintain correct backlash.
Figure 35. Low Contact Pattern. 0114
13. Recheck pinion gear-to-ring gear clearance for a full rotation of ring gear.
14. After establishing correct tooth contact, install two adjuster locks (Figure 36, Item 2) and new cotter pins
15. Install lockwire (Figure 36, Item 3) on four bearing cap bolts (Figure 36, Item 4).
Figure 36. Lock Nut Installation. 0114
0114-27
TM 5-3805-255-14 0114
16. Remove carrier (Figure 37, Item 1) from holding fixture. Position assembly with back face of ring gear (Figure
37, Item 5) facing up.
17. Hold jam nut (Figure 37, Item 3) and turn adjusting screw (Figure 37, Item 2) until thrust block (Figure 37, Item
4) is pressed firmly against back face of ring gear (Figure 37, Item 5).
18. Back off adjusting screw (Figure 37, Item 2) until recommended clearance of 0.010 to 0.015 in. (0.254 to 0.381
mm) is obtained.
19. Hold adjusting screw (Figure 37, Item 2) and tighten jam nut (Figure 37, Item 3) securely.
20. Recheck thrust block-to-ring gear clearance for a full rotation of ring gear.
Figure 37. Thrust Block Clearance Adjustment. 0114
0114-28
TM 5-3805-255-14 0114
21. Install oil distributor (Figure 38, Item 2), spring (Figure 38, Item 3), and pipe plug (Figure 38, Item 4) in rear
22. Install rear differential (WP 0055).
Figure 38. Oil Distributor Installation. 0114
END OF TASK
END OF WORK PACKAGE
0114-29/(30 blank)
6
TM 5-3805-255-14 0115
REAR PLANETARY ASSEMBLY REPAIR

0 1 1 5
INITIAL SETUP
0128, Item 20) 0

Materials/Parts 0

Oil, Lubricating, Gear, GO 80/90 (WP 0130, 0004) 0
Item 20) 0
Planetary assembly removed from rear axle

Oil, Lubricating, Gear, GO 85/140 (WP 0130, (WP 0056) 0
Item 21) 0
Brake drum removed (WP 0058) 0
O-ring (2) 0
0115-1
TM 5-3805-255-14 0115
NOTE
The disassembly and assembly procedures are for one planetary assembly. Repeat for
other side.
DISASSEMBLY 000115
1. Remove three nuts (Figure 1, Item 11) from pinion shafts (Figure 1, Item 3).
2. Remove three pinion shafts (Figure 1, Item 3) and pins (Figure 1, Item 12) from planetary carrier (Figure 1,
Item 1).
3. Remove three retaining rings (Figure 1, Item 7), six bearings (Figure 1, Items 4 and 10), and three spacers
(Figure 1, Item 6) from three pinion gears (Figure 1, Item 8).
4. Remove six cups (Figure 1, Items 5 and 9) from three pinion gears (Figure 1, Item 8).
5. Remove ring gear (Figure 1, Item 2) and ring gear hub (Figure 1, Item 20) from planetary carrier (Figure 1,
Item 1).
6. Remove eight bolts (Figure 1, Item 18), four lockplates (Figure 1, Item 19), and ring gear hub (Figure 1,
Item 20) from ring gear (Figure 1, Item 2).
7. Remove seal (Figure 1, Item 17) and bearing (Figure 1, Item 16) from hub (Figure 1, Item 13).
8. Remove cup (Figure 1, Item 15) from hub (Figure 1, Item 13).
9. Remove O-ring (Figure 1, Item 14) from hub (Figure 1, Item 13). Discard O-ring.
0115-2
TM 5-3805-255-14 0115
H100C-1162
END OF TASK
0115-3
TM 5-3805-255-14 0115
1. Clean and inspect all parts thoroughly IAW General Maintenance Instructions (WP 0019).
2. Inspect pinion gears for wear or damage; replace if necessary.
3. Inspect pinion shafts for wear or ridging; replace if necessary.
END OF TASK
ASSEMBLY 000115
1. Install new O-ring (Figure 2, Item 14) on hub (Figure 2, Item 13).
2. Install cup (Figure 2, Item 15) in hub (Figure 2, Item 13).
3. Install bearing (Figure 2, Item 16) and seal (Figure 2, Item 17) on hub (Figure 2, Item 13).
4. Install ring gear hub (Figure 2, Item 20), four lockplates (Figure 2, Item 19), and eight bolts (Figure 2, Item 18)
on ring gear (Figure 2, Item 2).
5. Install ring gear (Figure 2, Item 2) and ring gear hub (Figure 2, Item 20) on planetary carrier (Figure 2, Item 1).
6. Install six cups (Figure 2, Items 5 and 9) on three pinion gears (Figure 2, Item 8).
7. Install six bearings (Figure 2, Items 4 and 10), three retaining rings (Figure 2, Item 7), and spacers (Figure 2,
Item 6) on pinion gears (Figure 2, Item 8).
NOTE
Install all three pinion gears before installing pinion shafts.
8. Install three pinion gears (Figure 2, Item 8) in planetary carrier (Figure 2, Item 1).
NOTE
Chill pinion shafts for ease of installation.
9. Install three pinion shafts (Figure 2, Item 3) and pins (Figure 2, Item 12) in planetary carrier (Figure 2, Item 1).
NOTE
Position nuts to fit inside ID of gasket on planetary carrier.
10. Install three nuts (Figure 2, Item 11) on pinion shafts (Figure 2, Item 3) and torque to 450 lb-ft (610 Nm).
11. Install brake drum (WP 0058).
12. Install planetary assembly on rear axle (WP 0056).
0115-4
TM 5-3805-255-14 0115
H100C-1162
END OF TASK
END OF WORK PACKAGE
0115-5/(6 blank)
14
TM 5-3805-255-14 0116
STEERING GEAR REPAIR

0 1 1 6
Disassembly, Inspection, Repair, Assembly
INITIAL SETUP
0128, Item 20) 0

(WP 0128, Item 25) 0
Materials/Parts 0
Lubriplate Lubricating Fluid (WP 0130, Item Battery disconnect switch in OFF position (WP
17) 0
0004) 0
Steering gear removed (WP 0068) 0
Gasket 0
Seal (2) 0
0116-1
TM 5-3805-255-14 0116
DISASSEMBLY 000116
CAUTION
Place gear housing in a suitable holding device. Do not apply excess pressure to housing.
Failure to follow this caution may result in damage to component.
1. Place gear assembly (Figure 1, Item 3) in suitable holding device.
2. Mark on worm shaft (Figure 1, Item 4) in line with reference indicator on flange (Figure 1, Item 1) to insure
proper positioning of parts during assembly.
3. Remove flange bolt (Figure 1, Item 2) and flange (Figure 1, Item 1) from gear assembly (Figure 1, Item 3).
4. Loosen nut (Figure 1, Item 6) from lash adjuster screw (Figure 1, Item 5).
CAUTION
Remove load from worm bearing. Failure to comply may result in damage to equipment.
5. Turn lash adjuster screw (Figure 1, Item 5) three turns counterclockwise.
6. Loosen bearing adjuster nut (Figure 1, Item 7) and remove bearing adjuster (Figure 1, Item 8).
0116-2
TM 5-3805-255-14 0116
7. Remove three bolts (Figure 2, Item 3) and lockwashers (Figure 2, Item 4) from side cover (Figure 2, Item 7).
8. Remove side cover (Figure 2, Item 7), nut (Figure 2, Item 6) and spur shaft (Figure 2, Item 5) from gear
9. Remove and discard cover gasket (Figure 2, Item 8).
10. Remove worm shaft (Figure 2, Item 1) from gear housing (Figure 2, Item 2).
Figure 2. Cover Plate Removal. 0116
0116-3
TM 5-3805-255-14 0116
11. Remove and discard seal (Figure 3, Item 2) from gear housing (Figure 3, Item 1).
Figure 3. Gear Housing Disassembly. 0116
END OF TASK
1. Thoroughly clean all parts IAW General Maintenance Instructions (WP 0019). Dry with compressed air.
2. Inspect gear housing (Figure 4, Item 1) for cracks or stripped threads in tapped holes.
3. Inspect bushing for wear or damage and replace if necessary.
4. Measure bushing depth at housing bore. Bushing should be 0.03 in. below bore face. Replace bushing if
greater than 0.03 in. Refer to Figure 5. If bushing is worn, replace as outlined in this work package under
REPAIR.
5. Inspect upper (Figure 4, Item 12) and lower ball bearing (Figure 4, Item 6). If damaged or worn, replace.
6. Examine side cover (Figure 4, Item 4) for cracks or damage. Check clearance between spur shaft (Figure 4,
Item 3) and side cover bushing. If bushing is scored, damaged, or excessively worn, replace side cover and
bushing as an assembly.
7. Inspect spur shaft (Figure 4, Item 3) for damaged splines and/or threads. Examine sector gear teeth (Figure 4,
Item 5) for scuffing and scoring. Check that shaft outside diameter is 1.12 in. If excessive wear is evident at any
of these points, replace spur shaft.
8. Inspect bearing areas and thread groove on worm shaft (Figure 4, Item 11). If worm is galled, replace worm
shaft and ball nut as an assembly (Figure 4, Item 10).
9. Check worm ball nut teeth (Figure 4, Item 10) for scuffing and/or scoring. Inspect holes and passages for
obstructions. If damaged, replace worm shaft (Figure 4, Item 11) and worm ball nut teeth as an assembly.
10. Inspect threads on lower end of worm shaft (Figure 4, Item 11). Threads must be clean and free of nicks and
burrs.
11. Inspect cup (Figure 4, Item 7) for wear or damage and replace if necessary.
0116-4
TM 5-3805-255-14 0116
H100C-0884
Figure 4. Steering Gear Inspection. 0116
END OF TASK
0116-5
TM 5-3805-255-14 0116
REPAIR 000116
1. Remove pitman shaft bushing (Figure 5, Item 1) from housing (Figure 5, Item 2).
2. Install new shaft bushing (Figure 5, Item 1) in position. Press bushing flush with edge of housing bore (Figure
5, Item 3).
Figure 5. Housing Bushing and Seal Replacement. 0116
3. Remove cup (Figure 6, Item 1) from adjuster (Figure 6, Item 2).

4. Install a new cup (Figure 6, Item 1) in adjuster (Figure 6, Item 2) using a minimum of 7,000 lb (17,792 Nm)
force to seat cup.
Figure 6. Adjuster Cup Replacement. 0116
END OF TASK
0116-6
TM 5-3805-255-14 0116
ASSEMBLY 000116
NOTE
All parts must be kept clean. Grease and oil used during assembly must be free from dirt
or other contaminants. Prelubricate all bearings and moving parts with lubricating fluid.
1. Place worm shaft assembly (Figure 7, Item 1) horizontal on clean work bench. Place ball nut (Figure 7, Item 2)
over worm with return guide holes (Figure 7, Item 3) in ball nut facing up. Align groove in worm and ball nut by
sight.
2. Count and place half of balls (Figure 7, Item 4) in a clean container (Figure 7, Item 5).
3. Drop balls into one of the ball return guide holes (Figure 7, Item 3). Slowly rotate worm (Figure 7, Item 1) away
from hole while inserting balls. Continue until circuit is filled from bottom of hole to bottom of the other or until
stopped by reaching end of worm.
4. If balls are stopped at end of worm shaft (Figure 7, Item 1), hold down balls already installed with rod or punch.
Rotate worm shaft in a reverse direction a few turns. Filling of circuit may then be continued. It may be
necessary to work worm shaft back and forth holding balls down first in one hole and then in the other. This will
close-up spaces between balls, filling the circuit completely.
Figure 7. Worm and Ball Nut Assembly. 0116
0116-7
TM 5-3805-255-14 0116
5. Lay half of ball guide (Figure 8, Item 2) groove up, on bench. Place remaining balls (Figure 8, Item 1) in groove
of guide. Cover assembly with opposite half of guide (Figure 8, Item 3). Hold two halves together and plug
each end with technical petrolatum to prevent balls from dropping out while installing guide.
Figure 8. Ball and Guide Assembly. 0116
6. Push ball return guide (Figure 9, Item 1) completely in holes on ball nut (Figure 9, Item 2). If guide does not
push down all the way easily, tap it lightly into place. This completes one circuit of balls.
7. Fill remaining circuit with balls in the same manner described in step 6.
Figure 9. Ball Guide Installation. 0116
0116-8
TM 5-3805-255-14 0116
8. Install ball return guide clamp (Figure 10, Item 2) on ball nut (Figure 10, Item 4).
9. Install screw (Figure 10, Item 1) through guide clamp (Figure 10, Item 2) in ball nut (Figure 10, Item 4). Tighten
screw securely.
10. Make sure ball nut (Figure 10, Item 4) and balls (Figure 10, Item 5) are thoroughly lubricated. Test assembly by
rotating ball nut on worm shaft (Figure 10, Item 3). Do not rotate ball nut to end of worm shaft threads.
Assembly must move freely. Temporarily tape worm shaft at both ends of ball nut until ready to be installed
during assembly.
Figure 10. Ball Guide Fastener Installation. 0116
11. Remove tape from worm shaft (Figure 11, Item 2). Secure ball nut (Figure 11, Item 1) in place on shaft (Figure
11, Item 2).
12. Insert worm shaft (Figure 11, Item 2) in gear housing (Figure 11, Item 3).
Figure 11. Worm Shaft Installation. 0116
0116-9
TM 5-3805-255-14 0116
13. Install adjuster screw (Figure 12, Item 2) and shims (Figure 12, Item 3) into slotted end of spur shaft (Figure 12,
Item 1).
Figure 12. Pitman Arm Shaft Installation. 0116
14. Use a feeler gauge and measure clearance between head of screw (Figure 13, Item 2) and spur shaft (Figure
13, Item 1). Clearance must not be more than 0.002 in. (0.0500 mm). If clearance is greater than 0.002 in.
(0.0500 mm), select a thicker shim. Four sizes are available:
• HA-1440 Shim - 0.063 in. (1.600 mm)
• HA-1441 Shim - 0.065 in. (1.651 mm)
• HA-1445 Shim - 0.067 in. (1.702 mm)
• HA-1446 Shim - 0.069 in. (1.753 mm)
0116-10
TM 5-3805-255-14 0116
15. Install side cover (Figure 14, Item 2) on spur shaft (Figure 14, Item 1).
Figure 14. Pitman Shaft Installation. 0116
16. Install spur shaft (Figure 15, Item 2) into housing (Figure 15, Item 1).
17. Ensure spur shaft teeth (Figure 15, Item 3) and ball nut (Figure 15, Item 4) are properly aligned.
Figure 15. Ball Nut Gear Alignment. 0116
0116-11
TM 5-3805-255-14 0116
18. Install new gasket (Figure 16, Item 8) and side cover (Figure 16, Item 7) on housing (Figure 16, Item 2).
19. Back off adjuster screw to permit lash (play) between spur shaft and ball nut on worm shaft (Figure 16, Item 1).
20. Install three side cover bolts (Figure 16, Item 4) with new lockwashers (Figure 16, Item 3) and tighten to 25 to
40 lb-ft (34 to 54 Nm) torque.
21. Install nut (Figure 16, Item 6) on adjuster screw (Figure 16, Item 5).
Figure 16. Steering Gear Assembly. 0116
0116-12
TM 5-3805-255-14 0116
22. Install bearing cup (Figure 17, Item 3), bearing (Figure 17, Item 4) and retainer (Figure 17, Item 5) in adjuster
23. Install adjuster (Figure 17, Item 2) on worm shaft (Figure 17, Item 7) and gear housing (Figure 17, Item 6).
24. Install bearing adjuster nut (Figure 17, Item 1) on adjuster (Figure 17, Item 2). Do not tighten nut.
25. Install and adjust steering gear (WP 0068).
END OF TASK
END OF WORK PACKAGE
0116-13/(14 blank)
4
TM 5-3805-255-14 0117
0 1 1 7 STEERING PUMP ASSEMBLY REPAIR

Disassembly, Assembly
INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0


Seal Ring 0
Seal, Primary 0 0004) 0
Seal, Secondary 0 Steering pump removed (WP 0070) 0
0117-1
TM 5-3805-255-14 0117
DISASSEMBLY 000117
NOTE
Mark pump housing to pump body to aid in assembly.
1. Remove four bolts (Figure 1, Item 11) from pump housing (Figure 1, Item 1).
2. Remove pump assembly (Figure 1, Item 2) and seal ring (Figure 1, Item 3) from pump body (Figure 1, Item 4).
Discard seal ring.
3. Remove snap ring (Figure 1, Item 10) from shaft (Figure 1, Item 8).
4. Remove shaft (Figure 1, Item 8) and bearing (Figure 1, Item 9) from pump body (Figure 1, Item 4).
5. Remove washer (Figure 1, Item 7), primary seal (Figure 1, Item 6), and secondary seal (Figure 1, Item 5) from
pump body (Figure 1, Item 4). Discard seals.
6. Remove bearing (Figure 1, Item 9) from shaft (Figure 1, Item 8).
Figure 1. Steering Pump Assembly. 0117
END OF TASK
0117-2
TM 5-3805-255-14 0117
2. Inspect pump assembly for leaks or damage; replace if necessary.
END OF TASK
ASSEMBLY 000117
NOTE
Lubricate seal with technical petrolatum.
1. Install new secondary seal (Figure 1, Item 5) new primary seal (Figure 1, Item 6) and washer (Figure 1, Item 7)
on pump body (Figure 1, Item 4).
2. Install bearing (Figure 1, Item 9) and snap ring (Figure 1, Item 10) on shaft (Figure 1, Item 8).
3. Install shaft (Figure 1, Item 8) in pump body (Figure 1, Item 4).
4. Install new seal ring (Figure 1, Item 3) and pump assembly (Figure 1, Item 2) in pump body (Figure 1, Item 4).
5. Align pump housing (Figure 1, Item 1) marks with pump body (Figure 1, Item 4) and install four bolts (Figure 1,
Item 11) to pump body.
6. Install steering pump (WP 0070).
END OF TASK
END OF WORK PACKAGE
0117-3/(4 blank)
6
TM 5-3805-255-14 0118
HYDRAULIC STEERING CYLINDERS REPAIR

0 1 1 8
INITIAL SETUP
0128, Item 20) 0
References 0

Materials/Parts 0
22) 0

O-Ring (2) 0 0004) 0
Ring, Piston (2) 0 Steering cylinders removed (WP 0071) 0
Seal, Set 0
Seal (3) 0
0118-1
TM 5-3805-255-14 0118
DISASSEMBLY 000118
NOTE
Drain excess oil out of cylinder. Disassemble cylinder in a clean area.
1. Use spanner wrench to remove retaining cap (Figure 1, Item 12) from steering cylinder (Figure 1, Item 3).
2. Remove steering rod assembly (Figure 1, Item 11) from steering cylinder (Figure 1, Item 3).
3. Remove nut (Figure 1, Item 4) from threaded end of steering rod assembly (Figure 1, Item 11).
4. Remove piston (Figure 1, Item 5) from steering rod assembly (Figure 1, Item 11).
5. Remove two piston rings (Figure 1, Item 16) and set seals (Figure 1, Item 6) from piston (Figure 1, Item 5).
Discard rings and seals.
6. Remove gland (Figure 1, Item 7), seal (Figure 1, Item 8), and backup ring (Figure 1, Item 9) from steering rod
assembly (Figure 1, Item 11). Discard seal and backup ring.
7. Remove seals (Figure 1, Items 15 and 14) and O-ring (Figure 1, Item 13) from steering rod assembly (Figure 1,
Item 11). Discard seals and O-ring.
8. Remove retaining cap (Figure 1, Item 12) from steering rod assembly (Figure 1, Item 11).
9. Remove two lubrication fittings (Figure 1, Item 2) and set screws (Figure 1, Item 1) from steering rod assembly
(Figure 1, Item 11) and steering cylinder (Figure 1, Item 3).
10. Remove two bushings (Figure 1, Item 10) from steering cylinder (Figure 1, Item 3) and steering rod assembly
0118-2
TM 5-3805-255-14 0118
Figure 1. Steering Cylinder Assembly. 0118
END OF TASK
0118-3
TM 5-3805-255-14 0118
2. Flush cylinder with lubricant to protect cylinder walls from oxidation.
3. Check inside cylinder surface for scratches and pitted areas. Replace if necessary.
4. Inspect rod assembly and bushings for scores, grooves, or surface damage. Replace if necessary.
END OF TASK
ASSEMBLY 000118
CAUTION
Coat piston, seals, rings, and gland with lubricant to prevent damage to piston packing
rings. Failure to follow this caution may result in failure of steering cylinder.
1. Install two bushings (Figure 2, Item 10), lubrication fittings (Figure 2, Item 2), and set screws (Figure 2, Item 1)
on steering rod assembly (Figure 2, Item 11) and steering cylinder (Figure 2, Item 3).
2. Install retaining cap (Figure 2, Item 12) on steering rod assembly (Figure 2, Item 11).
3. Install new seals (Figure 2, Items 15 and 14) and new O-ring (Figure 2, Item 13) on steering rod assembly
4. Install gland (Figure 2, Item 7), new seal (Figure 2, Item 8), and new backup ring (Figure 2, Item 9) on steering
rod assembly (Figure 2, Item 4).
5. Install two new piston rings (Figure 2, Item 16) and new set seals (Figure 2, Item 6) on piston (Figure 2, Item 5).
6. Install piston (Figure 2, Item 5) on steering rod assembly (Figure 2, Item 11).
7. Install nut (Figure 2, Item 4) on threaded end of steering rod assembly (Figure 2, Item 11).
CAUTION
Insert steering rod into cylinder one ring at a time. The point of the “V” of each ring must
point toward threaded opening of retaining cap. Failure to follow this caution may result in
8. Install steering rod assembly (Figure 2, Item 11) on steering cylinder (Figure 2, Item 3).
9. Install retaining cap (Figure 2, Item 12), with spanner wrench, on steering cylinder (Figure 2, Item 3).
10. Install steering cylinder (WP 0071).
0118-4
TM 5-3805-255-14 0118
Figure 2. Steering Cylinder Assembly. 0118
END OF TASK
END OF WORK PACKAGE
0118-5/(6 blank)
14
TM 5-3805-255-14 0119
STEERING CONTROL VALVE REPAIR

0 1 1 9
INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0



Tag, Marker (WP 0130, Item 37) 0 0004) 0
Lockwasher (4) 0 Steering control valve removed (WP 0072) 0
O-ring (5) 0
Seal (2) 0
Seal Ring (4) 0
DISASSEMBLY 000119
1. Remove four capscrews (Figure 1, Item 3), lockwashers (Figure 1, Item 2), and plunger cap (Figure 1, Item 4)
from steering control valve body (Figure 1, Item 1).
Figure 1. Plunger Cap Removal. 0119
0119-1
TM 5-3805-255-14 0119
2. Remove two bolts (Figure 2, Item 6), washers (Figure 2, Item 5), plunger seal plate (Figure 2, Item 4), and
wiper (Figure 2, Item 3) from control valve (Figure 2, Item 1).
3. Remove and discard seal (Figure 2, Item 2) from valve bore.
Figure 2. Plunger Seal Plate Removal. 0119
4. Remove plunger assembly (Figure 3, Item 2) from valve (Figure 3, Item 1).
Figure 3. Plunger Assembly Removal. 0119
0119-2
TM 5-3805-255-14 0119
NOTE
Tie shim pack together and tag for ease of assembly.
5. Remove seal (Figure 4, Item 11) and backup ring (Figure 4, Item 10) from plunger (Figure 4, Item 7). Discard
seal.
6. Remove shim pack (Figure 4, Item 9), and spacer (Figure 4, Item 8) from plunger (Figure 4, Item 7).
7. Remove nut (Figure 4, Item 1) and slide washer (Figure 4, Item 2), spacer (Figure 4, Item 3), spring (Figure 4,
Item 4), and spacers (Figure 4, Items 5 and 6) from plunger (Figure 4, Item 7).
Figure 4. Control Plunger Disassembly. 0119
8. Remove cap (Figure 5, Item 4) and seal ring (Figure 5, Item 3) from control valve (Figure 5, Item 1) Discard
seal ring.
9. Remove lock plunger (Figure 5, Item 2) from valve (Figure 5, Item 1).
Figure 5. Lock Plunger Removal. 0119
0119-3
TM 5-3805-255-14 0119
10. Remove snap ring (Figure 6, Item 6) and slide plug (Figure 6, Item 5), spring (Figure 6, Item 3), and check
(Figure 6, Item 2) from plunger (Figure 6, Item 1).
11. Remove and discard O-ring (Figure 6, Item 4) from plug.
Figure 6. Lock Plunger Disassembly. 0119
12. Remove cap (Figure 7, Item 4) and seal ring (Figure 7, Item 3) and slide spring (Figure 7, Item 2) from valve
(Figure 7, Item 1). Discard seal ring.
Figure 7. Cap and Spring Removal. 0119
0119-4
TM 5-3805-255-14 0119
13. Remove nut (Figure 8, Item 6) and washer (Figure 8, Item 5) from control valve (Figure 8, Item 1). Discard
washer.
NOTE
Mark position of adjusting screw before disassembly, for ease of installation.
14. Hold adjusting screw (Figure 8, Item 4) and loosen jamnut (Figure 8, Item 3). Remove adjusting screw and
washer (Figure 8, Item 2). Discard washer.
Figure 8. Adjusting Screw Assembly Removal. 0119
0119-5
TM 5-3805-255-14 0119
15. Remove cap (Figure 9, Item 9) and slide spring (Figure 9, Item 7), poppet (Figure 9, Item 6), seat (Figure 9,
Item 5), spring (Figure 9, Item 3), check (Figure 9, Item 2), and O-rings (Figure 9, Items 4 and 8) from valve
(Figure 9, Item 1). Discard O-rings.
Figure 9. Poppet Removal. 0119
16. Remove cap (Figure 10, Item 7) and slide spring (Figure 10, Item 5), check (Figure 10, Item 4), seat (Figure 10,
Item 3), and O-rings (Figure 10, Items 2 and 6) from valve (Figure 10, Item 1). Discard O-rings.
Figure 10. Check Removal. 0119
0119-6
TM 5-3805-255-14 0119
17. Remove cap (Figure 11, Item 5) and slide spring (Figure 11, Item 3) and check (Figure 11, Item 2) from valve
18. Remove and discard seal ring (Figure 11, Item 4) from cap (Figure 11, Item 5).
Figure 11. Check Valve Removal. 0119
END OF TASK
2. Inspect all surfaces for burrs, scratches, nicks, scores, and other abrasions. Replace valve assembly if worn or
damaged.
END OF TASK
0119-7
TM 5-3805-255-14 0119
ASSEMBLY 000119
1. Lubricate new seal ring (Figure 12, Item 4) with technical petrolatum and install on cap (Figure 12, Item 5).
2. Install check (Figure 12, Item 2) and spring (Figure 12, Item 3) in control valve (Figure 12, Item 1).
3. Install cap (Figure 12, Item 5) and tighten securely.
Figure 12. Check Valve Installation. 0119
4. Lubricate new O-rings (Figure 13, Items 4 and 8) with technical petrolatum and install on seat (Figure 13,
Item 5) and cap (Figure 13, Item 9).
5. Install check (Figure 13, Item 2), spring (Figure 13, Item 3), seat (Figure 13, Item 5), poppet (Figure 13, Item 6),
and spring (Figure 13, Item 7) in valve (Figure 13, Item 1).
6. Install cap (Figure 13, Item 9) and tighten securely.
Figure 13. Check Installation. 0119
0119-8
TM 5-3805-255-14 0119
7. Install adjusting screw (Figure 14, Item 4) in valve (Figure 14, Item 1). Turn screw in to approximate position at
time of disassembly.
8. Install new washer (Figure 14, Item 2) and jamnut (Figure 14, Item 3).
9. Install new washer (Figure 14, Item 5) and nut (Figure 14, Item 6) finger tight. Refer to WP 0072 for correct
adjustment procedure.
11. Install spring (Figure 15, Item 2) in valve (Figure 15, Item 1).
12. Install cap (Figure 15, Item 4) on valve (Figure 15, Item 1) and tighten securely.
Figure 15. Cap Installation. 0119
0119-9
TM 5-3805-255-14 0119
13. Lubricate new O-ring (Figure 16, Item 4) with technical petrolatum and install on plug (Figure 16, Item 5).
14. Install check (Figure 16, Item 2), spring (Figure 16, Item 3), and plug (Figure 16, Item 5) in lock plunger (Figure
16, Item 1). Hold plug down and install snap ring (Figure 16, Item 6).
16. Install lock plunger assembly (Figure 17, Item 2) in control valve (Figure 17, Item 1).
17. Install cap (Figure 17, Item 4) on control valve (Figure 17, Item 1) and tighten securely.
Figure 17. Lock Plunger Installation. 0119
0119-10
TM 5-3805-255-14 0119
18. Lubricate new seal (Figure 18, Item 11) and control plunger (Figure 18, Item 7) with technical petrolatum.
NOTE
Word “OUTSIDE”, molded into seal, must face toward threaded end of plunger. DO NOT
push seal onto plunger past first land.
19. Install seal (Figure 18, Item 11) on plunger shoulder (Figure 18, Item 7) at threaded end of plunger. Use shim
stock on plunger to avoid damage to sealing lip of seal.
20. Slide backup ring (Figure 18, Item 10), shim pack (Figure 18, Item 9), and spacer (Figure 18, Item 8) on
plunger shoulder (Figure 18, Item 7). Be careful not to break backup ring.
21. Assemble spacers (Figure 18, Items 5 and 6), spring (Figure 18, Item 4), spacer (Figure 18, Item 3), and
washer (Figure 18, Item 2) on plunger (Figure 18, Item 7).
22. Apply Loctite 242 sealant to plunger threads and assemble nut (Figure 18, Item 1) on plunger. Clamp plunger
in a vise between wooden blocks and tighten nut securely.
Figure 18. Control Plunger Assembly. 0119
23. Install control plunger (Figure 19, Item 2) in valve (Figure 19, Item 1) until shoulder with seal (Figure 19, Item 3)
is far enough into valve bore to allow seal to be pressed into seat of bore. DO NOT at any time allow seal to
move off plunger shoulder into groove.
Figure 19. Control Plunger Installation. 0119
0119-11
TM 5-3805-255-14 0119
24. Align capscrew holes in shim pack (Figure 20, Item 2), spacer (Figure 20, Item 3), and plunger cap (Figure 20,
Item 6).
25. Install four new lockwashers (Figure 20, Item 4) and capscrews (Figure 20, Item 5). Tighten capscrews
securely.
Figure 20. Plunger Fastener Installation. 0119
0119-12
TM 5-3805-255-14 0119
26. Lubricate new seal (Figure 21, Item 2) and plunger (Figure 21, Item 7) with technical petrolatum. Install seal on
plunger shoulder and press into seat in valve bore (Figure 21, Item 8). Observe precautions outlined above to
avoid seal damage.
27. Install wiper (Figure 21, Item 3), seal plate (Figure 21, Item 4), two new lockwashers (Figure 21, Item 5) and
capcrews (Figure 21, Item 6) on control valve (Figure 21, Item 1).
Figure 21. Seal Plate Installation. 0119
28. Install steering control valve on loader (WP 0072).
END OF TASK
END OF WORK PACKAGE
0119-13/(14 blank)
6
TM 5-3805-255-14 0120
MAIN HYDRAULIC PUMP REPAIR

0 1 2 0
INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP Sealing Ring (4) 0
0128, Item 20) 0

Shaft Seal 0
Seal Installation Tool (WP 0125, Item 7) 0

Wiper, Felt 0
Materials/Parts 0
References 0

WP 0019 0
Backup Ring (4) 0

Lock Ring (2) 0

O-Ring (4) 0
Oil Seal Retainer (8) 0

0004) 0
Ring, Snap 0
Main hydraulic pump removed (WP 0077) 0
0120-1
TM 5-3805-255-14 0120
DISASSEMBLY 000120
NOTE
Mark pump housing to pump cover and pump body for ease of assembly.
1. Remove four bolts (Figure 1, Item 1) from cover (Figure 1, Item 2).
CAUTION
Before removing pump from housing note direction of rotation and GPM rating. It is
essential that pump be reassembled correctly. The direction of rotation is viewed from
shaft end; right-hand rotation is clockwise; left-hand, counterclockwise. Failure to follow
2. Remove cover (Figure 1, Item 2) and pump assembly (Figure 1, Item 3) from pump housing (Figure 1, Item 4).
3. Remove four bolts (Figure 1, Item 6) from housing (Figure 1, Item 4).
4. Remove housing (Figure 1, Item 4) from main hydraulic pump body (Figure 1, Item 13).
5. Remove second pump assembly (Figure 1, Item 5) from main hydraulic pump body (Figure 1, Item 13).
6. Remove sealing ring (Figure 1, Item 7) and shaft (Figure 1, Item 10) with bearing (Figure 1, Item 9) from main
hydraulic pump body (Figure 1, Item 13).
NOTE
Current bearings may not use snap ring and groove on outer bearing race OD. Note if
snap ring is present on shaft.
7. Remove flat washer (Figure 1, Item 11), oil seal, and felt wiper (Figure 1, Item 12) from pump body (Figure 1,
Item 13). Discard oil seal and felt wiper.
8. Remove and discard snap ring (Figure 1, Item 8) (if used) from shaft (Figure 1, Item 10).
9. Support inner race of bearing (Figure 1, Item 9) with suitable tool.
10. Remove bearing (Figure 1, Item 9) from shaft (Figure 1, Item 10).
0120-2
TM 5-3805-255-14 0120
END OF TASK
2. Coat all parts with clean hydraulic fluid to facilitate assembly and provide initial lubrication. Use small amounts
of technical petrolatum to hold O-rings in place during assembly.
END OF TASK
0120-3
TM 5-3805-255-14 0120
ASSEMBLY 000120
NOTE
Direction of rotation is viewed from shaft end; right hand rotation is clockwise; left hand,
counterclockwise. Use Seal Installation Tool for seal installation (WP 0116 01).
1. Install new oil seal and new felt wiper (Figure 2, Item 12), and flat washer (Figure 2, Item 11) in pump body
2. Support inner race of bearing (Figure 2, Item 9) with suitable tool.
3. Install shaft (Figure 2, Item 10) in bearing (Figure 2, Item 9).
4. Install new snap ring (if used) (Figure 2, Item 8) on shaft (Figure 2, Item 10).
5. Install shaft (Figure 2, Item 10) with bearing (Figure 2, Item 9), and new snap ring (if used) (Figure 2, Item 8) in
pump body (Figure 2, Item 13).
6. Secure with new sealing ring (Figure 2, Item 7).
NOTE
Lubricate O-rings and backup rings on pump with technical petrolatum.
7. Install pump assembly, on body (Figure 2, Item 13).
8. Install housing (Figure 2, Item 4) and four bolts (Figure 2, Item 6) to body (Figure 2, Item 13). Torque bolts to
85 to 95 lb-ft (115 to 128 Nm).
9. Install cover (Figure 2, Item 2) and pump assembly (Figure 2, Item 3) on housing assembly (Figure 2, Item 4)
with twisting action.
10. Line up scribe marks on cover (Figure 2, Item 2), housing (Figure 2, Item 4), and main hydraulic pump body
11. Install four bolts (Figure 2, Item 1) on cover (Figure 2, Item 2). Torque bolts to 65 to 75 lb-ft (88 to 101 Nm).
0120-4
TM 5-3805-255-14 0120
12. Install main hydraulic pump on loader (WP 0077).

13. Check and fill hydraulic reservoir (WP 0018).
14. Turn battery disconnect switch to ON position and start engine.
15. Check all hydraulic connections made for leaks. Check main hydraulic pump for proper operation.
END OF TASK
END OF WORK PACKAGE
0120-5/(6 blank)
26
TM 5-3805-255-14 0121
MAIN CONTROL VALVE OVERHAUL

0 1 2 1
INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP Seal Ring (2) 0
0128, Item 20) 0

Washer, Copper 0

Common #1 (WP 0128, Item 14) 0 WP 0019 0
Materials/Parts 0 Equipment Condition 0
(WP 0130, Item 3) 0

0130, Item 15) 0

0004) 0
Backup Ring (5) 0

Main control valve removed from loader (WP
O-ring (14) 0 0078) 0
0121-1
TM 5-3805-255-14 0121
DISASSEMBLY 000121
CAUTION
• Disassemble main control valve on a clean work bench.
• Plug or cap valve ports and openings to prevent entry of dirt.
• Note orientation of components as they are removed and disassembled.
• Failure to follow these cautions may result in damage to equipment.
1. Remove poppet plug (Figure 1, Item 3) from main control valve (Figure 1, Item 1).
2. Remove and discard seal ring (Figure 1, Item 2) from poppet plug (Figure 1, Item 3).
Figure 1. Main Control Valve (Spool End). 0121
3. Remove poppet plug (Figure 2, Item 1) from main control valve (Figure 2, Item 3).
Figure 2. Main Control Valve (Plunger Cap End). 0121
0121-2
TM 5-3805-255-14 0121
5. Remove poppet plug (Figure 3, Item 10), spring (Figure 3, Item 8), and poppet valve assembly (Figure 3, Item
2) from main control valve (Figure 3, Item 1).
7. Hold lower portion of poppet (Figure 3, Item 2) and remove locknut (Figure 3, Item 7).
8. Remove O-rings (Figure 3, Items 6 and 3), backup ring (Figure 3, Item 5), and spacer (Figure 3, Item 4) from
lower portion of poppet valve (Figure 3, Item 2). Discard O-rings and backup ring.
Figure 3. Poppet Removal. 0121
0121-3
TM 5-3805-255-14 0121
NOTE
Spacer is found only in bucket plunger. Spacer is not used on machines equipped with
bucket leveler.
9. Remove plug (Figure 4, Item 5) from sleeve (Figure 4, Item 1).
10. Slide piston (Figure 4, Item 2) and spacer (Figure 4, Item 3) (if used) from sleeve (Figure 4, Item 1).
11. Remove and discard O-ring (Figure 4, Item 4) from plug (Figure 4, Item 5).
12. Remove plug (Figure 4, Item 6) from sleeve (Figure 4, Item 9).
13. Slide piston (Figure 4, Item 8) from sleeve (Figure 4, Item 9).
14. Remove and discard O-ring (Figure 4, Item 7) from plug (Figure 4, Item 6).
Figure 4. Pistons Removal. 0121
15. Remove snap ring (Figure 5, Item 1) and spacer (Figure 5, Item 3) from detent sleeve (Figure 5, Item 2).
Discard snap ring.
Figure 5. Snap Ring and Spacer Removal. 0121
0121-4
TM 5-3805-255-14 0121
16. Remove two capscrews (Figure 6, Item 2) and plunger cap (Figure 6, Item 3) from valve body (Figure 6,
Item 1).
Figure 6. Plunger Cap Removal. 0121
17. Remove scraper ring (Figure 7, Item 3), spacer ring (Figure 7, Item 2), and O-ring (Figure 7, Item 1) from eye
end of plunger (Figure 7, Item 4). Discard O-ring.
Figure 7. Scraper, Spacer, and O-Ring Removal. 0121
0121-5
TM 5-3805-255-14 0121
18. Pull boom plunger assembly (Figure 8, Item 2) from valve body (Figure 8, Item 1).
Figure 8. Boom Plunger Assembly Removal. 0121
19. Slide detent sleeve (Figure 9, Item 1) from plunger (Figure 9, Item 3) using a punch to depress detent cam
(Figure 9, Item 4). Use caution to prevent loss of detent balls (Figure 9, Item 2).
Figure 9. Detent Sleeve Removal. 0121
0121-6
TM 5-3805-255-14 0121
20. Slide spring (Figure 10, Item 2), detent cam (Figure 10, Item 4), and detent balls (Figure 10, Item 3) from
plunger assembly (Figure 10, Item 1).
Figure 10. Spring, Cam and Detent Balls Removal. 0121
CAUTION
Use caution to prevent damage to holes. Failure to follow this caution may result in
damage to components.
21. Place eye end of plunger (Figure 11, Item 3) in vise with protective jaws. Remove plunger pin (Figure 11, Item
1) from plunger assembly (Figure 11, Item 2) using a rod of approximate diameter of holes in end of plunger.
Figure 11. Plunger Removal. 0121
0121-7
TM 5-3805-255-14 0121
WARNING
Exert pressure against plunger pin as it disengages plunger and release spring tension
slowly. Failure to follow this warning may result in injury to personnel.
22. Remove plunger pin (Figure 12, Item 5), spring (Figure 12, Item 4), spring seat (Figure 12, Item 3), and seal
plate (Figure 12, Item 1) from plunger (Figure 12, Item 2).
Figure 12. Plunger Disassembly. 0121
23. Repeat step 22 to remove bucket plunger.

24. Disassemble main relief valve (Figure 13, Item 1) as follows:
a. Loosen and remove acorn nut (Figure 13, Item 13) and washer (Figure 13, Item 11).
b. Remove jamnut (Figure 13, Item 12), washer (Figure 13, Item 11), and screw (Figure 13, Item 10).
c. Slide spring (Figure 13, Item 9) and poppet (Figure 13, Item 8) from plug (Figure 13, Item 7).
d. Remove plug (Figure 13, Item 7).
e. Remove and discard O-rings (Figure 13, Items 4 and 6) and backup ring (Figure 13, Item 5) from plug
f. Slide spring (Figure 13, Item 3), piston (Figure 13, Item 2), and poppet (Figure 13, Item 15) from sleeve
g. Remove and discard O-ring (Figure 13, Item 4) and backup ring (Figure 13, Item 5) from poppet (Figure
13, Item 15).
h. Tap sleeve (Figure 13, Item 14) from valve body (Figure 13, Item 1).
0121-8
TM 5-3805-255-14 0121
Figure 13. Main Relief Valve Disassembly. 0121
0121-9
TM 5-3805-255-14 0121
NOTE
The cylinder relief valves are cartridge type valves and may be removed as a unit.
25. Disassemble bucket cylinder relief valve assembly as follows:
26. Loosen and remove valve housing (Figure 14, Item 15) from control valve body (Figure 14, Item 1). Relief
valve may be placed on a bench for further disassembly.
27. Remove and discard O-ring (Figure 14, Item 7) from bucket cylinder relief valve housing (Figure 14, Item 15).
28. Remove plug (Figure 14, Item 8) from housing (Figure 14, Item 15). If desirable, plug assembly may be left
intact. In this manner valve setting will remain unchanged. For a thorough inspection however, valve must be
completely disassembled.
29. Remove and discard O-rings (Figure 14, Items 7 and 5) and backup ring (Figure 14, Item 6) from plug (Figure
14, Item 8).
30. Remove acorn nut (Figure 14, Item 14), copper washer (Figure 14, Item 12), jamnut (Figure 14, Item 13), and
second copper washer (Figure 14, Item 12) from adjusting screw (Figure 14, Item 11).
31. Remove adjusting screw (Figure 14, Item 11), spring (Figure 14, Item 10), and poppet (Figure 14, Item 9) from
plug (Figure 14, Item 8).
32. Remove check valve poppet (Figure 14, Item 17) from poppet (Figure 14, Item 16).
33. Remove and discard O-ring (Figure 14, Item 19) and backup ring (Figure 14, Item 18) from poppet (Figure 14,
Item 16).
34. Remove springs (Figure 14, Items 4 and 3) and poppet (Figure 14, Item 2) from check valve poppet (Figure 14,
Item 16).
0121-10
TM 5-3805-255-14 0121
Figure 14. Main Control Valve - Relief Valve. 0121
0121-11
TM 5-3805-255-14 0121
35. Remove three check valves (Figure 15, Item 1) from main valve body (Figure 15, Item 6).
36. Remove three check valve plugs (Figure 15, Item 4), springs (Figure 15, Item 3), and poppets (Figure 15, Item
2) from main valve body (Figure 15, Item 6).
37. Remove and discard three O-rings (Figure 15, Item 5) from poppets (Figure 15, Item 2).
Figure 15. Check Valves Removal. 0121
END OF TASK
1. Thoroughly wash and inspect all parts IAW General Maintenance Instructions (WP 0019) in a clean mineral oil
solvent. Dry with filtered compressed air and place on clean paper for inspection.
2. Inspect all surfaces for burrs, scratches, nicks, scores, and other abrasions. Stone or lap all burrs. If scoring is
deep enough to produce excessive leakage, replace valve assembly. Stone or use crocus cloth on small
scores.
3. Check orifice (Figure 16, Item 1) in boom spool bore (Figure 16, Item 2) to be sure there are no obstructions.
Figure 16. Boom Spool Bore Inspection. 0121
0121-12
TM 5-3805-255-14 0121
CAUTION
Listed below are instructions that must be followed to insure correct assembly and
effective sealing of O-rings. Failure to follow these instructions may result in damage to
equipment.
• Seal counter bores must be thoroughly cleaned.
• O-rings, plungers, and counter bores must be lubricated with clean oil (WP 0018) on
assembly.
• O-rings must be free of molding defects and handling damage.
• O-RINGS MUST NOT BE STRETCHED beyond yield point. (Wrap a stiff paper around
plunger to protect O-ring passing over sharp machined edges.)
• EXTREME care must be taken to avoid “ROLLING” O-ring into counter bore. (A twisted
O-ring is not likely to straighten itself after installation, and is almost certain to leak.)
• Care in handling of parts and hydraulic system cleanliness cannot be over stressed.
• Use ONLY oil type and viscosity ranges specified (WP 0018).
END OF TASK
0121-13
TM 5-3805-255-14 0121
ASSEMBLY 000121
1. Assemble main relief valve as follows:

a. Assemble sleeve (Figure 17, Item 14) in valve body bore (Figure 17, Item 1) being sure hollow end of
sleeve is toward relief valve end of bore.
a. Install new O-ring (Figure 17, Item 4) and backup ring (Figure 17, Item 5) on poppet (Figure 17, Item 15).
b. After lubricating with clean oil (WP 0018), install poppet (Figure 17, Item 15) in valve body bore opposite
relief valve. Seat poppet against sleeve (Figure 17, Item 14).
c. Install piston (Figure 17, Item 2) in poppet (Figure 17, Item 15).
d. Install spring (Figure 17, Item 3) over piston (Figure 17, Item 2) in recess of poppet (Figure 17, Item 15).
e. Install new O-ring (Figure 17, Item 6) and new backup ring (Figure 17, Item 5) in groove in small diameter
of plug (Figure 17, Item 7).
f. Install new O-ring (Figure 17, Item 4) in groove in large diameter of plug (Figure 17, Item 7).
g. Install plug (Figure 17, Item 7) in valve body (Figure 17, Item 1). After lubricating with clean oil (WP 0014),
be sure spring (Figure 17, Item 3) fits in recess of plug. Tighten plug securely.
h. Install pilot poppet (Figure 17, Item 8) in center bore of plug (Figure 17, Item 7).
i. Install spring (Figure 17, Item 9) on pilot poppet stem (Figure 17, Item 8).
j. Thread adjusting screw (Figure 17, Item 10) into plug bore (Figure 17, Item 7) until it begins to compress
spring (Figure 17, Item 9).
k. Place new copper washer (Figure 17, Item 11) over adjusting screw (Figure 17, Item 10) and install jamnut
(Figure 17, Item 12). Do not tighten jamnut. Valve is now ready for adjustment (WP 0078).
l. After adjustment, install new copper washer (Figure 17, Item 11) and acorn nut (Figure 17, Item 13).
0121-14
TM 5-3805-255-14 0121
Figure 17. Main Relief Valve Assembly. 0121
0121-15
TM 5-3805-255-14 0121
2. Assemble cylinder relief valve as follows.
a. Install new O-ring (Figure 18, Item 19) and new backup ring (Figure 18, Item 18) on poppet (Figure 18,
Item 17).
b. Lubricate O-rings with clean oil (WP 0018). Install poppet (Figure 18, Item 17) in check valve poppet (Fig-
ure 18, Item 16).
c. Install piston (Figure 18, Item 2) in center bore of poppet (Figure 18, Item 17).
d. Install spring (Figure 18, Item 3) over piston (Figure 18, Item 2) and place poppet assembly aside.
e. Place pilot poppet (Figure 18, Item 9) in center bore of plug (Figure 18, Item 8).
f. Install spring (Figure 18, Item 10) in plug center bore and over stem of pilot poppet (Figure 18, Item 9).
g. Thread adjusting screw (Figure 18, Item 11) into plug center bore until it begins to compress spring (Figure
18, Item 10).
h. Install a new backup ring (Figure 18, Item 6) in groove in center of plug (Figure 18, Item 8).
i. Install a new O-ring (Figure 18, Item 7) below backup ring.
j. Install a new O-ring (Figure 18, Item 7) in groove below flange of plug (Figure 18, Item 8).
k. Lubricate new O-ring (Figure 18, Item 7) and new backup ring (Figure 18, Item 6) with clean oil (WP 0018).
l. Install new O-ring (Figure 18, Item 5) on plug (Figure 18, Item 8).
NOTE
Be sure springs do not kink or bind and are seated correctly.
m. Place large spring (Figure 18, Item 4) over small diameter of plug (Figure 18, Item 8).
n. Carefully slide poppet assembly (Figure 18, Items 16, 17, 18, and 19) over plug (Figure 18, Item 8).
o. Place housing (Figure 18, Item 15) over poppet assembly and thread plug (Figure 18, Item 6) into housing
(Figure 18, Item 1). Hold housing and tighten plug (Figure 18, Item 8) securely.
p. Install new O-ring (Figure 18, Item 7) in groove above threads on housing (Figure 18, Item 1).
q. Lubricate O-ring with clean oil (WP 0018) and thread valve in main control valve body (Figure 18, Item 1).
Tighten valve assembly securely.
3. Install new copper washer (Figure 18, Item 12) on adjusting screw (Figure 18, Item 11). Thread jamnut (Figure
18, Item 13) on adjusting screw. Valve is now ready for adjustment (WP 0078).
4. After adjustment, install new copper washer (Figure 18, Item 12) and acorn nut (Figure 18, Item 14). Tighten
acorn nut securely.
0121-16
TM 5-3805-255-14 0121
Figure 18. Relief Valve. 0121
0121-17
TM 5-3805-255-14 0121
5. Assemble and install anti-void valves as follows:
a. Lubricate new O-ring (Figure 19, Item 3) with clean oil (WP 0018) and install in groove in poppet upper
portion (Figure 19, Item 4).
b. Place poppet upper portion (Figure 19, Item 4) over stem of lower portion (Figure 19, Item 2).
c. Install locknut (Figure 19, Item 7). Tighten locknut securely.
NOTE
Be sure O-ring is correctly seated in poppet groove during assembly.
d. Lubricate new O-ring and backup ring with clean oil (WP 0018). Install new backup ring (Figure 19, Item 5)
and new O-ring (Figure 19, Item 6) in groove of poppet assembly.
e. Install spring (Figure 19, Item 8) in recess of plug (Figure 19, Item 10).
f. Install poppet assembly in plug (Figure 19, Item 10).
g. Install new O-ring (Figure 19, Item 9) on valve plug (Figure 19, Item 10), being careful not to damage
O-ring on plug threads. Install poppet assembly in housing bore.
h. Install valve spring (Figure 19, Item 8) in poppet recess.
i. Lubricate O-ring with clean oil (WP 0018) and install plug in housing bore (Figure 19, Item 1). Be sure
valve spring centers in plug recess. Tighten plug securely.
6. Repeat step 5 for remaining anti-void valve.
0121-18
TM 5-3805-255-14 0121
Figure 19. Main Control Valve (Spool End). 0121
0121-19
TM 5-3805-255-14 0121
7. Assemble and install three check valves as follows:
a. Install three new O-rings (Figure 20, Item 2) on valve plugs (Figure 20, Item 1) being careful not to damage
O-rings on plug threads.
b. Install three poppets (Figure 20, Item 4) in housing bores (Figure 20, Item 5).
c. Install three valve springs (Figure 20, Item 3) in poppet recesses.
NOTE
Be sure valve springs center in plug recesses as plugs are installed to housing bores.
d. Lubricate three O-rings on plugs with clean oil (WP 0131) and install plugs to housing bores. Tighten plugs
securely.
Figure 20. Main Control Valve (Plunger Cap End). 0121
0121-20
TM 5-3805-255-14 0121
8. Assemble and install valve plungers as follows:
a. Lubricate valve plungers (Figure 21, Items 1 and 4) with clean oil (WP 0018) and install in respective
bores.
b. Align eyes in ends of plungers (Figure 21, Items 1 and 4) and install a 1/2 in. x 4NF capscrew (Figure 21,
Items 2) and hex nut (Figure 21, Items 3). Tighten nut hand tight.
Figure 21. Plunger Bolt and Nut Installation. 0121
0121-21
TM 5-3805-255-14 0121
9. Lubricate O-ring with clean oil (WP 0018) and slide DO NOT ROLL O-ring (Figure 22, Item 2) on bucket
plunger (Figure 22, Item 5).
10. Lubricate retaining ring (Figure 22, Item 1) with clean oil (WP 0018) and slide on bucket plunger against O-ring.
Use seal plate (Figure 22, Item 4) as a tool and push O-ring and retaining ring in seal counter bore in valve
Figure 22. O-Ring and Backup Ring Installation. 0121
0121-22
TM 5-3805-255-14 0121
11. Install spring seat (Figure 23, Item 1) on plunger (Figure 23, Item 2) against seal plate (Figure 23, Item 3).
CAUTION
Use caution to prevent damage to detent ball holes in plunger pin. Failure to follow this
12. Insert plunger pin (Figure 23, Item 2) through remaining spring seat (Figure 23, Item 5) and in plunger spring
(Figure 23, Item 4). With rod used during disassembly, screw plunger pin assembly in plunger and tighten
securely.
13. Lubricate detent cam assembly (Figure 24, Item 4) liberally with multi-purpose grease (WP 0018).
14. Install detent cam (Figure 24, Item 4) and spring (Figure 24, Item 2) in bore of plunger pin (Figure 24, Item1).
15. Place punch within bore of detent sleeve; depress detent cam with punch, place detent balls (Figure 24, Item
3) in respective holes and slide sleeve over detent cam assembly. Release punch.
0121-23
TM 5-3805-255-14 0121
16. Place plunger cap (Figure 25, Item 3) over detent assembly and firmly against seal plate with screw holes in
cap, plate, and valve housing (Figure 25, Item 2) properly aligned. Install two screws (Figure 25, Item 1) to
valve body. Tighten screws securely.
Figure 25. Plunger Cap Installation. 0121
17. Inspect spacer (Figure 26, Item 3) and snap ring (Figure 26, Item 1) for damage.
18. Install spacer (Figure 26, Item 3) and snap ring (Figure 26, Item 1) on detent sleeve (Figure 26, Item 2) on
being sure snap ring is properly seated in detent sleeve groove.
Figure 26. Spacer and Snap Ring Installation. 0121
0121-24
TM 5-3805-255-14 0121
19. Lubricate and install pistons (Figure 27, Items 2 and 8) and spacer (Figure 27, Item 3) in bore of detent sleeves
CAUTION
• Lubricate all parts with clean oil (WP 0018) before installation.
• Spacer is used in bucket plunger only.
• Take care when installing O-rings to avoid cutting O-ring on plug threads.
• Failure to follow these cautions may result in damage to equipment.
20. Lubricate and install new O-rings (Figure 27, Items 4 and 7) in plugs (Figure 27, Items 5 and 6).
21. Install plugs (Figure 27, Items 5 and 6) in bore of detent sleeves (Figure 27, Items 1 and 9) and tighten
securely.
Figure 27. Detent Sleeves Assembly. 0121
22. Remove capscrew (Figure 28, Item 2) and hex nut (Figure 28, Item 3) from plunger eyes (Figure 28, Items 1
and 4).
Figure 28. Plunger Bolt and Nut Removal. 0121
0121-25
TM 5-3805-255-14 0121
23. Working one plunger (Figure 29, Item 4) at a time, slide (DO NOT ROLL) a new O-ring (Figure 29, Item 1),
spacer (Figure 29, Item 2) and split scraper (Figure 29, Item 5) over plunger (Figure 29, Item 4).
24. Using retainer plate (Figure 29, Item 3), with a slight rocking motion push assembly into seal counter bore.
Install two retainer plate capscrews and tighten securely.
25. Repeat steps 23 and 24 for remaining plunger.
Figure 29. O-Ring and Spacer Ring Installation. 0121
END OF TASK
END OF WORK PACKAGE
0121-26
6
TM 5-3805-255-14 0122
0 1 2 2 BUCKET CYLINDER OVERHAUL

INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP O-ring (7) 0
0128, Item 20) 0

Piston Half 0
Shop Equipment, Automotive Maintenance Piston Packing 0
and Repair: Organizational Maintenance Seal Ring (2) 0
Wear Ring (2) 0
Materials/Parts 0
References 0

WP 0018 0
(WP 0130, Item 3) 0
WP 0019 0
Grease, Automotive and Artillery (GAA) (WP

0130, Item 15) 0
Oil, Lubricating, OE/HDO-10 (WP 0130, Item Machine parked on level ground (WP 0005) 0
22) 0
Backup Ring (4) 0

Bushing 0
0004) 0
Bolt, Piston (8) 0

Bucket cylinder removed from loader (WP
Lockwasher (6) 0
0081) 0
0122-1
TM 5-3805-255-14 0122
DISASSEMBLY 000122
1. Remove six bolts (Figure 1, Item 22), lockwashers (Figure 1, Item 21), and cylinder end cover (Figure 1,
Item 20) from bucket cylinder (Figure 1, Item 1). Discard lockwashers.
2. Slide cylinder end cover (Figure 1, Item 20) down rod (Figure 1, Item 25).
3. Remove cord ring (Figure 1, Item 16) from bucket cylinder (Figure 1, Item 1).
4. Remove and discard O-ring (Figure 1, Item 19) from cylinder end cover (Figure 1, Item 20).
5. Push cap assembly (Figure 1, Item 15) in slightly and remove segmented lockring (Figure 1, Item 14).
6. Remove rod (Figure 1, Item 25) and piston halves (Figure 1, Items 3 and 11) from bucket cylinder (Figure 1,
Item 1).
7. Remove eight bolts and washers (Figure 1, Item 2) and separate piston halves (Figure 1, Items 3 and 11). Dis-
card bolts and washers.
NOTE
Early type piston and piston packing is NOT shown in Figure 1. When rebuilding an early
type piston, new piston halves must be ordered to accommodate new wear rings and seal
rings. Late type pistons have wear rings and two seal rings in place of packing.
8. Remove two wear rings (Figure 1, Items 5 and 9), seals (Figure 1, Items 6 and 8), first piston half (Figure 1,
Item 3), two lockring halves (Figure 1, Item 7), and second piston half (Figure 1, Item 11) from rod (Figure 1,
Item 25). Discard wear rings and seals. DO NOT discard lockrings.
9. Remove and discard O-ring (Figure 1, Item 10) from second piston half (Figure 1, Item 11).
10. Remove and discard two O-rings (Figure 1, Items 12 and 13) from cap (Figure 1, Item 15).
11. Remove and discard O-ring (Figure 1, Item 4) from first piston half (Figure 1, Item 3).
12. Remove and discard two O-rings (Figure 1, Item 24) and four backup rings (Figure 1, Item 23) from grooves in
piston end of rod (Figure 1, Item 25). Remove rod wiper (Figure 1, Item 18) from bore of cylinder end cover
(Figure 1, Item 20) and slide cylinder cover assembly from rod.
13. Remove O-ring (Figure 1, Item 19) and rod seal (Figure 1, Item 17). Discard O-ring and rod seal.
0122-2
TM 5-3805-255-14 0122
END OF TASK
END OF TASK
0122-3
TM 5-3805-255-14 0122
ASSEMBLY 000122
NOTE
Lubricate all parts with lubricating oil (WP 0018).
1. Slide cylinder end cover (Figure 2, Item 20), new cord ring (Figure 2, Item 16), rod seal (Figure 2, Item 17), and
rod wiper (Figure 2, Item 18) on rod (Figure 2, Item 25).
2. Lubricate rod (Figure 2, Item 25) and cap rod seal ring and slide cap (Figure 2, Item 15) onto rod.
3. Install two new O-rings (Figure 2, Item 24) and four new backup rings (Figure 2, Item 23) in grooves in piston
end of rod (Figure 2, Item 25).
4. Install two new O-rings (Figure 2, Items 12 and 13) on cap (Figure 2, Item 15).
5. Install new O-ring (Figure 2, Item 10) on second piston half (Figure 2, Item 11).
6. Install new O-ring (Figure 2, Item 4) on first piston half (Figure 2, Item 3).
7. Install two new seals (Figure 2, Items 6 and 8) and new wear rings (Figure 2, Items 5 and 9) on piston halves
8. Slide piston half (Figure 2, Item 3) having tapped holes on rod (Figure 2, Item 25) just past lockring groove.
9. Slide second piston half (Figure 2 Item 11) on rod (Figure 2, Item 25), almost to lockring groove.
10. Insert two lockring halves (Figure 2, Item 7) between piston halves and seat in rod lockring groove.
11. Align bolt holes in piston halves (Figure 2, Items 3 and 11) and seat in rod lockring groove.
12. Align bolt holes in piston halves (Figure 2, Items 3 and 11) and lockring halves (Figure 2, Item 7).
13. Insert two new bolts and washers (Figure 2, Item 2) and start them into tapped holes in inner piston half (Figure
2, Item 3). Repeat procedure for second lockring half. Install six new remaining bolts and washers and tighten
eight bolts evenly to 170 lb-ft (230 Nm).
NOTE
Do not damage wear rings or seal assemblies.
14. Coat assembled piston halves (Figure 2, Items 3 and 11) with lubricating oil (WP 0018) and carefully start
piston and rod assembly in cylinder (Figure 2, Item 1).
NOTE
Be careful not to damage O-ring and backup ring when installing cap assembly. Be sure
O-ring and backup ring in cap are properly positioned, i.e., O-ring inside, backup ring
outside.
15. When piston assembly has fully entered cylinder, carefully push cap assembly (Figure 2, Item 15) in cylinder
(Figure 2, Item 1).
16. Install segmented lockring (Figure 2, Item 14) in cylinder recess. If needed, use grease (WP 0018) to hold
lockring segments in place.
17. Install new O-ring (Figure 2, Item 19) in cylinder end cover recess (Figure 2, Item 20).
18. Install six new lockwashers (Figure 2, Item 21), bolts (Figure 2, Item 22), and cylinder end cover (Figure 2,
Item 20) on bucket cylinder (Figure 2, Item 1).
19. Manually extend rod sharply several times, driving piston against cap assembly. This will cause segmented
lockring to seat properly.
20. Torque six bolts (Figure 2, Item 22) evenly to 170 lb-ft (230 Nm).
0122-4
TM 5-3805-255-14 0122
21. Install bucket cylinder on loader (WP 0081).

22. After installing bucket cylinder on loader, start engine and allow hydraulic oil to reach operating temperature.
Cycle cylinder several times.
23. Retorque cylinder bolts (Figure 2, Item 22) with cylinder under pressure evenly to 170 lb-ft (230 Nm).
24. Check for leaks at all connections made. Check bucket cylinder for proper operation.
END OF TASK
END OF WORK PACKAGE
0122-5/(6 blank)
6
TM 5-3805-255-14 0123
BOOM CYLINDER OVERHAUL

0 1 2 3
INITIAL SETUP
Tool Kit, General Mechanic’s, Automotive (WP O-ring (7) 0
0128, Item 20) 0

Piston Half 0
Shop Equipment, Automotive Maintenance Piston Packing 0
and Repair: Organizational Maintenance Seal Ring (2) 0
Wear Ring (2) 0
Materials/Parts 0
References 0

WP 0019 0
(WP 0130, Item 3) 0
Grease, Automotive and Artillery (GAA) (WP Equipment Condition 0
0130, Item 15) 0

22) 0

Backup Ring (4) 0
0004) 0
Bushing 0
Boom cylinder removed from loader (WP

Bolt, Piston (8) 0
0082) 0
Lockwasher (6) 0
0123-1
TM 5-3805-255-14 0123
DISASSEMBLY 000123
1. Remove six bolts (Figure 1, Item 22), lockwashers (Figure 1, Item 21), and cylinder end cover (Figure 1, Item
20) from cylinder (Figure 1, Item 1). Discard lockwashers.
2. Slide cylinder end cover (Figure 1, Item 20) down rod (Figure 1, Item 25).
3. Remove cord ring (Figure 1, Item 16) from cylinder (Figure 1, Item 1).
4. Push cap assembly (Figure 1, Item 15) in slightly and remove segmented lockring (Figure 1, Item 14).
5. Remove rod (Figure 1, Item 25) and piston halves (Figure 1, Items 3 and 11) from boom cylinder (Figure 1,
Item 1).
6. Remove eight bolts (Figure 1, Item 2) and separate piston halves (Figure 1, Items 3 and 11). Discard bolts.
NOTE
Early type piston and piston packing is NOT shown in Figure 1. When rebuilding an early
type piston, new piston halves must be ordered to accommodate new wear rings and seal
rings. Late type pistons have wear rings and two seal rings in place of packing.
7. Remove two wear rings (Figure 1, Items 5 and 9), seals (Figure 1, Items 6 and 8), first piston half (Figure 1,
Item 3), two lockring halves (Figure 1, Item 7), and second piston half (Figure 1, Item 11) from rod (Figure 1,
Item 25). Discard wear rings and seals. DO NOT discard lockrings.
8. Remove and discard O-ring (Figure 1, Item 10) from second piston half (Figure 1, Item 11).
9. Remove and discard two O-rings (Figure 1, Items 12 and 13) from cap (Figure 1, Item 15).
10. Remove and discard O-ring (Figure 1, Item 4) from first piston half (Figure 1, Item 3).
11. Remove and discard two O-rings (Figure 1, Item 24) and four backup rings (Figure 1, Item 23) from grooves in
piston end of rod (Figure 1, Item 25). Remove rod wiper (Figure 1, Item 18) from bore of cylinder end cover
(Figure 1, Item 15) and slide cap assembly from rod.
12. Remove O-ring (Figure 1, Item 19) and rod seal (Figure 1, Item 17). Discard O-ring and rod seal.
0123-2
TM 5-3805-255-14 0123
END OF TASK 000123
0123-3
TM 5-3805-255-14 0123
END OF TASK
ASSEMBLY 000123
NOTE
Lubricate all parts with lubricating oil (WP 0018).
1. Slide cylinder end cover (Figure 2, Item 20), rod seal (Figure 2, Item 17) and rod wiper (Figure 2, Item 18) on
rod (Figure 2, Item 25).
2. Lubricate rod (Figure 2, Item 25) and cap rod seal and slide cap (Figure 2, Item 15) onto rod (Figure 2, Item
25).
3. Install two new O-rings (Figure 2, Item 24) and four new backup rings (Figure 2, Item 23) in grooves in piston
end of rod (Figure 2, Item 25).
4. Install two new O-rings (Figure 2, Items 12 and 13) on cap (Figure 2, Item 15).
5. Install new O-ring (Figure 2, Item 10) on second piston half (Figure 2, Item 11).
6. Install new O-ring (Figure 2, Item 4) on first piston half (Figure 2, Item 3).
7. Install two new seals (Figure 2, Items 6 and 8) and new wear rings (Figure 2, Items 5 and 9) on piston halves
8. Slide first piston half (Figure 2, Item 3) having tapped holes on rod (Figure 2, Item 25) just past lockring groove.
9. Slide second piston half (Figure 2 Item 11) on rod (Figure 2, Item 25), almost to lockring groove.
10. Insert two lockring halves (Figure 2, Item 7) between piston halves and seat in rod lockring groove.
11. Align bolt holes in piston halves (Figure 2, Items 3 and 11) and seat in rod lockring groove.
12. Align bolt holes in piston halves (Figure 2, Items 3 and 11) and lockring halves (Figure 2, Item 7).
13. Insert two new bolts (Figure 2, Item 2) and start them into tapped holes in inner piston half (Figure 2, Item 3).
Repeat procedure for second lockring half. Install six new remaining bolts (Figure 2, Item 2) and tighten eight
bolts evenly to 70 lb-ft (95 Nm).
NOTE
Do not damage wear rings or seal assemblies.
14. Coat assembled piston halves (Figure 2, Items 3 and 11) with lubricating oil and carefully start piston and rod
assembly in cylinder (Figure 2, Item 1).
NOTE
Be careful not to damage O-ring and backup ring when installing cap assembly. Be sure
O-ring and backup ring in cap are properly positioned, i.e., O-ring inside, backup ring
outside.
15. When piston assembly has fully entered cylinder, carefully push cap assembly (Figure 2, Item 15) in cylinder
(Figure 2, Item 1).
16. Install segmented lockring (Figure 2, Item 14) in cylinder recess. If needed, use grease to hold lockring
segments in place.
17. Install new cord ring (Figure 2, Item 16) in boom cylinder (Figure 2, Item 1).
18. Install new O-ring (Figure 2, Item 19) in cap recess (Figure 2, Item 15).
0123-4
TM 5-3805-255-14 0123
19. Install six new lockwashers (Figure 2, Item 21), new bolts (Figure 2, Item 22), and end cover (Figure 2, Item
20) on boom cylinder (Figure 2, Item 1).
20. Manually extend rod sharply several times, driving piston against cap assembly. This will cause segmented
lockring to seat properly.
21. Torque six bolts (Figure 2, Item 22) evenly to 35 lb-ft (47 Nm).
22. Install cylinder on loader (WP 0082).

23. After installing cylinder on loader, start engine and allow hydraulic oil to reach operating temperature. Cycle
cylinder several times.
24. Retorque cylinder bolts with cylinder under pressure evenly to 35 lb-ft (47 Nm).
25. Check for leaks at all connections made. Check boom cylinder for proper operation.
END OF TASK
END OF WORK PACKAGE
0123-5/(6 blank)
4
TM 5-3805-255-14 0124
0 1 2 4 HYDRAULIC TANK/RESERVOIR REPAIR

INITIAL SETUP
0128, Item 20) 0
Materials/Parts 0

Oil, Lubricating, OE/HDO-10 (WP 0130, Item Engine OFF (WP 0005) 0
22) 0

Oil, Lubricating, OE/HDO-40 (WP 0130, Item 0004) 0
24) 0
Hydraulic tank/reservoir removed (WP 0083) 0
Personnel 0
Two 0
0124-1
TM 5-3805-255-14 0124
DISASSEMBLY 000124
1. Remove relief valve (Figure 1, Item 1) from reservoir cover (Figure 1, Item 11).
2. Remove nut plunger (Figure 1, Item 10), flat washer (Figure 1, Item 9), spring (Figure 1, Item 8), sleeve (Figure
1, Item 7), and flat washer (Figure 1, Item 6) from bottom of reservoir body (Figure 1, Item 5).
3. Remove drain valve (Figure 1, Item 4), elbow (Figure 1, Item 2), and plug (Figure 1, Item 3) from reservoir body
(Figure 1, Item 5).
4. Remove elbow (Figure 1, Item 2) and drain plug (Figure 1, Item 3) from drain valve (Figure 1, Item 4).
Figure 1. Hydraulic Reservoir/Tank Assembly. 0124
END OF TASK
END OF TASK
0124-2
TM 5-3805-255-14 0124
ASSEMBLY 000124
NOTE
Check interior of reservoir for cleanliness.
1. Install elbow (Figure 2, Item 2) and drain plug (Figure 2, Item 3) on drain valve (Figure 2, Item 4).
2. Install drain valve (Figure 2, Item 4) on reservoir body (Figure 2, Item 5).
3. Install washer (Figure 2, Item 6), sleeve (Figure 2, Item 7), spring (Figure 2, Item 8), flat washer (Figure 2, Item
9), and nut plunger (Figure 2, Item 10) on bottom of reservoir body (Figure 2, Item 5).
4. Install relief valve (Figure 2, Item 1) on reservoir cover (Figure 2, Item 11).
5. Install hydraulic tank/reservoir (WP 0083).
6. Install hydraulic reservoir filter (WP 0016).
Figure 2. Hydraulic Reservoir/Tank Assembly. 0124
END OF TASK
END OF WORK PACKAGE
0124-3/(4 blank)
18
TM 5-3805-255-14 0125
0 1 2 5 ILLUSTRATED LIST OF MANUFACTURED ITEMS
SCOPE 000125
This work package lists the fabricated tools that are needed to maintain the H100C Loader. The tools require
fabrication. Each image provides the materials and dimensions required to make the tool. Follow all shop and tool
safety procedures when manufacturing the fabricated tool.
1. Column (1) - Item Number: Lists fabricated tools by item number.

2. Column (2) - Nomenclature: The name of the fabricated tool.
3. Column (3) - Location: Indicates the work package in the TM where the fabricated tool is used.
0125-1
TM 5-3805-255-14 0125
1. Column (1) - Item Number: Lists fabricated tools by item number.

2. Column (2) - Nomenclature: The name of the fabricated tool.
3. Column (3)- Location: Indicates the work package in the TM where the fabricated tool is used.
Table 1. Fabricated Tools for H100C Loader.
(1)
ITEM (2) (3)
NUMBER NOMENCLATURE LOCATION
1 Transmission Lifting Eye WP 0048
2 Transmission Clutch Lifting Tool WP 0103
3 Transmission Snap Ring Groove Filler WP 0104
4 Axle Removal and Installation Tool WP 0053, WP 0056
5 Assembled Differential Holding Fixture WP 0111, WP 0114
5a Swivel Weldment (Two Required)
5b Stand Weldment Assembly - Left Hand (One Required)
5c Stand Weldment Assembly - Right Hand (One Required)
5d Clamp Assembly (Two Required)
5e Tube (Two Required)
5f Base (Two Required)
5g Slide - Stand Weldment (Right Hand)
5h Slide - Stand Weldment (Left Hand)
6 Wheel Hub Brake Drum Lifting Tool WP 0110, WP 0113
7 Main Hydraulic Pump and Steering Pump Seal Installation Tool WP 0120
8 Fan Drive Housing Coupling Flange Support Tool WP 0101
9 Fan Drive Housing Belleville Spring Compressing Tool WP 0101
10 Fan Drive Housing Snap Ring Installation Tool WP 0101
11 Cover Plate and Coupling for Testing Oil Cooler WP 0024
11a Cover Plate and Coupling for Testing Oil Cooler - Installed WP 0024
12 Fan Pulley Torque Fixture WP 0101
13 Fan Pulley Holding Fixture WP 0101
14 Fan Drive Assembly Torque Adapter WP 0038
0125-2
TM 5-3805-255-14 0125
Item 1. Transmission Lifting Eye.
Item 2. Transmission Clutch Lifting Tool.
0125-3
TM 5-3805-255-14 0125
Item 3. Transmission Snap Ring Filler.
Item 4. Axle Removal and Installation Tool.
0125-4
TM 5-3805-255-14 0125
Item 5. Assembled Differential Holding Fixture.
0125-5
TM 5-3805-255-14 0125
Item 5a. Swivel Weldment (Two Required).
0125-6
TM 5-3805-255-14 0125
Item 5b. Stand Weldment Assembly - Left Hand (One Required).
Item 5c. Stand Weldment Assembly - Right Hand (One Required).
0125-7
TM 5-3805-255-14 0125
Item 5d. Clamp Assembly - Right Hand (Two Required).
Item 5e. Tube (Two Required).
0125-8
TM 5-3805-255-14 0125
Item 5f. Base (Two Required).
Item 5g. Slide - Stand Weldment (Right Hand).
0125-9
TM 5-3805-255-14 0125
Item 5h. Slide - Stand Weldment (Left Hand).
0125-10
TM 5-3805-255-14 0125
Item 6. Wheel Hub - Brake Drum Lifting Tool.
Item 7. Main Hydraulic Pump and Steering Pump Seal Installation Tool.
0125-11
TM 5-3805-255-14 0125
Item 8. Fan Drive Housing Coupling Flange Support Tool.
Item 9. Fan Drive Housing Belleville Spring Compressing Tool.
0125-12
TM 5-3805-255-14 0125
Item 10. Fan Drive Housing Snap Ring Installation Tool.
0125-13
TM 5-3805-255-14 0125
Item 11. Cover Plate and Coupling for Testing Oil Cooler.
0125-14
TM 5-3805-255-14 0125
Item 11a. Cover Plate and Coupling for Testing Oil Cooler - Installed.
0125-15
TM 5-3805-255-14 0125
Item 12. Fan Pulley Torque Fixture.
0125-16
TM 5-3805-255-14 0125
Item 13. Fan Pulley Holding Fixture.
Item 14. Fan Drive Assembly Torque Adapter.
0125-17/(18 blank)
TM 5-3805-255-14
CHAPTER 9
SUPPORTING INFORMATION
2
TM 5-3805-255-14 0126
SUPPORTING INFORMATION -
0 1 2 6 REFERENCES
SCOPE 000126
This work package lists the publications referenced in this manual. DA PAM 25-30, Consolidated Index of Army
Publications and Blank Forms, should be consulted frequently for the latest changes and revisions and for new
publications relevant to material covered in this manual.
FORMS 000126
Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . DA Form 2404 and DA Form 5988E
Maintenance Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 2407
Preventive Maintenance Schedule and Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 314
Processing and Deprocessing Record for Shipment, Storage and Issue of Vehicles
and Spare Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 1397
Product Quality Deficiency Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE Form 368
Recommended Changes to Equipment Technical Publications . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028-2
Recommended Changes to Publications and Blank Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 2028
Report of Discrepancy (ROD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 364
FIELD MANUALS 000126
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 4-25.11

Manual for the Wheeled Vehicle Driver (Distribution Restricted). . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 21-305
Operation and Maintenance of Ordnance Materiel in Cold Weather (0°F to Minus 65°F). . . . . . . . . . .FM 9-207
Operational Terms and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 101-5-1
Railway Operating and Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 55-21
TECHNICAL MANUALS 000126
Inspection, Care and Maintenance of Antifriction Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 9-214

Materials Used for Cleaning, Preserving, Abrading and Cementing Ordnance Materiel
and Related Materials Including Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 9-247
Operator’s, Unit, Direct Support, and General Support Maintenance Manual for Care,
Maintenance, Repair, and Inspection of Pneumatic Tires and Inner Tubes . . . . . . . . . . TM 9-2610-200-14
Painting Instructions for Army Materiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 43-0139
Procedures for Destruction of Tank-automotive Equipment to Prevent Enemy Use . . . . . . . . . . . TM 750-244-6
Railcar Loading Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 55-601
Storage and Materials Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 743-200-1
Welding Theory and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-237 (1993)
TECHNICAL BULLETINS 000126
Color, Marking and Camouflage Painting of Military Vehicles, Construction Equipment, and
Materials Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0209
Towed Wheeled Vehicles, FSC Class 2330, Lunette Trailers and Semitrailers:
Repair of Frames. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TB 9-2510-242-40
Warranty Technical Bulletin for the H100C Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 5-3805-291-14
MISCELLANEOUS PUBLICATIONS 000126
Army Medical Department Expendable/Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTA 8-100

Fuels and Lubricants Standardization Policy for Equipment Design, Operation, and
Logistics Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 70-12
The Army Maintenance Management System (TAMMS) Users Manual . . . . . . . . . . . . . . . . . . . DA PAM 750-8
END OF WORK PACKAGE
0126-1/(2 blank)
4
TM 5-3805-255-14 0127
0 1 2 7 MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
THE ARMY MAINTENANCE SYSTEM MAC 000127
This introduction provides a general explanation of all maintenance and repair functions authorized at the two
maintenance levels under the Two-Level Maintenance System concept.
This MAC (immediately following the 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 and capabilities of the
designated maintenance levels, which are shown on the MAC in column (4) as:
Field (includes two subcolumns):
C - Crew
F - Maintainer
Sustainment (includes two subcolumns):
H - Below Depot
D - Depot
The maintenance to be performed at field and sustainment levels is described as follows:
1. Crew maintenance. The responsibility of a using organization to perform maintenance on its assigned
equipment. It normally consists of inspecting, servicing, lubricating, adjusting, and replacing parts, minor
assemblies, and subassemblies. The replace function for this level of maintenance is indicated by the letter “C”
in the third position of the SMR code. A “C” appearing in the fourth position of the SMR code indicates
complete repair is possible at the crew maintenance level.
2. Maintainer maintenance. Maintenance accomplished on a component, accessory, assembly, subassembly,
plug-in unit, or other portion either on the system or after it is removed. The replace function for this level of
maintenance is indicated by the letter “F” appearing in the third position of the SMR code. An “F” appearing in
the fourth position of the SMR code indicates complete repair is possible at the field maintenance level. Items
are returned to the user after maintenance is performed at this level.
3. Below depot sustainment. Maintenance accomplished on a component, accessory, assembly, subassembly,
plug-in unit, or other portion either on the system or after it is removed. The replace function for this level of
maintenance is indicated by the letter “H” appearing in the third position of the SMR code. An “H’ appearing in
the fourth position of the SMR code indicates complete repair is possible at the below depot sustainment
maintenance level. Items are returned to the supply system after maintenance is performed at this level.
4. Depot sustainment . Maintenance accomplished on a component, accessory, assembly, subassembly, plug-
in unit, or other portion either on the system or after it is removed. The replace function for this level of
maintenance is indicated by the letter “D” or “K” appearing in the third position of the SMR code. Depot
sustainment maintenance can be performed by either depot personnel or contractor personnel. A “D” or “K”
appearing in the fourth position of the SMR code indicates complete repair is possible at the depot sustainment
maintenance level. Items are returned to the supply systems after maintenance is performed at this level.
The tools and test equipment requirements table (immediately following the MAC) lists the tools and test
equipment (both special tools and common tool sets) required for each maintenance function as referenced from
the MAC.
The remarks table (immediately following the tools and test equipment requirements) contains supplemental
instructions and explanatory notes for a particular maintenance function.
0127-1
TM 5-3805-255-14 0127
MAINTENANCE FUNCTIONS 000127
Maintenance functions are limited to and defined as follows:

1. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical
characteristics with established standards through examination (e.g., by sight, sound, or feel). This includes
scheduled inspection and gaugings and evaluation of cannon tubes.
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 devices and hydrostatic testing of pressure hoses.
3. Service. Operations required periodically to keep an item in proper operating condition; e.g., to clean (includes
decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical fluids,
or gases. This includes scheduled exercising and purging of recoil mechanisms. The following are examples of
service functions:
a. Unpack. To remove from packing box for service or when required for the performance of maintenance
operations.
b. Repack. To return item to packing box after service and other maintenance operations.
c. Clean. To rid the item of contamination.
d. Touch up. To spot paint scratched or blistered surfaces.
e. Mark. To restore obliterated identification.
4. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by setting the
operating characteristics to specified parameters.
5. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.
6. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments of test, measuring,
and diagnostic equipment used in precision measurement. Consists of comparisons of two instruments, one of
which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the
instrument being compared.
7. Remove/Install. To remove and install the same item when required to perform service or other maintenance
functions. Installation may be the act of emplacing, seating, or fixing into position a spare, repair part, or
module (component or assembly) in a manner to allow the proper functioning of an equipment or system.
8. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. Replacement is
authorized by the MAC and the assigned maintenance level is shown as the third position code of the Source,
Maintenance and Recoverability (SMR) code.
9. Repair. Repair is the application of maintenance services, including fault location/troubleshooting, removal/
installation, disassembly/assembly procedures, and maintenance actions to identify troubles and restore
serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part, subassembly,
module (component or assembly), end item, or system.
0127-2
TM 5-3805-255-14 0127
MAINTENANCE FUNCTIONS – CONTINUED 000127
NOTE
The following definitions are applicable to the “repair” maintenance function:
• Services. Inspect, test, service, adjust, align, calibrate, and/or replace.
• Fault location/troubleshooting. The process of investigating and detecting the
cause of equipment malfunctioning; the act of isolating a fault within a system or
Unit Under Test (UUT).
• Disassembly/assembly. The step-by-step breakdown (taking apart) of a spare/
functional group coded item to the level of its least component, that is assigned an
SMR code for the level of maintenance under consideration (i.e., identified as
maintenance significant).
• Actions. Welding, grinding, riveting, straightening, facing, machining, and/or
resurfacing.
10. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely serviceable/
operational condition as required by maintenance standards in appropriate technical publications. Overhaul is
normally the highest degree of maintenance performed by the Army. Overhaul does not normally return an
item to like new condition.
11. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like
new condition in accordance with original manufacturing standards. Rebuild is the highest degree of materiel
maintenance applied to Army equipment. The rebuild operation includes the act of returning to zero those age
measurements (e.g., hours/miles) considered in classifying Army equipment/components.
EXPLANATION OF COLUMNS IN THE MAC 000127
Column (1) Group Number. Column (1) lists Functional Group Code (FGC) numbers, the purpose of which is to
identify maintenance significant components, assemblies, subassemblies, and modules with the Next Higher
Assembly (NHA).
Column (2) Component/Assembly. Column (2) contains the item names of components, assemblies,
subassemblies, and modules for which maintenance is authorized.
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).
0127-3
TM 5-3805-255-14 0127
EXPLANATION OF COLUMNS IN THE MAC 000127
Column (4) Maintenance Level. Column (4) specifies each level of maintenance authorized to perform each
function listed in column (3), by indicating work time required (expressed as manhours in whole hours or decimals)
in the appropriate subcolumn. This work time figure represents the active time required to perform that
maintenance function at the indicated level of maintenance. If the number or complexity of the tasks within the
listed maintenance function varies at different maintenance levels, appropriate work time figures are to be shown
for each level. The work time figure represents the average time required to restore an item (assembly,
subassembly, component, module, end item, or system) to a serviceable condition under typical field operating
conditions. This time includes preparation time (including any necessary disassembly/assembly time),
troubleshooting/fault location time, and quality assurance time in addition to the time required to perform the
specific tasks identified for the maintenance functions authorized in the MAC. The symbol designations for the
various maintenance levels are as follows:
Field:
C - Crew Maintenance
F - Maintainer Maintenance
Sustainment:
L - Specialized Repair Activity (SRA)
H - Below Depot Maintenance
D - Depot Maintenance
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 column (6). This code is keyed to the
remarks and the SRA complete repair application is explained there.
Column (5) Tools and Equipment Reference Code. Column (5) specifies, by code, those common tool sets (not
individual tools), common Test, Measurement and Diagnostic Equipment (TMDE), and special tools, special TMDE
and special support equipment required to perform the designated function. Codes are keyed to the entries in the
tools and test equipment table.
Column (6) Remarks Code. When applicable, this column contains a letter code, in alphabetical order, which is
keyed to the remarks table entries.
EXPLANATION OF COLUMNS IN THE TOOLS AND TEST EQUIPMENT REQUIREMENTS 000127
Column (1) Tool or Test Equipment Reference Code. The tool or test equipment reference code correlates with
a code used in column (5) of the MAC.
Column (2) Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment.
Column (3) Nomenclature. Name or identification of the tool or test equipment.
Column (4) National Stock Number (NSN). The NSN of the tool or test equipment.
Column (5) Tool Number. The manufacturer’s part number.
EXPLANATION OF COLUMNS IN THE REMARKS 000127
Column (1) Remarks Code. The code recorded in column (6) of the MAC.
Column (2) Remarks. This column lists information pertinent to the maintenance function being performed as
indicated in the MAC.
END OF WORK PACKAGE
0127-4
20
TM 5-3805-255-14 0128
0 1 2 8 MAINTENANCE ALLOCATION CHART (MAC)
Table 1. Maintenance Allocation Chart for the H100C.
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT
MAINT- BELOW TOOLS AND

CREW AINER DEPOT DEPOT EQUIPMENT
GROUP COMPONENT/ MAINTENANCE REFERENCE REMARKS
NUMBER ASSEMBLY FUNCTION C F H D CODE CODE
01 ENGINE
0100 Engine Test 1.0
Assembly, Diesel Service 1.0
Adjust 1.0
Align 2.0
Replace 9.5 2,14
Repair 5.0
Overhaul 55.0
Engine Replace 2.0
Mounting
0101 Crankcase, 20 A
Block, Cylinder
Head
Crankcase Replace 60.0 20
Repair 5.0 6,20
Cylinder Heads Replace 8.0 1,5,6,8,9,10, A
Assembly 11,14,18, 21
0102 Crankshaft Inspect 0.5 4
Replace 16.0
Overhaul 18.0
Bearings, Main Inspect 2.0
Replace 4.0 4,13,14,20
Damper Replace 5.0
0103 Flywheel Replace 16.0 14,20,23
Assembly
Repair 1.5
Flywheel Replace 11.0 15
Housing
Repair 2.0
0128-1
TM 5-3805-255-14 0128
Table 1. Maintenance Allocation Chart for the H100C - (Continued).
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

ENGINE -
01 CONTINUED
0104 Pistons,
Connecting Rods
Pistons Inspect 1.0
Replace 14.0 14,20
Connecting Rod Replace 14.0 3,20
Repair 1.0
Bearings, Replace 1.0 14,20
Connecting 1.0
Rods
0105 Valves, 15
Camshaft, and
Timing System
Rocker Arm Adjust 1.0
Assembly Replace 3.0
Valves Replace 4.0 14,15,18,20
Camshaft Replace 16.5 4,7,14,20,23 A
Gear and Shaft, Replace 12.5
Idler Pump
Timing Gears Replace 15.5 14
0106 Engine
Lubrication
System
Oil Pan Replace 5.0
Repair 1.0
Engine Oil Replace 8.0
Pump
Repair 1.0
Overhaul 2.0
Oil Cooler Replace 4.0 20 A
0108 Manifolds
Manifolds, Replace 4.5 20
Intake, and
Exhaust
0128-2
TM 5-3805-255-14 0128
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

03 FUEL SYSTEM
0301 Carburetor, Fuel Test 1.0
Injector Nozzles, Replace 1.0 20
and Holders
Repair 1.5 1,20
Pipes, Fuel Inspect 0.1
Injector Replace 1.0
0302 Fuel Pumps
Pump, Fuel Test 1.0
Injection Replace 2.5 14,20
Repair 5.5 19
Fuel Hoses and Replace 2.0
Tubes
0304 Air Cleaner Service 0.2 20
Replace 0.5
Repair 0.5
0305 Supercharger,
Blower, or
Turbocharger
Turbocharger Service 1.0
Replace 1.5 20
Repair 2.0
Overhaul 3.0
0306 Tanks, Lines,
Fittings, and
Headers
Fuel Tank Service 0.5
Replace 2.0 20
Repair 2.0
0308 Engine Speed
Governor and
Controls
Lever and Rod Replace 2.0
0309 Fuel Filters Service 0.5
0128-3
TM 5-3805-255-14 0128
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

FUEL SYSTEM -
03 CONTINUED
Replace 0.5
0311 Engine Starting
Aids
Ether Starting Kit Service 0.5
Replace 1.0
Repair 1.0
0312 Accelerator,
Throttle, or
Choke Controls
Cables Service 0.5
Adjust 0.5
Replace 2.0 20
EXHAUST
04 SYSTEM
0401 Muffler and Pipes Service 1.0
Replace 1.0 20
COOLING
05 SYSTEM
0501 Radiator,
Evaporative
Cooler, or Heat
Exchanger
Radiator Core Inspect 0.1
Service 0.5
Replace 3.0 20
Oil Cooler, Replace 2.5
Transmission
Grill Replace 1.0
0502 Cowling,
Deflectors, Air
Ducts, Shrouds,
Etc.
0128-4
TM 5-3805-255-14 0128
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

COOLING
SYSTEM -
05 CONTINUED
Shroud Replace 1.0
Repair 1.0
0503 Water Pump,
Headers,
Thermostats, and
Housing Gasket
Water Pump Replace 2.0 14,20
Repair 3.5
Thermostats Test 1.0
Replace 1.0 20
Hoses, Lines, Service 0.5
and Fittings
Replace 1.0
0505 Fan Assembly
Fan Drive Replace 1.5 7,14,20
Assembly
Repair 1.5 14 A
0508 Water Filter
Tube Replace 1.0
Assemblies
Repair 0.5
Filter Element Replace 0.5
0128-5
TM 5-3805-255-14 0128
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

ELECTRICAL
06 SYSTEM
0601 Generator,
Alternator
Alternators Test 0.5 12
Replace 1.5 20
Repair 1.0
Overhaul 1.5
Drive Belt Adjust 0.4
Replace 0.4
0603 Cranking Motor Test 0.5 12
Assembly Service 0.5
Replace 1.0 20
Repair 1.0
Switch Test 0.3
Assembly Replace 0.5 20
Repair 0.5
0607 Instrument or
Engine
Control Panel
Instrument Replace 1.0
Panel
Gage, Fuel Test 0.5 12
Replace 0.2 20
Temperature Test 0.5
Gage Replace 1.0
Meter, Time Replace 0.2
0609 Lights 12
Head, Tail, and Replace 0.2
Stop Lights Repair 0.5
0610 Sending Units
and Warning
Switches
Oil Pressure Replace 0.2 20
Sending Unit
0128-6
TM 5-3805-255-14 0128
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

ELECTRICAL
SYSTEM -
06 CONTINUED
Engine Test 0.4
Temperature Replace 0.5
Sending Unit
0612 Batteries Storage
Batteries Test 0.5 12
Service 0.5
Replace 0.5 20
Repair 1.0
Covers Service 0.5
Replace 0.5
0613 Chassis Wiring
Harness
Battery Cables Inspect 0.1 12
Replace 0.3
Wiring Harness, Inspect 0.1 12
Engine, and Test 1.0
Instrument Replace 1.0
Repair 2.5
07 TRANSMISSION
0705 Transmission 16 A
Shifting
Components
Levers and Replace
Control Cables 1.5 20
0708 Torque Converter
or Fluid Coupling
Torque Replace 0.5 20
Converter Repair 9.5 20,25
Hoses Replace 1.0
0128-7
TM 5-3805-255-14 0128
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

TRANSMISSION
07 - CONTINUED
0710 Transmission Inspect 0.2
Assembly Test 0.5
Replace 8.0 14,20 A
Repair 8.0 14,20 A
Overhaul 21.0
0713 Intermediate
Clutch
Clutch Package Replace 12.0
Assembly Repair 12.0 14,20 A
Overhaul 18.0
0721 Coolers, Pumps,
and Motors
Valve, Range Replace 1.5 20
Selector Repair 2.5
Overhaul 5.0
Forward and Replace 1.0
Reverse Valve Repair 1.5 20
Overhaul 3.0
Pump Oil, Inspect 0.2
Charging Test 0.5
Replace 4.0
Repair 4.0 14,20
Overhaul 4.0
Main Regulator Test 0.5
Valve Service 0.5
Replace 1.0 20
Repair 2.0
Overhaul 3.0
Converter Oil Replace 0.5
Filter Repair 0.3
0128-8
TM 5-3805-255-14 0128
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

PROPELLER,
PROPELLER
SHAFTS,
UNIVERSAL
JOINTS,
COUPLER, AND
CLAMP
09 ASSEMBLY
0900 Propeller Shafts 15,20
Propeller Shaft, Replace 1.5
Transmission to Repair 1.5
Transfer Drive
Propeller Shaft, Inspect 0.1 1.0
Transmission to Service 0.5
Front Axle Replace 1.5
Repair 1.0
Propeller Shaft, Inspect 0.1 1.0
Transmission to Service 0.5
Rear Axle Replace 1.5
Repair 1.0
Drive Shaft, Replace 1.5
Converter to Repair 1.0
Transmission
Transfer Drive Service 0.5
Assembly Replace 2.0 20
Repair 2.0
10 FRONT AXLE
1000 Front Axle Service 0.1 16,20,22
Repair 4.0 20,25 A
Overhaul 8.0
1002 Differential Service 0.1
Replace 8.0 20
Repair 4.0 20 A
Overhaul 4.0 24,25
1003 Planetary or Final Service 0.5
Drive Carrier Replace 4.0 20 A
Gear Planetary Repair 4.0 14,20
Assembly Overhaul 4.0
0128-9
TM 5-3805-255-14 0128
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

11 REAR AXLE
1100 Rear Axle Service 0.2 16,20
Repair 4.0 20,25 A
Overhaul 8.0
1101 Housing, Beam,
Housing Covers
Plugs, Seals, Etc.
Axle Assembly Replace 5.0
Repair 4.0
1102 Differential Inspect 0.1

Service 0.2
Replace 8.0 20
Repair 4.0 20 A
Overhaul 4.0 24,25
1103 Planetary or Final
Drive Carrier Service 0.5 20 A
Gear Planetary Replace 4.0 20
Assembly Repair 4.0
Overhaul 4.0
12 BRAKES
1201 Hand Brakes 16
Parking Brake Service 2.0
Lever Adjust 0.5
Replace 1.0
Repair 1.0
Parking Brake Service 0.5
Assembly Adjust 0.5
Replace 2.5 20
Repair 2.0
1202 Service Brakes Service 1.0
Adjust 1.0
Replace 1.2 20
Repair 4.0
0128-10
TM 5-3805-255-14 0128
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

BRAKES -
12 CONTINUED
1204 Hydraulic Brake
System
Spider Inspect 1.0
Repair 4.0
Power Cluster Inspect 0.1
Assemblies Replace 0.5 20
Repair 1.0
1208 Air Brake System
Treadle Valves, Service 0.1
Left and Right Replace 0.5 20
Repair 0.5
Hose and Tube Service 0.1
Assemblies Replace 0.3
Repair 0.5
Reservoirs Service 0.1
Replace 0.3 20
Relay Valve Replace 1.5
Repair 1.5
Alcohol Injector Replace 0.6
Repair 1.0 20
Valves, Drain, Replace 1.0
Safety, and Repair 1.5
Check
1209 Air Compressor Service 1.3
Assembly Replace 2.0 14,20
Repair 4.0
Overhaul 6.0
Hose Replace 1.0
Assemblies
Air Discharge Replace 2.0
System Valve,
Discharge
Governor Replace 0.5
Repair 1.0
0128-11
TM 5-3805-255-14 0128
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

13 WHEELS
1311 Wheel Assembly Inspect 0.1 16
Replace 0.2 20
Repair 0.8
1313 Tires, Tubes, and Service 0.5
Tire Chains Replace 2.0
14 STEERING
1401 Mechanical 16
Steering Gear
Assembly
Steering Wheel Replace 0.6 20
Steering Gear Service 0.2
and Column Adjust 1.0
Replace 3.0 20
Repair 2.0
Overhaul 3.0
1410 Hydraulic Pump
or Fluid Motor
Assembly
Pump Assembly Test 0.7
Service 0.2
Replace 2.0 20
Repair 3.0 20
Overhaul 4.0
1411 Hoses, Lines, Inspect 0.2
and Fittings Replace 1.0
1412 Hydraulic or Air
Cylinders
0128-12
TM 5-3805-255-14 0128
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

STEERING -
14 CONTINUED
Hydraulic Test 0.5
Steering Replace 2.0 20
Cylinders Repair 2.0 14,20
Overhaul 3.0
1414 Steering System
Valves
Steering Valves Test 0.5
Service 0.5
Replace 1.0 20
Repair 1.0 20
Overhaul 2.0
Demand Valve Replace 1.0 20
Repair 1.5
Overhaul 3.0
FRAME,
TOWING
ATTACH-
MENTS, AND
15 DRAWBARS
1501 Frame Assembly 16,17
Frame Inspect 0.3
Assemblies, Replace 3.0
Front and Rear Repair 6.0
Bolster Replace 5.0
Repair 13.0
1502 Counterweights Replace 2.0
BODY, CAB,
HOOD, AND
18 HULL
1801 Body, Cab, and
Hood Assemblies
Cab Assembly Replace 5.0 15,16,17,20
Repair 4.0
Hood Replace 2.0
Supports Replace 3.0
0128-13
TM 5-3805-255-14 0128
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

BODY, CAB,
HOOD, AND
HULL -
18 CONTINUED
1802 Fenders,
Windshield,
Glass, Etc.
Windshield Replace 2.5
Glass Replace 2.0
1805 Floors, Subfloors,
and Related
Parts
Plates Replace 2.0
1806 Upholstery,
Seats, and
Carpets
Seat Assembly Replace 1.0
Repair 1.5
BODY,
CHASSIS, AND
HULL
ACCESSORY
22 ITEMS
2202 Accessory Items
Heater Package Replace 3.0
Repair 2.8
Hose and Replace 1.0
Fittings, Heater,
and Defroster
Wiper Motor Replace 2.0 20
Assemblies Repair 1.0
Backup Alarm Replace 1.5
Kit Repair 1.0
Blades Replace 0.2
Air Horn Test 0.2
Assemblies Replace 0.2
Repair 0.5
0128-14
TM 5-3805-255-14 0128
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

BODY,
CHASSIS, AND
HULL
ACCESSORY
ITEMS -
22 CONTINUED
Air Horn Valve Replace 0.3
Assembly Repair 0.5
Blower Package Replace 1.5
Repair 1.8
2210 Data Plates and
Instruction
Holders
Data Plates Replace 0.2
HYDRAULIC
AND FLUID
24 SYSTEMS
2401 Pump and Motor
Hydraulic Pump Replace 2.5
Repair 1.5 20
Overhaul 2.0 20 A
2402 Manifold and/or
Control Valves
Main Control Adjust 1.0
Valves Replace 2.0 20
Overhaul 2.0 14,20
Reservoir Relief Replace 1.0 20

Valve Repair 1.5
Control Valve Test 1.0
Adjust 1.0
Replace 2.0
Repair 1.5
2403 Hydraulic
Controls and/or
Manual Controls
Levers Replace 1.0 20
Repair 1.0
0128-15
TM 5-3805-255-14 0128
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

HYDRAULIC
AND FLUID
SYSTEMS -
24 CONTINUED
2406 Strainers, Filters,
Lines and
Fittings, Etc.
Hoses and Replace 0.3
Tubes
Coupling Replace 0.2
2407 Hydraulic
Cylinders
Boom Cylinder Replace 1.0 20
Repair 2.0 14,20
Overhaul 2.5
Bucket Replace 1.5 20
Cylinders Repair 3.0 14,20
Overhaul 3.5
Hydraulic Air Replace 2.0
Cylinders
2408 Liquid Tanks or
Reservoirs
Reservoir Service 1.0
Assemblies Replace 2.0 20
Repair 2.0 20
GAGES (NON-
ELECTRICAL),
WEIGHING, AND
MEASURING
47 DEVICES
4702 Gages,
Mountings, Lines,
and Fittings
Pressure Gage Test 0.5
and Indicator Replace 1.0 20
0128-16
TM 5-3805-255-14 0128
(1) (2) (3) (4) (5) (6)
MAINTENANCE LEVEL
FIELD SUSTAINMENT

GAGES (NON-
ELECTRICAL),
WEIGHING, AND
MEASURING
DEVICES -
47 CONTINUED
Gage, Dial Test 0.5 12
Pressure, and Replace 1.0
Hydraulic
Pressure
Tachometer Kit Replace 1.0
CRANES,
SHOVELS, AND
EARTH MOVING
EQUIPMENT
74 COMPONENTS
7436 Lift Arms and 15,16
Pivot Assemblies
Boom, Left and Replace 4.0
Right
7437 Loader Bucket 15,16,17
Assembly or
Forklift
Bucket Replace 2.0
Bucket Shanks Replace 0.2
Bucket Tips Replace 0.2 15,16,17
7439 Circle Reverse
Drawbar Side
Shift and Lift
Mechanism
Boom Replace 3.5
Positioner
Control Valve Repair 1.5
0128-17
TM 5-3805-255-14 0128
NOTE
Unless otherwise noted, all maintenance functions can be accomplished with tools
contained in the following common tool sets.
Table 2. Tool and Test Equipment Requirements.
0 (1) 0 (2) (3)

0 0 (4) (5)
0
TOOL OR
0
TEST
EQUIPMENT
REFERENCE 0 MAINTENANCE NATIONAL
0
CODE LEVEL NOMENCLATURE

0 STOCK NUMBER 0 TOOL NUMBER
1 H 1 Adapter for Pressure Testing Valve Housing Part of PLT-365-2 4092 (75384) 1
to Injection Nozzle Lines 1 6635-01-144-

9000 1
2 H 2 Compression Test Adapter 2 2 PLT-521-8 2
3 H 3 Connecting Rod Bushing Removal and 3 PLT-544-1 3
Installation Tool 3
4 H 4 Crankshaft Gear Nut Torque Wrench Adapter 4 4 PLT-518 4
5 H 5 Cylinder Head Water Test Kit 5 5 PLT-508 5
6 H 6 Cylinder Sleeve Puller 6 6 PLT-502-3 6
7 F 7 Fan Drive Pulley Puller 7 7 PLT-506 7
8 H 8 Injector Rolling Sleeve 8 8 PLT-507-1 8
9 H 9 Injector Sleeve Bottoming Tool 9 9 PLT-507-4 9
10 H 10 Injector Sleeve Puller 10 10 PLT-507-3 10
11 H 11 Injector Sleeve Reamer and Guide Bushing 11 11 PLT-507-2 11
12 F 12 Multimeter 12 6625-00-999-7465 12 SCDL551651

(80063) 12
13 H 13 Rear Crankshaft Oil Seal 13 13 PLT-513-7A 13
14 F 14 Shop Equipment, Automotive Maintenance 4910-00-754- SC49910-

and Repair: Organizational Maintenance 0654 14 95CLA74(19204) 14
Common #1 14
15 F 15 Shop Equipment, Automotive Maintenance 4910-00-754- 15
and Repair: Organizational Maintenance 0650 15
Common #2 15
16 F 16 Shop Equipment, Machine Shop, Field 3740-00-754-0739 16 SC9999-01-SKO

Maintenance, Heavy, Supplemental No. 1, PUB 16
Less Power 16
17 F 17 Shop Equipment, Welding 17 4940-00-357-7268 17 SC3470-

95CLA08(19204) 17
18 F 18 Spring Load Tester Valve and Clutch Spring 18 PLT-100 18
Tester 18
0128-18
TM 5-3805-255-14 0128
Table 2. Tool and Test Equipment Requirements - (Continued).
0 (1) 0 (2) (3)

0 0 (4) (5)
0
TOOL OR
0
TEST
EQUIPMENT
REFERENCE 0 MAINTENANCE NATIONAL
0
CODE LEVEL NOMENCLATURE

0 STOCK NUMBER 0 TOOL NUMBER
19 F 19 Test Set, Diesel Injector 19 4910-00-317-8265 19 5910359 (19204) 19
20 F 20 Tool Kit, General Mechanic’s, Automotive 20 5180-01-483- SC9999-01-SKO 20
0249 20 LIN: T28688 20
21 F 21 Tool Kit, Machinist’s 21 5280-00-511-1950 21 SC5280-

95CLA02(19204) 21
22 F 22 Torque Wrench, 2,500 lb-ft 22 5120-00-482-2543 22 PD2501 (92059) 22
23 F 23 Vibration Damper Hub with Wear Sleeve and 23 PLT-542 23
Damper 23
24 F 24 Wrench Set, Socket 24 5130-00-357-5135 24 A-A-399A

3/4 in. Drive Hex Type (58536) 24
25 F 25 Wrench, Torque, 3/4 in. Drive 5120-00-542-5577 25 6017F (47805) 25
100 to 500 lb-ft 25
Table 3. Remarks.
REMARK CODE REMARK

A Procedure requires fabricated tool. Refer to procedure work package.
END OF WORK PACKAGE
0128-19/(20 blank)
2
TM 5-3805-255-14 0129
SUPPORTING INFORMATION -
BASIC ISSUE ITEMS (BII) LIST

0 1 2 9
Scope, General, Explanation of Columns
SCOPE 000129
There are no Basic Issue Items (BII) for the H100C Loader. 000129
0129-1/(2 blank)
6
TM 5-3805-255-14 0130
OPERATOR AND FIELD MAINTENANCE -
0 1 3 0 EXPENDABLE AND DURABLE ITEMS LIST
SCOPE 000130
This work package lists expendable and durable items you will need to install, operate, and maintain the H100C
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), CTA 50-909, Field and Garrison Furnishings and Equipment, or CTA 8-100, Army Medical Depart-
ment Expendable/Durable Items.
1. Column (1) - Item Number. This number is assigned to the entry in the listing and is referenced in the narra-
tive instructions to identify the item [e.g., WP 0131, Item 2)].
2. Column (2) - Level. This column identifies the lowest level of maintenance that requires the listed item.
C - Crew
F - Maintainer
H - Below Depot
D - Depot
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 iden-
tify the item.
5. Column (5) - Unit of Measure (U/M). This column shows the physical measurement or count of an item, such
as gallon, dozen, gross, etc.
0130-1
TM 5-3805-255-14 0130
Table 1. Expendable and Durable Items List for H100C Loader.
(1)
0 (2)
0 (3)
0 0 (4) 0 (5)
ITEM NATIONAL DESCRIPTION, CAGEC,

NUMBER LEVEL STOCK NUMBER AND PART NUMBER U/M
1 F 1 1 Adhesive, Thread 1 1
(05972) 242
2 2 2 Antifreeze 2 2
2 Permanent Ethylene Glycol, Inhibited, 2
2 Heavy-Duty 2
2 (58536) A-A-52624 2
6850-01-464-9125 2 1 Gallon Can GL 2
6850-01-441-3221 2 5 Gallon Can CO 2
6850-01-441-3223 2 55 Gallon Drum DR 2
3 F 3 5340-00-950-57188 3 Cap Set, Protective Dust and Moisture Seal 3 3
(19207) 10935405 EA 3
4 C 4 4 Cleaning Compound, Solvent, Type III 4 4
(81349) MIL-PRF-680
4 4 6850-01-474-2318 4 1 Gallon Can CN 4
6850-01-474-2320 4 5 Gallon Can CN 4
6850-01-474-2321 4 55 Gallon Drum DR 4
5 5 5 Cleaning Compound, Windshield 5 5
5 (0FTT5) 0854-000 5
6850-00-926-2275 5 16 Ounce Bottle BX 5
6 F 6 6 Cloth, Abrasive 6 6
(80204) ANSI B74.18

6 6 5350-00-584-4654 6 50 Sheet Package PG 6
7 C 7 7 Compound, Antiseize 7 7
(05972) 051135-08609
7 7 8030-00-251-3980 7 1 Pound Can CN 7
8 F 8 8 Compound, Prussian Blue Marking 8 8
8 (58536) AA-3108-2A-001 Q 8
8010-00-664-1414 8 1 Quart can QT 8
9 F 9 8040-00-664-1414 9 Compound, Sealing, RTV-732 9 9
Black (71794) TU 9
10 C 10 10 Detergent, General Purpose, Liquid 10 10
(83421) 7930-00-282-9699
10 C 10 7930-00-282-9699 10 1 Gallon Can CN 10
9140-00-286-5294 10 Bulk GL 10
9140-00-286-5295 10 5 Gallon Can CN 10
9140-00-286-5296 10 55 Gallon Drum DR 10
11 C 11 11 Fluid, Brake, Silicone, BFS 11 11
9150-01-102-9455 11 (81349) MIL-PRF-46176 GL 11
0130-2
TM 5-3805-255-14 0130
Table 1. Expendable and Durable Items List for H100C Loader - Continued.
(1)
0 (2)
0 0(3) 0 (4) 0 (5)

12 C 12 12 Fuel, Diesel, DF-1 Grade, Arctic 12 12
12 (81346) ASTM D 975 12
9140-00-286-5286 12 Bulk GL 12
9140-00-286-5287 12 5 Gallon CN 12
9140-00-286-5288 12 55 Gallon Drum DR 12
13 C 13 13 Fuel, Diesel, DF-2 Grade 13 13
13 (81346) ASTM D 975 13
9140-00-286-5294 13 Bulk GL 13
9140-00-286-5295 13 5 Gallon CN 13
9140-00-286-5296 13 55 Gallon Drum DR 13
14 C 14 14 Fuel, Turbine, Aviation 14 14
14 (81349) MIL-T-83133 GR JP-8 14
9130-01-031-5816 14 Gallon GL 14
15 C 15 15 Grease, Automotive and Artillery (GAA) 15 15
9150-01197-7688 15 (8139) M-10924-A 15
15 1-1/4 Ounce Tube TU 15
15 15
9150-01-197-7693 15 (81349) M-10924-B 15
15 14 Ounce Cartridge CA 15
15 15
9150-01-197-7690 15 (81349) M-10924-C 15
15 1-3/4 Pound Can CN 15
15 15
9150-01-197-7692 15 (81349) M-10924-E 15
15 35 Pound Can CN 15
16 F 16 16 Isopropyl Alcohol, USP 16 16
6505-00-205-6513 16 (58615) NDC-0923-0240-16# BT 16
17 F 17 17 Lubriplate Lubricating Fluid 17 17
7050-00-961-7663 17 (94259) 1754E81ITEM15 CN 17
18 F 18 7050-00-961-7662 18 Molykote, Dry Lubricant 18 18
(77777)
19 C 19 19 Oil, Lubricating, Gear, GO 75 19 19
19 (81349) MIL-PRF-2105 19
9150-01-035-5390 19 1 Quart Can QT 19
9150-01-035-5391 19 5 Gallon Can CN 19
20 C 20 20 Oil, Lubricating, Gear, GO 80/90 20 20
20 (81349) MIL-PRF-2105 20
9150-01-035-5392 20 1 Quart Can QT 20
9150-01-001-9395 20 5 Gallon Can CN 20
9150-01-035-5394 20 55 Gallon Drum DR 20
0130-3
TM 5-3805-255-14 0130
(1)
0 (2)
0 0(3) 0 (4) 0 (5)

21 C 21 21 Oil, Lubricating, Gear, GO 85/140 21 21
21 (81349) MIL-PRF-2105 21
9150-01-048-4592 21 1 Quart Can QT 21
9150-01-035-5395 21 5 Gallon Can CN 21
9150-01-035-5396 21 55 Gallon Drum DR 21
22 C 22 22 Oil, Lubricating, OE/HDO-10 22 22
22 (81349) MIL-PRF-2104 22
9150-00-189-6727 22 1 Quart Can CN 22
9150-00-186-6668 22 5 Gallon Can CN 22
9150-00-191-2772 22 55 Gallon Drum DR 22
23 C 23 23 Oil, Lubricating, OE/HDO-15/40 23 23
23 (81349) MIL-PRF-2104 23
9150-01-152-4117 23 1 Quart Can QT 23
9150-01-152-4118 23 5 Gallon Can CN 23
9150-01-152-4119 23 55 Gallon Drum DR 23
24 C 24 24 Oil, Lubricating, OE/HDO-40 24 24
24 (81349) MIL-PRF-2104 24
9150-00-188-9862 24 55 Gallon Drum DR 24
25 C 25 25 Oil, Lubricating, OEA-30 Arctic 25 25
9150-00-402-4478 25 (81349) MIL-L-46167 25
25 1 Quart Can QT 25
9150-00-402-2372 25 (81349) MIL-L-46167 25
25 5 Gallon Can CN 25
9150-00-491-7197 25 (81349) MIL-L-46167 25
55 Gallon Drum DR 25
26 F 26 26 Plastigage 26 26
26 (0.004 to 0.009 in. clearance range) 26
5210-00-640-6176 26 (74069) HPBl (Blue Color) 26
26 Box of 12 BX 26
26 Plastigage 26 26
5210-00-640-6177 26 (0.001 to 0.003 in. clearance range) 26
26 (74069) HPG1 (Green Color) 26
26 Box of 12 BX 26
26 Plastigage 26 26
5210-00-640-6178 26 (0.002 to 0.006 in. clearance range) 26
(74069) HPRl (Red Color) 26
Box of 12 BX 26
27 F 27 27 Petrolatum, Technical 27 27
27 (81348) 0511A0009 27
9150-00-250-0925 27 1.75 Pound Can CN 27
28 C 28 28 Rag, Wiping 28 28
(64067) A-A-431
28 28 7920-00-205-1711 28 50 Pound Bale BL 28
0130-4
TM 5-3805-255-14 0130
(1)
0 (2)
0 0(3) 0 (4) 0 (5)

29 F 29 29 Retaining Compound, Loctite 638 29 29
3930-01-513-8764 29 (1VHH8) 250 ml. bottle BT 29
30 F 30 8030-01-515-0564 30 Rust Arresting Coating 30 TU 30
(17595)
31 F 31 31 Sealant, Loctite 242 31 31
8030-01-014-5869 31 (05972) Medium strength threadlock adhesive OZ 31
(Blue)
32 F 32 32 Sealant, Loctite 270 32 TU 32
8030-01-044-5527 32 (05972) Adhesive, metal assembly (orange)

33 F 33 33 Sealant, Loctite 496 33 33
8040-00-164-1359 33 (05972) Adhesive (Mar-Seal) OZ 33
34 F 34 34 Sealant, Permatex 34 34
34 Form-A-Gasket No. 3 (77247) MIL-S-45180C, 34
8030-00-656-1426 34 1 Tube TU 34
35 F 35 35 Sealing Compound, Urethane 35 35
(52157) 051135-08609
35 35 8030-01-320-4710 35 10.5 Ounce Cartridge CA 35
36 F 36 36 Strap, Tiedown 36 36
Electrical Components
(06383) PLT35-C-O
36 36 5975-01-379-4997 36 Package of 100 PK 36
37 F 37 37 Tag, Marker 37 37
(64067) 9905-00-537-8954
37 37 9905-00-537-8954 37 Bundle of 50 BD 37
38 F 38 9505-00-596-0191 38 Wire, Nonelectrical 38 CL 38
(81346) ASTM A641

283 Foot Coil
END OF WORK PACKAGE
0130-5/(6 blank)
6
TM 5-3805-255-14 0131
FIELD MAINTENANCE -
0 1 3 1 TORQUE LIMITS
SCOPE 000131
This work package lists standard torque values and provides general information for applying torque. Special
torque values and tightening sequences are indicated in the maintenance procedures for applicable components.
GENERAL 000131
1. Always use torque values listed in Tables 1 and 2 when a maintenance procedure does not give a specific
torque value.
a. Table 1 provides torque limits for SAE standard fasteners.
b. Table 2 provides torque limits for metric fasteners.
2. Unless otherwise indicated, standard torque tolerance shall be r10%.
3. Torque values listed are based on clean, dry threads. Reduce torque by 10% when engine oil is used as a
lubricant. Reduce torque by 20% if new plated capscrews are used.
4. If the maintenance procedures do not specify a tightening order, use the following guides:
a. Unless otherwise specified, lubricate threads of fasteners with Oil Lubricating, OE/HDO-10 (WP 0131,
Item 22).
b. When tightening fasteners above 30 lb-ft (41 Nm), use the torque pattern but only tighten to 70% 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
0131-1
TM 5-3805-255-14 0131
CAUTION
If replacement capscrews are of higher grade than originally supplied, use torque specifications for the original.
This will prevent equipment damage due to overtorquing.
Table 1. Torque Limits - SAE Standard Fasteners.
Current Usage Much Used Much Used Used at Times Used at Times
QUALITY OF MINIMUM MEDIUM BEST

INDETERMINATE
MATERIAL COMMERCIAL COMMERCIAL COMMERCIAL
SAE Grade Number 1 or 2 5 6 or 7 8
Capscrew Head
Markings
Manufacturer’s
marks may vary
These are all
SAE Grade 5
(3 line)
CAPSCREW BODY TORQUE TORQUE TORQUE TORQUE

SIZE IN. - THREAD lb-ft (NM) lb-ft (NM) lb-ft (NM) lb-ft (NM)
1/4 20 5 (7) 8 (11) 10 (14) 12 (16)

28 6 (8) 10 (14) 14 (19)
5/16 18 11 (15) 17 (23) 19 (26) 24 (33)
24 13 (18) 19 (26) 27 (37)
3/8 16 18 (24) 31 (42) 34 (46) 44 (60)
24 20 (27) 35 (47) 49 (66)
7/16 14 28 (38) 49 (66) 55 (75) 70 (95)
20 30 (41) 55 (75) 78 (106)
1/2 13 39 (53) 75 (102) 85 (115) 105 (142)
20 41 (56) 85 (115) 120 (163)
9/16 12 51 (69) 110 (149) 120 (163) 155 (210)
18 55 (75) 120 (163) 170 (231)
5/8 11 83 (113) 150 (203) 167 (226) 210 (285)
18 95 (129) 170 (231) 240 (325)
3/4 10 105 (142) 270 (366) 280 (380) 375 (508)
16 115 (156) 295 (400) 420 (569)
7/8 9 160 (217) 395 (536) 440 (597) 605 (820)
14 175 (237) 435 (590) 675 (915)
1 8 235 (319) 590 (800) 660 (895) 910
14 250 (339) 660 (895) (1,234)
990
(1,342)
0131-2
TM 5-3805-255-14 0131
Table 2. Torque Limits - Metric Fasteners.
Torque values for metric thread fasteners with lubricated* or plated threads†
THREAD
DIAMETER-PITCH
Class 8.8 Bolt Class 8 Nut Class 10.9 Bolt Class 10 Nut
TORQUE TORQUE
lb-ft (NM) lb-ft (NM)
M6 5 (7) 7 (9)
M8 12 (16) 17 (23)
M8 x 1 13 (18) 18 (24)
M10 24 (33) 34 (46)
M10 x 1.25 27 (37) 38 (52)
M12 42 (57) 60 (81)
M12 x 1.5 43 (58) 62 (84)
M14 66 (89) 95 (129)
M14 x 1.5 72 (98) 103 (140)
M16 103 (140) 148 (201)
M16 x 1.5 110 (149) 157 (213)
M18 147 (199) 203 (275)
M18 x 1.5 165 (224) 229 (310)
M20 208 (282) 288 (390)
M20 x 1.5 213 (313) 320 (434)
M22 283 (384) 392 (531)
M22 x 1.5 315 (427) 431 (584)
M24 360 (488) 498 (675)
M24 x 2 392 (531) 542 (735)
M27 527 (715) 729 (988)
M27 x 2 569 (771) 788 (1,068)
M30 715 (969) 990 (1,342)
M30 x 2 792 (1,074) 1,096 (1,486)
* All plated and unplated fasteners should be coated with oil before installation.
† Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated,
cadmium-plated, or waxed).
0131-3
TM 5-3805-255-14 0131
TORQUE VALUES FOR STANDARD FASTENERS 000131
This chart provides tightening torque for general purpose applications using original equipment standard hardware
as listed in the Parts Catalog for the machine involved. DO NOT SUBSTITUTE. Original equipment standard hard-
ware is defined as IH Type 8, coarse thread bolts and nuts and thru hardened flat washer s (Rockwell “C” 38-45),
all phosphate coated and assembled without supplemental lubrication (as received condition).
The torques shown on the next page also apply to the following:
(1) Phosphate coated bolts used in tapped holes in steel or gray iron.
(2) Phosphate coated bolts used with phosphate coated prevailing torque nuts (nuts with distorted threads
or plastic inserts).
(3) Phosphate coated bolts used with copper plated weld nuts.
Markings on bolt heads or nuts indicate material grade ONLY and are NOT to be used to determine required
torque.
STANDARD TORQUE +10%

NOMINAL
THREAD
NEWTON
DIAMETER LB-FT
METERS
1/4 7 10
5/16 14 19
3/8 24 32
7/16 38 51
1/2 60 80
9/16 80 110
5/8 115 155
3/4 200 270
7/8 320 440
1 480 650
1-1/8 590 800
1-1/4 830 1100
1-3/8 1100 1500
1-1/2 1400 1900
1-3/4 2300 3100
2 3400 4600
0131-4
TM 5-3805-255-14 0131
TORQUE VALUES FOR HOSE CLAMPS 000131
The following chart provides the tightening torques for hose clamps used in all rubber applications (radiator, air
cleaner, operating lever boots, hydraulic system, etc).
TORQUE PLUS OR MINUS 5 LB-IN (0.6 NM)
RADIATOR, AIR CLEANER, BOOTS, ETC HYDRAULIC SYSTEM
CLAMP
LB-IN Nm LB-IN Nm
TYPE & SIZE
“T” Bolt (any Diameter) 60 7 45 5

Worm Drive - 1-3/4”
Open Diameter & Under 25 3 45 5
Worm Drive - Over 1-3/4”
Open Diameter 45 5 45 5
END OF WORK PACKAGE
0131-5/(6 blank)
TM 5-3805-255-14
INDEX
Subject WP Sequence No.-Page No.
A
Accelerator Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0033-1
Air Cleaner Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0029-1
Air Compressor
Replacement and Repair (Model 500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0064-1
Replacement and Repair (Model 501) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0065-1
Air Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0062-1
Alternator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0040-1
B
Basic Issue Items (BII) List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0129-1
Battery-Service and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0045-1
Brake
Parking Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0058-1
Parking Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0057-1
Service Replace/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0059-1
Bucket
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0086-1
Tips Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0085-1
Bucket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0086-1
C
Cab
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0075-1
Cab Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0075-1
Camshaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0096-1
Centerhinge Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0074-1
Circuit Breaker
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0021-1
Clutch Pack Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0104-1
Connecting Rod
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0094-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0093-1
Control Valve
Main Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0078-1
Crankshaft and Main Bearings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0090-1
Cylinder
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0122-1
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0122-1
Repair
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0123-1
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0123-1
Sleeves Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0087-1
Cylinder Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0089-1
Cylinder Replacement
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0082-1
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0081-1
INDEX-1
TM 5-3805-255-14
INDEX - CONTINUED
D
Demand Valve Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0073-1
Description and Use of Operator Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0004-1
E
Electrical
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0020-1
Electrical General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0020-1
Emergency Shutdown Control Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0034-1
Engine
Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0025-1
Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0024-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0022-1
Equipment
Characteristics, Capabilities, and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0002-1
Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0002-1
Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0002-1
Expendable and Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0130-1
F
Fabricated Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0125-1
Fan Drive Assembly
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0101-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0038-1
Fan Drive Assembly Replacement/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0101-1
Field Preventive Maintenance Checks and Services (PMCS)
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0017-1
Table (Includes Lubrication Instructions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0018-1
Field Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0014-1
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0016-1
Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0015-1
Flywheel Replacement/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0091-1
Front
Axle Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0051-1
Differential Repair/Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0111-1
Differential Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0052-1
Final Drive/Planetary Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0053-1
Planetary Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0112-1
Fuel
Injection Pump
Adapter Housing Replacement/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0100-1
Replacement and Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0028-1
Injector
Testing and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0099-1
Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0027-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0027-1
Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0031-1
INDEX-2
TM 5-3805-255-14
INDEX - CONTINUED
G
Gauge Replacement
Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0043-1
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0084-1
General
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-1
Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP --1
Maintenance Instructions Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0019-1
Governor
Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0032-1
H
Hydraulic
Control Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0080-1
Main Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0120-1
Main Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0077-1
Steering Cylinders Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0118-1
System Pressure Relieving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0019-2
Tank/Reservoir Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0124-1
Tank/Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0083-1
I
Illustrated List of Manufactured Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0125-1
Intake and Exhaust Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0026-1
L
Lubricating Oil and Water Pump
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0098-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0023-1
Lubricating Oil Filter
Housing and Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0039-1
M
Main Control Valve Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0121-1
Main Oil Seal Replacement
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0088-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0088-1
Maintenance Allocation Chart (MAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0128-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0127-1
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0128-1
Muffler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0035-1
O
Operation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-1
Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-1
INDEX-3
TM 5-3805-255-14
INDEX - CONTINUED
O - Continued
Operator Preventive Maintenance Checks and Services (PMCS)
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0012-1
Table (Including Lubrication Instructions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0013-1
Operator Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0009-1
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0011-1
Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0010-1
P
Pistons Inspection/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0092-1
Power Cluster Assemblies Replacement/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0060-1
Preparation for Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0008-1
Propeller Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0049-1
R
Radiator and Converter Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0036-1
Rear
Axle
Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0054-1
Differential
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0055-1
Differential Repair/Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0114-1
Final Drive/Planetary Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0056-1
Planetary Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0115-1
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0126-1
Reservoir Relief Valve
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0079-1
S
Safety Valve and Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0063-1
Sending Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0044-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0125-1
Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0041-1
Steering
Control Valve
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0119-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0072-1
Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0071-1
Gear Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0116-1
Gear Replacement/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0068-1
Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0069-1
Pump Assembly
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0117-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0070-1
Wheel and Column Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0067-1
Storage and Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0008-1
Stowage And Decal, Data Plate, And Stencil Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-1
Stowage and Decal, Data Plate, and Stencil Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-1
Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0042-1
INDEX-4
TM 5-3805-255-14
INDEX - CONTINUED
T
Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-1
Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0037-1
Timing Gears Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0097-1
Tools
Fabricated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0125-1
Special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0125-1
Torque Converter
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0102-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0047-1
Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0131-1
Transfer Drive Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0050-1
Transmission
Charging Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0106-1
Control Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0046-1
Forward and Reverse Valve Repair/Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0105-1
Main Regulator Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0107-1
Neutral Knockdown Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0108-1
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0103-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0048-1
Treadle Valves Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0061-1
Turbocharger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0030-1
V
Valves Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0095-1
W
Wheel
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0066-1
Windshield
Wiper Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0076-1
INDEX-5/(6 blank)
By Order of the Secretary of the Army:
GEORGE W. CASEY JR.

General, United States Army
Chief of Staff
Official:
0903702
DISTRIBUTION: To be distributed in accordance with the Initial Distribution Number (IDN) 251579, requirements
for TM 5-3805-255-14.
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-LC-LMP/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 Operator, Maint Manual for Loader,
Scoop Type, DED 4x4 Articulated Frame
TM 5-3805-255-14 20 Feb 09 Steer, 4.5 to 5 CY (IHC Model H100C)
ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
NO. NO. GRAPH NO. * NO. NO. (Provide exact wording of recommended changes, if possible).
*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-LC-LMPP/TECH PUBS form
PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
TITLE Operator & Maint Manual for Loader,
PUBLICATION NUMBER DATE
TM 5-3805-255-14 20 Feb 09 Scoop Type DED 4x4, IHC Model H100C)
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-LC-LMPP/TECH PUBS
PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE Operator & Maint Manual for Loader, Scoop, DED
TM 5-3805-255-14 20 Feb 09 4x4, Articulated Frame Steer, 4.5 to 5 CY (IHC Model H100C)
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 Operator & Maint Manual for Loader, Scoop
TM5-3805-255-14 20 Feb 09 DED 4x4, 4.5 to 5 CY (IHC Model H100C)
TOTAL NO.
SUPPORTED
USAPPC V3.00
PUBLICATION/FORM NUMBER DATE TITLE Operator & Maint Manual for Loader, Scoop
TM 5-3805-255-14 20 Feb 09 DED 4x4, 4.5 to 5 CY (IHC Model H100C)

EXTENSION
FROM: (Activity and location) (Include ZIP Code) DATE
TO: (Forward direct to addressee listed in publication)
TOTAL NO.
SUPPORTED
USAPPC V3.00
PUBLICATION/FORM NUMBER DATE TITLE Operator & Maint Manual for Loader, Scoop

EXTENSION
FROM: (Activity and location) (Include ZIP Code) DATE
TO: (Forward direct to addressee listed in publication)
TOTAL NO.
SUPPORTED
USAPPC V3.00
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: 085407-000

TM 5-3805-255-14 Ihc Model 100C

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*TM 5-3805-255-14

OPERATOR, FIELD, AND SUSTAINMENT

LOADER, SCOOP TYPE, DED 4 X 4,

*SUPERSEDURE NOTICE: Supersedes TM 5-3805-255-14&P, 15 July 1980, including all changes.

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

HEADQUARTERS, DEPARTMENT OF THE ARMY

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!

• ALWAYS shut down engine before refueling.

HAZARDOUS WASTE DISPOSAL

LIFTING/HOISTING HEAVY PARTS

HYDRAULIC SYSTEM PRESSURE

To order this NBC decal use:

PRESSURIZED COOLING SYSTEM

SLAVE STARTING ENGINE

When slave starting engine of H100C:

• DO NOT proceed if suitable cable is not available.

• DO NOT use civilian-type jumper cables.

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

SOLVENT CLEANING COMPOUND

LIST OF EFFECTIVE PAGES/WORK PACKAGES -

Front Cover . . . . . . . . . . . . . . . . . . . . . . 0 WP 0028 (14 pgs) . . . . . . . . . . . . . . . . . 0

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

WP 0063 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0098 (22 pgs) . . . . . . . . . . . . . . . . . 0

LOADER, SCOOP TYPE, DED, 4 X 4,

TYPE I WITH 4.5 CU. YD. BUCKET

TYPE II WITH 5 CU. YD.

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

*SUPERSEDURE NOTICE: Supersedes TM 5-3805-255-14&P, 15 July 1980, including all changes.

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

TABLE OF CONTENTS – CONTINUED -

Fuel Injection Pump Replacement and Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0028

TABLE OF CONTENTS – CONTINUED -

Steering Wheel and Column Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0067

TABLE OF CONTENTS – CONTINUED -

Transmission Forward and Reverse Valve Repair/Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0105

HOW TO USE THIS MANUAL

CONTENTS OF THIS MANUAL – CONTINUED

OPERATOR, FIELD, AND SUSTAINMENT MAINTENANCE -

Figure 1. Model H100C Loader. 01

MAINTENANCE FORMS, RECORDS, AND REPORTS 0001

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRS) 0001

For destruction of Army materiel to prevent enemy use, refer to TM 750-244-3.

Notify Field Maintenance to perform preparation for storage or shipment procedures.

SERIAL NUMBERS 0001

Figure 2. Loader Serial Number Plate. 01

Figure 3. Loader Serial Number Location on Rear Frame. 01

SERIAL NUMBERS – CONTINUED

Figure 4. 817 Series C Diesel Engine. 01

END OF WORK PACKAGE

OPERATOR, FIELD, AND SUSTAINMENT MAINTENANCE -

0 0 0 2 EQUIPMENT DESCRIPTION AND DATA

CHARACTERISTICS, CAPABILITIES, AND FEATURES 0002

Figure 1. Model H100C. 02

EQUIPMENT DESCRIPTION 0002

EQUIPMENT DESCRIPTION – CONTINUED

Make and Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . International Harvester, DT 817 Series C

EQUIPMENT DATA – CONTINUED

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24VDC neg ground

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . International Harvester

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . International Harvester