TM 5 3805 290 23 1

TM 5-3805-290-23-1
TECHNICAL MANUAL
FIELD MAINTENANCE MANUAL
FOR
LOADER, LIGHT, SCOOP:

2.5 CUBIC YARD MULTIPURPOSE (MP) CLAMSHELL BUCKET,
DIESEL ENGINE DRIVEN (DED), 4-WHEEL DRIVE
NSN 3805-01-533-1768
MODEL 924G
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY
NOVEMBER 2007
TM 5-3805-290-23-1
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 shows that particles flying through
the air will harm face.
HEAVY PARTS - hand with heavy object on top shows that heavy parts can crush and harm.
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TM 5-3805-290-23-1
HEAVY PARTS - heavy object on human figure shows that heavy parts present a danger to life or limb.
HOT AREA - hand over object radiating heat shows that part is hot and can burn.
HYDRAULIC FLUID PRESSURE - hydraulic fluid spraying human hand shows that fluid escaping
under great pressure can cause injury or death to personnel.
RADIOACTIVE - identifies a material that emits radioactive energy and can injure human tissue or
organs.
SLICK FLOOR - wavy line on floor with legs prone shows that slick floor presents a danger from
falling.
VAPOR - human figure in a cloud shows that material vapors present a danger to life or health.
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TM 5-3805-290-23-1
FOR INFORMATION ON FIRST AID, REFER TO FM 4-25.11.
WARNING
CARBON MONOXIDE (EXHAUST GASES) CAN KILL!

• Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives the body of oxy-
gen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of head-
ache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or
death can result from severe exposure.
• Carbon monoxide occurs in exhaust fumes of internal combustion engines. Carbon monoxide can
become dangerously concentrated under conditions of inadequate ventilation. The following precautions
must be observed to ensure safety of personnel when engine is operated.
1. DO NOT operate engine in enclosed areas.
2. DO NOT idle engine without adequate ventilation.
3. DO NOT drive machine with inspection plates or cover plates removed.
4. BE ALERT for exhaust poisoning symptoms. They are:
• Headache
• Dizziness
• Sleepiness
• Loss of muscular control
5. If you see another person with exhaust poisoning symptoms:
• Remove person from area.
• Expose to fresh air.
• Keep person warm.
• Do not permit physical exercise.
• Administer Cardiopulmonary Resuscitation (CPR), if necessary.
• Notify a medic.
6. BE AWARE. The field protective mask for Nuclear, Biological, and Chemical (NBC) protection will not protect
you from carbon monoxide poisoning.
The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!
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TM 5-3805-290-23-1
WARNING
BATTERIES
• To avoid injury, eye protection and acid-resistant gloves must be worn when working around bat-
teries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around bat-
teries. 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 termi-
nal, a direct short will result in instant heating or electric shock, damage to equipment, and injury
to personnel.
• Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte
makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning
effects. Failure to follow these procedures may result in death or serious injury to personnel.
a. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately.
b. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required.
c. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of
magnesia, beaten egg, or vegetable oil. Seek medical attention immediately.
d. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or
household ammonia.
WARNING
COMPRESSED AIR
Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure
when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning compo-
nents. DO NOT direct compressed air against human skin. Make sure air stream is directed away
from user and other personnel in the area. To prevent injury, user must wear protective goggles or
face shield. Failure to follow this warning may result in injury to personnel.
WARNING
ETHER COLD START SYSTEM
Ether fuel is extremely flammable and toxic. DO NOT smoke and make sure you are in a well-venti-
lated area away from heat, open flames or sparks. Wear eye protection. Avoid contact with skin and
eyes and avoid breathing ether fumes. If fluid enters or fumes irritate the eyes, wash immediately with
large quantities of clean water for 15 minutes. Seek medical attention immediately if ether is inhaled
or causes eye irritation. Failure to follow this warning may cause injury or death to personnel.
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TM 5-3805-290-23-1
WARNING
FIRE EXTINGUISHER
Discharging large quantities of dry chemical fire extinguisher inside an enclosed cab may result in
temporary breathing difficulty during and immediately after the discharge event. Discharge fire
extinguisher from outside the cab. Ventilate cab thoroughly prior to reentry.
WARNING
FUEL HANDLING
• DO NOT smoke or permit any open flame in area of grader while you are servicing fuel system.
Be sure hose nozzle is grounded against filler tube during refueling to prevent static electricity.
Failure to follow this warning may result in injury to personnel or equipment damage.
• DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire,
flames, or sparks. Fuel may ignite, causing injury or death to personnel or damage to equipment.
• Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel,
promptly wash exposed skin and change fuel-soaked clothing. Failure to follow this warning may
result in injury to personnel.
WARNING
HAZARDOUS WASTE DISPOSAL
• When servicing this machine, performing maintenance, or disposing of materials such as engine
coolant, hydraulic fluid, lubricants, battery acids or batteries, and CARC paint, consult your
unit/local 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.
• Lubricating/hydraulic oils and engine coolant 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.
WARNING
HEARING PROTECTION
Your hearing can be PERMANENTLY DAMAGED if you are exposed to constant high noise levels of
85 dB or greater. Hearing protection is required when operating machine or when working on
machine while it is operating. Failure to wear hearing protection may result in hearing loss.
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TM 5-3805-290-23-1
WARNING
HYDRAULIC SYSTEM PRESSURE
• DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and
hydraulic system pressure has been relieved. Tighten all connections before applying pressure.
Escaping hydraulic fluid under pressure can penetrate the skin, causing injury to personnel.
• At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting
any hydraulic lines. Failure to follow this warning may result in injury to personnel.
WARNING
HYDRAULIC SYSTEM PRESSURE
The accumulator is filled with dry nitrogen. DO NOT loosen or remove the valve or cap from the top
of the accumulator. Failure to follow this warning may cause injury to personnel.
WARNING
MACHINE OPERATION
• Use caution and maintain three-point contact at all times when mounting or dismounting
machine. DO NOT use steering wheel as a handhold. Failure to follow this warning may result in
injury or death to personnel.
• BE ALERT for personnel in the area while operating machine. Always check to ensure area is
clear of personnel and obstructions before moving. Failure to follow this warning may result in
injury or death to personnel.
• Use of seat belt while operating machine is mandatory. Fasten belt BEFORE operating machine.
Trying to fasten belt during operation creates a hazardous condition. Failure to follow this warn-
ing may result in injury or death to personnel.
• DO NOT allow riders on machine. Failure to follow this warning may result in injury or death to
personnel.
• NEVER leave operator compartment without applying parking brake. Failure to follow this
warning may result in injury or death to personnel.
• DO NOT use parking/emergency brake to stop a moving machine under usual conditions. Only if
service brakes fail, apply parking/emergency brake. Failure to follow this warning may result in
injury to personnel or damage to equipment.
• NEVER use starting fluid or spray to aid in starting the engine, other than the on-board ether cold
start system. Failure to follow this warning may cause injury or death to personnel or damage to
equipment.
• Always use a ground guide when driving machine up or down ramps in preparation for highway or
marine transport. Failure to use a ground guide may cause injury or death to personnel or damage
to equipment.
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TM 5-3805-290-23-1
WARNING
NBC EXPOSURE
• If NBC exposure is suspected, personnel wearing protective equipment must handle all air cleaner
media. Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures.
• Refer to FM 3-3, Chemical and Biological Contamination Avoidance, FM 3-5, NBC Decontamina-
tion, FM 3-3-1, Nuclear Contamination Avoidance.
• NBC contaminated filters must be handled using adequate precautions and must be disposed of
by trained personnel.
• Failure to follow these warnings may cause injury or death to personnel.
WARNING
IF NBC EXPOSURE IS SUSPECTED ALL AIR
FILTER MEDIA WILL BE HANDLED BY PER-
SONNEL WEARING FULL NBC 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 been allowed to cool down. This is a pressurized
cooling system and escaping steam or hot coolant may result in serious burns to personnel.
• 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 fol-
low this warning may result in serious burns to personnel.
• Wear effective eye, hand, and skin protection when handling coolants. Failure to do so may result in
injury to personnel.
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TM 5-3805-290-23-1
WARNING
SOLVENT CLEANING COMPOUND

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxic
material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in
well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to do so may
result in injury or death to personnel.
WARNING
TIRES
• Operating machine with underinflated or defective tire may lead to tire failure and loss of traction
or control. Failure to follow this warning may cause damage to equipment or injury to personnel.
• If tire pressure is 0 psi (0 kPa) DO NOT inflate. Notify Unit Maintenance. Failure to follow this
warning may cause injury or death to personnel.
• Use a self-inflating chuck and stand at a distance behind tire when inflating tire. Failure to follow
this warning may cause injury or death to personnel.
WARNING
WORK SAFETY
• Lifting cables, chains, hooks, and slings used for lifting machine must be in good condition and of
suitable capacity. Failure to follow this warning may cause injury or death to personnel and dam-
age to equipment.
• Improper use of lifting equipment and improper attachment of cables to machine may cause
injury to personnel and damage to equipment. Observe all standard rules of safety.
• Hitch and steering movement can reduce clearances suddenly and cause injury. Always stop
engine BEFORE working in area of hitch link.
• Use extreme caution when handling heavy parts. Provide adequate support and use assistance
during procedure. Ensure that any lifting device used is in good condition and of 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.
• Wear suitable eye protection and keep face and eyes away from exhausting air tank drain valves.
Failure to do so may cause injury to personnel.
• Hot oil or metal parts can cause severe burns. Wear insulated gloves, long sleeves, and eye protec-
tion when working with heated parts.
• DO NOT operate machine with steering frame lock connected. Steering frame lock must be dis-
connected and securely stowed. Failure to follow this warning may result in injury or death to
personnel.
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TM 5-3805-290-23-1
LIST OF EFFECTIVE PAGES/WORK PACKAGES
Date of issue for original manual is:
Original . . . . . . . 30 November 2007
Total number of pages for front and rear matter is 58 and total number of work packages is 26 consisting of the following:
Page/WP No. Change No. Page/WP No. Change No.
VOLUME I How to Use This Manual (2 pgs.). . . . . . . . . 0

CHAPTER 3 title page . . . . . . . . . . . . . . . . . 0
Front Cover (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0019 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
Warning Summary (8 pgs.) . . . . . . . . . . . . . . 0 WP 0020 00 (22 pgs.) . . . . . . . . . . . . . . . . . . 0
TOC (8 pgs.) . . . . . . . . . . . . . . . . . . . . . . . . . 0 WP 0021 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
How to Use This Manual (2 pgs.) . . . . . . . . . 0 WP 0022 00 (22 pgs.) . . . . . . . . . . . . . . . . . . 0
CHAPTER 1 title page . . . . . . . . . . . . . . . . . 0 WP 0023 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0001 00 (122 pgs.) . . . . . . . . . . . . . . . . . 0 WP 0024 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0002 00 (16 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0025 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0003 00 (196 pgs.) . . . . . . . . . . . . . . . . . 0 WP 0026 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
CHAPTER 2 title page . . . . . . . . . . . . . . . . . 0 WP 0027 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0004 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0028 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0005 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0029 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0006 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0030 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0007 00 (30 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0031 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0008 00 (100 pgs.) . . . . . . . . . . . . . . . . . 0 WP 0032 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0009 00 (156 pgs.) . . . . . . . . . . . . . . . . . 0 WP 0033 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0010 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0034 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0011 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0035 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0012 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0036 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0013 00 (72 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0037 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0014 00 (32 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0038 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0015 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0039 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0016 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0040 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0017 00 (26 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0041 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0018 00 (18 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0042 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
CHAPTER 5 title page . . . . . . . . . . . . . . . . . 0
WP 0043 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0203 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0044 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0204 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0045 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0205 00 (22 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0046 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0206 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0047 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0207 00 (22 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0048 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0208 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0049 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0209 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0050 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
Index (22 pgs.). . . . . . . . . . . . . . . . . . . . . . . . 0
WP 0051 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0210 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
Foldouts (36 pgs.) . . . . . . . . . . . . . . . . . . . . . 0 WP 0052 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
Back Cover (2 pgs.). . . . . . . . . . . . . . . . . . . . 0 WP 0053 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0054 00 (16 pgs.) . . . . . . . . . . . . . . . . . . 0
VOLUME II WP 0055 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0056 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
Front Cover (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0057 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
Warning Summary (8 pgs.) . . . . . . . . . . . . . . 0 WP 0058 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
TOC (8 pgs.) . . . . . . . . . . . . . . . . . . . . . . . . . 0 WP 0059 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
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TM 5-3805-290-23-1
Page/WP No. Change No. Page/WP No. Change No.

WP 0060 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0113 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0061 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0114 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0062 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0115 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0063 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0116 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0064 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0117 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0065 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0118 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0066 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0119 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0067 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0120 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0068 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0121 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0069 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0122 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0070 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0123 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0071 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0124 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0072 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0125 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0073 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0126 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0074 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0127 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0075 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0128 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0076 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0129 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0077 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0130 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0078 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0131 00 (28 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0079 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0132 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0080 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0133 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0081 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0134 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0082 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0135 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0083 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0136 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0084 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0137 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0085 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0138 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0086 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0139 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0087 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0140 00 (26 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0088 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0141 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0089 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0142 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0090 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0143 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0091 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0144 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0092 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0 CHAPTER 4 title page . . . . . . . . . . . . . . . . . 0
WP 0093 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0145 00 (38 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0094 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0146 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0095 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0147 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0096 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0148 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0097 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0149 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0098 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0150 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0099 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0151 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0100 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0152 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0101 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0153 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0102 00 (16 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0154 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0103 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0155 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0104 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0156 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0105 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0157 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0106 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0158 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0107 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0159 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0108 00 (24 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0160 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0109 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0161 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0110 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0162 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0111 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0163 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0112 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0164 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
B
TM 5-3805-290-23-1
WP 0165 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0190 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0

WP 0166 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0191 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0167 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0192 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0168 00 (26 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0193 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0169 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0194 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0170 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0195 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0171 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0196 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0172 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0197 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0173 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0198 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0174 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0199 00 (18 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0175 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0200 00 (18 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0176 00 (28 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0201 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0177 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0202 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0178 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 CHAPTER 5 title page . . . . . . . . . . . . . . . . . 0
WP 0179 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0203 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0180 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0204 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0181 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0205 00 (22 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0182 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0206 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0183 00 (30 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0207 00 (22 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0184 00 (20 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0208 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0185 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0209 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0186 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 Index (15 pgs.) . . . . . . . . . . . . . . . . . . . . . . . 0
WP 0187 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0210 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0188 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0 Foldouts (36 pgs.) . . . . . . . . . . . . . . . . . . . . . 0
WP 0189 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0 Back Cover (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
C/(D Blank)
TM 5-3805-290-23-1
TECHNICAL MANUAL HEADQUARTERS

TM 5-3805-290-23-1 DEPARTMENT OF THE ARMY
Washington, D.C. 30 November 2007
FIELD MAINTENANCE MANUAL
FOR
LOADER, LIGHT, SCOOP:

2.5 CUBIC YARD MULTIPURPOSE (MP) CLAMSHELL BUCKET,
DIESEL ENGINE DRIVEN (DED), 4-WHEEL DRIVE
NSN 3805-01-533-1768
MODEL 924G
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this publication. If you find any mistakes or if you know of a way to improve the pro-
cedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment Technical
Publications), 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, fax or E-mail your letter or DA Form 2028 direct to: TACOM Life Cycle Management Com-
mand, ATTN: AMSTA-LC-LMPP/TECH PUBS, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The
E-mail address is ROCK-TACOM-TECH-PUBS@conus.army.mil. The fax number is DSN 793-0726 or
Commercial (309) 782-0726.
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.
Table of Contents
Page
Number
VOLUME I
Warning Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
How to Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
CHAPTER 1 INTRODUCTORY INFORMATION, EQUIPMENT

DESCRIPTION AND DATA, AND THEORY OF OPERATION
WP 0001 00 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

WP 0002 00 Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-1
WP 0003 00 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1
i
TM 5-3805-290-23-1
Table of Contents - Continued

Page
Number
CHAPTER 2 TROUBLESHOOTING PROCEDURES
WP 0004 00 Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-1

WP 0005 00 How to Use On-Board Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-1
WP 0006 00 How to Use MSD With ET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-1
WP 0007 00 Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-1
WP 0008 00 Troubleshooting Without a Diagnostic Code . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-1
WP 0009 00 Troubleshooting With a Diagnostic Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009 00-1
WP 0010 00 Engine Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-1
WP 0011 00 Fuel System Tests, Inspections, and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . 0011 00-1
WP 0012 00 Cooling System Tests, Inspections, and Adjustments. . . . . . . . . . . . . . . . . . . . . 0012 00-1
WP 0013 00 Electrical System Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . 0013 00-1
WP 0014 00 Transmission Tests, Inspections, and Adjustments. . . . . . . . . . . . . . . . . . . . . . . 0014 00-1
WP 0015 00 Brake System Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . 0015 00-1
WP 0016 00 Steering System Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . 0016 00-1
WP 0017 00 Hydraulic System Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . 0017 00-1
WP 0018 00 Air Conditioning System Tests, Inspections, and Adjustments . . . . . . . . . . . . . 0018 00-1
CHAPTER 5 SUPPORTING INFORMATION
WP 0203 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203 00-1

WP 0204 00 Maintenance Allocation Chart (MAC) Introduction . . . . . . . . . . . . . . . . . . . . . . 0204 00-1
WP 0205 00 Maintenance Allocation Chart (MAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205 00-1
WP 0206 00 Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206 00-1
WP 0207 00 Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0207 00-1
WP 0208 00 Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208 00-1
WP 0209 00 Nomenclature Cross-Reference List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209 00-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
WP 0210 00 Schematics Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210 00-1
Foldouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-1
Electrical
FO-1. Electrical Schematics - Key to Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-1
FO-1. Electrical Schematics - Key to Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-3
FO-1. Electrical Schematics - Lighting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-5
FO-1. Electrical Schematics - Accessories Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-9
FO-1. Electrical Schematics - Accessories Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-11
FO-1. Electrical Schematics - Implement Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-15
FO-1. Electrical Schematics - Engine Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-19
FO-1. Electrical Schematics - Transmission Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-21
FO-1. Electrical Schematics - Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-25
FO-1. Electrical Schematics - Power Distribution Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-27
FO-1. Electrical Schematics - Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-29
Hydraulic
FO-2. Hydraulic Component Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-31
FO-2. Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-33
ii
TM 5-3805-290-23-1

Page
Number
VOLUME II
CHAPTER 3 UNIT MAINTENANCE INSTRUCTIONS
WP 0019 00 Preventive Maintenance Checks and Services (PMCS) Introduction . . . . . . . . . 0019 00-1
WP 0020 00 Preventive Maintenance Checks and Services (PMCS)
Including Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-1
WP 0021 00 Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1
WP 0022 00 Electrical General Maintenance Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-1
WP 0023 00 Mechanical General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-1
Engine
WP 0024 00 Valve Cover and Crankcase Vent Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-1
WP 0025 00 Changing Engine Oil and Oil Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . 0025 00-1
WP 0026 00 Engine Oil Filler Neck and Check Tube Replacement . . . . . . . . . . . . . . . . . . . . 0026 00-1
WP 0027 00 Engine Oil Filter Base and Oil Filter Bypass Valve Maintenance . . . . . . . . . . . 0027 00-1
WP 0028 00 Engine Oil Cooler Core and Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0028 00-1
Fuel System
WP 0029 00 Priming Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0029 00-1
WP 0030 00 Fuel Injector Lines Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030 00-1
WP 0031 00 Air Restriction Indicator and Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0031 00-1
WP 0032 00 Air Cleaner, Housing, and Precleaner Replacement . . . . . . . . . . . . . . . . . . . . . . 0032 00-1
WP 0033 00 Air Intake Hoses and Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0033 00-1
WP 0034 00 Aftercooler Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0034 00-1
WP 0035 00 Fuel Tank Lines, Fittings, and Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . 0035 00-1
WP 0036 00 Fuel Filters Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0036 00-1
WP 0037 00 Fuel Filter Bases Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-1
WP 0038 00 Fuel Filter Lines and Fittings Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0038 00-1
WP 0039 00 Throttle Pedal and Throttle Position Sensor Replacement . . . . . . . . . . . . . . . . . 0039 00-1
WP 0040 00 Ether Starting Aid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0040 00-1
Exhaust System
WP 0041 00 Exhaust System Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-1
Cooling System
WP 0042 00 Cooling System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042 00-1
WP 0043 00 Thermostat and Water Outlet Manifold Replacement. . . . . . . . . . . . . . . . . . . . . 0043 00-1
WP 0044 00 Cooling System Hoses, Clamps, and Tank Replacement . . . . . . . . . . . . . . . . . . 0044 00-1
WP 0045 00 Water Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0045 00-1
Electrical System
WP 0046 00 V-Belts Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0046 00-1
WP 0047 00 Alternator Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0047 00-1
WP 0048 00 Starter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0048 00-1
WP 0049 00 Control Switches and Panels Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049 00-1
WP 0050 00 Secondary Steering and Windshield Wiper Switches Replacement . . . . . . . . . . 0050 00-1
WP 0051 00 Instrument Cluster and Turnlamp Switch Replacement . . . . . . . . . . . . . . . . . . . 0051 00-1
WP 0052 00 Machine Electronic Control Module (ECM) Replacement. . . . . . . . . . . . . . . . . 0052 00-1
iii
TM 5-3805-290-23-1

Page
Number
Electrical System - Continued

WP 0053 00 Engine Electronic Control Module (ECM) Replacement . . . . . . . . . . . . . . . . . . 0053 00-1
WP 0054 00 Fuse, Relay, and Circuit Breaker Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 0054 00-1
WP 0055 00 Electrical Converter (24V to 12V) Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-1
WP 0056 00 Battery Disconnect Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00-1
WP 0057 00 Kickout Sensors Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057 00-1
WP 0058 00 Rear Turnlamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0058 00-1
WP 0059 00 Blackout Drive Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059 00-1
WP 0060 00 Worklights Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0060 00-1
WP 0061 00 Fuel Level Sending Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-1
WP 0062 00 Service Lights and Front Turnlamp Replacement. . . . . . . . . . . . . . . . . . . . . . . . 0062 00-1
WP 0063 00 Coolant Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0063 00-1
WP 0064 00 Inlet Air Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0064 00-1
WP 0065 00 Boost Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065 00-1
WP 0066 00 Engine Oil Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0066 00-1
WP 0067 00 Speed/Timing Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0067 00-1
WP 0068 00 Torque Converter and Transmission Oil Temperature Sensors Replacement . . 0068 00-1
WP 0069 00 Transmission and Torque Converter Speed Sensors Replacement . . . . . . . . . . . 0069 00-1
WP 0070 00 Hydraulic Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0070 00-1
WP 0071 00 Brake Charging Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0071 00-1
WP 0072 00 Brake Oil Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0072 00-1
WP 0073 00 Ride Control Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0073 00-1
WP 0074 00 Steering Oil Primary Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . 0074 00-1
WP 0075 00 Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0075 00-1
WP 0076 00 Backup Alarm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076 00-1
WP 0077 00 Batteries Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077 00-1
WP 0078 00 Battery Boxes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0078 00-1
WP 0079 00 Battery Cables Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079 00-1
WP 0080 00 NATO Slave Receptacle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080 00-1
Transmission
WP 0081 00 Shift Lever Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0081 00-1
WP 0082 00 Transmission Oil Fill/Check Tube Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 0082 00-1
WP 0083 00 Changing Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083 00-1
WP 0084 00 Transmission Magnetic Screen Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0084 00-1
WP 0085 00 Torque Converter Oil Cooler Lines Replacement. . . . . . . . . . . . . . . . . . . . . . . . 0085 00-1
WP 0086 00 Transmission Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0086 00-1
WP 0087 00 Transmission Oil Filter Base Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0087 00-1
WP 0088 00 Transmission Oil Cooler Bypass Valve Maintenance. . . . . . . . . . . . . . . . . . . . . 0088 00-1
WP 0089 00 Hydraulic/Transmission Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . 0089 00-1
Propeller and Propeller Shafts
WP 0090 00 Drive Shaft Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0090 00-1
Differential and Bevel Gear
WP 0091 00 Changing Differential and Final Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091 00-1
Brake System
WP 0092 00 Parking Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0092 00-1
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Brake System - Continued

WP 0093 00 Service Brake Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093 00-1
WP 0094 00 Brake Pedals and Stoplamp Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0094 00-1
WP 0095 00 Service Brake Lines and Fittings Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 0095 00-1
WP 0096 00 Brake Accumulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0096 00-1
Wheel and Tire
WP 0097 00 Tire and Wheel (Front or Rear) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0097 00-1
Steering System
WP 0098 00 Steering Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0098 00-1
WP 0099 00 Steering Column Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0099 00-1
WP 0100 00 Secondary Steering Pump and Electric Motor Replacement . . . . . . . . . . . . . . . 0100 00-1
WP 0101 00 Steering Metering Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0101 00-1
WP 0102 00 Steering Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0102 00-1
WP 0103 00 Steering Cylinders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103 00-1
WP 0104 00 Secondary Steering Relief Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 0104 00-1
Frame
WP 0105 00 Rear Axle Stops Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105 00-1
WP 0106 00 Ladder and Platforms Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0106 00-1
WP 0107 00 Chassis Guards and Covers Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0107 00-1
WP 0108 00 Remote Lubrication Lines, Hoses, and Fittings Replacement . . . . . . . . . . . . . . 0108 00-1
WP 0109 00 Counterweight Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109 00-1
Body and Cab
WP 0110 00 Hood and Side Covers Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110 00-1
WP 0111 00 Cab Doors Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111 00-1
WP 0112 00 Front Fenders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112 00-1
WP 0113 00 Seat Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113 00-1
WP 0114 00 Seat Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0114 00-1
WP 0115 00 Seat Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0115 00-1
WP 0116 00 Cab Liners and Mirrors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0116 00-1
WP 0117 00 Toolbox and BII Toolbox Bracket Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 0117 00-1
Body, Chassis, and Accessory Items
WP 0118 00 Windshield Washer Bottle, Mounting Bracket, and Hoses Replacement . . . . . . 0118 00-1
WP 0119 00 Front Windshield Wiper and Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . 0119 00-1
WP 0120 00 Rear Windshield Wiper and Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0120 00-1
WP 0121 00 Data Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0121 00-1
WP 0122 00 Rifle Rack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0122 00-1
Hydraulic System
WP 0123 00 Ride Control Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123 00-1
WP 0124 00 Combination Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0124 00-1
WP 0125 00 Implement Relief Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125 00-1
WP 0126 00 Pilot Oil Accumulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126 00-1
WP 0127 00 Ride Control Accumulator Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127 00-1
WP 0128 00 Tilt Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0128 00-1
WP 0129 00 Lift Cylinders Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0129 00-1
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Hydraulic System - Continued

WP 0130 00 Hydraulic Oil Filter Base and Mounting Replacement . . . . . . . . . . . . . . . . . . . . 0130 00-1
WP 0131 00 Implement Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . 0131 00-1
WP 0132 00 Hydraulic Oil Filter and Cooler Hoses, Lines, and Fittings Replacement . . . . . 0132 00-1
WP 0133 00 Ride Control Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . 0133 00-1
WP 0134 00 Main Control Valve Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . 0134 00-1
WP 0135 00 Implement Pump Hoses, Lines, and Fittings Replacement. . . . . . . . . . . . . . . . . 0135 00-1
WP 0136 00 Pilot System Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . 0136 00-1
WP 0137 00 Hydraulic System Oil Change and Filter Replacement. . . . . . . . . . . . . . . . . . . . 0137 00-1
WP 0138 00 Pin Coupler Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138 00-1
WP 0139 00 Bucket Cylinders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139 00-1
WP 0140 00 Hydraulic Tank and Mounting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0140 00-1
Special Purpose Kits
WP 0141 00 Arctic Heater Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0141 00-1
WP 0142 00 Forklift Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0142 00-1
Refrigeration and Air Conditioning
WP 0143 00 Air Conditioning/Heater Blower Motor Replacement . . . . . . . . . . . . . . . . . . . . 0143 00-1
Earthmoving Equipment
WP 0144 00 Bucket Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144 00-1
CHAPTER 4 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
Engine
WP 0145 00 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145 00-1
WP 0146 00 Cylinder Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0146 00-1
WP 0147 00 Crankshaft Vibration Damper and Pulley Replacement . . . . . . . . . . . . . . . . . . . 0147 00-1
WP 0148 00 Rear Main Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148 00-1
WP 0149 00 Front Main Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0149 00-1
WP 0150 00 Flywheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0150 00-1
WP 0151 00 Flywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0151 00-1
WP 0152 00 Front Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0152 00-1
WP 0153 00 Timing and Idler Gears Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0153 00-1
WP 0154 00 Front Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154 00-1
WP 0155 00 Intake/Exhaust Valve Lash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155 00-1
WP 0156 00 Rocker Arms and Push Rods Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156 00-1
WP 0157 00 Oil Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157 00-1
WP 0158 00 Engine Oil Bypass Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0158 00-1
WP 0159 00 Piston Cooling Jets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0159 00-1
WP 0160 00 Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0160 00-1
WP 0161 00 Exhaust Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0161 00-1
WP 0162 00 Intake Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0162 00-1
Fuel System
WP 0163 00 Fuel Injector Nozzles Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163 00-1
WP 0164 00 Fuel Injection Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164 00-1
WP 0165 00 Turbocharger and Oil Lines Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0165 00-1
WP 0166 00 Fuel Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0166 00-1
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Cooling System
WP 0167 00 Radiator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167 00-1
WP 0168 00 Radiator and Fan Group Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168 00-1
Electrical System
WP 0169 00 Instrument Panel Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0169 00-1
WP 0170 00 Engine Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0170 00-1
WP 0171 00 Transmission Control Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . 0171 00-1
WP 0172 00 Front Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172 00-1
WP 0173 00 Ride Control Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173 00-1
WP 0174 00 Rear Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174 00-1
WP 0175 00 Cab Wiring Harness Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175 00-1
Transmission
WP 0176 00 Transmission and Torque Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . 0176 00-1
WP 0177 00 Transmission Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0177 00-1
WP 0178 00 Transmission Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0178 00-1
Front Axle
WP 0179 00 Front Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0179 00-1
Rear Axle
WP 0180 00 Rear Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0180 00-1
WP 0181 00 Rear Axle Trunnion Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0181 00-1
Steering System
WP 0182 00 Piston Pump (Implement, Pilot, and Steering) Replacement . . . . . . . . . . . . . . . 0182 00-1
Frame
WP 0183 00 Separate Loader Frame and Rear Frame (Articulation Pivot Pins)
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0183 00-1
Body and Cab
WP 0184 00 Cab Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184 00-1
WP 0185 00 Windshield Front/Rear and Doors Glass Replacement . . . . . . . . . . . . . . . . . . . . 0185 00-1
Hydraulic System
WP 0186 00 Gear Pump Braking and Hydraulic Fan Replacement . . . . . . . . . . . . . . . . . . . . 0186 00-1
WP 0187 00 Gear Motor Hydraulic Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187 00-1
WP 0188 00 Pilot Operated Control (Joy Stick) and Hydraulic Lockout Valve
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0188 00-1
WP 0189 00 Main Control Valve (Three Function) Replacement. . . . . . . . . . . . . . . . . . . . . . 0189 00-1
WP 0190 00 Coupler Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190 00-1
Refrigeration and Air Conditioning
WP 0191 00 Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191 00-1
WP 0192 00 Air Conditioning Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192 00-1
WP 0193 00 Air Conditioning Hoses, Valves, Flanges,
Fittings, and Accumulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193 00-1
WP 0194 00 Inline Refrigerant Dryer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194 00-1
WP 0195 00 Air Conditioning Condenser Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195 00-1
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Refrigeration and Air Conditioning - Continued

WP 0196 00 Evaporator Core Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0196 00-1
WP 0197 00 Heater Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197 00-1
Earthmoving Equipment
WP 0198 00 Quick Coupler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198 00-1
WP 0199 00 Front Tilt Lever and Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199 00-1
WP 0200 00 Rear Tilt Lever and Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200 00-1
WP 0201 00 Lift Arms Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0201 00-1
WP 0202 00 Illustrated List of Manufactured Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202 00-1
CHAPTER 5 SUPPORTING INFORMATION
WP 0203 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203 00-1

WP 0204 00 Maintenance Allocation Chart (MAC) Introduction . . . . . . . . . . . . . . . . . . . . . . 0204 00-1
WP 0205 00 Maintenance Allocation Chart (MAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205 00-1
WP 0206 00 Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206 00-1
WP 0207 00 Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0207 00-1
WP 0208 00 Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208 00-1
WP 0209 00 Nomenclature Cross-Reference List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209 00-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
WP 0210 00 Schematics Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210 00-1
Foldouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-1
Electrical
FO-1. Electrical Schematics - Key to Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-1
FO-1. Electrical Schematics - Key to Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-3
FO-1. Electrical Schematics - Accessories Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-9
FO-1. Electrical Schematics - Engine Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-19
FO-1. Electrical Schematics - Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-25
FO-1. Electrical Schematics - Power Distribution Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-27
FO-1. Electrical Schematics - Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-29
Hydraulic
FO-2. Hydraulic Component Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-31
viii
TM 5-3805-290-23-1
HOW TO USE THIS MANUAL
NOTE
If at any time you are unsure how to use this manual or you cannot locate the information you need,
notify your supervisor.
INTRODUCTION
1. This manual is designed to help you troubleshoot and maintain the 924G Wheel Loader and to perform troubleshooting
and maintenance on the equipment.
2. This manual is written in work package format:
a. Chapters divide the manual into major categories of information (e.g., Introductory Information, Equipment
Description and Data, and Theory of Operation, Troubleshooting Procedures, Maintenance Instructions, Direct
Support and Maintenance Instructions, and Supporting Information).
b. Each Chapter is divided into work packages, which are identified by a 6-digit number (e.g., 0001 00, 0002 00)
located in the upper right-hand corner of each page. The work package page number (e.g., 0001 00-1, 0001 00-2) is
located centered at the bottom of each page.
c. If a Change Package is issued to this manual, added work packages use the 5th and 6th digits of their number to
indicate new material. For instance, work packages inserted between WP 0001 00 and WP 0002 00 are numbered
WP 0001 01, WP 0001 02, etc.
3. Read through this manual to become familiar with its organization and contents before attempting to operate or maintain
the equipment.
4. This manual is published in two volumes: Volume I covers Theory of Operation and Troubleshooting.
5. The second volume (TM 5-3805-290-23-2) covers Field Level Maintenance Instructions.
CONTENTS OF THIS MANUAL
1. A Warning Summary is located at the beginning of each volume of the manual. Become familiar with these warnings
before operating or performing operator troubleshooting or maintenance on the machine.
2. A Table of Contents in Volume I lists the contents of Volumes I and II. The Table of Contents in Volume II lists the con-
tents of Volume II only.
a. The Table of Contents also provides Reporting Errors and Recommending Improvements information and DA
Form 2028 addresses, for the submittal of corrections to this manual.
b. If you cannot find what you are looking for in the Table of Contents, refer to the alphabetical Index at the back of
the manual. The alphabetical index for each volume lists only those work packages found in that volume.
3. Chapter 1, Introductory Information, Equipment Description and Data, and Theory of Operation, provides general infor-
mation on the manual and the equipment.
4. Chapter 2 covers all Troubleshooting Procedures. Soldiers should become familiar with using the MSD in order to trou-
bleshoot electronic problems. WP 0004 00 provides a troubleshooting flowchart, operational checks, and a glossary. WP
0005 00 explains diagnostic codes. WP 0006 00 explains how to connect the MSD to the diagnostic connector. WP 0007
00 contains a Troubleshooting Symptom Index. If the machine malfunctions, this index should always be consulted to
locate the appropriate troubleshooting procedure.
5. Chapter 3 describes Unit Maintenance Instructions. Major areas covered are Preventive Maintenance Checks and Ser-
vices (PMCS) and unit level maintenance tasks.
6. Chapter 4 covers Direct Support Maintenance Instructions.
ix
TM 5-3805-290-23-1
CONTENTS OF THIS MANUAL - CONTINUED

7. Chapter 5 includes Supporting Information and is included in both volumes. Information includes: References, Mainte-
nance Allocation Chart (MAC) Introduction, Maintenance Allocation Chart (MAC), Expendable and Durable Items List,
Torque Limits, Preparation for Storage or Shipment, Nomenclature Cross-Reference List, and Schematics.
FEATURES OF THIS MANUAL

1. WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlighted in BOLD print as a
visual aid.
WARNING
A WARNING indicates a hazard which may result in injury or death to personnel.
CAUTION
A CAUTION is a reminder of safety practices or directs attention to usage practices that may result in
damage to equipment.
NOTE
A NOTE is a statement containing information that will make the procedures easier to perform.
2. Statements and words of particular interest may be printed in CAPITAL LETTERS to create emphasis.
3. Within a procedural step, reference may be made to another work package in this manual or to another manual. These ref-
erences indicate where you should look for more complete information.
a. If you are told: “Perform Torque Converter Stall Test (WP 0014 00),” go to WP 0014 00 in this manual for instruc-
tions on performing that test.
b. If you are told: “For complete information on servicing batteries, refer to TM 9-6140-200-14,” go to the Refer-
ences work package (WP 0203 00) for complete information.
4. Illustrations are placed after, and as close to, the procedural steps to which they apply. Callouts placed on the art are text or
numbers.
5. Numbers located at lower right corner of art (e.g., 427-B001; 427-B002) are art control numbers and are used for tracking
purposes only.
6. Dashed leader lines used in the Lubrication Chart and in the PMCS Table (WP 0020 00) indicate that called out lubrica-
tion points are located on both sides of the machine.
7. Technical instructions include metric units as well as standard units. For your reference, a Metric Conversion Chart is
located on the inside back cover of the manual.
x
TM 5-3805-290-23-1
CHAPTER 1
INTRODUCTORY INFORMATION, EQUIPMENT
DESCRIPTION AND DATA, AND THEORY OF OPERATION
122
TM 5-3805-290-23-1
GENERAL INFORMATION 0001 00
Maintenance Task Title Page
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

Maintenance Forms, Records, and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1
Reporting Equipment Improvement Recommendations (EIR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1
Corrosion Prevention and Control (CPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1
Destruction of Army Materiel to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1
Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-2
Nomenclature Cross-Reference List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-2
List of Abbreviations/Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-2
Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-4
SCOPE 0001 00
1. Type of Manual. This manual is for use in operating and performing operator troubleshooting and maintenance on the
924G Wheel Loader.
2. Equipment Name and Model Number. Loader, Light, Scoop: 2.5 Cubic Yard Clamshell Bucket, Diesel Engine Driven
(DED), 4-Wheel Drive, NSN 3805-01-533-1768, Model 924G.
3. Purpose of Equipment. The 924G Wheel Loader is used in worldwide earthmoving and construction projects by U.S.
Army forces in engineer troop support.
MAINTENANCE FORMS, RECORDS, AND REPORTS 0001 00
Department of the Army forms and procedures used for the equipment maintenance will be those prescribed by DA
PAM 738-750, Functional Users Manual for the Army Maintenance Management System (TAMMS).
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) 0001 00
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
do not like about your equipment. Let us know why you do not 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/aepspublic.cfm (scroll down and
choose “Submit Quality Deficiency Report” bar). The Internet form lets you choose to submit an EIR, a Product Quality Defi-
ciency Report (PQDR) or a Warranty Claim Action (WCA). You may also submit your information using an SF Form 368
(Product Quality Deficiency Report). You can send your SF Form 368 via e-mail, regular mail, or facsimile using the
addresses/facsimile numbers specified in DA PAM 738-750, Functional Users Manual for TAMMS. We will send you a reply.
CORROSION PREVENTION AND CONTROL (CPC) 0001 00
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 (heat), oxidation (oxygen), solva-
tion (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 738-750,
Functional Users Manual for TAMMS.
DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE 0001 00
For destruction of Army materiel to prevent enemy use, refer to TM 750-244-3, Procedure for Destruction of Equipment
to Prevent Enemy Use.
0001 00-1
TM 5-3805-290-23-1
GENERAL INFORMATION - CONTINUED 0001 00
PREPARATION FOR STORAGE OR SHIPMENT 0001 00

Refer to WP 0208 00.
NOMENCLATURE CROSS-REFERENCE LIST 0001 00
OFFICIAL NOMENCLATURE COMMON NOMENCLATURE
Transmission Direction Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F/N/R Switch
Tilt Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rack
LIST OF ABBREVIATIONS/ACRONYMS 0001 00
NOTE
Refer to ASME Y14.38-1999, Abbreviations and Acronyms for standard abbreviations.
ABBREVIATION/ACRONYM DEFINITION
AAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Authorization List
AAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Association of American Railroads
AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning
ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternating Current
AOAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Oil Analysis Program
ATAAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air-to-air After Cooler
AWG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . American Wire Gage
B.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blackout
BII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Issue Items
BTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before Top Center
C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Celsius
CAGEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial and Government Entity Code
CCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Cranking Amps
CG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center of Gravity
CID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Component Identifier
CID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cubic Inch Displacement
cm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centimeter
COEI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components of End Item
CONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continental United States
CPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosion Prevention and Control
DAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Decontamination Apparatus, Portable
dc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Current
DED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diesel Engine Driven
DIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Injection Turbocharged
ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Module
ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Unit
EEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Engine Control
EID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Event Identifier
EIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Improvement Recommendations
0001 00-2
TM 5-3805-290-23-1
LIST OF ABBREVIATIONS/ACRONYMS - CONTINUED 0001 00

ET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Technician
F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fahrenheit
FLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Load Setting
FMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Failure Mode Identifier
FMTV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Family of Medium Tactical Vehicles
F/N/R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Forward/Neutral/Reverse
FRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Ration Control
FTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Torque Setting
gal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gallon
GCWR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gross Combination Weight Rating
GVWR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gross Vehicle Weight Rating
Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hertz
in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inch
kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilogram
km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometer
kPa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilopascal
kph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers per Hour
kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilowatt
L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liter
lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound
lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound Inch
lb-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pound Foot
m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter
MIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Machine Interface Connector
MID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Module Identifier
mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Millimeter
MMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine Monitor System
MP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-Purpose
MPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Miles per Hour
MSD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Support Drive
N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutral
NATO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . North Atlantic Treaty Organization
NBC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuclear, Biological, and Chemical
Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Newton Meter
OCONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Outside Continental United States
PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Personal Computer
PLS-EMM-CMM . . . . . . . . . . . . . . . . . . . . . . . . . Palletized Load System-Engineer Mission Module-Concrete Mobile Mixer
PLS-EMM-DB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Palletized Load System-Engineer Mission Module-Dump Body
PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive Maintenance Checks and Services
0001 00-3
TM 5-3805-290-23-1
LIST OF ABBREVIATIONS/ACRONYMS - CONTINUED 0001 00

PPPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Proportional, Priority, Pressure Compensated System
PQDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Quality Deficiency Report
PR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ply Rating
psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pounds per Square Inch
PWM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulse Width Modulation
RO/RO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roll-On/Roll-Off
ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollover Protective Structure/Falling Object Protective Structure
rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repetitions per Minute
SDDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surface Deployment and Distribution Command
SG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spheroidal Graphite
TAMMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional Users Manual for The Army Maintenance Management System
TOE/MTOE. . . . . . . . . . . . . . . . . . . . . Table of Organization and Equipment/Modified Table of Organization and Equipment
VLPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Load Protection Module
WCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty Claim Action
yd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yard
WARRANTY INFORMATION 0001 00
For warranty information refer to TB 5-3805-290-14, Warranty Technical Bulletin for the 924G Wheel Loader. For a list
of Caterpillar Dealers please see Table 1. They are also located in the Warranty TB.
Caterpillar Dealers
Table 1. Caterpillar Dealers.

Dealer Name Country City State/Province/Region Phone
ALLIED MACHINERY 93 (20) 220 0287
AFGHANISTAN KARACHI SIND PROVINCE
LIMITED GENERAL INFO
ALLIED MACHINERY 93 (20) 2200287
AFGHANISTAN KARACHI SIND PROVINCE
355(42) 71.386
MAIA SHQIPERI SH.P.K. ALBANIA TIRANA TIRANA RRETH
GENERAL INFO
213(9) 73.66.63
MAGELLAN ALGERIA PICARDIE REGION
GENERAL INFO
213(2) 60.88.47
MAGELLAN ALGERIA PICARDIE REGION
GENERAL INFO
HAWTHORNE MACHINERY 684( ) 699 4320
AMERICAN SAMOA PAGO PAGO EASTERN DISTRICT
OF SAMOA, GENERAL INFO
BARLOWORLD 244(2) 399-824
ANGOLA LUANDA LUANDA PROVINCIA
EQUIPAMENTOS GENERAL INFO
54 (11) 4725-8800
FINNING ARGENTINA S.A. ARGENTINA SAN FERNANDO BUENOS AIRES PROVINCIA
GENERAL INFO
54 (3722) 428869
FINNING ARGENTINA S.A. ARGENTINA RESISTENCIA CHACO PROVINCIA
GENERAL INFO
0001 00-4
TM 5-3805-290-23-1
Table 1. Caterpiller Dealers - Continued.

COMODORO 54 (297) 4485232
FINNING ARGENTINA S.A. ARGENTINA CHUBUT PROVINCIA
RIVADAVIA GENERAL INFO
54 (299) 4436334
FINNING ARGENTINA S.A. ARGENTINA NEUQUEN NEUQUEN PROVINCIA
GENERAL INFO
54 (387) 4270648
FINNING ARGENTINA S.A. ARGENTINA SALTA SALTA PROVINCIA
GENERAL INFO
54 (2964) 426626
FINNING ARGENTINA S.A. ARGENTINA RIO GRANDE TIERRA DEL FUEGO
GENERAL INFO
SAN MIGUEL DE 54 (381) 4270777
FINNING ARGENTINA S.A. ARGENTINA TUCUMAN PROVINCIA
TUCUMAN GENERAL INFO
7 (374) 10 55 17 53
ZEPPELIN ARMENIA LLC ARMENIA ZUG
GENERAL INFO
7 (374) 10 55 17 53
ZEPPELIN ARMENIA LLC ARMENIA ZUG
GENERAL INFO
AUSTRALIAN CAPITAL 61 (2) 6290 4500
WESTRAC PTY. LTD. AUSTRALIA FYSHWICK
TERRITORY GENERAL INFO
61 (2) 6025 6799
WESTRAC PTY. LTD. AUSTRALIA ALBURY NEW SOUTH WALES STATE
GENERAL INFO
61 (2) 6331 6411
WESTRAC PTY. LTD. AUSTRALIA BATHURST NEW SOUTH WALES STATE
GENERAL INFO
CAVILL POWER PRODUCTS 61 (8) 8088 3877
AUSTRALIA BROKEN HILL NEW SOUTH WALES STATE
PTY. LTD. GENERAL INFO
61 (02) 6885 8000
WESTRAC PTY. LTD. AUSTRALIA DUBBO NEW SOUTH WALES STATE
GENERAL INFO
61 (2) 6642 8211
WESTRAC PTY. LTD. AUSTRALIA GRAFTON NEW SOUTH WALES STATE
GENERAL INFO
61 (2) 6752 4500
WESTRAC PTY. LTD. AUSTRALIA MOREE NEW SOUTH WALES STATE
GENERAL INFO
61 (2) 6541 5449
WESTRAC PTY. LTD. AUSTRALIA MUSWELLBROOK NEW SOUTH WALES STATE
GENERAL INFO
SOUTH TWEED 61 (7) 5513 1920
WESTRAC PTY. LTD. AUSTRALIA NEW SOUTH WALES STATE
HEADS GENERAL INFO
61 (2) 6701 7222
WESTRAC PTY. LTD. AUSTRALIA TAMWORTH NEW SOUTH WALES STATE
GENERAL INFO
61 (2) 4949 1866
WESTRAC PTY. LTD. AUSTRALIA THORNTON NEW SOUTH WALES STATE
GENERAL INFO
61 (2) 4949 1888
WESTRAC PTY. LTD. AUSTRALIA THORNTON NEW SOUTH WALES STATE
GENERAL INFO
61 (2) 4271 8925
WESTRAC PTY. LTD. AUSTRALIA UNANDERRA NEW SOUTH WALES STATE
GENERAL INFO
61 (2) 6971 7688
WESTRAC PTY. LTD. AUSTRALIA WAGGA WAGGA NEW SOUTH WALES STATE
GENERAL INFO
61 (02) 6752 4500
WESTRAC PTY. LTD. (NSW) AUSTRALIA WEST WYALONG NEW SOUTH WALES STATE
GENERAL INFO
61 (2) 9609 8888
WESTRAC PTY. LTD. AUSTRALIA WETHERILL PARK NEW SOUTH WALES STATE
GENERAL INFO
61 (2) 9609 8801
WESTRAC PTY. LTD. AUSTRALIA WETHERILL PARK NEW SOUTH WALES STATE
GENERAL INFO
0001 00-5
TM 5-3805-290-23-1

HASTINGS DEERING 61 (8) 8952 1888
AUSTRALIA ALICE SPRINGS NORTHERN TERRITORY
(AUSTRALIA) GENERAL INFO
ENERGY POWER SYSTEMS 61 (8) 8941 4309
AUSTRALIA DARWIN NORTHERN TERRITORY
AUSTRALIA GENERAL INFO
AUSTRALIA DARWIN NORTHERN TERRITORY
AUSTRALIA NHULUNBUY NORTHERN TERRITORY
AUSTRALIA PALMERSTON NORTHERN TERRITORY
AUSTRALIA ARCHERFIELD QUEENSLAND STATE
AUSTRALIA BURLEIGH HEADS QUEENSLAND STATE
AUSTRALIA CAIRNS QUEENSLAND STATE
AUSTRALIA CAIRNS QUEENSLAND STATE
AUSTRALIA DYSART QUEENSLAND STATE
AUSTRALIA EMERALD QUEENSLAND STATE
AUSTRALIA GARBUTT QUEENSLAND STATE
AUSTRALIA GLADSTONE QUEENSLAND STATE
AUSTRALIA MACKAY QUEENSLAND STATE
AUSTRALIA MOUNT ISA QUEENSLAND STATE
AUSTRALIA ROCKHAMPTON QUEENSLAND STATE
AUSTRALIA TOOWOOMBA QUEENSLAND STATE
AUSTRALIA WEIPA QUEENSLAND STATE
AUSTRALIA ENFIELD SOUTH AUSTRALIA STATE
AUSTRALIA MOUNT GAMBIER SOUTH AUSTRALIA STATE
AUSTRALIA PORT LINCOLN SOUTH AUSTRALIA STATE
AUSTRALIA PROSPECT SOUTH AUSTRALIA STATE
0001 00-6
TM 5-3805-290-23-1

AUSTRALIA ROXBY DOWNS SOUTH AUSTRALIA STATE
AUSTRALIA WHYALLA SOUTH AUSTRALIA STATE
AUSTRALIA WINGFIELD SOUTH AUSTRALIA STATE
AUSTRALIA WINGFIELD SOUTH AUSTRALIA STATE
61 (3) 6249 0566
WILLIAM ADAMS PTY. LTD. AUSTRALIA GLENORCHY TASMANIA STATE
GENERAL INFO
61 (3) 6326 6366
WILLIAM ADAMS PTY. LTD. AUSTRALIA MOWBRAY HEIGHTS TASMANIA STATE
GENERAL INFO
61 (3) 6433 8888
WILLIAM ADAMS PTY. LTD. AUSTRALIA SOMERSET TASMANIA STATE
GENERAL INFO
61 (3) 6466 1488
WILLIAM ADAMS PTY. LTD. AUSTRALIA SOMERSET TASMANIA STATE
GENERAL INFO
61 (3) 5444 5366
WILLIAM ADAMS PTY. LTD. AUSTRALIA BENDIGO VICTORIA STATE
GENERAL INFO
61 (3) 9308 8555
WILLIAM ADAMS PTY. LTD. AUSTRALIA CAMPBELLFIELD VICTORIA STATE
GENERAL INFO
61 (3) 9566 0666
WILLIAM ADAMS PTY. LTD. AUSTRALIA CLAYTON VICTORIA STATE
GENERAL INFO
AUSTRALIA HALLAM VICTORIA STATE
61 (3) 9703 2600
WILLIAM ADAMS PTY. LTD. AUSTRALIA HALLAM VICTORIA STATE
GENERAL INFO
61 (3) 5382 0071
WILLIAM ADAMS PTY. LTD. AUSTRALIA HORSHAM VICTORIA STATE
GENERAL INFO
61 (3) 5018 6100
WILLIAM ADAMS PTY. LTD. AUSTRALIA MILDURA VICTORIA STATE
GENERAL INFO
61 (3) 5154 3011
WILLIAM ADAMS PTY. LTD. AUSTRALIA NEWMERELLA VICTORIA STATE
GENERAL INFO
61 (3) 9931 9666
WILLIAM ADAMS PTY. LTD. AUSTRALIA NIDDRIE VICTORIA STATE
GENERAL INFO
61 (3) 9931 9666
WILLIAM ADAMS PTY. LTD. AUSTRALIA SUNSHINE VICTORIA STATE
GENERAL INFO
61 (3) 5175 6200
WILLIAM ADAMS PTY. LTD. AUSTRALIA TRARALGON VICTORIA STATE
GENERAL INFO
61 (3) 9329 9077
WILLIAM ADAMS PTY. LTD. AUSTRALIA WEST MELBOURNE VICTORIA STATE
GENERAL INFO
61 (2) 6024 4744
WILLIAM ADAMS PTY. LTD. AUSTRALIA WODONGA VICTORIA STATE
GENERAL INFO
61 (8) 9021 9300
WESTRAC PTY. LTD. AUSTRALIA BOULDER WESTERN AUSTRALIA STATE
GENERAL INFO
61 (8) 9725 4166
WESTRAC PTY. LTD. AUSTRALIA BUNBURY WESTERN AUSTRALIA STATE
GENERAL INFO
61 (8) 9071 5652
WESTRAC PTY. LTD. AUSTRALIA ESPERANCE WESTERN AUSTRALIA STATE
GENERAL INFO
0001 00-7
TM 5-3805-290-23-1

WESTRAC EQUIPMENT 61 (8) 9923 6210
AUSTRALIA GERALDTON WESTERN AUSTRALIA STATE
PTY. LTD. AFTER HOURS
61 (8) 9923 3233
WESTRAC PTY. LTD. AUSTRALIA GERALDTON WESTERN AUSTRALIA STATE
GENERAL INFO
AUSTRALIA KALGOORLIE WESTERN AUSTRALIA STATE
AUSTRALIA KARRATHA WESTERN AUSTRALIA STATE
61 (8) 9821 5555
WESTRAC PTY. LTD. AUSTRALIA KATANNING WESTERN AUSTRALIA STATE
GENERAL INFO
61 (8) 9353 2066
WESTRAC PTY. LTD. AUSTRALIA KEWDALE PEET PARK WESTERN AUSTRALIA STATE
GENERAL INFO
61 (8) 9168 1688
WESTRAC PTY. LTD. AUSTRALIA KUNUNURRA WESTERN AUSTRALIA STATE
GENERAL INFO
61 (8) 9167 1378
WESTRAC PTY. LTD. AUSTRALIA LAKE ARGYLE WESTERN AUSTRALIA STATE
GENERAL INFO
61 (8) 9377 9444
WESTRAC PTY. LTD. AUSTRALIA MIDLAND WESTERN AUSTRALIA STATE
GENERAL INFO
AUSTRALIA NAVAL BASE WESTERN AUSTRALIA STATE
61 (8) 9175 1653
WESTRAC PTY. LTD. AUSTRALIA NEWMAN WESTERN AUSTRALIA STATE
GENERAL INFO
61 (8) 9173 8300
WESTRAC PTY. LTD. AUSTRALIA PORT HEDLAND WESTERN AUSTRALIA STATE
GENERAL INFO
61 (8) 9189 2412
WESTRAC PTY. LTD. AUSTRALIA TOM PRICE WESTERN AUSTRALIA STATE
GENERAL INFO
AUSTRALIA WANGARA WESTERN AUSTRALIA STATE
AUSTRALIA WELSHPOOL WESTERN AUSTRALIA STATE
ZEPPELIN OESTERREICH 43 (4258) 8410-0
AUSTRIA STADELBACH KARNTEN BUNDESLAND
GMBH GENERAL INFO
ZEPPELIN OESTERREICH NIEDEROSTERRICH 43 (1) 2232 790
AUSTRIA FISCHAMEND
GMBH BUNDESLAND GENERAL INFO
ZEPPELIN OESTERREICH OBEROSTERREICH 43 (732) 757055
AUSTRIA LINZ
GMBH BUNDESLAND GENERAL INFO
ZEPPELIN OESTERREICH 43 (6235) 20 131 555
AUSTRIA THALGAU SALZBURG BUNDESLAND
GMBH GENERAL INFO
ZEPPELIN OESTERREICH 43 (3135) 50970
AUSTRIA KALSDORF BEI GRAZ STEIERMARK BUNDESLAND
GMBH GENERAL INFO
ZEPPELIN OESTERREICH 43 (512) 392341
AUSTRIA INNSBRUCK TIROL BUNDESLAND
GMBH GENERAL INFO
ZEPPELIN OESTERREICH 43 (5522) 54397 555
AUSTRIA FRASTANZ VORARLBERG BUNDESLAND
GMBH GENERAL INFO
MACHINE INTERNATIONAL 994(12) 498-9348
AZERBAIJAN VALETTA MALTA I.
TRADE GENERAL INFO
MACHINE INTERNATIONAL 994(12) 498-9348
AZERBAIJAN VALETTA MALTA I.
TRADE GENERAL INFO
0001 00-8
TM 5-3805-290-23-1

MACHINERY & ENERGY 1 (242) 352-5981
BAHAMAS FREEPORT GRAND BAHAMA I. DISTRICT
BAHAMAS NASSAU NEW PROVIDENCE I. DISTRICT
MOHAMED ABDULRAHMAN 973(17) 728270
BAHRAIN MANAMA AL MANAMAH
AL BAHAR GENERAL INFO
BAHRAIN MANAMA AL MANAMAH
AL-BAHAR GENERAL INFO
880(2) 885-9812
BANGLA TRAC LIMITED BANGLADESH GULSHAN DHAKA DIVISION
GENERAL INFO
1 (787) 273-5768
RIMCO (BARBADOS) SRL BARBADOS CHRIST CHURCH CHRIST CHURCH PARISH
GENERAL INFO
ZEPPELIN INTERNATIONAL 7 (910) 431 00 70
BELARUS MINSK MINSK OBLAST
AG GENERAL INFO
ZEPPELIN INTERNATIONAL 375(170) 226 92 38
BELARUS ZUG
AG PRIMARY BUSINESS
BERGERAT MONNOYEUR 32 (3) 544 76 55
BELGIUM ANTWERPEN ANTWERPEN PROVINCIE
S.A. GENERAL INFO
ENERGYST CAT RENTAL 32 (3) 457 5269
BELGIUM ANTWERPEN ANTWERPEN PROVINCIE
POWER GENERAL INFO
BELGIUM OVERIJSE BRABANT PROVINCIE
S.A. GENERAL INFO
BELGIUM OVERIJSE BRABANT PROVINCIE
S.A. GENERAL INFO
BERGERAT MONNOYEUR 32 (4) 247-29-47
BELGIUM GRACE-HOLLOGNE LIEGE PROVINCIE
S.A. GENERAL INFO
BELGIUM LIEGE LIEGE PROVINCIE
S.A. GENERAL INFO
32 (5) 5410 040
GUNCO BV BELGIUM SOLLENTUNA STOCKHOLM LAN
GENERAL INFO
BERGERAT MONNOYEUR WEST-VLAANDEREN 32 (51) 31 39 20
BELGIUM IZEGEM
S.A. PROVINCIE GENERAL INFO
BERGERAT MONNOYEUR WEST-VLAANDEREN 32 (51) 33 62 89
BELGIUM IZEGEM
S.A. PROVINCIE GENERAL INFO
GENERAL EQUIPMENT 501(25) 2117
BELIZE LADYVILLE BELIZE DISTRICT
COMPANY LTD. GENERAL INFO
229( ) 33 18 06
BENIN EQUIPEMENTS BENIN COTONOU ATLANTIQUE PROVINCE
GENERAL INFO
975(5) 253004
TIL LIMITED BHUTAN PHUNTSHOLING SAMCHI DZONG
GENERAL INFO
591(2) 81-4196
FINNING BOLIVIA S.A. BOLIVIA LA PAZ LA PAZ DEPARTAMENTO
GENERAL INFO
591(2) 78-4513
FINNING BOLIVIA S.A. BOLIVIA LA PAZ LA PAZ DEPARTAMENTO
GENERAL INFO
591(3) 42-9688
FINNING BOLIVIA S.A. BOLIVIA SANTA CRUZ SANTA CRUZ DEPARTAMENTO
GENERAL INFO
BOSTEK MACHINERY BOSNIA I HERZEGOVINA 387(55) 208 020
BOSNIA/HERZEGOW BIJELJINA
D.O.O. REPUBLIKA GENERAL INFO
0001 00-9
TM 5-3805-290-23-1

BOSTEK MACHINERY BOSNIA I HERZEGOVINA 387(33) 776 300
BOSNIA/HERZEGOW BLAZUJ
D.O.O. REPUBLIKA GENERAL INFO
387(33) 776 300
TEKNOXGROUP SA BOSNIA/HERZEGOW LUGANO TICINO CANTON
GENERAL INFO
BOTSWANA EARTHMOVING 267( ) 3951781
BOTSWANA GABORONE SOUTH-EAST DISTRICT
MACHINERY GENERAL INFO
55 (68) 226-4921
SOTREQ S.A. BRAZIL RIO BRANCO ACRE ESTADO
GENERAL INFO
55 (92) 654-3234
SOTREQ S.A. BRAZIL MANAUS AMAZONAS ESTADO
GENERAL INFO
BAHEMA EQUIPAMENTOS 55 (73) 3286.1227
BRAZIL ITAPEBI BAHIA ESTADO
S.A. GENERAL INFO
BAHEMA EQUIPAMENTOS 55 (71) 255-7577
BRAZIL ITAPEBI BAHIA ESTADO
S.A. GENERAL INFO
BRAZIL SALVADOR BAHIA ESTADO
S.A. GENERAL INFO
BRAZIL SALVADOR BAHIA ESTADO
S.A. GENERAL INFO
55 (85) 4011.3302
MARCOSA S/A MAQUINAS E BRAZIL SALVADOR BAHIA ESTADO
DIRECTOR
55 (73) 32915670
BAHEMA RENTAL BRAZIL TEIXEIRA DE FREITAS BAHIA ESTADO
GENERAL INFO
55 (73) 255-7576
MARCOSA S/A MAQUINAS E BRAZIL TEIXEIRA DE FREITAS BAHIA ESTADO
GENERAL INFO
55 (85) 4011.3300
MARCOSA S/A MAQUINAS E BRAZIL FORTALEZA CEARA ESTADO
GENERAL INFO
55 (85) 4011.3399
GENERAL INFO
55 (85) 4011.3399
GENERAL INFO
55 (62) 204-2000
SOTREQ S.A. BRAZIL GUARA DISTRITO FEDERAL
GENERAL INFO
55 (27) 3324.5747
MARCOSA S/A MAQUINAS E BRAZIL SERRA ESPIRITO SANTO ESTADO
GENERAL INFO
SOENERGY SISTEMAS BRAZIL SERRA ESPIRITO SANTO ESTADO
55 (27) 322-8311
SOTREQ S.A. BRAZIL VITORIA ESPIRITO SANTO ESTADO
GENERAL INFO
55 (62) 204-2000
SOTREQ S.A. BRAZIL GOIANIA GOIAS ESTADO
GENERAL INFO
55 (62) 379-1635
SOTREQ S.A. BRAZIL MINACU GOIAS ESTADO
GENERAL INFO
BRAZIL SAO LUIS MARANHAO ESTADO
S.A. GENERAL INFO
BRAZIL SAO LUIS MARANHAO ESTADO
S.A. GENERAL INFO
55 (98) 2107.1200
BAHEMA RENTAL BRAZIL SAO LUIS MARANHAO ESTADO
GENERAL INFO
55 (85) 4011.3302
MARCOSA S/A MAQUINAS E BRAZIL SAO LUIS MARANHAO ESTADO
DIRECTOR
0001 00-10
TM 5-3805-290-23-1

MATO GROSSO DO SUL 55 (67) 787-1020
SOTREQ S.A. BRAZIL CAMPO GRANDE
ESTADO GENERAL INFO
55 (65) 665-2121
SOTREQ S.A. BRAZIL CUIABA MATO GROSSO ESTADO
GENERAL INFO
55 (65) 665-2121
SOTREQ S.A. BRAZIL SINOP MATO GROSSO ESTADO
GENERAL INFO
55 (31) 3829-6978
SOTREQ S.A. BRAZIL BELO ORIENTE MINAS GERAIS ESTADO
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TM 5-3805-290-23-1

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TM 5-3805-290-23-1

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TM 5-3805-290-23-1

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0001 00-59
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TM 5-3805-290-23-1

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TM 5-3805-290-23-1

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TM 5-3805-290-23-1

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TM 5-3805-290-23-1

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0001 00-65
TM 5-3805-290-23-1

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27 (13) 752-3264
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27 (1524) 4541
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27 (152) 297-3603
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27 (12) 800-1024
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34 (958) 46-62-87
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34 (957) 32-58-66
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34 (950) 12-81-07
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34 (95) 224-31-50
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34 (976) 31-10-65
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0001 00-66
TM 5-3805-290-23-1

34 (985) 26-20-08
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34 (971) 43-21-46
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34 (983) 40-73-11
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34 (987) 28-21-85
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34 (93) 574-0090
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34 (972) 49-40-40
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34 (973) 20-05-94
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34 (924) 37-26-26
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34 (981) 79-51-33
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34 (941) 43-70-88
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34 (91) 874 0000
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34 (91) 871-2612
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0001 00-67
TM 5-3805-290-23-1

34 (91) 874 0000
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34 (968) 69-23-84
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34 (948) 31-76-71
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34 (96) 180-4585
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UNITED TRACTOR & 94 (25) 2222718
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CKC MACHINE HANDEL 597( ) 231560
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CKC MACHINEHANDEL 597( ) 404111
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597( ) 404111
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46 (291) 20260
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46 (85) 909-9600
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46 (31) 57 82 61
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46 (63) 13 24 10
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46 (921) 1-36-60
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46 (980) 18630
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0001 00-68
TM 5-3805-290-23-1

46 (13) 16 24 50
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46 (413) 13070
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46 (8) 623 54 00
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46 (8) 96 82 50
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46 (36) 690 30
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46 (54) 15 15 27
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46 (322) 62 07 40
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46 (476) 480 30
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0001 00-69
TM 5-3805-290-23-1

46 (26) 64 72 50
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0001 00-70
TM 5-3805-290-23-1

46 (300) 56 66 90
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0001 00-71
TM 5-3805-290-23-1

46 (19) 16 40 40
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0001 00-72
TM 5-3805-290-23-1

46 (370) 784 91
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46 (340) 64 14 80
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46 (36) 36 30 30
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0001 00-73
TM 5-3805-290-23-1

41 (61) 823 03 45
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41 (22) 704-1330
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0001 00-74
TM 5-3805-290-23-1

41 (27) 934 13 21
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0001 00-75
TM 5-3805-290-23-1

THAILAND KANCHANABURI KANCHANABURI CHANGWAT
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0001 00-76
TM 5-3805-290-23-1

228( ) 227 03 12
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0001 00-77
TM 5-3805-290-23-1

MACHINERY & ENERGY 1 (809) 3201
TURKS-CAICOS IS NASSAU NEW PROVIDENCE I. DISTRICT
UAE ABU DHABI ABU DHABI IMARAH
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256(41) 304000
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GENERAL INFO
44 (121) 707 3434
HEWDEN STUART PLC. UNITED KINGDOM BIRMINGHAM ENGLAND
GENERAL INFO
0001 00-78
TM 5-3805-290-23-1

44 (191) 410-2683
FINNING (U.K.) LTD. UNITED KINGDOM BIRTLEY ENGLAND
GENERAL INFO
44 (1202) 579 728
HEWDEN STUART PLC. UNITED KINGDOM BOURNEMOUTH ENGLAND
GENERAL INFO
44 (1278) 683888
HEWDEN STUART PLC. UNITED KINGDOM BRIDGWATER ENGLAND
GENERAL INFO
44 (1278) 420 480
HEWDEN STUART PLC. UNITED KINGDOM BRIDGWATER ENGLAND
GENERAL INFO
44 (117) 980 2170
FINNING (U.K.) LTD. UNITED KINGDOM BRISTOL ENGLAND
GENERAL INFO
44 (1275) 848866
HEWDEN STUART PLC. UNITED KINGDOM BRISTOL ENGLAND
GENERAL INFO
44 (1843) 604 888
HEWDEN STUART PLC. UNITED KINGDOM BROADSTAIRS ENGLAND
GENERAL INFO
44 (20) 8460 9111
HEWDEN STUART PLC. UNITED KINGDOM BROMLEY ENGLAND
GENERAL INFO
44 (1543) 452 050
HEWDEN STUART PLC. UNITED KINGDOM BROWNHILLS ENGLAND
GENERAL INFO
44 (1749) 812267
HEWDEN STUART PLC. UNITED KINGDOM BRUTON ENGLAND
GENERAL INFO
44 (1543) 461461
FINNING (U.K.) LTD. UNITED KINGDOM CANNOCK ENGLAND
GENERAL INFO
44 (870) 850 2244
FINNING (U.K.) LTD. UNITED KINGDOM CANNOCK ENGLAND
GENERAL INFO
44 (1354) 658 600
FINNPAVE UNITED KINGDOM CANNOCK ENGLAND
GENERAL INFO
44 (1242) 248 128
HEWDEN STUART PLC. UNITED KINGDOM CHELTENHAM ENGLAND
GENERAL INFO
44 (1246) 541541
FINNING (U.K.) LTD. UNITED KINGDOM CHESTERFIELD ENGLAND
GENERAL INFO
44 (1246) 541541
FINNING (U.K.) LTD. UNITED KINGDOM CHESTERFIELD ENGLAND
GENERAL INFO
44 (1249) 712362
HEWDEN STUART PLC. UNITED KINGDOM CORSHAM ENGLAND
GENERAL INFO
44 (1293) 542 520
HEWDEN STUART PLC. UNITED KINGDOM CRAWLEY ENGLAND
GENERAL INFO
44 (129) 355-4950
SUTRAC CO. (U.K.) LTD. UNITED KINGDOM CRAWLEY W. SUSSEX ENGLAND
GENERAL INFO
44 (208) 697 7413
HEWDEN STUART PLC. UNITED KINGDOM DAGENHAM ENGLAND
GENERAL INFO
44 (1322) 222221
HEWDEN STUART PLC. UNITED KINGDOM DARTFORD ENGLAND
GENERAL INFO
44 (2380) 618733
HEWDEN STUART PLC. UNITED KINGDOM EASTLEIGH ENGLAND
GENERAL INFO
44 (1392) 434 500
HEWDEN STUART PLC. UNITED KINGDOM EXETER ENGLAND
GENERAL INFO
44 (1452) 500959
HEWDEN STUART PLC. UNITED KINGDOM GLOUCESTER ENGLAND
GENERAL INFO
0001 00-79
TM 5-3805-290-23-1

44 (1375) 374 022
HEWDEN STUART PLC. UNITED KINGDOM GRAYS ENGLAND
GENERAL INFO
44 (1422) 349 696
HEWDEN STUART PLC. UNITED KINGDOM HALIFAX ENGLAND
GENERAL INFO
44 (1787) 472678
FINNING (U.K.) LTD. UNITED KINGDOM HALSTEAD ENGLAND
GENERAL INFO
44 (1279) 420 002
HEWDEN STUART PLC. UNITED KINGDOM HARLOW ESSEX ENGLAND
GENERAL INFO
44 (1423) 883 244
HEWDEN STUART PLC. UNITED KINGDOM HARROGATE ENGLAND
GENERAL INFO
44 (1484) 513 778
HEWDEN STUART PLC. UNITED KINGDOM HUDDERSFIELD ENGLAND
GENERAL INFO
44 (1482) 324 025
HEWDEN STUART PLC. UNITED KINGDOM HULL ENGLAND
GENERAL INFO
UNITED KINGDOM LEEDS ENGLAND
POWER GENERAL INFO
44 (113) 2534221
FINNING (U.K.) LTD. UNITED KINGDOM LEEDS ENGLAND
GENERAL INFO
44 (1530) 249605
FINNING (U.K.) LTD. UNITED KINGDOM LEICESTERSHIRE ENGLAND
GENERAL INFO
44 (1522) 522 833
HEWDEN STUART PLC. UNITED KINGDOM LINCOLN ENGLAND
GENERAL INFO
UNITED KINGDOM LONDON ENGLAND
POWER GENERAL INFO
44 (20) 8297 9118
HEWDEN STUART PLC. UNITED KINGDOM LONDON ENGLAND
GENERAL INFO
44 (20) 8840 8600
HEWDEN STUART PLC. UNITED KINGDOM LONDON ENGLAND
GENERAL INFO
BARLOWORLD 44 (1753) 824311
UNITED KINGDOM MAIDENHEAD ENGLAND
BARLOWORLD 44 (1753) 824311
EQUIPAMENTOS ANGOLA GENERAL INFO
MALAWI GENERAL INFO
UK LTD GENERAL INFO
ZAMBIA GENERAL INFO
BARLOWORLD NAMIBIA 44 (1753) 824311
BARLOWORLD TRADING 44 (1753) 824311
BOTSWANA GENERAL INFO
UK GENERAL INFO
UK GENERAL INFO
44 (208) 648 7070
HEWDEN STUART PLC. UNITED KINGDOM MITCHAM ENGLAND
GENERAL INFO
0001 00-80
TM 5-3805-290-23-1

44 (1524) 67810
HEWDEN STUART PLC. UNITED KINGDOM MORECAMBE ENGLAND
GENERAL INFO
44 (1635) 868088
HEWDEN STUART PLC. UNITED KINGDOM NEWBURY ENGLAND
GENERAL INFO
44 (1983) 530988
HEWDEN STUART PLC. UNITED KINGDOM NEWPORT ENGLAND
GENERAL INFO
44 (1626) 352596
HEWDEN STUART PLC. UNITED KINGDOM NEWTON ABBOT ENGLAND
GENERAL INFO
44 (1159) 761 234
HEWDEN STUART PLC. UNITED KINGDOM NOTTINGHAM ENGLAND
GENERAL INFO
44 (1689) 822 242
HEWDEN STUART PLC. UNITED KINGDOM ORPINGTON ENGLAND
GENERAL INFO
44 (1803) 524 137
HEWDEN STUART PLC. UNITED KINGDOM PAIGNTON ENGLAND
GENERAL INFO
44 (1768) 899 799
HEWDEN STUART PLC. UNITED KINGDOM PENRITH ENGLAND
GENERAL INFO
44 (1736) 365 317
HEWDEN STUART PLC. UNITED KINGDOM PENZANCE ENGLAND
GENERAL INFO
44 (1775) 761100
FINNING (U.K.) LTD. UNITED KINGDOM PETERBOROUGH ENGLAND
GENERAL INFO
44 (1752) 491 400
HEWDEN STUART PLC. UNITED KINGDOM PLYMOUTH ENGLAND
GENERAL INFO
44 (1202) 330700
FINNING (U.K.) LTD. UNITED KINGDOM POOLE ENGLAND
GENERAL INFO
44 (1202) 674371
HEWDEN STUART PLC. UNITED KINGDOM POOLE ENGLAND
GENERAL INFO
44 (1202) 670900
FINNING (U.K.) LTD. UNITED KINGDOM POOLE DOR. ENGLAND
GENERAL INFO
44 (2392) 821169
HEWDEN STUART PLC. UNITED KINGDOM PORTSMOUTH ENGLAND
GENERAL INFO
44 (1209) 218730
HEWDEN STUART PLC. UNITED KINGDOM REDRUTH ENGLAND
GENERAL INFO
44 (1634) 722223
HEWDEN STUART PLC. UNITED KINGDOM ROCHESTER ENGLAND
GENERAL INFO
44 (1010) 00 000
HEWDEN STUART PLC. UNITED KINGDOM SANDOWN ENGLAND
GENERAL INFO
20 (1723) 584 777
HEWDEN STUART PLC. UNITED KINGDOM SCARBOROUGH ENGLAND
GENERAL INFO
44 (1724) 840 222
HEWDEN STUART PLC. UNITED KINGDOM SCUNTHORPE ENGLAND
GENERAL INFO
44 (1743) 270128
HEWDEN STUART PLC. UNITED KINGDOM SHREWSBURY ENGLAND
GENERAL INFO
44 (1743) 241 441
HEWDEN STUART PLC. UNITED KINGDOM SHREWSBURY ENGLAND
GENERAL INFO
44 (2074) 733 219
FINNING (U.K.) LTD. UNITED KINGDOM SILVERTOWN ENGLAND
GENERAL INFO
UNITED KINGDOM SLOUGH ENGLAND
UK GENERAL INFO
0001 00-81
TM 5-3805-290-23-1

UNITED KINGDOM SLOUGH ENGLAND
UK GENERAL INFO
44 (1753) 497300
FINNING (U.K.) LTD. UNITED KINGDOM SLOUGH ENGLAND
GENERAL INFO
44 (1753) 497300
FINNING (U.K.) LTD. UNITED KINGDOM SLOUGH ENGLAND
GENERAL INFO
44 (1753) 695555
UNATRAC LIMITED UNITED KINGDOM SLOUGH ENGLAND
GENERAL INFO
44 (1753) 695555
GENERAL INFO
44 (1753) 695555
GENERAL INFO
44 (1753) 695555
GENERAL INFO
44 (1753) 695555
GENERAL INFO
44 (1753) 695555
GENERAL INFO
UNITED KINGDOM SOUTHAMPTON ENGLAND
POWER GENERAL INFO
44 (1702) 617 995
HEWDEN STUART PLC. UNITED KINGDOM SOUTHEND-ON-SEA ENGLAND
GENERAL INFO
44 (1726) 823322
FINNING (U.K.) LTD. UNITED KINGDOM ST. AUSTELL ENGLAND
GENERAL INFO
44 (1726) 823322
FINNING (U.K.) LTD. UNITED KINGDOM ST. AUSTELL ENGLAND
GENERAL INFO
44 (1782) 412223
HEWDEN STUART PLC. UNITED KINGDOM STOKE ON TRENT ENGLAND
GENERAL INFO
44 (1782) 271 333
HEWDEN STUART PLC. UNITED KINGDOM STOKE ON TRENT ENGLAND
GENERAL INFO
44 (1793) 611629
HEWDEN STUART PLC. UNITED KINGDOM SWINDON ENGLAND
GENERAL INFO
44 (1823) 331 920
HEWDEN STUART PLC. UNITED KINGDOM TAUNTON SOM. ENGLAND
GENERAL INFO
44 (1635) 864418
HEWDEN STUART PLC. UNITED KINGDOM THATCHAM ENGLAND
GENERAL INFO
44 (121) 557 7271
HEWDEN STUART PLC. UNITED KINGDOM TIPTON ENGLAND
GENERAL INFO
44 (1872) 276262
HEWDEN STUART PLC. UNITED KINGDOM TRURO ENGLAND
GENERAL INFO
44 (1892) 616 318
HEWDEN STUART PLC. UNITED KINGDOM TUNBRIDGE WELLS ENGLAND
GENERAL INFO
44 (20) 8669 9151
HEWDEN STUART PLC. UNITED KINGDOM WALLINGTON ENGLAND
GENERAL INFO
44 (1992) 763008
HEWDEN STUART PLC. UNITED KINGDOM WALTHAM CROSS ENGLAND
GENERAL INFO
44 (191) 417 0111
HEWDEN STUART PLC. UNITED KINGDOM WASHINGTON ENGLAND
GENERAL INFO
0001 00-82
TM 5-3805-290-23-1

WELWYN GARDEN 44 (1707) 393660
HEWDEN STUART PLC. UNITED KINGDOM ENGLAND
CITY GENERAL INFO
44 (1942) 495 293
HEWDEN STUART PLC. UNITED KINGDOM WIGAN ENGLAND
GENERAL INFO
44 (1902) 604564
HEWDEN STUART PLC. UNITED KINGDOM WILLENHALL ENGLAND
GENERAL INFO
44 (1606) 594311
FINNING (U.K.) LTD. UNITED KINGDOM WINSFORD ENGLAND
GENERAL INFO
44 (1993) 883733
HEWDEN STUART PLC. UNITED KINGDOM WITNEY ENGLAND
GENERAL INFO
44 (1189) 783 783
HEWDEN STUART PLC. UNITED KINGDOM WOKINGHAM ENGLAND
GENERAL INFO
ENERGYST CAT RENTAL 44 (1902) 797-000
UNITED KINGDOM WOLVERHAMPTON ENGLAND
POWER GENERAL INFO
MC CORMICK 44 (28) 90 435 355
UNITED KINGDOM BELFAST NORTHERN IRELAND
MC CORMICK 44 (28) 90 381 282
MC CORMICK 44 (28) 90 467 390
MC CORMICK 44 (28) 9266 1221
UNITED KINGDOM LISBURN NORTHERN IRELAND
MC CORMICK 44 (28) 9266 1221
MC CORMICK 44 (28) 92 601 275
MC CORMICK 44 (28) 90 843 767
UNITED KINGDOM NEWTOWNABBEY NORTHERN IRELAND
44 (1224) 820000
FINNING (U.K.) LTD. UNITED KINGDOM ABERDEEN SCOTLAND
GENERAL INFO
44 (1241) 872 227
HEWDEN STUART PLC. UNITED KINGDOM ARBROATH SCOTLAND
GENERAL INFO
44 (1382) 459 169
HEWDEN STUART PLC. UNITED KINGDOM DUNDEE SCOTLAND
GENERAL INFO
44 (1383) 624 800
HEWDEN STUART PLC. UNITED KINGDOM DUNFERMLINE SCOTLAND
GENERAL INFO
44 (1307) 461 666
HEWDEN STUART PLC. UNITED KINGDOM FORFAR SCOTLAND
GENERAL INFO
44 (1698) 713713
FINNING (U.K.) LTD. UNITED KINGDOM GLASGOW SCOTLAND
GENERAL INFO
44 (141) 550 0300
HEWDEN STUART PLC. UNITED KINGDOM GLASGOW SCOTLAND
GENERAL INFO
44 (1436) 676 883
HEWDEN STUART PLC. UNITED KINGDOM HELENSBURGH SCOTLAND
GENERAL INFO
44 (1563) 522 712
HEWDEN STUART PLC. UNITED KINGDOM KILMARNOCK SCOTLAND
GENERAL INFO
44 (1463) 870575
FINNING (U.K.) LTD. UNITED KINGDOM MUIR OF ORD SCOTLAND
GENERAL INFO
0001 00-83
TM 5-3805-290-23-1

44 (1738) 623181
FINNING (U.K.) LTD. UNITED KINGDOM PERTH SCOTLAND
GENERAL INFO
44 (1738) 634 968
HEWDEN STUART PLC. UNITED KINGDOM PERTH SCOTLAND
GENERAL INFO
44 (1779) 472 030
HEWDEN STUART PLC. UNITED KINGDOM PETERHEAD SCOTLAND
GENERAL INFO
44 (1786) 463 216
HEWDEN STUART PLC. UNITED KINGDOM STIRLING SCOTLAND
GENERAL INFO
44 (1698) 805 700
HEWDEN PLANT HIRE LTD. UNITED KINGDOM UDDINGSTON SCOTLAND
GENERAL INFO
44 (1772) 459460
HEWDEN STUART PLC. UNITED KINGDOM UDDINGSTON SCOTLAND
GENERAL INFO
44 (1512) 678 5777
GENERAL INFO
44 (1606) 834518
GENERAL INFO
44 (1524) 398728
GENERAL INFO
44 (1706) 641531
GENERAL INFO
44 (1642) 604441
GENERAL INFO
44 (1925) 725 541
GENERAL INFO
44 (1946) 694311
GENERAL INFO
44 (1332) 341 089
GENERAL INFO
44 (1827) 715 363
GENERAL INFO
44 (1234) 340801
GENERAL INFO
44 (1502) 7145745
GENERAL INFO
44 (121) 772 5900
GENERAL INFO
44 (1223) 837075
GENERAL INFO
44 (1480) 890205
GENERAL INFO
44 (1473) 216076
GENERAL INFO
44 (116) 269 4881
GENERAL INFO
44 (121) 505 2212
GENERAL INFO
44 (115) 943 0022
GENERAL INFO
0001 00-84
TM 5-3805-290-23-1

44 (1234) 711711
GENERAL INFO
44 (1733) 564378
GENERAL INFO
44 (1978) 821 717
GENERAL INFO
44 (1527) 524020
GENERAL INFO
44 (1698) 230222
GENERAL INFO
44 (1506) 654581
GENERAL INFO
44 (1698) 853939
GENERAL INFO
44 (1382) 889922
GENERAL INFO
44 (131) 452 3000
GENERAL INFO
44 (1343) 500400
GENERAL INFO
44 (141) 771 1777
GENERAL INFO
44 (1463) 234582
GENERAL INFO
44 (141) 764 0590
GENERAL INFO
44 (1698) 861686
GENERAL INFO
44 (1698) 861686
GENERAL INFO
44 (1745) 583121
GENERAL INFO
44 (1942) 882661
GENERAL INFO
44 (1248) 364944
GENERAL INFO
44 (1226) 288246
GENERAL INFO
44 (1229) 821819
GENERAL INFO
44 (2890) 617231
GENERAL INFO
44 (1642) 370511
GENERAL INFO
44 (0191) 492 9900
GENERAL INFO
44 (1977) 664382
GENERAL INFO
0001 00-85
TM 5-3805-290-23-1

44 (1385) 269311
GENERAL INFO
44 (1977) 600711
GENERAL INFO
44 (1469) 576212
GENERAL INFO
44 (1656) 745315
HEWDEN STUART PLC. UNITED KINGDOM BRIDGEND WALES
GENERAL INFO
44 (2920) 233491
HEWDEN STUART PLC. UNITED KINGDOM CARDIFF WALES
GENERAL INFO
44 (29) 2048 6321
HEWDEN STUART PLC. UNITED KINGDOM CARDIFF WALES
GENERAL INFO
44 (1443) 228186
HEWDEN STUART PLC. UNITED KINGDOM LLANTRISANT WALES
GENERAL INFO
44 (1685) 370 470
HEWDEN STUART PLC. UNITED KINGDOM MERTHYR TYDFIL WALES
GENERAL INFO
44 (1633) 855 444
HEWDEN STUART PLC. UNITED KINGDOM NEWPORT GWENT WALES
GENERAL INFO
44 (1443) 223456
FINNING (U.K.) LTD. UNITED KINGDOM PONTYCLUN WALES
GENERAL INFO
44 (1745) 342 222
HEWDEN STUART PLC. UNITED KINGDOM RHYL WALES
GENERAL INFO
44 (1905) 29371
HEWDEN STUART PLC. UNITED KINGDOM BARBOURNE
GENERAL INFO
44 (1273) 472177
HEWDEN STUART PLC. UNITED KINGDOM LEWES
GENERAL INFO
44 (1792) 321111
HEWDEN STUART PLC. UNITED KINGDOM LLANDARCY
GENERAL INFO
44 (118) 978 5555
HEWDEN STUART PLC. UNITED KINGDOM WOKINGHAM
GENERAL INFO
44 (1935) 425242
HEWDEN STUART PLC. UNITED KINGDOM YEOVIL
GENERAL INFO
MONTEVIDEO 598(2) 313-0131
FINNING URUGUAY S.A. URUGUAY MONTEVIDEO
DEPARTAMENTO GENERAL INFO
THOMPSON TRACTOR CO., 1 (256) 570-1100
USA ATTALLA ALABAMA
INC. GENERAL INFO
THOMPSON POWER 1 (205) 849-4361
USA BIRMINGHAM ALABAMA
INC. GENERAL INFO
INC. GENERAL INFO
INC. GENERAL INFO
INC. GENERAL INFO
1 (205) 849-3693
TIGER MACHINERY USA BIRMINGHAM ALABAMA
GENERAL INFO
0001 00-86
TM 5-3805-290-23-1

7 (4242) 429492
TIGER MACHINERY LLC USA BIRMINGHAM ALABAMA
GENERAL INFO
USA DECATUR ALABAMA
INC. GENERAL INFO
USA DOTHAN ALABAMA
INC. GENERAL INFO
USA DOTHAN ALABAMA
INC. GENERAL INFO
USA MADISON ALABAMA
INC. GENERAL INFO
USA MOBILE ALABAMA
INC. GENERAL INFO
USA MOBILE ALABAMA
INC. GENERAL INFO
USA MONTGOMERY ALABAMA
INC. GENERAL INFO
USA OPELIKA ALABAMA
INC. GENERAL INFO
USA OXFORD ALABAMA
INC. GENERAL INFO
USA OXFORD ALABAMA
INC. GENERAL INFO
USA THOMASVILLE ALABAMA
INC. GENERAL INFO
THOMPSON TRACTOR CO., 1 (334) 636 2903
USA THOMASVILLE ALABAMA
INC. GENERAL INFO
USA TUSCALOOSA ALABAMA
INC. GENERAL INFO
USA TUSCALOOSA ALABAMA
INC. GENERAL INFO
USA TUSCUMBIA ALABAMA
INC. GENERAL INFO
1 (907) 561-1766
N C MACHINERY CO. USA ANCHORAGE ALASKA
GENERAL INFO
1 (907) 581-1367
N C MACHINERY CO. USA DUTCH HARBOR ALASKA
GENERAL INFO
1 (907) 452-7251
N C MACHINERY CO. USA FAIRBANKS ALASKA
GENERAL INFO
1 (907) 789-0181
N C MACHINERY CO. USA JUNEAU ALASKA
GENERAL INFO
1 (928) 526-2800
EMPIRE MACHINERY USA FLAGSTAFF ARIZONA
GENERAL INFO
1 (928) 757-1159
EMPIRE MACHINERY USA KINGMAN ARIZONA
GENERAL INFO
1 (623) 760-1140
EMPIRE DEER VALLEY USA PHOENIX ARIZONA
GENERAL INFO
1 (480) 633-4000
EMPIRE MACHINERY USA PHOENIX ARIZONA
GENERAL INFO
0001 00-87
TM 5-3805-290-23-1

1 (520) 677-3375
GENERAL INFO
1 (602) 253-6851
GENERAL INFO
1 (480) 633-4000
GENERAL INFO
1 (480) 633 4315
GENERAL INFO
1 (480) 633 4352
GENERAL INFO
1 (602) 333-5600
EMPIRE POWER SYSTEMS USA PHOENIX ARIZONA
GENERAL INFO
1 (928) 499-6003
EMPIRE RENTAL USA PHOENIX ARIZONA
GENERAL INFO
1 (928) 537-7798
EMPIRE MACHINERY USA SHOW LOW ARIZONA
GENERAL INFO
1 (520) 746-8200
EMPIRE MACHINERY USA TUCSON ARIZONA
GENERAL INFO
1 (520) 407-3100
EMPIRE POWER SYSTEMS USA TUCSON ARIZONA
GENERAL INFO
1 (928) 317-7800
EMPIRE MACHINERY USA YUMA ARIZONA
GENERAL INFO
J.A. RIGGS TRACTOR 1 (870) 881-0800
USA EL DORADO ARKANSAS
COMPANY GENERAL INFO
USA EL DORADO ARKANSAS
USA FORT SMITH ARKANSAS
USA FORT SMITH ARKANSAS
COMPANY AFTER HOURS
USA HARRISON ARKANSAS
USA HARRISON ARKANSAS
USA JONESBORO ARKANSAS
USA JONESBORO ARKANSAS
USA LITTLE ROCK ARKANSAS
USA LITTLE ROCK ARKANSAS
USA MCGEHEE ARKANSAS
USA RUSSELLVILLE ARKANSAS
USA SPRINGDALE ARKANSAS
0001 00-88
TM 5-3805-290-23-1

USA SPRINGDALE ARKANSAS
USA WEST MEMPHIS ARKANSAS
COMPANY AFTER HOURS
1 (661) 393-0811
QUINN COMPANY USA BAKERSFIELD CALIFORNIA
ENGINES
1 (661) 393-5800
QUINN ENGINE SYSTEMS USA BAKERSFIELD CALIFORNIA
GENERAL INFO
HAWTHORNE RENT-IT 1 (760) 431-7000
USA CARLSBAD CALIFORNIA
SERVICE GENERAL INFO
1 (530) 343-1911
PETERSON TRACTOR CO. USA CHICO CALIFORNIA
GENERAL INFO
1 (559) 992-2193
QUINN COMPANY USA CORCORAN CALIFORNIA
GENERAL INFO
USA ESCONDIDO CALIFORNIA
1 (559) 659-3444
QUINN COMPANY USA FIREBAUGH CALIFORNIA
GENERAL INFO
1 (909) 574-6601
JOHNSON MACHINERY CO. USA FONTANA CALIFORNIA
GENERAL INFO
1 (949) 768-1777
QUINN COMPANY USA FOOTHILL RANCH CALIFORNIA
GENERAL INFO
1 (707) 725-1888
PETERSON TRACTOR CO. USA FORTUNA CALIFORNIA
GENERAL INFO
1 (559) 891-2425
QUINN COMPANY USA FRESNO CALIFORNIA
GENERAL INFO
1 (559) 896-4040
QUINN COMPANY USA FRESNO CALIFORNIA
GENERAL INFO
1 (559) 896-4040
QUINN ENGINE SYSTEMS USA FRESNO CALIFORNIA
GENERAL INFO
1 (760) 947-0967
JOHNSON MACHINERY CO. USA HESPERIA CALIFORNIA
GENERAL INFO
1 (760) 355-2443
EMPIRE MACHINERY USA IMPERIAL CALIFORNIA
GENERAL INFO
JOHNSON RENTAL 1 (760) 342-1597
USA INDIO CALIFORNIA
USA LAKESIDE CALIFORNIA
1 (661) 723-3125
QUINN COMPANY USA LANCASTER CALIFORNIA
GENERAL INFO
1 (661) 942-7777
QUINN COMPANY USA LANCASTER CALIFORNIA
GENERAL INFO
1 (562) 463-6000
QUINN COMPANY USA LOS ANGELES CALIFORNIA
GENERAL INFO
1 (562) 463-4000
QUINN COMPANY USA LOS ANGELES CALIFORNIA
GENERAL INFO
1 (209) 826-4919
HOLT OF CALIFORNIA USA LOS BANOS CALIFORNIA
GENERAL INFO
0001 00-89
TM 5-3805-290-23-1

1 (760) 934-8239
CASHMAN RENTALS USA MAMMOTH LAKES CALIFORNIA
GENERAL INFO
1 (951) 677-3787
JOHNSON MACHINERY CO. USA MURRIETA CALIFORNIA
GENERAL INFO
1 (951) 696-1063
JOHNSON RENTALS USA MURRIETA CALIFORNIA
GENERAL INFO
USA NATIONAL CITY CALIFORNIA
1 (805) 485-2171
QUINN COMPANY USA OXNARD CALIFORNIA
GENERAL INFO
1 (916) 991-8222
HOLT OF CALIFORNIA USA PLEASANT GROVE CALIFORNIA
GENERAL INFO
1 (530) 243-5410
PETERSON TRACTOR CO. USA REDDING CALIFORNIA
GENERAL INFO
1 (707) 374-7550
HOLT OF CALIFORNIA USA RIO VISTA CALIFORNIA
GENERAL INFO
1 (951) 686-4560
JOHNSON MACHINERY CO. USA RIVERSIDE CALIFORNIA
GENERAL INFO
1 (951) 683-5960
GENERAL INFO
1 (951) 774-3274
GENERAL INFO
1 (916) 772-9600
HOLT OF CALIFORNIA USA ROSEVILLE CALIFORNIA
GENERAL INFO
1 (916) 381-9940
HOLT OF CALIFORNIA USA SACRAMENTO CALIFORNIA
GENERAL INFO
1 (916) 991-8200
HOLT OF CALIFORNIA USA SACRAMENTO CALIFORNIA
GENERAL INFO
1 (831) 758-8461
QUINN COMPANY USA SALINAS CALIFORNIA
GENERAL INFO
HAWTHORNE MACHINERY 1 (858) 674-7000
USA SAN DIEGO CALIFORNIA
CO. GENERAL INFO
CO. GENERAL INFO
CO. GENERAL INFO
CO. GENERAL INFO
OF SAMOA, GENERAL INFO
HAWTHORNE POWER 1 (858) 974-6800
0001 00-90
TM 5-3805-290-23-1

PETERSON MACHINERY 1 (541) 302-9199
USA SAN LEANDRO CALIFORNIA
CO. GENERAL INFO
CO. GENERAL INFO
CO. GENERAL INFO
CO. GENERAL INFO
CO. GENERAL INFO
CO. GENERAL INFO
PETERSON POWER 1 (510) 895-8400
SYSTEMS, INC. GENERAL INFO
1 (510) 357-6200
PETERSON TRACTOR CO. USA SAN LEANDRO CALIFORNIA
GENERAL INFO
1 (408) 686-1195
PETERSON TRACTOR CO. USA SAN MARTIN CALIFORNIA
GENERAL INFO
1 (805) 925-8611
QUINN COMPANY USA SANTA MARIA CALIFORNIA
GENERAL INFO
1 (707) 576-1616
PETERSON TRACTOR CO. USA SANTA ROSA CALIFORNIA
GENERAL INFO
1 (209) 466-6000
HOLT OF CALIFORNIA USA STOCKTON CALIFORNIA
PRIMARY BUSINESS
1 (209) 946-1776
GENERAL INFO
1 (209) 463-3660
GENERAL INFO
1 (818) 767-7171
QUINN COMPANY USA SUN VALLEY CALIFORNIA
GENERAL INFO
1 (209) 664-3875
HOLT OF CALIFORNIA USA TURLOCK CALIFORNIA
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0001 00-91
TM 5-3805-290-23-1

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0001 00-92
TM 5-3805-290-23-1

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TM 5-3805-290-23-1

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0001 00-94
TM 5-3805-290-23-1

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0001 00-95
TM 5-3805-290-23-1

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TM 5-3805-290-23-1

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0001 00-97
TM 5-3805-290-23-1

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0001 00-98
TM 5-3805-290-23-1

1 (800) 452-4507
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TM 5-3805-290-23-1

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0001 00-100
TM 5-3805-290-23-1

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TM 5-3805-290-23-1

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0001 00-102
TM 5-3805-290-23-1

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TM 5-3805-290-23-1

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FABICK POWER SYSTEMS USA FENTON MISSOURI
GENERAL INFO
JOHN FABICK TRACTOR 1 (636) 343-5900
USA FENTON MISSOURI
1 (800) 539-9217
FABICK RENTAL SERVICES USA FORISTELL MISSOURI
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1 (217) 437-5421
ALTORFER INC. USA HANNIBAL MISSOURI
AFTER HOURS
1 (573) 636-3184
FABICK AND COMPANY USA JEFFERSON CITY MISSOURI
GENERAL INFO
1 (417) 624-3010
FABICK SOUTHWEST CO. USA JOPLIN MISSOURI
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1 (417) 624-3010
FABICK SOUTHWEST CO. USA JOPLIN MISSOURI
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1 (816) 753-5300
DEAN MACHINERY CO. USA KANSAS CITY MISSOURI
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1 (816) 753-5355
DEAN MACHINERY CO. USA KANSAS CITY MISSOURI
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1 (816) 756-1515
DEAN RENTAL SERVICES USA KANSAS CITY MISSOURI
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1 (816) 554-4700
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1 (660) 263-8200
ALTORFER INC. USA MOBERLY MISSOURI
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1 (816) 233-2516
DEAN MACHINERY CO. USA SAINT JOSEPH MISSOURI
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1 (816) 233-2516
DEAN RENTAL SERVICES USA SAINT JOSEPH MISSOURI
GENERAL INFO
0001 00-104
TM 5-3805-290-23-1

1 (800) 845-9175
FABICK CAT USA SCOTT CITY MISSOURI
PRIMARY BUSINESS
1 (660) 829-7400
DEAN MACHINERY CO. USA SEDALIA MISSOURI
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1 (417) 866-6652
FABICK SOUTHWEST CO. USA SPRINGFIELD MISSOURI
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1 (417) 866-2100
FABICK SOUTHWEST CO. USA SPRINGFIELD MISSOURI
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1 (573) 374-2266
DEAN RENTAL SERVICES USA SUNRISE BEACH MISSOURI
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1 (417) 256-6138
FABICK SOUTHWEST CO. USA WEST PLAINS MISSOURI
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1 (417) 256-6138
FABICK SOUTHWEST CO. USA WEST PLAINS MISSOURI
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MACHINERY POWER & 1 (406) 245-4426
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COMPANY PRIMARY BUSINESS
USA BOZEMAN MONTANA
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HIGH PLAINS POWER 1 (402) 845-6503
USA DONIPHAN NEBRASKA
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1 (402) 472-4448
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0001 00-105
TM 5-3805-290-23-1

1 (402) 379-1699
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USA NORTH PLATTE NEBRASKA
USA NORTH PLATTE NEBRASKA
1 (308) 532-3100
NEBRASKA RENTS USA NORTH PLATTE NEBRASKA
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COMPANY PRIMARY BUSINESS
1 (402) 861-9090
NEBRASKA RENTS USA OMAHA NEBRASKA
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USA SCOTTSBLUFF NEBRASKA
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1 (702) 566-4240
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1 (702) 633-4637
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1 (775) 332-5450
CASHMAN RENTALS USA SPARKS NEVADA
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1 (609) 561-0308
GILES & RANSOME INC. USA HAMMONTON NEW JERSEY
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1 (215) 245-2794
RANSOME ENGINE USA HAMMONTON NEW JERSEY
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1 (609) 371-5200
FOLEY RENTS USA MONROE TOWNSHIP NEW JERSEY
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1 (609) 371-5200
FOLEY RENTS USA PISCATAWAY NEW JERSEY
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1 (732) 885-5555
FOLEY, INCORPORATED USA PISCATAWAY NEW JERSEY
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1 (732) 885-5555
FOLEY, INCORPORATED USA PISCATAWAY NEW JERSEY
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1 (609) 272-8770
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0001 00-106
TM 5-3805-290-23-1

1 (732) 341-0404
GILES & RANSOME INC. USA TOMS RIVER NEW JERSEY
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1 (505) 343-2724
WAGNER EQUIPMENT CO. USA ALBUQUERQUE NEW MEXICO
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1 (915) 771-6000
WAGNER RENTS, INC. USA ALBUQUERQUE NEW MEXICO
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1 (505) 938-2000
WAGNER RENTS, INC. USA ALBUQUERQUE NEW MEXICO
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1 (505) 327-5331
WAGNER EQUIPMENT CO. USA FARMINGTON NEW MEXICO
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1 (505) 327-5331
WAGNER RENTS, INC. USA FARMINGTON NEW MEXICO
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1 (505) 393-2148
WAGNER EQUIPMENT CO. USA HOBBS NEW MEXICO
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CO., INC. GENERAL INFO
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1 (860) 525-8000
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CAROLINA TRACTOR & 1 (828) 251-2500
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1 (828) 252-8550
PIONEER MACHINERY, INC USA ASHEVILLE NORTH CAROLINA
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USA BEAUFORT NORTH CAROLINA
CAROLINA TRACTOR & 1 (828) 268 9992
USA BOONE NORTH CAROLINA
USA BRYSON CITY NORTH CAROLINA
USA CHARLOTTE NORTH CAROLINA
0001 00-107
TM 5-3805-290-23-1

1 (336) 294-2326
ARROW EQUIPMENT, LLC USA GREENSBORO NORTH CAROLINA
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1 (252) 752-3105
PIONEER MACHINERY, INC USA GREENVILLE NORTH CAROLINA
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SYSTEMS EMERGENCY
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1 (704) 924-8000
PIONEER MACHINERY, INC USA STATESVILLE NORTH CAROLINA
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0001 00-108
TM 5-3805-290-23-1

USA JAMESTOWN NORTH DAKOTA
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USA WILLISTON NORTH DAKOTA
1 (740) 593-6100
WALKER EXPRESS USA ATHENS OHIO
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1 (330) 874-1003
OHIO MACHINERY CO. USA BOLIVAR OHIO
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1 (440) 526-6200
OHIO MACHINERY CO. USA BROADVIEW HEIGHTS OHIO
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1 (440) 842-8200
OHIO MACHINERY CO. USA BROADVIEW HEIGHTS OHIO
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1 (740) 942-4626
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1 (330) 478-6525
OHIO MACHINERY CO. USA CANTON OHIO
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1 (614) 878-2287
OHIO MACHINERY CO. USA COLUMBUS OHIO
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1 (614) 878-2287
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1 (614) 851-3737
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1 (330) 530-9010
OHIO MACHINERY CO. USA GIRARD OHIO
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WALKER EXPRESS USA JACKSON OHIO
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OHIO MACHINERY CO. USA LUCASVILLE OHIO
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1 (440) 658-2000
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OHIO MACHINERY CO. USA PERRYSBURG OHIO
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1 (419) 874-7975
OHIO MACHINERY CO. USA PERRYSBURG OHIO
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1 (513) 771-0515
OHIO MACHINERY CO. USA SHARONVILLE OHIO
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1 (513) 612-5600
OHIO MACHINERY CO. USA SHARONVILLE OHIO
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1 (937) 335-7660
OHIO MACHINERY CO. USA TROY OHIO
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0001 00-109
TM 5-3805-290-23-1

1 (740) 453-0563
OHIO MACHINERY CO. USA ZANESVILLE OHIO
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WARREN POWER & 1 (580) 226-1400
USA ARDMORE OKLAHOMA
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USA ELK CITY OKLAHOMA
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USA ENID OKLAHOMA
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USA GUYMON OKLAHOMA
WARREN POWER & 1 (405) 947-6771
USA OKLAHOMA CITY OKLAHOMA
WARREN POWER & 1 (918) 647-8211
USA POTEAU OKLAHOMA
WARREN POWER & 1 (918) 660-5427
USA TULSA OKLAHOMA
MACHINERY, L.P. ENGINES
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1 (503) 288-6411
HALTON CO. USA PORTLAND OREGON
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1 (503) 288-6411
HALTON CO. USA PORTLAND OREGON
AFTER HOURS
1 (503) 364-0602
HALTON CO. USA SALEM OREGON
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HALTON CO. USA THE DALLES OREGON
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1 (888) 818-8000
HALTON CO. USA WILSONVILLE OREGON
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1 (610) 266-1029
RANSOME RENTS USA ALLENTOWN PENNSYLVANIA
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1 (215) 639-4300
GILES & RANSOME INC. USA BENSALEM PENNSYLVANIA
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1 (215) 245-2794
RANSOME ENGINE USA BENSALEM PENNSYLVANIA
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USA BLAWNOX PENNSYLVANIA
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COMPANY AFTER HOURS
BECKWITH MACHINERY CRANBERRY 1 (800) 442-8026
USA PENNSYLVANIA
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USA EPHRATA PENNSYLVANIA
USA ERIE PENNSYLVANIA
COMPANY AFTER HOURS
0001 00-110
TM 5-3805-290-23-1

1 (610) 926-5858
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1 (717) 564-0598
CLEVELAND BROTHERS USA HARRISBURG PENNSYLVANIA
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1 (214) 943-4800
RANSOME RENTS USA LEVITTOWN PENNSYLVANIA
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1 (412) 299-7530
ONE CALL RENTALS, L.P. USA NEVILLE ISLAND PENNSYLVANIA
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1 (724) 696-4080
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1 (717) 697-5672
CLEVELAND BROTHERS USA PITTSTON PENNSYLVANIA
AFTER HOURS
1 (610) 495-9500
GILES & RANSOME INC. USA POTTSTOWN PENNSYLVANIA
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1 (610) 495-9500
RANSOME RENTS USA POTTSTOWN PENNSYLVANIA
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USA SOMERSET PENNSYLVANIA
COMPANY AFTER HOURS
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1 (610) 261-4887
GILES & RANSOME INC. USA WHITEHALL PENNSYLVANIA
GENERAL INFO
0001 00-111
TM 5-3805-290-23-1

USA WILKES-BARRE PENNSYLVANIA
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INC. GENERAL INFO
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CO. GENERAL INFO
1 (803) 765-2040
ARROW EQUIPMENT, LLC USA COLUMBIA SOUTH CAROLINA
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CO. AFTER HOURS - EA
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1 (843) 678-8900
PIONEER MACHINERY, INC USA FLORENCE SOUTH CAROLINA
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1 (843) 527-4446
PIONEER MACHINERY, INC USA GEORGETOWN SOUTH CAROLINA
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1 (803) 808-1115
IRON MART USA LEXINGTON SOUTH CAROLINA
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1 (803) 356-0123
PIONEER MACHINERY, INC USA LEXINGTON SOUTH CAROLINA
PRIMARY BUSINESS
1 (803) 356-0123
PIONEER MACHINERY, INC USA LEXINGTON SOUTH CAROLINA
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1 (864) 269-7995
PIONEER MACHINERY, INC USA PIEDMONT SOUTH CAROLINA
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CO. GENERAL INFO
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0001 00-112
TM 5-3805-290-23-1

USA SUMMERVILLE SOUTH CAROLINA
1 (843) 538-2595
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1 (803) 936-9990
PIONEER MACHINERY, INC USA WEST COLUMBIA SOUTH CAROLINA
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STOWERS MACHINERY 1 (423) 698-6943
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STOWERS RENTAL & 1 (423) 622-9933
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SUPPLY, INC. GENERAL INFO
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STOWERS RENTAL & 1 (931) 484-4040
USA CROSSVILLE TENNESSEE
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USA JACKSON TENNESSEE
USA KINGSPORT TENNESSEE
STOWERS RENTAL & 1 (423) 323-4445
USA KINGSPORT TENNESSEE
USA KNOXVILLE TENNESSEE
0001 00-113
TM 5-3805-290-23-1

STOWERS RENTAL & 1 (865) 588-4500
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COMMERCE GENERAL INFO2
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WARREN POWER & 1 (325) 692-1600
USA ABILENE TEXAS
WARREN POWER & 1 (806) 335-1511
USA AMARILLO TEXAS
1 (512) 282-2011
HOLT TEXAS LTD. USA AUSTIN TEXAS
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MUSTANG TRACTOR & 1 (409) 892-8412
USA BEAUMONT TEXAS
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1 (940) 683-6298
HOLT TEXAS LTD. USA BRIDGEPORT TEXAS
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1 (956) 831-9336
HOLT TEXAS LTD. USA BROWNSVILLE TEXAS
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1 (361) 852-2200
HOLT RENTAL SERVICE USA CORPUS CHRISTI TEXAS
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1 (361) 852-2200
HOLT TEXAS LTD. USA CORPUS CHRISTI TEXAS
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WARREN POWER & 1 (806) 249-8772
USA DALHART TEXAS
1 (972) 785-6565
HOLT RENTAL SERVICE USA DALLAS TEXAS
GENERAL INFO
1 (972) 785-6565
HOLT TEXAS LTD. USA DALLAS TEXAS
GENERAL INFO
0001 00-114
TM 5-3805-290-23-1

1 (956) 383-5648
HOLT TEXAS LTD. USA EDINBURG TEXAS
GENERAL INFO
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1 (915) 821-7651
WAGNER EQUIPMENT CO. USA EL PASO TEXAS
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1 (817) 847-8880
HOLT RENTAL SERVICE USA FORT WORTH TEXAS
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1 (817) 246-6651
HOLT TEXAS LTD. USA FORT WORTH TEXAS
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1 (972) 647-4140
HOLT RENTAL SERVICE USA GRAND PRAIRIE TEXAS
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1 (972) 721-2089
HOLT TEXAS LTD. USA GRAND PRAIRIE TEXAS
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USA HOUSTON TEXAS
MUSTANG HYDRAULIC 1 (713) 856-7500
USA HOUSTON TEXAS
MUSTANG POWER 1 (713) 861-0777
USA HOUSTON TEXAS
MUSTANG POWER 1 (713) 460-2000
USA HOUSTON TEXAS
USA HOUSTON TEXAS
USA HOUSTON TEXAS
USA HOUSTON TEXAS
1 (713) 939-0007
PIPELINE MACHINERY USA HOUSTON TEXAS
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1 (972) 721-2000
HOLT TEXAS LTD. USA IRVING TEXAS
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1 (972) 721-2065
HOLT TEXAS LTD. USA IRVING TEXAS
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1 (956) 796-9090
HOLT RENTAL SERVICE USA LAREDO TEXAS
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1 (956) 722-0075
HOLT TEXAS LTD. USA LAREDO TEXAS
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1 (972) 785-6571
HOLT TEXAS LTD. USA LEWISVILLE TEXAS
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1 (903) 234-4747
HOLT RENTAL SERVICE USA LONGVIEW TEXAS
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1 (903) 758-6175
HOLT TEXAS LTD. USA LONGVIEW TEXAS
GENERAL INFO
0001 00-115
TM 5-3805-290-23-1

WARREN POWER & 1 (806) 745-4495
USA LUBBOCK TEXAS
USA LUFKIN TEXAS
USA LUFKIN TEXAS
WARREN POWER & 1 (432) 563-1863
USA MIDLAND TEXAS
WARREN POWER & 1 (432) 563-1863
USA MIDLAND TEXAS
WARREN POWER & 1 (432) 563-9228
USA MIDLAND TEXAS
1 (903) 832-7535
HOLT TEXAS LTD. USA NASH TEXAS
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WARREN POWER & 1 (432) 332-1681
USA ODESSA TEXAS
1 (512) 252-9696
HOLT RENTAL SERVICE USA PFLUGERVILLE TEXAS
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1 (512) 252-1183
HOLT TEXAS LTD. USA PFLUGERVILLE TEXAS
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1 (512) 990-7743
HOLT TEXAS LTD. USA PFLUGERVILLE TEXAS
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WARREN POWER & 1 (325) 655-1100
USA SAN ANGELO TEXAS
1 (210) 648-8407
HOLT POWER SYSTEMS USA SAN ANTONIO TEXAS
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1 (210) 333-8505
HOLT RENTAL SERVICE USA SAN ANTONIO TEXAS
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1 (210) 648-8854
HOLT TEXAS LTD. USA SAN ANTONIO TEXAS
PARTS
1 (325) 387-5303
HOLT TEXAS LTD. USA SONORA TEXAS
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1 (903) 595-6424
HOLT TEXAS LTD. USA TYLER TEXAS
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HOLT TEXAS LTD. USA VICTORIA TEXAS
AFTER HOURS
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HOLT RENTAL SERVICE USA WACO TEXAS
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HOLT TEXAS LTD. USA WACO TEXAS
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HOLT RENTAL SERVICE USA WESLACO TEXAS
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1 (956) 968-2161
HOLT TEXAS LTD. USA WESLACO TEXAS
GENERAL INFO
0001 00-116
TM 5-3805-290-23-1

WARREN POWER & 1 (940) 767-4384
USA WICHITA FALLS TEXAS
1 (435) 586-6323
WHEELER MACHINERY CO. USA CEDAR CITY UTAH
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1 (801) 732-9100
WHEELER MACHINERY CO. USA OGDEN UTAH
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WHEELER POWER 1 (435) 529-7423
USA SALINA UTAH
1 (801) 974-0511
WHEELER MACHINERY CO. USA SALT LAKE CITY UTAH
PRIMARY BUSINESS
1 (801) 974-0511
WHEELER MACHINERY CO. USA SALT LAKE CITY UTAH
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WHEELER POWER 1 (435) 789-0635
USA VERNAL UTAH
1 (435) 634-9904
WHEELER MACHINERY CO. USA WASHINGTON UTAH
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INC. GENERAL INFO
CARTER MACHINERY 1 (276) 669-7222
USA ABINGDON VIRGINIA
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0001 00-117
TM 5-3805-290-23-1

USA RICHMOND VIRGINIA
1 (804) 266-4911
PIONEER MACHINERY, INC USA RICHMOND VIRGINIA
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1 (540) 387-3965
PIONEER MACHINERY, INC USA SALEM VIRGINIA
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1 (804) 447-2400
PIONEER MACHINERY, INC USA SOUTH HILL VIRGINIA
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1 (703) 450-7875
ALBAN RENTS, LLC USA STERLING VIRGINIA
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1 (509) 884-6972
N C MACHINERY CO. USA EAST WENATCHEE WASHINGTON
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USA FIFE WASHINGTON
1 (253) 896-0878
N C MACHINERY CO. USA FIFE WASHINGTON
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0001 00-118
TM 5-3805-290-23-1

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0001 00-120
TM 5-3805-290-23-1

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0001 00-121
TM 5-3805-290-23-1

967(3) 228346
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BARLOWORLD EQUIPMENT 260(2) 211311
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END OF WORK PACKAGE
0001 00-122
16
TM 5-3805-290-23-1
EQUIPMENT DESCRIPTION AND DATA 0002 00
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES 0002 00

1. Characteristics.
a. The 924G Wheel Loader is an integral part of the Army’s mission to efficiently build roads, airstrips, and other engi-
neering assets in a wide variety of geographic, environmental, and tactical situations.
b. The loader’s Multi-Purpose (MP) clamshell bucket performs excavating, digging, lifting/loading, stripping, leveling,
and stockpiling operations.
c. The MP loader bucket has a hydraulically operated clamshell, which functions to remove obstacles such as large
stones, tree limbs, etc.
d. The MP bucket can be interchanged with forklift pallet forks to further increase machine versatility.
2. Capabilities and Features.
NOTE
Refer to Equipment Data at the end of this work package for machine dimensions, weights, fluid capacities,
and other miscellaneous equipment data.
a. The loader consists of two sections, a front frame section and rear frame section, with center-point frame articulation.
b. The loader, equipped with MP bucket, is capable of lifting, clearing, and dumping loads into the following dump
trucks/bodies:
(1) M929 Series, with 83 in. (2.11 m) sideboard height;
(2) Family of Medium Tactical Vehicles (FMTV), with 80 in. (2.03 m) sideboard height;
(3) M917 Series, with 114 in. (2.90 m) sideboard height;
(4) Palletized Load System-Engineer Mission Module-Dump Body (PLS-EMM-DB): Truck-Mounted, with
124 in. (3.15 m) sideboard height; and Trailer-Mounted, with 112 in. (2.84 m) sideboard height.
(5) Palletized Load System-Engineer Mission Module-Concrete Mobile Mixer (PLS-EMM-CMM): Truck-
Mounted, with 124 in. (3.15 m) sideboard height; and Trailer-Mounted, with 112 in. (2.84 m) sideboard
height.
c. The machine has the following capabilities and features:
(1) Caterpillar 3056E Direct Injection Turbocharged (DIT) Air-to-Air After Cooler (ATAAC) diesel engine
with six inline cylinders, generating 129 horsepower (96 kW) @ 2,300 rpm;
(2) Ether assist in cold weather starting down to -25°F (-32°C);
(3) Caterpillar autoshift transmission with four forward speeds and three reverse;
(4) 4-wheel drive: front fixed and rear oscillating axles with inboard planetary final drives;
(5) Self-adjusting service brakes with secondary and parking brake systems;
(6) Articulated frame steering with two double-acting steering cylinders;
(7) Air conditioned enclosed cab with adjustable seat and tilt steering wheel, gages and warning indicators,
work tool hydraulic controls, and heater/defroster/AC controls;
(8) Removable bolt-on Rollover Protective Structure/Falling Object Protective Structure (ROPS/FOPS);
(9) Interchangeable work tools including MP bucket and forklift pallet forks;
(10) Versalink loader arm with hydraulically-activated quick coupler that allows for easy and quick connection
and disconnection of work tools without the need for operator to leave cab;
(11) Lift and tiedown provisions conforming to MIL-STD-209K, Department of Defense Interface Standard for
Lifting and Tiedown Provisions;
(12) NATO slave receptacle;
0002 00-1
TM 5-3805-290-23-1
EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES - CONTINUED

(13) Two toolboxes, one inside cab and one at rear of machine; and
(14) Mounting provisions for M16A1, M16A2, or M4 rifle; portable fire extinguisher; and M13 Decontamina-
tion Apparatus, Portable (DAP).
d. The loader is transportable as follows:
(1) Without reconfiguration, it can be driven onto C-5 and C-17 aircraft and transported by Association of
American Railroads (AAR) rail.
(2) With ROPS/FOPS and exhaust stack removed, and with two rear counterweights relocated onto the MP
bucket, it can be driven onto C-130 and C-141 aircraft.
(3) With ROPS/FOPS and exhaust stack removed, it can be transported by highway and Gabarit International
de Chargement (GIC) rail.
(4) Marine vessels can also transport the 924G Wheel Loader.
e. The loader can fresh-water ford to a depth of 28 in. (71 cm) without damage or contamination of lubricants.
f. Machines that operate in extreme cold weather, from -25 to -40°F (-32 to -40°C), are factory equipped with an arctic
cold weather starting aid system which includes:
(1) A diesel-fired engine coolant heater, and
(2) Heavy-duty batteries.
0002 00-2
TM 5-3805-290-23-1
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS 0002 00
427-B0520
KEY COMPONENT DESCRIPTION

1 MP Bucket Hardened-steel, multi-purpose bucket has cutting edges, teeth, and
wear plates that can be replaced by Unit Maintenance. Hydraulic
cylinder-activated clamshell jaws open and close to pick up debris
(rocks, tree limbs, etc.). Refer to Equipment Data later in this work
package for more information.
2 Tilt Cylinder Single hydraulic cylinder tilts work tool.
3 Front Worklights Illuminate work area to front of machine. Mounted to roof bracket on
both sides of machine.
4 ROPS/FOPS Bolt-on structure provides rollover and falling object protection for
operator. Must be removed for transport by C-130 and C-141 aircraft,
highway, and GIC rail.
5 Hydraulic Tank Stores hydraulic fluid used in machine hydraulic systems. Contains
sight gage for fluid level check.
6 Engine Enclosure Access Gull-wing design with gas struts lifts for access to filters and service
Door points. Located on both sides of machine.
7 Battery Box Provides protection for batteries. There is one battery in each box,
located on both sides of machine.
8 Platforms Skid-free surface for gaining access to top of machine. Located on both
sides of machine.
9 Ladders Provide access to cab and platform. Located on both sides of machine.
10 Fenders Located over front tire, on both sides of machine.
0002 00-3
TM 5-3805-290-23-1
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED
427-B0521

11 Clam Cylinder Allows operator to open and close clam.
12 Grabhandles Provide handholds for personnel climbing on machine.
13 Interior Rearview Mirrors Provide operator with a view to rear and side of machine. Located on
both sides of machine, inside cab.
14 Cab Air conditioned/heated enclosure contains operator’s seat and all
driving and hydraulic controls.
15 Rear Worklights Illuminate work area to rear of machine. Mounted to roof bracket on
both sides of machine.
16 Exhaust Stack Directs exhaust away from machine. Must be removed for transport by
C-130 and C-141 aircraft, highway, and GIC rail.
17 Engine Air Precleaner Provides convenient means to remove debris filtered from incoming air
to engine.
18 Backup Alarm Sounds when transmission is in reverse. Alerts personnel behind
machine that machine is backing up. Mounted inside, above fan
housing.
19 Fan Housing Opens to provide access to cooling fan. Side engine enclosure access
doors must be opened before fan housing can be opened.
20 Counterweights Two counterweights at rear of machine weigh a total of 550 lb (250 kg).
Rear counterweights must be removed and relocated onto the MP
bucket in preparation for transport by C-130 and C-141 aircraft. Two
side counterweights weigh 518 lb (235 kg) each.
21 Towing Lugs Provide attachment points for medium-duty towbar.
22 Tiedown Points Used to tie machine down when being transported. There is one tiedown
point on each side of front frame section. There are two tiedown points
on each side of rear frame section. Refer to TM 5-3805-290-10,
Preparation for Transport Introduction, for an illustration of all
tiedown points.
23 NATO Slave Receptacle Provides connection point for NATO slave cable to slave start machine.
0002 00-4
TM 5-3805-290-23-1
427-B0522

24 Windshield Protects operator from inclement weather and flying objects. Includes
windshield wipers/washers.
25 Tilt Cylinder Allows operator to level bucket by tilting bucket forward and
backward.
26 Quick Disconnect Hydraulic hoses for quick disconnect.
27 Axles Powered by planetary final drives inboard from wheel ends.
28 Steering Cylinders Two hydraulic cylinders provide for 40-degree right and left turns with
articulated frame steering system.
29 Lift Points Attachment points for slinging or crane lift. There is one lift point on
each side of rear frame section. There is one lift point on each side of
front frame section. Refer to TM 5-3805-290-10, Preparation for
Transport Introduction, for an illustration of all lift points.
0002 00-5
TM 5-3805-290-23-1
427-B0523

30 Loader Arm One-piece steel construction, mounted to front frame section.
31 Lift Cylinders Two hydraulic cylinders raise and lower loader arm.
0002 00-6
TM 5-3805-290-23-1
427-B0524

32 Horn Operator sounds horn by pressing horn button on steering wheel to
alert personnel near machine.
33 Blackout (B.O.) Drive Light Used when operating in blackout mode.
34 Front Service Lights Inside light with white lens is headlight. Outside amber light is
turnlamp. Located on both sides at front of machine.
0002 00-7
TM 5-3805-290-23-1
427-B0739

35 Rear Composite Lights Contain the following lights: B.O. marker, tail, parking, and
directional signals. Located on both sides at rear of machine.
0002 00-8
TM 5-3805-290-23-1
427-B0525

36 Forklift Pallet Forks Work tool that allows loader to function as a forklift. Refer to
Equipment Data later in this work package for more information.
37 DAP Mounting Bracket Provides mounting for DAP on right-hand platform.
38 ROPS/FOPS Lift Points (4) Provide attachment points for lifting equipment when removing
ROPS/FOPS (2 on each side).
0002 00-9
TM 5-3805-290-23-1
EQUIPMENT DATA 0002 00

Machine Dimensions with MP Bucket
427-B0088
KEY DESCRIPTION DIMENSION

1 Height to top of ROPS/FOPS cab 128 in. (3.25 m)
2 Height to top of exhaust stack 127 in. (3.23 m)
3 Height to top of hood 88 in. (2.24 m)
4 Height to center of axle 28 in. (71.1 cm)
5 Ground clearance 17 in. (43.2 cm)
6 Overall length 282 in. (7.16 m)
7 Length - rear axle to bumper 80 in. (2.03 m)
8 Centerline of front axle to frame articulation point 55 in. (1.4 m)
9 Wheelbase 110 in. (2.79 m)
10 Dump clearance at maximum lift and 45-degree dump 112 in. (2.84 m)
11 Bucket clearance at maximum lift and level 140 in. (3.56 m)
12 Bucket pin height at maximum lift 152 in. (3.86 m)
13 Overall height - bucket raised 203 in. (5.16 m)
14 Reach at maximum lift and 45-degree dump 38.5 in. (97.8 cm)
15 Rack back (tilt) angle at maximum lift 58 degrees
16 Dump angle at maximum lift 45 degrees
17 Rack back (tilt) angle at ground 50 degrees
0002 00-10
TM 5-3805-290-23-1
EQUIPMENT DATA - CONTINUED

Machine Dimensions with MP Bucket - Continued

18 Rack back (tilt) angle at carry 51 degrees
19 Carry height 17 in. (43.2 cm)
20 Digging depth 3.5 in. (89 mm)
21 Width at tread center 74 in. (1.88 m)
22 Overall width over tires 97 in. (2.46 m)
23 Minimum turning radius over tires 202 in. (5.13 m)
24 Minimum turning radius over bucket 232 in. (5.89 m)
25 Steering angle - left/right 40 degrees
0002 00-11
TM 5-3805-290-23-1

Machine Dimensions with Pallet Forks
427-B0526

1 Overall length 292 in. (7.42 m)
2 Depth of forks below grade 7 in. (17.8 cm)
3 Reach at ground level 34 in. (86.4 cm)
4 Reach at level arm 59 in. (1.50 m)
5 Maximum fork height 135 in. (3.43 m)
6 Lift height at level arm 63 in. (1.60 m)
7 Reach at maximum lift 27 in. (68.6 cm)
0002 00-12
TM 5-3805-290-23-1

Forklift Pallet Forks
427-B0100
924G Wheel Loader Rated Load for Forklift Pallet Forks

(50% of full turn static tipping load, according to SAE J1197 FEB 91).
RATED
FORK PART FORK TINE PLACEMENT OPERATING LOAD
NUMBER LENGTH HEIGHT (A) LOAD CENTER (B) REACH (C)
283-6476 40 in. 135 in. 6,000 lb 24 in. 59 in.

(1.02 m) (3.43 m) (2,722 kg) (61.0 cm) (1.50 m)
0002 00-13
TM 5-3805-290-23-1

Refill Capacities 0002 00
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.4 gal. (225 L)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 gal. (42 L)
Front Axle Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 gal. (21 L)
Rear Axle Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 gal. (21 L)
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5 gal. (70 L)
Hydraulic System (Including Tank). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 gal. (125 L)
Engine Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 gal. (16 L)
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 gal. (23 L)
Engine
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Caterpillar Inc.
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3056E DIT ATAAC
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel, turbocharged, after-cooled
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 hp (96 kW) @ 2,300 rpm
Engine rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,450 (high idle); 825 (low idle)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6, inline
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366 CID (6 L)
Type of Combustion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.25:1
Valve Lash
Inlet Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.008 in. (0.20 mm)
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.018 in. (0.45 mm)
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1, 5, 3, 6, 2, 4
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.94 in. (100 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 in. (12.7 cm)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,874 lb (850 kg)
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection
Cooling System, Thermostat Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176° to 204°F (80° to 96°C)
Transmission
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 speeds forward, 3 reverse
Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autoshift; single lever control with F/N/R
and kickdown button
Axles
Type
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oscillating (±8 degrees)
Front and Rear Differentials
Type
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limited slip
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conventional
0002 00-14
TM 5-3805-290-23-1
Brakes
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosed wet-disc; fully hydraulic
Secondary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Provided by nitrogen-charged accumulators
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical shoe-type
Machine Weight
Operational. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26,600 lb (12,065 kg)
Miscellaneous
Fording Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 in. (71.1 cm)
Maximum Travel Speeds (Empty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 mph (38.5 kph)
Location of Center of Gravity (CG): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 in. (1.19 m) forward of rear axle
centerline; 43 in. (1.09 m) above
ground level; 0 in. (0 mm) left or
right of machine front-to-rear
centerline
Tires
Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5-25
Ply Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 PR, L-2
Load Rating
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24,000 lb (10,886 kg)
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,000 lb (4,536 kg)
Inflation Pressure
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 psi (248 kPa)
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 psi (172 kPa)
Axle Load
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,400 lb (5,170 kg)
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,200 lb (6,895 kg)
Average Tire Contact Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 in.2 (1,374 cm2) each tire
Steering
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center-point frame articulation, load sensing
primary and secondary systems
Number of cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Electrical System
System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Batteries:
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Cold Cranking Amps (CCA) Rating:
Standard Machine: Down to -25°F (-32°C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,000 CCA each
Arctic Operation Machine: Down to -40°F (-40°C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,400 CCA each
0002 00-15
TM 5-3805-290-23-1

MP BUCKET 0002 00
Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281-1604
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,835 lb (1,286 kg)
Ground Engaging Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Teeth
Rated Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 yd3 (1.9 m3)
Rated Operating Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,500 lb (3,400 kg)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 in. (261.6 cm)
FORK 0002 00
Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283-6476
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664 lb (301 kg)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 in. (101.6 cm)
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,000 lb @ 24 in.
(2,722 kg @ 61 cm)
center of load
END OF WORK PACKAGE
0002 00-16
196
TM 5-3805-290-23-1
THEORY OF OPERATION 0003 00
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-5
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-18
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-19
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-31
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-94
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-100
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-102
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-120
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-134
Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-192
INTRODUCTION 0003 00
This work package explains how 924G Wheel Loader components work together. A functional description for equip-
ment operation is given for: transmission, engine lubrication system, fuel system, air inlet and exhaust system, engine cooling
system, steering and brake system, electrical system, and machine.
ENGINE 0003 00
1. General. The major components of basic engine: cylinder block, cylinder head, pistons, connecting rods, crankshaft,
vibration damper, timing gear case and gears, and camshaft.
2. Cylinder Block.
a. Cylinder block is made of cast iron. Cylinder block provides support for full length of dry cylinder liners. Cylinder
block has flame ring above cylinder liner flange.
b. Cylinder liners are made of cast iron. Production liners and replacement liners are press fit in cylinder block. Both
types of cylinder liners are honed to specially controlled finish to ensure long life and low oil consumption.
c. Cylinder block has bushing installed for front camshaft journal.
d. Other camshaft journals run directly into cylinder block.
3. Cylinder Head.
a. Cylinder head assembly has one inlet valve and one exhaust valve for each cylinder. Each cylinder valve has single
valve spring. Valve and valve spring are held in position by valve spring cap and two collets.
b. Inlet valve and exhaust valve move in phosphated guides. An oil seal fits over top of each valve guide.
c. Inlet valve and exhaust valve ports are on right side of cylinder head.
4. Pistons.
a. Pistons have Fastram combustion chamber at top. This chamber ensures an efficient mix of fuel and air.
b. Pistons have two compression rings and an oil control ring. Groove for top ring has hard metal insert that reduces
groove wear. Skirt has a layer of graphite that reduces wear. Off-center piston pin reduces noise level.
c. Engine has piston cooling jets installed in cylinder block for each cylinder. Piston cooling jets spray lubricating oil
onto inner surface of piston to cool piston.
0003 00-1
TM 5-3805-290-23-1
THEORY OF OPERATION - CONTINUED 0003 00
ENGINE - CONTINUED
5. Connecting Rods.
a. Connecting rods are machined from forged molybdenum steel. Connecting rod has a small, wedged-shaped end.
b. Mating surface of bearing cap and connecting rod is made by serrations in both bearing cap and connecting rod.
Bearing cap is mounted to connecting rod by two bolts and two nuts.
c. Engine is equipped with connecting rods that have a fracture split cap. Fracture split caps are retained with torx
screws. Connecting rods that are fracture split have higher rod integrity and improved strength due to splitting,
which produces an accurately matched surface on each side.
6. Crankshaft.
a. Crankshaft is a chromium molybdenum forging. Crankshaft has seven main journals.
b. Crankshaft end play is controlled by two half-thrust washers located on both sides of center main bearing.
c. Main bearings are made with a steel back and a bearing material. Bearing material is an alloy of aluminum and tin.
Exception is center main bearing, which is lead bronze with a lead finish. Main bearing caps are made of cast iron
or spheroidal graphite (SG) iron.
7. Vibration Damper.
Force from combustion in cylinders will cause crank-

shaft to twist. This is called torsional vibration. If vibration is
too great, crankshaft will be damaged. Vibration damper lim-
its torsional vibration. Vibration damper is designed as a vis-
cous damper. Space between weight and case is filled with
viscous fluid.
427-B1502
8. Gears and Timing Gear Case.
a. Timing case is constructed of either aluminum or cast iron. Aluminum timing case cover contains front oil seal.
b. Timing gears are made of steel or cast iron.
c. Crankshaft gear drives upper idler gear and lower idler gear. Upper idler gear drives camshaft and fuel injection
pump. Lower idler gear drives oil pump. Water pump is driven by fuel injection pump gear.
d. Camshaft and fuel injection pump rotate at half engine speed.
0003 00-2
TM 5-3805-290-23-1
ENGINE - CONTINUED
427-B1503
9. Camshaft.
a. Engine has a single camshaft. Camshaft is made of cast iron. Camshaft lobes are chill hardened.
b. Camshaft is driven at front end. As camshaft turns, camshaft lobes move valve system components. Valve system
components move cylinder valves.
c. Camshaft gear must be timed to crankshaft gear. Relationship between lobes and camshaft gear causes valves in
each cylinder to open at correct time. Relationship between lobes and camshaft gear also causes valves in each cyl-
inder to close at correct time.
10. Valve System.
a. Valve system components control flow of inlet air into cylinders during engine operation. Valve system compo-
nents also control flow of exhaust gases out of cylinders during engine operation.
b. Crankshaft gear drives camshaft gear through an idler gear. Camshaft must be timed to crankshaft in order to
obtain correct relation between piston movement and valve movement.
c. Camshaft has two camshaft lobes for each cylinder. Lobes operate inlet and exhaust valves. As camshaft turns,
lobes on camshaft cause lifter to move pushrod up and down. Upward movement of pushrod against rocker arm
results in downward movement (opening) of valve.
d. Each cylinder has one inlet valve and one exhaust valve. Valve spring closes valve when lifter moves down.
0003 00-3
TM 5-3805-290-23-1
ENGINE - CONTINUED
11. Lubrication System.
a. Lubrication system pressure is supplied by engine oil pump which uses rotors. Engine oil pump is driven by an
idler gear. Crankshaft gear drives idler gear. Engine oil pump has an inner rotor and an outer rotor. The rotors’ axes
of rotation are off-center relative to each other. There is a key between inner rotor and drive shaft.
b. Inner rotor has four lobes which mesh with five lobes of outer rotor. When inner lobe rotates, distance between
lobes of outer rotor and inner rotor increases in order to create suction. When distance between lobes decreases,
pressure is created.
c. Lubricating oil from oil pan flows through a strainer and pipe to suction side of engine oil pump. Lubricating oil
flows from outlet side of pump through pipe and passage to filter head. Oil then flows from filter head through pipe
to plate type oil cooler. Oil cooler is located on left side of engine.
d. From oil cooler, oil returns through pipe to filter head. Oil then flows from filter head to bypass valve and from
bypass valve to oil filter.
e. Oil flows from oil filter through passage drilled across cylinder block to oil gallery. Oil gallery is drilled through
total length of left side of cylinder block. If oil filter is on right side of engine, oil flows through passage drilled
across cylinder block to pressure gallery.
f. Lubricating oil from oil gallery flows through high pressure passages to crankshaft main bearings. Then, oil flows
through passages in crankshaft to connecting rod bearing journals. Pistons and cylinder bores are lubricated by
splashing of oil and oil mist.
g. Lubricating oil from main bearings flows through passages in cylinder block to camshaft journals. Oil then flows
from second camshaft journal at reduced pressure to cylinder head. Oil then flows into rocker arm bushing of
rocker arm levers. Valve stems, valve springs, and valve lifters are lubricated by splashing and misting of oil.
h. Idler gear hub is lubricated by oil from oil gallery. Timing gears are lubricated by splashing of oil.
i. Turbocharger is lubricated by oil from oil filter passing through engine block. An external line from engine block
supplies oil to turbocharger. Oil then flows through a line to oil pan.
j. Piston cooling jets are installed in turbocharged engines. Piston cooling jets are supplied with oil from oil gallery.
Piston cooling jets spray lubricating oil on underside of pistons in order to cool them.
0003 00-4
TM 5-3805-290-23-1
FUEL SYSTEM 0003 00

1. Fuel Injection.
a. Engine has an electronically controlled axial piston distributor injection pump.
b. Electronically controlled axial piston distributor injection pump generates injection pressure for all cylinders in a
single pump. Injection pump is responsible for distributing fuel to fuel injectors. Injection pressure is generated by
a piston moving axially. Piston movement is parallel to fuel injection pump shaft.
c. When engine is cranking, fuel is pulled from fuel tank through fuel filter/water separator by fuel priming pump.
When fuel passes through water separator, any water in fuel will go to bottom of bowl. Fuel priming pump sends
fuel at low pressure to secondary fuel filter. From secondary fuel filter, fuel passes through fuel supply line to fuel
injection pump. Fuel injection pump sends fuel through high pressure fuel lines to each fuel injector. Injectors
spray atomized fuel into cylinder.
427-B1511
0003 00-5
TM 5-3805-290-23-1
FUEL SYSTEM - CONTINUED

d. Fuel injection pump needs fuel for lubrication. Precision pump parts are easily damaged. Engine must not be
started until fuel injection pump is full of fuel. System must be primed when any part of system is drained of fuel.
e. These services and repairs require system priming:
(1) Fuel filter changed
(2) Fuel line removed
(3) Fuel injection pump replaced
2. Primary Filter/Water Separator. Primary filter/water separator is located between fuel tank and priming pump. Pri-
mary filter/water separator has a rating of 10 microns.
3. Fuel Priming Pump. Pump is electronically operated to prime and transfer fuel to fuel system when engine is stopped.
In order to release air from system, orifice in cover of fuel filter is in inlet side of filter. It is located on top of primary
fuel filter base.
4. Secondary Fuel Filter. Secondary fuel filter is located after priming pump. Filter is always before fuel injection pump.
Filter has a rating of 2 microns.
5. Fuel Injection Pump.
NOTE
Refer to Schematic for the following fuel injection pump operations:
a. Delivery
b. Generation of high pressure
c. Distribution and injection
d. Timing
e. Shutoff
f. Control
0003 00-6
TM 5-3805-290-23-1
427-B1515
0003 00-7
TM 5-3805-290-23-1

a. Delivery.
(1) Fuel is supplied by priming pump. Fuel
enters transfer pump of fuel injection
pump. Fuel transfer pump is a vane type
pump driven by fuel injection pump
shaft. Pump supplies a constant amount
of fuel to interior of fuel injection pump.
Revolution of transfer pump is directly
related to speed of fuel injection pump
shaft.
427-B1507
(2) Rotor rotates inside cam ring. Cam ring is firmly attached to pump housing. Vanes are pressed against cam
ring by centrifugal force. Fuel flows through an inlet passage into recess in pump housing.
(3) Eccentric position of rotor is relative to cam ring. A volume is created between: vanes, rotor, and cam ring.
Fuel is transported by eccentric position relative to rotor and outlet passage. Fuel is transferred through
outlet passage into distributor plunger. Volume of fuel is reduced between inlet passage and outlet passage.
This creates pressure before delivery to distributor plunger.
(4) Fuel quantity increases as speed of
engine increases. Increased engine speed
increases fuel delivery pressure. Pressure
inside fuel injection pump is limited by
pressure regulator. Pressure regulator
controls fuel pressure. Fuel forces valve
spring open and flows back into inlet
passage from inside of fuel injection
pump.
427-B1516
0003 00-8
TM 5-3805-290-23-1

b. Generation of High Pressure.
(1) Fuel flows from fuel transfer pump outlet passage. High pressure is generated by distributor plunger axial
movement. Cam plate is driven by fuel injection pump shaft. Cam plate has six cams, corresponding to
number of engine cylinders. Cams on cam plate run on rollers. Rollers are fixed on cam ring. Rotating and
lifting movement of cam plate generates high pressure.
(2) Cam plate moves distributor plunger
toward distributor head. High pressure is
created by a decrease in volume between
distributor plunger and distributor head.
Cam plate is pressed to ring by two
springs, which brings distributor plunger
back to its original position. Fuel sole-
noid valve closes high pressure volume.
427-B1517
c. Distribution and Injection.

(1) Fuel distribution to injectors takes place through distributor plunger rotating movement. Fuel solenoid
valve meters amount of fuel by:
(a) Time of closure
(b) Duration time
(c) Start of injection
(d) Amount of fuel
427-B1518
0003 00-9
TM 5-3805-290-23-1

(2) Delivery valve ensures that pressure waves do not allow a reopening of injector. Pressure waves are cre-
ated at the end of injection process. Valve cone is lifted by fuel pressure.
(3) Fuel is forced through fuel line to injector. Delivery ends and fuel pressure drops. Valve spring presses
valve cone onto valve seat. Reopening a fuel injector has a negative effect on emissions.
427-B1519
427-B1520
d. Timing.
(1) Retarding of fuel injection is direct rela-
tionship between start of injection and
piston position. Timing compensates for
higher engine by advancing start of
injection.
(2) Timing advance for timing mechanism
for fuel injection pump.
427-B1521
0003 00-10
TM 5-3805-290-23-1

(3) Timing retard for timing mechanism for
fuel injection pump.
427-B1522
0003 00-11
TM 5-3805-290-23-1

(4) Steps for timing advance or timing retard of fuel injection pump are:
(a) ECU sends a signal to timing solenoid valve.
(b) Timing solenoid valve triggers timing mechanism.
(c) Timing solenoid valve changes pressure in timing mechanism.
(d) Timing mechanism changes position of cam ring.
(e) Cam ring changes position of rollers.
(f) Rollers change position of cam plate.
(g) Cam plate changes timing of fuel delivery.
e. Shutoff. Engine shuts off by interrupting fuel supply. Engine electronic control module (ECM) specifies amount of
fuel. Fuel solenoid valve is switched by define to zero.
f. Control. Injection pump ECU uses command from ECM and measured values from speed/timing sensor to actuate
fuel solenoid valve.
427-B1523
0003 00-12
TM 5-3805-290-23-1

(1) Injection pump ECU is mounted on top of pump. ECU has a connection to engine ECM and a connection
to speed/timing sensor. ECU has a connection for two solenoid valves. ECM functions as a control com-
puter. ECU calculates optimal parameters from ECM data. Fuel solenoid actuates valve accordingly.
(2) Speed/timing sensor in fuel injection pump determines precise angular position and speed of fuel injection
pump shaft. Timing wheel is permanently connected to fuel injection pump shaft. Speed/timing sensor gets
information from timing wheel. Sensor then sends electrical impulses to ECU. ECU also uses information
to determine average and momentary pump speed.
(3) Speed/timing signal sensor is constant.
427-B1524
0003 00-13
TM 5-3805-290-23-1

(4) Fuel amount is proportional to piston
stroke. Effective stroke is proportional to
angle of fuel delivery. A temperature
compensation takes place in ECU in
order to inject precise amount of fuel.
427-B1525
6. Fuel Injectors.
a. Each fuel injector is fastened to cylinder head by a gland nut on fuel injector holder. Fuel injectors are not service-
able.
b. Fuel injection pump forces fuel to flow under high pressure to fuel inlet hole. Fuel then flows around a needle
valve within fuel injector holder which causes fuel injection nozzle to fill with fuel. Fuel pressure pushes needle
valve and a spring. When fuel pressure force is greater than spring force, needle valve will lift up.
c. When needle valve opens, fuel under high pressure will flow through nozzle orifices into cylinder. Fuel is injected
into cylinder through orifices in nozzle as a very fine spray. When fuel is injected into cylinder, fuel pressure force
in nozzle body will decrease. Spring force will then be greater than fuel pressure force in nozzle body. Needle
valve will move quickly to closed position.
d. Needle valve fits closely with inside of nozzle.
This makes a positive seal for valve.
427-B1526
0003 00-14
TM 5-3805-290-23-1

7. Air Inlet and Exhaust System.
a. Air inlet and exhaust system controls quality and amount of air available for combustion. Air inlet and exhaust sys-
tem components are:
(1) Air cleaner
(2) Turbocharger
(3) Aftercooler
(4) Cylinder head
(5) Valves and valve system components
(6) Piston and cylinder
(7) Exhaust manifold
b. Air is drawn in through air cleaner into air inlet by turbocharger compressor wheel. Air is compressed and heated
to approximately 300°F (150°C) before being forced to aftercooler. As air flows through aftercooler, compressed
air temperature lowers to approximately 120°F (50°C). Cooling inlet air increases combustion efficiency.
Increased combustion efficiency helps achieve:
(1) Lower fuel consumption
(2) Increased horsepower output
(3) Reduced particulate emission
c. From aftercooler, air is forced into inlet manifold. Air flow from inlet chambers into cylinders is controlled by inlet
valves. There is one inlet valve and one exhaust valve for each cylinder. Inlet valves open when piston moves
down on intake stroke. When inlet valves open, cooled compressed air from inlet port is pulled into cylinder. Com-
plete cycle consists of four strokes:
(1) Inlet
(2) Compression
(3) Power
(4) Exhaust
d. Exhaust gases from exhaust manifold enter turbine side of turbocharger in order to turn turbocharger turbine
wheel. Turbine wheel is connected to shaft that drives compressor wheel. Exhaust gases from turbocharger pass
through exhaust outlet, muffler, and exhaust stack.
427-B1504
0003 00-15
TM 5-3805-290-23-1

8. Turbocharger.
a. Turbocharger is installed on center section or on top of exhaust manifold. All engine exhaust gases go through tur-
bocharger. Exhaust gases enter turbine housing through exhaust inlet. Exhaust gases then push turbine wheel
blades. Turbine wheel is connected to compressor wheel by a shaft.
b. When engine load increases, more fuel is injected into cylinders. Combustion of this additional fuel produces more
exhaust gases. Additional exhaust gases cause turbocharge turbine and compressor wheels to turn faster. As com-
pressor wheel turns faster, more air is forced into cylinders. This increased flow of air gives engine more power by
allowing engine to burn additional fuel with greater efficiency.
427-B1505
0003 00-16
TM 5-3805-290-23-1

9. Turbocharger with Wastegate.
a. Turbocharger has a wastegate to help improve emissions. Wastegate operation is controlled by boost pressure. At
high boost pressures, wastegate opens in order to decrease boost pressure. At low boost pressure, wastegate closes
in order to increase boost pressure.
b. When engine is operating under low boost conditions, a spring pushes on a diaphragm in canister. This action
moves actuating lever in order to close wastegate valve. Closing wastegate valve allows turbocharger to operate at
maximum performance.
c. As boost pressure through line increases against canister diaphragm, wastegate valve is opened. When wastegate
valve is opened, turbocharger rpm is limited by bypassing a portion of exhaust gases. Exhaust gases are routed
through wastegate, which bypasses turbocharger turbine wheel.
d. Turbocharger bearings use engine oil under pres-
sure for lubrication and cooling. Oil comes in
through oil inlet port, then goes through passages
in center section to lubricate and cool bearings.
Oil from turbocharger passes through oil outlet
port in bottom of center section, then returns to
engine oil pan.
427-B1506
0003 00-17
TM 5-3805-290-23-1
COOLING SYSTEM 0003 00

1. General. Engine has a basic cooling system. Cooling system has:
a. Radiator
b. Water pump
c. Oil cooler
d. Water temperature regulator (thermostat)
2. Coolant Flow.
a. Coolant flows from bottom of radiator to centrifugal water pump. Water pump is installed on front of timing case.
Water pump is driven by a gear. Fuel injection pump gear drives water pump gear. Water pump forces coolant
through a passage in timing case to front of cylinder block.
b. Coolant flow divides as it enters cylinder block. Most coolant flows along right-hand side of cylinder block, then
flows around outside of cylinders to rear of cylinder block.
c. Remainder of coolant flows along a passage in left side of cylinder block to oil cooler. Coolant flows around oil
cooler element to rear of cylinder block, then to rear of cylinder head.
d. Coolant flows forward through cylinder head, then flows into water temperature regulator housing. If thermostat is
closed, coolant goes directly through a bypass to inlet side of water pump. If thermostat is open, bypass is closed
and coolant flows to top of radiator.
427-B1508
0003 00-18
TM 5-3805-290-23-1
ELECTRICAL SYSTEM 0003 00

1. General.
a. Electrical system is a negative ground system.
b. Charging circuit operates when engine is running. Alternator in charging circuit produces direct current for electri-
cal system.
2. Starting Motor.
a. Starting motor turns engine flywheel. Rpm must be high enough to initiate a sustained operation of fuel ignition in
cylinders.
b. Starting motor has a solenoid. When ignition

switch is activated, voltage from electrical sys-
tem will cause solenoid to move pinion toward
engine flywheel ring gear. Electrical contacts in
solenoid close circuit between battery and start-
ing motor just before pinion engages ring gear.
This causes starting motor to rotate. This type of
activation is called a positive shift.
c. When engine begins to run, overrunning pinion
drive clutch prevents damage to armature caused
by excessive speeds. Clutch prevents damage by
stopping mechanical connection. However, pin-
ion will stay meshed with ring gear until ignition
427-B2155
switch is released. A spring in overrunning
clutch returns clutch to rest position.
3. Alternator.
a. Alternator produces three-phase, full-wave, rectified electrical output.
b. Alternator is an electro-mechanical component driven by a fan drive pulley belt. Alternator charges storage battery
during engine operation.
c. Alternator is cooled by an external fan mounted behind pulley. Fan forces air through holes in front of alternator.
Air exits through holes in back of alternator.
d. Alternator converts mechanical energy into ac voltage by rotating a dc electromagnetic field inside a three-phase
stator. Electromagnetic field is generated by electrical current flowing through a rotor. Stator generates ac voltage.
e. The ac is changed to dc by a three-phase, full-wave rectifier. Direct current flows to alternator output terminal.
Rectifier has three exciter diodes. The dc is used for charging process.
f. A regulator is installed on rear end of alternator. Two brushes conduct current through two slip rings, then to rotor
field. A capacitor protects rectifier from high voltages.
g. Alternator is connected to battery through ignition switch; therefore, alternator excitation occurs when switch is set
to ON.
4. Sensors.
a. Fuel level sending unit provides input to machine ECM which sends data to dash panel cluster. Data will position
fuel gage accurately.
b. Air filter restriction indicator provides information on air flow to dash panel cluster for indicator.
c. Engine oil temperature sensor provides data for engine oil temperature gage.
d. Engine speed sensor provides data to dash panel cluster.
e. Transmission oil filter circuit contains a sensor which activates indicator.
0003 00-19
TM 5-3805-290-23-1
ELECTRICAL SYSTEM - CONTINUED

5. CAT Data Link.
a. CAT data link is both an input and an output of engine ECM. Data link communicates with other ECMs on
machine and with service tools. Data link is bidirectional, meaning it can input and output information. Data link is
not a visible component. Data link consists of internal ECM circuits, related harness wiring, and diagnostic con-
nector.
b. Much information is available on CAT data link. ECM requires use of certain data that are sent back and forth on
CAT data link. Some shared information is described below:
(1) ECM receives commands from CAT data link to change operating modes.
(2) ECM receives commands from CAT data link to read service codes that are stored in ECM memory. Ser-
vice codes can also be cleared from memory.
(3) ECM sends this information to CAT data link: engine speed, direction, status of operator error, and ECM
fault information.
NOTE
All electronic control modules that use a CAT data link have a module identifier (MID).
(4) CAT data link shows information to operator on gages, alert indicators, and in the display area.
0003 00-20
TM 5-3805-290-23-1
427-B1634
0003 00-21
TM 5-3805-290-23-1
NOTE
If the data is lost to instrument cluster, an indicator will flash yellow.
(5) CAN data link is a serial data link used to communicate with engine ECM, machine ECM, display module,
and dash panel cluster.
6. Solenoids. Solenoids are installed on modulating
valves. Solenoids receive a signal from machine ECM
to energize. When solenoid energizes, modulating
valve spool moves to direct pressure oil to clutch.
Spool movement distance is proportional to strength
of signal sent to solenoid by machine ECM.
427-B1654
7. Parking Brake Switch. A parking brake switch acti-

vates an indicator light on the dash when parking
brake is engaged. When parking brake is engaged,
putting transmission in gear causes a switch in trans-
mission control to open. An audible alarm sounds.
427-B1657
0003 00-22
TM 5-3805-290-23-1
8. Speed Sensors. These sensors are installed on transmission:
a. Torque converter output speed sensor
b. Intermediate speed sensors
c. Output speed sensors
427-B1659
9. Diagnostic Connector. Diagnostic connector is located on right-hand console near floor. Connector is used to connect
to data communication equipment for diagnostic purposes.
427-B1662-1
0003 00-23
TM 5-3805-290-23-1
NOTE
Refer to the following schematic of electronic control.
427-B1527
0003 00-24
TM 5-3805-290-23-1

10. ECMs.
a. Machine ECM. Machine ECM is an environmentally sealed unit. Machine ECM is mounted under cab on left side
of machine. Machine ECM is protected by a cover that must be removed in order to access machine ECM.
b. Engine ECM. Engine ECM is a non-serviceable, environmentally sealed unit. Engine ECM is mounted on engine
on right side of machine. ECM functions as throttle and computer for fuel system. ECM receives all signals from
sensors in order to control timing and engine speed.
c. Passwords in an ECM are used to:
(1) Prevent reprogramming that is unauthorized
(2) Prevent erasing of logged events that is unauthorized
d. Factory passwords restrict changes to authorized personnel. Factory passwords are required to clear some event
codes.
e. ECM has an excellent record of reliability. Any problems in system are most likely connectors and wiring harness.
ECM should be considered last in troubleshooting engine.
f. Personality module contains software with all fuel setting information. Information determines engine perfor-
mance. Personality module is installed behind access panel on ECM.
g. Flash programming is used in programming or updating personality module.
h. ECM is sealed and needs no routine adjustment or maintenance.
11. Speed/Timing Sensor. Primary engine position is a
passive sensor. Timing wheel is located on crankshaft.
Speed/timing sensor receives a signal from teeth on
timing wheel. Extra space on timing wheel gives one
revolution per space. Space is oriented so that space is
40 degrees after top center.
427-B1529
0003 00-25
TM 5-3805-290-23-1

When engine is cranking, ECM uses speed/timing sensor signal from fuel injection pump. When engine is running,
ECM uses speed/timing sensor signal from crankshaft. This speed/timing sensor is primary source of engine position.
427-B1530
12. Pressure Sensors.

a. Boost pressure sensor and engine oil pressure sensor are active sensors.
b. Boost pressure sensor provides ECM with a measurement of inlet manifold pressure to control air/fuel ratio. This
will reduce engine smoke during transient conditions.
c. Boost pressure sensor operating range is 8 to 50 psi (55 to 345 kPa).
d. Engine oil pressure sensor provides ECM with a measurement of engine oil pressure. ECM can warn operator of
possible conditions that can damage engine, including detecting blocked oil filter.
e. Engine oil pressure sensor operating range is 8 to 50 psi (55 to 345 kPa).
427-B1531
0003 00-26
TM 5-3805-290-23-1

13. Temperature Sensors.
a. Air inlet temperature sensor and coolant temperature sensor are passive sensors. Each sensor provides a tempera-
ture input to ECM. ECM controls fuel delivery and injection timing.
b. Sensor operating range is -40 to 302°F (-40 to 150°C).
c. Sensors are also used for engine monitoring.
427-B1532
14. Voltage Load Protection Module. Voltage load pro-

tection module monitors system voltage. Voltage load
protection module will shut down fuel injection pump
if there is a high system voltage.
427-B1533
0003 00-27
TM 5-3805-290-23-1

15. Power Sources.
a. General. Engine supplies, ECM, fuel injection pump, and pressure sensors.
b. ECM Power Supply.
(1) Power supply to ECM and system is drawn from 24 volt battery. Power supply for ECM has battery dis-
connect switch, engine start switch, fuses, ground bolt, ECM connector, and machine interface connector
(MIC).
NOTE
The ground bolt is the only component that is mounted on the engine.
(2) ECM schematic shows main components for a typical power supply circuit. Battery voltage is normally
connected to ECM. Engine start switch input turns on ECM.
(3) Wiring harness can be bypassed for troubleshooting purposes.
(4) Display screen on Electronic Technician (ET) can be used to check voltage supply.
(5) ECM power supply comes from MIC, which receives power from power relay.
0003 00-28
TM 5-3805-290-23-1
NOTE
Two wires are used to reduce resistance.
427-B1535
427-B1537
427-B1536
0003 00-29
TM 5-3805-290-23-1

c. Pressure Sensors Power Supply. ECM supplies 5.0 ± 0.2 dc volts through ECM connector to each sensor. Power
supply is protected against short circuits. A short in a sensor or a wiring harness will not cause damage to ECM.
427-B1531
0003 00-30
TM 5-3805-290-23-1
TRANSMISSION 0003 00
1. General.
a. Powertrain has a transmission that is a countershaft transmission controlled by an ECM in order to provide
smoother shifting.
b. Diesel engine power is sent from flywheel to torque converter. Torque converter bolts to engine flywheel with a
flex plate connection. Torque converter is fastened to transmission with splines on torque converter hub. Power
flows directly from torque converter to transmission input shaft. Input shaft gears mesh with transmission gears in
order to provide power to transmission output shafts.
c. Transmission output shaft transfers power through drive shafts and universal joints to front and rear differentials.
Bevel gear and pinion of each differential sends power through differentials and sun gear shafts to final drives.
Axle shafts transmit power from final drives to wheels. An integral parking brake is mounted on transmission
front.
427-B1635
0003 00-31
TM 5-3805-290-23-1
TRANSMISSION - CONTINUED
d. Modulating control valves direct oil from transmission hydraulic pump to speed and direction clutches in transmis-
sion. Transmission has six clutches that are engaged hydraulically. Clutches are released by spring force. Axles are
equipped with hydraulically engaged inboard brakes.
e. Switches in transmission direction and shift lever inform machine ECM of direction and selected by operator.
ECM energizes modulating control valve solenoids to engage correct clutches for selected speed and direction.
f. Machine ECM communicates with engine ECM through CAN data link. Machine ECM also communicates with
monitoring system control and data link connector through CAT data link. Machine ECM can communicate with a
personal computer through diagnostic connector. Machine ECM transmits information to dash panel cluster.
Engine ECM also transmits information to dash panel cluster. Backup alarm is activated by ECM whenever trans-
mission is shifted to REVERSE.
g. Machine ECM uses information from transmission neutralizer override switch, brake pressure sensor, and parking
brake switch in order to provide proper output to modulating control valves and dash panel cluster. Intermediate
speed sensors, transmission oil temperature sensor, torque converter output speed sensor, and output speed sensors
also provide input to ECM in order to provide proper output to modulating control valves.
427-B1636
0003 00-32
TM 5-3805-290-23-1
h. Torque converter connects engine and transmis-
sion. This connection between engine and trans-
mission is a hydraulic connection. There is no
direct connection between engine and transmis-
sion. Torque converter transfers mechanical
energy from engine to transmission.
427-B1664
2. Transmission Oil Filter.

a. Oil filter is mounted on frame on left side of
machine. Externally mounted oil filter has a
bypass valve. If there is a restriction in oil filter
or if oil viscosity is very high, filter housing
bypass valve will open.
b. If inlet pressure to oil filter is 50 ± 1.7 psi (345 ±

12 kPa) greater than outlet pressure, bypass
valve will open. When oil does not go through
filter element, debris in oil will cause damage to
other hydraulic system components.
c. Correct maintenance procedures must be fol-

lowed to ensure that element does not become
427-B1665
full of debris. Debris could stop oil flow to
hydraulic system.
0003 00-33
TM 5-3805-290-23-1
3. Test Ports.
a. Modulating Valve Test Ports.
(1) Test port (A) for modulating valve for clutch 2 is located on modulating valve for clutch 2.
(2) Test port (B) for modulating valve for clutch 1 is located on modulating valve for clutch 1.
(3) Test port (C) for modulating valve for clutch 3 is located on modulating valve for clutch 3.
(4) Test port (D) for modulating valve for clutch 4 is located on modulating valve for clutch 4.
(5) Test port (E) for modulating valve for clutch 5 is located on modulating valve for clutch 5.
(6) Test port (F) for modulating valve for clutch 6 is located on modulating valve for clutch 6.
b. Torque Converter Inlet Oil Pressure Test

Port. Test port (G) for torque converter inlet oil
pressure is located on main relief valve.
427-B1670
c. Transmission Pump Pressure Test Port. Test

port (H) for transmission pump pressure is
located on main relief valve.
427-B1671
0003 00-34
TM 5-3805-290-23-1
d. Torque Converter Outlet Pressure Test Port.
Test port (I) for torque converter outlet pressure
is located on top of transmission. Test port for
torque converter outlet pressure is above torque
converter temperature sensor.
427-B1672
4. Transmission Relief Valve.

a. Transmission relief valve is located below modu-
lating valves on right side of machine.
b. Transmission relief valve controls maximum
pressure of engaged clutches, transmission relief
valve controls oil flow entering modulating
valves, and transmission relief valve directs
remaining oil to torque converter. Controlled
flow provides a constant fill time for clutches
through entire engine speed range.
427-B1667
0003 00-35
TM 5-3805-290-23-1
c. Pump oil flows into port from pump. Pump oil flows into orifice and unseats ball. When ball unseats, spring com-
presses against slug. Pump oil flows past ball and into chamber. Pressure in chamber moves spool to right against
spring. When spool moves to right, pump oil in port from pump flows past spool and into port to torque converter
as torque converter oil. Oil in chamber is vented to port to tank as tank oil.
d. Pressure in port from pump will vary slightly with demand from clutches. When pressure changes, spool will move
in order to maintain required engagement pressure to clutches. Spool will direct unneeded flow to port to torque
converter.
e. When pressure in port decreases, spring will move spool to left. When spool moves to left, oil flow into port to
torque converter will be blocked. As pressure drops further, spring will push ball to right. When ball moves to
right, oil flow from port from pump into chamber will be blocked. Oil in chamber will drain back into port from
pump through orifice when ball is moved to right.
427-B1703
5. Transmission Clutches.
a. There are six clutches used to transfer power from input shaft assembly to output shaft assembly.
(1) There are three direction clutches.
(a) Clutch 1 (forward low)
(b) Clutch 2 (forward high)
(c) Clutch 3 (Reverse)
(2) There are three speed clutches.
(a) Clutch 4 (second speed)
(b) Clutch 5 (third speed and fourth speed)
(c) Clutch 6 (first speed)
b. In order for power to be transferred through transmission to output shaft assembly, one direction clutch and one
gear clutch must be engaged. Each clutch is controlled by a modulating valve. Machine ECM controls proper
clutch engagement by sending a variable signal to modulating valve solenoids.
c. Clutch 2 and clutch 1 are co-located on one shaft assembly. Clutch 3 and clutch 4 are co-located on one shaft
assembly. Clutch 6 and clutch 5 are co-located on one shaft assembly.
d. When transmission is in NEUTRAL, clutch 5 is engaged.
0003 00-36
TM 5-3805-290-23-1
427-B1669
0003 00-37
TM 5-3805-290-23-1
6. Transmission Pump. Transmission pump is bolted to
transmission case and driven by torque converter.
Transmission gear pump is a one-section, positive dis-
placement type pump. Implement pump and steering
pumps are mounted on gear pump and driven by trans-
mission gear pump.
427-B1673
7. Transmission Oil Cooler. Transmission oil cooler is

located at rear of machine next to hydraulic oil cooler.
Outlet oil from torque converter flows through outlet
relief valve. Oil then flows to bypass valve for trans-
mission oil cooler. When transmission oil is cold,
bypass valve directs oil back to transmission. When
transmission oil becomes warmer, bypass valve directs
oil to transmission oil cooler. Transmission oil cooler
is located behind radiator. As oil flows through cooler,
air flows around core assembly. In this way, heat is
removed from oil. Oil from cooler provides lubrica-
tion and cooling to transmission. Lubrication oil flows
into each transmission shaft. This is done in order to
lubricate and cool bearings, gears, and clutches.
427-B1543
0003 00-38
TM 5-3805-290-23-1
8. Relief Valves.
a. Torque Converter Inlet Relief Valve. Torque converter inlet relief valve is located in torque converter housing
under transmission control valve. Torque converter inlet relief valve controls pressure sent to torque converter
from main relief valve in order to protect torque converter.
b. Torque Converter Outlet Relief Valve. Torque converter outlet relief valve is located at the top of torque con-
verter housing. Relief valve torque converter outlet controls minimum pressure in torque converter. When pressure
in torque converter is 85 ± 25 psi (585 ± 172 kPa), internal spring force moves spool to limit oil flow from torque
converter to oil cooler. When torque converter pressure rises above 85 ± 25 psi (585 ± 172 kPa), pressure over-
comes spring force and spool moves left to allow oil to flow from torque converter.
427-B1675
0003 00-39
TM 5-3805-290-23-1
9. Electrical Input Components.
NOTE
Refer to the following illustration for electrical inputs.
427-B1676
0003 00-40
TM 5-3805-290-23-1
a. Switches.
(1) General. Switches provide information to ECM. Switches are two-state devices, meaning they are either
open or closed.
(a) Closed - Switch closes circuit to ground or switch closes circuit to battery.
(b) Open - Switch opens a circuit to ECM input.
(2) Engine Start Switch.
(a) When engine start switch is in ON position, electrical power from batteries is supplied to ECMs.
(b) When engine start switch is in START position and conditions for starting engine are satisfied, start
relay is energized.
(3) Downshift Switch. Downshift switch tells ECM that operator wants transmission to downshift one gear.
Downshift switch has one input connection to ECM.
(4) Autoshift Switch.
(a) Autoshift switch tells ECM mode that is selected by operator.
(b) Autoshift switch has one input connection to ECM.
(c) When operator selects AUTO mode, ECM will select proper transmission gear.
(d) Proper transmission gear is based upon transmission speed.
(e) Machine must be in NEUTRAL to activate AUTO mode.
(f) When operator selects MANUAL mode, transmission gear selection is made by operator.
(g) Operator uses transmission direction and shift lever to select transmission gear.
(h) When operator selects ECONOMY mode, ECM will select transmission gear but transmission will
shift at lower transmission speeds.
(i) Machine ECM will use these inputs in order to engage proper clutches:
• Transmission shift lever
• Intermediate speed sensors
• Output speed sensors
• Torque converter output speed sensor
• Transmission neutralizer override switch
• Autoshift switch
• Downshift switch
• Remote F/N/R switch
• Brake charging pressure sensor
• Parking brake switch
• Engine ECM
0003 00-41
TM 5-3805-290-23-1
NOTE
Because two input lines are used for each direction, ECM can diagnose problems with circuits for direction
lever. A solenoid for direction is not activated and transmission remains in neutral if the following actions
occur:
a. Direction Switches. In normal operation, switches for transmission direction and shift lever
close direction inputs on ECM to ground. Closed switches tell ECM direction that is selected
by operator. ECM then activates appropriate directional solenoid. Direction lever does not
ground either of forward or reverse ECM inputs. Direction lever grounds both reverse and
forward input at the same time.
b. Speed Switches. In normal operation, switches for speed close speed inputs on ECM to
ground. Closed switches tell ECM speed selected by operator. ECM then activates
appropriate solenoid for the selected speed.
(5) Transmission Neutralizer Override Switch. When this switch is activated, transmission neutralizer over-
ride switch opens neutralizer input line of transmission ECM regardless of brake position. This switch is
used to disable neutralizer switch when neutralizing transmission during braking is not desired.
NOTE
A double-pole, single-throw switch is used for diagnostic purposes. If two poles are ever tied to +battery
voltage, control knows that a circuit failure is present. This fault is then shown on diagnostic indicator.
(6) Ride Control Switch. Ride control switch signals mode selected by operator to ECM. Operator may select
AUTO, ON, or OFF modes.
(7) Parking Brake Switch. Parking brake switch is used to signal status of parking brake to ECM. If parking
brake is applied and machine is in gear, machine remains in NEUTRAL. If machine is shifted into gear and
parking brake is applied, machine will stay in NEUTRAL. When parking brake is applied and machine
speed is above a preset speed, transmission will automatically downshift to slow machine.
b. Data Link. Machine ECM uses input from diagnostic connector via CAT data link. Machine ECM also uses input
from engine ECM via CAN data link.
c. Speed Sensors. All speed sensors are located on right side of transmission case. As gear teeth pass end of each sen-
sor, an ac voltage is produced. Frequency of voltage is proportional to gear teeth speed. ECM uses these signals
from these sensors to make decisions:
(1) Torque converter output speed sensor
(2) Intermediate speed sensors
(3) Output speed sensors
0003 00-42
TM 5-3805-290-23-1
d. Temperature Sensors.
(1) Transmission oil temperature sensor monitors temperature of transmission oil. Transmission oil tempera-
ture sensor is mounted below transmission relief valve.
(2) Torque converter temperature sensor monitors temperature of torque converter oil. Torque converter tem-
perature sensor is mounted on top of transmission on torque converter housing.
e. Brake Oil Pressure Sensor. Transmission neutralizer function consists of a brake pressure sensor mounted on brake
valve. When brakes are applied, pressure sensor sends a signal to machine ECM. Machine ECM will neutralize
transmission at proper brake pressure. Machine ECM will engage transmission when brakes are released.
f. Other Inputs. Machine ECM also receives information from diagnostic connector via CAT data link, engine ECM
via CAN data link, and instrument cluster.
10. Electronic Control Module (Machine). Machine ECM makes decisions for transmission operation based on informa-
tion from inputs and memory. Machine ECM controls many machine functions:
a. Powertrain is electronically controlled by

machine ECM (which is why, machine ECM can
be referred to as powertrain ECM).
b. Although some engine-related functions are con-
trolled by machine ECM, engine has an ECM
that controls most engine functions.
c. After machine ECM receives information from
inputs and memory, it will send a corresponding
response through outputs. Inputs and outputs of
machine ECM connect to machine harness by
two 70-pin connectors (J1 and J2).
427-B1687
11. Input/Output.
a. Machine has several input devices. Machine ECM receives information from components about machine opera-
tions. Machine has switch-type inputs and sensor-type inputs. Switches provide signals to switch ECM inputs. Pos-
sible outputs of a switch are listed: open signal, grounded signal, +battery signal. Sensors provide a signal to ECM
that constantly changes. Inputs to machine ECM are listed in Tables 1 and 2 for 70-pin connectors.
b. Machine ECM sends electrical signals through outputs. Outputs can create an action or provide information to
machine ECM. Outputs for machine ECM are listed in Tables 1 and 2. Engine ECM and machine ECM use CAT
data link to communicate with each other. Data link is bidirectional, meaning ECM can receive and send informa-
tion. Data link allows information sharing with other ECMs.
c. Machine ECM and instrument panel use CAN data link to communicate with each other. Data link is bidirectional,
meaning ECM can receive and send information. Engine information that needs to be displayed on instrument
panel is transmitted to machine ECM on CAT data link. Then, machine ECM sends information to instrument
panel on CAN data link.
d. A module identifier (MID) is assigned to each ECM. MID for machine ECM is 081.
0003 00-43
TM 5-3805-290-23-1
Table 1. Contact Description for Machine ECM J1.
NO.(1) FUNCTION TYPE
1 Engine Start Switch ON Input
2 Transmission Output Speed Sensor (Number 1) + Input
3 Transmission Output Speed Sensor (Number 1) - Input
4 Transmission Output Speed Sensor (Number 2) + Input
5 Transmission Output Speed Sensor (Number 2) - Input
6 Intermediate Speed Sensor (Number 1) + Input
7 Intermediate Speed Sensor (Number 1) - Input
8 Intermediate Speed Sensor (Number 2) + Input
9 Intermediate Speed Sensor (Number 2) - Input
10 CAT Data Link + Input/Output
11 5V Sensor Power Supply +Battery
12 Backup Power Output
13 Ground Ground
15 Torque Converter Output Speed Sensor + Input
16 Torque Converter Output Speed Sensor - Input
20 CAT Data Link - Input/Output
21 5V Sensor Return Ground
22 Fuel Level Sending Unit Input
23 Ground Ground
24 Secondary Steering Motor Relay Output
26 Autoshift Switch (Auto Position) Switch Input
27 Autoshift Switch (Manual Position) Switch Input
28 Autoshift Switch (VSC Position) Switch Input
29 Torque Converter Temperature Sensor Input
30 Hydraulic Oil Temperature Sensor Input
31 +Battery Power
0003 00-44
TM 5-3805-290-23-1
Table 1. Contact Description for Machine ECM J1 - Continued.
35 Transmission Oil Filter Bypass Switch Switch Input
36 Brake Charging Pressure Input
37 Transmission Neutralizer Sensor Input
39 +Battery Power
40 Downshift Switch Switch Input
41 Shifter Input (Second Speed) Switch Input
42 Shifter Input (Third Speed) Switch Input
43 Shifter Input (Fourth Speed) Switch Input
44 8V Sensor Power Supply Power
45 8V Sensor Return Ground
48 Clutch 6 Solenoid (First Speed) Output
49 Clutch 4 Solenoid (Second Speed) Output
50 Clutch Return (Clutch 4-6) Ground
51 Clutch 5 Solenoid (Third and Fourth Speed) Output
54 Return Ground
55 Return Ground
60 Return Ground
62 Clutch 2 Solenoid (Forward High) Output
65 Clutch 1 Solenoid (Forward Low) Output
66 Clutch 3 Solenoid (Reverse) Output
67 Demand Fan Solenoid Output
(1) The connector contacts that are not listed are not used. The connector has 70 contacts.
0003 00-45
TM 5-3805-290-23-1
Table 2. Contact Description for Machine ECM J2.
1 Engine Start Switch Input
2 Pilot Shutoff Solenoid Output
4 Return Ground
7 Start Relay Output
8 Return for Start Relay Ground
9 Secondary Steering Relay Output
10 Ride Control Relay Output
11 Autoshift Switch Indicator Output
13 Rear Window Defroster Output
14 Alternator R Terminal Output
21 Brake Neutralizer Switch Indicator Output
23 Shifter Input (Neutral) Input
24 Transmission Inlet Temperature Sensor Input
28 Shifter Input (Reverse) Input
29 Rear Window Defroster Output
31 Brake Neutralizer Set Switch Switch Input
36 Secondary Steering Test Switch Switch Input
37 Primary Steering Pressure Switch (N/O) Switch Input
38 Primary Steering Pressure Switch (N/C) Switch Input
45 Ride Control ON Switch Switch Input
46 Ride Control AUTO Switch Switch Input
49 Shifter Input (Forward) Input
50 Shifter Input (First Speed) Input
51 Brake Neutralizer Enable Switch Switch Input
52 Parking Brake Switch DISENGAGED Switch Input
53 Parking Brake Switch ENGAGED Switch Input
0003 00-46
TM 5-3805-290-23-1
Table 2. Contact Description for Machine ECM J2 - Continued.
54 Hydraulic Oil Filter Bypass Switch Switch Input
58 Hydraulic Lockout Control Switch (Normally Open) Input
59 Hydraulic Lockout Control Switch (Normally Closed) Input
62 Brake Neutralizer Disable Switch Switch Input
67 CAN Data Link + Input/Output
68 CAN Data Link - Input/Output
(1) Connector contacts that are not listed are not used. Connector has 70 contacts.
0003 00-47
TM 5-3805-290-23-1
12. Electrical Output Components.
427-B1688
0003 00-48
TM 5-3805-290-23-1
a. Relays. There are three system relays activated directly by machine ECM: ride control, parking brake alarm relay,
and backup alarm relay.
(1) Ride Control. Machine ECM activates ride control when ride control/load check switch is placed in ON
position. Activation is based on machine ground speed in AUTO position. Ride control system diminishes
effects of a loaded bucket when machine moves at higher speeds.
(2) Backup Alarm Relay. Backup alarm relay is used to activate backup alarm when transmission is placed in
REVERSE position.
b. Modulating Valves.
NOTE
Solenoid coils are not designed to be operated at 24 DCV directly. Machine ECM sends a 24 volt Pulse
Width Modulated (PWM) signal at a duty cycle which provides an average voltage of about 12 volts to sole-
noid coils. DO NOT energize solenoid coils with 24 DCV (+battery). Life of solenoid coils will be drastically
reduced if solenoid coils are energized with 24 DCV (+battery). If solenoid coils must be energized by a
source that is different from machine ECM, use 12 DCV to energize solenoid coils.
(1) Modulating valves are located on right side of machine on top of transmission.
(2) Two solenoids must be activated to move machine. One solenoid is for direction and one solenoid is for
speed. When solenoid is activated, it receives a signal from machine ECM. Each modulating valve is con-
trolled by a solenoid. Solenoids are controlled by machine (ECM). Modulating valves are used by machine
ECM to directly modulate oil pressure sent to each individual clutch. When operator selects a direction
and speed, machine ECM sends a PWM signal to vary current to solenoid on modulating valve. Amount of
current sent to solenoid regulates amount of oil pressure supplied to selected clutch. When machine ECM
sends maximum current to solenoid, oil pressure in clutch is at maximum. When no current is sent to mod-
ulating valve, oil pressure in clutch is at minimum.
0003 00-49
TM 5-3805-290-23-1
(3) Machine is equipped with these modu-
lating valves:
(a) Modulating valve for clutch 1 (for-
ward low).
(b) Modulating valve for clutch 2 (for-
ward high).
(c) Modulating valve for clutch 3
(reverse).
(d) Modulating valve for clutch 4 (sec-
ond speed).
(e) Modulating valve for clutch 5 (third
speed).
427-B1697
(f) Modulating valve for clutch 6 (first
speed).
(4) Neutral.
(a) When machine ECM requires a clutch to be disengaged, there is no flow of electric current to sole-
noid. Pump oil flows into valve body from pump passage. Oil then flows into passage, through orifice,
and into chamber. Since there is no signal sent to solenoid, pin cannot hold ball against orifice. Oil
flows through orifice, past ball, to tank passage. Oil in tank passage becomes return oil.
(b) Spring holds valve spool left. When valve spool is shifted left, oil in clutch passage flows to tank pas-
sage. When oil in clutch passage is vented to tank, clutch cannot be engaged. Oil in pump passage is
blocked from entering clutch passage.
427-B1699
0003 00-50
TM 5-3805-290-23-1
(5) Less Than Maximum Signal.
(a) When machine ECM requires a clutch to be engaged, a signal is sent to solenoid. Strength of signal is
proportional to desired clutch pressure.
(b) When signal is sent to solenoid, pin moves right and forces ball toward orifice. When ball moves
toward orifice, flow of return oil into tank passage is restricted. Pressure in chamber increases and oil
becomes reduced pilot oil pressure. Pressure moves valve spool to right against force of spring.
(c) When valve spool moves right, pump oil in pump passage enters clutch passage. Valve spool blocks
flow of oil from clutch passage to tank passage. Clutch pressure will increase due to flow of reduced
pressure oil into clutch passage. Oil in clutch passage also flows through passage into chamber.
(d) Initially, machine ECM sends a high signal to solenoid to fill clutch with oil quickly. Then, a reduced
signal is sent to solenoid to allow clutch to engage smoothly.
(e) Once clutch engages, machine ECM steadily increases signal to solenoid to further engage clutch.
When signal to solenoid increases, pin moves right. Pin pushes ball toward orifice and ball restricts oil
flow to tank passage. Oil pressure in chamber will rise and valve spool will move right. This causes
clutch pressure to increase.
427-B1700
0003 00-51
TM 5-3805-290-23-1
(6) Maximum Signal.
(a) When clutch is fully engaged, machine ECM sends maximum specified signal to solenoid to keep
clutch fully engaged.
(b) Signal sent to solenoid moves pin and ball right. This further restricts flow of return oil from clutch
passage to tank passage. Pressure in chamber increases and oil becomes pilot oil. Valve spool moves
further to right. Pump oil from pump passage flows to clutch passage and clutch will fully engage.
(c) Once clutch is fully engaged, pump oil in chamber and combined pressure of oil in chamber and
spring will equalize. This will cause valve spool to move left to a balanced position.
NOTE
• Modulating valves control engaging and disengaging of clutches.
• These are not simple ON/OFF valves. Machine ECM varies strength of signal sent to solenoid. Signal sent to
solenoid is programmed into machine ECM.
• Since main relief valve will control maximum amount of clutch pressure for all of modulating valves, pump
supply pressure and clutch pressure will be equal when clutch is fully engaged.
(d) In balanced position, oil flow from pump passage to clutch passage maintains desired clutch pressure.
In balanced position, oil flows to clutch to compensate for internal clutch leakage.
0003 00-52
TM 5-3805-290-23-1
427-B1701
0003 00-53
TM 5-3805-290-23-1
13. Other Outputs. Machine ECM also sends information to engine ECM via CAN data link. Machine ECM also sends
information to dash panel cluster and diagnostic connector via CAT data link.
14. Data Link.
a. Machine has two data links: CAT data link and CAN data link. A data link is not a visible component. A data link
consists of internal ECM circuits and connecting harness wiring. Data links are bidirectional, meaning they allow
ECMs to receive and send information.
b. CAT data link is an input and output of ECM. CAT data link is connected to ECM at connectors J1-10 and J1-20.
Machine ECM communicates with engine ECM on CAT data link.
c. CAN data link is an input and output of ECM. CAN data link is connected to ECM at connectors J2-67 and J2-68.
Data link is designed to communicate with other ECMs through machine harness. Machine ECM communicates
with engine ECM and instrument cluster on CAN data link. Engine ECM does not communicate directly with
instrument cluster. Engine information is sent to machine ECM. Then, machine ECM sends information to instru-
ment cluster.
d. Electronic Technician (ET) also communicates with other ECM modules through data link. ET will list other ECM
modules and available diagnostic information. Information on both data links is available to ET via diagnostic con-
nector.
0003 00-54
TM 5-3805-290-23-1
427-B1691
0003 00-55
TM 5-3805-290-23-1
15. Torque Converter.
a. Torque converter connects engine to transmission hydraulically. There is no direct mechanical connection between
engine and transmission.
b. Torque converter is welded into one piece and cannot be opened. These components are inside torque converter:
(1) Stator
(2) Turbine
(3) Impeller
c. Torque converter uses oil to send torque from engine to transmission. When machine is working against a load,
torque converter multiplies torque from engine and sends a higher torque to transmission.
d. Oil for torque converter operation comes from transmission oil pump. Oil pump is driven by gear. Oil flows to a
flow control valve in transmission case and is divided. Oil is directed to transmission circuit and torque converter
circuit. Torque converter inlet oil pressure is controlled by torque converter inlet relief valve. Converter inlet relief
valve is mounted in transmission case below transmission control valve. Relief valve limits maximum pressure to
torque converter to 130 psi (895 kPa). Torque converter inlet relief valve protects torque converter from high pres-
sure due to cold oil or some other restriction in torque converter or cooler circuit.
e. Flex plate is mounted to engine flywheel and torque converter. Impeller is connected to inside of torque converter.
Stator support slides over input shaft. Turbine connects to input shaft.
f. Stator connects to stator support. Stator support is mounted to transmission case and stator does not turn.
g. Teeth on gear mesh with splines on torque converter. Gear meshes with oil pump gear.
h. Oil from transmission hydraulic controls flows into torque converter. Impeller rotation gives force to oil.
i. Impeller turns with rotating torque converter housing at engine speed. Impeller causes oil to go to outside of impel-
ler. Oil goes around inside of housing and against turbine blades. Force of oil that hits turbine blades causes turbine
to turn. This sends torque to transmission input shaft.
j. After oil hits turbine blades, it flows to inside of turbine. Oil from turbine moves in a direction opposite rotation of
impeller. Stator causes oil to change direction, going back into impeller in direction of rotation.
k. Force of oil from stator can now add to torque output. This extra force can increase engine torque output to turbine.
Amount of oil force from stator is larger difference between impeller speed and turbine speed.
l. Difference in impeller speed and turbine speed is caused by machine load. When torque converter is at stall condi-
tion, torque multiplication of torque converter is at maximum. Oil from outlet passage flows to converter outlet
relief valve, then flows to oil cooler and transmission lubrication system.
0003 00-56
TM 5-3805-290-23-1
427-B1704
0003 00-57
TM 5-3805-290-23-1
16. Hydraulic System (Transmission).
427-B1708
0003 00-58
TM 5-3805-290-23-1
a. These components are part of the transmission hydraulic system:
(1) Transmission relief valve
(2) Solenoid for clutch 2 (forward high)
(3) Modulating valve for clutch 2 (forward high)
(4) Torque converter
(5) Torque converter outlet relief valve
(6) Solenoid for clutch 4 (second speed)
(7) Oil cooler
(8) Transmission line
(9) Modulating valve for clutch 4 (second speed)
(10) Clutch 4 (second speed)
(11) Solenoid for clutch 5 (third speed and fourth speed)
(12) Modulating valve for clutch 5 (third speed and fourth speed)
(13) Clutch 5 (third speed and fourth speed)
(14) Modulating valve for clutch 6 (first speed)
(15) Clutch 6 (first speed)
(16) Solenoid for clutch 6 (first speed)
(17) Modulating valve for clutch 3 (reverse)
(18) Clutch 3 (reverse)
(19) Clutch 1 (forward low)
(20) Solenoid for clutch 3 (reverse)
(21) Modulating valve for clutch 1 (forward low)
(22) Solenoid for clutch 1 (forward low)
(23) Tank
(24) Pump
(25) Filter
(26) Torque converter inlet relief valve
(27) Clutch 2 (forward high)
(28) Transmission oil cooler bypass valve
0003 00-59
TM 5-3805-290-23-1
17. Transmission Power Flow.
a. Machine ECM determines proper clutches to engage based on inputs, including machine speed, engine speed, and
operator inputs.
b. When engine is started, transmission oil pump pulls oil from sump and sends it through transmission oil filter.
Pressurized transmission oil flows from transmission oil filter to oil inlet in transmission housing, then through an
internal passage in transmission housing. Oil then flows through transmission relief valve into modulating valves.
c. Oil in clutches that are not engaged is sent back to sump as return oil.
d. Transmission relief valve controls pressure of pump oil supplied to modulating valves. Transmission relief valve
directs unneeded pump oil to torque converter as torque converter oil. Torque converter outlet oil flows through
torque converter outlet relief valve to oil cooler as lubrication oil. After oil cools, it flows through lubrication sys-
tem and to sump.
e. Table 3 gives clutch combinations that are engaged for each forward and reverse speed. There is a modulating
valve for each clutch which directs pressurized oil to clutch to engage it. A solenoid is located on each modulating
valve which controls modulating valve spool. Machine ECM controls solenoids.
Table 3. Transmission Clutch Combination.
Second Third Fourth Second Third

First Speed Speed Speed Speed First Speed Speed Speed
Forward Forward Forward Forward Neutral Reverse Reverse Reverse
Clutch 1 X X X
(forward
low)
Clutch 2 X
(forward
high)
Clutch 3 X X X
(reverse)
Clutch 4 X
(second
speed)
Clutch 5 X X X X
(third speed
and fourth
speed)
Clutch 6 X X
(first speed)
0003 00-60
TM 5-3805-290-23-1
427-B1709
0003 00-61
TM 5-3805-290-23-1
f. Countershaft transmission is a power shift transmission that has four forward speeds and three reverse speeds.
Transmission has six clutches that are engaged hydraulically. Five clutches are disengaged by a coil spring. Clutch
6 is disengaged by wave spring and balance seal assembly. Balance seal assembly helps prevent clutch from drag-
ging if an engine overspeed condition occurs.
g. Balance seal assembly and wave spring are assembled inside clutch piston. When clutch 6 is not engaged, force
from wave spring and pressure from lube oil combine to move clutch piston to clutch disengaged position.
h. Transmission has five shafts: Input shaft assembly, output shaft assembly, and three gear shafts. Input shaft assem-
bly is driven by torque converter turbine. One gear shaft assembly contains clutch 1 (forward low) and clutch 2
(forward high). Another gear shaft assembly contains clutch 3 (reverse) and clutch 4 (second speed), and a third
gear shaft assembly contains clutch 5 (third speed and fourth speed) and clutch 6 (first speed).
i. Parking brake assembly is mounted to transmission case.
j. Each transmission gear shaft assembly’s carry clutches has three internal oil passages. One passage carries oil for
lubrication and cooling of clutches, bearings, and gears. Two passages carry pressure oil for engagement of
clutches on each shaft.
k. In order to transfer power through transmission, both a speed clutch and a direction clutch must be engaged.
l. Torque converter inlet relief valve limits torque converter inlet oil pressure to protect torque converter.
0003 00-62
TM 5-3805-290-23-1
427-B1711
0003 00-63
TM 5-3805-290-23-1
18. First Speed Forward.
a. Machine ECM determines proper clutches to engage based on inputs such as machine speed, engine speed, and
operator inputs.
b. Machine ECM modulates electrical current sent to selected clutch solenoids. Clutch solenoids are located on mod-
ulating relief valves.
c. Modulating current to clutch solenoid controls clutch pressure by shifting spool in modulating valve.
d. When transmission direction and shift lever is moved to FIRST SPEED FORWARD, both modulating valve sole-
noid for clutch 6 (first speed) and modulating valve solenoid for clutch 1 (forward low) are energized. When mod-
ulating valve solenoid for clutch 1 is energized, modulating valve for clutch 1 directs pump oil to clutch 1 to
engage clutch. When modulating valve solenoid for clutch 6 is energized, modulating valve directs pump oil to
clutch 6 to engage clutch.
e. Oil in clutches that are not engaged is sent back to sump as return oil.
f. Transmission relief valve controls pump oil pressure supplied to modulating valves. Transmission relief valve
torque converter outlet relief valve to oil cooler as lubrication oil. After oil cools, it flows to transmission for trans-
mission lubrication. After transmission is lubricated and cooled, oil drains to sump.
g. Torque converter inlet relief valve limits torque converter inlet oil pressure to protect torque converter.
0003 00-64
TM 5-3805-290-23-1
427-B1712
0003 00-65
TM 5-3805-290-23-1
h. When transmission is in FIRST SPEED FORWARD, clutch 1 and clutch 6 are engaged. Torque from engine is
transferred through torque converter to input shaft assembly. Gear (1) is splined to input shaft assembly. Gear (1)
turns gear (2).
i. Gear (2) is splined to hub assembly (3) and causes hub assembly (3) to turn. Torque is transferred from input shaft
assembly, through gear (1) and gear (2), to hub assembly (3). When clutch 1 is engaged, torque is transferred from
hub assembly (3), through engaged clutch 1, to shaft assembly (4).
j. Gear (5) is part of shaft assembly (4). Gear (5) turns gear (6). Gear (6) is part of shaft assembly (7). Torque is trans-
ferred from shaft assembly (4), through gear (5), and gear (6), to shaft assembly (7).
k. Gear (8) is splined to shaft assembly (7). Gear (8) turns gear (9), which is splined to hub assembly (10). Torque is
transferred from shaft assembly (7), through gear (8) and gear (9), to hub assembly (10). When clutch 6 is engaged,
torque is transferred from hub assembly (10), through engaged clutch 6, to shaft assembly (11).
l. Gear (12) is splined to shaft assembly (11). Gear (12) turns gear (13), which is splined to output shaft assembly.
Torque is transferred from shaft assembly (11), through gear (12) and gear (13), to output shaft assembly.
0003 00-66
TM 5-3805-290-23-1
427-B1713
0003 00-67
TM 5-3805-290-23-1
19. Second Speed Forward.
a. Machine ECM determines proper clutches to be engaged based on inputs such as machine speed, engine speed,
and operator inputs.
d. When transmission direction and shift lever is moved to SECOND SPEED FORWARD, both modulating valve
solenoid for clutch 4 (second speed) and modulating valve solenoid for clutch 1 (forward low) are energized.
When modulating valve solenoid for clutch 1 is energized, modulating valve directs pump oil to clutch 1 to engage
clutch. When modulating valve solenoid for clutch 4 is energized, modulating valve directs pump oil to clutch 4 to
engage clutch.
g. Torque converter inlet relief valve limits torque converter inlet oil pressure in order to protect torque converter.
0003 00-68
TM 5-3805-290-23-1
427-B1714
0003 00-69
TM 5-3805-290-23-1
h. When transmission is in SECOND SPEED FORWARD, clutch 1 and clutch 4 are engaged. Torque from engine is
turns gear (2).
i. Gear (2) turns hub assembly (3). Torque is transferred from input shaft assembly, through gear (1) and gear (2), to
hub assembly (3). When clutch 1 is engaged, torque is transferred from hub assembly (3), through engaged clutch
1, to shaft assembly (4).
j. Gear (5) is part of shaft assembly (4). Gear (5) turns gear (6). Gear (6) is part of shaft assembly (7). Torque is trans-
ferred from shaft assembly (4), through gear (5) and gear (6), to shaft assembly (7).
k. When clutch 4 is engaged, torque is transferred from shaft assembly (7), through engaged clutch 4, to hub assem-
bly (14). Gear (15) is splined to hub assembly (14). Gear (15) turns gear (16). Gear (16) is part of shaft assembly
(11). Torque is transferred from hub assembly (14), through gear (15) and gear (16), to shaft assembly (11).
l. Gear (12) is splined to shaft assembly (11). Gear (12) turns gear (13). Gear (13) is splined to output shaft assembly.
0003 00-70
TM 5-3805-290-23-1
427-B1715
0003 00-71
TM 5-3805-290-23-1
20. Third Speed Forward.
operator inputs.
d. When transmission direction and shift lever is moved to THIRD SPEED FORWARD, both modulating valve sole-
noid for clutch 5 (third speed and fourth speed) and modulating valve solenoid for clutch 1 (forward low) are ener-
gized. When modulating valve solenoid for clutch 1 is energized, modulating valve directs pump oil to clutch 1 to
engage clutch. When modulating valve solenoid for clutch 5 is energized, modulating valve directs pump oil to
0003 00-72
TM 5-3805-290-23-1
427-B1716
0003 00-73
TM 5-3805-290-23-1
h. When transmission is in THIRD SPEED FORWARD, clutch 1 and clutch 5 are engaged. Torque from engine is
turns gear (2).
i. Gear (2) turns hub assembly (3). Torque is transferred from input shaft assembly, through gear (1) and gear (2), to
hub assembly (3). When clutch 1 is engaged, torque is transferred from hub assembly (3), through engaged clutch
1, to shaft assembly (4).
j. Gear (5) is part of shaft assembly (4). Gear (5) turns gear (6). Gear (6) is part of shaft assembly (7). Gear (6) turns
gear (17). Gear (17) is splined to hub assembly (18). Torque is transferred from shaft assembly (4), through gear
(5), gear (6), and gear (17), to hub assembly (18).
k. When clutch 5 is engaged, torque is transferred from hub assembly (18), through engaged clutch 5, to shaft assem-
bly (11).
0003 00-74
TM 5-3805-290-23-1
427-B1717
0003 00-75
TM 5-3805-290-23-1
21. Fourth Speed Forward.
a. Machine ECM determines proper clutches to engage based on inputs to machine speed, engine speed, and operator
inputs.
d. When transmission direction and shift lever is moved to FOURTH SPEED FORWARD, modulating valve solenoid
on for clutch 5 (third speed and fourth speed) is energized and modulating valve solenoid for clutch 2 (forward
high) is energized. When modulating valve solenoid for clutch 2 is energized, modulating valve directs pump oil to
clutch 2 to engage clutch. When modulating valve solenoid for clutch 5 is energized, modulating valve directs
pump oil to clutch 5 to engage clutch.
0003 00-76
TM 5-3805-290-23-1
427-B1718
0003 00-77
TM 5-3805-290-23-1
h. When transmission is in FOURTH SPEED FORWARD, clutch 2 and clutch 5 are engaged. Torque from engine is
turns gear (20).
i. Gear (20) turns hub assembly (21). Torque is transferred from input shaft assembly, through gear (19) and gear
(20), to hub assembly (21). When clutch 2 is engaged, torque is transferred from hub assembly (21) through
engaged clutch 2, to shaft assembly (4).
j. Gear (5) is part of shaft assembly (4). Gear (5) turns gear (6). Gear (6) is part of shaft assembly (7). Gear (6) turns
gear (17). Gear (17) is splined to hub assembly (18). Torque is transferred from shaft assembly (4), through gear
(5), gear (6), and gear (17), to hub assembly (18).
k. When clutch 5 is engaged, torque is transferred from hub assembly (18), through engaged clutch 5, to shaft assem-
bly (11).
0003 00-78
TM 5-3805-290-23-1
427-B1719
0003 00-79
TM 5-3805-290-23-1
22. Neutral.
a. When machine ECM determines that transmission should be in NEUTRAL, clutch 5 (third speed and fourth speed)
is engaged. If machine ECM detects machine movement, it will disengage clutch 5.
ulating relief valves. Modulating current to clutch solenoid controls clutch pressure by shifting spool in modulating
valve.
c. When transmission direction and shift lever is moved to NEUTRAL, or transmission neutralizer is activated, mod-
ulating valve solenoid for clutch 5 is energized. When modulating valve solenoid on for clutch 5 is energized,
modulating valve directs pump oil to clutch 5 to engage clutch.
d. Oil in clutches that are not engaged is sent back to sump as return oil.
e. Transmission relief valve controls pump oil pressure supplied to modulating valves. Transmission relief valve
f. Torque converter inlet relief valve limits torque converter inlet oil pressure to protect torque converter.
0003 00-80
TM 5-3805-290-23-1
427-B1720
0003 00-81
TM 5-3805-290-23-1
g. Torque from engine is transferred through torque converter to input shaft assembly. Since only a speed clutch is
engaged, there is no torque transfer from input shaft assembly to either shaft assembly (4) or shaft assembly (7).
427-B1721
23. First Speed Reverse.
operator inputs.
0003 00-82
TM 5-3805-290-23-1
valve.
c. When transmission direction and shift lever is moved to FIRST SPEED REVERSE, both modulating valve sole-
noid for clutch 6 (first speed) and modulating valve solenoid for clutch 3 (reverse) are energized. When modulat-
ing valve solenoid for clutch 3 is energized, modulating valve directs pump oil to clutch 3 to engage clutch. When
modulating valve solenoid for clutch 6 is energized, modulating valve directs pump oil to clutch 6 to engage
clutch.
427-B1722
0003 00-83
TM 5-3805-290-23-1
g. When transmission is in FIRST SPEED REVERSE, clutch 3 and clutch 6 are engaged. Torque from engine is
transferred through torque converter to input shaft assembly. Gear (1) is splined to input shaft assembly. Input shaft
assembly turns gear (22).
h. Gear (22) turns hub assembly (23). Torque is transferred from input shaft assembly, through gear (1) and gear (22),
to hub assembly (23). When clutch 3 is engaged, torque is transferred from hub assembly (23), through engaged
clutch 3, to shaft assembly (7).
i. Gear (8) is splined to shaft assembly (7). Gear (8) turns gear (9) which is splined to hub assembly (23). Torque is
transferred from shaft assembly (7), through gear (8) and gear (9) to hub assembly (23). When clutch 6 is engaged,
torque is transferred from hub assembly (23), through engaged clutch 6, to shaft assembly (11).
j. Gear (12) is splined to shaft assembly (11). Gear (12) turns gear (13). Gear (13) is splined to output shaft assembly.
0003 00-84
TM 5-3805-290-23-1
427-B1723
0003 00-85
TM 5-3805-290-23-1
24. Second Speed Reverse.
operator inputs.
valve.
c. When transmission direction and shift lever is moved to SECOND SPEED REVERSE, both modulating valve
solenoid for clutch 4 (second speed) and modulating valve solenoid for clutch 3 (reverse) are energized. When
modulating valve solenoid for clutch 3 is energized, modulating valve directs pump oil to clutch 3 to engage
clutch. When modulating valve solenoid for clutch 4 is energized, modulating valve directs pump oil to clutch 4 to
engage clutch.
0003 00-86
TM 5-3805-290-23-1
427-B1724
0003 00-87
TM 5-3805-290-23-1
g. When transmission is in SECOND SPEED REVERSE, clutch 3 and clutch 4 are engaged. Torque from engine is
i. When clutch 4 is engaged, torque is transferred from shaft assembly (7), through engaged clutch 4, to hub assem-
bly (14). Gear (15) is splined to hub assembly (14). Gear (15) turns gear (16). Gear (16) is part of shaft assembly
(11). Torque is transferred from hub assembly (14), through gear (15) and gear (16), to shaft assembly (11).
j. Gear (12) is splined to shaft assembly (11). Gear (12) turns gear (13). Gear (13) is splined to output shaft assembly.
0003 00-88
TM 5-3805-290-23-1
427-B1725
0003 00-89
TM 5-3805-290-23-1
25. Third Speed Reverse.
operator inputs.
valve.
c. When transmission direction and shift lever is moved to THIRD SPEED REVERSE, both modulating valve sole-
noid for clutch 5 (third speed and fourth speed) and modulating valve solenoid for clutch 3 (reverse) are energized.
When modulating valve solenoid on for clutch 3 is energized, modulating valve directs pump oil to clutch 3 to
engage clutch. When modulating valve solenoid on for clutch 5 is energized, modulating valve directs pump oil to
e. Transmission relief valve controls pump oil pressure that is supplied to modulating valves. Transmission relief
valve directs unneeded pump oil to torque converter as torque converter oil. Torque converter outlet oil flows
through torque converter outlet relief valve to oil cooler as lubrication oil. After oil cools, it flows to transmission
for transmission lubrication. After transmission is lubricated and cooled, it drains to sump.
0003 00-90
TM 5-3805-290-23-1
427-B1726
0003 00-91
TM 5-3805-290-23-1
g. When transmission is in THIRD SPEED REVERSE, clutch 3 and clutch 5 are engaged. Torque from engine is
i. Gear (6) is part of shaft assembly (7). Gear (6) turns gear (17). Gear (17) is splined to hub assembly (18). Torque is
transferred from shaft assembly (7), through gear (6) and gear (17), to hub assembly (18).
j. When clutch 5 is engaged, torque is transferred from hub assembly (18), through engaged clutch 5, to shaft assem-
bly (11).
k. Gear (12) is splined to shaft assembly (11). Gear (12) turns gear (13). Gear (13) is splined to output shaft assembly.
0003 00-92
TM 5-3805-290-23-1
427-B1727
0003 00-93
TM 5-3805-290-23-1
DIFFERENTIAL 0003 00
1. General. A differential divides and balances power sent to wheels. During a turn, differential allows inside wheel to
rotate at a slower rate in relation to outside wheel. Differential still sends same amount of torque to each wheel.
2. Straight Forward or Reverse (Rear Axle).
a. Operation. When machine moves in a straight direction with the same amount of traction under each drive wheel,
the same amount of torque on each axle holds pinions so they do not turn on spider. Bevel pinion turns bevel gear.
Bevel gear turns case. Case turns shaft. Shaft turns side gears through pinions. Pinions do not turn on shaft. Side
gears turn final drive sun gears. Same amount of torque is sent through final drives to each wheel.
b. Forward or Reverse Turn.
(1) When machine is in a turn, inside wheel is more resistant than outside wheel to turn. This resistance causes
different torques on opposite sides of differential. Outside wheel turns more easily than inside wheel. Out-
side wheel starts to turn faster than inside wheel.
(2) Bevel pinion turns bevel gear. Bevel gear turns case. Case turns shaft. Shaft turns side gears through pin-
ions. Since more force is needed to turn one side gear more than other side gear, pinions turn around shaft.
As pinions turn, they move around side gears. Differential allows inside wheel to turn at a slower rate than
outside wheel.
(3) Same amount of torque is sent through final drives to both inside and outside wheels. This torque is only
equal to amount of torque necessary to turn outside wheel.
0003 00-94
TM 5-3805-290-23-1
DIFFERENTIAL - CONTINUED
427-B1728
c. Loss of Traction (Wheel Slippage). When one wheel has more traction than other wheel, operation of differential
is identical to differential operation during a turn. Same amount of torque is sent to both wheels. This torque is
only equal to amount of torque necessary to turn wheel with least resistance.
0003 00-95
TM 5-3805-290-23-1
3. Limited Slip Differential (Front Axle).
a. General.
(1) Limited slip differential is a locking differential designed to provide equal power to both wheels until
ground conditions cause a variance in traction between left wheel and right wheel. Limited slip differential
transfers lost power from wheel with least traction to wheel with most traction.
(2) Limited slip differential is a direct replacement for standard differential. Limited slip differential is in both
front axle group and rear axle group.
(3) When wheels have equal traction, limited slip differential sends an equal amount of power to both wheels.
This is similar to standard differential function. One wheel begins to turn faster than other wheel if there is
a loss of traction. When this occurs, internal forces present between shaft and actuator housings will react
on a 45 degree angle. Internal forces push actuator housings against clutch packs. Torque of clutch pack
limits loss of traction to wheel that is turning faster.
(4) Locking effect is due to internal differential friction. This effect is produced by two clutch packs arranged
symmetrically in differential housing. In a standard differential, one wheel can be held in position when
engine is running and a gear is engaged. Other wheel will turn faster. In limited slip differential, above pro-
cedure would be more difficult because of clutch packs, and increase in difficulty as power increases.
(5) Limited slip differential is identical on left and right sides of two pinion shafts. Limited slip differential
contains two thrust washers, two clutch packs, two actuator housings, two bevel gears, and four pinion
gears.
(6) Inside splines of side gears are connected to sun gears for final drives. Outside splines of side gears are
meshed with inner friction discs in clutch packs. Side gears send power through sun gears and to final
drives.
(7) Housing is fastened to bevel gear. Housing has inner grooves which hold outer discs. Outer discs are in
clutch pack. Clutch pack also has inner discs between outer discs. Inner discs are splined to side gears.
Actuator housings also fit in same grooves. Actuator housings and discs are held from moving radially.
Side gears fit into actuator housings. Pinion shafts also fit into actuator housings. Pinion shafts lie in 45-
degree notches in load ring. Pinion gears are installed on pinion shafts.
0003 00-96
TM 5-3805-290-23-1
427-B1729
427-B1730
0003 00-97
TM 5-3805-290-23-1
4. Limited Slip Differential Operation.
a. Normal No-Slip Conditions. Limited slip differential operates identically to a standard differential during straight
forward or straight reverse operation. Limited slip differential provides 50 percent torque to each wheel.
427-B1732
0003 00-98
TM 5-3805-290-23-1
b. Maximum Slipping Conditions.
(1) When one wheel begins to turn faster than other wheel, clutch pack on faster turning wheel is slipping.
This means only 28 percent of input torque is available at that wheel, while 72 percent of input torque is
available to slower turning wheel. For example, inside tire during a turn provides 72 percent of traction.
(2) Advantage of a limited slip differential over a standard differential is shown by difference in torque.
(3) Torque at side with traction cannot exceed torque at slipping side with a standard differential. Torque at
side with traction is 2.6 times amount of torque to slipping side with a limited slip differential.
427-B1733
0003 00-99
TM 5-3805-290-23-1
AXLE 0003 00
1. Front and rear axle groups incorporate pinion and bevel gear set, differential, final drives, and disc brakes. While front
and rear axle housings are slightly different, internal components and operation are identical.
2. Power from transmission output shaft is transferred to front and rear axle groups by drive shafts. Power enters axles
through bevel pinion. Bevel pinion turns bevel gear which is fastened to differential case.
3. Power is transferred through differential by pinions and side gears to final drives. Main components of final drives are
carrier, planetary gears, ring gear, and sun gear. Each final drive has same components. Final drives cause last speed
reduction and last torque increase in drive train.
4. Sun gear is splined into differential side gear. Ring gear is pressed into axle housing. Three planetary gears are mounted
in carrier. Carrier has internal splines which fit into axle shaft splines.
5. As sun gear is driven by differential, planetary gears are forced to revolve around inside of ring gear. Movement of plan-
etary gears around ring gear causes carrier and axle shaft to rotate. This transfers power to rim and to tire which bolts to
flange on axle shaft.
6. Axles contain service brakes. Brake disc is splined to sun gear shaft, which rotates at speed of sun gear. When brakes are
applied, cavity behind brake piston is pressurized and brake piston clamps brake disc between piston and brake reaction
plate.
0003 00-100
TM 5-3805-290-23-1
AXLE -CONTINUED
427-B1734
0003 00-101
TM 5-3805-290-23-1
BRAKE SYSTEM 0003 00

1. General.
a. Braking and hydraulic fan system contains a fixed displacement hydraulic pump. Braking system has priority over
hydraulic fan system.
b. When engine is started, hydraulic oil is drawn from tank by braking and hydraulic fan pump. Flow of hydraulic oil
into hydraulic fan system is blocked by brakes flow control valve until accumulators are fully charged. Hydraulic
oil does flow from braking and hydraulic fan pump, through filter to orifice, and through check valve. Oil then
flows through shuttle valve to accumulators to charge accumulators. Shuttle valve will direct flow to accumulator
with lowest pressure. This allows both accumulators to charge to equal pressures.
c. Brakes flow control valve is controlled by a brake charging solenoid valve which is controlled by machine ECM.
Brake charging solenoid valve controls pressure drop across each orifice. Control of brake charging solenoid valve
is based on pressure detected by brake charging pressure sensor. When pressure in accumulators rises above cutout
pressure, brake charging pressure sensor will detect rise. Machine ECM will send a signal to brake charging sole-
noid valve to shift brake charging solenoid valve more open. When brake charging solenoid valve shifts more
open, pilot oil that acts on brakes flow control valve is vented to tank. Pressure drop across orifice will increase.
This pressure drop will cause brakes flow control valve to shift more open. When brakes flow control valve shifts
more open, oil flow from braking and hydraulic fan pump will be directed to fan motor. Check valve will stop oil
flow to accumulators.
d. Hydraulic oil flow from brake accumulators is blocked at brake control valve. When brake pedal is pressed, brake
control valve routes hydraulic oil from accumulators to rear and front service brakes. This engages service brakes.
Pressure feedback is sensed by each spool in brake control valve. This allows operator to feel application of service
brakes. Due to spring below bottom brake valve, maximum pressure to front brakes is lower than maximum pres-
sure to rear brakes.
e. Brake accumulators discharge partially when brakes are applied. When accumulator charge pressure falls below
cut-in pressure, machine ECM will send a signal to brake charging solenoid valve to close. When brake charging
solenoid valve is closed, pressure drop across orifice will decrease, causing brake flow control valve to close. This
will allow more oil to flow from pump to accumulators. Oil flow will open check valve. When check valve opens,
oil will flow to accumulators.
0003 00-102
TM 5-3805-290-23-1
BRAKE SYSTEM - CONTINUED
427-B1539
0003 00-103
TM 5-3805-290-23-1
2. Fan.
a. When engine is in operation, fan rotates at a speed of 700 to 1,625 rpm. Fan speed is limited by fan flow control
valve, which is controlled by demand fan solenoid valve. Demand fan solenoid valve is controlled by machine
ECM. Fan motor speed depends on amount of flow allowed through fan flow control valve. Control of fan speed is
based on:
(1) Inlet manifold temperature
(2) Transmission oil temperature
(3) Hydraulic oil temperature
(4) Engine coolant temperature
b. When machine ECM requires more air flow for cooling, it decreases amount of electric current sent to demand fan
solenoid valve to close it. When demand fan solenoid valve closes more, pilot oil pressure acting on fan flow con-
trol valve increases and pressure drop across orifice decreases. When pressure drop across orifice decreases, fan
flow control valve closes to restrict oil flow through fan flow control valve. When oil flow through fan flow con-
trol valve is restricted, oil flow from braking and hydraulic fan pump must flow through fan motor. This causes fan
motor to turn faster. Fan speed depends on amount of current sent to demand fan solenoid valve.
c. When machine ECM does not require more air flow for cooling, it increases amount of electric current to demand
fan solenoid valve to shift demand fan solenoid valve more open. When demand fan solenoid valve opens more,
pilot oil acting on fan flow control valve is sent to tank. Pressure drop across orifice increases.
d. When pressure drop across orifice increases, fan flow control valve will shift more open to increase oil flow
through fan flow control valve. When oil flow through fan flow control valve is increased, oil flow from braking
and hydraulic fan pump will flow through fan flow control valve instead of flowing to fan motor. This will cause
fan motor to turn more slowly. Fan speed depends on amount of current sent to demand fan solenoid valve.
e. Makeup valve prevents fan motor cavitation dur-

ing deceleration.
f. Hydraulic oil flows from fan motor to axle oil
cooler motor (if equipped). Hydraulic oil flows
from axle oil cooler motor to hydraulic oil
cooler. Bypass valve will open to allow hydraulic
oil to bypass oil cooler if pressure oil cooler inlet
rises because of a restriction in oil cooler. Bypass
valve will also open if hydraulic oil is cold.
g. From hydraulic oil cooler, hydraulic oil flows to
hydraulic oil filter. Then, hydraulic oil flows to
hydraulic oil tank.
427-B1540
0003 00-104
TM 5-3805-290-23-1

3. Hydraulic Oil Cooler.
a. Hydraulic oil cooler is located directly in front of
hydraulic fan. Hydraulic oil cooler provides
cooling for all hydraulic systems that use oil
from hydraulic oil tank.
b. Hydraulic oil cooler is located next to transmis-
sion oil cooler inside radiator door.
c. Hydraulic oil cooler keeps hydraulic oil at cor-
rect operating temperature.
427-B1543
d. Oil flows from hydraulic fan motor to hydraulic oil cooler. After oil is cooled, oil flows to hydraulic oil filter.
Then, oil is returned to tank.
e. If pressure differential between inlet and outlet of hydraulic oil cooler exceeds 30 psi (207 kPa), oil cooler bypass
valve will divert oil around hydraulic oil cooler.
f. These conditions could cause oil cooler bypass valve to divert oil around hydraulic oil cooler:
(1) Cold hydraulic oil
(2) Restriction in a hydraulic oil line
(3) Restriction in hydraulic oil cooler
427-B1544
0003 00-105
TM 5-3805-290-23-1

4. Gear Pump (Braking and Hydraulic Fan).
a. Hydraulic oil flows into pump from line from tank. Oil flows from pump through check valve to shuttle valve.
Shuttle valve directs oil flow to accumulator with lowest pressure through lines to brake accumulators. Brake sys-
tem pressure sensor sends a signal to machine ECM that is proportional to pressure in brake accumulators. When
accumulator pressure rises above 2,300 ± 50 psi (15,858 to 345 kPa), machine ECM sends a signal to brake charg-
ing solenoid valve to shift brake charging solenoid valve more open.
b. When brake charging solenoid valve opens, pressure drop across orifice increases. When pressure drop across ori-
fice increases, brakes flow control valve opens. When brakes flow control valve opens, oil from pump is also
directed to line to fan motor. Check valve will close to prevent oil flow from brake accumulators to pump.
NOTE
Brake charging solenoid valve is a proportional valve. Amount of flow that flows through the brakes flow
control valve is proportional to the amount of flow through the brake charging solenoid valve. Amount of
flow through the brake charging solenoid valve is proportional to amount of electric current sent from
ECM to the brake charging solenoid valve.
c. After several brake applications, pressure in brake accumulators will decrease below 1,400 to 50 psi (9,653 to 345
kPa). Then, machine ECM will signal brake charging solenoid valve to close. When brake charging solenoid valve
closes, pressure drop across orifice decreases. When pressure drop across orifice decreases, brake flow control
valve closes to direct more oil to accumulators. This will charge brake accumulators to provide proper brake sys-
tem pressure.
427-B1545
0003 00-106
TM 5-3805-290-23-1
427-B1546
0003 00-107
TM 5-3805-290-23-1
5. Gear Motor (Hydraulic Fan).

a. Hydraulic fan motor is a gear type motor located behind radiator. Hydraulic fan motor drives radiator fan. Fan
draws cooling air through radiator and hydraulic oil cooler. Hydraulic oil for hydraulic fan motor is provided by
gear pump.
b. When machine is started, oil flows into hydraulic fan motor through line from pump. Hydraulic oil flows into a
cavity formed by gears. Hydraulic oil pressure forces gears and output shaft to rotate.
c. Fan is attached to output shaft by an adapter. Output shaft rotation causes fan to rotate. As gears rotate, hydraulic
oil passes through outlet port and oil flows out of motor.
d. Hydraulic fan motor is equipped with a demand fan solenoid valve, a flow control valve, and a makeup valve.
Demand fan solenoid valve is controlled by machine ECM, which sends a signal to demand fan solenoid valve to
control fan speed. When machine ECM sends a maximum signal to demand fan solenoid valve, pressure drop
across orifice increases and flow control valve opens. Fan speed is at minimum because flow control valve is
diverting oil flow from pump around motor. When machine ECM sends a minimum signal to demand fan solenoid
valve, pressure drop across orifice decreases and flow control valve closes. Fan speed is at maximum because flow
control valve is no longer diverting oil flow around motor.
e. Machine ECM will send required signal to demand fan solenoid valve to provide proper fan speed for cooling sys-
tem. In order to provide proper fan speed, machine ECM will monitor:
(1) Coolant temperature
(2) Hydraulic oil temperature
(3) Transmission oil temperature
(4) Air inlet temperature
f. Makeup valve prevents hydraulic fan motor cavitation. During a quick deceleration, oil flow to fan motor can stop.
Makeup valve opens to allow oil to flow from outlet side of hydraulic fan motor to inlet side of fan motor.
g. Case drain, drains oil from motor to tank.
427-B1548
0003 00-108
TM 5-3805-290-23-1

6. Brake Accumulator.
a. Brake accumulators are located on right-hand side of machine directly behind cab.
427-B1553
b. There are two brake circuit accumulators, each with a sealed piston. Piston moves upward or downward inside
accumulator bore.
c. Chamber has a charge of dry nitrogen gas. Gas is put into accumulator through nitrogen charging valve.
d. When braking system pressure is higher than accumulator pressure, oil from brake and fan drive pump flows
through port and into chamber. Oil pressure in chamber pushes piston, which compresses dry nitrogen gas. When
accumulators are fully charged, brake charging solenoid valve diverts oil to hydraulic fan and check valve blocks
oil in accumulators.
e. When brake pedal is pushed, brake system pressure is lower than accumulator pressure and oil in accumulators
flows into brake system to engage brakes.
f. Brake pressure alert indicator will illuminate when accumulator pressure falls below 1,000 psi (6,895 kPa). Alert
indicator will remain illuminated until accumulator pressure rises above 1,100 psi (6,895 kPa).
0003 00-109
TM 5-3805-290-23-1

7. Brake Control Valve.
a. Service brake control valve is located under front
side of operator's cab.
b. A mechanical link connects two brake pedals to
each other. When a brake pedal is pressed, a
roller on cross shaft assembly actuates service
brake control valve. Control valve is a dual pres-
sure reducing valve with two independent output
pressures.
427-B1555
0003 00-110
TM 5-3805-290-23-1

c. When brake pedals are not depressed, upper valve spool and lower valve spool are held in place by springs.
d. Oil flows from outlet, to service brake passages, to hydraulic oil tank. This disengages brakes. Oil from accumula-
tors supplied from accumulator passages is blocked by upper and lower valve spools.
427-B1556
0003 00-111
TM 5-3805-290-23-1

e. Modulation of pressurized oil in service brake accumulators is controlled by service brake control valve. Position
of either brake pedal causes a specific pressure at service brakes. As position of pedal changes, pressure at service
brakes also changes.
f. When operator pushes brake pedal, a roller on brake pedal assembly forces piston downward. Piston applies a
force on springs. Force of springs moves retainer and ball. Movement of retainer and ball causes upper valve spool
to move away from seat in spacer.
g. Movement of upper valve spool causes movement of lower valve spool and compression of spring. When valve
upper and lower valve spools move, oil flow from outlet, to service brake passages, to hydraulic oil tank is
blocked.
h. This allows pressurized oil supply from accumulator ports to flow through upper and lower valve spool passages
and outlets to service brakes. Oil then flows through outlet to service brake passages to apply service brakes, while
at same time, pressurized oil flows into cavities through outlets to service brakes. Oil pressure at service brakes has
same pressure as oil in cavities.
i. Oil pressure in cavity and force of spring act to balance lower valve spool against force of pressure in cavity. In
same manner, pressure in cavity creates a force against bottom of upper valve spool. Upper valve spool is balanced
by force of springs at top of upper valve spool.
j. Force of springs is balanced by force applied to pedal. Upward movement of valve upper and lower valve spools
causes supply from accumulator ports to be restricted. Level of pressure in independent valve sections creates a
force of feedback. This allows operator to modulate pressure to service brakes.
k. Valve upper and lower valve spools balance between supply from accumulator ports and ports for service brakes to
maintain brake pressure until position of pedal changes. Change in pedal position means that more or less brake
pressure is necessary.
l. If piston moves downward to apply more compression on springs, valve upper and lower valve spools move to
allow more pressure oil to flow to service brakes outlets. This results in a higher oil pressure in cavities and service
brake outlets.
0003 00-112
TM 5-3805-290-23-1
427-B1557
0003 00-113
TM 5-3805-290-23-1

8. Service Brakes.
a. All four service brakes are located in axle assemblies. Service brakes are actuated by left or right brake pedal.
There are service brakes in front and rear axles.
b. Each service brake consists of piston, disc, plate, pins, and springs.
c. Plate and piston are held stationary by three pins fastened in differential housing and axle housing. Piston and plate
are able to slide on three pins. Springs keep piston retracted when not being used.
d. Inside diameter of disc has splines that fit on splines of sun gear. This causes disc to rotate at speed of sun gear.
e. Grooves are cut into faces of disc to allow passage of cooling oil even when service brakes are applied. As disc
rotates, cooling oil will constantly flow between disc and plate and between piston and disc.
f. Carrier is fastened to axle by splines. Axle turns with carrier. Gears in carrier rotate between sun gear and station-
ary ring gear.
g. When a brake pedal is pushed, pressurized oil from service brake control valve flows through oil passage in differ-
ential housing. Force of oil behind piston moves piston against force of springs.
h. Force of oil also pushes disc against plate. This causes friction between disc and piston and between disc and plate.
Friction causes sun gear, axle, carrier, and wheels to turn more slowly. If operator does not release brake pedal,
friction will eventually stop wheels.
i. Heat created from service brake friction is removed by oil in axle housings.
j. When brake pedal is released, oil behind piston flows through oil passage to service brake control valve. Oil then
returns to hydraulic oil tank. With no oil pressure behind piston, springs move piston to retracted position and ser-
vice brakes are released.
k. If machine loses power or hydraulic pump fails, service brakes can still be applied. Pressure in brake accumulators
allows several applications of brake pedals so machine can be slowed enough to engage parking brake.
0003 00-114
TM 5-3805-290-23-1
427-B1559
0003 00-115
TM 5-3805-290-23-1
9. Pressure Sensor.
a. Service brakes can be actuated by left or right brake pedal. This is also true for transmission neutralizer. When
brakes are applied, pressure sensor located on brake control valve senses an increase in brake system pressure. A
signal is sent by sensor to machine ECM. Machine ECM will neutralize transmission. This allows full engine
power to be used in hydraulic system.
b. When brake pedal is released, pressure in brake lines decreases. Pressure sensor sends a signal to machine ECM to
engage transmission.
c. Transmission neutralizer override switch is a momentary switch. Transmission neutralizer is active when it is not
illuminated.
d. When transmission neutralizer is deactivated, transmission will not shift to NEUTRAL when service brakes are
applied. Transmission neutralizer override switch will not be illuminated. This will result in increased wear on
brake discs.
e. When transmission neutralizer is activated, transmission will shift to NEUTRAL when service brakes are applied.
Transmission neutralizer override switch will be illuminated. This will prevent transmission from driving through
brakes. This will lengthen brake life.
10. Transmission Neutralization Point.
a. Transmission neutralization point can be adjusted to operator preferences. Transmission neutralization point deter-
mines distance service brake pedal travels to neutralize transmission. Amount of pressure in service brake system
is determined by travel of service brake pedal. When service brake is applied, brake system pressure rises. When
pressure for brake system reaches transmission neutralization point, transmission disengages. This will reduce
pressure required to push pedal. When service brakes are disengaged, brake system pressure decreases. When
brake system pressure becomes less than 44 psi (303 kPa) from previous maximum pressure, transmission
engages.
b. Service brake system pressure will rise higher when pedal is pushed quickly and vigorously. If service brake pres-
sure for is increased, pressure required to engage transmission is also increased.
c. For example: Pressure on a service brake pedal rises to 220 psi (1,517 kPa). Transmission neutralization point is
set at 130 psi (896 kPa). When service brake pressure reaches 130 psi (896 kPa), transmission will neutralize. Ser-
vice brake pressure is held at 220 psi (1,500 kPa). When service brakes are released and service brake pressure
decreases to 175 psi (1,207 kPa), transmission will re-engage. If transmission neutralization point is set at 87 psi
(600 kPa) and service brake pressure reaches 220 psi (1,517 kPa), transmission will neutralize at 87 psi (600 kPa)
and transmission will still engage at 175 psi (1,207 kPa).
d. A higher transmission neutralization point could be used when machine is on a slope. This will allow position of
machine to be held in place. A lower transmission neutralization point could be used to disengage transmission
during brake application to lengthen brake life.
e. Transmission neutralization point is a programmable parameter in ET. Minimum setting for “Minimum Neutraliza-
tion Brake Pressure Setting” is 58 psi (400 kPa). Nominal setting for “Maximum Neutralization Brake Pressure
Setting” is 130 psi (896 kPa). Adjustable range for setting “Maximum Neutralization Brake Pressure Setting” is 87
to 160 psi (600 to 1,108 kPa).
f. Display screen shows setting for “Minimum Neutralization Brake Pressure Setting” and “Maximum Neutralization
Brake Pressure Setting”.
0003 00-116
TM 5-3805-290-23-1
427-B1563
0003 00-117
TM 5-3805-290-23-1

11. Parking Brake.
a. Parking brake is located in drive line on forward end of transmission. Braking force is applied with lever and cable
assembly. Arrangement is manually actuated pulling upward on lever.
b. As drive shaft rotates, drum rotates. Brake group and lever assembly are fastened to cage. Cage remains stationary.
c. When parking brake is engaged, lever assembly moves upward, and brake group is actuated. Brake group consists
of three retraction springs and two brake shoes. These components are mounted on plate assembly.
d. When lever is pulled up, cable pulls lever assembly. When lever assembly is pulled, lever pulls apart plate sections.
This causes brake shoes to press against drum. Drive shaft is prevented from rotating.
e. When button on lever is pressed and lever is released, springs cause plate sections to close.
427-B1564
0003 00-118
TM 5-3805-290-23-1
427-B1565
427-B1566
0003 00-119
TM 5-3805-290-23-1
STEERING SYSTEM 0003 00

1. General.
a. Hydraulic steering system changes machine’s angle of articulation. Main steering system components are piston
pump, metering pump, and steering cylinders. A secondary steering system is an option for this machine. If
machine is equipped with secondary steering system, secondary steering pump, electric motor for secondary steer-
ing pump, and relief valve for secondary steering system are part of steering system.
b. Piston pump is a pressure-compensated, variable displacement axial piston pump which provides flow to steering
cylinders. Metering pump sends a signal to piston pump indicating amount of flow needed.
c. Piston pump is located on left side of machine under operator’s platform. Piston pump and vane pump (implement)
are mounted to transmission. Piston pump is driven by vane pump. Piston pump and vane pump have separate
hydraulic lines. Access to piston pump is gained by removing side panels on machine. Piston and vane pumps are
mounted to top of transmission housing. Transmission pump drives piston and vane pumps. Manifold is mounted
on top of transmission. Access is gained by articulating machine, or removing side panels.
d. Metering pump controls oil flow from piston pump to steering cylinders. Metering pump is located under opera-
tor’s platform above articulation pin. Access to metering pump is underneath operator platform.
e. Metering pump contains a control valve section and a metering section. Metering pump contains several valves.
Control valve section of metering pump connects to steering wheel through a mechanical linkage.
f. Steering cylinders change fluid energy from piston pump into mechanical energy. Mechanical energy changes
machine’s angle of articulation. Steering cylinders are located on each side of machine near articulation hitch.
Access to steering cylinders is gained from sides of machine.
g. Secondary steering pump is a gear pump. Secondary steering pump and electric motor for secondary steering pump
are located under engine in front of fuel tank. Access to secondary steering pump is underneath machine. Second-
ary steering pump and motor and secondary steering relief valve are beneath hydraulic tank. Secondary steering
pressure switch will detect a decrease in steering system pressure. Pressure switch will then send a signal to ECM
to activate secondary steering system.
h. Hydraulic tank and hydraulic tank breather are located at rear of machine. Hydraulic oil is added to tank by remov-
ing filler cap.
0003 00-120
TM 5-3805-290-23-1
STEERING SYSTEM - CONTINUED
427-B1567
0003 00-121
TM 5-3805-290-23-1

2. Secondary Steering. Steering wheel is connected to metering pump by steering column. If piston pump fails, steering
oil pressure is lost and a switch in pressure line closes. When switch closes, a signal is sent to dash panel to illuminate
alert indicator for primary steering system. Light will notify operator of pump failure. When secondary steering pump is
energized, a signal will be sent to dash panel to illuminate indicator for secondary steering system. Light will notify
operator that secondary steering system is active. Secondary steering pump will provide oil to steer machine.
3. Piston Pump (Steering and Pilot).
a. Piston pump supplies oil to pilot system, steering system and work tools.
b. Piston pump for work tools and piston pump for pilot system and steering system have: variable displacement, load
sensing, compensation for pressure, and compensation for flow. Piston type pumps have variable flow and pressure
dependent on system demands sensed by pressure and flow compensator valves. Pressure and flow compensator
valve for work tools piston pump is not shown.
c. When engine is OFF, there is no load sensing signal to pressure and flow compensator valve. Margin spring pushes
flow compensator spool completely right. Any pressure behind actuator piston is vented to case drain across flow
compensator spool.
d. When there is no pressure behind actuator piston, bias spring is able to hold swashplate at maximum angle.
e. When engine is started, drive shaft starts to rotate. Oil flows into piston bore from pump inlet. Oil is forced out of
pump outlet and into system as cylinder barrel assembly rotates.
0003 00-122
TM 5-3805-290-23-1
427-B1584
0003 00-123
TM 5-3805-290-23-1

4. Low Pressure Standby.
NOTE
Amount of system leakage and adjustments to the flow compensator spool can cause margin pressure to
equal low pressure standby. Margin pressure can never be higher than low pressure standby.
a. When work tools piston pump produces flow, system pressure begins to increase because oil flow is blocked at
bank valves. When pilot and steering system piston pump produces flow, system pressure begins to increase
because oil flow is blocked at steering metering pump. Pilot system does not contain a load signal circuit.
b. Blocked oil creates pressure which is felt at end of flow compensator spool, moving it left against margin spring.
This permits system oil to flow to actuator piston.
c. When pressure on actuator piston increases, force of bias spring is overcome and swashplate is moved to a slight
angle.
d. Piston pump produces enough flow to compensate for normal system leakage when swashplate is at a slight angle.
Also, piston pump has sufficient pressure to provide instantaneous response when a work tool or steering metering
pump is activated.
e. If there is no flow demand from a hydraulic circuit for work tool or steering metering pump, no load sensing signal
is generated.
f. Pressure at pump outlet must only overcome force of margin spring. Pressure at pump outlet is called “low pres-
sure standby”. For work tools piston pump low pressure standby is approximately 285 ± 35 psi (1,965 ± 241 kPa).
For pilot and steering system piston pump, low pressure standby is approximately 590 ± 30 psi (4,068 ± 207 kPa).
g. Low pressure standby is higher than margin pressure due to a higher back pressure created by oil blocked at closed
center valves when valves are in HOLD position.
h. When piston pump is at low pressure standby, supply oil from pump outlet pushes flow compensator spool left.
This further compresses margin spring. An increased amount of supply oil from pump outlet flows to actuator pis-
ton. This slightly destrokes piston pump.
0003 00-124
TM 5-3805-290-23-1
427-B1585
0003 00-125
TM 5-3805-290-23-1

5. Upstroking.
NOTE
Load sensing signal pressure does not need to increase in order to upstroke piston pump.
a. When a hydraulic circuit for work tool or steering system requires flow, pressure from pump outlet is reduced.
Reduced pump output pressure causes force from pump outlet pressure to decrease relative to force from load
sensing signal and margin spring. This force is on left side of flow compensator spool. Force is greater than pump
supply pressure at right of spool.
b. Spool moves right which blocks oil flow to actuator piston. Oil in chamber for actuator piston is vented to case
drain across flow compensator spool. This allows bias spring to move swashplate to a greater angle.
c. Pump now produces more flow. This condition is known as “upstroking”.
d. These conditions can result in upstroking pump:
(1) If a hydraulic circuit for work tool or steering system is initially activated from low pressure standby, load
sensing signal increases pump output flow. This increased pump output flow is routed to position of a con-
trol valve main control spool that demands oil.
(2) Piston pump upstrokes when demand increases from changing position of control valve main control
spool, or when hand metering unit is turned at a faster rate of speed.
(3) If another hydraulic circuit for work tool is engaged, there is a need for increased pump flow.
(4) If flow demand on hydraulic system remains constant, piston pump will upstroke when engine speed
decreases.
0003 00-126
TM 5-3805-290-23-1
427-B1586
0003 00-127
TM 5-3805-290-23-1

6. Constant Flow.
a. When a constant flow of oil is demanded by a hydraulic circuit for work tool or steering circuit, supply oil pressure
from pump outlet will increase on right side of flow compensator spool. Pressure on left side of flow compensator
spool is sum of load sensing signal and margin spring pressures. When flow demand is met, flow compensator
spool will meter force on both ends of spool. Once forces become equal on each end of spool, system will stabilize.
b. Swashplate is held at a relatively constant angle to maintain required flow.
c. Difference between load sensing signal pressure and supply oil pressure is called margin pressure.
d. Margin pressure is value of margin spring.
e. Margin pressure is adjusted by turning adjustment screw on flow compensator spool.
0003 00-128
TM 5-3805-290-23-1
427-B1587
0003 00-129
TM 5-3805-290-23-1

7. Destroking.
NOTE
Load sensing signal pressure does not need to decrease in order to destroke piston pump.
a. When less flow is required, piston pumps destroke. Piston pump destrokes when force at right of flow compensator
spool becomes greater than force at left.
b. Flow compensator spool moves left, which allows more oil flow to actuator piston. Pressure on actuator piston is
now increased.
c. Increased pressure overcomes force of bias spring, which moves swashplate to a reduced angle. When pressure
from pump outlet matches force at left of flow compensator spool, spool returns to a metering position. Piston
pump returns to a constant flow.
d. These conditions result in destroking piston pump:
(1) A control valve main control spool is moved to HOLD position.
(2) Control valve main control spool is moved to a position that requires less flow.
(3) If multiple control valves are being used, piston pump will destroke when there is a reduction in demand
from any one control valve.
(4) Engine speed increases.
e. When piston pump destrokes, supply oil pressure from pump outlet decreases on right side of flow compensator
spool. Pressure on left side of flow compensator spool is sum of load sensing signal and margin spring pressures.
Flow compensator spool will meter force on both ends of spool. Once forces become equal on each end of spool,
system will stabilize.
0003 00-130
TM 5-3805-290-23-1
427-B1588
0003 00-131
TM 5-3805-290-23-1

8. High Pressure Stall.
a. Pressure compensator spool is parallel with flow compensator spool. Pressure compensator spool limits maximum
system pressure at any pump displacement.
b. Pressure compensator spool is forced right by cutoff spring during normal operation.
c. If piston pump is at a high pressure stall or maximum system pressure, pressure of load sensing signal is equal to
pressure of oil supply from pump outlet.
d. Combined pressure of load sensing signal and margin spring forces flow compensator spool right. When flow
compensator spool moves right, a passage will normally be opened. This allows oil holding actuator piston to be
vented to case drain. This causes piston pump to upstroke.
e. If supply oil pressure from pump outlet is high enough, pressure compensator spool is forced left against cutoff
spring.
f. Movement of pressure compensator spool blocks oil from actuator piston from flowing to case drain. This allows
supply oil to flow to actuator piston.
g. Increase in pressure on actuator piston overcomes force of bias spring. Swashplate moves and piston pump
destrokes.
h. Piston pump is now at minimum flow and supply oil at pump outlet pressure is at maximum pressure. These condi-
tions are maintained for a single work tool in a stall condition.
i. Maximum system pressure is adjusted by turning adjustment screw for pressure compensator spool.
j. If multiple work tool hydraulic circuits are activated, work tool piston pump circuits still produce flow while one
circuit is at a high pressure stall. This flow meets other circuits needs that are operating at a lower work port pres-
sure. Piston pump could be producing maximum flow while pressure of supply oil from pump outlet is at maxi-
mum.
0003 00-132
TM 5-3805-290-23-1
427-B1589
0003 00-133
TM 5-3805-290-23-1
HYDRAULIC SYSTEM 0003 00

1. General.
a. Schematic for 924G Wheel Loader implement system is located in (WP 0210 00).
b. 924G Wheel Loader hydraulic system is made up of three systems: implement hydraulic system, brake and fan
drive system, and steering system. All three systems share a common hydraulic tank. Hydraulic tank is vented.
System only consumes horsepower from engine as required.
c. Implement Hydraulic System.
(1) Implement hydraulic system is composed of coupler cylinder, ride control accumulator, ride control sole-
noid valve, combination valve, tilt cylinder, lift cylinders, main control valve, pilot valve, screen, solenoid
valve (hydraulic lockout), oil pilot accumulator, pressure reducing valve, hydraulic tank, piston pump,
coupler control valve, manifold, check valve (return restrictor), ball valve (dead engine, lift arm lower),
coupler, ride control solenoid valve, tilt cylinder, lift cylinders, bypass valve for lowering loader arms,
bank valves, pilot valves, screen, shutoff for pilot valves, pilot valves accumulator, and control levers.
(2) Access piston pump by removing panels under platform. Lift cylinders are mounted under loader arms in
front frame. Bypass valve for lowering loader arms is located inside front frame by left tower. Ride control
solenoid valve is mounted on left side of machine.
(3) Access to pilot accumulator by opening door to engine compartment. Access to bank valves by removing
an access panel. Access pressure reducing valve and combination valve by removing access panels under
platform. Manifold is mounted in center of machine on piston pump.
(4) Implement hydraulic system features pilot-operated control valves. Control valves are closed center
valves. System is load sensing with a variable displacement pump. Control valves are parallel. Implement
hydraulic system is a Proportional, Priority, Pressure-Compensated (PPPC) System.
d. Braking and Hydraulic Fan System. Braking and hydraulic fan system circulates oil to cooler, to cool oil in
hydraulic system. Also, brake and hydraulic fan system provides supply oil to brake system.
e. Steering System. Steering system steers machine by changing angle of articulation of machine. This system also
provides oil to pilot oil system.
2. Oil Filter (Hydraulic).
a. Pressure oil from braking and hydraulic fan pump goes into fan motor, then to cooler. Then, hydraulic oil flows
through inlet line to filter. Oil flows through outlet line to tank.
b. During normal operation, oil goes through filter element and out through outlet line. Hydraulic tank filter element
stops any debris in oil. If filter element becomes full of debris, restriction to flow of oil causes a pressure increase
inside filter. Pressure oil then causes bypass valve, located in filter housing, to move against force of spring. Oil
then goes past open bypass valve and into hydraulic tank. When hydraulic oil is cold, increased pressure from cold
hydraulic oil can also cause bypass valve to open. When hydraulic oil heats up, hydraulic oil pressure drops. Drop
in hydraulic oil pressure closes bypass valve.
0003 00-134
TM 5-3805-290-23-1
HYDRAULIC SYSTEM - CONTINUED

3. Hydraulic Oil Cooler.
a. Hydraulic oil cooler is located directly in front of
hydraulic fan. Hydraulic oil cooler provides
cooling for all hydraulic systems that use oil
from hydraulic oil tank.
b. Hydraulic oil cooler is located next to transmis-
sion oil cooler.
c. Hydraulic oil cooler keeps hydraulic oil at cor-
rect operating temperature.
427-B1543
d. Oil flows from axle oil cooler pump and motor to

hydraulic oil cooler. If machine is not equipped
with an axle oil cooler pump and motor, oil flows
from hydraulic fan motor. After oil is cooled, oil
flows to hydraulic oil filter. Then, oil is returned
to tank.
e. If pressure differential between inlet and outlet
of hydraulic oil cooler exceeds 30 psi (207 kPa),
oil cooler bypass valve will divert oil around
hydraulic oil cooler.
427-B1744
0003 00-135
TM 5-3805-290-23-1

f. These conditions could cause oil cooler bypass valve to divert oil around hydraulic oil cooler:
(1) Cold hydraulic oil
(2) Restriction in a hydraulic oil line
(3) Restriction in hydraulic oil cooler
4. Piston Pumps.
a. Pumps are located on left side of machine under cab.
b. Piston pump supplies oil to pilot system and steering system.
c. Piston pump supplies oil to implements.
5. Piston Pump Pilot and Steering.
a. Pilot system piston pump and steering system piston pump has variable displacement, load sensing, compensation
for pressure, and compensation for flow. This piston type pump has variable flow and pressure dependent on sys-
tem demands sensed by pressure and flow compensator valves.
b. When engine is OFF, there is no load sensing signal to pressure and flow compensator valve. A margin spring
pushes a flow compensator spool completely right. Any pressure behind actuator piston is vented to case drain
across flow compensator spool.
c. When there is no pressure behind actuator piston, bias spring is able to hold swashplate at maximum angle.
d. When engine is started, drive shaft starts to rotate. Oil flows into piston bore from pump inlet. Oil is forced out of
0003 00-136
TM 5-3805-290-23-1
427-B1747
0003 00-137
TM 5-3805-290-23-1

e. Low Pressure Standby.
(1) When pilot system and steering system piston pump produces flow, system pressure begins to increase
because flow of oil is blocked at steering metering pump. Pilot system does not contain a load signal cir-
cuit.
(2) Blocked oil creates pressure which is felt at end of flow compensator spool. Flow compensator spool
moves left against margin spring. This permits system oil to flow to actuator piston.
(3) When pressure on actuator piston increases, force of bias spring is overcome and swashplate is moved to a
slight angle.
(4) Piston pump produces enough flow to compensate for normal system leakage when swashplate is at a
slight angle. Also, piston pump has sufficient pressure to provide instantaneous response when steering
metering pump is activated.
(5) If there is no flow demand from a steering metering pump hydraulic circuit, no load sensing signal is gen-
erated.
(6) Pressure at pump outlet must only overcome force of margin spring. Pressure at pump outlet is called “low
pressure standby”. For pilot system and steering system piston pump, low pressure standby is approxi-
mately 590 ± 30 psi (4,068 ± 207 kPa).
(7) Low pressure standby is higher than margin pressure due to a higher back pressure created by oil which is
blocked at closed center valves when valves are in HOLD position.
NOTE
(8) When piston pump is at low pressure standby, supply oil from pump outlet pushes flow compensator spool
to left. This will further compress margin spring. An increased amount of supply oil from pump outlet will
flow to actuator piston. This will slightly destroke piston pump.
0003 00-138
TM 5-3805-290-23-1
427-B1748
0003 00-139
TM 5-3805-290-23-1

f. Upstroking.
(1) When steering system hydraulic circuit requires flow, pressure from pump outlet is reduced. Reduced
pump output pressure causes force from pump outlet to decrease. Reduced pressure is relative to force
from load sensing signal and margin spring. This force is on left side of flow compensator spool. Force is
greater than pump supply pressure at right of spool.
(2) Spool moves right which blocks flow of oil to actuator piston. Oil in actuator piston chamber is vented to
case drain across flow compensator spool. This allows bias spring to move swashplate to a greater angle.
(3) Pump now produces more flow. This condition is known as “upstroking”.
NOTE
(4) These conditions can result in upstroking pump:
(a) If steering system is initially activated from low pressure standby, load sensing signal increases pump
output flow. This increased pump output flow is routed to steering circuit and pilot circuit compo-
nents.
(b) Piston pump will upstroke when hand metering unit is turned at a faster rate of speed.
(c) If flow demand on hydraulic system remains constant, piston pump will upstroke when engine speed
decreases.
0003 00-140
TM 5-3805-290-23-1
427-B1748
0003 00-141
TM 5-3805-290-23-1

g. Constant Flow.
(1) When a constant flow of oil is demanded by steering circuit, supply oil pressure from pump outlet will
increase on right side of flow compensator spool. Pressure on left side of flow compensator spool is sum of
load sensing signal and margin spring pressures. When flow demand is met, flow compensator spool will
meter force on both ends of spool. Once forces become equal on each end of spool, system will stabilize.
(2) Swashplate is held at a relatively constant angle to maintain required flow.
(3) Difference between load sensing signal pressure and supply oil pressure is called margin pressure. Margin
pressure is value of margin spring.
(4) Margin pressure is adjusted by turning adjustment screw on flow compensator spool.
0003 00-142
TM 5-3805-290-23-1
427-B1750
0003 00-143
TM 5-3805-290-23-1

h. Destroking.
(1) When less flow is required, piston pump destrokes. Piston pump destrokes when force at right of flow
compensator spool becomes greater than force at left.
(2) Flow compensator spool moves left, which allows more oil flow to actuator piston. Pressure on actuator
piston is now increased.
(3) Increased pressure overcomes force of bias spring, which moves swashplate to a reduced angle. When
pressure from pump outlet matches force at left of flow compensator spool, spool returns to a metering
position. Piston pump will return to a constant flow.
(4) These conditions result in destroking piston pump:
(a) Hand metering unit is turned at a slower rate of speed.
(b) Engine speed increases.
NOTE
Load sensing signal pressure does not need to decrease in order to destroke piston pump.
(5) When piston pump destrokes, supply oil pressure from pump outlet decreases on right side of flow com-
pensator spool. Pressure on left side of flow compensator spool is sum of load sensing signal and margin
spring pressures. Flow compensator spool will meter force on both ends of spool. Once forces become
equal on each end of spool, system will stabilize.
0003 00-144
TM 5-3805-290-23-1
427-B1751
0003 00-145
TM 5-3805-290-23-1

i. High Pressure Stall.
(1) Pressure compensator spool is parallel with flow compensator spool. Pressure compensator spool limits
maximum system pressure at any pump displacement.
(2) Pressure compensator spool is forced right by cutoff spring during normal operation.
(3) If piston pump is at a high pressure stall or maximum system pressure, pressure of load sensing signal is
equal to pressure of supply oil from pump outlet.
(4) Combined pressure of load sensing signal and margin spring forces flow compensator spool right. When
flow compensator spool moves right, a passage will normally be opened. This allows oil holding actuator
piston to be vented to case drain. This will cause piston pump to upstroke.
(5) If pressure of supply oil from pump outlet is high enough, pressure compensator spool is forced left
against cutoff spring.
(6) Movement of pressure compensator spool blocks actuator piston oil from flowing to case drain. This
allows supply oil to flow to actuator piston.
(7) Increase in pressure on actuator piston overcomes force of bias spring. Swashplate moves and piston pump
destrokes.
(8) Piston pump is now at minimum flow and supply oil at pump outlet pressure is at maximum pressure.
(9) Maximum system pressure is adjusted by turning adjustment screw for pressure compensator spool.
0003 00-146
TM 5-3805-290-23-1
427-B1752
0003 00-147
TM 5-3805-290-23-1

6. Piston Pump (Implement).
a. Implements piston pump has variable displacement, load sensing, compensation for pressure, and compensation
for flow. This piston type pump has variable flow and pressure dependent on system demands sensed by pressure
and flow compensator valves and signal limiter valve. Implements piston pump pressure and flow compensator
valve is not shown.
b. Pressure and flow compensator valves on each pump are identical. This paragraph is applicable to pressure and
flow compensator valves for both pumps. When engine is OFF, there is no load sensing signal to pressure and flow
compensator valve. Margin spring pushes flow compensator spool completely right. Any pressure behind actuator
piston is vented to case drain across flow compensator spool.
c. When there is no pressure behind actuator piston, bias spring is able to hold swashplate at maximum angle.
d. When engine is started, drive shaft starts to rotate. Oil flows into piston bore from pump inlet. Oil is forced out of
0003 00-148
TM 5-3805-290-23-1
427-B1753
0003 00-149
TM 5-3805-290-23-1

e. Low Pressure Standby.
(1) When implements piston pump produces flow, system pressure begins to increase because oil flow is
blocked at bank valves. Blocked oil creates pressure which is felt at end of flow compensator spool. Flow
compensator spool moves left against margin spring. This permits system oil to flow to actuator piston.
(2) When pressure on actuator piston increases, force of bias spring is overcome and swashplate is moved to a
minimum angle.
(3) Piston pump produces enough flow to compensate for normal system leakage when swashplate is at a min-
imum angle. Also, piston pump has sufficient pressure to provide instantaneous response when an imple-
ment is activated.
(4) If there is no flow demand from a hydraulic circuit for implements, no load sensing signal is generated.
(5) Pressure at pump outlet must only overcome force of margin spring. Pressure at pump outlet is called “low
pressure standby”. For implements piston pump, low pressure standby is approximately 290 ± 30 psi
(1,999 ± 207 kPa).
(6) Low pressure standby is higher than margin pressure due to a higher back pressure created by oil which is
blocked at closed center valves when valves are in HOLD position.
NOTE
(7) When piston pump is at low pressure standby, supply oil from pump outlet pushes flow compensator spool
left. This will further compress margin spring. An increased amount of supply oil from pump outlet will
flow to actuator piston. This will slightly destroke piston pump.
0003 00-150
TM 5-3805-290-23-1
427-B1748
0003 00-151
TM 5-3805-290-23-1

f. Upstroking.
(1) When a hydraulic circuit for implements requires flow, pressure from pump outlet is reduced. Reduced
pump output pressure causes force from pump outlet to decrease relative to force from load sensing signal
and margin spring. This force is on left side of flow compensator spool. Force is greater than pump supply
pressure at right of spool.
(2) Spool moves right which blocks oil flow to actuator piston. Oil that is in actuator piston chamber is vented
to case drain across flow compensator spool. This allows bias spring to move swashplate to a greater
angle.
(3) Pump now produces more flow. This condition is known as “upstroking”.
NOTE
(4) These conditions can result in upstroking pump:
(a) If a hydraulic circuit for an implement is initially activated from low pressure standby, load sensing
signal increases pump output flow. This increased pump output flow is routed to position of control
valve main control spool that demands oil.
(b) Piston pump will upstroke when flow demand increases from changing position of control valve main
control spool.
(c) When another hydraulic circuit for implements is engaged, there is a need for increased pump flow.
(d) If flow demand on hydraulic system remains constant, piston pump will upstroke when engine speed
decreases.
0003 00-152
TM 5-3805-290-23-1
427-B1749
0003 00-153
TM 5-3805-290-23-1

g. Constant Flow.
(1) As pump output flow in passage increases to meet system demand, pump supply pressure increases. When
output supply pressure equals signal oil pressure and pressure of margin spring, flow compensator spool
moves to a metering position and system is stabilized.
(2) Swashplate is held at a relatively constant angle to maintain required flow.
(3) Difference between load sensing signal pressure and supply oil pressure is called margin pressure. Margin
pressure is value of margin spring.
(4) Margin pressure is adjusted by turning adjustment screw on flow compensator spool.
0003 00-154
TM 5-3805-290-23-1
427-B1750
0003 00-155
TM 5-3805-290-23-1

h. Destroking.
(1) When less flow is required, piston pump destrokes. Piston pump destrokes when force at right of flow
compensator spool becomes greater than force at left.
(2) Flow compensator spool moves left, which allows more oil flow to actuator piston. Pressure on actuator
piston is now increased.
(3) Increased pressure overcomes force of bias spring which moves swashplate to a reduced angle. When pres-
sure from pump outlet matches force at left of flow compensator spool, spool returns to a metering posi-
tion. Piston pump returns to a constant flow.
(4) These conditions result in destroking piston pump:
(a) A main control spool for a bank valve is moved to HOLD.
(b) Main control spool for a bank valve is moved to a position that requires less flow.
(c) If multiple bank valves are being used, piston pump will destroke when there is a reduction in demand
from any one control valve.
(d) Engine speed increases.
NOTE
The load sensing signal pressure does not need to decrease in order to destroke piston pump.
(5) When piston pump destrokes, supply oil pressure from pump outlet increases on right side of flow com-
pensator spool. This overcomes pressure on left side of flow compensator spool. Flow compensator spool
moves left. Supply oil flows to cavity behind actuator piston. This destrokes pump. Once flow demand is
met, flow compensator spool meters force on both ends of spool. Once forces become equal on each end of
spool, system will stabilize.
0003 00-156
TM 5-3805-290-23-1
427-B1751
0003 00-157
TM 5-3805-290-23-1

i. High Pressure Stall.
(1) Pressure compensator spool is parallel with flow compensator spool. Pressure compensator spool is forced
right by cutoff spring during normal operation.
(2) If piston pump is at maximum system pressure, maximum system pressure is equal to hydraulic oil pres-
sure from signal limiter valve plus margin pressure. Signal limiter valve in main control valve limits signal
oil pressure to 3,450 ± 50 psi (25,855 ± 345 kPa). Pump cutoff pressure is 3,750 ± 50 psi (23,787 ± 345
kPa). Pump cutoff pressure is controlled by pressure compensator spool. Pump cutoff pressure serves as a
backup to oil pressure from signal limiter valve plus margin pressure.
(3) When a circuit is stalled, signal limiter valve opens to limit maximum system pressure.
(4) Combined pressure of load sensing signal and margin spring forces flow compensator spool right. Com-
bined forces of signal pressure and margin pressure are less than pump output pressure. System needs very
little flow when a circuit is stalled and pressure is high. Margin spool moves to a metering position to
maintain desired minimum flow rate. In metering position, margin spring and signal limiter valve equal
pump output pressure.
(5) Activate a second circuit while one circuit is in a stall condition. Pump will upstroke to meet new flow
demand. Without a signal limiter valve in PPPC system, if a single circuit is stalled, no other circuit will
operate.
0003 00-158
TM 5-3805-290-23-1
427-B1752
0003 00-159
TM 5-3805-290-23-1
7. Pilot Hydraulic System.
a. Oil for pilot circuit comes from steering pump section. Oil flows from pump. Oil flows through a manifold located
on piston pump, then through a pressure reducing valve. Oil then flows through a screen in pilot control valves.
Return oil flows back to manifold, then to tank.
b. Component Locations.
(1) Pilot oil pressure is located on pressure

reducing valve.
(2) Combination valve.
(3) Pressure reducing valve is located on
right side of machine under operator’s
platform. Valve controls pressure in pilot
system.
(4) Steering pressure test port is located on
pressure reducing valve.
c. When a pilot control valve is moved out of
HOLD position, pilot control valve directs flow
of pilot oil to a valve spool in bank valve. This
causes valve spool to shift to allow high pressure
oil from piston pump to flow to work tools.
427-B1754
d. Control Lever.
(1) Standard implement hydraulic system consists of a joystick control for lift and tilt.
(2) Joystick in lift position causes oil to flow into head end of lift cylinders to raise work tool.
(3) Joystick in lower position causes oil to flow into rod end of lift cylinders to lower work tool.
(4) Joystick in dump position causes oil to flow into head end of tilt cylinder to dump bucket for 924G Wheel
Loader machine.
(5) Joystick in tilt back position causes oil to flow into rod end of tilt cylinder to tilt back bucket for 924G
Wheel Loader machine.
(6) Switch for solenoid valve (hydraulic lockout) is used to block oil flow to pilot valves. Press top of switch.
Shutoff for pilot valve is in LOCKED position. Pilot oil to pilot control valves is blocked. This prevents
operation of implement even though operator can still move control levers.
(7) A machine that is equipped with an implement hydraulic system with a third function has one auxiliary
control valve.
(8) Move lever forward for third function hydraulic arrangement. This causes oil to flow into one side of aux-
iliary circuit.
0003 00-160
TM 5-3805-290-23-1

(9) Move lever backward for third function hydraulic arrangement. This causes oil to flow into other side of
auxiliary circuit.
(10) A machine that is equipped with an implement hydraulic system with a fourth function has two auxiliary
control valves.
(11) Move lever forward for fourth function hydraulic arrangement. This causes oil to flow into one side of
auxiliary circuit.
(12) Move lever backward for fourth function hydraulic arrangement. This causes oil to flow into other side of
auxiliary circuit.
e. Pilot Valve.
(1) Pilot valve controls pilot pressure to
main control valve. Main control valve
controls oil flow to implement and work
tool cylinders.
(2) In pilot hydraulic system, oil pressure is
generated in piston pump for steering
and pilot systems. Oil is directed to both
steering system and pilot system. Oil that
is directed to pilot system will flow
through a manifold and a pressure reduc-
ing valve. Next, hydraulic oil flows
through solenoid valve (hydraulic lock-
out) for pilot valve. Hydraulic oil flows
through an inlet filter screen in pilot
valve.
427-B1756
0003 00-161
TM 5-3805-290-23-1
(3) Pilot oil enters implement joystick at pilot pressure inlet. Illustration shows position of pilot pressure inlet,
connector for return line, and connectors of lines which go to end caps of main relief valve.
427-B1757
(4) Joystick controls pilot oil, which controls movement of spools in main control valve. When hand lever is
moved, lever assembly will rotate. Adjustment pin will push down on upper plunger.
427-B1758
0003 00-162
TM 5-3805-290-23-1

(5) Joystick control is equipped with detent
coils. When engine starts, detent coils
are energized by electricity. Four posi-
tions can have detent coils: TILTBACK,
RAISE, FLOAT, and AUXILIARY.
Operator must pull FLOAT and AUXIL-
IARY levers out of detent position by
hand. When joystick control is rotated to
90 percent of lever travel, retainer con-
tacts detent coil. Detent coil holds
retainer. Joystick will be held in position
until kickout switch interrupts flow of
current to detent coil. Detent coil de-
energizes and lever assembly can return
to HOLD position. Plunger initiates a
force against cup to assist spring in pull-
ing retainer from detent coil.
427-B1759
0003 00-163
TM 5-3805-290-23-1
8. Coupler Control. Engagement solenoid is energized in order to engage coupler pins. Disengagement solenoid is ener-
gized in order to disengage coupler pins. Load signal flows to resolver (A). Resolver (A) shifts. Load signal flows to
resolver (B). Resolver shifts (B). Load signal flows to pump. Pump flow increases.
427-B1764
9. Main Control Valve. Refer to schematic (WP 0210 00).

a. Oil flows from piston pump, through line from pump, to main control valve. Control valves in main control valve
control flow of hydraulic oil from pump to cylinders and work tools. Control valves send signal oil back to pres-
sure and flow compensator valve through line to pressure and flow compensator valve.
b. Hydraulic oil flows into main control valve. Line from pump to main control valve carries pressure oil from piston
pump to all control valves. Line from main control valve to tank carries return oil away from control valves to
tank. Control valves in main control valve are load sensing valves. Pressure compensator in each control valve
determines function with highest load. Highest load is applied to all pressure compensators. Also, highest load is
sent to pump. This is signal pressure.
c. Pump uses signal pressure to determine amount of required flow. If pump flow is not sufficient for all of functions,
flow of hydraulic oil to all functions is reduced proportionally.
d. Bank valve contains a signal limiter valve, a signal drain line flow control valve, and throttle pin. Signal limiter
valve limits signal oil pressure that flows to pressure and flow compensator valve on piston pump to 3,450 psi
(23,787 kPa). When control valves return to HOLD position, flow control valve for pilot drain valve allows signal
oil to flow to tank. Throttle pin dampens flow of signal oil to pressure and flow compensator valve to control
upstroking and destroking speed of pump. Signal limiter valve, signal drain valve flow control valve, and throttle
pin operate for all control valves in main control valve.
e. Spools are controlled by pilot oil from pilot valves.
0003 00-164
TM 5-3805-290-23-1
427-B1766
0003 00-165
TM 5-3805-290-23-1

10. Pressure Compensator Valve.
a. In HOLD position, hydraulic oil does not flow to pressure compensator valve. Signal oil pressure from hydraulic
circuit with highest hydraulic oil pressure flows to pressure compensator valve in each control valve. Signal oil
pressure from circuit with highest hydraulic oil pressure holds pressure compensator valve down.
427-B1767
0003 00-166
TM 5-3805-290-23-1
b. When a single hydraulic circuit is activated from the HOLD position and a pump STANDBY position, the spool
shifts due to pilot oil from the pilot lever. Pump supply oil flows over the metering slots on the spool to passage
(18). The hydraulic oil in passage flows to the pressure compensator valve (6).
c. When the hydraulic oil pressure increases, the pressure compensator valve moves up. As the pressure compensator
valve moves up, the cross-drilled passage is opened to passage (4). Some of the hydraulic oil flows around the
pressure compensator valve to spring (3). The hydraulic oil that flows to spring and passage is signal oil. Spring
and the signal oil balance the hydraulic oil pressure in passage (18). This controls the flow of hydraulic oil across
the spool.
d. If this circuit has the highest hydraulic oil pressure in the main control valve, the signal oil in passage (4) flows to
the pressure compensator valve in each control valve. The signal oil also flows to the pressure and flow compensa-
tor valve on the hydraulic pump in order to signal the pump. The hydraulic pump upstrokes and the hydraulic oil
pressure in passage (18) increases. When the hydraulic oil pressure in passage raises above circuit pressure, the
hydraulic oil unseats load check valve (21) and flows to passages (15 and 19).
e. More than one hydraulic circuit can be activated at a time. The highest signal oil pressure is sensed through pas-
sage (4) to the chamber and spring (3) above each pressure compensator valve. The hydraulic circuit with the high-
est hydraulic oil pressure controls the operating pressure differential between passages (18 and 19). The signal oil
pressure and the circuit pressure will match.
f. The same signal oil pressure will act on each pressure compensator valve. The pressure differential across each
activated spool will match. The hydraulic pump will attempt to meet all flow demands. If the pump cannot meet all
flow demands, the flow across each spool will be reduced proportionally.
427-B1768
0003 00-167
TM 5-3805-290-23-1

11. Control Valve (Tilt).
a. Hold Position.
(1) In the HOLD position, the springs (9 and 24) hold spool (25) in the centered position. No pilot oil enters
the control valve through the ports (11 and 22). Any pilot oil in the pilot lines drains through the pilot valve
to the tank. The spool blocks the flow of supply oil in passage (15).
(2) Passage (15) is common to all control valves in the bank valve. The passage has no outlet. Spool (25)
blocks the flow of pump supply oil until the operator moves the pilot valve.
0003 00-168
TM 5-3805-290-23-1
427-B1769
0003 00-169
TM 5-3805-290-23-1

b. DUMP Position.
(1) When the tilt circuit is the only hydraulic circuit in operation, the tilt circuit will have the highest load sig-
nal pressure in the hydraulic system. When the pilot valve is moved to the DUMP position, pilot oil enters
the control valve through port (22). The pilot oil flows into chamber (23) and passage (26). As the pilot oil
moves spool (25) to the right, spring (9) is compressed. The pilot oil also opens the pilot operated check
valve (12). When the spool moves to the right, pump supply oil flows over the metering slots in the spool
and into passage (17).
(2) The hydraulic oil in passage (17) flows to pressure compensator valve (6) and passage (27). In the pressure
compensator valve, the hydraulic oil flows into internal passages. The pressure compensator valve moves
up. As the pressure compensator valve moves up, the cross-drilled passage is opened to passage (4). Some
of the hydraulic oil flows around the pressure compensator valve to spring (3). The hydraulic oil that flows
to spring and passage (4) is signal oil. Spring and the signal oil balance the pressure compensator valve
against the hydraulic oil pressure in passage (17). This controls the flow across spool (25).
(3) The signal oil in passage (4) flows to the pressure compensator valve in each control valve. The signal oil
also flows to the pressure and flow compensator valve on the hydraulic pump. The signal oil helps to con-
trol the output of the hydraulic pump. The hydraulic pump upstrokes and the hydraulic oil pressure in pas-
sage (17) increases. When the hydraulic oil pressure in passage raises above circuit pressure, the hydraulic
oil unseats load check valve (20) and flows to passages (14 and 18).
(4) Hydraulic oil flows from the rod end of the tilt cylinder to port (5). The hydraulic oil flows through the
port to the pilot operated check valve (12). The hydraulic oil flows through the check valve to passage
(13). The spool blocks the hydraulic oil from flowing to the passage (8).
(5) In passage (14), the hydraulic oil flows around the spool into passages (16 and 18). The hydraulic oil com-
bines with the hydraulic oil from passage (27). All of the hydraulic oil flows into passage (19). The
hydraulic oil then flows through port (2) to the head end of the tilt cylinder.
(6) In passage (13), the hydraulic oil flows around spool (25) into passages (16 and 18). Then, the hydraulic
oil combines with the hydraulic oil from passage (27) and flows to passage (19). The hydraulic oil flows
through port (2) to the head end of the tilt cylinder.
(7) When the operator releases the pilot valve, the pilot oil flows toward the pilot valve and to the tank. Pilot
operated check valve (12) closes. Spring (9) moves spool (25) to the HOLD position. Pilot operated check
valve and load check valve (20) block the hydraulic oil in the hydraulic lines.
0003 00-170
TM 5-3805-290-23-1
427-B1769
0003 00-171
TM 5-3805-290-23-1

c. TILT BACK Position.
(1) When the tilt circuit is the only hydraulic circuit in operation, the tilt circuit will have the highest signal oil
pressure in the hydraulic system. When the pilot valve is moved to the TILTBACK position, pilot oil
enters the control valve through port (11). The pilot oil flows into chamber (10). As the pilot oil moves
spool (25) to the left, spring (24) is compressed. When the spool moves to the left, pump supply oil flows
from passage (15) over the metering slots in the spool into passage (17).
(4) In passage (18), the hydraulic oil flows around spool (25) into passage (16). From passage, the hydraulic
oil flows into passage (14). In passage, the hydraulic oil flows around spool (25) to passage (13). The
hydraulic oil then flows to the pilot operated check valve (12).
(5) The hydraulic oil flows through the pilot operated check valve. Then, the hydraulic oil flows through port
(5) to the rod end of the tilt cylinder.
(6) Hydraulic oil from the head end of the tilt cylinders flows to port (2). Then, the hydraulic oil flows to pas-
sage (19) around spool (25) to tank passage (21). Then, the hydraulic oil flows to the tank.
(7) When the operator releases the pilot valve, the pilot oil flows to the right. Pilot operated check valve (12)
closes. Spring (24) moves spool (25) to the HOLD position. Pilot operated check valve and load check
valve (20) block the hydraulic oil in the hydraulic lines.
0003 00-172
TM 5-3805-290-23-1
427-B1770
0003 00-173
TM 5-3805-290-23-1

d. Combination Valve.
(1) Combination valve is located under platform on right side of machine.
(2) Combination valve is a diverter valve and a relief valve. When operator drags work tool backward, func-
tion of relief valve is for head end of tilt cylinder.
(3) Spool in diverter valve is connected to each end of tilt cylinder. Diverter valve senses difference in pres-
sure between head end and rod end of cylinder. If difference in pressure exceeds 435 psi (3,000 kPa),
diverter valve opens and oil from head end of cylinder flows to relief valve. This can happen as operator
performs an operation which drags bucket backward. If pressure on relief valve exceeds 1,784 psi (12,300
kPa), relief valve opens and oil returns to tank.
(4) Combination valve relieves pressure from head end of tilt cylinder in certain dump operations. Lift arms
are level. Fully dump bucket. If lift arms are raised, pressure will increase in head end of tilt cylinder until
tilt cylinder collapses. When hydraulic oil pressure exceeds 435 psi (3,000 kPa), diverter valve opens. Oil
from head end of tilt cylinder flows to relief valve. If pressure on relief valve exceeds 1,784 psi (12,300
kPa), relief valve opens and oil returns to tank.
(5) Diverter valve keeps setting of relief valve low and diverter valve maintains high pressures during dump
operation that are needed for equalization of pressure.
0003 00-174
TM 5-3805-290-23-1
427-B1773
0003 00-175
TM 5-3805-290-23-1

12. Control Valve (Lift).
a. HOLD Position.
(1) In the HOLD position, the springs (9 and 26) hold spool (27) in the centered position. No pilot oil enters
the control valve through the ports (10 and 24). Any pilot oil in the pilot lines drains through the pilot
valve to the tank. The spool blocks the flow of pump supply oil in passage (16).
(2) Passage (16) is common to all control valves in the bank valve. The passage has no outlet. The spool
blocks the flow of pump supply oil until the operator moves the pilot valve.
0003 00-176
TM 5-3805-290-23-1
427-B1774
0003 00-177
TM 5-3805-290-23-1

b. RAISE Position.
(1) When the lift circuit is the only hydraulic circuit in operation, the lift circuit will have the highest signal oil
pressure in the hydraulic system. When the pilot valve is moved to the RAISE position, pilot oil enters the
control valve through port (10). The pilot oil flows into chamber (11). As the pilot oil moves spool (27) to
the left, spring (26) is compressed.
(2) Pump supply oil flows from passage (16) over the metering slots in the spool to passage (17). The hydrau-
lic oil from passage flows to the pressure compensator valve (6) and passage (29). In the pressure compen-
sator valve, the hydraulic oil flows into internal passages. The pressure compensator valve moves up. As
the pressure compensator valve moves up, the cross-drilled passage is opened to passage (4). Some of the
hydraulic oil flows around the pressure compensator valve to spring (3). The hydraulic oil that flows to
spring and passage (4) is signal oil. Spring and the signal oil balance the pressure compensator valve
oil unseats load check valve (20) and flows to passages (14 and 19). In passage, the hydraulic oil flows
around spool (27) to the regeneration check valve (18). The regeneration check valve blocks the flow of
the hydraulic oil.
(4) In passage (14), hydraulic oil flows around the spool (27) into passage (13). The hydraulic oil flows to the
pilot operated check valve (12). The hydraulic oil flows through the pilot operated check valve. Then, the
hydraulic oil flows through port (5) to the head end of the lift cylinders.
(5) Hydraulic oil flows from the rod end of the lift cylinder flows through port (2) into passage (20). The
hydraulic oil flows around spool (27) into passage (22). Then, the hydraulic oil flows to the tank.
(6) When the operator releases the pilot valve, the pilot oil flows to the right. Pilot operated check valve (12)
closes. Spring (26) moves spool (27) to the HOLD position. Pilot operated check valve and load check
0003 00-178
TM 5-3805-290-23-1
427-B1775
0003 00-179
TM 5-3805-290-23-1

c. LOWER Position.
(1) When the lift circuit is the only hydraulic circuit in operation, the tilt circuit will have the highest signal oil
pressure in the hydraulic system. When the pilot valve is moved to the LOWER position, pilot oil enter the
control valve through port (24). The pilot oil flows through the shock reducing check valve (23). The
shock reducing check valve moves to the right.
(2) Pilot oil flows into chamber (25) and passage (28). As the pilot oil moves spool (27) to the right, spring (9)
is compressed. When the spool moves to the right, pump supply oil flows over the metering slots in the
spool and into passage (17). Also, pilot oil opens the pilot operated check valve (12).
(5) In passage (14), spool (27) blocks the flow of oil. The hydraulic oil flows to passage (20) and through port
(2) to the rod end of the lift cylinders.
(6) Hydraulic oil from the head end of the lift cylinders flows through port (5) to the pilot operated check
valve (12). The hydraulic oil flows through the pilot operated check valve to passage (13). The hydraulic
oil flows around spool (27) into passages (8 and 15).
(7) The hydraulic oil in passage (8) flows to all control valves as makeup oil. The hydraulic oil in passage also
flows through passage (30) to back pressure check valve (1).
(8) Back pressure check valve (1) allows hydraulic oil pressure to develop in passages (8 and 15). This
hydraulic oil pressure allows the regeneration check valve to operate. When the oil pressure overcomes the
force of the spring in the back pressure check valve, the back pressure check valve opens. The hydraulic
oil flows through the valve. Then, the hydraulic oil flows to the tank.
(9) The hydraulic oil in passage (15) flows to the regeneration check valve (18). When the pressure in passage
overcomes the force of the spring in the regeneration check valve, the regeneration check valve opens.
Hydraulic oil flows into passage (19).
(10) In passage (19), the hydraulic oil from passage (15) combines with hydraulic oil from passage (29). Then,
the hydraulic oil flows around spool (27) into passage (20). The hydraulic oil flows through port (2) to the
rod end of the lift cylinders.
(11) When the operator releases the pilot valve, the flow of pilot oil to the pilot valve moves the shock reducing
check valve to the left. The hydraulic oil flows through an orifice. This dampens the flow of hydraulic oil
to the pilot valve. The spool slowly closes off the hydraulic oil to the circuit. Pilot operated check valve
(12) closes. Spring (9) moves spool (27) to the HOLD position. Pilot operated check valve and load check
0003 00-180
TM 5-3805-290-23-1
427-B1776
0003 00-181
TM 5-3805-290-23-1

d. FLOAT Position.
(1) When the lift circuit is the only hydraulic circuit in operation, the lift circuit will have the highest signal oil
pressure in the hydraulic system. When the pilot valve is moved to the FLOAT position, pilot oil enters the
control valve through port (24). The pilot oil flows through the shock reducing check valve (23). The
shock reducing check valve moves to the right.
(2) The pilot oil flows into chamber (25) and passage (28). As the pilot oil moves spool (27) to the right,
spring (9) is compressed. The pilot oil also opens the pilot operated check valve (12).
(3) No hydraulic oil flows from passage (16) to the pressure compensator valve (6) and passage (29). No
hydraulic oil flows into the internal passages in the compensator valve and to passage (4). No hydraulic oil
flows around the pressure compensator valve to spring (3).
(4) No signal oil enters passage (4) or flows to the pressure compensator valve in each control valve. No sig-
nal oil flows to the pressure and flow compensator valve on the hydraulic pump. The signal oil controls the
output of the hydraulic pump. The hydraulic pump is at standby pressure. No hydraulic oil flows to load
check valve (21) or to passages (14 and 19).
(5) The hydraulic oil from the rod end of the lift cylinders flows through port (2) to passage (20). Then, the oil
flows through passage (19) to passage (14). The hydraulic oil flows around the spool into passage (13).
(6) In passage (13), hydraulic oil flows from the head end of the lift cylinders to port (5). The hydraulic oil
flows to the pilot operated check valve (12). The hydraulic oil flows through the pilot operated check valve
to passage. The hydraulic oil flows around the spool to passages (8 and 15). The hydraulic oil flows
through passage (30) to the back pressure check valve (1). The back pressure check valve builds up the
hydraulic oil pressure in passages so that regeneration check valve (18) can activate.
(7) In passage (15), the flow of oil is blocked by the regeneration check valve (18). When the hydraulic oil
pressure overcomes the force of the spring in regeneration check valve, the regeneration check valve
opens. The hydraulic oil flows through the regeneration check valve to passage (19). The hydraulic oil
combines with the hydraulic oil in passage (29). Then, the hydraulic oil flows to passage (14). The hydrau-
lic oil flows around the spool into passage (13). The hydraulic oil flows around the spool to passages (8
and 15).
(8) The hydraulic oil in passage (8) flows through passage (30) to back pressure check valve (1). The hydrau-
lic oil in passage flows to other control valves as makeup oil. When the oil pressure overcomes the force of
the spring in the back pressure check valve, the back pressure check valve opens. The hydraulic oil flows
through the valve. Then, the hydraulic oil flows to the tank.
0003 00-182
TM 5-3805-290-23-1
427-B1777
0003 00-183
TM 5-3805-290-23-1

e. Ball Valve (Dead Engine, Lift Arm Lower). Ball valve for lowering loader arms is connected to head end of lift
cylinders. Ball valve for lowering loader arms is located inside front frame by left tower. Ball valve is used when
engine will not start and lift arms are raised. When stem of ball valve is turned, lift arms will lower to ground. Oil
from head end of lift cylinders will flow through ball valve to tank. Refer to Operation and Maintenance Manual,
Equipment Lowering with Engine Stopped for additional information on ball valve operation.
427-B1778
0003 00-184
TM 5-3805-290-23-1

13. Control Valve (Auxiliary).
a. In the HOLD position, springs (9 and 24) hold the spool (25) in the centered position. No pilot oil enters the con-
trol valve through ports (11 and 22). Any pilot oil in the pilot lines drains through the pilot valve to the tank. The
spool blocks the flow of pump supply oil in passage (15).
b. Passage (15) is common to all control valves in the bank valve. The passage has no outlet. The spool blocks the
flow of pump supply oil until the operator moves the pilot valve.
427-B1779
0003 00-185
TM 5-3805-290-23-1

c. When the auxiliary circuit is the only hydraulic circuit in operation, the auxiliary circuit will have the highest
hydraulic oil pressure in the hydraulic system. When the hydraulic oil exits the control valve through the port (2),
pilot oil enters the control valve through port (22). The pilot oil flows through the shock reducing check valve (21).
The shock reducing check valve moves to the right.
d. Pilot oil flows into chamber (23). As the pilot oil moves spool (25) to the right, spring (9) is compressed. When the
spool moves to the right, pump supply oil flows over the metering slots in the spool and into passage (16).
e. The hydraulic oil flows to the pressure compensator valve (6) and passage (26). In the pressure compensator valve,
the hydraulic oil flows into internal passages. The pressure compensator valve moves up. As the pressure compen-
sator valve moves up, the cross-drilled passage is opened to passage (4). Some of the hydraulic oil flows around
the pressure compensator valve to spring (3). The hydraulic oil that flows to spring and passage (4) is signal oil.
Spring and the signal oil balance the pressure compensator valve against the hydraulic oil pressure in passage (16).
This controls the flow across spool (25).
f. The signal oil in passage (4) flows to the pressure compensator valve in each control valve. The signal oil also
flows to the pressure and flow compensator valve on the hydraulic pump. The signal oil helps to control the output
of the hydraulic pump. The hydraulic pump upstrokes and the hydraulic oil pressure in passage (16) increases.
When the hydraulic oil pressure in passage raises above circuit pressure, the hydraulic oil unseats load check valve
(19) and flows to passages (14 and 17).
g. In passage (14), the spool blocks the flow of the hydraulic oil. In passage (17), the hydraulic oil flows to passage
(18) and through port (2) to the work tool.
h. Hydraulic oil flows from the work tool to port (5). The hydraulic oil flows through the port to passage (13). The
hydraulic oil flows around spool (25) and into tank passage (8). The hydraulic oil flows to all control valves as
makeup oil. The hydraulic oil flows through an internal passage to back pressure check valve (1). When the pres-
sure overcomes the spring in the check valve, the check valve opens. The hydraulic oil flows through the check
valve to the tank.
i. When the operator releases the pilot valve, the flow of pilot oil to the pilot valve moves the shock reducing check
valve to the left. The hydraulic oil flows through an orifice. This dampens the flow of hydraulic oil to the pilot
valve. The spool slowly closes off the hydraulic oil to the circuit. Spring (9) moves spool (25) to the HOLD posi-
tion. Load check valve (19) blocks hydraulic oil in the hydraulic lines.
0003 00-186
TM 5-3805-290-23-1
427-B1780
0003 00-187
TM 5-3805-290-23-1

j. When the auxiliary circuit is the only hydraulic circuit in operation, the auxiliary circuit will have the highest sig-
nal oil pressure in the hydraulic system. When the hydraulic oil exits port (5), pilot oil enters the control valve
through port (11). The pilot oil flows through the shock reducing check valve (12). The shock reducing check
valve moves to the left.
k. Pilot oil flows into chamber (10). As the pilot oil moves spool (25) to the left, spring (24) is compressed. When the
spool moves to the left, pump supply oil flows from passage (15) over the metering slots in the spool into passage
(16).
l. The hydraulic oil in passage (16) flows to the pressure compensator valve (6) and passage (26). In the pressure
compensator valve, the hydraulic oil flows into internal passages. The pressure compensator valve moves up. As
the pressure compensator valve moves up, the cross-drilled passage is opened to passage (4). Some of the hydrau-
lic oil flows around the pressure compensator valve to spring (3). The hydraulic oil that flows to spring and pas-
sage (4) is signal oil. Spring and the signal oil balance the pressure compensator valve against the hydraulic oil
pressure in passage (16). This controls the flow across spool (25).
m. The signal oil in passage (4) flows to the pressure compensator valve in each control valve. The signal oil also
flows to the pressure and flow compensator valve on the hydraulic pump. The signal oil controls the output of the
hydraulic pump. The hydraulic pump upstrokes and the hydraulic oil pressure in passage (16) increases. When the
hydraulic oil pressure in passage raises above circuit pressure, the hydraulic oil unseats load check valve (19) and
flows to passages (14 and 17).
n. In passage (17), the spool blocks the flow of the hydraulic oil. In passage (14), the hydraulic oil flows around spool
(25) to passage (13). Then, the hydraulic oil flows through port (5) to the work tool.
o. Hydraulic oil from the work tool flows to port (2). Then, the hydraulic oil flows to passage (18) around spool (25)
to tank passage (20). Then, the hydraulic oil flows to the tank.
p. When the operator releases the pilot valve, the flow of pilot oil to the pilot valve moves the shock reducing check
valve to the right. The hydraulic oil flows through an orifice. This dampens the flow of hydraulic oil to the pilot
valve. The spool slowly closes off the hydraulic oil to the circuit. Spring (24) moves spool (25) to the HOLD posi-
tion. Load check valve (19) blocks hydraulic oil in the hydraulic lines.
q. The flow of hydraulic oil through the control valve is adjustable. Remove cap (A). Loosen nut (B). Turn screw (C)
clockwise in order to decrease the flow of hydraulic oil through the valve. Turn screw counterclockwise in order to
increase the flow of hydraulic oil through the valve. Tighten nut. Install cap.
0003 00-188
TM 5-3805-290-23-1
427-B1781
0003 00-189
TM 5-3805-290-23-1

14. Relief Valve (Line).
NOTE
A typical view of a pilot operated makeup and relief valve.
a. The makeup and relief valves in the main control valves are pilot operated relief valves. Hydraulic oil in passage
(1) flows through passage (9) to spring chamber (3). When the pressure of the hydraulic oil in the spring chamber
overcomes the force of spring (5), the relief valve opens.
b. Valve (6) moves to the right. When the valve moves, hydraulic oil in the spring chamber is released. Hydraulic oil
in passage (1) moves relief valve (7) to the right. This opens port (8).
c. Some of the hydraulic oil from chamber (1) flows through passage (9) to passage (2). The hydraulic oil flows to the
tank. To prevent cavitation, the relief valve also provides makeup oil to the return circuit. Hydraulic oil in the
return circuit acts against the relief valve (7). The relief valve moves to the right. The hydraulic oil flows from pas-
sage (2) to passage (9).
d. The makeup and relief valve for the head end of the tilt cylinder functions only as a makeup valve. The makeup
and relief valve for the head end of the tilt cylinder is located on the main control valve next to the block valve for
the head end of the tilt circuit. The relief valve on the combination valve acts as the relief valve for the head end of
the tilt cylinder.
e. The makeup and relief valve for the rod end of the tilt cylinder is located next to the block valve for the rod end of
the tilt cylinder. To prevent cavitation, the makeup and relief valve provides hydraulic oil to the rod end of the tilt
cylinder. Also, the makeup and relief valve drains the hydraulic oil to the tank when the hydraulic oil pressure in
the hydraulic circuits gets too high.
427-B1782
0003 00-190
TM 5-3805-290-23-1

15. Ride Control System.
a. Ride control system provides means for absorbing forces from lift cylinders while machine is traveling. These
forces cause machine to pitch when machine is moving over rough terrain. Main components of ride control sys-
tem are accumulator, ride control valve, and lift cylinders.
427-B1783
b. Accumulator is mounted to left side of machine. Ride control valve is mounted on left side of machine.
c. Ride control switch is mounted on control panel in operator compartment.
d. When ride control system is activated and machine travels over rough terrain with a loaded implement, forces of
load act against lift cylinders. When load acts against head end of lift cylinders, oil from head end will try to flow
into accumulator.
e. Accumulator has a cylinder charged with nitrogen which acts as a shock absorber as piston resists oil flow.
Makeup oil for rod end can flow through solenoid valve.
0003 00-191
TM 5-3805-290-23-1
AIR CONDITIONING SYSTEM 0003 00
General
1. The orifice tube system uses an orifice tube in place of the expansion valve. The accumulator and the inline dryer with
orifice tube replace the receiver/dryer.
2. The orifice tube assembly is located in one end of the inline dryer. The inline dryer is located in the line that goes from
the condenser coil to the evaporator coil.
3. The desiccant is located in the inline dryer. The accumulator is located in the line that extends from the evaporator coil
to the compressor. The orifice tube assembly is before the inlet of the evaporator coils.
427-B2081
0003 00-192
TM 5-3805-290-23-1
AIR CONDITIONING SYSTEM - CONTINUED
NOTE
• In an orifice tube system that is properly charged, frost may form between the orifice tube and the compres-
sor. The frost may be present if the system is operating properly and if the system is properly charged.
• In an orifice tube system, a combination of abnormal pressure and frost may indicate blockage in the system.
427-B2082
0003 00-193
TM 5-3805-290-23-1
Orifice Tube Assembly
NOTE
The orifice tube systems do not have a sight glass for determining whether the system is low on refrigerant.
1. The orifice tube assembly has a plastic body, two screens, and a small brass tube located in the center of the body. The
O-ring seals are positioned on the body of the orifice tube to seal against leakage. The orifice tube assembly is contained
in the dryer. The orifice tube assembly is used in place of the thermostatic expansion valve.
2. The orifice tube assembly changes the refrigerant from

a high pressure and high temperature refrigerant into a
low pressure and low temperature liquid. The orifice
tube has a restriction. The restriction in the orifice tube
assembly allows the liquid refrigerant to be reduced
from a high pressure to a low pressure. The flow rate
is controlled by pressure differences across the orifice.
The flow rate is also controlled by the temperature of
the liquid refrigerant in the bottom of the condenser.
The flow rate is sensitive to temperature and pressure
differences. The flow rate is more sensitive to temper-
ature differences.
427-B2083
Refrigerant Accumulator
1. The accumulator is located at the outlet of the evapo-

rator coil. The accumulator separates the liquid refrig-
erant from the refrigerant vapor that passes through
the evaporator coil. The accumulator retains the liquid
refrigerant that is separated. Also, the accumulator
releases the vapor to the compressor.
2. The oil drain hole is located in the bottom of the accu-
mulator. The oil drain hole will drain refrigerant oil
that is separated. The oil drain hole will also drain
some of the liquid refrigerant. This liquid refrigerant
will go back to the compressor.
3. The flow of refrigerant out of the accumulator to the
compressor is mostly vapor. The vapor contains a
small amount of liquid refrigerant. This liquid refrig-
erant comes from the oil drain hole.
427-C2084
0003 00-194
TM 5-3805-290-23-1
Refrigerant Compressor
1. The compressor is driven by the engine. A belt con-

nects the engine to the clutch and pulley assembly.
The pulley is located on the clutch. The drive plate is
fastened to the shaft of the compressor. The clutch and
pulley assembly turns on the bearing. The clutch and
pulley assembly are not connected to the shaft. The
electric current from the thermostat controls a mag-
netic field in the coil assembly.
2. The magnetic field pulls the drive plate against the

clutch and pulley assembly. The clutch and the pulley
assembly turns the shaft that operates the compressor.
When the current to the coil assembly is stopped, the
magnetic field is removed. This allows the drive plate
to move away from the clutch and pulley assembly.
The clutch and the pulley assembly will turn freely on
the bearing. The sequence of connecting and discon-
necting the pulley to the compressor shaft is called
compressor cycling. The compressor cycling is con-
trolled by the thermostat. The thermostat is controlled
by the capillary tube, which is installed between the 427-B2085
fins of the evaporator coil.
Refrigerant Condenser
1. When the refrigerant leaves the compressor, the refrig-

erant is a vapor. The temperature of the refrigerant is
high and the pressure of the refrigerant is high when
the refrigerant leaves the compressor. The increase in
pressure of the refrigerant causes an increase in tem-
perature of the refrigerant. The refrigerant vapor
leaves the compressor and the refrigerant enters the
condenser.
2. The refrigerant must be converted into a liquid that

has high temperature and high pressure. The refriger-
ant must be converted into a liquid in order to increase 427-B2086
the efficiency of the air conditioning system. The con-

denser converts the refrigerant vapor into a liquid that
has high temperature and high pressure.
3. When the refrigerant vapor leaves the compressor, the refrigerant vapor enters the condenser. The condenser is in a loca-
tion that is exposed to outside air. In order to convert the refrigerant into a liquid, the refrigerant must lose heat. The
refrigerant must reach the temperature of saturation. At the temperature of saturation, the refrigerant vapor will become
a liquid. The temperature of saturation of the refrigerant depends on the pressure of the refrigerant.
0003 00-195
TM 5-3805-290-23-1

4. As the high temperature and high pressure refrigerant vapor passes through the condenser, the condenser absorbs heat
from the refrigerant vapor. The condenser transfers the heat to the outside air. The temperature of the refrigerant and the
pressure of the refrigerant decrease until the temperature of saturation is reached. When the temperature of the refriger-
ant vapor is equal to the temperature of saturation, the refrigerant becomes a high temperature and high pressure liquid.
When the refrigerant is converted into a liquid, the refrigerant leaves the condenser.
Evaporator Coil
1. The evaporator receives liquid refrigerant from the orifice tube assembly. The liquid refrigerant that is received by the
evaporator has low pressure and low temperature. Since the pressure of the liquid refrigerant is low, the temperature of
saturation of the refrigerant is low. At the temperature of saturation, the refrigerant changes from a liquid into a vapor.
The temperature of saturation of a fluid increases when the pressure of a fluid increases.
2. The evaporator coil is exposed to the air inside of the
cab. The heat from the air inside of the cab is absorbed
by the evaporator. The evaporator transfers the heat to
the refrigerant. The amount of heat required to reach
the temperature of saturation is called the latent heat
of vaporization. When this heat is absorbed by the
refrigerant, the temperature of the refrigerant will
reach the temperature of saturation. The refrigerant
will change from a liquid into a vapor. The vaporized
refrigerant will leave the evaporator. The vaporized
refrigerant will carry away heat from the cab. The
vaporized refrigerant will return to the compressor
when the refrigerant leaves the evaporator. This pro- 427-B2087
cess is repeated continuously.
END OF WORK PACKAGE
0003 00-196
TM 5-3805-290-23-1
CHAPTER 2
TROUBLESHOOTING PROCEDURES
14
TM 5-3805-290-23-1
TROUBLESHOOTING INTRODUCTION 0004 00
TROUBLESHOOTING INTRODUCTION 0004 00

This work package contains information needed to locate fault malfunctions on the 924G Wheel Loader and its compo-
nents and is organized as follows:
1. Troubleshooting Introduction. Troubleshooting Introduction gives a description of troubleshooting work packages,
provides a troubleshooting flow chart, identifies preliminary troubleshooting procedures, addresses operational tests,
and provides a glossary. Use the chart on the following page to start troubleshooting.
2. How to Use On-Board Diagnostics. How to Use On-Board Diagnostics (WP 0005 00) gives an overview of the capa-
bilities and features that are part of the machine’s electronic system.
3. How to Connect To MSD With ET. How to Use MSD with ET (WP 0006 00) gives an overview of how to install the
software and how to connect the hardware for the MSD with ET.
4. Troubleshooting Symptom Index. Troubleshooting Symptom Index is located in WP 0007 00. This directs you to the
appropriate troubleshooting procedure in WP 0008 00 or WP 0009 00.
5. Troubleshooting Without a Diagnostic Code. Troubleshooting without a diagnostic code is located in Tables 1 thru 8
of WP 0008 00.
6. Troubleshooting With a Diagnostic Code. Troubleshooting with a diagnostic code is located in Tables 1 thru 6 of WP
0009 00.
7. Test, Inspections, and Adjustments. Identifies additional tests, inspections, and adjustments required as part of the
troubleshooting procedures (WP 0010 00 thru WP 0018 00).
These procedures provide an organized step-by-step approach that directs inspections and tests toward the source of the
problem and its successful resolution.
Before performing troubleshooting, read and follow all safety instructions found in the Warning Summary at the front of
this manual.
Theory of Operation (WP 0003 00) and Schematics Introduction (WP 0210 00) and the foldout pages that follow pro-
vide useful information to aid in troubleshooting. Theory of Operation (WP 0003 00) presents a systems overview and pro-
vides a description and use of each component. Schematics (WP 0210 00) provides a detailed map of the electrical and
hydraulic components.
0004 00-1
TM 5-3805-290-23-1
TROUBLESHOOTING INTRODUCTION - CONTINUED 0004 00
TROUBLESHOOTING FLOW CHART 0004 00

Use the General Troubleshooting Flow Chart in this work package to start troubleshooting. If fault codes are logged or
active on your machine, but no troubleshooting steps appear in this manual, contact your local Caterpillar dealer.
427-B2050
PRELIMINARY TROUBLESHOOTING PROCEDURES 0004 00
NOTE
Fluid leaks are classified as either Class I, Class II, or Class III.
Class I: Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
Class II: Leakage of fluid great enough to form drops, but not enough to cause drops to drip from item being
checked/inspected.
Class III: Leakage of fluid great enough to form drops that fall from item being checked/inspected.
1. Visually check for ruptured fluid hoses or tubes and for Class II or Class III leaks.
2. Check for mechanical jamming or binding caused by rocks or other foreign matter.
3. Check fluid levels in subject area and service as required (TM 5-3805-290-10).
4. Ensure all applicable Operator Troubleshooting procedures have been performed before proceeding (TM 5-3805-290-
10).
0004 00-2
TM 5-3805-290-23-1
EXPLANATION OF TROUBLESHOOTING TABLE COLUMNS 0004 00

The columns in troubleshooting Tables 1 thru 8 in WP 0008 00 and Tables 1 thru 6 in WP 0009 00 are defined as fol-
lows:
1. MALFUNCTION. Indicates fault that has occurred in system/equipment.
2. INSPECTION OR TEST. Indicates inspection or test to be performed to isolate probable cause for fault symptom.
3. CORRECTIVE ACTION. Indicates procedure to correct the problem.
OPERATIONAL CHECKS (BRAKING AND HYDRAULIC FAN SYSTEM) 0004 00
WARNING
• When servicing this machine, performing maintenance, or disposing of materials such as engine cool-
ant, hydraulic fluid, lubricants, battery acids or batteries, and CARC paint, consult your unit/local
hazardous waste disposal center or safety office for local regulatory guidance. If further information is
needed, please contact The Army Environmental Hotline at 1-800-872-3845.
hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escap-
ing hydraulic fluid under pressure can penetrate the skin, causing injury to personnel.
• At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any
hydraulic lines. Failure to follow this warning may result in injury to personnel.
• Lubricating/hydraulic oils 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.
• To prevent injury to personnel, wear protective eye covering and gloves.
CAUTION
Wipe area clean around all connections to be opened during removal. Cap lines and hoses and plug open-
ings after removing lines. Contamination of system could result in premature failure.
NOTE
• Tag hoses prior to removal to ensure correct installation.
• Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local pol-
icy and ordinances. Ensure all spills are cleaned up.
• Many of these problems can create diagnostic or event codes in ET. These codes can help find root
cause of problem. ET should be used to retrieve logged and active codes.
• When you diagnose a problem in braking and hydraulic fan system, a visual inspection of system is
first step. Before any tests are performed, visually inspect entire braking and hydraulic fan system for
oil leaks and damaged parts.
1. Shut down engine (TM 5-3805-290-10).
2. Lower implement to ground (TM 5-3805-290-10).
3. Engage parking brake (TM 5-3805-290-10).
4. Check oil level in sight gage (TM 5-3805-290-10).
5. Look for air in oil in hydraulic tank immediately after engine is stopped. Use a clear container to obtain a sample of oil
if necessary. Look for air bubbles in oil in container.
6. Check all oil lines and all connections for damage and for leaks.
0004 00-3
TM 5-3805-290-23-1
OPERATIONAL CHECKS (BRAKING AND HYDRAULIC FAN SYSTEM) - CONTINUED 0004 00

7. Inspect braking and hydraulic fan pump for damage and inspect hydraulic fan motor for damage.
8. Start engine (TM 5-3805-290-10).
9. Ensure fan is operating.
10. Release parking brake and activate service brakes while machine is moving in both directions. Listen for any unusual
noises (TM 5-3805-290-10). Ensure brakes stop machine within an acceptable distance.
11. Lower implement and shut down engine (TM 5-3805-290-10).
OPERATIONAL CHECKS (HYDRAULIC SYSTEM) 0004 00
WARNING
CAUTION
NOTE
• Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local pol-
icy and ordinances. Ensure all spills are cleaned up.
• Many of these problems can create diagnostic or event codes in ET. These codes can help find root
cause of problem. ET should be used to retrieve logged and active codes.
• When you diagnose a problem in braking and hydraulic fan system, a visual inspection of system is
first step. Before any tests are performed, visually inspect entire hydraulic system for oil leaks and
damaged parts.
• Operational checks can be used to find leaks in system or a bad valve or pump. Rod movement speed
can be used to check condition of cylinders and pump.
• Three green bars, dead center on the gage reflects 140°F (60°C).
1. Check oil temperature. If hydraulic oil temperature is less than 140°F (60°C), then stall boom down for 60 seconds in
order to raise hydraulic oil temperature.
2. Operate loader bucket (TM 5-3805-290-10).
0004 00-4
TM 5-3805-290-23-1
OPERATIONAL CHECKS (HYDRAULIC SYSTEM) - CONTINUED

3. Lift loader bucket (TM 5-3805-290-10).
4. Lower loader bucket (TM 5-3805-290-10).
5. Dump loader bucket (TM 5-3805-290-10).
6. Tilt back loader bucket (TM 5-3805-290-10).
7. Repeat steps 2 thru 6 several times.
8. Turn steering wheel fully right and left (TM 5-3805-290-10).
9. Repeat step 8 several times.
10. Watch cylinders as they extend and retract. Movement must be smooth and regular.
11. Listen for noise from pump.
12. Listen for sound of line relief valves. Relief valves should open only when cylinders are fully extended or retracted or
bucket is empty.
13. Check lines and hoses for leaks.
14. Loader lift control lever has a detent solenoid in FLOAT position. Ensure that detent functions properly.
15. Loader bucket tilt control lever has a detent in RACK BACK position. RACK BACK operates when bucket is between
full dump and bucket angle in order to dig. Ensure detent functions properly.
Cycle Times for Hydraulics
1. Start engine and run engine at high idle (TM 5-3805-290-10).

2. Increase oil temperature to a minimum of 140°F (60°C) by operating each work tool several times.
NOTE
• Leave engine at high idle except for steering test at low idle. The test for bucket dump should be done
from the RACK BACK position. Rack back test should be done from DUMP position. The test for lift
should be done from GROUND position. The power down test and float lower test should be done from
FULL RAISED position. The steering test should be done from stop to stop.
• During tests, implement may hit ground heavily. Care should be taken in order to protect finished
ground surfaces.
Table 1. Cycle Times in Seconds.

POSITION CYCLE TIME
Rack Back 2.4 to 2.9
Bucket Dump 1.6 to 1.9
Lift 5.0 to 5.5
Power Down 3.0 to 3.5
Float Lower 2.5 to 3.0
Steering (Low Idle) 3.7
Steering (High Idle) 1.6
0004 00-5
TM 5-3805-290-23-1
OPERATIONAL CHECKS (HYDRAULIC SYSTEM) - CONTINUED
Drift Check for Loader Cylinders
NOTE
• Drift rates will change with different conditions of hydraulic components.
a. Drift rates change according to operation.
b. Drift rates change because of hydraulic oil temperature.
c. Drift rates change because of type of bucket.
d. Drift rates change because of load in bucket.
• Values in Table 2 are for an empty bucket. Before you measure drift on implement, cylinders must be
extended and retracted at least five times.
1. Place bucket in LEVEL position (TM 5-3805-290-10).
2. Raise bucket completely (TM 5-3805-290-10).
3. Place lift control lever in HOLD position (TM 5-3805-290-10).
4. Record amount of movement and time on lift cylinder. Compare time to Table 2.
Table 2. Drift For Loader Cylinders.

HYDRAULIC OIL
TEMPERATURE TIME MAXIMUM DRIFT
140°F (60°C) 5 minutes 0.20 in. (5 mm)
5. Steps for Correction.
NOTE
If drift of one or more cylinders is too much in any circuit, perform steps a thru c.
a. Check makeup valves or line relief valves in main control valves (WP 0017 00).
b. Replace main control valve (WP 0189 00).
c. Replace affected cylinder (WP 0128 00 and WP 0129 00).
OPERATIONAL CHECKS (RIDE CONTROL) 0004 00
1. Move directional control lever to NEUTRAL position (TM 5-3805-290-10).
3. Start engine (TM 5-3805-290-10).
4. Deactivate ride control (TM 5-3805-290-10).
5. Lower work tool to ground (TM 5-3805-290-10).
6. Continue to lower work tool (TM 5-3805-290-10).
7. Front machine wheels should rise off ground.
8. Lower front wheels to ground by raising work tool.
9. Activate ride control (TM 5-3805-290-10).
11. Continue to lower work tool (TM 5-3805-290-10).
12. Front machine wheels should not rise off ground.
0004 00-6
TM 5-3805-290-23-1
OPERATIONAL CHECKS (HYDRAULIC LOCKOUT CONTROL) 0004 00

2. Start engine (TM 5-3805-290-10).
3. Place switch for hydraulic lockout control in OFF position (TM 5-3805-290-10).
4. Activate loader controls to verify no implement movement occurs (TM 5-3805-290-10).
OPERATIONAL CHECKS (LOWERING OF LOADER LIFT CYLINDERS WITH A DEAD ENGINE) 0004 00
1. Start engine (TM 5-3805-290-10).
2. Raise lift arms until loader bucket is approximately 24 in. (61 cm) off ground (TM 5-3805-290-10).
3. Shut down engine (TM 5-3805-290-10).
4. Lower implement with engine stopped (TM 5-3805-290-10).
5. Verify procedures work properly.
OPERATIONAL CHECKS (QUICK COUPLER) 0004 00
2. Start engine (TM 5-3805-290-10).
4. Disengage and engage quick coupler to ensure quick coupler cylinders operate (TM 5-3805-290-10).
5. Ensure quick coupler is engaged before raising work tool from ground (TM 5-3805-290-10).
OPERATIONAL CHECKS (STEERING SYSTEM) 0004 00
NOTE
• Operational checks can be used to find leakage in steering system or identify a failed valve or hydraulic
and steering pump.
• Oil in the steering system must be at an operating temperature of 115 to 126°F (46 to 52°C).
1. Place steering frame lock securely in stowed position (TM 5-3805-290-10).
2. Release parking brake and place transmission direction and shift lever in NEUTRAL position (TM 5-3805-290-10).
3. Release service brakes (TM 5-3805-290-10). Turn steering wheel in both directions until steering cylinders extend and
retract completely. Extension and retraction of steering cylinders must be smooth and regular.
4. Listen for noise from hydraulic and steering pump.
5. Inspect steering system for leaks and damaged components.
0004 00-7
TM 5-3805-290-23-1
OPERATIONAL CHECKS (POWERTRAIN) 0004 00
WARNING
NOTE
• Operational checks can be used to find leakage in system and components that are not functioning cor-
rectly. Operational checks can be used to determine whether pumps are functioning properly. When
you perform operational checks, check for these conditions:
a. Abnormal noises in transmission.
b. Abnormal noises in pumps.
c. Abnormal engagement in clutches through all speeds.
• After you have completed operational checks, inspect powertrain for any leaking, damaged, or worn
components.
1. Start engine and allow transmission oil temperature to reach normal operating temperature (TM 5-3805-290-10).
2. Operate machine in FORWARD and REVERSE directions while in AUTOSHIFT mode. Operate machine in all speeds
for both directions. Ensure machine operates in both directions and all speeds (TM 5-3805-290-10).
3. Operate machine in all speeds while machine is in MANUAL mode. Use transmission direction and shift lever to oper-
ate machine in all speeds. Operate machine in both FORWARD and REVERSE directions (TM 5-3805-290-10). Ensure
machine operates in both directions and all speeds.
NOTE
MSD equipped with ET software can be used to view status of transmission neutralizer and programmable
parameters of transmission neutralizer can be changed by using ET.
4. Place transmission neutralizer override switch in ON position. Operate machine in FORWARD direction and apply ser-
vice brakes. Ensure transmission neutralizes when brake system pressure reaches neutralization setpoint (TM 5-3805-
290-10).
5. Stop machine. Shut down engine (TM 5-3805-290-10). Inspect powertrain components for any damaged parts or leak-
age.
0004 00-8
TM 5-3805-290-23-1
OPERATIONAL CHECKS (POWERTRAIN) - CONTINUED 0004 00
NOTE
• There is an oil filter bypass valve on inlet side of transmission oil filter. Oil filter bypass will open in
order to allow oil to bypass oil filter element. This happens whenever pressure difference between inlet
oil and outlet oil through oil filter is too high. Any oil that does not flow through filter element flows
directly into hydraulic control circuit. This dirty oil may cause restrictions in valve orifices, sticking
valves, etc.
• If any of the above particles are found during any visual check, a transmission malfunction exists.
Transmission may need to be replaced.
6. Drain transmission oil and remove and clean suction screen (WP 0083 00) in order to visually inspect. Inspect oil and
suction screen for foreign material. Use a magnet to separate ferrous particles (iron) from nonferrous particles. Inspect
transmission oil filter for foreign material. Look for:
a. Rubber particles indicating seal or hose failure.
b. Shiny steel particles indicating mechanical failure or gear wear of transmission or pump.
c. A heavy accumulation of fibrous material indicating worn clutch discs in transmission.
d. Aluminum particles which may indicate these conditions:
(1) Torque converter wear or failure.
(2) Wear on clutch piston.
e. Iron or steel chips indicating broken components in transmission.
NOTE
Cold oil causes a resistance.
7. Ensure drive shaft and universal joints are free to rotate. If shafts are not free to turn, disconnect shafts (WP 0090 00).
Ensure transmission will turn.
VISUAL INSPECTION OF AIR CONDITIONING SYSTEM 0004 00
1. Check condenser and evaporator.
a. Check for any type of restriction that will obstruct air flow. Check for dirt, insects, plastic bags, etc.
b. Check for restrictions. A clean condenser will lead to longer life for compressor.
2. Clean fresh air filters and clean recirculation filters (TM 5-3805-290-10).
3. Check for a loose belt on compressor (WP 0046 00).
4. Check drain tube on evaporator. Drain plug should not be obstructed (WP 0196 00).
5. Start machine. Set AC on HIGH (TM 5-3805-290-10). Feel accumulator with hand. In a properly charged system, entire
accumulator will be cooled or cold to touch.
0004 00-9
TM 5-3805-290-23-1
VISUAL INSPECTION OF COOLING SYSTEM 0004 00

1. Check coolant level in cooling system (TM 5-3805-290-10).
2. Look for leaks in cooling system.
NOTE
Small amounts of coolant leakage across surface of water pump seals is normal. This leakage is required to
provide lubrication for water pump seals. Hole is provided in water pump housing to allow this coolant/seal
lubricant to drain from pump housing. Intermittent leakage of small amounts of coolant from this hole is
not an indication of defective water pump seals.
3. Inspect radiator for bent fins and other restrictions to air flow through radiator.
4. Inspect fan blades for damage.
5. Inspect radiator filler cap for damage. Seal surface must be clean.
6. Look for dirt blocking radiator fins or coating engine.
7. Look for loose or missing shrouds that would reduce air flow for cooling.
GENERAL INFORMATION 0004 00
NOTE
Flash programming of a new rating interlock replaces old rating interlock.
This code does not need to be programmed when replacement ECM is from same engine rating.
If ECM is from a different engine rating, then these components may need to be changed: pistons, fuel injectors, other
components. Engine information ratings plate must also be changed to reflect new rating.
Some vehicle systems, such as cooling system or transmission, may also require changes when engine is rerated. Please
contact local OEM dealer for further information.
Glossary
1. Active Diagnostic Code. An active diagnostic code describes a condition currently present in order to alert operator or
service technician to an electronic system malfunction. Refer to “Diagnostic Code” in this glossary.
2. Alternating Current (ac). Alternating current is an electric current that reverses direction at a regular, recurring inter-
val.
3. American Wire Gage (AWG). AWG is a measure of electrical wire diameter. AWG is also a measure of electrical wire
current carrying capacity. When AWG number is smaller, diameter of wire is larger. When AWG number is larger, diam-
eter of wire is smaller.
4. Before Top Center (BTC). BTC is 180 degrees of crankshaft rotation before piston reaches top center position in nor-
mal direction of rotation.
5. Breakout Harness. Breakout harness is a test harness designed to connect into vehicle harness or engine harness. This
connection allows a normal circuit operation and simultaneously provides a breakout T in order to measure signals.
6. Boost Pressure Sensor. Difference between turbocharger outlet pressure and atmospheric pressure is commonly
referred to as “boost”.
7. Bypass Circuit. A bypass circuit is a circuit used as a substitute circuit for an existing circuit. A bypass circuit is typi-
cally used as a test circuit.
8. CAT Data Link. CAT Data Link is a serial communication port used for communication with other microprocessor-
based devices.
9. Code. Refer to “Diagnostic Code” or “Event Code” in this glossary.
0004 00-10
TM 5-3805-290-23-1
GENERAL INFORMATION - CONTINUED
Glossary - Continued
10. Cold Mode. Cold mode is a mode for cold starting and cold engine operation that includes retarded timing and raised
low idle. This mode is used for engine protection, reduced smoke emission, and faster warmup time.
11. Component Identifier (CID). CID is a number that identifies specific electronic control system component that has
experienced a diagnostic code.
12. Communication Adaptor Tool. Communication adapter provides a communication link between ECM and ET.
13. CAN Data Link. CAN data link is a serial communications port used for communication with other microprocessor-
based devices. Also referred to as J1939 data link.
14. Coolant Level Sensor. Coolant level sensor detects absence or presence of coolant at probe. Sensor then sends a signal
to ECM.
15. Coolant Temperature Sensor. Coolant temperature sensor detects engine coolant temperature for cold mode operation
and engine monitoring.
16. Desired Engine Speed. Desired engine speed is input to electronic governor within ECM. Electronic governor uses sig-
nal from throttle position sensor, engine speed/timing sensor, and other sensors in order to determine desired engine
speed.
17. Diagnostic Code. A diagnostic code is sometimes referred to as a fault code. These codes indicate electronic system
malfunction.
18. Diagnostic Lamp. A diagnostic lamp is sometimes called “check engine light.” Diagnostic lamp is used to warn opera-
tor of presence of an active diagnostic code.
19. Digital Sensors. Digital sensors produce a pulse width modulated (PWM) signal. Digital sensors are supplied with
+8 VDC from ECM.
20. Digital Sensor Return. Common line (group) from ECM is used as a ground for digital sensors.
21. Digital Sensor Supply. +8 VDC supply from ECM is used to power digital sensor.
22. Direct Current (dc). Direct current is a type of current that flows consistently in only one direction.
23. DT, DT Connector, or Deutsch DT. This is a type of connector used on CAT machines. Connectors are manufactured
by Deutsch.
24. Duty Cycle. Refer to “Pulse Width Modulation” in this glossary.
25. Electronic Control Module (ECM). ECM is an engine control computer. ECM provides power to electronics. ECM
monitors data input from engine sensors. ECM acts as a governor to control engine speed.
26. Electronic Engine Control (EEC). EEC is a complete electronic system. EEC monitors engine operation under all con-
ditions. EEC also controls engine operation under all conditions.
27. Electronic Technician (ET). ET is a service tool that uses a software program to run on an MSD to assist with trouble-
shooting.
28. Engine Monitoring. Engine Monitoring is part of electronic engine control that monitors sensors and warns operator of
detected problems.
29. Engine Oil Pressure Sensor. Engine oil pressure sensor measures engine oil pressure. Sensor sends its signal to ECM.
30. Engine Speed/Timing Sensor. Engine speed/timing sensor provides a variable amplitude and PWM signal to ECM.
ECM interprets this signal as crankshaft position and engine speed.
31. Event Code. An event code may be activated to indicate an abnormal engine operating condition. These codes usually
indicate a mechanical problem instead of an electrical system problem.
32. Failure Mode Identifier (FMI). This identifier indicates type of failure experienced by components. FMI has been
adopted from SAE practice of J1587 diagnostics.
0004 00-11
TM 5-3805-290-23-1
33. Flash Programming. Flash programming is a method of programming or updating an ECM with an electronic service
tool over data link instead of replacing components.
34. Fuel Temperature Sensor. Fuel temperature sensor detects fuel temperature. ECM monitors fuel temperature and
adjusts calculated fuel rate accordingly.
35. Fuel Ratio Control (FRC). FRC is a limit based on control of fuel air ratio. FRC is used to control emission. When
ECM senses a higher boost pressure (more air into cylinder), FRC increases FRC Limit (more fuel into cylinder).
36. Full Load Setting (FLS). FLS is a number that represents fuel system adjustment. This adjustment is made at factory in
order to fine tune fuel system. Correct value for this parameter is stamped on engine information ratings plate. This
parameter must be programmed.
37. Full Torque Setting (FTS). FTS is similar to full load setting. Parameter must be programmed.
38. Harness. Harness is a bundle of wiring (loom) that connects all electronic system components.
39. Hertz (Hz). Hertz measures electrical frequency in cycles per second.
40. Inlet Manifold Temperature Sensor. This sensor detects inlet manifold temperature. ECM monitors inlet manifold
temperature and other data in order to adjust injection timing and other performance functions.
41. Integrated Electronic Controls. Engine is designed with electronic controls as necessary part of system. Engine will
not operate without electronic controls.
42. J1939 CAN Data Link. Data link is an SAE diagnostic communications data link used to communicate between elec-
tronic engine and instrument clusters.
43. Logged Diagnostic Codes. Logged diagnostic codes are codes stored in memory. These codes are meant to be an indi-
cator of possible causes for intermittent problems. Refer to “Diagnostic Code” in this glossary for more information.
44. Open Circuit. An open circuit is a condition caused by an open switch or a broken electrical wire or connection. When
this condition exists, signal or supply voltage can no longer reach its intended destination.
45. Parameter. A parameter is a value or limit that is programmable. This helps determine specific engine characteristics or
behaviors.
46. Password. A password is a group of numeric or alphanumeric characters designed to restrict access to parameters. Elec-
tronic system requires correct passwords in order to change some parameters (Factory Passwords).
47. Personality Module. This module is attached to inside of ECM. Module contains all instructions (software) for ECM
and performance maps for a specific horsepower family. Personality module may be reprogrammed through flash pro-
gramming.
48. Power Cycle. Power cycle happens when power to ECM is cycled: ON, OFF, and ON. Power cycle refers to action of
cycling engine start switch from any position to OFF position, and to START/RUN position.
0004 00-12
TM 5-3805-290-23-1
49. Pulse Width Modulation (PWM). PWM is a signal

that consists of pulses of variable width. These pulses
occur at fixed intervals. Ratio of “TIME ON” versus
total “TIME OFF” can be varied. This ratio is also
referred to as a duty cycle.
427-B1899
50. Rated Fuel Limit. This term indicates maximum allowable fuel position (longest injection pulse). This position will
produce rated power for this engine configuration.
51. Reference Voltage. Reference voltage is a regulated and steady voltage supplied by ECM to a sensor. Reference volt-
age is used by sensor to generate a signal voltage.
52. Sensor. A sensor is a device used to detect a change in pressure, temperature, or mechanical movement. Information
detected is converted into an electrical signal.
53. Short Circuit. A short circuit is a condition where an electrical circuit is inadvertently connected to an undesirable
point. An example of a short circuit is a wire which rubs against a machine frame and this rubbing eventually wears off
wire insulation. Electrical contact with frame is made and a short circuit results.
54. Signal. Signal is a voltage or waveform used to transmit information, typically from a sensor to ECM.
55. Supply Voltage. Supply voltage is a constant voltage supplied to a component to provide electrical power required for
component to operate. Power may be generated by ECM or battery voltage supplied by machine wiring.
56. System Configuration Parameters. System configuration parameters are parameters that affect emissions and/or oper-
ating engine characteristics.
57. Throttle Position. Throttle position is interpretation by ECM of signal from throttle position sensor of throttle switch.
58. Throttle Position Sensor. Throttle position sensor is an electronic sensor connected to an accelerator pedal or hand
lever. This sensor sends a PWM signal to ECM used to calculate desired engine speed.
59. Throttle Switch. Throttle switch sends a signal to ECM used to calculate desired engine speed.
60. Top Center. Top center refers to crankshaft position when engine piston position is at highest point of travel. Engine
must be turned in normal direction of rotation to reach this point.
61. Total Tattletale. Total tattletale is total number of changes to all parameters stored in ECM.
62. Voltage Load Protection Module (VLPM). VLPM monitors electronic system voltage. VLPM will prevent fuel injec-
tion pump from injecting fuel if a high voltage condition occurs.
END OF WORK PACKAGE
0004 00-13/(0004 00-14 Blank)

10
TM 5-3805-290-23-1
HOW TO USE ON-BOARD DIAGNOSTICS 0005 00
THIS WORK PACKAGE COVERS
General, Understanding the Diagnostic Code Breakdown, Displaying Fault Codes on Instrument Panel, Diagnostic
Codes, Failure Mode Identifiers (FMIs)
INITIAL SETUP
Maintenance Level Equipment Conditions

Unit Machine parked on level ground (TM 5-3805-290-
Test Equipment 10)
Test set, electronic systems (MSD) (Item 91, WP Work tool lowered to ground (TM 5-3805-290-10)
0205 00)
Parking brake engaged (TM 5-3805-290-10)
Tools and Special Tools
Adapter, communication (Item 2, WP 0205 00) Wheels chocked
Software kit (Item 81, WP 0205 00) Battery disconnect switch in OFF position (TM 5-
3805-290-10)
Personnel Required
MOS 62B, Construction Equipment Repairer Engine start switch on OFF position (TM 5-3805-
290-10)
References
Drawings Required
WP 0006 00
WP 0007 00 TM 5-3805-290-23P, Figure 173
GENERAL
The 924G Wheel Loader has two ECMs: Engine and Machine/Powertrain. Each ECM generates diagnostic codes to
indicate that an ECM has detected an electrical or electronic problem which may affect system performance. Often, these
codes are generated even before operator notices a difference in performance. Diagnostic codes may also indicate the cause of
a problem.
If fault codes are logged or active on your machine, but no troubleshooting steps appear in this manual, contact your
local Caterpillar dealer.
0005 00-1
TM 5-3805-290-23-1
HOW TO USE ON-BOARD DIAGNOSTICS - CONTINUED 0005 00
UNDERSTANDING THE DIAGNOSTIC CODE BREAKDOWN 0005 00
NOTE
Some procedures may generate new diagnostic codes. Before any procedures are performed, make a list of
all active diagnostic codes in order to determine system problems. Clear logged diagnostic codes caused by
procedure itself once each procedure is complete.
When an ECM detects an engine problem, it generates a diagnostic code. There are two types of diagnostic codes: fault
codes and event codes. Fault codes indicate a problem with electronic control system. Event codes identify the symptoms of
operational problem and indicate how the machine will operate until the problem is solved.
Fault and event codes may be classified as “active” or “logged”. For active codes, the ECM records the code itself and a
brief description. For logged codes, the ECM records the hour of first occurrence, the hour of last occurrence, and the total
number of occurrences, using the ECM’s internal diagnostic clock.
A diagnostic code can be broken into the following four parts:
1. Type of Code. The screen display will show “A” for active, “E” for event, or “Blank” for logged.
2. Module Identifier (MID) or Event Identifier (EID).
a. MID identifies which ECM detected diagnostic code. Each ECM on machine has a unique two- or three-digit
MID. The engine ECM, designation is 036, and the Machine/Powertrain ECM, designation is 081 for 924G. Refer
to Table 1 in WP 0007 00 for a complete list of fault codes for the Engine ECM. Refer to Table 2 of WP 0007 00
for a complete list of fault codes for the Machine/Powertrain ECM.
b. The EID identifies an abnormal operating condition. Refer to Table 3 in WP 0007 00 for a complete list of event
codes.
3. Component Identifier (CID). CID is a number with four digits which indicates component generated code. For exam-
ple, CID number 0017 identifies the fuel shutoff valve. Any component that can generate a diagnostic code is assigned a
CID number.
4. Failure Mode Identifier (FMI). FMI is associated with either an engine or machine MID code and indicates the type of
sensor failure. The FMI is the last two digits of the diagnostic code. Refer to Table 1 in this work package for an expla-
nation of FMI codes. FMI codes are defined by SAE standards.
MODULE IDENTIFIER (MID)

081 = MACHINE ECM
036 = ENGINE ECM COMPONENT IDENTIFIER (CID)
TYPE OF CODE FAILURE MODE

“A” FOR ACTIVE, IDENTIFIER (FMI)
“BLANK” FOR LOGGED,
“E” FOR EVENT
427-B1895
INSTRUMENT PANEL SHOWING ACTIVE DIAGNOSTIC CODE DISPLAY
0005 00-2
TM 5-3805-290-23-1
DISPLAYING FAULT CODES ON INSTRUMENT PANEL 0005 00
1. Place engine start switch in OFF position (TM 5-3805-290-10).
2. Cycle engine start switch three times within 10 seconds to enter service mode. Then, leave engine start switch in ON
position (TM 5-3805-290-10).
3. Record all active diagnostic codes displayed on instrument panel (WP 0007 00).
4. Turn engine start switch to OFF position for five seconds to exit service mode.
5. Connect ET to MSD to view logged diagnostic codes (WP 0006 00).
6. Select Logged Diagnostic Codes from the Diagnostics menu in ET and press the print button.
DIAGNOSTIC CODES 0005 00
NOTE
For a complete list of diagnostic codes and how to find their diagnostic procedures, refer to the Trouble-
shooting Symptom Index (WP 0007 00).
1. Fault Codes.
a. Active Diagnostic Codes. An active diagnostic fault code represents a problem with the electronic control system.
Correct these problems as soon as possible.
(1) Before performing a procedure, always check all fuses and circuit breakers (TM 5-3805-290-10). Repair
the cause of any tripped circuit breaker.
(2) A screen is provided in ET for displaying active diagnostic codes. Active diagnostic codes include a CID,
an FMI, and a text description of the problem.
(a) Purpose. The Active Diagnostic Codes function provides information to warn the machine operator of
a potential problem and indicates to the service technician the nature of the problem. Codes diagnosed
in this screen are active (occurring as you view them).
(b) Accessing. To run the Active Diagnostic Codes function, select Active Diagnostic Codes from the
Diagnostics menu.
(c) Screen Layout. ET displays up to four status flag indicators across the top of the screen. These flags
are used to notify you of currently active conditions, such as low oil pressure, engine overspeed, etc.
When a warning condition exists, it is described in the appropriate flag indicator area. The name of the
active ECM is displayed above the flags. The Active Diagnostic Codes display area has two columns,
Code and Description. The numbers that appear in the code column are used to identify the diagnostic
codes. The Description column describes the problem that is occurring.
The list of codes is grouped according to the ECM from which they were retrieved. The ECM names
appear as subtitles in the list. If there is more that one ECM connected, the subtitles are arranged
alphabetically. When the Include All ECMs check box is checked, active codes from all available
ECMs are retrieved and displayed. When there is a single ECM on the data link, this check box is dis-
abled.
0005 00-3
TM 5-3805-290-23-1
DIAGNOSTIC CODES - CONTINUED 0005 00
NOTE
The “More Info” button is only enabled when diagnostic procedures are available. Buttons in the Active
Diagnostic Codes screen are “More Info” and “Print”.
b. Logged Diagnostic Codes. When an ECM generates a diagnostic code, it logs that code in permanent memory
using an internal diagnostic clock.
(1) The ECM records the hour of first occurrence, the hour of last occurrence, and the total number of occur-
rences using its internal diagnostic clock.
(2) A screen is provided in ET for displaying logged diagnostic codes. Logged diagnostic information
includes a CID, a FMI, and a text description of the problem.
(a) Purpose. The Logged Diagnostic Codes function provides a list of diagnostic codes logged by each
ECM. These codes are similar to active diagnostic codes except they are logged over time.
(b) Accessing. To run the Logged Diagnostic Codes function, select Logged Diagnostic Codes from the
Diagnostics menu.
(c) Screen Layout. The Logged Diagnostic Codes display area has five columns: Code, Description, Occ.,
First, and Last. The code numbers that appear are used to identify specific diagnostic codes. The
Description column informs you of the problem that is occurring. The Occ. (occurrences) column
shows the number of times the problem occurred. The First and Last columns indicate the first and last
ECM hour that the problem occurred.
The list of codes is grouped according to the ECM from which they were retrieved, and they appear
ordered chronologically by the most recent ECM hour of last occurrence. The ECM names appear as
subtitles in the list. On the same line as the ECM subtitle, the number of ECM diagnostic clock hours
is displayed. These hours represent the time that the ECM has been connected and running.
When the Include All ECMs check box is checked, logged codes from all available ECMs are
retrieved and displayed. When there is a single ECM on the data link, this check box is disabled. The
buttons available in the Logged Diagnostic Codes screen are: Clear, More Info, and Print.
(3) This information is a valuable indicator for troubleshooting intermittent problems. Any logged diagnostic
codes will automatically be deleted if no additional occurrences are recorded in 150 hours. Some diagnos-
tic codes may be easily triggered. Some diagnostic codes may log occurrences that did not result in com-
plaints. The most likely cause of any intermittent problem is a faulty connection or damaged wiring. The
next likely cause is a component failure. The least likely cause is an ECM failure. Diagnostic codes that
are logged repeatedly may indicate a problem that needs special investigation.
2. Event Codes.
a. Active Event Codes.
(1) Purpose. The Active Events Code function provides information about events currently occurring. These
codes are similar to active diagnostic codes except the event code represents the symptom on an opera-
tional level. These codes indicate to the manager or technician how the machine or equipment can be oper-
ated.
(2) Accessing. To run the Active Events Code function, select Events from the Diagnostics menu, then select
Active Events Code from the sub-menu. You may have to customize the tool bar to view Active Event
Codes.
(3) Screen Layout. The Active Event Codes display area has two columns: Code and Description. The code
numbers that appear in the Code column are used to identify the events. The Description column describes
the event that is occurring.
0005 00-4
TM 5-3805-290-23-1
DIAGNOSTIC CODES - CONTINUED 0005 00
NOTE
On some ECMs, a warning category indicator may immediately follow the code number and is in parenthe-
ses. It is a number ranging from 1 to 3, where 3 is the most severe, indications the severity of the associated
code number. The warning category provides an indication of the type of behavior and/or actions which
must be taken by the operator, or by the control system for some engine applications, to address the severity
of the associated situation.
The list of codes is grouped according to the ECM from which they were retrieved. They appear in chrono-
logical order by the most recent ECM hour of last occurrence. The ECM names appear as subtitles in the
list. If there is more than one ECM connected, the subtitles are arranged alphabetically.
When the Include All ECMs check box is checked, active codes from all available ECMs are retrieved and
displayed. When there is a single ECM on the data link, this check box is disabled. The only button avail-
able in the Active Event Codes screen is Print.
b. Logged Event Codes.
(1) Purpose. The Logged Event Codes function provides a list of event codes logged by each ECM. These
codes are similar to logged diagnostic codes except they represent the symptom on an operational level.
These codes indicate to the manager or technician how the machine or equipment can be operated.
(2) Accessing. To run the Logged Event Codes function, select Events from the Diagnostics menu, then select
Logged Event Codes from the sub-menu.
(3) Screen Layout. The Logged Event Codes display area groups the codes according to the ECM from which
they were retrieved. They appear in chronological order by the most recent ECM hour of last occurrence.
The ECM names appear as subtitles in the list. If there is more than one ECM connected, the subtitles are
arranged alphabetically. On the same line as the ECM subtitle, the number of ECM diagnostic clock hours
is displayed. These hours represent the time that the ECM has been connected and running.
The Logged Event Codes screen has five columns: Code, Description, Occ., First, and Last. The numbers
that appear in the Code column are used to identify events. The Description column describes of the symp-
tom that is occurring. The Occ. (occurrences) column displays the number of times the symptom occurred.
The First and Last columns indicate the first and last ECM hour when the problem occurred.
NOTE
On some ECMs, a warning category indicator may immediately follow the code number and is in parenthe-
ses. It is a number ranging from 1 to 3, where 3 is the most severe, indicating the severity of the associated
code number. The warning category provides an indication of the type of behavior and/or actions, which
must be taken by the operator, or by the control system for some engine applications, to address the severity
of the associated situation.
When the Include All ECMs check box is checked, logged codes from all available ECMs are retrieved
and displayed. When there is a single ECM on the data link, this check box is disabled. The buttons avail-
able in the Logged Event Codes screen are View Histogram and Print.
c. An event code is generated by detection of an abnormal operating condition. Logged codes may be useful to help
troubleshoot intermittent problems. Logged codes can also be used to review engine and electronic system perfor-
mance. For example, an event code will be generated if oil pressure is too low. In this case, the event code indicates
a symptom of a larger problem. Logged codes may not indicate a repair is needed. The problem may have been
temporary or resolved since logging the code. If the system is powered, it is possible to generate an active diagnos-
tic code whenever a component is disconnected. When a component is reconnected, the code is no longer active.
Logged events keep track of recurring or intermittent events.
0005 00-5
TM 5-3805-290-23-1
FAILURE MODE IDENTIFIERS (FMIS) 0005 00
427-B1894
Table 1. Detailed FMI Explanation.
FMI DESCRIPTION EXPLANATION
00 Data Valid but Above Every electronic control system sets a high limit for expected signal operating ranges.
Normal Operating This high limit includes over-range signals. A sensor that is still operating but sending
Range (may need a signal above the expected limit will cause an FMI 00 to be stored. Some possible
calibration). causes of an FMI 00 diagnostic code are:
• Signal is above normal.
• Signal is shorted to +batt.
• Sensor needs to be calibrated so that a PWM signal at a duty cycle
of 80 percent is a valid signal. If a PWM signal has a duty cycle of
81 percent, the sensor is still working, but the sensor signal is
above expected signal limits.
01 Data Valid but Below Every electronic control system sets a low limit for expected signal operating ranges.
Normal Operating This low limit includes signals under the lower limit. The sensor is still working, but
Range (may need sending a signal below expected limit will cause an FMI 01 to be stored. Some possible
calibration). causes of an FMI 01 diagnostic code are:
• Timing is retarded.
• Signal is below normal range. A PWM sensor is not expected to
generate a PWM signal below a duty cycle of 5 percent with zero
air pressure. If the sensor generates a signal with a duty cycle of 4
percent when the engine is shut down, the sensor is still working
but sending a signal below the expected limit, which will cause an
FMI 01 to be stored.
0005 00-6
TM 5-3805-290-23-1
FAILURE MODE IDENTIFIERS (FMIS) - CONTINUED 0005 00

Table 1. Detailed FMI Explanation - Continued.
02 Data Erratic, A signal from a component is present but the control that reads diagnostic information
Intermittent, or can not read the signal properly. The signal appears to be gone, unstable, or invalid.
Incorrect. Data can be correct or incorrect intermittently. Also, this condition relates to
communication between controls. For example, when the monitoring system is looking
for engine speed from the engine ECM over CAT data link. Some possible causes of
an FMI 02 diagnostic code are:
• There is a faulty connection.
• Signal is intermittent or erratic.
• Software has been changed.
• Signal is noisy.
• Signal is out of range.
03 Voltage Above Normal A component or system voltage is higher than its limit. FMI 03 most often relates to a
or Shorted High. signal circuit. Some possible causes of an FMI 03 diagnostic code are:
• Sensor or switch is faulty.
• Wiring harness is damaged.
• Electronic control has failed.
• A sensor has failed and voltage output is high.
• Any wiring harness has a sensor signal wire shorted to a high volt-
age. A high voltage is any voltage greater than sensor supply volt-
age.
• A wiring harness that has an open circuit in a sensor signal wire
will cause the control to pull up. When this occurs, the input circuit
is pulled up to supply voltage.
A faulty control will also cause an FMI 03, although this is very unlikely.
04 Voltage Below Normal A component or system voltage is lower than its limit. FMI 04 most often relates to a
or Shorted Low. signal circuit. Some possible causes of an FMI 04 diagnostic code are:
• Sensor or switch is faulty.
• Wiring harness is damaged.
• Electronic control has failed.
• A sensor has failed and voltage output is low.
• Any wiring harness has a sensor signal wire shorted to ground.
0005 00-7
TM 5-3805-290-23-1
FAILURE MODE IDENTIFIERS (FMIS) - CONTINUED
05 Current Below Normal Current through a component or system is lower than its limit. FMI 05 is most often
or Open Circuit. related to a driver circuit. Some possible causes of an FMI 05 diagnostic code are:
• There is an open circuit or a poor wiring harness connection.
• There is an open relay.
• There is a switch in OPEN position.
06 Current Above Normal Current through a component or system is higher than its limit. FMI 06 is most often
or Grounded Circuit. related to a driver circuit. This fault is very similar to FMI 04. Some possible causes
of an FMI 06 diagnostic code are:
• There is a short to ground in a wiring harness connection.
• There is a shorted relay.
07 Mechanical System Not Control detects a signal sent to a mechanical system and the response is not correct.
Responding Properly. Some possible causes of an FMI 07 diagnostic code are:
• Component responds improperly.
• Component is stuck in a position.
• Component has failed.
• Engine is shut down.
• Machine is being used improperly.
08 Abnormal Frequency, This code occurs when a signal is not in its expected range. FMI 08 can also relate to
Pulse Width, or Period. a faulty sensor. Some possible causes of an FMI 08 diagnostic code are:
• Wiring harness connections are intermittent or poor.
• Engine misfired.
• Signal is noisy due to nearby interference.
• There are loose mechanical devices.
09 Abnormal Update. This relates to communications on the data link. FMI 09 occurs when a control is not
able to get information from another control. Some possible causes of an FMI 09
diagnostic code are:
• Control module is not communicating on data link correctly.
• Rate of data transmission is abnormal.
• Data link has failed.
• There is a mismatch of software.
10 Abnormal Rate of This relates to a signal that changes too quickly. The rate of change is outside of its
Change. expected range.
11 Failure Mode Not Control identifies more than one FMI as being responsible for a single failure. Some
Identifiable. possible causes of an FMI 11 diagnostic code are:
• There is a mechanical failure.
• There is damage to multiple circuits.
0005 00-8
TM 5-3805-290-23-1
FAILURE MODE IDENTIFIERS (FMIS) - CONTINUED
12 Bad Device or Electronic control sends a signal and expects a response but receives no response or
Component. the response is incorrect. Some possible causes of an FMI 12 diagnostic code are:
• There is a failure of electronic control.
• There is a failure on the data link.
• There are one or more controls with mismatched software.
13 Out of Calibration. An electrical signal is not within limits for a specific mechanical condition. Some
possible causes of an FMI 13 diagnostic code are:
• Calibration is required.
• Data are out of range.
14 This code is not active.
16 Parameter Not Control does not support the requested parameter.
Available.
17 Module Not Control does not respond to a request for data.
Responding.
18 Sensor Supply Failure. The sensor power supply in a control has failed.
19 Condition Not Met. Conditions defined by the software were not met.
END OF WORK PACKAGE
0005 00-9/(0005 00-10 Blank)

12
TM 5-3805-290-23-1
HOW TO USE MSD WITH ET 0006 00
Software Installation and Connecting MSD, Using ET Software with MSD to Monitor Codes, Status Groups
INITIAL SETUP
Maintenance Level Equipment Conditions

Unit Machine parked on level ground (TM 5-3805-290-
Test Equipment 10)
Test set, electronic systems (MSD) (Item 91, WP Work tool lowered to ground (TM 5-3805-290-10)
0205 00)
Adapter, communication (Item 2, WP 0205 00) Wheels chocked
Software kit (Item 81, WP 0205 00) Battery disconnect switch in OFF position (TM 5-
3805-290-10)
Personnel Required
MOS 62B, Construction Equipment Repairer Engine start switch on OFF position (TM 5-3805-
290-10)
References
Drawings Required
WP 0005 00
WP 0013 00 TM 5-3805-290-23P, Figures 173 and 174
0006 00-1
TM 5-3805-290-23-1
HOW TO USE MSD WITH ET - CONTINUED 0006 00
SOFTWARE INSTALLATION AND CONNECTING MSD
NOTE
• For first-time users, review MSD operator’s training which is already installed on MSD.
• If this is the first use of ET, perform steps 1 thru 3 as necessary.
1. Install communication adapter driver software (1) on MSD (2).
2. Install ET software (3) (Caterpillar ET Military Version) on MSD (2).
NOTE
The tutorial is general in nature and may not reflect the configuration of your machine.
3. Review tutorial on ET CD.

4. Connect cable (4) to “PC CABLE” end of communication adapter (5) and to RS232 serial com port 1 (6) of MSD (2).
NOTE
Remove diagnostic connector cap and set aside.
5. Connect cable (7) to “DATA LINK” end of communication adapter (8) and diagnostic connector (9) on front of pilot
operator control console.
427-B2088
0006 00-2
TM 5-3805-290-23-1
SOFTWARE INSTALLATION AND CONNECTING MSD - CONTINUED
427-B1662
6. Turn battery disconnect switch and engine start switch to ON position (TM 5-3805-290-10) to establish communication
with ECMs.
0006 00-3
TM 5-3805-290-23-1
SOFTWARE INSTALLATION AND CONNECTING MSD - CONTINUED
NOTE
• If ET and communication adapter do not communicate with ECM, refer to CAT Data Link Circuit Test
(WP 0013 00).
• ET will list ECMs.
7. Select ET from Windows Desktop.
8. Click OK if the “What’s new...” Dialog box pops up.
NOTE
Software will display fault codes for all ECMs.
9. Select desired ECM.
10. To display active codes, active events, or status flags, click the buttons on bottom of screen. For a complete list of diag-
nostic codes and their meanings, refer to WP 0007 00.
11. If fault codes are logged or active on your machine, but no troubleshooting steps appear in this manual, contact your
local Caterpillar dealer.
0006 00-4
TM 5-3805-290-23-1
STATUS GROUPS 0006 00
Refer to Tables 1 and 2 for a list of parameters that ET monitors in real time. Access the status groups from the tool bar
or the drop down menus in ET. Refer to Table 3 in this work package for a list of monitoring system parameters, their trip
points, and delay times.
Table 1. Engine ECM.
STATUS SCREEN PARAMETERS
Screen 1 (Core Engine) Engine Speed
Desired Engine Speed
Smoke Limit Fuel Mass
Delivered Fuel Mass
Torque Limit Fuel Mass
Mass Fuel Flow
Fuel Temperature
Throttle Position
Boost Pressure
Screen 2 (Pressure & Temperature) Engine Speed
Engine Coolant Temperature
Inlet Air Temperature
Boost Pressure
Turbo Outlet Pressure (abs)
Engine Oil Pressure
Battery Voltage
Air Inlet Heater
Ether Injection
Screen 3 (Throttle Parameters) Engine Speed
Desired Engine Speed
Throttle Position
Trans Requested Eng Speed Limit
Throttle Lock Switch
Throttle Res/Accel Switch
Throttle Set/Decel Switch
Throttle Lock Mode
Throttle Lock Speed
Screen 4 (Machine Parameters) User Shutdown
Air Filter Restriction Status
Parking Brake From: Transmission
Actual Gear From: Transmission
Screen 5 (Tachometer) External Engine Speed Output
Screen 6 (Security System) Security System Immobilizer Status
0006 00-5
TM 5-3805-290-23-1
STATUS GROUPS - CONTINUED

Table 2. Machine ECM.
Screen 1 (Machine Status) Torque Conv Outlet Temp
Transmission Oil Temperature
Transmission Oil Filter Warning Indicator
Hydraulic Oil Temperature
Hydraulic Oil Filter Bypass Warning Indicator Status
Brake Accumulator Pressure Status
Fuel Gage
System Voltage
Alternator Status
Engine Coolant Temperature From: Engine
Engine Oil Pressure From: Engine
Screen 2 (Engine - Tier II) Engine Speed
Starter Relay
Fuel Gage
Security System Status
Engine Speed From: Engine
Engine Oil Pressure From: Engine
Air Filter Restriction Status From: Engine
Security System Immobilizer Status From: Engine
Screen 3 (Transmission - Basic) Gear
Desired Gear
Shift Lever Position
Transmission Switch
Auto Shift Indicator Status
Neutralizer Function Switch Position
Downshift Switch
Torque Conv Outlet Temp
Parking Brake
Powertrain Filter Bypass Status
0006 00-6
TM 5-3805-290-23-1

Table 2. Machine ECM - Continued.
Screen 4 (Transmission - Neutralizer) Actual Gear
Desired Gear
Parking Brake
Neutralizer Disable Indicator Status
Rear Brake Pressure
Minimum Neutralization Brake Pressure Setting
Maximum Neutralization Brake Pressure Setting
Screen 5 (Transmission - Speed) Gear
Engine Speed
Torque Converter Speed
Transmission Intermediate Speed #1
Transmission Intermediate Speed #2
Transmission Output Speed #1
Transmission Output Speed #2
Ground Speed/Direction
Backup Alarm
Screen 6 (Transmission - Solenoids) Gear
Desired Gear
Clutch #1 Current
Clutch #2 Current
Clutch #3 Current
Clutch #4 Current
Clutch #5 Current
Clutch #6 Current
Backup Alarm
Rear Brake Pressure
Minimum Neutralization Brake Pressure Setting
0006 00-7
TM 5-3805-290-23-1

Screen 7 (Display Gages) Action Alarm
Ground Speed
Fuel Gage
Screen 8 (Display Indicator - Upper) Action Alarm
Secondary Steering Flow Warning Indicator
Primary Steering System Warning Indicator Status
Brake Oil Pressure Warning Indicator
Low Engine Oil Pressure Warning Indicator Status
Action Lamp
Start Aid Indicator Status
Parking Brake Warning Indicator Status
Charging System Warning Indicator Status
Low Differential (Axle) Oil Pressure Warning
Indicator Status
Screen 9 (Display Indicator - Lower) Action Alarm
Air Filter Restriction Warning Indicator
Ride Control Active Indicator Status
Machine Security System Indicator Status
Screen 10 (Hydraulics - Basic) Hydraulic Oil Temperature
Hydraulic Filter Bypass Status
Implement Lockout Switch Position
Implement Lockout Solenoid Status
Screen 11 (Ride Control) Ride Control Configuration
Gear
Ride Control Switch
Ride Control
Ride Control Solenoid Status
0006 00-8
TM 5-3805-290-23-1

Screen 11 (Ride Control) - Continued Ride Control Active Indicator Status
Ride Control Activation Speed
Parking Brake Switch
System Voltage
Screen 12 (Fan Control) Engine Fan Control
Engine Cooling Fan Solenoid Current
Engine Speed
Engine Fan Reversing Feature
Engine Fan Reversing Solenoid Status
Engine Fan Reverse Switch Position
Engine Fan Purge Cycle Interval Remaining Time
Inlet Air Temperature From: Engine
Screen 13 (Neutral Start Status) Security System Status
Gear
Ignition Switch
Starter Relay
Security System Immobilizer Status From: Engine
Screen 14 (Brake System) Brake Accumulator Pressure Status
Brake Accumulator Pressure
Brake Oil Diverter Solenoid Status
Rear Brake Pressure
Brake Oil Pressure Warning Indicator
Heavy Duty Brake Installation Status
Low Differential (Axle) Oil Pressure Warning
Indicator Status
Screen 15 (Secondary Steering) Secondary Steering
Gear
Primary Steering Pressure Status
Secondary Steering Relay
0006 00-9
TM 5-3805-290-23-1

Screen 15 (Secondary Steering) - Continued Secondary Steering Test Switch Position
Throttle Position From: Engine
Screen 16 (Rear Defrost) Window Defroster Installation Status
Window Defroster Timer Duration
Window Defroster Timer Remaining Time
Window Defroster Switch Position
Window Defroster Relay Status
Screen 17 (Quick Steering) Machine Steering Configuration
Steering Mode Switch Position
Gear
Quick Steering Top Gear Limit
Steering Response Rate Setting
Quick Steering Solenoid Status
Quick Steering Indicator Status
Screen 18 (Hydraulics - 3rd Function) 3rd Lever Position Sensor Duty Cycle
3rd Lever Position
3rd Function Rearward Solenoid Command
3rd Function Forward Solenoid Command
3rd Function Operating Mode Switch Position
3rd Function Maximum Flow Rate Control Sensor
Duty Cycle
3rd Function Valve Maximum Flow Percentage
Implement Lockout Switch Position
Implement Lockout Solenoid Status
0006 00-10
TM 5-3805-290-23-1

Table 3. Monitoring System Parameters.
DELAY
DESCRIPTION STATE TRIP POINT
TIME
Low Engine Oil Pressure
Warn Operator On None 2 Sec
Engine Shutdown On None 2 Sec
High Engine Coolant Temperature

Warn Operator On 232°F 10 Sec
Engine Derate On 234°F 10 Sec
Engine Shutdown On 244°F 10 Sec
Engine Overspeed
Warn Operator On 3,300 rpm 1 Sec
Altitude (Atmospheric Pressure)

Engine Derate On 10.2 psi 1 Sec
High Hydraulic Oil Temperature

High Engine Inlet Air Temperature

Warn Operator On 179.6°F 10 Sec
Engine Derate On 186.8°F 10 Sec
High Transmission Oil Temperature

High Fuel Temperature

Unknown Event
Engine Derate On None None
END OF WORK PACKAGE
0006 00-11/(0006 00-12 Blank)

30
TM 5-3805-290-23-1
TROUBLESHOOTING SYMPTOM INDEX 0007 00
TROUBLESHOOTING WITHOUT A DIAGNOSTIC CODE
Malfunction/Symptom Troubleshooting Procedure Page
Engine System Troubleshooting

1. Engine Cannot Reach Top Rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-1
2. Engine Cranks but Will Not Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-2
3. Engine Misfires, Runs Rough, or is Unstable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-4
4. Mechanical Noise (Knock) in Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-6
5. Noise Coming from Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-6
6. Engine Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-6
7. Excessive Valve Lash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-7
8. Excessive Engine Oil Consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-7
9. Low Engine Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-8
10. Engine Has Early Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-8
11. Excessive Black Smoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-9
12. Excessive White Smoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-9
13. Elevated Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-10
14. Engine Speed Does Not Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-10
15. Engine Stalls at Low Rpm.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008 00-11
16. Poor Acceleration or Response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008 00-11
17. Low Power/Poor or No Response to Throttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-12
18. Intermittent Low Power or Power Cutout.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-14
19. Intermittent Engine Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-16
20. Inlet Air Temperature is Too High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-17
21. Coolant Temperature is Too High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-18
22. Engine Oil in Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-19
23. Coolant in Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-19
24. Engine ECM Will Not Communicate with Other Systems or Display Modules. . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-19
25. MSD Will Not Communicate with Engine ECM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-20
Electrical System Troubleshooting
1. Alternator (Charging Problem). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-21
2. Alternator (Noisy Operation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-21
3. Engine Will Not Crank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-21
4. Backup Alarm Always Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-22
5. Backup Alarm Always On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-23
6. One or More Worklights Are Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-24
7. One or Both Service Lights Are Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-27
8. One Service Stoplamp or One or More Turnlamps Are Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-29
9. All Stoplamps Are Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-33
10. One or Both Taillamps Are Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-35
11. One or Both Blackout Markers Are Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-35
12. One or Both Blackout Stoplamps Are Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-36
13. All Rear Lights Are Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-36
14. Blackout Drive Light is Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-37
15. Quick Coupler Switch is Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-37
16. Rear Defroster is Inoperative or Always On.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-38
0007 00-1
TM 5-3805-290-23-1
TROUBLESHOOTING SYMPTOM INDEX - CONTINUED 0007 00
TROUBLESHOOTING WITHOUT A DIAGNOSTIC CODE - CONTINUED
Electrical System Troubleshooting - Continued

17. One or More Kickouts Are Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-40
18. Arctic Heater is Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-44
19. Air Conditioning Compressor Does Not Run (Blower Operates Correctly). . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-46
20. One or More Blower Motor Speeds Are Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-50
21. Condenser Fan is Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-53
22. Wipers/Washers Do Not Operate or Do Not Operate Correctly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-55
23. Horn is Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-63
Transmission System Troubleshooting
1. Low Stall Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-65
2. High Stall Speed in Both Directions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-65
3. High Stall Speed in One Gear or in One Direction.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-66
4. There is High Converter Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-66
5. There is Low Converter Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-66
6. Torque Converter Gets Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-66
7. Transmission Does Not Operate in Any Gear.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-67
8. Transmission Slips in All Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-67
9. Transmission Gets Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-67
10. Pump Noise is Not Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-68
11. Transmission Operates in Forward Only.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-68
12. Transmission Operates in Reverse and Fourth Gear Forward Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-68
13. Transmission Operates in Reverse and First Through Third Gear Forward Only. . . . . . . . . . . . . . . . . . . . . . . . 0008 00-68
14. Transmission Does Not Operate in First Gear, Forward or Reverse.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-68
15. Transmission Does Not Operate in Second Gear, Forward or Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-69
16. Transmission Does Not Operate in Third Gear, Forward or Reverse, and Fourth Gear Forward. . . . . . . . . . . . 0008 00-69
17. Clutch Engagement is Slow for All Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-69
18. Clutch Engagement is Slow for All Forward Gears or All Reverse Gears or Clutch Engagement is
Slow for Any One Gear in Both Forward and in Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-69
19. Transmission Stays Engaged When Brake Pedal is Pushed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-69
20. Transmission Engages but Machine Does Not Move. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-69
21. While Engine is Running and Parking Brake is Engaged, Alarm Does Not Sound When
Transmission Selection Lever is Put into Either a Forward or a Reverse Direction. . . . . . . . . . . . . . . . . . . . . 0008 00-69
22. Backup Alarm Will Not Sound When Selection Lever is Put into Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-70
23. There is Low Lubrication Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-70
24. There is High Lubrication Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-70
25. Transmission Will Not Shift Automatically. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-70
26. Transmission Control (Shift Lever) Will Not Engage Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-70
0007 00-2
TM 5-3805-290-23-1
Differential and Final Drive System Troubleshooting

1. There is Constant Noise in Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-75
2. There is Noise at Different Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-75
3. There is Noise When Machine Turns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-75
4. Drive Wheels Do Not Turn but Universal Joint Turns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-75
Steering System Troubleshooting
1. Steering Metering Pump Makes Noise and Steering Cylinder Rods Do Not Move Freely. . . . . . . . . . . . . . . . . 0008 00-76
2. Too Much Force is Needed to Turn Steering Wheel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-77
3. Machine Does Not Turn When Steering Wheel is Turned. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-77
4. Machine Turns Slowly in Both Directions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-78
5. Machine Turns Slowly in One Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-78
6. Steering Wheel Does Not Return to Center Position Correctly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-78
7. Temperature of Oil is Too Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-79
8. Steering Wheel Turns Without Operator’s Action. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-79
9. Machine Will Not Stay in a Straight Line.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-79
10. Operation of Hand Metering Unit is Erratic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-79
11. Steering Wheel Has Excessive Free Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-79
12. Hand Metering Unit Locks Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-79
13. Machine Turns in Wrong Direction When Operator Turns Steering Wheel.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-79
14. Steering Wheel Kicks at Start or End of Steering Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-80
15. Severe Vibration Occurs When Steering is Activated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-80
16. Steering Wheel or Steered Wheels Move Unexpectedly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-80
Braking and Hydraulic Fan System Troubleshooting
1. Front and Rear Service Brakes Do Not Operate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-82
2. Front Service Brakes Do Not Operate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-82
3. Rear Service Brakes Do Not Operate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-82
4. Service Brakes Slip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-82
5. Service Brakes Are Not Applied Evenly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-82
6. Too Much Force is Needed to Push Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-83
7. Parking Brake Does Not Hold Machine Stationary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-83
8. Parking Brake Does Not Engage When Parking Brake Control Lever is Actuated. . . . . . . . . . . . . . . . . . . . . . . 0008 00-83
9. Low Oil Pressure Warning Indicator Will Not Turn Off.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-83
10. Pressure in Accumulators Does Not Decrease When Brakes Are Applied or Decreases
Without Applying Brakes.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-84
11. Fan Speed Will Not Adjust to Demands of Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-84
0007 00-3
TM 5-3805-290-23-1
Hydraulic System Troubleshooting

1. Hydraulic Power is Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-86
2. No Functions Will Operate or All Functions Operate Slowly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-86
3. Pilot Oil Pressure is Low.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-87
4. Piston Pump for Work Tools Will Not Reach High Pressure Cutoff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-87
5. Standby Pressure Cannot be Adjusted Correctly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-87
6. Hydraulic Circuit is Hammering.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-88
7. Boom Raises but Will Not Lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-88
8. Boom Will Not Raise or Lower.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-88
9. Cannot Tilt Bucket in Either Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-88
10. Oil Temperature is Too High.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-89
11. There Are Air Bubbles in Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-89
12. Cycle Times Are Not Correct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-89
13. Quick Coupler Does Not Operate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-89
14. Ride Control Function Does Not Operate.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-90
15. Implements Will Not Lower With Dead Engine Lower Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-90
16. Implement Drifts Downward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-90
Air Conditioning System Troubleshooting
1. Temperature of Air Flow is Partially Cool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-91
2. Temperature of Air Flow is Warm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-94
3. System Only Cools Cab in Morning and in Evening, Not During Hot Part of Day.
Air Flow is Very Cold but Air Flow Becomes Warm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-95
4. High Pressure (Liquid Line) is Very Hot. Compressor May Become Noisy and Drive Belt May Slip. . . . . . . . 0008 00-96
5. Water is in Vents and Leaking from Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-96
6. Compressor Will Not Engage. Air Flow to Operator’s Compartment is Warm. . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-96
7. Compressor Continues to Cycle or Clutch Will Not Disengage. Air Flow to Operator’s
Compartment is Very Cold or Air Flow May be Restricted Completely at Times. . . . . . . . . . . . . . . . . . . . . . 0008 00-97
8. Compressor Clutch is Engaged but System Has Insufficient Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-98
0007 00-4
TM 5-3805-290-23-1
TROUBLESHOOTING WITH A DIAGNOSTIC CODE

ENGINE ECM 0007 00
NOTE
If fault code(s) to be troubleshot are not located in this table, contact your local Caterpillar dealer.
Table 1. MID 036 - Engine Control System.
TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
CODE DESCRIPTION FAULT CONDITIONS/EFFECTS PAGE
0041 03 8V Sensor Power Supply ECM will log diagnostic code. This code is generated when ECM has 0009 00-1
Short to +Batt. been powered for at least three seconds and ECM reads signal voltage
above normal. ECM will return engine to low idle or safe speed. Engine
will remain at low idle or safe speed while diagnostic code remains
active. When this code is generated, a low power condition may also
be present.
0041 04 8V Sensor Power Supply ECM will log diagnostic code. This code is generated when ECM has 0009 00-1
Short to Ground. been powered for at least three seconds and ECM reads signal voltage
above normal. ECM will return engine to low idle or safe speed. Engine
will remain at low idle or safe speed while diagnostic code remains
active. When this code is generated, a low power condition may also
be present.
0091 02 Incorrect Throttle Switch ECM will log diagnostic code. This code is generated when signal from 0009 00-1
Inputs. throttle idle validation switch is invalid. Throttle switch is ignored by ECM
until fault is repaired. Throttle switch will also be ignored by ECM until
engine start switch has been turned to OFF position and then back to ON
position. When this code is generated, engine speed defaults to low idle
or a predetermined safe speed. Engine will remain at this speed while
diagnostic code remains active. Reduction of speed is determined by
current engine speed. When a fault is detected and engine is above
predetermined safe speed, engine will reduce speed to safe speed. When
a fault is detected and engine is below predetermined safe speed, engine
will match correct speed.
0091 03 Accelerator Pedal - ECM will log diagnostic code. This code is generated when ECM has 0009 00-1
Voltage Above Normal. been powered for at least three seconds or ECM reads a signal voltage
above normal. ECM will return engine to low idle or to predetermined
safe speed while diagnostic code remains active. When this code is
generated, a low power and reduced engine speed condition may also
be present.
0091 04 Accelerator Pedal - ECM will log diagnostic code. This code is generated when ECM has 0009 00-1
Voltage Below Normal. been powered for at least three seconds or ECM reads a signal voltage
above normal. ECM will return engine to low idle or to predetermined
safe speed while diagnostic code remains active. When this code is
generated, a low power and reduced engine speed condition may also
be present.
0007 00-5
TM 5-3805-290-23-1
TROUBLESHOOTING WITH A DIAGNOSTIC CODE - CONTINUED

ENGINE ECM - CONTINUED 0007 00
Table 1. MID 036 -Engine Control System - Continued.
TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
0091 08 Throttle Position Signal ECM will log diagnostic code. This code is generated when an open 0009 00-1
Abnormal. circuit for throttle position sensor or for voltage supply is present. ECM
returns engine to low idle or a safe speed when problem is detected.
Diagnostic code is logged only if engine is running. ET will indicate
DIAG and a throttle position of 0 percent while diagnostic code is
active. This will happen regardless of position of throttle pedal
assembly. Engine will remain at low idle or at safe speed while code is
active.
0091 12 Accelerator Pedal - ECM will log diagnostic code. This code is generated when ECM 0009 00-1
Power Supply Failure. detects a 5V failure or a 5V fault. ECM will return engine to low idle
or to predetermined safe speed while diagnostic code remains active.
When this code is generated, a low power and reduced engine speed
condition may also be present.
0100 03 Engine Oil Pressure This code is generated when ECM reads signal voltage above normal, 0009 00-1
Sensor Open/Short to has been powered for at least 15 seconds, and codes 262-03 and 262-
+Batt. 04 are not active. ECM will log diagnostic code. ECM flags oil pressure
as invalid data. Oil pressure is set to a default value of 600 kPa. This
diagnostic code will have no effect on engine performance.
0100 04 Engine Oil Pressure This code is generated when ECM reads signal voltage below normal, 0009 00-1
Sensor Short to Ground. has been powered for at least two seconds, and codes 262-03 and 262-
04 are not active. ECM will log diagnostic code. ECM flags oil pressure
as invalid data and a default value of 600 kPa is used.
0100 10 Engine Oil Pressure This code is generated when 5V connection to sensor is an open circuit. 0009 00-1
Sensor Abnormal Rate of ECM will log diagnostic code.
Change.
0102 03 Boost Pressure Sensor ECM detects no other active 262 or 102 codes. Engine speed is greater 0009 00-1
Short to +Batt. than 500 rpm, engine oil pressure signal is within expected range for
this failure mode, engine oil pressure signal remains abnormally
constant because variations in sensor signal are too small, and
conditions occur simultaneously for a period of 10 seconds. ECM will
log diagnostic code. ECM will flag engine oil pressure as invalid data.
Engine oil pressure is set to a default value. This diagnostic code will
have no effect on engine performance. ECM will set boost pressure to
a default value. MSD will display “Open/Short High” for boost pressure
on status screen. ECM will generate a CID 102-FMI 03 diagnostic code
on CAT data link. When this code is generated, a low power condition
may also be present.
0007 00-6
TM 5-3805-290-23-1

Table 1. MID 036 - Engine Control - Continued.
TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
0102 04 Boost Pressure Sensor This code is generated when ECM detects a signal voltage below 0009 00-1
Short to Ground. normal and has been powered for at least 15 seconds. ECM will set
boost pressure to a default value. ET will display “Short to Ground” for
boost pressure on status screen. ECM will generate a CID 102-FMI 04
diagnostic code on CAT data link. Diagnostic code will be displayed
on a diagnostic screen of ET. Engine could have low power while
diagnostic code is active.
0102 10 Boost Pressure Sensor This code is generated when 5V connection to sensor is an open circuit, 0009 00-1
Abnormal Rate of or for 30 seconds ECM detects no other 262 or 102 codes are active,
Change. engine speed is greater than 600 rpm, pressure sensor signal from intake
manifold is within expected range for this failure mode, and pressure
sensor signal from intake manifold remains abnormally constant
because variations in sensor signal are too small. ECM will log
diagnostic code. ECM will flag intake manifold pressure as invalid data.
Intake manifold pressure is set to a default value. This diagnostic code
will have no effect on engine performance.
0105 03 Intake Manifold This code is generated when ECM reads signal voltage above normal 0009 00-1
Temperature Sensor and ECM has been powered for at least 15 seconds. ECM will log
Open/Short to +Batt. diagnostic code. ECM flags intake air temperature as invalid data and
a default value is used. When this code is generated, a low power
condition and poor cold starting may occur.
0105 04 Intake Manifold This code is generated when ECM reads signal voltage below normal 0009 00-1
Temperature Sensor and has been powered for at least 15 seconds. ECM will log diagnostic
Short to Ground. code. ECM flags intake air temperature as invalid data and a default
value is used. When this code is generated, a low power condition and
poor cold starting may occur.
0110 03 Engine Coolant This code is generated when ECM reads signal voltage above normal 0009 00-1
Temperature Open/Short and has been powered for at least three seconds. ECM will log
to +Batt. diagnostic code. ECM flags intake air temperature as invalid data and
a default value is used.
0110 04 Engine Coolant This code is generated when ECM reads signal voltage below normal 0009 00-1
Temperature Short to and has been powered for at least three seconds. ECM will log
Ground. diagnostic code. ECM flags coolant temperature as invalid data and a
default value us used. When this code is generated, engine misfires, low
power, reduced engine speed (rpm), and poor cold starting may also
occur.
0007 00-7
TM 5-3805-290-23-1
TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
0174 02 Fuel Temperature Sensor This code is generated when ECM detects a fuel temperature signal that 0009 00-1
Data Erratic. is erratic or intermittent. Both 174-02 and 342-02 diagnostic codes will
be active if fuel injection pump has suffered a complete failure of
electrical supply or if there has been a communication fault between
ECM and CAN data link for fuel injection pump. ECM will log
diagnostic code only if engine is running. When this code is generated,
engine may shut down or have low power.
0247 09 J1939 Data Link This code is generated when ECM has detected a loss of 0009 00-1
Communications. communications with J1939 data link. Machine may not have engine
speed control. ECM will generate a 247-09 diagnostic code on CAT
data link.
0262 03 5V Sensor dc Power This code is generated when ECM reads signal voltage above normal 0009 00-1
Supply Short to +Batt. and ECM has been powered for at least three seconds. ECM will log
diagnostic code. While diagnostic code is active, engine may have low
power or misfire.
0262 04 5V Sensor dc Power This code is generated when ECM reads a signal voltage below normal 0009 00-1
Supply Short to Ground. and ECM has been powered for at least three seconds. ECM will log
diagnostic code. When this code is generated, engine may have low
power or misfire.
0007 00-8
TM 5-3805-290-23-1

TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
0320 02 Speed and Timing Sensor This code is generated when signal for speed/timing sensor is 0009 00-1
Loss of Signal. intermittent or lost for less than one second. This speed/timing sensor
is located near flywheel housing. ECM will use speed/timing sensor in
fuel injection pump to determine engine speed. ECM will log diagnostic
code. When this code is generated, ECM will derate engine to a
maximum speed of 1,200 rpm. If signal is lost from both engine speed
and timing sensors, ECM will shut down engine. ECM will not allow
engine to restart while diagnostic codes are active.
0320 11 Speed and Timing Sensor This code is generated when signal for speed/timing sensor is lost. ECM 0009 00-1
Mechanical Failure. will use speed/timing sensor in fuel injection pump to determine engine
speed. ECM will log diagnostic code. When this code is generated,
ECM will derate engine to a maximum speed of 1,200 rpm. If signal is
lost from both engine speed/timing sensors, ECM will shut down
engine. ECM will not allow engine to restart while diagnostic codes are
active.
0342 02 Loss of Secondary This code is generated when signal for speed/timing sensor is 0009 00-1
Engine Speed Signal. intermittent or lost for less than one second. If only 0342-02 is active,
problem is not a fault with electrical supply for fuel injection pump.
Both 174-02 and 342-02 diagnostic codes will be active if fuel injection
pump has suffered a complete failure of electrical supply. Also, both
174-02 and 342-02 diagnostic codes will be active if there has been a
communication fault between ECM and CAN data link for fuel
injection pump. ECM will log diagnostic code. ECM will derate engine
to a default value or a safe speed. When this code is generated, engine
will shut down.
0774 02 Secondary Throttle This code is generated when ECM detects erratic data, intermittent data, 0009 00-1
Position Sensor Data or incorrect data. ECM will log diagnostic code. Throttle is ignored by
Erratic. ECM until fault is repaired. Throttle switch will also be ignored by ECM
until engine start switch has been turned to OFF position and then back
to ON position. ECM will return engine to low idle or to a safe speed
while diagnostic code is active. When this code is generated, engine
speed defaults to low idle or a predetermined safe speed. Engine will
remain at this speed while diagnostic code remains active. Reduction
of speed is determined by engine current speed. When a fault is detected
and engine is above predetermined safe speed, engine will reduce speed
to safe speed. When a fault is detected and engine is below
predetermined safe speed, engine will match correct speed.
0007 00-9
TM 5-3805-290-23-1
TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
0774 03 Secondary Throttle This code is generated when ECM detects voltage for throttle position 0009 00-1
Position Sensor Open/ sensor is above normal or detects an invalid throttle position signal.
Short to +Batt. ECM will log diagnostic code. ECM will return engine to low idle or
to a safe speed while diagnostic code is active. When this code is
generated, a low power condition or reduced engine speed may also
occur.
Position Sensor Short to sensor is below normal or detects an invalid throttle position signal.
Ground. ECM will log diagnostic code. ECM will return engine to low idle or
to a safe speed while diagnostic code is active. When this code is
occur.
Position Sensor Signal sensor is below abnormal or detects an invalid throttle position signal.
Abnormal. ECM will log diagnostic code. ECM will return engine to low idle or
to a safe speed while diagnostic code is active.When this code is
occur.
0774 12 Secondary Throttle This code is generated when ECM detects abnormal throttle position 0009 00-1
Position Sensor - PSU sensor signal or when throttle position signal fails. ECM will log
Failure. diagnostic code. ECM will return engine to low idle or to a safe speed
while diagnostic code is active. When this code is generated, a low
power condition and reduced engine speed may also occur.
1627 03 Fuel Pump Relay This code is generated when ECM still receives signals from fuel 0009 00-1
Voltage High/Open injection pump relay and ECM has already switched off relay. ECM
Circuit. will log diagnostic code. This diagnostic code will have no effect on
engine performance.
1639 09 Machine Security This code is generated when ECM detects no response from Machine 0009 00-1
System Module Not Security System (MSS). ECM will log diagnostic code. ECM will
Communicating on Link. inhibit fuel injection and engine will not start.
0007 00-10
TM 5-3805-290-23-1
TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
1684 00 Fuel Injection Pump This code is generated when electronic fuel injection pump detects fuel 0009 00-2
Above Normal. temperature above normal operating range. This can occur when fuel
temperature may be above recommended maximum operating
temperature or there may be an internal fault within fuel injection pump.
Recommended maximum operating fuel temperature is 158°F (70°C)
at fuel injection pump intake. Electronic fuel injection pump will note
that fuel temperature is too high. ECM will log diagnostic code. When
this code is generated, fuel injection pump will be derated, and low
power and reduced engine speed may occur.
1684 02 Fuel Injection Pump Data This code is generated when fuel injection pump detects an internal 0009 00-2
Erratic. failure of fuel injection pump software. ECM will log diagnostic code.
ECM will not allow engine to start while diagnostic code is active. ECM
will cause engine to shut down. When this code is generated, engine
will not start while diagnostic code is active.
1684 03 Fuel Injection Pump This code is generated when fuel injection pump detects an internal 0009 00-2
Open/Short to +Batt. failure of fuel injection pump software. ECM will have no response to
this active code. ECM will log diagnostic code. When this code is
generated, an incorrect amount of fuel may be injected into cylinders.
Engine may have reduced power. Continuing to use engine may lead
to engine failure.
1684 04 Fuel Injection Pump This code is generated when fuel injection pump detects supply voltage 0009 00-2
Short to Ground. below normal or an intermittent signal while engine is running. ECM
will log diagnostic code. There is no obvious effect on engine
performance.
1684 05 Fuel Injection Pump This code is generated when ECM detects invalid PWM signal from 0009 00-2
Open Circuit. fuel injection pump, likely caused by a fault in CAN data link. ECM
will log diagnostic code. When this code is generated, ECM will cause
fuel injection pump to stop injecting fuel. ECM will then cause engine
to shut down.
1684 07 Fuel Injection Pump This code is generated when ECM detects improper response from fuel 0009 00-2
Improper Response. injection pump, fuel injection, or timing system. ECM will log
diagnostic code. ECM will cause fuel injection pump to stop injecting
fuel. ECM will then cause engine to shut down.
0007 00-11
TM 5-3805-290-23-1
TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
1684 08 Fuel Injection Pump This code is generated when fuel injection pump does not receive a 0009 00-2
Signal Abnormal. position signal or signal received by fuel injection pump is incorrect.
ECM will log diagnostic code. Fuel injection pump will use engine
speed/timing sensor in order to set engine timing. ECM will derate rpm
by 20 percent. Engine will also experience any of these conditions: low
power or a reduction of power, increased emissions, and hard starting.
1684 09 Fuel Injection Pump Not This code is generated when fuel injection pump detects a failure of 0009 00-2
Communicating on Link. CAN data link, ECM sent incorrect data, or fuel injection pump sent
incorrect data. ECM will log diagnostic code. ECM will cause fuel
injection pump to stop injection of fuel. When this code is generated,
ECM shuts down engine and will not allow it to restart.
1684 10 Fuel Injection Pump This code is generated when ECM detects an open circuit, wire shorted 0009 00-3
Abnormal Rate of high, or wire shorted low from fuel injection pump. ECM will log
Change. diagnostic code. Engine may shut down and not start while diagnostic
code is active.
1684 11 Fuel Injection Pump This code is generated by fuel injection pump when there is an internal 0009 00-3
Unknown Failure. problem with fuel injection pump. There may be air in fuel injection
pump. Voltage and/or resistance at J40/P40 fuel injection pump
connectors are incorrect. ECM will log diagnostic code. ECM will
derate engine speed by 20 percent. Engine may experience low power
and reduced speed while diagnostic code remains active.
1684 12 Fuel Injection Pump This code is generated by fuel injection pump when there is an internal 0009 00-3
Malfunction. problem with fuel injection pump. ECM will log diagnostic code. ECM
will derate engine speed by 20 percent. While diagnostic code is active,
engine will experience low power and reduced speed.
1684 14 Fuel Injection Pump. This code is generated when ECM detects a communication failure with 0009 00-3
fuel injection pump. Communication failure may be due to
disconnected connectors for fuel injection pump or a faulty wiring
harness for fuel injection pump. ECM will log diagnostic code. This
diagnostic code will have no effect on engine performance. Code 1684-
14 is normally accompanied by 174-02 or 320-02. Code 174-02 may
cause engine to have low power. If 320-02 is active, ECM will limit
engine to 1,200 rpm.
0007 00-12
TM 5-3805-290-23-1

MACHINE ECM 0007 00
Table 2. MID 081 - Machine Control System.
TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
0041 03 Power Supply (8V) This diagnostic code is recorded when powertrain ECM reads sensor 0009 00-4
Voltage Above Normal. supply circuit voltage as higher than normal because output of sensor
supply to battery has shorted or transmission oil temperature sensor is
faulty. When this code is generated, lockup clutch is disabled, there is
hesitation during direction shifts, and calibrations will not function.
0041 04 Power Supply (8V) This diagnostic code is associated with power supply for sensors. FMI 0009 00-5
Shorted to Ground. 04 means that ECM has determined sensor circuit voltage is below
normal due to a failed sensor, circuit shorted to ground, or ECM failure
(such a failure is unlikely).
0070 03 Switch (Parking Brake) This diagnostic code is associated with parking brake switch. Switch is 0009 00-6
Voltage Above Normal. connected to two ECM inputs. One contact is open and one contact is
grounded during proper operation because normally open contact and
normally closed contact are open or contact currently closed to ground
is shorted to +batt circuit.
0070 04 Switch (Parking Brake) This diagnostic code is associated with parking brake switch. Switch is 0009 00-8
Shorted to Ground. connected to two ECM inputs: “Normally Open” and “Normally
Closed”. One input is open and other is grounded during proper
operation. FMI 04 means ECM has determined that “Normally Open”
and “Normally Closed” circuits are grounded.
0096 03 Sensor (Fuel Level) This diagnostic code is recorded when ECM reads signal voltage of fuel 0009 00-11
Voltage Above Normal. level sending unit and voltage is too high. Possible causes of this
diagnostic code are:
• Sender has failed.
• Return sender circuit is open in machine harness.
• Signal circuit in machine harness is shorted to a
source of positive voltage.
• Signal circuit in machine harness is open or sender
is disconnected.
• ECM has failed (such a failure is unlikely).
This failure causes fuel gage to always indicate an empty fuel tank or
to intermittently indicate an empty fuel tank.
0096 04 Sensor (Fuel Level) This diagnostic code is recorded when ECM reads signal voltage of fuel 0009 00-12
Shorted to Ground. level sending unit and voltage is too low because sender failed, signal
circuit in machine harness is shorted to ground, or ECM has failed (such
a failure is unlikely). This failure causes fuel gage to always indicate
an empty fuel tank or to intermittently indicate an empty fuel tank.
0007 00-13
TM 5-3805-290-23-1

MACHINE ECM - CONTINUED 0007 00
Table 2. MID 081 - Machine Control System - Continued.
TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
0177 03 Temperature Sensor This diagnostic code is associated with temperature sensor 0009 00-13
(Transmission Oil) (transmission oil). FMI 03 means ECM has determined voltage of
Open or Short to +Batt. sensor circuit is above normal.
Possible causes of this diagnostic code are:
• Signal circuit for sensor is open.
• Signal circuit for sensor is shorted to +batt circuit.
• Sensor has failed.
• Power circuit or ground circuit has failed.
When this diagnostic code occurs, brake oil diverter solenoid is turned
off.
(Transmission Oil) (transmission oil). FMI 04 means ECM has determined voltage of
Shorted to Ground. position sensor circuit is below normal because sensor signal circuit is
shorted to ground, sensor has failed, or ECM has failed (such a failure
is unlikely).
(Transmission Oil). (transmission oil). FMI 08 means ECM has determined signal
frequency or signal pulse width is not within expected range.
• Sensor failed.
• Intermittent connections or poor connections.
• Mechanical devices are loose.
• ECM failed (such a failure is unlikely).
0247 09 CAN Data Link This diagnostic code is recorded when machine ECM stops receiving 0009 00-21
Abnormal Update. information on CAN data link.
0262 03 Power Supply (5V) This diagnostic code is recorded when powertrain ECM reads sensor 0009 00-23
Voltage Above Normal. supply circuit voltage as higher than normal, due to shorted sensor
supply output to battery, or faulty transmission oil temperature sensor.
When this code is generated, lockup clutch is disabled, there is
hesitation during direction shifts and calibrations will not function.
0262 04 Power Supply (5V) This diagnostic code is associated with sensor power supply. FMI 04 0009 00-24
Shorted to Ground. means ECM has determined sensor circuit voltage is below normal due
to failed sensor, circuit is shorted to ground, or failed ECM (such a
failure is unlikely).
0007 00-14
TM 5-3805-290-23-1

TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
0271 03 Action Alarm This diagnostic code is associated with action alarm. FMI 03 means 0009 00-26
Voltage Above Normal. ECM has determined alarm circuit voltage is above normal due to failed
alarm, alarm energize circuit is shorted to +batt circuit, or failed cluster
0271 05 Action Alarm This diagnostic code is associated with action alarm. FMI 05 means 0009 00-27
Open Circuit. ECM has determined alarm circuit current is below normal.
• Alarm energize circuit is open.
• Alarm return circuit is open.
• Alarm has failed.
0271 06 Action Alarm This diagnostic code is associated with action alarm. FMI 06 means that 0009 00-29
Shorted to Ground. ECM has determined that current of alarm circuit is above normal.
• Energize circuit of alarm is shorted to ground.
• Alarm has failed.
0291 03 Solenoid (Demand Fan) This diagnostic code is associated with demand fan solenoid. FMI 03 0009 00-31
Voltage Above Normal. means ECM has determined solenoid circuit voltage is above normal
because solenoid has failed, solenoid energize circuit is shorted to +batt
circuit, or ECM has failed (such a failure is unlikely).
Open Circuit. means ECM has determined solenoid current is below normal because
solenoid energize circuit is open, solenoid return circuit is open,
solenoid has failed, or ECM has failed (such a failure is unlikely). When
this diagnostic code occurs, fan speed will increase to maximum.
Shorted to Ground. means ECM has determined solenoid current is above normal because
solenoid energize circuit is shorted to ground, solenoid has failed, or
ECM has failed (such a failure is unlikely). ECM will log diagnostic
code. When this diagnostic code occurs, fan speed will increase to
maximum.
0367 02 Switch (Ride Control) This diagnostic code is associated with ride control switch. FMI 02 0009 00-37
Incorrect, Intermittent, or means ECM has determined one of two ride control switch signal wires
Erratic Data. is grounded intermittently due to failed wiring harness, failed switch,
or failed ECM (such a failure is unlikely).
0007 00-15
TM 5-3805-290-23-1

TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
0367 04 Switch (Ride Control) This diagnostic code is associated with ride control switch. Switch is 0009 00-38
Shorted to Ground. connected to two ECM inputs. Switch has an OFF position where both
inputs are open. One input is grounded during switch actuation and
other input remains open. FMI 04 means ECM has determined that both
circuits are grounded. Machine ECM will log diagnostic code. When
this diagnostic code occurs, ride control switch does not function.
0368 03 Switch (Transmission This diagnostic code is associated with transmission auto/manual/VSC 0009 00-42
Auto/Manual/VSC) switch. Switch is connected to three ECM inputs. Two contacts are open
Open/Short to +Batt. and other contact is grounded during proper operation. This FMI 03
means ECM has determined all three contacts are open.
0368 04 Switch (Transmission This diagnostic code is associated with transmission auto/manual/VSC 0009 00-45
Auto/Manual/VSC) switch. Switch is connected to three ECM inputs. Two contacts are open
Shorted to Ground. and other contact is grounded during proper operation. This FMI 04
means ECM has determined two contacts are open.
0426 03 Pressure Sensor (Brake This diagnostic code is associated with brake oil pressure sensor. FMI 0009 00-48
Oil) Voltage Above 03 means ECM has determined sensor circuit voltage is above normal.
Normal. Possible causes of this diagnostic code are:
• Sensor signal circuit is open.
• Sensor signal circuit is shorted to +batt circuit.
ECM will log diagnostic code. When this diagnostic code occurs,
throttle lock and brake neutralizer features do not work.
0426 04 Pressure Sensor (Brake This diagnostic code is associated with brake oil pressure sensor. FMI 0009 00-51
Oil) Shorted to Ground. 04 means ECM has determined sensor circuit voltage is below normal
because sensor signal circuit is shorted to ground, sensor has failed, or
ECM has failed (such a failure is unlikely). When this diagnostic code
occurs, throttle lock and brake neutralizer features do not work.
0444 03 Relay (Starter Motor) This diagnostic code is associated with starter motor relay. FMI 03 0009 00-53
Voltage Above Normal. means ECM has determined relay circuit voltage is above normal due
to failed relay, relay energize circuit is shorted to +batt, or failed ECM
Open Circuit. means ECM has determined relay current is below normal due to relay
energizer circuit open, relay return circuit open, failed relay, or failed
ECM (such a failure is unlikely).
0007 00-16
TM 5-3805-290-23-1
TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
Shorted to Ground. means ECM has determined relay current is above normal due to relay
energizer circuit shorted to ground, failed relay, or failed ECM (such a
failure is unlikely).
0473 03 Pressure Sensor (Brake This diagnostic code is associated with brake charging pressure sensor. 0009 00-58
Charging) Voltage FMI 03 means ECM has determined sensor circuit is above normal.
Above Normal. Possible causes of this diagnostic code are:
• Sensor signal circuit is open.
• Sensor signal circuit is shorted to +batt circuit.
• ECM has failed (such a signal is unlikely).
ECM will log diagnostic code. When this diagnostic code occurs, brake
oil diverter solenoid is turned off.
0473 04 Pressure Sensor (Brake This diagnostic code is associated with brake charging pressure sensor. 0009 00-61
Charging) Shorted to FMI 04 means ECM has determined position sensor circuit voltage is
Ground. below normal due to sensor signal circuit shorted to ground, failed
sensor, or failed ECM (such a failure is unlikely). When this diagnostic
code occurs, brake oil diverter solenoid is turned off.
0490 03 Switch (Pilot ON/OFF) This diagnostic code is associated with implement lockout switch. 0009 00-63
Voltage Above Normal. Switch is connected to two ECM inputs. One contact is open and other
contact is grounded during proper operation.
• Normally open contact and normally closed contact
are both open.
• Contact currently closed to ground is shorted to
+batt circuit.
Machine ECM will log diagnostic code. When this diagnostic code
occurs, implements are locked.
0490 04 Switch (Pilot ON/OFF) This diagnostic code is associated with implement lockout switch. 0009 00-67
Shorted to Ground. Switch is connected to two ECM inputs: “Normally Open” and
“Normally Closed.” One input is open and other input is grounded
during proper operation. FMI 04 means ECM has determined
“Normally Open” and “Normally Closed” circuits are both grounded.
Machine ECM will log diagnostic code. When this diagnostic code
0007 00-17
TM 5-3805-290-23-1

TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
0585 02 Speed Sensor This diagnostic code is associated with speed sensor transmission 0009 00-70
(Transmission Output 1) output No. 1. FMI 02 means ECM has determined signal frequency or
Incorrect, Intermittent, or pulse width is not within expected range. There are two speed sensors
Erratic Data Signal. for transmission output. This diagnostic code occurs when one sensor
is recording a speed and other sensor is not. ECM will log diagnostic
code.
0590 09 Engine ECM This diagnostic code is recorded when engine ECM is not sending 0009 00-72
Abnormal Update. parameters to machine ECM at proper rates. Update rate for parameters
generated by engine ECM is not correct.
• Data link circuit has an open circuit.
• Data link circuit is shorted to battery ground.
• Engine ECM is not operating properly.
• Software for engine ECM has been erased.
• Engine ECM has wrong software.
0600 03 Temperature Sensor This diagnostic code is recorded when ECM reads hydraulic oil 0009 00-74
(Hydraulic Oil) temperature sensor signal voltage and voltage is too high. Possible
Voltage Above Normal. causes of this diagnostic code are: sender has failed, sender return
circuit is open in machine harness, signal circuit in machine harness is
shorted to a source of positive voltage, signal circuit in machine harness
is open or sender is disconnected, or ECM has failed (such a failure is
unlikely). ECM will log diagnostic code.
0600 04 Temperature Sensor This diagnostic code is recorded when ECM reads hydraulic oil 0009 00-76
(Hydraulic Oil) temperature sensor signal voltage and voltage is too low. Possible
Shorted to Ground. causes of this failure are: sender has failed, signal circuit in machine
harness is shorted to ground, or ECM has failed (such a failure is
0629 04 Switch (Neutralizer) This diagnostic code is associated with transmission neutralizer 0009 00-77
Shorted to Ground. override switch. Switch is connected to one ECM input. Switch is a
momentary switch, and is only grounded when switch is pressed. This
FMI 04 means ECM has determined contact is closed for a too long
time period.
0668 02 Shift Lever Input This diagnostic code is recorded when ECM determines signal from 0009 00-79
Invalid Signal. shift lever is invalid.
0007 00-18
TM 5-3805-290-23-1

TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
0672 02 Speed Sensor (Torque This diagnostic code is associated with torque converter speed sensor. 0009 00-83
Converter Output) FMI 02 means ECM has determined signal frequency or pulse width is
Incorrect, Intermittent, or not within expected range. ECM will log diagnostic code. This
Erratic Data. diagnostic code occurs when transmission output speed sensor has a
valid signal and torque converter speed sensor does not.
0673 02 Speed Sensor This diagnostic code is associated with No. 2 transmission output speed 0009 00-85
(Transmission Output 2) sensor. FMI 02 means ECM has determined signal frequency or pulse
Incorrect, Intermittent, or width is not within expected range. ECM will log diagnostic code.
Erratic Data. There are two speed sensors for transmission output. This diagnostic
code occurs when one sensor is recording a speed and other sensor is
not.
0674 02 Speed Sensor This diagnostic code is associated with transmission intermediate No. 0009 00-87
(Transmission 1 speed sensor. FMI 02 means ECM has determined signal frequency
Intermediate 1) or pulse width is not within expected range. ECM will log diagnostic
Incorrect, Intermittent, or code. There are two speed sensors for transmission intermediate. This
Erratic Data. diagnostic code occurs when one sensor is recording a speed and other
sensor is not.
0675 02 Speed Sensor This diagnostic code is associated with transmission intermediate speed 0009 00-89
(Transmission sensor No. 2. FMI 02 means ECM has determined signal frequency or
Intermediate 2) pulse width is not within expected range. ECM will log diagnostic code.
Incorrect, Intermittent, or There are two transmission intermediate speed sensors. This diagnostic
Erratic Data. code occurs when one sensor is recording a speed and other sensor is
not.
0793 03 Pressure Switch This diagnostic code is associated with primary steering pressure 0009 00-91
(Primary Steering) switch. Switch is connected to two ECM inputs. One contact is open
Voltage Above Normal. and other contact is grounded during proper operation. Possible causes
of this diagnostic code are: normally open contact and normally closed
contact are both open, or contact currently closed to ground is shorted
to +batt circuit.
0793 04 Pressure Switch This diagnostic code is associated with primary steering pressure 0009 00-94
(Primary Steering) switch. Switch is connected to two ECM inputs: “Normally Open” and
Shorted to Ground. “Normally Closed.” One input is open and other input is grounded
during proper operation. FMI 04 means ECM has determined
“Normally Open” and “Normally Closed” circuits are both grounded.
0007 00-19
TM 5-3805-290-23-1

TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
0795 07 Relay (Secondary CID 0795 FMI 07 diagnostic code can only be recorded if optional 0009 00-97
Steering Intermediate) secondary steering system is installed and machine is moving. ECM
Mechanical System Not determines machine is moving via transmission output speed sensor.
Responding Properly. CID 0795 FMI 07 diagnostic code can only be recorded when ECM is
energizing secondary steering relay. Secondary steering relay energizes
an additional relay at secondary steering motor. This additional relay
provides power to motor. ECM monitors relay status at motor. If this
relay is not energized when secondary steering relay is energized,
diagnostic code is recorded. When machine is at rest, this diagnostic
code will always be inactive.
0811 09 Gage Cluster #1 This diagnostic code is recorded when machine ECM does not receive 0009 00-100
Abnormal Update. expected information from dash panel cluster for a period of more than
five seconds.
0826 03 Temperature Sensor This diagnostic code is recorded when ECM reads torque converter oil 0009 00-103
(Torque Converter Oil) temperature sender signal voltage and voltage is too high. Possible
Voltage Above Normal. causes of this diagnostic code are: sender has failed, sender return
circuit is open in machine harness, signal circuit in machine harness is
shorted to a source of positive voltage, signal circuit in machine harness
is open or sender is disconnected, or ECM has failed (such a failure is
0826 04 Temperature Sensor This diagnostic code is recorded when ECM reads torque converter oil 0009 00-105
(Torque Converter Oil) temperature sender signal voltage and voltage is too low. Possible
Shorted to Ground. causes of this failure are: sender has failed, signal circuit in machine
harness is shorted to ground, or ECM has failed (such a failure is
0882 03 Solenoid (Pilot ON/OFF) This diagnostic code is associated with implement lockout solenoid. 0009 00-106
Voltage Above Normal. FMI 03 means ECM has determined solenoid circuit voltage is above
normal. Possible causes of this diagnostic code are: solenoid has failed,
solenoid energize circuit is shorted to +batt circuit, or ECM has failed
(such a failure is unlikely). ECM will log diagnostic code. When this
diagnostic code occurs, implements are locked.
Shorted to Ground. FMI 04 means ECM has determined solenoid voltage is below normal.
Possible causes of this diagnostic code are: solenoid energize circuit is
shorted to ground, solenoid has failed, or ECM has failed (such a failure
is unlikely). ECM will log diagnostic code. When this diagnostic code
0007 00-20
TM 5-3805-290-23-1
TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
Open Circuit. FMI 05 means ECM has determined solenoid current is below normal.
open, solenoid return circuit is open, solenoid has failed, or ECM has
failed (such a failure is unlikely). ECM will log diagnostic code. When
this diagnostic code occurs, implements are locked.
1231 03 Solenoid (Brake Oil This diagnostic code is associated with brake charging solenoid. FMI 0009 00-110
Charging) Voltage 03 means ECM has determined solenoid circuit voltage is above
Above Normal. normal. Possible causes of this diagnostic code are: solenoid has failed,
(such a failure is unlikely). When this diagnostic code occurs, cooling
fan and brake charging solenoid return is disabled. Both systems go to
FAILSAFE mode.
Charging) Shorted to 04 means ECM has determined solenoid circuit voltage is above
Ground. normal. Possible causes of this diagnostic code are: solenoid energize
circuit is shorted to ground, solenoid has failed, or ECM has failed (such
a failure is unlikely). ECM will log diagnostic code. When this
diagnostic code occurs, cooling fan and brake charging solenoid return
is disabled. Both systems go to FAILSAFE mode.
Charging) Open Circuit. 05 means ECM has determined solenoid current is below normal.
failed (such a failure is unlikely). ECM will log diagnostic code. When
this diagnostic code occurs, cooling fan and brake charging solenoid
return is disabled. Both systems go to FAILSAFE mode.
1251 00 Alternator R-Terminal This diagnostic code is recorded when R-terminal frequency is above 0009 00-115
Signal Frequency Above 2,000 Hz.
2,000 Hz.
1251 01 Alternator R-Terminal This diagnostic code is recorded when R-terminal frequency is below 0009 00-116
Signal Frequency Below 10 Hz.
10 Hz.
0007 00-21
TM 5-3805-290-23-1

Table 2. MID 081 - Machine Control - Continued.
TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
1251 08 Alternator R-Terminal This diagnostic code is associated with alternator R-terminal connector. 0009 00-118
Signal Abnormal FMI 08 means ECM has determined terminal signal is abnormal.
Frequency. Possible causes of this diagnostic code are: alternator has failed,
intermittent connections or poor connections, mechanical devices are
loose, or ECM has failed (such a failure is unlikely).
1401 03 Solenoid (Clutch 1) This diagnostic code is associated with clutch 1 solenoid (forward low). 0009 00-120
Short to +Batt. FMI 03 means ECM has determined solenoid circuit voltage is above
(such a failure is unlikely). When this diagnostic code occurs, ECM will
disable all other transmission solenoid outputs.
failed (such a failure is unlikely). When this diagnostic code occurs,
ECM will disable all other transmission solenoid outputs.
Short to Ground. FMI 06 means ECM has determined solenoid current is above normal.
is unlikely). When this diagnostic code occurs, ECM will disable this
transmission solenoid.
1402 03 Solenoid (Clutch 2) This diagnostic code is associated with clutch 2 solenoid (forward 0009 00-124
Short to +Batt. high). FMI 03 means ECM has determined solenoid circuit voltage is
above normal. Possible causes of this diagnostic code are: solenoid has
failed, solenoid energize circuit is shorted to +batt circuit, or ECM has
ECM will disable all other transmission solenoid outputs.
Open Circuit. high). FMI 05 means ECM has determined solenoid current is below
normal. Possible causes of this diagnostic code are: solenoid energize
circuit is open, solenoid return circuit is open, solenoid has failed, or
occurs, ECM will disable this transmission solenoid.
0007 00-22
TM 5-3805-290-23-1

TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
Short to Ground. high). FMI 06 means ECM has determined solenoid current is above
a failure is unlikely). When this diagnostic code occurs, ECM will
disable this transmission solenoid.
1403 03 Solenoid (Clutch 3) This diagnostic code is associated with clutch 3 solenoid (reverse). FMI 0009 00-130
Short to +Batt. 03 means ECM has determined solenoid circuit voltage is above
disable all other transmission solenoid outputs.
Open Circuit. 05 means that ECM has determined that solenoid current is below
Short to Ground. 06 means ECM has determined solenoid current is above normal.
1404 03 Solenoid (Clutch 4) This diagnostic code is associated with clutch 4 solenoid (second 0009 00-136
Short to +Batt. speed). FMI 03 means ECM has determined solenoid circuit voltage is
above normal. Possible causes of this diagnostic code are: solenoid has
failed, solenoid energize circuit is shorted to +batt circuit, or ECM has
ECM will disable solenoids for gear 1 and gear 3.
Open Circuit. speed). FMI 05 means ECM has determined solenoid current is below
0007 00-23
TM 5-3805-290-23-1

TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
Short to Ground. speed). FMI 06 means ECM has determined solenoid current is above
a failure is unlikely). When this diagnostic code occurs, ECM will
disable this transmission solenoid.
1405 03 Solenoid (Clutch 5) This diagnostic code is associated with clutch 5 solenoid (third and 0009 00-142
Short to +Batt. fourth speed). FMI 03 means ECM has determined solenoid circuit
voltage is above normal. Possible causes of this diagnostic code are:
solenoid has failed, solenoid energize circuit is shorted to +batt circuit,
or ECM has failed (such a failure is unlikely). When this diagnostic
code occurs, ECM will disable solenoids for gear 1 and gear 2.
Open Circuit. fourth speed). FMI 05 means ECM has determined solenoid current is
below normal. Possible causes of this diagnostic code are: solenoid
energize circuit is open, solenoid return circuit is open, solenoid has
failed, or ECM has failed (such a failure is unlikely). When this
diagnostic code occurs, ECM will disable this transmission solenoid.
Short to Ground. fourth speed). FMI 06 means ECM has determined solenoid current is
above normal. Possible causes of this diagnostic code are: solenoid
energize circuit is shorted to ground, solenoid has failed, or ECM has
ECM will disable this transmission solenoid.
1406 03 Solenoid (Clutch 6) This diagnostic code is associated with clutch 6 solenoid (first speed). 0009 00-148
Short to +Batt. FMI 03 means ECM has determined solenoid circuit voltage is above
disable solenoid for gear 2 and gear 3.
ECM will disable this transmission solenoid.
0007 00-24
TM 5-3805-290-23-1

TROUBLE-
CID SHOOTING
FMI FAULT PROCEDURE
Short to Ground. FMI 06 means ECM has determined solenoid current is above normal.
1834 04 Ignition Switch This diagnostic code is recorded when ECM reads keystart switch 0009 00-153
Short to Ground. signal voltage and voltage is too low. Possible causes of this failure are:
signal circuit in machine harness is shorted to ground or ECM has failed
(such a failure is unlikely). ECM will log diagnostic code.
MISCELLANEOUS REFERENCE TABLES
Autoshift Switch Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009 00-154

Valid Shift Lever Input States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009 00-154
Machine ECM Connector Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009 00-154
0007 00-25
TM 5-3805-290-23-1
TROUBLESHOOTING WITH AN EVENT CODE

Table 3. Event Codes.
TROUBLE-
SHOOTING
EVENT FAULT FAULT PROCEDURE
CODE DESCRIPTION CONDITIONS/EFFECTS PAGE
E015 High Engine Coolant This code is generated when engine has been running for at least 0009 00-155
Temperature Derate. three minutes, engine coolant temperature has exceeded trip point,
and delay time has expired. Alarm output will activate and event is
logged. When this code is generated, engine power is reduced. A
factory password is required to clear the event code. Contact your
local Caterpillar dealer to clear this event code.
Temperature Shutdown. three minutes, engine coolant temperature has exceeded trip point,
and delay time has expired. If engine shutdown is ENABLED fuel
will be shut off. Event is logged. When this code is generated,
engine is shut down. A factory password is required to clear the
event code. Contact your local Caterpillar dealer to clear this event
code.
Temperature Warning. three minutes, engine coolant temperature has exceeded trip point
of 230°F (110°C), delay time of four seconds has expired, and no
other codes for engine coolant are active. Alarm output will
activated and code is logged. When this code is generated, engine
operation is not immediately affected. However, if coolant
temperature continues to rise, engine will be derated. A factory
password is required to clear the event code. Contact your local
Caterpillar dealer to clear this event code.
E023 High Hydraulic Oil This code is generated when ECM detects hydraulic oil temperature 0009 00-155
Temperature Derate. greater than 211°F (105°C) and hydraulic oil temperature is greater
than set point for four seconds or more. ECM will log event. ECM
will derate engine. At maximum derate, ECM will reduce fuel by
50 percent. Derate will become inactive after hydraulic temperature
returns below 208°F (98°C). When this code is generated, a low
power condition may also be present.
E025 High Inlet Air This code is generated when engine has been running for at least 0009 00-155
Temperature Derate. three minutes, inlet air temperature has exceeded set point, delay
time has expired, and no other codes for inlet air temperature are
active. Alarm output will activate and event is logged.When this
code is generated, engine power is reduced. A factory password is
required to clear the event code. Contact your local Caterpillar
dealer to clear this event code.
0007 00-26
TM 5-3805-290-23-1
TROUBLESHOOTING WITH AN EVENT CODE - CONTINUED
Table 3. Event Codes - Continued.
TROUBLE-
SHOOTING
E027 High Inlet Air This code is generated when engine has been running for at least 0009 00-155
Temperature Warning. three minutes, inlet air temperature has exceeded trip point for
machine application, delay time of four seconds has expired and no
other codes for inlet air temperature are active. ECM will reset when
inlet air temperature cools below trip point. ECM detected inlet air
temperature is greater than 168°F (76°C). ECM will reset when inlet
air temperature is less than 165°F (74°C). Alarm output is activated
and code is logged. When this code is generated, ECM will derate
engine and ECM will continue to derate engine at a higher rate as
inlet air temperature rises. A factory password is required to clear
the event code. Contact your local Caterpillar dealer to clear this
event code.
E028 High Transmission Oil This code is generated when ECM detects transmission oil 0009 00-155
Temperature Derate. temperature is greater than 226°F (108°C) and transmission oil
temperature is greater than set point for four seconds or more. When
this code is generated, alarm output is activated, ECM will log
event, ECM will derate engine, and reduce fuel by 50 percent at
maximum derate. Derate will become inactive after transmission
oil temperature returns below 208°F (98°C) or a low power
condition may also be present.
E030 High Transmission Oil This code is generated when ECM detects transmission oil 0009 00-155
Temperature Warning. temperature is greater than 222°F (106°C) and transmission oil
temperature is greater than set point for four seconds or more. When
this code is generated, ECM will log warning and will transmit a
warning to display. Warning lamp will be turned on and become
inactive after transmission oil temperature returns below 219°F
(104°C) for four seconds.
E040 Low Engine Oil This code is generated when ECM detects engine has been running 0009 00-155
Pressure Shutdown. for at least five seconds, engine speed is above 350 rpm, engine oil
pressure is less than 14.5 psi (100 kPa), two-second delay time has
expired, and no codes for engine oil pressure sensor are active.
When this code is generated, code is logged. ECM will reset
shutdown when oil pressure rises 3 psi (21 kPa) above low pressure
trip line for 20 seconds. If engine shutdown input is ENABLED and
there is no rise in oil pressure above trip line, fuel will be shut off
after two-second delay has expired, and engine will shut down. A
0007 00-27
TM 5-3805-290-23-1
TROUBLE-
SHOOTING
E054 High Fuel Temperature This code is generated when engine has been running for at least 0009 00-155
Derate. three seconds and fuel temperature is above trip point for machine
application. When this code is generated, warning lamp will flash
while “Derate” is active. ET will display “Engine Derate” in first
engine status box on any ET status screen. ECM will generate an
EID E054 event code on CAT data link. Event code will be
displayed on a ET diagnostic screen. A factory password is required
to clear the event code. Contact your local Caterpillar dealer to clear
this event code.
E100 Low Engine Oil This code is generated when ECM detects that engine has been 0009 00-155
Pressure Warning. running for at least five seconds, engine speed is at least 350 rpm,
engine oil pressure is lower than threshold for low oil pressure for
more than two seconds, and these codes are not active:
• 100-03 Engine oil pressure open/short to +batt.
• 100-04 Engine oil pressure short to ground.
• 100-10 Engine oil pressure sensor abnormal rate
of change.
When this code is generated, ECM will log event and will reset
warning when oil pressure rises 3 psi (21 kPa) above threshold for
at least four seconds. This code has no effect on performance. A
E190 Engine Overspeed This code is generated when engine speed is above 3,000 rpm for 0009 00-155
Warning. 3,054E for more than six seconds or engine speed is above 3,300
rpm for 3056E for more than six seconds. Reset point is 2,800 rpm.
This event indicates excessive engine speed. It does not represent
an electronic system fault with ECM or speed/timing sensor. When
this code is generated, event is logged in memory. This code has no
effect on performance. A factory password is required to clear the
event code. Contact your local Caterpillar dealer to clear this event
code.
E265 User Defined This code is generated when ECM detects user-defined shutdown 0009 00-156
Shutdown. switch has been activated for one second, parking brake is set, and
machine speed is zero.When this code is generated, ECM will log
event and engine will shut down.
0007 00-28
TM 5-3805-290-23-1
TROUBLE-
SHOOTING
E272 Inlet Air Restriction This code is generated when ECM detects inlet air restriction is 0009 00-156
Warning. greater than set point for four seconds or more. When this code is
generated, ECM will log event, ECM will transmit a warning to
display in cab, and machine will have low power.
E283 Low Hydraulic Charge This code is generated when ECM detects a low hydraulic charge 0009 00-156
Pressure. pressure. This is not an electronic problem. Event code is logged.
Event code is active when hydraulic charge pressure becomes low.
When this code is generated, engine operation will not be affected.
However, if hydraulic charge pressure remains low, there may be a
problem with hydraulic system.
E441 Idle Elevated to This code is generated when battery voltage has exceeded trip point 0009 00-156
Increase Battery of 24.5V. When this code is generated, ECM will log event and
Voltage. increase engine speed. Actual increase will be between 1,000 and
1,100 rpm. This event indicates low battery voltage.
E442 Engine Failed to Stop This code is generated when, engine shutdown was slow when 0009 00-156
With a No-Fuel engine start switch was turned to OFF position, engine failed to shut
Command. down when engine start switch was turned to OFF position, or
engine failed to shut down when fuel injection pump stopped fuel
injection.When this code is generated, if engine still fails to shut
down, ECM will disable power relay for fuel injection pump. Event
code is logged in ECM memory.
E600 High Hydraulic Oil This code is generated when ECM detects hydraulic oil temperature 0009 00-156
Temperature Warning. is greater than 223°F (106°C) and hydraulic oil temperature is
greater than set point for four seconds or more. ECM will log
warning and transmit a warning to display in cab. ECM will reset
warning when hydraulic oil temperature falls below 219°F (104°C)
for four seconds. When this code is generated, machine will have
low power.
E883 Engine Failed to Stop This code is generated when engine shutdown was slow when 0009 00-156
When Fuel Solenoid engine start switch was turned to OFF position, engine failed to stop
Disengaged. when ECM disabled fuel injection pump, or engine failed to shut
down when engine start switch was turned to OFF position. When
this code is generated, ECM attempts to shut down engine by
instructing fuel injection pump to stop fuel injection. Event code is
logged in ECM memory.
END OF WORK PACKAGE
0007 00-29/(0007 00-30 Blank)

100
TM 5-3805-290-23-1
TROUBLESHOOTING WITHOUT A DIAGNOSTIC CODE 0008 00
NOTE
• For a better understanding of each system, review the appropriate section in Theory of Operation (WP
0003 00).
• These procedures may give direction to replace wiring harnesses. However, limited repair of wiring har-
nesses is authorized. Refer to Electrical General Maintenance Instructions (WP 0022 00) for the correct
repair procedures.
• When directed to use a bypass harness and breakout Ts, refer to Electrical General Maintenance Instruc-
tions (WP 0022 00) for the correct hook-up procedures.
Table 1. Engine Troubleshooting.
MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION
1. Engine Cannot Reach Top NOTE

Rpm.
If this problem occurs only under load, refer to Malfunction 17. “Low
Power/Poor or No Response to Throttle.”
1. Check fuel gage by visually checking 1. If tank is low, add fuel (TM 5-3805-
for fuel in tank. 290-10).
2. If problem still exists, go to Test 2.
2. Connect MSD and check for active or 1. Troubleshoot any active codes before
logged diagnostic codes using ET continuing with this procedure. Refer
software (WP 0006 00). to Troubleshooting With a Diagnostic
Code (WP 0009 00).
3. Check fuel pressure. Refer to Fuel If problem still exists, go to Test 4.
System Pressure Test (WP 0011 00).
4. Perform Fuel Quality Test (WP 0011 If problem still exists, go to Test 5.
00).
5. Perform Air in Fuel Test (WP 0011 00). If problem still exists, go to Test 6.
6. Ensure all fuel lines are tight, properly 1. Replace, tighten, secure, or clean fuel
secured, and free of restriction (WP lines if necessary and replace fuel
0030 00, WP 0035 00, and WP 0038 filters as necessary (WP 0036 00).
00). 2. If problem still exists, go to Test 7.
7. If temperature is below 32oF (0oC) 1. If solidified fuel is found, drain and fill
check for solidified fuel (wax) in tank. fuel tank (WP 0166 00).
8. Check restriction indicator on air 1. If restriction in indicated, clean or
cleaner (TM 5-3805-290-10). replace air cleaner elements (WP 0032
00), remove any blockages or
restrictions, and replace damaged air
inlet and exhaust lines or hoses (WP
0033 00 and WP 0041 00).
0008 00-1
TM 5-3805-290-23-1
TROUBLESHOOTING WITHOUT A DIAGNOSTIC CODE - CONTINUED 0008 00
Table 1. Engine Troubleshooting - Continued.
1. Engine Cannot Reach Top 9. Perform Cylinder Balance Test (WP If problem still exists, go to Test 10.
Rpm - Continued. 0011 00).
10. Check valve lash (WP 0155 00). 1. Adjust valve lash as necessary.
11. Perform Compression Test (WP 0010 1. If compression on one or more
00). cylinders is low, replace engine (WP
0145 00).
2. If compression is OK or if problem still
exists, go to Test 12.
12. Perform Fuel Injector Nozzle Test (WP 1. If nozzles are damaged or defective,
0163 00). replace them as necessary.
13. Inspect turbocharger, drain, wastegate, 1. If necessary, replace turbocharger,
and mounting bolts (WP 0165 00). adjust wastegate, tighten bolts, or
unblock restricted drain.
14. Use MSD to ensure problem is not a 1. If necessary, remove user-defined
programmed parameter. parameter for top engine speed.
15. Use MSD to ensure correct mode was 1. If necessary, select correct mode.
selected. 2. If problem still exists, go to Test 16.
16. Use MSD to verify correct engine If rating is correct, go to Test 17.
rating for engine.
17. Use MSD to verify maximum engine 1. Use MSD to reset parameters to OEM
speed limit. specifications.
2. If problem still exists, use MSD to
observe signal for throttle position
sensor. If signal is erratic, perform
Throttle Position Sensor Circuit Test
(WP 0013 00).
2. Engine Cranks but Will Not 1. Visually check for fuel in tank (fuel 1. Add fuel if necessary (TM 5-3805-290-
Start. gage may be faulty). 10).
2. Connect MSD and check for active 1. Troubleshoot any active codes before
diagnostic codes using ET software. continuing with this procedure. Refer
to Troubleshooting With a Diagnostic
Code (WP 0009 00).
0008 00-2
TM 5-3805-290-23-1
2. Engine Cranks but Will Not 3. Visually inspect engine for these faults: 1. Correct faults as necessary.
Start - Continued. missing or damaged components, fluid 2. If problem still exists, go to Test 4.
leaks (coolant, fuel, hydraulic),
incorrect fluid levels (fuel, oil, coolant,
hydraulic), or damaged or improperly
secured electrical cables.
4. Try to start engine (TM 5-3805-290- 1. If crankshaft rotates normally with
10). If engine does not start, verify that engine start switch, go to Test 9.
crankshaft is rotating. If crankshaft 2. If crankshaft rotates very slowly with
does not rotate with engine start switch, engine start switch, go to Test 5.
use a suitable hand tool to rotate 3. If crankshaft does not rotate, remove
crankshaft. belts (WP 0046 00) and try again. If
crankshaft still does not rotate, replace
engine (WP 0145 00).
5. Turn engine start switch to OFF 1. Correct faults as necessary.
position (TM 5-3805-290-10). Check 2. If problem still exists, got to Test 6.
positive and negative battery
connections to engine ECM. Refer to
Electrical System Schematic (WP 0210
00) and Electrical Connectors
Inspection (WP 0022 00).
6. Check negative battery connection on 1. Clean and tighten any loose or corroded
ground stud and connections of starter connections and replace any damaged
motor terminals. wiring harnesses (WP 0169 00 thru WP
0175 00).
7. Remove starter motor (WP 0048 00) 1. If damaged, replace starter motor (WP
and check starter motor pinion and 0048 00) or flywheel (WP 0150 00).
flywheel ring gear for damage (WP 2. If problem still exists, go to Test 8.
0150 00).
8. Perform Electrical Power Supply If problem still exists, go to Test 9.
Circuit Test (WP 0013 00).
9. Check valve lash (WP 0155 00). 1. If necessary, reset valve lash
10. Perform Fuel Injector Nozzle Test (WP 1. If not operating as specified in test
0163 00). procedure, replace fuel injector
nozzle(s) (WP 0163 00).
0008 00-3
TM 5-3805-290-23-1
2. Engine Cranks but Will Not 11. Check restriction indicator on air 1. If restriction is indicated, clean or
Start - Continued. cleaner (TM 5-3805-290-10). replace air cleaner elements (WP 0032
inlet and exhaust system lines or hoses
(WP 0033 00 and WP 0041 00).
12. Perform Compression Test (WP 0010 1. If compression is low on one or more
00). cylinders, replace engine (WP 0145
00).
2. If compression is OK, go to Test 13.
13. Perform Fuel System Pressure Test If problem still exists, go to Test 14.
(WP 0011 00).
00).
15. Perform Air in Fuel System Test (WP If problem still exists, go to Test 16.
0011 00).
16. Check for fuel supply lines that are 1. Replace or repair any restricted fuel
restricted. lines (WP 0030 00, WP 0035 00, and
WP 0038 00) and replace fuel filters
(WP 0036 00).
17. If temperature is below 32oF (0oC), If solidified fuel is found, drain and fill fuel
check for solidified fuel (wax) in tank. tank (WP 0166 00).
3. Engine Misfires, Runs NOTE
Rough, or is Unstable.
If problem only occurs under certain conditions, test engine under those con-
ditions. Examples of certain conditions are high rpm, full load, and certain
engine operating temperatures. Troubleshooting symptoms under other con-
ditions can give misleading results.
1. Visually check fuel tank for fuel (fuel 1. Add fuel if necessary (TM 5-3805-290-
gage may be faulty). 10).
diagnostic codes using ET software continuing with this procedure. Refer
(WP 0006 00). to Troubleshooting With a Diagnostic
Code (WP 0009 00).
(WP 0011 00).
00).
0008 00-4
TM 5-3805-290-23-1
3. Engine Misfires, Runs 5. Perform Air in Fuel System Test (WP If problem still exists, go to Test 6.
Rough, or is Unstable - 0011 00).
Continued.
(WP 0036 00).
7. If temperature is below 32oF (0oC), 1. If solidified fuel is found, drain and fill
check for solidified fuel (wax) in tank. fuel tank (WP 0166 00).
8. Check restriction indicator on air 1. If restriction is indicated, clean or
(WP 0033 00 and WP 0041 00).
9. Perform Cylinder Balance Test (WP 1. If there is not a reduction in engine
0011 00). speed when every line is loosened,
determine if nozzle(s) are leaking and
replace leaky nozzle(s) (WP 0163 00).
10. Check valve lash (WP 0155 00). 1. If necessary, reset valve lash.
00).
12. Check fuel injector nozzle(s) (WP 1. If damaged, replace fuel injection
0163 00). nozzle(s).
13. Ensure engine speed/timing sensor is 1. Install speed/timing sensor and harness
installed correctly on cylinder block correctly.
(WP 0067 00) and harness is correctly 2. If problem still exists, go to Test 14.
connected (WP 0170 00).
14. Check wiring harness to ensure cables 1. Reinstall harness correctly.
to sensors are not too tight (WP 0170 2. If problem still exists, go to Test 15.
00). This could cause an intermittent
problem due to vibration.
15. Perform Engine Speed/Timing Circuit If problem still exists, go to Test 16.
Test (WP 0013 00).
0008 00-5
TM 5-3805-290-23-1
3. Engine Misfires, Runs 16. Use MSD to observe signal for throttle 1. If signal is erratic, perform Digital
Rough, or is Unstable - position sensor. Throttle Position Sensor Circuit Test
Continued. (WP 0013 00).
2. If problem still exits, perform Fuel
Injection Pump Circuit Test (WP 0013
00).
4. Mechanical Noise (Knock) 1. Isolate source of noise. Remove 1. If damaged, replace engine
in Engine. suspect engine accessories. Inspect accessories.
suspect engine accessories. 2. If problem still exists, go to Test 2.
2. Remove valve cover (WP 0024 00) and 1. If damaged, replace rocker arms, shaft
inspect valve train and cylinder head (WP 0156 00), or cylinder head (WP
for obvious signs of damage. 0146 00).
2. If problem still exist, replace engine
(WP 0145 00).
5. Noise Coming from 1. Perform Fuel Quality Test (WP 0011 1. Remove unsatisfactory fuel from tank
Cylinder. 00). (WP 0166 00). Install new fuel filters
(WP 0036 00). Use proper grade of
clean fuel in fuel tank.
2. Perform Fuel Injector Nozzle Test (WP 1. If not operating as specified in test
0163 00). procedure, replace fuel injector
nozzle(s).
2. If problem still exists, go to
Malfunction 7, Excessive Valve Lash in
this work package.
6. Engine Vibration. 1. Start and run engine through speed 1. Replace damaged or missing parts and
range (TM 5-3805-290-10). Check tighten any loose bolts.
engine mounts for any of these 2. If problem still exists, go to Test 2.
conditions: loose engine supports,
loose or broken mounting brackets,
loose bolts, or omitted bolts (WP 0145
00).
2. Perform Cylinder Balance Test (WP If there is not a reduction in engine speed
0011 00). then there is a problem with that cylinder.
Go to Test 3.
0145 00).
2. If compression is OK or if problem still
0008 00-6
TM 5-3805-290-23-1
6. Engine Vibration - 5. Perform Fuel Injector Nozzle Test (WP 1. If nozzles are damaged or defective,
Continued. 0163 00). replace them as necessary.
6. Inspect turbocharger, drain, bearings, If necessary, replace turbocharger, tighten
housing, and mounting bolts (WP 0165 bolts, adjust wastegate, or unblock
00). restricted drain.
7. Excessive Valve Lash. 1. Remove valve mechanism cover (WP 1. If oil flow is restricted, unblock
0024 00) and check lubrication in valve passages to valve train and adjust valve
compartment. Ensure there is adequate lash (WP 0155 00).
engine oil flow in valve compartment. 2. If problem still exists, go to Test 2.
Passages for engine oil must be clean.
2. Check engine crankcase breather for 1. If blocked, replace engine crankcase
blockage or restrictions (WP 0024 00). breather.
3. Remove valve mechanism cover (WP 1. If damaged, replace rocker arms, shaft
0024 00) and inspect valve train and (WP 0156 00), or cylinder head (WP
cylinder head for obvious signs of 0146 00).
damage. 2. If problem still exists, the camshaft is
suspect, replace engine (WP 0145 00).
8. Excessive Engine Oil 1. Check for excess oil (TM 5-3805-290- 1. Remove excess oil. Locate source of
Consumption. 10). excess fluid. Repair leaks that are
causing problems. Recheck all fluid
levels.
2. Check engine crankcase breather for 1. If blocked, replace engine crankcase
blockage or restrictions (WP 0024 00). breather.
(WP 0033 00 and WP 0041 00).
5. Ensure valve lash is correct (WP 0155 If compression on one or more cylinders is
00) and then perform Compression low, replace engine (WP 0145 00).
Test (WP 0010 00).
0008 00-7
TM 5-3805-290-23-1
9. Low Engine Oil Pressure. CAUTION

DO NOT operate engine with low oil pressure. Engine damage will result. If
measured oil pressure is low, discontinue engine operation until problem is
corrected.
Code (WP 0009 00).
2. Inspect engine oil level (TM 5-3805- 1. If necessary, add oil (TM 5-3805-290-
290-10). 10).
3. Perform Engine Oil Pressure Test (WP 1. Change engine oil and filters (WP 0025
0010 00). 00).
4. Inspect piston cooling jets for damage 1. Replace any piston cooling jet that
(WP 0159 00). appears cracked or broken
5. Inspect engine oil pump for excessive 1. Remove any material from oil suction
wear and check oil suction tube for tube. If damaged, replace oil pump.
build-up that restricts oil flow, cracks, 2. If problem still exists, replace engine
or a damaged O-ring seal (WP 0160 (WP 0145 00).
00).
10. Engine Has Early Wear. 1. Ensure correct engine oil and interval 1. Use correct engine oil and change
are used when changing engine oil. engine oil at correct interval (WP 0020
00).
2. Change engine oil and filters (WP 0025 If problem still exists, go to Test 3.
00).
3. If oil filter bypass valve is open, oil will 1. If spring is broken, replace spring (WP
not be filtered. Check oil filter bypass 0160 00).
valve for a weak or broken spring (WP 2. If problem still exists, go to Test 4.
0027 00).
4. Inspect air inlet system for leaks. 1. Repair any leaks and replace air cleaner
Inspect all gaskets and connections. elements if necessary (WP 0032 00).
5. Replace fuel filters (WP 0036 00). If problem still exists, go to Test 6.
6. Check for contaminated fuel. 1. If fuel is contaminated, drain tank and
lines and replace fuel filters (WP 0036
00).
0008 00-8
TM 5-3805-290-23-1
10. Engine Has Early Wear - 7. Perform Engine Oil Pressure Test (WP 1. If oil pressure is low, replace engine oil
Continued. 0010 00). pump (WP 0160 00).
2. If problem still exists, replace engine
(WP 0145 00).
11. Excessive Black Smoke. 1. Check restriction indicator on air 1. If restriction is indicated, clean or
(WP 0033 00 and WP 0041 00).
2. Check 5V supply for engine boost If problem still exists, go to Test 3.
pressure sensor. Refer to 5V Engine
Pressure Sensor Supply Circuit Test
(WP 0013 00).
0145 00).
2. If compression is OK, but problem still
2. If problem still exists, go to test 5.
5. Connect MSD and check for correct If diagnostic codes are present, engine
engine serial number, arrangement ECM must be programmed with correct
number, and software. Use ET to verify information (WP 0053 00).
any active diagnostic codes (WP 0006
00).
12. Excessive White Smoke. NOTE
Some white smoke may be present during cold start-up conditions when
engine is operating normally. If white smoke persists, there may be a prob-
lem.
(WP 0011 00).
00).
0008 00-9
TM 5-3805-290-23-1
12. Excessive White Smoke - 4. Perform Air in Fuel System Test (WP If problem still exists, go to Test 5.
Continued. 0011 00).
(WP 0036 00).
6. If temperature is below 32oF (0oC), 1. Drain and fill tank (WP 0166 00).
check for solidified fuel (wax) in tank. 2. If problem still exists, go to Test 7.
7. Perform Cylinder Balance Test (WP 1. If there is no reduction in engine speed,
0011 00). go to Test 10.
2. If all cylinders have been checked and
no problems were detected, go to Test
8.
9. Perform Compression Test (WP 0010 1. If compression in one or more cylinders
00). is low, replace engine (WP 0145 00).
2. If compression is OK, but problem still
10. Perform Fuel Injector Nozzle Test (WP 1. If nozzle(s) are damaged or defective,
0163 00). replace them as necessary.
11. Connect MSD and check for active If active diagnostic codes exist, perform
diagnostic codes for engine pressure or Engine Temperature Sensor Open or Short
temperature sensors (WP 0006 00). Circuit Test (WP 0013 00) or 5V Engine
Pressure Sensor Supply Circuit Test (WP
0013 00).
13. Elevated Idle. Refer to Troubleshooting With An Event
Code, E441 (WP 0009 00).
14. Engine Speed Does Not Connect MSD and check for active 1. Troubleshoot any active codes before
Change. diagnostic codes using ET software (WP continuing with this procedure. Refer
0006 00). to Troubleshooting With a Diagnostic
Code (WP 0009 00).
2. If problem still exists, perform Set
Speed Circuit Test (WP 0013 00).
0008 00-10
TM 5-3805-290-23-1
15. Engine Stalls at Low Rpm. CAUTION

DO NOT crank engine continuously for more than 30 seconds. Allow start-
ing motor to cool for two minutes before cranking engine again.
Code (WP 0009 00).
3. Perform Cylinder Balance Test (WP 1. If damaged, replace fuel injector
0011 00). nozzle(s) (WP 0163 00).
(WP 0011 00).
00).
0011 00).
(WP 0036 00).
9. Check all accessory equipment for 1. Repair or replace any damaged
problems that may create excessive components.
load on engine. 2. If problem still exists, go to Test 10.
10. Perform CAT Data Link Circuit Test If problem still exists, check engine and
(WP 0013 00). machine wiring harnesses for defects (WP
0169 00 thru WP 0175 00). Refer to
Electrical Connectors Inspection (WP
0022 00).
16. Poor Acceleration or 1. Connect MSD and check for active 1. Troubleshoot any active codes before
Response. diagnostic codes using ET software continuing with this procedure. Refer
Code (WP 0009 00).
0008 00-11
TM 5-3805-290-23-1
16. Poor Acceleration or 2. Visually check fuel tank for fuel (fuel 1. Add fuel if necessary (TM 5-3805-290-
Response - Continued. gage may be faulty). 10).
(WP 0011 00).
00).
0011 00).
(WP 0036 00).
0011 00). go to Test 12.
2. If there is a reduction in engine speed,
go to Test 9.
9. Check valve lash (WP 0155 00). 1. If necessary, adjust valve lash.
00).
11. Check fuel injection nozzles (WP 0163 If damaged, replace fuel injection
00). nozzle(s).
17. Low Power/Poor or No CAUTION
Response to Throttle.
Code (WP 0009 00).
2. Inspect engine oil level (TM 5-3805- 1. If necessary, add oil (TM 5-3805-290-
290-10). 10).
0008 00-12
TM 5-3805-290-23-1
17. Low Power/Poor or No 3. Visually check fuel tank for fuel (fuel 1. Add fuel if necessary (TM 5-3805-290-
Response to Throttle - gage may be faulty). 10).
Continued. 2. If problem still exists, go to Test 4.
(WP 0011 00).
00).
0011 00).
(WP 0036 00).
(WP 0033 00 and WP 0041 00).
0011 00). go to Test 14.
11. Check valve lash (WP 0155 00). 1. If necessary, adjust valve lash.
00).
13. Check fuel injector nozzles (WP 0163 1. If damaged, replace fuel injector
00). nozzle(s).
14. Inspect turbocharger, drain, bearings, 1. If necessary, replace turbocharger,
housing, and mounting bolts (WP 0165 tighten bolts, adjust wastegate, or
00). unblock restricted drain.
0008 00-13
TM 5-3805-290-23-1
17. Low Power/Poor or No 15. Use MSD to ensure problem is not a If problem still exists, go to Test 16.
Response to Throttle - programmed parameter, incorrect
Continued. mode is not selected, or incorrect
engine rating has not been provided.
16. Use MSD to verify maximum engine If problem still exists, go to Test 17.
speed limit and to reset parameters to
OEM specifications if necessary.
17. With engine shutdown, connect MSD If problem still exists, go to Test 18.
(WP 0006 00) and verify boost pressure
is 0 psi (0 kPa) and perform 5V Engine
Pressure Sensor Supply Circuit Test
(WP 0013 00).
18. Use MSD to verify throttle position 1. If maximum no-load speed cannot be
status. Run engine until speed is equal obtained, perform Set Speed Circuit
to maximum no-load speed. Test (WP 0013 00).
2. If engine speed is erratic, refer to
Digital Throttle Position Sensor
18. Intermittent Low Power or CAUTION
Power Cutout.
NOTE
Use this procedure only if engine does not shut down completely.
1. Perform Electrical Connector 1. If damaged, replace wiring harness(es)
Inspection (WP 0022 00). in question (WP 0169 00 thru WP 0175
00).
(WP 0011 00).
00).
0011 00).
(WP 0036 00).
0008 00-14
TM 5-3805-290-23-1
18. Intermittent Low Power or 7. If temperature is below 32oF (0oC), 1. If solidified fuel is found, drain and fill
Power Cutout - Continued. check for solidified fuel (wax) if tank. tank (WP 0166 00).
8. With engine shutdown, connect MSD 1. If no faults are found, go to Test 10.
and verify boost pressure is 0 psi (0 2. If either of these diagnostic codes are
kPa) and 102-03 Boost Pressure Sensor logged, go to Test 9.
Short to Batt or 102-04 Boost Pressure
Sensor Short to Ground diagnostic
codes are not active (WP 0006 00).
9. Perform Engine Pressure Sensor Open If problem still exists, go to Test 10.
or Short Circuit Test (WP 0013 00).
(WP 0033 00 and WP 0041 00).
11. Verify that J1/P1 connector is correctly 1. If necessary, reconnect J1/P1.
connected. 2. If problem still exists, go to Test 12.
13. Verify fuel injection pump electrical 1. If necessary, reconnect fuel injection
connector is correctly connected (WP pump connector.
0164 00). 2. If problem still exists, go to Test 14.
14. Perform Fuel Injection Pump Circuit If problem still exists, go to Test 15.
Test (WP 0013 00).
15. Operate engine at maximum no-load If percentages are not within
speed. If programmed upper demand specifications, perform Digital Throttle
limit cannot be obtained, check throttle Position Sensor Circuit Test (WP 0013
position to ensure it is within 00).
calibration (80 to 87%) at high idle. If
engine speed is erratic, reduce engine
speed. Check that low idle position is
within calibration (20 to 27%) at low
idle. Slowly increase engine speed.
Check that engine speed is steady.
Check that position increases with
more throttle.
0008 00-15
TM 5-3805-290-23-1
19. Intermittent Engine NOTE

Shutdown.
Use this procedure only if engine shuts down completely and must be
restarted.
Code (WP 0009 00).
(WP 0011 00).
00).
0011 00).
(WP 0036 00).
8. Check for correct installation of engine 1. If damaged, replace wiring harness(es)
ECM connectors at these locations (WP 0169 00 thru WP 0175 00).
(refer to Electrical Connectors 2. If problem still exists, go to Test 9.
Inspection [WP 0022 00]):
(a) J1/P1 engine ECM connector (WP
0053 00).
(b) J20/P20 MIC (WP 0170 00).
(c) J401/P401 speed/timing sensor
connector (WP 0067 00).
(d) J103/P103 inlet manifold
temperature sensor connector (WP
0064 00).
(e) J100/P100 engine coolant
temperature sensor connector (WP
0063 00).
(f) J201/P201 engine oil pressure
sensor connector (WP 0066 00).
0008 00-16
TM 5-3805-290-23-1
19. Intermittent Engine (g) J200/P200 boost pressure sensor

Shutdown - Continued connector (WP 0065 00).
(h) J40/P40 fuel injection pump
10. Inspect battery wires from engine ECM 1. If damaged, replace wiring harness(es)
back to battery compartment. Inspect (WP 0169 00 thru WP 0175 00).
wires and power relay. Check power 2. If problem still exists, go to Fuel
and ground connections to engine Injection Pump Circuit Test (WP 0013
ECM. Refer to Electrical System 00).
Schematic (WP 0210 00) and Fuel
Inspection Pump Circuit Test (WP
0013 00) for more information.
20. Inlet Air Temperature is 1. Determine if ambient air temperature is 1. Determine cause of high air
Too High. within design specifications for temperature. Make corrections when
cooling system (TM 5-3805-290-10). possible.
2. Refer to Malfunction 21, Coolant If problem still exists, go to Test 3.
Temperature is Too High in this work
package to continue troubleshooting.
NOTE
When inlet air pressure is low, turbocharger works harder in order to
achieve desired inlet manifold pressure. This increases inlet air temperature.
(WP 0033 00 and WP 0041 00).
4. Connect MSD (WP 0006 00). Allow air 1. If reading is not correct, switch sensor
inlet temperature sensor to cool and with a sensor that is know to be good.
remove it (WP 0064 00). Plug it into 2. If problem still exists, go to Test 5.
harness and check reading for inlet air
temperature using ET. If sensor is OK,
reading and ambient temperature are
approximately equal.
5. Check for sufficient flow of air through If air flow across aftercooler is insufficient,
aftercooler. clean aftercooler (WP 0034 00).
0008 00-17
TM 5-3805-290-23-1
21. Coolant Temperature is 1. Check radiator fins for dirt, debris, and/ 1. Remove any dirt and/or debris and
Too High. or damage. straighten any bent fins or replace
radiator (WP 0167 00).
8
WARNING
• DO NOT service cooling system unless engine has been allowed to
cool down. This is a pressurized cooling system and escaping steam
or hot coolant may result in serious burns.
• DO NOT remove cooling system radiator cap when engine is hot.
Allow engine to cool down. Loosen cap to first stop and let any pres-
sure out of cooling system, then remove cap. Failure to follow this
warning may result in serious burns.
• Wear effective eye, hand, and skin protection when handling cool-
ants. Failure to do so may result in injury to personnel.
8
2. Inspect coolant level (TM 5-3805-290- 1. If necessary, add coolant.

3. Talk to operator and ensure there is not 1. Reduce load and verify that condition
excessive load on system (TM 5-3805- does not reoccur.
290-10). 2. If problem still exists, go to Test 4.
4. Check cooling system for leaks by 1. Repair any leaks immediately.
performing System Pressure Test. 2. If problem still exists, replace
Refer to Testing Radiator and Cooling thermostat (WP 0043 00).
System for Leaks (Pressure Test) (WP 3. If problem still exists, go to Test 5.
0012 00).
5. With engine off and completely cool, 1. If bubbles are present in coolant,
remove pressure cap for coolant combustion gases may be entering
system. Start engine (TM 5-3805-290- cooling system. Replace cylinder head
10) and inspect coolant for presence of gasket (WP 0146 00).
bubbles. 2. If no bubbles are present, reinstall
pressure cap and go to Test 6.
6. Visually inspect cooling system for 1. If damaged, replace hoses (WP 0044
collapsed hoses and/or other 00). Clean and flush radiator (WP 0042
restrictions. 00).
0008 00-18
TM 5-3805-290-23-1
21. Coolant Temperature is 7. Connect MSD and monitor coolant 1. If ET shows a lower temperature,
Too High - Continued. temperature (WP 0006 00). Start replace instrument cluster (WP 0051
engine (TM 5-3805-290-10) and 00).
compare cluster reading with MSD 2. If problem still exists, inspect and
reading. replace water pump (WP 0045 00) as
necessary.
22. Engine Oil in Cooling 1. Check for leaks in oil cooler core (WP 1. If a leak is found, install a new oil
System. 0028 00). cooler core and change engine oil (WP
0025 00).
2. Remove cylinder head (WP 0146 00) 1. If damaged, replace cylinder head.
and inspect for signs of damage. 2. If problem still exists, replace engine
(WP 0145 00).
23. Coolant in Engine Oil. 1. Check for leaks in oil cooler core (WP 1. If a leak is found, install a new oil
0028 00). cooler core and change engine oil (WP
0025 00).
2. Remove cylinder head (WP 0146 00) 1. If damaged, replace cylinder head.
and inspect for signs of damage. 2. If problem still exists, replace engine
(WP 0145 00).
24. Engine ECM Will Not 1. Connect MSD (WP 0006 00). 1. If engine ECM does not communicate
Communicate with Other with ET, refer to Malfunction 25, MSD
Systems or Display Will Not Communicate with Engine
Modules. ECM in this work package.
2. Ensure these items are correctly If problem still exists, perform CAT Data
installed and undamaged (refer to Link Circuit Test (WP 0013 00).
Electrical Connectors Inspection [WP
0022 00]):
(a) J1/P1 engine ECM connector (WP
0053 00).
(b) J20/P20 MIC (WP 0170 00).
(c) Wiring to Instrument Cluster (WP
0051 00).
(d) Wiring to other control modules
(WP 0052 00 and WP 0053 00).
0008 00-19
TM 5-3805-290-23-1
25. MSD Will Not 1. Connect MSD (WP 0006 00). 1. If red power indicator lamp remains
Communicate with Engine OFF, go to Test 2.
ECM. 2. If communication adapter for MSD
activates and red power indicator lamp
is ON, go to Test 4.
2. Check battery voltage to data link If problem still exists, go to Test 3.
connector. Refer to CAT Data Link
Circuit Test, Test 4 (WP 0013 00).
3. Change MSD connection components. If problem still exists, go to Test 4.
Refer to CAT Data Link Circuit Test,
Test 6 (WP 0013 00).
4. Start ET. 1. If ET reports “Connected and 1 (or
more) module detected,” STOP.
2. If ET reports “Interface hardware is not
connected,” go to Test 5.
3. If ET cannot connect to engine ECM,
go to Test 6.
5. Inspect cable from MSD to Change MSD components. Refer to CAT
communication adapter. Verify correct Data Link Circuit Test, Test 6 (WP 0006
MSD port has been used. Inspect cable 00).
from MSD to diagnostic connector.
6. Check battery voltage at engine ECM If problem still exists, go to Test 7.
if MSD cannot connect engine ECM.
Refer to CAT Data Link Circuit Test,
Test 3 (WP 0013 00).
7. Connect MSD directly to engine ECM If problem still exists, connect MSD and
and follow test procedures for CAT engine ECM to another battery. Refer to
Data Link Circuit Test, Test 5 (WP CAT Data Link Circuit Test, Test 7 (WP
0013 00). 0013 00).
0008 00-20
TM 5-3805-290-23-1
Table 2. Electrical System Troubleshooting.
1. Alternator (Charging 1. Inspect condition and tension of 1. If alternator drive belts are worn,
Problem). alternator belts (WP 0046 00). damaged, or loose, replace or adjust
belts.
2. Inspect battery cables, wiring, and 1. Clean any corroded or dirty
connections in charging circuit. Refer connections, tighten any loose
to Electrical System Schematic (WP connections, and replace any faulty
0210 00). wiring harnesses (WP 0169 00 thru WP
0175 00).
3. Inspect and load test batteries (TM 9- 1. If batteries are damaged, defective, or
6140-200-14). do not pass load test, replace batteries
(WP 0077 00).
2. If problem still exists, test and replace
alternator as necessary (WP 0047 00).
2. Alternator (Noisy 1. Inspect condition and tension of 1. If alternator drive belts are worn,
Operation). alternator drive belts (WP 0046 00). damaged, or loose, replace or adjust
belts.
2. Ensure alternator drive belts are in 1. If necessary, replace mounting bracket
proper alignment. Inspect alternator to ensure alternator drive belts and
mounting bracket for cracks and wear alternator drive pulley are in alignment
(WP 0046 00 and WP 0047 00). (WP 0047 00).
3. Check torque on alternator pulley (WP 1. Loosen nut for alternator drive pulley
0047 00). and tighten nut to 33 to 40 lb-ft (45 to
55 Nm).
2. If problem still exists, replace
alternator (WP 0047 00).
3. Engine Will Not Crank. 1. Inspect battery disconnect switch, 1. If battery cables are corroded, remove
battery post, and battery cables for and clean battery cables (WP 0079 00).
loose connections and corrosion. Tighten and clean any loose or
corroded connections.
2. Load test batteries and inspect for 1. If damaged, replace batteries (WP 0077
damage or leaks (TM 9-6140-200-14). 00).
3. Test starting system. Refer to Electric If problem still exists, go to Test 4.
Starting System Test (WP 0013 00).
0008 00-21
TM 5-3805-290-23-1
Table 2. Electrical System Troubleshooting - Continued.
3. Engine Will Not Crank - 4. Check wiring to starting motor 1. If damaged, replace wiring harness in
Continued. solenoid. Refer to Electrical System question (WP 0169 00 thru WP 0175
Schematic (WP 0210 00). 00).
5. Inspect starter motor pinion (WP 0048 1. If damaged, replace starter or flywheel.
00) and flywheel ring gear (WP 0150 2. If problem still exists, go to Test 6.
00) for damage and turn engine over by
hand.
6. Perform Electrical Power Supply If problem still exists, replace engine (WP
Circuit Test (WP 0013 00). 0145 00).
4. Backup Alarm Always Off. 1. Check backup alarm. 1. If backup alarm operates correctly, go
(a) Disconnect backup alarm from to Test 2.
wiring harness (WP 0076 00). 2. If backup alarm has failed, replace
(b) Use jumpers to connect respective backup alarm (WP 0076 00).
backup terminals to +battery
circuit ground (WP 0210 00).
2. Check backup alarm circuit for a short 1. If wiring harness is OK, go to Test 3.
to ground. 2. If there is a short in wiring harness,
(a) Wiring harness remains short is between wire 321 BR (backup
disconnected from backup alarm. alarm signal) and circuit with low
(b) Turn engine start switch and resistance measurement. Replace
battery disconnect switch to OFF wiring harness in question (WP 0169
position (TM 5-3805-290-10). 00 thru WP 0175 00).
(c) Disconnect wiring harness
connectors J1 and J2 from
machine ECM (WP 0052 00).
(d) Bypass switch side of backup
alarm relay with jumper wire (WP
0210 00).
(e) At wiring harness connector J1,
measure resistance from J1-12
(backup alarm signal) to all
possible sources of ground. Check
resistance to all other connectors
used in ECM harness connector.
0008 00-22
TM 5-3805-290-23-1
4. Backup Alarm Always Off - 3. Check backup alarm circuit for an open 1. If wiring harness is OK, go to Test 4.
Continued. circuit. 2. If there is an open circuit in wiring
(a) Turn engine start switch and harness, open circuit is in wire 321 BR
battery disconnect switch to OFF (backup alarm signal) or wire H807YL
position (TM 5-3805-290-10). (return signal). Replace wiring harness
(b) At wiring harness connector for in question (WP 0169 00 thru WP 0175
backup alarm, place a jumper from 00).
contact 1 to contact 2.
(c) At wiring harness connector J2,
(backup alarm signal) to J2-4
(return signal).
4. Ensure problem is still active. 1. If problem is no longer active, initial
(a) Inspect and clean harness problem was probably caused by a poor
connector contacts. electrical connection and/or a short in
(b) Remove jumper from relay and a harness connector that was
reconnect harness connectors. disconnected and reconnected.
(c) Start engine (TM 5-3805-290-10). Resume normal machine operation.
2. If problem has not been corrected,
replace battery backup alarm relay
(WP 0054 00).
3. If problem still exists, replace machine
ECM (WP 0052 00).
5. Backup Alarm Always On. 1. Check backup alarm circuit for a short 1. If wiring harness is OK, go to Test 2.
to +battery circuit. 2. If there is a short in wiring harness,
(a) Turn engine start switch and short is between wire 321 BR (backup
battery disconnect switch to OFF alarm signal) and circuit with low
position (TM 5-3805-290-10). resistance measurement. Replace
(b) Disconnect wiring harness from wiring harness in question (WP 0169
backup alarm (WP 0076 00). 00 thru WP 0175 00).
connector J1 and connector J2
from machine ECM (WP 0052 00)
(d) At wiring harness connector J2,
(backup alarm signal) to all
possible sources of +battery.
Check resistance to all connectors
used in ECM harness connector.
2. Ensure problem is still active. 1. If problem has not been corrected,
(a) Inspect and clean harness replace backup alarm relay (WP 0054
connector contacts. 00.
(b) Reconnect all harness connectors. 2. If problem still exists, replace machine
(c) Start engine (TM 5-3805-290-10). ECM (WP 0052 00).
0008 00-23
TM 5-3805-290-23-1
6. One or More Worklights 1. Determine condition. 1. If one worklight is inoperative, replace

Are Inoperative. worklight bulb (WP 0060 00). If
problem still exists, go to Test 2.
2. If both front and back rear worklights
are inoperative, go to Test 4.
3. If all worklights are inoperative, go to
Test 6.
2. Check for open power circuit. 1. If battery voltage is present, go to Test
(a) Disconnect wiring harness from 3.
worklight housing (WP 0060 00). 2. If battery voltage is not present, there
(b) Turn battery disconnect switch, is an open circuit between worklight
engine start switch, and worklight switch and worklight housing. Replace
switch to ON position (TM 5- wiring harness in question (WP 0169
3805-290-10). 00 thru WP 0175 00).
(c) Select service drive mode on main
light switch (TM 5-3805-290-10).
(d) Measure voltage at worklight
between wiring harness pin 1,
circuit 615 (YL) or 608 (GN), and
ground.
3. Check for open ground circuit. 1. If continuity is present, replace
(a) Battery disconnect switch remains worklight housing (WP 0060 00).
in ON position (TM 5-3805-290- 2. If continuity is not present, there is an
10). open worklight ground circuit. Replace
(b) Wiring harness remains wiring harness in question (WP 0169
disconnected from worklight 00 thru WP 0175 00).
housing.
(c) Turn worklight switch and engine
start switch to OFF position (TM
5-3805-290-10).
(d) Check continuity at worklight
housing between wiring harness
pin 2, circuit 200 (BK), and
ground.
0008 00-24
TM 5-3805-290-23-1
6. One or More Worklights 4. Check for open power circuits. 1. If battery voltage is not present, go to
Are Inoperative - (a) Disconnect wiring harness from Test 5.
Continued. inoperative worklight housing 2. If battery voltage is present, there is an
(WP 0060 00). open worklight housing ground circuit.
(b) Turn battery disconnect switch, Replace wiring harness in question
engine start switch, and worklight (WP 0169 00 thru WP 0175 00).
switch to ON position (TM 5-
3805-290-10).
(d) Measure voltage at inoperative
worklight housing between wiring
harness pin 1, circuit 615 (YL) or
608 (GN), and ground.
5. Check for open worklight switch 1. If battery voltage is not present, there
power circuit. is an open circuit between worklight
(a) Disconnect wiring harness from relay and worklight switch. Replace
worklight switch (WP 0049 00). wiring harness in question (WP 0169
(b) Battery disconnect switch and 00 thru WP 0175 00).
engine start switch remain in ON 2. If battery voltage is present, replace
position (TM 5-3805-290-10). worklight switch (WP 0049 00). If
(c) Select service drive mode on main problem still exists, there is an open
light switch (TM 5-3805-290-10). circuit between worklight switch and
(d) If front worklights are inoperative, worklight. Replace wiring harness in
measure voltage at worklight question (WP 0169 00 thru WP 0175
switch between wiring harness pin 00).
2, circuit 338 (PK), and ground.
(e) If rear worklights are inoperative,
measure voltage at worklight
switch between wiring harness pin
5, circuit 338 (PK), and ground.
6. Check worklight fuse (TM 5-3805- 1. If fuse is open, replace it.
290-10). 2. If fuse is OK, go to Test 7.
7. Check for open worklight switch 1. If battery voltage is not present,
power circuit. temporarily replace worklight relay
(a) Disconnect wiring harness from (WP 0054 00). If problem still exists,
worklight switch (WP 0049 00). reinstall old relay and go to Test 8.
(b) Turn battery disconnect switch 2. If battery voltage is present, replace
and engine start switch to ON worklight switch (WP 0049 00).
position (TM 5-3805-290-10).
(d) Measure voltage at switch
circuit 338 (PK), and ground.
0008 00-25
TM 5-3805-290-23-1
6. One or More Worklights 8. Check for an open worklight relay coil 1. If battery voltage is not present, go to
Are Inoperative - power circuit. Test 9.
Continued. (a) Remove worklight relay (WP 2. If battery voltage is present, go to Test
0054 00). 10.
(b) Battery disconnect switch and
engine start switch remain in ON
position (TM 5-3805-290-10).
(d) Measure voltage at worklight relay
circuit 8630 (BU), and ground.
9. Check worklight relay coil power 1. If continuity is not present, there is an
circuit continuity. open circuit between worklight relay
(a) Disconnect wiring harness from and main light switch. Replace wiring
main light switch (WP 0049 00). harness in question (WP 0169 00 thru
(b) Worklight relay remains removed. WP 0175 00).
(c) Battery disconnect switch remains 2. If continuity is present, replace main
in ON position (TM 5-3805-290- light switch (WP 0049 00).
10).
(d) Check continuity between
worklight relay wiring harness pin
5, circuit 8630 (BU), and main
light switch wiring harness pin, J
circuit 8630 (BU).
10. Check for open worklight relay coil 1. If continuity is present, there is an open
ground circuit. ground circuit for worklight relay coil.
(a) Worklight relay remains removed. Replace wiring harness in question
(b) Battery disconnect switch remain (WP 0169 00 thru WP 0175 00).
in ON position (TM 5-3805-290- 2. If continuity is present, go to Test 11.
10).
(c) Turn engine start switch to OFF
position (TM 5-3805-290-10).
(d) Check continuity at worklight
relay between wiring harness pin
2, circuit 200 (BK), and ground.
0008 00-26
TM 5-3805-290-23-1
6. One or More Worklights 11. Check for an open worklight relay 1. If battery voltage is present, there is an
Are Inoperative - power circuit. open circuit between worklight switch
Continued. (a) Worklight relay remains removed. and worklight relay. Replace wiring
(b) Battery disconnect switch remains harness in question (WP 0169 00 thru
in ON position (TM 5-3805-290- WP 0175 00).
10). 2. If battery voltage is not present, there
(c) Engine start switch remains in is an open circuit between worklight
OFF position (TM 5-3805-290- fuse and worklight relay. Replace
10). wiring harness in question (WP 0169
(d) Measure voltage at worklight relay 00 thru WP 0175 00).
circuit 127 (OR), and ground.
7. One or Both Service Lights 1. Determine condition. 1. If one service light is inoperative,
Are Inoperative. replace service light bulb (WP 0062
00). If problem still exists, go to Test 2.
2. If both service lights are inoperative,
go to Test 4.
2. Check for open power circuit. 1. If battery voltage is present, go to Test
service light housing (WP 0062 2. If battery voltage is not present, there
00). is an open circuit between service light
(b) Turn battery disconnect switch relay and service light housing.
and engine start switch to ON Replace wiring harness in question
position (TM 5-3805-290-10). (WP 0169 00 thru WP 0175 00).
(d) Measure voltage at service light
circuit 619 (GN), and ground.
3. Check for open ground circuit. 1. If continuity is present, replace or
(a) Battery disconnect switch remains repair service light housing and wiring.
10). open service light ground circuit.
(b) Wiring harness remains Replace wiring harness in question
disconnected from service light (WP 0169 00 thru WP 0175 00).
housing.
position (TM 5-3805-290-10).
(d) Check continuity at service light
circuit 200 (BK), and ground.
4. Check service light breaker (TM 5- If breaker is open, replace it. If problem
3805-290-10). still exists or breaker is OK, go to Test 5.
0008 00-27
TM 5-3805-290-23-1
7. One or Both Service Lights 5. Check front turnlamps operation (TM 1. If both front turnlamps are inoperative,
Are Inoperative - 5-3805-290-10). there is an open service light housing
Continued. ground circuit. Replace wiring harness
in question (WP 0169 00 thru WP 0175
00).
2. If at least one front turnlamp is
operating correctly, go to Test 6.
6. Check for power to service light relay. 1. If battery voltage is present,
(a) Remove service light relay (WP temporarily replace service light relay
0054 00). (WP 0054 00) with a new one. If
(b) Turn battery disconnect switch problem still exists, reinstall old relay
and engine start switch to ON and go to Test 7.
position (TM 5-3805-290-10). 2. If battery voltage is not present, there
(c) Measure voltage at service light is an open circuit between service light
relay between wiring harness pin breaker and service light relay. Replace
1, circuit 102 (RD), and ground. wiring harness in question (WP 0169
00 thru WP 0175 00).
7. Check service light power circuit 1. If continuity is not present, there is an
continuity. open circuit between headight relay
(a) Service light relay remains and service lights. Replace wiring
removed. harness in question (WP 0169 00 thru
(b) Battery disconnect switch remains WP 0175 00).
in ON position (TM 5-3805-290- 2. If continuity is present, go to Test 8.
10).
position (TM 5-3805-290-10).
(d) Check continuity between service
light relay wiring harness pin 4,
8. Check for an open service light relay 1. If battery voltage is not present, go to
coil power circuit. Test 9.
(a) Service light relay remains 2. If battery voltage is present, there is an
removed. open service light relay ground circuit.
(b) Battery disconnect switch remains Replace wiring harness in question
in ON position (TM 5-3805-290- (WP 0169 00 thru WP 0175 00).
10).
(c) Turn engine start switch to ON
position (TM 5-3805-290-10).
(d) Select service drive mode on main
(e) Measure voltage at service light
5, circuit 8102 (BU), and ground.
0008 00-28
TM 5-3805-290-23-1
7. One or Both Service Lights 9. Check service light relay coil power 1. If continuity is not present, there is an
Are Inoperative - circuit continuity. open circuit between service light relay
Continued. (a) Disconnect wiring harness from and main light switch. Replace wiring
main light switch (WP 0049 00). harness in question (WP 0169 00 thru
(b) Service light relay remains WP 0175 00).
removed. 2. If continuity is present, go to Test 10.
(c) Turn battery disconnect switch
and engine start switch to OFF
position (TM 5-3805-290-10).
(d) Check continuity between service
light relay wiring harness pin 5,
circuit 8102 (BU), main light
switch wiring harness pin J, and
circuit 8102 (BU).
10. Check for open service light relay coil 1. If continuity is not present, there is an
ground circuit. open ground circuit for service light
(a) Service light relay remains relay coil. Replace wiring harness in
removed. question (WP 0169 00 thru WP 0175
(b) Turn battery disconnect switch to 00).
ON position (TM 5-3805-290-10). 2. If continuity is present, replace main
(c) Check continuity at service light light switch (WP 0049 00).
8. One Service Stoplamp or 1. Determine condition. 1. If one service stoplamp or one or more
One or More Turnlamps turnlamps (not all) are inoperative,
Are Inoperative. replace inoperative turnlamp bulb (WP
0058 00) or rear light housing cover
with a known good one (WP 0062 00).
If problem still exists (for rear turnlamp
only), reinstall old cover. If replaced,
go to Test 2.
2. If all turnlamps are inoperative, go to
Test 4.
3. If all stoplamps are inoperative, refer to
Malfunction 9, All Service Stoplamps
are Inoperative in this work package.
2. Check for open power circuit. 1. If continuity is present and rear
(a) Disconnect wiring harness from turnlamp is inoperative, replace
front turnlamp housing (WP 0062 turnlamp switch (WP 0051 00).
00) or rear light housing (WP 0058 2. If continuity is present and front
00). turnlamp is inoperative, go to Test 3.
(b) Disconnect wiring harness from 3. If continuity is not present, there is an
front turnlamp switch (WP 0051 open circuit between inoperative
00). turnlamp and turnlamp switch. Replace
(c) Turn battery disconnect switch wiring harness in question (WP 0169
and engine start switch to ON 00 thru WP 0175 00).
position (TM 5-3805-290-10).
0008 00-29
TM 5-3805-290-23-1
8. One Service Stoplamp or (d) Turn turnlamp switch to position

One or More Turnlamps with inoperative light (TM 5-
Are Inoperative - 3805-290-10).
Continued. (e) Select service drive mode on main
(f) For right front, check continuity at
turnlamp between wiring harness
pin 1, circuit 539 (BU), and
turnlamp switch pin 2, circuit 539
(BU).
(g) For left front, check continuity at
pin 1, circuit 540 (WH), and
(WH).
(h) For left rear, check continuity at
pin 1, circuit 605 (YE), and
(YE).
(i) For right rear, check continuity at
pin 1, circuit 606 (GY), and
(GY).
3. Check for open ground circuit. 1. If continuity is present, replace or
(a) Battery disconnect switch remains repair turnlamp housing and/or wiring
in ON position (TM 5-3805-290- (WP 0062 00).
10). 2. If continuity is not present, there is an
(b) Wiring harness remains open turnlamp ground circuit. Replace
disconnected from turnlamp wiring harness in question (WP 0169
housing (WP 0062 00). 00 thru WP 0175 00).
position (TM 5-3805-290-10).
(d) Check continuity at inoperative
pin 2, circuit 200 (BK), and
ground.
4. Check worklight fuse (TM 5-3805- 1. If fuse is open, replace it.
290-10). 2. If fuse is OK, go to Test 5.
0008 00-30
TM 5-3805-290-23-1
8. One Service Stoplamp or 5. Check for open turnlamp switch power 1. If battery voltage is not present,
One or More Turnlamps circuit. temporarily replace electronic flasher
Are Inoperative - (a) Disconnect wiring harness from located under instrument cluster (WP
Continued. turnlamp switch (WP 0051 00). 0051 00). If problem still exists,
(b) Turn battery disconnect switch reinstall old electronic flasher and go to
and engine start switch to ON Test 6.
position (TM 5-3805-290-10). 2. If battery voltage is present, replace
(c) Select service drive mode on main turnlamp switch (WP 0051 00).
(d) Measure voltage at switch
6. Check for open turnlamp flasher power 1. If battery voltage is not present,
circuit. temporarily replace turnlamp relay
(a) Disconnect wiring harness from (WP 0054 00). If problem still exists,
turnlamp flasher located under reinstall old turnlamp relay and go to
instrument cluster (WP 0051 00). Test 7.
(b) Turn battery disconnect switch 2. If battery voltage is present, there is an
and engine start switch to ON open circuit between flasher and
position (TM 5-3805-290-10). turnlamp switch. Replace wiring
(c) Select service drive mode on main harness in question (WP 0169 00 thru
light switch (TM 5-3805-290-10). WP 0175 00).
(d) Measure voltage at turnlamp
flasher between wiring harness
pin, circuit 695 (OR), and ground.
7. Check for open relay power circuit. 1. If battery voltage is not present, there
(a) Remove turnlamp relay (WP 0054 is an open circuit between turnlamp
00). relay and worklight fuse. Replace
(b) Turn battery disconnect switch wiring harness in question (WP 0169
and engine start switch to ON 00 thru WP 0175 00).
position (TM 5-3805-290-10). 2. If battery voltage is present, go to Test
(c) Select service drive mode on main 8.
(d) Measure voltage at turnlamp relay
circuit 127 (OR), and ground.
0008 00-31
TM 5-3805-290-23-1
8. One Service Stoplamp or 8. Check turnlamp flasher power circuit 1. If continuity is not present, there is an
One or More Turnlamps continuity. open circuit between turnlamp relay
Are Inoperative - (a) Disconnect wiring harness from and electronic flasher. Replace wiring
Continued. turnlamp flasher located under harness in question (WP 0169 00 thru
instrument cluster (WP 0051 00). WP 0175 00).
(b) Turnlamp relay remains removed. 2. If continuity is present, go to Test 9.
and engine start switch to ON
position (TM 5-3805-290-10).
(d) Check continuity at turnlamp
flasher between wiring harness
pin, circuit 695 (OR) and turnlamp
relay pin 4, circuit 695 (OR).
9. Check turnlamp relay coil ground 1. If continuity is not present, there is an
circuit. open turnlamp relay coil circuit.
(a) Turnlamp relay remains removed. Replace wiring harness in question
(b) Turn battery disconnect switch to (WP 0169 00 thru WP 0175 00).
ON position (TM 5-3805-290-10). 2. If continuity is present, go to Test 10.
(c) Check continuity at turnlamp relay
10. Check turnlamp relay coil power 1. If continuity is not present, replace
circuit. main light switch (WP 0049 00).
(a) Turnlamp relay remains removed. 2. If continuity is not present, there is an
(b) Disconnect main light switch from open circuit between turnlamp relay
wiring harness (WP 0049 00). and main light switch. Replace wiring
(c) Turn battery disconnect switch to harness in question (WP 0169 00 thru
ON position (TM 5-3805-290-10). WP 0175 00).
(d) Check continuity at turnlamp relay
circuit 8630 (BU) and main light
switch wiring harness pin J, circuit
8630 (BU).
0008 00-32
TM 5-3805-290-23-1
9. All Stoplamps Are 1. Check service stoplamp fuse (WP 0054 1. If fuse is open, replace it.
Inoperative. 00). 2. If fuse is OK, go to Test 2.
2. Check stoplamp power circuit. 1. If battery voltage is not present, go to
(a) Disconnect turnlamp switch from Test 3.
wiring harness (WP 0051 00). 2. If battery voltage is present, replace
(b) Turn battery disconnect switch turnlamp switch (WP 0051 00).
position (TM 5-3805-290-10).
(d) While pressing and holding brake
pedal, measure voltage at
turnlamp switch between wiring
harness pin 4, circuit 604 (OR),
and ground.
3. Check for power to stoplamp relay. 1. If battery voltage is present,
(a) Remove stoplamp relay (WP 0054 temporarily replace stoplamp relay
00). (WP 0054 00) with a new one. If
(b) Battery disconnect switch and problem still exists, reinstall old relay
engine start switch remain in ON and go to Test 4.
position (TM 5-3805-290-10). 2. If battery voltage is not present, there
(c) Measure voltage at stoplamp relay is an open circuit between stoplamp
between pin 3, circuit 130 (RD), relay and stoplamp fuse. Replace
and ground. wiring harness in question (WP 0169
00 thru WP 0175 00).
4. Check stoplamp power circuit 1. If continuity is not present, there is an
continuity. open circuit between stoplamp relay
(a) Stoplamp relay remains removed. and turnlamp switch. Replace wiring
(b) Turnlamp switch remains harness in question (WP 0169 00 thru
disconnected. WP 0175 00).
(c) Battery disconnect switch remains 2. If continuity is present, go to Test 5.
in ON position (TM 5-3805-290-
10).
(d) Turn engine start switch to OFF
position (TM 5-3805-290-10).
(e) Check continuity between
stoplamp relay wiring harness pin
5, circuit 604 (OR) and turnlamp
switch wiring harness pin 4, circuit
604 (OR).
0008 00-33
TM 5-3805-290-23-1
9. All Stoplamps Are 5. Check for an open stoplamp relay coil 1. If battery voltage is not present, go to
Inoperative - Continued. ground circuit. Test 6.
(a) Stoplamp relay remains removed. 2. If battery voltage is present, there is an
(b) Battery disconnect switch remains open stoplamp relay coil ground
in ON position (TM 5-3805-290- circuit. Replace wiring harness in
10). question (WP 0169 00 thru WP 0175
(c) Turn engine start switch to OFF 00).
position (TM 5-3805-290-10).
(d) Select service drive mode on main
(e) While pressing and holding brake
pedal, measure voltage at
stoplamp relay between wiring
harness pin 1, circuit 677 (GN),
and ground.
6. Check stoplamp relay coil power 1. If continuity is not present, there is an
circuit continuity. open circuit between stoplamp relay
(a) Disconnect main light switch from and main light switch. Replace wiring
wiring harness (WP 0049 00). harness in question (WP 0169 00 thru
(b) Stoplamp relay remains removed. WP 0175 00).
(c) Turn battery disconnect switch to 2. If continuity is present, go to Test 7.
OFF position (TM 5-3805-290-
10).
(d) Check continuity between
stoplamp relay wiring harness pin
1, circuit 677 (GN) and main light
switch wiring harness pin C,
circuit 677 (GN).
7. Check main light switch. 1. If continuity is present, replace main
(a) Main light switch remains light switch (WP 0049 00).
disconnected from wiring harness. 2. If continuity is not present, go to Test 8.
(b) While pressing and holding brake
pedal, check continuity at main
light switch between wiring
harness pin A, circuit 697 (GN)
and K, circuit 698 (PU).
8. Check main light switch output circuit. 1. If continuity is present, go to Test 9.
(a) Main light switch remains 2. If continuity is not present, there is an
disconnected from wiring harness. open circuit. Replace wiring harness in
(b) Disconnect stoplamp switch from question (WP 0169 00 thru WP 0175
wiring harness (WP 0049 00). 00).
(c) Check continuity at main light
A, circuit 697 (GN), and stoplamp
switch wiring harness pin A,
circuit 130 (RD).
0008 00-34
TM 5-3805-290-23-1
9. All Stoplamps Are 9. Check stoplamp switch. 1. If continuity is present, there is an open
Inoperative - Continued. (a) Stoplamp switch remains circuit between stoplamp switch and
disconnected from wiring harness. main light switch. Replace wiring
(b) While pressing and holding brake harness in question (WP 0169 00 thru
pedal, check continuity at WP 0175 00).
stoplamp switch between switch 2. If continuity is not present, replace
pins A and B. stoplamp switch (WP 0094 00).
10. One or Both Taillamps Are 1. Determine condition. 1. If only one taillamp is inoperative,
Inoperative. temporarily replace inoperative rear
light housing cover with a known good
one (WP 0062 00). If problem still
exists, there is an open circuit between
rear light housing and main light
switch. Reinstall old cover and repair
housing (WP 0062 00) or replace
wiring harness in question (WP 0169
00 thru WP 0175 00).
2. If both taillamps are inoperative but all
other rear lights operate correctly, go to
Test 2.
2. Check for open power circuit. 1. If continuity is present, replace main
(a) Disconnect wiring harness from light switch (WP 0049 00).
rear light housing (WP 0058 00). 2. If continuity is not present, there is an
(b) Disconnect wiring harness from open circuit between rear light housing
main light switch (WP 0049 00). and main light switch. Replace wiring
(c) Measure voltage at inoperative harness in question (WP 0169 00 thru
rear lamp between wiring harness WP 0175 00).
circuit 21 and main light switch
wiring harness pin H, circuit 614
(PU).
11. One or Both Blackout 1. Determine condition. 1. If one blackout marker is inoperative
Markers Are Inoperative. only, temporarily replace inoperative
rear light housing cover with a known
good one (WP 0058 00). If problem
still exists, there is an open circuit
between rear light housing and main
light switch. Reinstall old cover and
repair housing (WP 0058 00) or replace
wiring harness in question (WP 0169
00 thru WP 0175 00).
2. If both blackout markers are
inoperative but all other rear lights
operate correctly, go to Test 2.
0008 00-35
TM 5-3805-290-23-1
11. One or Both Blackout 2. Check for open power circuit. 1. If continuity is present, replace main
Markers Are Inoperative - (a) Disconnect wiring harness from light switch (WP 0049 00).
Continued. rear light housing (WP 0058 00). 2. If continuity is not present, there is an
wiring harness pin E, circuit 8628
(GY).
12. One or Both Blackout 1. Determine condition. 1. If only one blackout stoplamp is
Stoplamps Are Inoperative. inoperative, temporarily replace
inoperative rear light housing cover
with a known good one (WP 0058 00).
If problem still exists, there is an open
circuit between rear light housing and
main light switch. Reinstall old cover
and repair housing (WP 0058 00) or
replace wiring harness in question (WP
0169 00 thru WP 0175 00).
2. If both blackout stoplamps are
inoperative but all other rear lights
operate correctly, go to Test 2.
3. If both blackout stoplamps and both
service stoplamps are inoperative, refer
to Malfunction 9, All Stoplamps Are
Inoperative in this work package.
2. Check for open power circuit. 1. If continuity is present, replace main
(a) Disconnect wiring harness from light switch (WP 0049 00).
rear light housing (WP 0058 00). 2. If continuity is not present, there is an
wiring harness pin N, circuit 8627
(PK).
13. All Rear Lights Are There is an open rear light ground circuit. Replace wiring harness in question (WP
Inoperative. 0169 00 thru WP 0175 00).
0008 00-36
TM 5-3805-290-23-1
14. Blackout Drive Light is 1. Check voltage to lamp. 1. If battery voltage is present, replace
Inoperative. (a) Disconnect wiring harness from blackout drive light or repair ground at
blackout drive light (WP 0059 00). light (WP 0059 00).
(b) Turn battery disconnect switch 2. If battery voltage is not present, go to
and engine start switch to ON Test 2.
position (TM 5-3805-290-10).
(c) Select blackout drive light on main
(d) Measure voltage at blackout drive
light between wiring harness pin,
2. Check continuity between main light 1. If continuity is present, replace main
switch and blackout drive light. light switch (WP 0049 00).
(a) Disconnect wiring harness from 2. If continuity is not present, there is an
main light switch (WP 0049 00). open circuit between blackout drive
(b) Turn battery disconnect switch light housing and main light switch.
and engine start switch to OFF Replace wiring harness in question
(c) Check continuity at blackout drive
light between wiring harness pin
and main light switch wiring
harness pin D, circuit 8626 (GN).
15. Quick Coupler Switch is 1. Check coupler fuse (TM 5-3805-290- 1. If fuse is open, replace it.
Inoperative. 10). 2. If fuse is OK, go to Test 2.
2. Check voltage to coupler switch. 1. If battery voltage is present, go to Test
coupler switch (WP 0049 00). 2. If battery voltage is not present, there
(b) Turn battery disconnect switch is an open circuit between coupler
and engine start switch to ON switch and coupler fuse. Replace
position (TM 5-3805-290-10). wiring harness in question (WP 0169
(c) Measure voltage at coupler switch 00 thru WP 0175 00).
circuit 123 (WH), and ground.
3. Check coupler switch ground circuit. 1. If continuity is present, go to Test 4.
(a) Wiring harness remains 2. If continuity is not present, there is an
disconnected from coupler switch. open coupler switch ground circuit.
in ON position (TM 5-3805-290- (WP 0169 00 thru WP 0175 00).
10).
position (TM 5-3805-290-10).
(d) Check continuity at coupler switch
0008 00-37
TM 5-3805-290-23-1
15. Quick Coupler Switch is 4. Check coupler valve circuits. 1. If continuity is present for all circuits,
Inoperative - Continued. (a) Wiring harness remains temporarily replace coupler switch
disconnected from coupler switch. (WP 0049 00). If problem still exists,
(b) Battery disconnect switch remains replace coupler valve (WP 0190 00).
in ON position (TM 5-3805-290- 2. If continuity is not present for all
10). circuits, there is an open circuit
(c) Disconnect wiring harness from between coupler switch and coupler
coupler valve (WP 0190 00). valve. Replace wiring harness in
(d) Check continuity at coupler switch question (WP 0169 00 thru WP 0175
between wiring harness pin 1, 00).
circuit 779 (WH) and coupler
solenoid wiring harness pin 1,
circuit 779 (WH).
(e) Check continuity at coupler switch
circuit 780 (PU) and coupler
circuit 780 (PU).
(f) Check continuity at coupler switch
circuit 927 (BU) and coupler
circuit 927 (BU).
(g) Check continuity at coupler switch
circuit 739 (YL) and coupler
circuit 739 (YL).
16. Rear Defroster is 1. Check defroster fuse (WP 0054 00). 1. If fuse is open, replace it.
Inoperative or Always On. 2. If fuse is OK, go to Test 2.
2. Use MSD equipped with ET software 1. If machine ECM defroster switch
to monitor defroster switch status. status indicates switch is always closed
(a) Turn battery disconnect switch or always open, go to Test 3.
and engine start switch to ON 2. If machine ECM defroster switch
position (TM 5-3805-290-10). status indicates switch is changing
(b) Press defroster switch repeatedly status normally, go to Test 4.
while watching for status change
on MSD.
0008 00-38
TM 5-3805-290-23-1
16. Rear Defroster is 3. Check defroster switch. 1. If machine ECM indicates defroster
Inoperative or Always On - (a) Battery disconnect switch and switch status changed when switch was
Continued. engine start switch remain in ON unplugged or grounded, replace
position (TM 5-3805-290-10). defroster switch (WP 0049 00).
(b) Disconnect wiring harness from 2. If machine ECM indicates defroster
defroster switch (WP 0049 00) switch status did not change when
while monitoring defroster switch switch was unplugged or grounded,
status on MSD. there is an open circuit or short to
(c) Use a jumper wire to momentarily ground between machine ECM and
ground defroster switch wiring defroster switch. Replace wiring
harness pin 3, circuit 504 (GN) harness in question (WP 0169 00 thru
while monitoring defroster switch WP 0175 00).
status on MSD.
4. Check ECM. 1. If defroster operated when ECM
(a) Disconnect machine ECM harness was grounded, replace
connector J2 (WP 0052 00). machine ECM (WP 0052 00).
(b) Battery disconnect switch and 2. If defroster did not operate when ECM
engine start switch remain in ON harness was grounded, remove all
position (TM 5-3805-290-10). jumpers, reconnect all wiring
(c) Use a jumper wire to ground harnesses, and temporarily replace
machine ECM wiring harness J2- defroster relay (WP 0054 00). If
13, circuit 507 (YL). problem still exists, reinstall old relay
and go to Test 5.
5. Check power to defroster relay. 1. If battery voltage is present at both
(a) Remove defroster relay (WP 0054 pins, go to Test 6.
00). 2. If battery voltage is not present at both
(b) Turn battery disconnect switch pins, there is an open circuit between
and engine start switch to ON defroster relay and defroster fuse.
position (TM 5-3805-290-10). Replace wiring harness in question
(c) Measure voltage at defroster relay (WP 0169 00 thru WP 0175 00).
circuit 140 (BU), and ground; and
6. Check circuit to defroster grid. 1. If continuity is present, go to Test 7.
(a) Defroster relay remains removed. 2. If continuity is not present, there is an
(b) Disconnect wiring harness from open circuit between defroster relay
defroster switch (WP 0049 00). and defroster grid. Replace wiring
(c) Turn battery disconnect switch harness in question (WP 0169 00 thru
and engine start switch to OFF WP 0175 00).
position (TM 5-3805-290-10).
(d) Check continuity at defroster relay
circuit 538 (OR), and defroster
grid.
0008 00-39
TM 5-3805-290-23-1
16. Rear Defroster is 7. Check ground circuit for defroster grid. 1. If continuity is present, repair defroster
Inoperative or Always On - (a) Reconnect all wiring harnesses. grid.
Continued. (b) Turn battery disconnect switch to 2. If continuity is not present, there is an
ON position (TM 5-3805-290-10). open defroster ground circuit. Replace
(c) Check continuity between wiring harness in question (WP 0169
defroster grid circuit 200 (BK) and 00 thru WP 0175 00).
ground.
17. One or More Kickouts Are 1. Determine condition. 1. If one or more (not all) kickouts are
Inoperative. inoperative, go to Test 2.
2. If all kickouts are inoperative, go to
Test 4.
2. Ensure kickout sensor adjustment is 1. If necessary, adjust kickout sensor.
correct (TM 5-3805-290-10). 2. If problem still exists, go to Test 3.
3. Check sensor ground circuit. 1. If continuity is present, go to Test 4.
disconnected from kickout sensor. open kickout sensor ground circuit.
(b) Turn battery disconnect switch to Replace wiring harness in question
ON position (TM 5-3805-290-10). (WP 0169 00 thru WP 0175 00).
(c) Check continuity at kickout sensor
between wiring harness pin C,
circuit 200 (BK), and ground; or
between lift kickout sensor wiring
harness pin A, circuit 200 (BK),
and ground.
4. Check for power to kickout sensor. 1. If fuse is open, replace it.
(a) Check kickout fuse (TM 5-3805- 2. If battery voltage is present and
290-10). problem is with fork return-to-work
(b) Disconnect wiring harness from (tilt) kickout, go to Test 5.
kickout sensor (WP 0057 00). 3. If battery voltage is present and
(c) Turn battery disconnect switch, problem is with bucket return-to-work
kickout switch, and engine start (tilt) kickout, go to Test 7.
switch to ON position (TM 5- 4. If battery voltage is present and
3805-290-10). problem is with both return-to-work
(d) Turn implement lockout switch to (tilt) kickouts, go to Test 9.
10).
0008 00-40
TM 5-3805-290-23-1
17. One or More Kickouts Are (e) Measure voltage at inoperative 5. If battery voltage is present and
Inoperative - Continued. return-to-work kickout sensor problem is with lift or return-to-carry
between wiring harness pin A, kickout, go to Test 11.
circuit F766 (OR), and ground; or 6. If battery voltage is present and all
return-to-carry-or-lift kickout kickouts are inoperative, replace pilot
sensor wiring harness pin B, valve (WP 0188 00).
circuit F766 (WH), and ground. 7. If battery voltage is not present and one
or more (not all) kickouts are
inoperative, there is an open circuit
between kickout switch and kickout
sensor. Replace wiring harness in
question (WP 0169 00 thru WP 0175
00).
8. If battery voltage is not present and all
kickouts are inoperative, go to Test 12.
5. Check bucket/fork switch. 1. If continuity is present, go to Test 6.
(a) Disconnect wiring harness from 2. If continuity is not present, replace
bucket/fork switch (WP 0049 00). bucket/fork switch (WP 0049 00).
(b) Place bucket/fork switch in FORK
position (TM 5-3805-290-10).
(c) Check continuity of bucket/fork
switch between pin 2 and pin 3.
6. Check sensor output circuit to bucket/ 1. If continuity is present, replace kickout
fork switch. sensor (WP 0057 00).
disconnected from kickout sensor. open circuit between bucket/fork
(b) Wiring harness remains switch and kickout sensor. Replace
disconnected from bucket/fork wiring harness in question (WP 0169
switch. 00 thru WP 0175 00).
between wiring harness pin B,
circuit 964 (BU) and bucket/fork
964 (BU).
7. Check bucket/fork switch. 1. If continuity is present, go to Test 8.
(a) Disconnect wiring harness from 2. If continuity is not present, replace
bucket/fork switch (WP 0049 00). bucket/fork switch (WP 0049 00).
(b) Place bucket/fork switch in
BUCKET position (TM 5-3805-
290-10).
(c) Check continuity of bucket/fork
0008 00-41
TM 5-3805-290-23-1
17. One or More Kickouts Are 8. Check sensor output circuit to bucket/ 1. If continuity is present, replace kickout
Inoperative - Continued. fork switch. sensor (WP 0057 00).
disconnected from kickout sensor. open circuit between bucket/fork
(b) Wiring harness remains switch and kickout sensor. Replace
disconnected from bucket/fork wiring harness in question (WP 0169
switch. 00 thru WP 0175 00).
circuit 762 (YL) and bucket/fork
762 (YL).
9. Check sensor output circuit. 1. If continuity is present, replace pilot
(a) Disconnect wiring harness from valve (WP 0188 00).
pilot valve (WP 0188 00). 2. If continuity is not present, go to Test
(b) Wiring harness remains 10.
disconnected from kickout sensor.
position (TM 5-3805-290-10).
(d) Place bucket/fork switch in FORK
position (TM 5-3805-290-10).
(e) Check continuity at kickout sensor
circuit 964 (BU), and pilot valve
wiring harness pin 3, circuit 963
(GN).
10. Check bucket/fork switch. 1. If continuity is present, there is an open
(a) Disconnect wiring harness from circuit between pilot valve and bucket/
bucket/fork switch (WP 0049 00). fork switch. Replace wiring harness in
(b) Place bucket/fork switch in FORK question (WP 0169 00 thru WP 0175
position (TM 5-3805-290-10). 00).
(c) Check continuity of bucket/fork 2. If continuity is not present, replace
switch between pin 2 and pin 3. bucket/fork switch (WP 0049 00).
0008 00-42
TM 5-3805-290-23-1
17. One or More Kickouts Are 11. Check sensor output circuit. 1. If continuity is present, temporarily
Inoperative - Continued. (a) Disconnect wiring harness from replace kickout sensor (WP 0057 00).
pilot valve (WP 0188 00). If problem still exists, reinstall original
(b) Wiring harness remains kickout sensor and replace pilot valve
disconnected from kickout sensor. (WP 0188 00).
(c) Turn battery disconnect and 2. If continuity is not present, there is an
engine start switch to OFF position open circuit between pilot valve and
(TM 5-3805-290-10). kickout sensor. Replace wiring harness
(d) Check continuity between return- in question (WP 0169 00 thru WP 0175
to-carry kickout sensor wiring 00).
harness pin C, circuit 708 (BU),
and pilot valve wiring harness pin
1, circuit 708 (OR); or between lift
kickout sensor wiring harness pin
C, circuit 761 (GY), and pilot
valve wiring harness pin 2, circuit
761 (GY).
12. Check power to kickout sensors. 1. If continuity is present, go to Test 13
kickout switch (WP 0049 00). open circuit between kickout switch
(b) Wiring harness remains and kickout sensor. Replace wiring
disconnected from kickout sensor. harness in question (WP 0169 00 thru
(c) Turn battery disconnect switch WP 0175 00).
position (TM 5-3805-290-10).
(d) Check continuity between return-
to-carry kickout sensor wiring
harness pin B, circuit F766 (WH),
and kickout switch wiring harness
pin 3, circuit F766 (WH).
13. Check kickout switch. 1. If continuity is present, go to Test 14.
(a) Wiring harness remains 2. If continuity is not present, replace
disconnected from kickout switch. kickout switch (WP 0049 00).
(b) Kickout switch remains in ON
position (TM 5-3805-290-10).
(c) Check continuity of kickout
0008 00-43
TM 5-3805-290-23-1
17. One or More Kickouts Are 14. Check power circuit to kickout switch. 1. If continuity is present, go to Test 15.
Inoperative - Continued. (a) Disconnect wiring harness from 2. If continuity is not present, there is an
implement lockout switch (WP open circuit between kickout switch
0049 00). and implement lockout switch. Replace
disconnected from kickout switch. 00 thru WP 0175 00).
(c) Check continuity between
implement lockout switch wiring
harness pin 1, circuit G728 (YL),
and kickout switch wiring harness
pin 2, circuit G728 (YL).
15. Check implement lockout switch. 1. If continuity is present, there is an open
(a) Wiring harness remains circuit between implement lockout
disconnected from implement switch and kickout fuse. Replace
lockout switch. wiring harness in question (WP 0169
(b) Implement lockout switch remains 00 thru WP 0175 00).
in OFF position (TM 5-3805-290- 2. If continuity is not present, replace
10). implement lockout switch (WP 0049
(c) Check continuity of implement 00).
lockout switch between pin 1 and
pin 2.
18. Arctic Heater is 1. Check for cooling or fuel system leaks. Repair any leaks. If problem still exists, go
Inoperative. to Test 2.
2. Check two arctic heater fuses (TM 5- 1. If fuses are open, replace them.
3805-290-10). 2. If fuse is OK, go to Test 3.
3. Determine condition. 1. If arctic heater motor runs but arctic
heater fuel pump does not, go to Test 9.
2. If arctic heater motor does not run, go
to Test 4.
4. Check for power to arctic heater. 1. If battery voltage is present at both
(a) Disconnect wiring harness from pins, go to Test 8.
arctic heater (WP 0141 00). 2. If battery voltage is present at C2 only,
(b) Turn battery disconnect switch, go to Test 5.
arctic heater switch, and engine 3. If battery voltage is present on pin A1
start switch to ON position (TM 5- only, there is an open circuit between
3805-290-10). arctic heater fuse and arctic heater.
(c) Measure voltage between arctic Replace wiring harness in question
heater wiring harness pin A1, (WP 0141 00 or WP 0169 00 thru WP
circuit E524 (PK), and ground; 0175 00).
and between arctic heater wiring
harness pin C2, circuit 117 (RD),
and ground.
0008 00-44
TM 5-3805-290-23-1
18. Arctic Heater is Inoperative 5. Check power circuit to arctic heater. 1. If continuity is present, go to Test 6.
- Continued. (a) Disconnect wiring harness from 2. If continuity is not present, there is an
arctic heater switch (WP 0049 00). open circuit between arctic heater and
(b) Wiring harness remains arctic heater switch. Replace wiring
disconnected from arctic heater. harness in question (WP 0141 00 or WP
(c) Turn battery disconnect switch to 0169 00 thru WP 0175 00).
10).
(d) Check continuity of circuit E524
(PK) between arctic heater wiring
harness pin A1 and arctic heater
switch.
6. Check arctic heater switch. 1. If continuity is present across all pins,
(a) Wiring harness remains go to Test 7.
disconnected from arctic heater 2. If continuity is not present, replace
switch. arctic heater switch (WP 0049 00).
(b) Arctic heater switch remains in
ON position.
(c) Check continuity of arctic heater
switch between pin 1 and pin 2,
between pin 1 and pin 3, and
between pin 3 and pin 2.
7. Check arctic heater switch. 1. If battery voltage is present, go to Test
(a) Wiring harness remains 8.
disconnected from arctic heater 2. If battery voltage is not present, there
switch. is an open circuit between arctic heater
(b) Turn battery disconnect switch and arctic heater fuse. Replace wiring
and engine start switch to ON harness (WP 0141 00 or WP 0169 00
position (TM 5-3805-290-10). thru WP 0175 00).
(c) Measure voltage between arctic
heater switch circuit E523 (BR)
and ground.
8. Check arctic heater ground circuit. 1. If continuity is present, go to Test 9.
disconnected from arctic heater. open arctic heater ground circuit.
in ON position (TM 5-3805-290- (WP 0141 00 or WP 0169 00 thru WP
10). 0175 00).
(c) Check continuity between arctic
heater wiring harness pin C3,
0008 00-45
TM 5-3805-290-23-1
18. Arctic Heater is Inoperative 9. Check arctic heater fuel pump ground 1. If continuity is present, go to Test 10.
- Continued. circuit. 2. If continuity is not present, there is an
(a) Disconnect wiring harness from open arctic heater fuel pump ground
arctic heater fuel pump (WP 0141 circuit. Replace wiring harness in
00). question (WP 0141 00 or WP 0169 00
(b) Battery disconnect switch remains thru WP 0175 00).
10).
heater fuel pump wiring harness
pin B, circuit 200 (BK), and
ground.
10. Check arctic heater fuel pump power 1. If continuity is present, replace arctic
circuit. heater fuel pump. If problem still
(a) Wiring harness remains exists, replace arctic heater pump and
disconnected from arctic heater motor assembly (WP 0141 00).
and arctic heater fuel pump (WP 2. If continuity is not present, there is an
0141 00). open circuit between arctic heater fuel
(b) Turn battery disconnect switch pump and arctic heater. Replace wiring
and engine start switch to OFF harness in question (WP 0141 00 or WP
position (TM 5-3805-290-10). 0169 00 thru WP 0175 00).
heater fuel pump wiring harness
pin A, circuit 323 (WH) and arctic
heater wiring harness pin C4,
circuit 323 (WH).
19. Air Conditioning NOTE
Compressor Does Not Run
If AC compressor and condenser fan run at all, problem is most likely
(Blower Operates
NOT electrical.
Correctly).
1. Check AC fuse (TM 5-3805-290-10). 1. If fuse is open, replace it.
2. If fuse is OK, go to Test 2.
2. Verify condenser fan runs. 1. If condenser fan does not operate, refer
to Malfunction 21, Condenser Fan is
2. If condenser fan operates correctly, go
to Test 3.
3. Check AC system charge (WP 0191 1. If AC system charge is low, find and
00). repair system leak.
2. If AC system charge is OK, go to Test
4.
0008 00-46
TM 5-3805-290-23-1
19. Air Conditioning 4. Bypass AC pressure switch. 1. If AC compressor clutch engages with
Compressor Does Not Run (a) Disconnect wiring harness from switch bypassed, replace AC pressure
(Blower Operates AC pressure switch (WP 0193 00). switch (WP 0193 00).
Correctly) - Continued. (b) Use a jumper wire to short AC 2. If AC compressor clutch does not
pressure switch wiring harness engage with switch bypassed, go to
pins together. Test 5.
position (TM 5-3805-290-10).
(d) Turn AC/heater switch to air
conditioning ON position (TM 5-
3805-290-10).
(e) Verify AC clutch engages with
switch bypassed.
5. Check for power to AC pressure 1. If battery voltage is present, go to Test
switch. 6.
(a) Wiring harness remains 2. If battery voltage is not present, there
disconnected from AC pressure is an open circuit between AC/heater
switch. switch and AC pressure switch.
(b) Remove jumper from AC pressure Replace wiring harness in question
switch wiring harness pins. (WP 0169 00 thru WP 0175 00).
(c) Battery disconnect, engine start,
and AC switches remain in ON
position (TM 5-3805-290-10).
(d) Measure voltage between AC
pressure switch wiring harness pin
1, circuit 521 (YL), and ground.
0008 00-47
TM 5-3805-290-23-1
19. Air Conditioning 6. Check AC compressor clutch power 1. If battery voltage is present, go to Test
Compressor Does Not Run circuit. 7.
(Blower Operates (a) Wiring harness remains 2. If battery voltage is not present, there
Correctly) - Continued. disconnected from AC pressure is an open circuit between AC
switch (WP 0193 00). compressor and AC pressure switch.
(b) Disconnect wiring harness to AC Replace wiring harness in question
compressor clutch (WP 0192 00). (WP 0169 00 thru WP 0175 00).
(c) Use a jumper wire to short AC
pressure switch wiring harness
pins together.
(d) Turn battery disconnect switch
position (TM 5-3805-290-10).
(e) Turn AC/heater switch to AC ON
position (TM 5-3805-290-10).
(f) Measure voltage between AC
compressor clutch wiring harness
1, circuit 589 (GN), and ground.
7. Check AC compressor clutch power 1. If battery voltage is present, go to Test
circuit. 8.
(a) Jumper wire remains in place. 2. If battery voltage is not present, replace
(b) Connect wiring harness to AC AC compressor (WP 0192 00).
compressor clutch (WP 0192 00).
(c) Disconnect wiring harness from
thermostatic switch located in
blower case (WP 0196 00).
(d) Battery disconnect switch and
position (TM 5-3805-290-10).
(e) Turn AC/heater switch to AC ON
position (TM 5-3805-290-10).
(f) Measure voltage at back of
connector between AC
compressor clutch wiring harness
pin 2, circuit 522 (WH), and
ground.
0008 00-48
TM 5-3805-290-23-1
19. Air Conditioning 8. Check AC compressor clutch ground 1. If battery voltage is present, go to Test
Compressor Does Not Run circuit. 9.
(Blower Operates (a) Jumper wire remains in place. 2. If battery voltage is not present, there
Correctly) - Continued. (b) Wiring harness remains is an open circuit between thermostatic
disconnected from thermostatic switch and compressor. Replace wiring
switch. harness in question (WP 0169 00 thru
(c) Battery disconnect switch and WP 0175 00).
position (TM 5-3805-290-10).
(d) AC/heater switch remains in AC
ON position.
(e) Measure voltage between
thermostatic switch wiring
harness circuit 522 (WH) and
ground.
9. Check thermostatic switch ground 1. If continuity is present, replace
circuit. thermostatic switch (WP 0196 00).
(a) Jumper wire remains in place. 2. If continuity is not present, there is an
(b) Wiring harness remains open thermostatic switch ground
disconnected from thermostatic circuit. Replace wiring harness in
switch. question (WP 0169 00 thru WP 0175
(c) Battery disconnect switch and 00).
position (TM 5-3805-290-10).
(d) AC/heater switch remains in AC
ON position.
(e) Check continuity between
thermostatic switch wiring
harness, circuit 200 (BK), and
ground.
0008 00-49
TM 5-3805-290-23-1
20. One or More Blower Motor 1. Determine condition. 1. If only high speed is inoperative, go to
Speeds Are Inoperative. Test 2.
2. If only medium speed is inoperative, go
to Test 3.
3. If only low speed is inoperative, go to
Test 4.
4. If only medium and high speeds are
inoperative, go to Test 3.
5. If only low and high speeds are
inoperative, replace blower switch
(WP 0049 00).
6. If only medium and low speeds are
7. If all blower speeds are inoperative, go
to Test 7.
2. Check blower switch (high). 1. If continuity is present and only high
(a) Disconnect wiring harness from speed is inoperative, there is an open
blower switch (WP 0049 00). circuit between blower motor and
(b) Place blower switch in HIGH blower switch. Replace wiring harness
SPEED position (TM 5-3805-290- in question (WP 0169 00 thru WP 0175
10). 00).
(c) Check continuity between blower 2. If continuity is present and only
switch pins 2 and 3, and between medium and high speeds are
pins 5 and 6. inoperative, go to Test 2.
3. If continuity is not present, replace
blower switch (WP 0049 00).
3. Check blower switch (medium). 1. If continuity is present and only
(a) Disconnect wiring harness from medium speed is inoperative, there is
blower switch (WP 0049 00). an open circuit between blower motor
(b) Place blower switch in MEDIUM resistor and blower switch. Replace
SPEED position (TM 5-3805-290- wiring harness in question (WP 0169
10). 00 thru WP 0175 00).
(c) Check continuity between blower 2. If continuity is present and only
switch pins 2 and 3, and between medium and high speeds are
pins 4 and 5. inoperative, circuit E529 (YL) is open.
Replace wiring harness in question
(WP 0169 00 thru WP 0175 00).
blower switch (WP 0049 00).
0008 00-50
TM 5-3805-290-23-1
20. One or More Blower Motor 4. Check blower switch (low). 1. If continuity is present, go to Test 5.
Speeds Are Inoperative - (a) Disconnect wiring harness from 2. If continuity is not present, replace
Continued. blower switch (WP 0049 00). blower switch (WP 0049 00).
(b) Place blower switch in LOW
SPEED position (TM 5-3805-290-
10).
(c) Check continuity between blower
switch pins 1 and 2.
5. Check blower motor resistor. 1. If continuity is present, go to Test 6.
(a) Disconnect wiring harness from 2. If continuity is present and only
blower motor resistor (WP 0143 medium and low speeds are
00). inoperative, there is an open circuit
(b) Check continuity between blower between blower motor resistor and
motor resistor’s two outermost blower motor. Replace wiring harness
pins. in question (WP 0169 00 thru WP 0175
00).
blower motor resistor (WP 0143 00).
6. Check low speed circuit. 1. If continuity is not present, there is an
(a) Wiring harness remains open circuit between blower motor
disconnected from blower switch. resistor and blower switch. Replace
disconnected from blower motor 00 thru WP 0175 00).
resistor. 2. If continuity is present, there is an open
(c) Check continuity between blower circuit between blower motor resistor
switch wiring harness pin 1, circuit and blower motor. Replace wiring
517 (BU), and blower motor harness in question (WP 0169 00 thru
resistor wiring harness circuit 517 WP 0175 00).
(BU).
7. Check blower fuse (TM 5-3805-290- 1. If fuse is open, replace it.
10). 2. If fuse is OK, go to Test 8.
0008 00-51
TM 5-3805-290-23-1
20. One or More Blower Motor 8. Check power to AC/heater switch. 1. If battery voltage is present, go to Test
Speeds Are Inoperative - (a) Turn battery disconnect switch 9.
Continued. and engine start switch to ON 2. If battery voltage is not present, there
position (TM 5-3805-290-10). is an open circuit between blower fuse
(b) Disconnect wiring harness from and AC/heater switch. Replace wiring
AC/heater switch (WP 0049 00). harness in question (WP 0169 00 thru
(c) Measure voltage between AC/ WP 0175 00).
heater switch wiring harness, pin
2, circuit 124 (GN), and ground;
and between AC/heater switch
wiring harness, pin 5, circuit 124
(GN), and ground.
9. Check power to blower switch. 1. If battery voltage is present, go to Test
blower switch (WP 0049 00). 2. If battery voltage is not present, go to
(b) Connect wiring harness to AC/ Test 10.
heater switch.
(c) Battery disconnect switch and
position (TM 5-3805-290-10).
(d) Place AC/heater switch in AC ON
position.
(e) Measure voltage between blower
switch wiring harness, pin 2,
circuit E528 (PU), and ground.
10. Check power circuit to blower switch. 1. If continuity is present, replace AC/
(a) Wiring harness remains heater switch (WP 0049 00).
disconnected from blower switch. 2. If continuity is not present, there is an
(b) Disconnect wiring harness to AC/ open circuit between blower switch
heater switch (WP 0049 00). and AC/heater switch. Replace wiring
(c) Check continuity between blower harness in question (WP 0169 00 thru
switch wiring harness, pin 2, WP 0175 00).
circuit E528 (PU) and AC/heater
switch wiring harness, pin 3,
circuit E528 (PU); and between
blower switch wiring harness, pin
2, circuit E528 (PU) and AC/
heater switch wiring harness, pin
4, circuit E528 (PU).
0008 00-52
TM 5-3805-290-23-1
20. One or More Blower Motor 11. Check power to blower motor. 1. If battery voltage is present, replace
Speeds Are Inoperative - (a) Connect wiring harness to blower blower motor (WP 0143 00).
Continued. switch (WP 0049 00). 2. If battery voltage is not present, there
(b) Connect wiring harness to AC/ is an open circuit between blower
heater switch (WP 0049 00). switch and blower motor. Replace
(c) Disconnect wiring harness from wiring harness in question (WP 0169
blower motor (WP 0143 00). 00 thru WP 0175 00).
(d) Battery disconnect switch and
position (TM 5-3805-290-10).
(e) Place AC/heater switch in AC ON
position (TM 5-3805-290-10).
(f) Place blower switch in HIGH
10).
(g) Measure voltage between blower
motor wiring harness, pin 1, circuit
515 (GY), and ground.
21. Condenser Fan is 1. Check operation of blower motor (TM 1. If blower motor operates correctly, go
Inoperative. 5-3805-290-10). to Test 2.
2. If blower motor does not operate
correctly, refer to Malfunction 20, One
or More Blower Motor Speeds Are
2. Check operation of AC compressor 1. If clutch engages correctly, go to Test
clutch. 3.
2. If clutch does not engage correctly,
refer to Malfunction 19, Air
Conditioning Compressor Does Not
Run (Blower Operates Correctly) in
this work package.
3. Check AC fuses (TM 5-3805-290-10). 1. If fuses are open, replace them.
2. If fuses are OK, temporarily replace
condenser fan relay (WP 0054 00). If
problem still exists, reinstall original
relay and go to Test 4.
0008 00-53
TM 5-3805-290-23-1
21. Condenser Fan is 4. Check power to relay. 1. If battery voltage is present at both
Inoperative - Continued. (a) Remove condenser relay (WP pins, go to Test 5.
0054 00). 2. If battery voltage is not present, there
(b) Place AC/heater switch in AC ON is an open circuit between AC fuse and
position (TM 5-3805-290-10). condenser relay, or between AC/heater
(c) Place blower switch in HIGH switch and condenser relay. Replace
SPEED position (TM 5-3805-290- wiring harness in question (WP 0169
10). 00 thru WP 0175 00).
(d) Turn battery disconnect switch
position (TM 5-3805-290-10).
(e) Measure voltage at condenser
1, circuit 158 (BR), and ground;
and between wiring harness pin 2,
circuit 521 (YL), and ground.
5. Check relay coil ground circuit. 1. If continuity is present at both pins, go
(a) Condenser relay remains to Test 6.
removed. 2. If continuity is not present, there is an
(b) Battery disconnect switch remains open AC condenser relay coil ground
in ON position (TM 5-3805-290- circuit. Replace wiring harness in
10). question (WP 0169 00 thru WP 0175
(c) Turn engine start switch to OFF 00).
position (TM 5-3805-290-10).
(d) Check continuity at condenser
6. Check condenser power circuit. 1. If continuity is present, go to Test 7.
(a) Condenser relay remains 2. If continuity is not present, there is an
removed. open circuit between AC condenser
(b) Battery disconnect switch remains relay and AC condenser. Replace
in ON position (TM 5-3805-290- wiring harness in question (WP 0169
10). 00 thru WP 0175 00).
condenser fan (WP 0195 00).
(d) Check continuity at condenser
4, circuit 593 (GN) and condenser
fan wiring harness pin 2, circuit
593 (GN).
0008 00-54
TM 5-3805-290-23-1
21. Condenser Fan is 7. Check condenser ground circuit. 1. If continuity is present, replace
Inoperative - Continued. (a) Condenser fan remains removed. condenser fan (WP 0195 00).
(b) Battery disconnect switch remains 2. If continuity is not present, there is an
in ON position (TM 5-3805-290- open AC condenser ground circuit.
10). Replace wiring harness in question
(c) Check continuity at condenser fan (WP 0169 00 thru WP 0175 00).
22. Wipers/Washers Do Not 1. Determine condition. 1. If front and rear wipers and washers are
Operate or Do Not Operate all inoperative, go to Test 2.
Correctly. 2. If only front wiper and washer are
inoperative, replace front wiper switch
(WP 0049 00).
3. If front wiper is inoperative on HIGH
SPEED only, go to Test 3.
4. If front wiper is inoperative on LOW
5. If front wiper will not park but operates
in both HIGH and LOW speeds, go to
Test 7.
6. If only front wiper is completely
7. If only front washer is inoperative, go
to Test 11.
8. If only rear wiper and washer are
inoperative, replace rear wiper switch
(WP 0049 00).
9. If rear wiper is inoperative on HIGH
10. If rear wiper is inoperative on LOW
11. If rear wiper will not park but operates
in both HIGH and LOW speeds, go to
Test 19.
12. If only rear wiper is completely
13. If only rear washer is inoperative, go to
Test 23.
2. Check wiper fuse (TM 5-3805-290- 1. If fuse is open, replace it.
10). 2. If fuse is OK, there is an open circuit
between wiper fuse and wiper
switches. Replace wiring harness in
00.
0008 00-55
TM 5-3805-290-23-1
22. Wipers/Washers Do Not 3. Check front wiper motor high circuit. 1. If battery voltage is present, replace
Operate or Do Not Operate (a) Disconnect wiring harness from front wiper motor (WP 0119 00).
Correctly - Continued. front wiper motor (WP 0119 00). 2. If battery voltage is not present, go to
(b) Turn battery disconnect switch Test 4.
position (TM 5-3805-290-10).
(c) Turn front wiper switch to HIGH
10).
(d) Measure voltage at front wiper
motor between wiring harness pin
5, circuit 502 (OR), and ground.
4. Check front wiper motor high circuit 1. If continuity is present, replace front
for continuity. wiper switch (WP 0049 00).
front wiper switch (WP 0049 00). open circuit between wiper motor and
(b) Battery disconnect switch remains wiper switch. Replace wiring harness
in ON position (TM 5-3805-290- in question (WP 0169 00 thru WP 0175
10). 00).
position (TM 5-3805-290-10).
(d) Check continuity at front wiper
5, circuit 502 (OR), and front
wiper switch wiring harness pin 4,
circuit 502 (OR).
5. Check front wiper motor low circuit. 1. If battery voltage is present, replace
(a) Disconnect wiring harness from front wiper motor (WP 0119 00).
front wiper motor (WP 0119 00). 2. If battery voltage is not present, go to
position (TM 5-3805-290-10).
(c) Turn front wiper switch to low
speed position (TM 5-3805-290-
10).
4, circuit 501 (GN), and ground.
0008 00-56
TM 5-3805-290-23-1
22. Wipers/Washers Do Not 6. Check front wiper motor low circuit for 1. If continuity is present, replace front
Operate or Do Not Operate continuity. wiper switch (WP 0049 00).
Correctly - Continued. (a) Disconnect wiring harness from 2. If continuity is not present, there is an
front wiper switch (WP 0049 00). open circuit between wiper motor and
10). 00).
position (TM 5-3805-290-10).
4, circuit 501 (GN), and front
circuit 501 (GN).
7. Check front wiper motor park circuit. 1. If battery voltage is present, go to Test
front wiper motor (WP 0119 00). 2. If battery voltage is not present, there
(b) Turn battery disconnect switch is an open circuit between wiper motor
and engine start switch to ON and wiper switch. Replace wiring
position (TM 5-3805-290-10). harness in question (WP 0169 00 thru
(c) Turn front wiper switch to OFF WP 0175 00).
position (TM 5-3805-290-10).
6, circuit 118 (GY), and ground.
8. Check front wiper motor park circuit 1. If continuity is present, replace front
for continuity. wiper switch (WP 0049 00). If problem
(a) Disconnect wiring harness from still exists, replace front wiper motor
front wiper switch (WP 0049 00). (WP 0119 00).
in ON position (TM 5-3805-290- open circuit between wiper motor and
10). wiper switch. Replace wiring harness
(c) Turn engine start switch to OFF in question (WP 0169 00 thru WP 0175
position (TM 5-3805-290-10). 00).
3, circuit 500 (BR), and front
circuit 500 (BR).
0008 00-57
TM 5-3805-290-23-1
22. Wipers/Washers Do Not 9. Check power to front wiper switch. 1. If battery voltage is present, go to Test
Operate or Do Not Operate (a) Disconnect wiring harness from 10.
Correctly - Continued. front wiper switch (WP 0049 00). 2. If battery voltage is not present, there
(b) Turn battery disconnect switch is an open circuit between wiper fuse
(c) Measure voltage at front wiper WP 0175 00).
10. Check front wiper motor ground 1. If continuity is present, replace front
circuit. wiper switch (WP 0049 00). If problem
front wiper motor (WP 0119 00). (WP 0119 00).
in ON position (TM 5-3805-290- open wiper motor ground circuit.
10). Replace wiring harness in question
(c) Turn engine start switch to OFF (WP 0169 00 thru WP 0175 00).
position (TM 5-3805-290-10).
11. Check power to front washer portion of 1. If battery voltage is present, connect
switch. wiring harness from front wiper switch
(a) Disconnect wiring harness from and go to Test 12.
front washer switch (WP 0049 00). 2. If battery voltage is not present, there
(c) Measure voltage at front washer WP 0175 00).
12. Check front washer motor ground 1. If continuity is present, go to Test 13.
circuit. 2. If continuity is not present, there is an
(a) Disconnect wiring harness from open wiper motor ground circuit.
front washer motor (WP 0119 00). Replace wiring harness in question
(b) Battery disconnect switch remains (WP 0169 00 thru WP 0175 00).
10).
position (TM 5-3805-290-10).
(d) Check continuity at front washer
0008 00-58
TM 5-3805-290-23-1
22. Wipers/Washers Do Not 13. Check power to front washer motor. 1. If battery voltage is present, replace
Operate or Do Not Operate (a) Wiring harness remains washer pump (WP 0118 00).
Correctly - Continued. disconnected from front washer 2. If battery voltage is not present, go to
motor. Test 14.
(b) Turn battery disconnect switch
position (TM 5-3805-290-10).
(c) Measure voltage at front washer
1, circuit 506 (PU), and ground.
14. Check front washer motor power 1. If continuity is present, replace front
circuit for continuity. wiper switch (WP 0049 00). If problem
front wiper switch (WP 0049 00). (WP 0119 00).
(b) Wiring harness remains 2. If continuity is not present, there is an
disconnected from front washer open circuit between wiper motor and
motor. wiper switch. Replace wiring harness
position (TM 5-3805-290-10). 00).
(d) Check continuity at front washer
1, circuit 506 (PU) and front wiper
506 (PU).
15. Check rear wiper motor high circuit. 1. If battery voltage is present, replace
(a) Disconnect wiring harness from rear wiper motor (WP 0120 00).
rear wiper motor (WP 0120 00). 2. If battery voltage is not present, go to
position (TM 5-3805-290-10).
(c) Turn rear wiper switch to HIGH
10).
(d) Measure voltage at rear wiper
5, circuit 505 (OR), and ground.
0008 00-59
TM 5-3805-290-23-1
22. Wipers/Washers Do Not 16. Check rear wiper motor high circuit for 1. If continuity is present, replace rear
Operate or Do Not Operate continuity. wiper switch (WP 0049 00).
Correctly - Continued. (a) Disconnect wiring harness from 2. If continuity is not present, there is an
rear wiper switch (WP 0049 00). open circuit between wiper motor and
10). 00).
position (TM 5-3805-290-10).
(d) Check continuity at rear wiper
5, circuit 505 (OR) and rear wiper
505 (BU).
17. Check rear wiper motor low circuit. 1. If battery voltage is present, replace
(a) Disconnect wiring harness from rear wiper motor (WP 0120 00).
rear wiper motor (WP 0120 00). 2. If battery voltage is not present, go to
position (TM 5-3805-290-10).
(c) Turn rear wiper switch to LOW
SPEED position.
4, circuit 504 (YL), and ground.
18. Check rear wiper motor low circuit for 1. If continuity is present, replace rear
continuity. wiper switch (WP 0049 00).
rear wiper switch (WP 0049 00). open circuit between wiper motor and
10). 00).
position (TM 5-3805-290-10).
4, circuit 504 (YL), and rear wiper
504 (YL).
0008 00-60
TM 5-3805-290-23-1
22. Wipers/Washers Do Not 19. Check rear wiper motor park circuit. 1. If battery voltage is present, go to Test
Operate or Do Not Operate (a) Disconnect wiring harness from 20.
Correctly - Continued. rear wiper motor (WP 0120 00). 2. If battery voltage is not present, there
(b) Turn battery disconnect switch is an open circuit between wiper motor
(c) Turn rear wiper switch to OFF WP 0175 00).
position (TM 5-3805-290-10).
20. Check rear wiper motor park circuit for 1. If continuity is present, replace rear
continuity. wiper switch (WP 0049 00). If problem
(a) Disconnect wiring harness from still exists, replace rear wiper motor
rear wiper switch (WP 0049 00). (WP 0120 00).
in ON position (TM 5-3805-290- open circuit between wiper motor and
10). wiper switch. Replace wiring harness
position (TM 5-3805-290-10). 00).
3, circuit 503 (BR) and rear wiper
503 (BR).
21. Check power to rear wiper switch. 1. If battery voltage is present, go to Test
rear wiper switch (WP 0049 00). 2. If battery voltage is not present, there
(c) Measure voltage at rear wiper WP 0175 00).
22. Check rear wiper motor ground circuit. 1. If continuity is present, replace rear
(a) Disconnect wiring harness from wiper switch (WP 0049 00). If problem
rear wiper motor (WP 0120 00). still exists, replace rear wiper motor
(b) Battery disconnect switch remains (WP 0120 00).
10). open wiper motor ground circuit.
(c) Turn engine start switch to OFF Replace wiring harness in question
0008 00-61
TM 5-3805-290-23-1
22. Wipers/Washers Do Not 23. Check power to rear washer portion of 1. If battery voltage is present, connect
Operate or Do Not Operate switch. wiring harness from rear wiper switch
Correctly - Continued. (a) Disconnect wiring harness from and go to Test 24.
rear wiper switch (WP 0049 00). 2. If battery voltage is not present, there
(c) Measure voltage at rear wiper WP 0175 00).
24. Check rear washer motor ground 1. If continuity is present, go to Test 25.
circuit. 2. If continuity is not present, there is an
(a) Disconnect wiring harness from open wiper motor ground circuit.
rear washer motor (WP 0120 00). Replace wiring harness in question
10).
position (TM 5-3805-290-10).
(d) Check continuity at rear washer
25. Check power to rear washer motor. 1. If battery voltage is present, replace
(a) Wiring harness remains washer pump (WP 0118 00).
disconnected from rear washer 2. If battery voltage is not present, go to
motor. Test 26.
(b) Turn battery disconnect switch
position (TM 5-3805-290-10).
(c) Measure voltage at rear washer
1, circuit 507 (WH), and ground.
26. Check rear washer motor power circuit 1. If continuity is present, replace rear
for continuity. wiper switch (WP 0049 00). If problem
(a) Disconnect wiring harness from still exists, replace rear wiper motor
rear wiper switch (WP 0049 00). (WP 0120 00).
(b) Wiring harness remains 2. If continuity is not present, there is an
disconnected from rear washer open circuit between wiper motor and
motor. wiper switch. Replace wiring harness
position (TM 5-3805-290-10). 00).
(d) Check continuity at rear washer
1, circuit 507 (WH) and rear wiper
507 (PU).
0008 00-62
TM 5-3805-290-23-1
23. Horn is Inoperative. 1. Check dome light operation (TM 5- 1. If dome light operates correctly, go to
3805-290-10). Test 7.
2. If fuse is OK, temporarily replace horn
relay (WP 0054 00). If problem still
exists, reinstall original relay and go to
Test 3.
2. Check horn fuse (TM 5-3805-290-10). 1. If fuse is open, replace it.
2. If fuse is OK, temporarily replace horn
relay (WP 0054 00). If problem still
exists, reinstall original relay and go to
Test 3.
3. Check power to relay. 1. If battery voltage is present, go to Test
(a) Remove horn relay (WP 0054 00). 4.
(b) Turn battery disconnect switch 2. If battery voltage is not present, there
and engine start switch to ON is an open circuit between horn fuse
position (TM 5-3805-290-10). and horn relay. Replace wiring harness
(c) Measure voltage at horn relay in question (WP 0169 00 thru WP 0175
between wiring harness pin 1, 00).
circuit 114 (RD), and ground.
4. Check power to relay coil. 1. If battery voltage is present, go to Test
(a) Horn relay remains removed. 6.
(b) Battery disconnect switch and 2. If battery voltage is not present, go to
engine start switch remain in ON Test 5.
position (TM 5-3805-290-10).
(d) Measure voltage at horn relay
5. Check main light switch output circuit. 1. If continuity is present, replace main
(a) Turn battery disconnect switch light switch (WP 0049 00).
and engine start switch to OFF 2. If continuity is not present, there is an
position (TM 5-3805-290-10). open circuit between main light switch
(b) Horn relay remains removed. and horn relay. Replace wiring harness
(c) Disconnect main light switch from in question (WP 0169 00 thru WP 0175
wiring harness (WP 0049 00). 00).
(d) Check continuity at main light
J, circuit 8630 (BU) and horn relay
(BU).
0008 00-63
TM 5-3805-290-23-1
23. Horn is Inoperative - 6. Check horn relay coil ground circuit. 1. If continuity is present, there is an open
Continued. (a) Turn engine start switch to OFF circuit between horn relay and horn.
position (TM 5-3805-290-10). Replace wiring harness in question
10). open horn relay ground circuit. Replace
(c) Horn relay remains removed. wiring harness in question (WP 0169
(d) Check continuity at horn relay 00 thru WP 0175 00).
7. Check power to horn. 1. If battery voltage is present, go to Test
horn (WP 0075 00). 2. If battery voltage is not present, there
(b) Turn battery disconnect switch is an open circuit between horn and
and engine start switch to ON horn relay. Replace wiring harness in
position (TM 5-3805-290-10). question (WP 0169 00 thru WP 0175
(c) Select service drive mode on main 00).
(d) Measure voltage at horn between
(OR), and ground.
8. Check continuity to horn switch. 1. If continuity is present, go to Test 9.
horn switch (WP 0098 00). open circuit between horn and horn
(b) Wiring harness remains switch. Replace wiring harness in
disconnected from horn. question (WP 0169 00 thru WP 0175
(c) Turn battery disconnect switch 00).
position (TM 5-3805-290-10).
(d) Check continuity at horn between
(GY) and horn switch wiring
harness pin, circuit 332 (GY).
NOTE
Refer to Steering Wheel Replacement for location of ground wire (WP 0098
00).
9. Check horn switch continuity. 1. If continuity is present, replace horn
(a) Remove horn switch (WP 0098 (WP 0075 00). If problem still exists,
00). there is no continuity between horn
(b) While holding horn switch in switch and ground. Restore continuity
closed position, check continuity between horn switch and ground (WP
across horn switch. 0022 00).
horn switch (WP 0098 00).
0008 00-64
TM 5-3805-290-23-1
Table 3. Transmission System Troubleshooting.

8
WARNING
• Injury or death to personnel can result from sudden machine move-
ment.
• 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 skin, causing injury to
personnel.
• At opening temperature, hydraulic oil is hot. Allow hydraulic oil to
cool before disconnecting any hydraulic lines. Failure to follow this
warning may result in injury to personnel.
• To prevent injury to personnel, wear protective eye covering and
gloves.
8
CAUTION
Wipe area clean around all connections to be opened during removal. Cap
lines and hoses and plug openings after removing lines. Contamination of
system could result in premature failure.
NOTE
• Use a container to catch any fluid that may drain from hoses or sys-
tem. Dispose of fluid IAW local policy and ordinances. Ensure all
spills are cleaned up.
• Many of these problems can create diagnostic or event codes in the
ET. These codes can help find the root cause of a problem. ET should
be used to retrieve logged and active codes.
1. Low Stall Speed. Run engine until normal operating If problem still exists, there is a problem
temperature is reached (TM 5-3805-290- with engine performance. Troubleshoot
10). engine problems first.
2. High Stall Speed in Both 1. Check transmission oil level (TM 5- 1. Add oil as necessary.
Directions. 3805-290-10). 2. If problem still exists, go to Test 2.
2. Check for air in transmission oil. 1. If air is present, find and repair air entry
point.
0008 00-65
TM 5-3805-290-23-1
Table 3. Transmission System Troubleshooting - Continued.
2. High Stall Speed in Both 3. Perform all tasks in WP 0014 00. 1. If problem still exists, replace torque
Directions - Continued. converter (WP 0176 00).
transmission (WP 0176 00).
3. High Stall Speed in One Perform all tasks in WP 0014 00. If problem still exists, replace transmission
Gear or in One Direction. (WP 0176 00).
4. There is High Converter Check transmission oil passages and oil 1. If blocked, unblock passages.
Pressure. cooler (WP 0089 00). 2. If problem still exists, replace torque
converter (WP 0176 00).
5. There is Low Converter Perform Transmission Pressure Test and 1. If necessary, replace transmission oil
Pressure. Adjustment (WP 0014 00). pump (WP 0178 00).
6. Torque Converter Gets 1. Ensure operator is operating machine 1. If there is too much load causing torque
Hot. within specified parameters (TM 5- converter to slip, return to normal
3805-290-10). operation (TM 5-3805-290-10).
2. Check transmission oil level (TM 5- 1. Add oil as necessary.
3805-290-10). 2. If problem still exists, go Test 3.
8
WARNING
• DO NOT service cooling system unless engine has been allowed to
cool down. This is a pressurized cooling system and escaping steam
or hot coolant may result in serious burns.
• DO NOT remove cooling system radiator cap when engine is hot.
Allow engine to cool down. Loosen cap to first stop and let any pres-
sure out of cooling system, then remove cap. Failure to follow this
warning may result in serious burns.
• Wear effective eye, hand, and skin protection when handling cool-
ants. Failure to do so may result in injury to personnel.
8
3. Check coolant level (TM 5-3805-290- 1. Add coolant as necessary.

4. Check transmission oil cooler and lines Unblock or replace restricted or damaged
for restriction (WP 0085 00 and WP oil cooler and lines (WP 0085 00 and WP
0089 00). 0089 00).
0008 00-66
TM 5-3805-290-23-1
6. Torque Converter Gets Hot 5. Perform Transmission Pressure Test 1. If necessary, replace transmission oil
- Continued. and Adjustment (WP 0014 00). pump (WP 0178 00).
7. Transmission Does Not 1. Check transmission fuses (TM 5-3805- 1. If fuse is open, replace fuse.
Operate in Any Gear. 290-10). 2. If problem still exists, go to Test 2.
2. Connect MSD and check for active 1. Troubleshoot any active diagnostic
diagnostic codes (WP 0006 00). codes.
3. Verify system voltage is not low. Refer If system voltage is OK, go to Test 4.
to Malfunction 1, Table 2, Electrical
System Troubleshooting.
4. Perform Transmission Pressure Test If system voltage is OK, go to Test 5.
and Adjustment (WP 0014 00).
5. Perform Transmission Control (Shift 1. If problem still exists, replace brake oil
Lever) Test (WP 0014 00). pressure sensor (WP 0072 00).
transmission and torque converter (WP
0176 00).
8. Transmission Slips in All Perform Transmission Pressure Test and If problem still exists, replace transmission
Gears. Adjustment (WP 0014 00). and torque converter (WP 0176 00).
9. Transmission Gets Hot. 1. Check coolant level (TM 5-3805-290- 1. Add coolant as necessary.
2. Check transmission oil level (TM 5- 1. Add oil as necessary.
3805-290-10). 2. If problem still exists, go Test 3.
3. Ensure operator is operating machine 1. If there is too much load causing torque
within specified parameters (TM 5- converter to slip, return to normal
3805-290-10). operation (TM 5-3805-290-10).
4. Connect MSD (WP 0006 00) and 1. If gage is inaccurate, replace
monitor transmission temperature. instrument cluster (WP 0051 00).
Compare result to gage. 2. If problem still exists, go to Test 5.
5. Check for air in transmission oil. 1. If air is present, find and repair source
of air.
6. Check for restriction in transmission 1. Replace or unblock restricted or
oil cooler and lines (WP 0085 00 and damaged components.
WP 0089 00). 2. If problem still exists, go to Test 7.
7. Check for leaks in transmission lines. 1. Replace damaged lines.
0008 00-67
TM 5-3805-290-23-1
9. Transmission Gets Hot - 8. Perform Transmission Pressure Test If problem still exists, replace transmission
Continued. and Adjustment (WP 0014 00). and torque converter (WP 0176 00).
10. Pump Noise is Not Normal. Check for damaged or leaking line on inlet 1. Replace damaged lines.
side of pump (WP 0085 00 and WP 0087 2. If problem still exists, change
00). transmission oil (WP 0083 00).
11. Transmission Operates in Check Solenoid for clutch 3 (reverse). If problem still exists, it may be due to the
Forward Only. Perform Solenoid Valve (Transmission following:
Clutch) Testing (WP 0014 00). • Reverse clutch low pressure due to
leaking seals.
• Clutch discs and plates with too much
wear.
• Broken clutch components.
Replace transmission (WP 0176 00).
12. Transmission Operates in Check Solenoid for clutch 1 (forward If problem still exists, it may be due to the
Reverse and Fourth Gear high). Perform Solenoid Valve following:
Forward Only. (Transmission Clutch) Testing (WP 0014 • Speed clutch low pressure due to
00). leaking seals.
wear.
13. Transmission Operates in Check Solenoid for clutch 2 (forward If problem still exists, it may be due to the
Reverse and First Through high). Perform Solenoid Valve following:
Third Gear Forward Only. (Transmission Clutch) Testing (WP 0014 • Forward clutch low pressure due to
00). leaking seals.
wear.
14. Transmission Does Not Check Solenoid for clutch 6 (first speed). If problem still exists, it may be due to the
Operate in First Gear, Perform Solenoid Valve (Transmission following:
Forward or Reverse. Clutch) Testing (WP 0014 00). • First speed clutch low pressure due to
leaking seals.
wear.
0008 00-68
TM 5-3805-290-23-1
15. Transmission Does Not Check Solenoid for clutch 4 (second If problem still exists, it may be due to the
Operate in Second Gear, speed). Perform Solenoid Valve following:
Forward or Reverse. (Transmission Clutch) Testing (WP 0014 • Second speed clutch low pressure due
00). to leaking seals.
wear.
16. Transmission Does Not Check Solenoid for clutch 5 (third and If problem still exists, it may be due to the
Operate in Third Gear, fourth speed). Perform Solenoid Valve following:
Forward or Reverse, and (Transmission Clutch) Testing (WP 0014 • Third speed clutch low pressure due
Fourth Gear Forward. 00). to leaking steals.
wear.
• Clutch components broken.
17. Clutch Engagement is Slow Perform Transmission Pressure Test and
for All Gears. Adjustment (WP 0014 00).
18. Clutch Engagement is Slow There may be an electrical problem, check 1. If no electrical problem exists, replace
for All Forward Gears or for diagnostic codes (WP 0006 00). transmission control valve (WP 0177
All Reverse Gears or Clutch 00).
Engagement is Slow for Any 2. If problem still exists, perform
One Gear in Both Forward Solenoid Valve (Transmission Clutch)
and in Reverse. Testing (WP 0014 00).
19. Transmission Stays Check for a faulty transmission neutralizer 1. If problem does not exist with switch
Engaged When Brake Pedal override switch by disconnecting switch disconnected, replace transmission
is Pushed. (WP 0049 00) and re-verifying problem. neutralizer override switch (WP 0049
00).
2. If problem still exists, replace brake oil
pressure sensor (WP 0072 00).
20. Transmission Engages but 1. Check for a parking brake (WP 0092 If problem still exists, troubleshoot
Machine Does Not Move. 00) or service brake system problem. differential or final drive. Refer to Table 4
in this work package.
2. Perform Transmission Pressure Test If problem still exists, perform Solenoid
and Adjustment (WP 0014 00). Valve (Transmission Clutch) Testing (WP
0014 00).
21. While Engine is Running Check wiring between instrument cluster If wiring is OK, replace audible alarm (WP
and Parking Brake is and audible alarm. Alarm is mounted 0076 00).
Engaged, Alarm Does Not underneath instrument cluster, inside
Sound When Transmission cluster bezel. Refer to Electrical System
Selection Lever is Put Into Schematic (WP 0210 00) and Electrical
Either a Forward or a General Maintenance Instructions (WP
Reverse Direction. 0022 00).
0008 00-69
TM 5-3805-290-23-1
22. Backup Alarm Will Not 1. Check backup alarm fuse (TM 5-3805- 1. Replace fuse if open.
Sound When Selection 290-10). 2. If problem still exists, go to Test 2.
Lever is Put into Reverse.
2. Perform Transmission Control (Shift If problem still exists, go to Test 3.
Lever) Test (WP 0014 00).
3. Check alarm wiring. Refer to Electrical 1. Replace wiring harness in question
System Schematic (WP 0210 00) and (WP 0169 00 thru WP 0175 00).
Electrical General Maintenance 2. If wiring is OK, replace backup alarm
Instructions (WP 0022 00). (WP 0076 00).
23. There is Low Lubrication Perform Transmission Pressure Test and
Pressure. Adjustment (WP 0014 00).
24. There is High Lubrication Replace transmission and torque converter
Pressure. (WP 0176 00).
25. Transmission Will Not Shift Check position of autoshift switch (TM 5- If problem still exists, replace autoshift
Automatically. 3805- 290-10). switch (WP 0049 00).
26. Transmission Control (Shift 1. Verify problem. If transmission does not operate properly
Lever) Will Not Engage (a) Place implement handle remote and a problem in shift lever is still
Transmission. F/N/R switch and steering column suspected, go to Test 2.
shift lever both in NEUTRAL
position (TM 5-3805- 290-10).
(b) Start engine (TM 5-3805- 290-10).
(c) Place autoshift mode switch in
MANUAL position (TM 5-3805-
290-10).
0008 00-70
TM 5-3805-290-23-1
26. Transmission Control (Shift NOTE

Lever) Will Not Engage
Highest gear available in REVERSE is third gear.
Transmission - Continued.
(d) Disengage parking brake and
operate machine in all speeds and
in both directions using steering
column shift lever (TM 5-3805-
290-10). Implement handle
remote F/N/R switch should
remain in NEUTRAL position.
(e) Ensure transmission operates in all
gears and in both directions.
(f) Place steering column shift lever
in NEUTRAL and operate
machine in all speeds and in both
directions using implement handle
remote F/N/R switch (TM 5-3805-
290-10).
(g) Ensure transmission operates in all
gears and in both directions.
2. Check shift lever signal on ET status 1. If status of shift lever position changes
screen. properly, go to Test 6.
(a) Disconnect F/N/R switch harness 2. If status on ET screen is “DATA
4-pin connector CN-C50 from FAULT” in all shifter positions, go to
shift lever. Connect a jumper wire Test 3.
from pin 3 to pin 4 on shifter 4-pin 3. If status on ET screen is “DATA
connector. FAULT” in a particular position, go to
(b) Connect MSD to machine (WP Test 4.
0006 00).
position (TM 5-3805-290-10).
(d) Select powertrain ECM and go to
status screen 4.
(e) Move shift lever through all
possible positions. Observe status
of “Shift Lever Position” on ET
screen.
3. Check for power and ground at shifter. 1. If voltage is system voltage, go to Test
(a) At shifter, connect positive (red) 4.
multimeter lead to wire 110 (GN). 2. If voltage is not system voltage, first
(b) Connect negative (black) check fuse for wire 110 GN. If fuse is
multimeter lead to wire 200 (BK). bad, replace fuse. If fuse is good, wiring
(c) Measure voltage between two harness may have failed. Replace
wires. wiring harness between fuse and shifter
or between shifter and ground (WP
0169 00 thru WP 0175 00).
0008 00-71
TM 5-3805-290-23-1
26. Transmission Control (Shift 4. Check shifter harness and ECM. 1. If each combination of contracts is
Lever) Will Not Engage (a) Shift lever has three connectors. grounded, ET screen displays
Transmission - Continued. • 8-Pin Connector corresponding shifter position.
• 6-Pin Connector Replace shift lever (WP 0081 00).
• 4-Pin Connector 2. If one combination of contacts is
(b) At shifter, disconnect 8-pin incorrect, go to Test 5.
harness connector CN-C52. 6-pin
harness connector remains
connected to shifter 6-pin
connector. Shifter 4-pin connector
remains jumpered between pins 3
and 4.
(c) Refer to Table 4, Valid Shift Lever
Input States (WP 0009 00), and
connect two jumper wires from
ECM connectors to frame ground
to simulate each shifter position. If
a particular position is already
suspect, begin with wires for that
position.
(d) Monitor status of shifter on ET
screen.
0008 00-72
TM 5-3805-290-23-1
26. Transmission Control (Shift 5. Check ECM. 1. If each combination of contacts is

Lever) Will Not Engage (a) Turn battery disconnect switch to grounded, ET screen displays
Transmission - Continued. OFF position (TM 5-3805-290- corresponding shifter position.
10). 2. If one combination of contacts does not
(b) Based on information in Table 5, cause proper status to be displayed,
Machine ECM Connector Pin clean contacts for ECM harness
Assignments (WP 0009 00), connectors.
remove corresponding wires from
machine ECM harness connectors
J1 and J2. Also, use shifter
schematic for reference. After
removing all wires shown in
Table 5 (WP 0009 00), place DT
sockets into connectors and wire
sockets so they can be connected
to frame ground individually. Be
sure wires cannot accidentally
touch frame ground.
(c) Turn battery disconnect switch to
ON position. Power up machine
with key in RUN position (TM 5-
3805-290-10) and connect and
start up ET software MSD.
(d) Select powertrain ECM and go to
status screen 4.
(e) Monitor status of shifter on MSD.
0008 00-73
TM 5-3805-290-23-1
26. Transmission Control (Shift 6. Verify shift lever remote F/N/R switch 1. If shift lever position status changes
Lever) Will Not Engage functionality. properly, monitor machine to see if
Transmission - Continued. (a) Place shift lever on steering problems occur. If problem occurs,
column in NEUTRAL and FIRST repeat entire test procedures again.
GEAR (TM 5-3805-290-10). 2. If status on ET screen is “DATA
(b) At shifter 4-pin connector remove FAULT” in either a particular position
jumper wire between pin 3 and pin or all positions, go to Test 7.
4.
(c) Connect 4-pin receptacle
connector CN-C50 from cab
harness to shifter 4-pin plug. This
will enable shift handle remote
F/N/R switch circuit.
(d) Ensure pins and sockets are seated
properly and that connectors mate
correctly.
(e) Please remote F/N/R switch in
FORWARD position (TM 5-
3805-290-10).
(f) Verify ET shows “F1” as desired
gear.
(g) Place remote F/N/R switch in
REVERSE position.
(h) Verify ET shows “R1” as desired
gear.
7. Verify shift lever remote F/N/R 1. If shift lever position status changes
harness. properly, replace remote F/N/R switch
(a) Ensure shift lever on steering assembly (WP 0188 00).
column is in NEUTRAL and 2. If status on ET screen is “DATA
FIRST GEAR (TM 5-3805-290- FAULT” no matter which wire is
10). jumpered to pin 1, common signal pin
(b) Ensure cab harness 4-pin 1 202 BK may have lost connection to
receptacle connector CN-C50 is machine ground. Replace wiring
connected to shifter 4-pin plug. harness in question (WP 0169 00 thru
(c) Disconnect 6-pin connector to WP 0175 00).
remote F/N/R assembly. 3. If status on ET screen is “DATA
(d) On cab harness connector FAULT” when a particular wire is
CN-C23, place a jumper wire from jumpered to pin 1, replace wiring
pin 1 202 BK to pin 4 G787 GN. harness in question (WP 0169 00 thru
(e) Verify ET shows “F1” as desired WP 0175 00).
gear.
(f) Move jumper wire connection join
pin 1 202 BK to pin 6 G788 YL.
(g) Verify ET shows “R1” as desired
gear.
(h) Move jumper wire connection join
pin 1 202 BK to pin 5 P916 OR.
(i) Verify ET shows “N1” as desired
gear.
0008 00-74
TM 5-3805-290-23-1
Table 4. Differential and Final Drive Troubleshooting.

8
WARNING
ment.
personnel.
gloves.
8
CAUTION
NOTE
• Many of these problems can create diagnostic or event codes in ET.
These codes can help find the root cause of a problem. ET should be
used to retrieve logged and active codes.
1. There is Constant Noise in Check axle oil for correct level (WP 0091 1. Add, drain, or change oil as necessary
Differential. 00) and type (WP 0019 00). (WP 0091 00).
2. If problem still exists, replace axle (WP
0179 00 and WP 0180 00).
2. There is Noise at Different Replace axle (WP 0179 00 and WP 0180
Intervals. 00).
3. There is Noise When Replace axle (WP 0179 00 and WP 0180
Machine Turns. 00).
4. Drive Wheels Do Not Turn Replace axle (WP 0179 00 and WP 0180
but Universal Joint Turns. 00).
0008 00-75
TM 5-3805-290-23-1
Table 5. Steering System Troubleshooting.

8
WARNING
ment.
personnel.
gloves.
8
CAUTION
NOTE
1. Steering Metering Pump 1. Check hydraulic oil for correct oil level 1. Add or change oil if necessary (WP
Makes Noise and Steering (TM 5-3805-290-10), viscosity or 0137 00).
Cylinder Rods Do Not Move grade (WP 0019 00), and 2. If problem still exists, go to Test 2.
Freely. contamination.
2. Check for a loose connection at oil line 1. Tighten any loose connections or, if
on inlet side of pump (WP 0182 00). damaged, replace line(s) (WP 0182
00).
3. Check for blocked suction screen in 1. Unblock or replace hydraulic tank as
hydraulic tank. necessary (WP 0140 00).
0008 00-76
TM 5-3805-290-23-1
Table 5. Steering System Troubleshooting - Continued.
1. Steering Metering Pump 4. Check for air in steering hydraulic If problem is still present, refer to
Makes Noise and Steering circuit. Malfunction 10, Operation of Hand
Cylinder Rods Do Not Move Metering Unit is Erratic in this work
Freely - Continued. package.
5. Check for excessive pump wear or If damaged, replace steering piston pump
damaged. (WP 0182 00).
2. Too Much Force is Needed 1. Check hydraulic oil level (TM 5-3805- 1. Add or change oil if necessary (WP
to Turn Steering Wheel. 290-10). 0137 00).
2. Allow hydraulic oil to reach normal If problem still exists, go to Test 3.
operating temperature (TM 5-3805-
290-10).
3. Check steering metering pump for 1. Replace steering metering pump as
damage. necessary (WP 0101 00).
4. Check for blocked suction screen in 1. Unblock or replace hydraulic tank as
hydraulic tank. necessary (WP 0140 00).
5. Check margin and standby pressure 1. Adjust pressure as necessary.
(WP 0016 00). 2. If problem still exists, go to Test 6.
6. Check adjustment of pressure cutoff 1. Adjust pressure cutoff valve as
valve. Refer to Piston Pump Pressure necessary.
Test and Adjustment (WP 0017 00). 2. If problem still exists, go to Test 7.
7. Perform Steering Meter Pump Test If problem still exists, go to Test. 8.
(WP 0016 00).
8. Check steering cylinders for damage. 1. If damaged, replace steering cylinders
(WP 0103 00).
2. If problem still exists, replace coupler
valve (WP 0190 00).
3. Machine Does Not Turn 1. Ensure steering frame lock is not 1. Secure steering frame lock in stowed
When Steering Wheel is connected (TM 5-3805-290-10). position (TM 5-3805-290-10).
Turned. 2. If problem still exists, go to Test 2.
2. Check hydraulic oil for correct level 1. Add or change oil if necessary (WP
(TM 5-3805-290-10) and check for dirt 0137 00).
in system. 2. If problem still exists, go to Test 3.
3. Check for leaks at seals in steering 1. Repair any leaks.
cylinder pistons, accessory valve 2. If problem still exists, go to Test 4.
between cylinder lines, and ports.
4. Check for no oil flow going to hand 1. Repair as necessary.
metering unit. 2. If problem still exists, go to Test 5.
0008 00-77
TM 5-3805-290-23-1
3. Machine Does Not Turn 5. Check for air in hydraulic oil. 1. If air is present, repair any leaks.
When Steering Wheel is 2. If problem still exists, go to Test 6.
Turned - Continued.
6. Check for a restriction or binding in 1. Remove any restrictions or binding.
steering linkage. 2. If problem still exists, go to Test 7.
7. Perform Steering Metering Pump Test If problem still exists, go to Test 8.
(WP 0016 00).
8. Check steering column upper shaft and 1. Replace any damaged part (WP 0099
lower splines for looseness or damage. 00).
valve (WP 0190 00).
3. If problem still exists, replace steering
metering pump (WP 0101 00).
4. Machine Turns Slowly in 1. Ensure steering axle is not overloaded. If problem still exists, go to Test 2.
Both Directions.
2. Check margin pressure and standby 1. Adjust as necessary (WP 0016 00).
pressures (WP 0016 00). 2. If problem still exists, go to Test 3.
3. Perform Metering Pump (HMU) Test If problem still exists, go to Test 4.
(WP 0016 00).
4. Check steering cylinder for damage. 1. If damaged, replace steering cylinders
(WP 0103 00).
valve (WP 0190 00).
5. Machine Turns Slowly in 1. Check steering linkage for wear or 1. Replace any damaged parts (WP 0099
One Direction. damage. 00).
(WP 0016 00).
3. Check steering cylinders for damage. If damaged, replace steering cylinders (WP
0103 00).
6. Steering Wheel Does Not 1. Check steering return-to-tank line for 1. Remove restriction or replace line as
Return to Center Position restriction causing high pressure (WP necessary.
Correctly. 0102 00). 2. If problem still exists, go to Test 2.
(WP 0016 00).
3. Check steering column to ensure Realign if necessary.
correct alignment with steering
0008 00-78
TM 5-3805-290-23-1
7. Temperature of Oil is Too 1. Check hydraulic oil for correct 1. Add or change oil if necessary (WP
Hot. viscosity or grade (WP 0019 00). 0137 00).
2. Check restriction in steering line (WP 1. Remove restriction or replace lines as
0102 00). necessary.
3. Check for air mixed with oil. If air is present, repair any leaks.
8. Steering Wheel Turns Check steering column to ensure correct 1. Realign if necessary.
Without Operator’s Action. alignment with steering metering pump 2. If problem still exists, replace steering
(WP 0101 00). metering pump (WP 0101 00) and
change hydraulic system oil (WP 0137
00).
9. Machine Will Not Stay in a 1. Check for bent steering cylinder rod. 1. If damaged, replace steering cylinders
Straight Line. (WP 0103 00).
2. Check for loose steering cylinder 1. If damaged, replace steering cylinders
piston. (WP 0103 00).
3. Check for air mixed with oil. 1. If air is present, repair any leaks.
4. Check steering linkage for wear or 1. Replace any damaged or worn parts.
damage. 2. If problem still exists, go to Test 5.
5. Remove and check steering cylinder 1. If damaged or worn, replace steering
pins for wear or damage (WP 0103 00). cylinder pins.
10. Operation of Hand Check for loose steering cylinder piston. 1. If damaged, replace steering cylinders
Metering Unit is Erratic. (WP 0103 00).
11. Steering Wheel Has Torque steering wheel nut 27 ± 5 lb-ft (37 ± If problem still exists, replace steering
Excessive Free Play. 7 Nm) (WP 0098 00). column (WP 0099 00).
12. Hand Metering Unit Locks Perform Pump Performance (Steering) 1. If necessary, replace steering pump
Up. Test (WP 0016 00). (WP 0182 00).
metering pump (WP 0101 00) and
change hydraulic system oil (WP 0137
00).
13. Machine Turns in Wrong Check hydraulic lines to steering cylinders If hydraulic lines are connected to wrong
Direction When Operator (WP 0102 00 and WP 0103 00). ports on hand metering unit, connect lines
Turns Steering Wheel. correctly.
0008 00-79
TM 5-3805-290-23-1
14. Steering Wheel Kicks at Replace steering metering pump (WP 0101
Start or End of Steering 00).
Stroke.
15. Severe Vibration Occurs 1. Check for air in hydraulic system. 1. If air is in system, locate and repair
When Steering is Activated. source of leak.
2. Perform Piston Pump (Steering and If problem still exists, go to Test 3.
Pilot) High Pressure Stall Test and
Adjustment (WP 0016 00).
3. Perform Piston Pump (Steering and If problem still exists, perform Piston
Pilot) Margin Pressure Test and Pump (Steering and Pilot) Low Pressure
Adjustment (WP 0016 00). Standby Test and Adjustment (WP 0016
00).
16. Steering Wheel or Steered 1. Check steering column for correct 1. Realign if necessary.
Wheels Move alignment (WP 0099 00). 2. If problem still exists, go to Test 2.
Unexpectedly.
2. Check back pressure from hydraulic 1. If back pressure exceeds 150 psi
tank. (1,034 kPa), find out why hydraulic
tank is not venting and repair (WP 0140
00).
3. Check hoses to hand metering unit (WP If hoses are not connected correctly,
0131 00 thru WP 0136 00). reconnect hoses correctly.
0008 00-80
TM 5-3805-290-23-1
Table 6. Braking and Hydraulic Fan System Troubleshooting.

8
WARNING
ment.
personnel.
gloves.
8
CAUTION
NOTE
• This section provides probable causes to known problems. Since
there may be several probable causes, specific inspections or instru-
ment tests may be recommended. These inspections and tests will
help to identify causes that are the most probable.
• Make sure you use an oil with the correct viscosity for operating
conditions.
• Ensure that the tasks in Brake System Tests, Inspections, and Adjust-
ments (WP 0015 00) have been performed before continuing with
troubleshooting.
0008 00-81
TM 5-3805-290-23-1
Table 6. Braking and Hydraulic Fan System Troubleshooting - Continued.
1. Front and Rear Service Check service brake pedal and linkage for 1. If damaged, replace brake pedal
Brakes Do Not Operate. damage (WP 0094 00). assembly.
2. If pedal and linkage are OK, brake
control valve may not be functioning
correctly. Replace brake control valve
(WP 0093 00).
3. If problem still exists, replace braking
and hydraulic fan gear pump (WP 0186
00).
2. Front Service Brakes Do Check lines to front service brakes for 1. Replace damaged or leaking lines,
Not Operate. obstructions or leaks (WP 0131 00). tighten loose connections, and remove
restrictions or reposition kinked lines.
2. If lines are OK, replace brake control
valve (WP 0093 00).
00).
4. If problem still exists, replace front
axle (WP 0179 00).
3. Rear Service Brakes Do Not Check lines to rear service brakes for 1. Replace damaged or leaking lines,
Operate. obstructions or leaks (WP 0131 00). tighten loose connections, and remove
restrictions or reposition kinked lines.
2. If lines are OK, replace brake control
valve (WP 0093 00).
3. If problem still exists, replace rear axle
(WP 0180 00).
4. Service Brakes Slip. NOTE
Additives in oil in one or both axles are incorrect.
1. Change differential and final drive oil
(WP 0091 00).
2. If problems still exist, replace axle(s)
(WP 0179 00 and WP 0180 00).
5. Service Brakes Are Not Change hydraulic oil and filter (WP 0137 1. If problem still exists, replace brake
Applied Evenly. 00). control valve (WP 0093 00).
2. If problem still exists, replace axle(s)
(WP 0179 00 and WP 0180 00).
0008 00-82
TM 5-3805-290-23-1
6. Too Much Force is Needed 1. Check service brake pedal and linkage 1. If damaged, replace brake pedal
to Push Brake Pedal. for damage (WP 0094 00). assembly.
2. Check nitrogen charge in brake 1. If necessary, charge or replace
accumulators (WP 0096 00). Connect accumulators.
MSD (WP 0006 00) and compare gage 2. If gage and MSD reading do not match,
on nitrogen charging station with brake replace brake charging pressure sensor
charging pressure sensor reading on (WP 0071 00).
ET. 3. If problem still exists, replace brake
control valve (WP 0093 00).
00).
5. If problem still exists, replace axle(s)
(WP 0179 00 and WP 0180 00).
7. Parking Brake Does Not 1. Check parking brake adjustment (WP 1. If parking brake is out of adjustment,
Hold Machine Stationary. 0092 00). adjust parking brake.
2. If parking brake adjustment is OK, go
to Test 2.
2. Check parking brake linings for wear 1. If parking brake linings are worn,
(WP 0092 00). replace them.
2. If parking brake drums are oily, clean
drums.
8. Parking Brake Does Not Check parking brake cable for incorrect If damaged, stretched, or out of
Engage When Parking adjustment, damage, or disconnection (WP adjustment, replace or adjust parking brake
Brake Control Lever is 0092 00). cable as necessary.
Actuated.
9. Low Oil Pressure Warning 1. Check hydraulic system oil level (TM 1. Add oil as necessary.
Indicator Will Not Turn 5-3805-290-10). 2. If problem still exists, go to Test 2.
Off.
2. Run engine at high rpm while 1. If warning indicator turns off with
observing warning indicator (TM 5- engine at high idle, replace braking and
3805-290-10). hydraulic fan gear pump (WP 0186 00).
2. If problem still exists, refer to
Malfunction 10, Pressure in
Accumulators Does Not Decrease
When Brakes Are Applied, or
Decreases Without Applying Brakes in
this work package.
3. If problem still exists, pinpoint faulty
wiring harness and replace (WP 0169
00 thru WP 0175 00). Refer to
Electrical System Schematic (WP 0210
00).
0008 00-83
TM 5-3805-290-23-1
10. Pressure in Accumulators 1. Ensure all electrical connections to 1. Reconnect electrical connectors as
Does Not Decrease When braking and hydraulic fan gear pump necessary.
Brakes Are Applied or are connected (WP 0186 00 and WP 2. If problem still exists, go to Test 2.
Decreases Without 0210 00).
Applying Brakes.
2. Check brake control valve for leaks 1. If leaking or damaged, replace brake
(WP 0093 00). control valve.
00).
11. Fan Speed Will Not Adjust Perform fan speed calibration (WP 0017 1. If problem still exists, replace gear
to Demands of Machine. 00). motor hydraulic fan (WP 0187 00).
00).
0008 00-84
TM 5-3805-290-23-1
Table 7. Hydraulic System Troubleshooting.

8
WARNING
ment.
personnel.
gloves.
CAUTION
8
NOTE
• On 924G machines, each valve has poppets which act as load check
valves. Poppets close ports so there is almost zero drift of imple-
ments. Relief valves in auxiliary circuit and in tilt circuit protect
components from pressures in circuits when control valves are in
HOLD position.
a. Oil Pressure for opening relief valves for main system and auxiliary
circuits must be within specifications. Pressures that are too low will
cause a decrease in lifting force and dig characteristics. Pressures that
are too high will cause a decrease in life of hose and other components.
b. Circuit drift is caused by leakage past cylinder pistons, O-ring seals in
control valves, check valves that do not seat correctly, or makeup
valves that do not seat correctly. Poor adjustments of control valves or
incorrect fit may also contribute to circuit drift.
c. Cycle times that are longer than normal can result from oil leakage,
pump wear, or pump speed.
• If basic tests indicate a leak in circuit, install a flow meter and per-
form a test.
0008 00-85
TM 5-3805-290-23-1
Table 7. Hydraulic System Troubleshooting - Continued.
1. Hydraulic Power is Low. 1. Ensure engine is operating correctly. If problem still exists, go to Test 2.
Perform Torque Converter Stall Test
(WP 0014 00).
2. Check hydraulic oil level (TM 5-3805- 1. Add oil if necessary.
290-10). 2. If problem still exists, go to Test 3.
3. Check hydraulic system for leaks. 1. Repair any leaks (WP 0131 00 thru WP
0136 00).
4. Check oil temperature. If oil temperature is too high, refer to
Malfunction 10, Oil Temperature is Too
High in this work package.
5. Check for air bubbles in oil. If air bubbles are present, refer to
Malfunction 11, There Are Air Bubbles in
Oil in this work package.
6. Perform Pilot System Pressure If problem still exists, go to Test 7.
Pressure Test (WP 0017 00).
7. Check high pressure cutoff of If problem still exists, go to Test 8.
implement pump. Perform Piston
Pump Pressure Test (WP 0016 00).
8. Check line relief valves setting. If problem still exists, replace pilot
Perform Relief Valve (Line) Test and operated control (WP 0188 00).
2. No Functions Will Operate 1. Ensure lockout switch is in OFF If problem still exists, go to Test 2.
or All Functions Operate position (TM 5-3805-290-10).
Slowly.
2. Visually inspect hydraulic system for 1. Repair any leaks found.
leaks in system. 2. If problem still exists, go to Test 3.
3. Perform Pilot System Pressure If problem still exists, go to Test 4.
Pressure Test (WP 0017 00).
4. Check high pressure cutoff of If problem still exists, go to Test 5.
implement pump. Perform Piston
Pump Pressure Test (WP 0016 00).
5. Check standby pressure. Refer to 1. If standby pressure cannot be adjusted,
Piston Pump Pressure Test and refer to Malfunction 5, Standby
Adjustment (WP 0017 00). Pressure Cannot be Adjusted Correctly
0008 00-86
TM 5-3805-290-23-1
2. No Functions Will Operate 6. Drain hydraulic tank (WP 0137 00) and 1. Clean screen or replace pump as
or All functions Operate inspect inlet screen on implement necessary.
Slowly - Continued. pump for contamination (WP 0182 00). 2. If problem still exists, go to Test 7.
7. Check signal limiter valve adjustment. 1. Adjust signal limiter valve if necessary.
Refer to Piston Pump Pressure Test 2. If problem still exists, replace pilot
and Adjustment (WP 0017 00). operated control (WP 0188 00).
3. If problem still exists, replace main
4. If problem still exists, replace cylinders
(WP 0128 00 and WP 0129 00).
3. Pilot Oil Pressure is Low. 1. Check setting for pressure reducing 1. Adjust as necessary.
valve. Refer to Pilot System Pressure 2. If problem still exists, go to Test 2.
Test (WP 0017 00).
2. Steering pump pressure for low If problem still exists, go to Test 3.
pressure standby pressure is not
correct. Perform Piston Pump
(Steering and Pilot Oil) Low Pressure
Standby Test and Adjustment (WP
0016 00).
3. Signal drain valve is not functioning 1. Replace main control valve (WP 0189
correctly. 00).
2. If problem still exists, go to test 4.
4. Pressure reducing valve is Loosen adjusting screw on pressure
contaminated. reducing valve and turn screw inward (WP
0016 00).
4. Piston Pump for Work 1. Check hydraulic oil for correct oil 1. Add or change oil if necessary (WP
Tools Will Not Reach High viscosity or grade (WP 0019 00), 0121 00).
Pressure Cutoff. contamination, and correct level (TM 2. If problem still exists, go to Test 2.
5-3805-290-10).
2. Check for air in oil. 1. If air is present, refer to Malfunction
11, There Are Air Bubbles in Oil in this
work package.
3. Cutoff spool is stuck. 1. Loosen cutoff spool adjusting screw
and attempt to readjust high pressure
cutoff. Refer to Piston Pump Pressure
Test and Adjustment (WP 0017 00).
implement pump (WP 0182 00).
5. Standby Pressure Cannot Spring or margin spool is damaged. If problem still exists, replace implement
be Adjusted Correctly. pump (WP 0182 00).
0008 00-87
TM 5-3805-290-23-1
6. Hydraulic Circuit is 1. Check for air in system. 1. If air is present, refer to Malfunction
Hammering. 11, There Are Air Bubbles in Oil in this
work package.
2. If problem exists, go to Test 2.
2. Perform Relief Valve Line Test and If problem still exists, go to Test 3.
3. Margin pressure is not correct. Refer to If problem still exists, adjust pilot system
Piston Pump Pressure Test and pressure. Refer to Pilot System Pressure
Adjustment (WP 0017 00). Test (WP 0017 00).
7. Boom Raises but Will Not Make sure ride control switch is not in ON 1. Move ride control switch to OFF
Lower. position (TM 5-3805-290-10). position.
2. If problem still exists, refer to
Malfunction 8, Boom Will Not Raise
and Lower in this work package.
8. Boom Will Not Raise or 1. Determine malfunction. If no other functions are operating
Lower. correctly, refer to Malfunction 2, No
Functions Will Operate or All Functions
Operate Slowly in this work package.
2. Check lift cylinders for damage. 1. If damaged, replace lift cylinders (WP
0129 00).
3. Check mechanical boom linkage for 1. Repair damage (WP 0201 00).
damage. 2. If problem still exists, replace pilot
3. If problem still exists, replace ride
4. Replace lift cylinder(s) (WP 0129 00).
5. Replace main control valve (WP 0189 00).
9. Cannot Tilt Bucket in 1. Determine malfunction. If no other functions are operating
Either Direction. correctly, refer to Malfunction 2, No
Functions Will Operate or All Functions
Operate Slowly in this work package.
2. Check tilt cylinders for damage. 1. If damaged, replace tilt cylinders (WP
0128 00).
3. Line relief valves or combination valve 1. Check and adjust settings for line relief
are not operating correctly. valves (WP 0017 00).
2. If problem still exists, replace pilot
3. Replace lift cylinder(s) (WP 0129 00).
4. Replace main control valve (WP 0189 00).
0008 00-88
TM 5-3805-290-23-1
10. Oil Temperature is Too 1. Check hydraulic oil level (TM 5-3805- 1. Add oil if necessary.
High. 290-10). 2. If problem still exists, go to Test 2.
2. Inspect hydraulic oil cooler for 1. If damaged or restricted, clean or
restriction (WP 0089 00). replace hydraulic oil cooler.
3. Check for air in system. If air is present, refer to Malfunction 11,
There Are Air Bubbles in Oil in this work
package.
4. Check hydraulic oil for correct oil 1. Add or change oil and filter if necessary
viscosity or grade (WP 0019 00), (WP 0137 00). If dirty or obstructed,
contamination, and correct level (TM clean sump screen.
5-3805-290-10). Remove cap from 2. If problem still exists, perform Relief
hydraulic oil tank and inspect sump Valve (Line) Test and Adjustment (WP
screen (TM 5-3805-290-10). 0017 00).
11. There Are Air Bubbles in NOTE
Oil.
A problem with air in hydraulic oil must be corrected before hydraulic sys-
tem will operate at normal temperatures.
1. Check for a loose connection on oil line 1. Tighten all loose connections and
on inlet side of pump. Visually inspect replace leaking or damaged lines (WP
all pump lines for leaks or restrictions. 0131 00).
2. Return oil may be flowing into 1. Add oil if necessary.
hydraulic tank above level of oil in 2. If problem still exists, replace
tank. Check hydraulic oil level (TM 5- implement pump (WP 0182 00).
3805-290-10).
12. Cycle Times Are Not 1. Check standby pressure. Refer to If problem still exists, go to Test 2.
Correct. Piston Pump Pressure Test and
2. Check for leaks in system, specifically 1. Repair any leaks or replace damaged
O-rings. O-rings in system (WP 0131 00).
implement pump (WP 0182 00).
13. Quick Coupler Does Not 1. Replace quick coupler switch (WP If problem still exists, go to Test 2.
Operate. 0049 00).
2. Replace quick coupler solenoid valve If problem still exists, replace steering
(WP 0138 00). pump (WP 0182 00).
0008 00-89
TM 5-3805-290-23-1
14. Ride Control Function Does 1. Replace ride control switch (WP 0049 If problem still exists, go to Test 2.
Not Operate. 00).
2. Replace ride control solenoid valve If problem still exists, go to Test 3.
(WP 0123 00).
3. Test and charge accumulator (WP 0127 If problem still exists, replace dead engine
00). lower valve (WP 0131 00).
15. Implements Will Not Lower Replace dead engine lower valve (WP 1. If problem still exists, replace dead
With Dead Engine Lower 0131 00). engine lower valve (WP 0131 00).
Valve. 2. If problem still exists, replace pilot
valve (WP 0188 00).
16. Implement Drifts Charge pilot oil accumulator (WP 0126
Downward. 00).
0008 00-90
TM 5-3805-290-23-1
Table 8. Air Conditioning System Troubleshooting.
NOTE
• When ambient temperature is above 70°F (21°C), a low pressure gage reading of 10 to 20 psi (70 to 138
kPa) is a normal operating pressure for AC system. Also, when ambient temperature is above 70°F
(21°C), a high pressure gage reading of 120 to 190 psi (820 to 1,300 kPa) is a normal operating pressure
for AC system. In very hot weather, low pressure readings and high pressure readings will be at high
end of normal operating range. In cooler weather, low pressure reading will be in middle to low end of
normal operating range, while high pressure reading will be low. For correct gage reading in relation
to ambient temperature conditions, refer to table below. This table is only for reference.
• All pressures are given as a guide only. Weight is only absolute means of determining proper refriger-
ant charge. Improper refrigerant charge will cause premature failure of compressor.
• Unless directed otherwise, all troubleshooting listed requires that pressure gages be connected (WP
0191 00) to compare system pressures with table below.
• Ambient temperature is above 70°F (21°C) in all malfunctions.
• Arc Suppressor Test is available in WP 0018 00.
PRESSURE RANGE
Ambient Air Temperature High Pressure Test Fitting (Pressure May Low Pressure Test Fitting (Pressure Before
Be Slightly Higher in Very Humid Clutch Disengagement)
Conditions and Lower in Very Dry
Conditions)
70°F (21°C) 120 to 190 psi (820 to 1,300 kPa) 10 to 20 psi (70 to 138 kPa)
90°F (32°C) 170 to 240 psi (1,175 to 1,650 kPa) 15 to 30 psi (105 to 210 kPa)
1. Temperature of Air Flow is NOTE
Partially Cool.
Leaks in refrigerant circuit will cause system to be low on refrigerant.
1. Check low and high pressure gage 1. If both readings are below normal, go
during AC operation (WP 0018 00). to Test 2.
2. If low pressure gage reading is normal
but high pressure gage reading bounces
or reading is unsteady, go Test 3.
3. If low pressure gage reading is below
normal but high pressure gage reading
is normal to below normal range, go to
Test 4.
4. If low pressure gage reading does not
change and pressure gage reading is at
high end of normal range, go to Test 7.
5. If low pressure gage reading is above
normal, high pressure gage reading is
below normal, and system is fully
charged, go to Test 8.
0008 00-91
TM 5-3805-290-23-1
Table 8. Air Conditioning System Troubleshooting - Continued.
1. Temperature of Air Flow is 2. Perform Refrigerant Leakage Test (WP 1. Recover refrigerant (WP 0191 00) and
Partially Cool - Continued. 0018 00) to determine location of leak. repair leaks.
2. If a large amount of refrigerant was
lost, perform Refrigerant Compressor
Oil Check (WP 0018 00).
3. Evacuate system and re-charge system
with correct amount of refrigerant (WP
0191 00).
4. After system is charged, operate for a
minimum of 10 minutes (TM 5-3805-
290-10) and perform Performance
Checks for AC System (WP 0018 00) to
verify correct operation of AC system.
3. There is air is in system. Reclaim, evacuate, and recharge AC
system (WP 0191 00).
NOTE
• Restriction in high pressure liquid line can cause refrigerant to be
removed from evaporator at a faster rate. Restriction can cause
evaporator to be low on refrigerant from inline dryer. Clogged filters
or a failure of blower motor can cause possible restrictions to air
flow.
• Restrictions of refrigerant flow are identified by frost or cold spots
in line. Also, restrictions of refrigerant flow are identified by frost or
cold spots in inline dryer.
• Cap all open lines and fittings during repairs.
• Ambient temperature is above 70°F (21°C).
4. Check for restriction at inline dryer 1. If restriction is found, replace inline
(WP 0018 00). dryer (WP 0194 00).
2. Recover refrigerant, evacuate, and
charge system with correct amount of
refrigerant. Measure refrigerant by
weight (WP 0191 00).
Checks for Air Conditioning System
(WP 0018 00) to verify correct
operation of AC system.
0008 00-92
TM 5-3805-290-23-1
1. Temperature of Air Flow is 5. Check for restriction at liquid line (WP 1. If restriction is found, replace liquid
Partially Cool - Continued. 0018 00). line (WP 0193 00).
6. Check for restriction at cab filters. 1. Replace cab filters or remove any
restrictions found (TM 5-3805-290-
10).
NOTE
Pressure should rise when compressor is not in operation.
7. The system has air or moisture in 1. Recover refrigerant (WP 0191 00) and
system and does not have a full charge repair leaks.
of refrigerant. Perform Refrigerant 2. If a large amount of refrigerant was
Leakage Test (WP 0018 00) to lost, perform Refrigerant Compressor
determine location of leak. Oil Check (WP 0018 00).
0191 00).
0008 00-93
TM 5-3805-290-23-1

Partially Cool - Continued.
• Compressor has internal leaks.
• Read valve has leakage.
• Compressor piston, rings, or cylinders are worn.
8. Check drive belt for damage or If belt is loose or damaged, replace or
looseness. adjust belt (WP 0046 00) as necessary.
9. Perform Refrigerant Leakage Test (WP 1. If an internal leak is found, replace
0018 00) to isolate problem. compressor (WP 0192 00). Replace
inline dryer (WP 0194 00).
2. If an external leak such as a hose
connection is found, recover
refrigerant (WP 0191 00) and repair
leaks.
3. Evacuate and charge system with
correct amount of refrigerant. Measure
refrigerant by weight (WP 0191 00).
2. Temperature of Air Flow is 1. Check low and high pressure gage 1. If low pressure gage reading is below
Warm. during operation of AC (WP 0018 00). normal and high pressure gage reading
is above normal, go to Test 2.
2. If low and high pressure gage readings
are too high, go to Test 3.
2. There is air or moisture (water) in 1. The desiccant may be full of moisture.
system. Recover refrigerant (WP 0191 00) and
replace inline dryer (WP 0194 00).
Evacuate and charge system with
0008 00-94
TM 5-3805-290-23-1

Warm - Continued.
• Do not operate engine.
• With ambient temperature above 70°F (21°C), normal gage reading
for low pressure side is 10 to 20 psi (70 to 138 kPa) while normal
gage reading for high pressure side is 120 to 190 psi (820 to 1,300
kPa).
• The condenser is not functioning properly. System may have a nor-
mal or overcharge of refrigerant.
3. Check for blockage in flow of air 1. If a blockage is found in condenser,
through condenser (WP 0018 00). remove all blockages.
2. If low pressure gage reading and high
pressure gage readings are too high,
recover refrigerant (WP 0191 00) and
3. System Only Cools Cab in 1. Check low and high pressure gage 1. If low pressure gage reading is normal,
Morning and in Evening, during operation of AC (WP 0018 00). (gage reading may drop into vacuum
Not During Hot Part of Day. range during testing procedure) and
Air Flow is Very Cold but high pressure gage reading is normal
Air Flow Becomes Warm. and is below normal when low pressure
gage drops into vacuum range, go to
Test 2.
2. If readings are not as specified, exit this
Malfunction.
2. The system has a large amount of 1. Recover refrigerant (WP 0191 00) and
moisture. Desiccant in receiver/dryer replace inline dryer (WP 0194 00).
or inline dryer is full of water. Water is Evacuate and charge system with
released during high ambient correct amount of refrigerant. Measure
temperatures. Ice collects in orifice and refrigerant by weight (WP 0191 00).
ice can block flow of refrigerant. 2. After system is charged, operate for a
0008 00-95
TM 5-3805-290-23-1
4. High Pressure (Liquid Line) NOTE

is Very Hot. Compressor
The compressor is not operating under ambient temperatures that are
May Become Noisy and
extreme. Compressor is not operating under high humidity that is extreme.
Drive Belt May Slip.
1. Check low and high pressure gage 1. If low pressure gage reading is above
during operation of AC (WP 0018 00). normal and high pressure gage reading
is above normal, go to Test 2.
Malfunction.
2. The system is overcharged. 1. Recover refrigerant (WP 0191 00) and
5. Water is in Vents and Check non-return valve for proper
Leaking from Unit. positioning and direction.
6. Compressor Will Not 1. Check low and high pressure gage 1. If low pressure gage reading is above
Engage. Air Flow to during operation of AC (WP 0018 00). normal and high pressure gage reading
Operator’s Compartment is is below normal, go to Test 2.
Warm. 2. If readings are not as specified, exit this
Malfunction.
2. Check AC compressor (WP 0192 00).
(a) Check wire connectors on
thermostatic switch and on
compressor clutch.
(b) Check for broken insulation.
(c) Check for clutch coil resistance of
17.6 ± 0.6 Ohms with a
multimeter.
(d) Check for proper electrical ground
at magnetic clutch.
0008 00-96
TM 5-3805-290-23-1
6. Compressor Will Not (e) Touch two wires on switch 1. If problem is loose wire on switch or a
Engage. Air Flow to together. Check for proper loose wire on magnetic clutch, make
Operator’s Compartment is operation of magnetic clutch. repairs as needed or replace
Warm - Continued. compressor (WP 0192 00).
2. If wires to clutch were damaged,
damaged wires can cause switch to
remain open. Repair damaged wires.
3. Refer to Table 2, Electrical System If problem still exists, go to Test 4.
Troubleshooting to check AC control
system (WP 0022 00).
4. Check for lost charge of refrigerant in 1. If capillary tube has no charge or switch
capillary tube. remains open, problem is in
thermostatic switch, replace switch
(WP 0143 00).
7. Compressor Continues to NOTE
Cycle or Clutch Will Not
Cause of problem may be one of following conditions: low charge, over-
Disengage. Air Flow to
charge, or evaporator freeze-up.
Operator’s Compartment is
Very Cold or Air Flow May
be Restricted Completely at
Times.
1. Check low and high pressure gage 1. If low pressure gage reading is below
during operation of AC (WP 0018 00). normal and high pressure gage reading
is below normal, go to Test 2.
Malfunction.
0008 00-97
TM 5-3805-290-23-1
7. Compressor Continues to 2. The thermostat switch is held closed or Replace compressor as necessary (WP
Cycle or Clutch Will Not there is a short in wire to magnetic 0192 00).
Disengage. Air Flow to clutch and magnetic clutch will not
Operator’s Compartment is release. Check wire that goes to
Very Cold or Air Flow May magnetic clutch. Wire may have an
be Restricted Completely at electrical short.
Times - Continued.
8. Compressor Clutch is NOTE
Engaged but System Has
A restriction in liquid line can be detected by running a hand along line until
Insufficient Cooling.
there is a change in temperature. A change in temperature in line will usu-
ally indicate location of restriction.
1. Check for restriction.
(a) Check low and high pressure gage
during operation of AC (WP 0018
00).
(b) Start engine. Operate engine at
1,400 rpm. Move temperature
control knob to MAXIMUM
position and fan to HIGH position.
Close all windows and doors. In
order to stabilize system, operate
system for a minimum of 10
minutes (TM 5-3805-290-10).
(c) Outlet on accumulator should be 1. If low side reading is above 50 psi (345
cold to touch. If outlet is not cold, kPa), replace inline dryer (WP 0194
check readings on manifold gages. 00).
2. If low side reading is into vacuum,
check for a plugged orifice tube or a
restriction in line (WP 0193 00).
3. If problem still exits, go to Test 2.
2. Check that system is properly charged 1. Recover refrigerant (WP 0191 00),
(WP 0191 00). evacuate, and charge system with
3. Check drive belt for damage or 1. If belt is loose or damaged, replace or
looseness. adjust belt (WP 0046 00) as necessary.
0008 00-98
TM 5-3805-290-23-1
8. Compressor Clutch is 4. Check for restrictions, insects, foreign 1. If a blockage is found in condenser,
Engaged but System Has material in condenser, or any remove all blockages.
Insufficient Cooling - restriction of air flow through 2. If problem still exists, go to Test 5.
Continued. condenser.
5. Check inlet and outlet on accumulator 1. If inlet and outlet are warm, charge
for warmth. system with correct amount of
6. Perform Refrigerant Leakage Test (WP 1. Recover refrigerant (WP 0191 00) and
0018 00) to determine location of leak. repair leaks.
0191 00).
END OF WORK PACKAGE
0008 00-99/(0008 00-100 Blank)

156
TM 5-3805-290-23-1
TROUBLESHOOTING WITH A DIAGNOSTIC CODE 0009 00
NOTE
0003 00).
repair procedures.
Table 1. Engine Control System.
(MID 036)
TEST OR INSPECTION CORRECTIVE ACTION
CID FMI CODE
0041 03 0041 04 0091 02 Perform Digital Throttle Position Sensor

0091 03 0091 04 0091 08 Circuit Test (WP 0013 00).
0091 12
0100 03 0100 04 0100 10 Perform Engine Pressure Sensor Open or Short
0102 03 0102 04 0102 10 Circuit Test (WP 0013 00).
0105 03 0105 04 0110 03 Perform Engine Temperature Sensors Open or
0110 04 Short Circuit Test (WP 0013 00).
0174 02 Perform Fuel Injection Pump Circuit Test (WP
0013 00).
0247 09 Perform CAN Data Link Circuit Test (WP 0013
00).
0262 03 0262 04 Perform 5-Volt Engine Pressure Sensor Supply
0320 02 0320 11 Perform Engine Speed/Timing Sensor Circuit
Test (WP 0013 00).
0342 02 1. Perform Fuel Injection Pump Circuit Test If 342-02 diagnostic code is still active, go
(WP 0013 00). to Test 2.
2. Perform CAN Data Link Circuit Test (WP
0013 00).
0774 02 0774 03 0774 04 Perform Digital Throttle Position Sensor
0774 08 0774 12 Circuit Test (WP 0013 00).
1627 03 Perform Fuel Injection Pump Circuit Test (WP
0013 00).
1639 09 Perform CAT Data Link Circuit Test (WP 0013
00).
0009 00-1
TM 5-3805-290-23-1
TROUBLESHOOTING WITH A DIAGNOSTIC CODE - CONTINUED 0009 00
Table 1. Engine Control System - Continued.
(MID 036)
CID FMI CODE
1684 00 1. Check for restricted fuel supply lines and 1. Replace or repair any restricted fuel
fuel temperature. lines (WP 0030 00, WP 0035 00, and
(WP 0036 00).
2. Check for active diagnostic codes using 1. Troubleshoot any other active codes
MSD equipped with ET software (WP 0006 before continuing with this procedure.
3. Perform Fuel System Inspection (WP 0011
00).
1684 02 Ensure software version is correct and no If problem still exists, replace fuel
updates have been installed. injection pump (WP 0164 00). Recheck for
active diagnostic codes.
1684 03 1684 04 1684 05 Perform Fuel Injection Pump Circuit Test (WP
1684 07 0013 00).
1684 08 1. Connect MSD and check for active 320-02 If either code is active, go to Test 2.
and 322-11 code (WP 0006 00).
2. Perform Engine Speed/Timing Sensor If problem still exists, go to Test 3.
3. Check all associated electrical connections. Follow instructions for Electrical
Refer to Electrical Connectors Inspection Connectors Inspection (WP 0022 00) to
(WP 0022 00) and Electrical System make necessary repairs. If problem still
Schematic (WP 0210 00). Pay close exists, go to Test 4.
attention to P1/J1 engine ECM connectors
(WP 0053 00), P40/J40 fuel injection pump
connector (WP 0164 00), P1:59 engine
position, and P40:8 engine position.
4. Check continuity between P1:59 engine If no continuity is indicated, replace wiring
position and P40:8 engine position (WP harness in question (WP 0169 00 thru WP
0053 00). 0175 00). Ensure repairs have eliminated
problem.
1684 09 1. Perform CAN Data Link Circuit Test (WP 1. If problem still exists, replace fuel
0013 00). injection pump (WP 0164 00). Check
for active diagnostic codes. Ensure
repairs have eliminated problem.
2. If problem still exists, replace engine
ECM (WP 0053 00). Verify repair
eliminates the problem.
0009 00-2
TM 5-3805-290-23-1
Table 1. Engine Control System - Continued.
(MID 036)
CID FMI CODE
1684 10 While engine is cranking or running, use a 1. If voltage is correct, replace engine
multimeter to check voltage at J1:1 and P40:5. ECM (WP 0053 00).
Voltage at terminal should drop to 0V (WP 0022 2. If problem still exists, replace fuel
00). injection pump (WP 0164 00).
1684 11 1. Check tightness of all fuel line connections If problem still exists, go to Test 2.
(WP 0030 00, WP 0035 00, and WP 0038
00). Check for air in fuel injection pump by
priming system (WP 0029 00).
2. Perform Fuel Injection Pump Circuit Test Check for active diagnostic codes using
(WP 0013 00). MSD equipped with ET software (WP
0006 00). Ensure repairs have eliminated
problem.
1684 12 Connect MSD (WP 0006 00) and ensure If problem still exists, replace fuel
software version is correct and no software injection pump (WP 0164 00). Check for
updates have been installed. active diagnostic codes.
1684 14 Perform CAN Data Link Circuit Test (WP 0013 1. If problem still exists, replace suspect
00). ECM.
2. If problem still exists, using MSD
equipped with ET software, check for
active diagnostic codes (WP 0006 00).
If 1684-14 is still active, replace fuel
injection pump (WP 0164 00) and
recheck for active codes.
0009 00-3
TM 5-3805-290-23-1
Table 2. Machine Control System.
(MID 081)
CID FMI CODE
0041 03
427-B1850
1. Check for correct voltage at ECM. 1. If voltage is 8.0 or ± 0.5 DCV, sensor
(a) Turn battery disconnect switch and supply voltage is correct. Verify
engine start switch to ON position (TM diagnostic code is present. If diagnostic
5-3805-290-10). code is still present, replace machine
(b) Check voltage at ECM connector from ECM (WP 0052 00).
contact J1-44 (sensor supply) to 2. If voltage is greater than 8.0 ± 0.5 DCV,
contact J1-45 (ground). Do not sensor supply voltage is not correct. Go
disconnect wiring harness from ECM. to Test 2.
2. Check harness for a short to +battery circuit. 1. If voltage is 0.0 ± 0.5 DCV, replace
(a) Battery disconnect switch and engine machine ECM (WP 0052 00). Voltage
start switch remain in ON position (TM is correct.
5-3805-290-10). 2. If voltage is NOT 0.0 ± 0.5 DCV,
(b) Disconnect wiring harness from wiring harness is shorted to +battery
machine ECM (WP 0052 00). circuit. Replace wiring harness in
(c) At wiring harness connector for question (WP 0169 00 thru WP 0175
machine ECM, measure voltage from 00).
connector contact J1-44 (sensor
supply) to contact J1-45 (ground).
0009 00-4
TM 5-3805-290-23-1
Table 2. Machine Control System - Continued.
(MID 081)
CID FMI CODE
0041 04 1. Check voltage at ECM. 1. If voltage is 8.0 ± 0.5 DCV, sensor

(a) Turn battery disconnect switch and supply voltage is correct. Verify same
(b) Check voltage at ECM harness ECM (WP 0052 00).
connector from contact J1-44 (wire 2. If voltage is not 8.0 ± 0.5 DCV, sensor
X800 OR) to contact J1-45 (J764 BR). supply voltage is not correct. Go to Test
Do not disconnect wiring harness from 2.
ECM.
2. Check for a short to ground. 1. If resistance is greater than 5,000
(a) Turn engine start switch and battery Ohms, verify same diagnostic code is
disconnect switch to OFF position (TM present. If diagnostic code is still
5-3805-290-10). present, replace machine ECM (WP
(b) Disconnect wiring harness from ECM 0052 00).
(WP 0052 00).
2. If resistance is less than 5.0 Ohms, go
(c) At ECM harness connector, measure
resistance between frame ground and to Test 3.
contact J1-45 (wire J764 BR).
3. Disconnect sensors. 1. If, after disconnecting a particular
(a) Engine start switch and battery sensor, resistance changes and is
disconnect switch remain in OFF greater than 5,000 Ohms, sensor that
position (TM 5-3805-290-10). was just disconnected has failed.
(b) One at a time, disconnect any sensor Replace sensor in question.
that uses power supply from wiring 2. If, after disconnecting all sensors,
harness. resistance is less than 5.0 Ohms, wiring
(c) After disconnecting each sensor, check harness is shorted to ground. Replace
resistance from frame ground to wiring harness in question WP 0169 00
contact J1-45 at ECM harness thru WP 0175 00).
connector.
0009 00-5
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0070 03
427-B1852
1. Check parking brake switch ground circuit 1. If resistance is less than 5.0 Ohms,
in harness. circuit is correct. Go to Test 2.
(a) Turn engine start switch and battery 2. If resistance is greater than 5,000
disconnect switch to OFF position Ohms, circuit is open. Replace wiring
(TM 5-3805-290-10). harness in question (WP 0169 00 thru
(b) Disconnect wiring harness WP 0175 00).
connector(s) from ECM (WP 0052 00).
(c) Measure resistance between contact
J2-52 (wire E417 OR) of ECM wiring
harness and contact N/C (wire E417
OR) at switch.
0009 00-6
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0070 03 - 2. Check parking brake switch circuits for a 1. If each resistance measurement is
Cont. short to +battery circuit. greater than 5,000 Ohms, go to Test 3.
(a) Wiring harness connector(s) remain 2. If one or more measurements was less
disconnected from ECM. than 5.0 Ohms, there is a short between
(b) Battery disconnect switch and engine wire F765 BR and circuit with lowest
start switch remain in OFF position resistance measurement, or short
(TM 5-3805-290-10). Disconnect between wire E417-OR and circuit
contact N/O (wire F765 BR) and with the lowest resistance
contact N/C (wire E417-OR) from measurement. Replace wiring harness
switch connector. in question (WP 0169 00 thru WP 0175
(c) At ECM wiring harness connector, 00).
measure resistance from contact N/O
(wire F765 J2-53) and wiring harness
contact N/C (wire E417-OR) to all
contacts used in ECM wiring harness
connectors.
3. Check parking brake switch circuits in 1. If resistance is less than 5.0 Ohms, go
harness. to Test 4.
(a) Wiring harness remains disconnected 2. If resistance is greater than 5,000
from ECM and switch. Ohms, circuit is open. Replace wiring
(b) At switch harness connector, connect a harness in question (WP 0169 00 thru
jumper wire between contact N/O WP 0175 00).
(wire F765 BR) and contact N/C (wire
E417-OR). At ECM harness connector,
measure resistance from contact J2-53
(wire F765 BR) to contact J2-52 (wire
E417-OR).
4. Check parking brake switch operation. 1. If resistance from contact N/C to
(a) Remove jumper installed in Test 3. ground is less than 5.0 Ohms, and
(b) Wiring harness remains disconnected resistance from contact N/C to contact
from parking brake switch. N/O is greater than 5,000 Ohms, go to
(c) Connect one lead from multimeter to Test 5.
contact N/C (wire E417 OR) and other 2. If resistance measurements do not
lead to contact N/O (wire F765 BR) of differ for both contacts, or
switch harness connector. Refer to measurements have not changed from
Electrical System Schematic (WP 0210 previous test, replace parking brake
00). Measure resistance between switch (WP 0092 00).
contact N/C (wire E417 OR) and
contact N/O (wire F765 BR).
(d) Disconnect lead from contact N/O
(wire F765 BR) and connect lead to
ground (wire 202-BK).
(e) Measure resistance between contact N/
C (wire E417 OR) and ground (wire
202-BK).
0009 00-7
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0070 03 - 5. Check parking brake switch operation. 1. If resistance from ground to contact N/
Cont. (a) Wiring harness remains disconnected O is less than 5.0 Ohms and resistance
from parking brake switch. from contact N/C to ground is greater
(b) Press and hold parking brake switch. than 5,000 Ohms, go to Test 6.
(c) Connect one lead from multimeter to 2. If resistance measurements do not
ground (wire 202 BK) and other lead to differ for both contacts or
contact N/O (wire F765 BR) of switch measurements have not changed from
harness connector. previous test, replace parking brake
(d) Measure resistance between ground switch (WP 0092 00).
(wire E417 OR) and contact N/O (wire
F765 BR).
(e) Disconnect lead from contact N/O
contact N/C (wire E417 OR).
(f) Measure resistance between contact N/
C (wire E417 OR) and ground (wire
202 BK).
6. Verify diagnostic code remains active. 1. If CID 0070 FMI 03 is active,
(a) Inspect and clean harness connector diagnostic code has not been corrected.
contacts. Replace machine ECM (WP 0052 00).
(b) Reconnect all harness connectors. 2. If CID 0070 FMI 03 is not active, initial
(c) Turn battery disconnect switch and diagnostic code was probably caused
engine start switch to ON position (TM by a poor electrical connection or a
5-3805-290-10). short at a harness connector that was
(d) Operate machine (TM 5-3805-290- disconnected and reconnected.
10). Resume normal machine operation.
(e) Check status of CID 0070 FMI 03.
0070 04
427-B1852
0009 00-8
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0070 04 - 1. Check parking brake switch. 1. If CID 0070 FMI 04 has been replaced
Cont. (a) Turn engine start switch and battery by CID 0070 FMI 03, go to Test 3.
disconnect switch to OFF position (TM 2. If CID 0070 FMI 04 is still active, go
5-3805-290-10). to Test 2.
(b) Disconnect wiring harness from
parking brake switch (WP 0092 00).
(c) Turn engine start switch and battery
disconnect switch to ON position (TM
5-3805-290-10).
2. Check harness. 1. If each resistance measurement is
(a) Turn battery disconnect switch and greater than 5,000 Ohms, replace
engine start switch to OFF position machine ECM (WP 0052 00).
(TM 5-3805-290-10). 2. If one or more resistance
(b) Wiring harness remains disconnected measurements is less than 5.0 Ohms,
from parking brake switch. short is between J2-53 (wire F765 BR)
(c) Disconnect wiring harness and circuit with lowest resistance, or
connector(s) from machine ECM (WP short is between J2-52 (wire E417 OR)
0052 00). and circuit with lowest resistance.
(d) Measure resistance between contacts Replace wiring harness in question
J2-53 (wire F765 BR) and J2-52 (wire (WP 0169 00 thru WP 0175 00).
E417 OR) to all contacts used in ECM
harness connectors.
3. Check parking brake switch operation. 1. If resistance from contact N/C (wire
(a) Wiring harness remains disconnected E417 OR) to contact J1-13 (wire 202
from parking brake switch. BK) is less than 5.0 Ohms, and
(b) Connect one lead from multimeter to resistance from contact
contact N/C (wire E417 OR) and other N/C (wire E417 OR) to contact N/O
lead to contact N/O (wire F765 BR) of (wire F765 BR) is greater than 5,000
switch harness connector. Ohms, go to Test 4.
(c) Measure resistance between contact N/ 2. If resistance measurements do not
C (wire E417 OR) and contact N/O differ, replace parking brake switch
(wire F765 BR). (WP 0092 00).
(d) Disconnect lead from contact N/O
contact J1-13 (wire 202 BK).
(e) Measure resistance between contact N/
C (wire E417 OR) and contact J1-13
(wire 202 BK).
0009 00-9
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0070 04 - 4. Check parking brake switch operation. 1. If resistance from contact N/C (wire
Cont. (a) Wiring harness remains disconnected E417 OR) to contact N/O (wire F765
from parking brake switch. BR) is less than 5.0 Ohms, and
(b) Press and hold parking brake switch. resistance from contact N/C (wire
(c) Connect one lead from multimeter to E417 OR) to contact J1-13 (wire 202
contact N/C (wire E417 OR) and other BK) is greater than 5,000 Ohms, go to
lead to contact N/O (wire F765 BR) of Test 5.
switch harness connector. 2. If resistance measurements do not
(d) Measure resistance between contact N/ differ for both contacts, or
C (wire E417 OR) and contact N/O measurements have not changed from
(wire F765 BR). previous test, replace parking brake
(e) Disconnect lead from contact N/O switch (WP 0092 00).
contact J1-13 (wire 202-BK).
(f) Measure resistance between contact N/
C (wire E417 OR) and contact J1-13
(wire 202 BK).
5. Verify diagnostic code remains active. 1. If CID 0070 FMI 04 is active,
(a) Inspect and clean harness connector diagnostic code has not been corrected.
contacts. Replace machine ECM (WP 0052 00).
(b) Reconnect all harness connectors. 2. If CID 0070 FMI 04 is not active, initial
(c) Turn battery disconnect switch and diagnostic code was probably caused
engine start switch to ON position (TM by a poor electrical connection or a
5-3805-290-10). short at a harness connector that was
(d) Operate machine (TM 5-3805-290- disconnected and reconnected.
10). Resume normal machine operation.
(e) Determine if CID 0070 FMI 04 is
present.
0009 00-10
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0096 03
427-B1853
1. Check control and harness. 1. If voltage is between 4.5 and 8.0 DCV,
(a) Disconnect wiring harness connector replace fuel sending unit (WP 0177
from fuel level sending unit (TM 5- 00).
3805-290-10). 2. If voltage is not between 4.5 and 8.0
(b) Turn battery disconnect switch and DCV, go to Test 2.
engine start switch to ON position (TM
5-3805-290-10).
(c) At sender wiring harness connector,
measure voltage (DCV) between signal
contact 1 (wire 447 PK) and return
contact 2 (wire 202 BK).
2. Check harness return circuit. 1. If resistance is less than 5.0 Ohms, go
(a) Sender remains disconnected. to Test 3.
(b) Turn battery disconnect switch and 2. If resistance is greater than 5.0 Ohms,
engine start switch to OFF position there is an open circuit between ground
(TM 5-3805-290-10). contact and frame ground. Replace
(c) Disconnect J1 and J2 wiring harness wiring harness in question (WP 0169
connectors from ECM (TM 5-3805- 00 thru WP 0175 00).
290-10).
(d) Measure return circuit resistance
between sender wiring harness contact
2 (wire 202 BK) and ECM wiring
harness contact J1-23.
0009 00-11
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0096 03 - 3. Check for a shorted harness. 1. If each resistance measurement is

Cont. (a) Sender and ECM remain disconnected greater than 5,000 Ohms, replace
from wiring harness. machine ECM (WP 0052 00).
(b) Battery disconnect switch and engine 2. If one or more resistance
start switch remain in OFF position measurements is not correct, there is a
(TM 5-3805-290-10). short in wiring harness. Short is
(c) At sender wiring harness connector, between signal contact J1-22 (wire 447
measure resistance between signal PK) and circuit with low resistance
contact 1 (wire 447 PK) and all contacts measurement. Replace wiring harness
used in ECM wiring harness connector. in question (WP 0169 00 thru WP 0175
00).
0096 04
427-B1853
1. Check sender. 1. If diagnostic code changed from CID

Disconnect wiring harness from sender (WP 0096 FMI 04 to CID 0096 FMI 03, this
0177 00). indicates failure is no longer present.
Replace fuel sending unit (WP 0177
00).
2. If diagnostic code remains, go to Test 2.
0009 00-12
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0096 04 - 2. Check harness. 1. If resistance is greater than 5,000

Cont. (a) Sender remains disconnected from Ohms, replace machine ECM (WP
wiring harness. 0052 00).
(b) Turn battery disconnect switch and 2. If resistance is less than 5,000 Ohms,
engine start switch to OFF position there is a short between frame ground
(TM 5-3805-290-10). and signal circuit in wiring harness.
(c) Disconnect J1 and J2 wiring harness Replace wiring harness in question
connectors from ECM. (WP 0169 00 thru WP 0175 00).
(d) At sender wiring harness connector,
measure resistance between signal
contact 1 (wire 447 PK) and frame
ground.
0177 03
427-B1850
NOTE
This test procedure may create other diagnostic codes. Ignore these created diag-
nostic codes and clear diagnostic codes when original diagnostic code has been
corrected. Ensure diagnostic code CID 0473 FMI 03 is active before performing
this procedure.
0009 00-13
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0177 03 - 1. Check for power at sensor. 1. If voltage is 8 DCV, go to Test 2.

Cont. (a) Do not disconnect harness connector 2. If voltage is not 8 DCV, +battery circuit
from sensor. in wiring harness has failed. Replace
(b) Turn engine start switch and battery wiring harness in question (WP 0169
disconnect switch to ON position (TM 00 thru WP 0175 00).
5-3805-290-10).
(c) At back of harness connector for all
sensors, insert multimeter probe along
voltage supply wire (contact A).
(d) Measure voltage from contact A to
frame ground.
2. Check for proper ground at sensor. 1. If resistance is less than 5.0 Ohms, go
(a) Wiring harness remains connected to to Test 3.
sensor. 2. If resistance is greater than 5.0 Ohms,
(b) Turn engine start switch and battery ground circuit in wiring harness has
disconnect switch to OFF position (TM failed. Replace wiring harness in
5-3805-290-10). question (WP 0169 00 thru WP 0175
(c) Remove multimeter probe from 00).
(d) At back of sensor harness connector,
insert multimeter probe along ground
wire (contact B).
(e) Measure resistance from contact B to
frame ground.
3. Check sensor wiring harness for an open 1. If resistance measurement is less than
circuit. 5.0 Ohms, go to Test 4.
(a) Engine start switch and battery 2. If resistance is greater than 5.0 Ohms,
disconnect switch remain in OFF there is an open circuit in wiring
position (TM 5-3805-290-10). harness. Replace wiring harness in
(b) Disconnect wiring harness from question (WP 0169 00 thru WP 0175
sensor. 00).
(c) At sensor harness connector, connect a
jumper wire between contact B and
contact C.
(d) Disconnect wiring harness
connector(s) from ECM (WP 0052 00).
(e) At ECM harness connector, measure
resistance between contact C and
contact J2-24 (wire 428 OR).
0009 00-14
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0177 03 - 4. Check sensor wiring harness for a short to 1. If resistance measurement is greater
Cont. +battery circuit. than 5,000 Ohms, go to Test 5.
(a) Engine start switch and battery 2. If one or more resistance
disconnect switch remain in OFF measurements is not correct, short is
position (TM 5-3805-290-10). between signal contact J2-24 (wire 428
(b) Wiring harness remains disconnected OR) and circuit with low resistance
from sensor. Remove jumper wire measurement. Replace wiring harness
installed in Test 3. in question (WP 0169 00 thru WP 0175
(c) Wiring harness connector(s) remain 00).
disconnected from ECM.
(d) At ECM wiring harness connector,
measure resistance from wiring
harness signal contact J2-24 (wire 428
OR) to all contacts used in ECM wiring
harness connectors.
5. Check sensor output. 1. If sensor signal is valid, go to Test 6.
(a) Reconnect wiring harness connectors 2. If sensor signal is not valid, replace
to ECM. Reconnect wiring harness transmission oil temperature sensor
connector to sensor. (WP 0068 00).
(b) At back of sensor harness connector,
insert multimeter probe along signal
wire (contact C).
(c) At back of sensor harness connector,
wire (contact B).
(d) Turn battery disconnect switch and
5-3805-290-10).
(e) Measure sensor signal.
6. Verify if diagnostic code remains active. 1. If CID 0177 FMI 03 is active, replace
(a) Inspect and clean harness connector machine ECM (WP 0052 00).
contacts. 2. If CID 0177 FMI 03 is not active, initial
(b) Reconnect all harness connectors. diagnostic code was probably caused
(c) Turn battery disconnect switch and by a poor electrical connection at a
engine start switch to ON position (TM harness connector that was
5-3805-290-10). disconnected and reconnected.
(d) Operate machine (TM 5-3805-290- Resume normal machine operation.
10).
0009 00-15
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0177 04
427-B1850
NOTE
this procedure.
1. Check sensor. 1. If diagnostic code remains active, go to
(a) Turn battery disconnect switch and Test 2.
engine start switch to ON position (TM 2. If diagnostic code is no longer active,
5-3805-290-10). replace transmission oil temperature
(b) Ensure diagnostic code is active. sensor (WP 0068 00).
(c) Observe status of diagnostic code.
(d) Disconnect sensor from wiring harness
(WP 0068 00).
0009 00-16
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0177 04 - 2. Check sensor wiring harness for a short to 1. If each resistance measurement is
Cont. ground. greater than 5,000 Ohms, go to Test 3.
(a) Turn engine start switch and battery 2. If one or more resistance
disconnect switch to OFF position (TM measurements is not correct, short is
5-3805-290-10). between signal contact J2-24 (wire 428
(b) Disconnect wiring harness from sensor OR) and circuit with low resistance
(WP 0068 00). measurement. Replace wiring harness
(c) Disconnect wiring harness in question (WP 0169 00 thru WP 0175
connector(s) from machine ECM (WP 00).
0052 00).
measure resistance from wiring
harness signal contact J2-24 (wire 428
OR) to all possible sources of ground.
Measure resistance to all ECM wiring
harness connector contacts.
3. Verify if diagnostic code remains active. 1. If CID 0177 FMI 04 is active, replace
(c) Turn battery disconnect switch and by a poor electrical connection or a
engine start switch to ON position (TM short in a harness connector that was
10).
0009 00-17
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0177 08
427-B1850
NOTE
this procedure.
1. Check for power at sensor. 1. If voltage is 8.0 DCV, go to Test 2.
(a) Do not disconnect harness connector 2. If voltage is not 8.0 DCV, circuit is
from sensor. open. Replace wiring harness in
(b) At back of sensor harness connector, question (WP 0169 00 thru WP 0175
insert multimeter probe along voltage 00).
supply wire (contact C).
(c) Turn engine start switch and battery
5-3805-290-10).
(d) Measure voltage from contact C to
frame ground.
0009 00-18
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0177 08 - 2. Check sensor signal circuit. 1. If sensor’s frequency is 300 to 700 Hz

Cont. (a) Turn engine start switch and battery and stable, go to Test 3.
disconnect switch to OFF position (TM 2. If sensor’s signal frequency is not 300
5-3805-290-10). to 700 Hz and not stable, replace
(b) At back of sensor harness connector, transmission oil temperature sensor
remove multimeter probe from contact (WP 0068 00).
C and insert probe along signal wire
(contact A).
wire (contact B).
5-3805-290-10).
(e) Monitor sensor signal frequency with
multimeter.
NOTE
On some machines, it may be necessary to start engine in order to take sensor
through its full operating range.
(f) Without disconnecting sensor or
hardware associated with sensor from
machine, take sensor through its full
operating range.
3. Check signal circuit at ECM. 1. If sensor’s frequency is stable at 300 to
(a) Turn engine start switch and battery 700 Hz, go to Test 4.
disconnect switch to OFF position (TM 2. If sensor’s signal frequency is not 300
5-3805-290-10). to 700 Hz and is unstable, replace
(b) Insert multimeter probes into back of wiring harness in question (WP 0169
ECM connector along J2-24 (wire 428 00 thru WP 0175 00).
OR) and J1-45 (wire J764 BR).
(c) Turn battery disconnect switch and
5-3805-290-10).
(d) Monitor sensor signal frequency with
multimeter.
NOTE
On some machines, it may be necessary to start engine in order to take sensor
through its full operating range.
(e) Without disconnecting sensor or
hardware associated with sensor from
machine, take sensor through its full
operating range.
0009 00-19
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0177 08 - 4. Check signal circuit for a short in harness. 1. If resistance is greater than 5,000
Cont. (a) Engine start switch and battery Ohms, go to Test 5.
disconnect switch remain in OFF 2. If resistance is less than 5.0 Ohms,
position (TM 5-3805-290-10). signal circuit is shorted to another
(b) Disconnect wiring harness connectors circuit in harness. Replace wiring
from sensor (WP 0068 00) and machine harness in question (WP 0169 00 thru
ECM (WP 0052 00). WP 0175 00).
J2-24 (wire 428 OR) and all contacts
used in ECM wiring harness
connectors.
5. Verify diagnostic code remains active. 1. If CID 0177 FMI 08 is not active, initial
(a) Inspect and clean harness connectors. diagnostic code was probably caused
(b) Reconnect all harness connectors. by a poor connection or a short at a
(c) Turn battery disconnect switch and connector that was disconnected and
engine start switch to ON position (TM reconnected. Resume normal
5-3805-290-10). operation.
(d) Operate machine (TM 5-3805-290- 2. If CID 0177 FMI 08 is active, replace
10). machine ECM (WP 0052 00).
(e) Connect MSD and check status of CID
0177 FMI 08 (WP 0006 00).
0009 00-20
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0247 09 1. Inspect harness connections. Refer to 1. If wiring harness connectors are tight
Electrical Connectors Inspection (WP 0022 and free of corrosion, go to Test 2.
00). 2. If wiring harness connectors are in need
(a) Turn battery disconnect switch to OFF of repair, replace wiring harness in
(b) Inspect all harness connections related 00).
to CAN data link (WP 0210 00). Make
sure connectors are clean and tight.
(c) Check connectors for proper mating.
Ensure all seals are present and in
place.
(d) Check harness for signs of damage or
abrasion.
(e) Check wires at connector. Ensure wires
are secured tightly into connector. Take
care not to pull wire out of connector.
(f) Check exposed wires at connectors for
nicks or signs of abrasion.
(g) Check for moisture inside connector.
(h) Check connectors for dirty or corroded
contacts.
(i) Check each pin and socket of wiring
harness connectors. Ensure contacts
are properly installed. Contacts should
mate correctly when two pieces of
connector are placed together.
2. Check for shorts to ground. 1. If resistance is greater than 5,000
(a) Battery disconnect switch remains in Ohms, go to Test 3.
OFF position. 2. If resistance is less than 5,000 Ohms,
(b) Disconnect wiring harness connectors there is a short between frame ground
from all ECMs that use CAN data link and contacts J2-67 (wire F711 GN) and
(WP 0052 00 and WP 0053 00). J2-68 (wire F712 GY) of data link
(c) At wiring harness for machine ECM, circuit in wiring harness. Replace
measure resistance between frame wiring harness in question (WP 0169
ground and connector contacts J2-67 00 thru WP 0175 00).
(wire F711 GN) and J2-68 (wire F712
GY) of data link circuit.
0009 00-21
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0247 09 - 3. Check for short to +battery circuit. 1. If harness circuit resistance is correct,
Cont. (a) Battery disconnect switch remains in go to Test 4.
OFF position. 2. If one resistance measurement is less
(b) All related ECMs remain disconnected than 5,000 Ohms, there is a short
from wiring harness. between circuit with low resistance
(c) At wiring harness connector for measurement and contact J2-67 (wire
machine ECM, perform Tests (d) and F711 GN) or J2-68 (wire F712 GY) of
(e). data link circuit in wiring harness.
(d) Measure resistance between all Replace wiring harness in question
connector contacts used at machine (WP 0169 00 thru WP 0175 00).
ECM, and connector contact J2-67
(wire F711 GN).
(e) Measure resistance between all
connector contacts used at machine
(wire F712 GY).
4. Check for open harness. 1. If resistance is less than 5.0 Ohms, go
(a) Battery disconnect switch remains in to Test 5.
OFF position. 2. If resistance is greater than 5.0 Ohms,
(b) All related ECMs remain disconnected data link circuit is open in wiring
from wiring harness. harness. Replace wiring harness in
(c) Check resistance of data link circuit in question (WP 0169 00 thru WP 0175
wiring harness by performing Tests (d) 00).
and (e).
(d) Measure resistance between machine
ECM connector contact J2-67 (wire
F711 GN) and appropriate connector
contact (wire F711 GN) of other
devices connected to CAN data link.
(e) Measure resistance between machine
ECM connector contact J2-68 (wire
F712 GY) and appropriate connector
contact (wire F712 GY) of other
devices connected to CAN data link.
0009 00-22
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0247 09 - 5. Check for additional diagnostic codes for 1. If diagnostic codes are not present for
Cont. other ECMs. other ECMs, instrument cluster has
(a) Turn engine start switch and battery failed. Replace instrument cluster (WP
disconnect switch to OFF position (TM 0051 00).
5-3805-290-10). 2. If diagnostic codes are present for other
(b) One at a time, reconnect ECMs that use ECMs, replace machine ECM (WP
CAN data link (WP 0052 00 and WP 0052 00).
0053 00).
5-3805-290-10).
(d) After each ECM has been reconnected,
check for diagnostic codes logged
against that ECM.
0262 03
427-B1851
1. Check for correct voltage at ECM. 1. If voltage is 5.0 or ± 0.5 DCV, sensor
(a) Turn battery disconnect switch and supply voltage is correct. Verify
(b) Check voltage at ECM connector from ECM (WP 0052 00).
contact J1-11 (sensor supply) to 2. If voltage is greater than 5.0 ± 0.5 DCV,
contact J1-21 (ground). Do not go to Test 2.
disconnect wiring harness from ECM.
0009 00-23
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0262 03 - 2. Check harness for a short to +battery circuit. 1. If voltage is 0.0 ± 0.5 DCV, replace
Cont. (a) Battery disconnect switch and engine machine ECM (WP 0052 00).
start switch remain in ON position. 2. If voltage is not 0.0 ± 0.5 DCV, wiring
(b) Disconnect wiring harness from ECM harness is shorted to +battery circuit.
(WP 0052 00). Replace wiring harness in question
(c) At ECM wiring harness connector, (WP 0169 00 thru WP 0175 00).
measure voltage from connector
contact J1-11 (sensor supply) to
contact J1-21 (ground).
0262 04
427-B1851
1. Check voltage at ECM. 1. If voltage is 5.0 ± 0.5 DCV, sensor

(a) Turn battery disconnect switch and supply voltage is correct. Verify same
(b) Check voltage at ECM harness ECM (WP 0052 00).
connector from contact J1-11 (wire 2. If voltage is not 5.0 ± 0.5 DCV, go to
R997 OR) to contact J1-21 (L740 BR). Test 2.
Do not disconnect wiring harness from
ECM.
0009 00-24
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0262 04 - 2. Check for a short to ground. 1. If resistance is greater than 5,000

Cont. (a) Turn engine start switch and battery Ohms, verify same diagnostic code is
disconnect switch to OFF position (TM present. If diagnostic code is still
5-3805-290-10). present, replace machine ECM (WP
(b) Disconnect wiring harness from 0052 00).
machine ECM (WP 0052 00). 2. If resistance is less than 5.0 Ohms, go
(c) At machine ECM harness connector, to Test 3.
measure resistance between frame
ground and contact J1-21 (L740 BR).
3. Disconnect sensors. 1. If, after disconnecting a particular
(a) Engine start switch and battery sensor, resistance changes and is
disconnect switch remain in OFF greater than 5,000 Ohms, replace
position. sensor.
(b) One at a time, disconnect any sensor 2. If, after disconnecting all sensors,
that uses power supply from wiring resistance is less than 5.0 Ohms,
harness. replace wiring harness in question (WP
(c) After disconnecting each sensor, check 0169 00 thru WP 0175 00).
resistance from frame ground to
contact J1-11 at ECM harness
connector.
0009 00-25
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0271 03
427-B1855
NOTE
nostic codes and clear these diagnostic codes when original diagnostic code has
been corrected. Ensure diagnostic code CID 0271 FMI 03 is active before per-
forming this procedure.
1. Check alarm energize circuit for a short to 1. If each resistance measurement is
+battery circuit. greater than 5,000 Ohms, go to Test 2.
(a) Turn engine start switch and battery 2. If each resistance measurement is not
disconnect switch to OFF position (TM greater than 5,000 Ohms, there is a
5-3805-290-10). short in wiring harness between IC-23
(b) Disconnect wiring harness connectors (H414 YL) and circuit that has a low
from alarm and instrument cluster (WP resistance measurement. Replace
0051 00). wiring harness in question (WP 0169
(c) At instrument cluster wiring harness 00 thru WP 0175 00).
connector, measure resistance from
contact IC-23 (wire H414 YL) to all
contacts used in instrument cluster
wiring harness connectors.
0009 00-26
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0271 03 - 2. Verify diagnostic code remains active. 1. If CID 0271 FMI 03 is active, replace
Cont. (a) Inspect and clean harness connector instrument cluster (WP 0051 00).
engine start switch to ON position (TM short at a harness connector that was
10).
(e) Connect MSD (WP 0006 00) and
determine if CID 0271 FMI 03 is
active.
0271 05
427-B1855
0009 00-27
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0271 05 - NOTE
Cont.
1. Check alarm. 1. If diagnostic code remains active, go to
engine start switch to ON position. Do 2. If diagnostic code is no longer active,
not start engine (TM 5-3805-290-10). repeat this test to verify alarm failure.
(b) Disconnect alarm from wiring harness. Replace alarm (WP 0051 00). Verify
(c) At alarm wiring harness connector, new alarm corrects problem.
place a jumper wire from contact 1
(wire H414 YL) to contact 2 (wire 201
BK).
(d) Connect MSD (WP 0006 00) and
observe status of CID 0271 FMI 05.
2. Check harness for an open circuit. 1. If resistance is less than 5.0 Ohms, go
(a) Turn engine start switch and battery to Test 3.
disconnect switch to OFF position (TM 2. If resistance is greater than 5,000
5-3805-290-10). Ohms, there is an open circuit in wire
(b) Disconnect wiring harness H414 YL or in wire 201 BK of wiring
connector(s) from instrument cluster harness. Replace wiring harness in
(WP 0051 00). question (WP 0169 00 thru WP 0175
(c) Jumper wire installed in Test 1 remains 00).
in place.
(d) At wiring harness connector, measure
resistance from signal contact IC-23
(wire H414 YL) to contact IC-2 (wire
201 BK).
3. Verify diagnostic code remains active. 1. If CID 0271 FMI 05 is active, replace
(a) Inspect and clean harness connectors. instrument cluster (WP 0051 00).
(b) Reconnect all harness connector 2. If CID 0271 FMI 05 is not active, initial
contacts. diagnostic code was probably caused
10).
0009 00-28
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0271 06
427-B1855
NOTE
1. Check alarm. 1. If CID 0271 FMI 06 changes to CID
(a) Turn battery disconnect switch and 0271 FMI 05 when alarm is
engine start switch to ON position. Do disconnected, repeat this test to verify
not start engine (TM 5-3805-290-10). alarm failure. Replace alarm (WP 0051
(b) Connect MSD (WP 0006 00) and 00).
observe status of diagnostic code. 2. If CID 0271 FMI 06 remains active, go
(c) Disconnect alarm from wiring harness to Test 2.
located under instrument cluster.
0009 00-29
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0271 06 - 2. Check alarm energize circuit for a short to 1. If each resistance measurement is
5-3805-290-10). short in wiring harness between IC-23
(b) Alarm remains disconnected from (wire H414 YL) and circuit with low
wiring harness. resistance measurement. Replace
(c) Disconnect wiring harness wiring harness in question (WP 0169
connector(s) from instrument cluster 00 thru WP 0175 00).
(WP 0051 00).
resistance from signal contact IC-23
(wire H414 YL) to all contacts that are
used in instrument cluster wiring
harness connectors (WP 0051 00).
(a) Inspect and clean harness connector instrument cluster (WP 0051 00).
10).
0009 00-30
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0291 03
427-B1856
NOTE
1. Check solenoid energize circuit for a short to 1. If each resistance measurement is
5-3805-290-10). short in wiring harness between J1-67
(b) Disconnect wiring harness connectors (E998 YL) and circuit that has a low
from solenoid (WP 0187 00) and resistance measurement. Replace
machine ECM (WP 0052 00). wiring harness in question (WP 0169
(c) At ECM wiring harness connector, 00 thru WP 0175 00).
(wire E998 YL) to all contacts used in
ECM wiring harness connector.
0009 00-31
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
Cont. (a) Inspect and clean harness connector machine ECM (WP 0052 00).
10).
active.
0009 00-32
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0291 05
427-B1856
NOTE
1. Check solenoid. 1. If diagnostic code remains active, go to
not start engine (TM 5-3805-290-10). solenoid has failed. Repeat this test to
(b) Disconnect solenoid with active verify solenoid failure. Replace fan
diagnostic code from wiring harness motor (WP 0187 00). Verify new motor
(WP 0187 00). corrects problem.
(c) At solenoid wiring harness connector,
(wire E998 YL) to contact 2 (wire T799
BR).
0009 00-33
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0291 05 - 2. Check harness for an open circuit. 1. If resistance is less than 5.0 Ohms, go
Cont. (a) Turn engine start switch and battery to Test 3.
5-3805-290-10). Ohms, there is an open circuit in wiring
(b) Disconnect wiring harness harness in wire E998 YL or in wire
connector(s) from machine ECM (WP T799 BR. Replace wiring harness in
0052 00). question (WP 0169 00 thru WP 0175
in place.
resistance from signal contact J1-67
(wire E998 YL) to contact J1-54 (wire
T799 BR).
(a) Inspect and clean harness connectors. machine ECM (WP 0052 00).
(b) Reconnect all harness connector 2. If CID 0291 FMI 05 is not active, initial
contacts. diagnostic code was probably caused
10).
0009 00-34
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0291 06
427-B1856
NOTE
1. Check solenoid. 1. If CID 0291 FMI 06 changes to CID
(a) Turn battery disconnect switch and 0291 FMI 05 when solenoid is
engine start switch to ON position. Do disconnected, solenoid has failed.
not start engine (TM 5-3805-290-10). Repeat this test to verify solenoid
(b) Connect MSD (WP 0006 00) and failure. Replace fan motor (WP 0187
observe status of diagnostic code. 00).
(c) Disconnect solenoid with active 2. If CID 0291 FMI 06 remains active, go
diagnostic code from wiring harness to Test 2.
(WP 0187 00).
0009 00-35
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0291 06 - 2. Check solenoid energize circuit for a short 1. If each resistance measurement is
Cont. to ground. greater than 5,000 Ohms, go to Test 3.
(b) Solenoid remains disconnected from (wire E998 YL) and circuit with low
connector(s) from machine ECM (WP 00 thru WP 0175 00).
0052 00).
(d) At wiring harness connection, measure
(wire E998-YL) to all contacts used in
ECM wiring harness connectors.
10).
0009 00-36
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0367 02
427-B1857
NOTE
corrected.
Check ride control switch. 1. If diagnostic code does not stay active,
Disconnect switch (ride control) from wiring switch has failed or there is a poor
harness connector (WP 0049 00). This turns off electrical connection at switch. Inspect
ride control. Operate machine (TM 5-3805- harness connector and replace harness
290-10). if necessary. Refer to Electrical
Connectors Inspection (WP 0022 00).
If harness connector is good, replace
ride control switch (WP 0049 00).
2. If diagnostic code returns when
machine is operated, replace wiring
harness in question (WP 0169 00 thru
WP 0175 00). If wiring harness is
replaced and diagnostic code remains,
machine ECM may have failed.
Replace machine ECM (WP 0052 00).
0009 00-37
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0367 04
427-B1857
NOTE
This test procedure may create other diagnostic codes. Ignore these diagnostic
codes and clear these diagnostic codes when original diagnostic code has been
this procedure.
1. Check ride control switch. 1. If CID 367 FMI 04 is no longer active,
(a) Turn engine start switch and battery go to Test 3.
disconnect switch to OFF position (TM 2. If CID 367 FMI 04 is still active, go to
5-3805-290-10). Test 2.
(b) Connect MSD (WP 0006 00).
(c) Disconnect wiring harness from ride
control switch (WP 0049 00).
(d) Turn engine start switch and battery
5-3805-290-10).
0009 00-38
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0367 04 - 2. Check harness. 1. If each resistance measurement is

Cont. (a) Turn battery disconnect switch and greater than 5,000 Ohms, replace
from ride control switch. short is between J2-45 (wire E701 PK)
connector(s) from machine ECM (WP short is between J2-46 (wire F748 WH)
0052 00). and circuit with lowest resistance.
(d) Measure resistance between contacts Replace wiring harness in question
J2-45 (wire E701 PK) and J2-46 (wire (WP 0169 00 thru WP 0175 00).
F748 WH) of wiring harness to all
connectors.
3. Check ride control switch operation. 1. If resistance measurements are greater
(a) Wiring harness remains disconnected than 5,000 Ohms, go to Test 4.
from ride control switch. Place switch 2. If one resistance measurement is less
in OFF position. than 5.0 Ohms, replace ride control
(b) Connect one lead from multimeter to switch (WP 0049 00).
contact 2 (wire 202 BK) of switch
harness connector.
(c) Connect other lead from multimeter to
contact 1 (wire E701 PK) of switch
harness connector.
(d) Measure resistance between contact 2
(wire 202 BK) and contact 1 (wire
E701 PK).
(e) Disconnect lead from contact 1 (wire
E701 PK) and connect lead to contact
3 (wire F748 WH).
(f) Measure resistance between contact 2
(wire 202 BK) and contact 3 (wire F748
WH).
0009 00-39
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0367 04 - 4. Check ride control switch operation. 1. If resistance from contact 2 (wire 202
Cont. (a) Wiring harness remains disconnected BK) to contact 1 (wire E701 PK) is less
from ride control switch. than 5.0 Ohms and resistance from
(b) Place switch in ON position (TM 5- contact 2 (wire 202 BK) to contact 3
3805-290-10). (wire F748 WH) is greater than 5,000
(c) Connect one lead from multimeter to Ohms, go to Test 5.
contact 2 (wire 202 BK) of switch 2. If resistance measurements do not
harness connector. differ for both contacts, replace ride
(d) Connect other lead from multimeter to control switch (WP 0049 00).
harness connector.
(e) Measure resistance between contact 2
E701 PK).
(f) Disconnect lead from contact 1 (wire
3 (wire F748 WH).
(g) Measure resistance between contact 2
WH).
5. Check ride control switch operation. 1. If resistance from contact 2 (wire 202
(a) Wiring harness remains disconnected BK) to contact 1 (wire E701 PK) is
from ride control switch. greater than 5,000 Ohms and resistance
(b) Place ride control switch in AUTO from contact 2 (wire 202 BK) to contact
position (TM 5-3805-290-10). 3 (wire F748 WH) is less than 5.0
harness connector. differ for both contacts, replace ride
(d) Connect other lead from multimeter to control switch (WP 0049 00).
harness connector.
E701 PK).
3 (wire F748 WH).
WH).
0009 00-40
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
10).
present.
0009 00-41
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0368 03
427-B1858
NOTE
codes and clear diagnostic codes when original diagnostic code has been cor-
rected. Ensure diagnostic code CID 0368 FMI 03 is active before performing this
procedure.
1. Check switch ground circuit in harness. 1. If resistance is less than 5 Ohms, go to
(a) Turn engine start switch and battery Test 2.
5-3805-290-10). Ohms, circuit is open. Replace wiring
(b) Disconnect wiring harness harness in question (WP 0169 00 thru
connector(s) from machine ECM (WP WP 0175 00).
0052 00).
J1-13 (wire 202 BK) of ECM wiring
harness and contacts 2 and 5 (wire 202
BK) of switch.
0009 00-42
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0368 03 - 2. Check autoshift switch circuits for a short 1. If each resistance measurement is
Cont. to +battery circuit. greater than 5,000 Ohms, go to Test 3.
(a) Wiring harness connector(s) remains 2. If one or more measurements is less
disconnected from ECM. than 5.0 Ohms, short is between wire
(b) Battery disconnect switch and engine 977 YL and circuit with lowest
start switch remain in OFF position resistance measurement, wire 973 BR
(TM 5-3805-290-10). and circuit with lowest resistance
(c) Disconnect following contacts from measurement, or wire M998 OR and
Auto/Manual/VSC switch: 1, 4, and 5. circuit with lowest resistance
(d) At ECM wiring harness connector, measurement. Replace wiring harness
measure resistance from contact J1-26 in question (WP 0169 00 thru WP 0175
(wire 977 YL), contact J1-27 (wire 973 00).
BR), and contact J1-28 (wire M998
OR) of wiring harness to all contacts
connectors.
3. Check autoshift switch circuits in harness. 1. If each resistance measurement is less
(a) Wiring harness remains disconnected than 5.0 Ohms, go to Test 4.
from ECM and switch. 2. If one resistance measurement is
(b) At switch harness connector, connect a greater than 5,000 Ohms, circuit is
jumper wire between contact 1 (wire open. Replace wiring harness in
973 BR) and contact 4 (wire 977 YL). question (WP 0169 00 thru WP 0175
(c) At ECM harness connector, measure 00).
resistance from contact J1-27 (wire 973
BR) to contact J1-26 (wire 977 YL).
(d) At switch harness connector, connect a
jumper wire between contact 6 (wire
M998 OR) and contact 4 (wire 977
YL).
resistance from contact J1-28 (wire
M998 OR) to contact J1-26 (wire 977
YL).
0009 00-43
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0368 03 - 4. Check autoshift switch operation. Refer to 1. If resistance complies with table,
Cont. Autoshift Switch Status, Table 3, in this switch is operating correctly. Go to
section. Test 5.
(a) Remove jumper installed in Test 3. 2. If resistance does not comply with
(b) Wiring harness remains disconnected table, replace autoshift switch (WP
from ride control switch. 0049 00).
(c) Place switch in MANUAL position
(TM 5-3805-290-10).
(d) Connect one lead from multimeter to
harness connector.
(e) One at a time, connect other lead from
multimeter to contacts 1, 3, 4, and 6,
and measure resistance to contact 2
(wire 202 BK).
(f) Place switch in AUTO position (TM 5-
3805-290-10).
(g) One at a time, connect other lead from
(wire 202 BK).
(h) Rotate switch to VSC position (TM 5-
3805-290-10).
(i) One at a time, connect other lead from
(wire 202 BK).
10).
(e) Connect MSD (WP 0006 00) and check
status of CID 0368 FMI 03.
0009 00-44
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0368 04
427-B1858
NOTE
procedure.
1. Check switch ground circuit in harness. 1. If resistance is less than 5.0 Ohms, go
0052 00).
harness and contacts 2 and 5 (wire 202
BK) of switch.
0009 00-45
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0368 04 - 2. Check autoshift switch circuits for a short 1. If each resistance measurement is
Cont. to ground. greater than 5,000 Ohms, go to Test 3.
(a) Wiring harness connector(s) remains 2. If one or more measurement is less than
disconnected from ECM. 5.0 Ohms, there is a short in wiring
(b) Battery disconnect switch and engine harness between wire 977 YL and
start switch remain in OFF position circuit with lowest resistance
(TM 5-3805-290-10). measurement, wire 973 BR and circuit
(c) Disconnect contacts 1, 4, and 5 from with lowest resistance measurement, or
autoshift switch. wire M998 OR and circuit with lowest
(d) At ECM wiring harness connector, resistance measurement. Replace
measure resistance from contact J1-26 wiring harness in question (WP 0169
(wire 977 YL), contact J1-27 (wire 973 00 thru WP 0175 00).
BR), and contact J1-28 (wire M998
OR) of wiring harness to all contacts
connectors.
3. Check autoshift switch circuits in harness. 1. If each resistance measurement is less
(a) Wiring harness remains disconnected than 5.0 Ohms, go to Test 4.
from ECM and switch. 2. If one of resistance measurements is
(b) At switch harness connector, connect a greater than 5,000 Ohms, circuit is
jumper wire between contact 1 (wire open. Replace wiring harness in
973 BR) and contact 4 (wire 977 YL). question (WP 0169 00 thru WP 0175
(c) At ECM harness connector, measure 00).
BR) to contact J1-26 (wire 977 YL).
(d) At switch harness connector, connect a
jumper wire between contact 6 (wire
M998 OR) and contact 4 (wire 977
YL).
M998 OR) to contact J1-26 (wire 977
YL).
0009 00-46
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0368 04 - 4. Check autoshift switch operation. Refer to 1. If resistance complies with table, go to
Cont. Autoshift Switch Status, Table 3, in this Test 5.
section. 2. If resistance does not comply with
(a) Remove jumpers installed in Test 3. table, replace autoshift switch (WP
(b) Wiring harness remains disconnected 0049 00).
from ride control switch.
(c) Place switch in MANUAL position
(TM 5-3805-290-10).
(d) Connect one lead from multimeter to
harness connector.
(e) One at a time, connect other lead from
(wire 202 BK).
(f) Place switch in AUTO position (TM 5-
3805-290-10).
(g) One at a time, connect other lead from
(wire 202 BK).
(h) Rotate switch to VSC position (TM 5-
3805-290-10).
(i) One at a time, connect other lead from
(wire 202 BK).
10).
0009 00-47
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0426 03
427-B1859
NOTE
this procedure.
1. Check for power at sensor. 1. If voltage is 5V, go to Test 2.
(a) Do not disconnect harness connector 2. If voltage is not 5V, replace wiring
from sensor. harness in question (WP 0169 00 thru
(b) Turn engine start switch and battery WP 0175 00).
5-3805-290-10).
(c) At back of harness connector for all
sensors, insert multimeter probe along
frame ground.
0009 00-48
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0426 03 - 2. Check for proper ground at sensor. 1. If resistance is less than 5.0 Ohms, go
Cont. (a) Wiring harness remains connected to to Test 3.
(b) Turn engine start switch and battery replace wiring harness in question (WP
disconnect switch to OFF position (TM 0169 00 thru WP 0175 00).
5-3805-290-10).
(c) Remove multimeter probe from
wire (contact B).
frame ground.
(b) Disconnect wiring harness from sensor question (WP 0169 00 thru WP 0175
(WP 0072 00). 00).
contact C.
connector(s) from machine ECM (WP
0052 00).
resistance between contact J1-37 (wire
C949 YL) and contact J1-21 (wire
L740 BR).
4. Check sensor wiring harness for a short to 1. If each resistance measurement is
disconnect switch remain in OFF measurements is not correct, there is a
position (TM 5-3805-290-10). short in wiring harness between signal
(b) Wiring harness remains disconnected contact J1-37 (wire C949 YL) and
from sensor. Remove jumper wire circuit with low resistance
installed in Test 3. measurement. Replace wiring harness
(c) Wiring harness connector(s) remains in question (WP 0169 00 thru WP 0175
disconnected from ECM. 00).
measure resistance from signal contact
J1-37 (wire C949 YL) of wiring
harness to all contacts used in ECM
wiring harness connectors.
0009 00-49
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0426 03 - 5. Check sensor output. 1. If signal voltage from sensor is 0.5 to

Cont. (a) Reconnect wiring harness connectors 4.5V, go to Test 6.
to machine ECM (WP 0052 00). 2. If signal voltage from sensor is not 0.5
Reconnect wiring harness connector to to 4.5V, replace brake oil pressure
sensor (WP 0072 00). sensor (WP 0072 00).
(b) At back of sensor harness connector,
wire (contact C).
wire (contact B).
5-3805-290-10).
(e) Measure sensor signal voltage.
10).
0009 00-50
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0426 04
427-B1859
NOTE
this procedure.
5-3805-290-10). replace brake oil pressure sensor (WP
(b) Ensure diagnostic code is active. 0072 00).
(d) Disconnect sensor (WP 0072 00) from
wiring harness.
0009 00-51
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
disconnect switch to OFF position (TM measurements is not correct, there is a
5-3805-290-10). short in wiring harness between signal
(b) Disconnect wiring harness from sensor contact J1-37 (wire C949 YL) and
(WP 0072 00). circuit with low resistance
(c) Disconnect wiring harness measurement. Replace wiring harness
connector(s) from machine ECM (WP in question (WP 0169 00 thru WP 0175
0052 00). 00).
J1-37 (wire C949 YL) of wiring
harness to all possible sources of
ground. Measure resistance to all ECM
wiring harness connector contacts.
10).
0009 00-52
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0444 03
427-B1861
427-B1861
NOTE
1. Check relay energize circuit for a short to 1. If each resistance measurement is
(b) Disconnect wiring harness connector (374 PK) and circuit that has a low
from start relay (WP 0054 00) and resistance measurement. Replace
machine ECM (WP 0052 00). wiring harness in question (WP 0169
(c) At ECM wiring harness connector, 00 thru WP 0175 00).
(wire 374 PK) to all contacts used in
0009 00-53
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
10).
active.
0009 00-54
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0444 05
427-B1861
NOTE
1. Check relay. 1. If diagnostic code remains active, go to
not start engine (TM 5-3805-290-10). relay has failed. Repeat this test to
(b) Disconnect start relay from wiring verify relay failure. Replace relay.
harness (WP 0054 00). Verify new relay corrects problem (WP
(c) At relay wiring harness connector, 0054 00).
(wire 374 PK) to contact 2 (wire H803
BU).
(d) Observe status of CID 0444 FMI 05.
0009 00-55
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
(b) Disconnect wiring harness 751 GN or in wire 921 WH of wiring
connector(s) from machine ECM (WP harness. Replace wiring harness in
in place.
(wire 374 PK) to contact J2-8 (wire
H803 BU).
10).
0009 00-56
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0444 06
427-B1861
NOTE
1. Check relay. 1. If CID 0444 FMI 06 changes to CID
(a) Turn battery disconnect switch and 0444 FMI 05 when relay is
engine start switch to ON position. Do disconnected, relay has failed. Repeat
not start engine (TM 5-3805-290-10). this test to verify relay failure. Replace
(b) Observe status of diagnostic code. start relay (WP 0054 00).
(c) Disconnect start relay from wiring 2. If CID 0444 FMI 06 remains active, go
harness (WP 0054 00). to Test 2.
2. Check relay energizer circuit for a short to 1. If each resistance measurement is
ground. greater than 5,000 Ohms, go to Test 3.
(b) Relay remains disconnected from (wire 374 PK) and circuit with low
connector(s) from machine ECM (WP 00 thru WP 0175 00).
0052 00).
(wire 374 PK) to all contacts used in
0009 00-57
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
10).
0473 03
427-B1862
NOTE
this procedure.
1. Check for power at sensor. 1. If voltage is 5V, go to Test 2.
(a) Do not disconnect harness connector 2. If voltage is not 5V, +battery circuit in
from sensor (WP 0071 00). wiring harness has failed. Replace
(b) Turn engine start switch and battery wiring harness in question (WP 0169
disconnect switch to ON position (TM 00 thru WP 0175 00).
5-3805-290-10).
insert multimeter probe along voltage
supply wire (contact A).
frame ground.
0009 00-58
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0473 03 - 2. Check for proper ground at sensor. 1. If resistance is less than 5.0 Ohms, go
Cont. (a) Wiring harness remains connected to to Test 3.
(b) Turn engine start switch and battery ground circuit in wiring harness has
disconnect switch to OFF position (TM failed. Replace wiring harness in
5-3805-290-10). question (WP 0169 00 thru WP 0175
(c) Remove multimeter probe from 00).
wire (contact B).
frame ground.
(b) Disconnect wiring harness from brake question (WP 0169 00 thru WP 0175
charging pressure sensor. 00).
contact C.
0052 00).
resistance between contact J1-36 (wire
483 BR) and contact J1-21 (wire L740
BR).
4. Check sensor wiring harness for a short to 1. If each resistance measurement is
disconnect switch remain in OFF measurements is not correct, there is a
position (TM 5-3805-290-10). short in wiring harness between signal
(b) Wiring harness remains disconnected contact J1-36 (wire 483 BR) and circuit
from sensor. Remove jumper wire with low resistance measurement.
installed in Test 3. Replace wiring harness in question
(c) Wiring harness connector(s) remains (WP 0169 00 thru WP 0175 00).
disconnected from ECM.
J1-36 (wire 483 BR) of wiring harness
to all contacts used in ECM wiring
harness connectors.
0009 00-59
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0473 03 - 5. Check sensor output. 1. If sensor signal voltage is 0.5 to 4.5V,

Cont. (a) Reconnect wiring harness connectors go to Test 6.
to machine ECM. Reconnect wiring 2. If sensor signal voltage is not 0.5 to
harness connection to sensor. 4.5V, replace brake charging pressure
(b) At back of sensor harness connector, sensor (WP 0071 00).
wire (contact C).
wire (contact B).
5-3805-290-10).
(e) Measure sensor signal voltage.
10).
0009 00-60
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0473 04
427-B1862
NOTE
this procedure.
5-3805-290-10). replace brake charging pressure sensor
(b) Connect MSD (WP 0006 00) and (WP 0071 00).
ensure diagnostic code is active.
Disconnect brake charging pressure
sensor from wiring harness (WP 0071
00).
0009 00-61
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
disconnect switch to OFF position (TM measurements is not correct, there is a
5-3805-290-10). short between signal contact J1-36
(b) Disconnect wiring harness from brake (wire 483 BR) and circuit with low
charging pressure sensor (WP 0071 resistance measurement. Replace
00). wiring harness in question (WP 0169
(c) Disconnect wiring harness 00 thru WP 0175 00).
0052 00).
J1-36 (wire 483 BR) of wiring harness
to all possible sources of ground.
Measure resistance to all ECM wiring
harness connector contacts.
10).
0009 00-62
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0490 03
427-B1865
NOTE
procedure.
0052 00).
harness and contact 5 (wire 202 BK) at
switch.
0009 00-63
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0490 03 - 2. Check implement lockout switch circuits 1. If each resistance measurement is

Cont. for a short to +battery circuit. greater than 5.000 Ohms, go to Test 3.
(a) Wiring harness connector(s) remain 2. If one or more measurements is less
disconnected from ECM. than 5.0 Ohms, there is a short between
(b) Battery disconnect switch and engine wire E917 WH and circuit with lowest
start switch remain in OFF position resistance measurement, or between
(TM 5-3805-290-10). wire E918 GN and circuit with lowest
(c) Disconnect contact 6 (wire E917 WH) resistance measurement. Replace
and contact 4 (wire E918 GN) from wiring harness in question (WP 0169
connector of implement lockout switch 00 thru WP 0175 00).
(WP 0049 00).
measure resistance from contact 6
(wire E917 J2-58) and contact 4 (wire
E918 GN) of wiring harness to all
connectors.
3. Check implement lockout switch circuits in 1. If resistance is less than 5.0 Ohms, go
harness. to Test 4.
jumper wire between contact 6 (wire WP 0175 00).
E917 WH) and contact 4 (wire E918
GN).
E917 WH) to contact J2-59 (wire E918
GN).
0009 00-64
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0490 03 - 4. Check implement lockout switch operation. 1. If resistance from contact 5 to contact
Cont. (a) Remove jumper installed in Test 3. 4 is less than 5.0 Ohms and resistance
(b) Wiring harness remains disconnected from contact 5 to contact 6 is greater
from implement lockout switch. than 5,000 Ohms, go to Test 5.
contact 5 (wire 202 BK) of switch differ for both contacts, or
harness connector. measurements have not changed from
(d) Connect other lead from multimeter to previous test, replace implement
contact 6 (wire E917 WH) of switch lockout switch (WP 0049 00).
harness connector.
E917 WH).
E917 WH) and connect lead to contact
4 (wire E918 GN).
E918 GN).
5. Check implement lockout switch operation. 1. If resistance from contact 5 to contact
(a) Wiring harness remains disconnected 6 is less than 5.0 Ohms, and resistance
from switch. from contact 5 to contact 4 is greater
(b) Press and hold implement lockout than 5,000 Ohms, switch is operating
switch (TM 5-3805-290-10). correctly. Go to Test 6.
contact 5 (wire 202 BK) of switch differ for both contacts, or
harness connector. measurements have not changed from
(d) Connect other lead from multimeter to previous test, replace implement
contact 6 (wire E917 WH) of switch lockout switch (WP 0049 00).
harness connector.
E917 WH).
4 (wire E918 GN).
E918 GN).
0009 00-65
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
10).
0009 00-66
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0490 04
427-B1865
NOTE
this procedure.
1. Check implement lockout switch. 1. If CID 490 FMI 04 has been replaced
(a) Connect MSD (WP 0006 00). by CID 490 FMI 03, go to Test 3.
(b) Turn engine start switch and battery 2. If CID 490 FMI 04 is still active, go to
disconnect switch to OFF position (TM Test 2.
5-3805-290-10).
implement lockout switch (WP 0049
00).
5-3805-290-10).
0009 00-67
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE

from switch. short is between J2-58 (wire E917 WH)
connector(s) from machine ECM (WP between J2-59 (wire E918 GN) and
0052 00). circuit with lowest resistance. Replace
(d) Measure resistance between contacts wiring harness in question (WP 0169
J2-58 (wire E917 WH) and J2-59 (wire 00 thru WP 0175 00).
E918 GN) of wiring harness to all
connectors.
3. Check implement lockout switch operation. 1. If resistance from contact 5 (wire 202
(a) Wiring harness remains disconnected BK) to contact 4 (wire E918 GN) is less
from switch. than 5.0 Ohms and resistance from
(b) Connect one lead from multimeter to contact 5 (wire 202 BK) to contact 6
contact 5 (wire 202 BK) of switch (wire E917 WH) is greater than 5,000
harness connector. Ohms, go to Test 4.
(c) Connect other lead from multimeter to 2. If resistance measurements do not
contact 6 (wire E917 WH) of switch differ, replace implement lockout
harness connector. switch (WP 0049 00).
(d) Measure resistance between contact 5
E917 WH).
(e) Disconnect lead from contact 6 (wire
4 (wire E918 GN).
(f) Measure resistance between contact 5
E918 GN).
0009 00-68
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0490 04 - 4. Check implement lockout switch operation. 1. If resistance from contact 5 (wire 202
Cont. (a) Wiring harness remains disconnected BK) to contact 6 (wire E917 WH) is
from switch. less than 5.0 Ohms and resistance from
(b) Press and hold implement lockout contact 5 (wire 202 BK) to contact 4
switch (TM 5-3805-290-10). (wire E918 GN) is greater than 5,000
harness connector. differ for both contacts, or
(d) Connect other lead from multimeter to measurements have not changed from
contact 6 (wire E917 WH) of switch previous test, replace implement
harness connector. lockout switch (WP 0049 00).
E917 WH).
4 (wire E918 GN).
E918 GN).
10).
present.
0009 00-69
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0585 02
427-B1866
1. Check sensor case resistance. 1. If resistance is greater than 10,000

(a) Turn engine start switch and battery Ohms, go to Test 2.
disconnect switch (if equipped) to OFF 2. If resistance is not greater than 10,000
position (TM 5-3805-290-10). Ohms, replace transmission output
(b) Disconnect wiring harness connector speed sensor No. 1 (WP 0069 00).
from transmission output speed sensor
No. 1 (WP 0069 00).
(c) Measure resistance from contact 1
(wire E901 GN) and contact 2 (wire
E900 WH) to sensor case.
2. Check sensor resistance. 1. If resistance is approximately 1,075
(a) Wiring harness connector remains Ohms, go to Test 3.
disconnected. 2. If resistance is not approximately 1,075
(b) Measure resistance between contact 1 Ohms, replace transmission output
(wire E901 GN) and contact 2 (wire speed sensor No. 1 (WP 0069 00).
E900 WH) of sensor connector.
0009 00-70
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
585 02 - 3. Check for an open wire in wiring harness. 1. If resistance is approximately 1,075
disconnect switch remain in OFF 2. If resistance is not approximately 1,075
position (TM 5-3805-290-10). Ohms, replace wiring harness in
(b) Reconnect wiring harness connector to question (WP 0169 00 thru WP 0175
sensor. 00).
0052 00).
E901 GN) to J1-2 (wire E900 WH).
4. Check for a short in wiring harness return 1. If each resistance measurement is
circuit. greater than 5,000 Ohms, go to Test 5.
(a) Engine start switch and battery 2. If there is a short in wiring harness,
disconnect switch remain in OFF replace wiring harness in question (WP
transmission output speed sensor No. 1
(WP 0069 00).
(c) At wiring harness connector, measure
resistance between contacts J1-3 and
J1-2 to all sources of ground.
5. Verify diagnostic code remains active. 1. If diagnostic code CID 0585 FMI 02 is
(a) Inspect and clean harness connector not active, diagnostic code was
contacts. probably caused by a poor electrical
(b) Reconnect all harness connectors. connection or a short at a harness
engine start switch to ON position (TM reconnected. Resume normal machine
5-3805-290-10). operation.
(d) Operate machine (TM 5-3805-290- 2. If diagnostic code CID 0585 FMI 02 is
10). active, replace machine ECM (WP
(e) Connect MSD (WP 0006 00) and check 0052 00).
for active diagnostic code CID 0585
FMI 02.
0009 00-71
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0590 09 NOTE
Ensure diagnostic code is active before performing this procedure.
1. Connect MSD (WP 0006 00) and verify 1. If all part numbers are correct, go to
these hardware and software part numbers: Test 2.
(a) Part number for machine ECM flash 2. If all part numbers are not correct,
software. installed machine ECM or engine ECM
(b) Part number for engine ECM flash has wrong part number or incorrect
software. flash software installed. Replace
(c) Part number of machine ECM. incorrect machine ECM or engine
(d) Part number of engine ECM. ECM with a module that has correct
part number. Flash correct software
(WP 0052 00 and WP 0053 00).
NOTE
Consult your Caterpillar dealer for correct part numbers for flash software.
2. Inspect harness connections. Refer to 1. If wiring harness connectors are tight
Electrical Connectors Inspection (WP 0022 and free of corrosion, go to Test 3.
place.
abrasion.
contacts.
(i) Check each pin of wiring harness
connectors. Ensure contacts are
properly installed. Contacts should
0009 00-72
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0590 09 - 3. Check for shorts to ground. 1. If resistance is greater than 5,000

Cont. (a) Battery disconnect switch remains in Ohms, go to Test 4.
OFF position (TM 5-3805-290-10). 2. If resistance is less than 5,000 Ohms,
(WP 0048 00, WP 0049 00, WP 0052 J2-68 (wire F712 GY) of CAN data link
00, and WP 0053 00). circuit in wiring harness. Replace
(c) At machine ECM wiring harness, wiring harness in question (WP 0169
measure resistance between frame 00 thru WP 0175 00).
ground and connector contacts J2-67
GY) of CAN data link circuit.
4. Check for short to +battery circuit. 1. If harness circuit resistance is correct,
(a) Battery disconnect switch remains in go to Test 5.
(b) All related ECMs remain disconnected there is a short between +battery circuit
from wiring harness. and contact J2-67 (wire F711 GN) or
(c) At machine ECM wiring harness contact J2-68 (wire F712 GY) of CAN
connector, perform Tests (d) and (e). data link circuit in wiring harness.
(d) Measure resistance between connector Replace wiring harness in question
contact J1-31 (wire 126 RD) and (WP 0169 00 thru WP 0175 00).
connector contact J2-67 (wire F711
GN).
(e) Measure resistance between connector
contact J1-31 (wire 126 RD) and
connector contact J2-68 (wire F712
GY).
5. Check for open circuit in harness. 1. If resistance is less than 5.0 Ohms, go
OFF position (TM 5-3805-290-10). 2. If resistance is greater than 5.0 Ohms,
(b) All related ECMs remain disconnected CAN data link circuit is open in wiring
(c) Check resistance of CAN data link question (WP 0169 00 thru WP 0175
circuit in wiring harness by performing 00).
Tests (d) and (e).
(d) Measure resistance between connector
contact J2-68 (wire F712 GY) of
implement ECM and connector contact
61 of engine ECM.
contact J2-67 (wire F711 GN) of
implement ECM and connector contact
52 of engine ECM.
0009 00-73
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
Cont. other ECMs. other ECMs, replace engine ECM (WP
(a) Turn engine start switch and battery 0053 00).
disconnect switch to OFF position (TM 2. If diagnostic codes are present for other
5-3805-290-10). ECMs, replace machine ECM (WP
(b) One at a time, reconnect ECMs that use 0052 00).
CAN data link (WP 0048 00, WP 0049
00, WP 0052 00, and WP 0053 00).
5-3805-290-10).
check for diagnostic codes logged
against that ECM.
0600 03
427-B1867
(a) Turn battery disconnect switch and replace hydraulic oil temperature
engine start switch to ON position (TM sensor (WP 0070 00).
5-3805-290-10). 2. If voltage is not between 4.5 and 8.0
(b) Disconnect wiring harness connector DCV, go to Test 2.
from hydraulic oil temperature sensor
(WP 0070 00).
(c) At hydraulic oil temperature sensor
wiring harness connector, measure
voltage (DCV) between signal contact
1 (wire 442 GY) and return contact 2
(wire 202 BK).
0009 00-74
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0600 03 - 2. Check harness return circuit. 1. If resistance is less than 5.0 Ohms, go
Cont. (a) Hydraulic oil temperature sensor to Test 3.
remains disconnected. 2. If resistance is greater than 5.0 Ohms,
(b) Turn battery disconnect switch (if there is an open circuit between ground
equipped) and engine start switch to contact and frame ground. Replace
OFF position (TM 5-3805-290-10). wiring harness in question (WP 0169
(c) Disconnect J1 and J2 wiring harness 00 thru WP 0175 00).
connectors from ECM.
between contact 2 (wire 202 BK) of
hydraulic oil temperature sensor wiring
harness and contact J1-23 of ECM
wiring harness.
3. Check for a shorted harness. 1. If each resistance measurement is
(a) Hydraulic oil temperature sensor and greater than 5,000 Ohms, replace
ECM remain disconnected from wiring machine ECM (WP 0052 00).
harness. 2. If one or more resistance
(b) Battery disconnect switch and engine measurements is not correct, there is a
start switch remain in OFF position short in wiring harness between signal
(TM 5-3805-290-10). contact J1-30 (wire 442 GY) and circuit
(c) At hydraulic oil temperature sensor with low resistance measurement.
wiring harness connector, measure Replace wiring harness in question
resistance between signal contact 1 (WP 0169 00 thru WP 0175 00).
(wire 442 GY) and all contacts used in
ECM wiring harness connector.
0009 00-75
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0600 04
427-B1867
1. Check hydraulic oil temperature sensor. 1. If diagnostic code changed from CID
(a) Connect MSD (WP 0006 00). 0600 FMI 04 to CID 0600 FMI 03,
(b) Disconnect wiring harness from replace hydraulic temperature sensor
hydraulic temperature sensor (WP (WP 0070 00).
0070 00). 2. If diagnostic code remains, go to Test 2.
2. Check harness. 1. If resistance is greater than 5,000

(a) Hydraulic oil temperature sensor Ohms, replace machine ECM (WP
remains disconnected from wiring 0052 00).
harness. 2. If resistance is less than 5,000 Ohms,
(b) Turn battery disconnect switch and there is a short between frame ground
engine start switch to OFF position and signal circuit in wiring harness.
(TM 5-3805-290-10). Replace wiring harness in question
(c) Disconnect J1 and J2 wiring harness (WP 0169 00 thru WP 0175 00).
connectors from machine ECM (WP
0052 00).
(d) At hydraulic oil temperature sensor
wiring harness connector, measure
resistance between signal contact 1
(wire 442 GY) and frame ground.
0009 00-76
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0629 04
427-B1868
NOTE
procedure.
1. Check transmission neutralizer override 1. If resistance is greater than 5,000
switch. Ohms, go to Test 2.
(a) Turn engine start switch and battery 2. If resistance is less than 5.0 Ohms,
disconnect switch to OFF position (TM switch has failed. Replace transmission
5-3805-290-10). neutralizer override switch (WP 0049
(b) Disconnect transmission neutralizer 00).
override switch (WP 0049 00).
(c) At switch, measure resistance from
contact connected to wire 702 OR to
contact connected to wire 202 BK.
2. Check wiring harness. 1. If resistance is greater than 5,000
(a) Disconnect wire 702 OR from switch. Ohms, go to Test 3.
Remove wire 702 OR from J2 harness 2. If resistance is less than 5.0 Ohms, wire
connector. is shorted to ground. Replace wiring
(b) Measure resistance from 702 OR to harness in question (WP 0169 00 thru
frame ground. WP 0175 00).
0009 00-77
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0629 04 - 3. Check ECM. 1. If CID 0629 FMI 04 is active, replace

Cont. (a) 702 OR remains removed from J2 machine ECM (WP 0052 00).
harness connector. Connector remains 2. If CID 0629 FMI 04 is not active, initial
connected to ECM. diagnostic code was probably caused
(b) Turn battery disconnect switch and by a poor electrical connection or a
(c) Operate machine (TM 5-3805-290- Reconnect wire that was removed and
10). resume normal machine operation.
(d) Connect MSD (WP 0006 00) and check
0009 00-78
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0668 02
427-B1869
0009 00-79
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0668 02 - 1. Check shift lever signal on ET status screen. 1. If shift lever position status changes
Cont. (a) Disconnect F/N/R switch harness 4-pin properly, go to Test 6.
connector CN-C50 from shift lever. 2. If status on ET screen is “DATA
Connect a jumper wire from pin 3 to pin FAULT” in all shifter positions, go to
4 on shifter 4-pin connector (WP 0081 Test 2.
00). 3. If status on ET screen is “DATA
(b) Connect MSD (WP 0006 00). FAULT” in a particular position, go to
(c) Turn battery disconnect switch and Test 3.
5-3805-290-10).
(d) Select powertrain ECM and go to status
screen 4.
(e) Move shift lever through all possible
positions. Observe status of “Shift
Lever Position” on ET screen (TM 5-
3805-290-10).
2. Check for power and ground at shifter. 1. If voltage is system voltage, go to Test
(a) At shifter, connect positive (red) 4.
multimeter lead to wire 110 GN. 2. If voltage is not system voltage, go to
Connect negative (black) multimeter Test 3.
lead to wire 200 BK.
(b) Measure voltage between two wires.
3. Check fuse for wire 110 GN (WP 0210 00). 1. If fuse is bad, replace fuse (WP 0054
00).
2. If fuse is good, wiring harness may
have failed. Replace wiring harness
between fuse and shifter or between
shifter and ground (WP 0169 00 thru
WP 0175 00).
0009 00-80
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0668 02 - NOTE
Cont.
Shift lever has three connectors: 4-, 6-, and 8-pin connectors.
4. Check shifter harness and ECM. 1. If each combination of contacts is
(a) At shifter, disconnect 8-pin harness grounded and ET screen displays
connector CN-C52. 6-pin harness corresponding shifter position. Refer to
connector remains connected to shifter Table 4, Valid Shift Lever Input States,
6-pin connector. Shifter 4-pin in this section. Replace shift lever (WP
connector remains jumpered between 0081 00).
pins 3 and 4 (WP 0081 00). 2. If one combination of contacts is
(b) Refer to Shifter Schematic (WP 0081 incorrect, go to Test 5.
00) and connect two jumper wires from
ECM connectors to frame ground to
simulate each shifter position. If a
particular position is already suspect,
begin with wires for that position.
(c) Monitor shifter status on ET screen.
5. Check ECM. 1. If each combination of contacts is
(a) Turn battery disconnect switch to OFF grounded and ET screen displays
position. Based on information in corresponding shifter position, replace
Table 5, Machine ECM Connector Pin wiring harness in question (WP 0169
Assignments, in this section, remove 00 thru WP 0175 00).
corresponding wires from machine 2. If one combination of contacts does not
ECM harness connectors J1- and J2. cause proper status to be displayed,
Also use shifter schematic for clean contacts for ECM harness
reference. After removing all wires connectors. If problem remains,
shown in table (WP 0081 00), place DT replace machine ECM (WP 0052 00).
sockets into connectors and wire
sockets so they can be connected to
frame ground individually. Be sure
wires cannot accidentally touch frame
ground.
(b) Turn battery disconnect switch to ON.
Power up machine with key in RUN
position, and connect and start up ET
(WP 0006 00).
(c) Use shifter schematic and table as
references. Connect two wires from
machine ECM harness connectors to
frame ground to simulate each shifter
position. If a particular position is
already suspect, begin with wires for
that position.
(d) Monitor shifter status on ET screen.
0009 00-81
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0668 02 - 6. Verify shift lever remote F/N/R switch 1. If shift lever position status changes
Cont. functionality. properly, monitor machine to see if
(a) Place shift lever on steering column in problem occurs. If problem occurs,
NEUTRAL and FIRST GEAR (TM 5- repeat entire test procedure again.
3805-290-10). 2. If status on ET screen is “DATA
(b) At shifter 4-pin connector, remove FAULT” in either a particular position
jumper wire between pin 3 and pin 4. or all positions, go to Test 7.
(c) Connect 4-pin receptacle connector
CN-C50 from cab harness to shifter 4-
pin plug. This will enable remote F/N/
R switch circuit for shift lever.
(d) Ensure pins and sockets are seated
properly, and that connector mates
correctly.
(e) Place remote F/N/R switch in
FORWARD position (TM 5-3805-
290-10).
(f) Verify ET shows “F1” as desired gear.
(g) Place remote F/N/R switch in
REVERSE position.
(h) Verify ET shows “R1” as desired gear.
7. Verify shift lever remote F/N/R harness. 1. If shift lever position status changes
(a) Ensure shift lever on steering column properly, replace remote F/N/R switch
is in NEUTRAL and FIRST GEAR assembly (WP 0188 00).
(TM 5-3805-290-10). 2. If status on ET screen is “DATA
(b) Ensure cab harness 4-pin receptacle FAULT” no matter which wire is
connector CN-C50 is connected to jumpered to pin 1, common signal pin
shifter 4-pin plug. 1 202 BK may have lost connection to
(c) Disconnect 6-pin connector from machine ground. Repair wiring harness
remote F/N/R switch assembly (WP in question (WP 0169 00 thru WP 0175
0176 00). 00).
(d) On cab harness connector CN-C23, 3. If status on ET screen is “DATA
place a jumper wire from pin 1 202 BK FAULT” when a particular wire is
to pin 4 G787 GN. jumpered to pin 1, replace wiring
(e) Verify ET shows “F1” as desired gear. harness in question (WP 0169 00 thru
(f) Move jumper wire connection to pin 1 WP 0175 00).
202 BK and pin 6 G788 YL.
(g) Verify ET shows “R1” as desired gear.
(h) Move jumper wire connection to pin 1
202 BK and pin 5 P916 OR.
(i) Verify ET shows “N1” as desired gear.
0009 00-82
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0672 02
427-B1870

disconnect switch to OFF position (TM 2. If resistance is not greater than 10,000
5-3805-290-10). Ohms, replace torque converter speed
(b) Disconnect wiring harness connector sensor (WP 0069 00).
from torque converter speed sensor
(WP 0069 00).
(wire E909 WH) and contact 2 (wire
E908 BR) to sensor case.
(b) Measure resistance between contact 1 Ohms, replace torque converter speed
(wire E909 WH) and contact 2 (wire sensor (WP 0069 00).
E908 BR) of sensor connector.
0009 00-83
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
Cont. (a) Engine start switch and battery Ohms, circuit is correct. go to Test 4.
position (TM 5-3805-290-10). Ohms, circuit is open in wiring harness.
(b) Reconnect wiring harness connector to Replace wiring harness in question
torque converter speed sensor (WP (WP 0169 00 thru WP 0175 00).
0069 00).
0069 00).
E909 WH) to J1-15 (wire E908 BR).
(b) Disconnect wiring harness from torque
converter speed sensor (WP 0069 00).
5-3805-290-10). operation.
FMI 02.
0009 00-84
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0673 02
427-B1871

5-3805-290-10). Ohms, replace transmission output
(b) Disconnect wiring harness connector speed sensor No. 2 (WP 0069 00).
from transmission output speed sensor
No. 2 (WP 0069 00).
(wire E907 GY) and contact 2 (wire
E906 OR) to sensor case.
disconnected (TM 5-3805-290-10). 2. If resistance is not approximately 1,075
(b) Measure resistance between contact 1 Ohms, replace transmission output
(wire E907 GY) and contact 2 (wire speed sensor No. 2 (WP 0069 00).
E906 OR) of sensor connector.
0009 00-85
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
sensor. 00).
0052 00).
E907 GY) to J1-4 (wire E906 OR).
transmission output speed sensor (WP
0069 00).
5-3805-290-10). operation.
FMI 02.
0009 00-86
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0674 02
427-B1872

5-3805-290-10). Ohms, replace transmission
(b) Disconnect wiring harness connector intermediate speed sensor No. 1 (WP
from transmission intermediate speed 0069 00).
sensor No.1 (WP 0069 00).
(wire E902 PU) and contact 1 (wire
E903 YL) to sensor case.
(b) Measure resistance between contact 2 Ohms, replace transmission
(wire E902 PU) and contact 1 (wire intermediate speed sensor No. 1 (WP
E903 YL) of sensor connector. 0069 00).
3. Check for an open wire in wiring harness. 1. If resistance is approximately 1,075
(a) Engine start switch and battery Ohms, go to Test 4.
sensor. 00).
0052 00).
E902 PU) to J1-7 (wire E903 YL).
0009 00-87
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0674 02 - 4. Check for a short in wiring harness return 1. If each resistance measurement is
Cont. circuit. greater than 5,000 Ohms, go to Test 5.
transmission intermediate speed sensor
No. 1 (WP 0069 00).
5-3805-290-10). operation.
FMI 02.
0009 00-88
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0675 02
427-B1873

5-3805-290-10). Ohms, replace transmission
(b) Disconnect wiring harness connector intermediate speed sensor No. 2 (WP
from transmission intermediate speed 0069 00).
sensor No. 2 (WP 0069 00).
(wire E904 BR) and contact 1 (wire
E905 BU) to sensor case.
(b) Measure resistance between contact 2 Ohms, replace transmission
(wire E904 BR) and contact 1 (wire intermediate speed sensor No. 2 (WP
E905 BU) of sensor connector. 0069 00).
0009 00-89
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
Cont. (a) Engine start switch and battery Ohms, circuit is correct. Go to Test 4.
position (TM 5-3805-290-10). Ohms, circuit is open in wiring harness.
(b) Reconnect wiring harness connector to Replace wiring harness in question
sensor. (WP 0169 00 thru WP 0175 00).
0052 00).
E904 BR) to J1-9 (wire E905 BU).
transmission intermediate speed sensor
No. 2 (WP 0069 00).
5-3805-290-10). operation.
FMI 02.
0009 00-90
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0793 03
427-B1874
NOTE
procedure.
5-3805-290-10). Ohms, replace wiring harness in
(b) Disconnect wiring harness question (WP 0169 00 thru WP 0175
0052 00).
harness and contact A (wire 202 BK) at
switch.
0009 00-91
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0793 03 - 2. Check primary steering pressure switch 1. If each resistance measurement is

Cont. circuits for a short to +battery circuit. greater than 5,000 Ohms, go to Test 3.
(a) Wiring harness connector(s) remains 2. If one or more measurements is less
disconnected from ECM. than 5.0 Ohms, there is a short in wiring
(b) Battery disconnect switch and engine harness between wire 417 GY and
start switch remain in OFF position. circuit with lowest resistance
(c) Disconnect contact B (wire 417 GY) measurement, or between wire 484 YL
and contact C (wire 484 YL) from and circuit with lowest resistance
switch connector. measurement. Replace wiring harness
(d) At ECM wiring harness connector, in question (WP 0169 00 thru WP 0175
measure resistance from contact B 00).
(wire 417 J2-37) and contact C (wire
484 YL) of wiring harness to all
connectors.
3. Check primary steering pressure switch 1. If resistance is less than 5.0 Ohms, go
circuits in harness. to Test 4.
jumper wire between contact B (wire WP 0175 00).
417 GY) and contact C (wire 484 YL).
GY) to contact J2-38 (wire 484 YL).
4. Check primary steering pressure switch 1. If resistance from contact A to contact
operation. C is less than 5.0 Ohms and resistance
(a) Remove jumper installed in Test 3. from contact A to contact B is greater
(b) Wiring harness remains disconnected than 5,000 Ohms, go to Test 5.
from switch. 2. If resistance measurements do not
(c) Connect one lead from multimeter to differ for both contacts, or
contact A (wire 202 BK) of switch measurements have not changed from
harness connector. previous test, replace primary steering
(d) Connect other lead from multimeter to switch (WP 0074 00).
contact B (wire 417 GY) of switch
harness connector.
(e) Measure resistance between contact A
(wire 202 BK) and contact B (wire 417
GY).
(f) Disconnect lead from contact B (wire
417 GY) and connect lead to contact C
(wire 484 YL).
(g) Measure resistance between contact A
(wire 202 BK) and contact C (wire 484
YL).
0009 00-92
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0793 03 - 5. Check primary steering pressure switch 1. If resistance from contact A to contact
Cont. operation. B is less than 5.0 Ohms and resistance
(a) Wiring harness remains disconnected from contact A and contact C is greater
from switch. than 5,000 Ohms, go to Test 6.
(b) Press and hold switch. 2. If resistance measurements do not
(c) Connect one lead from multimeter to differ for both contacts, or
contact A (wire 202 BK) of switch measurements have not changed from
harness connector. previous test, replace primary steering
(d) Connect other lead from multimeter to pressure switch (WP 0074 00).
contact B (wire 417 GY) of switch
harness connector.
GY).
(wire 484 YL).
YL).
10).
0009 00-93
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0793 04
427-B1874
NOTE
this procedure.
1. Check primary steering pressure switch. 1. If CID 0793 FMI 04 has been replaced
(a) Connect MSD (WP 0006 00). by CID 0793 FMI 03, go to Test 3.
(b) Turn engine start switch and battery 2. If CID 0793 FMI 04 is still active, go
disconnect switch to OFF position (TM to Test 2.
5-3805-290-10).
(c) Disconnect wiring harness from switch
(WP 0074 00).
5-3805-290-10).
0009 00-94
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE

from switch. short is between J2-37 (wire 417 GY)
connector(s) from machine ECM (WP between J2-38 (wire 484 YL) and
0052 00). circuit with lowest resistance. Replace
(d) Measure resistance between contacts wiring harness in question (WP 0169
J2-37 (wire 417 GY) and J2-38 (wire 00 thru WP 0175 00).
484 YL) of wiring harness to all
connectors.
3. Check primary steering pressure switch 1. If resistance from contact A (wire 202
operation. BK) to contact C (wire 484 YL) is less
(a) Wiring harness remains disconnected than 5.0 Ohms, and resistance from
from switch. contact A (wire 202 BK) to contact B
(b) Connect one lead from multimeter to (wire 417 GY) is greater than 5,000
contact A (wire 202 BK) of switch Ohms, go to Test 4.
harness connector. 2. If resistance measurements do not
(c) Connect other lead from multimeter to differ, replace primary steering
contact B (wire 417 GY) of switch pressure switch (WP 0074 00).
harness connector.
(d) Measure resistance between contact A
GY).
(e) Disconnect lead from contact B (wire
(wire 484 YL).
(f) Measure resistance between contact A
YL).
0009 00-95
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0793 04 - 4. Check primary steering pressure switch 1. If resistance from contact A (wire 202
Cont. operation. BK) to contact B (wire 417 GY) is less
(a) Wiring harness remains disconnected than 5.0 Ohms and resistance from
from switch. contact A (wire 202 BK) to contact C
(b) Press and hold switch. (wire 484 YL) is greater than 5,000
contact A (wire 202 BK) of switch 2. If resistance measurements do not
harness connector. differ for both contacts, or
(d) Connect other lead from multimeter to measurements have not changed from
contact B (wire 417 GY) of switch previous test, replace primary steering
harness connector. pressure switch (WP 0074 00).
GY).
(wire 484 YL).
YL).
10).
present.
0009 00-96
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0795 07
427-B1875
1. Check system during self-test. Turn engine 1. If secondary steering light illuminates
start switch to ON position (TM 5-3805-290- and wheel can be turned, operate
10). Wait for instrument cluster self-test to machine and check for a recurrence of
complete. Then, secondary steering system diagnostic code.
performs a self-test. For three seconds, 2. If secondary steering light does not
secondary steering light should illuminate illuminate, and wheel will not turn
and wheel can be turned. during self-test, go to Test 2.
3. If secondary steering light does not
illuminate but wheel does turn during
self-test, go to Test 3.
4. If secondary steering light illuminates
but wheel does not turn during self-test,
go to Test 2.
0009 00-97
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0795 07 - 2. Check secondary steering motor cables. 1. If cables are properly connected and
Cont. (a) Turn battery disconnect switch to ON not damaged, go to Test 3.
position (TM 5-3805-290-10). 2. If cables are improperly connected or
(b) At secondary steering motor, check damaged, replace cables (WP 0079
black ground cable. Check red power 00).
cable that connects secondary steering
relay to starter +battery terminal.
Check red power cable that connects
other side of relay to secondary steering
motor.
3. Check secondary steering motor. 1. If secondary steering motor turns
(a) Battery disconnect switch remains ON normally, go to Test 4.
and engine remains OFF. 2. If secondary steering motor does not
(b) At secondary steering motor, connect a turn normally, secondary steering
jumper cable from -battery to -battery motor has failed. Replace motor (WP
terminal of motor. 0100 00).
(c) At secondary steering motor, briefly
connect a jumper cable from +battery
to +battery terminal of motor.
4. Check relay at secondary steering motor. 1. If relay energizes and secondary
(a) Battery disconnect switch remains ON steering motor turns ON, go to Test 5.
and engine remains OFF. 2. If relay does not energize and
(b) At relay by secondary steering motor, secondary steering motor does not turn
connect a jumper wire from +battery to ON, replace secondary steering relay
wire 727 GN. (WP 0079 00).
(c) At relay by secondary steering motor,
connect a jumper wire from -battery to
wire 200 BK.
5. Check wire from ECM to relay on 1. If resistance is less than 5.0 Ohms, go
secondary steering motor. to Test 6.
(a) Turn engine start switch and battery 2. If resistance is greater than 5.0 Ohms,
disconnect switch to OFF position (TM replace wiring harness in question (WP
5-3805-290-10). 0169 00 thru WP 0175 00).
(b) Connect one lead from multimeter to
wire 453 PK at relay by secondary
steering motor, and other lead from
multimeter to contact J1-24.
(c) Measure resistance of wire 453 PK
from ECM to relay.
0009 00-98
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0795 07 - 6. Check relay ground circuit at secondary 1. If resistance is less than 5.0 Ohms, go
Cont. steering motor. to Test 7.
(a) Battery disconnect switch remains in 2. If resistance is over 5.0 Ohms, relay
OFF position. ground circuit has failed. Repair
(b) At relay by secondary steering motor, ground circuit (wire 200 BK).
connect one lead from multimeter to
terminal for wire 200 BK.
(c) Measure resistance to frame ground.
7. Check signal wire between two relays. 1. If resistance is less than 5.0 Ohms, go
(a) At relay by secondary steering motor, to Test 8.
connect one lead from multimeter to 2. If resistance is over 5.0 Ohms, replace
signal wire (727 GN). wiring harness in question (WP 0169
(b) Connect other lead from multimeter to 00 thru WP 0175 00).
secondary steering relay (contact C5).
(c) Measure resistance between two
relays.
8. Check +battery circuit at secondary steering 1. If both voltage measurements are
relay. system voltage, go to Test 9.
(a) Turn battery disconnect switch and 2. If one or both voltage measurements is
engine start switch to ON position (TM not system voltage, power circuit to
5-3805-290-10). relay has failed. Replace wiring
(b) At secondary steering relay, connect harness (WP 0169 00 thru WP 0175
one lead from multimeter to contact C1 00).
(wire 136 GN).
(c) Measure voltage from C1 to frame
ground.
(d) Remove lead from contact C1 and
connect lead to contact C3 (wire 136
GN).
(e) Measure voltage from contact C3 to
frame ground.
9. Check circuit from ECM to relay. 1. If, during self-test, indicator for
(a) Turn engine start switch to OFF secondary steering system illuminates,
position (TM 5-3805-290-10). go to Test 10.
(b) Connect one end of a jumper wire to 2. If, during self-test, indicator for
contact C2 at relay. secondary steering system does not
(c) Connect other end of jumper wire to illuminate, replace secondary steering
frame ground. relay (WP 0054 00).
(d) Turn engine start switch to ON position
(TM 5-3805-290-10). During self-test
for secondary steering system, monitor
indicator for secondary steering
system.
0009 00-99
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0795 07 - 10. Check circuit from ECM to relay. 1. If, during self-test, indicator for
Cont. (a) Turn engine start switch to OFF secondary steering system illuminates,
position (TM 5-3805-290-10). replace machine ECM (WP 0052 00).
(b) Remove wire K748 OR from contact 2. If, during self-test, indicator for
J2-9 at ECM. secondary steering system does not
(c) Using a jumper wire, connect wire illuminate, wire K748 OR has failed.
K748 OR to frame ground. Replace wiring harness in question
(d) Turn engine start switch to ON position (WP 0169 00 thru WP 0175 00).
(TM 5-3805-290-10). During self-test
for secondary steering system, monitor
indicator for secondary steering
system.
0811 09 1. Verify these hardware and software part 1. If all part numbers are correct, go to
numbers: Test 2.
(a) Connect MSD (WP 0006 00). 2. If all part numbers are not correct,
(b) Part number of machine ECM flash installed machine ECM or instrument
software. cluster has wrong part number or
(c) Part number of machine ECM. incorrect flash software installed.
Replace incorrect machine ECM or
instrument cluster with a module that
has correct part number. Flash correct
software (WP 0052 00).
0009 00-100
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0811 09 - 2. Inspect harness connections. Refer to 1. If wiring harness connectors are tight
Cont. Electrical Connectors Inspection (WP 0022 and free of corrosion, go to Test 3.
place.
abrasion.
contacts.
(i) Check each pin and socket of wiring
harness connectors. Ensure contacts
are properly installed. Contacts should
3. Check for shorts to ground. 1. If resistance is greater than 5,000
(a) Battery disconnect switch remains in Ohms, go to Test 4.
(WP 0051 00, WP 0049 00, WP 0052 J2-68 (wire F712 GY) of data link
00, and WP 0053 00). circuit in wiring harness. Replace
(c) At machine ECM wiring harness, wiring harness in question (WP 0169
measure resistance between frame 00 thru WP 0175 00).
ground and connector contacts J2-67
GY) of data link circuit.
0009 00-101
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0811 09 - 4. Check for short to +battery circuit. 1. If harness circuit resistance is correct,
Cont. (a) Battery disconnect switch remains in go to Test 5.
OFF position. 2. If one resistance measurement is less
(b) All related ECMs remain disconnected than 5,000 Ohms, there is a short
from wiring harness. between circuit with low resistance
(c) At machine ECM wiring harness measurement and contacts J2-67 (wire
connector, perform checks in Tests (d) F711 GN) or J2-68 (wire F712 GY) of
and (e). data link circuit in wiring harness.
(d) Measure resistance between all Replace wiring harness in question
connector contacts used at machine (WP 0169 00 thru WP 0175 00).
(wire F711 GN).
(e) Measure resistance between all
connector contacts used at machine
(wire F712 GY).
5. Check for open harness. 1. If resistance is less than 5.0 Ohms, go
OFF position. 2. If resistance is greater than 5.0 Ohms,
(b) All related ECMs remain disconnected data link circuit is open in wiring
(c) Check resistance of data link circuit in question (WP 0169 00 thru WP 0175
wiring harness by performing Tests (d) 00).
and (e).
(d) Measure resistance between connector
contact J2-67 (wire F711 GN) of
machine ECM and connector contact
19 (wire F711 GN) of instrument
cluster.
contact J2-68 (wire F712 GY) of
machine ECM and connector contact
20 (wire F712 GY) of instrument
cluster.
0009 00-102
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
Cont. other ECMs. other ECMs, replace instrument cluster
(a) Turn engine start switch and battery (WP 0051 00).
disconnect switch to OFF position (TM 2. If diagnostic codes are present for other
5-3805-290-10). ECMs, replace machine ECM (WP
(b) One at a time, reconnect ECMs that use 0052 00).
CAN data link.
5-3805-290-10).
check for any diagnostic codes logged
against that ECM.
0826 03
427-B1876
(a) Turn battery disconnect switch and replace torque converter oil
engine start switch to ON position (TM temperature sensor (WP 0068 00).
5-3805-290-10). 2. If voltage is not between 4.5 and 8.0
(b) Disconnect wiring harness connector DCV, go to Test 2.
from torque converter oil temperature
sensor (WP 0068 00).
(c) At torque converter oil temperature
sensor wiring harness connector,
measure voltage (DCV) between signal
contact 1 (wire 443 YL) and return
contact 2 (wire 202 BK).
0009 00-103
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0826 03 - 2. Check harness return circuit. 1. If resistance is less than 5.0 Ohms, go
Cont. (a) Sensor remains disconnected. to Test 3.
(b) Turn battery disconnect switch and 2. If resistance is greater than 5.0 Ohms,
engine start switch to OFF position ground circuit in harness has failed.
(TM 5-3805-290-10). There is an open circuit between
(c) Disconnect J1 and J2 wiring harness ground contact and frame ground.
connectors from machine ECM (WP Replace wiring harness in question
0052 00). (WP 0169 00 thru WP 0175 00).
between contact 2 (wire 202 BK) of
torque converter oil temperature sensor
wiring harness and contact J1-13 of
ECM wiring harness.
3. Check for a shorted harness. 1. If each resistance measurement is
(a) Torque converter oil temperature greater than 5,000 Ohms, replace
sensor and ECM remain disconnected machine ECM (WP 0052 00).
from wiring harness. 2. If one or more resistance
(b) Battery disconnect switch and engine measurements is not correct, there is a
start switch remain in OFF position. short between signal contact J1-29
(c) At torque converter oil temperature (wire 443 YL) and circuit with low
sensor wiring harness connector, resistance measurement. Replace
measure resistance between signal wiring harness in question (WP 0169
contact 1 (wire 443 YL) and all 00 thru WP 0175 00).
connector.
0009 00-104
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0826 04
427-B1876
1. Check torque converter oil temperature 1. If diagnostic code changed from CID
sensor. 0096 FMI 04 to CID 0096 FMI 03,
(a) Connect MSD (WP 0006 00). failure is no longer present. Torque
(b) Disconnect wiring harness from torque converter oil temperature sensor has
converter oil temperature sensor (WP failed. Replace torque converter oil
0068 00). temperature sensor (WP 0068 00).
2. If diagnostic code remains, failure
remains present. Torque converter oil
temperature sensor is not causing
failure. Go to Test 2.
2. Check harness. 1. If resistance is greater than 5,000
(a) Torque converter oil temperature Ohms, replace machine ECM (WP
sensor remains disconnected from 0052 00).
wiring harness. 2. If resistance is less than 5,000 Ohms,
(b) Turn battery disconnect switch and there is a short between frame ground
engine start switch to OFF position and signal circuit in wiring harness.
(TM 5-3805-290-10). Replace wiring harness in question
(c) Disconnect J1 and J2 wiring harness (WP 0169 00 thru WP 0175 00).
0052 00).
(d) At torque converter oil temperature
sensor wiring harness connector,
measure resistance between signal
contact 1 (wire 443 YL) and frame
ground.
0009 00-105
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0882 03
427-B1877
NOTE
been corrected. Ensure diagnostic code CID 882 FMI 03 is active before perform-
ing this procedure.
1. Check implement lockout solenoid energize 1. If each resistance measurement is
circuit for a short to +battery circuit. greater than 5,000 Ohms, go to Test 2.
5-3805-290-10). short between J2-2 (G962 OR) and
(b) Disconnect wiring harness connectors circuit that has a low resistance
from implement lockout solenoid (WP measurement. Replace wiring harness
0188 00) and machine ECM (WP 0052 in question (WP 0169 00 thru WP 0175
00). 00).
(c) At ECM wiring harness connector,
(wire G962 OR) to all contacts used in
0009 00-106
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
10).
determine if CID 882 FMI 03 is active.
0882 04
427-B1877
NOTE
ing this procedure.
1. Check implement lockout solenoid. 1. If CID 882 FMI 04 changes to CID 882
(a) Turn battery disconnect switch and FMI 05 when implement lockout
engine start switch to ON position. Do solenoid is disconnected, implement
not start engine (TM 5-3805-290-10). lockout solenoid has failed. Repeat this
(b) Connect MSD (WP 0006 00) and test to verify implement lockout
observe status of diagnostic code. solenoid failure. Replace shut-off valve
(c) Disconnect implement lockout (WP 0188 00).
solenoid from wiring harness (WP 2. If CID 882 FMI 04 remains active, go
0188 00). to Test 2.
0009 00-107
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0882 04 - 2. Check implement lockout solenoid energize 1. If each resistance measurement is

Cont. circuit for a short to ground. greater than 5,000 Ohms, go to Test 3.
5-3805-290-10). short between J2-2 (wire G962 OR)
(b) Implement lockout solenoid remains and circuit with low resistance
disconnected from wiring harness. measurement. Replace wiring harness
0052 00).
J2-2 (wire G962 OR) to all contacts
connectors.
engine start switch to ON position. short at a harness connector that was
(TM 5-3805-290-10). disconnected and reconnected.
10).
0882 05
427-B1877
0009 00-108
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
0882 05 - NOTE
Cont.
ing this procedure.
1. Check implement lockout solenoid. 1. If diagnostic code remains active, go to
5-3805-290-10). Do not start engine. implement lockout solenoid has failed.
(b) Disconnect implement lockout Repeat this test to verify implement
solenoid from wiring harness (WP lockout solenoid failure. Replace shut-
0188 00). off valve (WP 0188 00). Verify new
(c) At implement lockout solenoid wiring implement lockout solenoid corrects
harness connector, place a jumper wire problem.
from contact (wire G962 OR) to
contact (wire H807 YL).
2. Check harness for an open circuit. 1. If resistance is less than 5.0 Ohms, go
5-3805-290-10). Ohms, replace wiring harness in
(b) Disconnect wiring harness question (WP 0169 00 thru WP 0175
0052 00).
(c) Jumper wire installed in Test 1 remains
in place.
(wire G962 OR) to contact J2-4 (wire
H807 YL).
10).
0009 00-109
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1231 03
427-B1878
NOTE
1. Check brake charging solenoid energize 1. If resistance measurement is greater
circuit for a short to +battery circuit. than 5,000 Ohms, go to Test 2.
5-3805-290-10). short between J1-68 (C881 BU) and
from brake charging solenoid (WP measurement. Replace wiring harness
00). 00).
(wire C881 BU) to all contacts used in
0009 00-110
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1231 03 - 2. Verify diagnostic code remains active. 1. If CID 1231 FMI 03 i active, replace
10).
active.
1231 04
427-B1878
NOTE
1. Check brake charging solenoid. 1. If CID 1231 FMI 04 changes to CID
(a) Turn battery disconnect switch and 1231 FMI 05 when brake charging
engine start switch to ON position (TM solenoid is disconnected, brake
5-3805-290-10). Do not start engine. charging solenoid has failed. Repeat
(b) Connect MSD (WP 0006 00) and this test to verify brake charging
observe status of diagnostic code. solenoid failure. Replace braking and
(c) Disconnect brake charging solenoid hydraulic fan gear pump (WP 0186 00).
from wiring harness (WP 0186 00). 2. If CID 1231 FMI 04 remains active, go
to Test 2.
0009 00-111
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1231 04 - 2. Check brake charging solenoid energize 1. If resistance measurement is greater

Cont. circuit for a short to ground. than 5,000 Ohms, go to Test 3.
5-3805-290-10). short between J1-68 (wire C881 BU)
(b) Brake charging solenoid remains and circuit with low resistance
0052 00).
(wire C881 BU) to all contacts used in
10).
0009 00-112
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1231 05
427-B1878
NOTE
1. Check brake charging solenoid. 1. If diagnostic code remains active, go to
5-3805-290-10). Do not start engine. brake charging solenoid has failed.
(b) Disconnect brake charging solenoid Repeat this test to verify brake charging
from wiring harness (WP 0186 00). solenoid failure. Replace braking and
(c) At wiring harness connector for brake hydraulic fan gear pump (WP 0186 00).
charging solenoid, place a jumper wire Verify new brake charging solenoid
from contact 1 (wire C881 BU) to corrects problem.
contact 2 (wire T799 BR).
0009 00-113
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
(b) Disconnect wiring harness C881 BU or wire T799 BR of wiring
in place.
(wire C881 BU) to contact J1-54 (wire
T799 BR).
10).
0009 00-114
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1251 00
427-B1879
1. Check R-terminal circuit for a short to 1. If resistance is greater than 5,000

+battery. Ohms, go to Test 2.
disconnect switch to OFF position (TM there is a short to +battery. Replace
5-3805-290-10). wire in circuit for R-terminal, or repair
(b) Disconnect J1 and J2 harness circuit (WP 0079 00).
0052 00).
(c) Measure resistance from alternator R-
terminal wire (403 GN 18) to all
contacts used in J1 and J2 harness
connectors.
2. Check machine alternator. 1. If alternator R-terminal is an 11 to 32V
(a) Disconnect wire (403 GN 18) from square-wave from 0 to 2 KHz, go to
alternator. Test 3.
(b) Start engine (TM 5-3805-290-10). 2. If alternator R-terminal is not an 11 to
(c) Measure alternator R-terminal to verify 32V square-wave from 0 to 2 KHz,
there is 11 to 32V square-wave from 0 replace alternator (WP 0047 00).
to 2 KHz. There should not be a steady
dc voltage equivalent to battery
present.
0009 00-115
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1251 00 - 3. Verify diagnostic code remains active. 1. If problem has not been corrected,
Cont. (a) Clean harness connector contacts. replace machine ECM (WP 0052 00).
(b) Reconnect all harness connectors. 2. If diagnostic code is not present, initial
(c) Turn engine start switch to ON position problem was probably caused by a poor
and operate machine (TM 5-3805-290- electrical connection or a short at a
10). harness connector that was
(d) Connect MSD (WP 0006 00) and disconnected and reconnected.
determine if CID 1251 FMI 00 Resume normal machine operation.
diagnostic code is present.
1251 01
427-B1879
1. Check R-terminal circuit for a short to 1. If resistance is greater than 5,000

ground. Ohms, go to Test 2.
disconnect switch to OFF position (TM there is a short to wire with low
5-3805-290-10). resistance measurement. Replace wire
(b) Disconnect J1 harness connector from in circuit for R-terminal, or repair
machine ECM (WP 0052 00). circuit.
(c) Measure resistance from alternator R-
terminal wire (403 GN 18) to all
contacts used in J1 and J2 harness
connectors.
0009 00-116
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1251 01 - 2. Check machine alternator. 1. If alternator R-terminal is an 11 to 32V

Cont. (a) Disconnect wire (403 GN 18) from square-wave from 0 to 2 KHz, go to
alternator (WP 0047 00). Test 3.
(b) Start engine (TM 5-3805-290-10). 2. If alternator R-terminal is not an 11 to
(c) Measure alternator R-terminal to verify 32V square-wave from 0 to 2 KHz,
there is 11 to 32V square-wave from 0 repair or replace alternator (WP 0047
to 2 KHz. There should not be a steady 00).
dc voltage equivalent to battery
present.
3. Verify diagnostic code remains active. 1. If problem has not been corrected,
(a) Clean harness connector contacts. replace machine ECM (WP 0052 00).
(b) Reconnect all harness connectors. 2. If diagnostic code is not present, initial
(c) Turn engine start switch to ON position problem was probably caused by a poor
and operate machine (TM 5-3805-290- electrical connection or a short at a
10). harness connector that was
(d) Connect MSD (WP 0006 00) and disconnected and reconnected.
determine if CID 1251 FMI 01 Resume normal machine operation.
diagnostic code is present.
0009 00-117
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1251 08
427-B1879
NOTE
this procedure.
1. Check signal circuit for an open circuit. 1. If resistance is less than 5.0 Ohms, go
5-3805-290-10). Ohms, there is an open circuit in wiring
(b) Disconnect alternator wiring harness harness. Replace wiring harness in
(WP 0047 00). question (WP 0169 00 thru WP 0175
(c) At harness connector for alternator, 00). Verify problem has been
install a jumper wire from wire (403 corrected.
GN).
(d) Disconnect J1 and J2 wiring harness
0052 00).
(e) At wiring harness connector J2,
wire (403 GN) to wire (403 GN) at
alternator harness connector.
0009 00-118
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1251 08 - 2. Check signal circuit for a short. 1. If wiring harness is correct, go to Test
Cont. (a) Engine start switch and battery 3.
disconnect switch remain in OFF 2. If resistance is not correct, there is a
position (TM 5-3805-290-10). short between circuit with low
(b) Wiring harness remains disconnected resistance measurement and wire (403
from alternator. GN). Replace harness in question (WP
(c) Remove jumper wire from Test 1. 0169 00 thru WP 0175 00).
(d) At wiring harness connectors J1 and J2,
measure resistance from contacts J2-14
(wire 403 GN) to all other J1 and J2
contacts.
3. Verify diagnostic code remains active. 1. If diagnostic code is no longer active,
(a) Clean all harness connector contacts. initial diagnostic code was probably
(b) Reconnect all harness connectors. caused by a poor electrical connection
(c) Turn battery disconnect switch and or a short at a harness connector that
engine start switch to ON position (TM was disconnected and reconnected.
5-3805-290-10). Resume normal machine operation.
(d) Clear all inactive diagnostic codes. 2. If diagnostic code remains active,
(e) Operate machine (TM 5-3805-290- replace machine ECM (WP 0052 00).
10).
(f) Connect MSD (WP 0006 00) and check
status of diagnostic code.
0009 00-119
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1401 03
427-B1880
NOTE
1. Check clutch 1 (forward low) solenoid 1. If each resistance measurement is
energize circuit for a short to +battery circuit. greater than 5,000 Ohms, go to Test 2.
5-3805-290-10). short between J1-65 (752 YL) and
from clutch 1 (forward low) solenoid measurement. Replace wiring harness
(WP 0177 00) and machine ECM (WP in question (WP 0169 00 thru WP 0175
0052 00). 00).
(wire 752 YL) to all contacts that are
connectors.
0009 00-120
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
10).
active.
1401 05
427-B1880
NOTE
1. Check clutch 1 (forward low) solenoid. 1. If diagnostic code remains active, go to
not start engine (TM 5-3805-290-10). clutch 1 (forward low) solenoid has
(b) Disconnect clutch 1 (forward low) failed. Repeat this test to verify clutch
solenoid from wiring harness (WP 1 (forward low) solenoid failure.
0177 00). Replace modulating valve (WP 0177
(c) At clutch 1 (forward low) solenoid 00). Verify new transmission control
wiring harness connector, place a valve corrects problem.
jumper wire from contact 1 (wire 752
YL) to contact 2 (wire X750 OR).
(d) Observe status of CID 1401 FMI 05.
0009 00-121
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
(b) Disconnect wiring harness 752 YL or in wire X750 OR of wiring
in place.
(wire 752 YL) to contact J1-55 (wire
X750 OR).
10).
1401 06
427-B1880
0009 00-122
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1401 06 - NOTE
Cont.
1. Check clutch 1 (forward low) solenoid. 1. If CID 1401 FMI 06 changes to CID
(a) Turn battery disconnect switch and 1401 FMI 05 when clutch 1 (forward
engine start switch to ON position (TM low) solenoid is disconnected, clutch 1
5-3805-290-10). Do not start engine. (forward low) solenoid has failed.
(b) Connect MSD (WP 0006 00) and Repeat this test to verify clutch 1
observe status of diagnostic code. (forward low) solenoid failure. Replace
(c) Disconnect clutch 1 (forward low) modulating valve (WP 0177 00).
solenoid (WP 0177 00) from wiring 2. If CID 1401 FMI 06 remains active, go
harness. to Test 2.
2. Check clutch 1 (forward low) solenoid 1. If each resistance measurement is
energize circuit for a short to ground. greater than 5,000 Ohms, go to Test 3.
5-3805-290-10). short between J1-65 (wire 752 YL) and
(b) Clutch 1 (forward low) solenoid circuit with low resistance
remains disconnected from wiring measurement. Replace wiring harness
harness. in question (WP 0169 00 thru WP 0175
(c) Disconnect wiring harness 00).
0052 00).
(wire 752 YL) to all contacts used in
10).
0009 00-123
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1402 03
427-B1881
NOTE
1. Check clutch 2 (forward high) solenoid 1. If each resistance measurement is
5-3805-290-10). short between J1-62 (751 GN) and
(b) Disconnect wiring harness connectors circuit resistance measurement.
from clutch 2 (forward high) solenoid Replace wiring harness in question
and ECM. (WP 0169 00 thru WP 0175 00).
(wire 751 GN) to all contacts used in
0009 00-124
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
10).
active.
0009 00-125
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1402 05
427-B1881
NOTE
1. Check clutch 2 (forward high) solenoid. 1. If diagnostic code remains active, go to
5-3805-290-10). Do not start engine. clutch 2 (forward high) solenoid has
(b) Disconnect clutch 2 (forward high) failed. Repeat this test to verify clutch
solenoid from wiring harness. 2 (forward high) solenoid failure.
(c) At clutch 2 (forward high) solenoid Replace modulating valve (WP 0177
wiring harness connector, place a 00). Verify new transmission control
jumper wire from contact 1 (wire 751 valve corrects problem.
GN) to contact 2 (wire R799 BR).
0009 00-126
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
(b) Disconnect wiring harness 751 GN or wire R799 BR of wiring
in place.
(wire 751 GN) to contact J1-60 (wire
R799 BR).
(a) Inspect and clean harness connector engine ECM (WP 0052 00).
10).
0009 00-127
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1402 06
427-B1881
NOTE
1. Check clutch 2 (forward high) solenoid. 1. If CID 1402 FMI 06 changes to CID
(a) Turn battery disconnect switch and 1402 FMI 05 when clutch 2 (forward
engine start switch to ON position (TM high) solenoid is disconnected, clutch
5-3805-290-10). Do not start engine. 2 (forward high) solenoid has failed.
observe status of diagnostic code. (forward high) solenoid failure.
(c) Disconnect clutch 2 (forward high) Replace modulating valve (WP 0177
solenoid (WP 0177 00) from wiring 00).
harness. 2. If CID 1402 FMI 06 remains active, go
to Test 2.
0009 00-128
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1402 06 - 2. Check clutch 2 (forward high) solenoid 1. If each resistance measurement is

Cont. energize circuit for a short to ground. greater than 5,000 Ohms, go to Test 3.
5-3805-290-10). short between J1-62 (wire 751 GN) and
(b) Clutch 2 (forward high) solenoid circuit with low resistance
0052 00).
(wire 751 GN) to all contacts used in
10).
0009 00-129
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1403 03
427-B1882
NOTE
1. Check clutch 3 (reverse) solenoid energize 1. If each resistance measurement is
circuit for a short to +battery circuit. greater than 5,000 Ohms, go to Test 2.
5-3805-290-10). short between J1-66 (754 BU) and
(b) Disconnect wiring harness connectors circuit with low resistance
from clutch 3 (reverse) solenoid (WP measurement. Replace wiring harness
00). 00).
(wire 754 BU) to all contacts used in
0009 00-130
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
10).
active.
0009 00-131
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1403 05
427-B1882
NOTE
1. Check clutch 3 (reverse) solenoid. 1. If diagnostic code remains active, go to
not start engine. clutch 3 (reverse) solenoid has failed.
(b) Disconnect clutch 3 (reverse) solenoid Repeat this test to verify clutch 3
(WP 0177 00) from wiring harness. (reverse) solenoid failure. Replace
(c) At clutch 3 (reverse) solenoid wiring modulating valve (WP 0177 00).
harness connector, place a jumper wire Verify new transmission control valve
from contact 1 (wire 754 BU) to contact corrects problem.
2 (wire X750 OR).
0009 00-132
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
(b) Disconnect wiring harness 754 BU or wire X750 OR of wiring
in place.
(wire 754 BU) to contact J1-55 (wire
X750 OR).
10).
0009 00-133
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1403 06
427-B1882
NOTE
1. Check clutch 3 (reverse) solenoid. 1. If CID 1403 FMI 06 changes to CID
(a) Turn battery disconnect switch and 1403 FMI 05 when clutch 3 (reverse)
engine start switch to ON position (TM solenoid is disconnected, clutch 3
5-3805-290-10). Do not start engine. (reverse) solenoid has failed. Repeat
(b) Connect MSD (WP 0006 00) and this test to verify clutch 3 (reverse)
observe status of diagnostic code. solenoid failure. Replace modulating
(c) Disconnect clutch 3 (reverse) solenoid valve (WP 0177 00).
(WP 0177 00) from wiring harness. 2. If CID 1403 FMI 06 remains active, go
to Test 2.
0009 00-134
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1403 06 - 2. Check clutch 3 (reverse) solenoid energize 1. If each resistance measurement is

Cont. circuit for a short to ground. greater than 5,000 Ohms, go to Test 3.
5-3805-290-10). short between J1-66 (wire 754 BU) and
(b) Clutch 3 (reverse) solenoid remains circuit with low resistance
0052 00).
J1-66 (wire 754 BU) to all contacts
connectors.
10).
0009 00-135
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1404 03
427-B1883
NOTE
1. Check clutch 4 (second speed) solenoid 1. If each resistance measurement is
5-3805-290-10). short between J1-49 (900 PU) and
(b) Disconnect wiring harness connectors circuit with low resistance
from clutch 4 (second speed) solenoid measurement. Replace wiring harness
(WP 0177 00) and machine ECM (WP in question (WP 0169 00 thru WP 0175
0052 00). 00).
(wire 900 PU) to all contacts used in
0009 00-136
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
10).
active.
0009 00-137
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1404 05
427-B1883
NOTE
1. Check clutch 4 (second speed) solenoid. 1. If diagnostic code remains active, go to
5-3805-290-10). Do not start engine. clutch 4 (second speed) solenoid has
(b) Disconnect clutch 4 (second speed) failed. Repeat this test to verify clutch
solenoid (WP 0177 00) from wiring 4 (second speed) solenoid failure.
harness. Replace modulating valve (WP 0177
(c) At clutch 4 (second speed) solenoid 00).
wiring harness connector, place a
jumper wire from contact 1 (wire 900
PU) to contact 2 (wire 975 WH).
0009 00-138
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
Cont (a) Turn engine start switch and battery to Test 3.
(b) Disconnect wiring harness 900 PU or wire 975 WH of wiring
in place.
(wire 900 PU) to contact J1-50 (wire
975 WH).
10).
0009 00-139
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1404 06
427-B1883
NOTE
1. Check clutch 4 (second speed) solenoid. 1. If CID 1404 FMI 06 changes to CID
(a) Turn battery disconnect switch and 1404 FMI 05 when clutch 4 (second
engine start switch to ON position (TM speed) solenoid is disconnected, clutch
5-3805-290-10). Do not start engine. 4 (second speed) solenoid has failed.
observe status of diagnostic code. (second speed) solenoid failure.
(c) Disconnect clutch 4 (second speed) Replace modulating valve (WP 0177
solenoid (WP 0177 00) from wiring 00).
harness. 2. If CID 1404 FMI 06 remains active, go
to Test 2.
0009 00-140
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1404 06 - 2. Check clutch 4 (second speed) solenoid 1. If each resistance measurement is

5-3805-290-10). short between J1-49 (wire 900 PU) and
(b) Clutch 4 (second speed) solenoid circuit with low resistance
0052 00).
J1-49 (wire 900 PU) to all contacts used
in ECM wiring harness connectors.
10).
0009 00-141
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1405 03
427-B1884
NOTE
1. Check clutch 5 (third and fourth speed) 1. If each resistance measurement is
solenoid energize circuit for a short to greater than 5,000 Ohms, go to Test 2.
+battery circuit. 2. If each resistance measurement is not
(a) Turn engine start switch and battery greater than 5,000 Ohms, there is a
disconnect switch to OFF position (TM short between J1-51 (901 WH) and
5-3805-290-10). circuit that has lowest resistance
(b) Disconnect wiring harness connectors measurement. Replace wiring harness
from clutch 5 (third and fourth speed) in question (WP 0169 00 thru WP 0175
solenoid (WP 0177 00) and machine 00).
ECM (WP 0052 00).
(wire 901 WH) to all contacts used in
0009 00-142
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
10).
active.
0009 00-143
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1405 05
427-B1884
NOTE
1. Check clutch 5 (third and fourth speed) 1. If diagnostic code remains active, go to
solenoid. Test 2.
(a) Turn battery disconnect switch and 2. If diagnostic code is no longer active,
engine start switch to ON position (TM clutch 5 (third and fourth speed)
5-3805-290-10). Do not start engine. solenoid has failed. Repeat this test to
(b) Disconnect clutch 5 (third and fourth verify clutch 5 (third and fourth speed)
speed) solenoid with active diagnostic solenoid failure. Replace modulating
code from wiring harness (WP 0177 valve (WP 0177 00). Verify new
00). modulating valve corrects problem.
(c) At clutch 5 (third and fourth speed)
solenoid wiring harness connector,
(wire 901 WH) to contact 2 (wire 975
WH).
0009 00-144
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
(b) Disconnect wiring harness 901 WH or wire 975 WH of wiring
in place.
(wire 901 WH) to contact J1-50 (wire
975 WH).
10).
0009 00-145
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1405 06
427-B1884
NOTE
1. Check clutch 5 (third and fourth speed) 1. If CID 1405 FMI 06 changes to CID
solenoid. 1405 FMI 05 when clutch 5 (third and
(a) Turn battery disconnect switch and fourth speed) solenoid is disconnected,
engine start switch to ON position (TM clutch 5 (third and fourth speed)
5-3805-290-10). Do not start engine. solenoid has failed. Repeat this test to
(b) Connect MSD (WP 0006 00) and verify clutch 5 (third and fourth speed)
observe status of diagnostic code. solenoid failure. Replace modulating
(c) Disconnect clutch 5 (third and fourth valve (WP 0177 00).
speed) solenoid with active diagnostic 2. If CID 1405 FMI 06, go to Test 2.
code from wiring harness (WP 0177
00).
0009 00-146
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1405 06 - 2. Check clutch 5 (third and fourth speed) 1. If each resistance measurement is
Cont. solenoid energize circuit for a short to greater than 5,000 Ohms, go to Test 3.
ground. 2. If each resistance measurement is not
(a) Turn engine start switch and battery greater than 5,000 Ohms, there is a
disconnect switch to OFF position (TM
5-3805-290-10). short between J1-51 (wire 901 WH)
(b) Clutch 5 (third and fourth speed) and circuit with low resistance
solenoid remains disconnected from measurement. Replace wiring harness
wiring harness. in question (WP 0169 00 thru WP 0175
0052 00).
J1-51 (wire 901 WH) to all contacts
connectors.
10).
0009 00-147
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1406 03
427-B1885
NOTE
1. Check clutch 6 (first speed) solenoid 1. If each resistance measurement is
5-3805-290-10). short between J1-48 (755 OR) and
(b) Disconnect wiring harness connectors circuit resistance measurement.
from clutch 6 (first speed) solenoid Replace wiring harness in question
(WP 0177 00) and machine ECM (WP (WP 0169 00 thru WP 0175 00).
0052 00).
(wire 755 OR) to all contacts used in
0009 00-148
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
10).
active.
0009 00-149
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1406 05
427-B1885
NOTE
1. Check clutch 6 (first speed) solenoid. 1. If diagnostic code remains active, go to
5-3805-290-10). Do not start engine. clutch 6 (first speed) solenoid has
(b) Disconnect clutch 6 (first speed) failed. Repeat this test to verify clutch
solenoid (WP 0177 00) from wiring
6 (first speed) solenoid failure. Replace
harness.
modulating valve (WP 0177 00).
(c) At clutch 6 (first speed) solenoid wiring
harness connector, place a jumper wire Verify new modulating valve corrects
from contact 1 (wire 755 OR) to contact problem.
2 (wire 975 WH).
0009 00-150
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
(b) Disconnect wiring harness 755 OR or wire 975 WH of wiring
harness. Replace wiring harness in
0052 00).
(c) Jumper wire installed in Test 1 remains
in place. 00).
(wire 755 OR) to contact J1-50 (wire
975 WH).
10).
0009 00-151
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1406 06
427-B1885
NOTE
1. Check clutch 6 (first speed) solenoid. 1. If CID 1406 FMI 06 changes to CID
(a) Turn battery disconnect switch and 1406 FMI 05 when clutch 6 (first
engine start switch to ON position (TM speed) solenoid is disconnected, clutch
5-3805-290-10). Do not start engine. 6 (first speed) solenoid has failed.
(b) Connect MSD (WP 0006 00) and Repeat this test to verify clutch 6 (first
observe status of diagnostic code. speed) solenoid failure. Replace
(c) Disconnect clutch 6 (first speed) modulating valve (WP 0177 00).
solenoid with active diagnostic code 2. If CID 1406 FMI 06 remains active, go
from wiring harness. to Test 2.
0009 00-152
TM 5-3805-290-23-1
(MID 081)
CID FMI CODE
1406 06 - 2. Check clutch 6 (first speed) solenoid 1. If each resistance measurement is

5-3805-290-10). short between J1-48 (wire 755 OR) and
(b) Clutch 6 (first speed) solenoid remains circuit with low resistance
disconnected from wiring harness (WP measurement. Replace wiring harness
0177 00). in question (WP 0169 00 thru WP 0175
0052 00).
J1-48 (wire 755 OR) to all contacts that
are used in ECM wiring harness
connectors.
10).
1834 04 Check harness. 1. If resistance is greater than 5,000
(a) Turn battery disconnect switch and Ohms, replace machine ECM (WP
engine start switch to OFF position 0052 00).
(TM 5-3805-290-10). 2. If resistance is less than 5,000 Ohms,
(b) Disconnect 309 GN wire from engine there is a short between frame ground
start switch. and signal circuit in wiring harness.
(c) Disconnect J1 and J2 wiring harness Replace wiring harness in question
connectors from machine ECM (WP (WP 0169 00 thru WP 0175 00).
0052 00).
(d) At engine start switch, measure
resistance between wire 309 GN and
frame ground.
0009 00-153
TM 5-3805-290-23-1
Table 3. Autoshift Switch Status.
Switch Position Manual J1-27 Auto J1-26 Variable Shift Control J1-28
Manual Closed Open Open
Auto Open Closed Open
Variable Shift Control (VSC) Open Open Closed
Table 4. Valid Shift Lever Input States.
Output Forward Neutral Reverse First Gear Second Gear Third Gear Fourth Gear
1F X O O X O O O
2F X O O O X O O
3F X O O O O X O
4F X O O O O O X
1N O X O X O O O
2N O X O O X O O
3N O X O O O X O
4N O X O O O O X
1R O O X X O O O
2R O O X O X O O
3R O O X O O X O
4R O O X O O O X
N O X O O O O O
Table 5. Machine ECM Connector Pin Assignments.
Function Wire Assignment Machine ECM Pin Assignments

Forward G750-BU Connector J2, Pin 49
Neutral G763-PU Connector J2, Pin 23
Reverse G755-GY Connector J2, Pin 28
First Gear G768-GN Connector J2, Pin 50
Second Gear G760-WH Connector J1, Pin 41
Third Gear G761-YL Connector J1, Pin 42
Fourth Gear G762-BR Connector J1, Pin 43
0009 00-154
TM 5-3805-290-23-1
TROUBLESHOOTING WITH AN EVENT CODE
Table 6. Event Codes.
EVENT CODES TEST OR INSPECTION CORRECTIVE ACTION
E015 Refer to Coolant Temperature is Too High in Engine Troubleshooting Table (WP 0008 00)
E016 to continue troubleshooting.
E017
E023 Connect MSD (WP 0006 00) and check for any 1. If diagnostic codes are present, repair
active or logged diagnostic codes. them first. Ensure repairs have
eliminated problem.
2. Refer to Table 7, Oil Temperature is
Too High in Hydraulic System
Troubleshooting (WP 0008 00).
E025 E027 Refer to Inlet Air Temperature is Too High in
Engine System Troubleshooting (WP 0008 00).
E028 Refer to Table 3, Transmission Gets Hot in
Transmission System Troubleshooting (WP
0008 00).
E030 Refer to Table 3, Transmission Gets Hot in If problem still exists, replace torque
Transmission System Troubleshooting (WP converter oil temperature sensor (WP 0068
0008 00). 00).
E040 Refer to Table 1, Low Engine Oil Pressure in If problem still exists, replace engine oil
Engine Troubleshooting (WP 0008 00). pressure sensor (WP 0066 00).
E054 1. Connect MSD (WP 0006 00) and check for 1. Troubleshoot any active codes before
any active or logged diagnostic codes. continuing with this procedure. Refer
Code in this work package.
2. If no diagnostic codes are active, go to
Test 2.
2. Perform Fuel System Inspection (WP 0011
00).
E100 1. Connect MSD (WP 0006 00) and check for 1. Troubleshoot any active codes before
any active or logged diagnostic codes. continuing with this procedure. Refer
2. If no diagnostic codes are active, go to
Test 2.
2. Perform a check of engine lubrication If there are no problems with engine oil
system. Refer to Table 1, Low Engine Oil pressure, there may be an intermittent
Pressure in Engine Troubleshooting (WP problem. Monitor engine operation. Repair
0008 00). any problem. Ensure repair eliminates
problem.
E190 This event records engine overspeed warning.
No troubleshooting is required.
0009 00-155
TM 5-3805-290-23-1
EVENT CODES TEST OR INSPECTION CORRECTIVE ACTION
E265 Determine reason for shutdown. If shutdown was unwanted, connect MSD
(WP 0006 00) and clear user-defined
shutdown.
E272 Check air cleaner elements for restriction (WP Clean or replace plugged air cleaner
0032 00). elements.
E283 Refer to Hydraulic System Troubleshooting in
(WP 0008 00).
E441 Diagnose charging system. Refer to Table 2,
Malfunction 1, Electrical System
E442 Connect MSD (WP 0006 00) and check for any Troubleshoot any active codes. Refer to
active or logged diagnostic codes. Troubleshooting With a Diagnostic Code
E600 Connect MSD (WP 0006 00) and check for any 1. Troubleshoot any active codes. Refer
active or logged diagnostic codes. to Troubleshooting With a Diagnostic
2. If no diagnostic codes are present, refer
to Table 7, Oil Temperature is Too
High in Hydraulic System
E883 Connect MSD (WP 0006 00) and check for any Troubleshoot any active codes. Refer to
active or logged diagnostic codes. Troubleshooting With a Diagnostic Code
END OF WORK PACKAGE
0009 00-156
8
TM 5-3805-290-23-1
ENGINE TESTS, INSPECTIONS, AND ADJUSTMENTS 0010 00
Compression Test Excessive Engine Oil Consumption Inspection

Engine Oil Pressure Test Increased Engine Oil Temperature Inspection
Finding Top-Center Position for No. 1 Piston
INITIAL SETUP
Maintenance Level References
Direct Support TM 9-6140-200-14

WP 0003 00
Test Equipment WP 0006 00
Adapter, communication (Item 2, WP 0205 00) WP 0020 00
Measuring equipment (Item 46, WP 0205 00) WP 0024 00
WP 0025 00
Software kit (Item 81, WP 0205 00)
WP 0027 00
Tester, cylinder compression (Item 90, WP 0205
WP 0038 00
00)
WP 0051 00
Test set, electronic systems (MSD) (Item 91, WP
WP 0066 00
0205 00)
WP 0145 00
Tools and Special Tools WP 0148 00
Tool kit, general mechanic’s (Item 96, WP 0205 00) WP 0149 00
WP 0155 00
Shop equipment, automotive maintenance and
repair: field maintenance, basic, less power (Item WP 0157 00
75, WP 0205 00) WP 0158 00
WP 0160 00
Materials/Parts
WP 0163 00
Oil, lubricating, OE/HDO-5/40 (Item 34, WP 0206
WP 0165 00
00)
Oil, lubricating, OE/HDO-15/40 (Item 35, WP Equipment Conditions

0206 00) Machine parked on level ground (TM 5-3805-290-
10)
Rag, wiping (Item 41, WP 0206 00)
Work tool lowered to ground (TM 5-3805-290-10)
Tape, reflective (Item 57, WP 0206 00) Parking brake engaged (TM 5-3805-290-10)
Spacers 0.2 in. (5 mm) thick Wheels chocked
Battery disconnect switch in OFF position (TM 5-
Personnel Required 3805-290-10)
MOS 62B, Construction Equipment Repairer Engine doors opened (TM 5-3805-290-10)
0010 00-1
TM 5-3805-290-23-1
ENGINE TESTS, INSPECTIONS, AND ADJUSTMENTS - CONTINUED 0010 00
NOTE
For a better understanding of each system, review the appropriate section in Theory of Operation (WP 0003
00).
COMPRESSION TEST 0010 00
NOTE
The cylinder compression test should only be used to compare cylinders of an engine. If one or more cylin-
ders vary by more than 51 psi (350 kPa), cylinder and related components may need to be replaced.
1. Before performing compression test, ensure these conditions exist:
a. Battery is in good condition (TM 9-6140-200-14).
b. Battery is fully charged (TM 9-6140-200-14).
c. Starting motor operates correctly (TM 5-3805-290-10).
d. Valve lash is set correctly (WP 0155 00).
e. All fuel injection nozzles are removed (WP 0163 00).
f. Fuel transfer pump electrical connector is disconnected (WP 0038 00).
2. Install cylinder compression tester in hole for fuel injector nozzle.
3. Operate starting motor to turn engine (TM 5-3805-290-10). Record maximum pressure indicated on compression gage.
4. Repeat steps 2 and 3 for all cylinders.
5. If one or more cylinders vary by more than 51 psi (350 kPa), replace engine (WP 0145 00).
ENGINE OIL PRESSURE TEST 0010 00
1. Use lubricating oil for this test. Refer to Preventive Maintenance Checks and Services (PMCS) (WP 0020 00) for oil rec-
ommendations for normal operation of machine.
2. Connect MSD equipped with ET software to machine (WP 0006 00).
3. Start and run engine (TM 5-3805-290-10).
NOTE
Engine oil pressure varies with engine speed. As engine speed increases, engine oil pressure increases up to
minimum of 29 psi (200 kPa).
4. Record engine oil pressure readings when engine is at operating temperature of 212°F (100°C) from MSD. Minimum
engine oil pressure at high idle is 29 psi (200 kPa). Minimum engine oil pressure at low idle is 14.5 psi (100.0 kPa).
5. Disconnect MSD from machine (WP 0006 00).
6. Remove engine oil temperature sensor (WP 0066 00).
7. Install measuring equipment in oil pressure sensor port in engine side cover.
8. Start and run engine (TM 5-3805-290-10).
0010 00-2
TM 5-3805-290-23-1
ENGINE OIL PRESSURE TEST - CONTINUED
NOTE
Engine oil pressure varies with engine speed. As engine speed increases, engine oil pressure increases up to
minimum of 29 psi (200 kPa).
9. Record engine oil pressure readings when engine is at
operating temperature of 212°F (100°C) from measur-
ing equipment. Minimum engine oil pressure at high
idle is 29 psi (200 kPa). Minimum engine oil pressure
at low idle is 14.5 psi (100 kPa).
10. Install engine oil pressure sensor (WP 0066 00).
11. Compare recorded engine oil pressures with oil pres-
sure indicator on instrument cluster.
427-B0647
NOTE
A defective engine oil pressure indicator or sensor will give false indication of low or high oil pressure.
a. If oil pressure indicator in cluster contradicts readings recorded from MSD or measuring equipment, replace oil
pressure sensor (WP 0066 00). If problem still exists, replace instrument cluster as necessary (WP 0051 00).
b. If engine oil pressure is too low, refer to Low Oil Pressure in this work package.
c. If engine oil pressure is too high, refer to High Oil Pressure in this work package.
0010 00-3
TM 5-3805-290-23-1
NOTE
• Oil level can be too far below oil pump supply tube, in which case oil pump will not supply enough
lubrication to engine components. If engine oil level is low, refer to step 1.
• Engine oil contaminated with fuel or coolant will cause low engine oil pressure. High engine oil
level in crankcase can be indication of contamination. If engine oil is contaminated, refer to step 2.
• If engine oil bypass valves are held in open position, a reduction in oil pressure can result. This
may be due to debris in engine oil. If engine oil bypass valves are open, refer to step 3.
• An oil line or oil passage that is open, broken, or disconnected will cause low engine oil pressure.
An open lubrication system could be caused by a missing or damaged piston cooling jet. If engine
lubrication system is open, refer to step 4.
• The oil pickup tube inlet screen for the engine oil pump can have a restriction. This restriction
will cause cavitation and loss of engine oil pressure. If oil pickup tube has a restricted inlet screen,
refer to step 5.
• Low engine oil pressure may also be a result of an oil pickup tube that is drawing in air. If oil
pickup tube has a leak, refer to step 6.
• Wear, damage, or air leakage in engine oil pump will cause cavitation and loss of oil pressure. If
engine oil pump is defective, refer to step 7.
• Excessive clearance at engine bearings will cause low engine oil pressure. If engine bearings are
suspected to have excessive clearance, refer to step 8.
Low Oil Pressure
1. Check engine oil level in crankcase (TM 5-3805-290-10). If engine oil level is low, add engine oil to correct engine oil
level (WP 0025 00).
2. Determine reason for engine oil contamination and make necessary repairs. Drain contaminated oil and fill with proper
grade of engine oil (WP 0025 00). If engine oil is contaminated with fuel or coolant it will cause low engine oil pressure.
High engine oil level in crankcase can be indication of contamination.
CAUTION
Use only oil filters designed for this machine. Using any other oil filter may result in damage to internal
engine components.
3. Remove and clean each bypass valve to correct problem. Replace engine oil bypass valve(s), as necessary (WP 0158
00). Install new engine oil filters (WP 0025 00).
4. Determine reason for open engine lubrication system and make necessary repairs. Refer to appropriate work package.
NOTE
• Piston cooling jets direct engine oil toward bottom of piston to cool piston. This also provides lubrica-
tion for piston pin. Breakage, restriction, or incorrect installation of piston cooling jets will cause sei-
zure of piston.
• Remove engine oil pan (WP 0157 00) to gain access to oil pickup tube and oil screen.
0010 00-4
TM 5-3805-290-23-1
Low Oil Pressure - Continued
5. Check inlet screen on oil pickup tube and remove any material that may be restricting engine oil flow.
6. Check joints of oil pickup tube for cracks or damaged O-ring seal. Replace inlet screen and oil pickup tube if necessary
(WP 0160 00).
7. Replace oil pump if necessary (WP 0160 00).
8. Replace engine (WP 0145 00).
NOTE
High oil pressure can be caused by debris in engine oil system causing restriction of oil flow and/or
restricted movement of engine oil bypass valves.
High Oil Pressure
1. If engine oil bypass valves are stuck in closed position, remove and clean each bypass valve to correct this problem (WP
0158 00). Replace engine oil bypass valve, if necessary.
2. Change engine oil and install new engine oil filters (WP 0025 00).
FINDING TOP-CENTER POSITION FOR NO. 1 PISTON 0010 00
1. Fasten temporary pointer (1) (a piece of tape) to front

of front cover. Position tip of pointer close to edge of
damper (2) on crankshaft or close to edge of pulley.
427-B0650
0010 00-5
TM 5-3805-290-23-1
FINDING TOP-CENTER POSITION FOR NO. 1 PISTON - CONTINUED

2. Remove valve mechanism cover (WP 0024 00).
3. Rotate crankshaft clockwise when facing front of
engine. Rotate crankshaft until pushrod for inlet valve
of rear cylinder begins to tighten.
427-B2078
4. Rotate crankshaft further clockwise by 1/8 turn. Insert lever between rocker lever and valve spring cap of No. 1 inlet
valve. Open inlet valve. Position spacer approximately 0.2 in. (5.0 mm) thick between valve stem and rocker lever.
5. Slowly rotate crankshaft counterclockwise until piston makes contact with open valve. Make temporary mark (2) on
damper or pulley to align with tip of pointer.
6. Rotate crankshaft clockwise by one or two degrees.
Remove spacer between valve stem and rocker lever.
Rotate crankshaft counterclockwise 1/4 turn. Position
spacer that is approximately 0.2 in. (5.0 mm) thick
between valve stem and rocker lever of No. 1 inlet
valve.
427-B0511-2
7. Slowly rotate crankshaft clockwise until piston makes contact with open valve. Make another temporary mark (2) on
damper or pulley to align with tip of pointer (1).
8. Make temporary mark (2) at center point between two marks on damper or pulley. Remove other two marks. Rotate
crankshaft counterclockwise 1/8 turn. Remove spacer between valve stem and rocker lever.
0010 00-6
TM 5-3805-290-23-1
FINDING TOP-CENTER POSITION FOR NO. 1 PISTON - CONTINUED

9. Slowly rotate crankshaft clockwise until mark (2) on damper or pulley, which was made in step 8, aligns with tip of
pointer (1). No. 1 piston is now at top-center on compression stroke.
10. Install valve mechanism cover (WP 0024 00).
11. Remove temporary pointer (1) from front of front

cover.
427-B0650
EXCESSIVE ENGINE OIL CONSUMPTION INSPECTION 0010 00

1. Check for leakage at seals at each end of crankshaft (WP 0148 00 and WP 0149 00).
2. Look for leakage at gasket for engine oil pan (WP 0157 00) and all lubrication system connections.
3. Look for any engine oil that may be leaking from crankcase breather. This can be caused by combustion gas leakage
around pistons. A dirty crankcase breather will cause high pressure in crankcase A dirty crankcase breather will cause
gaskets and seals to leak. Clean or replace breather as necessary (WP 0024 00).
NOTE
Engine oil that is leaking into the combustion area of the cylinders can be the cause of blue smoke. There
are several possible ways for engine oil to leak into the combustion area of the cylinders:
• Leaks between worn valve guides and valve stems.
• Worn components or damaged components (pistons, piston ring, or dirty return holes for
the engine oil).
• Incorrect installation of the compression ring and/or the intermediate in.
4. If any of these noted conditions are suspected, replace engine (WP 0145 00).
5. Look inside turbocharger for leaking seal rings in the turbocharger shaft (WP 0165 00).
6. Check for overfilled crankcase (TM 5-3805-290-10).
0010 00-7
TM 5-3805-290-23-1
EXCESSIVE ENGINE OIL CONSUMPTION INSPECTION - CONTINUED

7. Check for wrong dipstick or guide tube.
8. Talk to operator and check for sustained operation at light loads.
9. Check for engine oil with incorrect viscosity (WP 0020 00). Engine oil with a thin viscosity can be caused by fuel leak-
age into crankcase or by the increased engine temperature. If suspected, refer to Increased Engine Oil Temperature
Inspection in this work package.
INCREASED ENGINE OIL TEMPERATURE INSPECTION 0010 00
NOTE
Oil temperature may be higher than normal when the engine is operating. In such a case, the oil cooler may
have a restriction. A restriction in the oil cooler will not cause low oil pressure in the engine.
1. Look for a restriction in oil passages of oil cooler.
2. Determine if oil cooler bypass valve is held in open position. If so, replace bypass valve (WP 0027 00). This condition
will allow oil to pass through valve instead of the oil cooler. Oil temperature will increase.
END OF WORK PACKAGE
0010 00-8
10
TM 5-3805-290-23-1
FUEL SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS 0011 00

Air in Fuel Test Fuel System Inspection
Fuel Injection Timing Check Fuel System Pressure Test
Cylinder Balance Test Air Inlet and Exhaust System Inspection
Fuel Quality Test
INITIAL SETUP
Maintenance Level References - Continued
Unit WP 0024 00
Test Equipment WP 0029 00
WP 0031 00
Calibration fluid and diesel fuel test kit (Item 22,
WP 0205 00) WP 0032 00
Piston displacement gage (Item 58, WP 0205 00) WP 0033 00
WP 0035 00
WP 0036 00
Tool kit, general mechanic’s (Item 96, WP 0205 00)
WP 0038 00
Shop equipment, common no. 1 (Item 77, WP 0205 WP 0163 00
00)
WP 0164 00
Filter, fluid (Item 32, WP 0205 00)
WP 0166 00
Timing pin (Item 95, WP 0205 00)
WP 0177 00
Materials/Parts Equipment Conditions
Rag, wiping (Item 41, WP 0206 00) Machine parked on level ground (TM 5-3805-290-
Personnel Required 10)
MOS 62B, Construction Equipment Repairer (2) Work tool lowered to ground (TM 5-3805-290-10)
References
Wheels chocked
WP 0003 00
WP 0010 00 3805-290-10)
WP 0020 00 Engine doors opened (TM 5-3805-290-10)
0011 00-1
TM 5-3805-290-23-1
FUEL SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS - CONTINUED 0011 00
NOTE
00).
AIR IN FUEL TEST 0011 00
1. Inspect fuel system for leaks.

2. Ensure fuel line fittings are properly tightened (WP 0035 00 and WP 0038 00).
3. Check fuel level in fuel tank (TM 5-3805-290-10).
NOTE
• Air can enter fuel system on suction side between fuel transfer pump and fuel tank.
• When possible, install sight gage in straight section of fuel line that is at least 12 in. (30.5 cm) long. DO
NOT install sight gage near the following fittings which create turbulence: elbows, relief valves, and
check valves.
4. Install fluid filter (sight gage tool) in fuel return line.
5. Observe fuel flow during engine cranking. Check for air bubbles in fuel. If there is no fuel in sight gage, prime fuel sys-
tem (WP 0029 00).
6. If engine starts, check for air in fuel at varying engine speeds. If possible, operate engine under conditions which have
been noted to have problems.
NOTE
• Steady stream of small bubbles with diameter of approximately 0.063 in. (1.60 mm) is acceptable
amount of air in fuel.
• Bubbles with diameter of approximately 0.250 in. (6.35 mm) are also acceptable if there is a two- to
three-second interval between bubbles.
• Excessive air bubbles in fuel are not acceptable.
7. Refer to illustration below for acceptable amounts of air in fuel.
427-B0651
0011 00-2
TM 5-3805-290-23-1
AIR IN FUEL TEST - CONTINUED
NOTE
If second sight gage is not available, move sight gage from fuel return line and install sight gage at inlet to
fuel transfer pump.
8. If excessive air is seen in sight gage in fuel return line, install second sight gage at inlet to fuel transfer pump.
9. Observe fuel flow during engine cranking. Check for air bubbles in fuel.
10. If engine starts, check for air in fuel at varying engine speeds.
NOTE
• If excessive air is not seen at inlet to fuel transfer pump, air is entering system after fuel transfer pump.
• If excessive air is seen at inlet to fuel transfer pump, air is entering through suction side of fuel system.
11. Prime fuel system, if necessary (WP 0029 00).
11
11
WARNING
To avoid injury to personnel, always wear eye and face protection when using pressurized air.
11
CAUTION
To avoid damage to equipment, never use more than 5 psi (34 kPa) to pressurize fuel tank.
12. Pressurize fuel tank with air to 5 psi (35 kPa). Check for leaks in fuel lines between fuel tank and fuel transfer pump.
Replace any fuel system components found to be leaking or damaged.
13. Check fuel pressure. Refer to Fuel System Pressure Test in this work package.
14. If source of air is not found, disconnect supply line from fuel tank and connect external fuel supply to inlet of fuel trans-
fer pump. If this corrects problem, inspect fuel sending unit and replace if necessary (WP 0177 00).
15. If problem still exists, inspect and replace fuel tank (WP 0166 00).
0011 00-3
TM 5-3805-290-23-1
FUEL INJECTION TIMING CHECK 0011 00
NOTE
This procedure must be done before any of the following:
• Bolts that hold fuel injection pump to front housing are loosened (WP 0164 00).
• Removal of fuel injection pump (WP 0164 00).
• Fuel injection pump is timed at four degrees after top-center on compression stroke of No. 1 cylinder.
Timing is important to conform to allowable emissions.
1. Set No. 1 piston (1) at top-center on compression stroke. Refer to Finding Top-Center Position for No. 1 Piston (WP
0010 00).
NOTE
No. 5 fuel injector nozzle can be used, if necessary.
2. Remove No. 2 fuel injector nozzle (WP 0163 00).

3. Ensure seat washer for fuel injector nozzle is removed.
4. Check bore of fuel injector nozzle and seat for fuel injector nozzle.
5. Align alignment pin (2) of main body (3) with slot in

fuel injector nozzle hole.
6. Place main body (3) into fuel injector nozzle hole and
install gland nut (4).
7. Apply clean engine oil to probe (5).
8. Insert probe (5) into main body (3) and carefully lower
probe to contact top of piston (1).
427-B0652
0011 00-4
TM 5-3805-290-23-1
FUEL INJECTION TIMING CHECK - CONTINUED
9. Rotate crankshaft in direction of engine rotation until

machined face at top of probe (5) aligns with top of
main body (3). No. 1 piston is now at four degrees
after top-center on compression stroke.
427-B0653
NOTE
When step is complete, DO NOT rotate crankshaft until fuel injection pump is to be installed on engine.
10. Remove probe (5) from main body (3).
11. Remove gland nut (4).
12. Remove main body (3) from cylinder head.
13. Install fuel injector nozzle (WP 0163 00).
CYLINDER BALANCE TEST 0011 00
11
11
WARNING
• DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames, or
sparks. Fuel may ignite, causing injury or death to personnel or damage to machine.
• Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly wash
exposed skin and change fuel-soaked clothing. Failure to follow this warning may result in injury to personnel.
• Eye protection must be worn when performing this test procedure. Failure to take precautions could cause
injury to personnel.
11
CAUTION
• Use caution to ensure fuel system does not become contaminated. Keep work area clean. Contamina-
tion of fuel system could result in premature failure.
• Use two line wrenches for removal of injector lines to avoid damage to fittings and connectors.
NOTE
• Use a container to catch any fuel that may drain from system. Dispose of fuel IAW local policy and
ordinances. Ensure all spills are cleaned up.
• This on-vehicle test can be performed to find cylinder that is misfiring and causing erratic engine idle
and black smoke.
1. While running engine at low idle, loosen fuel line nut at fuel injector nozzle. This will stop flow of fuel to that cylinder.
0011 00-5
TM 5-3805-290-23-1
CYLINDER BALANCE TEST - CONTINUED
2. Listen for change in engine idle speed or for idle to become more erratic.
a. If change occurs, tighten fuel line and go to step c.
b. If no change occurs, this cylinder is misfiring.
c. Repeat steps a and b for each cylinder to be tested.
d. Record results of test and refer to Fuel Injector Nozzles Replacement (WP 0163 00) to test nozzles in question.
FUEL QUALITY TEST 0011 00
1. Determine if water and/or contaminants are present in fuel by checking water separator (TM 5-3805-290-10).
NOTE
A full fuel tank minimizes potential for overnight condensation.
2. Drain water separator, if necessary (TM 5-3805-290-10).
NOTE
Water separator can appear to be full of fuel when water separator is actually full of water.
3. Determine if contaminants are present in fuel by removing sample of fuel from bottom of fuel tank.
NOTE
Color of fuel is not necessarily an indication of fuel quality. However, fuel that is black, brown, and/or simi-
lar to sludge can be indication of bacteria or oil contamination. In cold temperatures, cloudy fuel indicates
that fuel may not be suitable for operating conditions.
4. Visually inspect fuel sample for contaminants.

5. Check fuel API with Calibration fluid and diesel fuel test kit (Item 22, WP 0205 00). Acceptable range of fuel API is 30
to 45 when API is measured at 60°F (15°C), but there is significant difference in energy within this range.
NOTE
• The measured fuel API rating and corresponding temperature must be corrected to 60°F (15°C) before
selecting fuel correction factor. Use Table 1 to determine fuel API rating at 60°F (15°C).
• A correction factor greater than 1.000 may be the cause of low power and/or excessive fuel consump-
tion.
Table 1. Fuel Density (API).
API at 60°F (15°C) Correction Factors
32.0 0.987
35.0 1.000
40.0 1.022
45.0 1.044
6. If fuel quality is still suspected as possible cause of problems regarding engine performance, disconnect fuel inlet line
from tank (WP 0035 00), and temporarily operate engine from source of fuel known to be good. This will determine if
problem is caused by fuel quality.
0011 00-6
TM 5-3805-290-23-1
FUEL QUALITY TEST - CONTINUED

7. If fuel quality is determined to be problem, drain fuel system (WP 0020 00) and replace fuel filters (WP 0036 00). Fill
tank with good fuel (TM 5-3805-290-10). Engine performance can be affected by these characteristics:
a. Cetane number of fuel.
b. Air in fuel.
c. Fuel mixed with other fluids.
FUEL SYSTEM INSPECTION 0011 00
NOTE
Problems with components that send fuel to engine can cause low fuel pressure. This can decrease engine
performance.
1. Check fuel level in fuel tank (TM 5-3805-290-10).
2. Ensure vent in fuel cap is not plugged with dirt (TM 5-3805-290-10).
3. Check all fuel lines for fuel leakage. Fuel lines must be free from dents, restrictions, and sharp bends. Verify fuel return
line is not collapsed.
4. Install new fuel filter(s) (WP 0036 00).
11
11
WARNING
DO NOT use a tool that causes sparks to cut open fuel filter. Failure to follow this warning may result in
death or injury to personnel.
11
5. Inspect filter for excessive contamination. Determine source of contamination. Make necessary repairs.
6. To remove air from fuel system, prime fuel system (WP 0029 00).
0011 00-7
TM 5-3805-290-23-1
FUEL SYSTEM PRESSURE TEST 0011 00
NOTE
• Pressure test measures output pressure of fuel transfer pump. Low fuel pressure and starting difficulty
may be indications of problems with fuel transfer pump.
• Fuel transfer pump is located on left side of machine at top of primary fuel filter.
1. Disconnect hose (1) from fuel outlet port at base of
primary fuel filter (2).
2. Install fuel pressure gage to fuel outlet port.
427-B0654
3. Prime fuel system (WP 0029 00), to eliminate air from fuel transfer pump.
4. Position fuel shutoff lever in OFF position. (TM 5-3805-290-10).
5. Turn engine start switch to ON position (TM 5-3805-290-10). Record maximum pressure. Pressure indication on gage
should be 10 psi (67 kPa).
6. If pressure is less than minimum pressure, replace fuel transfer pump (3) (WP 0031 00).
7. Observe rate at which pressure drops. If pressure drops to one-half of maximum pressure in less than 30 seconds,
replace fuel transfer pump (3) (WP 0031 00).
8. Remove pressure gage from fuel outlet port. Connect hose (1) to fuel outlet port. Prime fuel system to eliminate air from
fuel system (WP 0029 00).
0011 00-8
TM 5-3805-290-23-1
AIR INLET AND EXHAUST SYSTEM INSPECTION 0011 00

11
11
WARNING
Hot engine components can cause injury from burns. Before performing maintenance on engine, allow
engine and components to cool.
11
NOTE
General visual inspection should be made of air inlet and exhaust system. Make sure there are no signs of
leaks in system. There will be reduction in performance of engine if there is restriction in air inlet system or
exhaust system.
1. Inspect engine air cleaner inlet and ducting to ensure passageway is not blocked or collapsed (WP 0032 00 and WP 0033
00).
2. Inspect engine air cleaner element. Replace dirty engine air cleaner element with clean engine air cleaner element (WP
0032 00).
3. Check for dirt tracks inside air piping on clean side of engine air cleaner element. If dirt tracks are found, contaminants
are flowing past engine air cleaner element and/or seal for engine air cleaner element. Replace air cleaner element (WP
0032 00).
4. For engines with plastic valve mechanism covers, if excessive crankcase pressure has occurred, remove valve mecha-
nism cover (WP 0024 00), and check end of shroud for plastic skin. If found, remove plastic skin. Ensure all debris is
removed.
CAUTION
Attempting to clear obstruction by removing connection will damage valve mechanism cover.
5. If breather tube is made of plastic, use low pressure air to check for blockage in breather tube. If blockage is inside con-
nector, replace crankcase vent cover assembly (WP 0024 00).
END OF WORK PACKAGE
0011 00-9/(0011 00-10 Blank)

4
TM 5-3805-290-23-1
COOLING SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS 0012 00

Checking Filler Cap Testing Radiator and Cooling System for Leaks (Pres-
Cooling System Check (Engine and Cooling System sure Test)
Heat Problems)
INITIAL SETUP
Maintenance Level References

Unit WP 0003 00
WP 0042 00
Test Equipment
WP 0146 00
Test kit, radiator (Item 89, WP 0205 00)
WP 0167 00
Equipment Conditions
Tool kit, general mechanic’s (Item 96, WP 0205 00) Machine parked on level ground (TM 5-3805-290-
Shop equipment, common no. 1 (Item 77, WP 0205 10)
00) Work tool lowered to ground (TM 5-3805-290-10)
Materials/Parts Parking brake engaged (TM 5-3805-290-10)
Rag, wiping (Item 41, WP 0206 00) Wheels chocked

Personnel Required 3805-290-10)
MOS 62B, Construction Equipment Repairer Engine doors opened (TM 5-3805-290-10)
12
0012 00-1
TM 5-3805-290-23-1
COOLING SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS - CONTINUED 0012 00
12
12
WARNING
• DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling sys-
tem and escaping steam or hot coolant may result in serious burns.
• DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Loosen cap to
first stop and let any pressure out of cooling system, then remove cap. Failure to follow this warning may
result in serious burns.
• Wear effective eye, hand, and skin protection when handling coolants. Failure to do so may result in injury to
personnel.
• Cooling system conditioner contains alkali. Avoid contact with skin and eyes.
NOTE
• Coolant must be at correct level to check cooling system (TM 5-3805-290-10). Engine must be cool and not
running. After engine is cool, the radiator filler cap can be loosened to relieve any remaining pressure from
cooling system.
• Level of coolant should not be more than 0.5 in. (13 mm) from bottom of filler pipe. If cooling system is
equipped with sight glass, coolant should be at proper level in sight glass.
• Engine has pressure-type cooling system. Pressure-type cooling systems give two advantages. They can oper-
ate safely at higher temperatures than boiling point of water at range of atmospheric pressures. They also
reduce cavitation in water pump.
• Cavitation is formation of bubbles in liquids by mechanical forces. Forming of air bubbles or steam pockets is
much less common in pressure-type cooling systems.
• Regular inspections of cooling system should be made to identify problems before damage can occur. Visually
inspect cooling system before tests are made with test equipment.
• For a better understand of each system, review the appropriate section in Theory of Operation (WP 0003 00).
0012 00-2
TM 5-3805-290-23-1
CHECKING FILLER CAP 00012 00
NOTE
Pressure loss in cooling system can be caused by defective seal on radiator filler cap.
1. With engine cool, slowly loosen filler cap (1) to release any pressure from cooling system. Remove filler cap when pres-
sure is released (TM 5-3805-290-10).
2. Inspect filler cap seal (2). Check for damage to seal and sealing surface of radiator (3).
3. Remove any debris on cap (1), filler cap seal (2), or sealing surface of radiator (3).
427-B0655
4. Install filler cap (1) on cooling system pressure tester.

5. Note pressure at which filler cap (1) opens.
6. Compare noted pressure to pressure rating marked on top of filler cap (1).
7. If filler cap is not within specifications, replace filler cap (TM 5-3805-290-10).
0012 00-3
TM 5-3805-290-23-1
COOLING SYSTEM CHECK (ENGINE AND COOLING SYSTEM HEAT PROBLEMS) 00012 00
NOTE
• Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and
ordinances. Ensure all spills are cleaned up.
• The following conditions indicate that a heat problem exists:
a. Hot coolant is released through filler cap during normal engine operation. Hot coolant is also
released when engine is stopped.
b. Hot coolant is released from cooling system but not through filler cap during normal
operation of engine.
c. Coolant must be added frequently to cooling system. Coolant is not released through filler cap
or through outside leak.
• Running engine at medium idle will allow engine to cool before engine is stopped.
1. Run engine at medium idle (approximately 1,200 rpm) for three minutes after high idle shuts off (TM 5-3805-290-10).
2. Refer to Checking Filler Cap in this work package to determine if filler cap is damaged.
3. Refer to Testing Radiator and Cooling System for Leaks (Pressure Test), in this work package to check for cooling sys-
tem leaks.
NOTE
Engine may overheat if high idle rpm is set too high.
4. If coolant does not flow though radiator and other components of cooling system, perform these procedures:
a. Service cooling system (WP 0042 00).
NOTE
Compressed air may be used to remove materials from cooling system. Detergent added to water may also
be used. Identify cause of restriction before choosing method for cleaning.
b. Clean radiator and other components with hot water or steam at low pressure.
c. Straighten any bent radiator fins or replace radiator as necessary (WP 0167 00).
TESTING RADIATOR AND COOLING SYSTEM FOR LEAKS (PRESSURE TEST) 00012 00
1. When engine has cooled, loosen filler cap to first stop. Allow any remaining pressure to release from cooling system.
Remove filler cap when pressure is released (TM 5-3805-290-10).
2. Make sure coolant covers top of radiator core (WP 0042 00).
3. Pressurize cooling system with cooling system pressure tester to 3 psi (20 kPa) more than operating pressure of filler
cap.
NOTE
• Radiator and cooling system DO NOT have leakage if no leakage is observed after five minutes and
pressurizing pump gage remains constant for five minutes or more.
• Inside of cooling system has leakage only if reading on pressurizing pump gage goes down and no out-
side leakage is observed or outside leakage is observed.
4. Check outside of radiator for leakage. Replace radiator if necessary (WP 0167 00).
5. Check all connections and hoses of cooling system for leaks. Make any repairs, as required.
6. If reading on pressurizing pump gage goes down and no outside leakage is observed, refer to WP 0146 00 to inspect or
replace cylinder head gasket or head as necessary.
END OF WORK PACKAGE
0012 00-4
72
TM 5-3805-290-23-1
ELECTRICAL SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS 0013 00
General Engine Speed/Timing Sensor Circuit Test

5V Engine Pressure Sensor Supply Circuit Test Engine Temperature Sensors Open or Short Circuit Test
CAN Data Link Circuit Test Fuel Injection Pump Circuit Test
CAT Data Link Circuit Test
Fuel Transfer Pump Circuit Test
Charging System Test
Set Speed Circuit Test
Digital Throttle Position Sensor Circuit Test
Electrical Starting System Test Starting Aid Output Circuit Test
Electrical Power Supply Circuit Test Wiring Harness (Open Circuit) Test
Engine Pressure Sensor Open or Short Circuit Test Wiring Harness (Short Circuit) Test
INITIAL SETUP
Maintenance Level Materials/Parts

Unit
Tag, marker (Item 54, WP 0206 00)
Test Equipment Cotton swabs
Adapter, communication (Item 2, WP 0205 00) Denatured alcohol
Ammeter (Item 10, WP 0205 00) Personnel Required
Multimeter (Item 47, WP 0205 00) MOS 62B, Construction Equipment Repairer
References
0205 00) TM 9-6140-200-14
WP 0003 00
WP 0008 00
Shop equipment, common no. 1 (Item 77, WP 0205
00) WP 0020 00
WP 0022 00
WP 0025 00
00)
WP 0039 00
Adapter, cable breakout (Item 5, WP 0205 00) WP 0040 00
Breakout T (Item 15, WP 0205 00) WP 0045 00
WP 0046 00
Bypass harness, J1/P1 (Item 17, WP 0205 00)
WP 0047 00
Bypass harness, J1/P1 adapter (Item 18, WP 0205 WP 0048 00
00)
WP 0049 00
Cable, 3-pin assembly (Item 21, WP 0205 00) WP 0054 00
Remover, electrical contact (Item 71, WP 0205 00) WP 0063 00
WP 0064 00
WP 0065 00
Wrench, torque (Item 107, WP 0205 00) WP 0066 00
0013 00-1
TM 5-3805-290-23-1
ELECTRICAL SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS - CONTINUED 0013 00
INITIAL SETUP - CONTINUED
References - Continued References - Continued

WP 0067 00 WP 0175 00
WP 0077 00 WP 0176 00
WP 0079 00 WP 0186 00
WP 0136 00 WP 0192 00
WP 0145 00 WP 0210 00
WP 0164 00 Equipment Conditions
WP 0052 00 Machine parked on level ground (TM 5-3805-290-

10)
WP 0053 00
WP 0169 00 Parking brake engaged (TM 5-3805-290-10)
WP 0170 00 Wheels chocked
WP 0171 00 Battery disconnect switch in OFF position (TM 5-
3805-290-10)
WP 0172 00
Engine doors opened (TM 5-3805-290-10)
WP 0173 00
If necessary, chassis guards removed to gain access
WP 0174 00 to component (WP 0107 00)
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-4

5V Engine Pressure Sensor Supply Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-5
CAN Data Link Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-10
Charging System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-19
Digital Throttle Position Sensor Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-20
Electric Starting System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-26
Electrical Power Supply Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-29
Engine Pressure Sensor Open or Short Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-33
Engine Speed/Timing Sensor Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-40
Engine Temperature Sensors Open or Short Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-46
Fuel Injection Pump Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-51
Fuel Transfer Pump Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-59
Set Speed Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-62
Starting Aid Output Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-67
Wiring Harness (Open Circuit) Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-70
Wiring Harness (Short Circuit) Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-71
0013 00-2
TM 5-3805-290-23-1
NOTE
• For complete electrical schematic, refer to Electrical System Schematic (WP 0210 00).
• For a better understanding of each system, review the appropriate section in Theory of Operation (WP 0003
00).
• These procedures may give direction to replace wiring harnesses. However, limited repair of wiring harnesses
is authorized. Refer to Electrical General Maintenance Instructions (WP 0022 00) for the correct repair proce-
dures.
• When directed to use a bypass harness and breakout Ts, refer to Electrical General Maintenance Instructions
(WP 0022 00) for the correct hook-up procedures.
0013 00-3
TM 5-3805-290-23-1
GENERAL 0013 00
Use illustration below and Table 1 to locate connectors and components identified in the following tests.
427-B0809
427-B0666
Table 1. Connector Descriptions.

CONNECTOR FUNCTION
J1/P1 ECM connector (70-pin machine harness)
J20/P20 MIC connector (70-pin engine harness)
J40/P40 Electronic distributor pump (3-pin connector)
J100/P100 Engine coolant temperature sensor (2-pin connector)
J103/P103 Inlet manifold temperature sensor (2-pin connector)
J200/P200 Boost pressure sensor (3-pin connector)
J201/P201 Engine oil pressure sensor (3-pin connector)
J401/P401 Speed/timing sensor (2-pin connector)
0013 00-4
TM 5-3805-290-23-1
5V ENGINE PRESSURE SENSOR SUPPLY CIRCUIT TEST 0013 00
NOTE
• Use this procedure if another procedure
has directed you here or if diagnostic code
262-03 (5V Sensor dc Power Supply Short
to +Batt) or diagnostic code 262-04 (5-volt
Sensor dc Power Supply Short to Ground)
is active.
• Electronic control module (ECM) supplies
regulated +5 VDC to the following sensors:
a. J201/P201 Engine Oil Pressure
b. J200/P200 Boost Pressure
c. J40/P40 Throttle
427-B0665
• Supply or +5V engine pressure sensor is
routed from ECM, through ECM engine
harness connector terminal 26, to terminal
A of each pressure sensor connector. Sup-
ply voltage is 5.0 ± 0.5 VDC.
• +5V short circuit diagnostic code is probably caused by short circuit or open circuit in harness. Next probable
cause is sensor and least probable cause is ECM.
427-B0667
0013 00-5
TM 5-3805-290-23-1
5V ENGINE PRESSURE SENSOR SUPPLY CIRCUIT TEST - CONTINUED

1. Disconnect and inspect electrical connectors and wiring between sensor in question and ECM. Refer to Electrical Con-
nectors Inspection (WP 0022 00).
a. P1/J1 ECM engine harness connector (WP 0170 00).
b. P20/J20 machine interface connector (MIC) (WP 0170 00).
c. P201/J201 engine oil pressure sensor (WP 0066 00).
d. P200/J200 boost pressure sensor (WP 0065 00).
e. Perform 10 lb (45 N) pull test on each wire in
ECM connector associated with +5V sensor sup-
ply:
(1) P1-14 Boost Pressure
(2) P1-24 Engine Oil Pressure
(3) P1-26 +5V
(4) P1-34 Sensor Common
427-B0668
f. Check ECM connector (socket-head screw) for proper torque of 55 lb-in. (6 Nm).
g. Check harness and wiring for abrasion and pinch points from sensors back to ECM.
h. Expected Results. All connectors, pins, and sockets should be completely coupled and/or inserted and harness and
wiring should be free of corrosion, abrasion, or pinch points.
(1) If results are OK, reconnect all connectors and proceed to step 2.
(2) If results are not OK, replace wiring harness in question (WP 0169 00 thru WP 0175 00). Ensure seals are
properly in place and connectors are securely connected. Verify repair eliminates problem.
0013 00-6
TM 5-3805-290-23-1

2. Check for active diagnostic codes (WP 0005 00).
a. Connect MSD equipped with ET software to data link connector (WP 0006 00).
b. Turn engine start switch to ON position (TM 5-3805-290-10).
c. While engine is OFF, retrieve active and logged diagnostic codes on MSD. Record any diagnostic codes.
NOTE
Wait at least 15 seconds for diagnostic codes to become active.
d. Check for either of these codes. If these diagnostic codes are active, proceed to step 3.
(1) 262-03 5V Sensor dc Power Supply Short to +Batt.
(2) 262-04 5V Sensor dc Power Supply Short to Ground.
e. If ONLY above diagnostic codes are logged, proceed to step 5.
f. If above diagnostic codes are not active or logged, exit this test.
3. Disconnect ECM engine harness connector from ECM.
a. Connect MSD equipped with ET software to diagnostic connector of bypass harness (WP 0006 00).
CAUTION
DO NOT connect the bypass harness to the battery until the 20 Amp inline fuse has been removed from the
positive +battery line. If the fuse is not removed before connection to the battery, a spark may result.
b. Turn engine start switch to OFF position (TM 5-3085-290-10).
c. Disconnect J1/P1 ECM engine harness connector (WP 0053 00).
d. Connect J1/P1 bypass harness and adapter to ECM connector.
427-B0863
0013 00-7
TM 5-3805-290-23-1
NOTE
The bypass harness directly connects the engine start switch circuit to the ECM. The ECM will have power
until the connection to the + battery cable is disconnected. Remove the F1 fuse from the inline fuse holder in
order to switch off the ECM.
e. Remove fuse from bypass harness and battery circuit.
f. Connect unswitched battery cables directly to battery terminals.
g. Install fuse on bypass harness inline fuse holder.
h. Turn engine start switch to ON position (TM 5-3805-290-10).
NOTE
When ECM engine harness connector J1/P1 is disconnected and the engine start switch is in the ON posi-
tion, open circuit diagnostic codes will be “Active” or “Logged” for all of the engine sensors. This is normal.
i. Access active diagnostic code screen on ET. Check for one of these active diagnostic codes:
j. If +5V diagnostic code is active when bypass harness is connected, replace engine ECM (WP 0053 00). Verify
repair eliminates problem.
k. If +5V sensor diagnostic code is no longer active when bypass harness is connected, either harness or a sensor
attached to harness is causing problem. Reconnect ECM engine harness connector (WP 0053 00). Proceed to step
4.
4. Disconnect +5V sensors while active diagnostic codes are being monitored.
a. Connect MSD (WP 0006 00).
b. Turn engine start switch to ON position (TM 5-3805-290-10).
c. Access active diagnostic code screen on MSD. Verify one of these diagnostic codes is active:
d. Disconnect these sensors one at a time:
(1) Engine oil pressure sensor (WP 0066 00).
(2) Boost pressure sensor (WP 0065 00).
e. Wait for 30 seconds after each pressure sensor is disconnected while MSD is being monitored to verify that discon-
nection of specific sensor deactivates +5V diagnostic code.
0013 00-8
TM 5-3805-290-23-1
NOTE
When sensors are disconnected and engine start switch is in ON position, open circuit diagnostic codes will
be active or logged when +5V diagnostic codes are no longer active. This is normal. Clear these diagnostic
codes after this test step is completed.
f. Expected Results. Original +5V diagnostic code remains active.
(1) If +5V diagnostic code is still active, harness is cause of problem. Leave sensors disconnected. Proceed to
step 5.
(2) If +5V diagnostic code is not active when a specific sensor is disconnected, connect sensor that is sus-
pected of causing problem. If problem returns after connection of sensor, disconnect sensor. If problem
disappears after disconnection of sensor, replace sensor. Clear all diagnostic codes. Verify repair elimi-
nates problem.
5. Check engine harness.
a. Turn engine start switch to OFF position (TM 5-3805-290-10).
b. Disconnect ECM connector. Verify these +5V engine pressure sensors attached to ECM connectors are discon-
nected.
(1) Engine oil pressure sensor (WP 0066
00).
(2) Boost pressure sensor (WP 0065 00).
c. Measure resistance from P1:26 +5V Engine Oil
Pressure Sensor to each of these terminals:
(1) P1:14 Boost Pressure
(2) P1:24 Engine Oil Pressure
d. Wiggle harness during measurement to reveal
any intermittent short condition.
427-B0668
e. Expected Results. Each resistance measurement is more than 20 Ohms.

(1) If +5V line is not shorted in engine harness, ensure engine harness is connected to ECM (WP 0053 00) and
all sensors are connected (WP 0065 00 and WP 0066 00). There does not appear to be a problem at this
time. Clear all diagnostic codes. Continue to troubleshoot until original condition is resolved.
(2) If +5V line is shorted in engine harness, replace engine wiring harness (WP 0170 00). Clear all logged
diagnostic codes. Verify repair eliminates problem.
0013 00-9
TM 5-3805-290-23-1
CAN DATA LINK CIRCUIT TEST 0013 00
NOTE
• Use this procedure if another procedure has directed you here and if any of these diagnostic codes are active:
a. 342-2 Loss of Secondary Engine Speed Signal.
b. 174-02 Fuel Temperature Sensor Data Erratic.
c. 320-02 Speed/Timing Sensor Mechanical Failure.
d. 1684-14 Fuel Injection Pump no Communication.
• CAN data link is communication link between ECM and fuel injection pump. CAN data link uses J1:48/P40:1
CAN+ and J1:58/P40:2 CAN- connections to communicate with ECM.
• CAN data link is used to communicate engine timing, fuel demand to the fuel injection pump, data from fuel
injection pump, and status of fuel injection pump.
• Failure in CAN data link causes engine to shut down and engine to not start.
• If no communication between ECM and fuel injection pump occurs, a 1684-14 diagnostic code will be accom-
panied by 174-02 and 320-02 diagnostic codes.
• If 1684-14 is active and 174-02 and 320-02 are NOT active, then problem is intermittent loss of communica-
tions.
1. Check for problem with power delay to fuel injection pump under either of these conditions:
a. ECM has been activated and 1684-14 is active while 174-02 and 320-02 are not active.
b. 1684-14 is repeatedly logged after engine start switch is turned ON.
NOTE
DO NOT attempt to repair wiring harness between ECM and fuel injection pump. If wiring harness is
damaged, wiring harness must be replaced.
0013 00-10
TM 5-3805-290-23-1
CAN DATA LINK CIRCUIT TEST - CONTINUED
427-B0676
0013 00-11
TM 5-3805-290-23-1
2. Inspect electrical connectors and wiring. Refer to Electrical Connectors Inspection (WP 0022 00).
b. Disconnect and check connectors and wiring for these problems: damage, corrosion, abrasion, and incorrect
attachment (WP 0169 00 thru WP 0175 00).
c. Pay close attention to these areas (harness side and ECM side):
(1) P1:48 CAN +

(2) P1:58 CAN -
(3) P40:2 CAN +
(4) P40:1 CAN -
427-B0677
d. Expected Results. Connectors and wiring should be free of damage, corrosion, abrasion, and incorrect attachment.
(1) If connectors and wires are OK, reconnect all connectors and proceed to step 3.
(2) If connectors and wires are NOT OK:
(a) Replace connectors causing problem.
(b) Ensure all seals are properly placed and all connectors are secured correctly.
(c) Verify repair eliminates problem.
(d) If problem is still not corrected, replace wiring harness in question (WP 0169 00 thru WP 0175 00).
(e) If problem still exists, go to step 3.
3. Check CAN data link between ECM P40 and fuel injection pump control unit connector for open circuit.
a. Disconnect P1 from ECM (WP 0053 00).
NOTE
DO NOT disconnect P40 Fuel Pump Connector.
b. Measure resistance between terminal P1:48 and terminal P1:58.

c. Expected Results. Readings should be between 100 and 132 Ohms.
(1) If reading is OK, proceed to step 4.
(2) If reading is NOT OK, an open circuit exists in harness between P1 ECM connector and control unit for
fuel injection pump. Replace engine wiring harness (WP 0170 00).
0013 00-12
TM 5-3805-290-23-1

4. Check CAN data link between ECM and P40 fuel injection pump control unit connector for short circuit.
a. Disconnect P1 from ECM.
NOTE
DO NOT disconnect P40 fuel pump connector.
b. Measure resistance between terminal P1:58 and terminal P1:68.
c. Measure resistance between terminal P1:48 and terminal P1:68.
d. Expected Results. Readings should be more than 5,000 Ohms.
(1) If reading is OK, reconnect all connectors and proceed to step 5.
(2) If reading is NOT OK, a short circuit exists in harness between P1 ECM connector and control unit for fuel
injection pump. Replace wiring harness in question (WP 0169 00 thru WP 0175 00).
5. Verify supply voltage at fuel injection pump.
b. Disconnect P40 connector from fuel injection pump (WP 0164 00).
c. Turn engine start switch to ON position (TM 5-3805-290-10).
d. Measure voltage between terminal J40:7 and terminal J40:6.
e. Turn engine start switch to OFF position (TM 5-3805-290-10).
f. Reconnect P40 connector.
g. Expected Results. Voltage should be constant. Voltage should be between 22.0 and 27.0V.
(1) If voltage is OK, perform this repair:
Replace suspect ECM (WP 0053 00). Verify repair eliminates problem.
(2) If voltage is NOT OK (no voltage or voltage is less than permissible limit), refer to Fuel Injection Pump
Circuit Test in this work package. Reconnect fuel injector pump connector (WP 0164 00). Verify repair has
eliminated fault.
0013 00-13
TM 5-3805-290-23-1
CAT DATA LINK CIRCUIT TEST 0013 00
NOTE
• Use this procedure if MSD will not communicate with ECM through data link. If MSD will not power up,
refer to Electrical Power Supply Circuit Test in this work package.
• Use this test if engine monitoring system (EMS) displays error or if incorrect values are displayed. An incor-
rect value may be “0” for engine speed.
• CAT data link is standard data link used by ECM to communicate with MSD.
• ECM provides the following two connections for CAT data link from ECM connector J1:
a. J1:5 (CAT data link negative) to J20:5
b. J1:4 (CAT data link positive) to J20:4
• MSD may indicate the following error message: “Version of ECM is not recognized and integrity of changed
parameters and displayed data is not guaranteed.” This message indicates that the latest version of software is
not installed or software in ECM is newer than software in MSD.
1. Disconnect and inspect these electrical connectors. Refer to Electrical Connectors Inspection (WP 0022 00):
a. ECM connector J1/P1 (WP 0053 00).
427-B0678
427-B0679
0013 00-14
TM 5-3805-290-23-1
CAT DATA LINK CIRCUIT TEST - CONTINUED

b. Data link connectors J80 and J20/P20 (WP 0053 00 and WP 0170 00).
c. J20 customer connector (pin 4 and pin 5).
427-B0680
d. MSD and CAT communication adapter connectors.

e. CAT data link (terminal 4 and terminal 5) in J1/P1 ECM connector (WP 0053 00).
f. Perform 10 lb (45 N) pull test on each wire in ECM connector that is associated with CAT data link.
g. Check ECM connector (socket-head screw) for proper torque of 55 lb-in. (6 Nm).
h. Check harness and wiring for abrasion and pinch points from connector to ECM.
i. Expected Results. All connectors, pins, and sockets are completely connected and/or inserted and harness and wir-
ing are free of corrosion, abrasion, or pinch points.
(2) If results are NOT OK, replace wiring harness in question (WP 0169 00 thru WP 0175 00). Ensure all seals
are properly in place and that connectors are completely connected. Verify repair eliminates problem.
2. Determine type of problem.
a. Connect MSD to J80 diagnostic connector.
b. Start engine (TM 5-3805-290-10).
c. Expected Results.
(1) Engine starts. MSD powers up and communicates without error.
(a) There is no problem with CAT data link at this time.
(b) If intermittent condition exists, perform Electrical Connectors Inspection (WP 0022 00).
(2) Engine starts. MSD powers up but error is displayed. ECM is receiving battery power. Proceed to step 3.
(3) Engine cranks but will not start regardless of condition of MSD. Perform engine troubleshooting, Engine
Cranks but Will Not Start (WP 0008 00).
(4) Engine will not crank regardless of condition of MSD. Perform engine troubleshooting, Engine Will Not
Crank (WP 0008 00).
(5) Engine starts, but MSD does not power up. Ensure ECM is receiving correct battery power. Proceed to
step 4.
0013 00-15
TM 5-3805-290-23-1

3. Check battery voltage at ECM.
a. Ensure MSD is connected to J80 diagnostic con-
nector.
b. Disconnect ECM connector P1 from ECM con-
nector J1 (WP 0053 00).
c. Connect 70-pin breakout T to ECM harness.
d. Turn engine start switch to ON position (TM 5-
3805-290-10).
e. Measure voltage on P1 between sockets P1:56
(unswitched positive batt) and P1:68 (-batt).
f. Measure voltage on P1 between sockets P1:57 427-B0681
(unswitched batt) and P1:69 (-batt).

g. Measure voltage on P1 between sockets P1:70
(engine start switch) and P1:68 (-batt).
h. Expected Results. Voltage is between 22 VDC and 27 VDC when engine start switch is in ON position.
(1) If voltage is as specified, ECM is currently receiving correct voltage. Connect ECM and proceed to step 5.
(2) If voltage is not as specified, ECM is not receiving correct voltage. Perform Electrical Power Supply Cir-
cuit Test in this work package.
427-B0678
4. Check battery voltage to data link connector.

a. Turn engine start switch to ON position (TM 5-
3805-290-10).
b. Use multimeter to measure voltage between pin
A positive batt and pin B for negative batt on
data link connector.
427-B0682
0013 00-16
TM 5-3805-290-23-1
c. Expected Results. Voltage is between 22 VDC and 27 VDC.
(1) If voltage is as specified, data link connector is currently receiving correct voltage. Proceed to step 6.
(2) If voltage is not as specified, data link connector is not receiving correct voltage. Inspect wiring and fuses
to connector. Repair or replace wiring (WP 0022 00) or batteries (WP 0077 00), as required. Send machine
to OEM dealer for repair, if necessary. Verify repair eliminates problem.
5. Connect MSD directly to ECM.
13
WARNING
Batteries give off flammable fumes which can explode. To avoid injury or death, do not strike match, cause
spark, or smoke in vicinity of battery.
CAUTION
DO NOT connect bypass harness to battery until 20-Amp inline fuse has been removed from +battery line.
If fuse is not removed before connection to battery, spark may result.
b. Disconnect engine harness connector J1/P1 from ECM (WP 0053 00).
c. Connect bypass harness and adapter between MSD and ECM connector J1.
427-B0683
0013 00-17
TM 5-3805-290-23-1
NOTE
This bypass directly connects circuit for
engine start switch to ECM. ECM will
remain powered until connection to
unswitched battery line + is discon-
nected. Remove 20-Amp fuse from
inline fuse holder to power down ECM.
DO NOT connect bypass to battery
posts without first removing 20-Amp
inline fuse or DO NOT remove bypass
from battery posts without first remov-
ing 20-Amp inline fuse.
427-B0681
d. Expected Results. MSD is operating correctly.

(1) If MSD is operating properly, there is problem in wiring. Inspect wiring and fuses (WP 0210 00) to con-
nector. Repair or replace wiring harness in question (WP 0169 00 thru WP 0175 00) or batteries (WP 0077
00), as required. Verify repair eliminates problem.
(2) If MSD is NOT operating properly, verify 20-Amp fuse in bypass harness is NOT open. If fuse is open,
replace it and repeat this test. If fuse is OK, proceed to step 6.
6. Change MSD components.
a. If another 924G Wheel Loader is available, connect MSD to it. Ensure same communication adapter is used.
(1) Turn engine start switch to ON position (TM 5-3805-290-10).
(2) Determine if MSD operates correctly on other engine.
b. If another 924G Wheel Loader is not available, find different communication adapter.
(1) Connect MSD to data link connector. Ensure same cables are used.
c. If changing communication adapter allows MSD to operate properly, use this procedure:
(1) Replace communication adapter.
(2) Verify operation of MSD.
d. If changing communication adapter does not allow MSD to operate properly, connect another MSD.
(2) If original MSD works on another engine, proceed to step 7.
(3) If different MSD works on original engine, send faulty MSD for repairs.
0013 00-18
TM 5-3805-290-23-1
7. Connect MSD and ECM to another battery.

13
WARNING
CAUTION
DO NOT connect bypass harness to battery until 20-Amp inline fuse has been removed from +battery line.
If fuse is not removed before connection to battery, spark may result.
a. Connect battery wires from bypass harness to different battery.
b. If MSD is operating correctly, perform Electrical Power Supply Circuit Test in this work package.
c. If MSD is NOT operating correctly, perform these steps:
(1) Replace engine ECM (WP 0053 00).
NOTE
ECM should be programmed with correct software. All parameters should be set to same value as suspect
ECM.
(2) Remove all jumpers and reconnect all connectors.
(3) Recheck system for active diagnostic codes. Verify repair eliminates problem.
CHARGING SYSTEM TEST 0013 00
1. Verify alternator B+ terminal nut is tight and verify wire has a good connection to B+ terminal (WP 0047 00).
2. Start the engine and set the throttle to at least 75 percent using throttle lock (TM 5-3805-290-10). Turn ON all electrical
accessories for all tests below. Allow the engine to run for at least three minutes before continuing to step 3. Table 4 will
assist in making calculations during this test.
Table 4.
VOLTAGE MAXIMUM
TEST STEP READING VOLTAGE
3
4
3 minus 4 = 2.0V
5
6
5 minus 6 = 1.0V
7 1.0V
3. Measure the voltage between the alternator B+ terminal and the alternator case ground.
0013 00-19
TM 5-3805-290-23-1
CHARGING SYSTEM TEST - CONTINUED 0013 00
4. Measure the voltage across the battery. Put the red lead on the positive battery terminal, and put the black lead on the
negative battery terminal. Step 4 should be completed as quickly as possible after step 3.
Expected Results: Voltage is within 2V of voltage recorded in step 3.
a. If the voltage in step 3 is not more than 2V higher than the voltage in step 4 this test is complete and the related
wiring is correct at this time. Replace the alternator (WP 0047 00).
b. If the voltage in step 3 is more than 2V higher then the voltage in step 4, there is high circuit resistance: corrosion,
loose connections, and damaged wiring. Continue to step 5.
5. Check the voltage between the machine frame and alternator B+ terminal. Record the voltage.
6. Check the voltage between the machine frame and the positive battery post. Step 6 should be completed as quickly as
possible after step 5.
Expected Results: The voltage difference between step 5 and step 6 does not exceed 1V.
a. If voltage difference does not exceed the tolerance, charging circuit is good. Go to step 7.
b. If voltage difference exceeds the tolerance, there is high resistance in the charging circuit: loose cables, corroded
cables, damaged cables, and faulty circuit breaker. Correct the problem and retest the system.
7. Check the voltage between the negative battery post and the alternator case ground.
Expected Results: Voltage does not exceed 1V.
a. If voltage difference does not exceed the tolerance, ground circuit is good. There is an internal problem with the
alternator. Replace alternator (WP 0047 00).
b. If voltage difference exceeds the tolerance, there is high resistance in the ground circuit: loose cables, corroded
cables, loose alternator mounting, and poor engine ground. Correct problem and test system.
DIGITAL THROTTLE POSITION SENSOR CIRCUIT TEST 0013 00
NOTE
• Use this procedure if any of these diagnostic codes are active:
a. 91-08 Throttle Position signal abnormal.
b. 774-08 Sec Throttle Position Sensor Signal Abnormal.
c. 41-03 8 Volt dc Supply Short to +Batt.
d. 41-04 8 Volt dc Supply Short to Ground.
• Pedal-mounted throttle position sensor provides throttle position signal to ECM. Pedal-mounted throttle posi-
tion sensor is attached directly to throttle assembly. Foot or hand-operated versions of throttle assembly are
available.
• Pedal-mounted throttle position sensor will produce duty cycle of 10 to 22 percent at low idle and 75 to 90 per-
cent when accelerator pedal is fully pressed.
• Pedal-mounted throttle position sensor will produce minimum duty cycle when pedal is released. Pedal-
mounted throttle position sensor will produce maximum duty cycle when pedal is fully pressed.
• Pedal-mounted throttle position sensor sends pulse width modulated (PWM) signal. Signal varies with throttle
position. Signal is expressed as percentage.
0013 00-20
TM 5-3805-290-23-1
DIGITAL THROTTLE POSITION SENSOR CIRCUIT TEST - CONTINUED
1. Check for connector damage.
427-B0687

b. Disconnect engine ECM and throttle position sensor wiring harnesses (WP 0039 00 and WP 0053 00).
c. Check connectors and wiring for these problems: damage, abrasion, corrosion, and incorrect attachment.
d. Refer to Electrical Connectors Inspection (WP 0022 00), as necessary.
e. Perform 10 lb (45 N) pull test on each wire in ECM connector associated with pedal-mounted throttle position sen-
sor:
(1) P1:16
(2) P1:17
(3) P1:44
f. Connect engine ECM and throttle position sensor (WP 0039 00 and WP 0053 00).
g. Check ECM connector (socket-head screw) for proper torque of 55 lb-in. (6 Nm).
427-B0688
h. Expected Results. Connectors and wiring should be free of these problems: damage, abrasion, corrosion, and incor-
rect attachment.
(1) If connectors and wiring are OK, proceed to step 2.
(2) If connectors and wiring are NOT OK, replace wiring harness in question (WP 0169 00 thru WP 0175 00).
2. Check for active diagnostic codes.
a. Turn engine start switch to ON position (TM 5-3805-290-10).
b. Connect MSD (WP 0006 00).
c. Use MSD to check for diagnostic codes.
0013 00-21
TM 5-3805-290-23-1

d. Expected Results:
(1) If MSD displays 91-08 or 774-08, proceed to step 3.
(2) If MSD displays 41-03 or 41-04, proceed to step 5.
(3) If MSD displays no active diagnostic codes, proceed to step 7.
3. Check throttle position with MSD.
a. Connect MSD to diagnostic connector (WP 0006 00).
b. Turn engine start switch to ON position (TM 5-3805-290-10). Engine should be OFF.
c. Observe throttle position reading on MSD.
d. Press and release throttle.
e. Expected Results:
(1) Output should be 0 percent when pedal is released. Output should increase to 100 percent when throttle
pedal is fully pressed.
(2) Output should be between 20 and 27 percent at low idle position. Output should be between 80 and 87 per-
cent at high idle position.
(a) If results are OK, throttle position sensor is operating correctly. Proceed to step 5.
(b) If results are NOT OK, ECM is not receiving correct signal from sensor. There may be problem in
harness. Proceed to step 4.
4. Check voltage at throttle position sensor (WP 0039 00).
b. Install breakout T with three terminals for this test procedure.
d. Measure voltage between terminal A and terminal B.
e. Remove breakout T and reconnect throttle position sensor.
427-B2058
f. Expected Results. Supply voltage should be between 7.6 and 8.4 VDC.
(1) If results are OK, supply voltage is reaching sensor. Proceed to step 5.
(2) If results are NOT OK, proceed to step 6.
5. Disconnect throttle position sensor and check for active diagnostic codes.
a. Turn engine start switch to ON position (TM 5-3805-290-10). Use MSD to check for active diagnostic codes.
b. Ensure 41-03 or 41-04 is displayed on MSD as an active diagnostic code.
c. While throttle position sensor is connected and disconnected, monitor MSD screen. Check and record active diag-
nostic codes.
0013 00-22
TM 5-3805-290-23-1

d. Expected Results. Diagnostic codes are not active after disconnecting throttle sensor.
(1) If results are OK, diagnostic codes are not active after disconnecting throttle position sensor. Reconnect
throttle sensor and proceed to step 6.
(2) If results are NOT OK, install new throttle position sensor (WP 0039 00). Use MSD to verify diagnostic
codes are still active. Clear all logged codes.
6. Disconnect throttle position sensor supply terminals at

ECM.
a. Turn engine start switch to OFF position (TM 5-
3805-290-10).
b. Use pin removal tool to remove P1:17 (+8V) and
P1:44 (sensor common) from ECM connector
P1.
c. Turn engine start switch to ON position (TM 5-
3805-290-10).
d. Use MSD to check for active diagnostic codes.
427-B0689
e. Expected Results. Diagnostic codes are active.

(1) If results are OK, check for proper battery voltage. Check battery voltage for P1 between terminal 56 and
terminal 57 to terminal 68 and terminal 69. Voltage should be between 22.0 to 27.0V. If battery voltage is
present and diagnostic codes are still active, then ECM does not operate correctly.
Replace engine ECM (WP 0053 00). Verify repair eliminates problem.
(2) If results are NOT OK, a short circuit exists in harness or connectors. Connect cables one at a time. Con-
nect terminal 44 to ECM. Verify diagnostic code reappears, then connect terminal 17 to ECM. Use MSD
to verify diagnostic code reappears. Replace wiring harness in question (WP 0169 00 thru WP 0175 00).
Verify repair has eliminated fault.
7. Check position of throttle position sensor.
b. Install breakout T with three terminals on throttle position sensor.
d. Measure PWM signal. Connect one probe to terminal C (throttle position sensor) and other one probe to terminal B
(sensor common) of breakout T.
e. Observe position while engine speed control is moved from minimum to maximum position.
f. Expected Results. Position should be between 10 and 22 percent in low idle position. Position should be between
75 and 90 percent in high idle position.
(1) If results are OK, throttle position sensor is working properly. Proceed to step 8.
(2) If results are NOT OK, throttle position sensor is faulty. Proceed to step 9.
0013 00-23
TM 5-3805-290-23-1

8. Check throttle position sensor at ECM.
NOTE
Use 70-pin breakout T. This eliminates the need to disassemble ECM P1. If available, measure PWM signal
between P1:16 and P1:44.
b. Disconnect P1 from engine ECM (WP 0053 00).
c. Remove terminal 16 from P1.
d. Connect P1 to engine ECM (WP 0053 00).
e. Connect multimeter to terminal 16 and a chassis

ground.
f. Turn engine start switch to ON position (TM 5-

3805-290-10).
g. Use multimeter to display output signal of throt-

tle position sensor while engine speed control is
moved from minimum position to maximum 427-B0674
position.
h. Turn engine start switch to OFF position and

connect terminal 16 to P1 connector.
i. Expected Results. Position should be between 10 and 22 percent in low idle position. Position should be between
75 and 90 percent in high idle position.
(1) If results are OK, ECM terminals have correct signal for throttle position sensor. Check for proper supply
voltage at ECM. If voltage is correct, then ECM is suspect.
(2) If results are NOT OK, a fault exists in harness or connectors between sensor and ECM. Check terminals
between machine interface connector and throttle position sensor. Replace wiring harness in question (WP
0169 00 thru WP 0175 00). Verify repair eliminates problem.
0013 00-24
TM 5-3805-290-23-1

9. Remove throttle position sensor from engine speed control assembly (WP 0039 00).
b. Record position of sensor before removing throttle position sensor.
c. Remove throttle position sensor from housing (WP 0039 00) and inspect cables for signs of wear.
d. Connect multimeter to terminal C of breakout T.
e. Turn engine start switch to ON position (TM 5-3805-290-10).
f. Record output signal of throttle position sensor with sensor slot in released position.
g. Record output signal of throttle position sensor with sensor slot in advanced position.
427-B0675
h. Expected Results. Throttle position sensor output is 10 percent or less in released position. Throttle position sensor
output is 90 percent or more in advanced position.
(1) If results are OK, operation of throttle position sensor is correct. Fault is caused by foot pedal or lever
assembly. Adjust or replace throttle pedal assembly (WP 0039 00). Verify repair eliminates problem.
(2) If results are NOT OK, throttle position sensor is faulty. Replace throttle position sensor (WP 0039 00).
Verify repair eliminates problem.
0013 00-25
TM 5-3805-290-23-1
ELECTRIC STARTING SYSTEM TEST 0013 00
NOTE
• All electrical starting systems have four elements: ignition switch, start relay, starting motor solenoid, and
starting motor.
• Engine start switches have capacity of 5 to 20 amperes. Start relay coil draws approximately 1 ampere
between test points. Start reply switch contacts for starting motor are rated between 100 and 300 amperes.
Start relay can easily switch load of 5 to 50 amperes for starting motor solenoid.
• Starting motor solenoid is switch with capacity of approximately 1,000 amperes. Starting motor solenoid sup-
plies power to starter drive. Starting motor solenoid also engages pinion to engine flywheel.
• Starting motor solenoid has two coils. Pull-in coil draws approximately 40 amperes. Hold-in coil requires
approximately 5 amperes.
• When magnetic force increases in both coils, pinion gear moves toward ring gear of flywheel. Then, solenoid
contacts close to provide power to starting motor. When solenoid contacts close, ground is temporarily
removed from pull-in coil. Battery voltage is supplied on both ends of pull-in coil while starting motor cranks.
During this period, pull-in coil is out of circuit.
• Engine cranking continues until current to solenoid is stopped by releasing engine start switch.
• Power available during cranking varies according to temperature and condition of batteries. Table 2 shows
voltages expected from battery at various temperature ranges.
Table 2. Typical Electrical System Voltage During Cranking at Various Ambient Temperatures.
TEMPERATURE VOLTAGE
-10 to 20°F
12 to 16V
(-23 to -7°C)
20 to 50°F
14 to 18V
(-7 to 10°C)
50 to 80°F
16 to 24V
(10 to 27°C)
NOTE
• Table 3 shows maximum acceptable loss of voltage in battery circuit. Battery circuit supplies high current to
starting motor. Values in Table 3 are for engines which have service of 2,000 hours or more.
• Voltage drops greater than the amounts in Table 3 are caused most often by loose connections, corroded con-
nections, and faulty switch contacts.
Table 3. Maximum Acceptable Voltage Drop in Starting Motor Circuit During Cranking.
Circuit 24V System

Battery post “-” to starting motor terminal “-” 1.4V
Drop across disconnect switch 1.0V
Battery post “+” to terminal of starting motor solenoid “+” 1.0V
Solenoid terminal “Bat” to solenoid terminal “Mtr” 0.8V
0013 00-26
TM 5-3805-290-23-1
ELECTRIC STARTING SYSTEM TEST - CONTINUED
CAUTION
• Do not crank engine for more than 30 seconds. Allow starter to cool for two minutes before cranking again.
• Never turn disconnect switch off while engine is running. Serious damage to electrical system can result.
• If starting motor does not crank or cranks slowly, perform the following procedure.
1. Measure voltage of battery. Measure voltage across battery posts with multimeter when cranking or attempting to crank
engine. Do not measure voltage across cable post clamps.
a. If voltage is equal or greater than voltage specified in Table 2, proceed to step 2.
b. If battery voltage is less than voltage specified in Table 3, low charge in battery can be caused by several condi-
tions: battery deterioration, shorted starting motor, faulty alternator, loose drive belts, or current leakage in another
part of electrical system. Refer to TM 9-6140-200-14, Operator’s, Unit and Direct Support and General Mainte-
nance Manual for Lead-Acid Storage Batteries to test battery.
2. Measure current sent to starting motor solenoid from positive post of battery.
NOTE
If these conditions exist, DO NOT perform test in step 3 because starting motor has problem:
a. Voltage at battery post is within 2V of lowest value in applicable temperature range of Table 3.
b. Large starting motor cables get hot.
a. Use ammeter to measure current. Place jaws of ammeter around cable connected to battery terminal. Amperage
should be no more than 85 Amps at 18V.
b. Current and voltages are measured at temperature of 80°F (27°C). When temperature is below 80°F (27°C), volt-
age will be lower through starting motor. When temperature is below 80°F (27°C), current through starting motor
will be higher. If current is too great, problem exists in starting motor. Replace starting motor (WP 0048 00).
c. If current is within specification, proceed to step 3.
3. Use multimeter to measure voltage of starting motor while cranking or attempting to crank engine.
a. If voltage is equal or greater than voltage given in Table 3, battery and starting motor cable to starting motor are
within specifications. Proceed to step 5.
b. If starting motor voltage is less than voltage specified in Table 3, voltage drop between battery and starting motor
is too great. Proceed to step 4.
4. Measure voltage drops in cranking circuits with multimeter. Compare results with voltage drops allowed in Table 3.
a. Voltage drops are equal to or less than voltage drops given in Table 3. Proceed to step 5 to check engine.
b. Voltage drops are greater than voltage drops given in Table 3. Replace wire in question (WP 0079 00).
5. Rotate crankshaft by hand to ensure crankshaft is not stuck.
a. If crankshaft is stuck or difficult to turn, proceed to step 6.
b. If engine is not difficult to turn, replace starter (WP 0048 00).
6. Check oil viscosity.
a. Pull oil level gage and determine if oil is dirty (TM 5-3805-290-10).
b. Refer to PMCS (WP 0020 00) to determine if correct grade oil was used for current climate.
c. If oil is dirty or incorrect grade, change engine oil and filter (WP 0025 00).
d. If problem still exists go to step 7.
0013 00-27
TM 5-3805-290-23-1
ELECTRIC STARTING SYSTEM TEST - CONTINUED

7. Perform these procedures one at a time. Between each procedure, attempt to rotate crankshaft. Stop performing these
procedures when crankshaft rotates freely and proceed to step g.
a. Remove V-belts (WP 0046 00).
b. Remove starter (WP 0048 00).
c. Remove water pump (WP 0045 00).
d. Remove fuel injection pump (WP 0164 00).
e. Remove gear pump braking and hydraulic fan (WP 0186 00).
f. Unbolt torque converter from engine without removing engine (WP 0145 00).
g. If engine is not difficult to turn after performing step a, replace the alternator (WP 0047 00) or AC compressor
(WP 0192 00).
h. If engine is not difficult to turn after performing steps b thru e, replace the component last removed.
i. If engine is not difficult to turn after performing step f, replace transmission (WP 0176 00).
j. If crankshaft is still stuck or difficult to turn, replace engine (WP 0145 00).
8. Attempt to crank starting motor.
a. If starting motor cranks slowly, replace starting motor (WP 0048 00).
NOTE
Blocked engagement and open solenoid contacts will give same electrical symptoms.
b. If starting motor does not crank, remove starter and check for blocked engagement of starting motor pinion gear
and flywheel ring gear (WP 0048 00).
0013 00-28
TM 5-3805-290-23-1
ELECTRICAL POWER SUPPLY CIRCUIT TEST 0013 00
NOTE
• ECM receives electrical power (battery voltage) through wiring supplied by engine harness. ECM input at
connector P1:70 (engine start switch) receives battery voltage from engine start switch when engine start
switch is in ON position or START position. When ECM detects battery voltage at this input, ECM will power
up. When battery voltage is removed from this input, ECM will power down.
• Cause of intermittent power supply to ECM can occur on either positive side (unswitched +battery) or nega-
tive side (-battery). Both sides are routed from ECM to battery. Three connections for unswitched +battery
should be routed through dedicated protection circuit.
• Engine ECM requires engine start switch to be in ON position (TM 5-3805-290-10) to maintain communica-
tions.
• For intermittent problems such as intermittent shutdowns that could be caused by engine wiring, temporarily
bypassing engine wiring may be effective means of determining cause. If symptoms disappear with bypass
wiring, engine wiring is cause of problem. Means of bypassing engine wiring is explained in this test proce-
dure.
427-B0676
0013 00-29
TM 5-3805-290-23-1
ELECTRICAL POWER SUPPLY CIRCUIT TEST - CONTINUED

1. Inspect electrical connectors and wiring.
a. Disconnect and thoroughly inspect harness connector J1/P1. Also inspect connections for battery and connections
to engine start switch. Refer to Electrical Connectors Inspection (WP 0022 00, WP 0077 00, WP 0053 00, and WP
0169 00).
b. Perform 10 lb (45 N) pull test on each wire in ECM connector associated with these connections:
(1) P1:48, P1:56, and P1:57 (unswitched +battery)
(2) P1:61, P1:68, and P1:69 (-battery)
(3) P1:70 (engine start switch)
427-B0703
c. Check ECM connector (socket-head screw) for proper torque of 55 lb-ft (6 Nm).
d. Check harness and wiring for abrasions and pinch points from battery to ECM. Also, check harness and wiring for
abrasions and pinch points from engine start switch to ECM.
e. Expected Results. All connectors, pins, and sockets should be completely connected and/or inserted. Harness and
wiring should be free of corrosion, abrasions, and pinch points.
are properly in place and connectors are securely connected.
0013 00-30
TM 5-3805-290-23-1

2. Check battery voltage at ECM
a. Disconnect engine harness connector P1 from
ECM connector J1 and insert breakout T (WP
0053 00).
b. Connect harness to breakout T and breakout T to
ECM.
c. Turn engine start switch to ON position (TM 5-
3805-290-10).
d. Measure voltage between P1:56 (unswitched
+battery) and P1:68 (-battery).
e. Measure voltage between P1:57 (unswitched
+battery) and P1:69 (-battery).
427-B0704
f. Expected Results. Measured voltage is between 22 and 27 VDC with no suspected intermittent problems at this
time.
(1) If results are OK, ECM is receiving correct voltage.
(2) If intermittent condition is suspected, refer to Electrical Connectors Inspection (WP 0022 00).
(3) If battery voltage is out of range, proceed to step 3.
(4) If there is intermittent or no voltage, proceed to step 4.
(5) If engine start switch voltage is out of range, trace wiring for engine start switch from ECM through
engine start switch circuit to batteries (WP 0210 00). Find problem and replace wiring harness in question
(WP 0169 00 thru WP 0175 00). Verify repair eliminates problem.
3. Check batteries.
a. Measure no-load battery voltage at battery posts.
b. Load test batteries. Refer to TM 9-6140-200-14, Operator’s, Unit and Direct Support and General Maintenance
Manual for Lead-Acid Storage Batteries.
c. Expected Results. Batteries pass load test. Measured voltage is within specification.
(1) If results are OK, replace wiring harness in question (WP 0169 00 thru WP 0175 00). Ensure all seals are
properly connected.
(2) If results are NOT OK, recharge or replace faulty batteries (WP 0077 00). Verify repair eliminates prob-
lem.
0013 00-31
TM 5-3805-290-23-1

4. Use bypass harness and adapter for MSD to bypass machine wiring.
13
WARNING
13
13
CAUTION
Do not connect bypass harness to battery until 20-Amp inline fuse has been removed from +battery line. If
fuse is not removed before connection to battery, spark may result.
NOTE
This bypass harness is only for test applications. This bypass harness may only be left only on engine tem-
porarily. The bypass harness can be used to determine if cause of intermittent problem is interruptions in
battery power to ECM or engine start switch circuit.
b. Disconnect harness connector J1/P1 from ECM (WP 0053 00).
c. Connect bypass harness and adapter to ECM connector J1.
d. Remove inline fuse from +battery wire of bypass harness. Connect unswitched +battery wire and -battery wire
directly to battery posts.
NOTE
This bypass directly connects circuit for engine start switch to ECM. The ECM will remain powered until
connection to unswitched +battery line is disconnected from battery post. Remove 20-Amp fuse from inline
fuse holder to power down ECM. Do not connect bypass to battery posts without first removing 20-Amp
inline fuse. Do not remove bypass from battery posts without first removing 20-Amp inline fuse.
e. Connect MSD to bypass harness data link connector. Turn engine start switch to ON position (TM 5-3805-290-10)
and verify communication is established.
f. Restore all wiring to original condition after testing.
427-B0683
0013 00-32
TM 5-3805-290-23-1
g. Expected Results. Installing bypass eliminates problem.
(1) If results are OK, symptoms disappear when bypass harness is installed. Also, symptoms return when
bypass harness is removed. Problem is in wiring that supplies power to ECM. Replace wiring harness that
supplies power to ECM (WP 0169 00 thru WP 0175 00).
(2) If results are NOT OK, replace engine ECM. Remove all jumpers and reconnect all connectors. Recheck
system for active diagnostic codes (WP 0053 00). Verify repair eliminates problem.
ENGINE PRESSURE SENSOR OPEN OR SHORT CIRCUIT TEST 0013 00
NOTE
• Perform this procedure when there is active fault for oil pressure sensor or boost sensor.
• Troubleshooting procedures for diagnostic codes of each pressure sensor are identical. Pressure sensors are
sensors that have three terminals. Pressure sensors are active sensors. Active sensors require supply voltage
from ECM. ECM connector J1/P1 terminal 26 supplies + 5V to terminal A of each sensor. ECM connector J1/
P1 terminal 34 is common connection for pressure sensors. Sensor common connection is shared between all
pressure sensors. Common line is connected to each sensor connector terminal B. Signal voltage from terminal
C of each sensor is supplied to appropriate terminal at ECM connector J1/P1.
• Use this procedure for these diagnostic codes:
a. 100-03 Engine Oil Pressure Sensor Open Circuit

b. 100-04 Engine Oil Pressure Sensor Short Circuit
c. 102-03 Boost Pressure Sensor Open Circuit
d. 102-04 Boost Pressure Sensor Short Circuit
• These diagnostic codes should not be active:
a. 262-03 5V Sensor dc Power Supply Short to +Batt

b. 262-04 5V Sensor dc Power Supply Short to Ground
427-B0667
0013 00-33
TM 5-3805-290-23-1
ENGINE PRESSURE SENSOR OPEN OR SHORT CIRCUIT TEST - CONTINUED
1. Check for active +5V sensor supply diagnostic codes.

a. Connect MSD to diagnostic connector (WP 0006 00).
b. Turn engine start switch to ON position (TM 5-3805-290-10). Wait at least 15 seconds for activation of diagnostic
codes.
c. Verify any of these diagnostic codes are active:
(1) 262-03 5V Sensor dc Power Supply Short to +Batt
(2) 262-04 5V Sensor dc Power Supply Short to Ground
d. Expected Results. One or more diagnostic codes listed in step c are active.
(1) If results are as specified, perform 5V Engine Pressure Sensor Supply Circuit Test in this work package.
(2) If results are not as specified, proceed to step 2.
2. Verify all active diagnostic codes.
a. Turn engine start switch to ON position (TM 5-3805-290-10). Wait at least 15 seconds for activation of diagnostic
codes.
b. Verify any of these diagnostic codes are active:
(1) 100-03 Engine Oil Pressure Open Short to +Batt
(2) 100-04 Engine Oil Pressure Short to Ground
(3) 102-3 Boost Pressure Open Short to +Batt
(4) 102-4 Boost Pressure Short to Ground
NOTE
These diagnostic codes should not be active:
a. 262-03 5V Sensor dc Power Supply Short to +Batt

b. 262-04 5V Sensor dc Power Supply Short to Ground
c. Expected Results. One or more diagnostic codes listed in step b are active.
(1) If results are as specified, proceed to step 3.
(2) If codes are logged but not active and engine is not running properly, refer to Troubleshooting Without a
Diagnostic Code (WP 0008 00). If engine is running properly at this time, an intermittent condition may be
causing logged codes. Refer to Electrical Connectors Inspection (WP 0022 00).
3. Inspect electrical connectors and wiring.
a. Disconnect and thoroughly inspect these terminal connections on P1 ECM connector (WP 0053 00). Refer to Elec-
trical Connectors Inspection (WP 0022 00):
(1) P1:14 Boost Pressure
(2) P1:24 Engine Oil Pressure
(3) P1:26 +5V
(4) P1:34 Sensor Common
0013 00-34
TM 5-3805-290-23-1

b. Disconnect and thoroughly inspect these engine pressure sensors. Refer to Electrical Connectors Inspection (WP
0022 00):
(1) J1/P1 ECM Engine Harness Connector (WP 0053 00).
(2) J20/P20 Machine Interface Connector (WP 0170 00).
(3) J200/P200 Boost Pressure Sensor (WP 0065 00).
(4) J201/P201 Engine Oil Pressure Sensor (WP 0066 00).
c. Reconnect all connectors.
d. Perform 10 lb (45 N) pull test on each wire in
ECM connector and sensor connectors associ-
ated with active diagnostic code.
e. Check ECM connector (socket-head screw) for
proper torque of 55 lb-in. (6 Nm).
f. Check harness and wiring for abrasions and
pinch points from sensors back to ECM.
427-B0668
g. Expected Results. All connectors, pins, and sockets should be securely connected and inserted. Harness and wiring
should be free of corrosion, abrasions, and pinch points.
(1) If results are OK, proceed to step 4.
are properly in place and connectors are securely connected. Verify repair eliminates problem. Use MSD
to clear all logged diagnostic codes.
4. Verify diagnostic code is still active.
codes.
b. Use MSD to check for active diagnostic codes. Record all active diagnostic codes.
c. Determine if problem is related to open circuit diagnostic code or short circuit diagnostic code.
d. Expected Results. Either short circuit diagnostic code is active or open circuit diagnostic code is active.
(1) If short circuit diagnostic code is active, proceed to step 5.
(2) If open circuit diagnostic code is active, proceed to step 6.
0013 00-35
TM 5-3805-290-23-1
5. Disconnect sensor to create open circuit (WP 0065 00 or WP 0066 00).
b. Disconnect sensor connector of sensor with short circuit diagnostic code.
c. Turn engine start switch to ON position (TM 5-3805-290-10). Wait at least 15 seconds for activation of diagnostic
codes.
d. Use MSD to check Active Diagnostic Code screen. Check for open circuit diagnostic code.
e. Expected Results. Open circuit diagnostic code for disconnected sensor is now active.
(1) If results are OK, short circuit diagnostic code was active before disconnecting sensor. Open circuit diag-
nostic code became active after disconnecting sensor. Proceed to step 7.
(2) If results are NOT OK, a short circuit exists between sensor harness connector and ECM. Leave sensor
disconnected. Proceed to step 9.
6. Measure sensor supply voltage.
b. Disconnect sensor from engine harness.
c. Connect a 3-terminal breakout T to engine harness only. DO NOT connect sensor to breakout T.
d. Turn engine start switch to ON position (TM 5-3805-290-10).
e. Measure voltage from terminal A (5V supply) to terminal B (sensor common).
427-B0709
f. Expected Results. The dc voltage from terminal A to terminal B measures 4.5 to 5.5 VDC.
(1) If results are OK, sensor supply voltage is correct. Remove breakout T. Proceed to step 8.
(2) If results are NOT OK, sensor supply voltage is out of expected range. Continue testing sensor supply cir-
cuit. Perform 5V Engine Pressure Sensor Supply Circuit Test in this work package.
0013 00-36
TM 5-3805-290-23-1
7. Determine if short circuit is in connector or sensor.

a. Thoroughly inspect connector for moisture.
b. Inspect seals and reconnect sensor.
c. Refer to Electrical Connectors Inspection (WP 0022 00).
d. If short circuit diagnostic code reappears, sensor or pigtail harness connector is problem. Replace sensor (WP 0065
00 or WP 0066 00).
e. Use MSD to verify there is short circuit diagnostic code. New sensor should be connected to harness at this time.
f. Expected Results. Short circuit diagnostic code is not present when new sensor is connected.
(1) If results are OK, replace sensor (WP 0065 00 or WP 0066 00) verify repair eliminates problem. Use MSD
to clear logged diagnostic codes.
(2) If results are NOT OK, replace engine harness connector (WP 0170 00).
8. Create short circuit between signal and common terminals at engine harness connector.
b. Use jumper wire 6 in. (15 cm) long.
NOTE
Monitor Active Diagnostic Code screen of MSD before and after installing jumper wire.
c. Install jumper on engine harness connector. Install one end of jumper at sensor signal (terminal C). Install other
end of jumper at common connection for pressure sensor (terminal B). Wait at least 15 seconds for activation of
short circuit diagnostic code.
d. Expected Results. Short circuit diagnostic code is active when jumper is installed. Open circuit diagnostic code is
active when jumper is removed.
(1) If results are OK, engine harness and ECM are OK. Replace suspect sensor (WP 0065 00 or WP 0066 00).
Use MSD to verify repair eliminates problem.
(2) If results are NOT OK, open circuit diagnostic code remains active when jumper is installed. Most proba-
ble location for open is in sensor common or sensor signal wire in engine harness between ECM and sen-
sor. Remove jumper. Proceed to step 9.
9. Check operation of ECM by creating open and short circuits at ECM connector.
b. Disconnect J1/P1 ECM connector (WP 0053 00). Thoroughly inspect both halves of connectors for signs of corro-
sion or moisture.
c. Refer to Electrical Connectors Inspection (WP 0022 00).
d. Reconnect J1/P1 ECM connector.
e. Turn engine start switch to ON position (TM 5-3805-290-10). Monitor Active Diagnostic Code screen of MSD.
Wait at least 15 seconds for activation of code.
f. Open circuit diagnostic code should be active for suspect sensor.
0013 00-37
TM 5-3805-290-23-1
NOTE
When engine harness is disconnected, all open circuit diagnostic codes for pressure sensors will be active.
This is normal. Disregard diagnostic codes for other pressure sensors. Check diagnostic codes for suspect
sensor only.
g. Turn engine start switch to OFF position (TM 5-3805-290-10).
h. Use jumper wire 6 in. (15 cm) long.
i. Install jumper wire on ECM connector J1. Insert jumper wire between terminal for suspect sensor signal and com-
mon connection for engine’s pressure sensor (terminal 3).
j. Use MSD to verify there is short circuit diagnostic code active.
427-B0709
k. Expected Results. Open circuit diagnostic codes and short circuit diagnostic codes are active.
(1) If results are OK, ECM is operating properly. Proceed to step 10.
(2) If results are NOT OK, one of these conditions exists: open circuit diagnostic code is not active when har-
ness is disconnected on short circuit diagnostic code is not active when jumper wire is installed. Perform
this repair:
(a) Remove all jumpers and replace all connectors.
(b) Replace ECM (WP 0053 00). Verify repair eliminates problem.
0013 00-38
TM 5-3805-290-23-1

10. Bypass harness wiring between ECM and sensor con-
nector.
3805-290-10).
b. Disconnect J1/P1 ECM connector and sensor
c. Remove sensor signal wire from ECM connec-
tor.
d. Remove signal wire (terminal C) from sensor
connector on engine harness.
427-B0668
NOTE
Use a jumper wire with the correct connectors on each end that is long enough to reach from ECM to sen-
sor connector.
e. Insert jumper wire into P1 ECM connector on engine harness. Insert other end into sensor connector of engine har-
ness.
f. Reconnect J1/P1 ECM engine connector and sensor connector.
g. Turn engine start switch to ON position (TM 5-3805-290-10).
h. Use MSD to monitor Active Diagnostic Code screen for either open circuit diagnostic code for sensor or short cir-
cuit diagnostic code for sensor.
i. Expected Results: Diagnostic code disappears when jumper or bypass is installed.
(1) If results are OK, there is problem in wiring harness. Perform this repair:
(a) Replace wiring harness in question (WP 0169 00 thru WP 0175 00).
(b) Clear all diagnostic codes.
(c) Use MSD to verify repair eliminates problem.
(2) If results are NOT OK, repeat this entire test and carefully perform each step.
0013 00-39
TM 5-3805-290-23-1
ENGINE SPEED/TIMING SENSOR CIRCUIT TEST 0013 00
NOTE
• Use this test to troubleshoot system if there is active diagnostic code or easily repeated diagnostic code associ-
ated with engine speed/timing sensors.
• Engine uses two engine speed/timing sensors. One sensor is located in cylinder block. Speed/timing sensor
mounted on cylinder block measures crankshaft speed and calculates position of crankshaft. ECM counts
time between pulses created by sensor as gear rotates to determine rpm.
• Second speed/timing sensor is located in fuel injection pump. Speed/timing sensor measures speed and posi-
tion of fuel injection pump.
• ECM uses both sensor signals to calculate engine speed and correct engine timing.
• Engine will start and run when only one sensor signal is present from either sensor. Loss of signal from both
sensor during engine operation will result in termination of injection and shutting down of engine by ECM.
Loss of signal from both sensor during start-up will prevent engine from starting.
1. Inspect electrical connectors and cables. Refer to WP 0067 00 and WP 0053 00. Refer to Electrical Connectors Inspec-
tion (WP 0022 00).
b. Inspect electrical connectors for damage.
c. Expected Results. Electrical system is free from damage and faults.
(1) If results are OK, there is no damage or faults. Proceed to step 2.
(2) If results are NOT OK, there is damage to electrical system components.
(a) Replace wiring harness in question (WP 0169 00 thru WP 0175 00).
(b) Ensure all seals are in place and connectors are correctly installed.
(c) Verify repair has eliminated fault. If fault is not eliminated, proceed to step 2.
2. Check installation of engine speed/timing sensors.

3805-290-10).
b. Refer to Electrical Connectors Inspection (WP

0022 00).
c. Engine speed/timing sensor must be installed

with metal plate flat against cylinder block to
work properly.
d. Ensure O-rings have been installed on sensor

properly and are not damaged (WP 0067 00).
427-B0711
e. Install and reconnect sensors.
0013 00-40
TM 5-3805-290-23-1
ENGINE SPEED/TIMING SENSOR CIRCUIT TEST - CONTINUED 0013 00

f. Expected Results. Electrical connectors and cables are properly installed.
(1) If results are OK, electrical connectors and cables are properly installed. Proceed to step 3.
(2) If results are NOT OK, complete these tasks when sensors are being installed:
(a) Lubricate O-ring with oil.
(b) Ensure sensor has connector face seal inside connector body. If seal is damaged or missing, replace
wiring harness in question (WP 0169 00 thru WP 0175 00).
(c) Ensure sensor is fully seated in engine before tightening bracket bolt (WP 0067 00).
(d) Ensure connector is latched on both sides.
(e) Ensure harness is properly secured and attached to harness clip.
(f) Verify repair has eliminated fault.
427-B0710
0013 00-41
TM 5-3805-290-23-1
ENGINE SPEED/TIMING SENSOR CIRCUIT TEST - CONTINUED

3. Measure sensor resistance through wiring harness.
427-B0712

b. Disconnect P1 ECM connector (WP 0053 00).
c. Use multimeter to measure resistance of sensor from 41 terminal to 49 terminal.
d. Wiggle cables associated with engine speed/timing sensor while resistance is measured to check for an intermittent
open or short circuit. Resistance should be 75 to 230 Ohms
e. Expected Results. Readings agree with values listed in step d.
(1) If results are OK, neither short circuit nor open circuit is indicated. Proceed to step 5.
(2) If results are NOT OK, resistance is not within acceptable range when circuit resistance is measured
through engine harness. Reconnect and proceed to step 4.
4. Measure resistance of sensor.
b. Check harness and wiring for abrasions and pinch points from sensor back to ECM.
c. Disconnect P401 engine speed/timing sensor connector (WP 0067 00).
d. Thoroughly inspect J401/P401 engine speed/timing sensor connector. Refer to Electrical Connectors Inspection
(WP 0022 00). Resistance should be 75 to 230 Ohms.
e. Expected Results. Readings agree with values listed in step d.
(1) If results are OK, sensor resistance is within tolerance. There is fault in cable between P1 ECM connector
and P401 connector. Replace wiring harness in question (WP 0169 00 thru WP 0175 00). Verify repair has
eliminated faults.
(2) If results are NOT OK, sensor resistance is out of range. Perform this procedure to check and install new
sensor:
(a) Before installing new sensor, measure resistance of new sensor.
(b) If new sensor resistance is in correct range, install new sensor in engine (WP 0067 00).
(c) Ensure O-ring is installed and free of damage.
(d) Seat sensor and tighten setscrew. If sensor will not seat, replace sensor (WP 0067 00), as required.
(e) Ensure sensor is properly oriented and harness is secured in proper location.
(f) Verify repair eliminates problem.
0013 00-42
TM 5-3805-290-23-1

5. Measure resistance of cables between fuel injection pump and ECM.
427-B0676
0013 00-43
TM 5-3805-290-23-1
427-B0710
427-B0713
427-B1537

b. Disconnect P1 ECM connector and P40 fuel injection pump connector (WP 0053 00 and WP 0164 00).
c. Measure resistance from terminal 59 engine speed/timing sensor at ECM to terminal 8 engine speed/timing sensor
of P40 fuel injection pump connector. Resistance should be less than 2 Ohms.
d. Reconnect all connectors.
e. Expected Results. Readings agree with values listed in step c.
(1) If results are OK, ECM does not operate properly. Perform this repair on suspect ECM:
(2) If results are NOT OK, readings are higher than 2 Ohms. Proceed to step 6.
6. Check continuity of cables from ECM to fuel injection pump.
b. Disconnect J1/P1ECM connector and J40/P40 fuel injection pump connector (WP 0053 00 and WP 0164 00).
0013 00-44
TM 5-3805-290-23-1

c. Perform continuity test between P40:8 fuel injection pump connector and these terminals:
(1) P40:1
(2) P40:2
(3) P40:5
(4) P40:6
(5) P40:7
d. Expected Results. Continuity check is positive.
(1) If results are OK, there is fault with
cables between fuel injection pump and/
or ECM. Replace wiring harness in ques-
tion (WP 0169 00 thru WP 0175 00).
Verify repair eliminates problem.
(2) If results are NOT OK, ECM is suspect.
(a) Replace engine ECM (WP 0053
00).
(b) Verify repair eliminates problem.
427-B1537
0013 00-45
TM 5-3805-290-23-1
ENGINE TEMPERATURE SENSORS OPEN OR SHORT CIRCUIT TEST 0013 00
NOTE
• Use this test to troubleshoot system only when there is active diagnostic code or when diagnostic code can eas-
ily be activated. This procedure covers open circuit diagnostic codes and short circuit diagnostic codes that
are associated with these sensors:
a. Coolant temperature sensor

b. Inlet manifold temperature sensor
• Troubleshooting procedures for diagnostic codes of each temperature sensor are identical. Temperature sen-
sors are sensors that have two terminals. Temperature sensors do not require supply voltage from ECM.
ECM connector J1/P1 terminal 34 is common connection for engine temperature sensors. Sensor common
connection is shared between all temperature sensors. Common line is connected to each sensor connector ter-
minal 2. Terminal 1 is sensor output. Signal voltage from terminal 1 of each sensor is supplied to appropriate
terminal at ECM Connector J1/P1.
427-B0715
427-B0716
0013 00-46
TM 5-3805-290-23-1
ENGINE TEMPERATURE SENSORS OPEN OR SHORT CIRCUIT TEST - CONTINUED

1. Verify all active diagnostic codes.
a. Connect MSD to cab data link connector (WP 0006 00).
b. Turn engine start switch to ON position (TM 5-3805-290-10). Wait at least 15 seconds for activation of diagnostic
codes.
c. Use MSD to verify if any of these diagnostic codes are active:
(1) 105-03 Inlet Manifold Temperature Sensor Open/Short to +Batt
(2) 105-04 Inlet Manifold Temperature Sensor Short to Ground
(3) 110-03 Engine Coolant Temperature Open/Short to +Batt
(4) 110-04 Engine Coolant Temperature Short to Ground
d. Expected Results. One or more diagnostic codes listed in step c are active.
(1) If one or more diagnostic codes are active, proceed to step 2.
(2) If codes are logged but not active and engine is not running properly, refer to Troubleshooting Without a
Diagnostic Code (WP 0008 00). If engine is running properly at this time, an intermittent condition may be
causing logged codes. Refer to Electrical Connectors Inspection (WP 0022 00).
2. Inspect electrical connectors and wiring. Refer to

Electrical Connectors Inspection (WP 0022 00).
a. Disconnect Engine ECM from wiring harness
(WP 0053 00).
b. Thoroughly inspect ECM engine harness con-
nector J1/P1 and suspect sensor connector.
c. Perform 10 lb (45 N) pull test on each wire in
sensor connector and ECM connector associated
with active diagnostic code.
d. Verify connector latch tab is properly latched
and has returned to fully latching position.
e. Check ECM connector (socket-head screw) for
427-B0717
proper torque of 55 lb-in. (6 Nm).
f. Check harness and wiring for abrasions and
pinch points from sensor to ECM.
g. Connect engine ECM to wiring harness (WP
0053 00).
h. Expected Results. All connectors, pins, and sockets should be completely coupled and/or inserted. Harness and
wiring should be free of corrosion, abrasions, and pinch points.
are properly in place and connectors are completely coupled. Clear all inactive diagnostic codes. Verify
repair has eliminated problem. Proceed to step 3 if fault has not been eliminated.
3. Verify diagnostic code is still active.
codes.
b. Access Active Diagnostic Code screen on MSD and check for active diagnostic codes.
c. Determine if problem is related to open circuit diagnostic code or short circuit diagnostic code.
0013 00-47
TM 5-3805-290-23-1

d. Expected Results. Short circuit diagnostic code or open circuit diagnostic code is active.
(1) If short circuit diagnostic code is active, proceed to step 4.
(2) If open circuit diagnostic code is active, proceed to step 5.
4. Disconnect sensor to create open circuit (WP 0063 00 and WP 0064 00).
b. Disconnect sensor connector of sensor with short circuit diagnostic code.
c. Turn engine start switch to ON position (TM 5-3805-290-10). Wait at least 15 seconds for activation of diagnostic
codes.
d. Access Active Diagnostic Code screen of MSD. Check for active open circuit diagnostic code.
427-B0676
e. Expected Result. Open circuit diagnostic code for disconnected sensor is now active.
(1) If results are OK, short circuit diagnostic code was active before disconnecting sensor. Open circuit diag-
nostic code became active after disconnecting sensor. Refer to Electrical Connectors Inspection (WP 0022
00).
(a) Inspect connector seals for damage.
(b) Connect sensor and verify fault returns. If fault returns, sensor is faulty.
(c) Replace sensor (WP 0063 00 or WP 0064 00).
0013 00-48
TM 5-3805-290-23-1

(d) Remove all inactive diagnostic fault codes.
(2) If results are NOT OK, a short circuit exists between sensor harness connector and ECM. Leave sensor
disconnected. Proceed to step 6.
5. Create short circuit between signal and common terminals at sensor harness connector.
a. Turn engine start switch to ON position (TM 5-3805-290-10). Wait at least 15 seconds for activation of any diag-
nostic fault codes. Monitor Active Diagnostic Code screen on MSD before and after installing jumper wire.
b. Monitor Active Diagnostic Code screen on MSD before and after installing jumper wire.
c. Use jumper wire 6 in. (15 cm) long with correct terminals installed on both ends of wire.
d. Install jumper on back of engine harness connector. Install one end of jumper at sensor signal (positive terminal).
Install other end of jumper at common connection for engine temperature sensor (terminal 2). Wait at least 15 sec-
onds for activation of short circuit diagnostic code.
e. Expected Results. Short circuit diagnostic code is active when jumper is installed. Open circuit diagnostic code is
(1) If results are OK, engine harness and ECM are OK. Perform these repairs:
(a) Replace sensor (WP 0063 00 or WP 0064 00).
(b) Verify repair eliminates problem.
(c) Clear all inactive diagnostic codes.
(2) If results are NOT OK, an open circuit diagnostic code remains active with jumper in place. Most probable
location for open is in sensor common or sensor signal wire in engine harness between ECM and sensor.
Remove jumper. Proceed to step 6.
427-B2075
0013 00-49
TM 5-3805-290-23-1

6. Check ECM operation by creating open and short circuits at ECM connector.
3805-290-10).
b. Disconnect J1/P1 ECM connector (WP 0053 00).
c. Disconnect connector for ECM harness. Inspect
both halves of connector for corrosion or mois-
ture. Refer to Electrical Connectors Inspection
(WP 0022 00).
d. Turn engine start switch to ON position (TM 5-
3805-290-10). Use MSD to monitor Active
Diagnostic Code screen. Wait at least 15 seconds
for activation of code.
427-B0717
e. Expected Results. Open circuit diagnostic code should be active for suspect sensor.
NOTE
When engine harness is disconnected, all open circuit diagnostic codes for pressure sensors will be active.
This is normal. Disregard diagnostic codes for pressure sensors.
f. Turn engine start switch to OFF position (TM 5-3805-290-10).
g. Use jumper wire 6 in. (15 cm) long with correct terminals on both ends of wire.
h. Install jumper on back of engine harness connector. Install one end of jumper at sensor signal on bypass harness.
Install other end of jumper at terminal 34 common connection for bypass harness. Wait at least 15 seconds for acti-
vation of short circuit diagnostic code. Monitor Active Diagnostic Code screen on MSD before and after installing
jumper wire.
i. Expected Results. Short circuit diagnostic code is active when jumper is installed. Open circuit diagnostic code is
(1) If results are OK, use MSD to clear logged diagnostic codes. Proceed to step 7.
(2) If results are NOT OK, ECM does not operate correctly.
(b) Replace engine ECM (WP 0053 00).
0013 00-50
TM 5-3805-290-23-1
7. Bypass harness wiring between ECM and sensor connector.
b. Disconnect J1/P1connector for ECM harness and suspect sensor connector (WP 0053 00).
c. Remove sensor signal wire from P1 ECM connector.
d. Remove signal wire (positive terminal) from sensor connector on engine harness.
e. Use jumper wire long enough to reach from ECM to sensor connector with correct terminals on both ends of wire.
f. Insert one end of jumper into ECM connector. Insert other end of jumper into sensor connector of engine harness.
g. Reconnect connector for ECM harness and sensor connector (WP 0063 00, WP 0064 00, and WP 0053 00).
h. Turn engine start switch to ON position (TM 5-3805-290-10).
i. Use MSD to monitor Active Diagnostic Code

screen for either open circuit diagnostic code for
sensor or short circuit diagnostic code for sensor.
j. Expected Results. Diagnostic code disappears
when jumper is installed.
If results are OK, a problem exists in wiring harness.
Perform this repair:
(a) Replace wiring harness in question
(WP 0169 00 thru WP 0175 00).
(b) Clear all diagnostic codes.
427-B0717
FUEL INJECTION PUMP CIRCUIT TEST 0013 00
NOTE
• Use this test if pump is not serviceable or any of these diagnostic codes are active:
a. 1684-04 Fuel Injection Pump Short to Ground.

b. 174-02 Fuel Temperature Sensor Data Erratic plus 342-02 Loss of Secondary Engine Speed
Signal.
• Fuel injection pump receives electrical supply from OEM cables and from relay for fuel pump through
machine interface connector.
• Loss of power to fuel injection pump can occur on either positive or negative side. Positive side is supplied
from pump power relay to fuel injection pump. Positive supply includes fuse to protect circuit. Negative side is
connected directly to battery.
0013 00-51
TM 5-3805-290-23-1
FUEL INJECTION PUMP CIRCUIT TEST - CONTINUED
427-B0676
427-B0719
0013 00-52
TM 5-3805-290-23-1

1. Check batteries. Measure no-load battery voltage at battery terminals.
Expected Results. The battery voltage is no less 22V.
(2) If results are NOT OK, recharge or replace batteries (WP 0077 00). Verify repairs have eliminated prob-
lem.
a. Thoroughly inspect P40:6 Pump Supply (-) and P40:7 Pump Supply (+) terminal connections on fuel pump control
connector.
427-B0720
b. Disconnect and thoroughly inspect these terminal connections on P20/J20 Machine Interface Connector and per-
form 10 lb (45 N) pull test on each wire in MIC (WP 0170 00):
(1) P20: 58 (-) Batt Machine
(2) P20: 48 (+) Batt Machine
(3) P20: 42 Pump Power Control
c. Check ECM connector (socket-head screw) for proper torque of 55 lb-in. (6 Nm).
d. Check harness and wiring for abrasions and pinch points from battery to ECM. Also check harness and wiring for
abrasions and pinch points from engine start switch to ECM.
427-B0721
0013 00-53
TM 5-3805-290-23-1

e. Reconnect P20 (WP 0170 00).
f. Expected Results. All connectors, pins, and sockets are securely connected and/or inserted. Harness and wiring are
free of corrosion, abrasions, and pinch points.
(2) If results are NOT OK, there is problem with wiring or connectors. Replace wiring harness in question
(WP 0169 00 thru WP 0175 00). Verify repair has eliminated problem.
3. Check output voltage from fuel injection pump power relay.
b. Disconnect fuel pump relay (WP 0054 00).
c. Measure voltage between test point D on fuel injection pump power relay and engine ground and test point B and
engine ground.
e. Turn engine start switch to OFF position (TM 5-3805-290-10).
f. Reconnect fuel pump relay (WP 0054 00).
g. Expected Results. Measured voltage is between 22 and 27 VDC with no suspected intermittent problems at this
time.
(1) If results are OK, voltage is correct. Proceed to step 4.
(2) If there is intermittent voltage or no voltage, proceed to step 5.
4. Check supply voltage at fuel pump control.
b. Disconnect P40 connector from fuel pump control (WP 0164 00).
d. Measure voltage between P40:7 Pump Supply (+) and engine ground.
0013 00-54
TM 5-3805-290-23-1

e. Reconnect fuel pump (WP 0164 00).
f. Expected Results. Measured voltage is between 22 and 27 VDC with no suspected intermittent problems at this
time.
(1) If results are OK, verify wire on P40:6 (-) Pump Supply has continuity to negative battery.
(a) Wiring harness and voltage supply to fuel pump control are correct. Problem is in fuel injection pump
or there is communication problem between ECM and fuel injection pump. Refer to CAN Data Link
Circuit Test in this work package.
(b) If CAN data link is correct, problem is in fuel injection pump. Replace fuel injection pump (WP 0164
00) and verify problem has been eliminated.
NOTE
Voltage Load Protection Module (VLPM) should also be replaced when fuel injection pump is replaced.
427-B0676
0013 00-55
TM 5-3805-290-23-1
(2) If intermittent voltage or voltage is out of range, there is problem in wiring between fuel injection pump
power relay and fuel pump control. Perform these steps:
(a) Turn engine start switch to ON position (TM 5-3805-290-10).
(b) Measure voltage between engine ground and 1 (+) Batt Machine on VLPM.
(c) If voltage is not present at 1 (+) Batt Machine of VLPM, measure voltage from P20:48 (+) Batt
Machine of MIC to engine ground.
(1) If voltage is present on P20:48 (+) Batt Machine of MIC, repair wire between P20:48 (+) Batt
Machine of MIC and 1 (+) Batt Machine of VLPM (WP 0022 00).
(2) If voltage is not present on P20:48 (+) Batt Machine of MIC, repair wire between test point B of
fuel injection pump power relay and P20:48 (+) Batt Machine of MIC (WP 0022 00).
(d) If voltage is present at 1 (+) Batt Machine of VLPM, measure voltage from 2 (+) Batt Pump of VLPM
to engine ground.
(e) If voltage is present on 2 (+) Batt Pump of VLPM, repair wire between 2 (+) Batt Pump of VLPM and
P40:7 Pump Supply (+) of fuel pump control.
(f) If voltage is not present on 2 (+) Batt Pump of VLPM, proceed to step 7.
5. Check voltage from coil of fuel injection pump power relay to ECM.
b. Disconnect wire from test point D on fuel injection pump power relay (WP 0054 00).
427-B0721
d. Measure voltage between test point D and engine ground.

e. Turn engine start switch to OFF position.
f. Connect wire on test point D of fuel injection pump power relay.
g. Expected Results. Measured voltage is between 22 and 27 VDC with engine start switch in ON position and at
0 VDC with engine start switch in OFF position.
(1) If result is OK, voltage was present on test point D of fuel injection pump power relay.
0013 00-56
TM 5-3805-290-23-1

(a) Verify voltage is present at test point A on fuel injection pump power relay. If voltage is not present on
test point A on fuel injection pump power relay, verify fuse is not blown and/or repair wiring between
test point A and +battery.
(b) If voltage is present at test point A, proceed to step 6.
(2) If result is NOT OK, voltage was not present on test point D of fuel injection pump power relay.
(a) Measure voltage at test point C of fuel injection pump power relay. If voltage is present on test point C
of fuel injection pump power relay, replace fuel injection pump power relay (WP 0054 00).
(b) If voltage is not present on test point C of fuel injection pump power relay, verify fuse is not blown
and/or repair wiring between test point C and +battery by replacing wiring harness in question (WP
0169 00 thru WP 0175 00).
6. Check sinking driver for fuel injection pump power relay at ECM.
b. Disconnect ECM connector P1 (WP 0053 00).
c. Remove wire from ECM connector P1:42 pump power control. Install jumper wire into socket for P1:42 Pump
Power Control.
d. Connect multimeter between wire jumper in P1:42 Pump Power Control and +battery terminal.
f. Measure voltage between wire jumper in P1:42 Pump Power Control and +battery terminal.
g. Turn engine start switch to OFF position.
h. Remove jumper wire from P1:42 Pump Power Control.
i. Connect P1 (WP 0053 00).
j. Expected Results. Measured voltage is between 22 and 27 VDC with engine start switch in ON position and at
0 VDC with engine start switch in OFF position.
(1) If result is OK, sinking driver for fuel injection pump power relay is operating correctly. Repair wire
between P1:42 Pump Power Control and test point D on fuel injection pump power relay, by replacing wir-
ing harness in question (WP 0169 00 thru WP 0175 00). Problem may be at P20:42 Pump Power Control
of machine interface connector. Connect wire that was removed from P1:42 Pump Power Control. Recon-
nect ECM connector P1.
(2) If result is NOT OK, sinking driver for fuel injection pump power relay is not operating correctly. If prob-
lem is resolved, replace ECM (WP 0053 00).
0013 00-57
TM 5-3805-290-23-1

7. Check VLPM located above engine ECM.
a. Check 30 A auxiliary circuit breaker to see if it has been tripped (TM 5-3805-290-10).
NOTE
Use this test to verify VLPM has correct resistance. Also use this procedure if there is problem with tripped
auxiliary breaker. A faulty VLPM may be cause of problem.
b. Disconnect VLPM connector.
c. Measure resistance between 1 (+) Batt Machine and 2 (+) Batt Pump of VLPM.
d. Measure resistance between 3 Ground Pump and 4 (-) Batt Pump of VLPM.
e. Expected Results. Resistance is less than 1 Ohm between 1 (+) Batt Machine and 2 (+) Batt Pump. Resistance is
less than 1 Ohm between 3 Ground Pump and 4 (-) Batt Pump. Resistance is greater than 10 Ohm between 2 (+)
Batt Pump and 3 Ground Pump.
NOTE
Resistance between 2 (+) Batt Pump and 3 Ground Pump may differ. This is OK.
427-B0722
(1) If result is OK, VLPM is functioning properly.

(2) If result is NOT OK, replace fuel injection pump (WP 0164 00).
f. Replace VLPM if injection pump is replaced.
0013 00-58
TM 5-3805-290-23-1
FUEL TRANSFER PUMP CIRCUIT TEST 0013 00
NOTE
• Perform this procedure to check voltage for fuel transfer pump and to check operation of fuel transfer pump.
• ECM controls operation of fuel transfer pump through pump relay and P1:31.
427-B0724
427-B0900
a. Disconnect and inspect J1/P1 ECM connector and J20/P20 MIC (WP 0053 00 and WP 0170 00). Inspect terminal
connections on relay for fuel transfer pump (WP 0054 00).
b. Perform 10 lb (45 N) pull test on each wire in ECM connector associated with fuel transfer pump.
c. Check ECM connector (socket-head screw) for proper torque of 55 lb-in. (6 Nm).
d. Check harness and wiring for abrasion and pinch points from sensors back to ECM.
e. Reconnect all connectors.
f. Expected Results. All connectors, pins, and sockets should be completely connected and/or inserted and harness
and wiring should be free of corrosion, abrasions, or pinch points.
(1) If results are OK, wiring and connectors are good. Proceed to step 2.
(2) If results are NOT OK, a problem exists with wiring and connectors. Replace wiring harness in question
(WP 0169 00 thru WP 0175 00). Ensure all seals are properly in place and connectors are securely con-
nected. Verify repair eliminates problem.
0013 00-59
TM 5-3805-290-23-1
FUEL TRANSFER PUMP CIRCUIT TEST - CONTINUED
2. Check fuel transfer pump power relay supply.
b. Measure resistance between these contacts:
(1) Supply side (A) of fuel transfer pump power relay and NEG battery.
(2) Positive side (C) of fuel transfer pump relay coil and NEG battery.
c. Expected Results. Battery voltage is correct.
(2) If results are NOT OK, a problem exists in wires between battery and fuel transfer pump. Check fuse and
wires (TM 5-3805-290-10). Replace fuse or wiring harness in question (WP 0169 00 thru WP 0175 00).
Verify repairs have eliminated problem.
3. Check fuel transfer pump power relay output.
b. Measure voltage between these contacts:
(1) (B)
(2) NEG battery
c. Expected Results. Battery has proper voltage.
(1) If results are OK, a problem exists in wires. Replace wiring harness in question (WP 0169 00 thru WP
0175 00). Verify repair has eliminated problem (WP 0022 00).
(2) If results are NOT OK, proceed to step 4.
427-B0723
0013 00-60
TM 5-3805-290-23-1
4. Ground input to power relay at MIC.
b. Disconnect P20 connector from MIC and connect 70-pin breakout T (WP 0170 00).
c. Connect MSD to diagnostic connector (WP 0006 00).
e. Use override setting in MSD to engage fuel transfer pump.
f. Measure voltage between P20:31 fuel transfer pump control and socket 69 NEG battery on breakout T.
g. Expected Results. Voltage is 0 when fuel transfer pump is engaged.
(2) If results are NOT OK, problem exists in wires between fuel transfer pump power relay and MIC. Replace
wiring harness in question (WP 0169 00 thru WP 0175 00). Verify repair has eliminated problem.
427-B0900
5. Ground input to power relay at ECM connector.
b. Remove 70-pin breakout T and connect P20 MIC (WP 0170 00).
c. Disconnect P1 ECM connector from ECM and connect 70-pin breakout T (WP 0053 00).
d. Connect MSD to diagnostic connector (WP 0006 00).
f. Insert jumper wire between J1:31 on breakout T. Monitor status screen on MSD. Slowly connect and disconnect
other end of jumper wire to socket 69 NEG battery on breakout T.
0013 00-61
TM 5-3805-290-23-1
g. Expected Results. When jumper wire is con-

nected, relay should be closed. When jumper
wire is disconnected, relay should be open.
(2) If results are NOT OK, problem exists in
wiring harness between MIC and ECM
connector. Replace wiring harness in
00). Verify problem has been eliminated.
If repair has not eliminated problem,
proceed to step 6.
427-B0724
6. Override fuel transfer pump to test ECM.

b. Remove 70-pin breakout T.
c. Connect P1 ECM connector (WP 0053 00).
f. Use MSD to monitor status screen.
g. Use override parameter for fuel transfer pump to turn fuel transfer pump ON.
h. Verify fuel transfer pump is either enabled or disabled.
i. Expected Results. Fuel transfer pump is working properly.
(1) If results are OK, ECM is operating properly.
(2) If results are NOT OK, ECM is not working properly. Replace ECM (WP 0053 00). Verify repair has elim-
inated problem.
SET SPEED CIRCUIT TEST 0013 00
NOTE
• Use this test to verify set speed switch receives proper supply voltage and to check that set speed switches
operate correctly.
• Set speed switch provides operator with ability to select desired engine speed. Engine speed will decrease with
increasing load. Set speed control can be used for engine speed or for vehicle speed depending on engine appli-
cation.
• Set speed switches are:
a. P1:28 Set Speed Control ON or OFF
b. P1:11 Set Speed Continue or Accelerate
c. P1:20 Set Speed Set or Decelerate
• Warning lamps are used to indicate status of set speed control.
0013 00-62
TM 5-3805-290-23-1
SET SPEED CIRCUIT TEST - CONTINUED
427-B0910
1. Inspect electrical connectors and wiring. Refer to Electrical Connectors Inspection (WP 0022 00, WP 0052 00, WP
0053 00, and WP 0077 00).
b. Disconnect and thoroughly inspect ECM connector J1/P1, MIC J20/P20, and battery connections.
c. Check harness and wiring for corrosion, abrasions, and pinch points from throttle switch to ECM.
d. Reconnect all connectors.
e. Expected Results. All connectors, pins, and sockets should be completely inserted and connected. Harness and wir-
ing should be free of corrosion, abrasions, and pinch points.
(2) If results are NOT OK, replace wiring harness in question (WP 0169 00 thru WP 0175 00). Verify repair
eliminates problem.
2. Check SET SPEED switch on MSD.
b. Connect MSD at diagnostic connector (WP 0006 00).
d. Observe status of set speed switch on MSD while operating set speed switch from Speed 1 position to Speed 2
position.
e. Observe status of set speed switch on MSD while operating set speed switch from ON to OFF.
f. Observe status of set speed control Set/Resume switch while operating switch from OFF to ON position.
g. Expected Results.
NOTE
If engine application has two engine speed controls, ensure Speed 1 is selected.
(1) MSD shows that set speed control switch is in OPEN condition when set speed control switch is in OFF
position. MSD shows that set speed switch is in CLOSED position when set speed switch is in ON posi-
tion.
0013 00-63
TM 5-3805-290-23-1
NOTE
Set speed control lamp should be dark when set speed control switch is in OFF position. Set speed control
lamp should be flashing when set speed control switch is in ON position.
(2) When set speed control Set/Resume switch is in OFF position, display screen should show an OPEN con-
dition. When set speed control Set/Resume switch is in ON position, display screen should show CLOSED
condition.
NOTE
Set speed control lamp 1 should change from flashing to ON when set speed resume or accelerate switch is
CLOSED.
(a) If results are OK, set speed control switches operate correctly.
(b) If results are NOT OK, proceed to step 3.
427-B0911
427-B0912
0013 00-64
TM 5-3805-290-23-1
3. Check speed control switch.

b. Remove wire from MIC P20:11 set speed control Resume switch. Use jumper to join P20:11 together with each
wire listed below.
d. Monitor status screen on MSD. Slowly connect and disconnect jumper from P20:11.
(1) P20:20 Set Speed Control Set
(2) P20:28 Set Speed Control ON or OFF
e. Expected Results. When jumper wire is connected, set speed switch should be CLOSED. When jumper wire is dis-
connected, set speed switch should be OPEN.
427-B0912
(1) If results are OK, switch is faulty. Replace switch (WP 0049 00) and verify repair has eliminated problem.
(2) If results are NOT OK, a problem exists with wiring harness between set speed control switch and engine
ECM. Proceed to step 5.
4. Measure resistance of cables at MIC.
b. Connect meter to suspect switch.
c. Disconnect P20:11 Set Speed Control Resume switch from P20/J20 MIC.
d. Measure resistance from P20:11 Set Speed Control Resume switch to P20:68 -battery.
e. Measure resistance between P20:68 -battery and each of these connections:
0013 00-65
TM 5-3805-290-23-1

f. Expected Results. Measured resistance should be less than 10 Ohms with switch ON. Measured resistance should
be more than 2,000 Ohms with switch OFF.
(2) If results are NOT OK, a problem exists with wires between suspect switch and P20 connector. Replace
wiring harness in question (WP 0169 00 thru WP 0175 00). Verify repair has eliminated problem.
5. Measure resistance of cables at ECM.
b. Connect P20 MIC (WP 0170 00).
c. Disconnect P1 ECM connector from ECM (WP 0053 00).
d. Measure resistance between P1:11 Set Speed Control Resume and P1:68 -battery. First measure resistance with
switch in OFF position and then measure switch in ON position.
e. Measure resistance between P1:68 and each of these ECM pin locations:
f. Expected Results. Measured resistance should be less than 10 Ohms with switch in ON position. Measured resis-
tance should be more than 2,000 Ohms with switch in OFF position.
427-B0911

(2) If results are NOT OK, a problem exists in wires between MIC and ECM connector. Replace wiring har-
ness in question (WP 0169 00 thru WP 0175 00). Verify repair has eliminated problem. If problem has not
been eliminated, repeat Electrical Connectors Inspection (WP 0022 00).
6. Test engine ECM.
b. Insert 70-pin breakout T between P1 connector and J1 connector.
c. Insert one end of jumper wire into socket for suspect switch. Insert other end of jumper wire into P1:68 -battery.
d. Turn engine start switch to ON position (TM 5-3805-290-10) and monitor status screen on MSD. Slowly connect
and disconnect jumper wire from socket of pin 68 of breakout T.
0013 00-66
TM 5-3805-290-23-1

e. Repeat this procedure for each of these ECM pin connections:
(1) P1:11 Set Speed Control Continue Resume
f. Expected Results. Status screen should display OPEN condition with switch in OFF position. Status screen should
display CLOSED condition with switch in ON position.
(1) If results are OK, ECM is working correctly.
(2) If results are NOT OK, ECM is not working properly. Replace suspect ECM (WP 0053 00). Verify repair
eliminates problem.
STARTING AID OUTPUT CIRCUIT TEST 0013 00
NOTE
• Use this test to check starting aid voltage and operation.
• Starting aid is used to improve the engine’s ability to start when cold.
• 3056E engine uses ether start system.
• ECM controls operation of starting aid through starting aid relay and P1:43.
b. Disconnect and thoroughly inspect J1/P1 ECM connector and J20/P20 MIC (WP 0053 00 and WP 0170 00).
Inspect terminal connections on starting aid relay.
c. Perform 10 lb (45 N) pull test on each wire in ECM connector associated with starting aid.
d. Check ECM connector (socket-head screw) for proper torque of 55 lb-ft (6 Nm).
e. Check harness and wiring for abrasions and pinch points from sensors back to ECM.
f. Reconnect all connectors.
0013 00-67
TM 5-3805-290-23-1
STARTING AID OUTPUT CIRCUIT TEST - CONTINUED

g. Expected Results. All connectors, pins, and sockets are securely connected and/or inserted and harness and wiring
is free of corrosion, abrasions, or pinch points.
(2) If results are NOT OK, a problem exists with wiring and/or connectors. Replace wiring harness in question
(WP 0169 00 thru WP 0175 00). Ensure all seals are properly in place and connectors are completely con-
nected. Verify repair eliminates problem.
427-B0913
427-B0914
427-B0915
0013 00-68
TM 5-3805-290-23-1

2. Check starting aid power relay supply.
b. Measure voltage between these contacts:
(1) Supply side (A) of starting aid relay and NEG battery.
(2) Positive side (C) of relay coil for starting aid and NEG battery.
c. Expected Results. Battery voltage is present.
(2) If results are NOT OK, a problem exists in wires between battery and starting aid. Check fuse and wires.
Replace wiring harness in question (WP 0169 00 thru WP 0175 00). Verify repairs have eliminated prob-
lem.
3. Check starting aid power relay output.
a. Disconnect ether starting aid connector (WP 0040 00).
b. Place a jumper wire (A) and (B).
d. Measure voltage at ether starting aid connector pin 1 harness side.
e. Expected Results. Battery voltage is present.
(1) If result is OK, a problem exists in wires between relay and starting aid. Replace wiring harness in ques-
tion (WP 0169 00 thru WP 0175 00). Verify repair has eliminated problem.
(2) If result is NOT OK, proceed to step 4.
4. Ground input to power relay at MIC connector.
b. Disconnect P20 connector from MIC (WP 0170 00) and connect 70-pin breakout T.
c. Connect MSD to diagnostic connector (WP 0006 00).
e. Use override setting in MSD to engage starting aid.
f. Measure voltage between P20:43 starting aid control and socket 69 NEG battery on breakout T.
g. Expected Results. Voltage is 0 when starting aid is engaged.
(1) If result is OK, proceed to step 5.
(2) If result is NOT OK, problem exists in wires between starting aid relay and MIC. Replace wiring harness
in question (WP 0169 00 thru WP 0175 00). Verify repair has eliminated problem.
5. Ground input to power relay at ECM connector.
b. Remove 70-pin breakout T and connect P20 MIC (WP 0170 00).
c. Disconnect P1 ECM connector from ECM (WP 0053 00) and connect 70-pin breakout T.
f. Insert jumper wire between J1:43 on breakout T. Monitor status screen on MSD. Slowly connect and disconnect
other end of jumper wire to socket 69 NEG battery on breakout T.
0013 00-69
TM 5-3805-290-23-1

g. Expected Results. When jumper wire is connected, relay is CLOSED. When jumper wire is disconnected, relay is
OPEN.
(1) If result is OK, proceed to step 6.
(2) If result is NOT OK, problem exists in wiring harness between MIC and ECM connector. Replace wiring
harness in question (WP 0169 00 thru WP 0175 00). Verify problem has been eliminated. If repair has not
eliminated problem, proceed to step 6.
6. Override starting aid to test ECM.
b. Remove 70-pin breakout T.
c. Connect P1 ECM connector (WP 0053 00).
f. Use MSD to monitor status screen.
g. Use starting aid override parameter to override ether start system.
h. Verify starting aid is either ENABLED or DISABLED.
i. Verify lamp for starting aid is on.
j. Starting aid is working properly.
k. Expected Results.
(1) If result is OK, ECM is operating properly.
(2) If result is NOT OK, ECM is not working properly.
(b) Replace engine ECM (WP 0053 00). Verify repair eliminates problem.
WIRING HARNESS (OPEN CIRCUIT) TEST 0013 00
NOTE
• Open circuit results in no flow of electrical current. Open circuit is usually caused by failed electrical wires or
poor connection of electrical connectors. If electrical wire or connection is broken, flow of electrical current
through circuit is interrupted. Normally, closed circuit will have less than 5 Ohms of resistance.
• For complete electrical schematic, refer to WP 0210 00.
1. Identify connectors and wire numbers of suspect circuits. Use Schematics to identify circuits (WP 0210 00).
2. Turn engine start switch and disconnect switch to OFF position (TM 5-3805-290-10).
3. Disconnect component and ECM from wiring harness. Refer to appropriate work package.
4. At one disconnected harness connection, place jumper wire from contact of suspect wire to frame ground.
5. At other connector of wiring harness, use multimeter probes to measure resistance from contact of suspect wire to frame
ground.
6. Expected Results. Resistance is less than 5 Ohms.
a. If results are OK, circuit is correct.
b. If results are NOT OK, there is an open circuit in wiring harness. Replace wiring harness in question (WP 0169 00
thru WP 0175 00).
0013 00-70
TM 5-3805-290-23-1
WIRING HARNESS (SHORT CIRCUIT) TEST 0013 00
NOTE
• Short circuit is failure of electrical circuit that results in undesired electrical current. Usually, short circuit is
bypass of circuit across load. For example, short across wires in circuit for lamp produces too much current in
wires but no current is felt at lamp. Lamp is shorted out. Resistance in normal circuit can vary, but resistance
between particular circuit and other unrelated circuits is always greater than 5,000 Ohms. This test is for a
short circuit.
• For complete electrical schematic, refer to WP 0210 00.
1. Identify connectors and wire numbers of suspect circuits. Use Schematics (WP 0210 00) to identify circuits.
2. Turn engine start switch and disconnect switch to OFF position (TM 5-3805-290-10).
3. Disconnect component and ECM from wiring harness. Refer to appropriate work package.
4. At wiring harness connector for ECM, place one multimeter probe on contact of suspect wire.
5. Use other multimeter probe to check resistance across all other contacts in connector(s) of ECM and frame ground.
6. Expected Results. Resistance is greater than 5,000 Ohms for all measurements.
a. If results are OK, harness circuits are correct.
b. If results are NOT OK, a short exists in wiring harness between suspected wire and wire with lowest resistance
measurement. Replace wiring harness in question (WP 0169 00 thru WP 0175 00).
END OF WORK PACKAGE
0013 00-71/(0013 00-72 Blank)

32
TM 5-3805-290-23-1
TRANSMISSION TESTS, INSPECTIONS, AND ADJUSTMENTS 0014 00
Transmission Clutch Fill Calibration Transmission Pressures Test and Adjustment

Transmission Control (Shift Lever) Test Solenoid Valve (Transmission Clutch) Testing
Torque Converter Stall Test
INITIAL SETUP
Maintenance Level References - Continued

Unit WP 0081 00
00)
WP 0169 00
Adapter, communication (Item 2, WP 0205 00)
WP 0170 00
Multimeter (Item 47, WP 0205 00)
WP 0171 00
Remover, electrical contact (Item 71, WP 0205 00)
WP 0172 00
WP 0173 00
0205 00) WP 0174 00
Test stand, automotive (gage set) (Item 92, WP WP 0175 00
0205 00) WP 0188 00
Materials/Parts WP 0210 00
Personnel Required Machine parked on level ground (TM 5-3805-290-
MOS 62B, Construction Equipment Repairer (2) 10)
References Work tool lowered to ground (TM 5-3805-290-10)
WP 0003 00 Parking brake engaged (TM 5-3805-290-10)
WP 0006 00 Wheels chocked
WP 0008 00 Battery disconnect switch in OFF position (TM 5-
WP 0009 00 3805-290-10)
WP 0022 00 Engine doors opened (TM 5-3805-290-10)
Transmission Clutch Fill Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-2

Transmission Control (Shift Lever) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-12
Torque Converter Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-17
Transmission Pressures Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-19
Solenoid Valve (Transmission Clutch) Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-27
0014 00-1
TM 5-3805-290-23-1
TRANSMISSION TESTS, INSPECTIONS, AND ADJUSTMENTS - CONTINUED 0014 00
NOTE
00).
• These procedures may give direction to replace wiring harnesses. However, limited repair of wiring harnesses
is authorized. Refer to Electrical General Maintenance Instructions (WP 0022 00) for the correct repair proce-
dures.
TRANSMISSION CLUTCH FILL CALIBRATION 0014 00
14
WARNING
Use extreme caution when performing this test. Keep nonessential personnel away from area. Sudden
movement of machine may cause injury or death to personnel.
CAUTION
DO NOT connect or disconnect hose fittings to or from quick-disconnect nipples when there is pressure in
system. This will prevent damage to seals in fitting.
NOTE
Machine is equipped with these modulating valves and clutches:
a. Modulating valve for clutch 1 (1) (forward low)
b. Modulating valve for clutch 2 (2) (forward high)
c. Modulating valve for clutch 3 (3) (reverse)
d. Modulating valve for clutch 4 (4) (second speed)
e. Modulating valve for clutch 5 (5) (third speed and fourth speed)
f. Modulating valve for clutch 6 (6) (first speed)
427-B0919
0014 00-2
TM 5-3805-290-23-1
TRANSMISSION CLUTCH FILL CALIBRATION - CONTINUED

1. Preparation for Calibration Procedure.
a. Activate hydraulic lockout by pressing hydraulic lockout switch (TM 5-3805-290-10).
NOTE
Condition of parking brake can be checked. Refer to Parking Brake Maintenance (WP 0092 00).
b. Install steering frame lock (TM 5-3805-290-10).
c. Close engine access doors to provide proper operation of cooling system (TM 5-3805-290-10).
d. If new modulating valve was installed, start engine and shift transmission at least 12 times into speed or direction
that uses new clutch solenoid modulating valve. Refer to Table 1 to identify clutches engaged for each direction
and each gear. If new modulating valve was not installed, proceed to step 2.
Table 1. Clutch Combinations.
First Second Third Fourth First Second Third

Speed Speed Speed Speed Speed Speed Speed
Gear Forward Forward Forward Forward Neutral Reverse Reverse Reverse
Clutch 1
X X X
(forward low)
Clutch 2
X
(forward high)
Clutch 3
X X X
(reverse)
Clutch 4
X X
(second speed)
Clutch 5 (third
speed and X X X X
fourth speed)
Clutch 6 (first
X X
speed)
0014 00-3
TM 5-3805-290-23-1

2. Calibration Procedure.
a. Connect MSD equipped with ET Software and communication adapter to perform this test procedure (WP 0006
00).
b. Open software program. Select transmission ECM for machine being calibrated.
c. Select “Service” menu to begin calibration procedure. Then select “Calibrations”. Second menu will be displayed.
Select “Transmission Fill Calibration” from second menu.
427-B0920
d. Next screen is initial calibration screen. Once “Transmission Fill Calibration” has been selected, screen displays
instructions for calibration. Top display area displays status parameters monitored during calibration. Middle dis-
play area displays information about status of calibration. Display area on bottom will display conditions for setup
and calibration.
0014 00-4
TM 5-3805-290-23-1
NOTE
Hydraulic fan speed is controlled by transmission oil temperature during transmission clutch fill calibra-
tion.
e. Display area will show these setup conditions:

(1) Warm transmission oil to proper temperature. Temperature required to start calibration is different from
temperature required to maintain calibration procedure.
(2) Temperature for START of calibration must be 181 to 194°F (83 to 90°C).
(3) Temperature for MAINTAINING calibration must be 167 to 208°F (75 to 98°C).
(4) Place transmission direction and shift lever in NEUTRAL position.
(5) Engage parking brake (TM 5-3805-290-10).
(6) Operate engine at high idle.
f. Perform these procedures to satisfy setup condition.
(1) To warm transmission oil:
(a) Engage parking brake (TM 5-3805-290-10).
(b) Place autoshift switch in MANUAL position.
(c) Ensure transmission neutralizer override is enabled. Transmission neutralizer override is enabled
when transmission neutralizer switch is illuminated (TM 5-3805-290-10).
(d) Place transmission direction and shift lever in third gear position (TM 5-3805-290-10).
(e) Shift transmission direction and shift lever in FORWARD position (TM 5-3805-290-10). Since park-
ing brake is engaged, transmission direction and shift lever must be shifted to FORWARD position
twice within two seconds to shift transmission.
(f) Operate engine at high idle (TM 5-3805-290-10). Use throttle lock to set engine high idle speed (TM
5-3805-290-10). Monitor gage on instrument panel for transmission oil temperature. Reduce engine
speed when gage enters high temperature area.
(2) Use MSD calibration screen to monitor transmission oil temperature.
(3) Maintain transmission oil temperature displayed by MSD between 3 and 5 minutes to properly heat up
transmission.
(4) While transmission temperature is maintained, perform this procedure to warm hydraulic oil:
(a) Disengage hydraulic lockout (TM 5-3805-290-10).
(b) Stall raise circuit for 30 seconds (TM 5-3805-290-10).
(c) Stall tilt circuit for 30 seconds (TM 5-3805-290-10).
(d) Alternate stalling raise circuit and tilt circuit until hydraulic oil reaches normal operating temperature.
Oil is at normal operating temperature when needle on hydraulic oil temperature gage is at midpoint
of gage.
(e) Engage hydraulic lockout (TM 5-3805-290-10).
0014 00-5
TM 5-3805-290-23-1

(5) Ensure shift lever is in NEUTRAL (TM 5-3805-290-10).
(6) Ensure parking brake is engaged (TM 5-3805-290-10).
(7) Use throttle lock to set engine at high idle (TM 5-3805-290-10).
427-B0921
0014 00-6
TM 5-3805-290-23-1
NOTE
• To obtain correct calibration of modulating valves, hydraulic implement controls should not be oper-
ated during calibration procedure.
• When calibration has been performed on all clutches, dialog box will display results for each clutch.
There are only two possible results: “Success” and “At a limit”.
3. Press “Next” button to start calibration. If conditions for setup are not correct, condition that is not correct will display in
middle display area. Calibration will not start. When conditions are correct, press “Next” button to start fill calibration.
427-B0922
0014 00-7
TM 5-3805-290-23-1

4. Calibration procedure continues until ECM determines one step is not met. Middle display area will display message to
alert personnel of error. Personnel can correct error described in middle display area, or calibration can be cancelled by
pressing “Cancel” button. MSD will display message in middle display area to alert personnel of problem.
5. Calibration procedure could be stopped for several reasons. Refer to Table 2 for error codes that can be displayed by
MSD. When condition that caused error code has been corrected, restart calibration.
Table 2. Error Codes for Transmission Clutch Fill Calibration.
Error Code Description Procedure
0002 Active diagnostic present There is active diagnostic code. Exit calibration and
correct condition that caused diagnostic code.
0006 Aborted by user Calibration has been stopped by user. Restart
calibration procedure.
0009 Aborted by ECM Calibration has been stopped by ECM. Restart
calibration procedure.
1012 Engine rpm incorrect Engine rpm is not correct. Set engine rpm to high idle.
1018 Parking brake not engaged Parking brake is not engaged. Set parking brake.
101B Machine speed not zero Machine ECM detects machine movement. Machine
must not move during calibration.
1001F Direction lever not in NEUTRAL Transmission direction and shift lever is not in
NEUTRAL. Place transmission direction and shift
lever in NEUTRAL.
1021 Transmission oil temperature too low Transmission oil temperature is too low. Repeat
procedure to increase hydraulic oil temperature.
1022 Transmission oil temperature too high Transmission oil temperature is too high. Decrease
engine speed and ensure engine access doors are
closed.
0014 00-8
TM 5-3805-290-23-1

6. If fill calibration needs to be restarted, press “Restart” button.
7. If some clutches reach limit during calibration, ECM will make log. ECM will then move to next clutch. User may press
“Restart” button to restart calibration.
427-B0923
0014 00-9
TM 5-3805-290-23-1

8. When calibration has been successfully completed, press “FINISH” button. Select “File” menu, and then select “Exit”.
427-B0924
0014 00-10/(0014 00-11 Blank)

TM 5-3805-290-23-1
TRANSMISSION CONTROL (SHIFT LEVER) TEST 0014 00
427-B0925
0014 00-12
TM 5-3805-290-23-1
TRANSMISSION CONTROL (SHIFT LEVER) TEST - CONTINUED
1. Start engine (TM 5-3805-290-10).

2. Place autoshift mode switch in MANUAL position (TM 5-3805-290-10).
NOTE
Highest gear available in REVERSE is third gear.
3. Disengage parking brake and operate machine in all speeds and in both directions using steering column shift lever.
Implement handle remote F/N/R switch should remain in NEUTRAL position (TM 5-3805-290-10).
4. Observe transmission operating in all gears and in both directions.
5. Place steering column shift lever in NEUTRAL and operate machine in all speeds and in both directions using imple-
ment handle remote F/N/R switch.
6. Observe transmission operating in all gears and in both directions. If transmission does not operate properly and prob-
lem in shift lever is still suspected, proceed to step 8.
NOTE
Refer to Table 3 for the following tests.
7. Check shift lever signal on status screen.

a. Disconnect F/N/R switch harness 4-pin connector CN-C50 from shift lever. Connect jumper wire from pin 3 to pin
4 on shifter 4-pin connector (WP 0081 00).
b. Connect MSD to machine (WP 0006 00).
c. Turn disconnect switch and engine start switch to ON position (TM 5-3805-290-10).
d. Select machine ECM and go to status screen 4.
e. Move shift lever through all possible positions. Observe status of Shift Lever Position on MSD screen.
f. Expected Results. Status of shift lever position changes properly.
(1) If status of shift lever position changes properly, diagnostic code does not exist at this time. Proceed to step
12.
(2) If status on MSD screen is DATA FAULT in all shifter positions, proceed to step 9.
(3) If status on MSD screen is DATA FAULT in a particular position, proceed to step 10.
8. Check for power and ground at shifter.
a. At shifter, connect positive (red) multimeter lead to wire 110 GN. Connect negative (black) multimeter lead to
wire 200 BK.
b. Measure voltage between two wires.
c. Expected Results. Voltage is system voltage.
(1) If result is OK, voltage is system voltage. Proceed to step 10.
(2) If result is NOT OK, voltage is not system voltage. Wiring to shifter may have failed. Check fuse for wire
110 GN. If fuse is bad, replace fuse. If fuse is good, wiring harness may have failed. Replace wiring har-
ness in question (WP 0169 00 thru WP 0175 00) between fuse and shifter or between shifter and ground.
0014 00-13
TM 5-3805-290-23-1

9. Check shifter harness and ECM.
Table 3. Valid Shift Lever Input Status.
Output Forward Neutral Reverse First Gear Second Gear Third Gear Fourth Gear
1F X O O X O O O
2F X O O O X O O
3F X O O O O X O
4F X O O O O O X
1N O X O X O O O
2N O X O O X O O
3N O X O O O X O
4N O X O O O O X
1R O O X X O O O
2R O O X O X O O
3R O O X O O X O
4R O O X O O O X
N O X O O O O O
a. Shift lever has three connectors:
(1) 8-Pin Connector
(2) 6-Pin Connector
(3) 4-Pin Connector
b. At shifter, disconnect 8-pin harness connector CN-C52 (WP 0081 00). 6-pin harness connector remains connected
to shifter 6-pin connector. Shifter 4-pin connector remains connected between pins 3 and 4.
c. Refer to shifter schematic and connect two jumper wires from shifter connectors to frame ground to simulate each
position of shifter. If particular position is already suspect, begin with wires for that position.
d. Monitor status of shifter on MSD screen.
e. Expected Results. As each combination of contacts is grounded, MSD screen displays corresponding shifter posi-
tion.
(1) If results are OK, ECM and wiring harness appear to be working correctly. Replace shifter (WP 0081 00).
(2) If results are NOT OK, wiring harness or ECM is not working correctly. Proceed to step 11.
0014 00-14
TM 5-3805-290-23-1

10. Check ECM.
Table 4. Machine ECM Connector Pin Assignments.
Function Wire Assignment Machine ECM Pin Assignments
Forward G750-BU Connector J2, Pin 49

Neutral G763-PU Connector J2, Pin 23
Reverse G755-GY Connector J2, Pin 28
First Gear G768-GN Connector J2, Pin 50
Second Gear G760-WH Connector J1, Pin 41
Third Gear G761-YL Connector J1, Pin 42
Fourth Gear G762-BR Connector J1, Pin 43
a. Turn battery disconnect switch to OFF position (TM 5-3805-290-10).

b. Using information in Table 4, remove corresponding wires from machine ECM harness connectors J1 and J2.
Also, use shifter schematic for reference. After removing all wires shown in Table 4, momentarily connect to
frame ground individually. Ensure wires cannot accidentally touch frame ground.
c. Turn service disconnect switch to ON position. Start machine with key in RUN position, and connect and start up
MSD (WP 0006 00).
d. Select powertrain ECM and go to status screen 4.
e. Monitor status of shifter on MSD screen.
f. Expected Results. As each combination of contacts is grounded, MSD screen displays corresponding shifter posi-
tion.
(1) If results are OK, ECM is working properly. Wiring harness may have failed. Replace wiring harness in
question (WP 0169 00 thru WP 0175 00).
(2) If results are NOT OK, ECM may have failed. Clean contacts for ECM harness connectors. It is unlikely
that ECM has failed. Exit this procedure and perform entire procedure again. If problem remains, replace
ECM. It is preferable to show new ECM corrects problem and suspect ECM demonstrates problem.
11. Verify shift lever remote F/N/R switch functionality.
a. Place shift lever on steering column in NEUTRAL and FIRST GEAR (TM 5-3805-290-10).
b. At shifter 4-pin connector, remove jumper wire between pin 3 and pin 4.
c. Connect 4-pin receptacle connector CN-C50 from cab harness to shifter 4-pin plug (WP 0081 00). This will enable
remote F/N/R switch circuit for shift lever.
d. Ensure pins and sockets are seated properly and connector mates correctly.
e. Place remote F/N/R switch in FORWARD position.
f. Verify MSD shows “F1” as desired gear.
g. Place remote F/N/R switch in REVERSE position.
h. Verify MSD shows “R1” as desired gear.
i. Expected Results. As each combination is switched, MSD screen displays corresponding gear and direction.
(1) If status of shift lever position changes properly, monitor machine to check if problem occurs. If problem
occurs, repeat entire test procedure.
0014 00-15
TM 5-3805-290-23-1

(2) If status on MSD screen is DATA FAULT in either particular position or all positions, proceed to step 13.
12. Verify shift lever remote F/N/R harness.
a. Ensure shift lever on steering column is in NEUTRAL and FIRST GEAR (TM 5-3805-290-10).
b. Ensure cab harness 4-pin receptacle connector CN-C50 is connected to shifter 4-pin plug (WP 0081 00).
c. Disconnect 6-pin connector that goes to remote F/N/R switch assembly.
d. On cab harness connector CN-C23, place jumper wire from pin 1 202 BK to pin 4 G787 GN.
e. Verify MSD shows “F1” as desired gear.
f. Move jumper wire connection from pin 1 202 BK to pin 6 G788 YL.
g. Verify MSD shows “R1” as desired gear.
h. Move jumper wire connection from pin 1 202 BK to pin 5 P916 OR.
i. Verify MSD shows “N1” as desired gear.
j. Expected Results. As each jumper pin combination is checked, MSD screen displays corresponding gear and direc-
tion.
(1) If status of shift lever position changes properly, harness from remote F/N/R switch assembly to ECM is
working correctly. Replace remote F/N/R switch assembly (WP 0188 00).
(2) If status on MSD screen is DATA FAULT no matter which wire is jumped to pin 1, common signal pin 1
202 BK may have lost connection to machine ground. Wiring harness may have failed. Replace wiring
harness in question (WP 0169 00 thru WP 0175 00).
(3) If status on MSD screen is DATA FAULT when a particular wire is jumped to pin 1, wiring harness may
have failed. Replace wiring harness in question (WP 0169 00 thru WP 0175 00).
0014 00-16
TM 5-3805-290-23-1
TORQUE CONVERTER STALL TEST 0014 00

14
WARNING
14
NOTE
• Converter stall test is test of engine, torque converter, drivetrain, and brake system as a unit. Con-
verter output stalls with engine at full throttle. This test will indicate if engine and transmission perfor-
mance is acceptable under full load. Engine speed that is lower or higher than normal indicates engine
or transmission problems. When performance of engine is correct, but stall speed is not correct, prob-
lem is in converter or transmission.
• Drive wheels must not turn during stall test. Place machine in position against solid object that will not
move when subjected to full thrust of machine. Engage parking brake. When tests are made, service
brakes must be applied.
1. Start engine (TM 5-3805-290-10). Make sure transmission oil is at normal operating temperature of 180 to 200°F (82 to
93°C). Cold transmission oil temperature will result in a lower stall rpm.
2. Disengage parking brake (TM 5-3805-290-10).
3. Apply service brakes (TM 5-3805-290-10).
0014 00-17
TM 5-3805-290-23-1
TORQUE CONVERTER STALL TEST - CONTINUED 0014 00

CAUTION
DO NOT keep torque converter in full stall condition for more than 30 seconds. After torque converter
stalls, put control in NEUTRAL. Run engine at 1,200 to 1,500 rpm to cool oil. Failure to do so may result in
damage to machine.
4. Ensure transmission neutralizer override is enabled. Transmission neutralizer override is enabled when transmission
neutralizer override switch is illuminated (TM 5-3805-290-10).
5. Place shift lever in fourth speed FORWARD. Push accelerator pedal down completely. Allow engine rpm to stabilize
and take reading from tachometer.
6. Correct stall speed is 2,195 to 2,340 rpm. Stall speed that is low indicates that engine performance is not correct. Wait at
least two minutes with transmission in NEUTRAL before repeating test. If that does not correct the problem, refer to
Troubleshooting Torque Converter or Transmission (WP 0008 00).
0014 00-18
TM 5-3805-290-23-1
TRANSMISSION PRESSURES TEST AND ADJUSTMENT 0014 00
CAUTION
NOTE
Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy
and ordinances. Ensure all spills are cleaned up.
1. Install steering frame lock (TM 5-3805-290-10).
2. Remove right side covers to gain access (WP 0107 00).
CAUTION
DO NOT connect or disconnect hose fittings to or from quick-disconnect couplings when there is pressure
in system. This will prevent damage to seals that are in fitting.
NOTE
All tests and adjustments must be made while transmission oil is at normal operating temperature.
3. Use one of each pressure gage kit.
4. Test for transmission clutch pressure.
0014 00-19
TM 5-3805-290-23-1
TRANSMISSION PRESSURES TEST AND ADJUSTMENT - CONTINUED
NOTE
• Use this procedure to check pressure of direction clutch oil and speed clutch oil.
• Machine is equipped with these modulating valves:
a. Install correct hose assembly from pressure gage on pressure tap (1) through pressure tap (6). Attach opposite end
of hose assembly to 0 to 580 psi (0 to 3,400 kPa) pressure gage.
427-B0919
b. Engage parking brake. Shift transmission direction and shift lever to NEUTRAL position. Shift transmission direc-
tion control switch to NEUTRAL position (if equipped). Start engine and operate engine at low idle (TM 5-3805-
290-10).
c. Ensure transmission neutralizer override is enabled. Transmission neutralizer override is enabled when transmis-
sion neutralizer override switch on instrument panel is illuminated (TM 5-3805-290-10).
d. Place autoshift switch in MANUAL position (TM 5-3805-290-10).
14
WARNING
14
0014 00-20
TM 5-3805-290-23-1
NOTE
Machine can overcome service brakes when engine is at high idle.
5. Press and hold brake pedal. Disengage parking brake. Ensure machine is in FIRST SPEED position (TM 5-3805-290-
10). Check pressure gages. Shift transmission direction and shift lever from NEUTRAL to FORWARD position.
Increase engine speed to high idle. Ensure transmission oil is at normal operating temperature (TM 5-3805-290-10).
Needle on pressure gage for clutch 1 should rise. Needle on pressure gage for clutch 6 should rise. Pressure readings
must be within values in Table 5.
6. With transmission in FORWARD position, shift through remaining forward speeds and note clutch pressures for each
speed. Return to FIRST SPEED position (TM 5-3805-290-10). Use transmission direction and shift lever. Pressure read-
ing for each energized clutch must be within values in Table 1. This checks pressure of all speed clutches.
7. Repeat step 6 for all reverse speeds. Same pressure levels should be noted in all reverse speeds.
8. Repeat steps 5 thru 8 with engine at low idle. Same pressures should be observed. If pressures are lower, there is leak in
transmission control system.
Transmission Clutch Pressure Adjustment
NOTE
Transmission clutches should have the same clutch pressure.
1. If pressure readings for all transmission clutches are not within values shown in Table 5, transmission relief valve may
need to be adjusted. Refer to Transmission Oil Pump Pressure Adjustment in this work package for proper adjustment
procedure.
2. If one transmission clutch pressure is not within specification, ensure modulating valve for that clutch is operating cor-
rectly. Perform Solenoid Valve (Transmission Clutch) Testing in this work package.
Table 5. Transmission Pressures.
Pressure Tap Specifications Actual Pressure
Modulating valve for clutch 1 350 ± 25 psi

(2,400 ± 170 kPa)
(2,400 ± 170 kPa)
(2,400 ± 170 kPa)
(2,400 ± 170 kPa)
(2,400 ± 170 kPa)
(2,400 ± 170 kPa)
0014 00-21
TM 5-3805-290-23-1
Lubrication Oil Pressure Test
NOTE
• Use this procedure to check pressure of transmission lubrication oil.
• Inlet for transmission lubrication oil is located on right side of machine.
1. Install correct adapter at pressure tap (7).
2. Install hose assembly from pressure gage on pressure
tap (7). Attach opposite end of hose assembly to 0 to
58 psi (0 to 400 kPa) pressure gage.
427-B0927
3. Start engine and operate engine at high idle (TM 5-3805-290-10). Observe pressure gage. With oil at normal operating
temperature, lubrication oil pressure must be within values shown in Table 6.
Table 6. Transmission Oil Pressure.
Pressure Tap Specification Actual Pressure
Transmission lubrication 25 ± 5 psi

(170 ± 34 kPa)
0014 00-22
TM 5-3805-290-23-1
Transmission Oil Pump Pressure Test
NOTE
Use this procedure to check transmission oil pump pressure.
1. Remove right side covers to gain access (WP 0107
00).
2. Install correct hose assembly from pressure gage on
pressure tap (8). Attach opposite end of hose assembly
to 0 to 580 psi (0 to 3,400 kPa) to pressure gage.
427-B0928
temperature, transmission oil pump pressure must be within values shown in Table 7.
Table 7. Transmission Oil Pump Pressure.
Transmission oil pump 350 ± 25 psi

(2,400 ± 170 kPa)
0014 00-23
TM 5-3805-290-23-1
Transmission Oil Pump Pressure Adjustment
NOTE
Transmission relief valve is located
below modulating valves.
If transmission oil pump pressure at pressure tap (8) is
not within values shown in Table 7, adjust spring (10) of
transmission relief valve (9) using this procedure.
427-B0928
1. Remove cover (11).
427-B0929
NOTE
Turning adjustment screw clockwise increases pump pressure. Turning adjustment screw counterclock-
wise decreases pump pressure. One full turn of adjustment screw changes pump pressure by 23 psi (160
kPa).
2. Turn adjustment screw (12) in proper direction.
3. Install cover (11).
4. Repeat Transmission Oil Pump Pressure Test in this work package. Ensure transmission oil pump pressure is within val-
ues shown in Table 7.
0014 00-24
TM 5-3805-290-23-1
Torque Converter Inlet Pressure Test
NOTE
Pressure tap is located on transmission relief valve. Transmission relief valve is located below modulating
valves.
1. Remove right side covers to gain access (WP 0107
00).
pressure tap (13). Attach opposite end of hose assem-
bly to 0 to 290 psi (0 to 2,000 kPa) to pressure gage.
427-B0930
temperature, torque converter inlet pressure must be below values shown in Table 8.
Table 8. Transmission Torque Converter Inlet Pressure.
Torque converter inlet 130 psi

(895 kPa) maximum
0014 00-25
TM 5-3805-290-23-1
Torque Converter Outlet Pressure Test
NOTE
Pressure tap is located on top of transmission.
pressure tap (14). Attach opposite end of hose assem-
bly to 0 to 290 psi (0 to 2,000 kPa) pressure gage.
427-B0931
temperature, torque converter inlet pressure must be within values shown in Table 9.
Table 9. Transmission Torque Outlet Pressure.
Pressure Tap Specifications
Torque outlet 85 ± 25 psi

(585 ± 170 kPa)
0014 00-26
TM 5-3805-290-23-1
SOLENOID VALVE (TRANSMISSION CLUTCH) TESTING 0014 00
CAUTION
• Care must be taken to ensure that fluids are contained during inspection and testing of machine. Be
prepared to collect fluid with containers before opening any compartment or disassembling any com-
ponent containing fluids.
• Dispose of fluids according to local regulations and mandates.
1. Install steering frame lock (TM 5-3805-290-10).
2. Engage parking brake and stop engine (TM 5-3805-290-10).
Solenoid Valves Test
NOTE
• This test will determine whether solenoid coil is energized and solenoid plunger is shifting to permit flow of oil
through modulating valve.
• Solenoids are located on modulating valve that is controlled by solenoid. Direction clutch pressure taps and
speed clutch pressure taps are installed on modulating valves. Modulating valves are located on top of trans-
mission, beneath cab.
• Transmission is equipped with these modulating valves:
• All tests and adjustments must be made while transmission oil is at normal operating temperature.
427-B0919
0014 00-27
TM 5-3805-290-23-1
SOLENOID VALVE (TRANSMISSION CLUTCH) TESTING - CONTINUED
Solenoid Valves Test - Continued
CAUTION
DO NOT connect or disconnect hose fittings to or from quick-disconnect couplings when there is pressure
in system. This will prevent damage to seals that are in fitting.
1. Install correct hose assembly from pressure gage on pressure tap (1) through pressure tap (6). Attach opposite end of
hose assembly to 0 to 580 psi (0 to 3,400 kPa) pressure gage.
427-B0919
0014 00-28
TM 5-3805-290-23-1
427-B0925
0014 00-29
TM 5-3805-290-23-1

14
WARNING
14
2. Engage parking brake. Shift transmission shift lever to NEUTRAL position. Shift remote F/N/R switch to NEUTRAL
position. Start engine and operate engine at low idle (TM 5-3805-290-10).
3. Ensure transmission neutralizer override is enabled. Transmission neutralizer override is enabled when transmission
neutralizer override switch is illuminated (TM 5-3805-290-10).
4. Place autoshift switch in MANUAL position (TM 5-3805-290-10).
5. Press and hold right service brake pedal. Disengage parking brake. Ensure machine is in FIRST SPEED position (TM 5-
3805-290-10). Watch pressure gages. When transmission is in NEUTRAL, clutch 5 should be engaged. Move shift lever
from NEUTRAL position to FORWARD position (TM 5-3805-290-10).
6. Needle on pressure gage for clutch 1 should rise. Needle on pressure gage for clutch 6 should rise. With transmission in
FORWARD position, shift through remaining forward speeds and return to FIRST SPEED position. Use transmission
direction and shift lever to change speeds. Same pressure rise should be observed in each clutch when clutch is engaged.
This checks operation of all clutches.
7. Repeat steps 5 and 6 for all reverse speeds. Refer to Table 10 to identify clutches engaged for each direction and each
gear.
Table 10. Clutches That Are Engaged in Each Speed and in Each Direction.
Speed Range and Direction Engaged Clutches
Fourth Gear Forward Clutch 2 and clutch 5

Third Gear Forward Clutch 1 and clutch 5
Second Gear Forward Clutch 1 and clutch 4
First Gear Forward Clutch 1 and clutch 6
Neutral Clutch 5
First Gear Reverse Clutch 3 and clutch 6
Second Gear Reverse Clutch 3 and clutch 4
Third Gear Reverse Clutch 3 and clutch 5
8. Expected Results.
a. If pressure rise is noted, solenoid and related electrical circuit are functioning correctly.
b. If pressure rise is not noted, use screwdriver to ensure solenoid coil is energized. If screwdriver is attracted to sole-
noid coil, this indicates solenoid coil is energized. Problem is in solenoid cartridge. Problem could be bent solenoid
stem, screen that is dirty or plugged, or spring that is weak or broken. Replace transmission control valve (WP
0088 00).
c. If screwdriver does not indicate solenoid coil is energized, problem is in electrical circuit.
0014 00-30
TM 5-3805-290-23-1
NOTE
Refer to Troubleshooting (WP 0008 00 and WP 0009 00).
(1) Test wiring harness from solenoid to machine ECM (WP 0210 00).
(2) Perform Transmission Control (Shift Lever) Test in this work package.
(3) Test wiring harness from transmission shift lever to machine ECM.
(4) Replace machine ECM (WP 0052 00).
END OF WORK PACKAGE
0014 00-31/(0014 00-32 Blank)

6
TM 5-3805-290-23-1
BRAKE SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS 0015 00
Purge Brake System Air Service Brake Discs Wear Check

Service Braking System Pressure Test
INITIAL SETUP

Unit Rag, wiping (Item 41, WP 0206 00)
Transparent tube 0.25 in. (6.4 mm) diameter
Test Equipment
O-ring
Adapter, communication (Item 2, WP 0205 00) Personnel Required
Test set, electronic systems (MSD) (Item 91, WP MOS 62B, Construction Equipment Repairer (2)
0205 00) References
WP 0179 00
WP 0180 00
Shop equipment, common no. 1 (Item 77, WP 0205 Equipment Conditions
00)
Machine parked on level ground (TM 5-3805-290-
Brake wear gage (Item 14, WP 0205 00) 10)
Coupling half, quick disconnect (Item 28, WP 0205 Work tool lowered to ground (TM 5-3805-290-10)
00) Parking brake engaged (TM 5-3805-290-10)
Hose (Item 38, WP 0205 00) Wheels chocked
Software kit (Item 81, WP 0205 00) 3805-290-10)
T, tube (Item 93, WP 0205 00) Engine doors opened (TM 5-3805-290-10)
WARNING
• When servicing this machine, performing maintenance, or disposing of hazardous materials, 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.
• DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and
• At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydrau-
lic fitting. Failure to follow this warning may result in injury to personnel.
• Sudden movement of machine can cause injury to personnel on or near the machine.
0015 00-1
TM 5-3805-290-23-1
BRAKE SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS - CONTINUED 0015 00
NOTE
• Use a suitable container to catch any fluid that drains from hoses or system. Dispose of fluid IAW local
policy and ordinances. Ensure all spills are cleaned up.
• There are two purge screws at top of front and rear axles.
• Perform this procedure for one service brake at a time.
0003 00).
PURGE BRAKE SYSTEM AIR 0015 00
427-B0943
427-B0944
0015 00-2
TM 5-3805-290-23-1
PURGE BRAKE SYSTEM AIR - CONTINUED

1. Check oil level in hydraulic oil tank. Maintain correct oil level in hydraulic oil tank throughout air removal procedure.
2. Fasten one end of transparent tube 0.25 in. (6.4 mm) in diameter to one purge screw. Place other end of tube into con-
tainer for collecting hydraulic oil. Loosen purge screw.
3. Slowly press service brake pedal. Hold pedal in this position throughout step 4.
4. As hydraulic oil flows through tube, check for air bubbles in oil. Allow oil to flow into container until no air bubbles are
visible, then tighten purge screw. Release brake pedal.
5. Perform this procedure at each purge screw. Make sure to tighten each purge screw.
6. If service brake pedal is spongy, recheck oil level in hydraulic tank and repeat steps 3 thru 5.
7. Check hydraulic oil tank level and fill hydraulic tank if necessary.
SERVICE BRAKING SYSTEM PRESSURE TEST 0015 00
1. Turn engine start switch to ON position (TM 5-3805-290-10).
2. Remove hydraulic oil pressure from brake system by pushing on brake pedal until there is no brake pressure.
3. Connect and use MSD to monitor brake pressure (WP 0006 00).
4. Observe pressure before starting engine. Hydraulic oil pressure should be 0 psi (0 kPa).
5. Start engine. Allow hydraulic oil to reach normal operating pressure and temperature (TM 5-3805-290-10).
6. Press and hold brake pedal. DO NOT permit brake pedal to come up. Observe pressure. Pressure must be 810 ± 60 psi
(5,600 ± 400 kPa).
7. If brake pressure is not within specified range, but test for accumulator was in specified range, one of these conditions
exists:
a. Brake control valve is faulty.
b. Piston leakage is present in brake system.
8. Perform one of these steps to check brake pressure:
NOTE
Hydraulic oil pressure for upper brake port (rear brakes) should be approximately 250 psi (1,700 kPa)
higher than hydraulic oil pressure for lower brake port (front brakes). MSD monitors brake pressure from
rear brakes. Test port monitors pressure in front brakes.
a. Use MSD to monitor pressure for rear brakes.
b. Install new O-ring on coupling half. Install test fitting on tube T. Install T in brake line to rear axle if T is not in
line. Repeat procedure on line for rear service brakes.
0015 00-3
TM 5-3805-290-23-1
SERVICE BRAKE DISCS WEAR CHECK 0015 00
WARNING
Ensure steering frame lock is connected. DO NOT operate machine with steering frame lock connected.
Failure to follow this warning may result in injury or death to personnel.
NOTE
• There are two inspection plugs at front of each axle.
• The procedure to check front brake discs for wear is identical for rear brake discs.
• Mirror, light, and brake wear gage (for single disc brakes) are required.
427-B0947
427-B0946
1. Connect steering frame lock (TM 5-3805-290-10).

2. Start engine to build accumulator pressure.
3. Stop engine (TM 5-3805-290-10). Engage parking brake. Remove inspection plug for brake disc(s) being checked.
0015 00-4
TM 5-3805-290-23-1
SERVICE BRAKE DISCS WEAR CHECK - CONTINUED
NOTE
The following steps require accumulator pressure.
4. With assistance, hold down either brake pedal. This will hold piston, brake disc, and plate together.
NOTE
Light and mirror are needed to view brake discs through ports.
5. Use feeler gage to measure thickness of brake disc

(Dimension A). Minimum thickness should be
between 0.250 and 0.307 in. (6.35 and 7.8 mm) (front
brakes).
6. Insert brake wear gage between reaction plates while
brakes are applied. Tool is go/no-go gage. If tool fits
between reaction plates, thickness of brake disc is
acceptable. If tool does not fit between reaction plates,
thickness of brake disc is not acceptable and brake
discs need to be replaced (rear brakes).
427-B0948
CAUTION
Oil groove depth is the most critical dimension. If depth of oil grooves on friction discs are too shallow, oil
flow will be inadequate. This can cause excessive heat and abrasion.
7. Use a wire feeler gage to measure width of oil grooves (Dimension B) on both sides of friction discs in each axle hous-
ing. Depth of oil grooves cannot be less than 0.041 in. (1.05 mm).
NOTE
If one or more brake discs do not comply with minimum specifications, replace axle (WP 0179 00 or WP
0180 00) before returning machine to service.
8. Install inspection plugs.
END OF WORK PACKAGE
0015 00-5/(0015 00-6 Blank)

12
TM 5-3805-290-23-1
STEERING SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS 0016 00
Piston Pump (Steering and Pilot) Low Pressure Standby Pump Performance (Steering) Test
Test and Adjustment
Steering Time Check
Piston Pump (Steering and Pilot) High Pressure Stall
Steering Force Check
Test and Adjustment
Steering Wheel Slip Check
Piston Pump (Steering and Pilot) Margin Pressure Test
and Adjustment Metering Pump (HMU) Test
INITIAL SETUP
Maintenance Level Personnel Required

Unit MOS 62B, Construction Equipment Repairer (2)
Test Equipment References

Test stand, automotive (gage set) (Item 92, WP
WP 0003 00
0205 00) (2)
WP 0008 00
WP 0017 00
00)
WP 0101 00
Coupling, hose (Item 26, WP 0205 00)
WP 0104 00
Coupling, hose (Item 27, WP 0205 00)
WP 0107 00
Coupling half, quick disconnect (Item 28, WP 0205
00) WP 0182 00
Hose (Item 38, WP 0205 00)
Nipple, pipe (Item 49, WP 0205 00)
Plug, machine thread (Item 59, WP 0205 00) 10)
Tee, tube (Item 94, WP 0205 00) Work tool lowered to ground (TM 5-3805-290-10)
Wrench, torque (Item 102, WP 0205 00) Parking brake engaged (TM 5-3805-290-10)
Materials/Parts Wheels chocked
Rag, wiping (Item 41, WP 0206 00) Battery disconnect switch in OFF position (TM 5-
Transparent tube 0.2 in. (6.4 mm) diameter 3805-290-10)
O-ring (3J-1907) Engine doors opened (TM 5-3805-290-10)
0016 00-1
TM 5-3805-290-23-1
STEERING SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS - CONTINUED 0016 00
16
WARNING
• When servicing this machine, performing maintenance, or disposing of hazardous materials, consult your
unit/local hazardous waste disposal center or safety office for local regulatory guidance. If further informa-
tion is needed, please contact The Army Environmental Hotline at 1-800-872-3845.
• 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 fit-
ting. Failure to follow this warning may result in injury to personnel.
16
16
NOTE
00).
PISTON PUMP (STEERING AND PILOT) LOW PRESSURE STANDBY TEST AND ADJUSTMENT 0016 00
1. To release any steering system pressure, turn steering

wheel to left and right.
2. Remove chassis cover from right side of machine (WP
0107 00).
3. Connect Coupling, hose (Item 26, WP 0205 00) to end
of Hose (Item 38, WP 0205 00).
4. Connect Nipple, pipe (Item 49, WP 0205 00) to other
end of hose Hose (Item 38, WP 0205 00).
5. Install Coupling, hose (Item 27, WP 0205 00) on pres-
sure gage.
6. Connect Nipple, pipe (Item 49, WP 0205 00) onto one
end of hose to pressure gage.
7. Remove cap from pressure tap (1) of reducing valve
(2).
8. Connect Coupling, hose (Item 27, WP 0205 00) on
hose to pressure tap (1) on pressure reducing valve (2).
427-B0949
9. Start engine (TM 5-3805-290-10).

10. Run engine at high idle. DO NOT move steering wheel (TM 5-3805-290-10).
11. Expected Results. Pressure should be 590 ± 30 psi (4,065 ± 205 kPa).
0016 00-2
TM 5-3805-290-23-1
PISTON PUMP (STEERING AND PILOT) LOW PRESSURE STANDBY

TEST AND ADJUSTMENT - CONTINUED 0016 00
a. Do not adjust steering piston pump because of this test. If results are not acceptable, perform Piston Pump (Steer-
ing and Pilot) High Pressure Stall Test and Adjustment in this work package.
b. If pressure is correct, remove hose and gage. Place cap on pressure tap (1).
12. Install chassis cover on right side of machine (WP 0107 00).
PISTON PUMP (STEERING AND PILOT) HIGH PRESSURE STALL TEST AND ADJUSTMENT 0016 00
16
WARNING
16
16
1. To release any steering system pressure, turn steering wheel to left and right.
2. Remove chassis cover from right side of machine (WP 0107 00).
3. Connect Coupling, hose (Item 26, WP 0205 00) to end of Hose (Item 38, WP 0205 00).
4. Connect Nipple, pipe (Item 49, WP 0205 00) to other end of Hose (Item 38, WP 0205 00).
5. Install Coupling, hose (Item 27, WP 0205 00) on Hose (Item 38, WP 0205 00).
6. Connect Nipple, pipe (Item 49, WP 0205 00) to end of hose to pressure gage.
7. Install Nipple, pipe (Item 49, WP 0205 00) on Coupling, hose (Item 27, WP 0205 00).
8. Remove cap from pressure tap (1) of pressure reducing valve (2).
9. Connect Coupling, hose (Item 27, WP 0205 00) to hose to pressure tap (1).
10. Start engine (TM 5-3805-290-10).
11. Run engine at high idle (TM 5-3805-290-10).
12. Raise work tool off ground (TM 5-3805-290-10).
13. To initiate stall condition, turn steering wheel to left stop. Continue to turn steering wheel.
14. Observe pressure on gage. Pressure readings should be 3,000 ± 50 psi (20,500 ± 350 kPa).
15. To initiate stall condition, turn steering wheel to right stop. Continue to turn steering wheel.
16. Observe pressure on gage. Pressure readings should be 3,000 ± 50 psi (20,500 ± 350 kPa).
18. Run machine at low idle (TM 5-3805-290-10).
19. Stop engine (TM 5-3805-290-10).
0016 00-3
TM 5-3805-290-23-1
PISTON PUMP (STEERING AND PILOT) HIGH PRESSURE

STALL TEST AND ADJUSTMENT - CONTINUED
NOTE
Pressure compensator valve is located at
top of steering piston pump.
20. If pressure readings are correct, proceed to step 26. If
pressure readings are not correct, pressure compensa-
tor valve (3) needs to be adjusted. To adjust pressure
compensator valve, proceed to step 21.
427-B0950
21. Remove chassis cover from left side of machine (WP 0107 00).
22. Loosen locknut (4).
NOTE
When decreasing pressure setting, turn
adjusting screw counterclockwise below
needed pressure. Then turn adjusting
screw clockwise to correct pressure set-
ting. This method of adjusting pressure
setting eliminates any free play in threads.
23. Adjust pressure as needed. Turn adjusting screw (5)
clockwise to increase pressure. Turn adjusting screw
counterclockwise to decrease pressure. Adjusting
screw is 0.12 in. (3 mm).
24. Tighten locknut (4).
427-B0951
0016 00-4
TM 5-3805-290-23-1
PISTON PUMP (STEERING AND PILOT) HIGH PRESSURE

STALL TEST AND ADJUSTMENT - CONTINUED
25. To ensure pressure is correct, repeat steps 10 thru 19.

26. Remove gages and hoses.
27. Install left and right chassis covers (WP 0107 00).
PISTON PUMP (STEERING AND PILOT) MARGIN PRESSURE TEST AND ADJUSTMENT 0016 00
16
WARNING
16
CAUTION
• Care must be taken to ensure that fluids are contained during inspection and testing of machine. Be prepared
to collect fluid with containers before opening any compartment or disassembling any component containing
fluids.
NOTE
Margin pressure test should be used as reference only. Performing steering pump margin pressure test is
difficult. To obtain more accurate pressure readings, refer to Piston Pump (Steering and Pilot) Low Pressure
Standby Test and Adjustment in this work package.
1. To release any steering system pressure, turn steering wheel to left and right.
2. Remove chassis cover from right side of machine (WP 0107 00).
3. Connect Coupling, hose (Item 26, WP 0205 00) to one end of Hose (Item 38, WP 0205 00).
4. Connect Nipple, pipe (Item 49, WP 0205 00) to other end of Hose (Item 38, WP 0205 00).
5. Connect Nipple, pipe (Item 49, WP 0205 00) to one end of hose to pressure gage.
6. Install Nipple, pipe (Item 49, WP 0205 00) on Coupling, hose (Item 27, WP 0205 00).
0016 00-5
TM 5-3805-290-23-1
PISTON PUMP (STEERING AND PILOT) MARGIN PRESSURE

TEST AND ADJUSTMENT - CONTINUED
7. Remove cap from pressure tap (1) of pressure reduc-
ing valve (2).
hose to pressure tap (1).
427-B0949
9. Remove chassis cover from left side of machine (WP 0107 00).
10. Connect another Coupling, hose (Item 27, WP 0205 00) to one end of Hose (Item 38, WP 0205 00).
11. Connect another Nipple, pipe (Item 49, WP 0205 00) to other end of hose.
12. Connect Nipple, pipe (Item 49, WP 0205 00) to another pressure gage.
0016 00-6
TM 5-3805-290-23-1
PISTON PUMP (STEERING AND PILOT) MARGIN PRESSURE

TEST AND ADJUSTMENT - CONTINUED
NOTE
Pressure compensator valve is attached to top of steering piston pump.
13. Remove cap from pressure tap (6) of pressure com-

pensator valve (3).
hose to pressure tap (6).
427-B0940
15. Position both gages to be easily read.

16. Start engine (TM 5-3805-290-10).
17. Run engine at low idle. Check for hydraulic oil leaks.
18. Run engine at high idle.
19. Slowly turn steering wheel to left or right.
20. Record readings on both gages as steering wheel is turned.
21. Stop engine (TM 5-3805-290-10).
22. Margin pressure is difference between discharge pressure of steering piston pump and signal pressure to steering meter-
ing pump. Margin pressure should be 520 ± 15 psi (3,600 ± 100 kPa).
23. If margin pressure is not correct, perform Piston Pump (Steering and Pilot) Low Pressure Standby Test and Adjustment
and Piston Pump (Steering and Pilot) High Pressure Stall Test and Adjustment, in this work package, before making any
adjustments to pump controller.
24. Remove hoses and gages.
25. Install left and right chassis covers (WP 0107 00).
0016 00-7
TM 5-3805-290-23-1
PUMP PERFORMANCE (STEERING) TEST 0016 00
NOTE
• This test should be used to help determine if there is a problem with steering pump. Pump performance
should be checked if machine has slow steering times.
• Steering time is affected by amount of oil flow produced by steering pump. Check steering times to determine
if there is a problem with steering pump.
1. Start engine and warm hydraulic oil to normal operating temperature. Raise work tool slightly off ground (TM 5-3805-
290-10).
2. Maintain engine speed at high idle (TM 5-3805-290-10).
3. Record steering time from stop to stop. At high idle, steering cycle time should be 1.6 seconds.
NOTE
While parking brake is disengaged, difference between left turn and right turn must not differ by more
than 0.3 seconds. While parking brake is engaged, difference between left turn and right turn should
increase by no more than 0.2 seconds.
4. Lower work tool flat on ground (TM 5-3805-290-10).

5. Reduce engine speed to low idle (TM 5-3805-290-10).
6. Record steering time from stop to stop. At low idle, steering cycle time should be 3.7 seconds.
7. Stop engine (TM 5-3805-290-10).
8. Compare recorded cycle times with proper cycle times. If cycle times match, steering pump is working properly.
a. If cycle times do not match, one of these conditions may be present:
(1) Pressure setting for backup relief valve is not within specifications.
(2) Pump is not upstroking.

(3) Pump may have excessive wear.
b. Measure main relief pressure (WP 0017 00). If main relief pressure is low, cycle times should be retested after
main relief pressure has been corrected.
c. Test pressure of steering pump to ensure pump is upstroking (refer to Piston Pump (Steering and Pilot) High Pres-
sure Stall Test and Adjustment in this work package).
d. Pump may have excessive wear. If so, replace pump (WP 0182 00).
e. If cycle time is slow for only one steering circuit, circuit with slow cycle time should be tested for one of these
conditions:
(1) Low relief valve setting.

(2) Leak in circuit.
(3) Control spool that is not shifting fully.
f. If steering cycle times are consistently slow in one direction, replace secondary steering relief valve (WP 0104 00).
0016 00-8
TM 5-3805-290-23-1
STEERING TIME CHECK 0016 00
WARNING
Permit only one operator on machine. Keep other personnel away from machine and in sight of operator.
1. Start engine (TM 5-3805-290-10).
3. Turn steering wheel to either left or right until steering stop is contacted.
4. Turn steering wheel from steering stop to opposite steering stop. Record time needed.
5. Turn steering wheel from steering stop back to opposite steering stop. Record time needed.
7. Turn steering wheel to left or right until steering stop is contacted.
10. Disengage parking brake (TM 5-3805-290-10).
20. Stop engine (TM 5-3805-290-10).
NOTE
While parking brake is disengaged, difference between left turn and right turn must not differ by more
than 0.3 seconds. While parking brake is engaged, difference between left turn and right turn should
increase by no more than 0.2 seconds.
21. At all engine high idle speeds, steering times should be 1.6 seconds.
22. At all engine low idle speeds, steering times should be 3.7 seconds.
23. Compare recorded times with proper times. If times match, steering pump is working properly.
a. If times do not match, one of these conditions may be present:
(1) Pressure setting for backup relief valve is not within specifications.
(2) Pump is not upstroking.
(3) Pump may have excessive wear.
b. Measure main relief pressure (WP 0017 00). If main relief pressure is low, cycle times should be retested after
main relief pressure has been corrected.
c. Test pressure of steering pump to ensure that pump is upstroking (refer to Piston Pump (Steering and Pilot) High
Pressure Stall Test and Adjustment in this work package).
0016 00-9
TM 5-3805-290-23-1
STEERING TIME CHECK - CONTINUED
d. Pump may have excessive wear. If so, replace pump (WP 0182 00).
e. If cycle time is slow for only one steering circuit, circuit with slow cycle time should be tested for one of these
conditions:
(1) Low relief valve setting.
(2) Leak in circuit.
(3) Control spool that is not shifting fully.
f. If steering times are consistently slow in one direction, replace secondary steering relief valve (WP 0104 00).
STEERING FORCE CHECK 0016 00
1. Remove horn button from center of steering wheel. Disconnect wire from horn button. Push wire down shaft (WP 0098
00).
2. Place 0.7 in. (18 mm) socket on nut in center of steering wheel. Position torque wrench on nut. Use socket extension to
avoid interference with steering wheel.
3. Use torque wrench to turn steering wheel very slowly. Force needed to turn steering wheel should be 38 ± 2 lb-in.
(4.29 ± 0.23 Nm).
4. Start engine (TM 5-3805-290-10). Run engine at low idle.
5. Use torque wrench to turn steering wheel very slowly. Force needed to turn steering wheel should be 23 ± 2 lb-in.
(2.59 ± 0.23 Nm).
6. Pull wire from shaft. Connect wire to horn button.
7. Install horn button on steering wheel (WP 0098 00).
STEERING WHEEL SLIP CHECK 0016 00
1. Slightly raise work tool off ground (TM 5-3805-290-10).

2. Release service brakes (TM 5-3805-290-10).
3. Run engine at low idle (TM 5-3805-290-10).
4. Ensure machine is in straight-ahead position.
5. Slowly turn steering wheel through one revolution so there is minimum articulation.
6. Slowly turn steering wheel in opposite direction so there is minimum articulation.
7. Slowly turn steering wheel through one revolution to left three times. Record time needed for each revolution of steering
wheel.
8. Slowly turn steering wheel through one revolution to right three times. Record time needed for each revolution of steer-
ing wheel.
9. Add recorded times for three left turns together.
10. Add recorded times for three right turns together.
a. If total for three left turns and total for three right turns are 60 seconds or more, then slip is acceptable.
b. If each total is greater than 60 seconds, problem is in steering system. Refer to Steering System Troubleshooting in
WP 0008 00.
0016 00-10
TM 5-3805-290-23-1
METERING PUMP (HMU) TEST 0016 00

16
WARNING
16
CAUTION
• Care must be taken to ensure that fluids are contained during inspection and testing of machine. Be prepared
to collect fluid with containers before opening any compartment or disassembling any component containing
fluids.
• Dispose of all fluids according to local regulations and mandates.
NOTE
• Only perform this test if steering wheel does not return to center position correctly.
• When removing line to tank to install swivel T, oil will drain from both metering pump and line to tank. Oil
must be able to drain into container.
1. Remove line (7) to tank from metering pump. Install

6V-9510 Plug, machine thread (Item 59, WP 0205 00)
into line to tank.
2. Install 7X-0872 Swivel T onto metering pump. Point
port downward.
3. Install 3J-1907 O-ring Seal to 6V-3965 Fitting.
4. Install Coupling half, quick disconnect (Item 28, WP
0205 00) into port on swivel T.
5. Remove face seal plug from line (1) to tank.
6. Connect line (7) to swivel T.
427-B0952
0016 00-11
TM 5-3805-290-23-1
METERING PUMP (HMU) TEST - CONTINUED

7. Connect Nipple, pipe (Item 49, WP 0205 00) to one end of Hose (Item 38, WP 0205 00).
8. Connect Coupling, hose (Item 26, WP 0205 00) to other end of Hose (Item 38, WP 0205 00).
9. Install Coupling, hose (Item 26, WP 0205 00) on test stand.
10. Install Nipple, pipe (Item 49, WP 0205 00) into Coupling, hose (Item 27, WP 0205 00).
11. Install Coupling, hose (Item 27, WP 0205 00) on Coupling half, quick disconnect (Item 28, WP 0205 00).
12. Start machine (TM 5-3805-290-10). Raise work tool off ground. Disengage parking brake. Run machine at high idle.
13. Repeatedly turn machine from left steering stop to right steering stop. Observe pressure gage. Pressure on gage should
not register above 150 psi (1,034 kPa).
14. Straighten machine. Lower work tool to ground. Reduce speed to low idle. Engage parking brake.
15. Stop machine (TM 5-3805-290-10).
16. If pressure was above 150 psi (1,034 kPa), replace metering pump (WP 0101 00).
END OF WORK PACKAGE
0016 00-12
26
TM 5-3805-290-23-1
HYDRAULIC SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS 0017 00
General Pilot System Pressure Test
Piston Pump Pressure Test and Adjustment Relief Valve (Line) Test and Adjustment
Pump Performance (Implement) Test Fan Speed Calibration
INITIAL SETUP

Unit Tape, reflective (Item 57, WP 0206 00)
Test Equipment Tubing assembly set, nonmetallic (Item 99, WP

0205 00)
0205 00) Personnel Required
Test stand, automotive (gage set) (Item 92, WP MOS 62B, Construction Equipment Repairer
0205 00) (2)
References
WP 0003 00
WP 0006 00
00) WP 0008 00
Adapter bushing (Item 1, WP 0205 00) WP 0022 00
Adapter, communication (Item 2, WP 0205 00) WP 0107 00

Coupling, hose (Item 26, WP 0205 00) WP 0182 00
Hose (Item 38, WP 0205 00) (2) WP 0187 00
Indicator, point set (Item 40, WP 0205 00)
Nipple (Item 48, WP 0205 00)
Pin, shoulder, headless (Item 57, WP 0205 00) 10)
Rag, wiping (Item 41, WP 0206 00) Work tool lowered to ground (TM 5-3805-290-10)
Saddle assembly, lifting block (Item 74, WP 0205 Parking brake engaged (TM 5-3805-290-10)
00)
Wheels chocked
Sleeve (Item 80, WP 0205 00)
Software kit (Item 81, WP 0205 00) 3805-290-10)
Stand assembly (Item 83, WP 0205 00) Engine doors opened (TM 5-3805-290-10)
0017 00-1
TM 5-3805-290-23-1
HYDRAULIC SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS - CONTINUED 0017 00
17
17
WARNING
• DO NOT disconnect or remove any hydraulic system lines or fitting unless engine is shut down and hydrau-
lic 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.
• Permit only one operator on machine. Keep other personnel away from machine and in side of operator.
17
CAUTION
• Care must be taken to ensure that fluids are contained during inspection, and testing of machine. Be pre-
pared to collect fluid with containers before opening any compartment or disassembling any component
containing fluids.
NOTE
00).
repair procedures.
GENERAL 0017 00
1. Whenever work tool is raised for testing or adjusting, ensure work tool is supported securely. Also ensure work tool is
fully in DUMP position. Lift circuit has high oil pressure when lift arms raise front of machine.
2. Install steering frame lock so machine cannot articulate (TM 5-3805-290-10).
NOTE
• When any test is performed on hydraulic system, hydraulic oil must be at normal operating temperature.
• During diagnosis of hydraulic system, correct oil flow and pressure are necessary for proper machine oper-
ation. Pump output increases as engine speed increases.
3. Turn engine start switch to ON position without starting engine (TM 5-3805-290-10). Cycle hydraulic control levers
through all positions to release pressure in hydraulic system. Place tilt control lever in FLOAT position. Place lift control
lever in HOLD position.
0017 00-2
TM 5-3805-290-23-1
GENERAL - CONTINUED
5. Stop engine and engage parking brake (TM 5-3805-290-10).
6. Turn engine start switch to ON position without starting engine. Move control levers through full range of travel (TM 5-
3805-290-10). Repeat movement of levers several times to discharge accumulator for pilot system. This will relieve any
pressure that may be present in work tool hydraulic system.
PISTON PUMP PRESSURE TEST AND ADJUSTMENT 0017 00
1. Purging Process for Implement System.
a. Connect steering frame lock (TM 5-3805-290-10).
b. Remove left chassis covers (WP 0107 00) for access to piston pump (1).
c. Connect end of hose to test port (2) for piston pump (1) signal pressure.
d. Remove cap from hydraulic tank (TM 5-3805-290-10).
e. Place other end of hose assembly into hydraulic tank.
f. Start engine (TM 5-3805-290-10).
g. Raise work tool off ground (TM 5-3805-290-10).
h. Move work tool to RACK BACK position. Hold work tool in RACK BACK position for 30 seconds (TM 5-3805-
290-10).
i. Tilt work tool forward until level to ground. Lower lift arms to ground (TM 5-3805-290-10).
j. Shut off engine (TM 5-3805-290-10).

k. Remove hose assembly from tank and pump.
l. Install cap on hydraulic tank (TM 5-3805-290-
10).
2. Signal Limiter Pressure.
a. Connect pressure gage to hose.
b. Connect other end of hose assembly to test port
(2) for piston pump (1) signal pressure.
427-B0958
c. Adjust pump cutoff pressure to 4,350 psi (30,000 kPa). Refer to step 3.
0017 00-3
TM 5-3805-290-23-1
PISTON PUMP PRESSURE TEST AND ADJUSTMENT - CONTINUED

d. Start engine (TM 5-3805-290-10).
e. Raise lift arms and move work tool fully to TILT BACK position (TM 5-3805-290-10). Hold work tool against
stops.
f. Observe signal oil pressure on pressure gage. Pressure should be 3,450 ± 50 psi (23,750 ± 350 kPa).
(1) If signal oil pressure is correct, tilt work
tool forward until level to ground. Lower
lift arms to ground. Stop engine (TM 5-
3805-290-10). Remove test equipment.
(2) If pressure is not correct, adjust signal
limiter valve (3). Pressure should be
3,450 ± 50 psi (23,750 ± 350 kPa).
Loosen locknut (4). Rotate adjusting
screw (5) clockwise to increase pressure.
Rotate adjusting screw counterclockwise
to decrease pressure. Tighten locknut.
Repeat procedure until pressure is within
tolerances.
(3) When signal oil pressure is correct, tilt
work tool forward until level to ground.
Lower lift arms to ground. Stop engine
(TM 5-3805-290-10). Remove test
equipment.
427-B0955
0017 00-4
TM 5-3805-290-23-1

3. Pump Cutoff Pressure.
a. Remove right chassis covers (WP 0107 00) for
access to bank valves.
b. Connect pressure gage to hose.
c. Connect other end of hose assembly to test port
(6) for piston pump pressure. Test port is on top
of bank valve (7).
427-B0956
d. Adjust signal limiter valve pressure above pump cutoff pressure. Pump cutoff pressure should be 3,750 ± 50 psi
(25,850 ± 350 kPa). Refer to step 2.
e. Start engine (TM 5-3805-290-10).
f. Raise lift arms. Move work tool fully to TILT BACK position. Hold work tool against stops (TM 5-3805-290-10).
g. Observe pump cutoff pressure. Pump cutoff pressure should be 3,750 ± 50 psi (25,850 ± 350 kPa).
h. Lower lift arms to ground (TM 5-3805-290-10).
i. If pump cutoff pressure is correct, stop engine (TM 5-3805-290-10). Adjust signal limiter valve to proper pressure.
Refer to step 2. Remove all test equipment.
j. If pump cutoff pressure is not correct, stop engine and proceed to step 4.
0017 00-5
TM 5-3805-290-23-1

4. Pump Pressure Cutoff Adjustment.
a. Loosen locknut (8).
b. Rotate adjusting screw (9) clockwise to increase
pump cutoff pressure, or rotate adjusting screw
counterclockwise to decrease pump cutoff pres-
sure.
c. Tighten locknut (8).
d. Repeat step 3 to verify correct pump cutoff pres-
sure.
e. When pump pressure cutoff is correct, stop
engine (TM 5-3805-290-10). Remove all diag-
nostic equipment.
427-B0957
5. Margin Pressure.
NOTE
Only perform this test if standby pres-
sure is not correct. Perform standby
pressure test before performing margin
pressure test.
a. Connect pressure gage to hose.
b. Connect other end of hose to test port (2) for pis-
ton pump (1) signal pressure.
427-B0958
0017 00-6
TM 5-3805-290-23-1

c. Connect another hose to pressure tap (6) for
pump output located on top of bank valve (7).
Connect pressure gage to other end of hose
assembly.
427-B0956
d. Run engine until normal operating temperature is reached (TM 5-3805-290-10).

e. Raise lift arms slowly (TM 5-3805-290-10).
f. Maximum signal oil pressure should be 3,450 ± 50 psi (23,750 ± 350 kPa). Maximum pump output pressure
should be 3,750 ± 50 psi (25,850 ± 350 kPa). Difference between two gages is margin pressure. Margin pressure
should be 290 ± 15 psi (2,000 ± 103 kPa).
g. If margin pressure is correct, lower lift arms to ground. Stop engine (TM 5-3805-290-10). Remove diagnostic
equipment.
h. If margin pressure is not correct, stop engine (TM 5-3805-290-10). Proceed to step 6.
0017 00-7
TM 5-3805-290-23-1

6. Margin Pressure Adjustment.
a. Loosen locknut (8).
b. Rotate adjusting screw (9) clockwise to increase
margin pressure, or rotate adjusting screw coun-
terclockwise to decrease margin pressure.
c. Tighten locknut (8).
427-B0957
d. Perform test for margin pressure (step 5) to verify margin pressure after adjusting margin spring.
e. When margin pressure is correct, stop engine (TM 5-3805-290-10). Remove diagnostic equipment.
0017 00-8
TM 5-3805-290-23-1

7. Standby Pressure.
a. Remove right chassis cover (WP 0107 00) for
access to bank valve (7).
b. Connect pressure gage to hose.
c. Install other end of hose assembly on test port (6)
for piston pump pressure. Test port for piston
pump pressure is on top of bank valve (7).
427-B0956
NOTE
DO NOT move any work tool controls to check pump standby pressure.
d. Run engine at high idle. Observe pressure on test port for piston pump pressure. Pump standby pressure is 290 ± 30
psi (2,000 ± 207 kPa).
e. Stop engine (TM 5-3805-290-10).
f. Remove all test equipment.
0017 00-9
TM 5-3805-290-23-1

8. Case Drain Pressure.
NOTE
Only perform this pressure test if exces-
sive internal pump leakage is suspected.
When removing plug for case drain to
install pressure tap, oil must be able to
drain into container.
a. Remove left chassis covers (WP 0107 00) for
access to piston pumps.
b. Remove plug from top of piston pump (1) for
work tools.
c. Install nipple (10) on adapter bushing on port.
d. Connect pressure gage to hose.
427-B0961
e. Connect other end of hose assembly to valved nipple assembly.

f. Start engine (TM 5-3805-290-10).
g. Run engine at high idle. Operate controls for work tools.
h. Observe pressure gage. Maximum pressure for case drain is 30 psi (207 kPa). If case drain pressure exceeds 30 psi
(207 kPa), pump has excessive wear or damage. Replace pump (WP 0182 00).
PUMP PERFORMANCE (IMPLEMENT) TEST 0017 00
WARNING
• Permit only one operator on machine. Keep other personnel away from machine and in sight of operator.
• To prevent possible injury to personnel, perform this procedure before testing and adjusting hydraulic sys-
tem.
NOTE
• During diagnosis of hydraulic system, correct oil flow and pressure are necessary for proper machine oper-
ation. Pump output increases as engine speed increases.
• When any test is performed on hydraulic system, hydraulic oil must be at normal operating temperature.
• Use pressure tests and operational tests to verify cause of symptom. Once cause has been identified, repair
failure and repeat system test.
• This procedure should be used to determine if there is a problem with implement pump. Pump perfor-
mance should be checked if machine has slow implement (work tool) movement or low digging power.
Implement Cycle Time.
a. Relieve hydraulic system pressure (TM 5-3805-290-10).
b. Speed of implements is affected by amount of oil flow produced by implement pump. Check implement cycle
times to determine if there may be a problem with implement pump.
c. For information on troubleshooting hydraulic system, refer to Hydraulic System Troubleshooting in WP 0008 00.
0017 00-10
TM 5-3805-290-23-1
PILOT SYSTEM PRESSURE TEST 0017 00

1. Remove right chassis access covers (WP 0107 00).
2. Connect pressure gage to hose. Connect other end of hose to test port (1) for steering pressure in pressure reducing valve
(2).
NOTE
Prior to testing pilot system pressure, make sure steering pump standby pressure is within specification.
Maximum steering pump standby pressure is 625 ± 25 psi (4,300 ± 170 kPa).
3. Connect another pressure gage to another hose.
4. Connect other end of hose to test port (3) for pilot
pressure.
5. Start engine (TM 5-3805-290-10) and run engine at
high idle. With oil at normal operating temperature,
pressure reading must be 450 ± 25 psi (3,100 ± 170
kPa).
6. If pressure reading is correct, stop engine and remove
test equipment from test port (3).
7. If pressure reading is not correct, stop engine. Loosen
locknut (4) on relief valve (5). Turn stem of relief
valve clockwise to increase pressure or counterclock-
wise to decrease pressure. Repeat step 5 to retest pres-
sure.
8. If pressure reading is now correct, stop engine (TM 5-
3805-290-10) and remove test equipment from test
port (1).
427-B0962
0017 00-11
TM 5-3805-290-23-1
RELIEF VALVE (LINE) TEST AND ADJUSTMENT 0017 00
NOTE
Use Table 1 to determine line relief specification for cylinder that is being serviced.
Table 1. Line Relief Specifications for Cylinders.
CYLINDER HEAD END ROD END
Tilt 1,775 ± 29 psi 4,000 ± 50 psi

(12,300 ± 200 kPa) (27,550 ± 350 kPa)
Auxiliary for third function hydraulic 3,250 ± 50 psi 3,250 ± 50 psi
arrangement (22,400 ± 350 kPa) (22,400 ± 350 kPa)
NOTE
Before testing line relief valve, perform step 3 of Piston Pump Pressure Test and Adjustment in this work
package.
1. Line Relief Valve for Head End of Tilt Cylinder.
a. Connect steering frame lock (TM 5-3805-290-10).
b. Remove right chassis cover (WP 0107 00) for access to combination valve (1).
c. Connect pressure gage to hose.
d. Connect other end of hose assembly to test port (2) of line relief valve (3) for head end of tilt cylinder.
e. Start engine. Run engine at high idle. Operate control levers and move all cylinders to increase temperature of
hydraulic oil to normal operating temperature (TM 5-3805-290-10).
f. Raise arm to half of full height and dump bucket until cylinder rods are fully extended. Continue to raise lift arm
slowly (TM 5-3805-290-10). Observe pressure at port (2) for head end of tilt cylinder. As lift arms raise, linkage
pushes rod into cylinders.
g. Observe gage at test port (2) for relief valve setting and record pressure. Setting for relief valve should be 1,775 ±
29 psi (12,238 ± 200 kPa).
h. If line relief valve (3) is not set to correct specifications, stop engine (TM 5-3805-290-10). Adjust line relief valve
by performing steps i and j.
i. Loosen locknut (4). Turn adjusting screw (5) clockwise to increase relief valve setting. Turn adjusting screw coun-
terclockwise to decrease relief valve setting.
j. After adjusting screw (5) is adjusted, tighten locknut (4) to 3 ± 1 lb-ft (4 ± 1 Nm).
k. Start engine (TM 5-3805-290-10).
l. Observe pressure gage and record pressure for head end of tilt cylinder.
m. When pressure settings for line relief valve are correct, stop engine (TM 5-3805-290-10) and remove test equip-
ment.
0017 00-12
TM 5-3805-290-23-1
RELIEF VALVE (LINE) TEST AND ADJUSTMENT - CONTINUED

2. Line Relief Valve for Rod End of Tilt Cylinder.
a. Remove right chassis cover (WP 0107 00) for
access to combination valve (1).
b. Connect dial indicating pressure gage to hose.
c. Connect other end of hose assembly to test port

(6) for rod end of tilt cylinder.
d. Start engine (TM 5-3805-290-10). Run engine at

high idle. Operate control levers and move all
cylinders to increase temperature of hydraulic oil
to normal operating temperature.
e. Raise arm to level position. Tilt back work tool

until cylinder rods are fully retracted. Lower arm
until stops for TILT BACK position are engaged.
Slowly lower lift arm. Observe pressure at test
port (6) for rod end of tilt cylinder. As lift arms
lower, linkage pulls rod from cylinders and pres-
sure increases.
f. Observe gage at test port (6) for relief valve set-

427-B0963
ting and record pressure. Setting for relief valve
should be 4,000 ± 50 psi (27,580 ± 345 kPa).
g. If line relief valve (7) is not set to correct specifications, lower lift arm to ground. Stop engine (TM 5-3805-290-
10). Adjust line relief valve by preforming steps h and i.
h. Remove cap (8) from line relief valve (7).
Loosen locknut (9). Turn adjusting screw (10)
clockwise to increase relief valve setting. Turn
adjusting screw counterclockwise to decrease
relief valve setting.
i. After adjusting screw (10) is adjusted, tighten
locknut (9) to 15 ± 2 lb-ft (20 ± 3 Nm).
j. Start engine (TM 5-3805-290-10).
k. Observe pressure gage and record pressure on
gage.
l. When pressure setting for relief valve is correct,
stop engine (TM 5-3805-290-10) and remove
test equipment.
m. Install cap (8) on line relief valve (7).
427-B0964-1
0017 00-13
TM 5-3805-290-23-1

3. Auxiliary Line Relief Valves for Third Function Hydraulic Arrangement.
a. Connect dial indicating pressure gage to hose.
NOTE
Test port is at top of bank valve.
b. Connect other end of hose assembly to test port for piston pump pressure.
c. Start engine and run engine at low idle (TM 5-3805-290-10).
NOTE
In these steps, DO NOT keep auxiliary control lever in ENGAGED position for more than five seconds
while pressure is at line relief valve setting. This may cause rapid heating of hydraulic oil.
d. Observe pressure gage and move control lever to ENGAGED position. Position of control lever will depend on
which auxiliary line relief valve is being tested. Pressure setting for head end and rod end of hydraulic tilt cylinder
should be 3,250 ± 50 psi (22,407 ± 346 kPa).
e. If auxiliary line relief valve (11 or 12) is not set to correct specifications, stop engine (TM 5-3805-290-10). Adjust
line relief valve(s) by performing steps f thru h.
427-B0969
427-B0964-2
0017 00-14
TM 5-3805-290-23-1

f. Remove cap (13). Loosen locknut (14). Turn
adjusting screw (15) clockwise to increase relief
valve setting.
g. Turn adjusting screw (15) counterclockwise to
decrease relief valve setting.
h. After adjusting screw (15) is adjusted, tighten
locknut (14) to 15 ± 2 lb-ft (20 ± 3 Nm).
i. Install cap (13).
427-B0966
j. Start engine (TM 5-3805-290-10).

k. Observe pressure gage and move control lever to ENGAGED position.
0017 00-15
TM 5-3805-290-23-1

4. Pressure Compensators.
NOTE
Two situations can exist with pressure compensators that will affect operation of hydraulic system: Pres-
sure compensator is stuck at top of spool guide, or pressure compensator is stuck at bottom of spool guide.
a. Perform these steps when pressure compensator is stuck at top of spool guide (fully open).
b. Park machine on smooth, level surface (TM 5-3805-290-10).
c. Engage parking brake (TM 5-3805-290-10).
d. Remove left chassis covers (WP 0107 00) for access to piston pump.
e. Connect dial indicating pressure gage to hose.
Connect other end of hose assembly to test port
(16) of piston pump (17).
f. Start engine (TM 5-3805-290-10). Run engine at
high idle. Operate control levers and move all
cylinders to increase temperature of hydraulic oil
to normal operating temperature.
g. Actuate hydraulic circuit. DO NOT allow circuit
to reach pump cutoff pressure. Fully actuate
another hydraulic circuit. Allow second hydrau-
lic circuit to hit stops.
h. Observe pressure at test port (16) for pump sig-
nal pressure. When second hydraulic circuit hits
stops, observe hydraulic pressure at test port.
Hydraulic pressure is relief pressure for second
circuit. Continue to observe pressure at test port.
If pressure is not relief pressure, pressure com-
pensator is stuck. Replace implement pump (WP
0182 00).
427-B0970
0017 00-16
TM 5-3805-290-23-1
FAN SPEED CALIBRATION 0017 00

1. Preparation for Calibration.
a. Inspect fan drive hoses for damage. Inspect all connectors and components of fan drive for damage (WP 0187 00).
b. Remove 20 bolts and fan guard from machine.
NOTE
If there is already a piece of reflective tape on fan blade, proceed to step d.
c. Attach piece of reflective tape (3) to fan (4).
427-B0976
d. Reinstall guard (2) with 20 bolts (1). Tighten

bolts to 40 ± 7 lb-ft (55 ± 10 Nm).
e. Install point set indicator on guard (2).
427-B0971
0017 00-17
TM 5-3805-290-23-1
FAN SPEED CALIBRATION - CONTINUED
NOTE
To ensure proper operation of cooling system, engine access doors should be closed.
f. Connect MSD, equipped with ET software, to data link connector using communication adapter (WP 0006 00).
g. Start engine and run engine at low idle (TM 5-3805-290-10).
h. Open ET and check for active diagnostic codes. If there is an active diagnostic code, calibration procedure will be
stopped until condition that caused diagnostic code is corrected.
i. When active diagnostic codes are corrected, select transmission ECM from available ECM list.
j. Select “Service” menu to begin calibration procedure. Then select “Calibrations”. Second menu will be displayed.
Select “Engine Cooling Fan Calibration” from second menu.
427-B0800
0017 00-18
TM 5-3805-290-23-1

k. Read warning and press “OK” when ready to proceed.
427-B0801
l. Next screen allows unselecting tests that are not required. Select box next to test that is not desired. Check in check
box will disappear when test is unselected. Test for nominal fan speed should not be performed. Test for nominal
fan speed is used for testing purposes only. Tests for maximum and minimum fan speed are only tests that should
be used. When desired tests have been selected, press “Begin”.
427-B0802
m. Proceed to step 2 if test for maximum fan speed was selected.

n. Proceed to step 3 if test for minimum fan speed was selected.
0017 00-19
TM 5-3805-290-23-1

2. Calibration for Maximum Fan Speed.
a. Next screen is initial calibration screen. Screen displays instructions for calibration. Top display area displays sta-
tus parameters that are monitored during calibration. Middle display area displays information about status of cali-
bration. Display area on bottom will display conditions for setup and instructions for calibration.
427-B0803
b. Display area will show conditions for setup:

(1) Set parking brake (TM 5-3805-290-10).
(2) Operate engine at high idle. Use throttle lock switch on instrument panel to operate engine at high idle.
(3) Warm transmission oil to between 140 to 176°F (60 to 80°C).
c. Perform these procedures to obtain conditions for setup:
(1) Ensure parking brake is engaged.
(2) Run engine at high idle with throttle lock.
(3) Monitor hydraulic oil temperature with MSD screen and stall hydraulic function to increase hydraulic oil
temperature. Stall hydraulic function by moving function to end of travel.
d. When conditions for setup are obtained, press “Next” button to start calibration. If conditions for setup are not cor-
rect, condition that is not correct will be displayed in middle display area. Calibration will not start. When condi-
tions are correct, press “Next” button to start fan speed calibration.
0017 00-20
TM 5-3805-290-23-1
NOTE
• When maximum fan speed is calibrated, minimum signal will be sent to hydraulic demand fan solenoid to
obtain maximum fan speed.
• Cancel calibration at any time by pressing “Cancel” button.
e. Record fan speed. Maximum fan speed is 1,625 ± 25 rpm. Press left arrow (5) or right arrow (6) buttons at bottom
of screen until fan speed is approximately 1,000 rpm. Then, press left arrow button at bottom of screen until fan
speed is correct.
NOTE
• When right arrow button is pressed, signal to hydraulic demand fan solenoid will be increased. When signal
is increased, fan speed will decrease. When left arrow button is pressed, signal to hydraulic demand fan
solenoid will be decreased. When signal is decreased, fan speed will increase.
• When adjusting maximum speed of fan and maximum speed is exceeded, decrease speed of fan below 1,500
rpm and then increase speed of fan to 1,625 ± 25 rpm. This will allow fan speed to be properly set.
427-B0804
0017 00-21
TM 5-3805-290-23-1

f. Calibration procedure could be stopped for several reasons. Refer to Table 2 for error codes that can be displayed
by MSD. Correct condition that caused error code and restart calibration.
Table 2. Error Codes for Fan Speed Calibration.
ERROR
CODE DESCRIPTION PROCEDURE
0002 Active diagnostic present There is active diagnostic code. Exit calibration and correct
condition that caused diagnostic code.
0006 Calibration aborted by tool/monitor Calibration has been stopped by MSD. Restart calibration
procedure.
0009 Calibration aborted by ECM Calibration has been stopped by ECM. Restart calibration
procedure.
1010 Engine stopped Engine has stopped. Restart engine and set engine to high idle.
1012 Engine rpm incorrect Engine rpm is not correct. Set engine rpm to high idle.
1018 Parking brake not engaged Parking brake is not engaged. Set parking brake.
1020 Transmission gear incorrect Transmission gear is not correct. Transmission must be in
NEUTRAL.
1048 Hydraulic oil temperature too low Hydraulic oil temperature is too low. Repeat procedure to increase
hydraulic oil temperature.
1054 Hydraulic oil temperature too high Hydraulic oil temperature is too high. Decrease engine speed and
ensure engine access doors are closed.
1074 Engine rpm too low Engine rpm is too low. Set engine rpm to high idle.
0017 00-22
TM 5-3805-290-23-1

g. When maximum fan speed is correct, press “Next” button to complete test.
h. Next screen will show that test was successful. Press “Continue” to proceed.
427-B0805
i. If test for minimum fan speed was selected, proceed to step 3. If test for minimum fan speed was not selected, dis-
engage throttle lock and stop engine (TM 5-3805-290-10).
j. Remove test equipment.
0017 00-23
TM 5-3805-290-23-1

3. Calibration for Minimum Fan Speed.
a. Next screen is initial calibration screen. Screen displays instructions for calibration. Top display area displays sta-
tus parameters that are monitored during calibration. Middle display area displays information about status of cali-
bration. Display area on bottom will display conditions for setup and instructions for calibration.
b. Display area will show conditions for setup:
(1) Set parking brake (TM 5-3805-290-10).
(2) Operate engine at high idle. Use throttle lock switch on instrument panel to operate engine at high idle.
(3) Warm transmission oil between 140 to 176°F (60 to 80°C).
427-B0806
0017 00-24
TM 5-3805-290-23-1
c. Perform these procedures to obtain conditions for setup:

(1) Ensure parking brake is engaged (TM 5-3805-290-10).
(2) Run engine at high idle with throttle lock.
(3) Monitor hydraulic oil temperature with MSD screen and stall hydraulic function to increase hydraulic oil
temperature. Stall hydraulic function by moving function to end of travel.
d. When conditions for setup are obtained, press “Next” button to start calibration. If conditions for setup are not cor-
rect, condition that is not correct will be displayed in middle display area. Calibration will not start. When condi-
tions are correct, press “Next” button to start fan speed calibration.
NOTE
• When minimum fan speed is being calibrated, maximum signal will be sent to hydraulic demand fan sole-
noid to obtain minimum fan speed.
• Cancel calibration at any time by pressing “Cancel” button.
427-B0807
0017 00-25
TM 5-3805-290-23-1

e. Record fan speed. Minimum fan speed is 700 ± 100 rpm. Press left arrow (5) or press right arrow (6) buttons at
bottom of screen until fan speed is approximately 1,000 rpm. Then, press right arrow button at bottom of screen
until fan speed is correct.
NOTE
• When right arrow button is pressed, signal to hydraulic demand fan solenoid will be increased. When signal
is increased, fan speed will decrease. When left arrow button is pressed, signal to hydraulic demand fan
solenoid will be decreased. When signal is decreased, fan speed will increase.
• When adjusting minimum speed of fan and minimum speed is exceeded, increase speed of fan above 850
rpm and then decrease speed of fan to 700 ± 100 rpm. This will allow fan speed to be properly set.
f. Calibration procedure could be stopped for several reasons. Refer to Table 2 for error codes that can be displayed
by MSD. Correct condition that caused error code and restart calibration.
g. When minimum fan speed is correct, press “Next” button to end fan speed calibration.
h. Next screen will show that test was successful. Press “Continue” to proceed.
427-B0808
i. Disengage throttle lock and stop engine (TM 5-3805-290-10).

j. Remove test equipment.
END OF WORK PACKAGE
0017 00-26
18
TM 5-3805-290-23-1
AIR CONDITIONING SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS 0018 00
General Refrigerant Leakage Test

Refrigerant Quick-Check Procedure for R-134a Expan- Refrigerant Compressor Oil Check
sion Valve and Orifice Tube Systems Refrigerant System Charge
Performance Checks for Air Conditioning System Refrigerant Compressor Test
Test Procedure for Arc Suppressor in Air Conditioning
System
INITIAL SETUP
Maintenance Level Personnel Required

Direct Support MOS 52C, Utilities Equipment Repairer
References
TM 5-3805-290-10
Shop equipment, automotive maintenance and
repair: field maintenance, basic, less power (Item WP 0003 00
75, WP 0205 00)
WP 0008 00
Leak detection lamp (Item 42, WP 0205 00)
WP 0022 00
Leak detector, refrigerant gas (Item 43, WP 0205
00) WP 0046 00
Reclaimer, refrigerant (Item 70, WP 0205 00) WP 0191 00
Materials/Parts WP 0192 00
Cap set, protective (Item 8, WP 0206 00)
WP 0193 00
Cleaning compound, solvent, type III (Item 9, WP
0206 00) WP 0194 00
Oil, lubricating, refrigerant compressor (Item 37, WP 0195 00

WP 0206 00)
WP 0196 00
WP 0197 00
Refrigerant dye (Item 42, WP 0206 00)
Strap, tiedown, electrical (Item 53, WP 0206 00) Drawings Required
Tag, marker (Item 54, WP 0206 00) TM 5-3805-290-23P, Figure 175
Tetrafluoroethane, technical (Refrigerant, R-134a)
43 lb cyl (Item 58, WP 0206 00) Estimated Time to Complete Task
Refrigerant accumulator 1.0 hr
0018 00-1
TM 5-3805-290-23-1
AIR CONDITIONING SYSTEM TESTS, INSPECTIONS, AND ADJUSTMENTS - CONTINUED 0018 00
18
WARNING
• Injury to personnel can result from contact with refrigerant.
• This system is under pressure at all times, even if engine is not running. Heat should never be applied to a
charged system.
• Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury to person-
nel.
• Protective goggles and gloves must always be worn when refrigerant lines are opened, even if gages indicate
system is out of refrigerant.
• Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pres-
sure, evacuate system recovering refrigerant before removing fitting.
• Injury or death to personnel can result from inhaling refrigerant through a lit cigarette.
• Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes
released from a flame contacting air conditioner refrigerant gas can cause bodily harm or death.
• DO NOT smoke when servicing air conditioners or wherever refrigerant gas may be present.
• Before any checks of air conditioning and heating system are made, move machine to a smooth horizontal
surface. Lower all implements to ground. Ensure transmission is in neutral or park and parking brake is
engaged. Keep all other personnel away from machine or where they can be seen.
CAUTION
• Low refrigerant charge will cause a loss of cooling ability and a loss of lubrication in compressor, which will
result in failure of compressor.
• Overcharge of refrigerant will cause a loss of cooling ability. A system that is overcharged will contain
excess liquid refrigerant, which will severely damage compressor. An overcharged system will fail two times
faster than an undercharged system.
• Too much oil in system will contribute to a low refrigerant charge.
GENERAL
1. A small amount of moisture will penetrate hoses used in R-134a systems. Change dryer and change accumulator and
desiccant annually. Moisture causes sludge and moisture results in plugged systems. Moisture also causes formation of
ice at orifice tube assembly.
2. For a better understanding of each system, review the appropriate section in Theory of Operation (WP 0003 00).
3. Gage readings for an undercharged R-134a system may appear as symptoms of overcharge under certain conditions.
This occurs when ambient temperature is above 90°F (32°C) or in high humidity. Gage readings that are incorrect lead
to a loss of cooling ability and failure of compressor.
4. Refrigerant removed from a system cannot be weighed accurately. A 20 to 30% error can occur. Error is a result of oil
removed from system and a result of inaccuracies of devices used for recovery.
5. After recovering a system, if system pressure rises above 0 psi (0 kPa) within 5 minutes, system must be recovered again
until pressure does not increase. Recovering system again will empty accumulator of refrigerant.
6. Presence of frost on accumulator is a normal condition. Thickness of frost will depend on ambient temperature and
humidity.
7. Frost can appear anywhere on an R-134a air conditioning system. Appearance of frost does not always indicate a failure.
In order to diagnose a blockage in air conditioning system properly, air temperature at evaporator must be checked and
pressure readings must be taken.
0018 00-2
TM 5-3805-290-23-1
GENERAL - CONTINUED
8. All charging and leak testing must be done in a well ventilated area.
9. Avoid any physical contact with refrigerant.
10. Place a clean cloth over any valve or any connection that is opened.
11. Never weld any charged components.
12. Never solder any charged components.
13. Never steam clean any charged components.
14. Dispose of any oil that is polyalkaline glycol (PAG) that has been opened but not used. Moisture will contaminate
unused oil and air conditioning system.
15. These procedures may give direction to replace wiring harnesses. However, limited repair of wiring harnesses is autho-
rized. Refer to Electrical General Maintenance Instructions (WP 0022 00) for the correct repair procedures.
16. In order to check function of compressor, disconnect hose from inlet of inline dryer. Measure pressure of suction of
compressor. Pressure should be a vacuum between 24 to 28 inHg (81 to 95 kPa). Do not operate compressor for more
than 2 minutes when system pressure is below vacuum.
17. Secure lines and wires in order to prevent damage to lines and wires.
18. Formation of black sludge deposits in system is caused by presence of moisture in R-134a systems and by mixing
charges of R-134a and R-12. Black sludge deposits can cause a blockage in system.
19. Presence of white foam during recovery is normal. Foam is caused by mixing of oil and refrigerant.
20. R-134a system charges must be within 1.000 to 2.000 oz (0.03 to 0.06 kg) of specified charge for machine.
21. A drain line that is plugged or a drain line that is pinched may cause a backup of condensation and leakage into cab.
22. Missing drain valves may cause a backup of condensation and leakage into cab.
23. Missing drain valves will allow dust to be sucked into evaporator coil and heater coil.
24. A cab pressure of 0.200 to 0.600 in. of H2O (0.05 to 0.15 kPa) and proper maintenance of air conditioner filter will
result in the following conditions:
a. Reduction of dust.
b. Reduction of noise.
c. More efficient HVAC performance.
25. A loss of cooling ability of system and failure of compressor may be caused by one or more of following conditions:
a. Low charge.
b. Overcharge.
c. Too much oil.
d. Too little oil.
e. Dirty filter or plugged filter.
f. Dirty condenser or plugged condenser.
g. Dirty evaporator or plugged evaporator.
h. Dirty orifice tube or plugged orifice tube.
i. Dirty expansion valve or plugged expansion valve.
j. Too much moisture in system.
k. Missing drain valves for evaporator.
0018 00-3
TM 5-3805-290-23-1
REFRIGERANT QUICK-CHECK PROCEDURE FOR R-134A EXPANSION

VALVE AND ORIFICE TUBE SYSTEMS 0018 00
NOTE
In order to use this procedure, temperature of ambient air must be at least 70°F (21°C).
1. Start engine and run engine at approximately 1,000 rpm. Move control knob on air conditioner to position of MAXI-
MUM so cooling is at a maximum in order to stabilize system, put fan switch in HIGH position and operate system for a
minimum of 10 minutes (TM 5-3805-290-10).
2. Check for restrictions present in refrigerant lines from compressor to inline dryer. Refrigerant lines and components that
are high pressure and high temperature come from outlet side of compressor. Lines go to inlet side of orifice tube. Outlet
side will be warm during normal operation. Heavy frost or a decrease in temperature in a line or in a component on high
pressure side may be an indication of a restriction or blockage.
a. If there is no evidence of a restriction in condenser coil, inline dryer, or refrigerant lines from compressor to inline
dryer, use procedure in step 3.
b. If there is a restriction in condenser coil, inline dryer, or refrigerant lines from compressor to inline dryer, perform
the following procedures:
(1) Recover refrigerant (WP 0191 00).
(2) Remove restriction or replace component (WP 0193 00 thru WP 0195 00).
(3) Evacuate system (WP 0191 00).
(4) Charge system with correct amount of refrigerant (WP 0191 00).
(5) Perform a leak test. Refer to Refrigerant Leakage Test in this work package.
(6) Perform a performance check. Refer to Performance Checks for Air Conditioning System in this work
package.
(7) If problem still exists go to step 4.
3. Low system charge is indicated. Perform a leak test.
NOTE
If system is very low on refrigerant, a partial charge may be needed before you perform a leak test.
a. Recover remaining refrigerant (WP 0191 00).
b. Repair all leaks.
c. Evacuate system (WP 0191 00).
d. Charge system with correct amount of refrigerant. Measure refrigerant by weight (WP 0191 00).
e. Perform a performance check. Refer to Performance Checks for Air Conditioning System in this work package.
f. If problem still exists, go to step 4.
4. Feel low pressure line and feel high pressure line at compressor. In order to indicate normal systems operation, high
pressure line to condenser coil must be warm, while low pressure line to evaporator coil must be cool.
a. High pressure line and low pressure line at compressor have a minimal temperature difference between two lines.
Use procedure in step 5.
b. If there is a definite temperature difference between high pressure line and low pressure line at compressor, system
is operating correctly. High pressure line will be warm. Low pressure line will be cool. Use procedure in step 6.
0018 00-4
TM 5-3805-290-23-1

VALVE AND ORIFICE TUBE SYSTEMS - CONTINUED 0018 00
5. If system has no refrigerant charge or if system is nearly empty of refrigerant charge, perform the following procedure:
a. Stop engine (TM 5-3805-290-10).
b. Perform a partial charge of system (WP 0191 00).
c. Perform a leak test. Refer to Refrigerant Leakage Test in this work package.
d. Repair leaks.
e. Evacuate system (WP 0191 00).
f. Charge system with correct amount of refrigerant. Measure refrigerant by weight (WP 0191 00).
g. Perform a performance check. Refer to Performance Checks for Air Conditioning System in this work package.
NOTE
Refer to Table 1.
6. An overcharge of system is possible even though system can have a definite difference in temperature at low pressure
line and at high pressure line.
a. Recover refrigerant (WP 0191 00).
b. Evacuate system (WP 0191 00).
NOTE
All pressures are given as a guide only. Weight is only absolute means of determining proper refrigerant
charge. Improper refrigerant charge will cause premature failure of compressor.
Table 1. Pressure Range.
HIGH PRESSURE TEST FITTING

(PRESSURE MAY BE SLIGHTLY
HIGHER IN VERY HUMID LOW PRESSURE TEST FITTING
CONDITIONS AND LOWER IN (PRESSURE BEFORE CLUTCH
AMBIENT AIR TEMPERATURE VERY DRY CONDITIONS) DISENGAGEMENT)
c. Charge system with correct amount of refrigerant. Measure refrigerant by weight (WP 0191 00).
d. Perform a performance check. Refer to Performance Checks for Air Conditioning System in this work package.
e. Determine level of system charge. When both inlet of accumulator and outlet of accumulator are cool to touch, sys-
tem is charged correctly.
0018 00-5
TM 5-3805-290-23-1

VALVE AND ORIFICE TUBE SYSTEMS - CONTINUED 0018 00
NOTE
If outlet is warmer than inlet, system may not contain enough refrigerant.
(1) Recover refrigerant (WP 0191 00).
(2) Evacuate system (WP 0191 00).
(3) Charge system with correct amount of refrigerant. Measure refrigerant by weight (WP 0191 00).
(4) Perform a leak test. Refer to Refrigerant Leakage Test in this work package.
(5) Perform a performance check. Refer to Performance Checks for Air Conditioning System in this work
package.
PERFORMANCE CHECKS FOR AIR CONDITIONING SYSTEM 0018 00
NOTE
A performance check of AC system must be made with a manifold gage set. Manifold gage set must be con-
nected to diagnostic connectors on compressor.
1. Use refrigerant reclaimer as manifold gage set.
NOTE
Most system failures are caused by improper refrigerant charge. Refrigerant charge should be measured
by weight only. Do not use gage pressure when you charge system with refrigerant.
2. Start engine and operate engine at 1,000 rpm. Move temperature control knob to maximum cool position. Put fan switch
in HIGH position on AIR CONDITIONING side. In order to stabilize system, operate system for a minimum of 10 min-
utes. Operate engine at 1,000 rpm (TM 5-3805-290-10).
a. During normal operation of AC system in 70°F (21°C) temperature, discharge (high pressure test fitting) pressure
will be 120 to 190 psi (820 to 1,300 kPa), suction (low pressure test fitting) pressure will be 10 to 20 psi (70 to 130
kPa). Refer to Table 1 for temperature range. Outside temperature and humidity will have an effect on pressures. If
outside temperature is high, discharge pressure will be high.
b. In very hot weather, suction and discharge pressures will be high. In cooler weather, suction and discharge pressure
will be normal or pressure can be lower.
c. If suction and discharge pressures are not within normal operating range, refer to Table 8, Troubleshooting (WP
0008 00).
0018 00-6
TM 5-3805-290-23-1
TEST PROCEDURE FOR ARC SUPPRESSOR IN AIR CONDITIONING SYSTEM 0018 00
NOTE
AC systems use pressure switches in order to protect AC system. Arc suppressors protect other electrical
components in AC system. Arc suppressors protect other electrical components in AC system. Arc suppres-
sors are applied in order to discharge electrical inductance when compressor disengages. Failure of arc sup-
pressor can affect reliability of pressure switch. Failure of arc suppressor may cause failure of pressure
switch.
427-B2113
1. Place multimeter in DIODE test mode.

2. Place red probe in red terminal (positive terminal) of multimeter.
3. Place black probe in black terminal (negative terminal) of multimeter.
4. Place red probe on Pin 2 of connector on arc suppressor. Place black probe on Pin 1 of connector.
5. Multimeter should display a value between 0.5 and 1.0 VDC.
6. Place red probe on Pin 1 of connector on arc suppressor. Place black probe on Pin 2 of connector on arc suppressor.
7. Multimeter should display OL.
8. If conditions listed in steps 5 and 7 do not exist, component should be considered faulty. Component will not provide
adequate protection.
9. Replace component if component has failed.
0018 00-7
TM 5-3805-290-23-1
REFRIGERANT LEAKAGE TEST 0018 00
Dye
NOTE
• Finding leaks and repairing leaks from refrigerant is important since AC is a closed circuit system.
• System must contain at least 0.88 lb (0.4 kg) of refrigerant to perform leak test. Install manifold gage set to
determine if pressure exists in system. A leak test can be performed if system indicates pressure.
• Refrigerant vapor is heavier than air. For best results, place black light directly below possible leaks.
• Leaks in high pressure side of system are more easily found if AC is operated for 5 to 10 minutes. Leak test
must be performed immediately after unit is turned OFF. Leak test for high pressure side is performed
before pressures in system equalize. Leaks in low pressure side of system are more easily found if AC has
been turned OFF for 5 to 10 minutes. Leak test for low pressure side is performed after pressures in system
equalize.
1. Move black light along possible leak points. When a leak is present, black light will illuminate dye in refrigerant.
2. If a leak is found in AC system, use a Refrigerant Leak Detector in order to confirm leak was detected by use of black
light.
Leak Detector
NOTE
• Refrigerant Leak Detectors are designed to detect leaks as small as 0.25 oz (7.4 ml) per year of refrigerant
in air conditioning system. Perform the following procedure in order to determine if system has a leak.
• Refrigerant vapor is heavier than air. For best results, place sensor tip directly below possible leaks.
• Under normal conditions, R-134a AC systems that have P80 hoses may lose as much as 0.0400 lb (0.018 kg)
of refrigerant per foot of hose per year.
• Refrigerants which are not approved may have higher leakage rates.
1. Move sensor tip along possible leak points at a rate of 1 in. (2.5 cm) per second.
2. It may not be necessary to recover refrigerant if a loose fitting or a loose connection is causing a leak. Tighten loose con-
nection and perform performance check procedure. If necessary, add refrigerant to AC system (WP 0191 00).
3. If repair of a leak calls for removal or replacement of a component, refer to WP 0192 00 thru WP 0197 00.
0018 00-8
TM 5-3805-290-23-1
REFRIGERANT COMPRESSOR OIL CHECK
NOTE
• A special refrigerant oil is used in AC system. Oil mixes completely with refrigerant so all components
receive lubrication. A check of refrigerant oil in compressor will give an indication of amount of oil in sys-
tem.
• Refer to Theory of Operation (WP 0003 00) for more information.
• Generally, oil in compressor is checked when there is evidence of a major loss of oil. These conditions may
cause loss of oil:
• Broken refrigerant hose.
• Hose fitting (leaks).

• Badly leaking compressor seal.
• Component damage.
Complete Check of Compressor Oil
1. Operate engine at 1,000 rpm. Set temperature on maximum cooling setting. Move fan speed switch to HIGH. System
will stabilize in a minimum of 10 minutes (TM 5-3805-290-10).
2. Stop engine. Remove refrigerant charge from system (WP 0191 00).
3. Remove compressor from machine (WP 0192 00). Place protective caps on all fittings and hoses.
427-B2091
4. Place compressor in a horizontal position so oil plug is facing downward. Remove oil plug from compressor. Drain oil
into a clean container. Rock compressor back and forth in order to remove all oil. Also, rotate compressor shaft in order
to drain rest of oil that is in oil sump. Record volume of drained refrigerant. Inspect oil for these items:
a. Contaminants
b. Metal chips
c. Rubber particles
d. Foreign material
0018 00-9
TM 5-3805-290-23-1
REFRIGERANT COMPRESSOR OIL CHECK - CONTINUED
Complete Check of Compressor Oil - Continued
5. Dispose of oil in a suitable container. Use the following list as a guide for adding oil into compressor:
a. If amount of oil drained from compressor is 6 to 8 fl oz (177 to 237 ml), put same amount of new refrigerant oil in
compressor. Never refill with more than 8 fl oz (237 ml) of oil in compressor unless system has been flushed.
b. If amount of oil drained from compressor is less than 6 fl oz (177 ml), add 6 to 8 fl oz (177 to 237 ml) of new
refrigerant oil to compressor.
c. If a new compressor or a rebuilt compressor is installed, drain all oil from compressor and add 6 to 8 fl oz (177 to
237 ml) of new refrigerant oil to compressor.
d. If system was flushed do not remove oil from a new compressor.
e. Refer to Table 2 if individual components are replaced without charging compressor or without flushing system.
Table 2. Oil Capacities for Component Replacement.
Accumulator 1 fl oz (30 ml)

Compressor Refer to Refrigerant Compressor Oil Check in this work
package.
Condenser 1 fl oz (30 ml)
Evaporator 3 fl oz (90 ml)
Inline Dryer (1) 1 fl oz (30 ml)
Receiver/Dryer 1 fl oz (30 ml)
6. If failure of a component causes particles of metal or other foreign material to be present in system, it is necessary to
flush system. Refer to Troubleshooting Without a Diagnostic Code (WP 0008 00).
NOTE
• If too much oil has been added to system and a total of more than 11 fl oz (325 ml) of oil is in system, cooling
capacity of system will be reduced. If too little oil has been added to system, compressor may fail due to a
lack of lubrication.
• Add oil to compressor through opening for oil plug or inject oil through ports for charging. Compressor
must be positioned so refrigerant oil will not flow out of service valves. Do not rest compressor on compres-
sor shaft. Turn compressor shaft by hand when you fill compressor. Oil will slowly flow into compressor.
Only use refrigerant oil approved and recommended.
• Add oil to any components being installed.
• Inject oil into pressurized system through port for low pressure charging while engine is running and com-
pressor is operating.
7. After correct amount of refrigerant oil has been added to system, install compressor and drive belt (WP 0192 00).
0018 00-10
TM 5-3805-290-23-1
REFRIGERANT SYSTEM CHARGE 0018 00
Relationship Between Temperature and Pressure (R-134a Refrigerant)
Table 3 can be used in order to determine pressure level and contamination level of a container of refrigerant. Table 3
can also be used for an AC system that is not operating. This same system must be stabilized to ambient temperature. In order
to stabilize an AC system at ambient temperature, machine must not operate for 10 to 12 hours. Machine must not be stored in
direct sunlight.
If pressure measured at any specific temperature does not match pressure given in chart, the following problems may
exist:
• Contaminants in system.
• Incorrect refrigerant.
• Incorrect refrigerant charge.
0018 00-11
TM 5-3805-290-23-1
REFRIGERANT SYSTEM CHARGE - CONTINUED
Relationship Between Temperature and Pressure (R-134a Refrigerant) - Continued
Table 3. Relationship Between Temperature and Pressure (R-134a Refrigerant).
TEMPERATURE °F (°C) PRESSURE PSI(1) (KPA)
0.0°F (-18°C) 6.4 psi (44 kPa)

2.0°F (-17°C) 7.4 psi (51 kPa)
4.0°F (-16°C) 8.5 psi (59 kPa)
6.0°F (-14°C) 9.6 psi (66 kPa)
8.0°F (-13°C) 10.7 psi (74 kPa)
10.0°F (-12°C) 11.9 psi (82 kPa)
12.0°F (-11°C) 13.1 psi (90 kPa)
14.0°F (-10°C) 14.3 psi (99 kPa)
16.0°F (-9°C) 15.6 psi (108 kPa)
18.0°F (-8°C) 17.0 psi (117 kPa)
20.0°F (-7°C) 18.4 psi (127 kPa)
21.0°F (-6°C) 19.1 psi (132 kPa)
22.0°F (-6°C) 19.8 psi (137 kPa)
23.0°F (-5°C) 20.5 psi (141 kPa)
24.0°F (-4°C) 21.3 psi (147 kPa)
25.0°F (-4°C) 22.0 psi (152 kPa)
26.0°F (-3°C) 22.8 psi (157 kPa)
27.0°F (-3°C) 23.6 psi (163 kPa)
28.0°F (-2°C) 24.4 psi (168 kPa)
29.0°F (-2°C) 25.2 psi (174 kPa)
30.0°F (-1°C) 26.0 psi (179 kPa)
31.0°F (-1°C) 26.8 psi (185 kPa)
32.0°F (0°C) 27.7 psi (191 kPa)
33.0°F (1°C) 28.5 psi (197 kPa)
34.0°F (1°C) 29.4 psi (203 kPa)
35.0°F (2°C) 30.3 psi (209 kPa)
36.0°F (2°C) 31.2 psi (215 kPa)
37.0°F (3°C) 32.1 psi (221 kPa)
38.0°F (3°C) 33.0 psi (228 kPa)
0018 00-12
TM 5-3805-290-23-1
Table 3. Relationship Between Temperature and Pressure (R-134a Refrigerant) - Continued.

39.0°F (4°C) 34.0 psi (234 kPa)
40.0°F (4°C) 34.9 psi (241 kPa)
41.0°F (5°C) 35.9 psi (248 kPa)
42.0°F (6°C) 36.9 psi (254 kPa)
43.0°F (6°C) 37.9 psi (261 kPa)
44.0°F (7°C) 38.9 psi (263 kPa)
45.0°F (7°C) 39.9 psi (275 kPa)
46.0°F (8°C) 41.0 psi (283 kPa)
47.0°F (8°C) 42.0 psi (290 kPa)
48.0°F (9°C) 43.1 psi (297 kPa)
49.0°F (9°C) 44.2 psi (305 kPa)
50.0°F (10°C) 45.3 psi (312 kPa)
51.0°F (11°C) 46.4 psi (320 kPa)
52.0°F (11°C) 47.5 psi (328 kPa)
53.0°F (12°C) 48.7 psi (336 kPa)
54.0°F (12°C) 49.9 psi (344 kPa)
55.0°F (13°C) 51.0 psi (352 kPa)
56.0°F (13°C) 52.2 psi (360 kPa)
57.0°F (14°C) 53.5 psi (369 kPa)
58.0°F (14°C) 54.7 psi (377 kPa)
59.0°F (15°C) 55.9 psi (385 kPa)
60.0°F (16°C) 57.2psi (394 kPa)
61.0°F (16°C) 58.2 psi (403 kPa)
62.0°F (17°C) 59.8 psi (412 kPa)
63.0°F (17°C) 61.1 psi (421 kPa)
64.0°F (18°C) 62.4 psi (430 kPa)
65.0°F (18°C) 63.8 psi (440 kPa)
66.0°F(19°C) 65.2 psi (450 kPa)
67.0°F (19°C) 66.8 psi (459 kPa)
0018 00-13
TM 5-3805-290-23-1

68.0°F (20°C) 68.0 psi (469 kPa)
69.0°F (21°C) 69.4 psi (478 kPa)
70.0°F (21°C) 70.8 psi (488 kPa)
71.0°F (22°C) 72.3 psi (498 kPa)
72.0°F (22°C) 73.8 psi (509 kPa)
73.0°F (23°C) 75.3 psi (519 kPa)
74.0°F (23°C) 76.8 psi (530 kPa)
75.0°F (24°C) 78.3 psi (540 kPa)
76.0°F (24°C) 79.9 psi (551 kPa)
77.0°F (25°C) 81.5 psi (562 kPa)
78.0°F (26°C) 83.1 psi (573 kPa)
79.0°F (26°C) 84.7 psi (584 kPa)
80.0°F (27°C) 86.3 psi (595 kPa)
81.0°F (27°C) 88.0 psi (607 kPa)
82.0°F (28°C) 89.7 psi (618 kPa)
83.0°F (28°C) 91.4 psi (630 kPa)
84.0°F (29°C) 93.1 psi (642 kPa)
85.0°F (29°C) 94.8 psi (654 kPa)
86.0°F (30°C) 96.6 psi (666 kPa)
87.0°F (31°C) 98.4 psi (678 kPa)
88.0°F (31°C) 100.2 psi (691 kPa)
89.0°F (32°C) 102.0 psi (703 kPa)
90.0°F (32°C) 103.8 psi (716 kPa)
91.0°F (33°C) 105.7 psi (729 kPa)
92.0°F (33°C) 107.6 psi (742 kPa)
93.0°F (34°C) 109.5 psi (755 kPa)
94.0°F (34°C) 111.4 psi (768 kPa)
95.0°F (35°C) 113.4 psi (782 kPa)
96.0°F (36°C) 115.4 psi (796 kPa)
0018 00-14
TM 5-3805-290-23-1

97.0°F (36°C) 117.4 psi (809 kPa)
98.0°F (37°C) 119.4 psi (823 kPa)
99.0°F (37°C) 121.5 psi (838 kPa)
100.0°F (38°C) 123.5 psi (852 kPa)
101.0°F (38°C) 125.6 psi (866 kPa)
102.0°F (39°C) 127.8 psi (881 kPa)
103.0°F (39°C) 129.9 psi (896 kPa)
104.0°F (40°C) 132.1 psi (911 kPa)
105.0°F (41°C) 134.3 psi (926 kPa)
106.0°F (41°C) 136.5 psi (941 kPa)
107.0°F (42°C) 138.7 psi (956 kPa)
108.0°F (42°C) 141.0 psi (972 kPa)
109.0°F (43°C) 143.3 psi (988 kPa)
110.0°F (43°C) 145.6 psi (1,004 kPa)
111.0°F (44°C) 147.9 psi (1,020 kPa)
112.0°F (44°C) 150.3 psi (1,036 kPa)
113.0°F (45°C) 152.7 psi (1,053 kPa)
114.0°F (46°C) 155.1 psi (1,069 kPa)
115.0°F (46°C) 157.6 psi (1,087 kPa)
116.0°F (47°C) 160.0 psi (1,103 kPa)
117.0°F (47°C) 162.5 psi (1,120 kPa)
118.0°F (48°C) 165.1 psi (1,138 kPa)
119.0°F (48°C) 167.6 psi (1,156 kPa)
120.0°F (49°C) 170.2 psi (1,173 kPa)
121.0°F (49°C) 172.8 psi (1,191 kPa)
122.0°F (50°C) 175.4 psi (1,209 kPa)
123.0°F (51°C) 178.1 psi (1,228 kPa)
124.0°F (51°C) 180.8 psi (1,247 kPa)
125.0°F (52°C) 183.5 psi (1,265 kPa)
0018 00-15
TM 5-3805-290-23-1

126.0°F (52°C) 186.3 psi (1,285 kPa)
127.0°F (53°C) 189.1 psi (1,304 kPa)
128.0°F (53°C) 191.9 psi (1,323 kPa)
129.0°F (54°C) 194.7 psi (1,342 kPa)
130.0°F (54°C) 197.6 psi (1,362 kPa)
131.0°F (55°C) 200.5 psi (1,382 kPa)
132.0°F (56°C) 203.4 psi (1,402 kPa)
133.0°F (56°C) 206.3 psi (1,422 kPa)
134.0°F (57°C) 209.3 psi (1,443 kPa)
(1) All pressures in this table are gage pressures.

REFRIGERANT COMPRESSOR TEST 0018 00
NOTE
• If compressor fails any one of the steps, AC system should be diagnosed in order to find root cause of fail-
ure. Root cause of failure should be repaired. If compressor is considered to be “good”, additional assis-
tance with diagnosis of AC system can be found by contacting your Caterpillar dealer.
• Identifying compressors that function is the purpose of this test. Compressors that function should be iden-
tified before compressors are removed from a machine. Compressors that function should produce both
high pressure and low pressure.
1. Check Air Filters. If complaint of customer is poor cooling of cab, past experience has shown plugged air filters can
often be cause. Most AC systems have return air filters and fresh air filters. Be sure to check both return air filters and
fresh air filters (TM 5-3805-290-10).
2. Test Voltage. While engine is running and AC is switched ON, check voltage at compressor. Voltage at compressor
should be a minimum 23V. Routinely used electrical loads should be turned ON. For example, a lighting system which
is added by customer could cause available voltage to decrease below minimum specification.
3. Test Resistance. Measure resistance of clutch coil at compressor connector. Measured resistance should be within -1.3
to +5.5 of 17.6 + 0.6 Ohms. Resistance range listed compensates for effect of temperature on clutch coil.
4. Check Belt Tension. Refer to WP 0046 00.
0018 00-16
TM 5-3805-290-23-1
REFRIGERANT COMPRESSOR TEST - CONTINUED 0018 00
WARNING
• Accidental machine starting can cause injury or death to personnel working on machine.
• To avoid accidental machine starting, turn battery disconnect switch to OFF position and remove key. If
machine is not equipped with a battery disconnect switch, disconnect battery cables from battery and tape
battery clamps.
• Place a DO NOT OPERATE tag at battery disconnect switch location to inform personnel that machine is
being worked on.
NOTE
Electrical power supply to compressor should be switched OFF in order to perform this test.
5. Test Rotation. Rotate compressor in direction of belt travel by turning nut on end of main shaft of compressor. Rotation
should be smooth with no binding. If not, replace compressor (WP 0192 00).
6. Check Charge Level. AC system must be correctly charged per Caterpillar specification or an incorrect diagnosis will
occur. Recovering, evacuating, and recharging with clean refrigerant to correct level is best method of achieving correct
refrigerant charge for system. Charging AC system must be conducted by weighing refrigerant with a calibrated scale in
order to ensure accuracy. Also, be sure to replace oil which was removed during refrigerant recovery with new oil (WP
0191 00).
7. Test For Low Pressure. Test for low pressure should be performed with ambient temperatures of less than 86°F (30°C).
Park machine in an area not in direct sunlight. Close all cab doors and windows. Block flow of fresh air into cab. If AC
system is equipped, bypass low pressure switch. Start machine. Operate machine at high idle. Turn ON AC (TM 5-3805-
290-10). Set cab blower on LOW. After 10 to 15 minutes of operation, measure low-side pressure at refrigerant com-
pressor. If pressure reading is less than 10 psi (69 kPa) then suction valves of compressor are operating correctly (WP
0191 00). If not, replace compressor (WP 0192 00).
NOTE
If cab temperature is above 77°F (25°C), then cab blower may need to be set to HIGH in order to reduce
temperature before starting procedure.
8. Test For High Pressure. Start engine and set speed at approximately 1,200 rpm. Turn ON AC. Place a sheet of card-
board over condenser in order to block flow of air. Limiting flow of air over condenser will cause discharge pressure of
compressor to increase. Check if discharge of compressor is able to increase up to 350 psi (2,414 kPa). Once specified
pressure is reached, immediately remove cardboard. If compressor passes test, discharge valves are operating correctly
(WP 0191 00). If not, replace compressor (WP 0192 00).
END OF WORK PACKAGE
0018 00-17/(0018 00-18 Blank)

TM 5-3805-290-23-1
CHAPTER 5
SUPPORTING INFORMATION
2
TM 5-3805-290-23-1
REFERENCES 0203 00
SCOPE
This work package lists all publication indexes, forms, field manuals, technical bulletins, technical manuals and other
publications referenced in this manual and which apply to maintenance of the 924G Wheel Loader.
PUBLICATION INDEXES
The following indexes should be consulted frequently for latest changes or revisions and for new publications relating to
material covered in this technical manual.
Consolidated Army Publications and Forms Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 25-30
Functional Users Manual for the Army Maintenance Management System (TAMMS) . . . . . . . . . . . . . . . . . DA PAM 738-750
FORMS
NOTE
Refer to PAM 738-750, Functional Users Manual for the Army Maintenance Management System (TAMMS),
for instructions on the use of maintenance forms.
Accident Identification Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 518
Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2404, DA Form 5988-E
Maintenance Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2407
Motor Vehicle Accident Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 91
Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 368
Recommended Changes to Publications and Blank Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028
Report of Discrepancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 364
Uncorrected Fault Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408-14
Vehicles and Spare Engines, Processing and Deprocessing Record for Shipment, Storage, and Issue of . . . . . . DD Form 1397
FIELD MANUALS
Army Motor Transport Unit and Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 55-30
Basic Cold Weather Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 31-70
Chemical and Biological Contamination Avoidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 3-3
Desert Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 90-3
First Aid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 4-25.11
NBC Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 3-5
NBC Field Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 3-7
Northern Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 31-71
Nuclear Contamination Avoidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-3-1
Operations and Maintenance of Ordnance Materiel in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 9-207
Recovery and Battlefield Damage Assessment and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 9-43-2
Rigging Techniques, Procedures, and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 5-125
TECHNICAL BULLETINS
CARC Spot Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0242
Color, Marking, and Camouflage Painting of Military Vehicles, Construction Equipment
and Materials Handling Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0209
Solder and Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB SIG 222
0203 00-1
TM 5-3805-290-23-1
REFERENCES - CONTINUED 0203 00
TECHNICAL BULLETINS - CONTINUED

Use of Antifreeze Solutions, Antifreeze Extender, Cleaning Compounds and Test Kit in Engine
Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 750-651
Warranty Bulletin for the 924G Wheel Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TB 5-3805-290-14
TECHNICAL MANUALS
Inspection, Care, and Maintenance of Antifriction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-214
Materials Used for Cleaning, Preserving, Abrading and Cementing Ordnance Materiel and
Related Materiels Including Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-247
Operator’s and Organizational Maintenance Manual Including RPSTL
for STE/ICE-R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-4910-571-12&P
Operator’s Manual for the 924G Wheel Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 5-3805-290-10
Operator’s, Unit, Direct Support, and General Support Maintenance
Manual for Lead-Acid Storage Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-6140-200-14
Painting Instructions for Army Materiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 43-0139
Procedures for Destruction of Equipment to Prevent Enemy Use (Mobility Equipment Command) . . . . . . . . . . TM 750-244-3
Transportability Guidance for the 924G Wheel Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 5-3805-290-14
Unit, Direct Support, and General Support Including Depot Maintenance RPSTL for the
924G Wheel Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 5-3805-290-24P
OTHER PUBLICATIONS
Abbreviations and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASME Y14.38-1999
Army Medical Department Expendable/Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CTA 8-100
Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items) . . . . . . . . . . . . . . . . . . . . .CTA 50-970
Fuels and Lubricants Standardization Policy for Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 70-12
Operator’s Circular for Welding Theory and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TC 9-237
END OF WORK PACKAGE
0203 00-2
4
TM 5-3805-290-23-1
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION 0204 00
THE ARMY MAINTENANCE SYSTEM MAC

1. This introduction provides a general explanation of all maintenance and repair functions authorized at the two mainte-
nance levels under the Two-Level Maintenance System concept.
2. The MAC immediately following this introduction designates overall authority and responsibility for the performance
of maintenance functions on the identified end item or component. The application of the maintenance functions to the
end item or component shall be consistent with the capacities of the designated maintenance levels, which are shown in
the MAC (WP 0193 00) in column (4) as:
Field - includes subcolumns:
C - Operator/Crew
O - Unit
D - Direct Support
Sustainment - includes subcolumns:

H - General Support
D - Depot
3. The tools and test equipment requirements (immediately following the MAC) list the tools and test equipment (both spe-
cial tools and common tool sets) required for each maintenance function as referenced from the MAC.
4. The remarks (immediately following the tools and test equipment requirements) contain supplemental instructions and
explanatory notes for a particular maintenance function.
MAINTENANCE FUNCTIONS
Maintenance functions are limited to and defined as follows:
1. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical characteris-
tics with established standards through examination (e.g., by sight, sound or feel).
2. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of an item
and comparing those characteristics with prescribed standards on a scheduled basis, i.e., load testing of lift 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 decon-
taminate, when required), to preserve, to drain, to paint or to replenish fuel, lubricants, chemical fluids or gases.
4. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position or by setting the operating
characteristics to specified parameters.
5. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.
6. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments of test, measuring, and diag-
nostic equipment used in precision measurement. Consists of comparisons of two instruments, one of which is a certi-
fied standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared.
7. Remove/Install. To remove and install the same item when required to perform service or other maintenance functions.
Install may be the act of emplacing, seating or fixing into position a spare, repair part, or module (component or assem-
bly) in a manner to allow the proper functioning of an equipment or system.
8. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. “Replace” is authorized by
the MAC and assigned maintenance level is shown as the third position code of the Source, Maintenance and Recover-
ability (SMR) code.
9. Repair. The application of maintenance services, including fault location/troubleshooting, removal/installation, disas-
sembly/assembly procedures, and maintenance actions to identify troubles and restore serviceability to an item by cor-
recting specific damage, fault, malfunction or failure in a part, subassembly, module (component or assembly), end item
or system.
0204 00-1
TM 5-3805-290-23-1
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - CONTINUED 0204 00
MAINTENANCE FUNCTIONS - CONTINUED
NOTE
The following definitions are applicable to the “repair” maintenance function:
• Services - Inspect, test, service, adjust, align, calibrate and/or replace.
• Fault location/troubleshooting - The process of investigating and detecting the cause of equipment malfunc-
tioning; the act of isolating a fault within a system or Unit Under Test (UUT).
• Disassembly/assembly - The step-by-step breakdown (taking apart) of a spare/functional group coded item
and to the level of its least component, that is assigned an SMR code for the level of maintenance under consid-
eration (i.e., identified as maintenance significant).
• Actions - Weld, grind, rivet, straighten, face, machine and/or resurface.
10. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely serviceable/operational
condition as required by maintenance standards in appropriate technical publications. Overhaul is normally the highest
degree of maintenance performed by the Army. Overhaul does not normally return an item to like new condition.
11. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like new con-
dition in accordance with original manufacturing standards. Rebuild is the highest degree of materiel maintenance
applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurements (hours/
miles, etc.) considered in classifying Army equipment/components.
EXPLANATION OF COLUMNS IN THE MAC, TABLE 1
1. Column (1) - Group Number. Column (1) lists Functional Group Code numbers, the purpose of which is to identify
maintenance significant components, assemblies, subassemblies and modules with the Next Higher Assembly (NHA).
2. Column (2) - Component/Assembly. Column (2) contains the item names of components, assemblies, subassemblies
and modules for which maintenance is authorized.
3. Column (3) - Maintenance Function. Column (3) lists the functions to be performed on the item listed in Column (2).
(For a detailed explanation of these functions refer to “Maintenance Functions” outlined above).
4. Column (4) - Maintenance Level. Column (4) specifies each level of maintenance authorized to perform each function
listed in column (3), by indicating work time required (expressed as manhours in whole hours or decimals) in the appro-
priate subcolumn. This work time figure represents the active time required to perform that maintenance function at the
indicated level of maintenance. If the number or complexity of the tasks within the listed maintenance function varies at
different maintenance levels, appropriate work time figures are to be shown for each level. The work time figure repre-
sents the average time required to restore an item (assembly, subassembly, component, module, end item, or system) to
a serviceable condition under typical field operating conditions. This time includes preparation time (including any nec-
essary disassembly/assembly time), troubleshooting/fault location time, and quality assurance time in addition to the
time required to perform the specific tasks identified for the maintenance functions authorized in the MAC. The symbol
designations for the various maintenance levels are as follows:
Field:
C - Operator/Crew Maintenance
O - Unit Maintenance
D - Direct Support Maintenance
Sustainment:
H - General Support Maintenance
D - Depot Maintenance
0204 00-2
TM 5-3805-290-23-1
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - CONTINUED 0204 00
MAINTENANCE FUNCTIONS - CONTINUED
NOTE
The “L” maintenance level is not included in column (4) of the MAC. Functions to this level of maintenance
are identified by a work time figure in the “H” column of column (4), and an associated reference code is
used in the REMARKS CODE column (6). This code is keyed to the remarks and the SRA complete repair
application is explained there.
5. Column (5) - Tools and Equipment Reference Code. Column (5) specifies, by code, those common tool sets (not indi-
vidual tools), common Test, Measurement and Diagnostic Equipment (TMDE), 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 2.
6. Column (6) - Remarks Code. When applicable, this column contains a letter code, in alphabetical order, which is
keyed to the Remarks Entries Table in Table 3.
EXPLANATION OF COLUMNS IN THE TOOLS AND TEST EQUIPMENT REQUIREMENTS, TABLE 2
1. Column (1) - Tool or Test Equipment Reference Code. The tool and test equipment reference code correlates with a
code used in column (5) of the MAC.
2. Column (2) - Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment.
3. Column (3) - Nomenclature. Name or identification of the tool or test equipment.
4. Column (4) - National Stock Number (NSN). The NSN of the tool or test equipment.
5. Column (5) - Tool Number. The manufacturer's part number, model number, or type number.
EXPLANATION OF COLUMNS IN THE REMARKS, TABLE 3
1. Column (1) - Remarks Code. The code recorded in column (6) of the MAC.
2. Column (2) - Remarks. This column lists information pertinent to the maintenance function being performed as indi-
cated in the MAC.
END OF WORK PACKAGE
0204 00-3/(0204 00-4 Blank)

22
TM 5-3805-290-23-1
MAINTENANCE ALLOCATION CHART (MAC) 0205 00
Table 1. Maintenance Allocation Chart (MAC) for 924G Wheel Loader.
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT
UNIT DS GS DEPOT TOOLS AND

GROUP COMPONENT/ MAINTENANCE EQUIPMENT REMARKS
NUMBER ASSEMBLY FUNCTION C O F H D REF CODE CODE
01 ENGINE
0100 Engine Assembly Inspect 0.03 0.5 43.0 B
Test 0.5 2,46,75,81,90, E
91,96
Service 1.0 77,96 B
Replace 18.0 75,96
Rebuild 40.0 D
Engine Mounts Inspect 0.3 B
Replace 0.8 75,96
0101 Crankcase, Block,

Cylinder Head
Cylinder Block Inspect 0.7 B,D
Replace 20.0 D
Repair 8.0 D
Cylinder Head Inspect 0.5
Assembly Replace 10.0 13,33,75,87,96, A
103
Rebuild 8.0 D
0102 Crankshaft
Crankshaft Inspect 0.5 D
Replace 14.5 D
Rear Main Seal Replace 21.0 75,96,108
Front Main Seal Replace 2.0 8,69,75,96
Vibration Damper and Inspect 0.3 40,96,
Pulley Replace 7.5 39,75,96,107
Adjust 7.8 39,75,96,107
0103 Flywheel
Flywheel Inspect 20.0 13,39,75,96,
103
Replace 20.0 13,39,75,96,
103
0205 00-1
TM 5-3805-290-23-1
MAINTENANCE ALLOCATION CHART (MAC) - CONTINUED 0205 00
Table 1. Maintenance Allocation Chart (MAC) for 924G Wheel Loader - Continued.
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

01 ENGINE - Continued
Flywheel Housing Inspect 23.5 13,39,75,96,
103
Replace 23.5 13,39,75,96,
103
0104 Pistons, Connecting Inspect 0.5 D
Rods Replace 8.0 D
0105 Valves, Camshaft, and
Timing System
Camshaft Inspect 0.5 D
Replace 3.5 D
Valve Cover Inspect 0.2
Replace 1.0 77,96,104
Front Cover Replace 7.0 75,96,107
Timing and Idler Gear Inspect 13.0 19,23,35,39,61, A
62,75,96,101,
107
Replace 13.2 19,23,35,39,61,
62,75,96,101,
107
Front Housing Replace 14.0 75,96,107
Intake/Exhaust Valves Inspect 0.5 75,96 B
Replace 4.0 75,96
Adjust 2.0
Rocker Arm and Push Inspect 0.5 B
Rods Replace 4.0 23,35,76,96,
103,106
0106 Engine Lubrication Inspect 0.5 46,96 E
System
Oil Pan Replace 10.0 75,96
Oil Filter Base Replace 1.0 77,96,102 A
Oil Level and Filler Inspect 0.01 B
Service 0.1 B
Replace 0.6 96
Crankcase Vent Service 1.2 96
Replace 1.2 96
0205 00-2
TM 5-3805-290-23-1
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

01 ENGINE - Continued
Oil Pump Inspect 0.5 23,39,75,87,96,
107
Replace 16.0 23,39,75,96,
107
Oil Bypass Valve Replace 11.0 23,76,96
Piston Cooling Jets Replace 16.0 75,96,103
Oil Cooler, Core Inspect 0.2 77,96,102 A
Replace 4.0 77,96,102
Oil Cooler Lines, Inspect 0.01
Fittings, and Hoses Replace 0.5 77,96,102 B
0108 Manifolds
Exhaust Manifold Replace 4.0 75,96,107
Intake Manifold Replace 2.5 75,96,107
03 FUEL SYSTEM Inspect 0.3 96 E
Test 0.3 22,32,58,77,95, E
96
0301 Fuel Injector Assembly Test 0.5 3,24,25,66,98
Replace 2.0 76,90
0302 Fuel Injector Lines Inspect 0.5 77,96,102
Replace 1.6 77,96,102
Fuel Injection Pump Replace 5.5 76,95,96,107
Repair 4.0 D
0304 Air Cleaner Housing and Inspect 0.2 B
Precleaner Service 0.3 96 B
Replace 1.0 96 A
Air Restriction Replace 1.5 96
Indicator
0305 Turbocharger
Turbocharger Oil Lines Replace 1.0 96
and Fittings
Engine After cooler Inspect 0.02 B
Replace 1.5 96
Turbocharger Inspect 0.5 96
Adjust 0.5 40,75,96,107
Replace 2.0 40,75,96,107
0205 00-3
TM 5-3805-290-23-1
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

03 FUEL SYSTEM -
Continued
Turbocharger and Replace 0.5 96
Aftercooler Air Lines
and Clamps
0306 Tanks, Lines, Fittings,
and Headers
Fuel Tank Inspect 0.01 B
Service 0.2 B
Replace 9.0 77,96
Fuel Lines Inspect 0.1
Replace 1.0
0309 Fuel Filter
Primary Fuel Filter Inspect 0.3
Replace 0.5 96 B
Secondary Fuel Filter Inspect 0.1 0.1 B
Replace 0.3 96
Fuel Filter Bases Replace 1.0 77,96
0311 Engine Starting Aids
Ether Starting Aid Inspect 0.01
Replace 0.5 96 A
Ether Starting Aid, Replace 0.5 96
Lines
0312 Throttle Pedal and Inspect 0.01 B
Throttle Position Sensor Replace 1.0 77,96,102 A
04 EXHAUST SYSTEM
0401 Muffler and Pipes Inspect 0.1 B
Replace 0.4 78,96,102
Exhaust Pipes and Inspect 0.1 B
Clamps Replace 0.3 78,96,102
Mounting Bracket Replace 0.3 78,96,102
05 COOLING SYSTEM
Cooling System Inspect 0.5 96 B
Test 0.2 0.2 77,89,96 E
Service 0.2 1.0 77,96 B,E
0205 00-4
TM 5-3805-290-23-1
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

05 COOLING SYSTEM -
Continued
0501 Radiator Inspect 0.03 0.3 B
Replace 4.0 13,75,96
Tank, Overflow Replace 1.0 77,96
Radiator and Fan Replace 6.0 11,77,96
0503 Thermostat Replace 0.5 77,96,102 B
Water Outlet Manifold Replace 1.0 77,96,102
Hoses, Tubes, and Replace 2.0 77,96
Clamps
0504 Water Pump Inspect 3.5 96
Replace 3.0 77,96,102
0505 Fan and Motor Adjust 2.0 2,40,81,91,96 E
Calibrate 0.5 . 40,91,96
Replace 2.5 61,64,78,96, A
103
Gear Motor Hydraulic Adjust 2.0 2,40,81,91,96 E
Fan Replace 2.5 61,78,96,103 A
06 ELECTRICAL Test 1.0 2,5,10,15,17, E
SYSTEM 18,21,47,71,81,
77,78,91,96,
107
0601 Generator, Alternator
Assembly
Alternator Replace 1.0 77,96,103 A
Alternator Mounting Replace 0.5 96
V-Belts Inspect 0.02 0.2 B
Adjust 0.3 36,77,96,102
Replace 0.5 36,77,96,102
0603 Starting Motor Test 0.5 10,47,77,96
Starter Inspect 1.5 78,96,102,104
Replace 1.5 78,96,102,104
0607 Instrument or Engine
Control Panel
Control Panels and Inspect 0.01 B
Switches Replace 0.4 77,96
0205 00-5
TM 5-3805-290-23-1
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

06 ELECTRICAL
SYSTEM - Continued
Turnlamp Switch Replace 0.2 77,96
Instrument Cluster Replace 0.5 2,77,96
Fuses, Relay, and Replace 0.3 96
Circuit Breakers
Instrument Panel Replace 2.3 96
Harness
0608 Miscellaneous Items
Engine Control Unit Replace 2.0 2,75,81,91,96
(ECU)
Machine ECM Replace 2.0 2,75,81,91,96
Electrical Converter Replace 1.0 96
(24V to 12V)
Electrical Switches, Replace 0.3 96
Relays, Circuit
Breakers, and Lights
0609 Lights
Rear Inspect 0.01 B
Replace 0.2 96
Blackout Drive Inspect 0.01 B
Replace 0.2 96
Worklights Inspect 0.01 B
Replace 0.3 96
Service Lights and Inspect 0.01 B
Front Turnlamps Replace 0.2 96
0610 Sending Units and
Warning Switches
Temperature Sensors Replace 1.0 77,96,102
Pressure Sensors Replace 1.0 77,96,102
Engine Sensors Replace 1.0 77,96,102
Transmission Sensors Replace 1.0 77,96,102
Fuel Level Sending Replace 2.5 96
Unit
Pressure Switches Replace 1.0 77,96,102
0205 00-6
TM 5-3805-290-23-1
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

06 ELECTRICAL
SYSTEM - Continued
Kickout Sensors Adjust 0.2 C
Replace 1.0 96
0611 Horns, Siren
Electric Horn Inspect 0.01 B
Replace 0.3 96
Backup Alarm Replace 0.3 96
0612 Batteries, Storage
Batteries Inspect 0.01 0.2 B
Test 0.2 10,47,77,96
Service 1.0 96
Replace 0.7 96
Battery Cables Inspect 0.01 0.02 B
Replace 3.0 77,96
NATO Slave Inspect 0.01 B
Receptacle Replace 0.5 96
Battery Disconnect Replace 0.5 96
Switch
Battery Boxes Replace 3.5 77,96
0613 Hull or Chassis Wiring
Harness
Engine Harness Replace 3.0 96
Transmission Control Replace 7.0 96
Assembly Harness
Front Harness Replace 1.5 96
Ride Control Harness Replace 1.5 96
Rear Harness Replace 2.0 96
Cab Harness Replace 4.0 96
Secondary Steering Replace 1.5 96
Harness
Engine Control Replace 1.5 96
Harness
Work Light Harness Replace 1.5 96
0205 00-7
TM 5-3805-290-23-1
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

07 TRANSMISSION Test 1.0 2,47,71,77,81, E
91,92,96
Adjust 1.0 2,47,71,77,81,
91,92,96
Calibrate 1.0 2,47,71,77,81,
91,92,96
0705 Transmission Shifting
Components
Shift Lever Replace 1.0 77,96
0710 Transmission Assembly Inspect 0.01 B

with Torque Converter
Service 1.0 77,96 B
Replace 0.2 24.0 11,13,75,96 A
Rebuild 16.0 D
0714 Transmission Control Adjust 3.0 2,81,91,96 E
Valve A
Replace 4.0 75,96,107
0721 Transmission Oil Pump Replace 12.0 75,64,96
Repair 14.0 D
Transmission/ Replace 2.5 77,96
Hydraulic Oil Cooler
Transmission Oil Replace 2.0 75,96
Cooler Bypass Valve
Transmission Filter Replace 0.3 77,96 B
Element
Magnetic Screen Service 0.3 77,96 B
Oil Filter Base Replace 1.5 77,96
Torque Converter Oil Replace 2.6 77,96
Lines and Hoses
Fill/Check Tube Replace 0.5 96
09 PROPELLER AND
PROPELLER
SHAFTS
0900 Drive Shaft Assembly Inspect 0.01 B
(Front) Replace 0.5 77,96,102
U-Joints Replace 2.0 77,96,102
0205 00-8
TM 5-3805-290-23-1
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

09 PROPELLER AND
PROPELLER
SHAFTS - Continued
Drive Shaft Assembly Inspect 0.01 B
(Rear) Replace 0.5 77,96,102
U-Joints Replace 2.0 77,96,102
Slip Joint Assembly Inspect 0.01 B
(Center) Service 0.3 B,C
Replace 0.5 77,96,102
U-Joint Replace 2.0
10 FRONT AXLE
1000 Front Axle Assembly Inspect 0.2 25.0 B,D
Adjust 25.0 D
Service 0.5 77,96 B
Replace 8.0 77,96,103 A
Rebuild 40.0 D
11 REAR AXLE
1100 Rear Axle Assembly Inspect 0.2 25.0 B,D
Adjust 25.0 D
Service 0.5 77,96 B
Replace 8.0 77,96,103 A
Rebuild 40.0 D
Axle Trunnion Support Replace 10.0 20,75,96 A
12 BRAKES Inspect 0.2 14,77,96 E
Test 0.5 2,14,28,38,77, E
81,91,93,96
1201 Parking Brake Group
Parking Brake Cable Adjust 0.3 77,96,102,103
Replace 1.0 77,96,102,103
Parking Brake Lining Inspect 0.01 0.5 96 B
Replace 1.0 77,96,102,103
Parking Brake Control Replace 0.5 77,96,102,103
Lever
1202 Service Brake Control Replace 1.0 77,96,102 A
Valve
Service Brake Discs Inspect 0.1 0.5 14,77,96 B
0205 00-9
TM 5-3805-290-23-1
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

12 BRAKES - Continued
1204 Brake Accumulator Inspect 0.1 B
Test 0.5 2,38,39,50,81,
91,96
Service 0.5 2,38,39,50,81,
91,96
Replace 1.0 96
Service Brake Lines Replace 3.0 77,96
and Hoses
1206 Service Brake Pedal Inspect 0.01 B
Adjust 0.2 96
Replace 0.8 96 A
13 WHEEL AND TRACK
1311 Wheel and Tire Inspect 0.02 B
Assembly Service 0.2 B,C
Replace 1.5 33,77,96,103
1313 Tire Replace 1.5 77 D
14 STEERING
1401 Steering System Inspect 0.03 0.3 B
Test 1.0 26,27,28,38,49, E
59,77,92,94,96,
102
Steering Wheel Replace 1.0 77,96,102
Steering Column Replace 2.0 77,96
1410 Secondary Steering Replace 2.0 96
Pump/Motor Assembly
Relief Valve Replace 1.0 96
Steering Metering Replace 2.0 77,96
Pump
Steering/Pilot Pump Replace 2.0 77,96
Repair 3.0 D
1411 Steering Hoses, Lines, Inspect 0.3 B
and Fittings Replace 3.5 77,96
1412 Steering Cylinders Service 0.2 77,96 B,C
Replace 2.0
Repair 4.0 D
0205 00-10
TM 5-3805-290-23-1
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

14 STEERING -
Continued
1414 Steering Relief Valve Test 0.3 77
Replace 0.5 96
15 FRAME, TOWING,
AND ATTACH-
MENTS
1501 Rear Frame Inspect 0.01 B
Rear Axle Stop Inspect 0.2 B
Replace 0.2 77,96
Remote Lubrication Inspect 0.01 B
Lines and Fittings Service 0.4 B,C
Replace 4.0 96
1502 Counterweight Inspect 0.01 B
Replace 1.0 77,96
1503 Articulation Pivot Pins Service 0.2 B,C
Replace 16.0 4,6,7,41,53,67,
68,75,82,96
18 BODY, CAB, AND
HOOD
1801 Cab Assembly Replace 8.0 77,96
ROPS Inspect 0.01 B,C
Replace 1.0 96 C
Hood and Side Covers Inspect 0.03 0.3 B
Replace 2.0 96
Door Inspect 0.1 B
Replace 0.7 96
Repair 0.5 96
Ladder and Platform Replace 1.0 96
Chassis Guards Replace 1.0 96
1802 Fenders, Windshield,
and Glass
Front Fenders Replace 0.5 96
Windshield Inspect 0.1 96 B
Replace 1.5
Glass (Door) Replace 1.0 96
0205 00-11
TM 5-3805-290-23-1
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

18 BODY, CAB, AND
HOOD - Continued
Window (Cab) Replace 0.5 96
Glass (Front) Replace 3.0 96
Window (Door) Replace 0.5 96
Glass (Rear) Replace 3.0 96
1806 Seat Assembly Inspect 0.1 B
Replace 0.5 96
Repair 3.0 75,96
Seat Belt Inspect 0.01
Replace 0.3 96 B
Cab Liners Replace 1.2 96
1808 Rifle Rack and Tool Box Replace 0.3 96
22 BODY ACCESSORY
ITEMS
2202 Accessory Items
Mirrors Inspect 0.01 B
Replace 0.3 96
Windshield Wiper Inspect 0.2 B
Replace 0.3 96 A
Windshield Washer Service 0.1 B
Bottle Replace 2.0 77,96
Windshield Wiper Replace 3.0 77,96,102
Motor (Front)
Windshield Wiper Replace 1.0 77,96,102
Motor (Rear)
2207 Cab Air Filter Inspect 0.1 B
Service 0.3 B
Replace 0.3 B
Toolbox Inspect 0.02 B
Replace 0.5 96
2210 Data Plates Inspect 0.2
Replace 0.3 37,77,96
0205 00-12
TM 5-3805-290-23-1
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

24 HYDRAULIC AND
FLUID SYSTEMS
2401 Piston Pump Test 1.0 1,2,26,40,41, E
(Implement) 48,57,74,77,80,
83,96
Adjust 1.0 1,2,26,40,41, E
48,57,74,77,80,
83,96
Replace 12.0 76,96,106 A
Repair 7.1 D
Gear Pump Braking Replace 3.0 76,96 A
and Hydraulic Fan Repair 5.0 D
Dead Engine Lowering Replace 1.0 96
Control Valve
2402 Hydraulic Control
Valves
Main Control Valve Replace 5.0 75,96 A
(Three Function) Repair 5.3 D
Pilot Control Valve Replace 5.0 75,96
Lockout Valve Replace 1.0 75,96
Ride Control Valve Replace 2.0 77,96 A
Coupler Valve Replace 5.0 75,96 A
Implement Relief Adjust 0.5 38,77,92,96 E
Valve Test 0.5 38,77,92,96 E
Replace 1.5 77,102,103
Tilt Control Valve Replace 3.0 77,96
2403 Pilot Oil Accumulator Service 0.8 31,38,50,77,92,
96
Test 0.2 50,92,96
Replace 1.0 31,38,50,77,92,
96
Hydraulic Controls Replace 0.3 96
Ride Control Service 0.8 31,50,77,92,96
Accumulator Test 0.2 50,92,96
Replace 1.0 31,50,77,92,96
0205 00-13
TM 5-3805-290-23-1
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

24 HYDRAULIC AND
FLUID SYSTEMS -
Continued
2404 Tilt Cylinder Inspect 0.01 B
Replace 3.0 2,41,51,52,54, A
55,63,65,67,88,
96
Repair 5.0 D
2405 Lift Cylinders Inspect 0.01
Replace 3.0 41,51,55,63,67, A
77,88,96
Repair 5.0 D
2406 Hydraulic Filters, Lines,
and Fittings
Hydraulic Oil Filter Replace 0.5 77,96 B
Hoses, Lines, and Inspect 0.02 77,96 B
Fittings Replace 0.5
Safety Relief Valve Replace 0.3 96
Hydraulic Oil Filter Replace 1.4 96 A
Base
2407 Hydraulic Cylinders
Pin Coupler Cylinder Replace 1.5 77,96 A
Bucket Cylinders Inspect 0.01

Replace 0.5 96
Repair 2.0 D
2408 Tanks and Reservoirs
Hydraulic Tank Inspect 0.02 B
Service 0.1 77,96,100 B
Replace 8.0 13,77,102 A
33 SPECIAL PURPOSE
KITS
3303 Arctic Heater Inspect 0.2 B
Replace 4.0 77,96 A
3307 Forklift Assembly Inspect 0.1 B
Install 0.2
Repair 1.5 96
0205 00-14
TM 5-3805-290-23-1
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

52 REFRIGERATION Test 2.0 42,43,70,75,96 E
AND AIR
CONDITIONING
COMPONENTS
(HVAC)
5200 Air Conditioner and
Mounting
Evac and Recharge Service 2.0 70,75,96
AC Compressor Replace 3.0 75,96
V-Belt Inspect 0.1
Adjust 0.2 36,77,96,102
Replace 0.5 36,77,96,102
5217 AC Hoses, Valves, Replace 4.0 75,96
Flanges, and Fittings
Inline Refrigerant Replace 3.0 75,96
Dryer
5221 AC Refrigerant Replace 2.0 75,96 B
Accumulator
5230 Air Conditioner Inspect 0.2
Condenser Group Replace 7.5 75,96
5241 Air Conditioner Replace 4.0 75,96,104
Evaporator Core
5243 Air Conditioner Blower Replace 2.0 78,96,104
Motor
5245 Air Filter, Air Inspect 0.01
Conditioner/Heater Replace 0.3
5247 Heater Core Replace 5.0 76,96
74 CRANES, SHOVELS,
AND EARTH
MOVING
EQUIPMENT
7436 Lift Arms Inspect 0.02 B
Service 0.4 B
Replace 7.0 77,87 A
Front Tilt Lever and Replace 6.0 9,20,34,53,67, A
Link 68,76,84,86,87
0205 00-15
TM 5-3805-290-23-1
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

74 CRANES, SHOVELS,
AND EARTH
MOVING
EQUIPMENT -
Continued
Rear Tilt Lever and Replace 6.0 75,96
Link
Quick Coupler Replace 2.7 64,81
7437 Loader Buckets Inspect 0.01 B
Service 0.2 B
Replace 0.1
Repair 8.5 65,87,81
0205 00-16
TM 5-3805-290-23-1
Table 2. Tools and Test Equipment Requirements for 924G Wheel Loader.
0(1) 0(2) 0(3) 0(4) 0(5)
ITEM MAINTENANCE NATIONAL PART NUMBER/

NO. LEVEL ITEM NAME STOCK NUMBER CAGEC
1 O 1 Adapter bushing 1 4730-01-471-4393 1 6H-4746 (11083) 1

2 O 2 Adapter, communication 2 6625-01-476-1432 2 171-4400 (11083) 2
3 F 3 Adapter, injector nozzle 3 5120-01-448-9785 3 5P-7448 (11083) 3
4 F 4 Adapter, bearing puller 4 4 9U-5339 (11083) 4
5 O 5 Adapter, cable breakout 5 4910-01-473-8748 5 7X6370 (11083) 5
6 F 6 Adapter, mechanic 6 5120-01-288-2717 6 5P-4184 (11083) 6
7 F 7 Adapter, mechanic 7 5120-01-484-9382 7 9U-5336 (11083) 7
8 F 8 Adapter, mechanical puller 8 5120-01-437-0474 8 9U-6210 (11083) 8
9 F 9 Adapter, mechanical puller 9 5120-01-286-8432 9 1P-1837 (11083) 9
10 O 10 Ammeter 10 6625-01-343-3370 10 8T-0900 (11083) 10
11 O 11 Bracket, link 11 4940-01-268-2201 11 138-7573 (11083) 11
12 F 12 Bracket, link 12 5340-01-476-1734 12 138-7574 (11083) 12
13 O 13 Bracket, link 13 5120-01-451-1401 13 1387575 (11083) 13
14 O 14 Brake wear gage 14 14 221-6893 (11083) 14
15 O 15 Breakout T 15 15 208-0059 (11083) 15
16 O 16 Brush, acid swabbing 16 7920-00-223-8005 16 9503 (45092) 16
17 O 17 Bypass harness, J1/P1 17 17 217-0113 (11083) 17
18 O 18 Bypass harness, J1/P1 adapter 18 18 224-4899 (11083) 18
19 F 19 Bushing driver set 19 5120-01-030-1626 19 1P-0510 (11083) 19
20 F 20 Bushing driver set 20 2150-01-039-4811 20 1P-0520 (11083) 20
21 O 21 Cable, 3-pin assembly 21 6625-01-484-9404 21 8T-8726 (11083) 21
22 O 22 Calibration fluid and diesel fuel test kit 22 22 9U-7840 (11083) 22
23 F 23 Caliper, micrometer, outside 23 5210-00-221-1945 23 103-217 (SA251) 23
24 F 24 Can, screw cap 24 8110-01-345-9803 24 8S-2270 (11083) 24
25 F 25 Coupling assembly, hose 25 4730-01-435-7174 25 1U-8857 (11083) 25
26 O 26 Coupling, hose 26 4730-01-375-5884 26 6V4143 (11083) 26
27 O 27 Coupling, hose 27 4730-01-375-5883 27 6V4144 (11083) 27
28 O 28 Coupling half, quick disconnect 28 4730-01-164-1777 28 6V-3965 (11083) 28
29 O 29 Crimping tool, terminal 29 5120-01-537-9251 29 4C-4075 29
0205 00-17
TM 5-3805-290-23-1
Table 2. Tools and Test Equipment Requirements for 924G Wheel Loader - Continued.
0(1) 0(2) 0(3) 0(4) 0(5)

30 O 30 Crimping tool, terminal, hand 30 5120-01-486-7811 30 1U5804 30

31 F 31 Extension assembly 31 31 1U-5551 (11083) 31
32 O 32 Filter, fluid 32 2910-01-343-8535 32 2P-8278 (11083) 32
33 F 33 Gage, angle 33 5210-01-388-2682 33 TA360 (55719) 33
34 F 34 Gage, depth, micrometer 34 5210-00-058-0898 34 445BZ-3RL (57163) 34
35 F 35 Gage set, telescoping 35 5210-00-473-9350 35 155-903 (SA251) 35
36 O 36 Gage, profile 36 5220-01-480-5571 36 BT3397 (45225) 36
37 O 37 Heater, gun type, electric 37 4940-01-028-7493 37 EP-5UL (59164) 37
38 F 38 Hose 38 4720-01-485-7426 38 177-7860 (11083) 38
39 F 39 Dial indicator set 39 5210-01-794-9178 39 J5959 (55509) 39
40 O 40 Indicator, point set 40 4940-01-268-2200 40 9U-7400 (11083) 40
41 O 41 Inserter and remover, pin 41 5120-01-288-2793 41 6V-4035 (11083) 41
42 F 42 Leak detection lamp 42 192-2331 42
43 F 43 Leak detector, refrigerant gas 43 4940-01-387-0948 16600 43
44 O 44 Light, test 44 6625-01-260-2387 44 21300 (9A194) 44
45 O 45 Maintenance kit, electrical connector 45 5935-01-507-0644 45 190-8900 45
46 O 46 Measuring equipment 46 5210-01-362-8593 46 4C-4890 (11083) 46
47 O 47 Multimeter 47 6625-01-131-8586 47 FLUKE 87 (89536) 47
48 O 48 Nipple 48 4730-01-485-8578 48 8T-3613 (11083) 48
49 O 49 Nipple, pipe 49 4730-01-357-9580 49 6V4142 (11083) 49
50 F 50 Nitrogen gas charging system 50 4940-01-046-7109 50 12252157 (19200) 50
51 O 51 Nut 51 51 9U-6833 (11083) 51
52 O 52 Nut 52 52 9U-5345 (11083) 52
53 F 53 Nut, plain, round 53 5310-01-480-6693 53 9U-6832 (11083) 53
54 O 54 Pin, drive, guided 54 5315-01-485-8586 54 9U-5342 (11083) 54
55 O 55 Pin driver cap 55 55 9S-5563 (11083) 55
56 O 56 Pin, guide 56 56 237-4986(11083) 56
57 F 57 Pin, shoulder, headless 57 5315-01-270-2832 57 8S-7615 (11083) 57
58 O 58 Piston displacement gage 58 58 226-2270 (11083) 58
59 O 59 Plug, machine thread 59 5365-01-429-3163 59 8T-8737 (11083) 59
0205 00-18
TM 5-3805-290-23-1
0(1) 0(2) 0(3) 0(4) 0(5)

60 O 60 Plug, machine thread 60 5365-01-514-6500 60 6V-9510 (11083) 60

61 F 61 Puller group 61 5120-01-128-0725 61 8S-2264 (11083) 61
62 F 62 Puller group 62 62 1U-6671 (11083) 62
63 O 63 Puller, hydraulic 63 5130-00-363-6680 63 6V-3160 (11083) 63
64 F 64 Puller, mechanical 64 5120-01-518-2383 64 6V-3010 (11083) 64
65 O 65 Puller stud 65 65 9U-5343 (11083) 65
66 F 66 Pumping unit, hydraulic, hand-driven 66 4320-01-263-9716 66 5P-4150 (11083) 66
67 O 67 Pump, hydraulic ram, hand driven 67 4320-00-374-1403 67 9U-6600 (11083) 67
68 F 68 Puller, hydraulic 68 5130-01-296-4277 68 6V-3175 (11083) 68
69 F 69 Puller kit, universal 69 5180-01-124-1903 69 1U-7600 (11083) 69
70 F 70 Reclaimer, refrigerant 70 4250-01-396-8928 70 EEEAC304A (55719) 70
R-134a 70
71 O 71 Remover, electrical contact 71 5120-01-491-0560 71 151-6320 (11083) 71
72 F 72 Repair kit, diesel engine 72 2815-01-521-1638 72 175-3700 72
73 F 73 Repair stand, heavy duty 2,000 lb 73 73 1U-7502 (11083) 73
74 O 74 Saddle assembly, lifting block 74 2510-01-264-8424 74 8S-8048 (11083) 74
75 F 75 Shop equipment, automotive maintenance 4910-00-754-0705 75 4910-95-A31 75
and repair: field maintenance, basic, less (19204) 75
power 75 (LIN: T24660) 75
76 F 76 Shop equipment, machine shop, field 3470-00-754-0738 76 3470-95-A15 (19204)
maintenance, heavy, less power 76 (LIN: T15640) 76
77 O 77 Shop equipment, automotive maintenance 4910-00-754-0654 77 SC4910-95-CLA74
and repair: organizational maintenance, (19204) 77
common no. 1 77 (LIN: W32593) 77
Shop equipment, common no. 1 77
78 O 78 Shop equipment, automotive maintenance 4910-00-754-0650 78 SC4910-95-CLA72

and repair: organizational maintenance, (19204) 78
common no. 2 78 (LIN: W32730) 78
Shop equipment, common no. 2 78
79 O 79 Shop equipment, welding 79 4940-00-357-7268 79 SC3470-95CLA08

(19204) 79
80 F 80 Sleeve 80 80 FT-1028 (11083) 80
81 O 81 Software kit 81 7030-01-488-3978 81 EERE3500 (11083) 81
82 F 82 Spacer 82 82 5P-7304 (11083) 82
0205 00-19
TM 5-3805-290-23-1
0(1) 0(2) 0(3) 0(4) 0(5)

83 O 83 Stand assembly 83 4910-01-264-4034 83 8S-7630 (11083) 83

84 F 84 Stud, plain 84 5307-01-485-7432 84 4C-9634 (11083) 84
85 O 85 Sling, nylon 85 2835-01-078-2081 85 4X8FTX2IN (91796) 85
86 F 86 Spacer, sleeve 86 5365-01-484-9383 86 1M-6756 (11083) 86
87 F 87 Straight edge 87 6675-00-224-8807 87 564000-36 (74067) 87
88 O 88 Stud, plain 88 5307-01-484-9378 88 4C-9633 (11083) 88
89 O 89 Test kit, radiator 89 4910-00-728-8227 89 10513874 (56161) 89
90 F 90 Tester, cylinder compression 90 4910-00-250-2423 90 MILT13011 (81349) 90
91 O 91 Test set, electronic systems (MSD) 91 6625-01-493-8984 91 713000-3 (54418) 91
92 O 92 Test stand, automotive (gage set) 92 4910-01-504-2154 92 6V-7830 (11083) 92
93 O 93 T, tube 93 4730-01-414-3294 93 8T-8902 (11083) 93
94 O 94 Tee, tube 94 4730-01-523-8542 94 7X0872 (11083) 94
95 F 95 Timing pin 95 95 150-3992 (11083) 95
96 O 96 Tool kit, general mechanic’s, 5180-01-483-0249 96 12B470000-1
automotive 96 (59678) 96
(LIN: T28688) 96
Tool kit, general mechanic’s 96
97 O 97 Tool group, flow check 97 5120-01-217-9642 97 1P-0540 (11083) 97

98 F 98 Tube assembly, metal 98 4710-01-264-3509 98 6V-2170 (11083) 98
99 O 99 Tubing assembly set, nonmetallic 99 4710-01-480-6677 99 8S-7641 (11083) 99
100 O 100 Vacuum transducer 100 100 5P-0306 (11083) 100
101 F 101 Wrench bit 101 101 173-9774 (11083) 101
102 O 102 Wrench, torque 102 5120-01-355-1734 102 QC 2FR75 (55719) 102
5 to 75 lb-ft, 3/8 in. drive
103 O 103 Wrench, torque 103 5120-01-042-0982 103 2503MFR (08194) 103
50 to 250 lb-ft cap, 1/2 in. sq dr
104 O 104 Wrench, torque 104 5120-00-853-4538 104 3305725-1 (99251) 104
(39.5) 0 to 200 lb-in. cap, 3/8 in. sq dr
105 O 105 Wrench, torque 105 5120-01-462-8874 105 162-8718 (11083) 105
200 to 600 lb-ft, 3/4 in. drive 105
106 F 106 Wrench, torque 106 5120-00-230-6380 106 TQ12B (55719) 106
3/8 in. sq-dr, 0 to 150 in. lg, w/rvsbl rcht,
w/case
0205 00-20
TM 5-3805-290-23-1
0(1) 0(2) 0(3) 0(4) 0(5)

107 F 107 Wrench, torque 107 5120-00-554-7292 107 GGGW00686 107

3/8 in. dr. 0 to 75 lb-ft 107 (81348) 107
108 O 108 Wrench, Torque 108 5120-01-462-8874 108 162-8717 (11083) 108
Table 3. Remarks for the 924G Wheel Loader.
A Limited repair authorized by replacement of components ONLY.

B Preventive maintenance checks and services (PMCS).
C Task requires use of BII.
D Function performed by specialized repair activity (SRA) (Theater Logistics Support Center, Army), or
authorized contractor facility.
E System tests found in Volume I of this manual.
END OF WORK PACKAGE
0205 00-21/(0205 00-22 Blank)

6
TM 5-3805-290-23-1
EXPENDABLE AND DURABLE ITEMS LIST 0206 00
SCOPE
This work package lists expendable and durable items you will need to maintain the 924G Wheel Loader. This listing is
for informational purposes only and is not authority to requisition the listed items. These items are authorized to you by CTA
50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items), or CTA 8-100, Army Medical
Department Expendable/Durable Items.
EXPLANATION OF COLUMNS
1. Column (1) - Item Number. This number is assigned to the entry in the listing and is referenced in the narrative instruc-
tions to identify the item [e.g., Use Antifreeze (Item 1, WP 0206 00)].
2. Column (2) - Level. This column identifies the lowest level of maintenance that requires the listed item.
C - Operator/Crew
O - Unit Maintenance
F - Direct Support Maintenance
3. Column (3) - National Stock Number. This is the National Stock Number assigned to the item which you can use to
requisition it.
4. Column (4) - Description, CAGEC, and Part Number. This provides the other information you need to identify the
item.
5. Column (5) - Unit of Measure (U/M). This column shows the physical measurement or count of an item, such as gal-
lon, dozen, gross, etc.
0206 00-1
TM 5-3805-290-23-1
EXPENDABLE AND DURABLE ITEMS LIST - CONTINUED 0206 00
Table 1. Expendable and Durable Items List for 924G Wheel Loader.
0(1) 0(2) 0(3) 0(4) 0(5)
ITEM NATIONAL DESCRIPTION, CAGEC,

NUMBER LEVEL STOCK NUMBER AND PART NUMBER U/M
1 O Antifreeze 1
6850-01-383-4068 (1QK63) 6724354 (1 Gallon Bottle) GAL
6850-01-441-3257 (58536) A-A52624 (5 Gallon Can) CN
6850-01-383-3918 (58536) A-A52621 (55 Gallon Drum) CN
2 F 8030-01-451-1403 Antiseize compound 2 EA
(11083) 5P-3931
3 F Antiseize compound 3 EA
(11083) 4C-5598
4 F Antiseize compound 4 EA
(11083) 1E-2078
5 O 8135-00-132-9589 Barrier material, grease proofed, flexible 5 RO
(81349) MIL-B-121
6 O 6840-00-300-6373 Biocide, fuel preservative 6 QT
(0U7J1) BIOBOR JF
7 F 6850-01-234-2260 Calibration fluid, diesel 7
8 O 5340-00-450-5718 Cap set, protective 8 EA
Dust and moisture seal
(19207) 10935405
9 O Cleaning compound, solvent, type III 9
(81349) MIL-PRF-680
6850-01-474-2318 1 Gallon Can CN
6850-01-474-2320 5 Gallon Can CN
6850-01-474-2321 55 Gallon Drum DR
10 C Cleaning compound, windshield 10
(0FTT5) 0584-000
6850-00-926-2275 16 Ounce Bottle BT
11 O Cloth, abrasive 11
(80204) ANSI B74.18
5350-00-584-4654 50 Sheet Package PG
12 O 8030-00-251-3980 Compound, antiseize 12 LB
(05972) 76764
13 O Compound, antiseize 13
(11083) 4C-5591
14 F 138-8440 (11083) Cleaner 14 LB
15 O Detergent, general purpose, liquid 15
6850-01-159-4844 (83421) 7930-00-282-9699 (1 Gallon Can) CN
0206 00-2
TM 5-3805-290-23-1
Table 1. Expendable and Durable Items List for 924G Wheel Loader - Continued.
0(1) 0(2) 0(3) 0(4) 0(5)

16 C Diesel fuel, DF-1 16
(81346) ASTM D 975
9140-00-286-5286 Bulk GL
9140-00-286-5287 5 Gallon Can CN
9140-00-286-5288 55 Gallon Drum DR
17 O Flux, soldering 17
(58536) A-A-51145TY FORM A
18 C 9140-00-286-5294 Fuel oil, diesel, DF-2 18
ASTM D 975 (81346) GAL
19 C 9130-01-031-5816 Fuel, turbine, aviation 19 GAL
(81349) MIL-T-83133 GR JP-8
20 F 8040-01-437-6864 Gasket cement 20
(11083) 1U-8846 EA
21 F Gasket sealant 21
4C-9502
22 C Grease, automotive and artillery, GAA 22
9150-01-197-7688 (81349) M-10924-A TU
2-1/4 Ounce Tube
9150-01-197-7690 (81349) M-10924-C CN
1-3/4 Pound Can
9150-01-197-7692 (81349) M-10924-E CN
35 Pound Can
9150-01-197-7693 (81349) M-10924-B OZ
14 Ounce Cartridge
23 O Grease, molybdenum 23
5P-0960
24 O 9150-01-361-8919 Grease, electrically conductive 24 OZ
(53711) 5190179
25 O Insulating sleeving, electrical 25
(11530) 08-196485-06
5970-00-815-1295 250 Foot Spool FT
26 O Insulating varnish, electrical 26
(75037) 1602
5970-00-476-6717 13 Ounce Aerosol Can CN
27 O 9150-00-111-0208 Lubricating oil, engine 27 GAL
(81349) MIL-PRF-21260
28 O 5935-01-507-0644 Maintenance kit, electrical connector 28 EA
(11083) 190-8900
29 O Nitrite test strips 29
6850-01-154-3653 100 Strip Package PK
0206 00-3
TM 5-3805-290-23-1
0(1) 0(2) 0(3) 0(4) 0(5)

30 O 6803-00-782-2641 Nitrogen technical dry cylinder 30 CYL
(58536) A-A-59503-1B1187
31 O Oil additive, hydraulic 31 QT
(11083) 1U-9891
32 Oil, lubricating, OEA-30, Arctic 32
9150-00-402-4478 1 Quart Can QT

(81349) MIL-L-46167
9150-00-402-2372 5 Gallon Can GAL
(81349) MIL-PRF-46167
9150-00-491-7197 55 Gallon Drum GAL
(81349) MIL-PRF-46167
33 Oil, lubricating, OE/HDO-40 33
(81349) MIL-PRF-2104
9150-00-188-9862 55 Gallon Drum DR
34 C Oil, lubricating, OE/HDO-5/40 34
(81349) MIL-PRF-2104
9150-01-524-9155 55 Gallon Drum DR
35 C Oil, lubricating, OE/HDO-15/40 35
(81349) MIL-PRF-2104
9150-01-152-4117 1 Quart Can CN
9150-01-152-4118 5 Gallon Can CN
9150-01-152-4119 55 Gallon Drum DR
36 O Oil, lubricating, TO-4 36
36 9150-00-402-2372 5 Gallon Can GAL
(11083) 8T-9576
36 9150-00-491-7197 55 Gallon Drum GAL
(11083) 8T-9577
37 F 9150-01-524-4276 Oil, lubricating, refrigerant compressor 37 QT
Synthetic ester
(59595) Capella HFC-68NA
1 Quart Can CN
38 O 8010-00-616-4009 Paint, heat resisting (81349) MIL-P-14105 38 GAL
1 Gallon Can 38
39 O Petrolatum, technical 39
(81348) VV-P-236
9150-00-250-0933 7.5 lb Can CN
40 O 8010-01-359-9245 Primer coating 40 GAL
(80244) GG00265
0206 00-4
TM 5-3805-290-23-1
0(1) 0(2) 0(3) 0(4) 0(5)

41 O Rag, wiping 41
(64067) 7920-00-205-1711
42 Refrigerant dye 42
43 O 2815-01-521-1638 Repair kit, diesel engine 43 EA
(11083) 175-3700
44 O 8030-01-509-1597 Sealing compound 44
(11083) 9S-3263
45 O 8030-00-111-6404 Sealing compound 45
(11083) 9S-3265
46 O Sealant, silicone 1 lb 46
(11083) 8T-9013
47 F 119-0781 (11083) Silicone adhesive 1 lb 47
48 F 8T-9014 (11083) Silicone sealant 1 lb 48
49 F 121-3911 (11083) SIKA 206 G+P primer 1 lb 49
50 O 6810-00-297-0092 Sodium bicarbonate, technical 50 BG
(81346) ASTM D 928
51 O Solder, lead-tin alloy, rosin core 51
(81346) SN60WRP2 0.032 1LB
3439-00-555-4629 1 Pound Spool LB
52 O 4235-01-510-1292 Spill containment unit, hazardous material 52 PG
20 x 20 in. box of 4
(1WB54) B-1400-ROP
53 Strap, tiedown, electrical 53
Components
4 Inch Length, Black, Package of 100 HD
(96906) MS3367-4-0
6 Inch Length, Black, Package of 100 HD
(96906) MS3367-1-0
13.35 Inch Minimum Length, PG
black, Package of 100
(96906) MS3367-2-1
54 O Tag, marker 54
(64067) 9905-00-537-8954
9905-00-537-8954 Bundle of 50 BD
55 O Tape, duct 55
Roll RL
56 O 7510-00-040-5895 Tape, pressure sensitive adhesive 56 RL
(81755) P5113-3
0206 00-5
TM 5-3805-290-23-1
0(1) 0(2) 0(3) 0(4) 0(5)

57 O 9390-00-023-8223 Tape, reflective 57
Roll EA
58 6830-01-439-0614 Tetrafluoroethane, technical (Refrigerant, R-134a)
43 lb cyl 58 LB
59 O Thread lock compound 59 EA
(11083) 4C-4030
60 O Volatile corrosion inhibitor (VCI) oil 60 GAL
(11083) 4C-6793
END OF WORK PACKAGE
0206 00-6
22
TM 5-3805-290-23-1
TORQUE LIMITS 0207 00
SCOPE
This work package lists standard torque values and provides general information for applying torque. Special torque val-
ues and tightening sequences are indicated in maintenance procedures for applicable components.
GENERAL
1. Always use torque values listed in (Tables 1 thru 6) when maintenance procedure does not show a specific torque value.
a. (Tables 1 thru 3) provides torque limits for SAE standard fasteners.
b. (Tables 4 thru 6) provides torque limits for metric fasteners.
2. Unless otherwise indicated, standard torque tolerance shall be r10%.
3. Torque values listed are based on clean, dry threads. Reduce torque by 10% when engine oil is used as lubricant. If new
plated capscrews are used, reduce torque by 20%.
4. If maintenance procedures do not specify a tightening order, use the following guides:
a. Unless otherwise specified, lubricate threads of fasteners with oil (OE/HDO-10 or OEA-30).
b. When tightening fasteners above 30 lb-ft (41 Nm), use torque pattern only to tighten to 70% of final value (multi-
ply 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
0207 00-1
TM 5-3805-290-23-1
TORQUE LIMITS - CONTINUED 0207 00
METRIC (ISO) FASTENERS

CAUTION
If replacement capscrews are of higher grade than originally supplied, use torque specifications for
original. This will prevent equipment damage due to over-torquing.
NOTE
The following tables have recommended standard torque values for metric nuts and bolts for use on
Caterpillar engines.
ENGLISH (SAE) FASTENERS
Table 1. English (SAE) Nuts and Bolts. 427-B0145
Thread Size (mm) Torque

1/4 9 ± 2 lb-ft (12 ± 3 Nm)
5/16 18 ± 4 lb-ft (24 ± 8 Nm)
3/8 35 ± 7 lb-ft (47 ± 9 Nm)
7/16 50 ± 11 lb-ft (68 ± 15 Nm)
1/2 75 ± 15 lb-ft (101 ± 20 Nm)
9/16 120 ± 22 lb-ft (163 ± 30 Nm)
5/8 160 ± 30 lb-ft (217 ± 41 Nm)
3/4 275 ± 37 lb-ft (373 ± 50 Nm)
7/8 460 ± 60 lb-ft (624 ± 81 Nm )
1 660 ± 75 lb-ft (895 ± 102 Nm)
1 1/8 960 ± 110 lb-ft (1,302 ± 149 Nm)
1 1/4 1,320 ± 150 lb-ft (1,790 ± 203 Nm)
1 3/8 1,780 ± 220 lb-ft (2,413 ± 298 Nm)
1 1/2 2,280 ± 260 lb-ft (3,091 ± 353 Nm)
0207 00-2
TM 5-3805-290-23-1
ENGLISH (SAE) FASTENERS - CONTINUED
Table 2. English (SAE) Taperlock Studs.

1/4 6 ± 2 lb-ft (8 ± 3 Nm)
5/16 13 ± 4 lb-ft (18 ± 5 Nm)
3/8 26 ± 4 lb-ft (35 ± 5 Nm)
7/16 33 ± 7 lb-ft (45 ± 9 Nm)
1/2 48 ± 7 lb-ft (65 ± 9 Nm)
5/8 80 ± 15 lb-ft (108 ± 20 Nm)
3/4 125 ± 22 lb-ft (169 ± 30 Nm)
7/8 190 ± 30 lb-ft (258 ± 41 Nm)
1 300 ± 44 lb-ft (407 ± 60 Nm)
1 1/8 390 ± 44 lb-ft (529 ± 60 Nm)
1 1/4 550 ± 60 lb-ft (746 ± 81 Nm)
1 3/8 700 ± 90 lb-ft (949 ± 122 Nm)
1 1/2 880 ± 110 lb-ft (1,193 ± 149 Nm)
ENGLISH (SAE) MACHINE SCREWS
427-B0144
Table 3. English (SAE) Machine Screws.

0-80 0.9 ± 0.1 lb-in. (0.10 ± 0.01 Nm)
1-64 1.3 ± 0.1 lb-in. (0.15 ± 0.01 Nm)
2-56 2.2 ± 0.2 lb-in. (0.25 ± 0.02 Nm)
3-48 3.1 ± 0.4 lb-in. (0.35 ± 0.05 Nm)
4-40 4.4 ± 0.4 lb-in. (0.50 ± 0.05 Nm)
5-40 6.2 ± 0.4 lb-in. (0.70 ± 0.05 Nm)
6-32 8.0 ± 0.9 lb-in. (0.90 ± 0.10 Nm)
8-32 15.0 ± 2.2 lb-in. (1.69 ± 0.25 Nm)
10-24 19.9 ± 2.2 lb-in. (2.25 ± 0.25 Nm)
12-24 30.0 ± 5.3 lb-in. (3.40 ± 0.60 Nm)
0207 00-3
TM 5-3805-290-23-1
METRIC (ISO) FASTENERS
427-B0143
Table 4. Metric (ISO) Nuts and Bolts.

M6 9 ± 2 lb-ft (12 ± 3 Nm)
M8 21 ± 5 lb-ft (28 ± 7 Nm)
M10 41 ± 7 lb-ft (55 ± 9 Nm)
M12 75 ± 15 lb-ft (101 ± 20 Nm)
M14 120 ± 22 lb-ft (163 ± 30 Nm)
M16 175 ± 30 lb-ft (237 ± 41 Nm)
M20 340 ± 44 lb-ft (461 ± 60 Nm)
M24 590 ± 75 lb-ft (800 ± 102 Nm)
M30 1,180 ± 150 lb-ft (1,600 ± 203 Nm)
M36 2,000 ± 220 lb-ft (2,712 ± 298 Nm)
Table 5. Metric (ISO) Taperlock Studs.

M6 71 ± 27 lb-ft (96 ± 37 Nm)
M8 13 ± 4 lb-ft (18 ± 5 Nm)
M10 26 ± 4 lb-ft (35 ± 5 Nm)
M12 48 ± 7 lb-ft (65 ± 9 Nm)
M16 80 ± 15 lb-ft (108 ± 20 Nm)
M20 125 ± 22 lb-ft (169 ± 30 Nm)
M24 300 ± 44 lb-ft (408 ± 60 Nm)
M30 550 ± 60 lb-ft (746 ± 81 Nm)
M36 880 ± 110 lb-ft (1,193 ± 149 Nm)
0207 00-4
TM 5-3805-290-23-1
METRIC (ISO) FASTENERS - CONTINUED
427-B0144
Table 6. Metric (ISO) Machine Screws.

M1.6 0.9 ± 0.1 lb-in. (0.10 ± 0.01 Nm)
M2 1.3 ± 0.1 lb-in. (0.15 ± 0.01 Nm)
M2.5 3.1 ± 0.4 lb-in. (0.35 ± 0.05 Nm)
M3 4.4 ± 0.4 lb-in. (0.50 ± 0.05 Nm)
M4 15.0 ± 2.2 lb-in. (1.69 ± 0.25 Nm)
M5 19.9 ± 2.2 lb-in. (2.25 ± 0.25 Nm)
GROUND ENGAGING TOOL (G.E.T.) FASTENERS

Ground Engaging Tools (G.E.T.) are secured by many types of bolts. Refer to Table 7 for correct torque for following
combinations of fasteners for G.E.T.:
• Plow bolts and nuts.
• Hex head bolt and nuts.
Table 7. Ground Engaging Tool (G.E.T.) Fasteners.
Torque (1)
Thread Size Inches
lb-ft Nm
5/8 in. 200 ± 30 271 ± 41
3/4 in. 350 ± 45 475 ± 61
7/8 in. 550 ± 65 746 ± 88
1 in. 850 ± 110 1,152 ± 149
1 1/4 in. 1,700 ± 220 2,305 ± 298
(1)
These values are only for Caterpillar bolts for cutting edges.
0207 00-5
TM 5-3805-290-23-1
PLOW BOLTS
WARNING
Personal injury can result when installing plow bolts. Appropriate safety equipment must be worn
when striking plow bolts. To avoid injury to your eyes and ears, wear protective glasses and hearing
protection during this procedure.
427-B0146
1. Clean all surfaces that had contact with bolt. Remove all occurrences of the following conditions: rust, paint, nicks, and
burrs.
2. Tighten nut to correct torque. Refer to Table 7.
3. Use hammer to bolt head. Bolt head must be struck with significant force.
NOTE
Bolt head may be recessed below mounting surface. Use suitable punch to transfer hammer blow to
bolt head.
4. Tighten nut to correct torque. Refer to Table 7.
INSTALLATION OF FITTINGS
NOTE
Tightening sequence of the fasteners that attach tube assembly or hose assembly to the machine is
very critical to proper function of machine. Sealing surfaces of tube assembly or hose assembly should
be secured squarely. Sealing surfaces of the tube assembly or hose assembly should be tightened to the
serviced component (control valve, cylinder, hydraulic motor, etc.). Perform this procedure prior to
final tightening of any clamps or slips that are used to fasten the tube assembly or hose assembly to
machine.
Fittings have different connections. Fittings may have two completely different ends. Use proper torque for end of fit-
ting. The following list contains some common types of fittings:
• Straight Thread O-Ring (STOR)
• Adjustable Straight Thread O-Ring (STOR)
• O-Ring Face Seal (ORFS)
• Tapered Pipe Thread (NPT and NPTF)
• 37 Degree Flare Fitting
• 45 Degree Flare Fitting
• 45 Degree Inverted Flare Fitting
• Split Flange Coupling
0207 00-6
TM 5-3805-290-23-1
INSTALLATION OF SPLIT FLANGE COUPLINGS

1. For a metal tube to hose installation, install the tube and tighten all bolts finger tight at rigid end.
2. Install hose and tighten all bolts finger tight.
3. Put hose in a position where hose does not make contact with machine or other hoses.
427-B0147
4. Tighten bolts on both connections to proper torque. Follow the prescribed torque sequence for split-flange connections.
Add measurement of gap (A) to measurement of gap (B). Total must not exceed 0.16 in. (4.0 mm).
5. Start engine (TM 5-3805-290-10).
6. Move implement control levers to all positions.
7. Look at hose during movement of implement. Ensure hose is not making contact with machine or other hoses.
NOTE
For hoses that cross an articulation hitch, check for contact during articulation. For hoses that con-
nect to the steering system, check for contact during steering.
8. Shut off engine (TM 5-3805-290-10).
9. If hose contacts other hoses or machine during test, loosen bolts, and reposition hose. Repeat steps 3 thru 8 until there is
no contact.
0207 00-7
TM 5-3805-290-23-1
INSTALLATION OF ADJUSTABLE STOR FITTINGS

This type of fitting is used in many applications. One end of the fitting will be an adjustable STOR fitting. Other end
will be different. Always use same installation procedure for STOR end. Adjustable STOR fittings should be positioned before
tightening.
427-B0148
1. Put locknut (3), backup washer (4), and O-ring seal (5) as far back on fitting body (2) as possible. Hold these compo-
nents in this position. Turn fitting into mating part. Turn the fitting until backup washer contacts the surface of mating
part.
2. Put fitting assembly in correct position. Loosen fitting (1) until the correct assembly position is achieved. Do not loosen
the fitting more than 360 degrees. Install tube or hose hand tight to verify the orientation of fitting. Tighten locknut (3)
to torque that is shown on correct chart for fitting.
0207 00-8
TM 5-3805-290-23-1
INSTALLATION OF ADJUSTABLE STOR FITTINGS - CONTINUED
NOTE
If fitting is not adjustable, hex bolt/nuts on body replaces locknut. To install this type of fitting, tighten
hex bolt/nuts against face of the mating part.
427-B0149
Table 8. Ferrous Straight Thread O-Ring Fitting Torques for Mating with Ferrous Materials.
Nominal Outer Thread Size

Standard Torque
Diameter of the Tube (Inches)
.125 in. (3.18 mm) 5/16 - 24 70 ± 9 lb-in. (95 ± 12 Nm)
.188 in. (4.76 mm) 3/8 - 24 9 ± 1 lb-ft (12 ± 1 Nm)
.250 in. (6.35 mm) 7/16 - 20 16 ± 1 lb-ft (22 ± 1 Nm)
.312 in. (7.94 mm) 1/2 - 20 22 ± 2 lb-ft (30 ± 3 Nm)
.375 in. (9.52 mm) 9/16 - 18 35 ± 4 lb-ft (47 ± 5 Nm)
.500 in. (12.70 mm) 3/4 - 16 60 ± 6 lb-ft (81 ± 8 Nm)
.625 in. (15.88 mm) 7/8 - 14 105 ± 10 lb-ft (142 ± 14 Nm)
.750 in. (19.05 mm) 1 1/16 - 12 140 ± 11 lb-ft (190 ± 15 Nm)
.875 in. (22.22 mm) 1 3/16 - 12 185 ± 15 lb-ft (250 ± 20 Nm)
1.000 in. (25.40 mm) 1 5/16 - 12 220 ± 22 lb-ft (298 ± 30 Nm)
1.250 in. (31.75 mm) 1 5/8 - 12 260 ± 26 lb-ft (353 ± 35 Nm)
1.500 in. (38.10 mm) 1 7/16 - 12 305 ± 30 lb-ft (413 ± 40 Nm)
2.000 in. (50.80 mm) 2 1/2 - 12 320 ± 30 lb-ft (434 ± 41 Nm)
Note: Use 50 percent of the torque values from Table 8 when the fitting of the port material is
nonferrous.
0207 00-9
TM 5-3805-290-23-1
427-B0160
Table 9. Straight Thread O-Ring Plugs (Hex Bolt/Nut Drive).
Thread Size
Torque
(Inches)
5/16 80 ± 9 lb-in. (9.0 ± 1.0 Nm)
3/8 12.5 ± 1.1 lb-ft (17 ± 1.5 Nm)
7/16 17 ± 1 lb-ft (23 ± 1 Nm)
1/2 21 ± 2 lb-ft (28 ± 3 Nm)
9/16 25 ± 2 lb-ft (34 ± 3 Nm)
3/4 44 ± 4 lb-ft (60 ± 5 Nm)
7/8 85 ± 7 lb-ft (115 ± 9 Nm)
1 1/16 103 ± 10 lb-ft (140 ± 14 Nm)
1 3/16 140 ± 14 lb-ft (190 ± 19 Nm)
1 5/16 155 ± 15 lb-ft (210 ± 20 Nm)
1 5/8 215 ± 18 lb-ft (292 ± 24 Nm)
1 7/8 240 ± 22 lb-ft (325 ± 30 Nm)
2 1/2 310 ± 30 lb-ft (420 ± 41 Nm)
0207 00-10
TM 5-3805-290-23-1
427-B0161
Table 10. Straight Thread O-Ring Plugs (Socket Drive).
Thread Size
Torque
(Inches)
5/16 44 ± 9 lb-in. (5.0 ± 1.0 Nm)
3/8 97 ± 9 lb-in. (132 ± 1.0 Nm)
7/16 12 ± 1 lb-ft (16 ± 1.4 Nm)
1/2 15 ± 1 lb-ft (20 ± 1 Nm)
9/16 26 ± 3 lb-ft (35 ± 4.0 Nm)
3/4 52 ± 5 lb-ft (70 ± 7 Nm)
7/8 73 ± 7 lb-ft (99 ± 9 Nm)
1 1/16 125 ± 11 lb-ft (169 ± 15 Nm)
1 3/16 160 ± 15 lb-ft (217 ± 20 Nm)
1 5/16 200 ± 18 lb-ft (271 ± 24 Nm)
1 5/8 250 ± 20 lb-ft (339 ± 27 Nm)
1 7/8 275 ± 25 lb-ft (373 ± 34 Nm)
2 1/2 305 ± 30 lb-ft (414 ± 41 Nm)
0207 00-11
TM 5-3805-290-23-1
427-B0162
NOTE
Plug (A), plug (B), and plug (C) are used with gasket. Conical seal plug (D) does not use gasket.
Table 11. Drain Plugs with Straight Threads.
Plug Thread Size

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

3/4 -16
7/8 - 14 52 ± 11 lb-ft (70 ± 15 Nm)
1 1/8 - 12
1 5/16 - 12 66 ± 11 lb-ft (89 ± 15 Nm)
B 1 1/2 - 12
2 - 12 92 ± 11 lb-ft (125 ± 15 Nm)
1 1/8 - 12 52 ± 11 lb-ft (70 ± 15 Nm)
C
1 5/16 - 12 66 ± 11 lb-ft (89 ± 15 Nm)
1/2 - 20 97 ± 35 lb-ft (131 ± 47 Nm)
7/8 - 14 41 ± 5 lb-ft (56 ± 7 Nm)
D
1 3/8 - 13 66 ± 11 lb-ft (90 ± 15 Nm)
1 1/12 - 12 92 ± 11 lb-ft (125 ± 15 Nm)
0207 00-12
TM 5-3805-290-23-1
427-B0163
Table 12. Straight Thread O-Ring Plugs (Mechanical Joint Tube Assemblies).
Thread Size
Torque
(Inches)
7/8 92 ± 11 lb-ft (125 ± 15 Nm)
1 1/16 130 ± 11 lb-ft (176 ± 15 Nm)
1 3/16 185 ± 15 lb-ft (250 ± 20 Nm)
1 1/4 185 ± 15 lb-ft (250 ± 20 Nm)
1 5/16 275 ± 15 lb-ft (372 ± 20 Nm)
1 5/8 310 ± 20 lb-ft (420 ± 27 Nm)
1 7//8 390 ± 25 lb-ft (529 ± 34 Nm)
2 1/2 665 ± 40 lb-ft (902 ± 54 Nm)
0207 00-13
TM 5-3805-290-23-1
O-RING FACE SEAL FITTINGS
427-B0142
O-ring face seal fitting (OFRS fitting):

(1) O-ring face seal connector
(2) O-ring groove
(3) O-ring seal
(4) Nut for O-ring face seal
Table 13. Ferrous ORFS Fitting.
Thread Size
Standard Torque for Nut (3)
(Inches)
9/16 - 18 18 ± 2 lb-ft (24 ± 3 Nm)
11/16 - 16 30 ± 3 lb-ft (41 ± 4 Nm)
13/16 - 16 41 ± 4 lb-ft (56 ± 5 Nm)
1 - 14 65 ± 6 lb-ft (88 ± 8 Nm)
1 3/16 - 12 90 ± 11 lb-ft (122 ± 15 Nm)
1 7/16 - 12 120 ± 11 lb-ft (163 ± 15 Nm)
1 11/16 - 12 150 ± 15 lb-ft (203 ± 20 Nm)
2 - 12 180 ± 15 lb-ft (244 ± 20 Nm)
0207 00-14
TM 5-3805-290-23-1
BULKHEAD NUTS
BULKHEAD CONNECTOR (ORFS) (1) AND BULKHEAD NUT (2)

427-B0164
NOTE
• The bulkhead connector may have different connections. Type of fluid connection does not affect torque for
nut (2).
• When you assemble the fluid connection, do not use bulkhead nut as leverage for backup wrench. Use the hex
bolt on body of connector for leverage.
Table 14. Bulkhead Nuts.
Thread Size Torque

(Inches)
5/16 53 ± 9 lb-in. (6 ± 1 Nm)
3/8 71 ± 9 lb-in. (8 ± 1 Nm)
7/16 10 ± 1 lb-ft (14 ± 1.3 Nm)
1/2 13 ± 1.4 lb-ft (18 ± 2 Nm)
9/16 16 ± 1.4 lb-ft (22 ± 2 Nm)
11/16 23 ± 2 lb-ft (31 ± 3 Nm)
3/4 27 ± 3 lb-ft (37 ± 4 Nm)
13/16 30 ± 3 lb-ft (41 ± 4 Nm)
7/8 32 ± 3 lb-ft (43 ± 4 Nm)
1 45 ± 4 lb-ft (61 ± 5 Nm)
1 1/16 52 ± 5 lb-ft (70 ± 7 Nm)
1 3/16 67 ± 7 lb-ft (91 ± 9 Nm)
1 5/16 83 ± 7 lb-ft (113 ± 9 Nm)
1 7/16 92 ± 9 lb-ft (125 ± 12 Nm)
1 5/8 110 ± 11 lb-ft (149 ± 15 Nm)
1 11/16 110 ± 11 lb-ft (149 ± 15 Nm)
1 7/8 115 ± 11 lb-ft (156 ± 15 Nm)
2 125 ± 13 lb-ft (169 ± 18 Nm)
2 1/2 160 ± 15 lb-ft (217 ± 20 Nm)
0207 00-15
TM 5-3805-290-23-1
FLARE FITTINGS
37 Degree Flare Fittings
427-B0165
Table 15. Nuts for 37 Degree Flare Fittings.

Standard Torque
.125 in. (3.18 mm) 5/16 44 ± 13 lb-in. (5.0 ± 1.5 Nm)
.188 in. (4.76 mm) 3/8 100 ± 15 lb-in. (11 ± 2 Nm)
.250 in. (6.35 mm) 7/16 12 ± 3 lb-ft (16 ± 4 Nm)
.312 in. (7.94 mm) 1/2 15 ± 4 lb-ft (20 ± 5 Nm)
.375 in. (9.52 mm) 9/16 18 ± 4 lb-ft (24 ± 5 Nm)
.375 in. (9.52 mm) 5/8 26 ± 4 lb-ft (35 ± 5 Nm)
.500 in. (12.70 mm) 3/4 37 ± 5 lb-ft (50 ± 7 Nm)
.625 in. (15.88 mm) 7/8 48 ± 5 lb-ft (65 ± 7 Nm)
.750 in. (19.05 mm) 1 1/16 75 ± 7 lb-ft (102 ± 9 Nm)
.875 in. (22.22 mm) 1 3/16 90 ± 7 lb-ft (122 ± 9 Nm)
1.000 in. (25.40 mm) 1 5/16 100 ± 11 lb-ft (136 ± 15 Nm)
1.250 in. (31.75 mm) 1 5/8 135 ± 11 lb-ft (183 ± 15 Nm)
1.500 in. (38.10 mm) 1 7/8 165 ± 11 lb-ft (224 ± 15 Nm)
2.000 in. (50.80 mm) 2 1/2 240 ± 22 lb-ft (325 ± 30 Nm)
Note: Use 50% of torque values from Table 15 when the fitting or port material is nonferrous.
0207 00-16
TM 5-3805-290-23-1
FLARE FITTINGS - CONTINUED
45 Degree Flare and 45 Degree Inverted Flare Fittings
(1) 45 Degree Inverted Flare Fittings

(2) 45 Degree Flare Fittings
427-B0166
Table 16. 45 Degree Flare Fittings and 45 Degree Inverted Flare Fittings.

Standard Torque
.125 in. (3.18 mm) 5/16 44 ± 13 lb-in. (5.0 ± 1.5 Nm)
.188 in. (4.76 mm) 3/8 70 ± 13 lb-in. (8.0 ± 1.5 Nm)
.250 in. (6.35 mm) 7/16 100 ± 15 lb-in. (11 ± 2 Nm)
.312 in. (7.94 mm) 1/2 13 ± 2 lb-ft (18 ± 3 Nm)
.375 in. (9.52 mm) 5/8 22 ± 2 lb-ft (30 ± 3 Nm)
.375 in. (9.52 mm) 5/8 26 ± 4 lb-ft (35 ± 5 Nm)
.438 in. (11.11 mm) 11/16 22 ± 2 lb-ft (30 ± 3 Nm)
.500 in. (12.70 mm) 3/4 28 ± 3 lb-ft (38 ± 4 Nm)
.625 in. (15.88 mm) 7/8 37 ± 4 lb-ft (50 ± 5 Nm)
.750 in. (19.05 mm) 1 1/16 65 ± 6 lb-ft (88 ± 8 Nm)
.875 in. (22.22 mm) 1 1/4 75 ± 7 lb-ft (102 ± 9 Nm)
0207 00-17
TM 5-3805-290-23-1
AIR CONDITIONING FITTINGS
(1) O-RING SEAL (2) 45 DEGREE FLARE FITTING 427-B0167
Table 17. Air Conditioning Fittings.
O-Ring Fitting End 45 Degree Flare Fitting End

Thread Size
(Inches) Torque for Torque for
Torque
Steel Tubes Aluminum Tubes
5/8 - 18 10 ± 3 lb-ft 22 ± 2 lb-ft 17 ± 2 lb-ft
(14 ± 4 Nm) (30 ± 3 Nm) (23 ± 3 Nm)
3/4 - 16 20 ± 3 lb-ft 38 ± 4 lb-ft 24 ± 4 lb-ft
(27 ± 4 Nm) (52 ± 5 Nm) (33 ± 5 Nm)
7/8 - 14 30 ± 3 lb-ft 44 ± 5 lb-ft 28 ± 3 lb-ft
1 - 14 (41 ± 4 Nm) (60 ± 7 Nm) (38 ± 4 Nm)
1 1/16 - 14 33 ± 4 lb-ft 55 ± 6 lb-ft 37 ± 4 lb-ft
(45 ± 5 Nm) (75 ± 8 Nm) (50 ± 5 Nm)
0207 00-18
TM 5-3805-290-23-1
TAPERED PIPE THREAD FITTINGS

Torque is based on diameter of thread. Torque values are identical for coarse and fine threads.
NOTE
Table 18 has recommended standard torque value for tapered pipe thread fitting for use on Caterpil-
lar engines.
Table 18. Tapered Pipe Thread Fittings.
Standard Torque
Diameter of the Pipe
Thread (Inches) Threads with Threads without
5P-3413 Pipe Sealant Pipe Sealant
1/16 90 lb-in. (10 Nm) 90 lb-in. (10 Nm)
1/8 12 lb-ft (16 Nm) 12 lb-ft (16 Nm)
1/4 15 lb-ft (20 Nm) 18 lb-ft (24 Nm)
3/8 26 lb-ft (35 Nm) 33 lb-ft (45 Nm)
1/2 33 lb-ft (45 Nm) 44 lb-ft (60 Nm)
3/4 44 lb-ft (60 Nm) 55 lb-ft (75 Nm)
1 55 lb-ft (75 Nm) 65 lb-ft (88 Nm)
1 1/4 65 lb-ft (88 Nm) 80 lb-ft (108 Nm)
1 1/2 80 lb-ft (108 Nm) 95 lb-ft (129 Nm)
2 95 lb-ft (129 Nm) 120 lb-ft (163 Nm)
Note: Use 50 percent of torque values from Table 18 when fitting, plug, or port
material is nonferrous. Use 50 percent of torque values from Table 18 when tapered
thread is mating with straight thread.
0207 00-19
TM 5-3805-290-23-1
MISCELLANEOUS FITTINGS
Hi-Duty Tube Fittings (Shear Sleeve)
427-B0169
Put nut (1) over tube and push tube into counterbore of fitting body as far as possible. Turn nut with wrench until small
decrease in torque is felt. Small decrease in torque indicates that sleeve (2) has been broken off of the nut. Hold tube to prevent
tube from turning. Tighten nut for an additional 1 1/2 turns.
SAE FLARELESS FITTINGS
427-B0180
Installing New Flareless Fitting
Put nut (1) and sleeve (2) over tube. Head end of sleeve should be next to nut. Head end has shoulder. Push tube into
counterbore of fitting body as far as possible. Turn nut clockwise until sleeve grips tube. Sleeve must stop all movement of
tube. Tighten nut until sudden increase in torque is felt. Next, tighten fitting for an additional 1/6 to 1/3 turn to seat sleeve.
Flex Fittings
427-B0181
Put nut (1) and sleeve (2) over tube and push tube into counterbore of fitting body as far as possible. Tighten nut until
nut is against hex part of fitting body.
0207 00-20
TM 5-3805-290-23-1
HOSE CLAMPS
Worm Drive Band Type Clamps
427-B0182
Table 19. Worm Drive Band Type Clamps.
Width (A) of Clamp Torque for New Hose

0.31 in. (7.9 mm) 8 ± 2 lb-in. (0.9 ± 0.2 Nm)
0.53 in. (13.5 mm) 40 ± 4 lb-in. (4.5 ± 0.5 Nm)
0.63 in. (15.9 mm) 65 ± 4 lb-in. (7.3 ± 0.5 Nm)
Width (A) of Clamp Torque for Reused Hose(1)
0.31 in. (7.9 mm) 6 ± 2 lb-in. (0.7 ± 0.2 Nm)
0.53 in. (13.5 mm) 27 ± 4 lb-in. (3.0 ± 0.5 Nm)
0.63 in. (15.9 mm) 40 ± 4 lb-in. (4.5 ± 0.5 Nm)
(1)
Use this value when hose is reused. However, clamp may be new or
reused.
0207 00-21
TM 5-3805-290-23-1
HOSE CLAMPS - CONTINUED
Constant Torque Hose Clamps
427-B0183
Use a constant torque hose clamp instead of any worm drive band type clamp. Ensure constant torque hose clap is same
size as worm drive band type clamp. Because of extreme temperature changes, hose will heat set. Heat setting can cause worm
drive band type clamps to become loose. Loose hose clamps can result in leaks. There have been reports of component failures
that have been caused by loosened worm drive band type clamps. Constant torque hose clamp will help prevent these failures.
Use a torque wrench for proper installation of all constant torque hose clamps. There are two types of constant torque
hose clamps: Belleville washer (1) and T bolt and spring (4).
When constant torque hose clamp of Belleville washer (1) is assembled correctly, Belleville washers (2) are nearly col-
lapsed flat. The proper torque for screw (3) is based on diameter (B) of clamp. Refer to Table 20 for the correct torque.
Table 20.
Diameter (B) Standard Torque

2 in. (Up to 50.8 mm) 65 ± 5 lb-in. (7.3 ± 0.6 Nm)
2 in. (Greater than 50.8 mm) 95 ± 10 lb-in. (11 ± 1 Nm)
The correct torque for constant torque hose clamp (T bolt and spring) (4) is 60 ± 10 lb-in. (7 ± 1 Nm).
END OF WORK PACKAGE
0207 00-22
8
TM 5-3805-290-23-1
PREPARATION FOR STORAGE OR SHIPMENT 0208 00
Preparation for Short-Term Storage Preparation for Return to Service from Long-Term
Preparation for Return to Service from Short-Term Storage
Storage Preparation for Shipment
Preparation for Long-Term Storage
INITIAL SETUP
Maintenance Level Materials/Parts - Continued

Unit Strap, tiedown, electrical (Item 53, WP 0206 00)
Tools and Special Tools Tag, marker (Item 54, WP 0206 00)
Tool kit, general mechanic’s (Item 96, WP 0205 00) Tape, pressure sensitive adhesive (Item 56, WP
0206 00)
00) Volatile corrosion inhibitor (VCI) oil (Item 60, WP
0206 00)
Brush, acid swabbing (Item 16, WP 0205 00)
Tool group, flow check (Item 97, WP 0205 00) Personnel Required
MOS 62B, Construction Equipment Repairer (2)
Materials/Parts
Barrier material, grease proofed, flexible (Item 5, References
WP 0206 00) TB 43-0242
Biocide, fuel preservative (Item 6, WP 0206 00) TB 750-651
Diesel fuel, DF-1 (Item 16, WP 0206 00) TM 9-6140-200-14
Fuel oil, diesel, DF-2 (Item 18, WP 0206 00) WP 0019 00
Fuel, turbine, aviation (Item 19, WP 0206 00) WP 0020 00
Grease, automotive and artillery, GAA (Item 22, WP 0024 00
WP 0206 00)
WP 0025 00
Lubricating oil, engine (Item 27, WP 0206 00)
WP 0029 00
Nitrite test strips (Item 29, WP 0206 00)
WP 0032 00
Oil, lubricating, OEA-30, Arctic (Item 32, WP
0206 00) WP 0035 00
Oil, lubricating, OE/HDO-40 (Item 33, WP 0206 WP 0036 00
00) WP 0042 00
Oil, lubricating, OE/HDO-5/40 (Item 34, WP 0206 WP 0046 00
00)
WP 0048 00
Paint, heat resisting (81349) MIL-P-14105 (Item
WP 0077 00
38, WP 0206 00)
WP 0083 00
Primer coating (Item 40, WP 0206 00)
Rag, wiping (Item 41, WP 0206 00) WP 0091 00
Sodium bicarbonate, technical (Item 50, WP 0206 WP 0163 00

00) WP 0164 00
0208 00-1
TM 5-3805-290-23-1
PREPARATION FOR STORAGE OR SHIPMENT - CONTINUED 0208 00
INITIAL SETUP- CONTINUED
Equipment Conditions Equipment Conditions - Continued

Wheels chocked
10) Battery disconnect switch in OFF position (TM 5-
3805-290-10)
Estimated Time to Complete Task
Parking brake engaged (TM 5-3805-290-10) 8.0 hr
PREPARATION FOR SHORT-TERM STORAGE 0208 00
NOTE
Short-term storage is storage for 90 days or less.
1. Thoroughly clean machine.
2. Perform all Operator PMCS (TM 5-3805-290-10).
3. Fill fuel tank completely to prevent condensation from forming (TM 5-3805-290-10).
4. Perform Unit PMCS (WP 0019 00 and WP 0020 00).
5. Schedule next PMCS on ULLS-G (Unit Level Logistics System – Ground).
6. Store machine in a dry, protected area with work tools lowered to ground (TM 5-3805-290-10).
7. If storage exceeds 30 days, disconnect battery cables (WP 0077 00) and secure away from contact with battery terminals
using Strap, tiedown, electrical (Item 53, WP 0206 00). Place a sign that says “BATTERIES ARE DISCONNECTED”
in driver’s compartment. Maintain batteries IAW TM 9-6140-200-14.
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 bat-
tery is giving off gases, it can explode and cause injury. Remove all jewelry such as rings, ID tags,
watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will cause instant
heating, damage to equipment, and injury to personnel.
• 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.
a. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention
immediately.
b. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention
as required.
c. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow
with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately.
d. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with
baking soda or household ammonia.
0208 00-2
TM 5-3805-290-23-1
PREPARATION FOR SHORT-TERM STORAGE - CONTINUED
8. Remove batteries (WP 0077 00) and clean batteries, clamps, supports, retainers, and battery box using a Brush, acid
swabbing (Item 16, WP 0205 00) and a solution of 1/2 lb (0.23 kg) of Sodium bicarbonate, technical (Item 50, WP 0206
00), to 1 gal. (3.8 L) of water. Flush with clean water and dry (TM 9-6140-200-14). Place batteries back in battery
boxes.
9. Check engine coolant to ensure coolant has correct mixture for expected temperatures (WP 0020 00).
10. Seal all openings in engine, including air intake, exhaust outlet, and crankcase breather tube, with Tape, pressure sensi-
tive adhesive (Item 56, WP 0206 00).
11. Ensure battery disconnect switch is in OFF position (TM 5-3805-290-10).
12. Fill in DD Form 1397, Vehicles and Spare Engines, Processing and Deprocessing Record for Shipment, Storage and
Issue of, completely and attach to a conspicuous part of machine.
13. Inflate tires to 36 psi (248 kPa) for front and 25 psi (172 kPa) for rear with dry air (TM 5-3805-290-10). Annotate air
pressure and/or if nitrogen was used on DA Form 2258, Depreservation Guide for Vehicles and Equipment.
PREPARATION FOR RETURN TO SERVICE FROM SHORT-TERM STORAGE 0208 00
1. Inflate tires to 36 psi (248 kPa) for front and 25 psi (172 kPa) for rear with dry air (TM 5-3805-290-10).
2. Remove tape from all engine openings, including air intake, exhaust outlet, and crankcase breather tube.
3. If disconnected, connect battery cables (WP 0077 00).
4. Check coolant level in radiator (TM 5-3805-290-10).
5. Ensure fuel tank is full (TM 5-3805-290-10).
6. Start engine and perform machine warm-up (TM 5-3805-290-10). Verify proper operation of all gages, switches, and
lights.
7. Operate machine without a load and check engine, transmission, brakes, steering, and electrical accessories for correct
operation (TM 5-3805-290-10).
PREPARATION FOR LONG-TERM STORAGE 0208 00
NOTE
Long-term storage is storage for more than 90 days.
1. Thoroughly clean machine.
4. Schedule next PMCS on ULLS-G.
5. Inspect machine for corrosion. Use touch-up paint where necessary to prevent rust (TB 43-0242, CARC Spot Painting).
6. Where practical, store hydraulic cylinders in fully retracted position, which is normal locked/stored position for equip-
ment. Fill hydraulic systems to operating level (TM 5-3805-290-10). Coat exposed surfaces of hydraulic cylinder with
Grease, automotive and artillery, GAA (Item 22, WP 0206 00). Wrap Barrier material, grease proofed, flexible (Item 5,
WP 0206 00), around greased surfaces and secure wrap with Tape, pressure sensitive adhesive (Item 56, WP 0206 00).
Place a tag on cylinder requiring grease to be cleaned off exposed surface prior to use. This is necessary to prevent cyl-
inder seal from being damaged by contaminated grease.
0208 00-3
TM 5-3805-290-23-1
PREPARATION FOR LONG-TERM STORAGE - CONTINUED
NOTE
If machine has accumulated a very low amount of hours (250 hours or less) since its last scheduled
lubrication service, do not drain and refill transmission and differential; skip step 7.
7. Drain and refill transmission (WP 0083 00) and differential (WP 0091 00).
8. Preserve engine as follows:
CAUTION
If an engine is not used for prolonged periods, oil can run off the cylinder walls, piston rings, main
bearings, connecting rod bearings, crankshaft, gears, and other parts that normally get lubrication.
This lack of lubricant allows corrosion to start on the metal, especially in areas of high humidity
(water content in the air).
a. First, clean engine of all dirt, rust, grease, and oil. Inspect exterior of engine, and paint areas that have paint dam-
age with Paint, heat resisting (81349) MIL-P-14105 (Item 38, WP 0206 00).
b. Remove any dirt from air cleaner. Check all seals and gaskets and filter element for damage (WP 0032 00).
c. Drain and refill crankcase oil and change oil filter(s) (WP 0025 00).
NOTE
If the engine crankcase is full, drain enough engine oil to add the mixture.
d. Add Volatile corrosion inhibitor (VCI) oil (Item 60, WP 0206 00) to crankcase at a rate of 3 to 4% by volume.
e. Remove air filter element (WP 0032 00). Disconnect fuel injection pump electrical connector (WP 0164 00) and
crank engine. Use a sprayer or Tool group, flow check (Item 97, WP 0205 00) to add a mixture of 50% Volatile
corrosion inhibitor (VCI) oil (Item 60, WP 0206 00) and 50% Oil, lubricating, OEA-30, Arctic (Item 32, WP 0206
00); Oil, lubricating, OE/HDO-40 (Item 33, WP 0206 00); or Oil, lubricating, OE/HDO-5/40 (Item 34, WP 0206
00) into air intake or turbocharger inlet. Install air filter element and completely enclose element with dark plastic
bags, sealing it with Tape, pressure sensitive adhesive (Item 56, WP 0206 00). Reinstall air filter covers. Put Tape,
pressure sensitive adhesive (Item 56, WP 0206 00) over all openings to seal VCI vapors in engine.
f. Use a sprayer or Tool group, flow check (Item 97, WP 0205 00) to apply a mixture of 50% Volatile corrosion
inhibitor (VCI) oil (Item 60, WP 0206 00) and 50% Oil, lubricating, OEA-30, Arctic (Item 32, WP 0206 00); Oil,
lubricating, OE/HDO-40 (Item 33, WP 0206 00); or Oil, lubricating, OE/HDO-5/40 (Item 34, WP 0206 00) into
exhaust openings. The minimum application volume is 1.4 oz (40 ml). Seal exhaust pipe, including drain holes in
muffler, with Tape, pressure sensitive adhesive (Item 56, WP 0206 00).
g. Replace both primary and secondary fuel filters (WP 0036 00). Apply a spray of 11oz (340 ml) of 50% Volatile
corrosion inhibitor (VCI) oil (Item 60, WP 0206 00) and 50% Oil, lubricating, OEA-30, Arctic (Item 32, WP 0206
00); Oil, lubricating, OE/HDO-40 (Item 33, WP 0206 00); or Oil, lubricating, OE/HDO-5/40 (Item 34, WP 0206
00) to prevent rust in fuel tank. Add 2 oz (50 mL) of Biocide, fuel preservative (Item 6, WP 0206 00) to fuel.
Apply a small amount of oil to threads on fuel tank filler neck, and install cap (TM 5-3805-290-10). Seal all open-
ings to tank with Tape, pressure sensitive adhesive (Item 56, WP 0206 00), to prevent evaporation of fuel and pre-
servative.
h. Remove fuel injectors (WP 0163 00) and apply 1 oz (30 mL) of VCI oil mixture [50% Volatile corrosion inhibitor
(VCI) oil (Item 60, WP 0206 00) and 50% Oil, lubricating, OEA-30, Arctic (Item 32, WP 0206 00); Oil, lubricat-
ing, OE/HDO-40 (Item 33, WP 0206 00); or Oil, lubricating, OE/HDO-5/40 (Item 34, WP 0206 00)] into each cyl-
inder. Rotate crankshaft by hand slowly; this will put oil on cylinder walls. Reinstall fuel injectors.
0208 00-4
TM 5-3805-290-23-1
PREPARATION FOR LONG-TERM STORAGE - CONTINUED

i. Remove starter (WP 0048 00) and spray a thin amount of VCI oil mixture [50% Volatile corrosion inhibitor (VCI)
oil (Item 60, WP 0206 00) and 50% Oil, lubricating, OEA-30, Arctic (Item 32, WP 0206 00); Oil, lubricating, OE/
HDO-40 (Item 33, WP 0206 00); or Oil, lubricating, OE/HDO-5/40 (Item 34, WP 0206 00)] on flywheel, ring gear
teeth, and starter pinion. Install starter to keep in VCI vapors.
NOTE
Install all covers and make sure that tape has been installed over all openings: air intake, exhaust, fly-
wheel housing, crankcase breather, dipstick tubes, etc.
j. Attach a tag to engine with a notation of date machine was preserved, saying “THIS CRANKCASE IS FILLED
TO OPERATING LEVEL WITH PRESERVATIVE LUBRICATING OIL GOOD FOR OPERATION UNTIL
THE FIRST REQUIRED OIL CHANGE - DO NOT DRAIN - CHECK OIL LEVEL - IF LOW, FILL TO OPER-
ATING LEVEL WITH OPERATIONAL OIL”.
k. Inspect outside of engine every two or three months for corrosion. If engine shows signs of corrosion on outside at
check period, repeat this procedure.
9. Check engine coolant to ensure coolant has correct mixture for expected temperatures (TB 750-651).
10. Release belt tension on all belts after completing engine preservation. Coat unpainted surfaces of pulley grooves with a
Primer coating (Item 40, WP 0206 00). Tag machine indicating “BELT TENSIONS RELIEVED, ADJUST PRIOR TO
STARTING ENGINE” and attach annotated DA Form 2258.
11. Ensure battery disconnect switch is in OFF position (TM 5-3805-290-10).
12. Remove batteries (WP 0077 00) and tape all battery cable ends with Tape, pressure sensitive adhesive (Item 56, WP
0206 00). Clean batteries, clamps, supports, retainers, and battery box using a Brush, acid swabbing (Item 16, WP 0205
00) and a solution of 1/2 lb (0.23 kg) of Sodium bicarbonate, technical (Item 50, WP 0206 00) to 1 gal. (3.8 L) of water.
Flush with clean water and dry (TM 9-6140-200-14). Store batteries where they can be checked periodically and
recharged. Discharged batteries will be damaged if they are stored in below freezing temperatures. Secure battery cables
to battery box with Strap, tiedown, electrical (Item 53, WP 0206 00).
13. Completely drain fuel tank (WP 0035 00), remove filler cap and drain plug, and coat with Lubricating oil, engine (Item
27, WP 0206 00).
14. Place blocking under axles to remove weight from tires.
15. Fill in Form DD 1397, Vehicles and Spare Engines, Processing and Deprocessing Record for Shipment, Storage and
Issue of, completely and attach to a conspicuous part of machine.
16. Inflate tires to 36 psi (248 kPa) for front and 25 psi (172 kPa) for rear with dry air (TM 5-3805-290-10). Dry nitrogen
may be considered for long-term outside storage. Annotate air pressure and/or if nitrogen was used on DA Form 2258.
PREPARATION FOR RETURN TO SERVICE FROM LONG-TERM STORAGE 0208 00
1. Inflate tires to 36 psi (248 kPa) for front and 25 psi (172 kPa) for rear with dry air (TM 5-3805-290-10).
2. Remove blocking from under axles.
3. Remove tape from battery cable ends and install batteries fully charged (WP 0077 00).
4. Fill hydraulic systems to operating level (TM 5-3805-290-10). Remove barrier material, tape, and tags from cylinders.
5. Fill fuel tank with Diesel fuel, DF-1 (Item 16, WP 0206 00); Fuel oil, diesel, DF-2 (Item 18, WP 0206 00); or Fuel, tur-
bine, aviation (Item 19, WP 0206 00) (TM 5-3805-290-10).
6. Check oil and hydraulic fluid levels in engine crankcase, transmission, and hydraulic reservoir (TM 5-3805-290-10).
7. Check oil level in front and rear axles (WP 0091 00)
8. Check coolant level in radiator (TM 5-3805-290-10).
0208 00-5
TM 5-3805-290-23-1
PREPARATION FOR RETURN TO SERVICE FROM LONG-TERM STORAGE - CONTINUED
9. Prepare engine for operation as follows:

a. Remove all outside protective covers.
b. Change engine oil and filter (WP 0025 00).
c. Check condition of V-belts. Tighten or replace belts, as necessary (WP 0046 00).
d. Replace fuel filter elements (WP 0036 00).
e. Remove plastic covers from air cleaner elements.
CAUTION
If an engine is not used for prolonged periods, oil can run off the cylinder walls, piston rings, main
bearings, connecting rod bearings, crankshaft, gears, and other parts that normally get lubrication.
This lack of lubricant allows corrosion to start on the metal, especially in areas of high humidity
(water content in the air).
f. Turn engine in normal direction of rotation (TM 5-3805-290-10) by hand to make sure there are no hydraulic locks
or excessive resistance.
g. Before starting engine, remove valve cover (WP 0024 00) and put a large amount of engine oil [Oil, lubricating,
OEA-30, Arctic (Item 32, WP 0206 00); Oil, lubricating, OE/HDO-40 (Item 33, WP 0206 00); or Oil, lubricating,
OE/HDO-5/40 (Item 34, WP 0206 00)] on camshaft, cam followers, and valve mechanism to prevent damage to
mechanism.
h. Before starting engine, test coolant mixture for proper nitrite and conditioner level with Nitrite test strips (Item 29,
WP 0206 00). Drain and fill coolant, if necessary (WP 0042 00).
i. Prime engine with clean diesel fuel before starting (WP 0029 00).
CAUTION
The engine must have adequate lubrication during the first few seconds of operation. A “dry start”
(without adequate lubrication) can cause bearing damage. To prevent the possibility of a “dry start”
and bearing damage during the first seconds of operation, pressure lubricate the engine.
j. To get immediate lubrication, and to prevent damage to engine in the first few seconds after starting, pressure
lubricate engine as follows:
(1) Fill main oil passages with oil under pressure. Sources of clean oil under pressure, such as a service shop
central oil supply, can be used for pressure lubrication.
(2) Use a clean source of oil.
(3) Put correct amount of engine oil in crankcase.
(4) Connect oil source to engine’s main oil passage.
(5) Do not exceed an oil pressure of 35 ± 5 psi (242 ± 35 kPa).
(6) Fill crankcase with correct oil: Oil, lubricating, OEA-30, Arctic (Item 32, WP 0206 00); Oil, lubricating,
OE/HDO-40 (Item 33, WP 0206 00); or Oil, lubricating, OE/HDO-5/40 (Item 34, WP 0206 00). Amount
of oil used in pressure lubrication procedure must be subtracted from refill capacity given in TM 5-3805-
290-10. Maintain oil level between ADD and FULL marks on dipstick.
k. Check condition of ALL rubber hoses. Replace damaged hoses as necessary.
0208 00-6
TM 5-3805-290-23-1
PREPARATION FOR RETURN TO SERVICE FROM LONG-TERM STORAGE - CONTINUED

10. On the first day of returning to operation, check entire engine several times for leaks and correct operation. The quality
of oil control components used in engines is such that, following engine storage, only an operational check at initial start
is necessary before operation. This operational check ensures correct pressures and temperatures are kept in lubrication,
cooling, and fuel systems, and leaks are detected. To be sure of a safe, uniform check at initial start, use this procedure:
(1) Disconnect fuel injection pump electrical connector (WP 0164 00) and crank engine until engine oil pres-
sure is present.
(2) Reconnect fuel injection pump electrical connector (WP 0164 00) and start engine and allow it to run for
10 minutes at low idle speed (TM 5-3805-290-10).
(3) Operate engine for 15 minutes at half-load and three-quarter rated speed (TM 5-3805-290-10).
(4) Operate engine for 30 minutes at rated load and speed (TM 5-3805-290-10).
(5) Check frequently for leaks such as oil, coolant, and fuel during first few hours of operation. Repair any
leaks as soon as they are detected.
PREPARATION FOR SHIPMENT 0208 00
3. Schedule next PMCS on ULLS-G (Unit Level Logistics System – Ground).
4. Seal exhaust stack opening and engine air cleaner precleaner opening with Tape, pressure sensitive adhesive (Item 56,
WP 0206 00).
5. Consult shipping and transportation data on data plate (TM 5-3805-290-10).
END OF WORK PACKAGE
0208 00-7/(0208 00-8 Blank)

4
TM 5-3805-290-23-1
NOMENCLATURE CROSS-REFERENCE LIST 0209 00
Table 1. 924G Wheel Loader Nomenclature Cross-Reference List.
MANUALS SCHEMATICS/ET SOFTWARE
+8 V SUPPLY +8V SENSOR SUPPLY

+BATTERY BATTERY +1
BATTERY +2
+V +BATTERY
5V SENSOR POWER SUPPLY 5V SENSOR SUPPLY
8V SENSOR POWER SUPPLY 8V SENSOR SUPPLY
ARC_SUPRESSOR_SEC_STEER SECONDARY STEERING ARC SUPRESSOR
AUTO/MANUAL SWITCH (AUTO POSITION) AUTOSHIFT SWITCH - AUTO
AUTO/MANUAL SWITCH (MANUAL POSITION) AUTOSHIFT SWITCH - MANUAL
AUTO/MANUAL SWITCH (VSC POSITION) AUTOSHIFT SWITCH - VSC
AUTO/MANUAL/VSC_SW AUTOSHIFT SWITCH
BACKUP BACKUP ALARM RELAY
BATT-1 BATTERY -1
BRAKE NEUTRALIZER SET SWITCH NEUTRALIZER SET SWITCH
CAN CAN DATA
CONDENSER RELAY CONDENSER FAN RELAY
ENGINE COOLANT TEMPERATURE SENSOR COOLANT TEMP SENSOR
ENGINE START SWITCH KEY START SWITCH
FRONT WASHER MOTOR FRONT WASHER PUMP
GROUND BATTERY -1
BATTERY -2
GROUND BATTERY -2
HYD OIL TEMP SENSR HYDRAULIC OIL TEMPERATURE SENSOR
HYDRAULIC LOCKOUT CONTROL SWITCH IMPLEMENT DISABLE SWITCH
IC INSTRUMENT CLUSTER
IGNITION SWITCH INPUT KEY SWITCH INPUT
IMPLEMENT LOCKOUT IMPLEMENT DISABLE
IMPLEMENT LOCKOUT SOLENOID PILOT SHUTOFF SOLENOID
INLET MANIFOLD TEMPERATURE INLET AIR TEMPERATURE
INLET MANIFOLD TEMPERATURE SENSOR INLET AIR TEMPERATURE SENSOR
KEY START SWITCH ON KEY START SWITCH (ON)
KEY SWITCH START KEY START SWITCH
0209 00-1
TM 5-3805-290-23-1
NOMENCLATURE CROSS-REFERENCE LIST - CONTINUED 0209 00
Table 1. 924G Wheel Loader Nomenclature Cross-Reference List - Continued.
LIFT PUMP CONVERTER ELECTRICAL CONVERTER

LOAD RTN 2 LOAD RETURN 2
LOCKOUT SW DISABLE SW
MODULATING VALVE FOR CLUTCH 1 (FORWARD CLUTCH SOLENOID #1 (FORWARD LOW GEAR)
LOW) SOL
MODULATING VALVE FOR CLUTCH 1 SOLENOID CLUTCH SOLENOID #1 (FORWARD LOW GEAR)
(FORWARD LOW)
MODULATING VALVE FOR CLUTCH 2 (FORWARD CLUTCH SOLENOID #2 (FORWARD HIGH GEAR)
HIGH) SOL
MODULATING VALVE FOR CLUTCH 2 SOLENOID CLUTCH SOLENOID #2 (FORWARD HIGH GEAR)
(FORWARD HIGH)
MODULATING VALVE FOR CLUTCH 3 (REVERSE) SOL CLUTCH SOLENOID #3 (REVERSE GEAR)
MODULATING VALVE FOR CLUTCH 3 SOLENOID CLUTCH SOLENOID #3 (REVERSE GEAR)
(REVERSE)
MODULATING VALVE FOR CLUTCH 4 (SECOND CLUTCH SOLENOID #4 (2ND GEAR)
SPEED) SOL
MODULATING VALVE FOR CLUTCH 4 (SECOND CLUTCH SOLENOID 4 (2ND GEAR)
SPEED) SOLENOID
MODULATING VALVE FOR CLUTCH 4 SOLENOID CLUTCH SOLENOID #4 (2ND GEAR)
(SECOND SPEED)
MODULATING VALVE FOR CLUTCH 5 (THIRD AND CLUTCH SOLENOID #5 (3RD AND 4TH GEAR)
FOURTH SPEED) SOL
MODULATING VALVE FOR CLUTCH 5 (THIRD AND CLUTCH SOLENOID 5 (3RD AND 4TH GEAR)
FOURTH SPEED) SOLENOID
MODULATING VALVE FOR CLUTCH 5 SOLENOID CLUTCH SOLENOID #5 (3RD AND 4TH GEAR)
(THIRD AND FOURTH SPEED)
MODULATING VALVE FOR CLUTCH 6 (FIRST SPEED) CLUTCH SOLENOID #6 (1ST GEAR)
SOL
MODULATING VALVE FOR CLUTCH 6 (FIRST SPEED) CLUTCH SOLENOID 6 (1ST GEAR)
SOLENOID
MODULATING VALVE FOR CLUTCH 6 SOLENOID CLUTCH SOLENOID #6 (1ST GEAR)
(FIRST SPEED)
MOTOR_SEC_STEER SECONDARY STEERING MOTOR
PARKING BRK SW PARK BRAKE SWITCH
PRIM STEER PRESS SW PRIMARY STEERING PRESSURE SWITCH
PRIMARY STEER PRESS SW PRIMARY STEERING PRESSURE SWITCH
0209 00-2
TM 5-3805-290-23-1
MACHINE ECM POWERTRAIN ECM

MACHINE ECM TRANSMISSION ECM
REAR DEFROSTER REAR WINDOW DEFROSTER
DEFROSTER
REAR WASHER MOTOR REAR WASHER PUMP
RETURN LOAD RETURN 1
RETURN BATTERY -2
RLY_SEC_STEER_928 SECONDARY STEERING RELAY
SEC STEER MTR RLY SECONDARY STEERING MOTOR RELAY
SEC STEER RELAY SECONDARY STEERING RELAY
SEC_STEER_RLY SECONDARY STEERING RELAY (FUSE BOX)
SENSOR RETURN GROUND
SET SPEED CONTINUE THROTTLE LOCK RESUME
SET SPEED RESUME
SET SPEED CONTROL THROTTLE LOCK
SHIFTER FIRST GEAR INPUT SHIFT LEVER FIRST GEAR INPUT
SHIFTER FORWARD INPUT SHIFT LEVER FORWARD INPUT
SHIFTER INPUT (FIRST SPEED) SHIFT LEVER FIRST GEAR INPUT
SHIFTER INPUT (FORWARD) SHIFT LEVER FORWARD INPUT
SHIFTER INPUT (FOURTH SPEED) SHIFTER FOURTH GEAR INPUT
SHIFTER INPUT (NEUTRAL) SHIFT LEVER NEUTRAL INPUT
SHIFTER INPUT (REVERSE) SHIFT LEVER REVERSE INPUT
SHIFTER INPUT (SECOND SPEED) SHIFTER SECOND GEAR INPUT
SHIFTER INPUT (THIRD SPEED) SHIFTER THIRD GEAR INPUT
SHIFTER NEUTRAL INPUT SHIFT LEVER NEUTRAL INPUT
SHIFTER REVERSE INPUT SHIFT LEVER REVERSE INPUT
START RELAY STARTER RELAY CONTROL
STARTER RELAY CNTRL STARTER RELAY CONTROL
STARTING AID ETHER STARTING AID
TC TEMP SNSR TORQUE CONVERTER TEMP SENSOR
TORQUE CONV SPD- CONVERTER OUTPUT SPEED SENSOR -
TORQUE CONV SPD+ CONVERTER OUTPUT SPEED SENSOR +
0209 00-3
TM 5-3805-290-23-1
TORQUE CONVERTER OUTPUT SPEED SENSOR CONVERTER OUTPUT SPEED SENSOR

TORQUE CONVERTER SPEED SENSOR TORQUE CONVERTER OUTPUT SPEED SENSOR
TRANS INTERMED SPD 1- INTERMEDIATE SPEED SENSOR (1)-
TRANS INTERMED SPD 1+ INTERMEDIATE SPEED SENSOR (1)+
TRANS INTERMED SPD 2- INTERMEDIATE SPEED SENSOR (2)-
TRANS INTERMED SPD 2+ INTERMEDIATE SPEED SENSOR (2)+
TRANS NEUTRALIZER SENSOR BRAKE OIL PRESSURE SENSOR
TRANS OUTPUT SPD 1- TRANSMISSION OUTPUT SPEED SENSOR (1) -
TRANS OUTPUT SPD 1+ TRANSMISSION OUTPUT SPEED SENSOR (1) +
TRANS OUTPUT SPD 2- TRANSMISSION OUTPUT SPEED SENSOR (2)-
TRANS OUTPUT SPD 2+ TRANSMISSION OUTPUT SPEED SENSOR (2)+
TRANSMISSION INLET TEMPERATURE SENSOR TRANSMISSION INLET TEMP
TRANSMISSION INTERMEDIATE SPEED SENSOR (NO. TRANSMISSION INTERMEDIATE OUTPUT SPEED
2) SENSOR 2
TRANSMISSION INTERMEDIATE SPEED SENSOR TRANSMISSION INTERMEDIATE OUTPUT SPEED
(NO.1) SENSOR 1
TRANSMISSION OIL TEMP SENSOR TRANSMISSION OIL TEMPERATURE SENSOR
XMSN INLET TEMP TRANSMISSION INLET TEMP
END OF WORK PACKAGE
0209 00-4
TM 5-3805-290-23-1
INDEX
Subject Work Package/Page
A
AC
Blower Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143 00-1
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191 00-6
Compressor
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192 00-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192 00-2
Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192 00-1
Condenser
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195 00-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195 00-2
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195 00-1
Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191 00-4
Fan Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195 00-3
Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193 00-1
Flanges Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193 00-1
Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193 00-1
Mounting Bracket
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192 00-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192 00-5
Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-6
Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192 00-1
Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191 00-2
System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191 00-1
Test Procedure for ARC Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-7
Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-1
Valves Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193 00-1
Visual Inspection of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-9
Accumulator, Brake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0096 00-1
Action Alarm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051 00-3
Active Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-3
Adjust
Piston Pump (Steering and Pilot) High Pressure Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-3
Piston Pump (Steering and Pilot) Low Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-2
Piston Pump (Steering and Pilot) Margin Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-5
Adjustment Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0046 00-2
Aftercooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0034 00-1
Air
Cleaner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032 00-1
Cleaner, Housing, and Precleaner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032 00-1
Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032 00-1
Inlet Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-9
Precleaner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032 00-1
Air Filter Restriction Indicator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0031 00-1
Index-1
TM 5-3805-290-23-1
INDEX - Continued
A - Continued
Air Intake
Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0033 00-1
Air Restriction Indicator
and Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0031 00-1
Alarm, Backup, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076 00-1
Alternator
Mounting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0047 00-1
Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0047 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0047 00-1
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0047 00-1
Arctic Heater Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0141 00-1
Arm, Lift Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0201 00-1
Axle
Front Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0179 00-1
Rear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0180 00-1
Rear Stops Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105 00-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-100
Trunnion Support Replacement, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0181 00-1
B
Backlight Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050 00-3
Backup Alarm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076 00-1
Base
Filter Replacement, Oil, Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0087 00-1
Primary Fuel Filter
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-2
Secondary Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-3
Base, Filter, Oil, Hydraulic Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0130 00-1
Battery
Boxes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0078 00-1
Cables Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079 00-1
Disconnect Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077 00-1
Belt
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0046 00-1
Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0046 00-2
Seat, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0115 00-1
V, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0046 00-1
Index-2
TM 5-3805-290-23-1
INDEX - Continued
B - Continued
BII Toolbox Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0117 00-3
Blackout Drive Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059 00-1
Boost Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065 00-1
Boxes, Battery, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0078 00-1
Bracket
Assembly and Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0062 00-7
BII Toolbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0117 00-3
Mounting, Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-3
Brake
Accumulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0096 00-1
Charging Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0071 00-1
Control Valve, Service, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093 00-1
Hydraulic Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095 00-1
Oil Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0072 00-1
Parking, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0092 00-1
Pedals Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0094 00-1
Brake System
Purge Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-2
Bucket Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144 00-1
Bypass Valve
Engine Oil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0158 00-1
Transmission Oil Cooler Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088 00-1
C
Cab
Component Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184 00-10
Door Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111 00-1
Heater Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0044 00-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184 00-1
Liners Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0116 00-1
Mirrors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0116 00-1
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184 00-1
Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175 00-1
Cables, Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079 00-1
Calibration, Transmission Clutch Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-2
Capacities
Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-14
Changing Differential and Final Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091 00-1
Index-3
TM 5-3805-290-23-1
INDEX - Continued
C - Continued
Changing Engine Oil and Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0025 00-1
Changing Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083 00-1
Characteristics, Capabilities, and Features, Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-1
Chassis
Covers Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0107 00-1
Guards Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0107 00-1
Check Service Brake Disc Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-5
Circuit Breaker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0054 00-13
Column, Steering Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0099 00-1
Combination Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0124 00-1
Component Identifier (CID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-2
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-2
Compressor, AC Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192 00-1
Condenser, AC Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195 00-1
Control Switches and Panels Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049 00-1
Left-Side Control Panel and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049 00-2
Right-Side Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049 00-5
Right-Side Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049 00-4
Control Valve
Brake Service, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093 00-1
Main Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0134 00-1
Main Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0189 00-1
Transmission, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0177 00-1
Converter
dc to dc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-1
Electrical (24V to 12V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-1
Transmission and Torque Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176 00-1
Coolant
Tank and Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0044 00-1
Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0063 00-1
Cooler
Bypass Valve, Transmission Oil Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088 00-1
Oil, Hydraulic/Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089 00-1
Cooling
Jets Replacement, Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0159 00-1
Index-4
TM 5-3805-290-23-1
INDEX - Continued
C - Continued
Cooling System
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042 00-1
Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042 00-2
Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042 00-1
Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042 00-1
Hoses, Clamps, and Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0044 00-1
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042 00-1
Visual Inspection of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-10
Cooling System Service
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042 00-3
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042 00-3
Core
Evaporator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0196 00-1
Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197 00-1
Corrosion Prevention and Control (CPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1
Counterweight Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109 00-1
Coupler
Cylinder Replacement, Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138 00-1
Quick Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198 00-1
Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190 00-1
Cover
Crankcase Vent Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-1
Cover Replacement, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0152 00-1
Crankshaft Vibration Damper Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147 00-1
Cylinder
Balance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-5
Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0146 00-1
Replacement, Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0129 00-1
Replacement, Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0128 00-1
Steering Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103 00-1
D
Data Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0121 00-1
dc to dc Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-1
Destruction of Army Materiel to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-3
Door
Cab, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111 00-1
Glass Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185 00-1
Index-5
TM 5-3805-290-23-1
INDEX - Continued
D - Continued
Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0090 00-1
Dryer, Inline Refrigerant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194 00-1
E
ECM
Copy Configuration From . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052 00-3
Electronic Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052 00-1
Engine, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00-1
Flash Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052 00-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052 00-6
Programing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052 00-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052 00-4
System Configuration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052 00-2
Electrical
Converter (24V to 12V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-1
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-1
Breakout T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-21
Bypass Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-21
Engine
Component Transfer
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145 00-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145 00-12
ECM Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00-1
Excessive Oil Temperature Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-7
Increased Oil Temperature Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-8
Oil Bypass Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0158 00-1
Oil Cooler Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0028 00-1
Oil Filler Neck Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0026 00-1
Oil Filter Base Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027 00-1
Oil Filter Bypass Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027 00-1
Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0025 00-1
Oil Level Gage Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0026 00-1
Oil Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0066 00-1
Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-2
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145 00-1
Index-6
TM 5-3805-290-23-1
INDEX - Continued
E - Continued
Equipment
Characteristics, Capabilities, and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-1
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-10
Improvement Recommendations (EIR), Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1
Ether Starting Aid
Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0040 00-6
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0040 00-1
Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0040 00-2
Evaporator Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0196 00-1
Event Identifier (EID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-2
Excessive Engine Oil Consumption Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-7
Exhaust
Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0161 00-1
Pipe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-1
System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-9
Valve Lash Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155 00-1
Exhaust System Replacement
Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-2
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-3
Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206 00-1
F
Failure Mode Identifier (FMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-2
Fan
Group Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168 00-1
Speed Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00-17
Fenders Replacement, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112 00-1
Fill Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042 00-3
Filter
Base Replacement, Oil, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0130 00-1
Element Replacement, Oil, Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0086 00-1
Engine Oil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0025 00-1
Fuel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0036 00-1
Fuel, Bases Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-1
Finding Top-Center Position for No. 1 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-5
Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0108 00-2
Flush Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042 00-3
Flywheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0150 00-1
Index-7
TM 5-3805-290-23-1
INDEX - Continued
F - Continued
Force Check, Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-10
Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-16
Forklift Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0142 00-1
Frame, Radiator, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168 00-1
Front
Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0179 00-1
Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0152 00-1
Fenders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112 00-1
Main Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0149 00-1
Platforms Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0106 00-3
Tilt Lever and Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199 00-1
Windshield Wiper and Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0119 00-1
Fuel
Air in, Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-2
Filter Bases Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-2
Filter Bases Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-2
Filter Bases Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-1
Filter Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0038 00-1
Filters Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0036 00-1
Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0038 00-1
Injection Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164 00-1
Injection Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-4
Injector Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030 00-1
Injector Nozzles Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163 00-1
Level Sending Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-1
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0029 00-1
Quality Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-6
Secondary Filter Bases Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-3
System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-7
System Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-8
Tank
Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0035 00-1
Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0035 00-1
Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0035 00-1
Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0166 00-1
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0054 00-2
Fywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0151 00-1
Index-8
TM 5-3805-290-23-1
INDEX - Continued
G
Gear
Motor Hydraulic Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187 00-1
Pump Braking and Hydraulic Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0186 00-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1
General Maintenance Instructions
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-1
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-1
Glass
Door Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185 00-1
Front Windshield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185 00-1
Rear Windshield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185 00-1
H
Harness
Cab Wiring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175 00-1
Engine, Wring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0170 00-1
Front, Wiring, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172 00-1
Instrument Panel Wiring, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0169 00-1
Rear, Wiring, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174 00-1
Ride Control, Wiring, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173 00-1
Transmission Control Wiring, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0171 00-1
Heater
Blower Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143 00-1
Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197 00-1
Hood Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110 00-1
Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0075 00-1
Hoses, Lines, and Fittings Replacement
Brake, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095 00-1
Hydraulic Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0132 00-1
Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0132 00-1
Implement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0131 00-1
Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0135 00-1
Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0134 00-1
Pilot System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136 00-1
Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0133 00-1
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102 00-1
Housing
Flywheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0151 00-1
Front, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154 00-1
Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0060 00-4
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032 00-1
Service Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0062 00-5
Index-9
TM 5-3805-290-23-1
INDEX - Continued
H - Continued
How To Use MSD With ET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-1
How To Use On-Board Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-1
Hydraulic
Brake Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095 00-1
Cooler Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0132 00-1
Fan Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187 00-1
Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0186 00-1
Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0137 00-1
Lockout Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0188 00-1
Mounting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0130 00-1
Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089 00-1
Oil Filter Base Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0130 00-1
Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0132 00-1
Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0070 00-1
System Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0137 00-1
Tank and Mounting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0140 00-1
Transmission Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089 00-1
I
Idler Gears Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0153 00-1
Illustrated List of Manufactured Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202 00-1
Implement
Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0131 00-1
Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125 00-1
Increased Engine Oil Temperature Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-8
Indicator, Restriction, Air Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0031 00-1
Injection Pump, Fuel, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164 00-1
Injector
Lines Replacement, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030 00-1
Nozzles, Fuel, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163 00-1
Inlet Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0064 00-1
Inline Refrigerant Dryer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194 00-1
Instrument
Cluster and Turnlamp Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051 00-1
Cluster Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051 00-2
Panel Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0169 00-1
Index-10
TM 5-3805-290-23-1
INDEX - Continued
I - Continued
Intake
Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0162 00-1
Valve Lash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155 00-1
J
Jets, Piston Cooling Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0159 00-1
Joystick, Pilot Operated Control Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0188 00-1
K
Kickout Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057 00-1
L
Ladder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0106 00-1
Lamp
and Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0060 00-2
Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0058 00-2
Lever, Shift, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0081 00-1
Lift
Arms Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0201 00-1
Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0129 00-1
Light
Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050 00-3
Blackout, Drive, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059 00-1
Front Turnlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0062 00-1
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0062 00-1
Turnlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0062 00-2
Worklights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0060 00-1
Liners, Cab, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0116 00-1
Lines
Hoses, and Fittings, Lubrication, Remote, Lubrication Replacement . . . . . . . . . . . . . . . . 0108 00-1
Oil, Turbocharger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0165 00-1
Link Replacement
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199 00-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200 00-1
Index-11
TM 5-3805-290-23-1
INDEX - Continued
L - Continued
List
Abbreviations/Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-2
Expendable and Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206 00-1
Manufactured Items, Illustrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202 00-1
Nomenclature Cross-Reference
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209 00-1
Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-2
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203 00-1
Loader Frame and Rear Replacement, Separate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0183 00-1
Location and Description of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-3
Logged
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-3
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-3
Lubrication General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-12
M
Magnetic Screen Service, Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0084 00-1
Main Control Valve (Three Function) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0189 00-1
Main Seal Replacement
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0149 00-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148 00-1
Maintenance Allocation Chart (MAC)
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0204 00-1
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205 00-1
Maintenance Forms, Records, and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1
Major Components, Location and Description of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-3
Manifold
Exhaust, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0161 00-1
Intake, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0162 00-1
Mechanical General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-1
Metering Pump
(HMU) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-11
Steering, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0101 00-1
Mirrors, Cab, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0116 00-1
Module Identifier (MID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-2
Motor, Hydraulic Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187 00-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-3
Mounting Bracket, Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-3
Index-12
TM 5-3805-290-23-1
INDEX - Continued
M - Continued
MP Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-16
Muffler
Mounting Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-1
N
NATO Slave Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080 00-1
Nomenclature Cross-Reference List
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209 00-1
Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-2
Nozzles, Fuel Injector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163 00-1
O
Oil
Bypass Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0158 00-1
Cooler Bypass Valve Maintenance, Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088 00-1
Fill/Check Tube Maintenance, Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082 00-1
Filter Base Replacement, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0130 00-1
Filter Replacement, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0025 00-1
Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157 00-1
Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0160 00-1
Pump, Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0178 00-1
Oil Change
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091 00-1
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091 00-1
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091 00-1
Oil Cooler
Hydraulic Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089 00-1
Torque Converter Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0085 00-1
Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089 00-1
Oil Lines, Turbocharger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0165 00-1
Oil, Changing, Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083 00-1
P
Panel Wiring Harness, Instrument, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0169 00-1
Parking Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0092 00-1
Pedals, Brake, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0094 00-1
Pilot
Oil Accumulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126 00-1
Operated Control (Joy Stick) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0188 00-1
System Hoses, Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136 00-1
Index-13
TM 5-3805-290-23-1
INDEX - Continued
P - Continued
Pilot System Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00-11
Pin Coupler Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138 00-1
Pipe, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-2
Piston
Cooling Jets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0159 00-1
No. 1, Finding Top-Center Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-5
Pump (Implement, Pilot, and Steering) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182 00-1
Pump (Steering and Pilot) High Pressure Stall Test and Adjustment . . . . . . . . . . . . . . . . . 0016 00-3
Pump (Steering and Pilot) Low Pressure Standby Test and Adjustment . . . . . . . . . . . . . . 0016 00-2
Pump (Steering and Pilot) Margin Pressure Test and Adjustment . . . . . . . . . . . . . . . . . . . 0016 00-5
Pump Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00-3
Pump Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00-3
Plates, Data, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0121 00-1
Platform Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0106 00-1
Preparation
Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208 00-3
Return to Service
From Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208 00-5
From Short-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208 00-3
Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208 00-7
Short-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208 00-2
Preventive Maintenance Checks and Services (PMCS)
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-1
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-1
Primary
Fuel Filter Base
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-2
Priming Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0029 00-1
Pump
Braking and Hydraulic Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0186 00-1
Fuel Injection Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164 00-1
Implement Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0135 00-1
Implement Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182 00-1
Oil, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0160 00-1
Performance (Implement) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00-10
Performance (Steering) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-8
Pilot Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182 00-1
Steering Metering, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0101 00-1
Transmission Oil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0178 00-1
Water, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0045 00-1
Index-14
TM 5-3805-290-23-1
INDEX - Continued
P - Continued
Purge Brake System Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-2
Push Rods Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156 00-1
Q
Quick Coupler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198 00-1
R
Radiator
and Fan Group Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168 00-1
Frame Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167 00-1
Rear
Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0180 00-1
Axle Stops Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105 00-1
Axle Trunnion Support Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0181 00-1
Main Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148 00-1
Platforms Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0106 00-3
Tilt Lever and Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200 00-1
Toolbox Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0117 00-2
Turn Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0058 00-1
Windshield Wiper and Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0120 00-1
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203 00-1
Refill Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-14
Refilling Breather, Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083 00-3
Refrigerant
Compressor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-16
Dryer Replacement, Inline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194 00-1
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-8
Quick-Check Procedure for R-134a Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-4
Quick-Check Procedure for R-134a Orifice Tube Systems . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-4
System Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-11
Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0054 00-4
Relief Valve (Line) Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00-12
Remote Lubrication Lines, Hoses, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0108 00-1
Reporting Equipment Improvement Recommendations (EIR) . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1
Restriction Indicator, Air Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0031 00-1
Index-15
TM 5-3805-290-23-1
INDEX - Continued
R - Continued
Return to
Carry Kickout Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057 00-3
Work Kickout Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057 00-2
Ride Control
Accumulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127 00-1
Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0073 00-1
Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123 00-1
Rifle Rack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0122 00-1
Rocker Arms Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156 00-1
S
Schematic Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210 00-1
Screen, Service, Magnetic, Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0084 00-1
Seat
Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0114 00-1
Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113 00-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0115 00-1
Secondary
Fuel Filter Base Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-3
Steering and Windshield Wiper Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050 00-1
Steering Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050 00-3
Sending Unit Replacement, Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-1
Sensor
Boost Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065 00-1
Brake Charging Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0071 00-1
Brake Oil Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0072 00-1
Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0063 00-1
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0066 00-1
Hydraulic Oil Temperature, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0070 00-1
Inlet Air Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0064 00-1
Kickout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057 00-1
Return to Carry Kickout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057 00-3
Return to Work Kickout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057 00-2
Speed Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0067 00-1
Throttle Position Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039 00-1
Torque Converter Oil, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068 00-1
Torque Converter Output Speed Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-2
Torque Converter Output Speed Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-2
Torque Converter, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-1
Transmission Oil Temperature, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068 00-1
Index-16
TM 5-3805-290-23-1
INDEX - Continued
S - Continued
Sensor - Continued
Transmission Output Speed Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-3
Transmission Output Speed Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-3
Transmission Speed, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-1
Separate Loader Frame and Rear Frame (Articulation Pivot Pins) Replacement . . . . . . . . . . . 0183 00-1
Service Brake
Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093 00-1
Discs Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-5
System Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-4
Service Light
and Front Turnlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0062 00-1
Housing Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0062 00-5
Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1
Inspection Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1
Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1
Shift Lever Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0081 00-1
Short-Term Storage, Preparation for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208 00-2
Side Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110 00-1
Slave Receptacle, NATO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080 00-1
Solenoid Valve (Transmission Clutch) Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-27
Speed Timing Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0067 00-1
Stall Test, Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-17
Starter
Ether Aid, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0040 00-1
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0048 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0048 00-1
Status Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-7
Steering
Column Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0099 00-1
Cylinders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103 00-1
Force Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-10
Metering Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0101 00-1
Oil Primary Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0074 00-1
Operational Checks, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-7
Pump Performance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-8
Time Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-9
Index-17
TM 5-3805-290-23-1
INDEX - Continued
S - Continued
Steering - Continued
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0098 00-1
Wheel Slip Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-10
Stops Replacement, Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105 00-1
Support, Rear Axle Trunnion Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0181 00-1
Switch
Battery Disconnect Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00-1
Control Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049 00-1
Control, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049 00-1
Instrument Cluster Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051 00-1
Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192 00-1
Ride Control Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0073 00-1
Secondary Steering Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050 00-3
Steering Oil Primary Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0074 00-1
Turnlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051 00-3
Turnlamp Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051 00-4
Turnlamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051 00-1
Windshield Wiper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0050 00-1
T
Tank and Mounting Replacement, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0140 00-1
Tank, Fuel, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0166 00-1
Test
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-2
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-2
Metering Pump (HMU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-11
Piston Pump (Steering and Pilot) High Pressure Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-3
Piston Pump (Steering and Pilot) Low Pressure Standby . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-2
Piston Pump (Steering and Pilot) Margin Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-5
Pump Performance (Steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-8
Service Braking System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-4
Solenoid Valve (Transmission Clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-27
Transmission Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-19
Tests, Inspections, and Adjustments
AC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-1
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-1
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-1
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-1
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00-1
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-1
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-1
Index-18
TM 5-3805-290-23-1
INDEX - Continued
T - Continued
Theory of Operation
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-100
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-102
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-18
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-5
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-134
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-120
Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043 00-1
Throttle
Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039 00-1
Position Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039 00-1
Tilt Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0128 00-1
Tilt Lever and Link Replacement
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199 00-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200 00-1
Time Check, Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-9
Timing Gears Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0153 00-1
Tire and Wheel (Front or Rear) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0097 00-1
Toolbox Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0117 00-1
Toolbox, Rear, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0117 00-2
Torque Converter
Oil Cooler Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0085 00-1
Output Speed Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-2
Output Speed Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-2
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176 00-1
Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-1
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-17
Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0207 00-1
Transmission
and Torque Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176 00-1
Clutch Fill Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-2
Control (Shift Lever) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-12
Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0177 00-1
Control Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0171 00-1
Draining Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083 00-2
Magnetic Screen Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0084 00-1
Oil Cooler Bypass Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088 00-1
Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089 00-1
Index-19
TM 5-3805-290-23-1
INDEX - Continued
T - Continued
Transmission - Continued
Oil Fill/Check Tube Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082 00-1
Oil Filter Base Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0087 00-1
Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0086 00-1
Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0178 00-1
Output Speed Sensors Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-3
Output Speed Sensors Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-3
Pressures Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-19
Refilling Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083 00-3
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176 00-1
Solenoid Valve (Clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-27
Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-1
Troubleshooting
Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-1
Operational Checks
Braking and Hydraulic Fan System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-3
Hydraulic Lockout Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-7
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-4
Lowering of Loader Lift Cylinders with a Dead Engine . . . . . . . . . . . . . . . . . . . . . . . 0004 00-7
Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-8
Quick Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-7
Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-6
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-7
Preliminary Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-2
Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-1
With a Diagnostic Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009 00-1
Without a Diagnostic Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-1
Trunnion Support Replacement, Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0181 00-1
Turbocharger and Oil Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0165 00-1
Turnlamp
Flasher Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051 00-4
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0062 00-2
Replacement Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0058 00-1
Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051 00-3
U
Understanding the Diagnostic Code Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-2
Index-20
TM 5-3805-290-23-1
INDEX - Continued
V
Valve
Combination Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0124 00-1
Control, Service Brake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093 00-1
Coupler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190 00-1
Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-1
Hydraulic Lockout Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0188 00-1
Main Control Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0189 00-1
Ride Control Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123 00-1
Transmission Control Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0177 00-1
Relief, Implement, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125 00-1
V-Belts Maintenance
Air Conditioner Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0046 00-2
Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0046 00-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0046 00-2
Visual Inspection of
AC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-9
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-10
Voltage Load Protection Module (VLPM) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0054 00-15
W
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-4
Water
Outlet Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043 00-1
Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0045 00-1
Wheel
Slip Check, Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-10
Windshield
Front/Rear and Doors Glass Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185 00-1
Glass, Front Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185 00-1
Washer Bottle, Mounting Bracket, and Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . 0118 00-1
Wiper Motor Replacement
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0119 00-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0120 00-1
Wiring Harness
Engine, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0170 00-1
Front, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172 00-1
Instrument Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0169 00-1
Rear, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174 00-1
Replacement, Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175 00-1
Ride Control, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173 00-1
Transmission Control, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0171 00-1
Worklights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0060 00-1
Index-21/(Index-22 Blank)
1 July 2009
AMSTA-LC-LMPP/TECH PUBS
1 Rock Island Arsenal
Rock Island, IL 61299-7630
Field Maintenance Manual (Includes

TM 5-3805-290-23-1 13 August 2007 Unit and DS Maintenance) for 924G
Loader, Light Type II
0017 00-2 Part number supplied for item 2 is incorrect.


TM 5-3805-290-23-1 Unit and DS Maintenance) for 924G
13 August 2007 Loader, Light Type II


By Order of the Secretary of the Army:
GEORGE W. CASEY JR.

General, United States Army
Chief of Staff
Official:
0730201
DISTRIBUTION: To be distributed in accordance with the initial distribution requirements for IDN: 256940,
requirements for TM 5-3805-290-23-1.
2
TM 5-3805-290-23-1
SCHEMATICS INTRODUCTION 0210 00
INTRODUCTION
This work package contains schematic diagrams for the 924G Wheel Loader.
SCHEMATICS
Electrical
FO-1. Electrical Schematics - Key to Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-1/(FP-2 Blank)

FO-1. Electrical Schematics - Key to Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-3/(FP-4 Blank)
FO-1. Electrical Schematics - Lighting Circuit (Sheet 1 of 13) . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-5/(FP-6 Blank)
FO-1. Electrical Schematics - Lighting Circuit (Sheet 2 of 13) . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-7/(FP-8 Blank)
FO-1. Electrical Schematics - Accessories Circuit (Sheet 3 of 13) . . . . . . . . . . . . . . . . . . . . . . . FP-9/(FP-10 Blank)
FO-1. Electrical Schematics - Accessories Circuit (Sheet 4 of 13) . . . . . . . . . . . . . . . . . . . . . . FP-11/(FP-12 Blank)
FO-1. Electrical Schematics - Accessories Circuit (Sheet 5 of 13) . . . . . . . . . . . . . . . . . . . . . . FP-13/(FP-14 Blank)
FO-1. Electrical Schematics - Implement Circuit (Sheet 6 of 13) . . . . . . . . . . . . . . . . . . . . . . . FP-15/(FP-16 Blank)
FO-1. Electrical Schematics - Implement Circuit (Sheet 7 of 13) . . . . . . . . . . . . . . . . . . . . . . . FP-17/(FP-18 Blank)
FO-1. Electrical Schematics - Engine Circuit (Sheet 8 of 13) . . . . . . . . . . . . . . . . . . . . . . . . . . FP-19/(FP-20 Blank)
FO-1. Electrical Schematics - Transmission Circuit (Sheet 9 of 13) . . . . . . . . . . . . . . . . . . . . . FP-21/(FP-22 Blank)
FO-1. Electrical Schematics - Transmission Circuit (Sheet 10 of 13) . . . . . . . . . . . . . . . . . . . . FP-23/(FP-24 Blank)
FO-1. Electrical Schematics - Starting Circuit (Sheet 11 of 13). . . . . . . . . . . . . . . . . . . . . . . . . FP-25/(FP-26 Blank)
FO-1. Electrical Schematics - Power Distribution Circuit (Sheet 12 of 13). . . . . . . . . . . . . . . . FP-27/(FP-28 Blank)
FO-1. Electrical Schematics - Legend (Sheet 13 of 13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-29/(FP-30 Blank)
Hydraulic
FO-2. Hydraulic Component Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-31/(FP-32 Blank)

FO-2. Hydraulic Schematic (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-33/(FP-34 Blank)
FO-2. Hydraulic Schematic (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-35/(FP-36 Blank)
END OF WORK PACKAGE
0210 00-1/(0210 00-2 Blank)

TM 5-3805-290-23-1
FO-1 Electrical Schematics - Key to Components

FP-1/(FP-2 Blank)
TM 5-3805-290-23-1
FO-1. Electrical Schematics - Key to Harnesses

FP-3/(FP-4 Blank)
TM 5-3805-290-23-1
FO-1. Electrical Schematics - Lighting Circuit (Sheet 1 of 13)

FP-5/(FP-6 Blank)
TM 5-3805-290-23-1
FO-1. Electrical Schematics - Lighting Circuit (Sheet 2 of 13)

FP-7/(FP-8 Blank)
TM 5-3805-290-23-1
FO-1. Electrical Schematics - Accessories Circuit (Sheet 3 of 13)

FP-9/(FP-10 Blank)
TM 5-3805-290-23-1

FP-11/(FP-12 Blank)
TM 5-3805-290-23-1

FP-13/(FP-14 Blank)
TM 5-3805-290-23-1
FO-1. Electrical Schematics - Implement Circuit (Sheet 6 of 13)

FP-15/(FP-16 Blank)
TM 5-3805-290-23-1
FO-1. Electrical Schematics - Implement Circuit (Sheet 7 of 13)

FP-17/(FP-18 Blank)
TM 5-3805-290-23-1
FO-1. Electrical Schematics - Engine Circuit (Sheet 8 of 13)

FP-19/(FP-20 Blank)
TM 5-3805-290-23-1
FO-1. Electrical Schematics - Transmission Circuit (Sheet 9 of 13)

FP-21/(FP-22 Blank)
TM 5-3805-290-23-1
FO-1. Electrical Schematics - Transmission Circuit (Sheet 10 of 13)

FP-23/(FP-24 Blank)
TM 5-3805-290-23-1
FO-1. Electrical Schematics - Starting Circuit (Sheet 11 of 13)

FP-25/(FP-26 Blank)
TM 5-3805-290-23-1
FO-1. Electrical Schematics - Power Distribution Circuit (Sheet 12 of 13)

FP-27/(FP-28 Blank)
TM 5-3805-290-23-1
FO-1. Electrical Schematics - Legend (Sheet 13 of 13)

FP-29/(FP-30 Blank)
TM 5-3805-290-23-1
427-B1294-3
FO-2 Hydraulic Component Locator
FP-31/(FP-32 Blank)
TM 5-3805-290-23-1
427-B1294-1
FO-2. Hydraulic Schematic (Sheet 1of 2)
FP-33/(FP-34 Blank)
TM 5-3805-290-23-1
427-B1294-2
FO-2. Hydraulic Schematic (Sheet 2 of 2)
FP-35/(FP-36 Blank)
THE METRIC SYSTEM AND EQUIVALENTS
Linear Measure Square Measure
1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches
1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet
1 Kilometer = 1000 Meters = 0.621 Miles 1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles
Weights Cubic Measure
1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches
1 Kilogram = 1000 Grams = 2.2 Pounds 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet
1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons
Temperature
Liquid Measure
5/9 (°F - 32) = °C
1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 212° Fahrenheit is equivalent to 100° Celsius
1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 90° Fahrenheit is equivalent to 32.2° Celsius
32° Fahrenheit is equivalent to 0° Celsius
9/5 C° +32 = F°
APPROXIMATE CONVERSION FACTORS
To Change To Multiply By To Change To Multiply By
Inches Centimeters 2.540 Centimeters Inches 0.394
Feet Meters 0.305 Meters Feet 3.280
Yards Meters 0.914 Meters Yards 1.094
Miles Kilometers 1.609 Kilometers Miles 0.621
Sq Inches Sq Centimeters 6.451 Sq Centimeters Sq Inches 0.155
Sq Feet Sq Meters 0.093 Sq Meters Sq Feet 10.764
Sq Yards Sq Meters 0.836 Sq Meters Sq Yards 1.196
Sq Miles Sq Kilometers 2.590 Sq Kilometers Sq Miles 0.386
Acres Sq Hectometers 0.405 Sq Hectometers Acres 2.471
Cubic Feet Cubic Meters 0.028 Cubic Meters Cubic Feet 35.315
Cubic Yards Cubic Meters 0.765 Cubic Meters Cubic Yards 1.308
Fluid Ounces Milliliters 29.573 Milliliters Fluid Ounces 0.034
Pints Liters 0.473 Liters Pints 2.113
Quarts Liters 0.946 Liters Quarts 1.057
Gallons Liters 3.785 Liters Gallons 0.264
Ounces Grams 28.349 Grams Ounces 0.035
Pounds Kilograms 0.454 Kilograms Pounds 2.205
Short Tons Metric Tons 0.907 Metric Tons Short Tons 1.102
Pound-Feet Newton-Meters 1.356 Newton-Meters Pound-Feet 0.738
Pounds per Sq Kilopascals 6.895 Kilopascals Pounds per Sq 0.145

Inch Inch
Miles per Gallon Kilometers per Liter 0.425 Kilometers per Liter Miles per Gallon 2.354
Miles per Hour Kilometers per Hour 1.609 Kilometers per Hour Miles per Hour 0.621
PIN: 084055-000
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FIELD MAINTENANCE MANUAL

LOADER, LIGHT, SCOOP:

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!

HAZARDOUS WASTE DISPOSAL

HYDRAULIC SYSTEM PRESSURE

HYDRAULIC SYSTEM PRESSURE

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

To order this NBC decal use:

SOLVENT CLEANING COMPOUND

LIST OF EFFECTIVE PAGES/WORK PACKAGES

Date of issue for original manual is:

Original . . . . . . . 30 November 2007

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

VOLUME I How to Use This Manual (2 pgs.). . . . . . . . . 0

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

WP 0165 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0190 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0

TECHNICAL MANUAL HEADQUARTERS

FIELD MAINTENANCE MANUAL

LOADER, LIGHT, SCOOP:

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

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

CHAPTER 1 INTRODUCTORY INFORMATION, EQUIPMENT

WP 0001 00 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

Table of Contents - Continued

CHAPTER 2 TROUBLESHOOTING PROCEDURES

WP 0004 00 Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-1

CHAPTER 5 SUPPORTING INFORMATION

WP 0203 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203 00-1

Table of Contents - Continued

FO-2. Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-35

CHAPTER 3 UNIT MAINTENANCE INSTRUCTIONS

Table of Contents - Continued

Electrical System - Continued

Table of Contents - Continued

Brake System - Continued

Table of Contents - Continued

Hydraulic System - Continued

CHAPTER 4 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS

Table of Contents - Continued

Table of Contents - Continued

Refrigeration and Air Conditioning - Continued

CHAPTER 5 SUPPORTING INFORMATION

WP 0203 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203 00-1

HOW TO USE THIS MANUAL

CONTENTS OF THIS MANUAL

CONTENTS OF THIS MANUAL - CONTINUED

FEATURES OF THIS MANUAL

GENERAL INFORMATION 0001 00

Maintenance Task Title Page

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

GENERAL INFORMATION - CONTINUED 0001 00

PREPARATION FOR STORAGE OR SHIPMENT 0001 00

GENERAL INFORMATION - CONTINUED 0001 00

LIST OF ABBREVIATIONS/ACRONYMS - CONTINUED 0001 00

GENERAL INFORMATION - CONTINUED 0001 00

LIST OF ABBREVIATIONS/ACRONYMS - CONTINUED 0001 00

Table 1. Caterpillar Dealers.

GENERAL INFORMATION - CONTINUED 0001 00