Case 521e Tier3 - en

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521E
TIER III
Service Manual
Print No. 87728450 A - EU

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521E
Loader
87728450 A - EU
Use for Repair Manual

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Copyright ©
521E Wheel Loader

Repair Manual
87728450 A - EU
Table of Contents
Description Section No.
General Tab 1
Section Index - General
Standard Torque Specifications 1001
Fluids and Lubricants 1002
Metric Conversion Chart 1003
Engines Tab 2
Section Index - Engines
Engine and Radiator Removal and Installation 2000
Stall Tests 2002
After Cooler 2003
For Engine Repair, See the Engine Service Manual 87630273
Fuel System Tab 3

Section Index - Fuel System
For Fuel System Repair, See the Engine Service Manual 87630273
Electrical Tab 4
Section Index - Electrical
Removal and Installation of Starter and Alternator 4001
Electrical Specifications and Troubleshooting 4002
Batteries 4003
Instrument Cluster 4005
Steering Tab 5
Section Index - Steering
Removal and Installation of Steering Components 5001
Steering Specifications, Pressure Checks, and Troubleshooting 5002
Steering Cylinders 5005
Center Pivot 5006
Auxiliary Steering Motor and Pump 5008
Copyright © 2008 CNH Italia S.p.A.

CNH Italia S.p.A. All rights reserved.
Viale delle Nazioni, 55
41100 Modena Printed in E.C.
Italia 87728450 A - EU Issued April, 2008
Copyright ©
521E Wheel Loader

Repair Manual
87728450 A - EU
Table of Contents
Power Train Tab 6
Section Index - Power Train
Removal and Installation of Power Train Components 6001
Transmission Specifications, Pressure Checks, and Troubleshooting 6002
Transmission 6003
Front Axle 6004
Rear Axle 6004
Drive Shafts, Center Bearing, and Universal Joints 6005
Wheels and Tires 6006
Transmission Control Valve 6007
Brakes Tab 7
Section Index - Brakes
Removal and Installation of Brake Components 7001
Hydraulic Brake Troubleshooting 7002
Brake Pump 7003
Brake Accumulators 7004
Parking Brake 7008
Hydraulics Tab 8
Section Index - Hydraulics
How to Read Hydraulic Schematics 8000
Removal and Installation of Hydraulic Components 8001
Hydraulic Specifications, Troubleshooting, and Pressure Checks 8002
Cleaning the Hydraulic System 8003
Loader Control Valve 8005
Cylinders 8006
Coupler Solenoid Locking Valve 8007
Ride Control Accumulator 8013
Ride Control Valve 8014

Copyright ©
521E Wheel Loader

Repair Manual
87728450 A - EU
Table of Contents
Mounted Equipment Tab 9
Section Index - Mounted Equipment
Air Conditioning Troubleshooting and System Checks 9002
Air Conditioner System Service 9003
Removal And Installation Of Air Conditioning And Heater Components 9004
Loader 9006
Roll Over Protective Structure (ROPS), Cab Structural Frame (CSF) 9007
Cab Glass Installation 9010
Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear Pocket

Copyright ©
Copyright ©
SECTION INDEX
GENERAL
Section Title Section Number
Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001

Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003

Copyright ©
Copyright ©
1001
Section
1001
GENERAL TORQUE SPECIFICATIONS

Copyright ©
1001-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
87728450 A - EU Issued 4-08 Printed in E.C.

Copyright ©
1001-3
TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special torques
are not given. These torques apply to fasteners with Grade 8 Bolts, Nuts, and Studs
both UNC and UNF threads as received from
suppliers dry, or when lubricated with engine oil. Not
applicable if special graphities, Molydisulfide
greases, or other extreme pressure lubricants are
Pound- Newton
used.
Size Inches metres
1/4 inch 144 to 180 16 to 20
Grade 5 Bolts, Nuts, and Studs
5/16 inch 288 to 348 33 to 39
3/8 inch 540 to 648 61 to 73
Pound- Newton Pound- Newton

Size Inches metres Size Feet metres
1/4 inch 108 to 132 12 to 15 7/16 inch 70 to 84 95 to 114
5/8 inch 220 to 264 298 to 358
Pound- Newton 3/4 inch 380 to 456 515 to 618
Size Feet metres
7/8 inch 600 to 720 814 to 976
7/16 inch 54 to 64 73 to 87
1.0 inch 900 to 1080 1220 to 1465
1/2 inch 80 to 96 109 to 130
1-1/8 inch 1280 to 1440 1736 to 1953
9/16 inch 110 to 132 149 to 179
1-1/4 inch 1820 to 2000 2468 to 2712
5/8 inch 150 to 180 203 to 244
1-3/8 inch 2380 to 2720 3227 to 3688
3/4 inch 270 to 324 366 to 439
1-1/2 inch 3160 to 3560 4285 to 4827
7/8 inch 400 to 480 542 to 651
NOTE: Use thick nuts with Grade 8 bolts.
1.0 inch 580 to 696 787 to 944
1-1/8 inch 800 to 880 1085 to 1193
1-1/4 inch 1120 to 1240 1519 to 1681
1-3/8 inch 1460 to 1680 1980 to 2278
1-1/2 inch 1940 to 2200 2631 to 2983

Copyright ©
1001-4
TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following torques when specifications are not
given. Grade 10.9 Bolts, Nuts, and Studs
These values apply to fasteners with coarse threads
as received from supplier, plated or unplated, or 10.9
when lubricated with engine oil. These values do not
apply if graphite or Molydisulfide grease or oil is Pound- Newton
used. Size Inches metres
M4 36 to 48 4 to 5
Grade 8.8 Bolts, Nuts, and Studs M5 84 to 96 9 to 11
M6 132 to 156 15 to 18
8.8
M8 324 to 384 37 to 43
Pound- Newton
Size Inches metres Pound- Newton
M4 24 to 36 3 to 4 Size Feet metres
M5 60 to 72 7 to 8 M10 54 to 64 73 to 87
M6 96 to 108 11 to 12 M12 93 to 112 125 to 150
M8 228 to 276 26 to 31 M14 149 to 179 200 to 245
M10 456 to 540 52 to 61 M16 230 to 280 310 to 380

M20 450 to 540 610 to 730
Pound- Newton M24 780 to 940 1050 to 1275

Size Feet metres M30 1470 to 1770 2000 to 2400
M12 66 to 79 90 to 107 M36 2580 to 3090 3500 to 4200
M14 106 to 127 144 to 172
Grade 12.9 Bolts, Nuts, and Studs
M16 160 to 200 217 to 271
M20 320 to 380 434 to 515
12.9
M24 500 to 600 675 to 815
M30 920 to 1100 1250 to 1500
Usually the torque values specified for grade 10.9
M36 1600 to 1950 2175 to 2600 fasteners can be used satisfactorily on grade 12.9
fasteners.

Copyright ©
1001-5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
37 Degree Flare Fitting Straight Threads with O-ring

Tube OD Thread Pound- Newton Tube OD Thread Pound- Newton
Hose ID Size Inches metres Hose ID Size Inches metres
1/4 inch 7/16-20 72 to 144 8 to 16 1/4 inch 7/16-20 144 to 228 16 to 26
6.4 mm 6.4 mm
7.9 mm 7.9 mm
9.5 mm 9.5 mm
12.7 mm 12.7 mm
5/8 inch 7/8-14 300 to 696 34 to 79
15.9 mm Tube OD Thread Pound- Newton
Hose ID Size Feet metres
Tube OD Thread Pound- Newton 5/8 inch 7/8-14 58 to 92 79 to 124
Hose ID Size Feet metres 15.9 mm
3/4 inch 1-1/16-12 40 to 80 54 to 108 3/4 inch 1-1/16-12 80 to 128 108 to 174
19.0 mm 19.0 mm
7/8 inch 1-3/16-12 60 to 100 81 to 135 7/8 inch 1-3/16-12 100 to 160 136 to 216
22.2 mm 22.2 mm
1.0 inch 1-5/16-12 75 to 117 102 to 158 1.0 inch 1-5/16-12 117 to 187 159 to 253
25.4 mm 25.4 mm
1-1/4 inch 1-5/8-12 125 to 165 169 to 223 1-1/4 inch 1-5/8-12 165 to 264 224 to 357
31.8 mm 31.8 mm
1-1/2 inch 1-7/8-12 210 to 250 285 to 338 1-1/2 inch 1-7/8-12 250 to 400 339 to 542
38.1 mm 38.1 mm
Split Flange Mounting Bolts

Pound- Newton
Size Inches metres
5/16-18 180 to 240 20 to 27
3/8-16 240 to 300 27 to 34
7/16-14 420 to 540 47 to 61
Pound- Newton
Size Feet metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203

Copyright ©
1001-6
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
O-ring Boss End

O-ring Face Seal End Fitting or Lock Nut
Nom.
SAE
Dash Thread Pound- Newton Thread Pound- Newton
Size Tube OD Size Inches metres Size Inches metres
-4 1/4 inch 9/16-18 120 to 144 14 to 16 7/16-20 204 to 240 23 to 27
6.4 mm
-6 3/8 inch 11/16-16 216 to 240 24 to 27 9/16-18 300 to 360 34 to 41
9.5 mm
-8 1/2 inch 13/16-16 384 to 480 43 to 54 3/4-16 540 to 600 61 to 68
12.7 mm
Thread Pound- Newton

Size Feet metres
-10 5/8 inch 1-14 552 to 672 62 to 76 7/8-14 60 to 65 81 to 88
15.9 mm
Nom. 1-1/16-12 85 to 90 115 to 122

SAE
Dash Thread Pound- Newton 1-3/16-12 95 to 100 129 to 136
Size Tube OD Size Feet metres
-12 3/4 inch 1-3/16-12 65 to 80 90 to 110 1-5/16-12 115 to 125 156 to 169
19.0 mm
-14 7/8 inch 1-3/16-12 65 to 80 90 to 110 1-5/8-12 150 to 160 203 to 217
22.2 mm
-16 1.0 inch 1-7/16-12 92 to 105 125 to 140 1-7/8-12 190 to 200 258 to 271
25.4 mm
-20 1-1/4 inch 1-11/16-12 125 to 140 170 to 190
31.8 mm
-24 1-1/2 inch 2-12 150 to 180 200 to 254
38.1 mm

Copyright ©
1002
Section
1002
FLUIDS AND LUBRICANTS

Copyright ©
1002-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TRANMISSION Temperature CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HYDRAULIC/BRAKE SYSTEM Temperature CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Model 521E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Model 521E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Copyright ©
1002-3
CAPACITIES AND LUBRICANTS

Engine Oil
Capacity .................................................................................................................. 10.9 liters (11.5 U.S. Quarts)
Capacity with Filter Change ..................................................................................... 11.8 liters (12.5 U.S. Quarts)
Type of oil........................................................................................................Case AKCELA (SAE 15W-40)
Engine Cooling System
Capacity....................................................................................................................... 22 liters (23.2 U.S. Quarts)
Type of Coolant ............................................................................................50% water and 50% Ethylene Glycol
Fuel Tank
Capacity ................................................................................................................... 189.3 liters (50 U.S. Gallons)
Type of Fuel ............................................................................................ See Diesel fuel specifications on page 6
Hydraulic System
Hydraulic Reservoir Refill Capacity ..........................................................................56.8 liters (15.0 U.S. Gallons)
Total System Capacity ...........................................................................................113.6 liters (30.0 U.S. Gallons)
Type of Oil ............................................................................................................. Case AKCELA Hy-Tran Ultra®
Transmission
Refill Capacity with Filter Change ................................................................................ 18.9 liters (20 U.S. Quarts)
Total System Capacity ................................................................................................. 26 liters (27.5 U.S. Quarts)
Type of Oil .......................................................................................................Case AKCELA (SAE 15W-40)
Axles
Capacity
Front...................................................................................................................... 22.0 liters (23.2 U.S. Quarts)
Rear ...................................................................................................................... 22.0 liters (23.2 U.S. Quarts)
Type of Lubricant ........................................................................ Case AKCELA Transaxle Fluid (SAE 80W-140)
NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result of using an
alternate oil. Machines are shipped from the factory with break-in oil.
Brake System
Type of Fluid (Same as Hydraulic System) .............................................................. Case AKCELA Hy-Tran Ultra®
Fittings
Grease as required ................................................................................................... Case AKCELA Molydisulfide

Copyright ©
1002-4
ENGINE OIL RECOMMENDATIONS

Case AKCELA No. 1 Engine oil is recommended
for use in your Case engine. Case AKCELA No. 1
Engine Oil will lubricate your engine correctly
under all operating conditions.
If Case AKCELA No. 1 Multi-Viscosity Oil is not
available, use only oil meeting API engine oil service
category CI-4.
See the chart below for recommended viscosity at
ambient air temperature ranges.
NOTE: Do not put performance additives or other oil
additive products in the engine crankcase. The oil change
intervals given in this manual are according to tests with BD03A102
Case AKCELA lubricants.
BC02N250

Copyright ©
1002-5
TRANMISSION TEMPERATURE CHART
BC04F193
HYDRAULIC/BRAKE SYSTEM TEMPERATURE CHART
BC04F192

Copyright ©
1002-6
DIESEL FUEL SYSTEM

Use No. 2 diesel fuel in the engine of this machine. Fuel Storage
The use of other fuels can cause the loss of engine
power and high fuel consumption. If you keep fuel in storage for a period of time, you
can get foreign material or water in the fuel storage
In very cold temperatures, a mixture of No. 1 and No. tank. Many engine problems are caused by water in
2 diesel fuels is temporarily permitted. See the the fuel.
following Note.
Keep the fuel storage tank outside and keep the fuel
NOTE: See your fuel dealer for winter fuel requirements in as cool as possible. Remove water from the storage
your area. If the temperature of the fuel lowers below the container at regular periods of time.
cloud point (wax appearance point), wax crystals in the fuel
will restrict the fuel filter and cause the engine to lose power Fill the fuel tank at the end of the daily operating
or not start. period to prevent condensation in the fuel tank.
The diesel fuel used in this machine must meet the

specifications as shown below in, “Specifications for
Acceptable No. 2 Diesel Fuel”, or Specification
(ASTM-D-975) of the American Society for Testing
and Materials.
Specifications for Acceptable No. 2 Diesel Fuel

API gravity, minimum ............................................................................................................................................. 34
Flash point, minimum ............................................................................................................................60°C (140°F)
Cloud point (wax appearance point), maximum ...........................................................-20°C (-5°F) See Note above
Pour point, maximum ..................................................................................................-26°C (-15°F) See Note above
Distillation temperature, 90% point ................................................................................282 to 338°C (540 to 640°F)
Viscosity, at 38°C (100°F)
Centistokes ......................................................................................................................................... 2.0 to 4.3
Cetane number, minimum .......................................................................... 43 (45 to 55 for winter or high altitudes)
Water and sediment, by volume, maximum .................................................................................................... 0.05%

Copyright ©
1002-7
MAINTENANCE SCHEDULE
Model 521E
FREQUENCY IN HOURS
Initial Service
LUBRICATE
SERVICE
REPLACE
NUMBER
CHANGE
SERVICE POINTS
ADJUST
INTERVAL
CHECK
CLEAN
DRAIN
ITEM
29 Air cleaner * *
18 Bleed Fuel Filter of Condensation *
Variable 19 Hydraulic Filter *
Periodic 22 Alternator, AC, Drive Belt *
(*) 13 Radiator Coolant Level *
XX Fire extinguisher *
14 Tires *
Every 10 Hours 1 Check Engine Oil Level 10
2 Check Engine Coolant Level 50
3 Check Transmission Oil Level 50
Every 50 Hours
4 Check Hydraulic Oil Level 50
5&6 Grease Bucket Mounting Fittings 50
7 Grease Front Drive Shaft Support Bearing 100
Lubricate The Steering Cylinder Pivots - Rod And
8&9 100
Every 100 Hours Closed End (4 Fittings)
10 Lubricate Loader Lift & Cylinder Pivots (10) Z-bar 100
11 Lubricate Loader Lift & Cylinder Pivots (18) XT 100
12 Check Cab Air Filter 250
Every 250
13 Check Tire Pressure & Wheel Torque 100 250
Hours
14 Check Drive Belt 250
15 Check Battery Electrolyte Level 500
16 Check Axle Oil Level 500
17 Drain Fuel Tank Condensation & Water Separator 500
Every 500
18 Change Engine Oil and Filter 100 500
Hours
18 Change Crankcase Filter 500
19 & 27 Replace Fuel Filter 100 500
XX ROPS/CSF and seat belt torques 500
20 Change Front & Rear Axle Oil 100 1000
21 Replace Hydraulic Oil filter 100 1000
22 Replace Cab Air Filter 1000
23 Replace Drive Belt 1000
24 Change Transmission Oil and Filter 100 1000
Every 1000
25 Grease Articulation Fittings 1000
Hours
26 Check Injector Calibration 1000
27 Fuel Pre-Filter 1000
XX Drive Shaft Slip Joint 1000
XX Check Valve Adjustment (Engine Manual) 1000
XX Trans Clutch Calibration (See Section 6002) 250 1000
28 Change Hydraulic Oil 2000
Every 2000
29 Change Coolant 2000
Hours
30 Replace Engine Air Cleaner 2000
Every 4000
XX Valve Clearance (Engine Manual) 4000
Hours

Copyright ©
1002-8
MAINTENANCE POINTS
Model 521E
12 22
11
27 18 10
19
13 20 16 21 24 8 16 20 6 5
10 4
11
30
15
2 26
18
14 23
7 25 9 3
6 17 18 29 28 5
BS08B289
See your Operators manual for maintenance of If you operate the machine in severe conditions,
safety related items and for detailed information of lubricate and service the machine more frequently.
the service items on this chart. Operators and service
manuals are available for this machine from your
dealer.

Copyright ©
Section
1003
1003
METRIC CONVERSION CHART

Copyright ©
1003-2
TABLE OF CONTENTS
CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Copyright ©
1003-3
CONVERSION FACTORS
Metric to U.S.
MULTIPLY BY TO OBTAIN
Area: sq. meter 10.763 91 square foot

hectare 2.471 05 acre
Force: newton 3.596 942 ounce force

newton 0.224 809 pound force
Length: millimeter 0.039 370 inch

meter 3.280 840 foot
kilometer 0.621 371 mile
Mass: kilogram 2.204 622 pound
Mass/Area: kilogram/hectare 0.000 466 ton/acre
Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.

Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.
Power: kilowatt 1.341 02 horsepower
Pressure: kilopascal 0.145 038 lb/sq. inch

bar 14.50385 lb/sq. inch
Temperature: degree C 1.8 x C +32 degree F
Torque: newton meter 8.850 748 lb/inch

newton meter 0.737 562 lb/foot
Velocity: kilometer/hr. 0.621 371 miles/hr.
Volume: cubic centimeter 0.061 024 cubic inch

cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
milliliter 0.033 814 ounce (US fluid)
litre 1.056 814 quart (US liquid)
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

litre/min. 0.219 969 gallon/min. (Imperial)

Copyright ©
1003-4
U.S. to Metric
MULTIPLY BY TO OBTAIN
Area: square foot 0.092 903 square meter

acre 0.404 686 hectare
Force: ounce force 0.278 014 newton

pound force 4.448 222 newton
Length: inch 25.4 * millimeter

foot 0.304 8 * meter
mile 1.609 344 * kilometer
Mass: pound 0.453 592 kilogram

ounce 28.35 gram
Mass/Area: ton/acre 2241 702 kilogram/hectare
Mass/Energy: lb/hp/hr 608.277 4 gr/kW/hr
Mass/Volume: lb/cubic yd. 0.593 276 kg/cubic meter
Power: horsepower 0.745 700 kilowatt
Pressure: lbs/sq. in. 6.894 757 kilopascal

lbs/sq. in. 0.069 bar
lbs/sq. in. 0.070 303 kg/sq. cm
Temperature: degree F 1.8 F - 32 degree C
Torque: pound/inch 0.112 985 newton meter

pound/foot 1.355 818 newton meter
Velocity: miles/hr. 1.609 344 * kilometer/hr.
Volume: cubic inch 16.387 06 cubic centimeter

cubic foot 0.028 317 cubic meter
cubic yard 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallons (Imperial) 4.546 092 litre
Volume/Time: gallon/min. 3.785 412 litre/min.
* = exact

Copyright ©
SECTION INDEX
ENGINES
Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000

Stall Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2002
After Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2003
FOR ENGINE REPAIR, SEE THE ENGINE REPAIR MANUAL

87630273

Copyright ©
Copyright ©
Section
2000
ENGINE AND RADIATOR REMOVAL AND

INSTALLATION
2000

Copyright ©
2000-2
TABLE OF CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Copyright ©
2000-3
ENGINE
Removal STEP 5
STEP 1
BD02N160
Put a container capable of holding at least 22.7 liter

BD03A040
(6.0 gallon) below radiator drain. Remove radiator
Park machine on a level surface and lower bucket to cap. Remove cap and drain coolant into container.
ground. Put articulation lock in LOCKED position. Install cap after coolant has drained. Install radiator
cap.
STEP 2
STEP 6
Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.
STEP 3
Slowly loosen the filler cap for hydraulic reservoir to
release air pressure in hydraulic reservoir.
STEP 4
BD02N160
Put a container capable of holding at least 12.3 liter

(13 U.S. quarts) below engine oil drain. Remove cap
and drain oil into container. Install cap after oil has
drained.
NOTE: After draining oil disconnect drain hose from
frame for removal with engine.
BD07N563-01
The master disconnect is located under the hood on

the left read side of the machine. Raise the hood put
master disconnect switch in OFF position. Remove
both battery covers and disconnect batteries from the
machine.

Copyright ©
2000-4
STEP 7 STEP 10
BD03A231
Double up a nylon lifting strap (1) and slide through BD07N565-01
the exhaust stack (2) on the hood. Remove the rear lift cylinder from the machine.
STEP 8 STEP 11
BD07N564-01 BD07N566-01
Place a solid steel bar through the strap, raise the Tag and disconnect hood wiring harness connector
hood and release tension on the lifting motor. and backup alarm connector from rear chassis wiring
harness connector.
STEP 9
STEP 12
1
BD07N597-01
Remove the right front lift cylinder from the hood. BD07N567-01
Repeat the procedure for the left hand side. Have another person balance the hood, and remove
the hood hinge mounting bolts (1) located outside the
hood by the cab (2) from the cooler frame. Repeat
procedure for the other side.

Copyright ©
2000-5
STEP 13 STEP 16
BD03A232 BD07N569-01
Carefully raise and remove hood from loader. Lower Loosen clamps on turbocharger and air cleaner,
hood onto suitable platform and disconnect lifting remove the intake hose.
equipment.
STEP 17
STEP 14
BD07N590-01
BD07N568-01
Tag and disconnect engine wiring harness connector Remove the air cleaner by removing the four bolts.
from air filter restriction switch.
STEP 18
STEP 15
BD07N569-01
BD07N569-01 Loosen the clamp on the turbocharger for the after

Loosen clamp on air cleaner intake hose and remove cooler inlet hose.
the crankcase ventilation hose.

Copyright ©
2000-6
STEP 19 STEP 22
BD07N565-01 BD07N572-01
Loosen the clamp on the after cooler and remove the Loosen the exhaust clamp from the turbocharger.
after cooler inlet hose from the machine.
STEP 23
STEP 20
BD07N592-01
BD07N570-01 Remove the muffler from the bracket.

Loosen the clamp on the intake manifold for the after
cooler output hose.
STEP 21
BD07N571-01
Loosen the clamp on the after cooler and remove the

after cooler outlet hose from the machine.

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2000-7
STEP 24 STEP 26
BD07N600-01 BD07N577-01
Loosen clamps and remove lower cooler hose from

the engine.
STEP 27
BD07N573-01
Remove the four mounting bolts from the belt cover,

remove the cover.
NOTE: After removing the belt cover remove the cover
BD07N579-01
mounting brackets from the machine frame.
STEP 25
1
BD07N578-01
BD07N576-01 If loader is equipped with air conditioning, identify,

Remove the drive belt from the engine. tag, and disconnect the engine wiring harness
connectors from air compressor clutch connector (1).
Remove the two mounting bolts (2) for the
compressor and set the compressor on the left
battery cover.

Copyright ©
2000-8
STEP 28 STEP 30
1
2
3
BD07N575-01 BD07N581-01
Tag and disconnect the wiring from the alternator. Tag and remove the wires from the starter solenoid
(2), remove the ground cable and ground strap (3)
STEP 29 from the starter. Then remove the two mounting bolts
(1).
NOTE: Move the starter cables away from the engine,
move the wiring harness away from the engine.
2
STEP 31
BD07N580-01
BD07N599-01
Disconnect the engine coolant vent hose and route to

the rear of the engine.
2
BD07N582-01
Remove bolt securing wiring harness clamp (1) to the

engine. Remove ground wires (2) from the engine.

Copyright ©
2000-9
STEP 32 STEP 33
BD07N596-01 BD07N585-01
Tag and remove the grid heater cable.
STEP 34
BD07N583-01
BD07N586-01
Disconnect the wiring harness from the EDC 7

3 controller.
NOTE: Lifting up on the lever will release the connector
from the controller.
STEP 35
BD07N584-01
Remove the radiator hose (1) from the rear of the

engine, remove the heater hose from the rear of the
engine (2), remove the clamp bolts and clamps (3)
from the bell housing.
BD07N591-01
Remove the fuel line from the top of the EDC 7

controller, plug the line and cap the fitting.

Copyright ©
2000-10
STEP 36 STEP 39
1
BD07N598-01 BD03A172
Tag and disconnect the fuel filter heater wires (1), Remove the drive shaft bolts from the flywheel. Move
disconnect the fuel line (2) from the fuel filter head, the drive shaft clear of the flywheel.
plug the line and cap the fitting.
STEP 40
STEP 37 Connect suitable lifting equipment to engine lifting
brackets. Take up all slack in lifting equipment.
Remove the engine mounting bolts and lift the engine
enough to gain access to the drain hose, pull the
engine oil drain hose with the engine.
STEP 41
Slowly raise engine from rear chassis. Be sure all
harness connections and hoses have been
disconnected and are clear of the engine. Remove
engine from machine.
BD07N588-01
Connect and turn on vacuum pump to hydraulic

reservoir. Tag and remove the hydraulic lines from
the brake system pump, plug the lines and cap the
fittings.
STEP 38
BD07N589-01
Remove the lower cover for the drive shaft.

Copyright ©
2000-11
Installation
4
5
6
7
BS08A031
1. ENGINE MOUNT BOLT 3. INSOLATOR UPPER 5. WASHER 7. NUT 9. OIL FILL TUBE
2. WASHER 4. INSOLATOR LOWER 6. WASHER 8. REMOTE OIL DRAIN HOSE
STEP 42 STEP 43
Slowly raise engine and move into position over rear
If engine rubber isolators require replacement,
chassis. Be sure all harness connections and hoses
remove and discard isolators (3 and 4). Install new
are out of the way then lower engine. Put washer (5)
rubber isolator (4), then rubber isolator (3).
between front rubber isolator (4) and chassis. Install
washer (2), bolt (1), washer (6), and nut (7) in engine
isolators. Lower engine into position.

Copyright ©
2000-12
STEP 44 STEP 49
Tighten engine mounting bolts to a torque of 244 to
298 Nm (180 to 220 lb-ft).
STEP 45
Disconnect lifting equipment from engine lifting
brackets.
STEP 46
Connect engine oil drain hose to frame bracket.
STEP 47
BD07N588-01
Connect and turn on vacuum pump to the hydraulic

reservoir. Remove caps from fittings and plugs from
hoses. Connect hoses to brake pump following tags
installed during removal. Remove and discard tags.
Turn off and disconnect vacuum pump from hydraulic
reservoir.
STEP 50
BD03A172
2
At front of engine, position drive shaft on engine
coupling. Install six bolts to secure drive shaft to
engine coupling. Apply Loctite 242 to threads and
tighten the six bolts to a torque of 53 to 62 Nm (39 to
46 lb-ft).
STEP 48
1
BD07N598-01
Remove cap from fitting and plug from the hose,

connect fuel line (2). Connect fuel filter heater wires
(1). Remove and discard tag.
STEP 51
BD07N589-01
Install the lower cover for the drive shaft.
BD07N591-01
Remove cap from fitting and plug from the hose,

connect fuel line to EDC 7.

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2000-13
STEP 52
BD07N586-01 BD07N583-01
Connect wiring harness to EDC 7 controller.

NOTE: Start the connector on the EDC 7 with lever
straight out from EDC 7. Use lever to pull connector into
position.
3
STEP 53
BD07N584-01
Install the heater hose (2) to the rear of the engine,

mount the clamps (3), install the radiator hose (1).
STEP 55
BD07N585-01
Connect grid heater cable to grid heater. Remove

and discard tag.
STEP 54
BD07N599-01
Connect the engine coolant vent hose.
BD07N596-01

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2000-14
STEP 56 STEP 58
2
3
BD07N581-01 BD07N575-01
Connect the wiring to the alternator. Remove and

discard tags.
4
STEP 59
BS08A030
Install the wires (2) to the starter solenoid, install the

ground cable and ground strap (3), to the starter.
Torque starter mounting nuts (1) to 40 to 50 Nm (29 BD07N579-01
to 37 pound-feet). Remove and discard tags.
NOTE: If the starter mounting studs (4) have to be
replaced apply Loctite 747 primer to studs and holes
2
and apply Loctite 271 to each stud and hole and
torque to 19 to 29 Nm (14 to 21 pound-feet).
STEP 57
1
BD07N578-01
If loader is equipped with air conditioning, mount the

compressor using the two mounting bolts (2),
connect the engine wiring harness connectors to air
2 compressor clutch connector (1). Remove and
discard tags.
BD07N582-01
Install bolt securing wiring harness (1) clamp to the

engine. Install ground wires (2) to the engine.

Copyright ©
2000-15
STEP 60 STEP 62
BD07N577-01 BD07N600-01
Install lower cooler hose to the engine and tighten
the clamps to a torque of 10.1 to 11.3 Nm (90 to 100
lb-inch).
STEP 61
1
2
BD07N573-01
Install the cover mounting brackets to the machine

frame. Install the belt cover, install the four mounting
bolts for the belt cover.
BD07N576-01 STEP 63
BD07N592-01
BS08A051 Place the muffler on the bracket. Install the mounting

DRIVE BELT ROUTING W/O AC (SEPARATE BELT FOR AC) bolts in the muffler and leave loose at this time.
Install the drive belt (1) on the pulleys. If equipped
with air conditioning install belt (2).
NOTE: A/C compressor belt tension:
A. Tension for a new belt is 45 Kg (100 lbs.).
B. Tension for a belt used more than 20 hours is 41 Kg
(90 lbs).

Copyright ©
2000-16
STEP 64 STEP 67
BD07N570-01
BD07N590-01
Tighten the clamp on the intake manifold for the after
Place air cleaner on bracket. Install four mounting cooler output hose.
bolts in air cleaner and tighten.
STEP 68
STEP 65
BD07N565-01
BD07N572-01
Place the after cooler inlet hose on the machine.
Install and tighten the exhaust clamp on the Tighten the clamp on the after cooler.
turbocharger, tighten the muffler mounting bolts.
STEP 69
STEP 66
BD07N572-01
BD07N571-01 Tighten the clamp on the turbocharger for the after
Place the after cooler outlet hose on the machine. cooler inlet hose.
Tighten the clamp on the after cooler.

Copyright ©
2000-17
STEP 70 STEP 73
BD07N569-01 BD03A232
Install the intake hose and tighten the clamps on Carefully raise and place hood over loader.
turbocharger and air cleaner.
NOTE: Refer to step 7 and 8 of removal for lifting
procedure.
STEP 71
STEP 74
1
BD07N569-01
Install the crankcase ventilation hose and tighten the

BD07N567-01
clamp on air cleaner intake hose.
Have another person balance the hood. Install the
hood hinge mounting bolts (1) to the cooler frame (2)
STEP 72 located outside the hood by the cab from the cooler
frame. Repeat procedure for the other side.
STEP 75
BD07N568-01
Connect engine wiring harness connector to air filter

restriction switch. Remove and discard tag.
BD07N597-01
Install the right front lift cylinder from the hood.

Repeat the procedure for the left hand side.

Copyright ©
2000-18
STEP 76 STEP 80
If hydraulic reservoir was drained, fill reservoir with
113.6 liters (30.0 gallons) of Case AKCELA Hy-Tran
Ultra® fluid.
STEP 81
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 22 liters (5.8 gallons). Install the radiator
cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.
STEP 82
BD07N565-01
Install the rear lift cylinder on the machine.
STEP 77
BD07N562-01
Connect the batteries, install battery covers, put

master disconnect switch in ON position.
BD07N566-01
Connect hood wiring harness connector and backup

alarm connector to the rear chassis wiring harness
and remove tags.
STEP 78
BD02N160
Check and make sure that drain caps are tight.
STEP 79
Install a new oil filter on engine. Fill engine with 11.8
liters (12.5 quarts) of Case AKCELA No. 1 Engine Oil
(SAE 15W-40).

Copyright ©
2000-19
STEP 83
Start engine and run the engine at low idle. Run the
engine at operating temperature for approximately
five minutes to completely mix the Ethylene Glycol
and water. Wh en the co ola nt is at opera ting
temperature, stop the engine. When engine has
cooled, check the coolant level at the reservoir.
WARNING: Hot coolant can spray out if radiator cap is
removed. To remove radiator cap: Let system cool, turn to
first notch, then wait until all pressure is released. Scalding
can result from fast removal of radiator cap.
STEP 84
Lower the hood.
STEP 85
Put articulation lock in OPERATING position.

Copyright ©
2000-20
RADIATOR
Removal STEP 4
STEP 1
Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.
1
STEP 2
BD03A231
Double up a nylon lifting strap (1) and slide through

the exhaust stack (2) on the hood.
STEP 5
BD03A040
Put articulation lock in LOCKED position.
STEP 3
BD07N564-01
Place a solid steel bar through the strap, raise the

hood and release tension on the lifting motor.
STEP 6
BD07N563-01
Put master disconnect switch in OFF position.
BD07N597-01
Remove the right front lift cylinder from the hood.


Copyright ©
2000-21
STEP 7 STEP 10
BD03A232
BD07N565-01
Carefully raise and remove hood from loader. Lower
Remove the rear lift cylinder from the machine. hood onto suitable platform and disconnect lifting
equipment.
STEP 8
STEP 11
BD07N566-01
Tag and disconnect hood wiring harness connector BD07N593-01

and backup alarm connector from rear chassis wiring
harness connector.
STEP 9
BD07N594-01
1 Remove two bolts and washers securing LH fender.
Remove LH fender.
BD07N567-01
Have another person balance the hood, and remove

the hood hinge mounting bolts (1) located outside the
hood by the cab (2) from the cooler frame. Repeat
procedure for the other side.

Copyright ©
2000-22
STEP 12 STEP 15
BD02N160 BD06F129
Put a 22.7 liter (6 gallon) container below radiator Loose and remove the lower radiator hose from the
drain. Remove radiator cap then remove cap and radiator.
drain coolant into container. Install cap after coolant
has drained. Install radiator cap. STEP 16
STEP 13
BD03A113
Disconnect overflow hose from radiator. Disconnect

BD03A109
connector from coolant level sender.
Release catch and tilt air conditioning condenser
core up to gain access to upper radiator hose. STEP 17
STEP 14
2 1 2
BD03A106
Remove screws and install lifting eyes (1). Attach

BD03A108
suitable lifting equipment to lifting eyes. Remove four
Loosen the upper radiator hose clamps, remove the mounting bolts (2), remove radiator from machine.
hose.

Copyright ©
2000-23
Installation STEP 21
STEP 18
Move radiator into position above cooling frame.
Carefully lower radiator while guiding it into position
in cooling frame.
STEP 19
BD06F129
2 1 2 At bottom of radiator, install bottom radiator hose.

Position and tighten two hose clamps to a torque of
10.1 to 11.3 Nm (90 to 100 lb-inch).
STEP 22
BD03A106
Install four lock washers and bolts (2) to secure

radiator to cooling frame. Disconnect lifting
equipment from lifting eyes. Remove lifting eyes and
install screws (1).
STEP 20
BD03A108
At top of cooling system frame, install hose. Position

hose clamps and tighten to a torque of 10.1 to 11.3
Nm (90 to 100 lb-inch).
BD03A113
Connect connector to coolant level sender, connect

overflow hose to radiator.

Copyright ©
2000-24
STEP 23 STEP 25
BD07N595-01 BD02N160
Align the slots in the fender with the tabs on the body Check that coolant drain cap is tight.
of the machine.
STEP 26
STEP 24 Fill engine coolant system with a solution of 50%
capacity is 22 liter (5.8 gallon). Install the radiator
the reservoir.
STEP 27
1
BD07N593-01
BD03A231
Double up a nylon lifting strap (1) and slide through

the exhaust stack (2) on the hood.
STEP 28
BD07N594-01
Align the whole in the fender and install the bolt and
washer.
BD07N564-01
Place a solid steel bar through the strap, raise the

hood and release tension on the lifting motor.
Copyright ©
2000-25
STEP 29 STEP 32
BD03A232
Carefully raise and place hood over loader. BD07N565-01
Install the rear lift cylinder on the machine.

STEP 30
STEP 33
BD07N567-01
Have another person balance the hood. Install the BD07N566-01
hood hinge mounting bolts (1) to the cooler frame (2) Connect hood wiring harness connector and backup
located outside the hood by the cab from the cooler alarm connector to the rear chassis wiring harness
frame. Repeat procedure for the other side. and remove tags.
STEP 31 STEP 34
BD07N597-01
BD07N562-01
Install the right front lift cylinder from the hood.
Put master disconnect switch in ON position.

Copyright ©
2000-26
STEP 35 WARNING: Hot coolant can spray out if radiator cap is
Start engine and run the engine at low idle. Run the removed. To remove radiator cap: Let system cool, turn to
engine at operating temperature for approximately first notch, then wait until all pressure is released. Scalding
five minutes to completely mix the Ethylene Glycol can result from fast removal of radiator cap.
and water. Wh en th e co olan t is at opera ting
temperature, stop the engine. When engine has STEP 36
cooled, check the coolant level at the reservoir. Put articulation lock in OPERATING position.

Copyright ©
2002
Section
2002
STALL TEST

Copyright ©
2002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stall Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTRUMENT CLUSTER DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PROCEDURE TO HEAT THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
POWER MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PERFORMING STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Copyright ©
2002-3
SPECIFICATIONS
Low idle ..........................................................................................................................................1020 to 1080 rpm
Alternate low idle .................................................................................................................................870 to 930 rpm
Cold low idle ....................................................................................................................................1170 to 1230 rpm
In gear low idle in boost mode (see note)........................................................................................1050 to 1150 rpm
Full throttle (no load)........................................................................................................................2074 to 2244 rpm
Temperature of the torque converter oil ......................................................................82° to 104° C (180° to 220° F)
Temperature of the hydraulic oil ...................................................................................... 54° to 57°C (129° to 134°F)
NOTE: This low idle will be held after the engine has accelerated over 1400 rpm while in gear. It will remain at this accelerated
level until the transmission is placed back into neutral for two seconds.
Stall Speeds
Torque converter .............................................................................................................................1950 to 2030 rpm
Hydraulic system .............................................................................................................................1900 to 2100 rpm
Torque converter and hydraulic system together ............................................................................1300 to 1700 rpm
STALL TESTS
During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or
both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor
performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic
system.
INSTRUMENT CLUSTER DISPLAYS

1. With the engine running, press the up or down
key and scroll through the information screens
and trip screens. The following sequence is
using the down key only.
NOTE: Pressing the escape key will return the LCD back
to the normal driving screen.
BD06F183-01
3. Info 1 is the first information screen using the

down arrow from the driving screen. It displays
engine RPM’s, speed, fuel level, and the voltage
level.
BD06F188-01
2. From the driving screen push the down arrow, as

shown.

Copyright ©
2002-4
BD06F027-01 BD06F169-01
4. Info 2 will be displayed next. The Info 2 screen 6. Press the down button again and the Trip 1
will display coolant temperature, turbocharger air screen will display. The LCD provides two trip
temperature, engine oil temperature in either computers. These will display since last reset the
Fahrenheit or Celsius, as well as oil pressure total time in hours, the total fuel, and the average
PSI. fuel consumption per hour.
BD06F170-01
BD06F184-01
5. Push the down button again and the Info 3 7. By continuing to scroll down, the fifth screen will
screen. This screen displays the temperature in display the Trip 2 screen. Trip 1 and Trip 2
Fahrenheit or Celsius of the transmission oil, screens can be reset independently. The
hydraulic oil, sump oil, and radiator coolant previous screen can be accessed by using the
temperature. up arrow key.

Copyright ©
2002-5
PROCEDURE TO HEAT THE OIL
Torque Converter Hydraulic System

1. Sit in the seat. 1. Apply the parking brake.
2. Start the engine and run the engine at low idle. 2. Start the engine and run at full throttle.
3. To measure the oil temperature with the 3. To measure the oil temperature with the
instrument cluster: instrument cluster:
A. Press the up or down arrow key. A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures B. Stop at the info screen with the temperatures
that need to be monitored. that need to be monitored are on.
4. Place the declutch switch in the OFF position. 4. Hold the bucket control lever in the ROLLBACK
position while raising and lowering the lift arms
5. Place the automatic switch in the manual mode
from ground level to full height.
position. Push down and hold the brake pedal for
the remainder of this procedure. 5. Continue this procedure until the temperature of
the hydraulic oil is 54° to 57°C (129° to 134°F).
6. Release the parking brake.
7. Move the transmission control lever to Forward
and turn the transmission control lever to 3rd
gear.
8. Increase the engine speed to full throttle and run
the engine at this speed for 30 seconds.
9. Decrease the engine speed to low idle and move
the transmission control lever to the Neutral
position for 15 seconds.
10. Repeat steps 7, 8, and 9 until the temperature of
the torque converter oil is 82° to 104°C (180° to
220°F).

Copyright ©
2002-6
POWER MODE SELECTION

1. After the oil temperatures have been raised to 3. Use down arrow to scroll through the menu’s.
operating temperatures the power mode must be
4. High light Power Mode and press the enter key.
set to “Auto”.
5. Power Mode Menu
A. Max - Maximum power possible
B. Standard - Standard operation
C. Auto - Will cycle between Max and Standard
D. Eco - Limited power for economy
6. High light Auto mode and press the enter key.
7. Press the escape key to return to the normal
driving screen.
BD06H038-01
2. Press and hold the confirmation “enter” button for

two seconds to arrive at the above service
screen.

Copyright ©
2002-7
PERFORMING STALL TESTS
Test No. 1 - Torque Converter and Test No. 2 - Torque Converter Stall
Hydraulic Stall Together 1. Sit in the seat.
1. Sit in the seat.
2. Start the engine and run the engine at low idle.
3. Press the brake pedal, release the park brake,
3. Press the brake pedal, release the park brake, shift into Forward.
shift into Forward.
4. Push the clutch cutout switch to OFF. Put the
4. Push the clutch cutout switch to OFF. Put the transmission in manual mode. Push down and
transmission in manual mode. Push down and hold the brake pedal for the remainder of this
hold the brake pedal for the remainder of this procedure.
procedure.
5. Turn the transmission control lever to third gear.
5. Turn the transmission control lever to third gear.
6. Increase the engine speed to full throttle.
7. Check the engine speed.
7. Hold the bucket control lever in the ROLLBACK
8. Decrease the engine speed to low idle.
position and raise the lift arms.
9. Place the transmission in neutral and apply the
NOTE: The stall speed must be read while the lift arms are
parking brake.
in motion.
10. Stop the engine.
9. Release the bucket control lever. Understanding the Results of Test
10. Decrease the engine speed to low idle. No. 2
1. If the engine speed was as specified, the engine,
11. Lower the bucket to the ground, place the
torque converter and transmission are probably
transmission in neutral and apply the parking
good.
brake.
2. If the engine speed was more than specified, the
problem can be in the torque converter or the
transmission. See Section 6002 for
Understanding the Results of Test troubleshooting information.
No. 1
3. If the engine speed was less than specified, do
1. If the engine speed was as specified, the engine,
Test No. 3.
torque converter, transmission and hydraulic
system are probably good.
2. If the engine speed was not as specified, do Test
No. 2 and 3.

Copyright ©
2002-8
Test No. 3 - Hydraulic Stall Understanding the Results of Test

1. Sit in the seat. No. 3
1. If the engine speed was as specified, the engine
and hydraulic system are good.
2. If the engine speed was more or less than
4. Hold the bucket control lever in the ROLLBACK specified the main relief setting may be too low
position and raise the lift arms. or too high. See Section 8002 for troubleshooting
information.
NOTE: The stall speed must be read while the lift arms are
in motion. 3. If the engine speed was less than specified in all
tests, the engine is probably the cause.
6. Release the bucket control lever.
8. Lower the bucket to the ground.
9. Stop the engine.

Copyright ©
Section
2003
2003
AFTER COOLER

Copyright ©
2003-2
TABLE OF CONTENTS
TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Copyright ©
2003-3
TROUBLESHOOTING AFTER COOLER

STEP 1
Park machine on level ground, lower the bucket. Put
transmission in neutral, apply the parking brake. Turn
off engine.
STEP 2
Raise hood. Install ‘T’ fitting in waste gate valve
hose. Attach pressure gauge. Install another
pressure gauge into the intake manifold port.
STEP 3
Have assistant start engine and run at 2000 r/min
(rpm). Record pressure readings for both gauges. If BD03A118-01
the pressure difference is greater than 60 mbar Inspect the after cooler outlet flex hose for leaks or
(0.87 psi), inspect cooler components for damaged holes and insure that the clamps are tight.
or missing parts.
STEP 6
STEP 4
BD03A119-01
BD03A116-01
Inspect the intake manifold flex hose for leaks or
Inspect the turbocharger flex hose for leaks or holes holes and insure that the clamps are tight.
and insure that the clamps are tight.
STEP 7
STEP 5
BD03A109-01
BD03A115-01
Visually inspect top of after cooler for damage or
Inspect the after cooler inlet flex hose for leaks or leaks
holes and insure that the clamps are tight.
NOTE: If the leak source has not been located, remove
and test the after cooler.
Copyright ©
2003-4
AFTERCOOLER REMOVAL
Removal STEP 4
STEP 1
BD03A118-01
Loosen clamps and remove air cooler outlet hose.

BD03A116-01
Loosen clamps and remove turbocharger outlet STEP 5

components.
STEP 2
BD03112-01
Raise air conditioning/air cooler cover. Support cover

with appropriate lifting device. Remove cover support
BD03A115-01 latch.
Loosen clamps and remove air cooler inlet hose.
STEP 6
STEP 3
BD03A111-01
BD03A119-01 Remove three cover mounting bolts and lift cover off.
Loosen clamps and remove Intake hose.

Copyright ©
2003-5
STEP 7 STEP 10
BD03A109-01 BD03A113-01
Unlatch air conditioning condenser clamp. Remove two bolts, one from each side of the after
cooler mounting frame.
STEP 8
STEP 11
Lift air cooler and frame from machine with
appropriate lifting devise.
STEP 12
BD03A107-01
Rotate air conditioning condenser up and remove the

two retaining bolts, one on each side. Move the air
conditioning condenser back away from the air
cooler
BD03A111-01
STEP 9 Remove four bolts that mount air cooler in the air
cooler frame. Remove air cooler from frame.
BD03A117-01
Remove the two bolts at the rear of the after cooler

mounting frame.

Copyright ©
2003-6
Leak Test Installation

STEP 1
BS03B028
Check the core for leaks by closing off the outlet tube
BD03A111-01
and attaching regulated air pressure 550kPa (80psi)
Install after cooler in its frame. Install four mounting
to the inlet tube. Submerge the cooler in water and
bolts. Support after cooler with appropriate lifting
watch for air leakage.
device. Install the after cooler and frame in the
NOTE: If leakage is detected replace the after cooler. machine.
STEP 2
BD03A113-01
Install two side mounting bolts
STEP 3
BD03A117-01
Install two bolts at the rear of the after cooler

mounting frame.

Copyright ©
2003-7
STEP 4 STEP 7
BD03A107-01 BD03A116-01
Position air conditioner condenser and install Install air cooler inlet hose. Tighten clamps at
mounting bolts. Rotate the condenser down and turbocharger outlet.
latch.
STEP 8
STEP 5
BD03A115-01
BD03112-01 Tighten clamps at air cooler inlet.

Support cover with appropriate lifting device. Raise
air conditioning/air cooler cover over machine. Install STEP 9
cover support latch.
STEP 6
BD03A119-01
Install air cooler outlet hose and tighten clamps at

engine intake.
BD03A111-01
Install three cover mounting bolts.

Copyright ©
2003-8
STEP 10 STEP 11
Install ‘T’ fitting in waste gate valve hose. Attach
pressure gauge. Install another pressure gauge into
the intake manifold port.
STEP 12
Have assistant start engine and run at 2000 r/min
(rpm). Record pressure readings for both gauges.
confirm that the pressure difference is less than 60
mBar (0.87 psi).
BD03A118-01
Tighten clamps at air cooler outlet.

Copyright ©
SECTION INDEX
FUEL SYSTEM
FOR FUEL SYSTEM REPAIR, SEE THE ENGINE REPAIR MANUAL

87630273

Copyright ©
Copyright ©
SECTION INDEX
ELECTRICAL
Removal and Installation of Starter and Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4001

Electrical Specifications and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005

Copyright ©
Copyright ©
4001
Section
4001
REMOVAL AND INSTALLATION OF STARTER AND

ALTERNATOR

Copyright ©
4001-2
TABLE OF CONTENTS
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
With Out Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
With Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Copyright ©
4001-3
STARTER
Removal STEP 4
STEP 1
Park machine on a level surface and lower bucket to
ground.
STEP 2
BD07N590-01
Remove the air cleaner by removing the four bolts.
STEP 5
BD07N563-01
Raise the hood, place the master disconnect switch

in the OFF position.
STEP 3
BD07N581-01
Place identification tags on the positive cables and

remove the positive cables from the starter.
STEP 6
BD07N569-01
Loosen clamp on air cleaner intake hose and

remove.
BD07N581-01
Remove the ground cable and ground strap (1) from

the starter, remove the starter mounting bolts (2),
remove the stater.

Copyright ©
4001-4
Installation STEP 9
STEP 7
BD07N581-01
Install and tighten the wires on the starter solenoid.

Remove and discard tags.
STEP 10
BC05G047
1. STUDS
2. NUTS
Apply Loctite 747 primer to studs and holes, apply 2

drops of Loctite 271 to each hole and stud.
Immediately install and torque studs to 19 to 29 Nm
(14 to 21 pound-feet). Allow adhesive to cure for 20
minutes before installing starter.
STEP 8
BD07N562-01
Place the master disconnect switch in the ON

position. Lower the engine hood.
BD07N581-01
Position the starter on the machine, attach the

ground cable and ground strap (1). Torque the two
nuts (2) to 40 to 50 Nm (29 to 37 pound-feet).

Copyright ©
4001-5
ALTERNATOR
Removal STEP 4
STEP 1
ground.
STEP 2
BD07N600-01
BD07N563-01
Raise the hood,. place the master disconnect switch

in the OFF position.
STEP 3
BD07N573-01
Remove four belt cover mounting bolts, remove

cover.
STEP 5
BD07N575-01
Disconnect wires from the alternator.
BD07N576-01
Use a wrench to move the belt tensioner to loosen

the tension on the belt. Remove the belt.

Copyright ©
4001-6
STEP 6 Installation
STEP 7
BD07N607-01
BD07N607-01
Place alternator onto engine, install mounting bolts

for alternator and tighten.
STEP 8
BS08A050
Remove mounting bolts for alternator, remove

alternator.
BD07N576-01
Use a wrench to move the belt tensioner, install the

belt.
NOTE: Belt routing instructions are on belt cover. See belt
routing on page 8.

Copyright ©
4001-7
STEP 9 STEP 10
BD07N600-01 BD07N575-01
Connect wires to the alternator, place rubber boot

over positive post.
STEP 11
BD07N573-01
Install belt cover, install four belt cover mounting

bolts and tighten.
BD07N562-01

position. Lower the hood.

Copyright ©
4001-8
BELT INSTALLATION
BS08A051 BD07N606-01
WITH OUT AIR CONDITIONING WITH AIR CONDITIONING

Copyright ©
4002
Section
4002
ELECTRICAL SPECIFICATIONS AND

TROUBLESHOOTING

Copyright ©
4002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
STARTING AND CHARGING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Starting Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Crank Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Crank Request Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Time Delay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Neutral Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Voltmeter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
POWER RELAY MODULES AND COLD STARTING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Power Relay Module A, Ignition Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Power Relay Module B, Ignition Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Power Relay Module C, For Fuel Filter Heater and Water Separator Heater . . . . . . . . . . . . . . . . . . . . . . . . . 46
Grid Heater Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Circuit breaker Cab B+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Water Separator Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Fuel Filter Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Power Relay Module D, Accessory Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Water In Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Throttle Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Electronic Diesel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Return-To-Travel/Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Height Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Electromagnetic Detents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Return-To-Dig Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pilot Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Height Control/Return-To-Travel Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Return to Dig Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pin Engage Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Pilot Pressure Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Pin Engage Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
PILOT CONTROL - RIDE CONTROL - FAN CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Ride Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Ride Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fan Reversing Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Fan Reverse Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Pilot Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Ride Control Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Rollback Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Rollback Jumper (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Fan PWM Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Fan Reversing Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Copyright ©
4002-3
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Output Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transmission Solenoid Valve and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Filter Maintenance Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Torque Converter Output Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Intermediate Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transmission Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transmission Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
FNR Switch for Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick Option; Next to Hydraulic Levers for
Single Axis Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
FNR Switch for Single Axis Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transmission Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Brake Declutch Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Declutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Instrument Cluster Connector 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Parking Brake Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Air Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Radiator Coolant Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Brake Warning Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Switch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Instrument Cluster Connector 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Hydraulic Filter Restriction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Hydraulic Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Redundant Brake Pressure Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Redundant Brake Pressure Switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Coolant Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
BACK UP ALARM CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Back-up Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Back-up Alarm Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
LIGHTS - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Work Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Rotating Beacon (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Beacon Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Left Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Right Hand Front Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Left Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Right Hand Rear Work Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Lights Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
LIGHTS - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Brake Lamp Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Brake Lamps Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Flasher Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Copyright ©
4002-4
Turn Signal, High-Low Beam, and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Driving Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
LIGHTS - 03 AND HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Left Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Right Hand Front Combination Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LIGHTS - 04 AND BACK UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Right Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Right Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Left Hand Rear Combination Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Left Hand Rear Combination Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
License Plate Lamp (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
License Plate Lamp (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Back-up Alarm (North America Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Back-up Alarm (Europe Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
CAB WINDOW WASHER AND WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Front Wiper High Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Front Wiper Cut Out Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Front Wiper Low Speed Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Rear Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Front Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Front Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Wiper Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
SECONDARY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Secondary Steering Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Secondary Steering Solenoid (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Secondary Steering Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Secondary Steering Motor (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Secondary Steering Pressure Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
CAN COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
CAN Communication Diagnostics Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
RADIO AND POWER CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Power Relay Module E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Power Converter 24 volts to 12 volts (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Power Outlet (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
12 Volt Radio Ready (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Right Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Left Speaker (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Seat Compressor and Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Cigar Lighter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
A/C High/Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
HEATING, VENTILATION, AND AIR-CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Air Recirculation Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Electronic Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Blower Motor Speed Resistors with Thermal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Copyright ©
4002-5
Air Conditioning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Water Valve Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Air Recirculating Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Copyright ©
4002-6
NOTES

Copyright ©
4002-7
SPECIFICATIONS
Electrical System ............................................................Two 12 volt batteries connected in series, negative ground

System Voltage .............................................................................................................................................. 24 volts
Batteries
Group Size ..........................................................................................................................................................31
Reserve Capacity ................................................................................................................................ 170 minutes
Cold Cranking Capacity At -17°C (0°F) for 60 Seconds At 6.0 Volts.................................................700 amperes
Load of Capacity (Load) Test .............................................................................................................400 amperes
Alternator ..................................................................................................................................... 24 volt, 65 amperes
Voltage Regulator............................................................................................................. Solid State, Not Adjustable
Starter................................................................................................................................ 24 volt, Solenoid Actuated
Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20°C (68°F) (Nominal) ................ 68.2 ohms
Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20°C (68°F) (Nominal) ............ 305 ohms
Fuel Level Sender .............................................................................................................................. 33 to 240 ohms
Coolant, Torque Converter, and Hydraulic Temperature Sender 20°C (68°F) ......................................... 3521 ohms
Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open)
Closing Set point ............................................................................................................................ 2.8 Bar (40 psi)
Hydraulic Filter Restriction Switch (Normally Open) Closing Set point .............................................. 2.8 Bar (40 psi)
Air Filter Restriction Switch (Normally Open) Closing Set point ................................. -6.4 kPa (Gauge) (-0.928 psig)
A/C Trinary Pressure Switch (Closed With Normal System Pressure)
Opens With Pressure ............................................................................ Above 28.5 ± 2.5 bar (413.3 ± 36,25 psi)
Below 2.5 ± 0.25 bar (36.25 ± 3.6 psi)
Brake Declutch Pressure Switch (Normally Closed) Opening Set point............................................ 24 Bar (350 psi)
Brake Warning Pressure Switch (Normally Closed) Opening Set point ................. 106 to 115 bar (1530 to 1670 psi)
Brake Redundant Pressure Switches (Normally Open) Closing Set point 55 to 69 bar decreasing (800 to 1000 psi)
Brake Lamp Pressure Switch (Normally Open) Closing Set point........................ 5 to 6 bar increasing (75 to 85 psi)
Secondary Steering Pressure Switch (Form C) Closing Set point ..................................................... 2.4 Bar (35 psi)
Fuel Filters Heater Resistance At 20°C (68°F) (Nominal)............................................................................ 1.9 ohms
Parking Brake Solenoid DC Resistance At 20°C (68°F) (Nominal) ........................................................... 40.3 ohms
Pilot Pressure Solenoid (Joystick) DC Resistance At 20°C (68°F) (Nominal) ........................................... 29.9 ohms
Pilot Pressure Solenoid (Single Axis) DC Resistance At 20°C (68°F) (Nominal) ...................................... 27.4 ohms
Ride Control Solenoid DC Resistance At 20°C (68°F) (Nominal) .............................................................. 22.7 ohms
Pin Engage Solenoid DC Resistance At 20°C (68°F) (Nominal) ............................................................... 28.8 ohms
Secondary Steering Solenoid DC Resistance At 20°C (68°F) (Nominal) .................................................. 39.3 ohms
Fan Reversing Solenoid DC Resistance At 20°C (68°F) (Nominal)........................................................... 39.3 ohms
Fan PWM Solenoid DC Resistance At 20°C (68°F) (Nominal) .................................................................. 29.3 ohms
Rollback Pressure Switch (Normally Closed) Opening Set point ....................................................... 6.2 Bar (90 psi)
Fuel Temperature Sensor At 20°C (68°F) (Nominal) ................................................................................ 2500 ohms
Grid Heater .................................................................................................................................................. 500 ohms
Engine Control Unit ............................................................................................... Electronic Diesel Control (EDC 7)
Analog Throttle ................................................................................. Idle Validation Switch Closes At 0.775V ± 0.1V
Throttle Position Potentiometer ................................................................................................. 5V Reference ± 0.2V
Low Idle Position .............................................................................................................................. 0.4V ± 0.025V
High Idle Position ................................................................................................................................. 4.0V ± 0.1V

Copyright ©
4002-8
ELECTRICAL WIRE IDENTIFICATION
Wire Identification Codes

21C Bk - 1.0
Wire Size (mm2) 0.8 mm 1.0 mm 2.0 mm 5.0 mm
Wire Color Bk = Black DU = Dark Blue S = Gray LG = Light Green K = Pink

Wire Name T = Tan W = White N = Brown G = Green U = Blue
LU = Light Blue Or = Orange R = Red P = Purple Y = Yellow
Wire Identification From Connector To Connector

Color, Size,
Wire Circuit Connector Cavity Connector Cavity
and Material
14 Alternator D+ Lg 1.0 SXL AD, Alternator D+ 1 ENG, Engine Cab 26
42 Work Lights Switched Fused Pwr R2.0 GXL SPL-WL, Ultrasonic A ECC, Work Lights 23
44 Brake Lt Control Power T 1.0 SXL FRONT, Cab Front Chassis 23 PBL, Brake Light Press Switch 2
49 Back Lt Power DU1.0 GXL D-OR, Diode OR C SPL-BCK-LGT, Spl Back Lgt Pwr A
52 Fan Reverse LSD W 0.8 TXL AIC-1, Adv Instr Clust 1 23 ECB, Electrical Center B B8
56 Fan Control PWM W 0.8 TXL CAB-E, Cab Engine 23 AIC-1, Adv Instr Clust 1 26
57 Pin Engage Sol Pwr W 1.0 SXL FRONT, Cab Front Chassis 20 YPE, Pin Engage Option A
58 Ride Control Sol Pwr W 1.0 SXL PRBF, Rollback Press Sw A YRC, Ride Control Option 1
64 Horn Power Or 1.0 SXL FRONT, Cab Front Chassis 13 HN1, Horn Power 1
SPL-BCK-LT-GD2, Spl Back Lgt

0 29 RTT/Float Ground Bk 0.8 GXL SFL, Return To Travel Sw 4 K
Gnd
0 AA Proximity Switch Grnd Bk 1.0 SXL PXH, Height Control RTT B SPL-A2, Ultrasonic A
0 AB Proximity Switch Grnd Bk 1.0 SXL SPL-A2, Ultrasonic A GND-FC, Ground A 1
0 AC Proximity Switch Grnd Bk 1.0 SXL PXF, RTD B SPL-A2, Ultrasonic A
0 AD Ride Control Ground Bk 1.0 SXL YRC, Ride Control Option 2 SPL-A1, Ultrasonic A
0 AE Pin Engage Ground Bk 1.0 SXL SPL-A1, Ultrasonic A YPE, Pin Engage Option B
0 AF Horn Ground Bk 1.0 SXL HN2, Horn Ground 1 SPL-A1, Ultrasonic A
0 AG Front Chassis Ground Bk 2.0 SXL SPL-A1, Ultrasonic A GND-FC, Ground A 1
0 AH RH Front Lights Ground Bk 1.0 SXL SPL-A1, Ultrasonic A LRF, Lights RH 1
0 AJ LH Front Lights Ground Bk 1.0 SXL SPL-A1, Ultrasonic A LLF, Lights LH 1
0 AK Park Brake/Warning Ground Bk 1.0 SXL SPL-A4, Ultrasonic A GND-FC, Ground A 1
0 AL Brake Warning Press Sw Gnd Bk 1.0 SXL PBW, Brake Warn Press Sw 2 SPL-A4, Ultrasonic A
0 AM RTD Grnd Bk 1.0 SXL PXM, RTD B PXT, RTD B
0 AN Park Brake Solenoid Ground Bk 1.0 SXL YPB, Park Brake Solenoid 2 SPL-A4, Ultrasonic A
0 AP Front To Rear Chassis Ground Bk 5.0 SXL GND-S1, Ground A 1 GND-S2, Ground A 1
0 AQ Comfort Steering Solenoid Gnd Bk 1.0 SXL YCS, Comfort Steer Solenoid B SPL-A4, Ultrasonic A
0 AR Front Axle Temp Sensor Ground Bk 1.0 SXL FRONT, Cab Front Chassis 9 HOT-FA, Front Axle Oil Temp 2
0B Front Washer Ground Bk 1.0 SXL FWW, Front Washer 2 SPL-ENG-GRD, Gnd Spl 6 Pck E
SPL-PED-BL-GD, Spl Bk Lgt

0 B1 Back Light Ground Bk 0.8 GXL SPC, Pilot Control Switch 7 B
Grnd 6 Pck

Copyright ©
4002-9

21C Bk - 1.0


Color, Size,
and Material
SPL-BCK-LT-GD2, Spl Bk Lt
0 B2 Back Light Ground Bk 0.8 GXL SFL, Return To Travel Switch 7 B
Grnd
0 B3 Back Light Ground Bk 0.8 GXL SHC, Height Control Switch 7 C
Grnd
0 B4 Back Light Ground Bk 0.8 GXL SRTD, Detent Switch 7 D
Grnd
0 B5 Back Light Ground Bk 0.8 GXL SPE, Pin Engage Switch 9 E
Grnd
0 B6 Cab2 Ground Bk 1.0 GXL GND-CAB2, Ground A 1 F
Grnd
0 B7 Back Light Ground Bk 0.8 GXL SFC, Fan Control Switch 7 M
Grnd
SPL-BCK-LT-GD, Spl Bk Lt
0 B8 Front Wiper Motor Ground Bk 0.8 GXL H FWMG, Wiper Ground A
Grnd
SPL-PED-BL-GD, Spl Bk Lt Grnd
0 B9 Back Light Ground Bk 0.8 GXL SCS, Comfort Steering Sw 7 A
6 Pck
SPL-HOOD-GRND, Hood
0 B10 Hood Ground Bk 1.0 GXL E GND-CAB2, Ground A 1
Grnd 6 Pck
SPL-BCK-LT-GD2, Spl Bk Lt SPL-PED-BL-GD, Spl Bk Lt Grnd
0 B11 Back Light Ground Bk 0.8 GXL L F
Grnd 6 Pck
SPL-HOOD-GRND, Hood
0 B12 Hood Down Relay Ground Bk 1.0 GXL A ECC, Work Lights C4
Grnd 6 Pck
SPL-BCK-LT-GD, Spl Bk Lt
0 B13 Back Light Ground Bk 1.0 GXL A GND-CAB2, Ground A 1
Grnd
0 B14 Back Light Ground Bk 0.8 GXL SWL, Work Lights Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd B
0 B15 Back Light Ground Bk 0.8 GXL SBE, Beacon Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd C
SPL-HOOD-GRND, Hood
0 B16 Hood Down Control Ground Bk 1.0 GXL B ECC, Work Lights B4
Grnd 6 Pck
0 B17 Back Light Ground Bk 0.8 GXL STA, Trans Auto Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd E
0 B18 Back Light Ground Bk 0.8 GXL SDC, Declutch Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd F
0 B19 Back Light Ground Bk 0.8 GXL SDR, Driving Lights Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd G
0 B20 Back Light Ground Bk 0.8 GXL SRC, Ride Control Switch 7 J
Grnd
0 B21 Back Light Ground Bk 1.0 GXL SBU, Backup Alarm Disc Sw 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd J
SPL-HOOD-GRND, Hood
0 B22 Hood Up Relay Ground Bk 1.0 GXL C ECC, Work Lights C2
Gnd 6 Pck

Copyright ©
4002-10

21C Bk - 1.0


Color, Size,
and Material
0 B23 Back Light Ground Bk 0.8 GXL SRWP, Rear Wiper Switch 7 SPL-BCK-LT-GD, Spl Bk Lt Grnd L

0 B24 Back Light Ground Bk 0.8 GXL SHZ, Hazard Switch 7 C
6 Pck
SPL-HOOD-GRND, Hood
0 B25 Hood Up Control Ground Bk 1.0 GXL D ECC, Work Lights B2
Gnd 6 Pck
0 B26 Buzzer/Switch Pad Ground Bk 0.8 GXL SPL-BUZ, Ultrasonic A 6
Grnd
0 B27 Buzzer Ground Bk 0.8 GXL SPL-BUZ, Ultrasonic A BUZ, AIC Buzzer 2
0 B28 Switch Pad Ground Bk 0.8 TXL SW-PD, Switch Pad 10 SPL-BUZ, Ultrasonic A
0 B29 RTT/Float Ground Bk 0.8 GXL SPB, Parking Brake Switch 7 E
6 Pck
0 B30 Back Light Ground Bk 0.8 GXL SETHR, Ether Switch 7 D
6 Pck
0 BA Pedestal Gnd Strap Bk 5.0 SXL. GND-PDST, Ground A 1 GND-PDST2, Ground A 1
0 BAC EDC7 Ground Bk 2.0 SXL SPL-EDC1, Ultrasonic A GND-ENG2, WIF, EDC 1
0 BAE EDC7 Sender Ground Bk 1.0 SXL RECT, Engine Coolant Temp B GND-ENG7, Tranny, Cool Temp 1
0 BAF Coolant Lever Sender Ground Bk 1.0 SXL CLS, Cool Jump-Cool Sender B GND-ENG7, Tranny, Cool Temp 1
0 BAG Hood Grounds (EURO) Bk 1.0 SXL GND-ENG4, Rear Lighting 1 E-HD, Trans Hood c
0 BAG
Hood Grounds (NA) Bk 1.0 SXL ENG-H, Engine to Hood 1 GND-ENG4, Rear Lighting 1
N
0 BAH QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 29
0 BAI QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 30
0 BAJ QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 39
0 BAK QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 40
0 BAL QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 41
0 BAM Ether Relay Signal Ground Bk 1.0 SXL PRM-C2, PRM signal B GND-ENG2, WIF, EDC 1
GND-ENG3, Spl Pck Washer

0 BAN Ether Start Ground Bk 1.0 SXL ETHR, Ether Solenoid B 1
Motor
0 BAP QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 50
GND-WIF, Gnd WIF Ring

0 BAR WIF Body Ground Bk 1.0 SXL 1 GND-ENG6, Dedicated 1
Term
0 BAS Rear Axle Temp Sensor Ground Bk 1.0 SXL HOT-RA, Rear Axle Oil Temp 2 GND-ENG7, Tranny, Cool Temp 1
0 BB Fan Reverse Solenoid Ground Bk 1.0 SXL YFR, Fan Reverse Sol Opt 2 SPL-FAN, Ultrasonic A
0 BC EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 11
Copyright ©
4002-11

21C Bk - 1.0


Color, Size,
and Material
0 BD EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 10
0 BE EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 5
0 BF EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 6
0 BG AIC Power Ground Bk 0.8 GXL ENG, Engine Cab 19 GND-ENG6, Dedicated 1
0 BH AIC Power Ground Red Bk 0.8 GXL ENG, Engine Cab 20 GND-ENG6, Dedicated 1
0 BJ AIC Sensor Ground Bk 0.8 GXL ENG, Engine Cab 17 GND-ENG6, Dedicated 1
0 BK Trans Splice Grounds Bk 1.0 GXL ENG-T, Engine to Trans 2 GND-ENG7, Tranny, Cool Temp 1
0 BL Rear Washer Ground Bk 1.0 SXL RWW, Rear Washer 2 SPL-ENG-GRD, Grd Spl 6 Pck F
SPL-ENG-GRD, Grd Spl 6 GND-ENG3, SPLC-PK, Washer

0 BM Engine Splice Grounds Bk 1.0 SXL A 1
Pck Motor
0 BN Filter Heater Control Bk 0.8 GXL PRM-C2, PRM Signal B EDC7, Engine Controller 13
0 BP WIF Sensor Ground Bk 1.0 SXL GND-ENG2, WIF, EDC 1 WIF, Water In Fuel Sensor 2
0 BQ Fan Speed PWM Sol Grd Bk 1.0 SXL YFN, Fan PWM Solenoid B SPL-FAN, Ultrasonic A
0 BR RH Rear Light Ground (EURO) Bk 1.0 SXL LRR-E, RH Rear Comb Lamp 5 GND-ENG4, Rear Lighting 1
0 BR N LH Rear Light Ground (NA) Bk 1.0 SXL LLR-N, LH Rear Comb Lamp D SPL-J1, Ultrasonic A
0 BS Fan Control Ground Bk 1.0 SXL SPL-FAN, Ultrasonic A SPL-ENG-GRD, Grd Spl 6 Pck D
0 BT LH Rear Light Ground (EURO) Bk 1.0 SXL LLR-E, LH Rear Comb Lamp 5 GND-ENG4, Rear Lighting 1
0 BT N RH Rear Light Ground (NA) Bk 1.0 SXL LRR-N, RH Rear Comb Lamp D SPL-J1, Ultrasonic A
0 BU Fuel Level Sender Ground Bk 1.0 SXL RFLG, Fuel Send Ground 1 GND-ENG7, Tranny, Cool Temp 1
0 BV Grid Heater Control Grnd Bk 0.8 TXL GHC, Grid Heater Relay 2 EDC7, Engine Controller 75
GND-ENG1, Start, FFH,

0 BW Water Separator Htr Ground Bk 2.0 SXL 1 WSH, Water Separator Heater A
WSH
0 BX Fuel Filter Heater Ground Bk 2.0 SXL FFH, Fuel Filter Heater B GND-ENG1, Start, FFH, WSH 1
SPL-ENG-GRD, Grd Spl 6

0 BY Air Filter Restriction Sw Grd Bk 1.0 SXL B PAF, Air Filter Restriction Sw 2
Pck
GND-ENG3, SPLC-PK, Washer
0 BZ Sec. Steering Splice Grd Bk 1.0 SXL ENG-T, Engine To Trans 1 1
Motor
0 CA Sec. Steering Signal Ground Bk 1.0 SXL SSM, Sec. Steering Mod 11 SPL-SEC-STR, Sec. Steer 6 Pck B
0 CB Sec. Steering Signal Ground Bk 1.0 SXL SSM, Sec. Steering Mod 12 SPL-SEC-STR, Sec. Steer 6 Pck A
PSS, Sec. Steer Press

0 CC Sec. Steering Press Sw Ground Bk 1.0 SXL B SPL-SEC-STR, Sec. Steer 6 Pck C
Switch
SPL-SEC-STR, Sec. Steer 6
0 CD Sec. Steering Splice Ground Bk 1.0 SXL F SS-TR, SS Mod Trans D
Pck

Copyright ©
4002-12

21C Bk - 1.0


Color, Size,
and Material
0 CE Sec. Steering Chassis Ground Bk 1.0 SXL SSM, Sec. Steering Mod 4 GND-SSMOD, Sec. Str Chas Gnd 1
0 CF Sec. Steering Sol Ground Bk 1.0 SXL YSS, Sec. Strg Sol 2 SPL-SEC-STR, Sec. Steer 6 Pck D
0 DA AIC Chassis Ground Bk 0.8 TXL GND-PDST1, Ground A 1 AIC-2, Advanced Inst Cluster 2 22
SPL-BCK-LT-GD, Splice Back

0 DAP Back Light Ground S 0.8 GXL STE, Trans Enable Switch 7 K
Light Ground
0 DAV TECM Diagnostic Ground Bk 0.8 GXL 108F, Diagnostic connector 3 GND-CAB3D, Ground A 1
0 DB AIC Power Ground Red Bk 0.8 TXL CAB-E, Cab Engine 20 AIC-2, And Instr Cluster 2 15
GND-CAB-SPL2, Spl Back

0 DC Time Delay Module Ground Bk 0.8 GXL A TDM, Time Delay Module 3
Light Ground
0 DD Voltmeter Relay Control Ground Bk 0.8 GXL E ECB, Elect Center B B2
Light Ground
0 DE Neutral Start Relay Control Grd Bk 0.8 GXL G ECB, Elect Center B B4
Light Ground
Crank Request Relay Control GND-CAB-SPL2, Spl Back
0 DF Bk 0.8 GXL F ECB, Elect Center B B6
Ground Light Ground
0 DG Cab Splice Grounds Bk 1.0 GXL GND-CAB-SPL, Cab Grd Spl F GND-CAB3, Ground C 1
0 DH Diagnostic Connector Ground Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl M DIA, Diagnostic A
0 DJ AC Relay Control Ground Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl K ECD, Elect Center D B10
0 DK Seat Compressor Motor Ground Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl I SC, Seat Comp Motor B
Power Converter Relay Control

0 DL Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl H PRM-E2, PRM Signal B
Ground
0 DM Speed Sensor Grounds Bk 0.8 TXL CAB-T, Cab Transmission 11 TECM, Trans 3
0 DN Output Speed Sensor Ground Bk 0.8 TXL CAB-T, Cab Transmission 28 TECM, Trans 4
0 DP DIAG TECM Ground Bk 0.8 TXL GND-CAB3D, Ground A 1 TECM, Trans 1
0 DQ DIAG TECM Ground Bk 0.8 TXL GND-CAB3D, Ground A 1 TECM, Trans 2
0 DR Roof Splice Grounds Bk 1.0 GXL CAB-RF, Cab to Roof Conn. F GND-CAB1, Ground A 1
0 DS Roof Splice Grounds Bk 1.0 GXL CAB-RF, Cab to Roof Conn. G GND-CAB1, Ground A 1
0 DT Front Wiper/Washer Sw Grd Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl G SFWW, Front Wiper/Washer 2
0 DU Pilot Pressure Sol Grd Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl L YPP, Pilot Press Sol B
0 DV Cigar Lighter Ground Bk 3.0 SXL CL, Cigar Lighter 2 GND-CAB3, Ground C 1
0 DW AIC Power Ground Bk 0.8 TXL CAB-E, Cab Engine 19 AIC-1, Adv Instr Cluster 1 12
0 DX AIC Sensor Ground Bk 0.8 TXL CAB-E, Cab Engine 17 AIC-1, Adv Instr Cluster 1 6
0 DY Front Axle Temp Sensor Grnd Bk 1.0 GXL CAB-F, Cab Front Chassis 9 GND-CAB3D, Ground A 1

Copyright ©
4002-13

21C Bk - 1.0


Color, Size,
and Material
0 EA Time Delay relay Control Grnd Bk 0.8 GXL B PRM-B2, PRM Signal B
Light Ground
0 EB Ignition Relay Control Ground Bk 0.8 GXL C PRM-A1, PRM Signal B
Light Ground
0 EC ACC Relay Control Ground Bk 0.8 GXL D PRM-D1, PRM Signal B
Light Ground
0 ED HVAC Grounds Bk 3.0 SXL HVAC2, HVAC2 2 GND-CAB4, Ground C 1
GND-CAB-SPL, Cab Grnd

0 EE DIODE Suppression Grounds Bk 0.8 GXL A 140M, DIODE Module C
Spl
0 EF Brake Lights Relay Ctrl Grnd Bk 0.8 GXL M ECC, Work Lights B6
Light Ground
GND-CAB-SPL2, Spl Back Light
0 EG Flasher Module Ground Bk 0.8 GXL FLSHR, Flasher Module 4 L
Ground
GND-CAB-SPL2, Spl Back Light
0 EH Flasher Module Ground Bk 0.8 GXL FLSHR, Flasher Module 3 K
Ground
CNV, 24V to 12V Pwr
0 EJ Power Converter Ground Bk 1.0 GXL 3 GND-CAB4, Ground C 1
Convert
0 EK AUX Power Outlet 1 Grnd Bk 1.0 GXL PO1, Power Outlet C GND-CAB5, Ground C 1
0 EL AUX Power Outlet 2 Grnd Bk 1.0 GXL PO2, Power Outlet C GND-CAB5, Ground C 1
0 EM Radio Ground Bk 0.8 GXL CAB-RF, Cab to Roof Conn. M GND-CAB-SPL, Cab Grnd Spl B
0 EN Radio Ground Bk 0.8 GXL ROOF, Roof to Cab Conn. M RAD, Radio Power 8
0 EP Horn Switch Ground Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl C SRHSTLK, RH Stalk Switch 31
Splice Pack GND-CAB-SPL2 GND-CAB-SPL2, Spl Back GND-CAB6, Start, FFH, Water
0 EQ Bk 0.8 GXL H 1
Grnd Light Ground Sep Htr
0 ER Power Converter Grnd Bk 1.0 GXL CNV, 24V to 12V Pwr Conv 6 GND-CAB4, Ground C 1
GND-GH1, STRT, FFH, Water

0 ES Grid Heater Ground Bk 19.0 SXL GH-1, Grid Heater 1 1
Sep Htr
GND-ENG1, STRT, FFH, Water
0 GB Starter Relay Control Ground Bk 1.0 SXL SRC-1, Relay 2 1
Sep Htr
SPL-TRN-GND, Spl Trans
0 HC Trans Splice Grounds Bk 1.0 SXL A TRAN-E, Trans to Engine 2
Ground
0 HD Speed Sensor Grounds Bk 1.0 SXL TRANS, Cab Transmission 11 SPL-H2, Ultrasonic A
0 HE Output Speed Sensor Grnd Bk 1.0 SXL TRANS, Cab Transmission 28 OSS, Out Speed Sensor 1
Bk 0.8 GXL
0 HF Engine Speed Sensor Grnd ESS, Engine Speed Sensor 2 SPL-H2, Ultrasonic A
Twist

Copyright ©
4002-14

21C Bk - 1.0


Color, Size,
and Material
Bk 0.8 GXL
0 HG Inter Speed Sensor Grnd ISS, Inter Speed Sensor 2 SPL-H2, Ultrasonic A
Twist
Bk 0.8 GXL
0 HH Turbine Speed Sensor Grnd TSS, Turbine Speed Sensor 2 SPL-H2, Ultrasonic A
Twist
0 HL Redundant Brake Switch Grnd Bk 1.0 SXL PRB2, Redundant Brake Sw B SPL-TRN-GRD, Spl Trans Grd E
0 HM Redundant Brake Switch Grnd Bk 1.0 SXL PRB1, Redundant Brake Sw B SPL-TRN-GRD, Spl Trans Grd F
0 HP Sec. Steering Splice Grnd Bk 1.0 SXL TRAN-E, Trans to Engine 1 TR-SS, Sec. Steering Module Opt D
0 HV Coolant Level Sender Grnd Bk 1.0 SXL CLS, Cool Jump Cool Sender B SPL-TRN-GRD, Spl Trans Grd D
HOT, Hydraulic Oil Temp

0 HW Hot Ground Bk 1.0 SXL B SPL-TRN-GRD, Spl Trans Grd C
Send
0 JA Hood Grounds (EURO) Bk 1.0 SXL HD-E, Hood Trans C SPL-J1, Ultrasonic A
0 JA N Hood Grounds (NA) Bk 1.0 SXL HD-N, Hood to Engine 1 SPL-J1, Ultrasonic A
0 JB Backup Alarm Grnd Bk 1.0 SXL BU1, Backup Alarm Grnd 1 SPL-J1, Ultrasonic A
0 JC License Plate Light Grnd Bk 1.0 SXL LPL, Lic Plate Light B SPL-J1, Ultrasonic A
0 LA Rear Light Grnd Bk 1.0 SXL HD-9, Hood to Engine 1 SPL-B1, Ultrasonic A
0 LB Rear Light Grnd Bk 1.0 SXL LLR-9, LH Rear Comb Light 5 SPL-B1, Ultrasonic A
0 LC Rear Light Grnd Bk 1.0 SXL SPL-B1, Ultrasonic A LRR-9, RH Rear Comb Light 5
0 LD Rear Light Grnd Bk 1.0 SXL SPL-B1, Ultrasonic A E-HD9, Trans Hood C
0 MA Rear Wiper Motor Grnd Bk 1.0 GXL SPL-ROOF, Spl Rood Grnd F RWMG, Rear Wiper Motor Grnd A
0 MB Dome Light Grnd Bk 0.8 GXL LDM3, Dome Light Grnd 1 SPL-ROOF, Spl Rood Grnd B
0 MC Beacon Light Grnd Bk 1.0 GXL LBEGRD, Light Beacon Grnd 1 SPL-ROOF, Spl Rood Grnd A
0 MD Beacon Light Grnd Bk 1.0 GXL LBEE, Lgt Beacon Extension B LBEG, Light Beacon Grnd 1
0 ME LH Rear Work Light Grnd Bk 1.0 GXL LLRW, LH Rear Work Light B SPL-ROOF, Spl Rood Grnd D
0 MF RH Rear Work Light Grnd Bk 1.0 GXL LRRW, RH Rear Work Light B SPL-ROOF, Spl Rood Grnd E
0 MJ RH Front Work Light Grnd Bk 1.0 GXL LRFW, RH Front Work Light B SPL-ROOF, Spl Rood Grnd J
0 MK Roof Grounds Bk 1.0 GXL ROOF, Roof to Cab Conn. G SPL-ROOF, Spl Rood Grnd M
0 MN Roof Grounds Bk 1.0 GXL ROOF, Roof to Cab Conn. F SPL-ROOF, Spl Rood Grnd L
0 MU LH Front Work Light Grnd Bk 1.0 GXL LLFW, LH Front Work Light B SPL-ROOF, Spl Rood Grnd C
0 NB Master Disconnect Grnd Bk 62.0 SGR DC2, Discon Black Grnd 1 STTR-GRN, Grid Heater Fuse 1
0 NC Battery Disconnect Bk 62.0 SGR BT4, Discon Black Grnd 1 DC1, Disconnect Battery 1
242F, Chassis Grnd Sec. GND-SSCHAS, SSM Ground

0 ND SSM Ground Bk 62.0 SGR 1 1
Strg Motor Cable

Copyright ©
4002-15

21C Bk - 1.0


Color, Size,
and Material
0 PA Left Speaker Grnd Bk 0.8 GXL LSPK, Left Speaker 2 SPK, Speaker 8
0 PB Right Speaker Grnd Bk 0.8 GXL RSPK, Right Speaker 2 SPK, Speaker 2
12ACC Ignition Switch ACC Power W 0.8 GXL S-KEY, Ignition Switch 4 SPL-ACC, Ultrasonic A
12ACC
ACC PRM control Power W 0.8 GXL SPL-ACC, Ultrasonic A PRM-D1, PRM Signal A
B
12ACC Power Converter PRM Control
W 0.8 GXL SPL-ACC, Ultrasonic A PRM-E2, PRM Signal A
C Power
12V 12V Pwr To Outlet 1 Or 1.0 GXL PO1, Power Outlet A ECD, Elect Center D AA4
12V A 12V Pwr To Outlet 2 Or 1.0 GXL PO2, Power Outlet A ECD, Elect Center D AA5
12V B 12V Fused Pwr to Radio Or 1.0 GXL CAB-RF, Cab to Roof Conn. N ECD, Elect Center D AA6
12V C 12V Switched Power Or 2.0 GXL CNV, 24V to 12V Pwr Conver 5 SPL-12V, Ultrasonic A
12V D Plug 1 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECD, Elect Center D A4
12V E Plug 2 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECD, Elect Center D A5
12V F Radio 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECD, Elect Center D A6
12V G 2 Way Radio 12V Switched Pwr Or 1.0 GXL SPL-12V, Ultrasonic A ECD, Elect Center D A7
12V H 12V Fused Power to Radio Or 0.8 GXL ROOF, Roof to Cab Conn. N SPL-RAD, Ultrasonic A
12V
12V Fused Power to Radio Or 0.8 GXL SPL-RAD, Ultrasonic A RAD, Radio Power 7
HA
12V
12V Fused Power to Radio Or 0.8 GXL SPL-RAD, Ultrasonic A RAD, Radio Power 4
HB
13C Fuel Shutoff Fused Power Or 1.0 SXL DC3, Fuel Solenoid Disc 1 DISC, Disconnect Engine A
13C A Fuel Shutoff Fused Power Or 1.0 SXL ENG-D, Disc Harness A ENG, Engine Cab 21
13C B Fuel Shutoff Fused Power Or 1.0 SXL CAB-E, Cab Engine 21 ECA, Elect Center A A9
13D Time Delay Relay Control Pwr Or 1.0 SXL TDM, Time Delay Module 1 PRM-B2, PRM Signal A
13H Time Delay Power Or 3.0 GXL SPL-DLY-RL, Ultrasonic A PRM-B1 PRM Output C
13H B AIC Time Delay Power Or 0.8 GXL SPL-DLY-RL, Ultrasonic A ECD, Elect Center D A3
13H C Trans ECM Time Delay Power Or 0.8 GXL SPL-DLY-RL, Ultrasonic A ECD, Elect Center D A1
13H D Engine ECM Time Delay Power Or 3.0 GXL SPL-DLY-RL, Ultrasonic A ECD, Elect Center D A2
13K Ignition Switch Pwr Or 1.0 GXL S-KEY, Ignition Switch 3 SPL-PK1, Slice 3-4 Way E
13K A Ignition Switch Pwr Or 1.0 GXL TDM, Time Delay Module 5 SPL-PK1, Slice 3-4 Way G
13K B Ignition Switch Pwr Or 1.0 GXL SPL-PK1, Slice 3-4 Way F PRM-A1, PRM Signal A
13K C Ignition Switch Pwr Or 1.0 GXL SPL-PK1, Slice 3-4 Way H ECB, Elect Center B D1

Copyright ©
4002-16

21C Bk - 1.0


Color, Size,
and Material
13M Fuel Shutoff Fused Power Or 1.0 SXL DC4, Fuel Sol Disconnect 1 DISC, Disconnect Engine B
13M A Fuel Shutoff Fused Power Or 0.8 TXL ENG-D, Disconnect Harness B EDC7, Engine Controller 40
13M B Key Switch Power Disc Sw Or 1.0 GXL ENG-D, Disconnect Harness B QSM11, Engine Controller 38
13V Voltmeter Input ANALOG Or 0.8 TXL AIC-1, Adv Instr Cluster 1 1 ECB, Elect Center B D2
14 A Alternator D+ LG 0.8 GXL CAB-E, Cab Engine 26 215F, Alternator Resistor 1
17P A Switch Pad Power From AIC Pwr Or 0.8 TXL SW-PD, Switch Pad 9 AIC-1, Advanced Instr Cluster 25
18B LH High Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 7 LLF, Lights LH 3
18B A LH High Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 7 ECB, Elect Center B AA3
18C RH High Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 16 LRF, Lights RH 3
18C A RH High Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 16 ECB, Elect Center B AA4
18D LH Low Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 14 LLF, Lights LH 2
18D A LH Low Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 14 ECB, Elect Center B AA6
18E RH Low Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 15 LRF, Lights RH 2
18E A RH Low Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 15 ECB, Elect Center B AA5
18F LH Position/Tail Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 6 LLF, Lights LH 4
18F A LH Position/Tail Fused Power Or 0.8 GXL CAB-E, Cab Engine 5 SPL-POS-L, Ultrasonic
18F
LH Position/Tail Fused Power Or 1.0 SXL ENG, Engine Cab 5 ENG-H, Engine to Hood 6
AN
18F B LH Position/Tail Fused Power Or 1.0 SXL ENG, Engine Cab 5 LLR-E, LH Rear Comb Light 3
18F LLR-N LH Rear Combination
LH Position/Tail Fused Power Or 1.0 SXL HD-N, Hood to Engine 6 B
BN Light
18F C LH Position/Tail Fused Power Or 1.0 GXL SPL-POS-L, Ultrasonic ECB, Electric Center B AA7
18F E LH Position/Tail Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 6 SPL-POS-L, Ultrasonic
18F F LH Position/Tail Fused Power Or 1.0 SXL HD-9, Hoof to Engine 6 LLR-9, LH Rear Comb Light 3
18G RH Position/Tail Fused Power Or 1.0 GXL SPL-POS-R, Ultrasonic ECB, Elect Center B AA8
18G A RH Position/Tail Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 5 LRF, Lights RH 4
18G LRR-N, RH Rear Combination
RH Position/Tail Fused Power Or 1.0 SXL SPL-POS-NA, Ultrasonic A B
CN Light
18G D Licence Plate Light Fused Pwr Or 1.0 SXL SPL-POS, Ultrasonic A E-HD, Trans Hood A
18G E Licence Plate Light Fused Pwr Or 0.8 GXL HD-E, Hood Trans A LPL, Licence Plate Light A
18G
Licence Plate Light Fused Pwr Or 1.0 SXL LPL, Licence Plate Light A SPL-POS-NA, Ultrasonic A
EN

Copyright ©
4002-17

21C Bk - 1.0


Color, Size,
and Material
18G F RH Position/Tail Fused Power Or 0.8 GXL CAB-E, Cab Engine 9 SPL-POS-R, Ultrasonic
18G G RH Position/Tail Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis A SPL-POS-R, Ultrasonic
18G H RH Position/Tail Fused Power Or 1.0 SXL ENG, Engine Cab 9 SPL-POS, Ultrasonic A
18G
RH Position/Tail Fused Power Or 1.0 SXL ENG, Engine Cab 9 ENG-H, Engine to Hood 5
HN
18G J RH Position/Tail Fused Power LRR-E, RH Rear 3 A

Or 1.0 SXL SPL-POS, Ultrasonic
Combination Light
18G
RH Position/Tail Fused Power Or 1.0 SXL HD-N, Hood to Engine 5 SPL-POS-NA, Ultrasonic A
JN
18G K RH Position/Tail Fused Power Or 1.0 SXL HD-N, Hood to Engine 5 SPL-P9, Ultrasonic A
18G L RH Position/Tail Fused Power Or 1.0 SXL SPL-P9, Ultrasonic A E-HD9, Trans Hood A
LRR-9, RH Rear Combination

18G M RH Position/Tail Fused Power Or 1.0 SXL SPL-P9, Ultrasonic A 3
Light
18J EDC7 Time Delay Fused Power Or 2.0 GXL CAB-E, Cab Engine 18 SPL-D2, Ultrasonic A
18J A EDC7 Time Delay Fused Power Or 2.0 GXL ENG, Engine Cab 18 SPL-EDC2, Ultrasonic A
18J B EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 3
18J C EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 2
18J D EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC4, Ultrasonic A EDC7, Engine Controller 8
18J E EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC4, Ultrasonic A EDC7, Engine Controller 9
18J F EDC7 Time Delay Fused Power Or 2.0 SXL ENG, Engine Cab 14 SPL-EDC4, Ultrasonic A
18J G EDC7 Time Delay Fused Power Or 2.0 GXL CAB-E, Cab Engine 14 SPL-D2, Ultrasonic A
18J H Water In Fuel Sensor Fused Pwr Or 1.0 GXL SPL-EDC4, Ultrasonic A WIF, Water In Fuel Sensor 3
18J K EDC7 Time Delay Fused Power Or 3.0 GXL SPL-D2, Ultrasonic A ECD, Elect Center D AA2
18J L QSM11 Time Delay Power Or 0.8 GXL SPL-EDC4, Ultrasonic A QSM11, Engine controller 17
18J M QSM11 Time Delay Power Or 0.8 GXL SPL-EDC2, Ultrasonic A QSM11, Engine controller 7
18J N QSM11 Time Delay Power Or 0.8 GXL SPL-EDC2, Ultrasonic A QSM11, Engine controller 8
18J P QSM11 Time Delay Power Or 0.8 GXL SPL-EDC4, Ultrasonic A QSM11, Engine controller 18
18J Q QSM11 Time Delay Power Or 0.8 GXL SPL-EDC4, Ultrasonic A QSM11, Engine controller 28
18K A Diagnostic Fused Power Or 0.8 GXL DIA, Diagnostic B ECC, Work Lights A9
18L A Comfort Steer Fused Power Or 0.8 GXL SPL-CSTR, Ultrasonic A ECA, Elect Center A A2
18L B Comfort Steer Fused Power Or 0.8 GXL SPL-CSTR, Ultrasonic A ECC, Work Lights D9
18L C Comfort Steer Fused Power Or 0.8 GXL SPL-CSTR, Ultrasonic A ECC, Work Lights B9

Copyright ©
4002-18

21C Bk - 1.0


Color, Size,
and Material
18L D Comfort Steer Fused Power Or 0.8 GXL SCS, Comfort Steer Switch 2 SPL-CSTR, Ultrasonic A
18M AC Relay Fused Power Or 0.8 GXL ECA, Elect Center A C5 ECD, Elect Center D B9
18N Blower Motor Fused Power Or 3.0 GXL SPL-BLWR, Ultrasonic A ECA, Elect Center A C1
18N A Blower Motor Fused Power Or 0.8 GXL SPL-BLWR, Ultrasonic A HVAC1, HVAC1 2
18N B Blower Motor Fused Power Or 3.0 GXL SPL-BLWR, Ultrasonic A HVAC2, HVAC2 1
18R Voltmeter Relay Fused Power Or 2.0 SXL ENG, Engine Cab 13 PRM-C1, PRM Output A
18R A Voltmeter Relay Fused Power Or 2.0 GXL CAB-E, Cab Engine 13 ECB, Elect Center B B1
19A Output Speed Sensor Fused Pwr Or 1.0 SXL TRANS, Cab Transmission 29 OSS, Out Speed Sensor 3
19A A Brake Declutch Sw Fused Pwr Or 1.0 SXL FRONT, Cab Front Chassis 27 PBD, Dec. Pressure Switch A
19A B FNR Switched Fused Power Or 0.8 GXL 197M, FNR Main Cab 1 SPL-FNR, Ultrasonic A
19A C FNR Switched Fused Power Or 0.8 GXL 197F, Main Cab FNR 1 SPL-TRNS-PWR, Trans Pwr F
19A D Trans Enable Switch Fused Pwr Or 0.8 GXL STE, Trans Enable Switch 2 SPL-D15, Ultrasonic A
19A E Trans Enable Switch Fused Pwr Or 0.8 GXL STE, Trans Enable Switch 10 SPL-D15, Ultrasonic A
19A F Trans Enable Switch Fused Pwr Or 0.8 GXL SPL-TRNS-PWR, Trans Pwr B SPL-D15, Ultrasonic A
19A G FNR Sw Fused Power Or 0.8 GXL SPL-FNR, Ultrasonic A SFNR, FNR Switch 8
19A H Trans Shifter Fused Power Or 0.8 GXL TS1, Transmission Shifter A SPL-TRNS-PWR, Trans Pwr M
19A J Pilot Control Switched Fused Or 0.8 GXL SPC, Pilot Control Switch 2 SPL-PB1, Ultrasonic A
Pwr
SPL-TRANS-PWR, Trans
19A K TECM Fused Power Or 0.8 TXL J TECM, Trans 45
Pwr
19A L Park Brake Switched Fused Pwr Or 0.8 GXL SPB, Parking Brake Switch 2 SPL-PB1, Ultrasonic A
19A M Output Speed Sensor Fused Pwr Or 0.8 TXL CAB-T, Cab Transmission 29 SPL-TRNS-PWR, Trans Power K
19A N Trans Fused Power Or 1.0 GXL A ECA, Elect Center A A1
Pwr
19A P Backup Alarm Relay Control Bk 1.0 GXL

SPL-TRANS-PWR, Trans G ECD, Elect Center D AA10
Fused Power Pwr
19A Q Trans/Auto Switch Fused Power Or 0.8 GXL STA, Trans Auto Switch 2 SPL-TRANS-PWR, Trans Pwr C
19A R Declutch Switch Fused Power Or 0.8 GXL SDC, Declutch Switch 2 SPL-TRANS-PWR, Trans Pwr H
19A S Trans Fused Power Or 0.8 GXL L SPL-PB1, Ultrasonic A
Pwr
19A T Brake Declutch Switch Fused Or 0.8 GXL CAB-F, Cab Front Chassis 27 SPL-TRANS-PWR, Trans Pwr D
Power

Copyright ©
4002-19

21C Bk - 1.0


Color, Size,
and Material
19A U Trans Dick Down Switch Fused Or 0.8 GXL SPL-FNR, Ultrasonic A 20M, Trans Kick Down 1
Power
19A V FNR Switch Fused Power Or 0.8 GXL SFNR, FNR Switch 5 SPL-FNR, Ultrasonic A
19A W Diagnostic Conn. Fused Power Or 0.8 GXL 108F, Diagnostic Connector 1 SPL-TRANS-PWR, Trans Pwr E
19B Turn Signal Fused Power Or 0.8 GXL SRHSTLK, RH Stalk Switch 49a ECA, Elect Center A A8
19C A Pilot Ctrl Fused Pwr Or 1.0 GXL SPL-D24, Ultrasonic A ECA, Elect Center A A5
19C B Pilot Ctrl Fused Pwr Or 1.0 GXL SPL-D24, Ultrasonic A ECD, Elect Center D B5
19C C Pilot Ctrl Fused Pwr Or 0.8 GXL SPL-D24, Ultrasonic A ECD, Elect Center D D5
19C D Ride Control Fused Pwr Or 1.0 GXL SRC, Ride Control Switch 2 SPL-D24, Ultrasonic A
19D A Parking Brake Relay Fused Pwr Or 1.0 GXL SPL-PBS, Ultrasonic A ECA, Elect Center A A6
19D B Parking Brake Relay Fused Pwr Or 0.8 GXL SPL-PBS, Ultrasonic A ECB, Elect Center B D9
19D C Parking Brake Relay Fused Pwr Or 1.0 GXL SPL-PBS, Ultrasonic A ECB, Elect Center B B9
19E A AIC Wake Up Ignition Or 0.8 TXL AIC-2, Adv Instr Cluster 2 21 ECA, Elect Center A A3
19H Backup Alarm Relay Fuse Pwr Or 1.0 GXL ECA, Elect Center A C4 ECD, Elect Center D A10
19J Front Wiper Fused Pwr Or 0.8 GXL SPL-PK3, Splice 3-4 Way K ECA, Elect Center A C2
19J A Front Wiper Motor Fused Pwr Or 0.8 GXL SPL-PK3, Splice 3-4 Way M FWM, Front Wiper Motor C
19J B Front Wip Wash Sw Fused Pwr Or 0.8 GXL SFWW, Front Wiper/Washer 5 SPL-PK3, Splice 3-4 Way J
19J C Front Wiper Relay Fused Power Or 0.8 GXL SPL-PK3, Splice 3-4 Way L SPL-FW, Ultrasonic A
19J D Front Wiper Relay HS Control Or 0.8 GXL SPL-FW, Ultrasonic A ECD, Elect Center D D1
Fused Power
19J E Front Wiper Relay Fused Power Or 0.8 GXL SPL-FW, Ultrasonic A ECD, Elect Center D B1
Front Wiper Relay LS Control

19J F Or 0.8 GXL SPL-FW, Ultrasonic A ECD, Elect Center D D3
Fused Power
19J G Wiper Cutout Relay Fused Pwr Or 0.8 GXL SPL-FW, Ultrasonic A K-WCO, Wiper Cutout 86
19K Rear Wiper Fused Pwr Or 1.0 GXL SPL-RWW, Ultrasonic A ECA, Elect Center A C3
19K A Rear Wiper Sw Fused Pwr Or 1.0 GXL SRWP, Rear Wiper Sw 3 SPL-RWW, Ultrasonic A
19K B Rear Wip Wash Fused Pwr Or 0.8 GXL SRWP, Rear Wiper Sw 5 SPL-RWW, Ultrasonic A
CAB-RF, Cab to Roof

19K C Rear Wiper Motor Fused Pwr Or 1.0 GXL J SPL-RWW, Ultrasonic A
Connect
19K D Rear Wiper Motor Fused Pwr Or 1.0 SXL ROOF, Roof to Cab Connect J RWM, rear Wiper Motor C
19L Pwr Converter Fused Power Or 2.0 GXL PRM-E1, PRM Output C SPL-CNV, Ultrasonic A
19L A Pwr Converter Fused Power Or 2.0 GXL CNV, 24V to 12V Pwr Conver 1 SPL-CNV, Ultrasonic A

Copyright ©
4002-20

21C Bk - 1.0


Color, Size,
and Material
19L B Pwr Converter Fused Power Or 2.0 GXL CNV, 24V to 12V Pwr Conver 2 SPL-CNV, Ultrasonic A
Sec. Steering Accessory Fused

19M Or 0.8 GXL CAB-T, Cab Transmission 3 ECA, Elect Center A C7
Pwr
19M A Sec. Steering Accessory Fused Or 1.0 SXL TRANS, Cab Transmission 3 TR-SS, Sec. Steering Module Opt A
Pwr
19M C Sec. Steering Accessory Fused Or 1.0 SXL SSM, Sec. Steering Module 7 SS-TR, Sec. Steering Mod Trans A
Pwr
19N Seat Compressor Fused Pwr Or 1.0 GXL SC, Seat Compressor Motor A ECA, Elect Center A C6
19P Pin Engage/Fan Fused Pwr Or 0.8 GXL SPL-PIN, Spl Back Lgt Pwr B ECA, Elect Center A A7
19P A Pin Engage Sw Fused Pwr Or 0.8 GXL SPE, Pin Engage Sw 2 SPL-PIN, Spl Back Lgt Pwr A
19P C Fan Rev Sw Fused Pwr Or 0.8 GXL SFC, Fan Control Switch 5 SPL-PIN, Spl Back Lgt Pwr C
19P D Fan Rev Relay Fused Pwr Or 0.8 GXL SPL-PIN, Spl Back Lgt Pwr E ECB, Elect Center B D7
19P E Fan Rev Relay Fused Pwr Or 0.8 GXL SPL-PIN, Spl Back Lgt Pwr F ECB, Elect Center B B7
19R Sec. Steering Ign Fused Pwr Or 0.8 GXL DM, Diode OR C SPL-2 Ultrasonic A
19RR Sec. Steering Ign Fused Pwr Or 0.8 GXL DM, Diode OR A ECA, Elect Center A A4
19R A Sec. Steering Ign Fused Pwr Or 1.0 SXL TRANS, Cab Transmission 4 TR-SS, Sec. Steering Module Opt B
19R C Sec. Steering Ign Fused Pwr Or 1.0 SXL SSM, Sec. Steering Module 1 SS-TR, Sec. Steering Mod Trans B
19R D Alternator Resistor Fused Pwr Or 0.8 GXL SPL-2, Ultrasonic A 216F, Alternator Resistor 1
19R E Sec. Steering Ign Fused Pwr Or 0.8 GXL SPL-2, Ultrasonic A CAB-T, Cab Transmission 4
19S1 Sec. Steering Fused Pwr Or 1.0 GXL SS, Sec. Steering Fused Pwr 1 CAB-T, Cab Transmission 26
19S1 E Sec. Steering Fused Pwr Or 1.0 SXL TRANS, Cab Transmission 26 TR-SS, Sec. Steering Module Opt E
SS-TR, Sec. Steering Module

19S1 X Sec. Steering Fused Pwr R 1.0 SXL SSM, Sec. Steering Module 3 E
Trans
19S B AIC Delay Fused Power Or 0.8 GXL SPL-DKY3, Ultrasonic A ECD, Elect Center D AA3
19S C AIC Delay Fused Power Or 0.8 TXL SPL-DKY3, Ultrasonic A AIC-2, Advanced Instr Cluster 2 20
19S D AIC Delay Fused Power Or 0.8 TXL SPL-DKY3, Ultrasonic A AIC-2, Advanced Instr Cluster 2 14
19T A TECM Delay Fused Power Or 0.8 TXL TECM, Trans 23 ECD, Elect Center D AA1
19U Horn Relay Fused Power Or 0.8 GXL SPL-HRN, Ultrasonic A ECC, Work Lights A6
19U A Horn Relay Fused Power Or 0.8 GXL SPL-HRN, Ultrasonic A ECC, Work Lights B7
19U B Beacon Dome Lt Fused Pwr Or 1.0 GXL SPL-LT, Ultrasonic A ECC, Work Lights A1
ROOF, Roof to Cab

19U C Dome Lt Fused Pwr Or 0.8 GXL D LDM1, Dome Light B+ 1
Connection

Copyright ©
4002-21

21C Bk - 1.0


Color, Size,
and Material
CAB-RF, Cab to Roof
19U D Dome Lt Fused Pwr Or 0.8 GXL D SPL-LT, Ultrasonic A
Connection
19U E Horn Relay Fused Power Or 0.8 GXL SPL-HRN, Ultrasonic A ECC, Work Lights D7
ROOF, Roof to Cab

19U F Door Sw Fused Power Bk 0.8 GXL S DS, Door Switch A
Connection
CAB-RF, Cab to Roof
19U G Door Sw Fused Power Or 0.8 GXL S SPL-LT, Ultrasonic A
Connection
19U H Beacon Switch Fused Power Or 1.0 GXL SBE, Beacon Switch 2 SPL-LT, Ultrasonic A
19W Cigar Lighter Pwr Or 3.0 GXL CL, Cigar Lighter 1 ECC, Work Lights A8
19Y Hood control Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Work Lights A7
19Y A Hood Up Relay Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Work Lights D2
19Y B Hood Down Relay Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Work Lights D4
19Y C Hood Switch Fused Power Or 1.0 GXL CAB-E, Cab Engine 35 SPL-HOOD, Ultrasonic A
19Y D Hood Switch Fused Power Or 1.0 GXL ENG, Engine Cab 35 HD, Hood Switch B
19Z Driving Lights Sw Fused Power Or 1.0 GXL SPL-PK2, Splice 3-4 Way G ECC, Work Lights A3
19Z A Driving Lights Sw Fused Power Or 1.0 GXL SDR, Driving Lights Sw 2 SPL-PK2, Splice 3-4 Way E
19Z B Driving Lights Sw Fused Power Or 1.0 GXL SDR, Driving Lights Sw 5 SPL-PK2, Splice 3-4 Way F
19Z C High Beam Flash Fused Power Or 1.0 GXL SRHSTLK, RH Stalk Switch 56d SPL-PK2, Splice 3-4 Way H
1A Ign Switch Fused Power R 1.0 GXL S-KEY, Ignition Switch 1 SPL-DLY, Ultrasonic A
1CB Cab CB Protected Power R 19.0 SXL CB1A, Circuit Breaker 1 CBPW, Cab Power 1
1CB A Cab CB Protected Power R 19.0 SXL P-A3, B+ Power 1 CAB-PW, Cab Power 1
1DM Time Delay/Ign Sw Fused Pwr R 1.0 GXL SPL-DLY, Ultrasonic A ECC, Work Lights A5
1DN Time Delay Fused Power R 1.0 GXL TDM, Time Delay Module 2 SPL-DLY, Ultrasonic A
1NC Cab CB PRM Power R 19.0 SXL B1, Starter Power Stud 1 CB2B, Cab B+ CB 1
1 AA Brake Lt Sw Pwr R 1.0 SXL FRONT, Cab Front Chassis 22 PBL, Brake Light Press Switch 1
1 B9 PRM C Power R 8.0 SXL CB3B, Cab B+ CB 1 P-C5, B+ Power from PRMC 1
1 BA Alternator B+ R 13.0 SXL AB+, Alternator B+ 1 B2 Starter Power 1
1 BB Starter Solenoid Pwr R 8.0 SXL 193 Starter Relay 1 194 Starter Signal 1
1 BC Cab CB Power R 19.0 SXL P-C3, B+ Power From PRMC 1 CB1B, Cab B+ CB 1
1 BE Grid Htr Pwr R 19.0 SXL 115 Grid Htr Pwr 1 GH, Grid Htr 1
1C ECC Bat Power R 8.0 GXL P-A1, B+ Power 1 L1-ECC, ECC Battery Power cs01
1 DR Brake Light Switch Power R 1.0 GXL CAB-F, Cab Front Chassis 22 SPL-FLSHR-PWR, Ultrasonic A

Copyright ©
4002-22

21C Bk - 1.0


Color, Size,
and Material
1 DU Flasher Module Pwr R 1.0 GXL FLSHR, Flasher Module 1 SPL-FLSHR-PWR, Ultrasonic A
SPL-FLSHR-PWR,
1 DV Brake Lights/Flasher Bat Pwr R 2.0 GXL A ECC, Work Lights A4
Ultrasonic
SPL-FLSHR-PWR,
1 DW Brake Lt Relay Bat Pwr R 1.0 GXL A ECC, Work Lights B5
Ultrasonic
1E Grid heater Fuse Bat Power R 19.0 SXL P-C2, B+ Power from PRMC 1 GHF1, Grid Heater Fuse 1
1 GA Filter Htr Pwr R 3.0 SXL PRM-C1, PRM Output C SPL-HTR, Ultrasonic A
1 GB Fuel Filter Htr Pwr R 2.0 SXL SPL-HTR, Ultrasonic A FFH, Fuel Filter Heater A
1 GC Water Sep Htr Pwr R 2.0 SXL SPL-HTR, Ultrasonic A WSH, Water Separator Heater B
1 KA Hazard Switch Pwr R 1.0 GXL SHZ, Hazard Switch 2 SPL-FLSHR-PWR, Ultrasonic A
1 NA Battery Crossover R 62.0 SGR BT3, Starter Battery 1 BT2, Disconnect Battery 1
1 NB Battery Starter R 62.0 SGR BT1, Battery Starter 1 B3, Starter Battery 1
1 NC B+ Power PRMC R 19.0 SXL B1, Starter Power Stud 1 P-C1, B+ Power From PRMC 1
1 ND SSM Power R 62.0 SGR 244F Starter Sec. Strg Mtr 1 B4, Starter Power 1
1Y Grid Heater Fused Power R 19.0 SXL GHF3, Grid heater Fuse 1 GHF4, Grid Heater 1
1Z Starter Relay Battery Power R 8.0 SXL P-C4, B+, Power From PRMC 1 195, Starter Relay Power 1
20G A EDC7 ESO-K Interface W 0.8 TXL ENG, Engine Cab 31 EDC7, Engine Controller 89
20G B EDC7 ESO-K Interface W 0.8 GXL CAB-E, Cab Engine 31 DIA, Diagnostic E
21C Neutral Start Relay Output W 0.8 GXL SPL-CR, Ultrasonic A ECB, Elect Center B D4
21C A Neutral Start Relay Output W 0.8 GXL SPL-CR, Ultrasonic A ECB, Elect Center B D5
21C B Neutral Start Relay Output W 0.8 GXL SPL-CR, Ultrasonic A ECB, Elect Center B A10
21C C Starter Relay Signal W 0.8 GXL CAB-E, Cab Engine 1 SPL-CR, Ultrasonic A
21C D Starter Relay Signal W 1.0 SXL SR-9, Starter Relay Signal 1 ENG, Engine Cab 1
21D Starter Relay Signal W 1.0 SXL SRC-1, Relay 1 ENG, Engine Cab 15
21D A Starter Relay Signal W 0.8 GXL SPL-4, Ultrasonic A ECB, Elect Center B AA9
21D B Starter Relay Signal W 0.8 GXL 140M, Diode Module E SPL-4, Ultrasonic A
21D C Starter Relay Signal W 0.8 GXL CAB-E, Cab Engine 15 SPL-4, Ultrasonic A
21E Key Switch Crank W 0.8 GXL CAB-E, Cab Engine 27 ECB, Elect Center B D6
21E A Key Switch Crank W 0.8 TXL ENG, Engine Cab 27 EDC7, Engine Controller 32
21F EDC7 Digital Ground W 0.8 GXL CAB-E, Cab Engine 11 ECB, Elect Center B B5
21F A EDC7 Digital Ground W 0.8 GXL ENG, Engine Cab 11 SPL-EDC3, Ultrasonic A

Copyright ©
4002-23

21C Bk - 1.0


Color, Size,
and Material
21F B EDC7 Digital Ground W 0.8 TXL SPL-EDC3, Ultrasonic A EDC7, Engine Controller 29
21F C EDC7 Digital Ground W 0.8 TXL RTHP, Throttle Pedal 1 SPL-EDC3, Ultrasonic A
21G EDC7 Crank Control relay W 0.8 GXL CAB-E, Cab Engine 3 ECB, Elect Center B AA10
21G A EDC7 Crank Control relay W 0.8 TXL ENG, Engine Cab 3 EDC7, Engine Controller 37
21H Crank control relay LSD W 0.8 GXL CAB-E, Cab Engine 4 ECB, Elect Center B A9
21H A Crank control relay LSD W 0.8 TXL ENG, Engine Cab 4 EDC7, Engine Controller 17
21K Ign Sw Start Signal W 0.8 GXL S-KEY, Ignition Switch 2 SPL-CRK, Ultrasonic A
21K A Ign Sw Start Signal W 0.8 TXL SPL-CRK, Ultrasonic A AIC-2, Adv Instrument Cluster 2 17
21K B Ign Sw Start Signal W 0.8 GXL SPL-CRK, Ultrasonic A ECB, Elect Center B B3
24B Throttle Signal W 0.8 TXL RTHP, Throttle Pedal 3 EDC7, Engine Controller 79
24B A Throttle Signal W 0.8 TXL RTHP, Throttle Pedal 3 QSM11, Engine Controller 47
24L Low Idle Sw W 0.8 TXL RTHP, Throttle Pedal 6 EDC7, Engine Controller 48
24R Throttle Pos Sens Grnd W 0.8 TXL RTHP, Throttle Pedal 4 EDC7, Engine Controller 78
24R A Throttle Pos Sens Grnd W 0.8 TXL RTHP, Throttle Pedal 4 QSM11, Engine Controller 49
24S Throttle Supply W 0.8 TXL RTHP, Throttle Pedal 5 EDC7, Engine Controller 77
24S A Throttle Supply W 0.8 TXL RTHP, Throttle Pedal 5 QSM11, Engine Controller 48
W 0.8 GXL
25A Eng Speed Sig TRANS, Cab Transmission 7 ESS, Engine speed Sensor 1
Twist
25A A Eng Speed Sig LU 0.8 TXL CAB-T, Cab Transmission 7 TECM, Trans 19
W 0.8 GXL
25B Int Speed Sig TRANS, Cab Transmission 9 ISS, Int Speed Sensor 1
Twist
25B A Int Speed Sig LU 0.8 TXL CAB-T, Cab Transmission 9 TECM, Trans 42
W 0.8 GXL
25C Turbine Speed Sig TRANS, Cab Transmission 8 TSS, Turbine Speed Sensor 1
Twist
25C A Turbine Speed Sig LU 0.8 TXL CAB-T, Cab Transmission 8 TECM, Trans 41
25D Output Speed Sig LU 1.0 SXL TRANS, Cab Transmission 10 OSS, Output Speed Sensor 2
25D A Output Speed Sig LU 0.8 TXL CAB-T, Cab Transmission 10 TECM, Trans 62
25F Forward Signal LU 0.8 TXL TS1, Transmission Shifter B TECM, Trans 43
25G Brake Declutch Switch LU 1.0 SXL FRONT, Cab Front Chassis 28 PBD, Declutch Pressure Switch B
25G A Brake Declutch Switch LU 0.8 GXL CAB-F, Cab Front Chassis 28 SPL-DC, Ultrasonic A
25G B Brake Declutch Switch LU 0.8 GXL SDC, Declutch Switch 1 SPL-DC, Ultrasonic A
25G C Brake Declutch Switch LU 0.8 TXL SPL-DC, Ultrasonic A TECM, Trans 66

Copyright ©
4002-24

21C Bk - 1.0


Color, Size,
and Material
25H Trans Auto Signal LU 0.8 TXL STA, Trans Auto Switch 3 TECM, Trans 29
25J Trans Sol Valve Y6 LU 0.8 TXL TRANS, Cab Transmission 21 TRC, Trans Control 6
25J A Trans Sol Valve Y6 LU 0.8 TXL CAB-T, Cab Transmission 21 TECM, Trans 51
25K Trans Sol Valve Y1 LU 0.8 TXL TRANS, Cab Transmission 16 TRC, Trans Control 1
25K 9 Trans Sol Valve Y2 LU 0.8 TXL TRANS, Cab Transmission 16 TRC, Trans Control 2
25K A Trans Sol Valve Y1 LU 0.8 TXL CAB-T, Cab Transmission 16 TECM, Trans 56
25L Trans Sol Valve Y2 LU 0.8 TXL TRANS, Cab Transmission 17 TRC, Trans Control 2
25L 9 Trans Sol Valve Y1 LU 0.8 TXL TRANS, Cab Transmission 17 TRC, Trans Control 1
25L A Trans Sol Valve Y2 LU 0.8 TXL CAB-T, Cab Transmission 17 TECM, Trans 10
25M Trans Sol Valve Y3 LU 0.8 TXL TRANS, Cab Transmission 18 TRC, Trans Control 3
25M A Trans Sol Valve Y3 LU 0.8 TXL CAB-T, Cab Transmission 18 TECM, Trans 32
25N Trans Sol Valve Y4 LU 0.8 TXL TRANS, Cab Transmission 19 TRC, Trans Control 4
25N A Trans Sol Valve Y4 LU 0.8 TXL CAB-T, Cab Transmission 19 TECM, Trans 55
25P Trans Sol Valve Y5 LU 0.8 TXL TRANS, Cab Transmission 20 TRC, Trans Control 5
25P A Trans Sol Valve Y5 LU 0.8 TXL CAB-T, Cab Transmission 20 TECM, Trans 9
25R Reverse Signal LU 0.8 TXL TS1, Transmission Shifter C TECM, Trans 64
25S Output Sw Power VPS1 LU 0.8 TXL TRANS, Cab Transmission 22 TRC, Transmission Control 7
25S A Output Sw Power VPS1 LU 0.8 TXL CAB-T, Cab Transmission 22 SPL D12, Ultrasonic A
25S B Output Sw Power VPS1 LU 0.8 TXL SPL D12 Ultrasonic A TECM, Trans 12
25S C Output Sw Power VPS1 LU 0.8 TXL SPL D12 Ultrasonic A TECM, Trans 13
25T Neutral Signal LU 0.8 GXL SPL-NEU, Ultrasonic A ECB, Elect Center B D3
25T B Neutral Signal LU 0.8 GXL TS1, Transmission Shifter D SPL-NEU, Ultrasonic A
25T C Neutral Signal LU 0.8 TXL SPL-NEU, Ultrasonic A TECM, Trans 67
25W 3rd And 4th Gear Signal LU 0.8 TXL TS2, Transmission Shifter B TECM, Trans 65
25Y Trans Kick Down Signal LU 0.8 GXL TS2, Transmission Shifter D SPL D11, Ultrasonic A
25Y A Trans Kick Down Signal LU 0.8 TXL SPL D11, Ultrasonic A TECM, Trans 22
25Y B Trans Kick Down Signal LU 0.8 GXL 197F, Main Cab FNR 6 SPL D11, Ultrasonic A
25Y C Trans Kick Down Signal LU 0.8 GXL 20M, Trans Kick Down 2 197M, FNR Main Cab 6
25Z 1st And 4th Gear Signal LU 0.8 TXL TS2, Transmission Shifter C TECM, Trans 63
26E Trans Enable Signal LU 0.8 TXL STE, Trans Enable Switch 3 TECM, Trans 31
26F A FNR Forward Signal LU 0.8 GXL 197M, FNR Main Cab 2 SFNR, FNR Switch 6

Copyright ©
4002-25

21C Bk - 1.0


Color, Size,
and Material
26F B FNR Forward Signal LU 0.8 TXL 197F, Main Cab FNR 2 TECM, Trans 20
26J FNR Switch Jumper LU 0.8 GXL SFNR, FNR Switch 2 SFNR, FNR Switch 4
26N A FNR Neutral Signal LU 0.8 GXL SFNR, FNR Switch 3 197M, FNR Main Cab 3
26N B FNR Neutral Signal LU 0.8 TXL 197F, Main Cab FNR 3 TECM, Trans 44
26R A FNR Reverse Signal LU 0.8 GXL SFNR, FNR Switch 1 197M, FNR Main Cab 4
26R B FNR Reverse Signal LU 0.8 TXL 197F, Main Cab FNR 4 TECM, Trans 30
28E Ether Relay Signal W 1.0 SXL PRM-C2, PRM Signal A ENG, Engine Cab 16
28F Filter Htrs Relay Control W 0.8 TXL PRM-C2,PRM Signal A EDC7, Engine Controller 36
28G Grid Heater Source Dr. W 1.0 GXL GHC, Grid Htr Relay 1 EDC7, Engine Controller 12
28H Ether Switch Signal W 0.8 GXL CAB-E, Cab Engine 16 SETHR, Ether Switch 3
28J Ether AIC Ok Signal W 0.8 GXL SETHR, Ether Switch 2 AIC-1, Adv Instrument Cluster 1 19
28P Ether Solenoid Power W 1.0 SXL PRM-C1, PRM Output C ETHR, Ether Solenoid A
31D Coolant Level Signal Y 1.0 SXL TRANS, Cab Transmission 2 CLS, Cool Jump-Cool Send A
31D A Coolant Level Signal Y 0.8 TXL CAB-T, Cab Transmission 2 AIC-2, Adv Instrument Cluster 2 26
31D B Coolant Level Sender Eng Trans Y 1.0 SXL TRANS, Cab Transmission 2 TRAN-E, Trans to Engine 3
31D C Coolant Level Sender Eng Trans Y 1.0 SXL CLS, Cool Jump Cool Send A ENG-T, Engine to Trans 3
31F Air Filter Rest Sw Signal Y 1.0 SXL ENG, Engine Cab 28 PAF, Air Filter Rest Sw 1
31F A Air Filter Rest Sw Signal Y 0.8 TXL CAB-E, Cab Engine 28 SW-PD, Switch Pad 5
31H Hyd Filter Rest Sw Signal Y 1.0 SXL TRANS, Cab Transmission 23 PHF, Hyd Oil Filter Rest Sw 1
31H A Hyd Filter Rest Sw Signal Y 0.8 GXL SW-PD, Switch Pad 4 CAB-T, Cab Transmission 23
31L Pilot Control Switch High Y 0.8 TXL SPC, Pilot Control Switch 3 AIC-2, Advance Instr Cluster 2 18
32F Trans Filter Maint Sw Y 1.0 SXL TRANS, Cab Transmission 31 FM, Filter Maint Sw 1
32F A Trans Filter Maint Sw Y 0.8 TXL CAB-T, Cab Transmission 31 TECM, Trans 17
32J A Trans Enable Indiction Y 0.8 GXL SFNR, FNR Switch 7 197M FNR Main Cab 5
32J C Trans Enable Indiction Y 0.8 GXL STE, Trans Enable Switch 9 SPL-D16, Ultrasonic A
32J D Trans Enable Indiction Y 0.8 TXL SPL-D16, Ultrasonic A TECM, Trans 5
32J E Trans Enable Indiction Y 0.8 GXL 197F, Main Cab FNR 5 SPL-D16, Ultrasonic A
33P Brake Warning Press Low Y 1.0 SXL FRONT, Cab Front Chassis 26 PBW, Brake Warning Press Sw 1
33P A Brake Warning Press Low Y 0.8 TXL CAB-F, Cab Front Chassis 26 AIC-2, Advance Instr Cluster 2 5
Redundant Brake Accumulator

33R Y 0.8 TXL CAB-T, Cab Transmission 1 AIC-2, Advance Instr Cluster 2 4
Pressure Low

Copyright ©
4002-26

21C Bk - 1.0


Color, Size,
and Material
33R A Redundant Brake Accumulator Y 1.0 SXL TRANS, Cab Transmission 1 SPL-RD, Ultrasonic A
Pressure Low
33R B Redundant Brake Accumulator Y 1.0 SXL SPL-RD, Ultrasonic A PRB2, Redundant Brake Switch A
Pressure Low
33R C Redundant Brake Accumulator Y 1.0 SXL SPL-RD, Ultrasonic A PRB1, Redundant Brake Switch A
Pressure Low
33U Parking Brake Switch Y 0.8 TXL SPB, Parking Brake Switch 3 AIC-2, Advance Instr Cluster 2 6
35A 9 Backup Alarm Power Y 1.0 SXL HD-9, Hood to Engine 7 E-HD9, Transmission-Hood B
35A A Backup Alarm Relay Out Y 0.8 GXL SPL-PK1, Splice 3-4 Way L ECD, Elect Control D AA9
35A B Backup Alarm Disable Switch Y 0.8 GXL SBU, Backup Alarm Dis Sw 2 SPL-PK1, Splice 3-4 Way K
35A C Backup Alarm Relay Out Y 0.8 GXL CAB-E, Cab Engine 7 SPL-PK1, Splice 3-4 Way M
209M, Backup Alarm Dis

35A D Backup Alarm Relay Out Y 0.8 GXL A SPL-PK1, Splice 3-4 Way J
Jump
209F, Backup Alarm Dis
35A E Backup Alarm Relay Out Y 0.8 SXL A SPL-D8-C1, Ultrasonic A
Jump
35A F Backup Alarm Relay Out Y 0.8 SXL CAB-E, Cab Engine 40 SPL-D8-C1, Ultrasonic A
35A G Backup Alarm Relay Out Y 0.8 SXL ENG, Engine Cab 40 E-HD, Trans Hood B
35A
Backup Alarm Relay Out Y 1.0 SXL ENG, Engine Cab 40 ENG-H, Engine to Hood 7
GN
35A H Backup Alarm Relay Out Y 1.0 SXL HD-E, Hood Trans B BU2, Backup Alarm 1
35A
Backup Alarm Relay Out Y 1.0 SXL HD-N, Hood to Engine 7 BU2, Backup Alarm 1
HN
35A J Revers Light K 1.0 SXL ENG, Engine Cab 7 SPL-A1A, Ultrasonic A
35A K Revers Light K 1.0 SXL SPL-A1A, Ultrasonic A LRR-E, RH rear Comb Light 4
35A L Revers Light K 1.0 SXL SPL-A1A, Ultrasonic A LLR-E, LH rear Comb Light 4
35A M Revers Light K 1.0 SXL SPL-REV, Ultrasonic A HD-9, Hood to Engine 8
35A N Revers Light K 1.0 SXL SPL-REV, Ultrasonic A LLR-9, LH Rear Comb Light 4
35A P Revers Light K 1.0 SXL LRR-9, RH rear Comb Light 4 SPL-REV, Ultrasonic A
35A R Backup Alarm Relay Out Y 1.0 SXL ENG, Engine Cab 7 ENG-H, Engine to Hood 8
35B AIC Buzzer HSD W 0.8 TXL BUZ, AIC Buzzer 1 AIC-1, Advance Instr Cluster 1 13
35C Backup Alarm Relay Control Y 0.8 TXL TECM, Trans 7 ECD, Elect Center D A9
35R C Backup Alarm Sw Y 0.8 GXL SBU, Backup Alarm Dis Sw 1 SPL-D8-C1, Ultrasonic A
35W Water In Fuel Indicator W 0.8 TXL WIF, Water In Fuel Sensor 1 EDC7, Engine Controller 42

Copyright ©
4002-27

21C Bk - 1.0


Color, Size,
and Material
35X Sec. Str Low Press Sig Y 0.8 TXL CAB-T, Cab Transmission 6 AIC-2, Advance Instr Cluster 2 11
35X A Sec. Str Low Press Sig Y 1.0 SXL SPL-C3, Ultrasonic A PSS, Sec. Steering Press Sw C
35X B Sec. Str Low Press Sig Y 1.0 SXL TRANS, Cab Transmission 6 TR-SS, Sec. Steering Mod Option C
35X C Sec. Str Low Press Sig Y 1.0 SXL SPL-C3, Ultrasonic A SS-TR, SS Module Trans C
35X D Sec. Str Low Press Sig Y 1.0 SXL SSM, Sec. Steering Module 8 SPL-C3, Ultrasonic A
36A Rear Axle Temp P 0.8 TXL CAB-E, Cab Engine 32 AIC-1, Advance Instr Cluster 1 5
36A A Rear Axle Temp P 1.0 SXL ENG, Engine Cab 32 HOT-RA, Rear Axle Oil Temp 1
36B Front Axle Temp P 0.8 TXL AIC-1, Adv Instr Cluster 1 8 CAB-F, Cab Front Chassis 8
36B A Front Axle Temp P 1.0 SXL FRONT, Cab Front Chassis 8 HOT-FA, Front Axle Oil Temp 1
36C Radiator Cool Temp Signal P 1.0 SXL ENG, Engine Cab 34 RECT, Engine Coolant Temp A
36C A Radiator Cool Temp Signal W 0.8 TXL CAB-E, Cab Engine 34 AIC-1, Advance Instr Cluster 1 11
36F Fuel Level Analog P 1.0 SXL ENG, Engine Cab 33 RFL, Fuel Sender 1
36F A Fuel Level Analog P 0.8 TXL CAB-E, Cab Engine 33 AIC-1, Advance Instr Cluster 1 2
Torque Conv Output Temp

36G P 1.0 SXL TRANS, Cab Transmission 13 TCOT, TCO Sender 1
Signal
36G A Torque Conv Output Temp P 0.8 TXL CAB-T, Cab Transmission 13 TECM, Trans 49
Signal
36H Hydraulic Oil Temp Signal P 1.0 SXL TRANS, Cab Transmission 30 HOT, Hydraulic Oil Temp Sender A
36H A Hydraulic Oil Temp P 0.8 TXL CAB-T, Cab Transmission 30 AIC-1, Advance Instr Cluster 1 9
36R A Trans Temps/Filter Return P 1.0 SXL TRANS, Cab Transmission 12 SPL H1, Ultrasonic A
36R B Trans Filter Maint Sw Return P 1.0 SXL SPL H1, Ultrasonic A FM, Filter Maint Switch 2
36R C Valve Body Temp Return P 0.8 TXL SPL H1, Ultrasonic A TRC, Trans Control 9
36R D TCO Temp Return P 1.0 SXL SPL H1, Ultrasonic A TCOT, TCO Sender 2
36R E Trans Temps/Filter Return P 0.8 TXL CAB-T, Cab Transmission 12 TECM, Trans 46
36T Valve Body Temp Sig P 0.8 TXL TRANS, Cab Transmission 5 TRC, Trans Control 8
36T A Valve Body Temp Sig P 0.8 TXL CAB-T, Cab Transmission 5 TECM, Trans 39
37D A Diagnostic Signal P 0.8 TXL 108F, Diagnostic Connector 2 TECM, Trans 15
37E Diagnostic Signal Switched P 0.8 TXL 108F, Diagnostic Connector 4 TECM, Trans 18
41H A High Beam Pwr Or 1.0 GXL SRHSTLK, RH Stalk Switch 56a SPL-PK2, Splice 3-4 Way L
41H B High Beam LH Pwr Or 0.8 GXL SPL-PK2, Splice 3-4 Way K ECB, Elect Center B A3
41H C High Beam RH Pwr Or 0.8 GXL SPL-PK2, Splice 3-4 Way J ECB, Elect Center B A4

Copyright ©
4002-28

21C Bk - 1.0


Color, Size,
and Material
41H D High Beam Pwr Or 0.8 TXL SW-PD, Switch Pad 1 SPL-PK2, Splice 3-4 Way M
41J Driving Light Power Or 1.0 GXL SDR, Driving Lights Switch 6 SRHSTLK, RH Stalk Switch 56
41L A Low Beam Power Or 1.0 GXL SRHSTLK, RH Stalk Switch 56b SPL-LB, Ultrasonic
41L B Low Beam RH Power Or 0.8 GXL SPL-LB, Ultrasonic ECB, Elect Center B A6
41L C Low Beam LH Power Or 0.8 GXL SPL-LB, Ultrasonic ECB, Elect Center B A5
41T Position Lights Switched Pwr K 1.0 GXL SDR, Driving Lights Switch 3 SPL-PK2, Splice 3-4 Way C
41T A Position Lights RH Switched Pwr K 1.0 GXL SPL-PK2, Splice 3-4 Way D ECB, Elect Center B A8
41T B Position Lights LH Switched Pwr K 1.0 GXL SPL-PK2, Splice 3-4 Way A ECB, Elect Center B A7
41T C Position Lights Switched Pwr K 1.0 GXL D-OR, Diode OR B SPL-D, Ultrasonic
41T D Position Lights Switched Pwr K 0.8 TXL SW-PD, Switch Pad 2 SPL-D, Ultrasonic
41T E Position Lights Switched Pwr K 1.0 SXL SPL-PK2, Splice 3-4 Way B SPL-D, Ultrasonic
42C A Front Work Lights Fused Pwr DU 1.0 GXL CAB-RF, Cab to Roof Conn. C SPL-PK1, Splice 3-4 Way A
42C C Front Work Lights Fused Pwr DU 1.0 GXL SPL-PK1, Splice 3-4 Way D ECB, Elect Center B AA1
42C D Front Work Lights Fused Pwr DU 1.0 GXL SPL-PK1, Splice 3-4 Way C D-OR, Diode OR A
42C E Front Work Lights Fused Pwr DU 0.8 TXL SW-PD, Switch Pad 3 SPL-PK1, Splice 3-4 Way B
42C F Front Work Lights Fused Pwr DU 1.0 GXL ROOF, Roof to Cab Conn. C SPL-WRKF, Ultrasonic A
42C G RH Front Work Lights Fused Pwr DU 1.0 SXL SPL-WRKF, Ultrasonic A LRFW, RH Front Work Light A
42C H LH Front Work Lights Fused Pwr DU 1.0 SXL SPL-WRKF, Ultrasonic A LLFW, LH Front Work Light A
42FS Front Work Lights Switched Pwr DU 1.0 GXL SWL, Work Lights Switch 3 ECB, Elect Center B A1
42RS Rear Work Light Switched Pwr DU 1.0 GXL SWL, Work Lights Switch 6 ECB, Elect Center B A2
42R C Rear Work Lights Fused Pwr DU 1.0 GXL CAB-RF, Cab to Roof Conn. B ECB, Elect Center B AA2
42R F Rear Work Lights Fused Pwr DU 1.0 GXL ROOF, Roof to Cab Conn. B SPL-WRKR, Ultrasonic A
42R G RH Rear Work Lt Fused Pwr DU 1.0 SXL SPL-WRKR, Ultrasonic A LRRW, RH Rear Work Light A
42R H LH Rear Work Lt Fused Pwr DU 1.0 SXL SPL-WRKR, Ultrasonic A LLRW, LH Rear Work Light A
42 A Work Lights Fused Power R 2.0 GXL SWL, Work Lights Switch 2 SPL-WL, Ultrasonic A
42 B Work Lights Fused Power R 2.0 GXL SWL, Work Lights Switch 5 SPL-WL, Ultrasonic A
43S A Door Open Signal W 0.8 GXL CAB-RF, Cab to Roof Conn. R SPL-DS, Ultrasonic A
43S B Door Open Signal W 0.8 GXL ROOF, Roof to Cab Conn. R DS, Door Switch B
43S C Door Open Signal W 0.8 TXL SPL-DS, Ultrasonic A AIC-2, Adv Instrument Cluster 2 2
43S D Time Delay Mod Door Sw Reset W 0.8 TXL TDM, Time Delay Module 4 SPL-DS, Ultrasonic A
43 A Dome Light Auto Mode DU 0.8 TXL CAB-RF, Cab to Roof Conn. A AIC-1, Adv Instrument Cluster 1 7

Copyright ©
4002-29

21C Bk - 1.0


Color, Size,
and Material
43 B Dome Light Auto Mode DU 0.8 GXL ROOF, Roof to Cab Conn. A LDM2, Dome Light Auto 1
44A A Brake Light Relay Out T 0.8 GXL SPL-BRK, Ultrasonic A ECC, Work Lights D6
44A B Brake Light Relay Out T 0.8 TXL SPL-BRK, Ultrasonic A AIC-1, Adv Instrument Cluster 1 15
44A C Brake Light Relay Out T 0.8 GXL CAB-E, Cab Engine 8 SPL-BRK, Ultrasonic A
44A D Brake Light Relay Out T 1.0 SXL ENG, Engine Cab 8 SPL-B8, Ultrasonic A
44A
Brake Light Relay Out T 1.0 SXL ENG, Engine Cab 8 ENG-H, Engine to Hood 2
DN
44A E Brake Light Relay Out T 1.0 SXL LLR-E, LH Rear Comb Light 1 SPL-B8, Ultrasonic A
44A
Brake Light Relay Out T 1.0 SXL HD-N, Hood to Engine 2 SPL-J2-N, Ultrasonic A
EN
44A F Brake Light Relay Out T 1.0 SXL LRR-E, RH Rear Comb Light 1 SPL-B8, Ultrasonic A
44A
Brake Light Relay Out T 1.0 SXL LLR-N, LH Rear Comb Light A SPL-J2-N, Ultrasonic A
FN
44A
Brake Light Relay Out T 1.0 SXL LRR-N, RH Rear Comb Light A SPL-J2-N, Ultrasonic A
GN
44A J Brake Light Power T 1.0 SXL SPL-L1, Ultrasonic A HD-9, Hood to Engine 2
44A K Brake Light Power T 1.0 SXL SPL-L1, Ultrasonic A LRR-9, RH Rear Comb Light 1
44A L Brake Light Power T 1.0 SXL LLR-9, LH Rear Comb Light 1 SPL-L1, Ultrasonic A
44 A Brake Light Control Power T 0.8 GXL CAB-F, Cab Front Chassis 23 ECC, Work Lights D5
45A A Left Turn Switch Power N 0.8 GXL FLSHR, Flasher Module 9 SRHSTLK, RH Stalk Switch L
45B A Right Turn Switch Power N 0.8 GXL FLSHR, Flasher Module 10 SRHSTLK, RH Stalk Switch R
45H Hazard Switch Power N 0.8 GXL FLSHR, Flasher Module 11 SHZ, Hazard Switch 3
45L Left Turn Signal N 1.0 SXL FRONT, Cab Front Chassis 1 LLF, Lights LH 5
45L 9 Left Turn Signal N 1.0 SXL HD-9, Hood to Engine 3 LLR-9, LH Rear Comb Light 2
45L A Left Turn Signal N 1.0 SXL ENG, Engine Cab 10 LLR-E, LH Rear Comb Light 2
45L AN Left Turn Signal N 1.0 SXL ENG, Engine Cab 10 ENG-H, Engine to Hood 3
45L B Left Turn Signal N 0.8 GXL CAB-E, Cab Engine 10 SPL-PK3, Splice 3-4 Way D
45L BN Left Turn Signal N 1.0 SXL HD-N, Hood to Engine 3 LLR-N, LH Rear Comb Light C
45L C Left Turn Signal N 0.8 GXL CAB-F, Cab Front Chassis 1 SPL-PK3, Splice 3-4 Way C
45L D Left Turn Signal N 0.8 GXL FLSHR, Flasher Module 8 SPL-PK3, Splice 3-4 Way B
45L E Left Turn Signal N 0.8 TXL SPL-PK3, Splice 3-4 Way A AIC-2, Adv Instrument Cluster 2 9
45N A Flasher OPP Side Control N 0.8 GXL FLSHR, Flasher Module 2 64F, Flasher Connector 1

Copyright ©
4002-30

21C Bk - 1.0


Color, Size,
and Material
45N B Flasher OPP Side Control N 0.8 GXL FLSHR, Flasher Module 12 64M, Flasher Connector 1
45R Right Turn Signal N 1.0 SXL FRONT, Cab Front Chassis 3 LRF, Lights RH 5
45R 9 Right Turn Signal N 1.0 SXL HD-9, Hood to Engine 4 LRR-9, RH Rear Comb Light 2
45R A Right Turn Signal N 1.0 SXL ENG, Engine Cab 12 LRR-E, RH Rear Comb Light 2
45R
Right Turn Signal N 1.0 SXL ENG, Engine Cab 12 ENG-H, Engine to Hood 4
AN
45R B Right Turn Signal N 0.8 GXL CAB-E, Cab Engine 12 SPL-PK3, Splice 3-4 Way H
45R
Right Turn Signal N 1.0 SXL HD-N, Hood to Engine 4 LRR-N, RH Rear Comb Light C
BN
45R C Right Turn Signal N 0.8 TXL SPL-PK3, Splice 3-4 Way E AIC-2, Adv Instrument Cluster 2 10
45R D Right Turn Signal N 0.8 GXL CAB-F, Cab Front Chassis 3 SPL-PK3, Splice 3-4 Way G
45R E Right Turn Signal N 0.8 GXL FLSHR, Flasher Module 7 SPL-PK3, Splice 3-4 Way F
46 C Beacon Switched Power K 1.0 GXL CAB-RF, Cab to Roof Conn. E SBE, Beacon Switch 3
46 D Beacon Switched Power K 1.0 GXL ROOF, Roof to Cab Conn. E LBEPWR, Light Beacon power 1
46 E Beacon Switched Power K 1.0 GXL LBEE, Light Beacon Exten A LBEP, Light Beacon power 1
49A Back Light Power S 0.8 GXL HVAC1, HVAC1 3 SPL-BCK-LGT, Spl Back Lgt Pwr F
49S Back Light Power S 0.8 GXL STA, Trans Auto Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr J
SPL-PED-BL, Spl Back Lgt Pwr 6

49U Back Light Power S 0.8 GXL SETHR, Ether Switch 8 D
Pck
49 A Back Light Power S 0.8 GXL SWL, Work Lights Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr M
49 B Back Light Power S 0.8 GXL SBE, Beacon Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr L
49 C Back Light Power S 0.8 GXL SRWP, Rear Wiper Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr C

49 D Back Light Power S 0.8 GXL SHZ, Hazard SWitch 8 C
Pck
SPL-BCK-LGT2, Spl Back
49 E Back Light Power S 0.8 GXL A SPL-BCK-LGT, Spl Back Lgt Pwr K
Lgt Pwr
SPL-BCK-LGT2, Spl Back Lgt
49 F Back Light Power S 0.8 GXL SPE, Pin Engage Switch 10 F
Pwr
49 G Back Light Power S 0.8 GXL SRC, Ride control Switch 8 K
Pwr
49 H Back Light Power S 0.8 GXL STE, Trans Enable Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr D

49 J Back Light Power S 0.8 GXL SRTD, Detent Switch 8 C
Pwr

Copyright ©
4002-31

21C Bk - 1.0


Color, Size,
and Material
49 K Back Light Power S 0.8 GXL SFL, Return to Travel Switch 8 E
Pwr
49 L Back Light Power S 0.8 GXL SBU, Back Up Alarm Dis Sw 8 SPL-BCK-LGT, Spl Back Lgt Pwr E

49 M Back Light Power S 0.8 GXL SHC, Height Control Switch 8 D
Pwr
49 N Back Light Power S 0.8 GXL SPC, Pilot Control Switch 8 B
Pck
49 P Back Light Power S 0.8 GXL SDR, Driving Lights Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr G

49 Q Back Light Power S 0.8 GXL SFC, Fan Control Switch 8 G
Pwr
49 R Back Light Power S 0.8 GXL SDC, Declutch Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr H
SPL-PED-BL, Spl Back Lgt SPL-BCK-LGT2, Spl Back Lgt

49 S Back Light Power S 0.8 GXL F M
Pwr 6 Pck Pwr
49 T Back Light Power S 0.8 GXL SFWW, Front Wiper/Washer 8 H
Pwr
49 U Back Light Power S 0.8 GXL SCS, Comfort Steer Switch 8 A
Pck
49 V Back Light Power S 0.8 GXL SPB, Parking Brake Switch 8 E
Pck
51B A Comfort Steer Solenoid Power W 0.8 GXL SCS, Comfort Steer Switch 6 SPL-CSS, Ultrasonic A
51B B Comfort Steer Solenoid Power W 0.8 GXL SPL-CSS, Ultrasonic A ECC, Work Lights D10
51B C Comfort Steer Solenoid Power W 0.8 GXL SPL-CSS, Ultrasonic A CAB-F, Cab Front Chassis 2
51B D Comfort Steer Solenoid Power W 1.0 SXL FRONT, Cab Front Chassis 2 YCS, Comfort Steer Solenoid A
AIC-1, Adv Instrument

51C Comfort Steer control W 0.8 TXL 21 ECC, Work Lights B10
Cluster 1
51CS Comfort Steer Switch W 0.8 TXL SCS, Comfort Steer Switch 3 AIC-1, Adv Instrument Cluster 1 17
51P A Sec. Str High Press W 1.0 SXL SSM, Sec. Steer Module 9 PSS, Sec. Steer Pressure Switch A
51S Standard Steering Signal W 0.8 TXL SCS, Comfort Steer Switch 1 AIC-1, Adv Instrument Cluster 1 16
51 A Sec. Str Motor Control W 1.0 SXL SSM, Sec. Steer Module 2 SPL-SS, Ultrasonic A
51 B Sec. Str Motor Control W 1.0 SXL SPL-SS, Ultrasonic A SSS, SS Mag Switch 1
51 C Sec. Strg Sol Control W 1.0 SXL SPL-SS, Ultrasonic A YSS, Sec. Steering Solenoid 1
52AU Fan Reverse Auto W 0.8 TXL SFC, Fan Control Switch 3 AIC-2, Adv Instrument Cluster 2 8
52A A Fan Reverse Relay Out W 1.0 GXL CAB-E, Cab Engine 22 ECB, Elect Center B D8
52A B Fan Reverse Relay Out W 1.0 SXL ENG, Engine Cab 22 YFR, Fan Rev Solenoid Option 1

Copyright ©
4002-32

21C Bk - 1.0


Color, Size,
and Material
52C Parking Brake Solenoid LSD W 0.8 TXL 14 ECB, Elect Center B B10
Cluster 1
52J Fan Control Switch Jumper W 0.8 GXL SFC, Fan Control Switch 4 SFC, Fan Control Switch 2
52M Fan Reverse Manual W 0.8 TXL SFC, Fan Control Switch 6 AIC-2, Adv Instrument Cluster 2 7
52P Parking Brk Relay Out W 1.0 SXL FRONT, Cab Front Chassis 24 YPB, Park Brake Solenoid 1
52P A Parking Brk Relay Out W 0.8 GXL CAB-F, Cab Front Chassis 24 SPL-PB, Ultrasonic A
52P B Parking Brk Relay Out W 0.8 GXL SPL-PB, Ultrasonic A ECB, Elect Center B D10
52P C Parking Brk Relay Out W 0.8 TXL SPL-PB, Ultrasonic A TECM, Trans 21
53A RTD Switch Power W 0.8 GXL SRTD, Detent Switch 3 EM, RTD Height Control RTT 3
53B RTD Signal W 1.0 SXL FRONT, Cab Front Chassis 12 PXF, RTD C
53B A RTD Signal W 1.0 SXL PXM, RTD A PXT, RTD A
53B B RTD Signal W 0.8 GXL EM, RTD Height Control RTT 4 CAB-F, Cab Front Chassis 12

53C A Pilot Control Solenoid LSD W 0.8 TXL 20 ECD, Elect Center D B6
Cluster 1
53P A Pilot Control Relay Out W 0.8 GXL SPL-D25, Ultrasonic A YPP, Pilot Pressure Solenoid A
53P B Pilot Control Relay Out W 0.8 GXL SFL, Return to Travel Switch 2 SPL-D25, Ultrasonic A
53P C Pilot Control Relay Out W 1.0 GXL SPL-D25, Ultrasonic A ECD, Elect Center D D6
53P D Pilot Control Relay Out W 0.8 GXL SHC, Height Control Switch 2 SPL-D25, Ultrasonic A
53P E Pilot Control Relay Out W 0.8 GXL SRTD, Detent Switch 2 SPL-D25, Ultrasonic A
53P F Pilot Control Relay Out W 0.8 GXL CAB-F, Cab Front Chassis 19 SPL-D25, Ultrasonic A
53P G Pilot Control Relay Out W 1.0 SXL FRONT, Cab Front Chassis 19 SPL-A3, Ultrasonic A
53P H Pilot Control Relay Out W 1.0 SXL SPL-A3, Ultrasonic A PXF, RTD C
53P I Pilot Control Relay Out W 1.0 SXL PXM, RTD C PXT, RTD C
53P J Pilot Control Relay Out W 1.0 SXL SPL-A3, Ultrasonic A PXH, Height Control RTT C
54A Height Control Switch Power W 0.8 GXL SHC, Height Control Switch 6 EM, RTD Height Control RTT 2
54B Height RTT Control Signal W 1.0 SXL FRONT, Cab Front Chassis 11 PXH, Height Control RTT A
54B A Height RTT Control Signal W 0.8 GXL CAB-F, Cab Front Chassis 11 SPL-D1, Ultrasonic A
54B B Height RTT Control Signal W 0.8 GXL EM, RTD Height Control RTT 5 SPL-D1, Ultrasonic A
54B C Height RTT Control Signal W 0.8 GXL SFL, Return to Travel Switch 6 SPL-D1, Ultrasonic A
55A A RTT Float Sw Power W 0.8 GXL EM, RTD Height Control RTT 1 SPL-RTT, Ultrasonic A
55A B RTT Float Sw Power W 0.8 GXL SFL, Return to Travel Switch 1 SPL-RTT, Ultrasonic A

Copyright ©
4002-33

21C Bk - 1.0


Color, Size,
and Material
55A C RTT Float Sw Power W 0.8 GXL SFL, Return to Travel Switch 3 SPL-RTT, Ultrasonic A
55B RTT Float Switch Control W 0.8 GXL SFL, Return to Travel Switch 5 EM, RTD Height Control RTT 6
56 A Fan Control PWM W 1.0 SXL ENG, Engine Cab 23 YFN, Fan PWM Solenoid A
57 A Pin Engage Sol Pwr W 0.8 GXL CAB-F, Cab Front Chassis 20 SPL-PINE, Ultrasonic A
57 B Pin Engage Sol Pwr W 0.8 GXL SPE, Pin Engage Switch 1 SPL-PINE, Ultrasonic A
57 C Pin Engage Sol Pwr W 0.8 TXL SPL-PINE, Ultrasonic A AIC-2, Adv Instrument Cluster 2 16
58C Ride Control Switch Jumper W 0.8 GXL SRC, Ride Control Switch 5 SRC, Ride Control Switch 3
58H A Ride Control Sw Pwr VPS2 W 0.8 TXL TECM, Trans 8 ECD, Elect Center D D7
58L Ride Control Relay LSD Bk 0.8 TXL TECM, Trans 57 ECD, Elect Center D B8
58S E Ride Control Sol to Front Cab W 1.0 SXL FRONT, Cab Front Chassis 21 YRC, Ride Control Option 1
58T Ride Control Relay Sw Pwr W 0.8 GXL SRC, Ride Control Switch 4 ECD, Elect Center D B7
58 A Ride Control Sol Pwr W 1.0 SXL 202M, Rollback Jumper A 202M, Rollback Jumper B
58 B Ride Control Sol Pwr W 1.0 SXL FRONT, Cab Front Chassis 21 PRBF, Rollback Pressure Switch B
58 C Ride Control Sol Pwr W 0.8 GXL CAB-F, Cab Front Chassis 21 SPL-D26, Ultrasonic A
58 D Ride Control Sol Pwr W 0.8 GXL 140M, Diode Module D SPL-D26, Ultrasonic A
58 E Ride Control Sol Pwr W 0.8 GXL SPL-D26, Ultrasonic A ECD, Elect Center D D8
58 F Ride Control Sol Pwr W 0.8 GXL SRC, Ride Control Switch 6 SPL-D26, Ultrasonic A
59D Hood Relay Control Down W 1.0 GXL CAB-E, Cab Engine 37 ECC, Work Lights D3
59D A Hood Relay Control Down W 1.0 SXL ENG, Engine Cab 37 HD, Hood Switch A
59U Hood Relay Control Up W 1.0 GXL CAB-E, Cab Engine 39 ECC, Work Lights D1
59U A Hood Relay Control Up W 1.0 SXL ENG, Engine Cab 39 HD, Hood Switch C
60D Hood Down Relay Out W 1.0 GXL CAB-E, Cab Engine 36 ECC, Work Lights B3
60D A Hood Down Relay Out W 1.0 SXL ENG, Engine Cab 36 HDM, Hood Lift Motor 2
60U Hood Up Relay Out W 1.0 GXL CAB-E, Cab Engine 38 ECC, Work Lights B1
60U A Hood Up Relay Out W 1.0 SXL ENG, Engine Cab 38 HDM, Hood Lift Motor 1
61A Trinary Press Sw Input W 1.0 SXL ENG, Engine Cab 30 PR, Trinary Press Sw A
61A B Trinary Press Sw Input W 0.8 GXL CAB-E, Cab Engine 30 HVAC1, HVAC1 1
61C AC Relay Out Or 0.8 GXL CAB-E, Cab Engine 2 ECD, Elect Center D D10
61C A AC Relay Out Or 1.0 SXL ENG, Engine Cab 2 ACT, AC Comp Clutch 1
61C B AC Relay Out Or 1.0 SXL ENG, Engine Cab 2 ACT-9, AC Comp Clutch 1
61R AC Relay Control W 1.0 SXL ENG, Engine Cab 29 PR, Trinary Press Sw B

Copyright ©
4002-34

21C Bk - 1.0


Color, Size,
and Material
61R B AC Relay Control W 0.8 GXL CAB-E, Cab Engine 29 ECD, Elect Center D D9
63C Front Wiper Park Control W 0.8 GXL FWM, Front Wiper Motor D ECD, Elect Center D C4
63C2 Front Wiper Park Control W 0.8 GXL ECD, Elect Center D D4 ECD, Elect Center D C2
63C3 Front Wiper Park Control W 0.8 GXL K-WCO, Wiper Cutout 87a ECD, Elect Center D B3
63HC Front Wiper High Speed Rly Ctrl W 0.8 GXL SFWW, Front Wiper/Washer 9 SPL-HC, Ultrasonic A
63HC
Wiper Cutout Relay Control W 0.8 GXL SPL-HC, Ultrasonic A K-WCO, Wiper Cutout 85
A
63HC
Front Wiper High Speed Rly Ctrl W 0.8 GXL SPL-HC, Ultrasonic A ECD, Elect Center D B2
B
63H A Front Wiper High Speed Rly Out W 0.8 GXL FMW, Front Wiper Motor A SPL-WHS, Ultrasonic A
63H B Front Wiper High Speed Rly Out W 0.8 GXL SPL-WHS, Ultrasonic A ECD, Elect Center D D2
63H C Front Wiper High Speed Rly Out W 0.8 GXL 140M, Diode Module A SPL-WHS, Ultrasonic A
63LC Front Wiper Low Speed Rly Ctrl W 0.8 GXL SFWW, Front Wiper/Washer 3 ECD, Elect Center D B4
63L A Front Wiper Low Speed Rly Out W 0.8 GXL FMW, Front Wiper Motor B SPL-WLS, Ultrasonic A
63L B Front Wiper Low Speed Rly Out W 0.8 GXL K-WCO, Wiper Cutout 30 SPL-WLS, Ultrasonic A
63L C Front Wiper Low Speed Rly Out W 0.8 GXL 140M, Diode Module B SPL-WLS, Ultrasonic A
63W Front Washer Pump W 0.8 GXL CAB-E, Cab Engine 25 SFWW, Front Wiper/Washer 7
63W A Front Washer Pump W 1.0 SXL ENG, Engine Cab 25 FWW, Front Washer 1
64C Horn Relay Control Or 0.8 GXL SRHSTLK, RH Stalk Switch 31b ECC, Work Lights B8
64 A Horn Power Or 0.8 GXL CAB-F, Cab Front Chassis 13 ECC, Work Lights D8
65L Left Speaker Or 0.8 GXL LSPK, Left Speaker 1 SPK, Speaker 7
65R Right Speaker Or 0.8 GXL RSPK, Right Speaker 1 SPK, Speaker 1
68C Rear Wiper Park Control Or 1.0 GXL CAB-RF, Cab to Roof Conn. K SRWP, Rear Wiper Switch 1
68C A Rear Wiper Park Control Or 1.0 GXL ROOF, Roof to Cab Conn. K RWM, Rear Wiper Motor D
68L Rear Wiper Switch Power Or 1.0 GXL SRWP, Rear Wiper Switch 2 SPL-3, Ultrasonic A
68L A Rear Wiper Switch Power Or 1.0 GXL ROOF, Roof to Cab Conn. L RWM, Rear Wiper Motor B
68L B Rear Wiper Switch Power Or 1.0 GXL CAB-RF, Cab to Roof Conn. L SPL-3, Ultrasonic A
68L C Rear Wiper Switch Power Or 1.0 GXL 140M, Diode Module F SPL-3, Ultrasonic A
68W Rear Washer Pump W 0.8 GXL CAB-E, Cab Engine 24 SRWP, Rear Wiper Switch 6
68W A Rear Washer Pump W 1.0 SXL ENG, Engine Cab 24 RWW, Rear Washer 1
Y 0.8 TXL
CAN H CAN High CAN2, CAN Bulk Head A EDC7, Engine Controller 35
TWIST

Copyright ©
4002-35

21C Bk - 1.0


Color, Size,
and Material
CAN Y 0.8 TXL
CAN High SPL-CAN-HVAC, Ultrasonic A CAN, CAN Bulk Head A
HA TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-DIAG, Ultrasonic A DIA, Diagnostic C
HB TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-TRANS, Ultrasonic A SPL-CAN-DIAG, Ultrasonic A
HC TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-TRANS, Ultrasonic A TECM, Trans 25
HD TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN, Ultrasonic A SPL-CAN-TRANS, Ultrasonic A
HE TWIST
CAN Y 0.8 TXL
CAN High SW-PD, Switch Pad 7 SPL-CAN, Ultrasonic A
HF TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN, Ultrasonic A AIC-1, Adv Instrument Cluster 1 3
HG TWIST
CAN Y 0.8 TXL
CAN High From Engine CAN2, CAN Bulk Head A QSM11, Engine controller 46
HJ TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-HVAC, Ultrasonic A HVAC-CAN1, CAN HVAC AIC A
HK TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-HVAC, Ultrasonic A SPL-CAN-DIAG, Ultrasonic A
HM TWIST
G 0.8 TXL
CAN L CAN Low CAN2, CAN Bulk Head B EDC7, Engine Controller 34
TWIST
CAN G 0.8 TXL SPL-CAN-HVAC-L,
CAN Low A CAN, CAN Bulk Head B
LA TWIST Ultrasonic
CAN G 0.8 TXL
CAN Low SPL-CAN-DIAG-L, Ultrasonic A DIA, Diagnostic D
LB TWIST
CAN G 0.8 TXL SPL-CAN-TRANS-L,
CAN Low A SPL-CAN-DIAG-L, Ultrasonic A
LC TWIST Ultrasonic
CAN G 0.8 TXL
CAN Low SPL-D5, Ultrasonic A SPL-CAN-TRANS-L, Ultrasonic A
LD TWIST
CAN G 0.8 TXL
CAN Low SPL-CAN-L, Ultrasonic A SPL-CAN-TRANS-L, Ultrasonic A
LE TWIST
CAN G 0.8 TXL
CAN Low SW-PD, Switch Pad 8 SPL-CAN-L, Ultrasonic A
LF TWIST
CAN G 0.8 TXL
CAN Low SPL-CAN-L, Ultrasonic A AIC-1, Adv Instrument Cluster 1 4
LG TWIST

Copyright ©
4002-36

21C Bk - 1.0


Color, Size,
and Material
CAN G 0.8 TXL
CAN Low SPL-D5, Ultrasonic A TECM, Trans 27
LJ TWIST
CAN G 0.8 TXL
CAN Low SPL-D5, Ultrasonic A TECM, Trans 26
LK TWIST
CAN Low A HVAC-CAN1, CAN HVAC AIC B
LL TWIST Ultrasonic
CAN G 0.8 TXL
CAN Low From Engine CAN2, CAN Bulk Head B QSM11, Engine Controller 37
LM TWIST
CAN Low A SPL-CAN-DIAG-L, Ultrasonic A
LN TWIST Ultrasonic
ECC
Beacon/Dome Light L1 ECC BUSS L1-ECC, ECC Batt Power cs01 ECC, Work Lights L1-1
L1
J1 Trans ECM Power ECA-BUSS ECA-L1, B+ Power cs01 ECA, Elect Center A L1
J2 Trans ECM Comfort Steer ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J3 Comfort Steer AIC Power ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J4 Emergency Steer AIC Power ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J5 Emergency Steer Pltem Dtnts ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J6 Pltem Dtnts Park Brk Sol ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J7 Park Brake Solenoid Horn ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J8 Fan Reverse Turn Signal ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J9 Turn Signal Engine Shut Down ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J11 Blower Motor Power ECA-BUSS ECA-L2, B+ Power cs01 ECA, Elect Center A L2
Blower Motor Front Wiper

J12 ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
Washer
J13 Front Wiper Rear Wiper Washer ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J14 Rear Wiper Washer Backup ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J15 Backup AC ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J16 AC Seat Compressor ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J18 Seat Comp Emergency Steer ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J2
Beacon/Dome Lt Work Lights ECA-BUSS ECC, Work Lights L1-1 ECC, Work Lights L1-2
ECC
J3
Work Lights Driving Lights ECA-BUSS ECC, Work Lights L1-2 ECC, Work Lights L1-3
ECC

Copyright ©
4002-37

21C Bk - 1.0


Color, Size,
and Material
J4
Driving Lights Brake Lights ECA-BUSS ECC, Work Lights L1-3 ECC, Work Lights L1-4
ECC
J5
Brake Lights Delay Power ECA-BUSS ECC, Work Lights L1-4 ECC, Work Lights L1-5
ECC
J6
Delay Power Horn ECA-BUSS ECC, Work Lights L1-5 ECC, Work Lights L1-6
ECC
J7
Horn HOD Control ECA-BUSS ECC, Work Lights L1-6 ECC, Work Lights L1-7
ECC
J8
HOD Control Cigar Lighter ECA-BUSS ECC, Work Lights L1-7 ECC, Work Lights L1-8
ECC
J9
Diagnostic Power ECA-BUSS ECC, Work Lights L1-9 ECC, Work Lights L1-8
ECC
PRM A Ignition Power Fuse Sec. BUSS PRM-A, Power Relay Mod A PRM-A, Power Relay Mod A
Steering
PRM B Time Delay Fuse Ignition Pwr BUSS PRM-A, Power Relay Mod A
Fuse
PRM D Accessory Pwr Fuse Spare BUSS PRM-D, Power Relay Mod D PRM-D, Power Relay Mod D
PRM Ignition Power Fuse
BUSS PRM-A, Power Relay Mod A PRM-D, Power Relay Mod D
PWR Accessory Power Fuse
RAD1 Radio Ground W 0.8 GXL RAD-J3, Radio Jumper 5 RAD-J1, Radio Power 8
RAD2 12V Fused Power to Radio W 0.8 GXL RAD-J3, Radio Jumper 12 RAD-J1, Radio Power 7
RAD3 12V Fused Power to Radio W 0.8 GXL RAD-J3, Radio Jumper 7 RAD-J1, Radio Power 4
RAD4 Left Speaker Ground W 0.8 GXL RAD-J3, Radio Jumper 3 RAD-J2, Speaker 8
RAD5 Left Speaker W 0.8 GXL RAD-J3, Radio Jumper 10 RAD-J2, Speaker 7
RAD6 Not Used W 0.8 GXL RAD-J3, Radio Jumper 4 RAD-J2, Speaker 6
RAD10 Right Speaker Ground W 0.8 GXL RAD-J3, Radio Jumper 1 RAD-J2, Speaker 2
RAD11 Right Speaker W 0.8 GXL RAD-J3, Radio Jumper 8 RAD-J2, Speaker 1

Copyright ©
4002-38
UNDERSTANDING THE TROUBLESHOOTING TABLES
1 – Alternator 1
Correct
Check Points 2 Possible Cause of Bad Reading
Reading
3 4
Check the 10 ampere fuse at
Good Bad fuse.
location 3 and 4C in the fuse block.
Check wire 1A between the starter terminal (21) and the
Terminal for wire 1A to ground 12 volts
alternator (1).
NOTE: If the readings are good, see Section 4004 and check the starter. 5
6
1. This title is the number and component name on the Electrical Schematic.
2. This column shows the location of the check point.
3. This column shows the indication of the check.
4. This column shows the possible cause of a bad test indication.
5. The numbers in the parentheses show the number of the component on the Electrical Schematic.
6. This statement assumes that all other problems are solved at this point in the test.
LOCATING COMPONENTS ON THE SCHEMATIC POSTERS

NOTE: For the System Electrical Schematic refer to the Schematic Posters located at the rear of this manual.
Components can be located on the Electrical
Schematic posters (rear pocket) by item number
using the key at the bottom of the posters.

Copyright ©
4002-39
STARTING AND CHARGING SYSTEMS
9 3
10
5
1 2 7
4 11
6 12
BS06H241 / BS06H242
1. STARTING RELAY 7. TIME DELAY MODULE

2. RESISTOR 75 OHM 8. MASTER DISCONNECT SWITCH
3. ALTERNATOR 9. STARTER
4. CRANK CONTROL RELAY 10. IGNITION SWITCH
5. BATTERIES 11. NEUTRAL START RELAY
6. CRANK REQUEST RELAY 12. VOLT METER RELAY
NOTE: The battery must be at full charge and all connections clean and tight before doing any testing of the electrical system.
Use a Multimeter for the following tests.

Copyright ©
4002-40
1 – Starting Relay
Located in the right side of the engine compartment on cooling fan housing, open engine compartment to gain access.
Correct
Check Points Possible Cause of Bad Reading
Reading
Terminal for wire 0-GB to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position.
Terminal for wire 1-Z to ground 24 volts Check circuit to batteries.
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
Terminal for wire 21D to ground 24 volts Check crank control relay (4), also check circuit 21D.
Terminal for wire 1-BB to ground 24 volts Bad starting relay.
2 – Resistor
Located in the cab access panel for fuses and relays.
NOTE: Turn master disconnect switch off, disconnect terminals from resistor.
Correct
Reading
Between terminals of resistor 75 ohms Bad resistor.
3 – Alternator
Located on left side of engine, open engine compartment to gain access.
Correct
Reading
Between housing of alternator and Continuity Bad ground connection.

ground
Between the B+ terminal of Check circuit to positive post of left battery. Bad master
24 volts
alternator and ground disconnect switch.
Between terminal for wire 1-BA and 24 volts Bad wire 1-BA.
ground
NOTE: Put the ignition switch in the ON position.
Between the B+ terminal of 24 volts Check circuit to positive post of left battery.
alternator and ground
Check circuit 14, 75 ohm resistor, and diode module. Bad fuse
Terminal for wire 14 to ground 20 volts ECA-F4. Check power relay module A, and 105 ampere circuit
breaker in engine compartment of machine.
NOTE: If the readings are good, repair or replace the alternator.

Copyright ©
4002-41
4 – Crank Control Relay

Correct
Reading
Terminal for wire 21H to ground Continuity Bad ground circuit or bad EDC7 (24).
NOTE: Put the master disconnect switch in the ON position. Put the transmission in NEUTRAL. Have another
person hold the ignition switch in the START position.
Terminal for wire 21C-B to ground 24 volts Bad neutral start relay (11), check wire circuit 21C.
Terminal for wire 21G to ground 24 volts Bad EDC7 (24), check wire circuit 21G.
Terminal for wire 21D-A to ground 24 volts Bad crank control relay.
5 – Batteries
Located on right and left rear sides of the machine.
NOTE: See Section 4003 and check the batteries.
6 – Crank Request Relay

Correct
Reading
Terminal for wire 0-DF to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position. Have another person hold the ignition switch in the
START position.
Terminal for wire 21C-A to ground 24 volts Check circuit 21 to neutral start relay (11).
Terminal for wire 21E to ground 24 volts Bad crank request relay.

Copyright ©
4002-42
7 – Time Delay Module

Located in the cab access panel for fuses and relays at rear of compartment.
Correct
Reading
Terminal for wire 0-DC to ground Continuity Bad ground circuit.
Bad 10 ampere fuse in ECC F5. Check wire 1DN to SPL-DLY

Terminal for wire 1DN to ground 24 volts
and wire 1DM to fuse ECC F5.
Terminal for wire 13K-A to ground 24 volts Bad ignition switch (10), also check circuit 13K.
NOTE: Put the ignition switch in the ON position. Turn ignition switch to the OFF position. After 30 seconds time
delay an audible click will be heard.
Within 30 seconds of putting the 24 volts

ignition switch in the OFF position, Key OFF
Bad time delay module.
check terminal for wire 13D to 0 volt after 30
ground seconds
After 30 seconds of turning ignition

switch to the OFF position, check 0 volt Bad time delay module.
terminal for wire 13D to ground
8 – Master Disconnect Switch

Located on right side battery box cover, remove battery box cover to gain access.
Correct
Reading
NOTE: Disconnect cables from both terminals of master disconnect switch (main contact). Put master disconnect
switch in ON position.
Between terminals of master Continuity If there is no continuity, the master disconnect switch (2) is bad.
disconnect switch
NOTE: Put the master disconnect switch in the OFF position.
Between terminals of master Open Circuit If there is continuity, the master disconnect switch is bad.
disconnect switch
NOTE: Use the same method to check the master disconnect switch (auxiliary contact).

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4002-43
9 – Starter Motor
Located on left side of engine, open engine compartment to gain access.
Correct
Reading
Between housing of starter and Continuity Bad ground connection.

ground
Starter B+ stud to ground 24 volts Check circuit to batteries.
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
Bad starting relay (1). Also check wire 1-BB between starter
Terminal S to ground 24 volts
and starting relay (1).
NOTE: If the readings are good, repair or replace the starter.
10 – Ignition Switch
Located on steering column.
Correct
Reading
Terminal for wire 1A to ground 24 volts Check circuit 1A to ECC-F5 fuse.
NOTE: Disconnect the connector from the ignition switch. Turn the switch to ON.
Between Bat and Ign Continuity Bad ignition switch.
Between Bat and Accessory Continuity Bad ignition switch.
NOTE: Hold the ignition switch in the START position.
Between Bat and Starter Continuity Bad ignition switch.
Between Bat and Ign Continuity Bad ignition switch.
NOTE: Put the switch in the Accessory position.
Between Bat and Accessory Continuity Bad ignition switch.

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11 – Neutral Start Relay

Correct
Reading
Terminal for wire 0-DE to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL.
Terminal for wire 25T to ground 24 volts Check circuit 25T, check FNR switch (55).
NOTE: Have another person hold the ignition switch in the START position.
Terminal for wire 21K-B to ground 24 volts Check circuit 21K-B and ignition switch (10).
Terminal for wire 21C to ground 24 volts Bad neutral start relay.
12 – Voltmeter Relay
Correct
Reading
Terminal for wire 0-DB to ground Continuity Bad ground circuit.
Check circuit 18R to power relay module C in engine

Terminal for wire 18-RA to ground 24 volts
compartment.
NOTE: Turn ignition switch to the ON position.
Terminal for wire 13K-C to ground 24 volts Check circuit 13K or ignition switch.
Terminal for wire 13V to ground 24 volts Bad voltmeter relay.

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POWER RELAY MODULES AND COLD STARTING SYSTEMS
15 19 13
20 17
16 14
21
18
BS06H241 / BS06H242
13. POWER RLEAY MODULE A 18. POWER RELAY MODULE D

14. POWER RELAY MODULE B 19. CIRCUIT BREAKER CAB +
15. POWER RELAY MODULE C 20. WATER SEPARATOR HEATER
16. GRID HEATER RELAY 21. FUEL FILTER HEATER
17. GRID HEATER

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4002-46
13 – Power Relay Module A, Ignition Power

Correct
Reading
Terminal for wire 0-EB to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.
Check circuit 1CB to 105 Amp circuit breaker in engine

Terminal for wire 1CB-A to ground 24 volts
compartment, check circuit breaker.
Terminal for wire 13K-B to ground 24 volts Check circuit 13K and check ignition switch (10).
Terminal for wire J1 BUSS to ground 24 volts Bad power relay module A.
14 – Power Relay Module B, Ignition Power

Correct
Reading
Terminal for wire 0-EA to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.
Terminal for wire PRM-B BUSS to Check circuit 1CB to 105 Amp circuit breaker in engine
24 volts
ground compartment, check circuit breaker.
Check circuit 13 to Time Delay Module, check TDM (7), check

Terminal for wire 13D to ground 24 volts
ignition switch (10).
Terminal for wire 13H to ground 24 volts Bad power relay module B.
15 – Power Relay Module C, For Fuel Filter Heater and Water Separator Heater
Correct
Reading
NOTE: Make sure engine temperature is below -0 °C (32 °F).
Terminal for wire 0-GA to ground Continuity Bad ground circuit or bad EDC7 (24).
Terminal for wire 1-NC to ground 24 volts Check circuit 1 and circuit to batteries.
Terminal for wire 28F to ground 24 volts Check EDC7 (24).
Terminal for wires 1-GA ground 24 volts Check 40 ampere fuse, bad power relay module.

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16 – Grid Heater Relay

Correct
Reading
Terminal for wire 0-BV to ground Continuity Bad ground circuit or bad EDC7 (24).
NOTE: Put the master disconnect switch in the ON position and the ignition switch in ON position.
Terminal for wire 1-Y to ground 24 volts Bad 150 ampere fuse. Check wires 1-Y and 1-E.
NOTE: Have an assistant put the transmission in neutral and the ignition switch in the START position. Make sure
engine temperature is below -0 °C (32 °F).
Terminal for wire 28G to ground 24 volts Bad EDC7 (24), also check circuit 28G.
Terminal for wire 1-BE to ground 24 volts Bad grid heater relay.
17 – Grid Heater
Located in the right side of the engine in intake manifold, open engine compartment to gain access.
Correct
Reading
NOTE: Disconnect terminal for wire 1-BE from grid heater.
Terminal for wire 0-ES to ground Continuity Bad ground circuit.
Terminal for wire 1-BE of grid heater Resistance If an open or short circuit is obtained, replace the grid heater.
to ground
18 – Circuit breaker Cab B+

Correct
Reading
Between terminal A and B on circuit Continuity Bad circuit breaker

breaker
19 – Water Separator Heater

Located in the right side of the engine compartment on water separator housing, open engine compartment to gain
access.
Correct
Reading
Terminal for wire 0-BW to ground Continuity Bad ground circuit.
NOTE: Disconnect connector WSH from water separator heater.
Between terminals A and B of heater 1.9 ohms Bad heater.
NOTE: If the readings are good, check circuit 1-G between water separator heater connector WSH and power
relay module C connector PRM-C1.

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20 – Fuel Filter Heater

Located in the right side of the engine compartment on fuel filter housing, open engine compartment to gain access.
Correct
Reading
Terminal for wire 0-BX to ground Continuity Bad ground circuit.
NOTE: Disconnect connector FFH from fuel filter heater.
Between terminals A and B of heater 1.9 ohms Bad heater.
NOTE: If the readings are good, check circuit 1-G between fuel filter heater connector FFH and power relay
module C connector PRM-C1.
21 – Power Relay Module D, Accessory Power

Correct
Reading
Terminal for wire 0-EC to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Accessory or the ON
position.
Terminal for wire PRM-D BUSS to Check circuit 1CB to 105 Amp circuit breaker in engine
24 volts
Terminal for wire ACC-B to ground 24 volts Check circuit 12ACC, check ignition switch (10).
Terminal for wire J11 BUSS-ECA to 24 volts Bad power relay module D.
ground

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ENGINE CONTROLLER
24
22
23
BS06H241 / BS06H242
22. WATER IN FUEL SENSOR

23. THROTTLE POTENTIOMETER
24. ENGINE CONTROLLER

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4002-50
22 – Water In Fuel Sensor

Located in the right side of the engine compartment on water separator housing, open engine compartment to gain
access.
Correct
Reading
Terminal for wire 0-BP to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position.
Check fuse ECD-F2, power relay module B (14), also check

Terminal for wire 18J-H to ground 24 volts
circuit 18J.
NOTE: Remove sensor from filter and place probes in water.
Terminal for wire 35W to ground 24 volts Bad water separator sensor.
23 – Throttle Potentiometer
Located below cab under throttle pedal.
Correct
Reading
NOTE: Put the master disconnect switch in the ON position and the ignition switch in ON position.
Terminal for wire 24S to 24R 5 volts Bad EDC7 (24). Also check wire 24S.
Terminal for wire 24R to ground Continuity Bad EDC7 (24). Also check wire 24R.
NOTE: Throttle pedal in low idle position.
0.4 ± 0.025
Terminal for wire 24B to 24R Bad potentiometer.
volts
NOTE: Throttle pedal in high idle position.
Terminal for wire 24B to 24R 4.0 ± 0.1 volts Bad potentiometer.
NOTE: Put the ignition switch in OFF position and the master disconnect switch in the OFF position. Disconnect
connector RTHP. Throttle pedal in low idle position.
Between pin 1 and 6 at pedal Open Bad potentiometer.
NOTE: Throttle pedal in high idle position.
1000 ± 400
Between pin 1 and 6 at pedal ohms at 20° C Bad potentiometer.
(68° F)
NOTE: Throttle pedal in any position.
1200 ± 400
Between pin 4 and 5 at pedal ohms at 20° C Bad potentiometer.
(68° F)

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4002-51
24 – Electronic Diesel Control

Located on right side of engine, open engine compartment to gain access.
Correct
Reading
NOTE: Put the ignition switch in the OFF position. Put the master disconnect switch in the OFF position.
Disconnect connector EDC7.
Terminal for wire 0-BE pin 5 to Continuity Bad ground circuit.

ground
Terminal for wire 0-BF pin 6 to Continuity Bad ground circuit.
ground
Terminal for wire 0-BD pin 10 to Continuity Bad ground circuit.

ground
Terminal for wire 0-BC pin 11 to Continuity Bad ground circuit.

ground
NOTE: Put the master disconnect switch in the ON position. Put the ignition switch in the ON position.
Terminal for wire 18J-C pin 2 to 24 volts Bad fuse ECD-F2, bad wire 18J.
ground
Terminal for wire 18J-B pin 3 to 24 volts Bad fuse ECD-F2, bad wire 18J.
ground
Terminal for wire 18J-D pin 8 to 24 volts Bad fuse ECD-F2, bad wire 18J.
ground
Terminal for wire 18J-E pin 9 to 24 volts Bad fuse ECD-F2, bad wire 18J.
ground
NOTE: Use diagnostic service tool for additional tests on EDC7.

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RETURN TO TRAVEL - RETURN TO DIG - PIN ENGAGE
28 30
25 26 31 32
29 27
33
34
BS06H241 / BS06H242
25. RETURN TO TRAVEL FLOAT SWITCH 30. HEIGHT CONTROL/RETURN TO TRAVEL PROXIMITY SWITCH
26. HEIGHT CONTROL SWITCH 31. RETRUN TO DIG SWITCH
27. ELETROMAGNETIC DETENTS 32. PIN ENGAGE SWITCH (OPTION)
28. RETURN TO DIG PROXIMITY SWITCH 33. PILOT PRESSURE SOLENOID
29. PILOT CONTROL RELAY ECD-K3 34. PIN ENGAGE SOLENOID (OPTION)

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25 – Return-To-Travel/Float Switch
Located on right side console.
Correct
Reading
Terminal for wire 0-B2 to ground Continuity Bad ground circuit.
Terminal for wire 0-29 to ground Continuity Bad ground circuit.
NOTE: Disconnect the wiring harness connector from the return-to-travel/float switch. Put the return-to-
travel/float switch in FLOAT position.
Between switch terminals 1 and 2 Continuity Bad return-to-travel/float switch.
NOTE: Put the return-to-travel/float switch in the TRAVEL position.
Between switch terminals 2 and 3 Continuity Bad return-to-travel/float switch.
NOTE: Put ignition switch in OFF position. Connect wiring harness connector to return-to-travel/float switch. Put
ignition switch in ON position. Put driving lamp switch (95) in position 3.
Bad circuit 49-K. Also check driving lamp switch (95). If

Terminal for wire 49-K to ground 24 volts return-to-travel/float switch illumination LED is not ON with 24
volts at check point, replace return-to-travel/float switch.
26 – Height Control Switch

Correct
Reading
Terminals for wire 0-B3 to ground Continuity Bad ground circuit.
NOTE: Turn the master disconnect to the ON position, the ignition switch to the ON position and the pilot control
switch to the ON position.
Terminal for wire 53P-D to ground. 24 volts Bad pilot control relay (29), check fuse ECA-F5.
NOTE: Turn the height control switch to the ON position.
Terminal for wire 54A to ground. 24 volts Bad height control switch.

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4002-54
27 – Electromagnetic Detents
Located under right side console.
Correct
Reading
NOTE: For joystick controller.
74 ohms @
Between pins 3 and 4 Bad electromagnetic detent
20° C (68° F)
74 ohms @
20° C (68° F)
74 ohms @
20° C (68° F)
NOTE: For single axis controller.
328 ohms @
20° C (68° F)
328 ohms @
20° C (68° F)
328 ohms @
20° C (68° F)
NOTE: Put the master disconnect switch and ignition switch in ON position. Put pilot control switch (39) in OFF position and
return to travel/float switch (25) in ON position.
Wiring harness connector EM, pin 1 24 volts Bad return to travel/float switch (25). Also check wires 55A.
to ground
NOTE: Place the height control switch in the ON position.
Wiring harness connector EM, pin 2 24 volts Bad height control switch. Also check wires 54A.
to ground
NOTE: Place the return to dig switch in the ON position.
Wiring harness connector EM, pin 3 24 volts Bad return to dig switch. Also check wires 53A.
to ground
28 – Return-To-Dig Proximity Switch

Located on bucket cylinder.
Correct
Reading
NOTE: Disconnect the connector from the return-to-dig proximity switch. Put the master disconnect switch and
the ignition switch in the ON position. Put the pilot control switch (39) in the OFF position and the return to dig switch in the
ON position.
Terminal B for wire 0-AC to ground Continuity Bad ground circuit.
Bad bucket control valve detent electromagnets (27) or return

Terminal A for wire 53B to ground 24 volts
to dig switch. Also check circuit 53B.
Terminal C for wire 53P-H to ground 24 volts Bad pilot relay (29), also check circuit 53P.
NOTE: If the readings are good, replace the return-to-dig proximity switch.

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4002-55
29 – Pilot Control Relay

Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure pilot control switch (39) is
OFF.
Terminal for wire 19C-C to ground 24 volts Bad fuse ECA-F5, also check circuit 19C.
Terminal for wire 53C-A to ground 0 volt Bad instrument cluster (62). Also check circuit 53C.
Terminal for wire 53P-A to ground 24 volts Bad pilot control relay.
NOTE: Put the pilot control switch in ON position.
Terminal for wire 53C-A to ground 24 volts Bad instrument cluster (62). Also check circuit 53C.
30 – Height Control/Return-To-Travel Proximity Switch

Located on left front frame at lift arm pivot.
Correct
Reading
NOTE: Disconnect the connector from the height control/return-to-travel proximity switch. Put the master
disconnect switch and the ignition switch in the ON position. Put the pilot control switch (39) in the OFF position and the
return to travel switch in the ON position.
Terminal B for wire 0-AA to ground Continuity Bad ground circuit.
Bad bucket control valve detent electromagnets (27) or return

Terminal A for wire 54B to ground 24 volts
to travel switch. Also check circuit 54B.
Terminal C for wire 53P-J to ground 24 volts Bad pilot relay (29), also check circuit 53P.
NOTE: If the readings are good, replace the height control/return-to-travel proximity switch.
31 – Return to Dig Switch

Correct
Reading
Terminals for wire 0-B4 to ground Continuity Bad ground circuit.
NOTE: Turn the master disconnect to the ON position, the ignition switch to the ON position and the pilot control
switch to the ON position.
Terminal for wire 53P-E to ground. 24 volts Bad pilot control relay (29), check fuse ECA-F5.
NOTE: Turn the height control switch to the ON position.
Terminal for wire 53A to ground. 24 volts Bad return to dig switch.

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4002-56
32 – Pin Engage Switch (Option)

Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put pin engage switch in OFF
position.
Bad fuse ECA-F7 or power relay module A. Also check circuit

Terminal for wire 19P-A to ground 24 volts
19P.
Terminal for wire 57-B to ground 0 volt Bad pin engage switch.
NOTE: Put the pin engage switch in the ON position.
Terminal for wire 57-B to ground 24 volts Bad pin engage switch.
NOTE: Put the driving lamp switch (95) in position 3.
Check the driving lamp switch (95). Also check circuit 49. If
Terminal for wire 49-F to ground 24 volts LED in pin engage switch is not ON with 24 volts at check point,
replace pin engage switch.
33 – Pilot Pressure Solenoid

Located on bottom side of pilot controls.
Correct
Reading
Terminal for wire 0-DU to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the pilot control
switch (39) is OFF.
Terminal A for wire 53P-A to ground 24 volts Bad pilot control relay (29), also check circuit 53P.
NOTE: If the readings are good, replace the pilot pressure solenoid.
34 – Pin Engage Solenoid (Option)

Located on.
Correct
Reading
Terminal for wire 0-AE to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the pin engage switch (32) in the ON
position.
Terminal for wire 57 to ground 24 volts Bad pin engage switch (32), also check circuit 57.
NOTE: If the readings are good, replace the pin engage solenoid.

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4002-57
PILOT CONTROL - RIDE CONTROL - FAN CONTROL
43 44
35 37 39
36 40
38 41
42
BS06H241 / BS06H242
35. RIDE CONTROL SWITCH (OPTION) 40. RIDE CONTROL SOLENOID (OPTION)
36. RIDE CONTROL RELAY (OPTION) 41. ROLLBACK PRESSURE SWITCH (OPTION)
37. FAN CONTROL SWITCH (OPTION) 42. ROLLBACK JUMPER
38. FAN REVERSE RELAY (OPTION) 43. FAN PWM SOLENOID
39. PILOT CONTROL SWITCH 44. FAN REVERSE SOLENOID (OPTION)

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4002-58
35 – Ride Control Switch

Correct
Reading
NOTE: Disconnect connector SRC from ride control switch.
Connector SRC pin 7 to ground Continuity Bad ground circuit.
Ride control switch terminal 6 Continuity Bad ride control switch.

(positive) to terminal 7 (negative)
NOTE: Connect connector SRC to ride control switch. Put master disconnect switch and ignition switch in ON
position. Put ride control switch in OFF position.
Check fuse ECA-F5 and power relay module A. Also check

Terminal for wire 19C-D to ground 24 volts
circuit 19C.
Terminal for wire 58C to ground 0 volt Bad ride control switch.
NOTE: Put the ride control switch in the ON position.
Terminal for wire 58C to ground 24 volts Bad ride control switch.
NOTE: Put the driving light switch (95) in position 3.
Check driving lamp switch (95). Also check circuit 49. If LED in
Terminal for wire 49-G to ground 24 volts ride control switch is not ON with 24 volts at check point,
replace ride control switch.
36 – Ride Control Relay

Correct
Reading
Terminal 85 for wire 58L to

Continuity Check wire 58L.
connector TECM pin 57
Terminal 86 for wire 58H-A to Continuity Check wire 58H-A.

connector TECM pin 8
Terminal 87 for wire 58-E to ride Continuity Check wire 58-E

control switch (35) pin 6
NOTE: Put master disconnect switch and ignition switch in ON position. Put ride control switch in ON position.
Terminal for wire 58T to ground 24 volts Bad ride control switch. Also check wire 58T.
NOTE: If readings are normal, replace ride control relay.

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4002-59
37 – Fan Reversing Switch (Option)

Correct
Reading
Check fuse ECA-F7, power relay module A (13), also check

Terminal for wire 19P-C to ground 24 volts
circuit 19P.
NOTE: Put fan reversing switch in position 1.
Terminal for wire 52AU to ground 24 volts Bad fan reversing switch.
NOTE: Put fan reversing switch in momentary position, hold rocker.
Terminal for wire 52M to ground 24 volts Bad fan reversing switch.
NOTE: Put driving lamp switch in position 3.
Check driving lamp switch. If LEDs in fan reversing switch are

Terminal for wire 49-Q to ground 24 volts not ON with 24 volts at check point, replace fan reversing
switch.
38 – Fan Reverse Relay

Correct
Reading
NOTE: Put master disconnect switch and ignition switch in ON position.
Terminal for wire 19P-D and 19P-E 24 volts Check fuse ECA-F7 and circuit 19P.
to ground
NOTE: Put the fan reverse switch in the manual reverse position.
Bad fan reverse solenoid, bad fan reverse switch (37), bad
Terminals for wire 52A-A to ground 24 volts
advanced instrument cluster (62).

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4002-60
39 – Pilot Control Switch

Located on steering column pedestal.
Correct
Reading
Terminal for wire 0B1 to ground Continuity Bad ground circuit.
Terminal for wire 19C to ground 24 volts Bad fuse ECA-F1, also check circuit 19C.
NOTE: Press pilot control switch to turn ON switch LED.
Terminal for wire 31L to ground 24 volts Bad pilot control switch.
NOTE: Put the driving lamp switch (95) in position 3.
Check driving lamp switch (95) and fuse ECC-F3. Also check
Terminal for wire 49-N to ground 24 volts
circuit 49.
NOTE: If the readings are correct replace the pilot control switch.
40 – Ride Control Solenoid

Located on ride control valve inside of front frame.
Correct
Reading
NOTE: Disconnect connector YRC from ride control solenoid.
Connector YRC pin 2 to ground Continuity Bad ground circuit.
Between terminals 1 and 2 of ride 20 to 26 ohms Bad ride control solenoid.

control solenoid
41 – Rollback Pressure Switch (Option)

Located inside of front frame.
Correct
Reading
NOTE: Switch opens at 6.2 bar (90 psi). Release all hydraulic pressure from the system, disconnect the wiring
harness from the rollback pressure switch.
Between terminals A and B on Continuity Bad rollback pressure switch.

switch
Terminal for wire 58S to ground 37 to 43 ohms Bad ride control solenoid (40).
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the ride control switch (35) in the
ON position. Accelerate the machine to at least 5 km/hr (3 m.p.h.).
24 volts at
Bad ride control relay (36) or ride control switch (35). Also
Terminal for wire 58-B to ground 5 km/hr
check circuit 58.
(3 m.p.h.)

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4002-61
42 – Rollback Jumper (Option)

Located inside of front frame.
Correct
Reading
Between terminals A and B on Continuity Bad rollback jumper.

switch
43 – Fan PWM Solenoid (Option)

Located on fan control valve.
Correct
Reading
NOTE: Disconnect wiring harness connector YFN from fan PWM solenoid.
Between pins 1and 2 of fan PWM 26 to 32 ohms Bad fan reversing solenoid.
solenoid
Pin 2 of wiring harness connector Continuity Bad ground circuit.

YFN to ground
NOTE: In the options menu of the instrument cluster select auto for the fan. Stall the transmission to raise
transmission temperature to high operating range.
Pin 1 of wiring harness connector 24 volts Bad instrument cluster. Also check wire 56.
YFN to ground
44 – Fan Reversing Solenoid (Option)

Located on fan control valve.
Correct
Reading
NOTE: Disconnect wiring harness connector YFR from fan reversing solenoid.
Between pins 1and 2 of fan 36 to 42 ohms Bad fan reversing solenoid.

reversing solenoid
Pin 2 of wiring harness connector Continuity Bad ground circuit.

YFR to ground
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put fan reversing switch in ON
position (hold rocker in momentary position).
Pin 1 of wiring harness connector 24 volts Bad fan reversing switch. Also check wire 52-A.
YFR to ground

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4002-62
TRANSMISSION
46 48
52
55 56 57 60
49 50 45 53 54
51 47 61 58
BS06H241 / BS06H242
45. OUTPUT SPEED SENSOR 54. TRANSMISSION ENABLE SWITCH

46. TRANSMISSION SOLENOID VALVE AND TEMPERATURE SENSORS 55. FNR SWITCH FOR JOYSTICK CONTROLS
47. FILTER MAINTENANCE SWITCH 56. TRANSMISSION KICK-DOWN SWITCH
48. TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 57. FNR SWITCH FOR SINGLE AXIS CONTROLS
49. ENGINE SPEED SENSOR 58. TRANSMISSION AUTO SWITCH
50. INTERMEDIATE SPEED SENSOR 59. BRAKE DECLUTCH PRESSURE SWITCH
51. TURBINE SPEED SENSOR 60. DECLUTCH SWITCH
52. TRANSMISSION SHIFTER 61. DIAGNOSTIC CONNECTOR
53. TRANSMISSION ELECTRONIC CONTROL MODULE

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4002-63
NOTE: If you have transmission shifting problems, see Section 6002 for complete troubleshooting information for
Items 45 through 61.
45 – Output Speed Sensor

46 – Transmission Solenoid Valve and Temperature Sensors
47 – Filter Maintenance Switch
48 – Torque Converter Output Temperature Sender
49 – Engine Speed Sensor
50 – Intermediate Speed Sensor
51 – Turbine Speed Sensor
52 – Transmission Shifter
53 – Transmission Electronic Control Module
54 – Transmission Enable Switch
55 – FNR Switch for Joystick Controls
56 – Transmission Kick-down Switch (Located In Hydraulic Controller for Joystick
Option; Next to Hydraulic Levers for Single Axis Controls)
57 – FNR Switch for Single Axis Controls
58 – Transmission Auto Switch
59 – Brake Declutch Pressure Switch
60 – Declutch Switch
61 – Diagnostic Connector

Copyright ©
4002-64
WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE
66
62 63
67 68
69
65 64
BS06H241 / BS06H242
62. INSTRUMENT CLUSTER CONNECTOR 1 66. AIR FILTER RESTRICTION SWITCH

63. WARNING BUZZER 67. PARKING BRAKE SOLENOID
64. PARKING BRAKE RELAY 68. RADIATOR COOLANT TEMPERATURE SENDER
65. FUEL LEVEL SENDER 69. BRAKE PRESSURE WARNING SWITCH

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4002-65
62 – Instrument Cluster Connector 1

Located on instrument cluster.
Correct
Reading
NOTE: Disconnect the connector AIC-1 from the instrument cluster and SW-PD from the switch pad.
Connector terminal SW-PD 5 to Open Circuit Bad air filter restriction switch (66). Also check circuit 31F-A.
ground
Connector terminal SW-PD 4 to Bad hydraulic filter restriction switch (72). Also check circuit
Open Circuit
ground 31H-A.
Connector terminal AIC-1 6 and 12 Continuity Bad ground circuit. Check wires 0-DW and 0-DX.
to ground
Connector terminal AIC-1 11to 130 to 9500 Bad engine coolant temperature sender (68). Also check circuit
ground ohms circuit 36C-A and ground circuit at sender.
Connector terminal AIC-1 2 to Bad fuel level sender (65). Also check circuit 36F-A and ground
33 to 240 ohms
ground circuit at sender.
Connector terminal AIC-1 9to 130 to 9500 Bad hydraulic oil temperature sender (73). Also check circuit
ground ohms 36H-A and ground circuit at sender.
Connector terminal AIC-1 25 to Continuity Bad wire 17P-A.

connector terminal SW-PD 9
Connector terminal AIC-2 4 to Open Circuit Bad redundant brake switche(s) (75). Also check circuit 33R.
ground
Connector terminal AIC-1 4 and

SW-PD 8 to terminals 26 and 27 on Continuity Bad circuit CAN-L.
the transmission electronic control
module (53)
Connector terminal AIC-1 3 and

SW-PD 7 to terminal 25 on the Continuity Bad circuit CAN-H.
transmission electronic control
module (53)
Connector terminal AIC-1 15 to Check LH and RH stop lamps and circuit 44A-B. Also check
Continuity
ground ground circuit at lamps.
NOTE: Put the parking brake switch in the ON position.
Connector terminal AIC-1 14to Bad parking brake switch. Also check fuse ECA-F6 and circuit
24 volts
ground 19D and 52C.
NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
Check fuse G, blower switch, thermostat switch, and A/C low

Connector terminal 10 to ground 24 volts
pressure switch. Also check circuits 61R, 61A, and 61T.

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4002-66
NOTE: Put the driving lamp switch in position four or five. Put the high/low beam switch in HIGH BEAM position.
Connector terminal SW-PD 1to Check high/low beam switch, driving lamp switch, and fuse
24 volts
ground ECC-F3. Also check circuit 41H-D.
Connector terminal AIC-1 14 to Bad parking brake relay or fuse ECA-F6. Also check circuits
24 volts
ground 52C and 19D.
Connector terminal AIC-1 20 to Bad pilot control relay or fuse ECA-F5. Also check circuits 53C
24 volts
ground and 19C.
63 – Warning Buzzer
Located on steering column under instrument cluster.
Correct
Reading
NOTE: Buzzer sounds for five seconds during self test when ignition switch is turned on.
Terminal for wire 0_B27 to ground Continuity Bad ground circuit.
NOTE: Turn the ignition switch to the ON position
Terminal for wire 35B to ground 24 volts Bad instrument cluster
NOTE: If all readings are good, replace buzzer.
64 – Parking Brake Relay

Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the parking brake
switch (74) is OFF.
Terminal for wire 19D-B and 19D-C 24 volts Bad fuse ECA-F6, also check circuit 19D.
to ground
Terminal for wire 52C to ground 0 volt Bad instrument cluster (62). Also check circuit 52C.
Terminal for wire 52P-B to ground 24 volts Bad parking brake relay.
NOTE: Put the parking brake switch in the ON position.
Terminal for wire 52C to ground 24 volts Bad instrument cluster (62). Also check wire 52C.

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4002-67
65 – Fuel Level Sender

Located on the fuel tank top right side.
Correct
Reading
Terminal for wire 0-BU to ground Continuity Bad ground circuit.
Approximately
Terminal for wire 36F to ground Check the instrument cluster (62).
5 volts
NOTE: Put the ignition switch and the master disconnect switch in the OFF position. Tag and disconnect the wires
from the fuel level sender.
Between terminals of fuel level 33 to 240

Bad fuel level sender.
sender ohms
66 – Air Filter Restriction Switch

Located on the air filter left side.
Correct
Reading
NOTE: Air filter restriction switch closes at -6.4 kPa (Gauge) (-0.928 psig).
Terminal for wire 0-BY to ground Continuity Bad ground circuit.
Approximately
Terminal for wire 31F to ground Check the instrument cluster (62).
11.5 volts
NOTE: If the readings are correct replace the air filter restriction indicator switch.
67 – Parking Brake Solenoid

Located on the foot brake valve.
Correct
Reading
Terminal for wire 0-AL to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and ignition switch in ON position. Put parking brake switch in OFF
position.
Terminal 1 for wire 52P to ground 24 volts Bad parking brake relay (64). Also check circuit 52P
NOTE: If the readings are good, replace the parking brake solenoid.

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4002-68
68 – Radiator Coolant Temperature Sender

Located on the lower radiator hose to engine on left side of engine compartment.
Correct
Reading
Terminal for wire 0-BAE to ground Continuity Bad ground circuit.
NOTE: Disconnect the connector from the radiator coolant temperature sender.
Between terminals of radiator 3521 ohms

Replace radiator coolant temperature sender.
coolant temperature sender at 20° C (68° F)
Approximately
Terminal A for wire 36C to ground Check the instrument cluster (62).
5 volts
69 – Brake Warning Pressure Switch

Correct
Reading
NOTE: Brake warning pressure switch opens at 110.3 bar (1600 psi).
Terminal 2 for wire 0-AL to ground Continuity Bad ground circuit.
Approximately
Terminal 1 for wire 33P to ground Check circuit 33P.
11.5 volts
NOTE: With engine not running pump brakes at least 12 times. Disconnect the wires from the brake warning
pressure switch.
Between terminals 1 and 2 of the Continuity Bad brake warning pressure switch.
switch
NOTE: Start and run the engine at idle two minutes.
Bad brake warning pressure switch or brake pressure is below

Between terminals 1 and 2 of the Open Circuit 110.3 bar (1600 psi). Refer to Section 7002 to check brake
switch
pressure.

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4002-69
SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE
77
70 71 74
75
76
72
73
BS06H241 / BS06H242
70. SWITCH PAD 74. PARK BRAKE SWITCH

71. INSTRUMENT CLUSTER CONNECTOR 2 75. REDUNDANT BRAKE PRESSURE SWITCH 1
72. HYDRAULIC FILTER RESTRICTION SWITCH 76. REDUNDANT BRAKE PRESSURE SWITCH 2
73. HYDRAULIC OIL TEMPERATURE SENDER 77. COOLANT LEVEL SENDER

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4002-70
70 – Switch Pad
Correct
Reading
NOTE: Disconnect switch pad connector, put master disconnect switch and ignition switch in ON position.
Terminal for wire 17P-A to ground. 24 volts Bad instrument cluster (62).
NOTE: Disconnect instrument cluster connector 1.
Between terminals for wire 17P-A Continuity Bad wire 17P-A.

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4002-71
71 – Instrument Cluster Connector 2

Located on instrument cluster.
Correct
Reading
NOTE: Disconnect the connector AIC-2 from the instrument cluster and SW-PD from the switch pad.
Connector terminal AIC-2 5 to Bad brake warning pressure switch (69). Also check circuit
Continuity
ground 33P-A and ground circuit at brake warning pressure switch.
Connector terminal AIC-2 26 to Bad coolant level sender (77). Also check circuit 31D-A and
Continuity
ground ground circuit at coolant level sender.
Connector terminal AIC-2 11 to Bad secondary steering pressure switch (118). Also check
Continuity
ground circuit 35X and ground circuit at pressure switch.
Connector terminal SW-PD 5 to Open Circuit Bad air filter restriction switch (66). Also check circuit 31F-A.
ground
Connector terminal SW-PD 4 to Bad hydraulic filter restriction switch (72). Also check circuit
Open Circuit
ground 31H-A.
Connector terminal AIC-2 15 and 22 Continuity Bad ground circuit. Check wires 0-DB and 0-D-A.
to ground.
Connector terminal AIC-2 4 to Open Circuit Bad redundant brake switche(s) (75). Also check circuit 33R.
ground
Connector terminal AIC-2 14 and 20 Bad fuse ECD-F3. Also check circuit 19S-C and 19S-D. Also
24 volts
to ground check power relay module B (14).
Connector terminal AIC-2 21 to Bad fuse ECA-F3. Also check circuit 19E-A. Also check power
24 volts
ground relay module A (13).
NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
Check fuse G, blower switch, thermostat switch, and A/C low

Connector terminal 10 to ground 24 volts
pressure switch. Also check circuits 61R, 61A, and 61T.
NOTE: Put the driving lamp switch in position four or five. Put the high/low beam switch in HIGH BEAM position.
Connector terminal SW-PD 1to Check high/low beam switch, driving lamp switch, and fuse
24 volts
ground ECC-F3. Also check circuit 41H-D.
NOTE: Put the turn signal switch in the LEFT TURN position.
24 volts on and Check fuse ECA-F8, turn signal switch, and flasher module.
Connector terminal AIC-2 9to off every 1-2 Also check wire 19B, circuit 45A-A to flasher module, and
ground seconds circuit 45L from flasher module to instrument cluster.
NOTE: Put the turn signal switch in the RIGHT TURN position.
24 volts on and Check fuse ECA-F8, turn signal switch, and flasher module.
Connector terminal AIC-2 10to off every 1-2 Also check wire 19B, circuit 45B-A to flasher module, and
ground seconds circuit 45R from flasher module to instrument cluster.
Connector terminal AIC-2 18to Bad pilot control switch or fuse ECA-F1. Also check wire 31L
24 volts
ground and circuit 19A.

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4002-72
]
72 – Hydraulic Filter Restriction Switch

Located on hydraulic filter block.
Correct
Reading
NOTE: Hydraulic filter restriction switch closes at 2.8 bar (40 psi).
Check between the housing of the

Bad ground connection between the hydraulic filter restriction
hydraulic filter restriction switch and Continuity
switch and ground.
ground
Approximately
Terminal for wire 31H to ground. Check the instrument cluster (62).
11.5 volts
NOTE: If the readings are correct replace the hydraulic filter restriction switch.
73 – Hydraulic Oil Temperature Sender

Located on hydraulic filter block.
Correct
Reading
Terminal for wire 0-HW to ground Continuity Bad ground circuit.
NOTE: Disconnect the connector from the hydraulic oil temperature sender.
Between terminals of hydraulic oil 3521 ohms

Replace hydraulic oil temperature sender.
temperature sender at 20° C (68° F)
Approximately
Terminal A for wire 36H to ground Check the instrument cluster (62).
5 volts

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4002-73
74 – Parking Brake Switch

Correct
Reading
Terminal for wire 19A-L to ground 24 volts Check fuse ECA-F1, also check circuit 19A.
NOTE: Apply parking brake switch.
Terminal for wire 33U to ground 24 volts Bad parking brake switch.
NOTE: Put the driving lamp switch (95) in position 3, 4, or 5.
Bad driving lamp switch. Also check fuse ECC-F3 and circuits
Terminal for wire 49-V to ground 24 volts
41 and 19Z.
NOTE: If 24 volts between wire 49 and ground and parking brake switch is not illuminated, replace parking brake
switch.
75 – Redundant Brake Pressure Switch 1

Located on steel lines at accumulators.
Correct
Reading
NOTE: Redundant brake switch close at 62 bar (900 psi).
Terminal for wireS 0-HM to ground Continuity Bad ground circuit.
Approximately
Terminal A for wire 33R-C to ground Bad instrument cluster (62), also check circuit 33R.
11.5 volts
NOTE: If the readings are good, replace the redundant brake pressure switch(es).
76 – Redundant Brake Pressure Switch 2

Located on steel lines at accumulators.
Correct
Reading
NOTE: Redundant brake switches close at 62 bar (900 psi).
Terminal for wireS 0-HL to ground Continuity Bad ground circuit.
Terminal A for wireS 33R-B to Approximately

Bad instrument cluster (62), also check circuit 33R.
ground 11.5 volts
NOTE: If the readings are good, replace the redundant brake pressure switch(es).

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4002-74
77 – Coolant Level Sender

Located on radiator top tank.
Correct
Reading
Terminal for wire 0-HV to ground Continuity Bad ground circuit.
Approximately
Terminal A for wire 31D to ground Check circuit 31D, also check the instrument cluster (62).
1.6 volts AC
NOTE: If the readings are correct replace the coolant level sender.

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4002-75
BACK UP ALARM CONTROLS
79
78
BS06H241 / BS06H242
78. BACK UP ALARM RELAY 79. BACK UP ALARM DISABLE SWITCH


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4002-76
78 – Back-up Alarm Relay

Correct
Reading
NOTE: Disconnect the transmission electronic control module (53) connector TECM.
Terminal for wire 35C to terminal 7 of Continuity Bad wire 35C.

connector TECM
Bad fuse ECA-F1, also check wires 19A-P, power relay module
Terminal for wire 19A-P to ground 24 volts
A, Ignition power (13).
Bad fuse ECA-F14, also check wires 19H, power relay module
Terminal for wire 19H to ground 24 volts
D, accessory power (21).
NOTE: Put parking brake switch in OFF position. Depress brake pedal once and put gear selector in REVERSE.
Terminal for wire 35A-A to ground 24 volts Bad back-up alarm relay.
79 – Back-up Alarm Disable Switch

Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position and the park brake to the OFF
position. Depress brake pedal once. Move the transmission shift lever to REVERSE.
Terminal for wire 35A-B to ground 24 volts Bad back-up alarm relay (78), also check circuit 35A-B.
NOTE: Wires 35A-E and 35A-D are connected together, connectors 209F and 209M, and switch is removed in
North American models. The connectors are disconnected and the switch is installed in TUV road approved
(Germany) models.
Terminal for wire 35R-C to ground 24 volts Bad back-up alarm disable switch.

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4002-77
LIGHTS - 01
87
82 85
81
86
88
83
80 84
89
BS06H241 / BS06H242
80. WORK LIGHTS SWITCH 85. LEFT HAND FRONT WORK LAMP
81. DOOR SWITCH 86. RIGHT HAND FRONT WORK LAMP
82. ROTATING BEACON (OPTIONAL) 87. LEFT HAND REAR WORK LAMP
83. DOME LIGHT 88. RIGHT HAND REAR WORK LAMP
84. ROTATING BEACON SWITCH (OPTIONAL) 89. DIODES

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4002-78
80 – Work Lamps Switch

Correct
Reading
Terminal for wire 0-B14 to ground Continuity Bad ground circuit
NOTE: Put master disconnect witch in the ON position.
Terminal for wire 42-A and 42-B to 24 volts Bad fuse ECC-F2.
ground
NOTE: Put the work lamps switch in position 2 for front work lamps.
Terminal for wire 42FS to ground 24 volts Bad work lamps switch.
NOTE: Put the wok lamps switch in position 3 for rear work lamps.
Terminal for wire 42RS to ground 24 volts Bad work lamps switch.
81 – Door Switch
Located above door in cab.
Correct
Reading
Terminal for wire 19U-F to ground 24 volts Bad fuse ECC-F1.
NOTE: Disconnect connector DS at door switch.
Between pins on door switch with Continuity Bad door switch.

door open
Between pins on door switch with Open circuit Bad door switch
door closed
82 – Rotating Beacon (Option)

Plug is located on left side front of cab.
Correct
Reading
Bulb Continuity Bad bulb.
Terminal for wire 0-MC to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and beacon switch (84) in ON position.
Bad circuit between the beacon and the beacon switch (84).
Terminal for wire 46-D to ground 24 volts
Also check the beacon switch (84).
NOTE: If readings are good replace the rotating beacon.

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4002-79
83 – Dome Lamp
Located in top of cab.
Correct
Reading
Terminal for wire 0-MB to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put dome lamp switch in ON position.
Terminal for wire 19U-C to ground 24 volts Check fuse ECC-F1, also check circuit 19U.
24 volts Check circuit 43, also check advanced instrument cluster (62)
Terminal for wire 43-B to ground 3 to 5 seconds and time delay module (7).
NOTE: If readings are good, replace dome lamp.
84 – Beacon Switch (Option)

Correct
Reading
NOTE: Put master disconnect switch in ON position and driving lamp switch (95) in position 3.
Terminal for wire 19U-H to ground 24 volts Check fuse ECC-F1, also check circuit 19U.
NOTE: Put the beacon switch in the ON position.
Terminal for wire 46-C to ground 24 volts Bad beacon switch.
85 – Left Hand Front Work Lamp

Located on left front side of cab.
Correct
Reading
NOTE: Disconnect wiring harness connector LLFW from LH front work lamp connector.
Flood lamp connector pin A to pin B Continuity Bad lamp bulb.
NOTE: Connect wiring harness connector LLFW to LH front work lamp connector.
Terminal for wire 0-MU to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 3.
Check fuse ECB-F1 and driving lamp switch (95). Also check
Terminal for wire 42C-H to ground 24 volts circuit 42C from flood lamp to lamp switch (95) and wire 42-A
to fuse ECC-F2.

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4002-80
86 – Right Hand Front Work Lamp

Located on right front side of cab.
Correct
Reading
NOTE: Disconnect wiring harness connector LRFW from RH front work lamp connector.
NOTE: Connect wiring harness connector LRFW to RH front work lamp connector.
Terminal for wire 0-MJ to ground Continuity Bad ground circuit.
Terminal for wire 42C-G to ground 24 volts circuit 42C from flood lamp to lamp switch (95) and wire 42-A
to fuse ECC-F2.
87 – Left Hand Rear Work Lamp

Located on left rear side of cab.
Correct
Reading
NOTE: Disconnect wiring harness connector LLRW from LH rear work lamp connector.
NOTE: Connect wiring harness connector LLRW to LH rear work lamp connector.
Terminal for wire 0-ME to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put driving lamp switch (95) in position 4 or 5.
Terminal for wire 42R-H to ground 24 volts circuit 42R from flood lamp to lamp switch (95) and wire 42-B
to fuse ECC-F2.
88 – Right Hand Rear Work Lamp

Located on right rear side of cab.
Correct
Reading
NOTE: Disconnect wiring harness connector LRRW from RH rear work lamp connector.
NOTE: Connect wiring harness connector LRRW to RH rear work lamp connector.
Terminal for wire 0-MF to ground Continuity Bad ground circuit.
Terminal for wire 42R-G to ground 24 volts circuit 42R from flood lamp to lamp switch (95) and wire 42-B
to fuse ECC-F2.

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4002-81
89 – Lights Diodes
Located in the cab access panel for fuses and relays, rear of compartment.
Correct
Reading
NOTE: Disconnect wiring harness connector D-OR from diode connector.
Multimeter positive on pin A to pin C None Bad diode.
Multimeter positive on pin B to pin C None Bad diode.
Multimeter positive on pin C to pin A Continuity Bad diode.
Multimeter positive on pin C to pin B Continuity Bad diode.

Copyright ©
4002-82
LIGHTS - 02
93 94
95
92 91 90
BS06H241 / BS06H242
90. BRAKE LIGHTS SWITCH 93. HAZARD SWITCH

91. BRAKE LIGHTS RELAY 94. TURN SIGNAL, HIGH-LOW BEAM, AND HORN SWITCH
92. FLASHER MODULE 95. DRIVING LIGHTS SWITCH

Copyright ©
4002-83
90 – Brake Lamp Pressure Switch

Correct
Reading
NOTE: Put master disconnect switch in ON position.
Terminal for wire 1-AA to ground 24 volts Check fuse ECC-F4, also check wires 1-AA and 1-DR.
Terminal for wire 44 to ground 0 volt Bad brake lamp pressure switch.
NOTE: Put ignition switch in ON position. Have another person press and hold down brake pedal.
Terminal for wire 44 to ground 24 volts Bad brake lamp pressure switch.
91 – Brake Lamps Relay

Correct
Reading
Terminal for wire 0-EF to ground Continuity Bad ground circuit.
Terminal for wire 1-DW to ground 24 volts Check fuse ECC-F4 and wires 1-DW and 1-DV.
Terminal for wire 44A to ground 0 volt Bad brake lamp pressure switch (90).
Terminal for wire 44A-A to ground 0 volt Bad brake lamps relay.
NOTE: Put ignition switch in ON position. Have another person press and hold down brake pedal.
Terminal for wire 44A to ground 24 volts Bad brake lamp pressure switch (90).
Terminal for wire 44A-A to ground 24 volts Bad brake lamps relay.

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4002-84
92 – Flasher Module
Correct
Reading
NOTE: Wiring harness connectors 64F and 64M must be connected for North American Machines for opposite
side steady on operation and disconnected for European machines for opposite side off operation.
Terminal for wire 0-EG to ground Continuity Bad ground circuit.
Terminal for wire 0-EH to ground Continuity Bad ground circuit.
Terminal for wire 45N-A to terminal

for wire 45N-B (North American Continuity Bad 45N circuit.
machines only)
Terminal for wire 1-DU to ground 24 volts Check fuse ECC-F4. Also check wires 1-DU and 1-DV.
NOTE: Put ignition switch in the ON position. Put the hazard switch (93) ON.
Terminal for wire 45H to ground 24 volts Bad hazard switch (93). Also check wire 45H.
Intermittent 24
Terminal for wire 45L-D to ground Bad flasher module.
volts
Intermittent 24
Terminal for wire 45R-E to ground Bad flasher module.
volts
NOTE: Put hazard switch (93) in OFF position. Put turn signal switch (94) in RIGHT turn position.
Bad turn signal switch (94) or fuse ECA-F8. Also check wires
Terminal for wire 45B-A to ground 24 volts
45B-A and 45B.
Intermittent 24
Terminal for wire 45R-E to ground Bad flasher module.
volts
NOTE: Put turn signal switch (94) in LEFT turn position.
Terminal for wire 45A-A to ground 24 volts Bad turn signal switch (94) or fuse B. Also check wire 45A-A.
Intermittent 24
Terminal for wire 45L-D to ground Bad flasher module.
volts

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4002-85
93 – Hazard Switch
Correct
Reading
Terminal for wire 1-KA to ground 24 volts Check fuse ECC-F6. Also check wires 1-KA and 1-DV.
NOTE: Put hazard switch in ON position.
Bad hazard switch. If hazard switch LED is not ON with 24 volts

Terminal for wire 45H to ground 24 volts
at check point, replace hazard switch.
NOTE: Put driving lamp switch (95) in position 3.
Check driving lamp switch (95). Also check circuit 49 to lamp

Terminal for wire 49-D to ground 24 volts switch (95). If hazard switch LED is not ON with 24 volts at
check point, replace hazard switch.
94 – Turn Signal, High-Low Beam, and Horn Switch

Correct
Reading
HORN SWITCH
Terminal for wire 0-EP to ground Continuity Bad ground circuit.
Check fuse ECC-F6 and horn relay (98). Also check wires 64C
Terminal for wire 64C to ground 24 volts
and circuit 19U.
NOTE: If readings are good, replace the switch.
TURN SIGNAL
Check fuse ECA-F8 and power relay module A (13). Also check
Terminal for wire 19B to ground 24 volts
wire 19B.
NOTE: Move turn signal lever to RIGHT turn position.
Terminal for wire 45B-A to ground 24 volts Bad turn signal switch.
NOTE: Move turn signal lever to LEFT turn position.
Terminal for wire 45A-A to ground 24 volts Bad turn signal switch.
HIGH-LOW BEAM SWITCH
Terminal for wire 0-EP to ground Continuity Bad ground circuit.

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4002-86
95 – Driving Lamp Switch

Correct
Reading
Terminal for wire 19Z to ground 24 volts Check fuse ECC-F3, also check circuit 19Z.
NOTE: Put the driving lamp switch in position 2.
Terminal for wire 41T to ground 24 volts Bad driving lamp switch.
Terminal for wire 41J to ground 24 volts Bad driving lamp switch.

Copyright ©
4002-87
LIGHTS - 03 AND HORN
96 99
97
98
BS06H241 / BS06H242
96. LEFT HAND FRONT COMBINATION LAMPS 98. HORN RELAY

97. RIGHT HAND FRONT COMBINATION LAMPS 99. HORN

Copyright ©
4002-88
96 – Left Hand Front Combination Lamp

Located on the left front of the machine.
Correct
Reading
NOTE: Disconnect wiring harness connector LF from LH front combination lamp connector.
Combination lamp connector pin 3 to Continuity Bad high beam lamp bulb.
pin 1
Combination lamp connector pin 4 to Continuity Bad position lamp bulb.

pin 1
Combination lamp connector pin 2 to Continuity Bad low beam lamp bulb.
pin 1
Combination lamp connector pin 5 to Continuity Bad turn signal lamp bulb.
pin 1
NOTE: Connect wiring harness connector LF to LH front combination lamp connector.
Terminal for wire 0-AJ to ground Continuity Bad ground circuit.
Terminal for wire 18F to ground 24 volts
circuit 18F.
NOTE: Put high/low beam lever (94) in HIGH beam position.
Check fuse ECB-F3, high/low beam relay (80), driving lamp

Terminal for wire 18B to ground 24 volts switch (95), and high/low beam switch (94). Also check circuit
18B and wire 41H.
NOTE: Put high/low beam lever (94) in LOW beam position.
Check fuse ECB-F6, driving lamp switch (95), and high/low

Terminal for wire 18D to ground 24 volts
beam switch (94). Also check circuit 18D and wire 41L-A.
NOTE: Put ignition switch in ON position. Put turn signal lever in LEFT turn position.
Intermittent 24 Check the turn signal switch (94) and flasher module (92). Also
Terminal for wire 45L to ground volts check circuit 45L to flasher module.
NOTE: If all readings are good, and lamps still do not turn ON replace the LH front combination lamp.

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4002-89
97 – Right Hand Front Combination Lamp

Located on the right front of the machine.
Correct
Reading
NOTE: Disconnect wiring harness connector RF from RH front combination lamp connector.
Combination lamp connector pin 3 to Continuity Bad high beam lamp bulb.
pin 1
Combination lamp connector pin 4 to Continuity Bad position lamp bulb.

pin 1
Combination lamp connector pin 2 to Continuity Bad low beam lamp bulb.
pin 1
Combination lamp connector pin 5 to Continuity Bad turn signal lamp bulb.
pin 1
NOTE: Connect wiring harness connector RF to RH front combination lamp connector.
Terminal for wire 0-AH to ground Continuity Bad ground circuit.
Terminal for wire 18G-A to ground 24 volts
circuit 18G and wire 41T-A.
NOTE: Put high/low beam lever (94) in HIGH beam position.

Terminal for wire 18C to ground 24 volts
beam switch (94). Also check circuit 18C and wire 41H.
NOTE: Put high/low beam lever (94) in LOW beam position.

Terminal for wire 18E to ground 24 volts
beam switch (94). Also check circuit 18E and wire 41L-C.
NOTE: Put ignition switch in ON position. Put turn signal lever in RIGHT turn position.
Terminal for wire 45R to ground volts check circuit 45R to flasher module.
NOTE: If all readings are good, and lamps still do not turn ON replace the RH front combination lamp.

Copyright ©
4002-90
98 – Horn Relay
Correct
Reading
Terminal for wire 19U-A to ground 24 volts Check fuse ECC-F6, also check wire 19U-A.
Terminal for wire 19U-E to ground 24 volts Check wire 19U-E.
Terminal for wire 64C to ground 24 volts Bad horn relay.
NOTE: Have another person push and hold the horn switch.
Terminal for wire 64C to ground 0 volt Bad horn switch.
Terminal for wire 64-A to ground 24 volts Bad horn relay.
99 – Horn
Located on the left front of the machine with combination lamps.
Correct
Reading
Terminal for wire 0-AF to ground Continuity Bad ground circuit.
NOTE: Disconnect the wire 64 from the horn. Have an assistant push and hold the horn switch.
Terminal for wire 64 to ground. 24 volts Check the horn relay (98). Also check wires 64 and 64-A.
NOTE: If the readings are good replace the horn.

Copyright ©
4002-91
LIGHTS - 04 AND BACK UP ALARM
101
103
100
102
BS06H241 / BS06H242
100.RIGHT HAND REAR COMBINATION LAMPS 102.LICENSE PLATE LAMP

101.LEFT HAND REAR COMBINATION LAMPS 103.BACK UP ALARM

Copyright ©
4002-92
100 – Right Hand Rear Combination Lamp (North America Only)

Located on the right rear of the machine.
Correct
Reading
NOTE: Disconnect wiring harness connector LRR-N from RH rear combination lamp connector.
Combination lamp connector pin A Continuity Bad stop lamp bulb.

to pin D
Combination lamp connector pin C Continuity Bad turn lamp bulb.

to pin D
Combination lamp connector pin B Continuity Bad tail lamp bulb.

to pin D
NOTE: Connect wiring harness connector LRR-N to RH rear combination lamp connector.
Terminal for wire 0-BT to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Have another person press and hold
down the brake pedal.
Check brake lamps relay (91). Also check circuit 44 to brake

Terminal for wire 44A-GN to ground 24 volts
lamps relay (91).
NOTE: Put turn signal lever in RIGHT turn position.
Terminal for wire 45R-BN to ground volts check circuit 45R to flasher module.
NOTE: Put driving lamp switch (95) in position 2 or 3.
Check fuse ECB-F8 and lamp switch (95). Also check circuit
Terminal for wire 18G-CN to ground 24 volts
18G.
NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp.

Copyright ©
4002-93
100 – Right Hand Rear Combination Lamp (Europe Only)

Located on the right rear of the machine.
Correct
Reading
NOTE: Disconnect wiring harness connector LRR-E from RH rear combination lamp connector.
Combination lamp connector pin 1 to Continuity Bad stop lamp bulb.

pin 5
Combination lamp connector pin 2 to Continuity Bad turn lamp bulb.

pin 5
Combination lamp connector pin 3 to Continuity Bad tail lamp bulb.

pin 5
Combination lamp connector pin 4 to Continuity Bad reverse lamp bulb.

pin 5
NOTE: Connect wiring harness connector LRR-E to RH rear combination lamp connector.
Terminal for wire 0-BR to ground Continuity Bad ground circuit.

Terminal for wire 44A-F to ground 24 volts
lamps relay (91).
NOTE: Have assistant put transmission in reverse.
Check backup alarm relay (78). Also check circuit 35A to

Terminal for wire 35A-K to ground 24 volts
backup alarm relay (78).
NOTE: Have assistant put transmission in neutral. Put turn signal lever in RIGHT turn position.
Terminal for wire 45R-A to ground volts check circuit 45R to flasher module.
Terminal for wire 18G-A to ground 24 volts
18G.
NOTE: If all readings are good, and lamps still do not turn ON replace the RH rear combination lamp.

Copyright ©
4002-94
101 – Left Hand Rear Combination Lamp (North America Only)

Located on the left rear of the machine.
Correct
Reading
NOTE: Disconnect wiring harness connector LLR-N from LH rear combination lamp connector.
Combination lamp connector pin A Continuity Bad stop lamp bulb.

to pin D
Combination lamp connector pin C Continuity Bad turn lamp bulb.

to pin D
Combination lamp connector pin B Continuity Bad tail lamp bulb.

to pin D
NOTE: Connect wiring harness connector LLR-N to LH rear combination lamp connector.
Terminal for wire 0-BR-N to ground Continuity Bad ground circuit.

Terminal for wire 44A-FN to ground 24 volts
lamps relay (91).
NOTE: Put turn signal lever in LEFT turn position.
Terminal for wire 45L-BN to ground volts check circuit 45L to flasher module.
Terminal for wire 18F-BN to ground 24 volts
18F.
NOTE: If all readings are good, and lamps still do not turn ON replace the LH rear combination lamp.

Copyright ©
4002-95
101 – Left Hand Rear Combination Lamp (Europe Only)

Correct
Reading
NOTE: Disconnect wiring harness connector LLR-E from LH rear combination lamp connector.
Combination lamp connector pin 1 to Continuity Bad stop lamp bulb.

pin 5
Combination lamp connector pin 2 to Continuity Bad turn lamp bulb.

pin 5
Combination lamp connector pin 3 to Continuity Bad tail lamp bulb.

pin 5
Combination lamp connector pin 4 to Continuity Bad reverse lamp bulb.

pin 5
NOTE: Connect wiring harness connector LLR-E to LH rear combination lamp connector.
Terminal for wire 0-BT to ground Continuity Bad ground circuit.

Terminal for wire 44A-E to ground 24 volts
lamps relay (91).
NOTE: Have assistant put transmission in reverse.
Check backup alarm relay (78). Also check circuit 35A to

Terminal for wire 35A-L to ground 24 volts
backup alarm relay (78).
NOTE: Have assistant put transmission in neutral. Put turn signal lever in LEFT turn position.
Terminal for wire 45L-A to ground volts check circuit 45L to flasher module.
102 – License Plate Lamp (North America Only)

Located on the right rear of the machine with combination lamp.
Correct
Reading
Terminal for wire 0-JC to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put the driving lamp switch (95) in position 2.
Check fuse ECB-F8 and five driving lamp switch (95). Also
Terminal for wire 18G-E to ground 24 volts
check circuit 18G.

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102 – License Plate Lamp (Europe Only)

Located on the right rear of the machine with combination lamp.
Correct
Reading
Terminal for wire 0-JC to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch in ON position. Put the driving lamp switch (95) in position 2.
Check fuse ECB-F8 and five driving lamp switch (95). Also
Terminal for wire 18G-E to ground 24 volts
check circuit 18G.
103 – Back-up Alarm (North America Only)

Located on the left rear of the machine inside engine compartment.
Correct
Reading
Terminal for wire 0-JB to ground Continuity Bad ground circuit.
position. Depress brake pedal once. Move the transmission shift lever to REVERSE. If machine is a TUV model,
depress back-up alarm switch to turn LED ON (back-up alarm enabled).
Bad back-up alarm disable switch (79). If machine is not a TUV

model, check connector 209F and 209M is connected.
NOTE: If the readings are good, replace the back-up alarm.
103 – Back-up Alarm (Europe Only)

Located on the left rear of the machine inside engine compartment.
Correct
Reading
Terminal for wire 0-JB to ground Continuity Bad ground circuit.
position. Depress brake pedal once. Move the transmission shift lever to REVERSE. If machine is a TUV model,
depress back-up alarm switch to turn LED ON (back-up alarm enabled).
Bad back-up alarm disable switch (79). If machine is not a TUV

model, check connector 209F and 209M is connected.
NOTE: If the readings are good, replace the back-up alarm.

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CAB WINDOW WASHER AND WIPER SYSTEM
110
109
111
107 108
112
104 106
113
105
BS06H241 / BS06H242
104.FRONT WIPER HIGH SPEED RELAY 109.FRONT WIPER MOTOR

105.WIPER CUT OUT RELAY 110.REAR WIPER MOTOR
106.FRONT WIPER LOW SPEED RELAY 111.REAR WASHER MOTOR
107.REAR WIPER/WASHER SWITCH 112.FRONT WASHER MOTOR
108.FRONT WIPER/WASHER SWITCH 113.DIODES

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104 – Front Wiper High Speed Relay

Correct
Reading
Terminal for wire 19J-D and 19J-E to Bad fuse ECA-F12, check circuit 19J, also check power relay
24 volts
ground module D (21).
NOTE: Put the front wiper switch in the HIGH position.
Terminals for wire 63HC-B to ground Continuity Bad front wiper and washer switch (108).
Terminals for wire 63HC-B to ground 24 volts Bad wiper high speed relay.
NOTE: Put the front wiper switch in the LOW position.
Terminals for wire 63C2 to ground 24 volts Bad wiper high speed relay.
105 – Front Wiper Cut Out Relay

Correct
Reading
Check fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-G to ground 24 volts
module D (21).
Terminal for wire 63L-B to ground 24 volts Bad wiper cut out relay.
Terminals for wire 63HC-A to ground Continuity Bad front wiper and washer switch (108).
Terminals for wire 63L-B to ground 0 volts Bad wiper cut out relay.

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4002-99
106 – Front Wiper Low Speed Relay

Correct
Reading
Bad fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-F to ground 24 volts
module D (21).
NOTE: Put the front wiper switch in the LOW position.
Terminals for wire 63C to ground 24 volts Bad wiper low speed relay.
Terminals for wire 63LC to ground Continuity Bad front wiper and washer switch (108).
Bad wiper low speed relay, also check high speed wiper relay
Terminals for wire 63C3 to ground 24 volts
(104).
107 – Rear Wiper and Washer Switch

Correct
Reading
Bad fuse ECA-F13 or power relay module D (21). Also check

Terminal for wire 19K-B to ground 24 volts
circuit 19K.
Bad fuse ECA-F13 or power relay module D (21). Also check

Terminal for wire 19K-A to ground 24 volts
circuit 19K.
NOTE: Put the rear wiper and washer switch in the ON position.
Terminal for wire 68L to ground 24 volts Bad rear wiper and washer switch.
NOTE: Press and hold the rear wiper and washer switch in the WASH position.
Terminal for wire 68W to ground 24 volts Bad rear wiper and washer switch.
Check rotary lamp switch (95) and circuit 49. If LEDs in rear
Terminal for wire 49-C to ground 24 volts wiper and washer switch are not ON with 24 volts at check
point, replace rear wiper and washer switch.

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108 – Front Wiper and Washer Switch

Correct
Reading
Terminal for wire 0-DT to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the front wiper and
washer switch is in the OFF position.
Check fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-B to ground 24 volts
module D (21).
NOTE: Put the front wiper and washer switch in the LOW position.
Bad front wiper and washer switch also check grounding

Terminal for wire 63LC to ground Continuity
circuit.
NOTE: Put the front wiper and washer switch in the HIGH position.
Bad front wiper and washer switch also check grounding

Terminal for wire 63HC to ground Continuity
circuit.
NOTE: Put the front wiper and washer switch in the wash position.
Terminal for wire 63W to ground 24 volts Bad front wiper and washer switch.

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109 – Front Wiper Motor

Located in front of steering column.
Correct
Reading
NOTE: Make sure the front wiper and washer switch (108) is in the OFF position.
Between terminals B and D for wires Continuity Bad front wiper motor.
63C and 63L
Terminal for wire 19J to ground 24 volts Check fuse ECA-F12, also check circuit 19J.
NOTE: Put the front wiper and washer switch (108) in the LOW position.
Check fuse ECA-F12, also check circuit 19J. Bad front wiper
Terminal for wire 63L-A to ground 24 volts
and washer switch (108), low speed relay or cut out relay.
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (75)
NOTE: Put the front wiper and washer switch (108) in the HIGH position.
Check fuse ECA-F12, also check circuit 19J. Bad front wiper
Terminal for wire 63H-A to ground 24 volts
and washer switch (108), high speed relay or cut out relay.
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (108).
NOTE: Put the front wiper and washer switch in the intermittent position.
Terminal for wire 63L to ground 24 volts pulse Bad front wiper and washer switch (108).
Terminal for wire 63C to ground 24 volts pulse Bad front wiper and washer switch (108).
NOTE: If the readings are good, replace the front wiper motor.

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110 – Rear Wiper Motor

Located in top of rear cab head liner.
Correct
Reading
Terminal for wire 0-MA to ground Continuity Bad ground circuit.
NOTE: Make sure the rear wiper and washer switch (107) is in the OFF position.
Between terminals for wires 68C-A Continuity Bad rear wiper and washer switch (107).
and 68L-A
Terminal for wire 19K-C to ground 24 volts Check fuse ECA-F13, also check circuit 19K.
NOTE: Put the rear wiper and washer switch (107) in the ON position.
Terminal for wire 68C-A to ground 24 volts Bad rear wiper and washer switch (107).
Terminal for wire 68L-A to ground 0 volt Bad rear wiper and washer switch (107).
NOTE: If the readings are good, replace the rear wiper motor.
111 – Rear Washer Pump Motor

Located in left side engine compartment.
Correct
Reading
Terminal for wire 0-BL to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Depress and hold rear wiper and washer
switch (107) in WASH position.
Bad rear wiper and washer switch (107) Also check wires
Terminal for wire 68W-A to ground 24 volts
68W-A and 68W.
NOTE: If the readings are good, replace the rear washer pump motor.
112 – Front Washer Pump Motor

Located in left side engine compartment.
Correct
Reading
Terminal for wire 0-B to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Connect volt meter to check
point then push down on front wiper and washer switch (108).
Bad front wiper and washer switch (108), also check circuit
Terminal for wire 63W-A to ground 24 volts
63W.
NOTE: If the readings are good, replace the front washer pump motor.

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113 – Wiper Diodes

Correct
Reading
NOTE: Disconnect wiring harness connector 140M from diode connector.
Multimeter positive on pin D to pin C None Bad diode.
Multimeter positive on pin E to pin C None Bad diode.
Multimeter positive on pin F to pin C None Bad diode.
Multimeter positive on pin C to pin D Continuity Bad diode.
Multimeter positive on pin C to pin E Continuity Bad diode.
Multimeter positive on pin C to pin F Continuity Bad diode.

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SECONDARY STEERING
114 116 118

115 117
BS06H241 / BS06H242
114.SECONDARY STEERING DIODES 117.SECONDARY STEERING MOTOR

115.SECONDARY STEERING SOLENOID 118.SECONDARY STEERING PRESSUR SWITCH
116.SECONDARY STEERING MODULE

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114 – Secondary Steering Diodes

Correct
Reading
NOTE: Disconnect wiring harness connector DM from diode connector.
115 – Secondary Steering Solenoid (Option)

Located in the rear frame of the machine.
Correct
Reading
NOTE: Disconnect connector YSS from secondary steering solenoid.
Between pins A and B of secondary 36 to 42 ohms Bad secondary steering solenoid.

steering solenoid
Between pin 2 of connector YSS and Continuity Bad ground circuit.

ground
NOTE: Disconnect wire 51-B from secondary steering motor relay; make sure that wire does not touch any metal
part of machine during the remainder of this check. Put the master disconnect switch in ON position. Start and
run engine for two or three minutes while turning steering wheel left and right several times. DO NOT TURN
STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then immediately
to ON position.
Between pin 1 of connector YSS and Check secondary steering module (116) and secondary
24 volts
ground steering pressure switch (118).

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116 – Secondary Steering Module (Option)

Correct
Reading
NOTE: Disconnect the wiring harness connector SSM from the secondary steering module.
Bad relay on secondary steering motor (117) or bad secondary

Pin 2 of connector SSM to ground Continuity steering solenoid (115). Also Check wires 51-A, 51-B, and 51-C
and ground circuit connections (wires 0-ND and 0-CF).
Pin 4 of connector SSM to ground Continuity Bad ground circuit.
Bad secondary steering pressure switch (118). Also check

Pin 8 of connector SSM to ground Continuity
wires 35X-D, 35X-C, and 35X-A.
Bad secondary steering pressure switch (118). Also check wire

Pin 9 of connector SSM to ground Open Circuit
51P-A.
NOTE: Put the master disconnect switch and the ignition switch in ON position.
Pin 3 of connector SSM to ground 24 volts Bad wire 19S1-X to power relay module A fuse 2 (13).
Pin 7 of connector SSM to ground 24 volts Bad fuse ECA-F17 or ignition switch. Also check circuit 19M.
Check fuse ECA-F4, power relay module A (13), ignition

Pin 1 of connector SSM to ground 24 volts
switch, and diode module. Also check circuit 19R.
NOTE: Start and run engine at idle speed.
Pin 9 of connector SSM to ground Continuity Bad secondary steering pressure switch.
Check circuit 35X to instrument cluster. If circuit 35X okay,

Pin 8 of connector SSM to ground 11 volts
problem is bad instrument cluster.
NOTE: Put ignition switch in OFF position to stop engine. Connect wiring harness connector SSM to secondary
steering module. Disconnect wire 51-B from secondary steering motor (117) relay terminal. Start and run engine at idle
speed. Disconnect wiring harness connector PSS from secondary steering pressure switch (118). Apply a ground to pin C of
connector PSS.
Terminal for wire 51-B to ground 24 volts Bad secondary steering module.

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117 – Secondary Steering Motor (Option)

Correct
Reading
Motor ground stud to ground Continuity Bad ground circuit.
Secondary steering motor relay Continuity Bad ground circuit.

ground terminal to ground
Bad secondary steering motor relay coil or secondary steering

Terminal for wire 51-B to ground. 10 to 45 ohms solenoid (115). Also check relay coil and solenoid ground
circuit.
NOTE: Put the master disconnect switch in ON position.
Terminal for red wire to ground 24 volts Check circuit to batteries.
NOTE: Start and run engine for two or three minutes while turning steering wheel left and right several times. DO
NOT TURN STEERING WHEEL TO STEERING STOPS. Turn ignition switch to OFF position to stop engine, then
immediately to ON position. Secondary steering motor should be heard operating. If motor is heard, problem is
associated pump; refer to Section 5002. If motor is not heard, leave ignition switch in ON position and disconnect
wire 51-B from secondary steering motor relay.
Check fuses ECA-F4 and F17, secondary steering module

(116), and secondary steering pressure switch (118). If 24 volts
is obtained the secondary steering motor is bad. If fuse ECA-F4
Terminal for wire 51-B to ground 24 volts or F17 was replaced: if fuse F4 blows again, secondary
steering module is bad; if fuse F17 blows again, secondary
steering module is bad or secondary steering motor relay or
secondary steering solenoid is shorted.
118 – Secondary Steering Pressure Switch (Option)

Correct
Reading
NOTE: Disconnect wiring harness connector PSS from secondary steering pressure switch.
Pressure switch pin B to pin C Continuity Bad secondary steering pressure switch.
Pressure switch pin B to pin A Open Circuit Bad secondary steering pressure switch.
Pressure switch pin A to pin C Open Circuit Bad secondary steering pressure switch.
NOTE: Start and run engine at idle speed.
Pressure switch pin B to pin A Continuity Bad secondary steering pressure switch.
Pressure switch pin B to pin C Open Circuit Bad secondary steering pressure switch.

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CAN COMMUNICATION
119
BS06H241 / BS06H242
119.DIAGNOSTIC CONNECTOR

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4002-109
119 – CAN Communication Diagnostics Connector

Correct
Reading
Terminal A for wire 0-DH to ground Continuity Bad ground circuit.
Terminal B for wire 18K-A to ground 24 volts Check fuse ECC-F9, check circuit 18K.

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RADIO AND POWER CONVERTER
125
124 122 123
120
121
BS06H241 / BS06H242
120.POWER RELAY MODULE E 123.RADIO

121.POWER CONVERTER 24 TO 12 VOLT 124.RIGHT SPEAKER
122.12 VOLT POWER OUTLETS (OPTION) 125.LEFT SPEAKER

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120 – Power Relay Module E

Correct
Reading
Terminal for wire 0-DL to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position. Turn ignition switch to the Accessory or the ON
position.
Terminal for wire PRM-E BUSS to Check circuit 1CB to 105 Amp circuit breaker in engine
24 volts
Terminal for wire 19L to ground 24 volts Bad power relay module E, bad fuse F1.
121 – Power Converter 24 volts to 12 volts (Option)

Correct
Reading
Terminal for wire 0-EJ to ground Continuity Bad ground circuit.
Terminal for wire 19L-B and 19L-A to 24 volts Bad fuse F1 in power relay module E, also check circuit 19L.
ground
Terminal for wire 12V-C to ground 12 volts Bad power converter.
122 – Power Outlet (Option)

Located in the cab.
Correct
Reading
Terminal for wire 0-EK or 0-EL to Continuity Bad ground circuit.

ground
Terminal for wire 12V or 12V-A to Bad power converter (121), check fuse ECD-F4 and F5, also
12 volts
ground check wire 12V-A.
NOTE: If the readings are good replace the power outlet.

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123 – 12 Volt Radio Ready (Option)

Located in the cab.
Correct
Reading
Terminal in radio connector for wire Continuity Bad ground circuit.

0-EN to ground
Terminal in radio connector for wire Check fuse ECD-F6, also check circuit 12V. Also check the
12 volts
12V-HA to ground remote radio power converter (121).
124 – Right Speaker (Option)

Located in the cab.
Correct
Reading
NOTE: Disconnect connector from right speaker. Put master disconnect switch and ignition switch in ON position.
Turn radio (123) on. Put balance control for RH and LH speakers to center position.
Pin 1 in wiring harness connector Bad circuit between the right speaker and the radio or a bad
Voltage
RSPK to ground radio (123).
Pin 2 in wiring harness connector Continuity Bad circuit between the right speaker and the radio (123).
RSPK to ground
NOTE: If the readings are good, replace the right speaker.
125 – Left Speaker (Option)

Located in the cab.
Correct
Reading
NOTE: Disconnect connector from left speaker. Put master disconnect switch and ignition switch in ON position.
Turn radio (123) on. Put balance control for RH and LH speakers to center position.
Pin 1 in wiring harness connector Bad circuit between the left speaker and the radio or a bad
Voltage
LSPK to ground radio (123).
Pin 2 in wiring harness connector Continuity Bad circuit between the left speaker and the radio (123).
LSPK to ground
NOTE: If the readings are good, replace the left speaker.

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AIR SEAT - CIGAR LIGHTER - AIR CONDITIONING COMPRESSOR
126 130
129
127
128
BS06H241 / BS06H242
126.AIR SEAT 129.HIGH/LOW SWITCH

127.CIGAR LIGHTER 130.AIR CONDITIONING COMPRESSOR CLUTCH
128.AIR CONDITIONING CLUTCH REALY

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126 – Seat Compressor and Switch (Option)

Located in the cab.
Correct
Reading
Terminal for wire 0-DK to ground Continuity Bad ground circuit.
Check fuse ECA-F16 and power relay module A (13). Also

Terminal for wire 19N at seat switch 24 volts
check wire 19N.
NOTE: Put the seat compressor switch in the ON position.
Terminal for wire from seat switch at 24 volts Bad seat switch, also check circuit from seat switch to
compressor compressor.
NOTE: If the readings are good replace the seat compressor.
127 – Cigar Lighter (Option)

Located in the cab.
Correct
Reading
Terminal for wire 19W to ground 24 volts Check fuse ECC-F8, also check circuit 19W.
Terminal for wire 0-DV to ground Continuity Bad ground circuit.
NOTE: If the readings are good replace the cigar lighter.
128 – Compressor Clutch Relay

Correct
Reading
Terminal for wire 0-DJ to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (137) to HIGH and thermostat
switch to COLD.
Terminal for wire 61R-B to ground 24 volts Check thermostat switch, also check wire 61R-B.
Terminal for wire 61C to ground 24 volts Bad compressor clutch relay.
NOTE: Put ignition switch in OFF position. Disconnect wiring harness connector PR from A/C trinary pressure
switch. Connect a jumper wire between pins A and B of connector PR. Put ignition switch in ON position.
Terminal for wire 61R-C to ground 24 volts Check wires 61R-B and 61R.

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129 – A/C High/Low Pressure Switch

Located on the rear frame in front of the rear axle.
Correct
Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put the blower switch (137) to HIGH and the
thermostat switch to COLD.
Terminal B for wire 61A to ground 24 volts Check the thermostat switch, also check circuit 61A.
NOTE: Disconnect the wiring harness connector PR from the A/C trinary pressure switch.
Bad A/C low pressure switch, also check refrigerant charge

Between terminals of trinary Continuity level. (Pressure must be above 2.75 bar (40 psi) or below 26
pressure switch
bar (377 psi) for switch to be closed.)
130 – Compressor Clutch

Located on the left side of the engine.
Correct
Reading
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (137) to HIGH and thermostat
switch to COLD.
Check the compressor clutch relay (128), also check circuit

Terminals for wire 61C-A to ground 24 volts
61C.

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HEATING, VENTILATION, AND AIR-CONDITIONING
131 132 133

134 135 136
137
137 138 139

140 141
BS06H241 / BS06H242
131.AIR RECIRCULATION MOTOR 137.FAN SPEED SWITCH

132.DRIVER 138.AIR CONDITIONING SWITCH
133.ELETRONIC WATER VALVE 139.CONTROL PANEL LIGHTS
134.BLOWER FAN RESISTOR 140.WATER VALVE POTENTIOMETER
135.BLOWER MOTOR 141.AIR RECIRCULATING SWITCH
136.THERMOSTAT

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131 – Air Recirculation Motor

Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Place recirculation switch in
oust side air position.
Terminal for pin 5 to ground (red) 0.5 volt Bad driver (132)
Terminal for pin 6 to ground (pink) 0 volt Bad driver (132)
NOTE: While measuring voltage at pin 5 change recirculation switch from inside air to outside air.
24 volt for
Terminal for pin 5 to ground (red) approximately Bad driver (132)
10 seconds
NOTE: Place recirculation switch in inside air position
Terminal for pin 5 to ground (red) 0 volt Bad driver (132)
Terminal for pin 6 to ground (pink) 0.5 volt Bad driver (132)
NOTE: While measuring voltage at pin 6 change recirculation switch from outside air to inside air.
24 volt for
Terminal for pin 6 to ground (pink) approximately Bad driver (132)
10 seconds
NOTE: If all readings are good, replace the recirculation motor.
132 – Driver
Correct
Reading
Terminal for pin 2 to ground 24 volts Bad fuse ECA-F11, check circuit 18N.
Terminal for pin 3 to ground Continuity Bad ground circuit

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133 – Electronic Water Valve

Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Disconnect connector in the
harness not at the valve.
Terminal for pin 1 to ground 24 volt Bad fuse ECA-F11, check circuit 18N.
Terminal for pins 3 and 4 to ground 0.5 volt Bad driver (132)
NOTE: Change position of heater control knob from maximum heat to maximum cooling.
0.2 to 0.5 volt

for
Terminal for pins 5 and 6 to ground Bad driver (132)
approximately
30 seconds
NOTE: Change position of heater control knob from maximum cooling to maximum heat.
0.2 to 0.5 volt

for
Terminal for pins 5 and 6 to ground Bad driver (132)
approximately
30 seconds
NOTE: If all readings are good, replace the valve.
134 – Blower Motor Speed Resistors with Thermal Fuse

Correct
Reading
NOTE: Disconnect the wiring harness connector DNS RESISTOR from the resistor.
Between terminals 1 and 4 of Approximately

Bad blower motor resistor.
resistor 7.0 ohm

resistor 5.5 ohm

resistor 3.5 ohm
135 – Blower Motor

Correct
Reading
Terminals for wire DNS66 to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Turn the blower switch (137) to position
4.
Terminal for wire DNS65 to ground 24 volts Check the blower switch (137).
NOTE: If the readings are correct and the blower motor does not run, replace the blower motor. Turn the blower
switch (137) to position 1. If the blower motor ran in position 4 but not in position 1, 2,or 3, check the blower motor resistor
(134).

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136 – Thermostat
Correct
Reading
NOTE: Disconnect wires from switch. Thermostat contacts closed at or above 5°C (40° F).
Terminal to terminal Continuity Bad thermostat switch
137 – Blower Switch

Correct
Reading
Terminal for wire DNS74 to ground 24 volts Check fuse ECA-F11, check circuit 18N.
NOTE: Turn the blower switch to position 1.
Terminal for wire DNS61 to ground 24 volts Bad blower switch.
138 – Air Conditioning Switch

Correct
Reading
terminal for wire DNS-2 to ground 24 volts Check fuse ECA-F11, check circuit 18N.
NOTE: Push AC switch to turn ON.
Terminal for wire DNS-68 to ground 24 volts Bad AC switch
139 – Control Panel Lights

Correct
Reading
NOTE: Turn driving light switch to position 2 or 3.
Terminal for wire DNS-70 to ground Continuity Bad ground circuit
Terminal for wire DNS-69 to ground 24 volts Bad control panel bulbs.

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140 – Water Valve Potentiometer

Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Take reading between pins on
potentiometer.
Place potentiometer in maximum 4 volts Bad potentiometer

heat position
Place potentiometer in mid range 2.5 volts Bad potentiometer

position
Place potentiometer in maximum 0 volts Bad potentiometer

cool position
NOTE: If no voltage is present at potentiometer check the driver (132).
141 – Air Recirculating Switch

Correct
Reading
NOTE: Disconnect connector from the switch. Place switch in outside air position.
Between terminals on switch Continuity Bad recirculating switch.
NOTE: Place switch in recirculate air position.
Between terminals on switch Open Bad recirculating switch.

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CONNECTORS
CONNECTOR 108F - DIAGNOSTIC CONNECTOR CONNECTOR 197F - MAIN CAB FNR
291663A1 225350C1
CAV WIRE IDENT CIRCUIT CAV WIRE IDENT CIRCUIT

1 19A-W Diagnostic Conn. Fused Power 1 19A-C FNR Switch Fused Power
2 37D-A Diagnostic Signal 2 26F-B FNR Forward Signal
3 0-DAV Diagnostic TECM Ground 3 26N-B FNR Neutral Signal
4 37E Diagnostic Signal Switched 4 26R-B FNR Reverse Signal
5 Not Used 5 32J-E Trans Enable Indication Lamp
6 Not Used 6 25Y-B Trans Kick Down Signal
CONNECTOR 140M - DIODE MODULE CONNECTOR 197M - FNR MAIN CAB
225351C1
245488C1 CAV WIRE IDENT CIRCUIT

CAV WIRE IDENT CIRCUIT 1 19A-B FNR Switched Fused Power
A 63H-C Front Wiper High Speed 2 26F-A FNR Forward Signal
B 63L-C Front Wiper Low Speed 3 26N-A FNR Neutral Signal
C 0-EE Diode Suppression Grounds 4 26R-A FNR Reverse Signal
D 58-D Ride Control Solenoid Power 5 32J-A Trans Enable Indication Lamp
E 21D-B Starter Relay Signal 6 25Y-C Trans Kick Down Signal
F 68L-C Rear Wiper Switch Power

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CONNECTOR 202M - ROLLBACK JUMPER CONNECTOR 20M - TRANSMISSION KICK-DOWN
SWITCH
245482C1
CAV WIRE IDENT CIRCUIT 225316C1
A 58-A Ride Control Solenoid Power CAV WIRE IDENT CIRCUIT

B 58-A Ride Control Solenoid Power 1 19A-U Trans Kick Down Switched Pwr
2 25Y-C Trans Kick Down Signal
CONNECTOR 209F - BACKUP ALARM DISABLE

JUMPER CONNECTOR 215F - ALTERNATOR RESISTOR
245481C1 199436A1

A 35A-E Backup Alarm Relay Out 1 14-A Alternator D+
CONNECTOR 209M - BACKUP ALARM DISABLE CONNECTOR 216F - ALTERNATOR RESISTOR

JUMPER
199436A1
CAV WIRE IDENT CIRCUIT

245480C1
1 19R-D Alternator Resistor Fused Pwr
A 35A-D Backup Alarm Relay Out

Copyright ©
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CONNECTOR 64F - FLASHER CONNECTOR CONNECTOR AIC1 - ADV INSTRUMENT
CLUSTER 1
245481C1

1 45N-A Flasher Optional Side Control
87419488

CONNECTOR 64M - FLASHER CONNECTOR 1 13V Voltmeter Input ANALOG
2 36F-A Fuel Level ANALOG
3 CAN-HG CAN High
4 CAN-LG CAN Low
5 36A Rear Axle Temperature
6 0-DX AIC Sensor Ground
7 43-A Dome Light Auto Mode
8 36B Front Axle Temperature
9 36H-A Hydraulic Oil Temperature
245480C1 10 Not Used
CAV WIRE IDENT CIRCUIT 11 36C-A Radiator Coolant Temp Signal
1 45N-B Flasher Optional Side Control 12 0-DW AIC Power Ground

13 35B AIC Buzzer HSD
14 52C Park Brake Solenoid LSD
CONNECTOR ACT - AIR CONDITIONING
15 44A-B Brake Light Relay Out
COMPRESSOR CLUTCH
16 51S Standard Steering Signal
17 51CS Comfort Steering Switch
18 Not Used
19 28J Ether AIC OK Signal
20 53C-A Pilot Control Solenoid LSD
8602417 21 51C Comfort Steering Control
CAV WIRE IDENT CIRCUIT 22 Not Used
1 61C-A AC relay out 23 52 Fan Reverser LSD
24 Not Used
25 17P-A Switch Pad Pwr From AIC Pwr
26 56 Fan Control PWM

Copyright ©
4002-124
CONNECTOR AIC2 - ADV INSTRUMENT CONNECTOR ALT5 - ALTERNATOR
CLUSTER 2

1 Not Used
2 30 Battery Sensing
3 14-5 ENG
4 Not Used
5 Not Used
87410948
CONNECTOR BUZ - AIC BUZZER
1 Not Used
2 43S-C Door Open Signal
3 Not Used
4 33R Redundant Brk Accm Press Low
5 33P-A Brake Low Pressure Warning
6 33U Park Brake Switch
7 52M Fan Reverse Manual
8 52AU Fan Reverse Auto
9 45L-E Left Turn Signal
222136A1
10 45R-C Right Turn Signal
11 35X Sec. Steering Low Press Signal
1 35B AIC Buzzer HSD
12 Not Used
2 0-B27 Buzzer Ground
13 Not Used
14 19S-D AIC Delay Fused Power
15 0-DB AIC Power Ground Red
16 57-C Pin Engage Solenoid Power
17 21K-A Ignition Switch Start Signal
18 31L Pilot Control Switch High
19 Not Used
20 19S-C AIC Delay Fused Power
21 19E-A AIC Wake Up Ignition
22 0-DA AIC Chassis Ground
23 Not Used
24 Not Used
25 Not Used
26 31D-A Coolant Level Signal

Copyright ©
4002-125
CONNECTOR CAB-E - CAB TO ENGINE CAV WIRE IDENT CIRCUIT
37 59D Hood Down Relay Control
38 60U Hood Up Relay Out
39 59U Hood Up Relay Control
40 35A-F Backup Alarm Relay Out
225415C1

1 21C-C Starter Relay Signal
2 61C AC Relay Out
3 21G EDC7 Crank Control Relay
4 21H Crank Control Relay LSD
5 18F-A LH Position/Tail Fused Power
6 Not Used
7 35A-C Backup Alarm Relay Out
8 44A-C Brake Light Relay Out
9 18G-F RH Position/Tail Fused Power
10 45L-B Left Turn Signal
11 21F EDC7 Digital Ground
12 45R-B Right Turn Signal
13 18R-A Voltmeter Relay Fused Power
14 18J-G EDC7 Time Delay Fused Power
15 21D-C Starter Relay Signal
16 28H Ether Switch Signal
17 0-DX AIC Sensor Ground
18 18J EDC7 Time Delay Fused Power
19 0-DW AIC Power Ground
20 0-DB AIC Power Ground Red
21 13C-B Fuel Shutoff Fused Power
22 52A-A Fan Reverse Relay Out
23 56 Fan Control PWM
24 68W Rear Washer Pump
25 63W Front Washer Pump
26 14-A Alternator D+
27 21E Key Switch Crank
28 31F-A Air Filter Restriction Sw Signal
29 61R-B AC Relay Control
30 61A-B Trinary Pressure Switch Input
31 20G-B EDC7 ISO-K Interface
32 36A Rear Axle Temperature
33 36F-A Fuel Level ANALOG
34 36C-A Radiator Coolant Temp Signal
35 19Y-C Hood Switch Fused Power
36 60D Hood Down Relay Out

Copyright ©
4002-126
CONNECTOR CAB-F - CAB FRONT CHASSIS CONNECTOR CAB-RF - CAB TO ROOF
CONNECTION
388710A1
291661A1 A 43-A Dome Light Auto Mode
CAV WIRE IDENT CIRCUIT B 42R-C Rear Work Light Fused Power
1 45L-C Left Turn Signal C 42C-A Front Work Lights Fused Power
2 51B-C Comfort Steering Solenoid Pwr D 19U-D Dome Light Fused Power
3 45R-D Right Turn Signal E 46-C Beacon Switch Power
4 Not Used F 0-DR Roof Splice Grounds
5 18G-G Position RH Fused Power G 0-DS Roof Splice Grounds
6 18F-E Position LH Fused Power J 19K-C Rear Wiper Motor Fused Power
7 18B-A High Beam LH Fused Power K 68C Rear Wiper Park Control
8 36B Front Axle Temperature L 68L-B Rear Wiper Switch Power
9 O-DY Front Axle Temperature Ground M 0-EM Radio Ground
10 Not Used N 12V-B 12V Fused Power to Radio
11 54B-A Height-RTT Signal R 43S-A Door Open Signal
12 53B-B RTD Signal S 19U-G Door Switch Fused Power
13 64A Horn Power

14 18D-A Low Beam LH Fused Power
15 18E-A Low Beam RH Fused Power
16 18C-A High Beam RH Fused Power
17 Not Used
18 Not Used
19 53P-F Pilot Control Relay Out
20 57-A Pin Engage Sol Pwr
21 58-C Ride Control Sol Pwr
22 1-DR Brake Lamp Switch Power
23 44-A Brake Lamp Control Power
24 52P-A Park Brake Relay Out
25 Not Used
26 33P-A Low Brake Pressure Warning
Brake Declutch Switch Fused
27 19A-T
Power
28 25G-A Brake Declutch Switch Control
29 Not Used
30 Not Used
31 Not Used

Copyright ©
4002-127
CONNECTOR CAB-T - CAB TO TRANMISSION CONNECTOR CAN - CAN BULK HEAD
380839A1

Front Brake Accumulator
1 33R
Pressure Low
2 31D-A Coolant Level Signal
Secondary Steering Accessory 87315266
3 19M
Fused Power
Sec. Steering Ignition Fused
4 19R-E A CAN-HA CAN High
Power
5 36T-A Valve Body Temp Signal B CAN-LA CAN Low
Secondary Steer Low Press

6 35X
Signal
CONNECTOR CAN2 - CAN BULK HEAD
7 25A-A Engine Speed Signal
8 25C-A Turbine Speed Signal
9 25B-A Intermediate Speed Signal
10 25D-A Output Speed Signal
11 0-DM Speed Sensor Ground
12 36R-E Trans Temp/Filter Return
13 36G-A TCO Temp Signal
14 Not Used
15 Not Used
16 25K-A Trans Solenoid Valve Y1
17 25L-A Trans Solenoid Valve Y2
18 25M-A Trans Solenoid Valve Y3
87315267
19 25N-A Trans Solenoid Valve Y4
20 25P-A Trans Solenoid Valve Y5
A CAN-H CAN High
21 25J-A Trans Solenoid Valve Y6
A CAN-HJ CAN High From Engine
22 25S-A Output Sw Power VPS1
B CAN-L CAN Low
23 31H-A Hyd Filter Restriction Switch Sig
B CAN-LM CAN Low From Engine
24 Not Used
25 Not Used
26 19S1 Sec. Steering Fused Power
27 Not Used
28 0-DN Output Speed Sensor Ground
29 19A-M Output Speed Sen. Fused Pwr
30 36H-A Hydraulic Oil Temp
31 32F-A Trans Filter Maint Switch

Copyright ©
4002-128
CONNECTOR CL - CIGAR LIGHTER CONNECTOR D-OR - DIODE OR
245485C1

3227856R1 A 42C-D Front Work Lights Fused Power
CAV WIRE IDENT CIRCUIT B 41T-C Position Lights Switched Power
1 19W Cigar Lighter Fused Power C 49 Back Light Power
2 0-DV Cigar Lighter Ground
CONNECTOR DIA - DIAGNOSTIC

CONNECTOR CLS - COOL JUMP - COOL SEND
194788A1
CAV WIRE IDENT CIRCUIT 310057A1
A 31D Coolant Level Signal CAV WIRE IDENT CIRCUIT

B 0-HV Coolant Level Sender Ground A 0-DH Ground
B 18K-A Diagnostics Fused Power
CONNECTOR CNV - 24V TO 12V POWER C CAN-HB Controller Area Network High
CONVERTER D CAN-LB Controller Area Network Low
E 20G-B EDC7 ISO-K Interface
CONNECTOR DISC - DISCONNECT ENGINE
225351C1

1 19L-A Power Converter Fused Power
2 19L-B Power Converter Fused Power 245482C1
3 0-EJ Power Converter Ground CAV WIRE IDENT CIRCUIT

4 Not Used A 13C Fuel Shutoff Fused Power
5 12V-C 12V Switched Power B 13M Fuel Shutoff Fused Power
6 0-ER Power Converter Ground

Copyright ©
4002-129
CONNECTOR DM - DIODE OR CONNECTOR DNS-CTRL-PANEL-LIGHT

1 DNS69
2 DNS70
245485C1
CONNECTOR DNS-WATER-VALVE-POT
A 19RR Sec. Steering Ignition Fused Pwr
B Not Used
C 19R Sec. Steering Ignition Fused Pwr
1 DNS55
2 DNS54
CONNECTOR DNS-AC-SWITCH
CONNECTOR DNS-RECIRCULATING-SWITCH

1 DNS72
2 DNS68
1 DNS51
4 DNS71
2 DNS53
CONNECTOR DNS-ACTUATOR
CONNECTOR DNS-THERMOSTAT-1

5 DNS48
1 DNS67
6 DNS49
CONNECTOR DNS-THERMOSTAT-2
CONNECTOR DNS-SPEED-SELECTOR

1 DNS6
1 DNS74
2 DNS61
3 DNS62 CONNECTOR DNS-ELECTRIC-FAN
4 DNS63
5 DNS73

1 DNS65
2 DNS66

Copyright ©
4002-130
CONNECTOR DNS-RESISTOR CONNECTOR DNS-HVAC1-S

1 DNS61
2 DNS62
3 DNS63
4 DNS64
5 Not used
225294C1

CONNECTOR DNS-ELECT-WATER-VALVE-S A DNS67
B DNS76
C DNS69
1 DNS60
CONNECTOR DNS-HVAC2-S
2 Not used
3 DNS56
4 DNS57
5 DNS58
6 DNS59
CONNECTOR DNS-DRIVER
225315C1

1 DNS74
2 DNS75
411311A1 CONNECTOR DS - DOOR SWITCH

2 DNS50
3 DNS52
4 DNS49
5 DNS48
6 DNS55
7 DNS57
8 DNS58
245482C1
9 DNS59
11 DNS51
A 19U-F Door Switch Fused Power
12 DNS53
B 43S-B Door Open Signal
13 DNS54
14 DNS56

Copyright ©
4002-131
CONNECTOR ECA - ELECTRICAL CENTER A
87315248
CAV WIRE IDENT CIRCUIT L1 J6 Pltem Dtnts Park Brake Sol
A1 19A-N Transmission Fused Power L1 J7 Park Brake Solenoid Horn
A2 18L-A Comfort Steering Fused Power L1 J8 Fan Reverse/Turn Signal
A3 19E-A AIC Wake Up Ignition L1 J9 Turn Signal Engine Shutdown
Sec. Steering Ignition Fused L2 J11 Blower Motor Power

A4 19RR
Pwr
L2 J12 Blower Mtr Front Wiper Washer
A5 19C-A Pilot Control Relay Fused Pwr
L2 J13 Front Wiper Rear Wiper Washer
A6 19D-A Park Brake Relay Fused Power
L2 J14 Rear Wiper Washer Backup
A7 19P Pin Engage/Fan Fused Power
L2 J15 Backup AC
A8 19B Turn Signal Fused Power
L2 J16 AC Seat Compressor
A9 13C-B Fuel Shutoff Fused Power
Seat Compressor Emergency
L2 J18
C1 18N Blower Motor Fused Power Steering
C2 19J Front Wiper Fused Power

C3 19K Rear Wiper Fused Power
C4 19H Backup Alarm Relay Fused Pwr
C5 18M AC Relay Fused Power
C6 19N Seat Compressor Fused Pwr
C7 19M Sec. Steering ACC Fused Pwr
L1 J1 Transmission ECM Power
L1 J2 Trans ECM Comfort Steering
L1 J3 Comfort Steering AIC Power
L1 J4 Emergency Steering AIC Pwr
L1 J5 Emergency Strg Plt Em Dtnts

Copyright ©
4002-132
CONNECTOR ECB - ELECTRICAL CENTER B
87312843
CAV WIRE IDENT CIRCUIT B3 21K-B Ignition Switch Start Signal
A1 42FS Front Work Lights Power B4 0-DE Neutral Start Relay Control Gnd
A2 42RS Rear Work Lights Power B5 21F EDC7 Digital Ground
A3 41H-B High Beam LH Power B6 0-DF Crank Request Relay Ctrl Gnd
A4 41H-C High Beam RH Power B7 19P-E Fan Reverse Relay Fused Pwr
A5 41L-C Low Beam LH Power B8 52 Fan Reverser LSD
A6 41L-B Low Beam RH Power B9 19D-C Park Brake relay Fused Pwr
A7 41T-B Position Lights LH Sw Power B10 52C Park Brake Solenoid LSD
A8 41T-A Position Lights RH Sw Power D1 13K-C Ignition Switch Power
A9 21H Crank Control Relay LSD D2 13V Voltmeter Input ANALOG
A10 21C-B Neutral Start Relay Output D3 25T Neutral Signal
AA1 42C-C Front Work Lights Fused Power D4 21C Neutral Start Relay Output
AA2 42R-C Rear Work Lights Fused Power D5 21C-A Neutral Start Relay Output
AA3 18B-A High Beam LH Fused Power D6 21E Key Switch Crank
AA4 18C-A High Beam RH Fused Power D7 19P-D Fan Reverse Relay Fused Pwr
AA5 18E-A Low Beam RH Fused Power D8 52A-A Fan Reverse Relay Out
AA6 18D-A Low Beam LH Fused Power D9 19D-B Park Brake Relay Fused Pwr
AA7 18F-C Pos Tail Lights LH Fused Power D10 52P-B Park Brake Relay Out
AA8 18G Pos Tail Lights RH Fused Power

AA9 21D-A Starter Relay Signal
AA10 21G EDC7 Crank Control Relay
B1 18R-A Voltmeter Relay Fused Power
B2 0-DD Voltmeter Relay control Ground

Copyright ©
4002-133
CONNECTOR ECC - ELECTRICAL CENTER C
87315249

D4 19Y-B Hood Down Relay Fused Power
A1 19U-B Beacon/Dome Lt Fused Pwr
D5 44-A Brake Light Control Power
A2 42 Work Lights Sw Fused Pwr
D6 44A-A Brake Light Relay Out
A3 19Z Driving Lights Sw Fused Pwr
D7 19U-E Horn relay Fused Power
A4 1-DV Brake Lts/Flasher Bat Pwr
D8 64-A Horn Power
A5 1DM Time Delay/Ign Sw Fused Pwr
D9 18L-B Comfort Steering Fused Power
A6 19U Horn Relay Fused Power
D10 51B-B Comfort Steering Solenoid Pwr
A7 19Y Hood Control Fused Power
L1-1 ECC-L1 Beacon/Dome Lights LI ECC
A8 19W Cigar Lighter Fused Power
L1-1 J2-ECC Beacon/Dome Lt Work Lights
A9 18K-A Diagnostic Fused Power
L1-2 J2-ECC Beacon/Dome Lt Work Lights
B1 60U Hood Up Relay Out
L1-2 J3-ECC Work Lights Driving Lights
B2 0-B25 Hood Up Control Ground
L1-3 J3-ECC Work Lights Driving Lights
B3 60D Hood Down Relay Out
L1-3 J4-ECC Driving Lights Brake Lights
B4 0-B16 Hood Down Control Ground
L1-4 J4-ECC Driving Lights Brake Lights
B5 1-DW Brake Light Relay Bat Power
L1-4 J5-ECC Brake Lights Delay Power
B6 0-EF Brake Light Relay Control Gnd
L1-5 J5-ECC Brake Lights Delay Power
B7 19U-A Horn Relay Fused Power
L1-5 J6-ECC Delay Power Horn
B8 64C Horn Relay Control
L1-6 J6-ECC Delay Power horn
B9 18L-C Comfort Steering Fused Pwr
L1-6 J7-ECC Horn HOD Control
B10 51C Comfort Steering Control
L1-7 J7-ECC Horn HOD Control
C2 0-B22 Hood Up Relay Ground
L1-7 J8-ECC HOD Control Cigar Lighter
C4 0-B12 Hood Down Relay Ground
L1-8 J8-ECC HOD Control Cigar Lighter
D1 59U Hood Up Relay Control
L1-8 J9-ECC Diagnostic Power
D2 19Y-A Hood Up Relay Fused Power
L1-9 J9-ECC Diagnostic Power
D3 59D Hood Down Relay Control

Copyright ©
4002-134
CONNECTOR ECD - ELECTRICAL CENTER D
87312843
CAV WIRE IDENT CIRCUIT B5 19C-B Pilot Control Relay Fused Pwr
A1 13H-C Trans ECM Time Delay Pwr B6 53C-A Pilot Control Solenoid LSD
A2 13H-D Engine ECM Time Delay Pwr B7 58T Ride Control Relay Switch Pwr
A3 13H-B AIC Time Delay Power B8 58L Ride Control Relay LSD
A4 12V-D Plug 1 12V Switched Power B9 18M AC Relay Fused Power
A5 12V-E Plug 2 12V Switched Power B10 0-DJ AC Relay Control Ground
A6 12V-F Radio 12V Switched Power C2 63C2 Front Wiper Park Control
A7 12V-G 2 Way Radio 12V Sw Power C4 63C Front Wiper Park Control
A9 35C Backup Alarm Relay Control Front Wiper Relay HS Ctrl

D1 19J-D
Fused Pwr
A10 19H Backup Alarm Relay Fused Pwr
D2 63H-B Front Wiper HS Relay Out
AA1 19T-A TECM Delay Fused Power
Front Wiper Relay LS Ctrl Fused
AA2 18J-K EDC7 Time Delay Fused Power D3 19J-F
Pwr
AA3 19S-B AIC Delay Fused Power
D4 63C2 Front Wiper Park Control
AA4 12V 12V Power to Outlet 1
D5 19C-C Pilot control Relay Fused Pwr
AA5 12V-A 12V Power to Outlet 2
D6 53P-C Pilot Control Relay Out
AA6 12V-B 12V Fused Power to Radio
D7 58H-A Ride Ctrl Switched Pwr VPS2
AA9 35A-A Backup Alarm Relay Out
D8 58-E Ride Control Solenoid Power
Backup Alarm Relay Ctrl Fused
AA10 19A-P D9 61R-B AC Relay Control
Pwr
D10 61C AC Relay Out
B1 19J-E Front Wiper Relay Fused Power
B2 63HC-B Front Wiper HS Relay Control
B3 63C3 Front Wiper Park Control
B4 63LC Front Wiper LS Relay Control

Copyright ©
4002-135
CONNECTOR EDC7 - ENGINE CONTROLLER CAV WIRE IDENT CIRCUIT
42 35W Water In Fuel Indicator
48 24L Low Idle Switch
75 0-BV Grid Heater Control Ground
77 24S Throttle Supply
78 24R Throttle Ground
79 24B Throttle Signal
89 20G-A EDC7 ISO-K Interface
CONNECTOR EM - HEIGHT CONTROL RTD - RTT
225351C1

1 55A-A RTT/Float Switched Power
2 54A Height Control Switched Power
3 53A RTD Switched Power
4 53B-B RTD Control Signal
5 54B-B HC-RTT Control Signal
BOSCH-89-POLE 6 55B RTT Float Switch Control
2 18J-C EDC7 Time Delay Fused Power
3 18J-B EDC7 Time Delay Fused Power
5 0-BE EDC7 Ground
6 0-BF EDC7 Ground
8 18J-D EDC7 Time Delay Fused Power
9 18J-E EDC7 Time Delay Fused Power
10 0-BD EDC7 Ground
11 0-BC EDC7 Ground
12 28G Grid Heater Source DR
13 0-BN Filter Heater Control
17 21H-A Crank Control Relay LSD
29 21F-B EDC7 Digital Ground
32 21E-A Key Switch Crank
34 CAN-L CAN Low
35 CAN-H CAN High
36 28F Fuel Filter Heater Relay Control
37 21GA EDC7 Crank Control Relay
40 13M-A Fuel Shutoff Fused Power

Copyright ©
4002-136
CONNECTOR ENG - ENGINE TO CAB CAV WIRE IDENT CIRCUIT
30 61A Trinary Pressure Switch Input
31 20G-A EDC7 ISO-K Interface
32 36A-A Rear Axle Temperature
33 36F Fuel Level ANALOG
34 36C Radiator Coolant Temp Signal
35 19Y-D Hood Switch Fused Power
225414C1 36 60D-A Hood Down Relay Out
CAV WIRE IDENT CIRCUIT 37 59D-A Hood Down Relay Control
1 21C-D Starter Relay signal 38 60U-A Hood Up Relay Out
2 61C-A AC Relay Out 39 59U-A Hood Up Relay Control
2 61C-B AC Relay Out 40 35A-G Backup Alarm Relay Out
3 21GA EDC7 Crank Control Relay 40 35A-GN Backup Alarm Relay Out
4 21H-A Crank Control Relay LSD

5 18F-AN LH Position/Tail Fuse Power CONNECTOR ENG-D - DISCONECT HARNESS
5 18F-B LH Position/Tail Fuse Power
6 Not Used
7 35A-R Backup Alarm Relay Out
7 35A-J Reverse Light
8 44A-D Brake Light Relay Out
8 44A-DN Brake Light Relay Out
9 18G-H RH Position/Tail Fuse Power
9 18G-HN RH Position/Tail Fuse Power
245483C1
10 45L-A Left Turn Signal
10 45L-AN Left Turn Signal
A 13C-A Fuel Shutoff Fused Power
11 21F-A EDC7 Digital Ground
B 13M-A Fuel Shutoff Fused Power
12 45R-A Right Turn Signal
B 13M-B Key Switch Power Disc Switch
12 45R-AN Right Turn Signal
13 18R Voltmeter Relay Fused Power
14 18J-F EDC7 Time Delay Fused Power
15 21D Starter Relay Signal
16 28E Ether Relay Signal
17 0-BJ AIC Sensor Ground
18 18J-A EDC7 Time Delay Fused Power
19 0-BG AIC Power Ground
20 0-BH AIC Power Ground Red
21 13C-A Fuel Shutoff Fused Power
22 52A-B Fan Reverse Relay Out
23 56-A Fan Control PWM
24 68W-A Rear Washer Pump
25 63W-A Front Washer Pump
26 14 Alternator D+
27 21E-A Key Switch Crank
28 31F Air Filter Restriction Sw Signal
29 61R AC Relay Control

Copyright ©
4002-137
CONNECTOR ENG-HT1 - ENGINE TO HOOD CONNECTOR ENG-T - ENGINE TO
TRANSMISSION
225326C1

1 0-BZ Sec. Steering Splice Ground
225326C1 2 0-BK Transmission Splice Grounds
CAV WIRE IDENT CIRCUIT Coolant Level Sender Eng

3 31D-C
Transmission
1 0-BAG-T Hood Ground (NA)
4 Not Used
2 44A-DT Brake Light Relay Out
3 45L-AT Left Turn Signal
4 45R-AT Right Turn Signal CONNECTOR ESS - ENGINE SPEED SENSOR
CONNECTOR ENG-HT2 - ENGINE TO HOOD
291718A1

1 25A Engine Speed Signal
2 0-HF Engine Speed Sensor Ground
225294C1

CONNECTOR FFH - FUEL FILTER HEATER
A 18G-HT RH Posn/Tail Fused PWR
B 18F-AT LH Posn/Tail Fused PWR
C 35A-GT Backup Alarm Relay Out
182069A1

A 1-GB Fuel Filter Heater Power
B 0-BX Fuel Filter Heater Ground

Copyright ©
4002-138
CONNECTOR FLSHR - FLASHER MODULE CONNECTOR FRONT - CAB FRONT CHASSIS
225389C1

373358A1
1 1-DU Flasher Module Power
2 45N-A Flasher Optional Side Control
1 45L Left Turn Signal
3 0-EH Flasher Module Ground
2 51B-D Comfort Steering Sol Power
4 0-EG Flasher Module Ground
3 45R Right Turn Signal
5 Not Used
4 Not Used
6 Not Used
5 18G-A RH Position/Tail Fused Power
7 45R-E Right Turn Signal
6 18F LH Position/Tail Fused Power
8 45L-D Left Turn Signal
7 18B LH High Beam Fused Power
9 45A-A Left Turn Switch Power
8 36B-A Front Axle Temperature
10 45B-A Right Turn Switch Power
9 0-AR Front Axle Temp Sensor GND
11 45H Hazard Switch Power
10 Not Used
12 45N-B Flasher Optional Side Control
11 54B Height-RTT Control Signal
12 53B RTD Control Signal
CONNECTOR FM - FILTER MAINTENANCE 13 64 Horn Power
SWITCH 14 18D LH Low Beam Fused Power
15 18E RH Low Beam Fused Power
16 18C RH High Beam Fused Power
17 Not Used
18 Not Used
19 53P-G Pilot Control Relay Out
20 57 Pin Engage Sol Pwr
21 58-B Ride Control Sol Pwr
Ride Control Solenoid to Front
21 58S-E
Cab
22 1-AA Brake Lamp Switch Power
371614A1
23 44 Brake Lamp Control Power
24 52P Park Brake Relay Out
1 32F Trans Filter Maint Sw
25 Not Used
2 36R-B Trans FM Switch Return
26 33P Low Brake Pressure Warning
27 19A-A Brake Declutch Sw Fused Pwr
28 25G Brake Declutch Switch Control
29 Not Used
30 Not Used
31 Not Used

Copyright ©
4002-139
CONNECTOR FWM - FRONT WIPER MOTOR CONNECTOR FWW - FRONT WASHER
245715C1 3227856R1

A 63H-A Front Wiper High Speed Rly Out 1 63W-A Front Washer Pump
B 63L-A Front Wiper Low Speed Rly Out 2 0-B Front Washer Ground
C 19J-A Front Wiper Motor Fused Power
D 63C Front Wiper Park Control
CONNECTOR GHC - GRID HEATER RELAY
CONNECTOR FWMG - FRONT WIPER MOTOR

GROUND
3227856R1
245480C1
1 28G Grid Heater Source DR
2 0-BV Grid Heater Control Ground
1 0-B8 Front Wiper Ground

Copyright ©
4002-140
CONNECTOR GND-CAB-SPL - CAB GROUND CONNECTOR GND-CAB-SPL2 - SPLICE BACK
SPLICE LIGHT GROUND
87324393 87324393
A 0-EE Diode Suppression Grounds A 0-DC Time Delay Module Ground
B 0-EM Radio Ground B 0-EA Time Delay Relay Control Gnd
C 0-EP Horn Switch Ground C 0-EB Ignition Relay Control Ground
D Not Used D 0-EC ACC Relay Control Ground
E Not Used E 0-DD Voltmeter Relay Control Gnd
F 0-DG Cab Splice Grounds Crank Request Relay Control

F 0-DF
Gnd
G 0-DT Front Wiper/Washer Sw Gnd
G 0-DE Neutral Start Relay Control Gnd
H 0-DL Power Converter Relay Ctrl Gnd
Splice Pack Gnd Cab SPL2
I 0-DK Seat Compressor Motor Ground H 0-EQ
GND
K 0-DJ AC Relay Control Ground J Not Used
L 0-DU Pilot Pressure Solenoid Gnd K 0-EH Flasher Module Ground
M 0-DH Diagnostic Connector Ground L 0-EG Flasher Module Ground
M 0-EF Brake Lights Relay Control Gnd
CONNECTOR HD-NT1 - HOOD TO ENGINE
239451A1

1 0-JA-T Hood Grounds(NA)
2 44A-ET Brake Light Relay Out
3 45L-BT Left Turn Signal
4 45R-BT Right Turn Signal

Copyright ©
4002-141
CONNECTOR HD-NT2 - HOOD TO ENGINE CONNECTOR HVAC1 - HVAC1
225295C1

1 61A-B Trinary Pressure Switch Input
2 18N-A Blower Motor Fused Power
225295C1
3 49A Back Light Power
A 18G-JT RH Posn/Tail Fused Power
CONNECTOR HVAC2 - HVAC2
B 18F-BT LH Posn/Tail Fused Power
C 35A-HT Backup Alarm Relay Out
CONNECTOR HOT - HYDRAULIC OIL

TEMPERATURE SENDER
87552622
194788A1
1 0-ED HVAC Grounds
A 36H Hydraulic Oil Temp Signal
2 18N-B Blower Motor Fused Power
B 0-HW Hydraulic Oil Temp Ground

Copyright ©
4002-142
CONNECTOR HVAC-CAN1 - CAN-HVAC-ATC CONNECTOR K-WCO - WIPER CUTOUT
245731C1

87315267
30 63L-B Front Wiper LS Relay Out
85 63HC-A Wiper Cut Out Relay Control
A CAN-HK CAN High
86 19J-G Wiper Cut Out Relay Fused Pwr
B CAN-LL CAN Low
87 Not Used
87A 63C3 Front Wiper Park Control
CONNECTOR ISS - INT-SPEED-SENSOR
CONNECTOR LBEE - LIGHT BEACON EXTESION
291718A1

1 25B INT Speed Signal 291730A1
2 0-HG INT Speed Sensor Ground CAV WIRE IDENT CIRCUIT

A 46-E Beacon Light Power
B 0-MD Beacon Light Ground

Copyright ©
4002-143
CONNECTOR LLF - LH FRONT LIGHTS CONNECTOR LLR-12 - LH REAR COMBINATION
LAMP
225351C1

239451A1
1 0-AJ Lights Ground LH
2 18D Low Beam LH
1 0-BR-N LH Rear Light Ground (NA)
3 18B High Beam LH
2 44A-FN Brake Lamp Relay Out
4 18F Position LH Fused Power
3 18F-BN LH Tail Lamp Fused Pwr
5 45L Left Turn Signal
4 45L-BN Left Turn Signal
6 Not Used
CONNECTOR LLR-E - LH REAR COMBINATION

CONNECTOR LLFW - LH FRONT WORK LAMP
LAMP
245483C1
A 42C-H LH Front Work Lamp Power CAV WIRE IDENT CIRCUIT

B 0-MU LH Front Work Lamp Ground 1 44A-E Brake Light Relay Out
2 45L-A Left Turn Signal
3 18F-B Left Tail Fused Power
4 35A-L Reverse Lamp
5 0-BT LH Ground (EURO)
6 Not Used

Copyright ©
4002-144
CONNECTOR LLR-N - LH REAR COMBINATION CONNECTOR LRF - RH FRONT COMBINATION
LAMP LAMP
225351C1
245715C1
CAV WIRE IDENT CIRCUIT 1 0-AH RH Front Lights Ground
A 44A-FN Brake Lamp Relay Out 2 18E RH Low Beam Fused Pwr
B 18F-BN LH Tail Lamp Fused Pwr 3 18C RH High Beam Fused Pwr
C 45L-BN Left Turn Signal 4 18G-A RH Position/Tail Fused Pwr
D 0-BR-N LH Rear Light Ground (NA) 5 45R Right Turn Signal
6 Not Used
CONNECTOR LLRW- LH REAR WORK LAMP

CONNECTOR LRFW - RH FRONT WORK LAMP
245483C1

245483C1
A 42R-H LH Rear Work Lamp Fused Pwr
B 0-ME LH Rear Work Lamp Ground
A 42C-G RH Front Work Lamp Fused Pwr
B 0-MJ RH Front Work Lamp Ground
CONNECTOR LPL - LICENSE PLATE LAMP
245482C1

A 18G-E License Plate Lamp Fused Pwr
A 18G-EN License Plate Lamp Fused Pwr
B 0-JC License Plate Lamp Ground

Copyright ©
4002-145
CONNECTOR LRR-12 - RH REAR COMBINATION CONNECTOR LRR-N - RH REAR COMBINATION
LAMP LAMP
239451A1 245715C1

1 0-BT-N RH Rear Light Ground (NA) A 44A-GN Brake Lamp Relay Out
2 44A-GN Brake Lamp Relay Out RH Position/Tail Lamp Fused
B 18G-CN
RH Position/Tail Lamp Fused Pwr
3 18G-CN
Pwr C 45R-BN Right Turn Signal
4 45R-BN Right Turn Signal D 0-BT-N RH Rear Light Ground (NA)
CONNECTOR LRR-E - RH REAR COMBINATION CONNECTOR LRRW - RH REAR WORK LAMP

LAMP
245483C1

225351C1
A 42R-G RH Rear Work Lamp Fused Pwr
B 0-MF RH Rear Work Lamp Ground
1 44A-F Brake Light Relay Out
2 45R-A Right Turn Signal
3 18G-J Right Position/Tail Fused Pwr CONNECTOR LSPK - LEFT SPEAKER
4 35A-K Reverse Lamp
5 0-BR Ground (EURO)
6 Not Used
195552A1

A 65L Left Speaker Signal
B 0-PA Left Speaker Ground

Copyright ©
4002-146
CONNECTOR OSS - OUTPUT SPEED SENSOR CONNECTOR PBD - BRAKE DECLUTCH
PRESSURE SWITCH
245482C1
291719A1 CAV WIRE IDENT CIRCUIT

CAV WIRE IDENT CIRCUIT A 19A-A Brake Declutch Sw Fused Pwr
1 0-HE Output Speed Ground B 25G Brake Declutch Switch Control
2 25D Output Speed Signal
3 19A Output Speed Fused Pwr
CONNECTOR PBL - BRAKE LAMP PRESSURE
SWITCH
CONNECTOR PAF - AIR FILTER RESTRICTION
SWITCH
222136A1

1 1-AA Brake Lamp Switch Power
291718A1
2 44 Brake Lamp Control Power
Air Filter Restriction Switch
1 31F
Signal
CONNECTOR PBW - BRAKE PRESSURE
Air Filter Restriction Switch WARNING SWITCH
2 0-BY
Grnd
225316C1

1 33P Low Brake Press Warning
2 0-AL Brake Press Warn Sw Ground

Copyright ©
4002-147
CONNECTOR PO1 - POWER OUTLET CONNECTOR PR - TRINARY PRESSURE SWITCH
182068A1

12176446
A 61-A Trinary Pressure Switch Input
B 61R AC Relay Control
A 12V 12V Pwr to Outlet 1
B Not Used
C 0-EK Aux Power Outlet 1 Gnd CONNECTOR PRB1 - REDUNDANT BRAKE
SWITCH
CONNECTOR PO2 - POWER OUTLET
245483C1

RDNT Brake Accumulator Press
A 33R-C
Low
B 0-HM Ground
12176446

CONNECTOR PRB2 - REDUNDANT BRAKE
A 12V 12V Pwr to Outlet 2 SWITCH
B Not Used
C 0-EK Aux Power Outlet 2 Gnd
245483C1

RDNT Brake Accumulator Press
A 33R-B
Low
B 0-HL Ground

Copyright ©
4002-148
CONNECTOR PRBF - ROLLBACK PRESSURE CONNECTOR PRM-B2 - PRM SIGNAL
SWITCH
245483C1
CAV WIRE IDENT CIRCUIT 256340A1
A 58 Ride Control Solenoid Power CAV WIRE IDENT CIRCUIT

B 58-B Ride Control Solenoid Power A 13D Time Delay Relay Control Pwr
B 0-EA Time Delay Relay Control Gnd
CONNECTOR PRM-A1 - PRM SIGNAL

CONNECTOR PRM-C1 - PRM OUTPUT
409084A1

CAV WIRE IDENT CIRCUIT A 18R Voltmeter Relay Fused Pwr
A 13K-B Ignition Switch Power C 28P Ether Solenoid Power
B 0-EB Ignition Relay Control Ground C 1-GA Filter Heater Power
CONNECTOR PRM-B1 - PRM SIGNAL
409084A1

A Not Used
C 13H Time Delay Power

Copyright ©
4002-149
CONNECTOR PRM-C2 - PRM SIGNAL ONNECTOR PRM-E1 - PRM SIGNAL
409084A1

256340A1 A Not Used
CAV WIRE IDENT CIRCUIT C 19L Power Converter FSD Power
A 28E Ether Relay Signal
A 28F Fuel Filter Heater Relay Control
CONNECTOR PRM-E2 - PRM SIGNAL
B 0-BAM Ether Relay Signal Ground
B 0-BN Filter Heater Control ground
CONNECTOR PRM-D1 - PRM SIGNAL
256340A1

A 12ACC-C Pwr Converter PRM Control Pwr
B 0-DL Pwr Converter Relay Ctrl Gnd
256340A1

CONNECTOR PSS - SECONDARY STEERING
A 12ACC-B ACC PRM Control Power PRESSURE SWITCH
B 0-EC ACC Relay Control Ground
245485C1

A 51P-A Secondary Steer High Pressure
B 0-CC Sec. Steer Press Switch Ground
C 35X-A Secondary Steer Low Press Sig

Copyright ©
4002-150
CONNECTOR PXF - RTD CONNECTOR PXT - RTD
245485C1 245485C1

A 53B RTD Signal A 53B-A RTD Control Signal
B 0-AC Proximity Switch Ground B 0-AM RTD Ground
C 53P-H Pilot Control Relay Out C 53P-I Pilot Control Relay Out
CONNECTOR PXH - HEIGHT CONTROL RTT CONNECTOR RAD - RADIO POWER
245485C1

A 54B RTT Signal 292495A1
B 0-AA Proximity Switch Ground CAV WIRE IDENT CIRCUIT
C 53P-J Pilot Control Relay Out 1 Not Used
2 Not Used
CONNECTOR PXM - RTD 3 Not Used

4 12V-HB 12V Fused Power to Radio
5 Not Used
6 Not Used
7 12V-HA 12V Fused Power to Radio
8 0-EN Radio Ground
245485C1

A 53B-A RTD Control Signal
B 0-AM RTD Ground
C 53P-I Pilot Control Relay Out

Copyright ©
4002-151
CONNECTOR RAD-J1 - RADIO POWER CONNECTOR RAD-J3 - RADIO JUMPER
411311A1

1 RAD10 Right Speaker Ground
2 RAD8 Not Used
292497A1 3 RAD4 Left Speaker Ground
CAV WIRE IDENT CIRCUIT 4 RAD6 Not Used
1 Not Used 5 RAD1 Radio Ground
2 Not Used 6 Not Used
3 Not Used 7 RAD3 12V Fused Power to Radio
4 RAD3 12V Fused Power to Radio 8 RAD11 Right Speaker
5 Not Used 9 RAD9 Not Used
6 Not Used 10 RAD5 Left Speaker
7 RAD2 12V Fused Power to Radio 11 RAD7 Not Used
8 RAD1 Radio Ground 12 RAD2 12V Fused Power to Radio
13 Not Used
14 Not Used
CONNECTOR RAD-J2 - SPEAKER
CONNECTOR RECT - ENGINE COOLANT

TEMPERATURE
194788A1
292501A1
A 36C Radiator Coolant Temp Signal
1 RAD11 Right Speaker
B 0-BAE EDC7 Sender Ground
2 RAD10 Right Speaker Ground
3 RAD9 Not Used
4 RAD8 Not Used
5 RAD7 Not Used
6 RAD6 Not Used
7 RAD5 Left Speaker
8 RAD4 Left Speaker Ground

Copyright ©
4002-152
CONNECTOR ROOF - ROOF TO CAB CONNECTOR RTHP - THROTTLE PEDAL
CONNECTION
388708A1
A 43-B Dome Light Auto Mode CAV WIRE IDENT CIRCUIT

B 42R-F Rear Work Light Fused Power 1 21F-C EDC7 DIGITAL Ground
C 42C-F Front Work Lights Fused Power 2 Not Used
D 19U-C Done Light Fused Power 3 24B Throttle Signal
E 46-D Beacon Switch Power 3 24B-A Throttle Signal
F 0-MN Roof Grounds 4 24R Throttle Position Sensor Ground
G 0-MK Roof Grounds 4 24R-A Throttle Position Sensor Ground
J 19K-D Rear Wiper Motor Fused Power 5 24S Throttle Supply
K 68C-A Rear Wiper Park Control 5 24S-A Throttle Supply
L 68L-A Rear Wiper Switched Power 6 24L Low Idle Switch
M 0-EN Radio Ground
N 12V-H 12V Fused Power to Radio
CONNECTOR RWM - REAR WIPER MOTOR
R 43S-B Door Open Signal
S 19U-F Door Switch Fused Power
CONNECTOR RSPK - RIGHT SPEAKER
245715C1

195552A1 A Not Used
CAV WIRE IDENT CIRCUIT B 68L-A Rear Wiper Switch Power
A 65R Right Speaker Signal C 19K-D Rear Wiper Motor Fused Power
B 0-PB Right Speaker Ground D 68C-A Rear Wiper Park Control

Copyright ©
4002-153
CONNECTOR RWMG - REAR WIPER MOTOR CONNECTOR S-KEY - IGNITION SWITCH TO
GROUND PEDESTAL HARNESS
245480C1
225253C1
1 0-MA Rear Wiper Motor Ground
1 1A Ign Sw Fused Power
2 21K Ign Switch Start Signal
CONNECTOR RWW - REAR WASHER 3 13K Ignition Switch Power
4 12ACC Ign Switch Accessory Power
5 Not Used
6 Not Used
CONNECTOR SBE - BEACON SWITCH
3227856R1

1 68W-A Rear Washer Pump
2 0-BL Rear Washer Ground
382391A1

1 Not Used
2 19U-H Beacon Switch Fused Power
3 46-C Beacon Switched Power
4 Not Used
5 Not Used
6 Not Used
7 0-B15 Back Light Ground
8 49-B Back Light Power
9 Not Used
10 Not Used

Copyright ©
4002-154
CONNECTOR SBU - BACKUP ALARM DISABLE CONNECTOR SDC - DECLUTCH SWITCH
SWITCH
382391A1
382391A1
1 25G-B Brake Declutch Switch Control
1 35R-C Backup Alarm Switch
2 19A-R Declutch Switch Fused Power
2 35A-B Backup Alarm Disable Switch
3 Not Used
3 Not Used
4 Not Used
4 Not Used
5 Not Used
5 Not Used
6 Not Used
6 Not Used
8 49-R Back Light Power
8 49-L Back Light Power
9 Not Used
9 Not Used
10 Not Used
10 Not Used
CONNECTOR SDR - DRIVING LIGHTS SWITCH

CONNECTOR SC - SEAT COMPRESSOR MOTOR
245482C1
382391A1
A 19N Seat Compressor Fused Pwr
1 Not Used
B 0-DK Seat Compressor Motor Ground
2 19Z-A Driving lights Switch Fused Pwr
3 41T Position Lights Switch Power
4 Not Used
Driving Lights Switch Fused
5 19Z-B
Power
6 41J Driving Lights Power
8 49-P Back Light Power
9 Not Used
10 Not Used

Copyright ©
4002-155
CONNECTOR SETHR - ETHER SWITCH CONNECTOR SFL - RETURN-TO-TRAVEL
SWITCH
382391A1
382391A1
1 Not Used
1 55A-B RTT/Float Switch Power
2 28J Ether AIC OK Signal
2 53P-B Pilot Control Relay Out
3 28H Ether Switch Signal
3 55A-C RTT/Float Switch Power
4 Not Used
4 0-29 RTT/Float Ground
5 Not Used
5 55B RTT Float Switch Control
6 Not Used
6 54B-C HC-RTT Control Signal
8 49U Back Light Power
8 49-K Back Light Power
9 Not Used
9 Not Used
10 Not Used
10 Not Used
CONNECTOR SFC - FAN CONTROL SWITCH

CONNECTOR SFNR - FNR SWITCH
382391A1
382391A1
1 Not Used
1 26R-A FNR Reverse Signal
2 52J Fan Control Switch Jumper
2 26J FNR Switch Jumper
3 52-AU Fan Reverse Auto
3 26N-A FNR Neutral Signal
4 52J Fan Control Switch Jumper
4 26J FNR Switch Jumper
5 19P-C Fan Reverse Switch Fused Pwr
5 19A-V FNR Switch Fused Power
6 52M Fan Reverse Manual
6 26F-A FNR Forward Signal
7 32J-A Trans Enable Indication
8 49-Q Back Light Power
8 19A-G FNR Switch Fused Power
9 Not Used
9 Not Used
10 Not Used
10 Not Used

Copyright ©
4002-156
CONNECTOR SFWW - REAR WIPER AND CONNECTOR SHZ - HAZARD SWITCH
WASHER SWITCH
87345132 382391A1
2 0-DT Front Wiper/Washer Sw Gnd 2 1-KA Hazard Switch Power
3 63LC Front Wiper LS Relay Control 3 45H Hazard Switch Power
INT Wiper/Washer Sw Fused 5 Not Used

5 19J-B
Pwr
6 Not Used
6 Not Used
7 0-b24 Back Light Ground
7 63W Front Washer Pump
8 49-D Back Light Power
8 49-T Back Light Power
9 Not Used
9 63HC Front Wiper HS Relay Control
10 Not Used
10 Not Used
CONNECTOR SPB - PARKING BRAKE SWITCH

CONNECTOR SHC - HEIGHT CONTROL SWITCH
382391A1
382391A1
CAV WIRE IDENT CIRCUIT 1 Not Used
1 Not Used 2 19A-L Park Brk Switch Fused Power
2 53P-D Pilot Control Relay Out 3 33U Park Brake Switch
6 54A HC Control Switch Power 7 0-B29 RTT/Float Ground
7 0-B3 Back Light Ground 8 49-V Back Light Power
8 49-M Back Light Power 9 Not Used
10 Not Used

Copyright ©
4002-157
CONNECTOR SPC - PILOT CONTROL SWITCH CONNECTOR SPK - SPEAKER
382391A1
292494A1
1 Not Used CAV WIRE IDENT CIRCUIT
2 19A-j Pilot Control Switch Fused Pwr 1 65R Right Speaker
3 31L Pilot Control Switch High 2 0-PB Right Speaker Ground
7 0-B1 Back Light Ground 6 Not Used
8 49-N Back Light Power 7 65L Left Speaker
9 Not Used 8 0-PA Left Speaker Ground
10 Not Used
CONNECTOR SPE - PIN ENGAGE SWITCH
382391A1

1 57-B Pin Engage Solenoid Power
2 19P-A Pin Engage Sw Fused Power
3 Not Used
4 Not Used
5 Not Used
6 Not Used
7 Not Used
8 Not Used
10 49-F Back Light Power

Copyright ©
4002-158
CONNECTOR SPL-BCK-LGT - SPLICE BACK CONNECTOR SPL-BCK-LGT2 - SPLICE BACK
LIGHT POWER LIGHT POWER
87324393
87324393
A 49 Back Light Power
A 49-E Back Light Power
B Not Used
B Not Used
C 49-C Back Light Power
C 49-J Back Light Power
D 49-H Back Light Power
D 49-M Back Light Power
E 49-L Back Light Power
E 49-K Back Light Power
F 49A Back Light Power
F 49-F Back Light Power
G 49-P Back Light Power
G 49-Q Back Light Power
H 49-R Back Light Power
H 49-T Back Light Power
J 49S Back Light Power
J Not Used
K 49-E Back Light Power
K 49-G Back Light Power
L 49-B Back Light Power
L Not Used
M 49-A Back Light Power
M 49-S Back Light Power

Copyright ©
4002-159
CONNECTOR SPL-BCK-LT-GD - SPLICE BACK CONNECTOR SPL-BCK-LT-GD2 - SPLICE BACK
LIGHT GROUND LIGHT GROUND
87324393
87324393
A Not Used
A 0-B13 Back Light Ground
B 0-B2 Back Light Ground
B 0-B14 Back Light Ground
C 0-B3 Back Light Ground
C 0-B15 Back Light Ground
D 0-B4 Back Light Ground
D Not Used
E 0-B5 Back Light Ground
E 0-B17 Back Light Ground
F 0-B6 CAB2 Ground
F 0-B18 Back Light Ground
G 0-B26 Buzzer Switch Pad Ground
G 0-B19 Back Light Ground
H Not Used
H 0-B8 Front Wiper Motor Ground
J 0-B20 Back Light Ground
J 0-B21 Back Light Ground
K 0-29 RTT/Float Ground
K 0-DAP Back Light Ground
L 0-B11 Back Light Ground
L 0-B23 Back Light Ground
M 0-B7 Back Light Ground
M Not Used

Copyright ©
4002-160
CONNECTOR SPL-ENG-GND - GROUND SPLICE CONNECTOR SPL-PED-BL - SPL BACK LIGHT
6 PACK POWER 6 PACK
87324391 87324391

A 0-BM Engine Splice Grounds A 49-U Back Light Power
B 0-BY Air Filter Restriction Switch Gnd B 49-N Back Light Power
C Not Used C 49-D Back Light Power
D 0-BS Fan Control Ground D 49U Back Light Power
E 0-B Front Washer Ground E 49-V Back Light Power
F 0-BL Rear Washer Ground F 49-S Back Light Power
CONNECTOR SPL-HOOD-GND - HOOD GROUND CONNECTOR SPL-PED-BL-GD - SPL BACK

6 PACK LIGHT GROUND 6 PACK
87324391 87324391

A 0-B12 Hood Down Relay Ground A 0-B9 Back Light Ground
B 0-B16 Hood Down Control Ground B 0-B1 Back Light Ground
C 0-B22 Hood Up Relay Ground C 0-B24 Back Light Ground
D 0-B25 Hood Up Control Ground D 0-B30 Back Light Ground
E 0-B10 Hood Ground E 0-B29 RTT/Float Ground
F Not Used F 0-B11 Back Light Ground

Copyright ©
4002-161
CONNECTOR SPL-PIN - SPL PIN ENGAGE/FAN CONNECTOR SPL-PK1 - SPLICE 3 - 4 WAY
REVERSE POWER
87324462
87324391 CAV WIRE IDENT CIRCUIT

CAV WIRE IDENT CIRCUIT A 42C-A Front Work Lights Fused Pwr
A 19P-A Pin Engage Switch Fused Pwr B 42C-E Front Work Lights Fused Pwr
B 19P Pin Engage/Fan Fused Power C 42C-D Front Work Lights Fused Pwr
C 19P-C Fan Reverse Switch Fused Pwr D 42C-C Front Work Lights Fused Pwr
D Not Used E 13K Ignition Switch Power
E 19P-D Fan Reverse Relay Fused Pwr F 13K-B Ignition Switch Power
F 19P-E Fan Reverse Relay Fused Pwr G 13K-A Ignition Switch Power
H 13K-C Ignition Switch Power
J 35A-D Backup Alarm Relay Out
K 35A-B Backup Alarm Disable Switch
L 35A-A Backup Alarm Relay Out
M 35A-C Backup Alarm Relay Out

Copyright ©
4002-162
CONNECTOR SPL-PK2 - SPLICE 3 - 4 WAY CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY
87324462 87324462

A 41T-B Position Lights LH Switch Pwr A 45L-E Left Turn Signal
B 41T-E Position Lights Switch Pwr B 45L-D Left Turn Signal
C 41T Position Lights Switch Pwr C 45L-C Left Turn Signal
D 41T-A Position Lights RH Switch Pwr D 45L-B Left Turn Signal
E 19Z-A Driving Light Switch Fused Pwr E 45R-C Right Turn Signal
F 19Z-B Driving Light Switch Fused Pwr F 45R-E Right Turn Signal
G 19Z Driving Light Switch Fused Pwr G 45R-D Right Turn Signal
H 19Z-C High Beam Flash Fused Pwr H 45R-B Right Turn Signal
J 41H-C High Beam RH Power Front Wiper/Washer Sw Fused
J 19J-B
Pwr
K 41H-B High Beam LH Power
K 19J Front Wiper Fused Power
L 41H-A High Beam Power
L 19J-C Front Wiper Relay Fused Power
M 41H-D High Beam Power
M 19J-A Front Wiper Motor Fused Power

Copyright ©
4002-163
CONNECTOR SPL-ROOF - SPLICE ROOF CONNECTOR SPL-SEC-STR - SEC STR 6PK
GROUND
87324391
87324393 CAV WIRE IDENT CIRCUIT

CAV WIRE IDENT CIRCUIT A 0-CB Sec. Steering Signal Ground
A 0-MC Beacon Light Ground B 0-CA Sec. Steering Signal Ground
B 0-MB Dome Light Ground C 0-CC Sec. Steering Press Switch Gnd
C 0-MU LH Front Work Light Ground D 0-CF Sec. Steering Solenoid Ground
D 0-ME LH Rear Work Light Ground E Not Used
E 0-MF RH Rear Work Light Ground F 0-CD Sec. Steering Splice Ground
F 0-MA Rear Wiper Motor Ground
G Not Used
CONNECTOR SPL-TRN-GRD - SPLICE
H Not Used
TRANSMISSION GROUND
J 0-MJ RH Front Work Light Ground
K Not Used
L 0-MN Roof Grounds
M 0-MK Roof Grounds
87324391

A 0-HC Transmission Splice Grounds
B Not Used
C 0-HW HOT Ground
D 0-HV Coolant Level Sender Ground
E 0-HL Redundant Brake Switch Grd
F 0-HM Redundant Brake Switch Grd

Copyright ©
4002-164
CONNECTOR SPL-TRNS-PWR - TRANSMISSION CONNECTOR SRC - RIDE CONTROL SWITCH
POWER
382391A1

1 Not Used
87324393
2 19C-D Ride Ctrl Switch Fused Pwr
3 58C Ride Ctrl Switch Jumper
A 19A-N Trans Fused Power
4 58T Ride Ctrl Relay Switch Pwr
B 19A-F Trans Enable Switch Fused Pwr
5 58C Ride Ctrl Switch Jumper
C 19A-Q Trans/Auto Switch Fused Pwr
6 58-F Ride Ctrl Solenoid Pwr
D 19A-T Brake Declutch Sw Fused Pwr
E 19A-W Diagnostic Conn. Fused Pwr
8 49-G Back Light Power
F 19A-C FNR Switch Fused Pwr
9 Not Used
Backup Alarm Rly Ctrl Fused
G 19A-P 10 Not Used
Pwr
H 19A-R Declutch Switch Fused Pwr
J 19A-K TECM Fused Pwr CONNECTOR SRC-1 - STARTER RELAY
Output Speed Sensor Fused
K 19A-M
Pwr
L 19A-S Trans Fused Pwr
M 19A-H Trans Shifter Fused Pwr
225316C1

1 21D Starter Relay Signal
2 0-GB Starter Relay Control Ground

Copyright ©
4002-165
CONNECTOR SRHSTLK - RH STALK SWITCH CONNECTOR SRWP - REAR WIPER SWITCH
382391A1

1 68C Rear Wiper Park Control
87318288
2 68L Rear Wiper Switch Power
3 19K-A Rear Wiper Switch Fused Power
31b 64C Horn Relay Control
4 Not Used
49a 19B Turn Signal Fused Power
5 19K-B Rear Wiper Switch Fused Power
56a 41H-A High Beam Power
6 68W Rear Washer Pump
56b 41L-A Low Beam Power
56d 19Z-C High Beam Flash Fused Power
8 49-C Back Light Power
31 0-EP Horn Switch Ground
9 Not Used
56 41J Drive Lights Power
10 Not Used
L 45A-A Left Turn Switch Power
R 45B-A Right Turn Switch Power
CONNECTOR SS-TR - SS-MOD-TRANS
CONNECTOR SRTD - DETENT SWITCH
245489C1

A 19M-C Sec. Str Accessory Fused Pwr
B 19R-C Sec. Str Ignition Fused Pwr
C 35X-C Sec. Str Low Press Signal
382391A1
D 0-CD Sec. Str Splice Ground
CAV WIRE IDENT CIRCUIT E 19S1-X Sec. Str Fused Power
1 Not Used F Not Used
2 53P-E Pilot Control Relay Out

3 53A RTD Switched Power
4 Not Used
5 Not Used
6 Not Used
8 49-J Back Light Power
9 Not Used
10 Not Used

Copyright ©
4002-166
CONNECTOR SSM - SECONDARY STEERING CONNECTOR STA - TRANSMISSION AUTO
MODULE SWITCH
225389C1
382391A1
1 19R-C 1 Not Used
Pwr
2 19A-Q Trans Auto Sw Fused Power
2 51-A Secondary Steer Control
3 25H Trans Auto Signal
3 19S1-X Secondary Steer Fused Power
4 Not Used
4 0-CE Secondary Steer Chassis Grnd
5 Not Used
5 Not Used
6 Not Used
6 Not Used
Secondary Steer ACC Fused
7 19M-C
Pwr 8 49S Back Light Power
8 35X-D Secondary Steer Low Press Sig 9 Not Used
9 51P-A Secondary Steer High Press 10 Not Used
10 Not Used
11 0-CA Secondary Steer Signal Grnd
CONNECTOR STE - TRANSMISSION ENABLE
12 0-CB Secondary Steer Signal Grnd SWITCH
382391A1

1 Not Used
2 19A-D Trans Enable Sw Fused Power
3 26E Trans Enable Signal
4 Not Used
5 Not Used
6 Not Used
7 0-DAP Back Light Ground
8 49-H Back Light Power
9 32J-C Trans Enable Indiction
10 19A-E Trans Enable Sw Fused Pwr

Copyright ©
4002-167
CONNECTOR SWL - WORK LIGHTS SWITCH CONNECTOR TCOT - TORQUE CONVERTER
OUTPUT SENDER
382391A1

1 Not Used 291718A1
2 42-A Work Lights Fused Power CAV WIRE IDENT CIRCUIT
3 42FS Front Work Lights Switch Power A 36G TCO Temperature Signal
4 Not Used B 36R-D TCO Temperature Return
5 42-B Work Lights Fused Power

6 42RS Rear Work Lights Switch Power
CONNECTOR TDM - TIME DELAY MODULE
8 49-A Back Light Power
9 Not Used
10 Not Used
CONNECTOR SW-PD - SWITCH PAD
225351C1

1 13D Time Delay Relay Ctrl Power
2 1DN Time Delay Fused Power
3 0-DC Time Delay Module Ground
4 43S-D Time Delay Mod Door Sw Reset
5 13K-A Ignition Switch Power
6 Not Used
87552623

1 41H-D High Beam Power
2 41T-D Position Lights Switch Pwr
3 42C-E Front Work Light Fused Pwr
4 31H-A Hydraulic Filter Rest Sw Signal
5 31F-A Air Filter Rest Switch Signal
6 Not Used
7 CAN-HF CAN High
8 CAN-LF CAN Low
9 17P-A Switch Pad Pwr From AIC Pwr
10 0-B28 Switch Pad Ground

Copyright ©
4002-168
CONNECTOR TECM - TRANSMISSION CAV WIRE IDENT CIRCUIT
ELECTRONIC CONTROL MODULE
21 52P-C Park Brake Relay Out
22 25Y-A Trans Kick Down Signal
23 19T-A Time Delay Fused Power
25 CAN-HD CAN High
26 CAN-LK CAN Low
27 CAN-LJ CAN Low
29 25H Trans Auto Signal
30 26R-B FNR Reverse Signal
31 26E Trans Enable Signal
32 25M-A Trans Sol Valve Y3
39 36T-A Valve Body Temp Signal
41 25C-A Turb Speed Signal
42 25B-A Int Speed Signal
43 25F Forward Signal
44 26N-B FNR Neutral Signal
45 19A-K TECM Fused Power
46 36R-E Trans Temp/Filter Return
49 36G-A Torque Conv Out Temp Signal
51 25J-A Trans Sol Valve Y6
55 25N-A Trans Sol Valve Y4
56 25K-A Trans Sol Valve Y1
57 58L Ride Control Relay LSD
62 25D-A Output Speed Signal
63 25Z 1st and 4th Gear Signal
64 25R- Reverse Signal
65 25W 3rd and 4th Gear Signal
66 25G-C Brake Declutch Switch Control
411398A1
67 25T-C Neutral Signal
1 0-DP Diag TECM Ground
2 0-DQ Diag TECM Ground
3 0-DM Speed Sensors Ground
4 0-DN Out Speed Sensor Ground
5 32J-D Trans Enable Indicator Lamp
7 35C Backup Alarm Relay Control
8 58H-A Ride Control Sw Power VPS2
9 25P-A Trans Sol Valve Y5
10 25L-A Trans Sol Valve Y2
12 25S-B Output Sw Power VPS1
13 25S-C Output Sw Power VPS1
15 37D-A Diagnostic Signal
17 32F-A Trans Filter Maint Switch
18 37E Diagnostic Signal Switched
19 25A-A Engine Speed Signal
20 26F-B FNR Forward Signal

Copyright ©
4002-169
CONNECTOR TR-SS - SEC-STR-MOD-OPT CONNECTOR TRANS - CAB TO TRANSMISSION
380838A1

1 33R-A Redundant Brake Switch Signal
Coolant Level Sender Eng
245488C1 2 31D-B
Trans
2 31D Coolant Level Signal
A 19M-A Sec. Steering ACC Fused Pwr
3 19M-A Sec. Steering ACC Fused Pwr
B 19R-A Sec. Steering Ignition Fused
Pwr 4 19R-A
Pwr
C 35X-B Sec. Steering Low Press Signal
5 36T Valve Body Temp Signal
D 0-HP Sec. Steering Splice Ground
6 35X-B Sec. Steering Low Press Signal
E 19S1-E Sec. Steering Fused Power
7 25A Engine Speed Signal
F Not Used
8 25C Turb Speed Signal
9 25B Intermediate Speed Signal
CONNECTOR TRAN-E - TRANS TO ENG 10 25D Output Speed Signal
11 0-HD Speed Sensor Ground
12 36R-A Trans Temp/Filter Return
13 36G Torque Conv Output Temp Sig
14 Not Used
15 Not Used
16 25K Trans Solenoid Valve Y1
16 25K-9 Trans Solenoid Valve Y2
17 25L-9 Trans Solenoid Valve Y1
17 25L Trans Solenoid Valve Y2
239451A1 18 25M Trans Solenoid Valve Y3
CAV WIRE IDENT CIRCUIT 19 25N Trans Solenoid Valve Y4
1 0-HP Sec. Steering Splice Ground 20 25P Trans Solenoid Valve Y5
2 0-HC Trans Splice Grounds 21 25J Trans Solenoid Valve Y6
Coolant Level Sender Eng 22 25S Output Sw Power VPS1
3 31D-B
Trans
23 31H Hyd Filter Restriction Sw Signal
4 Not Used
24 Not Used
25 Not Used
26 19S1-E Sec. Steering Fused Power
27 Not Used
28 0-HE Output Speed Sensor Ground
Output Speed Sensor Fused
29 19A
Pwr
30 36H Hydraulic Oil Temperature Sign
31 32F Trans Filter Maint Switch

Copyright ©
4002-170
CONNECTOR TRC - TRANSMISSION CONTROL CONNECTOR TS1 - TRANSMISSION SHIFTER
245486C1
CAV WIRE IDENT CIRCUIT A 19A-H Trans Shifter Fused Power
1 25K Trans Solenoid Valve Y1 B 25F Forward Signal
1 25L-9 Trans Solenoid Valve Y1 C 25R Reverse Signal
2 25K-9 Trans Solenoid Valve Y2 D 25T-B Neutral Signal
2 25L Trans Solenoid Valve Y2

3 25M Trans Solenoid Valve Y3
CONNECTOR TS2 - TRANSMISSION SHIFTER
4 25N Trans Solenoid Valve Y4
5 25P Trans Solenoid Valve Y5
6 25J Trans Solenoid Valve Y6
7 25S Output Sw Power VPS1
8 36T Valve Body Temp Signal
9 36R-C Valve Body Temp Return
10 Not Used
11 Not Used
12 Not Used
245487C1
13 Not Used
14 Not Used
A Not Used
15 Not Used
B 25W 3rd and 4th Gear Signal
16 Not Used
C 25Z 1st and 4th Gear Signal
D 25Y Transmission Kick Down Signal

Copyright ©
4002-171
CONNECTOR TSS - TURBINE SPEED SENSOR CONNECTOR YFN - FAN PWM SOLENOID
291718A1 256340A1

1 25C Turbine Speed Signal A 56-A Fan Control PWM
2 0-HH Turbine Speed Ground B 0-BQ Fan Speed PWM Solenoid Gnd
CONNECTOR WIF - WATER IN FUEL SENSOR CONNECTOR YFR - FAN REVERSING SOLENOID
8602416 225316C1

1 35W Water Indicator 1 52A-B Fan Reversing Relay Out
2 0-BP Sensor Ground 2 0-BB Fan Reversing Solenoid Ground
3 18J-H Sensor Fused Power
CONNECTOR YPB - PARKING BRAKE

CONNECTOR WSH - WATER SEPARATOR SOLENOID
HEATER
291718A1
182069A1
1 52P Parking Brake Relay Out
A 0-BW Water Separator Heater Ground
2 0-AN Park Brake Solenoid Ground
B 1-GC Water Separator Heater Power

Copyright ©
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CONNECTOR YPE - PIN ENGAGE OPT CONNECTOR YRC - RIDE CONTROL OPT
245482C1

291718A1
A 57 Pin Engage Solenoid Power
B 0-AE Pin Engage Ground CAV WIRE IDENT CIRCUIT
1 58 Ride Control Solenoid Power
1 58S-E Ride Control Sol To Front Cab
CONNECTOR YPP - PILOT PRESSURE
2 0-AD Ride Control Ground
SOLENOID
CONNECTOR YSS - SECONDARY STEERING

SOLENOID
245482C1

A 5P-A Pilot Control Relay Out
B 0-DU Pilot Pressure Solenoid Gnd 225316C1

1 51-C Sec. Steering Solenoid Control
2 0-CF Sec. Steering Solenoid Ground

Copyright ©
4002-173
INDEX
Symbols Connector 209F ...................................................122
12 Volt Radio .......................................................112 Connector 209M ..................................................122
Connector 20M ....................................................122
A Connector 215F ...................................................122
A/C High/Low Pressure Switch ............................115 Connector 216F ...................................................122
Air Filter Restriction Switch ....................................67 Connector 64F .....................................................123
Air Seat Compressor and Switch .........................114 Connector 64M ....................................................123
Alarm Connector 69 .......................................................153
Back-up (Europe Only) ......................................96 Connector ACT ....................................................123
Back-up (North America Only) ..........................96 Connector AIC1 ...................................................123
Back-up, Disable Switch ...................................76 Connector AIC2 ...................................................124
Back-up, Relay ..................................................76 Connector ALT5 ..................................................124
Alternator ...............................................................40 Connector BUZ ....................................................124
Connector CAB_E ...............................................125
B Connector CAB_F ...............................................126
Back-up Alarm (Europe Only) ................................96 Connector CAB_RF .............................................126
Back-up Alarm (North America Only) ....................96 Connector CAB_T ...............................................127
Back-up Alarm Disable Switch ..............................76 Connector CAN ...................................................127
Back-up Alarm Relay .............................................76 Connector CAN2 .................................................127
Batteries ................................................................41 Connector CL ......................................................128
Beacon Switch .......................................................79 Connector CLS ....................................................128
Beacon, Rotating (Option) .....................................78 Connector CNV ...................................................128
Brake Lamp Pressure Switch ................................83 Connector D_OR .................................................128
Brake Lamps Relay ...............................................83 Connector DIA .....................................................128
Brake Warning Pressure Switch ............................68 Connector DISC ..................................................128
Buzzer ...................................................................66 Connector DM .....................................................129
Connector DNS-AC-SWITCH ..............................129
C Connector DNS-ACTUATOR ..............................129
CAN Communication Diagnostics Connector ......109 Connector DNS-CTRL-PANEL-LIGHT ................129
Cigar Lighter ........................................................114 Connector DNS-DRIVER ....................................130
Circuit Breaker Cab B+ ..........................................47 Connector DNS-ELECTRIC-FAN ........................129
Climate Control, Standard Connector DNS-ELECT-WATER-VALVE-S ........130
Air Conditioning Switch ...................................119 Connector DNS-HVAC1-S ..................................130
Air Recirculation Motor ....................................117 Connector DNS-HVAC2-S ..................................130
Air Recirculation Switch ..................................120 Connector DNS-RECIRCULATING-SWITCH .....129
Blower Motor ...................................................118 Connector DNS-RESISTOR ................................130
Blower Motor Speed Resistors with Thermal Fuse Connector DNS-SPEED-SELECTOR .................129
118 Connector DNS-THERMOSTAT-1 ......................129
Blower Switch ..................................................119 Connector DNS-THERMOSTAT-2 ......................129
Control Panel Lights ........................................119 Connector DNS-WATER-VALVE-POT ................129
Driver ...............................................................117 Connector DS ......................................................130
Electronic Water Valve ....................................118 Connector ECA ...................................................131
Thermostat ......................................................119 Connector ECB ...................................................132
Water Valve Potentiometer .............................120 Connector ECC ...................................................133
Cluster, Instrument Connector 1 ............................65 Connector ECD ...................................................134
Cluster, Instrument Connector 2 ............................71 Connector EDC7 .................................................135
Compressor Clutch ..............................................115 Connector EM .....................................................135
Compressor Clutch Relay ....................................114 Connector ENG ...................................................136
Compressor, Seat ................................................114 Connector ENG_D ..............................................136
Connector 108F ...................................................121 Connector ENG_HT1 ..........................................137
Connector 140M ..................................................121 Connector ENG_HT2 ..........................................137
Connector 197F ...................................................121 Connector ENG_T ...............................................137
Connector 197M ..................................................121 Connector ESS ....................................................137
Connector 202M ..................................................122 Connector FFH ....................................................137
Connector FLSHR ...............................................138
Copyright ©
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Connector FM ......................................................138 Connector RAD_J2 .............................................151
Connector FRONT ...............................................138 Connector RAD_J3 .............................................151
Connector FWM ..................................................139 Connector RECT ................................................. 151
Connector FWMG ................................................139 Connector ROOF ................................................152
Connector FWW ..................................................139 Connector RSPK ................................................. 152
Connector GHC ...................................................139 Connector RTHP ................................................. 152
Connector GND_CAB_SPL .................................140 Connector RWM ..................................................152
Connector GND_CAB_SPL2 ...............................140 Connector RWMG ...............................................153
Connector HD_NT1 .............................................140 Connector RWW ................................................. 153
Connector HD_NT2 .............................................141 Connector S_KEY ...............................................153
Connector HOT ...................................................141 Connector SBE .................................................... 153
Connector HVAC_CAN1 .....................................142 Connector SBU ...................................................154
Connector HVAC1 ...............................................141 Connector SC ......................................................154
Connector HVAC2 ...............................................141 Connector SDC ...................................................154
Connector ISS .....................................................142 Connector SDR ...................................................154
Connector K_WCO ..............................................142 Connector SETHR ...............................................155
Connector LBEE ..................................................142 Connector SFC .................................................... 155
Connector LLF .....................................................143 Connector SFL .................................................... 155
Connector LLFW .................................................143 Connector SFNR ................................................. 155
Connector LLR_12 ..............................................143 Connector SFWW ...............................................156
Connector LLR_E ................................................143 Connector SHC ...................................................156
Connector LLR_N ................................................144 Connector SHZ .................................................... 156
Connector LLRW .................................................144 Connector SPB .................................................... 156
Connector LPL .....................................................144 Connector SPC ...................................................157
Connector LRF ....................................................144 Connector SPE .................................................... 157
Connector LRFW .................................................144 Connector SPK .................................................... 157
Connector LRR_12 ..............................................145 Connector SPL_BCK_LGT ..................................158
Connector LRR_E ...............................................145 Connector SPL_BCK_LGT2 ................................158
Connector LRR_N ...............................................145 Connector SPL_BCK_LT_GD .............................159
Connector LRRW ................................................145 Connector SPL_BCK_LT_GD2 ........................... 159
Connector LSPK ..................................................145 Connector SPL_ENG_GND ................................160
Connector OSS ...................................................146 Connector SPL_HOOD_GND .............................160
Connector PAF ....................................................146 Connector SPL_PED_BL .................................... 160
Connector PBD ....................................................146 Connector SPL_PED_BL_GD .............................160
Connector PBL ....................................................146 Connector SPL_PIN ............................................161
Connector PBW ...................................................146 Connector SPL_PK1 ........................................... 161
Connector PO1 ....................................................147 Connector SPL_PK2 ........................................... 162
Connector PO2 ....................................................147 Connector SPL_PK3 ........................................... 162
Connector PR ......................................................147 Connector SPL_ROOF ........................................ 163
Connector PRB1 ..................................................147 Connector SPL_SEC_STR ................................. 163
Connector PRB2 ..................................................147 Connector SPL_TRN_GRD ................................. 163
Connector PRBF .................................................148 Connector SPL_TRNS_PWR .............................. 164
Connector PRM_A1 .............................................148 Connector SRC ...................................................164
Connector PRM_B1 .............................................148 Connector SRC_1 ...............................................164
Connector PRM_B2 .............................................148 Connector SRHSTLK ..........................................165
Connector PRM_C1 ............................................148 Connector SRTD ................................................. 165
Connector PRM_C2 ............................................149 Connector SRWP ................................................165
Connector PRM_D1 ............................................149 Connector SS_TR ...............................................165
Connector PRM_E1 .............................................149 Connector SSM ...................................................166
Connector PRM_E2 .............................................149 Connector STA .................................................... 166
Connector PSS ....................................................149 Connector STE .................................................... 166
Connector PXF ....................................................150 Connector SW_PD .............................................. 167
Connector PXH ....................................................150 Connector SWL ...................................................167
Connector PXM ...................................................150 Connector TCOT ................................................. 167
Connector PXT ....................................................150 Connector TDM ...................................................167
Connector RAD ...................................................150 Connector TECM ................................................. 168
Connector RAD_J1 ..............................................151 Connector TR_SS ...............................................169

Copyright ©
4002-175
Connector TRAN_E .............................................169 Front Wiper Motor ...............................................101
Connector TRANS ...............................................169 Fuel Filter Heater ...................................................48
Connector TRC ....................................................170 Fuel Filter Heater Relay ........................................46
Connector TS1 ....................................................170 Fuel Level Sender .................................................67
Connector TS2 ....................................................170
Connector TSS ....................................................171 G
Connector WIF ....................................................171 Grid Heater ............................................................47
Connector WSH ...................................................171 Grid Heater Relay ..................................................47
Connector YFN ....................................................171
Connector YFR ....................................................171 H
Connector YPB ....................................................171 Hazard Switch .......................................................85
Connector YPE ....................................................172 Heater
Connector YPP ....................................................172 Fuel Filter ..........................................................48
Connector YRC ...................................................172 Grid ...................................................................47
Connector YSS ....................................................172 Water Separator ................................................47
Connector, Diagnostic ...........................................63 Height Control Switch ............................................53
Coolant Level Sender ............................................74 Height Control/Return-To-Travel Proximity Switch 55
Crank Control Relay ..............................................41 High-Low Beam Switch .........................................85
Crank Request Relay ............................................41 Horn .......................................................................90
Horn Relay ............................................................90
D Horn Switch ...........................................................85
Declutch Brake Switch ...........................................63 Hydraulic Filter Restriction Switch .........................72
Declutch Switch .....................................................63 Hydraulic Oil Temperature Sender ........................72
Diagnostic Connector ............................................63
Diodes I
Lights .................................................................81 Ignition Switch .......................................................43
Secondary Steering .........................................105 Instrument Cluster Connector 1 ............................65
Wipers .............................................................103 Instrument Cluster Connector 2 ............................71
Dome Lamp ...........................................................79 Intermediate Speed Sensor ...................................63
Door Switch ...........................................................78
Driving Lamp Switch ..............................................86 L
Lamp
E Dome ................................................................79
Electrical Wire Identification ....................................8 High Beam ..................................................88, 89
Electromagnetic Detents .......................................54 Left Hand Front Combination ............................88
Electronic Diesel Control .......................................51 Left Hand Front Work ........................................79
Engine Speed Sensor ............................................63 Left Hand Rear Combination (Europe Only) .....95
Left Hand Rear Combination (North America Only)
F ............................................................94
Fan PWM Solenoid ................................................61 Left Hand Rear Work ........................................80
Fan Reverse Relay ................................................59 License Plate (Europe Only) .............................96
Fan Reversing Solenoid ........................................61 License Plate (North America Only) ..................95
Fan Reversing Switch ............................................59 Low Beam ...................................................88, 89
Filter Maintenance Switch .....................................63 Position .......................................................88, 89
Flasher Module ......................................................84 Right Hand Front Combination ..........................89
FNR Switch for Joystick Controls ..........................63 Right Hand Front Work .....................................80
FNR Switch for Single Axis Controls .....................63 Right Hand Rear Combination (Europe Only) ...93
Front Right Hand Rear Combination (North America
Left Hand Work Lamp .......................................79 Only) ..................................................92
Right Hand Work Lamp .....................................80 Right Hand Rear Work ......................................80
Front Left Hand Combination Lamp ......................88 Switch, Driving ..................................................86
Front Right Hand Combination Lamp ....................89 Turn .............................................................88, 89
Front Washer Pump Motor ..................................102 Left Hand Front Combination Lamp ......................88
Front Wiper and Washer Switch ..........................100 Left Hand Front Work Lamp ..................................79
Front Wiper Cut Out Relay ....................................98 Left Hand Rear Combination Lamp (Europe Only) 95
Front Wiper High Speed Relay ..............................98 Left Hand Rear Combination Lamp (North America
Front Wiper Low Speed Relay ...............................99 Only) .........................................................94
Copyright ©
4002-176
Left Hand Rear Work Lamp ...................................80 Left Hand Work Lamp ....................................... 80
Left Speaker ........................................................112 Right Hand Combination Lamp (Europe Only) .93
License Plate Lamp .........................................95, 96 Right Hand Combination Lamp (North America
License Plate Lamp (Europe Only) ........................96 Only) ..................................................92
License Plate Lamp (North America Only) ............95 Right Hand Work Lamp .....................................80
Lights Diodes .........................................................81 Rear Washer Pump Motor ...................................102
Locating Components on the Schematic Posters ..38 Rear Wiper and Washer Switch ............................ 99
Rear Wiper Motor ................................................102
M Redundant Brake Pressure Switch 1 ....................73
Magnetic Detents ...................................................54 Redundant Brake Pressure Switch 2 ....................73
Master Disconnect Switch .....................................42 Relay
Module Backup Alarm ....................................................76
Flasher ..............................................................84 Brake Lamps .....................................................83
Secondary Steering .........................................106 Compressor Clutch .........................................114
Time Delay ........................................................42 Crank Control ....................................................41
Transmission Electronic Control .......................63 Crank Request ..................................................41
Motor Fan Reverse .....................................................59
Starter ...............................................................43 Front Wiper Cut Out .......................................... 98
Front Wiper High Speed ................................... 98
N Front Wiper Low Speed ....................................99
Neutral Start Relay ................................................44 Fuel Filter Heater ..............................................46
Grid Heater ....................................................... 47
O Horn ..................................................................90
Outlet, Power .......................................................111 Neutral Start ...................................................... 44
Output Speed Sensor ............................................63 Parking Brake ................................................... 66
Pilot Control ...................................................... 55
P Power Relay Module A Ignition Power ..............46
Parking Brake Relay ..............................................66 Power Relay Module B Ignition Power ..............46
Parking Brake Solenoid .........................................67 Power Relay Module C Water Separator Htr ....46
Parking Brake Switch ............................................73 Power Relay Module D Accessory Power ........48
Pilot Control Relay .................................................55 Power Relay Module E Power Converter ....... 111
Pilot Control Switch ...............................................60 Ride Control ...................................................... 58
Pilot Pressure Solenoid .........................................56 Starting ..............................................................40
Pin Engage Solenoid .............................................56 Voltmeter ...........................................................44
Pin Engage Switch ................................................56 Resistor
Potentiometer Alternator .......................................................... 40
Throttle ..............................................................50 Return to Dig Switch Switch ..................................55
Power Converter (24 volts to 12 volts) ................111 Return-To-Dig Proximity Switch ............................ 54
Power Outlet ........................................................111 Return-To-Travel/Float Switch ..............................53
Power Relay Module Ride Control Relay ................................................ 58
A Ignition Power ................................................46 Ride Control Solenoid ...........................................60
B Ignition Power ................................................46 Ride Control Switch ...............................................58
C Fuel Filter Heater ...........................................46 Right Hand Front Combination Lamp ....................89
D Accessory Power ...........................................48 Right Hand Front Work Lamp ................................ 80
E Power Converter 24V to 12V .......................111 Right Hand Rear Combination Lamp (Europe Only) .
Proximity Switch 93
Height Control/Return-To-Travel .......................55 Right Hand Rear Combination Lamp (North America
Return-To-Dig ...................................................54 Only) ......................................................... 92
Right Hand Rear Work Lamp ................................ 80
R Right Speaker ......................................................112
Rollback Jumper ....................................................61
Radiator Coolant Temperature Sender .................68
Rollback Pressure Switch ...................................... 60
Radio
Rotating Beacon (Option) ...................................... 78
12 Volt .............................................................112
Rear
Left Hand Combination Lamp (Europe Only) ....95 S
Left Hand Combination Lamp (North America Seat Compressor and Switch .............................. 114
Only) ...................................................94 Secondary Steering

Copyright ©
4002-177
Module ............................................................106 Front Wiper and Washer .................................100
Motor ...............................................................107 Hazard ..............................................................85
Pressure Switch ..............................................107 Height Control ...................................................53
Solenoid ..........................................................105 High-Low Beam .................................................85
Secondary Steering Diodes .................................105 Horn ..................................................................85
Sender Hydraulic Filter Restriction ................................72
Coolant Level ....................................................74 Ignition ..............................................................43
Fuel Level ..........................................................67 Master Disconnect ............................................42
Hydraulic Oil Temperature ................................72 Pad ....................................................................70
Radiator Coolant Temperature ..........................68 Parking Brake ....................................................73
Torque Converter Output Temperature .............63 Pilot Control Switch ...........................................60
Sensor Pin Engage .......................................................56
Engine Speed ....................................................63 Proximity, Height Control/Return-To-Travel ......55
Intermediate Speed ...........................................63 Proximity, Return-To-Dig ...................................54
Output Speed ....................................................63 Rear Wiper and Washer ....................................99
Transmission Solenoid Valve and Temperature ... Redundant Brake Pressure 1 ............................73
63 Redundant Brake Pressure 2 ............................73
Turbine Speed ...................................................63 Return to Dig .....................................................55
Water In Fuel .....................................................50 Return-To-Travel/Float ......................................53
Shifter, Transmission .............................................63 Ride Control ......................................................58
Solenoid Rollback Pressure .............................................60
Fan PWM ..........................................................61 Seat Compressor ............................................114
Fan Reversing ...................................................61 Secondary Steering Pressure .........................107
Parking Brake ....................................................67 Transmission Auto ............................................63
Pilot Pressure ....................................................56 Transmission Enable .........................................63
Pin Engage ........................................................56 Transmission Kick-down ...................................63
Ride Control ......................................................60 Turn Signal ........................................................85
Secondary Steering .........................................105 Work Lamps ......................................................78
Speaker Switch Pad ............................................................70
Left ..................................................................112
Right ................................................................112 T
Specifications ..........................................................7 Thermal Fuse
Speed Resistors Blower Motor ...................................................118
Blower Motor ...................................................118 Throttle Potentiometer ...........................................50
Starter Motor ..........................................................43 Time Delay Module ...............................................42
Starting Relay ........................................................40 Torque Converter Output Temperature Sender ....63
Steering Transmission Auto Switch .....................................63
Secondary, Module .........................................106 Transmission Electronic Control Module ...............63
Secondary, Motor ............................................107 Transmission Enable Switch .................................63
Secondary, Pressure Switch ...........................107 Transmission Kick-down Switch ............................63
Secondary, Solenoid .......................................105 Transmission Shifter ..............................................63
Switch Transmission Solenoid Valve and Temperature Sen-
A/C High/Low Pressure ...................................115 sors ...........................................................63
Air Filter Restriction ...........................................67 Turbine Speed Sensor ..........................................63
Back-up Alarm Disable ......................................76 Turn Signal Switch ................................................85
Beacon ..............................................................79
Blower .............................................................119 U
Brake Lamp Pressure .......................................83 Understanding the Troubleshooting Tables ..........38
Brake Warning Pressure ...................................68
Declutch ............................................................63 V
Declutch Brake ..................................................63 Voltmeter Relay .....................................................44
Door ..................................................................78
Driving Lamp .....................................................86 W
Fan Reversing ...................................................59 Warning Buzzer .....................................................66
Filter Maintenance .............................................63 Water In Fuel Sensor ............................................50
FNR for Joystick Controls .................................63 Water Separator
FNR for Single Axis Controls ............................63 Heater ...............................................................47
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4002-178
Heater Relay .....................................................46
Wiper
Front Cut Out Relay ..........................................98
Front Motor ......................................................101
Front Switch ....................................................100
Front Washer Pump Motor ..............................102
Front Washer Switch .......................................100
Front Wiper High Speed Relay .........................98
Front Wiper Low Speed Relay ..........................99
Rear Motor ......................................................102
Rear Switch .......................................................99
Rear Washer Pump Motor ..............................102
Rear Washer Switch .........................................99
Wiper Diodes .......................................................103
Wire Identification ....................................................8
Work Lamp Switch .................................................78

Copyright ©
Section
4003
4003
BATTERIES

Copyright ©
4003-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging Guide For Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging Guide For Batteries Other Than Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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4003-3
SAFETY RULES
WARNING: Never try to charge the battery if WARNING: Battery acid causes severe
the electrolyte in the battery is frozen. burns. Batteries contain sulfuric acid. Avoid
47-83A contact with skin, eyes, or clothing. Antidote:
EXTERNAL-Flush with water.
WARNING: Never cause sparks to occur or
INTERNAL-Drink large quantities of water or
smoke near batteries that are charging or
milk. Follow with milk of magnesia, beaten
have been recently charged.
egg, or vegetable oil. Call physician
13-8A
immediately. Eyes: Flush with water for 15
WARNING: Disconnect the ground cable minutes and get prompt medical attention.
first when the battery cables are Batteries produce explosive gases. Keep
disconnected from the battery. sparks, flame, and cigarettes away. Ventilate
Connect the ground cable last when the when charging or using in enclosed area.
battery cables are connected to the battery. Always shield eyes when working near
47-55A batteries.
WARNING: Some batteries have a Keep out of reach of children.

ventilation tube. If there is battery acid in the D-47-53A
ventilation tube, this battery acid can be

released when the battery is turned upside
down. If you turn the battery upside down,
make sure that the end of the ventilation tube
is away from you and away from any other
people in the area. Battery acid can cause
severe burns.
48-57B
SPECIAL TOOLS
B795328
The CAS10147 tester is used to do the Capacity

(Load) Test. This tool is first used on Page 6.
87728450 A - EU Issued April, 2008 Printed in E.C.

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4003-4
MAINTENANCE
Electrolyte Level Inspecting and Cleaning a Battery

If the battery is a maintenance free battery, check the If damage causes an electrolyte leak, replace the
level of the electrolyte every 1000 hours of operation battery.
or six months, whichever occurs first. For all other
Inspect the battery at regular intervals for dirt,
batteries, check the level of the electrolyte every 250
corrosion, and damage. Electrolyte and dirt on the
hours of operation.
top of the battery can cause the battery to discharge
NOTE: A maintenance free battery will have the words by making a passage for the current to flow.
Maintenance Free on the decal on the top of the battery. If
If the battery must be cleaned, remove the battery
the center part of the decal has been removed for access to
from the battery carrier and clean the battery, cable
the battery caps, it is possible that the words Maintenance
terminals, and the battery carrier. When available,
Free have been removed from the decal.
use Case Battery Saver and Cleaner according to
Check the level of the electrolyte more often during the instructions on the container. Case Battery Saver
hot weather. The use of a large amount of water by and Cleaner also helps prevent corrosion. If Case
the battery can be caused by high battery Battery Saver and Cleaner is not available, use
temperature or a voltage regulator setting that is too baking soda and water as a cleaner. DO NOT permit
high. Keep the electrolyte level above the top of the any type of cleaner to enter the cells of the battery.
plates in the battery at all times to prevent damage to
Install the battery in the machine and make sure the
the battery.
fasteners are tight. Apply Case Battery Saver and
NOTE: On maintenance free batteries it is necessary to Cleaner or Urethane Seal Coat to the cable terminals
remove the center part of the decal for access to the battery to prevent corrosion. See the Parts Counter Catalog.
caps. Do not discard the center part of the decal. Install the DO NOT apply grease.
center part of the decal after the battery caps have been
installed.
If the level of the electrolyte is low, add distilled water
or other clean water until the electrolyte is just below
the cell opening. Do not add more water than is
needed. Too much water can cause bad
performance, a short service life, and corrosion
around the battery.
NOTE: Add water only. DO NOT add electrolyte.

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4003-5
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the battery. 1 2
Visual Checks
1. Make sure the cable connections are clean and
tight. Clean foreign material from the top of the
battery.
2. Inspect the battery case, battery posts, and
cables for damage.
3. Check the electrolyte level. See Page 4.
4. If you added water to the battery, the battery
must be charged for 15 minutes at 15 to 25
amperes to mix the water with the electrolyte.
Specific Gravity Check B790863
A hydrometer is used to check the specific gravity 1. TEMPERATURE IN F 2. TEMPERATURE IN C

(weight) of the electrolyte. The specific gravity is an SPECIFIC GRAVITY CHART
indication of the level of charge for each cell. 4. Make a record of the corrected specific gravity
Hydrometers are made to show the correct specific reading for each cell.
gravity when the temperature of the electrolyte is 5. If the difference between the high reading and
26.7°C (80°F). the low reading is 0.050 or more, charge the
When you check the specific gravity, you must know battery and check the specific gravity again. If
the temperature of the electrolyte. If your hydrometer after charging, the difference is still 0.050 or
does not have a thermometer, get a thermometer to more, install a new battery.
check the temperature of the electrolyte. The 6. The corrected specific gravity reading shows the
thermometer must indicate a high temperature of at level of charge for the cell. The level of charge
least 52°C (120°F). must be at least 75% in each of the cells. ln
1. Remove enough electrolyte from a cell so that maintenance free batteries the level of charge is
the float is free in the tube. at least 75% if the corrected specific gravity
reading is 1.240 or higher. In all other batteries
NOTE: If the specific gravity cannot be checked without the level of charge is at least 75% if the corrected
first adding water to the cell, the battery must be charged specific gravity reading is 1.230 or higher.
for 15 minutes at 15 to 25 amperes to mix the water with
the electrolyte. Then check the specific gravity. 7. If the difference between the high reading and
the low reading is less than 0.050, and the level
2. Read the float. of charge is at least 75% in all of the cells, do the
3. Read the thermometer. If the reading is above Capacity (Load) Test.
26.7°C (80°F) add specific gravity points to the 8. If the difference between the high reading and
reading for specific gravity. If the reading is the low reading is less than 0.050, but the level
below 26.5°C (80°F) subtract specific gravity of charge is less than 75% in any of the cells,
points from the reading for specific gravity. See charge the battery and check the specific gravity
the following illustration and add or subtract again. If after charging:
specific gravity points as needed.
A. The level of charge is less than 75% in any of
the cells, discard the battery.
B. The level of charge is at least 75% in all of the
cells, do the Capacity (Load) Test.

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4003-6
Capacity (Load) Test NOTE: Never apply a load for longer than 15 seconds.
After each 15 seconds, turn the load control knob to OFF for
This test can be done using a variable load tester at least one minute.
such as the Sun Electric VAT -33. Other test
equipment can be used. Connect the test equipment 4. Apply a 15 ampere load to the battery for 15
according to the instructions of the manufacturer of seconds. Wait at least three minutes before
the equipment. applying the load again.
1. The level of charge of the battery must be at 5. Check and make a record of the temperature of
least 75%. Do the Specific Gravity Check in this the electrolyte.
section. 6. Find the correct load for this test in Specifications
2. Prepare the tester (Sun Electric VAT-33 shown) in Section 4002.
for the test. NOTE: The correct load is half of the cold cranking
A. Select the voltmeter range that will measure 1 amperes at -17°C (0°F).
to 18 volts. 7. Turn the load control knob until the ammeter
B. Make sure the load control knob is in the OFF indicates the specified load. Keep the load for 15
position. seconds and read the voltmeter. Turn the load
control knob to OFF.
C. Select the ammeter range that will measure 0
to 1000 amperes. 8. Compare the test reading and the temperature of
the electrolyte to the chart below.
D. Move the volt lead switch to the NT. position. Temperature of . . . . . . . . . . . . . . . Minimum Voltage
3. Connect the tester to the battery as shown. electrolyte
21°C (70°F) and above . . . . . . . . . . . . . . . . . . . . 9.6
16°C (60°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
10°C (50°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
2
4°C (40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
-1°C (30°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
-7°C (20°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
-12°C (10°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7
1 -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
A. If the test result is equal to or more than the
voltage shown, the battery is in good
condition.
B. If the test result is less than the voltage
shown, discard the battery.
B790499
1. LOAD CONTROL KNOB 2. AMMETER CLAMP (TIP OF

ARROW AWAY FROM
BATTERY)

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4003-7
CHARGING A BATTERY
See Specifications in Section 4001 for the reserve
WARNING: Never try to charge the battery if capacity of the battery in this machine.
the electrolyte in the battery is frozen.
47-83
The charging rate must be decreased if:
Before you charge the battery, check the level of the 1. Too much gas causes the electrolyte to flow from
electrolyte. the cells.
It is difficult to give an exact charging rate because of 2. The temperature of the electrolyte rises above
the following variable conditions: (1) temperature of 52°C (125°F).
the electrolyte, (2) level of charge, and (3) condition
NOTE: For the best charge, use the slow charging rates.
of the battery. Use the charging guide for the correct
charging rate and time. The battery is fully charged when, over a three hour
Charging Guide For Maintenance Free Batteries

Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See

Reserve Capacity under Slow Charge Fast Charge
Specifications
10 Hours at 5 Amperes 2.5 Hours at 20 Amperes

80 Minutes or Less 5 Hours at 10 Amperes 1.5 Hours at 30 Amperes

Above 80 to 125 Minutes 7.5 Hours at 10 Amperes 1 .5 Hours at 50 Amperes
20 Hours at 5 Amperes 5 Hours at 20 Amperes

Above 125 to 170 Minutes

Above 170 to 250 Minutes 15 Hours at 10 Amperes 3 Hours at 50 Amperes
*lnitial rate for standard taper charger.
NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If the center part
of the decal has been removed to get access to the battery caps, it is possible the words Maintenance Free will have been
removed from the decal.
Continued on next page

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4003-8
Charging Guide For Batteries Other Than Maintenance Free Batteries

Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See

Reserve Capacity under Slow Charge Fast Charge
Specifications

80 Minutes or Less 5 Hours at 10 Amperes 1.5 Hours at 30 Amperes

Above 80 to 125 Minutes 7.5 Hours at 10 Amperes 1 .5 Hours at 50 Amperes


6 Hours at 40 Amperes
Above 250 Minutes 24 Hours at 10 Amperes
4 Hours at 60 Amperes
*lnitial rate for standard taper charger.
PREPARING A DRY CHARGED BATTERY FOR USE

1. Remove the caps from the battery. 5. Charge the battery at 30 amperes until the
specific gravity is 1.250 or more an d the
2. Fill each cell to the top of the separators with
temperature of the electrolyte is at least 15.5°C
electrolyte. This will permit the volume of
(60°F).
electrolyte to increase when heated by charging
the battery. 6. If necessary, fill each cell with electrolyte until the
electrolyte is just below split ring at the bottom of
3. Install the caps on the battery.
the cell opening.
4. Connect a battery charger to the battery.

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Section
4005
INSTRUMENT CLUSTER
4005

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4005-2
TABLE OF CONTENTS
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Navigating Through The LCD Multi-function Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Entering The Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Select Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hardware Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Software Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Language Screen, Measurement Units, and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fan Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Auto Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Display Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MPH/KPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fault Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LCD Fault Code Display Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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4005-3
INSTRUMENT CLUSTER
5
4 6
1 2 3 7 8 9 10
15 11
14 12
13
BD06H039
1. LOW BRAKE PRESSURE INDICATOR 9. LACK OF AUX STEER PRESSURE (OPTIONAL)
2. HIGH BEAM INDICATOR 10. PARKING BRAKE INDICATOR
3. TRANSMISSION OIL TEMPERATURE GAUGE 11. RIGHT TURN INDICATOR
4. CAUTION MASTER INDICATOR 12. FUEL LEVEL GAUGE
5. MULTI FUNCTION LCD DISPLAY 13. FUEL LEVEL AT MINIMUM
6. STOP MASTER INDICATOR 14. ENGINE COOLANT TEMPERATURE GAUGE
7. HYDRAULIC OIL TEMPERATURE GAUGE 15. LEFT TURN INDICATOR
8. WAIT TO START ENGINE PREHEAT
The instrument cluster monitors a number of functions and can be tailored to fit the operator’s preferences. The
instrument cluster not only monitors machine functions, it warns the operator when caution is needed due to a
possible malfunction and when immediate action is needed due to a possible critical malfunction. When the
machine is started, the instrument cluster will perform the following self-test:

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4005-4
Self-Test Power Circuit Test

1. Turn the ignition (key) switch to the ON position. A. Check fuse ECA-F3. If the fuse is bad, replace
the fuse and repeat Self-Test. If the fuse is
2. The instrument cluster will automatically check good, go to next step.
each monitored system.
B. Check wire 19EA for continuity.
3. All LED’s (Light Emitting Diodes) will illuminate Repair/replace the wire as required. If
for 2 - 3 seconds. continuity is found go to next step.
4. Four gauges will energize for 2 - 3 seconds. C. Check power relay module A for proper
operation, see Section 4002. If the power
5. The warning alarm will sound for 2 - 3 seconds.
relay module checks good, go to next step.
6. If there is an open circuit between a sensor and D. Check the ignition switch for proper operation,
the instrument cluster, the LED will flash and the see Section 4002. If the ignition switch checks
warning alarm will sound for 5 seconds. good, go to next step.
7. If there were no faults detected during the check, E. Check fuse ECC-F5. If the fuse is bad, replace
all monitored systems will return to normal the fuse.
operation.
8. If only some of the LEDs illuminate, replace the
instrument cluster.
9. If the LEDs illuminate, but the warning alarm
does not sound, see section 4002 and test the
alarm circuit.
10. If the warning alarm sounds but the LEDs do not
illuminate, if no power is present at buzzer,
replace the instrument cluster, if power is present
at the buzzer, replace the buzzer.
11. If the warning alarm does not sound and the
LEDs do not illuminate on the instrument cluster,
do the following steps to test the power circuit:

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4005-5
LCD Multi-function Display 3. This example shows the maximum gear allowed
when in Automatic mode. If display is blank the
Manual mode has been selected.
4. This example shows the current transmission
mode that has been selected.
A. If the Transmission is operating normally it will
display either
● A - Automatic
● M - Manual operation.
B. If the Transmission is not operating normally
the display will show
● C - Substitute Clutch.
● L - Limp Home.
BD06J132
● S - Transmission Shutdown.
The LCD Multi-Function Display is located at the
center of the modular dashboard. On start up the ● U - TCU Shutdown.
cluster will flash the instructional lamps and the LCD 5. This example (not displayed) will show the
Multi-Display will display, CASE, with the machine transmission clutches disengaged provided the
model and current hour reading. Park Brake is OFF.
6. This example shows the Power Boost Status.
● MAX - Maximum Power.
● STD - Normal/Standard mode of Operation.
1 ● AUTO - Switches automatically between
Maximum and Standard Power.
● ECO - Limited Power for fuel efficiency.
2 7. This example will show the Time in either 12
3
4 hour or 24 hour.
6
7
BD06F185-01
LCD MULTI-FUNCTION DISPLAY
Information will be displayed in different zones on the
LCD, as directed by the operator or machine. In
most situations the operator or technician will be
given specific information to follow if conditions are
not correct.
1. In the example above the machine hours are
displayed. Machine hours will always be
displayed briefly on start up. After the machine is
started the display will show engine rpm’s. After
beginning travel the machine will display travel
speed provided default settings were not
changed by the operator.
2. This example, shows that the Transmission
Control Lever is in Neutral. The display will show
Forward, Neutral, or Reverse, depending on
where the Directional Control Lever is
positioned.
NOTE: Forward and Reverse will blink if the transmission
clutches are disconnected.

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4005-6
Navigating Through The LCD Using The Arrow Keys
Multi-function Display Screens At any time, during operation or with the key switch
on, the operator may scroll through three information
screens and two trip screens by using the arrow
A C keys. These five screens are in a circular loop and
may be reached by pressing the up or down key. The
following sequence is using the down key only.
NOTE: Pressing the escape key will return the LCD back
to the normal driving screen.
B D
BD06H037-01
Located on the steering column, just to the left of the
Park Switch, is the key pad. Use this key pad to
move from one screen to another, choose various
selections, monitor the machine functions, and
retrieve information. All functions can be accessed in
the same basic manner.
A. Escape key: Use this key to exit and return to
BD06H037-01
the driving screen. Use this key anytime you
From the driving screen push the down arrow, as
would like to start over and begin again, plus
shown.
use to check active, acknowledge errors.
B. Enter key: Use this key to confirm, yes, this is
the desired function.
C. Up arrow key: Use this key to scroll up to
selections.
D. Down arrow key: Use this key to scroll down
to selections.
NOTE: Arrows on the screen will indicate if selections are
up or down from the current selection.
NOTE: Display units can be changed by the operator.
BD06F183-01
Info 1 is the first information screen using the down

arrow from the driving screen. It displays engine
RPM’s, speed, fuel level, and the voltage level.

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4005-7
BD06F027-01 BD06F169-01
Info 2 will be displayed next. The Info 2 screen will Press the down button again and the Trip 1 screen
display coolant temperature, turbocharger air will display. The LCD provides two trip computers.
temperature, engine oil temperature in either These will display since last reset the total time in
Fahrenheit or Celsius, as well as oil pressure PSI. hours, the total fuel, and the average fuel
consumption per hour.
BD06F184-01
Push the down button again and the Info 3 screen. BD06F170-01
This screen displays the temperature in Fahrenheit By continuing to scroll down, the fifth screen will
or Celsius of the transmission oil, hydraulic oil, sump display the Trip 2 screen. Trip 1 and Trip 2 screens
oil, and radiator coolant temperature. can be reset independently. The previous screen can
be accessed by using the up arrow key.

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4005-8
Reset The Trip Information
BD06F172-01
BD06F170-01
The trip screen will indicate a reset message. At this
Highlight the trip screen you wish to set. screen, press confirm to clear the numbers and reset
the trip information. The current date and time will
display automatically. The hours, fuel consumption,
and fuel used per hour will reset and revert to zero.
BD06H037-01
Press the confirm button to reset the trip selection to
zero.

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4005-9
Entering The Service Screens

After the machine has been started or the key switch has been turned to the “ON” position, either the operator or
service technican may use this service menu to adjust machine configurations to working conditions, test
components, view faults or select preferences.
NOTE: When all the selections have been made they will be stored in memory. If there is an abrupt battery disconnect you may
loose all of your selections and need to reprogram the LCD Multi-function display.
BD06H038-01 / BD06H037-01
Press and hold the confirmation button for two seconds to arrive at the above service screen. Use down arrow to
scroll through the menu’s.
Items and selections in this menu are: ● Month
1. Power Mode Menu ● Year
● Max - Maximum power possible 6. Cluster H/W
● Standard - Standard operation ● Part Number
● Auto - Will cycle between Max and Standard ● Serial Number
● Eco - Limited power for economy ● ID
2. Preferences Menu ● Version
● Language - English, Italian, French, Spanish, 7. Cluster S/W
Portuguese, German ● Part Number
● Units - Metric, English or Imperial ● Loader Version
● Clock - 24 or 12 hour ● ID
3. Options Menu ● Version
● Fan Auto - manual or automatic 8. Config Menu
● Idle Auto - manual or automatic ● Change Model *
● Show RPM ● Select Tires (Select tire sizes)
● Show MPH/KPH ● Clutch Calibration (calibrate gear box)*
4. Display Menu ● Gear Limits (choose maximum gear)
● Day Display ● Park Brake (Park brake test)
● Day LED ● Cold Start (choose cold start system)
● Night Display ● FAN Test (sound level)
● Night LED ● Special
5. Clock Menu - Reset Error
● Hour - Factory Set
● Minute
● Day

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4005-10
* The tests in the configuration menu should be Software Screen
performed only by a qualified operator or technician,
as some tests require the engine to be running at
high RPM’s.
Select Screen
The select screen will allow you to make time
settings as well as give access to machine
information. Navigate this screen also by highlighting
your selection and pressing confirm. This will allow
you to change clock settings or view the hardware
and software screens. No operator changes can be
made to the hardware or software screens.
BD06H028-01
The cluster software selection will display the CNH
part number, serial number, ID number and software
version of the Instrument cluster. This display is a
convenient source of information when ordering parts
or accessories. Press escape to exit from this field
and return to the selection menu or use the up or
down arrow key to toggle to the software information
screen.
Selecting Power Modes
The power mode allows the operator to choose the
BD06F177-01 most effective machine power for the current job
Hardware Screen conditions. Most commonly auto is chosen, as the
power will automatically increase or decrease
Scroll to the hardware selection and press confirm to between maximum power and standard power while
display machine information. the machine is working. This allows for maximum
power if necessary, but will switch to standard mode
for economy. Maximum power can be chosen for
more severe work conditions. Economy can be
chosen for limited power and fuel efficiency.
Press and hold the confirmation button for two
seconds to arrive at the service screen.
BD106F193-01
The cluster hardware selection will display the CNH
part number, serial number, ID number and version
of the Instrument cluster. This display is a convenient
source of information when ordering parts or
accessories. Press escape to exit from this field and
return to the selection menu or use the up or down
arrow key to toggle to the software information BD06H038-01
screen. At the screen shown above, highlight the power
mode and press the confirmation button to move to
the Power Mode Selection Menu.

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4005-11
Preferences
BD06F178-01
At the Power Mode Menu press the confirmation BD06F179-01
but t on agai n t o a c t i v a t e t h e s e l e c t i o n s. T he
Language Screen, Measurement Units,
highlighted section will flash to indicate a new
selection can be made. and Clock
Press the up or down button to select the Power The LCD screen can be set with language, units, and
Mode, and then press the confirmation button again. clock preferences. Use the arrow keys to scroll to the
This changes the mode and locks it into memory. preferences menu. Press confirm.
The selected mode will display in zone 3 (bottom) of Choose the preferences desired, language in
the Multi-Function Display when power mode is (English, Italian, Spanish, Portuguese, German,
correctly selected. French, measurement units in English, Metric, or
Imperial and clock units in either 12 or 24 hour).
NOTE: Selecting options and navigating through the Highlight the preference you wish to change and
screen menus are the same for all functions. The display press the confirm key. The preference will flash and
will tell the operator if errors have occurred. allow you to scroll through the choices. When the
correct preference is chosen, use the confirm key to
lock in the preference for the display. The escape
key will allow you to leave this application.
BD06F176-01
Shou ld an erro r me ssage display, pres s the
confirmation button to acknowledge and begin again.

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4005-12
Clutch Calibration
After warming the oil temperature:
1. Park the machine on a firm level surface.
2. Place the Transmission Control Lever in
NEUTRAL.
3. Set the Park Brake.
4. With the engine running, at idle, enter the
Service Screen Menu and scroll to Config.
BD06F196-01
If, conditions are not correct, an error message will
appear and guide the operator or technician.
There are six, if conditions not met, screens:
● Not in neutral
● Park Brake OFF
● Machine moving
● Oil temp too low
● Oil temp too high
BD06F202-01 ● Engine RPM low
Use the confirm and arrow button to scroll to the
● Engine RPM high
screen shown above. At this screen push the confirm
button again. If conditions are correct the operator or technician
will see six calibration screens pass. They will display
in this order:
● Adjust K1
● Adjust K2
● Adjust K3
● Adjust K4
● Adjust KV
● Adjust KR
Once the process is completed this screen will direct
the operator or technician to shut the engine OFF
and then re-start.
BD06F195-01 If the process is not completed the operator or
This screen will prompt the operator or technician to technician will be prompted to escape.
confirm or escape.

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4005-13
Options Menu Auto Idle

Use the arrow keys to choose the options menu. Idling can be changed from automatic to a fixed rate.
Press the confirm key, and the options sub-menu will The fixed idle rate is defined as Standard Idle at 900
appear. The options menu will allow the operator to RPM. Highlight the auto idle selection by using the
choose options for the fan, idle. arrow keys, then press confirm. When you have
chosen the selection, lock the selection into memory
by pressing the confirm key.
Display Menu
The display menu can be used to change the
background and brightness of the screen. Use the
arrow keys to make your selection from the display
menu and press the confirm key to lock the selection
into memory. The screen display can be changed to
suit working conditions for day and night separately.
RPM
Engine speed in RPM will show on the display if the
engine speed is running up to 550 RPM’s, and will
BD06F174-01
disappear if the engine speed is lower than 300
Fan Auto RPM.
The fan can be set to run at automatic or the fan will MPH/KPH
run at maximum speed. Automatic is the more
common or preferred setting. It will switch between Vehicle speed will show on the display if it is up to 1.0
high speed, low speed, or reverse as conditions MPH / 1.5 KPH and will disappear if the vehicle
require depending on actual temperature of the speed is less than 0.6 MPH / 1.0 KPH.
coolant, turbocharger air, transmission oil, and
hydraulic oil.
The operator can choose fan speed or reversing
capabilities. Highlight the fan auto selection by using
the arrow keys, then press confirm. When you have
chosen the selection, lock the selection into memory
by pressing the confirm key.

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4005-14
RETRIEVING FAULT CODES
General Fault Code Identification Fault Code Display

1. Press and hold the escape key and up arrow key
for more than 2 seconds to access the fault
codes.
A C
BD07C010
B D 1. If a fault code occurs, it will be displayed in the

upper zone of the LCD. Depending on how
critical the code is, the RED master STOP or the
BD06H037-01
YELLOW caution indicator will also come on.
A. Escape key
B. enter key
C. up key
D. down key
2. Yellow Faults, buzzer will beep once every 2
seconds:
A. Operator can acknowledge it by pressing the
enter key.
B. The message will disappear.
C. Buzzer will not beep anymore.
D. Yellow lamp will stay ON. BD07C011
E. Fault will remain in Yellow list until it is closed. 2. To retrieve the code/s, press the two upper
buttons of the keypad for 2 seconds. When the
3. Red Faults, buzzer will be continuous, screen comes up press ENTER on the category
alternating sounds: with codes present.
A. Operator can acknowledge it by pressing the
enter key.
B. Buzzer will change to a less stressing sound,
but will remain.
C. Message will remain on display with indication
of URGENT STOP.
BD07C012
3. If more than one code is present in the category,
scroll through to each by pressing the DOWN
button on the keypad.
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4005-15
LCD Fault Code Display Breakdown
BD07C009
Fault Code Grouping

1. 1000 to 1999 vehicle errors.
2. 2000 to 2999 not used.
3. 3000 to 3999 engine errors.
4. 4000 to 4999 transmission errors.
5. 5000 to 5999 eltro-hydraulic system errors.
6. 6000 to 6999 reserved.
7. 7000 to 7999 reserved.
8. 8000 to 8999 optional equipment IE: GPS.
9. 9000 to 9999 internal AIC errors.

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4005-16
VEHICLE FAULT CODES
CODE DEFINITION POSSIBLE STEPS FOR REPAIR
1310 Hydraulic filter blocked Change filter

1311 Engine air filter blocked Change filter
1312 Hydraulic oil temperature above normal 1. Stop machine operations
2. Run engine at 1500 rpm
1313 Hydraulic oil temperature to high 3. Check fan operation
1314 Transmission oil temperature above normal 4. Check cooling core for clogs
1315 Transmission oil temperature to high

1. Stop machine operations
1316 Brake pressure too low 3. Check brake system pressure
4. Check brake system for leaks
1317 Steering pressure too low 3. Check steering system for operation
4. Check steering system for leaks
1318 Engine coolant temperature above normal 1. Stop machine operations
1319 Engine coolant temperature high - critical 3. Check fan operation
4. Check radiator core for clogs
1320 Engine oil pressure too low 1. Stop machine operations
2. Check engine oil level
1321 Engine oil pressure below normal 3. Check pressure sender unit
1. Check engine oil for proper type
1322 Engine oil pressure above normal 2. Check pressure sender unit
1323 Battery voltage low
Check charging system
1324 Battery voltage high
1325 Oil temperature too high 2. Run engine at 1500 rpm
3. Check sending unit
1326 Coolant level low Fill radiator level
1327 Moved during accelerated idle No information available at time of print.
1328 Moving when shifting to low idle No information available at time of print.
Electrical charging system voltage low - 1. Stop machine operations
1331 2. Check charging system
critical level
1332 Water detected in fuel Drain fuel filter
1333 Engine overspeed Check engine speeds
1334 Intake manifold temperature high - critical Check for defective or clogged after cooler
1335 Brake pressure too low 3. Check brake system pressure
4. Check brake system for leaks
1336 Transmission oil filter blocked Replace filter

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4005-17
ENGINE FAULT CODES
DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR
Idle switch defect or wiring of idle switch broken

or accelerator pedal defect.
3001 Foot throttle sensor signal not plausible
Check wiring, replace idle switch or replace
accelerator pedal.
Short circuit in wiring or in accelerator pedal.
3002 Foot throttle sensor signal above range max.
Check wiring or replace accelerator pedal.
Short circuit in wiring or in accelerator pedal.
3003 Foot throttle sensor signal below range min.
Check wiring or replace accelerator pedal.
3004 Foot throttle sensor - no signal Check wiring or replace accelerator pedal
Coolant temperature sensor signal not See OTS (Oil Temperature Sensor) plausibility
3006
plausible check (Fault 3033)
Sensor defective or short circuit to external
Coolant temperature sensor signal above
3007 source.
range max.
Check wiring or replace sensor.
Coolant temperature sensor signal below Sensor defective or short circuit to ground.
3008
range min. Check wiring or replace sensor.
No CAN plausibility check performed, restart
3009 Coolant temperature sensor null (via CAN) system, if problem reoccurs.
3015 Fuel temperature signal above range max. source.
3016 Sensor defective or short circuit to ground.

Fuel temperature signal below range min.
Boost pressure sensor signal above range
3019 source.
max.
3021 Boost pressure sensor null (via CAN) system, if problem reoccurs.
Difference of ambient and boost pressure is out
3022 Boost pressure sensor signal not plausible of range.
3023 Atmospheric pressure sensor signal not

plausible
Ambient pressure sensor inside ECU is defect.
Atmospheric pressure sensor signal above
3024 Replace ECU (not necessary if never running in
range max.
high altitude and if turbocharger is without VGT)
Atmospheric pressure sensor signal below
3025
range min.

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4005-18

CODE DEFINITION
STEPS FOR REPAIR
Inaccurate oil pressure sensor or defect (e.g. too

low oil level, leakage...) in the oil system.
3028 Oil pressure sensor pressure too low
Check oil pressure sensor for accuracy and
check oil system.
3029 Oil pressure sensor short-circuit to battery source.
Sensor defective or short circuit to ground.
3030 Oil pressure sensor short-circuit to ground
3031 Oil pressure sensor ADC conversion error No information available at time of print.
Inaccurate oil pressure sensor or defect (e.g.
blocked piping) in the oil system.
3032 Oil pressure sensor pressure too high
Check oil pressure sensor for accuracy and
check oil system.
Inaccurate oil or coolant temperature sensors or
insufficient oil or coolant recirculation (low
coolant level etc.).
3033 Oil temperature sensor signal not plausible
Check oil and coolant temperature sensor for
accuracy and check oil and coolant system for
proper functioning.
Oil temperature sensor signal above range
3034 source.
max.
Oil temperature sensor signal below range Sensor defective or short circuit to ground.
3035
min. Check wiring or replace sensor.
Oil temperature sensor signal CAN
3036 system, if problem reoccurs.
transmission disturbed
Sensor defective or short circuit to ground.
3037 Boost pressure sensor signal low
Vehicle speed sensing hardware conversion
3043 No information available at time of print.
error
3046 Vehicle speed sensing signal not plausible No information available at time of print.
Alternator voltage governor defect.
3051 Battery voltage to ECM too high
Replace alternator governor device or alternator.
Battery defect, alternator defect, wiring problems
(too high resistance) or ECU defect. Occurrence
3052 Battery voltage to ECM too low possible during cold start.
Replace battery or alternator. Check ECU and
wiring.
Depending on the pattern, various reasons can
cause the defect, internal ECU problems also
3060 Cylinder 1 unclassified error in injector possible.
Check the wiring and the injection signals,
replace ECU

Copyright ©
4005-19

CODE DEFINITION
STEPS FOR REPAIR
Cylinder 1 injector cable short-circuit low side Short circuit in wiring with external source.
3061
to battery Check the wiring or replace injector
3062 Cylinder 1 signal low
replace ECU
Defective coil of injector.
3063 Cylinder 1 short-circuit high side to ground
Check the wiring and replace injector
replace ECU
3069
replace ECU.
3071 Defective coil of injector.

Cylinder 3 short-circuit high side to ground
replace ECU
3077
replace ECU.
replace ECU
3081
replace ECU.
Signal interrupted do to wiring problem, defective
or incorrectly installed crankshaft speed sensor.
3088 Crankshaft sensor lost synchronization Check wiring, sensor installation and proper
functioning of crankshaft sensor (evaluate raw
signals)

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4005-20

CODE DEFINITION
STEPS FOR REPAIR
Check wiring, sensor installation and proper

3089 Crankshaft sensor defective functioning of crankshaft sensor (evaluate raw
signals).
or incorrectly installed camshaft phase sensor.
3090 Camshaft sensor lost phase Check wiring, sensor installation and proper
functioning of camshaft phase sensor (evaluate
raw signals)
Camshaft sensor phase synchronization
3091 functioning of camshaft phase sensor (evaluate
failure
raw signals).
or incorrectly installed camshaft or crankshaft
Offset between camshaft and crankshaft sensor.
3093
outside boundaries Check wiring, sensor installations and proper
functioning of camshaft and crankshaft sensors
(evaluate raw signals)
3095 Operating with camshaft sensor only functioning of crankshaft sensor (evaluated raw
signals).
Short circuit of wiring to ground or defective
Rail pressure sensor CP3 signal below range pressure sensor.
3102
min. Check wiring and proper functioning of rail
pressure sensor
Defective rail pressure sensor, defect in other
injection relevant component.
3104 Rail pressure relief valve open Check rail pressure sensor for plausible values,
ensure proper functioning of the injection
components
PRV does not open once the pressure limit is
reached: Mechanical defect or wrong application
Rail pressure relief valve pressure shock
3105 parameter.
requested
Check application value of maximum rail
pressure, check functioning of the PRV
PRV does not open even after pressure shock:
Rail pressure relief valve did not open after Stuck PRV or wrong application parameter.
3106
pressure shock Check application value of maximum rail
pressure, check functioning of the PRV
Short circuit of wiring to external source or inside
Metering unit output short-circuit to battery on
3107 relay.
low side
Check wiring or replace relay
Rail pressure sensor offset monitoring signal
3110 Rail pressure sensor inaccurate.
above range max.
Ensure correct wiring and proper functioning of
Rail pressure sensor offset monitoring signal rail pressure sensor, replace sensor
3111
below range min.

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4005-21

CODE DEFINITION
STEPS FOR REPAIR
Short circuit of wiring to external source or

defective pressure sensor, rail pressure
Rail pressure sensor CP3 signal above range
3112 overshoot.
max.
Check wiring and proper functioning of rail
pressure sensor
Short circuit of main relay to external source or
Grid heater battery switch relay short-circuit to defective main relay.
3113
battery Check the wiring connecting the battery to the
EDC or replace main relay
Short circuit to ground of main relay or defective
Grid heater battery switch relay short-circuit to main relay.
3114
ground Check the wiring connecting the battery to the
EDC or replace main relay
3118 ECM 12V sensor supply voltage high Ambient pressure sensor inside ECU is defective.
Replace ECU (not necessary if never running in
3119 ECM 12V sensor supply voltage low high altitude and if turbocharger without VGT)
Short circuit to ground of grid heater.
3131 Grid heater always switched on
Check grid heater switch and replace it
Broken or disconnected wiring or defective relay.
3137 Metering unit open load
Check of wiring or replace relay
Defective wiring, ECU, power stage or metering
unit.
3138 Metering unit signal not plausible
Check wiring, ECU, power stage and metering
unit
High pressure system: Rail pressure sensor
inaccurate, high pressure pump defective.
Set point of fuel volume flow through metering
3141 Low pressure system: Metering unit reflux too
unit is lower than calculated limit
low.
Check for defects according to failure list.
Oil temperature sensor signal above normal Check oil temperature sensor for accuracy and
3147
range check oil system.
3154 Grid heater relay short-circuit to battery relay.
Short circuit of wiring to ground or inside relay.
3155 Grid heater relay short-circuit to ground
Broken or disconnected wiring or defective relay.
3156 Grid heater relay no load
3161 Fan actuator signal low No information available at time of print.
High pressure side: Leakage in high pressure
section, injection nozzle stuck in open position,
worn high pressure pump, worn injector, leaking
3171 Fuel rail/system pressure - too low pressure relieve valve
Low pressure side: Pressure before gear pump
too low, gear pump output too low (fuel filter
clogged, leakage in low pressure side).

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4005-22

CODE DEFINITION
STEPS FOR REPAIR
Metering unit stuck in open position,

zero-delivery throttle clogged, metering unit
without power due to electrical error.
3172 Fuel rail/system pressure - too high
Low pressure side: Pressure before gear pump
too high (e.g. by pressure relieve valve), pressure
after zero-delivery throttle too high.
3173 Fuel rail/system pressure - too low See fault 3171
3174 Fuel rail/system pressure - too high See fault 3172
Leakage in the high pressure section, injection
nozzle stuck in open position, worn high pressure
3175 Fuel system leak detected – large leak
pump, worn injector, leaking pressure relieve
valve, injector reflux too high.
High pressure system: Leakage in the high
pressure section, injection nozzle stuck in open
position, worn or defective high pressure pump,
Fuel delivery exceeded threshold for pressure worn injector, leaking pressure relieve valve.
3176
in overrun mode Low pressure system: 'Zero delivery' is not active
in metering unit (excessive leakage in metering
unit).
Check for defects according to failure list.
Defective CAN controller of Body Computer,
3178 Time-out of CAN message BC2EDC1 undervoltage of BC, missing BC, CAN cable
connecting the BC is disconnected or broken.
Short circuit in wiring. Check presence and
correct connection of the BC to the network,
3179 Time-out of CAN message BC2EDC2 Check correct functioning of the BC CAN
controller and its voltage supply. Check wiring.
Defective CAN controller of Vehicle Control
Module, undervoltage of VCM, missing VCM,
CAN cable connecting the VCM is disconnected
or broken. Short circuit in wiring. Check presence
3180 Time-out of CAN message VCM2EDC
and correct connection of the VCM to the
network, Check correct functioning of the VCM
CAN controller and its voltage supply. Check
wiring.
3188 Cylinder 1 open load
3192 Cylinder 2 open load Broken wire or disconnection of wiring or inside
injector.
3196 Cylinder 3 open load Check the wiring or replace injector.
3200 Cylinder 4 open load
Short circuit of high-side to battery or ground.
3210 Bank 1 general short-circuit on injection cable
Check the wiring or replace injector.
Short circuit of low-side to ground in injector
Bank 1 injection cable short-circuit low side to
3211 cable.
ground
3212 Bank 1 no signal No information available at time of print.

Copyright ©
4005-23

CODE DEFINITION
STEPS FOR REPAIR

cause the defect, internal ECU problem.
3213 Bank 1 unclassified error
replace ECU
Short circuit of high-side to battery or ground.
3218 Bank 2 general short-circuit on injection cable
Short circuit of low-side to ground in injector
Bank 2 injection cable short-circuit low side to
3219 cable.
ground
3220 Bank 2 no signal No information available at time of print.
cause the defect, internal ECU problem.
3221 Bank 2 unclassified error
replace ECU
Clock error or interruption of the power supply
3227 voltage.
Injection processor error - stop engine
Check the power supply or replace ECU if
problem reoccurs.
3228 Defective ECU, reset ECU.

Injection processor error - stop engine
If no recovery, replace ECU.
Internal failure of ECU or 'TESTMODE' takes too
long.
3229 Injection processor error - stop engine
Check 'TESTMODE' parameters or replace ECU
if problem reoccurs
Defective SPI-bus participant, timing problem
due to software bug.
Replace ECU if problem reoccurs (Send in ECU
for investigation)
3232 Injection processor error - stop engine Defective ECU.
3233 Injection processor error - stop engine Replace ECU if problem reoccurs

Electric disturbances, internal defect of the ECU
3238 Communication error of CJ940 processor leading to a SPI bus communication error.
Replace ECU if failure remains present
3242 Recovery which is locked Electronic disturbances, various hardware
defects (ECU internal) or configuration problems.
3243 Recovery which is suppressed
Analyze what error triggered the recovery (Read
out label HWEMon_numRecovery and compare
the value with the according table). If error occurs
3244 Recovery which is visible
repeatedly, reprogram EDC. If error remains,
replace EDC.

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4005-24

CODE DEFINITION
STEPS FOR REPAIR
Defective monitoring module or CPU (e.g.

impaired functioning of the CPU clock) of the
EDC. Disturbed SPI-Bus.
Communication supervision watchdog control If error exists only temporary (i.e. injection
3245
flag reoccurs) error can be ignored and error deleted
in the fault memory. In case of a permanent error
the injection remains blocked and the ECU has to
be replaced
Watch dog switch off path defect.
3246 Redundant shutoff paths during initial If failure remains after ECU initialization: replace
ECU
3247 Redundant shutoff paths during initial Electronic disturbances, internal ECU problem.
If failure remains after ECU initialization: replace
3248 Redundant shutoff paths during initial ECU
3253 Error status ADC monitoring
3254 Error status ADC monitoring Buffer overrun
3255 Error status ADC monitoring No additional information available at time of print
3256 Error status ADC monitoring

Short-circuit to battery at high side power
3258 relay.
stage
Short-circuit to ground at high side power Short circuit of wiring to ground or inside relay.
3259
stage Check of wiring or replace relay
3260 Broken or disconnected wiring or defective relay.

Open load at low side power stage
Short-circuit to battery or excessive
3261 relay.
temperature at low side power stage
Short circuit of wiring to ground or inside relay.
3262 Short-circuit to ground at low side power stage
Electronic disturbances, requested torque
increase via tester, wrong application of injection
Energizing time exceeds limit of over run
3265 relevant parameters, defective ECU.
monitoring
Check injection relevant application, if failure
persists replace ECU
Electronic disturbances, internal ECU problem.
3266 Plausibility error in engine speed check
If failure persists after reinstallation replace ECU
Excessive voltage supply of a CJ940 component:
High battery voltage, defective wiring, internal
defect of the EDC.
3278 Supply voltage CJ940 upper limit
Check the battery for correct voltage supply,
check wiring. If defect remains replace EDC
(internal defect)

Copyright ©
4005-25

CODE DEFINITION
STEPS FOR REPAIR
Insufficient voltage supply of a CJ940

component: Low battery voltage, defective wiring,
internal defect of the EDC.
3279 Supply voltage CJ940 lower limit
Check the battery for sufficient voltage supply,
check wiring. If defect remains replace EDC
(internal defect)
Excessive battery voltage, defect in wiring
harness, electrical failure in connected sensors
or in the EDC.
3280 Sensor supply voltage 1 high
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC
Insufficient battery voltage, defect in wiring
harness, electrical failure connected sensors or
in the EDC.
3281 Sensor supply voltage 1 low
replace EDC
or in the EDC.
3283 Sensor supply voltage 2 high
replace EDC
in the EDC.
3284 Sensor supply voltage 2 low
replace EDC
3285 or in the EDC.
Sensor supply voltage 3 high
replace EDC
3286 in the EDC.
Sensor supply voltage 3 low
replace EDC
Turbo compound monitoring signal not
3290 No information available at time of print.
plausible

Copyright ©
4005-26
TRANSMISSION FAULT CODES
1. Check the cables from the TCU to the FNR

switch.
4113 Logical error at FNR switch 2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch.
switch.
4114 Logical error at direction select signal 2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch signal combinations.
1. Check the cables from the TCU to the
4116 Logic error at park brake status instrument cluster connector 2 pin 6.
2. Check park brake switch.
switch.
4117 Logic error at direction select signal 2 2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch signal combinations.
4119 Short circuit to ground at ride control 1. Check the cables from the TCU to the ride
control relay.
4120 Short circuit to battery voltage at ride control 2. Check the connectors from the TCU to the ride
control relay.
4121 Open circuit at ride control 3. Check the ride control relay.
Short circuit to battery voltage or open circuit 1. Check the connectors.
4133
at temperature sensor 2. Check the temperature sensor.
4134 Short circuit to ground at temperature sensor
Short circuit to battery voltage or open circuit 1. Check the cables from TCU to the sensor.
4135
at converter output temperature sensor 2. Check the connectors.
3. Check the temperature sensor.
Short circuit to ground at converter output
4136
temperature sensor
1. Check the cables from TCU to the sensor.
Short circuit to battery voltage or open circuit 2. Check the connectors.
4137
at parking brake sensor input 3. Check the parking brake sensor.
Short circuit to battery voltage or open circuit 1. Check the parking brake fuse.
4145
at engine speed sensor 2. Check the parking brake relay.
4146 3. Check the parking brake solenoid.
Short circuit to ground at engine speed sensor
2. Check the connectors.
3. Check the speed sensor.
4147 Logical error at engine speed sensor input
NOTE: This fault code is reset after power up of the
TCU. It is also reset if the signal is above zero
speed threshold.

Copyright ©
4005-27
Short circuit to battery voltage or open circuit

4148 1. Check the cables from TCU to the sensor.
at turbine speed sensor input
Short circuit to ground at turbine speed sensor 3. Check the speed sensor.
4149
input
4150 Logical error at turbine speed sensor input 3. Check the speed sensor.
TCU.
Short circuit to battery voltage or open circuit
4151 1. Check the cables from TCU to the sensor.
at intermediate speed sensor input
Short circuit to ground at intermediate speed 3. Check the speed sensor.
4152
input
Logical error at intermediate speed sensor 3. Check the speed sensor.
4153
input
TCU.
Short circuit to battery voltage or open circuit 1. Check the cables from TCU to the sensor.
4154
at output speed sensor 2. Check the connectors.
4155 3. Check the speed sensor.
Short circuit to ground at output speed sensor
4156 Logical error at output speed sensor 3. Check the speed sensor.
TCU.
1. Check the sensor signal of the output speed
sensor.
2. Check the connector connected to the output
Output speed zero, does not match other speed.
4158
speeds. 3. Check the cable from the TCU to the sensor.
TCU.
1. Check the cluster controller.
4160 Invalid gear range restriction (CAN) 2. Check wire of CAN-Bus.
3. Check the cable to the cluster controller.
4180 Vehicle controller time-out (CAN)
1. Check the cluster controller.
4185 Invalid test mode signal (CAN) 2. Check wire of CAN-Bus.
3. Check the cable to the cluster controller.
4186 Invalid park brake status (CAN)

Copyright ©
4005-28
4209 Short circuit to battery voltage at clutch K1

4210 Short circuit to ground at clutch K1
4211 Open circuit at clutch K1
1. Check the cable from the TCU to the
4216 Short circuit to ground at clutch K3 transmission control valve.
4217 Open circuit at clutch K3 2. Check the connectors from the TCU to the
transmission control valve.
4225 Short circuit to battery voltage at clutch K4 3. Check the regulator resistance.
4. Check internal wire harness of the transmission
control valve.
4228 Short circuit to battery voltage at clutch KV
4229 Short circuit to ground at clutch KV
4230 Open circuit at clutch KV
4231 Short circuit to battery voltage at clutch KR
4232 Short circuit to ground at clutch KR
4233 Open circuit at clutch KR
4241 Short circuit to ground at backup alarm relay 1. Check the cable from the TCU to the backup.
alarm relay.
Short circuit to battery voltage at backup alarm 2. Check the connectors from the backup alarm
4242
relay relay to TCU.
3. Check the resistance of backup alarm relay
4243 Open circuit at backup alarm relay circuit.
1. Check pressure at clutch K1.
2. Check main pressure in the system.
4273 Slippage at clutch K1 3. Check signal at internal speed sensor.
4. Check signal at output speed sensor.
5. Replace clutch.
5. Replace clutch.
5. Replace clutch.

Copyright ©
4005-29

5. Replace clutch.
1. Check pressure at clutch KV.
4277 Slippage at clutch KV 3. Check signal at internal speed sensor.
5. Replace clutch.
1. Check pressure at clutch KR.
4278 Slippage at clutch KR 3. Check signal at internal speed sensor.
5. Replace clutch.
1. A critical stop function warning has occurred.
2. Red stop indicator comes on and continuous
buzzer sounds.
3. Stop machine and perform required service on
4279 Oil temperature at valve body is above limit the critical area.
4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.
Engine speed is measured above 5,000 rpm
4281 Check engine speed sensor
for 0.2 seconds
1. Check oil filter.
2. Check wiring from TCU to filter maintenance
TCU sensed a voltage at oil filter maintenance switch.
4282
switch out of the allowed range (dirty filter) 3. Check filter maintenance switch (measure
resistance).
4284 Overspeed output No information available at time of print.
4288 Engine torque or engine power overload No information available at time of print.
4289 Transmission output torque overload No information available at time of print.
4290 Transmission input torque overload No information available at time of print.
1. A critical stop function warning has occurred.
2. Red stop indicator comes on and continuous
buzzer sounds.
Oil temperature at converter output is above 3. Stop machine and perform required service on
4291
limit the critical area.
4. Cool down machine.
5. Check oil level.
6. Check temperature sensor.
1. Check the cables from the TCU to the joystick.
2. Check the connectors from the TCU to the
4292 Joystick status indicator short-circuit to ground joystick.
3. Check the resistance of the joystick.

Copyright ©
4005-30

Joystick status indicator short-circuit to battery 2. Check the connectors from the TCU to the
4293
voltage joystick.
2. Check the connectors from the TCU to the
4294 Joystick status indicator over current joystick.
Power supply for sensors short-circuit to 1. Check the cables from the sensors TCU.
4305 2. Check the connectors from the sensors to the
battery voltage
TCU.
Power supply for sensors short-circuit to
4306
ground
4307 Low voltage at battery 1. Check batteries.
2. Check B+ wires from batteries to TCU.
4308 High voltage at battery 3. Check voltage at TCU connector pin 45.
4309 Error at VPS 1 for solenoid power supply 1. Check fuse A2.
2. Check cable from control valve to TCU.
4310 Error at VPS 2 for solenoid power supply 3. Check connectors from control valve to TCU.
4. Replace TCU.
4325 Vehicle ID #1 time out No information available at time of print.
4326 Undefined VIN request via CAN. No information available at time of print.
4337 General EEPROM fault Replace the TCU.
Reprogram the correct configuration for the
4338 Configuration error
vehicle.
4339 Application error (ZF internal) Replace the TCU.
4341 Clutch calibration fault
Do the transmission clutch calibration procedure.
4342 Clutch adjustment data lost
INSTRUMENT CLUSTER FAULT CODES

CODE DEFINITION
STEPS FOR REPAIR
9128 CAN timed out during operation

If error is permanent or repeats often, check CAN
9129 CAN timed out during operation wiring harness and connections on the CAN bus
circuits.
9130 CAN timed out during operation

Copyright ©
SECTION INDEX
STEERING
Removal and Installation of Steering Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5001

Steering Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5002
Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5005
Center Pivot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5006
Auxiliary Steering Motor and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5008

Copyright ©
Copyright ©
5001
Section
5001
REMOVAL AND INSTALLATION OF STEERING

COMPONENTS

Copyright ©
5001-2
TABLE OF CONTENTS
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AUXILIARY STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Copyright ©
5001-3
STEERING CONTROL VALVE
Removal STEP 8
NOTE: When disconnecting hydraulic fittings, plug hoses
and cap fittings to prevent entry of foreign matter into
hydraulic system.
STEP 1
Park loader on level ground and lower bucket to
ground. Put transmission in NEUTRAL, apply parking
brake, and shut down engine.
STEP 2
Put master disconnect switch in OFF position.
BD07B099
STEP 3 Pull floor mat away from the column.

Remove the front skirt from the cab or canopy.
STEP 9
STEP 4
Remove all dirt and grease from steering control
valve.
STEP 5
Remove hydraulic reservoir fill cap, attach a vacuum
pump to the reservoir, start the pump.
STEP 6
Tag hoses connected to steering control valve.
STEP 7 BD07B100
Remove the mounting screws from the lower trim.
STEP 10
BD06G262
Disconnect hoses from steering control valve, cap or
plug the fittings and hoses, turn off the vacuum
pump.
BD07B101
Tilt the steering wheel and remove the mounting

screws from lower trim, remove the trim.

Copyright ©
5001-4
STEP 11 Installation
STEP 12
1 2
BD07B102
Remove the four mounting bolts for the steering

control valve, two shown and two in the front. BD07B141
IMPORTANT: Have an assistant support and remove the Put the rubber bushing (1) on the spacer with the
valve while removing the mounting bolts. tapered end towards the steering valve. Rubber
bushing (2) is mounted between the cab and the
steering valve.
STEP 13
Put one rubber bushing on the sleeve and place in
the mounting hole and hold in place, have an
assistant push the other rubber bushing onto the
sleeve.
STEP 14
Have an assistant push the valve into place while
turning the steering shaft, this will engage the
splines.
STEP 15
BD07B102
Install and tighten the four mounting bolts for the

steering control valve, two shown and two in the
front.
NOTE: Finger tighten all bolts before tightening, check for
proper wheel operation after tightening.

Copyright ©
5001-5
STEP 16 STEP 19
BD07B101 BD06G262
Install the lower trim onto the column, tilt the steering Start the vacuum pump, remove the caps and plugs
wheel and install and tighten the mounting screws. the fittings and hoses. Connect hoses to steering
control valve according to the tags installed during
STEP 17 removal, remove and discard the tags.
STEP 20
Remove the vacuum pump from the reservoir, install
and tighten the reservoir fill cap.
STEP 21
Put battery disconnect switch in ON position. Start
and run the machine at low idle, turn the wheel to full
left and then to full right, stop the machine and check
for leaks.
BD07B100
STEP 22
Install and tighten the mounting screws into the lower Install the front skirt onto the cab or canopy.
trim.
STEP 23
STEP 18 Check fluid level in hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
BD07B099
Put floor mat back into position on the cab floor.

Copyright ©
5001-6
AUXILIARY STEERING PRIORITY VALVE

Removal Installation
1. Park loader on level ground and lower bucket to 1. Install and tighten cap screws.
ground. Put transmission in NEUTRAL, apply 2. Connect and tighten pressure hose (11).
parking brake, and shut down engine,
3. Connect and tighten pressure hose (7).
2. Put master disconnect switch in OFF position.
4. Connect and tighten steering pressure hose (1).
3. Remove all dirt and grease from auxiliary
5. Connect and tighten steering load sensing hose
steering priority valve and adjacent area. See
(4).
illustration on page 7.
6. Connect and tighten load sensing hose (3).
4. Remove hydraulic reservoir fill cap.
7. Connect electrical connector to the pressure
5. Connect a vacuum pump to hydraulic reservoir.
switch (5).
6. Start vacuum pump.
8. Connect electrical connector to the steering
7. Tag and disconnect tank return tube (8) from the solenoid (16).
priority valve. Install a cap on the elbow and a
plug in the tube.
10. Connect and tighten tank return tube (8).
8. Stop the vacuum pump.
11. Stop vacuum pump. Disconnect vacuum pump
9. Tag and disconnect the wiring from the steering
from hydraulic reservoir.
solenoid (16).
12. Install fill cap on hydraulic reservoir.
10. Tag and disconnect the wiring from the pressure
switch (5). 13. Put battery disconnect switch in ON position.
Start engine and run at low idle for 30 seconds.
11. Tag and disconnect load sensing hose (3) from
Stop engine and check for leaks.
auxiliary steering priority valve (14). Install a cap
on the elbow and a plug in the hose. 14. Check to make sure priority valve operates
correctly. See Section 5002.
12. Tag and disconnect load sensing hose (4) from
the priority valve (14). Install a cap on the elbow 15. Check fluid level in hydraulic reservoir. Add oil as
and a plug in the hose. required. See Section 1002 for specifications.
13. Tag and disconnect steering pressure hose (1)
from priority valve (14). Install a cap on the fitting
and a plug in the hose.
14. Tag and disconnect pressure hose (7) from
priority valve (14). Install a cap on the fitting and
a plug in the hose.
15. Tag and disconnect pressure hose (11) from
priority valve (14). Install a cap on the fitting and
a plug in the hose.
16. Support auxiliary steering priority valve (14).
Remove cap screws.
17. Remove auxiliary steering priority valve (14).

Copyright ©
5001-7
2
6
1 5
4
3
7
15 8
14
9
13 11
10
12
BS08A012
1
7
3
4
17
14 16
8
11
BS08A015
1. STEERING PRESSURE HOSE 10. STEERING SUCTION HOSE

2. STEERING CONTROL VALVE 11. STEERING PRESSURE HOSE
3. STEERING LOAD SENSING HOSE TO STEERING VALVE 12. TO STARTER POSITIVE CABLE
4. STEERING LOAD SENSING HOSE TO PRIORITY VALVE 13. FILTER IN HYDRAULIC TANK
5. STEERING PRESSURE SWITCH 14. PRIORITY VALVE
6. LOADER VALVE 15. CONTROL MODULE
7. PRESSURE HOSE PUMP OUTPUT 16. STEERING SOLENOID VALVE
8. TANK RETURN HOSE 17. CHECK VALVE
9. AUXILIARY STEERING PUMP MOTOR
AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION

Copyright ©
5001-8
AUXILIARY STEERING PUMP AND MOTOR
Removal 6. Connect ground cable (4) to ground stud of

auxiliary steering pump and motor (1) following
1. Park loader on level ground with enough tag installed during removal.
clearance around the machine to allow you to
completely steer from side to side. Lower bucket 7. Connect positive cable (5) to B+ stud of auxiliary
to ground. Put transmission in NEUTRAL, apply steering pump and motor (1) following tag
parking brake, and shut down engine, installed during removal.
2. Put master disconnect switch in OFF position. 8. Connect wire (6) to auxiliary steering pump and
motor following tag installed during removal.
3. Tag and disconnect wire (6) from auxiliary
steering pump and motor solenoid. See 9. Put master disconnect switch in ON position.
illustration on page 9. 10. Start and run engine at low idle and raise bucket
4. Tag and disconnect positive cable (5) from B+ 500 mm (20 inches) above ground. Check that
stud of auxiliary steering pump and motor (1). auxiliary steering light on instrument cluster is
OFF.
5. Tag and disconnect ground cable (4) from
ground stud of auxiliary steering pump and motor IMPORTANT: In following Steps, do not run auxiliary
(1). steering pump and motor continuously for more than 20
seconds at a time without a two minute cool down.
6. Remove hydraulic reservoir fill cap.
11. With engine at low idle and machine steering
7. Connect a vacuum pump to hydraulic reservoir. straight ahead, turn key switch to OFF position to
8. Start vacuum pump. stop engine and then immediately back to ON
position (not START position). Auxiliary steering
9. Disconnect suction hose (2). Install a plug in pump and motor should start operating
suction hose and cap on fitting. immediately. Check that auxiliary steering light
10. Stop vacuum pump. on instrument cluster is ON and auxiliary steering
pump and motor is operating.
11. Disconnect pressure hose (3). Install a plug in
suction hose and cap on fitting. 12. Turn steering wheel full left into the end of travel,
and hold the pump at high pressure for 4-5
12. Support auxiliary steering pump and motor (1). seconds to confirm no leakage to the pressure
Remove nuts, cap screws, and washers securing switch. Then full right to confirm that the
auxiliary steering pump and motor (1). secondary steering system is working and there
13. Remove auxiliary steering pump and motor (1). is no binding in the steering.
13. Restart engine to build steering pressure.
Confirm that auxiliary steering light and auxiliary
steering pump and motor is operating. After
Installation about three seconds motor should stop operating
1. Position auxiliary steering pump and motor (1) on and auxiliary steering light should go out.
its mounting plate, have an assistant install cap 14. Let engine run and allow batteries to recharge for
screws, washers, and nuts to secure auxiliary a minimum of 10 minutes.
steering pump and motor (1), tighten the nuts.
See illustration on page 9. WARNING: Do not turn the key switch off if the machine
is steered against either the right or left hand steering stop.
2. Remove plug from pressure hose (3) and cap The steering wheel may kick back.
from elbow. Connect pressure hose to the
auxiliary steering pump and motor (1).
4. Remove plug from suction hose (2) and cap from
elbow. Connect suction hose to elbow installed in
auxiliary steering pump and motor (1).
5. Stop and disconnect vacuum pump. Install fill
cap in hydraulic reservoir.

Copyright ©
5001-9
BS08A013
3 1
4
2
BS08A014
1. AUXILIARY STEERING PUMP AND MOTOR 4. GROUND CABLE

2. SUCTION HOSE 5. POSITIVE CABLE (TO STARTER)
3. PRESSURE HOSE 6. WIRE TO CONTROL MODULE
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

Copyright ©
5001-10
STEERING CYLINDER
1. Loosen the fill cap for the hydraulic reservoir to 1. Put steering cylinders (11) in position in machine.
release pressure in the reservoir, then tighten the Make sure th at wa shers (1) are installed
fill cap. between steering cylinder (11) and rear frame.
See illustration on page 11.
2. Disconnect grease hoses (12) from steering
cylinders (11). See illustration on page 11. NOTE: Install a washer (1) on top and bottom of steering
cylinders (11) if possible. If only one washer (1) can be
3. Disconnect hydraulic hoses (13, 14, 15, and 16)
installed, place washer (1) at bottom of steering cylinders
from steering cylinders (11).
(11).
4. Install a plug in each hose (13, 14, 15, and 16) to
2. Make sure washers (9) are installed between
prevent entry of foreign matter.
steering cylinders (11) and front frame of
5. Remove locknut (10). machine.
6. Remove shoulder bolt (7). 3. Install the pivot pin (2) to secure rear of steering
cylinders (11) to machine frame. Install spacer
7. Remove pin (6).
(5), washer (4), and bolt (3) to secure pivot pin
8. Remove washers (9). (2).
9. Remove bolt (3), washer (4), and spacer (5) 4. Tighten bolt (3).
securing pivot pin (2) at rear of steering cylinders
5. Install pin (6) in front of steering cylinders (11).
(11).
Make sure that washers (9) are installed in
10. Use a suitable driver and drive pivot pin (2) out of correct position.
steering cylinder (11).
6. Install shoulder bolt (7) and new locknut (10) in
11. Remove washer(s) (1) from between steering steering cylinders (11) rod end and pin (6).
cylinders (11) and rear frame of machine. Tighten locknut (10).
12. Remove steering cylinders (11). NOTE: Shoulder bolt (7) should turn freely in hole after
tightening.
7. Connect hose assemblies (13, 14, 15, and 16) to
steering cylinders (11).
8. Connect grease hoses (12) to steering cylinders
(11).
9. Tighten hydraulic reservoir fill cap.
10. Start engine.
11. Turn steering wheel all the way to right and then
to the left several times.
12. Stop the engine. Check fluid level in hydraulic
reservoir. Add oil as required. See Section 1002
for specifications.

Copyright ©
5001-11
3 4
5
2
6
12 11
7
8
10
9
11
BS08A009
15
16
11
12
14
13
11
8
BS08A010
1. WASHER 5. SPACER 9. WASHER 13. HOSE ASSEMBLY

2. PIVOT PIN 6. PIN 10. LOCKNUT 14. HOSE ASSEMBLY
3. BOLT 7. SHOULDER BOLT 11. STEERING CYLINDER 15. HOSE ASSEMBLY
4. WASHER 8. GREASE FITTING 12. GREASE HOSE 16. HOSE ASSEMBLY
STEERING CYLINDER ILLUSTRATION

Copyright ©
5001-12
STEERING BACK PRESSURE VALVE
1. Remove the fill cap for the hydraulic reservoir to 1. Install the valve, bolts, spacers and nuts onto the
release pressure in the reservoir, attach a machine, tighten the bolts.
vacuum pump to the reservoir, start the pump.
2. Install new O-rings onto the fittings of the hoses,
2. Disconnect hoses (2) and (5) from the pressure install and tighten the hoses.
relief valve.
3. Stop the vacuum pump, install and tighten the
3. Remove the nuts, bolts and spacers from the reservoir filler cap.
pressure relief valve, remove the valve from the
4. Start and run the machine at low idle, turn the
machine.
steering wheel from full left lock to full right lock
holding the steering over relief.
5. Stop the machine and check for leaks.
6. Check fluid level in hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.

Copyright ©
5001-13
6 3
5 4
BS08A008
1. STEERING CONTROL VALVE 4. RELIEF VALVE

2. RETURN HOSE 5. RETURN HOSE TO FILTERS
3. CONNECTOR M27 ORB 6. RETURN MANIFOLD
STEERING BACK PRESSURE VALVE ILLUSTRATION

Copyright ©
5001-14
NOTES

Copyright ©
5002
Section
5002
STEERING SPECIFICATIONS, PRESSURE CHECKS,

AND TROUBLESHOOTING

Copyright ©
5002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUXILIARY STEERING SYSTEM PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AUXILIARY STEERING SYSTEM MOTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
UNDERSTANDING THE RESULTS OF THE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STEERING RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Copyright ©
5002-3
SPECIAL TOOLS
B785789 B009638
OEM1239 (CAS10280) FLOWMETER CAS1804 PRESSURE TEST FITTING KIT
B797157
CAS1808 FLOWMETER FITTING KIT
TROUBLESHOOTING THE STEERING SYSTEM

NOTE: The steering hydraulic schematic is included in the 3. Do the main hydraulic pump test. See Section
hydraulic schematic. Refer to the rear pocket of this 8002. If the main pump is bad, repair or replace
manual. the main hydraulic pump.
1. Make sure the oil level in the hydraulic reservoir 4. Test the steering cylinders for leakage, refer to
is correct. Visually inspect the steering system instructions on page 10. If a steering cylinder is
for leakage and damage. leaking, repair or replace the steering cylinder.
2. Do the steering relief valve pressure test. Refer
to page 7. If the pressure is above or below
specifications, adjust the steering relief valve in
the loader control valve.

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5002-4
AUXILIARY STEERING SYSTEM PUMP TEST
Equipment Required
1. CAS10280 Flowmeter
2. CAS1808 Flowmeter fitting kit
Test Procedure
1
BB830300
1. AMMETER CLAMP
6. Connect the ammeter clamp (1) to the cable as
1 in illustration above.
7. Make sure that the parking brake is applied and
the bucket is on the floor.
BD00M030
8. Make sure that the oil is at operating
1. ARTICULATION LOCK temperature.
1. Install articulation lock. 9. Make sure that the load valve for the flowmeter is
open (zero pressure).
NOTE: When performing this pressure check, always be
sure the articulation lock is in place, especially when 10. Start and run the engine.
working in the articulation joint areas. 11. Stop the engine and turn the key back to the On
2. Loosen and remove the outlet hose of the position.
Auxiliary Steering Pump from the Steering 12. Turn the steering wheel, this will activate the
Priority Valve. auxiliary steering pump.
3. Install a plug into the hose. 13. Turn the load valve on the flowmeter towards
4. Connect the inlet of the flowmeter to the outlet CLOSED until the pressure is 104 bar (1500 psi).
fitting on the Steering Priority Valve. 14. Read the flowmeter and ammeter gauges and
5. Install the outlet hose of the flowmeter in the record the readings.
hydraulic reservoir and hold in place with wire. 15. The flowmeter reading must not be less than
24.6 L/min, (6.5 U.S. gpm). The ammeter
reading must be 315 amps.
16. Turn the key switch to the OFF position. If the
flow was less than the specification, or if the
amperage was more than 315 amperes, remove
the auxiliary steering motor and pump. Test the
auxiliary steering motor. If the motor is good,
make repairs to the pump.

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5002-5
AUXILIARY STEERING SYSTEM MOTOR TEST
Test Equipment
1. A 24 volt battery that is fully charged. 2
1
NOTE: A 24 volt battery system (two 12 volt batteries in a
series) is used for this test. A 12 volt battery system will
cause damage to the auxiliary steering motor. 4
3
2. A remote starter switch.
3. A tachometer to check the armature speed.
4. A Sun Electric VAT-33 Starting and Charging
System Tester.
5
Test Procedure B790852
1. Remove the connector that is between the 1. REMOTE STARTER SWITCH

terminals on the magnetic switch and the 2. TESTER
3. AUXILIARY STEERING MOTOR
auxiliary steering motor.
4. AMMETER CLAMP
2. Remove the auxiliary steering motor from the 5. 24 VOLT BATTERY SYSTEM
auxiliary steering pump.
3. Remove the drive coupling from the auxiliary
steering motor (3).
4. Connect the auxiliary steering motor (3), remote
starter switch (1) and tester (2) to the 24 volt
battery system (5) as illustrated in Figure 3. 8
6 7
5. Push the button on the remote starter switch (1)
and look at the voltmeter in the tester.
6. Turn the load control (8) until the voltmeter (7)
indicates 24 volts. Refer to figure 4. Look at the
ammeter (6) in the tester. Make a record of the
ammeter indication.
B795328
7. Hold the tachometer against the armature shaft.
Look at the tachometer. Make a record of the 6. AMMETER
7. VOLTMETER
indication.
8. LOAD CONTROL
8. Release the button on the remote starter switch
(1).

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5002-6
UNDERSTANDING THE RESULTS OF THE TEST

1. If the ammeter indication in step 6 was 30 4. If the armature did not turn, and the ammeter
amperes or less and the tachometer indication in indication was zero amperes, possible causes
step 7 was 6950 r/min (rpm) or more, the include the following:
auxiliary steering motor is good.
A. An open field coil.
2. If the armature speed was less than 6950 r/min
B. An open armature coil. After the motor is
(rpm) and the ammeter indication was higher
disassembled, look at the commutator on the
than 30 amperes, possible causes include the
armature. If the commutator is badly burned,
following:
the armature coil is probably open.
A. Damaged bearings.
C. Broken brush springs or worn brush springs.
B. Loose pole shoes.
5. If the armature speed was less than 6950 r/min
C. A short circuit in the armature coil. The (rpm) and the ammeter indication was less than
armature coil must be checked on an 30 amperes, possible causes include the
armature tester after the motor is following:
disassembled.
A. Bad connections between the brushes and the
D. A ground connection in the field coil. field coil.
3. If the armature did not turn and the ammeter B. Dirty commutator.
indication was higher than 30 amperes, possible
6. If the armature speed was 6950 r/min (rpm) or
causes include the following:
more and the ammeter indication was more than
A. The motor terminal is in contact with the field 30 amperes, there is probably a short circuit in
frame. the field coil. A short circuit in the field coil is
difficult to find. It is recommended that a new
B. A damaged bearing that will not let the
field frame assembly be installed.
armature turn.

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5002-7
STEERING RELIEF VALVE

NOTE: The pump differential pressure must be properly adjusted before doing this test. Refer to Section 8002 Testing and
Adjusting the Pump Differential Pressure.
Pressure Setting Test
1
1
BD03A092
1. SAFETY LINK
BD03A092
1. SAFETY LINK
3. Remove the safety link (1) and lower the loader
arms to the ground.
1. Install the safety link (1) and lower the loader
arms slowly, until the safety link is supporting the 4. Stop the engine.
loader arms.
1
BD00M030
BD00M041 1. ARTICULATION LOCK

1. COVER PLATE
5. Install articulation lock (1).
2. Remove the cover plate (1) to gain access to the IMPORTANT: When performing the following pressure
loader control valve. check and adjustment, the articulation lock must be
installed. Use caution when working in or near the
articulation area.

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5002-8
6. Make sure that the temperature of the hydraulic
oil is at least 52° C (125° F).
7. To measure the temperature of the oil using the
instrument panel:
A. Press the program switch (left side of the
program/reset switch).
B. Press the up count switch to function 008.
C. Return the program switch to the OFF (center)
position.
1
8. Apply the parking brake.
2
9. Start and run the engine at full throttle. BD00N018
10. Hold the bucket control lever in the rollback 1. LOADER CONTROL VALVE
position. 2. PUMP PRESSURE TEST
PORT
11. Hold the lift lever in the “FLOAT” position.
15. Remove the dust cap from the test port (2).
12. Continue holding until the specified temperature
16. Connect a 345 bar (5000 psi) pressure gauge to
of the oil is reached.
the test port (2) on the front of the loader control
13. Stop the engine. valve (1).
14. Remove the cap on the hydraulic reservoir to NOTE: Make sure when you connect the pressure gauge
release any pressure in the hydraulic system. that you do so in a manner that you can read the pressure
gauge while sitting in the operators seat.
17. Start the engine and operate the machine at full
throttle.
18. With the articulation lock still in place, turn and
hold the steering wheel for a hard right turn.
19. Continue holding the steering wheel, and read
the pressure gauge.
20. The pressure gauge must indicate 239 to 243
bar (3465 to 3523 psi). If the pressure is not
correct, adjust the steering relief valve.

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5002-9
Pressure Setting Adjustment
1
1
BD03A092
1. SAFETY LINK
BD03A092
1. SAFETY LINK
3. Remove the safety link (1), and lower the loader
arms to the ground.
1. Install the safety link (1) before adjusting the
steering relief valve. 4. If the pressure gauge is still connected, repeat
steps 17 through 20 in the Pressure Setting Test
Procedure. If the pressure gauge is not
connected, do the entire Pressure Setting Test
Procedure.
5. If necessary, adjust the relief valve again until
the relief valve is within the specified range.
6. Stop the engine before removing the pressure
gauge.
BS01A046
1. LOADER CONTROL VALVE

2. STEERING RELIEF VALVE
2. Turn the adjusting screw clockwise to increase

the pressure setting. Turn the adjusting screw
counterclockwise to decrease the pressure
setting.
NOTE: 1/4 turn of the adjusting screw will change the
pressure by approximately 35 bar (500 psi).

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5002-10
STEERING CYLINDER LEAK TEST

NOTE: Make sure all persons are clear of the area of the 9. Connect the tube to the rod end of the left-hand
center pivot. Make sure the center pivot is free of any steering cylinder.
obstructions.
10. Turn the machine all the way to the left.
1. Park the machine on a level surface.
2. Turn the machine all the way to the right.
12. Find the tube that is connected to the rod end of
3. Stop the engine and apply the parking brake. the right-hand steering cylinder. Disconnect the
tube from the right-hand steering cylinder.
4. Find the tube that is connected to the rod end of
the left-hand steering cylinder. Disconnect the 13. Install a plug in the tube.
tube from the left-hand cylinder.
14. Start and run the engine at full throttle.
5. Install a plug in the tube.
15. Turn the steering wheel to the left. Hold the
6. Start and run the engine at full throttle. steering wheel for a full left turn. Have another
person check for leakage at the opening of the
7. Turn the steering wheel to the right. Hold the
rod end of the right-hand steering cylinder.
steering wheel for a full right turn. Have another
person check for leakage from the opening of the 16. If there is constant leakage from the rod end, the
rod end of the left-hand steering cylinder. piston packing in the right-hand steering cylinder
is damaged. Repairs must be made. See Section
8. If there is constant leakage from the rod end, the
5005.
piston packing in the left-hand steering cylinder
is damaged. Repairs must be made. See Section 17. Connect the tube to the rod end of the right-hand
5005. steering cylinder.

Copyright ©
Section
5005
STEERING CYLINDERS
5005

Copyright ©
5005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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5005-3
SPECIFICATIONS
Torque for piston cap screw ..........................................................................585 to 720 Nm (431 to 531 pound-feet)
Torque for gland ............................................................................................339 to 475 Nm (250 to 350 pound-feet)
STEERING CYLINDER
Disassembly Inspection
1. Fasten the tube (1) in a vise. Be careful not to 1. Discard the O-ring (6), backup ring (7), seal (4),
damage the tube (1). Refer to the illustration on seal (5), wiper (9), and guide (8) from the gland
page 4. (3). Refer to the illustration on page 4.
2. Loosen and remove the gland (3) from the tube 2. Discard the seal (12), backup ring (13), and wear
(1). ring (14) that were removed from the piston (11).
3. Pull the piston (11) straight out of the tube (1). 3. Clean all parts in cleaning solvent.
4. Fasten the yoke on the piston rod (10) in the vise 4. Check to be sure that the piston rod (10) is
and put a support below the piston rod (10) near straight. If the piston rod (10) is bent, install a
the piston (11). Use a shop cloth between the new piston rod (10).
support and the piston rod (10) to prevent
5. Inspect the inside of the tube (1) for deep
damage to the piston rod (10).
grooves and other damage. If there is any
5. Loosen and remove the bolt (15) that hold the damage to the tube (1), a new tube (1) must be
piston (11). used.
6. Remove the piston (11) from the piston rod (10). 6. Remove small scratches on the piston rod (10)
or inside the tube (1) with emery cloth of medium
7. Remove the seal (12), backup ring (13), and
grit. Use the emery cloth with a rotary motion.
wear ring (14) from the piston (11).
7. Inspect the bushings (2) and replace as required.
8. Remove the gland (3) from the piston rod (10).
9. Remove the O-ring (6), backup ring (7), seal (4),
seal (5), wiper (9), and guide (8) from the gland
(3).

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5005-4
9
4
5
3
7
6
11
12
13
14
15
1
16
BS01B202

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5005-5
1. TUBE 7. BACKUP RING 13. BACKUP RING

2. BUSHING 8. GUIDE 14. WEAR RING
3. GLAND 9. WIPER 15. BOLT
4. SEAL 10. PISTON ROD 16. REMOTE GREASE
5. SEAL 11. PISTON HOSE FITTING
6. O-RING 12. SEAL
STEERING CYLINDER ILLUSTRATION
Assembly 12. Install a new backup ring (13) on the piston (11).
1. Install the seal (4) in the gland (3). The seal (4) 13. Install a new seal (12) over the backup ring (13).
must be installed so that the lips of the seal (4) 14. Clean the threads on the end of the piston rod
are toward the small end of the gland (3). The (10) and the threads of the bolt (15) using Loctite
seal (4) can be difficult to install. Use tools that cleaning solvent. Allow to dry. Apply Loctite 242
will not damage the seal (4). Refer to the to the piston rod threads 1/4 inch from the open
illustration on page 4. end of the piston rod so that there is 1/2 inch of
2. Install the seal (5) in the gland (3). Loctite 242 on the piston rod threads. DO NOT
apply Loctite to the first 1/4 inch of the piston rod
3. Install the guide (8) in the gland (3). threads.
4. Install the wiper (9) in the gland (3). 15. Install the bolt (15) in the piston (11).
5. Install the O-ring (6) on the gland (3). The O-ring 16. Install the piston (11) on the piston rod (10) and
(6) must be toward the small end of the gland (3). start the bolt (15) into the piston rod (10).
6. Install the backup ring (7) on the gland (3). The 17. Tighten the bolt (15) according to torque
backup ring (7) must be toward the large end of specifications listed on page 2.
the gland (3). If the backup ring (7) is not flat on
both sides, the side that is not flat must be 18. Fasten the tube (1) in the vise. Be careful not to
toward the O-ring (6). damage the tube (1).
7. Fasten the yoke on the piston rod (10) in the 19. Apply petroleum jelly to the O-ring (6) and
vise. backup ring (7) on the gland (3) and to the
sealing surface in the tube (1).
8. Lubricate the piston rod (10) and the bore in the
gland (3) with clean hydraulic oil. 20. Lubricate the piston (11) and the inside of the
tube (1) with clean hydraulic oil.
NOTE: If a new gland (3) is being installed, write the part
number of the cylinder on the gland (3). 21. Push the piston (11) straight into the tube (1). Be
careful not to damage the wear ring (14) and seal
9. Push the gland (3) onto the piston rod (10). If (12) on the piston (11).
necessary, use a soft hammer to drive the gland
(3) onto the piston rod (10). 22. When the piston (11) is in the smooth part of the
tube (1), start the gland (3) into the tube (1).
10. Put the support below and near the end of the
piston rod (10). Put a cloth between the support 23. Tighten the gland (3) to 339 to 475 Nm (250 to
and the piston rod (10) to prevent damage to the 350 pound-feet).
piston rod (10).
11. Install a new wear ring (14) on the piston (11).

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5005-6
NOTES

Copyright ©
Section
5006
CENTER PIVOT
5006

Copyright ©
5006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CENTER PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONNECTING THE FRONT FRAME TO THE REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Copyright ©
5006-3
SPECIFICATIONS
SPECIAL TORQUES
M16 bolt for upper pivot pin.......................................................................224 to 278 Nm (165 to 205 pound-feet)
M12 bolts for bearing retainers and lower pivot pin ......................................124 to 132 Nm (91 to 97 pound-feet)
M12 bolts for lower pin plate .........................................................................124 to 132 Nm (91 to 97 pound-feet)
Ferry head screws for the drive shaft ................................................................61 to 81 Nm (45 to 60 pound-feet)
LUBRICANT
Pivot bearings and seals ............................................................................... Case AKCELA molydisulfide grease
Steering cylinder rod eyes............................................................................. Case AKCELA molydisulfide grease
FLUIDS
Hydraulic system reservoir ..................................................................................... Case AKCELA Hy-Tran® Ultra
SPECIAL TOOLS
CAS10219 ....................................................................................................................... Hand pump (hydraulic ram)
CAS10512 ....................................................................................................................................... 10 ton ram (long)
CAS10592 ........................................................................................................... Puller set, includes 24827 leg ends
CAS10600 ................................................................................Bearing cup and seal puller, includes 24850 adapter
CAS10193 ..............................................................................................................................Vacuum pump (12 volt)
CAS1960 and CAS2029........................................................... *Top bearing driver, bottom bearing driver and plate
* (Requires screw, two nuts, and two washers from CAS10592)
BC06A173 BC06A174
CAS1960 DRIVER SET CAS2029 DRIVER SET
NOTE: The upper bearing can be installed using CAS1960 Driver Set and the lower bearing can be installed using CAS2029
Driver Set.

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5006-4
CENTER PIVOT
Disassembly 19. Disconnect the supply hose.
1. Remove all dirt and grease from the area of the 20. Install a cap on the hose and a plug in the fitting.
center pivot. Park the machine on a level 21. Stop the vacuum pump.
surface.
22. Loosen and remove the self-locking nut and bolt
2. Lower the bucket until the bucket is flat on the that hold the pivot pin for the steering cylinder
floor. rod eye.
3. Stop the engine and apply the parking brake. 23. Remove the pivot pin from the rear frame and the
4. Remove the covers from both sides of the steering cylinder rod eye.
machine. 24. Remove the washer from the rear frame. Move
5. Disconnect the front wiring harness from the cab the steering cylinder out of the way.
floor. 25. Repeat steps 22, 23 and 24 for the other steering
6. Remove any tie straps that fasten the front wiring cylinder.
harness to the chassis near the center pivot. 26. Loosen and remove the Ferry head screws and
7. Loosen and remove the nut and washer that retainers that fasten the drive shaft to the front
fasten the chassis ground wire and cab ground yoke. Move the drive shaft out of the way.
wire to the studs. 27. Place two stands below and in contact with the
8. Loosen and remove the bolt, lock washer, and front frame.
nut that fasten the clamp on the front wiring 28. Install blocks between the rear axle and the rear
harness to the bracket on the rear frame. Move frame on both sides of the machine to prevent
the front wiring harness out of the way. the rear frame from tipping.
9. Loosen and remove the fill cap for the hydraulic 29. Put a jack in contact with both sides of the rear
reservoir. frame near the center pivot area. Use another
10. Connect a vacuum pump to the hydraulic jack at the rear of the machine to prevent the
reservoir. Start the vacuum pump. rear frame from tipping.
11. Disconnect the brake hose from the backside of 30. Loosen and remove the bolt (1), washer (2), and
front brake line bracket. spacer (3) that fasten the upper pivot pin (4) to
the rear chassis (5).
12. Install a plug in the tube and a cap on the fitting.
31. Use a prybar to remove the upper pivot pin (4).
13. Disconnect the hoses for the steering cylinder.
32. Loosen and remove the bolts (1) and washers
14. Install caps on the fittings and plugs in the hoses. (2) that fasten the lower pin plate (15) to the
15. Loosen and remove the bolts, lock washers, and lower pivot pin (10).
self-locking nuts that fasten the mounting bracket 33. Loosen and remove the bolts (1) and washers
for the hoses to the bracket on the front frame. (2) that fasten the lower pin plate (15) to the
16. Loosen and remove the bolts, flat washers, and bottom of the rear chassis (5).
self-locking nuts that fasten the bracket for the 34. Use the ram and hand pump to remove the lower
hoses to the rear frame. pivot pin (10).
17. Disconnect the return hose. 35. Install the puller on the bottom spacer (14), see
18. Install the cap on the hose and a plug in the Special Tools in this section.
fitting.

Copyright ©
5006-5
1 2
3
4
5
1
6
2
7
5
8
10
6 9
16 12 11
6
8
13
6
2
14
1
8
15 2
2
1
1
BS03B152
1. BOLT 5. REAR CHASSIS 9. UPPER PIVOT BEARING 13. BEARING RETAINER

2. WASHER 6. SEAL 10. LOWER PIVOT PIN 14. BOTTOM SPACER
3. SPACER 7. BEARING RETAINER 11. LOWER BEARING SPACER 15. LOWER PIN PLATE
4. UPPER PIVOT PIN 8. SHIM 12. LOWER PIVOT BEARING 16. FRONT CHASSIS
CENTER PIVOT ASSEMBLY

Copyright ©
5006-6
36. Remove the bottom spacer (14). Assembly
37. Release the parking brake. 1. Pack the bearing cones with grease. Be careful
38. Use prybars to turn the left rear wheel backwards not to mix the bearing cones.
and the right rear wheel forward to move the 2. Lubricate the bore in the top pivot with grease.
front of the rear frame to the left for access to the
bearings. Install blocks under the wheels to 3. Install a bearing cup (20) in the top pivot (22).
prevent the rear frame from moving. 4. Install the bearing driver (17) and plate (21).
39. Apply the parking brake.
17 18 19
40. Hold the bearing retainer (13) in place and
loosen and remove the bolts (1) and washers (2)
that fasten the bearing retainer (13) and shims
(8) to the bottom of the rear pivot.
41. Remove the bearing retainer (13) and shims (8).
42. Remove the lower bearing spacer (11) from the
top of the lower pivot.
20
43. Loosen and remove the bolts (1) and washers
21 22
(2) that fasten the bearing retainer (7) and shims
(8) to the top of the top pivot. BC06A118
44. Remove the bearing retainer (7) and shims (8). 17. BEARING DRIVER 20. BEARING CUP
18. NUT 21. PLATE
45. Use the puller to remove the seal (6) from the top 19. SCREW 22. TOP PIVOT
of the bottom pivot.
5. Tighten a nut (18) on the screw (19) until the
46. Use the puller to remove the seal (6) from the bearing cup (20) is seated in the bore of the top
bottom of the top pivot. pivot (22). Remove the bearing driver (17) and
plate (21) from the top pivot (22).
47. Use an acceptable driver, the hydraulic ram, and
the hand pump to remove the upper pivot 6. Install a bearing cone (25), spacer (24), the other
bearing (9) from the top pivot. See Special Tools bearing cone (23), and the remaining bearing
in this section. cup (26) in the top pivot (22).
NOTE: The spacers are matched to the bearing sets. Do 7. Install the bearing driver (17) and plate (21).
not mix the spacers. Do not use the old spacers if new
bearing sets are being installed.
bearing cup (26) is seated against the spacer
48. Use an acceptable driver, the hydraulic ram, and (24). Remove the bearing driver (17) and plate
the hand pump to remove the lower pivot bearing (21) from the top pivot (22).
(12) from the bottom pivot. See Special Tools in
this section. 17 18 19
23
NOTE: The spacers are matched to the bearing sets. Do 26
not mix the spacers. Do not use the old spacers if new 24
bearing sets are being installed.
49. Use an acceptable driver to press the seal (6) out
of each bearing retainer (7 and 13).
25
21 22
BC06A119
23. BEARING CONE 25. BEARING CONE

24. SPACER 26. BEARING CUP

Copyright ©
5006-7
9. Put the bearing retainer (7) in place on the upper 18. Use an acceptable driver to install the seal (6) in
pivot bearing assembly (9). the bottom of the top pivot.
10. Install the bearing driver (17) and plate (21). 19. The bottom of the seal (6) must be even with the
bottom of the top pivot.
bearing retainer (7) is tight against the upper
pivot bearing assembly (9).
17 18 19 27
7
BC06A125
21 22 20. Apply grease to the upper pivot pin (4).

BC06A120 21. Install the upper pivot pin (4) in the top pivot.
12. Measure the gap (27) between the bearing
22. Lubricate the top pivot until grease is forced out
retainer (7) and the top pivot (22). Make a record
of the seal (6).
of the measurement. Subtract 0.0762 to 0.1016
mm (0.003 to 0.004 inch) from the measurement. 23. Rotate the upper pivot pin (4) to check the
Select shims (8) equal to that value. bearing assembly. The upper pivot pin (4) must
rotate smoothly, but not easily. Leave the upper
13. Remove the bearing driver (17), plate (21), and
pivot pin (4) in place to keep dirt out of the upper
bearing retainer (7) from the top pivot.
pivot bearing (9).
14. Install the shims (8) and the bearing retainer (7).
24. Lubricate the bore for the bottom pivot with
15. Install the washers (2) and M12 bolts (1). Apply grease. Install a bearing cup in the bottom pivot.
one drop of 15W40 engine oil to each bolt and
25. Install the bearing driver (17) and plate (21).
immediately torque the M12 bolts (1) to 124 - 132
Nm (91 - 97 pound-feet).
19
16. Install the seal (6) in the bearing retainer (7). The 21
top of the seal (6) must be even with the top of 18
the bearing retainer (7).
28
29
17
BC06A123

bearing cup (28) is seated in the bore in the
bottom pivot (29).
27. Remove the bearing driver (17) and plate (21)
BC06A121
from the bottom pivot (29).
17. Fill the other seal (6) for the top pivot with
grease.

Copyright ©
5006-8
28. Install a bearing cone (25), spacer (24), the other 38. Apply one drop of 15W40 engine oil to each bolt
bearing cone (23), and the remaining bearing and immediately torque the M12 bolts (1) to 124 -
cup (26) in the bottom pivot (29). 132 Nm (91 - 97 pound-feet).
29. Install the bearing driver (17) and plate (21). 39. Fill the seal (6) for the bearing retainer (13) with
grease.
21 18 19
25 40. Install the seal (6) in the bearing retainer (13).
The bottom of the seal (6) must be even with the
24 bearing retainer (13).
29
23 26
17
BC06A124

bottom bearing cup (26) is seated against the
spacer (24).
31. Remove the bearing driver (17) and plate (21) BC06A126
from the bottom pivot (29). 41. Install the other seal (6) in the bottom pivot. The
top of the seal (6) must be even with the top of
32. Put the bearing retainer (13) in place on the
the bottom pivot.
lower pivot bearing (12).
33. Install the bearing driver and plate.
21 18 19
29
12 30
13 BC06A121
17 42. Install the lower bearing spacer (11) and the
BC06A125 bottom spacer (14).
43. Apply grease to the lower pivot pin (10).
bearing retainer (13) is tight against the lower
pivot bearing assembly (12). 44. Install the lower pivot pin (10) in the bottom pivot.
35. Measure the gap (30) between the bearing 45. Hold the bottom spacer (14) in place and
retainer (13) and the bottom pivot (29). Make a lubricate the bottom pivot until grease is forced
record of the measurement. Subtract 0.0762 to out of the seal (6).
0.1016 mm (0.003 to 0.004 inch) from the
46. Rotate the lower pivot pin (10) to check the
measurement. Select shims (8) equal to that
bearing assembly. The lower pivot pin (10) must
value.
rotate smoothly, but not easily.
36. Remove the bearing driver (17), plate (21) and
47. Remove the lower pivot pin (10) and the upper
bearing retainer (13) from the bottom pivot.
pivot pin (4).
37. Install the shims (8), the bearing retainer (13),
48. Remove the bottom spacer (14).
washers (2) and M12 bolts (1).

Copyright ©
5006-9
CONNECTING THE FRONT FRAME TO THE REAR FRAME

1. Release the parking brake. 25. Put the steering cylinder rod eye in position in the
2. Move the rear frame into alignment with the front frame. Install the washer between the steering
frame. cylinder rod eye and the rear frame.
3. Move the steering cylinders as required to move 26. Align the hole in the pivot pin with the holes in the
the rear frame into alignment with the front steering cylinder rod eye, and install the pivot
frame. pin.
4. Apply the parking brake. 27. Install the bolt and self-locking nut that hold the
pivot pin.
5. Apply grease to the upper pivot pin (4).
28. Repeat steps 25, 26 and 27 for the other steering
6. Install the upper pivot pin (4), spacer (3), washer cylinder.
(2) and M16 bolt (1). Be careful not to damage
the seal (6). 29. Start the vacuum pump.
7. Apply one drop of 15W40 engine oil to the bolt 30. Connect the return hose.
and immediately torque the M16 bolt (1) to 224 - 31. Connect the supply hose.
278 Nm (165 - 205 pound-feet). 32. Put the bracket for the hoses in position on the
8. Apply grease to the lower pivot pin (10). rear frame. Install the bolts, flat washers, and
9. Install the lower pivot pin (10) in the frames. Be self-locking nuts that fasten the bracket to the
careful not to damage the seal (6). rear frame.
10. Use the ram and hand pump to install the bottom 33. Put the bracket for the hoses in position on the
spacer (14). See Special Tools in this section. front frame.
11. Install the lower pin plate (15), three inner M12 34. Install the bolts, flat washers, and self-locking
bolts (1), and washers (2) that fasten the lower nuts that fasten the bracket to the front frame.
pin plate (15) to the lower pivot pin (10). 35. Connect the hoses for the steering cylinders.
12. Apply one drop of 15W40 engine oil to the bolts 36. Connect the brake hose for the front brakes at
and immediately torque the M12 bolts (1) to 69 the front bracket.
Nm (51 pound-feet). 37. Stop the vacuum pump.
13. Measure the gap between the lower pin plate 38. Connect the front wiring harness to the rear
(15) and the bottom pivot. Make a record of the wiring harness.
measurement. Subtract 0.0762 to 0.1016 mm
(0.003 to 0.004 inch) from the measurement. 39. Put the clamp on the wiring harness in position
Select shims equal to that value. on the bracket. Install the bolt, lock washer, and
nut that fasten the clamp on the wiring harness to
14. Loosen the bolts (1) that fasten the lower pin the bracket.
plate (15) to the lower pivot pin (10).
40. Put the ground wire in position on the stud. Install
15. Start the six outer bolts (1) into the lower pin the washer and nut that fasten the ground wire to
plate (15) and the bottom pivot. the stud.
16. Install the shims (8). 41. Install a tie strap to fasten the wiring harness to
17. Apply one drop of 15W40 engine oil to the bolts the tube.
and immediately torque the six outer M12 bolts 42. Disconnect the vacuum pump from the hydraulic
(1) to 124 to 132 Nm (91 to 97 pound-feet). reservoir.
18. Tighten the three inner bolts (1) to 124 to 132 43. Check the fluid level in the hydraulic reservoir.
Nm (91 to 97 pound-feet). Add oil as required.
19. Remove the jacks from the rear frame. 44. Install the fill cap in the hydraulic reservoir.
20. Remove the blocks from the rear axle. 45. Bleed air from the front axle bleed screws. Refer
21. Remove the stands from the front frame. to Section 7002 for complete brake bleeding
22. Put the drive shaft in position on the front yoke. instructions.
23. Install new Ferry head screws that fasten the 46. Lubricate the pivot pins for the steering cylinder
drive shaft to the front yoke. rod eyes.
24. Tighten the Ferry head screws to 61 to 81 Nm 47. Install the covers on both sides of the machine.
(45 to 60 pound-feet).
Copyright ©
5006-10
NOTES

Copyright ©
Section
5008
AUXILIARY STEERING MOTOR AND PUMP
5008

Copyright ©
5008-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Copyright ©
5008-3
SPECIFICATIONS
Auxiliary steering motor
Maximum amperes...............................................................................................................................30 amperes
Minimum armature speed ............................................................................................................ 6950 r/min (rpm)
Motor .......................................................................................................................................................... 24 volts
Auxiliary steering pump
Minimum flow ..............................................................................................24.6 L/min at 104 bar at 315 amperes
(6.5 U.S. gpm at 1500 psi at 315 amperes)

Copyright ©
5008-4
AUXILIARY STEERING MOTOR AND PUMP
Disassembly Assembly
NOTE: Refer to Section 5001 for removal and installation 1. Lubricate all parts with clean hydraulic oil before
of the auxiliary steering motor and pump. assembly.
NOTE: The pump is the only component that is 2. Lubricate and install a new seal (4) and retaining
disassembled. The switch (8) and motor (1) are replaced as ring (3) on the plate (17). Refer to the illustration
units and are not serviced. Refer to the illustration on page on page 5.
5.
3. Lubricate and install a new backup ring (5) and a
1. Make an alignment mark on the pump assembly new seal (6) on the plate (17).
and motor (1).
4. Lubricate and install new O-rings (7) on the body
2. Loosen and remove the two screws (15) and lock (18).
washers (14) that hold the pump assembly to the
5. Lubricate and install the pins (22), drive gear
motor (1).
(20), driven gear (19) and wear plates (23) on the
3. Remove and discard the mounting gasket (13), body (18).
retaining ring (3) and seal (4) from the pump
6. Lubricate and install a new backup ring (5) and a
assembly.
new seal (6) on the end plate (21).
4. Loosen and remove the four bolts (2) that hold
7. Align the marks, made during disassembly, on
the pump assembly together.
the end plate (21), body (18) and plate (17) and
5. Remove the end plate (21) from the body (18). install the four bolts (2). Tighten the four bolts (2).
6. Remove and discard the seal (6) and backup 8. Install a new gasket (13) on the pump assembly.
ring (5) from the end plate (21).
9. Align the marks, made during disassembly, on
7. Remove the wear plate (23), drive gear (20) and the pump assembly and the motor (1).
driven gear (19) from the body (18).
10. Install the lock washer (14) and screw (15).
8. Remove the body (18) from the plate (17). Torque the screw (15) to 35 to 39 Nm (312 to
348 pound-inches).
9. Remove and discard the O-rings (7) from the
body (18).
10. Remove the pins (22) and wear plate (23) from
the body (18).
11. Remove and discard the seal (6) and backup
ring (5) from the plate (17).
NOTE: The only serviceable items on the pump assembly
are the seals (6), backup rings (5), O-rings (7), seal (4),
retaining ring (3) and gasket (13). If any of the other items
are damaged, replace the pump assembly.
Inspection
1. Inspect the wear plates (23) for grooves, scoring
and pitting. If damage is found replace the pump
assembly. Refer to the illustration on page 5.
2. Inspect the drive gear (20) and driven gear (19).
If the shafts are worn or damaged, replace the
pump assembly.
3. Clean all parts in cleaning solvent and air dry.
4. Inspect the plate (17), end plate (21) and body
(18). Replace the pump assembly as necessary.

Copyright ©
5008-5
10 8
9
11
12 16
13
3 17
4 14
15
5
6
23
19
7
22
18
22
7
20
23
6
5
21
2
BS01C121
1. MOTOR 7. O-RING 13. GASKET 19. DRIVEN GEAR

2. BOLT 8. SWITCH 14. LOCK WASHER 20. DRIVE GEAR
3. RETAINING RING 9. CABLE 15. SCREW 21. END PLATE
4. SEAL 10. SCREW 16. WIRE 22. PINS
5. BACKUP RING 11. LOCK WASHER 17. PLATE 23. WEAR PLATE
6. SEAL 12. WASHER 18. BODY
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

Copyright ©
5008-6
NOTES

Copyright ©
SECTION INDEX
POWER TRAIN
Removal and Installation of Power Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6001

Transmission Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6002
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004
Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004
Drive Shafts, Center Bearing, and Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6005
Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6006
Transmission Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6007

Copyright ©
Copyright ©
6001
Section
6001
REMOVAL AND INSTALLATION OF POWER TRAIN

COMPONENTS

Copyright ©
6001-2
TABLE OF CONTENTS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rear Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Copyright ©
6001-3
TRANSMISSION
Removal STEP 7
STEP 1
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
STEP 2
Place the master disconnect switch in the OFF
position.
STEP 3
Refer to Section 9007 and remove ROPS cab or
ROPS canopy. BD01D315-01
Disconnect transmission wiring harness connector

STEP 4 from control valve connector. Remove socket head
Refer to Section 8001 and remove the hydraulic bolt securing wiring harness clamp. Move wiring
pump. harness away from transmission.
STEP 5 STEP 8
Put a 28 liter (30 quarts) container under
transmission drain plug. Remove drain plug and
drain transmission oil. Install drain plug after oil has
drained.
NOTE: Remove optional skid plate if equipped to gain
access to transmission drain plug.
STEP 6
BD01D317-01
Just above where clamp was installed, tag and

disconnect transmission wiring harness connector
from temperature sensor. Move wiring harness away
from transmission.
BD01D306-01
Identify, tag, and disconnect brake pump pressure

hose and brake to hydraulic reservoir hose. Position
hoses away from transmission. Remove and discard
O-ring face seals from fittings. Plug hoses and cap
fittings to prevent entry of foreign matter into
hydraulic system.

Copyright ©
6001-4
STEP 9 STEP 12
BD01D310-01 BD07N603-01
Remove two socket head bolts securing transmission Identify, tag, and disconnect transmission wiring
wiring harness clamps. harness connectors from filter maintenance switch
and output speed sensor. Move transmission wiring
STEP 10 harness away from transmission.
STEP 13
BD01D312-01
Identify, tag, and disconnect transmission wiring

harness connectors from engine speed sensor, BD03A165-01
intermediate speed sensor, and turbine speed Identify, tag, and disconnect parking brake hose from
sensor. Move transmission wiring harness away from parking brake. Plug hose and cap fitting to prevent
transmission. entry of foreign matter into hydraulic system. Move
hose away from transmission. Remove four bolts and
STEP 11 two straps securing center drive shaft to transmission
output flange. Disconnect center drive shaft from
transmission.
BD01D316-01
Remove socket head bolt securing wiring harness

clamp. Move wiring harness away from transmission.

Copyright ©
6001-5
STEP 14 STEP 16
BD03A161-01 BD01D318-01
Remove four bolts and two straps securing rear drive Identify, tag, and disconnect cooler hose from fitting
shaft to transmission output flange. Disconnect rear installed in LH side of transmission. Install a plug in
drive shaft from transmission. hose. Remove and discard O-ring face seal from
fitting.
STEP 15
STEP 17
BD07N608-01
Remove two bolts. Remove fill tube, with cap and oil BD01D339-01
gauge assembled, two seals, and metal strainer. Remove fitting. Remove and discard O-ring from
Discard seals. fitting. Install a plug in transmission port.
STEP 18
BD01D340-01
Repeat Steps (16) and (17) and disconnect the other

cooler hose and remove fitting.

Copyright ©
6001-6
STEP 19 STEP 21
BD01D340-01 BD03A163-01
Connect lifting equipment to transmission lifting eyes. Remove bolts and washers securing RH and LH
Take up all slack in lifting equipment. mounting brackets to rear chassis.
STEP 20 STEP 22
BD01D342-01 BD03A164-01
In area between the transmission and the engine, Raise transmission just enough to enable removal of
remove four bolts and two straps. Use pry bar to RH and LH mounting brackets. Remove two bolts
disconnect engine drive shaft from transmission. and washers securing RH and LH mounting brackets
Using 3/4 inch drive socket, extensions, and impact to transmission. Remove RH and LH mounting
wrench, remove four bolts and washers securing brackets.
transmission to top mounting bracket.

Copyright ©
6001-7
STEP 23 STEP 24
BD01D345-01 BD01D361-01
Slowly and carefully raise transmission from loader If top mounting bracket requires removal, remove
while checking that all hoses, electrical connectors, bolt and washer then remove bracket.
and wires have been disconnected and nothing
interferes with transmission removal. Remove
transmission from loader.

Copyright ©
6001-8
Transmission Mounting
3
2
C 3
B
2 3
7
1 1
5 8
2
3
8
1
2 9
7
1
6
7
8
7 4
8
BS08A032
1. ISOLATOR 7. WASHER
2. WASHER 8. BOLT
3. ISOLATOR BOLT 9. TRANSMISSION FILL TUBE
4. TOP MOUNTING BRACKET A. REAR CHASSIS TRUNNION
5. LEFT MOUNTING BRACKET B. MOUNTING BRACKET
6. RIGHT MOUNTING BRACKET C. ISOLATOR (SMALLER PIECE ON TOP)

Copyright ©
6001-9
STEP 25
Check isolators for deterioration, tears, deformation,
or other damage. Replace as necessary: refer to
Page 8.
STEP 26
BD03A164-01
Install RH and LH mounting brackets on transmission

using two washers and bolts. Do not tighten bolts.
STEP 29
BD01D361-01
If top mounting bracket was removed, put bracket on

rear chassis trunnion and secure using washer and
bolt. Do not tighten bolt.
STEP 27
BD03A163-01
Loosely install washers and bolts to secure RH and

LH mounting brackets to rear chassis. Tighten bolts
securing RH and LH mounting brackets to
transmission to a torque of 481 to 590 Nm (355 to
435 pound feet).
BD01D345-01
Move transmission into position above loader. Slowly

lower transmission into loader.

Copyright ©
6001-10
STEP 30 STEP 32
NOTE: In this step, new straps and bolts securing the
drive shaft must be installed whenever these parts are
removed. Bolts have a nylon patch to maintain torque which
requires new bolts.
BD01D343-01
Disconnect lifting equipment from transmission lifting

eyes.
BD01D342-01
STEP 33
Using 3/4 inch drive socket, extensions, and impact
wrench, install four washers and bolts to secure top
mounting bracket to transmission. Then tighten bolts
to a torque of 251 to 319 Nm (185 to 235 pound feet).
If bracket had been removed, tighten bolt to a torque
of 890 to 1000 Nm (655 to 735 pound feet). Connect
engine drive shaft to transmission. Install two new
straps and four new bolts. Tighten bolts to a torque of
34 to 41 Nm (25 to 30 pound feet).
STEP 31
BD01D34-01
Install new O-ring on fitting and install fitting in

transmission. Install new O-ring face seal in fitting
then connect cooler hose to fitting following tag
installed during removal. Remove and discard tag.
BD03A163-01
Tighten bolts securing RH and LH mounting brackets

to a torque of 890 to 1000 Nm (655 to 735 pound
feet).

Copyright ©
6001-11
STEP 34 STEP 36
BD01D318-01 BD03A161-01
Install new O-ring on fitting and install fitting in Connect rear drive shaft to transmission then install
transmission. Install new O-ring face seal in fitting two straps and four bolts. Tighten bolts to a torque of
then connect cooler hose to fitting following tag 61 to 81 Nm (45 to 60 pound feet).
installed during removal. Remove and discard tag.
STEP 37
STEP 35
BD03A165-01
BD07N608-0 Connect center drive shaft to transmission and install
Position fill tube, two new seals, and metal strainer two straps and four bolts. Tighten bolts to a torque of
on transmission; metal strainer is installed between 61 to 81 Nm (45 to 60 pound feet). Connect parking
seals. Secure using two bolts. Tighten bolts to a brake hose to parking brake following tag installed
torque of 17 to 33 Nm (12 to 24 pound feet). during removal. Remove and discard tag.

Copyright ©
6001-12
STEP 38 STEP 40
BD01D314-01 BD01D312-01
Connect transmission wiring harness connectors to Connect transmission wiring harness connectors to
output speed sensor and filter maintenance switch turbine speed sensor, intermediate speed sensor,
following tags installed during removal. Remove and and engine speed sensor following tags installed
discard tags. during removal. Remove and discard tags.
STEP 39 STEP 41
BD01D316-01 BD01D310-01
Install socket head bolt to secure wiring harness Install two socket head bolts to secure transmission
clamp. wiring harness clamps.
STEP 42
BD01D317-01
Connect transmission wiring harness connector to

temperature sensor following tag installed during
removal. Remove and discard tag.
Copyright ©
6001-13
STEP 43 STEP 45
BD01D315-01 BD03A177-01
Install socket head bolt to secure wiring harness Check that transmission drain plug is tight.
clamp. Connect transmission wiring harness
NOTE: Install optional skid plate if equipped.
connector to control valve connector.
STEP 46
STEP 44
Fill transmission with 15-40W engine oil until oil level
is up to the arrow in sight glass.
STEP 47
Refer to Section 8001 and install the hydraulic pump.
STEP 48
Refer to Section 9007 and install ROPS cab or
ROPS canopy.
STEP 49
Start and run engine at idle speed with transmission
in neutral. If transmission oil level is at or below
BD01D306-01
bottom of crosshatch region, put articulation lock in
At brake valve, install new O-ring face seals in
LOCKED position and add oil specified in Section
fittings. Connect brake to hydraulic reservoir hose
1002 until oil level is up to crosshatch region. Shut
and brake pump pressure hose following tags
down engine and put articulation lock in
installed during removal. Remove and discard tags.
OPERATING position.

Copyright ©
6001-14
FRONT AXLE
Removal STEP 4
STEP 1
BD03A167-01
Remove four bolts and two straps securing front

BD03A040-01
drive shaft to front axle.
Park machine on level surface. Have assistant put
articulation lock in LOCKED position. STEP 5
IMPORTANT: If machine is equipped with quick-attached
components, disconnect them from machine prior to
proceeding.
STEP 2
BD03A166-01
Remove clamp securing lubrication hose to machine

and nut securing opposite end of hose. Remove four
bolts and two straps securing center drive shaft to
front drive shaft. Use a pry bar to separate drive
shafts. While supporting center bearing and front
BD03A092-01 drive shaft, remove four nuts and bolts and eight
Raise bucket and have assistant install safety link. washers. Lower center bearing and front drive shaft
Lower loade r arm s slowly until sa fe ty link is from mounting plate and remove from machine.
supporting loader arms.
STEP 3
Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from

Copyright ©
6001-15
STEP 6 STEP 9
BD03A168-01 BD01F297-01
Disconnect brake hose from elbow. Remove and Use an acceptable jack to hold front axle.
discard O-ring face seal from elbow.
STEP 10
STEP 7
BD01F295-01
BD01F298-01 Remove bolts and washers from front wheels.

Remove both wheels from front axle.
STEP 11
BD01D392-01
Using an acceptable hydraulic jack, raise one tire

from ground and install an acceptable jack stand
under machine. BD01F296-01
Remove eight nuts bolts, and washers securing front

STEP 8 axle to machine.
Repeat Step 7 to raise other front axle tire from
ground. STEP 12
Carefully lower front axle and remove from under
machine.
Copyright ©
6001-16
Front Axle Mounting
BS08A035
1. BOLT (8)
2. WASHER (16))
3. NUT (8)
4. FRONT CHASSIS

Copyright ©
6001-17
BS07D018
FRONT AXLE TORQUE SEQUENCE
STEP 13
Carefully move front axle under machine and raise
against mounting pads on machine.
STEP 14
BD01F295-01
BD01F296-01
Apply one drop of engine oil to threads prior to

assembly. Install washers, bolts, and nuts to secure
front axle to machine. Tighten bolts to a torque of 783
to 857 Nm (577 to 632 pound feet) using torque
sequence shown.
B0987A88
Install both wheels on front axle and secure. Tighten

bolts to a preliminary torque of 298 Nm (230 pound
feet) in sequence indicated; then tighten to a torque
of 640 to 720 Nm (475 to 530 pound feet) in same
sequence.

Copyright ©
6001-18
STEP 16 STEP 19
BD01F297-01 BD03A168-01
Remove jack from front axle. Install a new O-ring face seal in elbow. Connect
brake hose to elbow.
STEP 17
STEP 20
BD01F298-01
BD03A166-01
Position and support center bearing and front drive

shaft and install eight washers and four bolts and
nuts. Tighten bolts to a torque of 99 to 128 Nm (73 to
94 pound feet). Install two straps and four bolts.
Tighten bolts to a torque of 61 to 81 Nm (45 to 60
pound feet). Secure lubrication hose to machine
using clamp; secure opposite end of hose using nut.
BD01D392-01
Using an acceptable hydraulic jack, raise axle and

remove jack stand from under machine.
STEP 18
Repeat Step 17 to remove other jack stand from
under machine.

Copyright ©
6001-19
STEP 21 STEP 23
Refer to Section 7002 and bleed brakes.
STEP 24
BD03A167-01
Secure drive shaft to front axle using two straps and

four bolts. Tighten bolts to a torque of 61 to 81 Nm
(45 to 60 pound feet). BD03A092-01
Start engine and raise bucket. Have assistant

STEP 22 remove safety link. Lower bucket to ground and stop
If necessary, fill axle with gear lubricant specified in engine.
Section 1002.
STEP 25

Copyright ©
6001-20
REAR AXLE
Removal STEP 5
STEP 1
Park machine on a level surface; be sure to allow
adequate space at side of machine for removal of
rear axle. Stop engine. Actuate brake pedal several
times to discharge brake accumulators. Put key
switch in ON position and move loader control lever
back and forth at least 30 times to release any
pressure from hydraulic circuit.
STEP 2
BD03A169-01
Disconnect brake hose from elbow. Remove and

discard O-ring face seal from elbow.
STEP 6
BD03A040-01
STEP 3
Install wood blocks between rear axle and chassis to
prevent rear axle from pivoting.
BD01F299-01
STEP 4 Using an acceptable hydraulic jack, raise one tire
from ground and install an acceptable jack stand
under machine. Repeat this step for other tire.
STEP 7
BD03A162-01
Remove four bolts and two straps. Use a pry bar to

disconnect rear drive shaft from rear axle.
BD01F302-01
Use an acceptable jack to hold rear axle.

Copyright ©
6001-21
STEP 8 STEP 10
Carefully lower rear axle and remove through side of
machine.
STEP 11
Remove and discard two seals from rear axle pivot
point.
BD01F295-01
Remove bolts and washers from rear wheels.

Remove both wheels from rear axle.
STEP 9
BD03A170-01
At front of trunnion, remove two Allen head bolts and

washers. Remove front cap: if necessary use two
M12 by 32 mm (1.25 inches) bolts in puller holes (A);
tighten bolts evenly to pull cap from axle and
trunnion. Remove and discard O-ring from cap.
Repeat this step at rear of trunnion except remove
and retain shim(s) after removal of rear cap. Remove
pivot shaft using acceptable sleeve or rod if
necessary.

Copyright ©
6001-22
Rear Axle Mounting
6
1 5
4
3
6
2
5
7
11
10
5 9
2
6
3
12
5 8
6
BS08A036
1. TRUNNION 5. WASHER 9. REAR AXLE

2. O-RING 6. BOLT 10. PIVOT PIN
3. SEAL 7. WASHER 11. SHIM(S)
4. FRONT CAP 8. BOLT 12. REAR CAP

Copyright ©
6001-23
NOTE: If shim(s) (11) have been lost or pivot pin (10) has
been replaced, do Step 12 to determine required shim(s)
otherwise go to Step 13. A
STEP 12
6 1 6
1
10
4
12
BD01D482A-01
A
B
BS01E091A
Install pivot pin (10) and caps (4 and 12) in trunnion

(1) without rear axle or shim(s). Install washers (5)
and bolts (6). Tighten bolts securely. Push
assembled pivot pin and caps to rear of machine as
far as possible. Measure and record gap (A) between
rear cap (12) and trunnion. Select shims from the
following:
NOTE: Shims are available in following sizes: 0.50 mm
(0.020 inch), 1.0 mm (0.039 inch), and 1.50 mm (0.059 BD01D499-01
inch). Clean front (A) and rear (B) pivot area of rear axle
where seals (3) will be installed.
MEASURED SHIM(S) REQUIRED
GAP (mm) (mm) STEP 14
0.07 to 0.55 None
A
0.56 to 1.09 0.50
1.10 to 1.59 1.0 3
1.60 to 2.09 1.50 4
2.10 to 2.59 0.50 plus 1.50 12
2.60 to 3.02 1.0 plus 1.50
2
BS01E092
Lubricate two new seals (3) and new O-rings (2)

using Molydisulfide Grease. Install seals, smooth
side out, into front and rear of axle housing (A) until
seal bottoms out in housing counterbore. Install an
O-ring in each cap (4 and 12).
STEP 15
Carefully move rear axle under machine. Raise axle
into position in trunnion and align pivot holes in
trunnion with pivot holes in axle.
Copyright ©
6001-24
STEP 16 STEP 17
11
A 4 6
6 12
10 1
1
BS01E091
Lubricate pivot pin (10) using Molydisulfide Grease. BD01F295-01
At rear of trunnion (1), install pivot pin into trunnion

and axle (A). Install shim pack (11), rear cap (12)
with O-ring installed, and two washers and bolts (6).
At front of trunnion install front cap (4) with O-ring
installed. Use Loctite primer 747 on bolt threads and
let dry for 70 seconds. Then, apply Loctite 243 on
bolt threads and install washers and bolts (6).
Tighten bolts (6) to a torque of 325 to 353 Nm (240 to
260 pound feet).
B0987A88
Install both wheels on front axle and secure. Tighten

bolts to a preliminary torque of 298 Nm (220 pound
feet) in sequence indicated; then tighten to a torque
of 640 to 720 Nm (475 to 530 pound feet) in same
sequence.
STEP 18
Remove hydraulic jack supporting rear axle and jack
stands supporting loader.

Copyright ©
6001-25
STEP 19 STEP 21
If necessary, fill axle with gear lubricant specified in
Section 1002.
STEP 22
Refer to Section 7002 and bleed brakes.
STEP 23
BD03A169-01
Install a new O-ring face seal in elbow. Connect

brake hose to elbow.
STEP 20
BD03A162-01
Connect rear drive shaft to rear axle. Install two

straps and four bolts. Tighten bolts to a torque of 61
to 81 Nm (45 to 60 pound feet).

Copyright ©
6001-26
NOTES

Copyright ©
6002
Section
6002
TRANSMISSION SPECIFICATIONS, PRESSURE

CHECKS, AND TROUBLESHOOTING

Copyright ©
6002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission ECM Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission Sensor Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Automatic Problem Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Clutch Modulation Substitute Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Limp-Home Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission/Transmission ECM Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Upshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Downshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Upshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Downshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cold Start Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONSUMPTION TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . 19

Copyright ©
6002-3
SPECIAL TOOLS
CAS-1953A Transmission supplemental fitting kit. CAS-1808 Flowmeter kit
Includes: CAS-2324 special 90 degree adapter and
CAS-2702 Flowmeter adapter
CAS-2325 plug and cap set.
CAS-2278 Flow test kit
CAS-1804 Master pressure test kit
SPECIFICATIONS
Main pressure and clutch pressure ................................................................................16 to 18 bar (232 to 261 psi)
Converter in pressure .......................................................................................................8 to 10 bar (116 to 145 psi)
Pressure reduction for solenoids ........................................................................................7 to 9 bar (102 to 131 psi)
Converter out pressure........................................................................................................ 2.5 bar (36 psi) minimum
Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi)
Minimum pump output (at 2000 rpm) .....................................................................................52 L/min (14 U.S. gpm)
Transmission oil operating temperature .........................................................................80 to 120 °C (176 to 248 °F)
Clutch KV........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch KR .......................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K1 ........................................................................................................................16 to 18 bar (232 to 261 psi)

Copyright ©
6002-4
4 1
3 2
5 12
9
6
11
14
13 7
10
BS01A190
1. TRANSMISSION ELECTRONIC CONTROL MODULE 8. INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR
2. DOWNSHIFT BUTTON 9. INDUCTIVE TRANSMITTER - TURBINE SPEED SENSOR
3. DECLUTCH ROCKER SWITCH 10. INDUCTIVE TRANSMITTER - ENGINE SPEED SENSOR
4. MANUAL/AUTOMATIC ROCKER SWITCH 11. HALL SENSOR - OUTPUT SPEED SENSOR
5. SHIFTER 12. TRANSMISSION CONTROL VALVE CABLE
6. SUPPLY SYSTEM CONNECTIONS B+ AND RETURN 13. DECLUTCH LIMIT SWITCH
7. TRANSMISSION 14. PLUG
COMPONENT LOCATIONS SYSTEMS

Copyright ©
6002-5
12
11
1
2
10
9
4
5
15
6
14
8
13 7
BS03A262
1. CLUTCH SHAFT KR 9. TRANSMISSION PUMP
2. POWER TAKE OFF 10. INPUT FLANGE
3. CLUTCH SHAFT KV 11. CONVERTER
4. CLUTCH SHAFT K2 12. INDUCTIVE TRANSMITTER FOR ENGINE SPEED
5. CLUTCH SHAFT K3 13. CLUTCH SHAFT K4
6. OUTPUT FLANGE REAR 14. CONVERTER RELIEF VALVE
7. OUTPUT FLANGE CONVERTER SIDE 15. CLUTCH SHAFT K1
8. OUTPUT SHAFT
COMPONENT LOCATIONS TRANSMISSION LAYOUT

Copyright ©
6002-6
2 2
2
2
1 3
4
BS01A191
3. OUTPUT FLANGE CONVERTER
1. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK
SIDE
2. TRANSMISSION SUSPENSION BORES 4. OIL DRAIN PLUG
COMPONENT LOCATIONS FRONT VIEW

Copyright ©
6002-7
1
2
3
10
6
7
BS01A192
1. CONVERTER BELL HOUSING 6. OUTPUT FLANGE REAR
2. BREATHER 7. OIL DRAIN PLUG
3. TRANSMISSION CASE COVER 8. OUTPUT FLANGE CONVERTER SIDE
4. FILTER HEAD 9. TRANSMISSION CASE
5. FILTER 10. PARKING BRAKE
COMPONENT LOCATIONS SIDE VIEW

Copyright ©
6002-8
2
1
1
7 3
4 4
BS01B048
1. LIFTING LUGS 5. OUTPUT FLANGE REAR
2. POWER TAKE OFF 6. FILTER
3. TRANSMISSION CONTROL VALVE 7. FILTER HEAD
4. TRANSMISSION SUSPENSION BORES
COMPONENT LOCATIONS REAR VIEW

Copyright ©
6002-9
TRANSMISSION OPERATION
General Transmission ECM Tasks

The transmission is equipped with a Transmission The Transmission ECM performs a variety of tasks in
ECM (Electronic Control Module). This module the overall system. The Transmission ECM:
controls modulation and shifting that were normally
A. Determines which clutches to engage in the
associated with hydraulically modulated
transmission.
transmissions, providing smoother shifts and
enhanced clutch life. B. Protects the engine and transmission turbine
from overspeed conditions during
The Transmission ECM relies on signals from
downloading.
several sensors that are incorporated into the design.
These sensors measure the speed of several C. Receives speed information from the engine
components, as well as other sensors that measure speed sensor, the turbine speed sensor, the
temperature. These solenoids and sensors are intermediate shaft speed sensor and the
further defined in the following paragraphs. transmission output shaft speed sensor.
These speed sensors are checked to
I n a dd i t i o n, t h e t ra n s m i s s i o n i n c o rp o r a t es a
determine if normal sensor operation is
two-piece transmission case for ease of transmission
present. The data is also used to control
maintenance, helical cut gears that help reduce
modulation during shifting and to determine
noise, and all external hoses have been eliminated
the appropriate shift patterns.
(all oil passages are internal).
D. Detects system failures and determines the
Transmission ECM appropriate alternative actions.
Modulation and shifting are controlled by the E. Provides various diagnostic messages to the
Transmission Electronic Control Module Information Center.
(Transmission ECM). This module replaces the oil F. Provides other information to the information
and springs that are found in hydraulically modulated center, which in turn displays engine speed,
transmissions. wheel speed, gear shift selection, and actual
The Transmission ECM controls the clutch gear selection.
engagement, providing smoother shifts and G. Provides a method to calibrate the
enhanced clutch life, whether the transmission is set transmission clutch control.
to the automatic or manual shift mode.
H. Establishes clutch modulation pressure during
The Transmission ECM also informs the Information transmission shifts.
Center, by the use of diagnostic codes, of any
transmission error and the hours of operation that the
error occurred.
Electrical Shift Solenoids

Electrical Shift Solenoids control the modulation of
the clutches, eliminating the need for a modulation
valve, and providing a smooth shift while maintaining
constant control over clutch engagement as follows:
A. A temperature sensor relays the oil
temperature to the Transmission ECM.
B. The Transmission ECM times the rate the
solenoid energizes and de-energizes.
C. As the transmission changes gears, there is
reduced hesitation from one gear to the next.

Copyright ©
6002-10
Transmission Sensor Data Clutch Modulation Substitute Mode

Collection In this mode, the transmission clutch modulation is
The Transmission ECM collects and uses time dependant rather than load dependant. The
information from four sensors to accurately shift the transmission will go into the Clutch Modulation
transmission and determine if any clutches are Substitute Mode if any of the four speed sensors fail.
slipping. These sensors are: If the output speed sensor is working and the
Engine (Speed) Sensor - monitors engine speed to transmission is in gear, the shift points in Automatic
determine the load on the engine for shift points and mode will be speed dependant but the modulation
sends the engine rpm to the Transmission ECM, will be a predetermined amount of time.
which sends the information to the tachometer in the If the output speed sensor is not working and the
Information Center. transmission is in gear, the shift points will be load
Turbine (Speed) Sensor - assists the engine speed d e p e n d a n t b u t t h e m o d u l a t i o n w i ll s t i l l b e a
sensor in determining the load going into the predetermined amount of time.
transmission and helps determine shift points. If the transmission is shifted from neutral into a
Intermediate (Shaft Speed) Sensor - determines direction in the Clutch Modulation Substitute Mode in
differential gear speed in the transmission to check automatic, the transmission will shift into 4th gear
for clutch slippage. and shift down until it gets the correct output speed
from the turbine.
Output (Speed) Sensor - monitors transmission
output shaft speed to help determine the load on the Limp-Home Mode
transmission and to assist in determining shift points.
Sends output shaft speed to Transmission ECM In this mode, the transmission will go into second
which sends the information to the speedometer in gear, forward or reverse, no matter what gear is
the Information Center. selected. If second gear is not obtainable, the
Transmission ECM selects a series of prioritized
The transmission ECM also reviews voltage
gears until an operable gear is found. The
information from the shifter and transmission
transmission will go into the Limp Home Mode if
solenoids to determine if there are any short circuits
there is a fault on one clutch, a fault on one clutch
or open circuits in the system.
valve, or a fault on more than one speed sensor.
Automatic Problem Modes Transmission/Transmission ECM

If the Transmission ECM detects an error condition in Shutdown Mode
the transmission system, it will generate a service
code in the Information Center and will enter one of In this mode, the Transmission ECM has detected a
three modes: severe failure that disables control of the
transmission. The transmission will go into Shutdown
A. Clutch Modulation Substitute Mode
Mode if there is a fault on more than one clutch, a
B. Limp-Home Mode fault on the solenoid power supply, or invalid voltage.
C. Transmission/Transmission ECM Shutdown In this mode, the Transmission ECM will shut off all
Mode solenoid valves and the power supply and the
transmission shifts into and stays in neutral.
If the Transmission ECM generates a code, a
warning triangle will be illuminated on the Information
Center.

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6002-11
Transmission Clutch Calibration Gear Selections

The Transmission ECM has the capability to find the The transmission provides 4 forward and 3 reverse
optimal adjustment of the clutch filling parameters for gear selections. The transmission ratios were
each individual transmission, providing the ability to designed to give optimized speed and torque for
individually adjust the optimum fill time for the each gear selection. The torque converter is a single
individual transmission in the machine. Clutch Filling stage torque converter (one locking unit in the torque
Parameter Calibration is performed on each machine converter).
at the plant and should be repeated at the first 250
hours of use and every 1000 hours thereafter. Automatic/Manual Modes
Before doing the following transmission clutch The automatic/manual switch is located on the right
calibration procedures make sure of the following: control panel. The transmission is in automatic mode
1. The machine is running and the transmission oil when the top of the automatic/manual switch is
is warm. depressed. The Transmission Display Center
indicates when the machine is in the automatic
2. Engine low idle speed is correct. mode.
3. The transmission is in neutral.
4. The park brake is applied.
Upshifting in Automatic Mode
5. If steps 1 through 4 have been accomplished, Upshifting is determined by machine speed and the
calibrate the transmission clutches as follows: torque on the transmission.
A. Press and hold the enter key for 2 to 3 The transmission will shift from first or second gear
seconds and the monitor will change to up to the highest gear selected as the accelerator is
SELECT. depressed, machine speed increases, and required
torque is reduced.
B. Use the down arrow and high light “CONFIG”,
press the enter key. If the machine speed is increasing, but the operator
is not depressing the accelerator (such as when
C. Press the down arrow and high light “CALIB going down a hill), the transmission will not upshift.
G/B”, press the enter key.
As the operator depresses the accelerator and the
D. Monitor will state “CALIB G/B” “CONFIRM torque on the transmission is lowered, the
PLEASE”, press the enter key. transmission will upshift.
E. If the conditions are not correct for clutch
calibration the monitor will display the problem Downshifting in Automatic Mode
that needs to be corrected.
Downshifting is determined directly by machine
F. Clutch calibration status will be displayed on speed and transmission torque. The transmission will
the monitor, “ADJUST K1, K2, K3, K4, KV, downshift to first or second gear as machine speed
KR”. decreases and transmission torque increases. For
example, if the unit begins to climb a hill in forth gear
G. After completing the Clutch Calibration and the machine speed decreases, as the torque
procedure, turn the machine OFF for 15 requirement increases, the transmission will
seconds. This sets the calibration in the downshift into third, then second, and down to first
controller. gear, if necessary.
Upshifting in Manual Mode

In the manual mode, the transmission starts out in
the selected gear and stays in that gear until the
operator selects another gear or direction. The
transmission can be upshifted without reducing
engine speed or machine speed.
If the gear selected is two or more gears higher than
the present gear, the transmission will shift up
through the gears at 2.5 second intervals until the
selected gear has been reached.

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6002-12
Downshifting in Manual Mode Manual Mode

The transmission can be downshifted in the manual In the manual mode, the downshift button toggles
mode without reducing engine speed or machine between 1st and 2nd gear. The manual mode is
speed. useful in short haul operations. In this mode, the
downshift button functions in two ways in 1st and 2nd
If 1st gear is selected from 3rd or 4th gear, the
gear.
transmission will downshift into 2nd gear for 1.2
seconds and then will shift into 1st gear. When the operator is in 2nd gear and pushes the
downshift button, the transmission instantly shifts into
Downshift Button 1st gear. When the operator pushes the downshift
button again, the transmission upshifts into 2nd gear.
The downshift button is located on front of the
joystick control lever in machines with a single lever If the machine is in 2nd gear and the downshift
configuration, and on top of the control tower in button is pushed, the transmission instantly shifts
machines with a three lever configuration. into 1st gear. When the operator shuttles the shifter,
the transmission upshifts back into 2nd gear.
With the number of different ways the downshift
button functions, the operator can tailor the use of Cold Start Protection System
the machine to the application at hand.
The transmission has a cold start protection system.
Automatic Mode When the transmission sump temperature is minus
10° C (14° F), the Transmission ECM will keep the
In the Automatic Mode, the downshift button only transmission in neutral.
shifts down. The downshift button allows the operator
to downshift through the entire range of gears. This is When the transmission sump temperature warms up
useful in long haul applications or roading. to minus 10° C (14°F) (within approximately one
minute), the machine will operate in all gears.
Each time the button is pushed the transmission will
instantly downshift one gear from 4th to 3rd, then Brake Pedal Transmission
from 3rd to 2nd, and then from 2nd to 1st.
Declutch
The transmission will automatically downshift and
then upshift, as needed, to the last gear that was A transmission declutch feature concentrates more
selected with the downshift button. engine power on the loader when digging in heavy or
tough conditions, providing smoother stops and
Example: If the downshift button was used to shift from starts. Total disconnection of the transmission from
4th to 3rd gear, the transmission will automatically shift the engine is prevented. This feature will function in
from 3rd down and then back up to 3rd again. It will not 1st, 2nd, or 3rd gear only. It will not function in 4th
shift into 4th until the transmission has been returned to the gear.
full range automatic mode.
When the transmission declutch switch is in the on
The transmission will return to the full range position and the brake pedal is pushed, the
automatic mode when: Transmission ECM reduces the pressure to the
A. Another gear is selected. transmission forward or reverse clutch.
B. The shifter is moved into neutral and then into The Transmission ECM will not completely
forward or reverse. disconnect the clutch from the engine, but gradually
reduces the forward or reverse clutch pressure down
C. The autoshift switch is recycled. to a lower level.
When the brake pedal is released, the Transmission
ECM gradually increases the forward or reverse
clutch back up to system clutch pressure.
If the direction is changed while the transmission is
declutched, the selected forward or reverse clutch
will be filled and maintain a low pressure until the
brake pedal is released. Then the selected forward or
reverse clutch pressure will gradually increase up to
system clutch pressure.

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6002-13
TRANSMISSION PRESSURE TEST POINTS DIAGRAM

DESIGNATION ON
No. IDENTIFICATION/LOCATION CONNECTION
VALVE BLOCK
Measuring Points for Pressure Oil and Temperature
51 Before the Converter - Opening Pressure 8 bar (116 psi) M10x1 H
52 Behind the Converter - Opening Pressure 2.5 bar (36 psi) M14x1.5
53 Clutch Forward 16+2 bar (232 + 29 psi) KV M10x1 B
55 Clutch Reverse 16+2 bar (232 + 29 psi) KR M10x1 E
56 Clutch 16+2 bar (232 + 29 psi) K1 M10x1 D
57 Clutch 16+2 bar (232 + 29 psi) K2 M10x1 A
58 Clutch 16+2 bar (232 + 29 psi) K3 M10x1 C
60 Clutch 16+2 bar (232 + 29 psi) K4 M10x1 F
63 Behind the Converter Temperature 100° C, Short Time 120° C M14x1/5
65 System Pressure 16+2 bar (232 + 29 psi) M10x1 K
Measuring Points for Delivery Rates
15 Connection to the Heat Exchanger 1 5/16” - 12 UNF-2B
16 Connection from the Heat Exchanger 1 5/16” - 12 UNF-2B
Inductive Transmitter and Speed Sensor
21 Inductive Transmitter for Turbine Speed M18x1.5
34 Output Speed Sensor
47 Inductive Transmitter for Central Gear Train Speed M18x1.5
48 Inductive Transmitter for Engine Speed M18x1.5
Connections
49 Plug Connection on the Hydraulic Control Unit
68 System Pressure M16x1.5 G
69 Pilot Pressure M16x1.5 J
NOTE: See next page for Measuring Point, Transmitter, Sensor and Connection locations.

Copyright ©
6002-14
BC01B047
MEASURING POINTS AND CONNECTIONS

Copyright ©
6002-15
CHART FOR RECORDING PRESSURE READINGS

Use this chart to record the pressure readings.
P.I.N. Number: Date:
TEST POINTS
Shift P V R 1 2 3 4 5 6
LP
Speed 65 53 55 56 57 58 60 51 52
1st F
2nd F
3rd F
4th F
1st R
2nd R
3rd R
Neut
P= MAIN PRESSURE 1= FIRST GEAR CLUTCH 4= FOURTH GEAR CLUTCH LP= LUBE PRESSURE
V= FORWARD CLUTCH 2= SECOND GEAR CLUTCH 5= CONVERTER IN
R= REVERSE CLUTCH 3= THIRD GEAR CLUTCH 6= CONVERTER OUT

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6002-16
PRESSURE TEST RESULTS
All or Most Pressures Low and/or Not Enough Power

Flow Test Low Possible causes include:
Possible causes include: 1. Check Electrical Troubleshooting in this Section
1. Oil level not correct. to verify actual gear selected.
2. Oil type and grade not correct. 2. Engine RPM below Stall Test specified RPM.
(Refer to Section 2002 for specifications.)
3. Oil operating temperature high.
A. Check engine and fuel system for problem.
4. Screen for suction tube plugged.
B. Check that torque converter installation is
5. Suction tube or gaskets leak. correct.
6. Main pressure valve, springs, or valve bore. 3. Engine RPM above Stall Test specified RPM.
7. Reduction valve, springs, or valve bore. (Refer to Section 2002 for specifications.)
8. Charge pump seals or gaskets leak. A. Check converter pressures and flow.
9. Charge pump worn. B. Check that torque converter installation is

correct.
10. Oil supply flange not sealing correctly.
Machine Stops or Hesitates While
Some Pressures Low Shifting - Intermittent
Possible causes include:
Possible causes include:
1. Circuit isolation does not correct low pressure.
1. Check orifice and O-ring. (See Section 6007 for
A. Control valve or gasket. replacing.)
B. Channel plate or gasket. 2. Check for foreign material plugging orifices or
sticking valves.
2. Circuit isolation corrects low pressure.
3. Check for reduced pressure at test pressure
A. Clutch shaft or seals.
points.
B. Clutch drum or piston.
4. See Electrical Troubleshooting in this Section for
electrical system problem.

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6002-17
CONVERTER OUT PRESSURE CHECK
Test Equipment Required 2. Apply the parking brakes.
0 to 28 bar (400 psi) gauge with hose long enough to 3. Install the pressure gauge.
take readings in the cab and CAS-2324 Special 4. Heat the oil to an operating temperature of 80 to
Adapter. 100° C (176 to 212° F).
5. While in the cab, put the transmission in
Test Procedure NEUTRAL. Run the engine at full throttle. Record
1. Block the machine tires. the reading in the chart on page 16. Pressure
must be a minimum of 2.5 bar (36 psi).
LUBRICATION PRESSURE CHECK
Test Equipment Required 3. Install the pressure gauge in the cooler return
line at the transmission.
0 to 7 bar (100 psi) gauge.
4. Heat the oil to an operating temperature of 80 to
100° C (176 to 212 ° F).
Test Procedure
5. While in the cab, run the engine at full throttle.
1. Block the machine tires. Put the transmission in each gear and record the
2. Apply the parking brakes. reading in the chart on page 16. Pressure must
be 0.2 to 1.2 bar (3 to 18 psi).
FLOWMETER TEST
Test Equipment Required 3. Heat the oil to an operating temperature of 80 to

100° C (176 to 212° F).
CAS-1808 Flowmeter Kit; CAS-2702 Flowmeter
Adapter. 4. Remove the filter and install the CAS-2702
adapter.
Flowmeter Test Procedure 5. Install the flowmeter between the adapter and
the filter.
1. Block the machine tires.
2. Apply the parking brakes. Put the transmission in NEUTRAL and record the
flow measurement. The correct flow is 52 L/min
(14 U.S. gpm) at 2000 rpm.
CONSUMPTION TEST PROCEDURE

1. Block the machine tires. 6. Repeat the procedure with the transmission in
FORWARD in third gear. The flow must be 9.1
2. Apply the parking brakes.
L/min (2 U.S. gpm).
3. Heat the oil to an operating temperature of 80 to
7. Repeat the procedure with the transmission in
100° C (176 to 212 ° F).
REVERSE in third gear. The flow must be 9.1
4. Install the flowmeter to converter outlet line (line L/min (2 U.S. gpm).
to cooler) in series.
Put the transmission in NEUTRAL and record the
flow measurement. The flow must be 9.1 L/min
(2 U.S. gpm).

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6002-18
TRANSMISSION OVERHEATING
1. Operate machine in normal operating conditions and observe:
A. Verify actual oil temperature at test point. Normal operating temperature can be 56°C (100°F) above the
ambient temperatures.
B. Use a stop watch to establish the exact length of time required to reach the overheating condition.
C. Observe engine temperature, does the engine overheat? Which overheats first - engine or transmission?
2. When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast idle
(1250 to 1450 RPM).
A. Oil temperature returns to Normal - establish length of time.
1. Check oil level, type and grade is correct (See Section 1002).
2. Check operator’s gear selection is correct for conditions.
3. Make sure brakes are fully released.
4. Check the engine full throttle and stall speeds are correct as specified (See Section 2002).
B. Oil temperature remains overheated.
1. Check for dirty radiator - airflow restricted.
2. Check for engine overheating problem.
3. Check for faulty oil temperature gauge and sender or switch (See Section 4002).
3. Perform all the pressure and flow tests.
4. Compare the pressure and flow test results to the specifications in this section to determine if any circuits are
not within specifications.
5. Refer to Pressure Test Results to determine possible cause of any test results not within specifications.

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6002-19
ERROR CODES
In case of possible errors in the system, an amber or red warning appears on the instrument panel, combined with
a recorded error number. See section 4005 for error code retrieval procedures and definitions.
TRANSMISSION SHIFTER LOGIC INFORMATION

Shifter Wire Shifter Tower Shifter Shroud Harness Harness
Function Shifter Trans. ECM #
Color Connector Connector Wire # ped/cab #
power B+ black/red A A 19A_H 43 45
forward V yellow - B 25F 44 43
reverse R pink - C 25R 45 64
neutral N gray - D 25T_B 46 67
gear2(3-4) B2 green B - 25W 48 65
gear1(1-2) B1 blue C - 25Z 49 63
downshift DS purple D - 25Y 50 22
NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within the shifter are limit
switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. In neutral N is high. In first gear,
B1 is high and B2 is low. In second gear, B1 and B2 are low. In third gear, B1 is low and B2 is high. In fourth gear, B1 and B2 are
high. Downshift, DS, is activated when the end of the shifter is engaged.
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES

Transmission ECM Transmission Transmission Transmission Trans/Cab
Clutch # Wire #
Function ECM Pin # Valve Valve Pin # Pin #
A1P1 56 Y1 K4 1 25K 16
A1P2 10 Y2 KR 2 25L 17
A1P3 32 Y3 K1 3 25M 18
A1P4 55 Y4 K3 4 25N 19
A1P5 9 Y5 KV 5 25P 20
A1P6 51 Y6 K2 6 25J 21
VPSI 12,13 all Y all K 7 25S 22
TEMP 39 TEMP none 8 36T 5
TEMP 46 TEMP none 9 36R 12

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6002-20
NOTES

Copyright ©
Section
6003
6003
TRANSMISSION

Copyright ©
6003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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6003-3
SPECIAL TOOLS
CAS2885 TRANSMISSION VALVE

ADJUSTMENT TOOL SET
CAS2807 TRANSMISSION
INPUT/OUTPUT SHAFT SEAL CAS2869 TRANSMISSION
INSTALLATION TOOL OUTPUT SHAFT SEAL
CAS2803 TRANSMISSION INSTALLATION TOOL
TORQUE CONVERTER SEAL (521 AND 621
INSTALLATION TOOL MODELS ONLY)
BS02C093 THRU 096

CAS40075 TRANSMISSION TOOL KIT
CAS2802 ALIGNMENT
CAS2799 CLUTCH PACK DOWEL SET
H0LDER AND SPRING
COMPRESSOR TOOLS
CAS2801 TRANSMISSION
CAS2796 NESTING MOUNTING BRACKETS
PLATE
CAS2868 CLUTCH SPRING

COMPRESSOR
(521 AND 621
CAS2800 CLUTCH CAS2797 LIFTING MODELS ONLY)
ASSEMBLY HOLDING EYEBOLT SET
CAS2798 GEAR KNOB SET
PULLER COLLET SET
BS02C097 THRU 104
CAS40079 TRANSMISSION OVERHAUL KIT
SPECIAL TORQUES
Oil pipes
Studs ............................................................................................................................... 9 Nm (80 pound inches)
Socket head screw ...................................................................................................... 23 Nm (204 pound inches)
Screw plug ......................................................................................................................... 51 Nm (38 pound feet)
Clutch K1, K2, K3, K4 Stud ............................................................................................. 17 Nm (150 pound inches)
Plugs................................................................................................................................. 25 Nm (221 pound inches)
Output shaft
Output shaft screws (apply Loctite 243 to threads) ..................................................... 23 Nm (204 pound inches)
Housing cover screws (apply Loctite 574 to threads).................................................. 46 Nm (407 pound inches)
Output flange screws .................................................................................................. 34 Nm (301 pound inches)
Oil feed housing and transmission pump
Transmission pump screws......................................................................................... 46 Nm (407 pound inches)
Oil feed housing screws .............................................................................................. 25 Nm (221 pound inches)
Engine connection and converter
Input shaft screws ............................................................................................................ 115 Nm (85 pound feet)
Converter housing screws.................................................................................................. 68 Nm (50 pound feet)
Cover............................................................................................................................ 23 Nm (204 pound inches)
Converter cover........................................................................................................... 46 Nm (407 pound inches)
Input flange .................................................................................................................. 34 Nm (301 pound inches)

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6003-4
SPECIAL TORQUES (CONTINUED)

Duct plate
Screws ........................................................................................................................ 25 Nm (221 pound inches)
Screw plug .................................................................................................................. 30 Nm (265 pound inches)
Hydraulic control unit ........................................................................................................ 9.5 Nm (84 pound inches)
Filter
Filter head screws ....................................................................................................... 25 Nm (221 pound inches)
Oil distribution cover screws ....................................................................................... 25 Nm (221 pound inches)
Speed sensor and inductive transmitter
Speed sensor screw.................................................................................................... 23 Nm (204 pound inches)
Inductive transmitter .................................................................................................... 30 Nm (265 pound inches)
Cover plate.................................................................................................................. 23 Nm (204 pound inches)
Screw plug ..................................................................................................................... 140 Nm (103 pound feet)
SPECIFICATIONS
Clutch KV and KR plate clearance ......................................................................... 2.5 to 2.7 mm (0.098 to 0.106 in)
Clutch K1, K2 and K3 plate clearance.................................................................... 2.1 to 2.3 mm (0.083 to 0.090 in)
Clutch K4 plate clearance....................................................................................... 1.2 to 1.4 mm (0.047 to 0.055 in)

Copyright ©
6003-5
DISASSEMBLY
STEP 1 STEP 4
GD98M833 GD98M837
Fasten transmission on an assembly stand using Remove two socket head screws and install
CAS2801 transmission mounting brackets. CAS2885 transmission valve adjustment tool set.
Remove remaining 21 socket head screws securing
STEP 2 control valve. Loosen and remove hex rods (part of
CAS2885) from studs then remove control valve.
STEP 5
GD98M835
Remove and discard oil filter.
STEP 3 GD98M838
Remove both gaskets and the intermediate plate.
STEP 6
GD98M836
Remove hex head screws securing filter head.

Remove filter head from transmission. GD98M839
Remove socket head screws and hex nuts. Remove

duct plate. Remove flat gasket.
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6003-6
STEP 7 STEP 10
GD98M844 GD98M847
Bend lock plate away from hex head screws.
Using proper size rod, press input shaft and
Remove two hex head screws, lock plate, and
converter from cover.
washer. Remove input flange from shaft.
STEP 11
STEP 8
GD98M845 GD98M848
Put alignment marks on converter cover and Remove retaining ring then remove bearing.
housing to aid in assembly. Remove 12 nuts and
hex head screws. STEP 12
STEP 9
GD98M849
Remove four hex head screws and remove

GD98M846
diaphragm and input shaft.
Connect suitable lifting equipment to shaft.
Remove cover, shaft, and converter from
transmission and place in hydraulic press.

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6003-7
STEP 13 STEP 16
GD98M853
GD98M850
Put input shaft and diaphragm in vise as shown. Remove the socket head screws for removal of the
Remove 12 hex head screws to separate transmission pump.
diaphragm and input shaft.
STEP 17
STEP 14
GD98M854
GD98M851 Apply a bearing separator on the splines shoulder of

Remove the inductive transmitter. the stator shaft and pull the pump out of the housing
bores, using two-leg puller.
STEP 15 NOTE: If traces of wear should be encountered in the
pump housing or the cam disk, the complete pump has to
be replaced.
STEP 18
GD98M852
Remove the hex head screws and remove the

converter housing.
GD98M855
Separate the transmission pump from stator.

Separate the cam plate from pump.
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6003-8
STEP 19 STEP 23
Turn the transmission 180 degrees and remove the
rear output flange.
STEP 24
GD98M856
Remove the hex head screws and remove the oil

feed housing. Remove the flat gasket.
STEP 20 GD98M862
Remove the speed sensor and both inductive

transmitters.
STEP 25
GD98M860
Remove the hex head screws, cover, and flat gasket.
STEP 21
GD98M863
Remove the hex nuts and the two covers.
STEP 26
GD98M861
Remove the lock plate, hex head screws, and pry the
converter side output flange from the shaft.
STEP 22 GD98M864
Pry the shaft seal out of the housing bore. Install CAS2802 alignment dowel set.
NOTE: The following steps describe the common removal
of all clutches.
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6003-9
STEP 27 STEP 30
Remove CAS2800 clutch assembly holding knob
set and lift cover free.
STEP 31
BK00D029
Install CAS2800 clutch assembly holding knob set.

With knobs installed on all clutches in housing cover,
install CAS2797 lifting eyebolt set and lifting device
to transmission cover. GD98M867
Remove the socket head screws and remove the

STEP 28 output shaft and both oil baffle plates.
STEP 32
BK00D028
Separate the cover along with clutches from the

transmission housing, using lifting device. GD98M872
STEP 29 Remove clutch K2.
STEP 33
BK00D026
Place clutch disc carriers onto CAS2796 nesting

GD98M873
plate.
Remove clutch K1 while lifting clutch K4.

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6003-10
STEP 34 STEP 37
GD98M877
GD98M874
Remove clutch K3. Remove the bearing outer race and pull output shaft
out of the housing bore.
STEP 35
STEP 38
GD98M875
GD98M878
Remove clutch K4 while lifting input shaft slightly.
Remove the rectangular ring and separate ball
STEP 36 bearing from the shaft.
NOTE: The following steps are for the disassembly of the
clutch KV. The disassembly of the clutch KR is similar.
STEP 39
GD98M876
Remove clutches KV and KR together with input

shaft.
GD98M979
Remove the sealing ring. Pull the tapered roller

bearing from the shaft. Remove the opposite tapered
roller bearing.

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6003-11
STEP 40 STEP 43
GD98M881 BK00D020
Separate the clutch disc carrier from the shaft. Remove snap ring.
STEP 41 STEP 44
GD98M882 BK00D019
Remove the snap ring and remove the clutch disc Remove the compression spring.
pack.
STEP 45
STEP 42
GD98M885
BK00D018 Remove piston from clutch pack holder. Remove and

Preload compression spring using CAS2799 clutch discard the O-rings from piston.
pack holder and spring compressor tool.

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6003-12
STEP 46 STEP 48
GD98M886 GD98M889
Remove the snap ring. Remove the snap ring and remove the ball bearing.
STEP 47 NOTE: The following steps are for disassembly of clutch

K3. Disassembly of clutches K1 and K2 is similar
STEP 49
GD98M887
GD98M890
Remove the rectangular ring. Pull the tapered roller

bearing from the shaft.
STEP 50
GD98M888
Press the idler gear from the shaft using a bearing

separator. Remove released needle bearing.
GD98M892
Remove the thrust washer, thrust bearing, and thrust

washer.

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6003-13
STEP 51 STEP 54
GD98M893 BK00D018
Remove the idler gear. Preload compression spring using CAS2799 clutch
STEP 52
STEP 55
GD98M894
Remove the needle bearings and thrust bearing. BKOOD020
Remove the snap ring.

STEP 53
STEP 56
GD98M895
Remove the snap ring and remove the clutch disc BK00D019
pack. Remove the compression spring.

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6003-14
STEP 57 STEP 59
BS00G001 GD98M800
Remove the sealing ring. Remove bearing using Remove and discard two sealing rings. Pull two
bearing puller. Tap assembly until piston drops out of bearings from shaft using bearing puller. Remove the
the clutch pack carrier. Then, remove and discard snap ring and separate the clutch disc carrier from
O-rings from piston. the shaft.
STEP 58 STEP 60
BK00D022 GD98M801
Remove the clutch disc carrier from the shaft. Remove the snap ring and remove the clutch disc
pack.
NOTE: The following steps are for the disassembly of the
clutch K4.
STEP 61
BK00D018
Preload compression spring using CAS2799 clutch


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6003-15
STEP 62 NOTE: The following two steps are for disassembly of the
input shaft.
NOTE: A snap ring is used to lock turbine shaft in input
shaft. Snap ring will be destroyed when turbine shaft is
pressed from input shaft.
STEP 64
BK00D020
Remove the snap ring.
STEP 63
GD98M803
If turbine shaft is to be removed from input shaft, use

proper size diameter sleeve or rod and press turbine
shaft out of input shaft.
STEP 65
Remove bearings from input shaft using a bearing
puller.
BK00D019
Remove the compression spring.

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6003-16
ASSEMBLY
NOTE: The following steps are for the reassembly of the STEP 69
oil pipes.
STEP 66
3 GD98M607
Install a new O-ring on plug. Tighten the plug to a

torque of 51 Nm (38 pound feet).
1
STEP 70
GD98M603
Install suction tube (1), pressure pipes (2), and

lubrication pressure pipe (3) in housing.
STEP 67
Secure suction tube (1) and pressure pipes (2) with
socket head screw and hex nuts. Tighten to a torque
of 23 Nm (204 pound inches)
STEP 68
GD98M608
Install all bearing outer races in housing bores.
STEP 71
GD98M605
Tilt the cover 180 degrees. Install the suction tubes

and pressure pipes into the housing bores using a
rolling tool.
NOTE: Pipe end of the pressure pipes must be slightly GD98M609
below the housing plane face.
Install both oil pipes into the housing cover. Tilt the
cover 180 degrees and install pipes into the housing
bores using a rolling tool.
NOTE: The pipe end must be slightly below the housing
plane face.
Copyright ©
6003-17
STEP 72 STEP 75
GD98M610 BK00D019
Install the studs. Tighten the studs to a torque of 9

Nm (80 pound inches).
NOTE: The following steps are for the assembly of
clutches KV and KR, starting with assembly of the clutch
disc carrier.
STEP 73
BK00D018
Install compression spring and two spring cups in

clutch disc carrier. Preload compression spring
using CAS2799 clutch pack holder and spring
compressor tool.
STEP 76
GD98M612
Check that drain hole is clear and free of foreign

matter. Install both O-rings in recesses of the piston
and apply oil.
STEP 74
BK00D020
Install the snap ring.

NOTE: The following steps are for the KV and KR clutch
disc packs. The disc stacking of clutches KV and KR is
identical.
GD98M613
Install piston in clutch disc carrier.

Copyright ©
6003-18
STEP 77 STEP 79
GD98M617
225B Install end shim and snap ring.

1. PLATE CARRIER
2. PISTON STEP 80
3. OUTER PLATE - ONE-SIDED COATED
4. INNER PLATES
5. OUTER PLATES - COATED ON BOTH SIDES
6. SNAP RING
7. END SHIM
A RUNNING CLEARANCE 2.5 TO 2.7 MM (0.098 TO 0.106
IN)
Install clutch disc plates in KV and KR clutch disc

carriers in position and sequence shown above.
Install outer plates (3) with steel faced side facing
piston and end shim (7). Install two inner plates (4)
on the end shim side.
NOTE: Snap rings of different thickness are available for
GD98M618
adjustment of the running clearance. To ensure correct
adjustment, do not apply oil to clutch discs until after Adjust running clearance to 2.5 to 2.7 mm (0.098 to
adjustment is completed. 0.106 in). Press down on the end shim with
approximately 10 kg (20 lb). Measure and record
STEP 78 dimension (A) from carrier face to end shim using
depth gauge as shown.
Example
Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in)
GD98M616
Install the clutch disc pack.

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6003-19
STEP 81 STEP 84
GD98M619 GD98M621
Use tools to lift the end shim against snap ring Apply Loctite 243 to stud. Tighten stud to a torque of
(upward) until contact is obtained. Measure and 17 Nm (150 pound inches).
record dimension (B) from carrier face to end shim
using depth gauge as shown. Subtract this STEP 85
measurement from the measurement of Step 80. The
difference is the running clearance.
Example
Dimension A . . . . . . . . . . . . . . . . . 7.25 mm (0.29 in)
Dimension B . . . . . . . . . . . . . . . . . 4.75 mm (0.19 in)
Difference = Running. . . . . . . . . . . 2.50 mm (0.10 in)
Clearance
Required running clearance is 2.5 to 2.7 mm (0.098
to 0.106 in). Use snap ring(s) of different thickness
as necessary to obtain correct running clearance.
STEP 82
GD98M622
Remove clutch disc pack, apply oil to discs, and
install clutch disc pack, end shim, and snap ring as Install ball bearing until contact is obtained. Secure
determined in Step 81. using snap ring.
STEP 83 STEP 86
GD98M623
GD98M620
Install idler gear to align and engage all inner discs, Install needle bearing.
then remove idler gear.

Copyright ©
6003-20
STEP 87 STEP 90
GD98M624 BP00G020
Support the idler gear on the bearing inner race. Install gear and shaft into heated bore.
Press the idler gear against the shoulder.
STEP 91
STEP 88
BK00D024
GD98M625 Heat bearing.

Secure idler gear using snap ring.
STEP 92
STEP 89
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A
BK00D023
Use heat gun to heat assembled clutch disc carrier

inner bore.
BK00D025
Install heated bearing on shaft against shaft

shoulder.

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6003-21
STEP 93 STEP 96
Check operation of the clutch using compressed air.
NOTE: The following steps are for assembly of clutch K1,
K2, and K3.
STEP 94
GD98M632

matter. Install both O-rings in recesses of piston and
apply oil.
STEP 97
GD98M630
Press bearing against shoulder of shaft. Apply

Loctite 243 to the stud and install the stud. Tighten
the stud to a torque of 17 Nm (150 pound inches).
STEP 95
GD98M633
Install piston in clutch disc carrier.
STEP 98
GD98M631
Install the clutch disc carrier until contact is obtained.
GD98M634
Install the compression spring and spring cup.

Copyright ©
6003-22
STEP 99 STEP 101
BK00D019
232A
1. PLATE CARRIER
2. PISTON
4. INNER PLATES
6. SNAP RING
7. END SHIM
A. RUNNING CLEARANCE 2.1 TO 2.3 MM (0.083 TO 0.090
IN)
Install clutch disc plates in K1, K2, and K3 clutch disc

carriers in position and sequence shown above.
BK00D018 Install outer plate (3) with steel faced side facing
Install compression spring and two spring cups in piston. Install two outer and inner plates each on the
clutch disc carrier. Preload compression spring end shim side.
using CAS2799 clutch pack holder and spring NOTE: Snap rings of different thickness are available for
compressor tool. adjustment of the running clearance. To ensure correct
adjustment, do not apply oil to clutch discs until after
STEP 100 adjustment is completed.
STEP 102
BK00D020
Install the snap ring.

GD98M636
NOTE: The following steps are for K1, K2 and K3
clutches. The assembly of clutches K1, K2, and K3 is Install the clutch disc pack.
identical.

Copyright ©
6003-23
STEP 103 STEP 105
GD98M637 GD98M639
Install the end shim and snap ring. Use tools to lift the end shim against snap ring
(upward) until contact is obtained. Measure and
STEP 104 record dimension (B) from carrier face to end shim
using depth gauge as shown. Subtract this
measurement from the measurement of Step 104.
The difference is the running clearance.
Example
Dimension A . . . . . . . . . . . . . . . . . . .8.2 mm (0.32 in)
Dimension B . . . . . . . . . . . . . . . . . . .6.1 mm (0.24 in)
Difference = Running Clearance . . .2.1 mm (0.08 in)
STEP 106
GD98M638
Remove clutch disc pack, apply oil to discs, and
Adjust running clearance for K1, K2 and K3 to 2.1 to install clutch disc pack, end shim, and snap ring as
2.3 mm (0.083 to 0.090 in). Press down on the end determined in Step 105.
shim with approximately 10 kg (20 lb). Measure and
record dimension (A) from carrier face to end shim STEP 107
using depth gauge as shown.
Example
3
Dimension A . . . . . . . . . . . . . . . . . . 8.2 mm (0.32 in)
2
1
GD98M640
Install the thrust washer (1), thrust bearing (2), and

thrust washer (3).
NOTE: Install the thrust washer (1) with the chamfer
facing the thrust bearing.

Copyright ©
6003-24
STEP 108 STEP 111
GD98M641 BK00D024
Install both needle bearings. Heat bearing.
STEP 109 STEP 112

SM121A
GD98M642
Install idler gear until all inner discs are engaged.
STEP 110
BK00D025
1 Place heated bearing on the shaft.
2 STEP 113
3
GD98M643
Install the thrust washer (3), thrust bearing (2), and

thrust washer (1). Install the thrust washer (1) with
the chamfer facing the thrust bearing.
NOTE: Ensure the thrust washer (1) is overlapping with
the chaff collar to accommodate all the inner discs.

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6003-25
NOTE: The following steps are for assembly of clutch K4. STEP 116
STEP 114
SM121A
GD98M649
Apply Loctite 243 to the stud and install the stud.

Tighten the stud to a torque of 17 Nm (150 pound
inches).
STEP 117
GD98M647
Heat the gear to about 120° C (248° F) and install

until seated in position.
STEP 115
GD98M650

matter. Install both O-rings in recesses of the piston
and apply oil.
GD98M648 STEP 118

Install retaining ring to secure gear.
GD98M651
Install piston in clutch disc carrier. Be sure piston

bottoms out.

Copyright ©
6003-26
STEP 119 STEP 121
BK00D019 BS02C131
1. PLATE CARRIER
2. PISTON
4. INNER PLATES
6. SNAP RING
7. END SHIM
A. RUNNING CLEARANCE 1.2 TO 1.4 MM (0.047 TO 0.055
IN)
Install clutch disc plates in K4 clutch disc carrier in

position and sequence shown above. Install outer
plate (3) with steel faced side facing piston.
NOTE: Snap rings of different thickness are available for
BK00D018 adjustment of the running clearance. To ensure correct
Install compression spring and two spring cups in adjustment, do not apply oil to clutch discs until after
clutch disc carrier. Preload compression spring adjustment is completed.
using CAS2799 clutch pack holder and spring
compressor tool. STEP 122
STEP 120
GD98M653
Install clutch disc pack.

BK00D020
Install snap ring.

NOTE: The following steps are for installing the clutch
disc pack in clutch K4.

Copyright ©
6003-27
STEP 123 STEP 125
GD98M654 GD98M656
Install end shim and snap ring. Use tools to lift the end shim against snap ring
(upward) until contact is obtained. Measure and
STEP 124 record dimension (B) from carrier face to end shim
using depth gauge as shown. Subtract this
measurement from the measurement of Step 124.
The difference is the running clearance.
Example
Dimension A . . . . . . . . . . . . . . . . . . .7.2 mm (0.28 in)
Dimension B . . . . . . . . . . . . . . . . . . .6.0 mm (0.24 in)
Difference = Running . . . . . . . . . . . .1.2 mm (0.04 in)
Clearance
GD98M655 STEP 126
Adjust running clearance to 1.2 to 1.4 mm (0.047 to Remove clutch disc pack, apply oil to discs, and
0 . 0 5 5 i n ) . P r e ss d o w n o n t h e e n d s h i m w i t h install clutch disc pack, end shim, and snap ring as
approximately 10 kg (20 lb). Measure and record determined in Step 125.
dimension (A) from carrier face to end shim using
depth gauge as shown. STEP 127
Example
Dimension A . . . . . . . . . . . . . . . . . . 7.2 mm (0.28 in)
GD98M657
Install the idler gear until all inner discs are engaged,
then remove idler gear.

Copyright ©
6003-28
STEP 128 STEP 131
GD98M658 GD98M661
Assemble two thrust washers and thrust bearing. Assemble thrust washer (3), thrust bearing (2), and
thrust washer (1). Install the thrust washer (1) with
NOTE: Upper and lower thrust washers are the same
the chamfer facing the thrust bearing.
thickness.
STEP 132
STEP 129
GD98M662
GD98M659
Install the assembled clutch disc carrier until all the
Install both needle bearings.
inner discs are engaged.
STEP 130 STEP 133
GD98M660
GD98M663
Install the idler gear.
Install snap ring to secure clutch disc carrier.

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6003-29
STEP 134 STEP 138
SM121A
BK00D024
Heat bearing.
STEP 135
WARNING: Always wear heat protective GD98M666
gloves to prevent burning your hand when Heat gear to about 120° C (248° F) and install on
handling heated parts. input shaft until contact is obtained.
SM121A
STEP 139
BK00D025
Install heated bearing on the shaft shoulder. GD98M667
Secure gear with snap ring.

STEP 136
Repeat Steps 134 and 135 to install bearing on STEP 140
opposite end of shaft.
STEP 137
NOTE: The following steps are for the reassembly of the
input shaft.
GD98M668
Install snap ring into recess of turbine shaft.

Copyright ©
6003-30
STEP 141 STEP 144
GD98M669 GD98M672
Install the turbine shaft until the snap ring snaps into Install output shaft into housing bore until contact is
the recess of the input shaft. made.
STEP 142 NOTE: The following steps are for the installation of the
output shaft and clutches. All clutches have a common
WARNING: Always wear heat protective installation.
handling heated parts. STEP 145
SM121A
K1 K4
AN KR
AB
K3 K2
KV
GD98M673
BK00D024 Install bearing outer races into housing cover until

Heat bearings and install on turbine shaft until contact is obtained.
bearings are against shoulder.
STEP 146
STEP 143
BK00F003
GD98M671 Install the clutches onto CAS2796 nesting plate.

Install bearing then install rectangular ring.

Copyright ©
6003-31
STEP 147 STEP 150
BK00D029 GD98M681
Using CAS2797 lifting eye bolt set and acceptable Install the sealing rings and insert rings in their
liftin g equipm ent, in stall hou sing co ve r onto respective grooves. Apply grease to the sealing rings
clutches. Install CAS2800 clutch assembly holding and align the rings centrally.
knob set to secure clutch shafts to cover.
STEP 151
STEP 148
KR
KV
K4
K2
K1 K3
GD98M692
GD98M679 Install both the O-rings into the annular groove of the
The above photo shows the position of the single oil pipes and apply grease.
clutches in the housing cover.
STEP 152
STEP 149
Tilt the housing cover 180 degrees.
AN
KV KR
K2 K4
K3 K1
AB
GD98M866
The above shows the position of the single clutches

and the input and output clutches.

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6003-32
STEP 153 STEP 156
BK00D028 GD98M686
Install output gear and shaft in transmission housing. Install screen sheet on output shaft. Press front and
Install alignment screws. Carefully lower the cover rear bearings on output shaft until contact with
and clutches into the gear box housing. shoulder of output shaft is made.
STEP 154 STEP 157

Remove CAS2800 clutch assembly holding knob set.
STEP 155
GD98M688
Install the screening plate.
GD98M685 STEP 158

Separate the housing cover from the gearbox, using
a lifting device.
NOTE: The following steps are for the reassembly of the
output shaft.
GD98M689
Install the output shaft.

Copyright ©
6003-33
STEP 159 STEP 162
GD98M690 GD98M697
Apply Loctite 243 to the socket head screws and Heat the output flange to about 90° C (194° F). Apply
install the screws. Tighten the screws to a torque of Loctite 574 to the contact area and assemble the
23 Nm (204 pound inches). flange with the washers and hex head screws.
Tighten the screws to a torque of 34 Nm (301 pound
STEP 160 inches). Bend corner of lock plate over hex head
screws.
STEP 163
Repeat Steps 161 and 162 to install shaft seal and
output flange on converter side.
NOTE: The following steps are for the assembly of the oil
feed housing and transmission pump.
STEP 164
GD98M691
Install rectangular rings in grooves of clutch shafts.

Apply grease to rings and align rings.
STEP 161
GD98M702
Install two alignment studs and install the gasket.
GD98M696
Position shaft seal with sealing lip facing oil chamber.

Apply grease to sealing lip. Use CAS2869
transmission output shaft seal installation tool to
install seal.

Copyright ©
6003-34
STEP 165 STEP 168
GD98M703 GD98M706
Install the oil feed housing with washers and hex Install transmission pump.
head screws. Screw the hex head screws in only
until contact is obtained, do not tighten. STEP 169
STEP 166
GD98M707
Apply grease to new O-rings. Install the O-rings on

GD98M704 the socket head screws.
Install the two alignment screws and install the stator
shaft. STEP 170
STEP 167
GD98M708
Secure the transmission pump with the socket head

GD98M705 screws. Tighten screws to a torque of 46 Nm (407
Apply oil and install the O-ring. pound inches).

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6003-35
STEP 171 STEP 173
GD98M709 GD98M712
Install the oil feed housing with the hex head screws Position converter housing. Secure with hex head
and flat washers. Tighten the screws to a torque of screws. Tighten the screws to a torque of 68 Nm (50
25 Nm (221 pound inches). pound feet).
STEP 172 STEP 174
GD98M711 GD98M713
Position the gasket and cover. Secure the cover with Put input shaft in a vise as shown. Positio n
the hex head screws. Tighten the screws to a torque diaphragm on input shaft and secure using 12 hex
of 23 Nm (204 pound inches). head screws. Tighten screws to a torque of 115 Nm
(85 pound feet).
NOTE: The following steps are for the assembly of the
engine connection and converter. STEP 175
GD98M714
Position diaphragm and input shaft on converter.

Apply Loctite 262 to threads of hex head screws.
Install screws and tighten to a torque of 115 Nm (85
pound feet).
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6003-36
STEP 176 STEP 178
GD98M715 GD98M718
Position converter cover on converter housing. Make

sure alignment marks made during removal of cover
are aligned. Install input flange, two hex head
screws, lock plate, and washer. Pull cover against
housing by tightening two hex head bolts evenly.
STEP 179
GD98M716
Position converter. Check and ensure that impulse

disk of converter is centered on the bore for the
inductive transmitter.
STEP 177
GD98M719
Secure converter cover using 12 hex head screws

and nuts. Tighten screws to a torque of 46 Nm (407
pound inches).
GD98M717
Position converter cover as shown. Install bearing

against shoulder in cover. Secure using retaining
ring.

Copyright ©
6003-37
STEP 180 NOTE: The following steps are for installation of
transmission control valve.
STEP 183
GD98M720
Tighten input flange hex head screws to a torque of

34 Nm (301 pound inches). Lock screws by bending
258
corners of lock plate over screws.
Install CAS2885 transmission valve adjustment tool
STEP 181 set. Be sure hex rods (part of tool set) are not
installed on studs. Mount the gasket (1), intermediate
plate (2), and gasket (3).
STEP 184
Install the screw plug with new O-ring. Tighten the
plug to a torque of 30 Nm (265 pound inches).
STEP 185
GD98M724
Install new sealing rings and both plugs in duct plate.
STEP 182
GD98M727
Install control valve on duct plate and CAS2885

studs. Install hex rods on studs and tighten against
control valve. Install 21 socket head screws. Tighten
screws to a torque of 9.5 Nm (84 pound inches).
Remove CAS2885 transmission valve adjustment
tool set. Install remaining two socket head screws.
Tighten screws to a torque of 9.5 Nm (84 pound
inches).
GD98M725
NOTE: The following steps are for the installation of the
Install the gasket and place the duct plate against filter.
shoulder. Install socket head screws and hex nuts.
Tighten to a torque of 25 Nm (221 pound inches).

Copyright ©
6003-38
STEP 186 STEP 189
GD98M729 GD98M735
Install new O-rings in recesses of oil filter head. Apply grease to the new O-ring and install the speed
Position filter head on transmission and secure using sensor with the socket head screw. Tighten the
two socket head screws. Tighten screws to a torque screw to a torque of 23 Nm (204 pound inches).
of 25 Nm (221 pound inches).
STEP 190
STEP 187
GD98M736
GD98M730 With new O-rings, install the inductive transmitters.

Install a new transmission filter. Tighten to a torque of 30 Nm (265 pound inches).
STEP 188 STEP 191

Install the breather.
STEP 192
GD98M733
Install new O-rings in oil distribution covers. Install GD98M737

the two oil distribution covers on the housing with hex
Install the gasket and the cover plate. Tighten to a
nuts and flat washers. Tighten to a torque of 25 Nm
torque of 23 Nm (204 pound inches). With a new
(221 pound inches).
O-ring, install the screw plug. Tighten to a torque of
140 Nm (103 pound feet).
Copyright ©
Section
6004
6004
FRONT AXLE

Copyright ©
6004-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WHEEL END AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REPLACing HUB SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Drive Pinion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Brake Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Brake Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Drive Pinion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Drive Pinion Bearing Rolling Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Setting Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Contact Pattern Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Copyright ©
6004-3
SPECIFICATIONS
Lubricant Capacity............................................................................................................ 22 liters (23.2 U.S. Quarts)
Brake Wear Measurement..................................................................................................... 4.0 mm Max (0.16 inch)
Sun Gear Shaft End Play ............................................................................................................1.00 mm (0.04 inch)
Drive Pinion Rolling Torque................................................................................... 1.1 to 2.3 Nm (9.7 to 20.4 lb-inch)
SPECIAL TORQUES
Bolts Securing Brake Housing to Axle Housing...................................................................390 Nm (288 pound feet)
Wheel End Retainer Bolts ...................................................................................................500 Nm (369 pound feet)
Nut Securing Input Flange (Apply Loctite 262 to Threads)..................................................700 Nm (516 pound feet)
Bolts Securing Differential Housing to Axle Housing...........................................................390 Nm (288 pound feet)
Bolts Securing Differential Cover and Ring Gear ................................................................410 Nm (302 pound feet)
Nut for Securing Brake Tube to Axle Housing.......................................................................100 Nm (74 pound feet)
Brake Tube to Axle Housing Fitting .......................................................................................100 Nm (74 pound feet)
Brake Tube Axle Housing Fitting .............................................................................................36 Nm (27 pound feet)
Breather Plug...........................................................................................................................50 Nm (37 pound feet)
Oil Drain Plugs (Outputs).........................................................................................................50 Nm (37 pound feet)
Oil Fill Plug / Dipstick...............................................................................................................50 Nm (37 pound feet)
Brake Lining Check Plug .........................................................................................................50 Nm (37 pound feet)
Brake Bleeder Valve.................................................................................................................6 Nm (4.4 pound feet)
Brake Return Spring Retainer Bolts ........................................................................................34 Nm (25 pound feet)

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6004-4
GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased
BS01D011 BS01D009
COAST SIDE (CONCAVE)
BS01D013
BS01D012
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)

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6004-5
Pinion Distance Must Be Decreased
BS01D016
BS01D010 DRIVE SIDE (CONVEX)
BS01D015

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6004-6
LUBRICATION
6
4
3
5
5
4
6
2
1
BC06G003
1. OIL DRAIN HOLE (AXLE HOUSING) 3. OIL FILL PLUG & DIPSTICK 5. BREATHER
2. OIL DRAIN HOLE (OUTPUTS) 4. BRAKE BLEEDER 6. BRAKE INLET
NOTE: Rear axle shown. Refer to section 1002 of this service manual for proper lubricant.
WEAR MEASUREMENT ON MULTI-DISC BRAKE
BD07N211-01 BS00M071
NOTE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement should also be
made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking function is impaired.
Wear measurement must be made on both wheel end sides.
Remove plug, actuate brake and determine dimension (A) using a thickness gauge. If dimension (A) is less than or
equal to 4.0 mm (0.16 inch) the lined discs on both output sides must be replaced. Replace O-ring when installing
the plug. Tighten plug to a torque of 50 Nm (40 pound feet).

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6004-7
WHEEL END AND BRAKE
Disassembly STEP 3
NOTE: Tools and axle shown in the following
photographs may appear slightly different than the tools
and axle you may have. The use of the tools and
disassembly/assembly of axle is the same regardless of
appearance.
STEP 1
BD06G004-01
Use lifting bracket, to hold wheel end. Loosen and

remove the bolts and washers.
STEP 4
2
BD08A277-01
Fasten axle on a stand. 1
STEP 2
BD07N013-01
Carefully pull the wheel end from the axle housing.

Remove and discard O-ring (1) from axle housing
wheel end and O-ring from brake port (2).
STEP 5
BD06G002-01
BD06G005-01
Mount the wheel end on a stand.

BD06G003-01
Remove drain plugs and drain oil from axle housing.

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6004-8
STEP 6 STEP 9
BD07N113-01 BD07N110-01
Remove sun gear from the planetary gears. Do not Remove the end shim from the brake housing.
loose the shim (s) located in the sun gear shaft.
STEP 10
STEP 7
BD07N109-01
BD07N112-01 Remove plate from brake housing.

Remove snap ring on all three planetary gears.
STEP 11
STEP 8
BD07N108-01
BD07N045-01 Remove brake disk from brake housing.

Use an acceptable tool and remove planetary gear
and bearing, repeat procedure for the other two
gears.

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6004-9
STEP 12 STEP 15
BD07N107-01
Remove brake plate from brake housing. BD07N093-01
Remove the four bolts holding the wheel end to the

STEP 13 output shaft of the carrier.
Repeat Steps 11, and 12 to remove the remaining
brake plates, and friction plates. STEP 16
STEP 14
BD07N090-01
Remove the retainer from the wheel end.

BD07N097-01
STEP 17
BD07N094-01
Pry the cover off from the output shaft. Remove and
BD07N089-01
discard O-ring from cover.
Attach an acceptable lifting device to the wheel end
and remove the wheel end of axle from the brake
housing.

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6004-10
STEP 18 STEP 20
BD07N087-01 BD07N047-01
Attach an acceptable lifting device to the brake Inspect the carrier output shaft bearing. If damaged
housing and remove from the carrier. score with a die grinder and remove bearing cage.
Then score bearing with die grinder and break with a
STEP 19 hammer and chisel.
STEP 21
BD07N046-01
BD07N035-01
Remove the face seal ring metal ring from the wheel
end shaft using a pry bar.
BD06G015-01
Inspect the stop pin (plug) for wear. If necessary drill

a hole into the pin, use acceptable tool and remove
the pin.

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6004-11
STEP 22 STEP 25
BD07N052-01
BD06G022
Inspect bearing on wheel end shaft. If damaged Remove return spring from the brake housing.
score with a die grinder and remove bearing cage.
Then score bearing with die grinder and break with a STEP 26
hammer and chisel.
STEP 23
BD07N055-01
Remove shim from the brake housing.
STEP 27
BD07N049-01
Remove six bolts from the return spring retainer.
STEP 24
BD07N056-01
Pry brake piston from the brake housing alternate

sides in order to raise piston evenly.
BD07N054-01
Remove return spring retainer.

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6004-12
STEP 28 STEP 31
BD07N059-01 BD07N063-01
Remove brake piston from brake housing. Remove upper seal from break housing.
STEP 29 STEP 32
BD07N065-01
BD07N067-01
Remove wear ring from brake housing. Remove lower seal, located in the same groove as
lower back-up ring from the brake housing.
STEP 30
STEP 33
BD07N064-01
BD07N066-01
Remove upper back-up ring, located in same groove
as upper seal from the brake housing. Remove lower back-up ring from the brake housing.

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6004-13
STEP 34 Cleaning and Inspection
IMPORTANT: Do not use compressed air to dry bearings.
Allow bearings to air dry.
STEP 37
Clean all parts except friction plates in brake disc
pack using cleaning solvent. WEAR FACE
PROTECTION WHEN USING COMPRESSED AIR.
Use compressed air to clear passages in planetary
ring gear and brake housing.
STEP 38
Inspect bearing rollers for pitting, scoring,
BD07N079-01
deformation, or other damage. Check inner face and
Drive out the outer bearing cup on the brake housing. bearing cage for deformation, dents, and other
damage. Ch eck associated bearing cups for
STEP 35 scratches, grooves, or cracks. Check bearings for
rough spots or binding by holding bearing and
rotating. If bearing binds or action is not smooth,
replace the bearing.
STEP 39
Inspect bearing cups for pitting, scoring, cracks, or
other damage. Replace if any of these conditions are
seen.
NOTE: If a bearing or bearing cup requires replacement,
the associated part must also be replaced.
STEP 40
BD07N080-01
Check planetary ring gear, planetary gears, and
Flip brake housing over and pry out face seal. planetary carrier gear teeth for cracks, breaks,
chipping, or other damage. Replace the part if any of
STEP 36 these conditions are seen. Check planetary carrier
shaft splines for broken, cracked, or twisted
condition. Replace if necessary.
STEP 41
Check wheel end shaft for cracked, broken, or
twisted splines. Replace if any of these conditions
are seen.
BD07N081-01
Drive out inner bearing from the brake housing.

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6004-14
Assembly STEP 44
appearance.
STEP 42
SM121A
BD07N038-01
Apply Loctite 574 to the seal ring mounting surface.
STEP 45
SM121A
BD07N040-01
Heat the wheel end shaft outer bearing to 120° C

(248° F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearing on the wheel
end shaft until the bearing is against the shoulder on
the wheel end shaft.
STEP 43
BD07N039-01
Heat the seal ring to approximately 120° C (248° F),

place the face seal ring on the wheel end shaft.
BD07N037-01
Clean mounting surface of seal ring area on wheel

end.

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6004-15
STEP 46 STEP 48
WARNING: Always wear gloves to prevent
frostbite to your hands when handling frozen
parts.
SM118A
BD06G084-01
Use acceptable tool to drive seal ring into position on

hub.
NOTE: Be sure the sealing ring is fully seated.
BD07N082-01
STEP 47 Place outer bearing cup in dry ice for several hours to
freeze. Install the outer bearing cup into the brake
WARNING: Always wear gloves to prevent housing until seated against the shoulder in the
frostbite to your hands when handling frozen brake housing.
parts.
SM118A
BD07N083-01
Place inner bearing cup in dry ice for several hours to

freeze. Install the inner bearing cup into the brake
housing until seated against the shoulder in the
brake housing.

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6004-16
STEP 49 STEP 51
BD06G032-01 BD07N070-01
Install the lower back-up ring (1) into the brake

A A housing.
A 1 STEP 52
BS00M073
1. FACE SEAL
2. BRAKE HOUSING
A FILL WITH GREASE BD07N072-01
Wet the outer diameter of the face seal with a Install the lower seal (2) in the same groove as the
solution of 50% water and 50% mineral spirits. Use lower back-up ring (1). Make sure seal is installed as
suitable tool to install the face seal with the seal lip shown in Step 56.
positioned as shown. Apply grease to seal as
indicated by (A) above. STEP 53
STEP 50
BD07N074-01
Install the upper seal (4) into the brake housing.

BD07N069-01 Make sure seal is installed as shown in Step 56.
Clean seal grooves in brake housing with solvent.

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6004-17
STEP 54 STEP 56
BD07N075-01
2
Install upper back-up ring (5) into the same groove
as the upper seal. 1
STEP 55 BC08A246
WEAR RING, BACK-UP RINGS AND SEAL LOCATION
1. LOWER BACK-UP RING 4. UPPER SEAL

2. LOWER SEAL 5. UPPER BACK-UP RING
3. BRAKE HOUSING 6. WEAR RING
NOTE: Install the back-up rings and seals in the grooves
of the brake housing as shown in the illustration above.
STEP 57
BD07N077-01
Clean the groove of the brake housing with cleaning

solvent. Install wear ring (6) into the top groove of the
brake housing.
IMPORTANT: Ensure correct installation position of wear
ring end points must be in the 12 o’clock position in the
axle when installed in the machine in the area of brake oil
supply and vent hole.
NOTE: Make sure that the wear ring is installed correctly BD07N086-01
in the groove around the entire circumference of the brake Drive the adjustment pins flush with the surface of
housing. Then apply Loctite 415 at its end points. the brake piston.
NOTE: Orientation of brake piston when driving in pins.

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6004-18
STEP 58 STEP 60
BD00M283
BD07N061-01 Install return spring in the brake housing. Install with
the tapered end facing upward.
STEP 61
BD07N062-01
Apply oil on the sliding surface of the brake piston,

Carefully install piston in the brake housing.
BD07N054-01
STEP 59 Install the return spring retainer into the brake
housing.
STEP 62
BD07N057-01
Install shim into the brake housing.
BD00M285
Install the six bolts into the return spring retainer and
tighten to 34 Nm (25.1 pound feet).

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6004-19
STEP 63 STEP 65
SM121A
BD08A441-01
Coat the spline of the carrier output shaft with Loctite

767 antiseize lubricant.
STEP 66
BD07N048-01
Heat the carrier output shaft to 120° C (248° F) in a

bearing oven. Wearing heat resistant gloves or
mittens, install the bearing on the shaft until the
bearing is against the carrier gear.
STEP 64
BD07N087-01
Attach an acceptable lifting device to the brake

housing and insert the brake housing on to the
carrier output shaft.
STEP 67
BD06G053-01
Install a new stop pin if it was removed, damaged or

worn.
BD07N089-01
Attach an acceptable lifting device to the wheel end

and install the wheel end on to the brake housing. A
slight rotation of the wheel end maybe necessary to
align the splines on the carrier output shaft.

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6004-20
STEP 68 STEP 70
BD07N095-01
BD07N090-01
Install the retainer into the wheel end on the output

shaft of the carrier.
STEP 69
BD07N096-01
Install a new O-ring on the cover and use a mallet

and install the cover into the wheel end.
BD07N092-01
Install the four new bolts holding the wheel end to the
output shaft of the carrier. Tighten the bolts to a
torque of 500 Nm (368.8 pound feet). Rotate brake
housing several times in both directions and recheck
torque.
IMPORTANT: Do not reuse locking bolts, just one time
installation is permitted.

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6004-21
6
5
2 4
3
2
1
8
BS08A216
BRAKE DISC ASSEMBLY LAYOUT
1. END SHIM 3. BRAKE PLATE (THICK) 5. RETURN SPRING 7. BOLT (QUANTITY 6)

2. PLATE (2.0 MM) 4. SPRING RETAINER 6. SHIM 8. BRAKE DISK
STEP 71 STEP 72
BD07N107-01 BD07N108-01
Install 2.0 mm plate (2) into the brake housing. Install brake disk (8) into the brake housing.

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6004-22
STEP 73 STEP 75
BD07N109-01
BD07N110-01
Install end shim (1) on top of the 2.0 mm plate (2).
STEP 76
SM121A
BD07N108-01
Install a brake plate (3) and brake disk (8) into brake
housing alternately as shown on page 21 until all the
brake discs (8) are installed.
STEP 74
BD08B032-01
Heat the sun gears to 120° C (248° F) in a bearing

oven. Wearing heat resistant gloves or mittens,
install the sun gears on the shaft until the bearing is
against the carrier gear.
BD07N107-01
Install last 2.0 mm plate (2) into the brake housing.

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6004-23
STEP 77 Sun Gear Shaft End Play Adjustment
appearance.
STEP 78
BD07N112-01
2
Install the snap rings on planetary gear shafts with
snap ring pliers.
BD07N013-01
Install a new O-ring onto the axle housing (2) and a
new O-ring in brake port (1) in axle housing.
STEP 79
BD08B036-01
Take a measurement from the straight edge to the
face of the brake housing, the difference between
this measurement and the next measurement will be
dimension A.
Mount the sun gear into the planet gears. Then,
determine dimension A, from the inner face of the
sun gear to the face of the brake housing.
Example:
Dimension A . . . . . . . . . . . . . 97.90 mm (3.85 inch)
STEP 80
Install the stub shaft in the spline of the axle bevel
gear. Make sure the stub shaft is installed all the way
into the axle bevel gear.

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6004-24
STEP 81 STEP 84
BD08B033-01 BD08B035-01
Install the sun gear onto the stub shaft with out the Install the sun gear shaft into the stub shaft with the
shims. determined shim set. (size as determined in Step 83)
into the sun gear shaft with grease.
STEP 82
STEP 85
BD08B034-01 BD06G072-01
Determine dimension B from the face of the sun gear Use lifting bracket, and install the assembled wheel
to the mounting face of the axle housing. end onto the axle housing.
Example: NOTE: Turn the input flange to align splines of the stub
Dimension B . . . . . . . . . . . . 100.20 mm (3.95 inch) shaft into the sun gear.
STEP 83 STEP 86
Subtract dimension A from dimension B. Then
subtract 1.30 mm (0.05 inch) from the difference. The
difference is the required shim size.
Example:
Dimension B 100.20 mm (3.94 inch)
Dimension A − 97.90 mm (3.85 inch)
Difference 2.30 mm (0.09 inch)
Required end play − 1.30 mm (0.05 inch)
Difference = shim
1.00 mm (0.04 inch)
size
BD02D154-01
Install the washers and bolts to secure the wheel end

to the axle housing. Tighten the bolts to a torque of
390 Nm (287.7 pound feet).
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6004-25
STEP 87
BD07N212-01
Remove dip stick from axle housing. Refill the axle

with 22 Liters (23.2 quarts) of Transaxle fluid (SAE
80W-140).
STEP 88
BD07N213-01
Insert dip stick back into the axle but do not screw in
set it off on the edge fill hole, oil level should be
between upper and lower level on the dip stick.
Install plug into axle housing and torque plug to

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6004-26
BRAKE HYDRAULICS LEAKAGE TEST

IMPORTANT: DO NOT EXCEED 100 BAR (1450 PSI) High Pressure Test
PRESSURE IN THE FOLLOWING STEPS. If the maximum
pressure of 100 bar (1450 psi) is exceeded, the piston will
STEP 91
move too much changing the gripping rings adjustment. If
the gripping rings adjustment changes, the wheel end must Operate the hand pump to increase pressure to 100
be removed and disassembled and the gripping rings bar (1450 psi) maximum. Close connection to hand
adjusted to the correct dimension. pump using the shutoff valve. During a 5 minute
period, pressure shall not drop more than 3% or
3 bar (43.5 psi).
STEP 89
Low Pressure Test
STEP 92
Reduce pressure to 5 bar (72.5 psi) and close the
shutoff valve. During a 5 minute period there should
be no pressure drop.
BD00M305
Connect a hand pump with pressure gauge to the

brake port as shown above. Fill the hand pump with
hydraulic oil.
STEP 90
BD07N208-01
Build up pressure in the axle internal brake lines then

bleed air from the lines. After air is bled, actuate the
brakes a minimum of 5 times to a pressure of 100 bar
(1450 psi) by operating the hand pump.

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6004-27
REPLACING HUB SEAL
Removal STEP 95
appearance.
STEP 93
BD07N094-01
Remove and discard the O-ring.
STEP 96
BD06G074-01
Remove drain plug and drain oil from the brake

housing.
STEP 94
BD07N093-01
Remove the four bolts from the carrier output shaft.
STEP 97
BD07N097-01
Use pry bar and remove the end cover.
BD07N090-01
Remove the retainer from the wheel end.

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6004-28
appearance.
STEP 101
BD06G078-01
Use lifting bracket, to hold wheel end. Separate the

output shaft using a puller.
STEP 99
BD06G081-01
A A
A 1
BD06G079-01
Use a pry bar and remove the seal from the brake
housing.
STEP 100
BS00M073
1. FACE SEAL 2. BRAKE HOUSING A. GREASE

Wet the outer diameter of the face seal with a
solution of 50% water and 50% mineral spirits. Use
appropriate tool to install the face seal with the seal
lip positioned as shown. Apply grease to seal as
indicated by (A) above.
BD07N035-01
Inspect the metal face seal ring for damage or wear

marks where the seal makes contact, if required
remove the bushing.

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6004-29
STEP 102 STEP 105
BD07N037-01 BD06G084-01
Clean the seal ring mounting surface with solvent. Use suitable tool and drive the metal face seal ring
into position onto the hub.
STEP 103 NOTE: Be sure the sealing ring is properly seated.
STEP 106
BD06G082
BD06G086-01
STEP 104 Grease the seal lip of the shaft seal, use lifting
bracket, and install the wheel end onto the brake
WARNING: Always wear heat protective housing.
SM121A
BD07N090-01
Install the retainer on the wheel end.
BD07N039-01
Heat the meal face seal ring to 120° C (248° F),
place the face seal ring onto the wheel end shaft.

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6004-30
STEP 108 STEP 111
BD07N092-01 BD07N212-01
Install the four bolts and tighten to a torque of Remove the dip stick from the axle housing. Refill the
500 Nm (369 pound feet). Rotate brake housing axle with 22 Liters (23.2 quarts) of the proper
several times in both directions and recheck torque. Transaxle fluid (SAE 80W-140).
STEP 109 STEP 112
BD07N095-01
BD07N213-01
Install a new O-ring on the wheel end cover.
Insert dip stick back into the axle but do not screw in
set it off on the edge fill hole, oil level should be
STEP 110 between upper and lower level on the dip stick.
Install plug into axle housing and torque plug to
BD02D053-01
Install the wheel end cover into the wheel end.

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6004-31
DIFFERENTIAL
Removal STEP 114

appearance.
STEP 113
BD06G126-01
Fasten the axle to a stand, support the center of the

axle as shown, facing the input shaft attach suitable
lifting equipment to the left axle housing, remove the
mounting bolts and axle half.
ATTENTION: Differential can fall out of housing when
axle half is removed.
BD06G002-01
STEP 115
BD06G003-01
Remove drain plugs and drain oil from axle. BD06G127-01
Connect lifting bracket to the differential and remove

the differential from axle housing.
NOTE: Make sure that the right axle stub shaft releases
from the differential.

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6004-32
Disassembly STEP 119

STEP 116
BD07N162-01
BD01F075-01
Remove the ring gear from the differential housing.
If required, remove the bearing from the housing
cover using appropriate tools. STEP 120
STEP 117
BD07N159-01
BD07N165-01
Place the differential in a press to prevent it from

turning. Remove the bolts.
STEP 118
BD07N148-01
Remove the outer set of clutch plates, thrust washer,

and bevel gear from the differential housing.
BD07N163-01
Remove the housing cover from the differential

housing.

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6004-33
STEP 121 STEP 123
BD07N145-01 BD07N136-01
Remove the differential shaft from the differential

Drive both roll pins out of the differential housing and
housing.
remove pins.
STEP 124
STEP 122
BD07N131-01
BD07N140-01
Remove the two bevel gears and thrust washers
from the differential housing.
BD07N139-01
NOTE: Remove the two differential half shafts, bevel

gears and thrust washers from the differential housing.

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6004-34
STEP 125 STEP 127
BD07N129-01 BD06G131-01
Pull the bearing cups and shims from both axle

housings.
NOTE: Make sure to identify the shims into which axle
housing they were removed.
BD07N114-01
Remove the inner set of clutch plates, thrust washer,

STEP 126
BD07N104-01
If required, remove bearing from differential housing

using a bearing puller and a press.

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6004-35
8
6 7
5
3
2
1
10
11
12
3
14
11
15
8
16
13
2 10
4
9
BS08A334
DIFFERENTIAL ASSEMBLY EXPLODED VIEW
1. INNER BEVEL GEAR AXLE 5. DIFFERENTIAL 9. THRUST WASHER 13. OUTER BEVEL GEAR
2. THRUST WASHER (COPPER COLOR) 6. ROLL PIN 10. SPIDER GEAR 14. RING GEAR
3. REACTION PLATES 7. ROLL PIN 11. HALF SHAFT 15. COVER DIFFERENTIAL
4. FRICTION PLATES 8. BEARING 12. SHAFT 16. BOLT

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6004-36
Assembly STEP 131

appearance.
STEP 128
BD07N119-01
Install one friction plate on the inner bevel gear.
STEP 132
BD07N105-01
Install bearing on differential housing using a press.
STEP 129
Check reaction plates, friction plates and thrust
washers for damage or wear, replace if necessary.
NOTE: Be sure to apply oil to all parts before assembly.
STEP 130 BD07N120-01
STEP 133
BD07N118-01
Install the thrust washer (copper color) on the inner

bevel gear.
NOTE: Clutch plates must be installed on the inner bevel BD07N122-01
gear in the correct order, refer to illustration on Install two reaction plates on the inner bevel gear.
page 35.

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6004-37
STEP 134 STEP 137
BD07N124-01 BD07N127-01
Install two friction plates on the inner bevel gear. Install one reaction plate on the inner bevel gear.
STEP 138
STEP 135
BD07N128-01
BD07N125-01
Align all tabs of reaction plates on the inner bevel
Install one reaction plate on the inner bevel gear. gear.
STEP 136
BD07N126-01

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6004-38
STEP 139 STEP 141
BD07N129-01 BD07N136-01
BD07N130-01 BD07N137-01
Install the clutch pack and inner bevel gear assembly Install the full differential shaft into the housing
into the differential housing. through both thrust washers and spider gears
installed in the previous step. Make sure position of
hole in center of differential shaft is horizontal to the
STEP 140
differential housing.
1 STEP 142
2 1
BD07N131-01
1. THRUST WASHER 2. SPIDER GEAR

Install a thrust washer (1) and spider gear (2) into the BD07N139-01
differential housing. Install another thrust washer (1) 1. THRUST WASHER 2. SPIDER GEAR
and spider gear (2) directly across from the first.
Make sure to install in the correct location for the full Install a thrust washer (1) and spider gear (2) into the
differential shaft. differential housing. Install another thrust washer (1)
and spider gear (2) directly across.
NOTE: The torsional stop (tab) on the thrust washer must
be positioned upwards see image above.

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6004-39
STEP 143 STEP 145
BD07N140-01 BD07N142-01
Install new roll pins into differential housing.

2 NOTE: Use new roll pins only.
STEP 146
BD07N138-01
Install both differential half shafts into housing

through thrust washers and spider gears installed in
previous step. The tapered end of half shafts (1)
insert into the hole in center of differential shaft.
BD07N144-01
Make sure the holes on the other end of the half
shafts (2) align with the holes in the differential Drive the new roll pins into differential housing to
housing (3). secure half shafts.
STEP 144 STEP 147
BD07N149-01
BD07N138-01
Spider gear assembly installed in differential Install the thrust washer (copper color) on the outer
housing. bevel gear.
NOTE: Clutch plates must be installed on the outer bevel
gear in the correct order, refer to illustration on page 35.

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6004-40
STEP 148 STEP 151
BD07N150-01 BD07N155-01
Install one reaction plate on the outer bevel gear. Install two friction plates on the outer bevel gear.
STEP 149 STEP 152
BD07N151-01 BD07N156-01
Install one friction plate on the outer bevel gear. Install one reaction plate on the outer bevel gear.
STEP 150
BD07N153-01
Install two reaction plates on the outer bevel gear.

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6004-41
STEP 153 STEP 156
BD07N156-01 BD07N160-01
Install one friction plate on the outer bevel gear. Clean ring gear mounting surface on differential
housing.
STEP 154
STEP 157
BD07N158-01
Align all tabs of reaction plates on the outer bevel BD07N161-01
gear. Clean mating surfaces of ring gear and differential

cover.
STEP 155 NOTE: The ring gear and the drive pinion are a matched
gear set and cannot be serviced separately.
STEP 158
BD07N159-01
Install the clutch pack and outer bevel gear assembly

into the differential housing.
BD07N162-01
Install ring gear on differential housing.

NOTE: Make sure to align bolt holes when installing ring
gear and differential cover.
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6004-42
STEP 159 Drive Pinion Removal
NOTE: Ring and drive pinion are matched set and can not
be serviced separately.
STEP 162
BD07N163-01
NOTE: Install cover on differential housing.
STEP 160
BD07N168-01
Heat locknut securing flange with a hot air blower to

loosen Loctite, approximately 120° C (248° F)
STEP 163
BD07N166-01

turning. Install new bolts and tighten to a torque of
NOTE: Use new locking bolts do not reuse old bolts.
STEP 161 BD07N169-01
If bearing was removed from differential cover install Use suitable tool to hold input flange. Hold flange
bearing using a press. using holding tool and remove lock nut and washer.
Remove holding tool from flange.

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6004-43
STEP 164 STEP 167
BD07N181-01
BD07N173-01 Drive inner bearing cup from the differential housing.
Remove the input flange from the drive pinion and
seal. STEP 168
STEP 165
BD06G141-01
Remove inner bearing cup and shim from differential

housing.
BD07N174-01
Press the input pinion out of the housing. STEP 169
STEP 166
BD07N175-01
Remove the spacer ring from the drive pinion.

BD07N183-01
Drive outer bearing cup from the differential housing.

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6004-44
STEP 170 Brake Tube Removal
STEP 171
BD06G167
Remove inner bearing from the drive pinion using a

suitable tool and a press. BD07N030-01
Remove the plug with the breather installed from the

axle housing on the differential end.
STEP 172
BD07N001-01
Remove fitting from the brake tube on the axle

housing on the differential end of the axle.

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6004-45
STEP 173 STEP 174
BD07N004-01 BD07N008-01
BD07N006-01 BD07N010-01
Loosen and remove the nut holding the brake tube to Loosen the brake tube at wheel end of axle housing
the axle housing on the differential end of the axle. then remove the brake tube from the axle housing.
STEP 175
BD07N015-01
Remove the fitting on the wheel end of the axle

housing.
NOTE: Repeat steps 171 through 174 for the other side of
the axle.

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6004-46
Brake Tube Installation
6 1
5 4 3 2
BS08B043
1. HEXAGON NUT 100 NM (73.8 LB.-FT.) 3. BRAKE TUBE 5. SCREW NUT 100 NM (73.8 LB.-FT.)
2. O-RING 4. AXLE HOUSING 6. SCREW CONNECTOR 36 NM (26.6 LB.-FT.)
STEP 176 STEP 177
BD07N017-01 BD07N018-01
Install a new O-rig on the fitting removed from the Install the connector in the axle and tighten to a
wheel end of the axle. torque of 36 Nm (26.6 pound feet).

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6004-47
STEP 178 STEP 180
BD00M343-01 BD07N006-01
Install a new O-ring in the groove of the brake tube

fitting.
STEP 179
BD07N005-01
Install the nut to secure the brake tube. Tighten the

nut to a torque of 100 Nm (73.8 pound feet).
BD07N010-01 STEP 181

Install the brake tube in axle housing.
BD07N009-01
Connect opposite end of brake tube to connector
installed in wheel end. Tighten brake tube nut to 100
Nm (73.8 pound feet).
IMPORTANT: Use the two wrench tightening method to
prevent the connector in axle from turning.
NOTE: Do steps 176 through 181 for the other wheel end.

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6004-48
STEP 182 STEP 183
1
2
3
BD00M347-01 BD07N003-01
BREATHER VENT EXPLODED VIEW Install the plug in axle housing. Tighten plug to a
torque of 50 Nm (36.9 pound feet). Tighten breather
1. O-RING 2. PLUG 3. BREATHER
valve to standard torque specification.
Remove and discard O-ring (1) from plug (2) and
install a new O-ring. Install breather (3) in plug. Drive Pinion Installation
STEP 184
BD06G137-01
Find and record the housing dimension “X” located

inside the differential housing where the pinion shaft
is located.
Dimension X (Example).......205.30 (8.08 inch)

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6004-49
STEP 185 STEP 187
Calculation example A:
36.13 mm
Dimension I
-------(1.422 inch)
+ 167.95 mm
Dimension II
-------(6.612 inch)
= 204.08 mm
Results in dimension Y
------(8.034 inch)
Calculation example B:
205.30 mm
Dimension X
-------(8.080 inch)
− 204.08 mm
Dimension Y
BD06G138-01 -------(8.034 inch)
Measure the thickness of the inner bearing and Difference = shim = 1.22 mm
record its measurement, dimension “I”. thickness ------(0.046 inch)
Dimension I (Example)..... 36.13 mm (1.422 inch)
NOTE: Deduct the thickness of the gauge blocks being Shims are available in 0.10 mm (0.004 inch), round up or
used to support the bearing from the overall measurement. down to the next available shim thickness, s = 1.20 (0.044
IE: overall measurement 106.13 mm (4.178 inch) inch).
minus gauge block thickness 70 mm (2.756 inch) will equal
dimension I. STEP 188
STEP 186
1
1
3
2 BD06G140-01
NOTE: Heat the bearing hole to approximately 120°

BD06G139-01 C (248° F) and install the outer bearing cup until
1. MATING NUMBER (MARKED MANUALLY) contact is made using an acceptable tool.
2. PINION BASIC DIMENSION (STAMPED)
3. PINION DISTANCE DEVIATION + OR - (MARKED
MANUALLY)
Distance deviation is indicated in 1/100 mm. If no

distance deviation is indicated the pinion basic
dimension is identical with the pinion dimension.
Record this as dimension “II”.
Dimension II (Example) 168 -0.05 mm = 167.95 mm
.........................(6.614 inch -0.002 inch = 6.612 inch)

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6004-50
STEP 189 STEP 190
WARNING: Always wear heat protective WARNING: Always wear heat protective
gloves to prevent burning your hand when gloves to prevent burning your hand when
handling heated parts. handling heated parts.
SM121A SM121A
BD06G141-01 BD07N178-01
Heat the pinion inner bearing to 120° C (248° F) in a

bearing oven. Wearing heat resistance gloves or
mittens, install the bearing on the pinion shaft until
contact.
After installing bearing on pinion shaft, allow the bearing to
cool to ambient temperature.
Drive Pinion Bearing Rolling

Torque Adjustment
STEP 191
BD06G142-01
Heat the inner bearing hole on the differential

housing to approximately 120° C (248° F). Install the
shim set determined in Step 187 in the bearing bore
and press the bearing cup into to the bearing hole
using a suitable tool.
BD07N175-01
Install a 9.03 mm (0.35 inch) thick spacer on the

pinion shaft.

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6004-51
STEP 192 STEP 194
SM121A
BD06G147-01
Install the input flange on the pinion shaft.
STEP 195
BD07N186-01
Heat the pinion shaft outer bearing to 120° C

(248° F) in a bearing oven. Wearing heat resistance
gloves or mittens, install the bearing on the pinion
shaft until contact.
Prior to mounting the input flange and tightening the nut,
allow the bearing to cool to ambient temperature.
STEP 193
BD07N171-01
BD06G146-01
Press the dust shield on the input flange.
BD07N170-01
Install the washer and nut on the pinion shaft.

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6004-52
STEP 196 STEP 197
BD07N169-01 BD07N204-01
Use a suitable tool to hold input flange. Hold flange Check the rolling torque of the drive pinion bearing.
using holding tool and tighten nut to a torque of 700 The rolling torque should be 1.1 to 2.3 Nm (9.7 to
Nm (515 pound feet). Remove holding wrench. 20.4 pound-inch). If rolling torque is too low, install a
thinner spacer (Step 191); if rolling torque is too high,
When tightening rotate the pinion shaft in both directions install a thicker spacer (Step 191).
several times.
STEP 198
Remove the nut and input yoke from the drive pinion
shaft.

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6004-53
Setting Backlash and Bearing Preload

Deviation Value -20 -10 0 +10 +20
1.20 mm 1.10 mm 1.00 mm 0.90 mm 0.80
Shim A
(0.047 inch) (0.043 inch) (0.039 inch) (0.035 inch (0.032 inch)
0.80 mm 0.90 mm 1.00 mm 1.10 1.20
Shim B
(0.032 inch) (0.035 inch) (0.039 inch) (0.043 inch) (0.047 inch)
STEP 199 STEP 200
1 2
A B
BD06G163-01
Record the deviation value from side of ring gear, the

value will be a + or -, use the table to determine shim
thicknesses needed.
Example: Deviation value of +10 requires the
following shims: 5 3
Shim A = 0.90 mm (0.035 inch) 4
BC06G004
Shim B = 1.10 mm (0.043 inch)
1. DIFFERENTIAL 5. AXLE HOUSING
2. DRIVE HOUSING A. RING GEAR SIDE
3. AXLE HOUSING B. CARRIER SIDE
4. INPUT PINION
STEP 201
BD06G164-01
Insert shim A- 0.90 mm (0.354 inch) and install the

bearing outer ring with a suitable tool until seated in
axle housing.

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6004-54
STEP 202 STEP 205
BD06G165-01
Insert shim B- 1.10 mm (0.043 inch) and install the BD07N202-01

bearing outer ring with a suitable tool until seated in Position the axle housing on the drive housing, install
axle housing. 4 bolts, top center, bottom center, front center, rear
center, torque bolts evenly to 390 Nm (285 pound
Contact Pattern Check feet).
STEP 203 STEP 206
BD06G166-01 BD06G169-01
Apply marking ink on several teeth of the ring gear. Roll the input pinion several times in both directions
over the ring gear. Remove the differential and
STEP 204 compare the contact pattern with examples on page
4 and page 5.
If the tooth contact pattern differs, the wrong shim size was
selected in Step 187. Remove differential and repeat Steps
184 though 187.
BD07N199-01
Position the differential assembly in the axle drive

housing.

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6004-55
STEP 207
BD06G171-01
Loosen and remove the nut and input flange.

BD07N199-01
Position the differential assembly in the axle drive STEP 210

housing.
STEP 208
BD06G172
Install the shaft seal with the sealing lip towards oil
sump using appropriate tool.
BD06G170-01 NOTE: Wet the outer diameter of the seal with a solution
Install a new O-ring on the axle housing. Position the of 50% water and 50% mineral spirits. Fill the space
axle housing on the drive housing. between the sealing and dust lip with grease.
BDO7N207-01
Install bolts and torque bolts evenly to 290 Nm

(215 pound feet).

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6004-56
STEP 211 STEP 213
BD06G173-01 BD07N213-01
Install the input flange. Using a suitable holding tool, Insert dip stick back into the axle but do not screw in
on input flange. Apply Loctite No. 262, on the threads set it off on the edge fill hole, oil level should be
of the locknut. Install the washer and locknut by between upper and lower level on the dip stick.
hand. Hold flange using holding tool and tighten nut Install plug into axle housing and torque plug to
to a torque of 700 Nm (516 pound feet). 50 Nm (36.9 pound feet).
NOTE: Rotate the input pinion several times in both
directions when tightening.
STEP 212
BD07N212-01
Remove the dip stick from the axle housing. Refill the
axle with 22 Liters (23.2 quarts) of Transaxle fluid
(SAE 80W-140).

Copyright ©
Section
6004
6004
REAR AXLE

Copyright ©
6004-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WHEEL END AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REPLACE HUB SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Drive Pinion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Brake Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Brake Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Pivot Pin Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Pivot Pin Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Drive Pinion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Drive Pinion Bearing Rolling Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Setting Backlash and Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Contact Pattern Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Copyright ©
6004-3
SPECIFICATIONS
Lubricant Capacity...........................................................................................................22 Liters (23.2 U.S. Quarts)
Brake Wear Measurement.............................................................................................................4.0 mm (0.16 inch)
Sun Gear Shaft End Play ....................................................................................0.5 to 2.00 mm (0.02 to 0.079 inch)
Drive Pinion Rolling Torque......................................................................... 1.1 to 2.3 Nm (9.75 to 20 pound inches)
SPECIAL TORQUES
Bolts Securing Brake Housing to Axle Housing...................................................................390 Nm (288 pound feet)
Wheel End Retainer Bolts ...................................................................................................500 Nm (369 pound feet)
Nut Securing Input Flange (Apply Loctite 262 to Threads)..................................................700 Nm (516 pound feet)
Bolts Securing Differential Housing to Axle Housing...........................................................390 Nm (288 pound feet)
Bolts Securing Differential Cover and Ring Gear ................................................................410 Nm (302 pound feet)
Nut for Securing Brake Tube to Axle Housing.......................................................................100 Nm (74 pound feet)
Brake Tube to Axle Housing Fitting .......................................................................................100 Nm (74 pound feet)
Brake Tube Axle Housing Fitting .............................................................................................36 Nm (27 pound feet)
Oil Drain Plugs (Outputs).........................................................................................................50 Nm (37 pound feet)
Oil Fill Plug/Dipstick.................................................................................................................50 Nm (37 pound feet)
Brake Lining Check Plug .........................................................................................................50 Nm (37 pound feet)
Brake Bleeder...........................................................................................................................6 Nm (4.4 pound feet)
Brake Return Spring Retainer Bolts ........................................................................................34 Nm (25 pound feet)

Copyright ©
6004-4
GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased
BS01D011 BS01D009
BS01D013
BS01D012
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)

Copyright ©
6004-5
Pinion Distance Must Be Decreased
BS01D016
BS01D010 DRIVE SIDE (CONVEX)
BS01D015

Copyright ©
6004-6
LUBRICATION
6
4
3
5
5
4
6 7
2
1
BC06G003
1. OIL DRAIN HOLE (AXLE HOUSING) 4. BRAKE BLEEDER 7. OIL FILL PLUG
2. OIL DRAIN HOLE (OUTPUTS) 5. BREATHER
3. OIL FILL PLUG & DIPSTICK 6. BRAKE LINING CHECK PLUG
NOTE: Refer to section 1002 of this service manual for proper lubricant.
WEAR MEASUREMENT ON MULTI-DISC BRAKE
BD07N211-01 BS08B041
NOTE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement should also be
made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking function is impaired.
Wear measurement must be made on both wheel end sides.
Remove plug, actuate brake and determine dimension (X) using a thickness gauge. If dimension (X) is less than or
equal to 4.0 mm (0.16 inch) the lined discs on both output sides must be replaced. Replace O-ring when installing
the plug. Tighten plug to a torque of 50 Nm (37 pound feet).

Copyright ©
6004-7
WHEEL END AND BRAKE
Disassembly STEP 3
appearance.
STEP 1
BD06G004-01
Using acceptable lifting equipment to hold wheel

end. Loosen and remove the bolts and washers.
STEP 4
BD06G001-01
Fasten axle on a stand.
STEP 2
BD06G072
Carefully pull the wheel end from the axle housing.

NOTE: Pay attention for shim(s) that are placed between
the sun gear and stub shaft. Mark location of shim(s) to aid
in assembly.
STEP 5
BD06G002-01
BD07N013-01
BD06G003-01 Remove and discard the O-ring from the brake port
Remove drain plugs and drain oil from axle housing. (1) and axle housing (2).
Copyright ©
6004-8
STEP 6 STEP 9
BD06G005-01 BD07N045-01
Mount the wheel end on a stand or suitable work Using a suitable puller remove the three planetary
bench. gears.
STEP 7 STEP 10
BD07N113-01 BD07N110-01
Remove the shim(s) from the sun gear shaft. Remove the steel end shim from brake housing.
Pull the sun gear shaft out of the planetary gears and
remove.
NOTE: Mark location of shim(s) to aid in assembly.
STEP 8
BD07N112-01
Using snap ring pliers remove the retaining rings

from the three planetary gears.

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6004-9
STEP 11 STEP 13
BD07N094-01
BD07N107-01 Remove and discard O-ring.
STEP 14
BD07N108-01
Remove the reaction and friction brake plates BD07N093-01
alternately until all brake plates have been removed. Remove the wheel end retainer bolts.
STEP 12 STEP 15
BD07N090-01
BD07N097-01
Remove the wheel end retainer.
Remover cover from wheel end.

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6004-10
STEP 16 STEP 18
BD07N089-01 BD07N046-01
Use acceptable lifting equipment and lift the wheel

end from the brake housing.
STEP 17
BD06G015-01
Inspect the stop pin for wear, if necessary drill a hole

into the pin, use CAS10846-3 adapter and OEM4252
BD00M251
striker and remove the pin.
Use acceptable lifting equipment and lift the brake
housing from the planetary carrier. STEP 19
BD07N047-01
Inspect wheel bearing, if bearing needs replaced cut

bearing cage with a die-grinder and remove cage.
Score the bearing surface with a die-grinder and
break bearing from planetary carrier using a hammer
and chisel.

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6004-11
STEP 20 STEP 23
BD07N049-01 BD07N056-01
Loosen and remove the six bolts that secure the Carefully pry brake piston up, alternate sides in order
return spring retainer to the brake housing. to raise piston evenly.
STEP 21 STEP 24
BD07N051-01 BD07N059-01
Remove the retainer and return spring from the brake Once brake piston is free remove from housing.
housing.
STEP 25
STEP 22
BD07N067-01
BD07N055-01 Remove and discard the wear ring from top groove in
Remove the shim from the brake housing. brake housing.

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6004-12
STEP 26 STEP 29
BD07N064-01 BD07N066-01
Remove and discard the upper back up ring from the Remove and discard the lower back up ring from the
brake housing. brake housing.
STEP 27 STEP 30
BD07N063-01 BD07N079-01
Remove and discard the upper piston seal from the Inspect outer bearing cup, if worn or damaged drive
brake housing. outer bearing cup from brake housing and discard.
STEP 28 STEP 31
BD07N065-01
BD07N081-01
Remove and discard the lower piston seal from the Inspect inner bearing cup, if worn or damaged drive
brake housing. inner bearing cup from brake housing and discard.

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6004-13
STEP 32 STEP 34
BD07N080-01 BD07N036-01
Remove and discard the face seal from brake Remove the metal face seal ring and discard.
housing.
STEP 35
STEP 33
BD07N033-01
BD07N035-01
Inspect wheel end bearing, if bearing needs replaced
Inspect the metal face seal ring, if worn or damaged cut bearing cage with a die-grinder and remove cage.
loosen from wheel end shaft using a pry bar. Score the bearing surface with a die-grinder and
break bearing from wheel end shaft using a hammer
and chisel.

Copyright ©
6004-14
Cleaning and Inspection Assembly

IMPORTANT: Do not use compressed air to dry bearings. NOTE: Tools and axle shown in the following
Allow bearings to air dry. photographs may appear slightly different than the tools
STEP 36 disassembly/assembly of axle is the same regardless of
Clean all parts except friction plates in brake disc appearance.
pack using cleaning solvent. WEAR FACE
PROTECTION WHEN USING COMPRESSED AIR. STEP 41
Use compressed air to clear passages in planetary
ring gear and brake housing.
STEP 37 SM121A
Inspect bearing rollers for pitting, scoring,
deformation, or other damage. Check inner face and
bearing cage for deformation, dents, and other
dam age . Ch eck a ssociated be aring cup s for
scratches, grooves, or cracks. Check bearings for
rough spots or binding by holding bearing and
rotating. If bearing binds or action is not smooth,
replace the bearing.
STEP 38
Inspect bearing cups for pitting, scoring, cracks, or
other damage. Replace if any of these conditions are
seen.
BD07N040-01
NOTE: If a bearing or bearing cup requires replacement,
Heat the wheel end shaft outer bearing to 120° C
the associated part must also be replaced.
(248° F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearing on the wheel
STEP 39 end shaft until the bearing is against the shoulder on
Check planetary ring gear, planetary gears, and the wheel end shaft.
planetary carrier gear teeth for cracks, breaks,
chipping, or other damage. Replace the part if any of STEP 42
these conditions are seen. Check planetary carrier
shaft splines for broken, cracked, or twisted
condition. Replace if necessary.
STEP 40
Check wheel end shaft for cracked, broken, or
twisted splines. Replace if any of these conditions
are seen.
BD07N037-01
Clean the seal ring mounting surface with solvent.

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6004-15
STEP 43 STEP 45
BD07N038-01 BD06G084-01
Apply Loctite 574 to the seal ring mounting surface. Use special tool CAS2860 and drive the sealing ring
NOTE: Only use the special tool to install the sealing ring
STEP 44
to ensure proper seating.
gloves to prevent burning your hand when STEP 46
SM121A
parts.
SM118A
BD07N039-01
Heat the metal face seal ring to approximately 120°

C (248° F), place the face seal ring on the wheel end
BD07N083-01
shaft.
Freeze new inner bearing cup in dry ice for several
hours. Install bearing cup in brake housing.

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6004-16
STEP 47 STEP 49
parts.
SM118A
BD07N069-01
Clean the seal grooves of the brake housing with

solvent.
BD07N082-01
STEP 50
Freeze new outer bearing cup in dry ice for several
hours. Install bearing cup in brake housing.
STEP 48
BD07N070-01
BD06G032-01
6
A A 5 7
A 1
4
2 3
2
1
BC08A246
BS00M073 WEAR RING, BACK-UP RINGS AND PISTON SEAL LOCATION
1. FACE SEAL 2. BRAKE HOUSING A GREASE 1. LOWER BACK-UP RING 5. UPPER BACK-UP RING
Wet the outer diameter of the face seal with a 2. LOWER PISTON SEAL 6. WEAR RING
solution of 50% water and 50% mineral spirits. Use a 3. BRAKE HOUSING 7. BRAKE PISTON
4. UPPER PISTON SEAL
suitable seal installer to install the face seal with the
seal lip positioned as shown. Apply grease to seal as Install the lower back-up ring (1) in the brake
indicated by (A) above. housing.
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6004-17
STEP 51 STEP 54
BD07N077-01
BD07N072-01
Install the lower piston seal (2) in the brake housing, Install the wear ring (6) in the top groove of the brake
make sure the groove in the seal is facing upwards. housing. End points of the wear ring must be
installed in the 12 o’clock (top) position of the brake
STEP 52 housing. Make sure the wear ring is installed
completely in its groove in the brake housing.
NOTE: Apply Loctite 415 to the end points of the wear
ring.
STEP 55
BD07N074-01
Install the upper piston seal (4) in the brake housing,

make sure the groove in the seal is facing
downwards.
STEP 53 BD07N086-01
Set the slack adjuster pins on the brake piston by

driving them in until they are flush with the pin mount.
BD07N075-01
Install the upper back up ring (5) in the brake

housing.

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6004-18
STEP 56 STEP 59
BD07N061-01 BD07N052-01
Apply oil on the sliding surface of the piston, back-up Install the brake return spring, make sure that the
rings, seals and wear ring. Carefully install piston in tapered end of the spring is facing up.
the brake housing.
STEP 60
STEP 57
BD07N054-01
BD07N062-01 Install the brake spring retainer.

Using a plastic mallet fully seat the brake piston.
Strike piston on alternate sides to seat piston evenly. STEP 61
STEP 58
BD07N057-01 BD07N050-01
Apply oil to both sides of return spring shim and Install the six retainer bolts and tighten to a torque of
install in brake housing. 34 Nm (25 pound feet).

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6004-19
STEP 62 STEP 64
BD00M251
BD06G053-01
Use acceptable lifting equipment and lower the brake
If stop pin was removed, drive a new stop pin into the housing onto the planetary carrier.
planetary carrier until contact.
STEP 65
STEP 63 Coat the splines of the planetary carrier shaft with
WARNING: Always wear heat protective Loctite No. 767 antiseize lubricant.
SM121A
BD07N089-01
BD07N046-01 Using acceptable lifting equipment lower the wheel

If inner wheel bearing was removed, heat the wheel end onto the brake housing. A slight rotation of the
bearing to 120° C (248° F) in a bearing oven. wheel end may be necessary in order align the
Wearing heat resistant gloves or mittens, install the splines of the carrier shaft with the splines in the
bearing on the planetary carrier until the bearing is wheel end.
against the shoulder on the carrier shaft.

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6004-20
STEP 67 STEP 69
BD07N095-01
BD07N090-01 Install a new O-ring on the wheel end cover.
Install the wheel end retainer.
STEP 70
STEP 68
BD07N096-01
BD07N092-01 Install the cover on the wheel end.

Install new bolts, evenly tighten the four bolts in a
cross pattern to a torque of 500 Nm (369 pound feet).
While tightening bolts rotate the brake housing
several time in both directions.
NOTE: Use only new bolts.

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6004-21
6 7
2 5
2
1
BS08A216
BRAKE PLATE AND RETURN SPRING PARTS LOCATION
1. END SHIM 5. RETURN SPRING RETAINER

2. THIN REACTION PLATE (2.0 MM) 6. RETURN SPRING
3. THICK REACTION PLATE 7. SHIM
4. FRICTION BRAKE DISC 8. RETAINER BOLT (6)
STEP 71 STEP 72
BD07N108-01
BD07N107-01 Install a friction brake disc into the brake housing.

Install a thin (2.0 MM) reaction brake plate into the
brake housing.
NOTE: Refer to Illustration above for correct brake plate
installation.

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6004-22
STEP 73 STEP 75
BD07N107-01 BD07N110-01
Install the end shim into the brake housing.
STEP 76
SM121A
BD07N108-01
Install a thick reaction brake plate and then another

friction brake disc. Repeat this step until all thick
reaction plates and friction brake discs have been
installed.
STEP 74
BD08B032-01
Heat the three planetary gears to 120° C (248° F) in a

bearing oven. Wearing heat resistant gloves or
mittens, install the planetary gears on the planetary
carrier.
BD07N107-01
Install a thin (2 mm) reaction plate.

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6004-23
STEP 77 STEP 79
BD07N112-01 BD08B036-01
Install the three planetary gear retaining rings with Take a measurement from the straight edge to the
snap ring pliers. face of the brake housing, the difference between
this measurement and the next measurement will be
dimension A.
Sun Gear Shaft End Play Adjustment Measure from the stop pin to the face of the brake
housing.
STEP 78 Example:
Dimension A . . . . . . . . . . . . . 21.25 mm (0.84 inch)
3 4
STEP 80
Install the stub shaft in the spline of the axle bevel
gear. Make sure the stub shaft is installed all the way
into the axle bevel gear.
STEP 81
1 2 5 6 7
BS08B042
1. PLANETARY CARRIER 5. SUN GEAR SHAFT

2. STOP PIN 6. SHIM(S)
3. BRAKE HOUSING 7. STUB SHAFT
4. AXLE HOUSING
BD08B033-01
Install the sun gear on the stub shaft (without shim)

until contact.

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6004-24
STEP 82 STEP 84
BD08B034-01 BD07N113-01
Determine dimension B from the mounting face of
the axle housing to the face of the sun gear.
Example:
Dimension B . . . . . . . . . . . . . . . . 19 mm (0.75 inch)
STEP 83
Subtract dimension A from dimension B. Then
subtract 1.25 mm (0.05 inch) from the difference. The
difference is the required shim size.
Example:
Dimension A 21.25 mm (0.84 inch)
Dimension B − 19.00 mm (0.75 inch)
BD08B035-01
Difference 2.25 mm (0.09 inch)
Install the sun gear shaft into the planetary gears.
Required end play − 1.25 mm (0.05 inch) Install the shim set (size as determined in Step 83)
Difference = shim into the sun gear shaft with grease.
1.00 mm (0.04 inch)
size
STEP 85
BD07N013-01
Install a new O-ring in brake port (1), and a new

O-ring on the axle housing (2).

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6004-25
STEP 86 STEP 89
BD06G072-01
Using acceptable lifting equipment, install the BD06G003-01
assembled wheel end onto the axle housing. Install axle drain plug in differential housing and
torque to 50 Nm (37 pound feet).
NOTE: Turn the input flange to align splines of the stub
shaft into the sun gear.
STEP 90
STEP 87
BD07N212-01
Remove dip stick from axle housing and wipe clean.

BD02D154-01
Install the washers and bolts to secure the wheel end
to the axle housing. Tighten the bolts to a torque of STEP 91
390Nm (288 pound feet).
STEP 88
BD07N213-01
To check oil level, do not screw in dip stick, but bring

it into contact with the face of the axle housing.
BD06G002-01
Remove dip stick, oil level should be between upper
Install drain plug in wheel end and torque to 50 Nm and lower marks on dip stick. Add Transaxle Fluid
(37 pound feet). (SAE 80W-140) as needed.
Install dip stick and torque to 50 Nm (37 pound feet).

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6004-26
BRAKE HYDRAULICS LEAKAGE TEST

IMPORTANT: DO NOT EXCEED 100 BAR (1450 PSI) High Pressure Test
PRESSURE IN THE FOLLOWING STEPS. If the maximum
pressure of 100 bar (1450 psi) is exceeded damage to
STEP 94
brake piston seals may occur.
Operate the hand pump to increase pressure to 100
bar (1450 psi) maximum. Close connection to hand
STEP 92
pump using the shutoff valve. During a 5 minute
period, pressure shall not drop more than 3 bar (44
psi).
Low Pressure Test

STEP 95
Reduce pressure to 5 bar (72.5 psi) and close the
shutoff valve. During a 5 minute period pressure shall
not drop.
BD07N209-01
Connect a hand pump with pressure gauge to the

brake port as shown above.
STEP 93
BD07N208-01
Fill the hand pump with hydraulic oil. Build up

pressure in the axle internal brake lines then bleed
air from the lines. After air is bled, actuate the brakes
a minimum of 5 times to a pressure of 100 bar (1450
psi) by operating the hand pump.
Torque brake bleeder to 6 Nm (4.4 pound feet)

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6004-27
REPLACE HUB SEAL
Removal STEP 98
appearance.
STEP 96
BD07N094-01
Remove and discard O-ring.
STEP 99
BD06G002-01
Remove drain plug and drain oil from the brake

housing.
STEP 97
BD07N093-01
Loosen and remove the wheel end retainer bolts.
STEP 100
BD06G075-01
Use a pry bar and remove the end cover.
BD07N090-01
Remove the wheel end retainer.

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6004-28
Installation
STEP 103
BD06G078-01
Use acceptable lifting equipment to hold the wheel

end. Separate the output shaft using a puller.
BD06G081-01
STEP 101
A A
A 1
BD06G079-01 BS00M073
Use a pry bar and remove the face seal from the 1. FACE SEAL
brake housing and discard. 2. BRAKE HOUSING
A FILL WITH GREASE
STEP 102 Wet the outer diameter of the face seal with a
solution of 50% water and 50% mineral spirits. Use a
suitable seal installer to install the face seal with the
seal lip positioned as shown. Apply grease to seal as
indicated by (A) above.
BD07N035-01
Inspect the metal face seal ring for damage or wear,

if required remove the seal ring and discard.

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6004-29
STEP 104 STEP 107
BD07N037-01 BD06G084-01
Clean the seal ring mounting surface with solvent. Use special tool CAS2860 and drive the sealing ring
STEP 105 NOTE: Only use special tool to install the sealing ring to
ensure proper seating.
STEP 108
BD07N038-01
STEP 106 BD06G086-01

Use acceptable lifting equipment and install the
wheel end onto the brake housing.
STEP 109
SM121A
BD06G088
BD07N039-01
Install the wheel end retainer.
Heat the metal face seal ring to approximately 120°
C (248° F), place the face seal ring onto the wheel
end shaft.

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6004-30
STEP 110 STEP 113
BD07N092-01 BD06G002-01
Install new bolts, evenly tighten the four bolts in a
Install drain plug on brake housing and torque to 50
cross pattern to a torque of 500 Nm (369 pound feet).
Nm (37 pound feet).
While tightening bolts rotate the brake housing
several time in both directions.
STEP 114
NOTE: Use only new bolts.
STEP 111
BD07N212-01
Remove dip stick from axle housing and wipe clean.

BD07N095-01
Install a new O-ring on the wheel end cover.
STEP 115
STEP 112
BD07N213-01
To check oil level, do not screw in dip stick, but bring

BD02D053-01
it into contact with the face of the axle housing.
Install the wheel end cover into the wheel end.
Remove dip stick, oil level should be between upper
and lower marks on dip stick. Add Transaxle Fluid
(SAE 80W-140) as needed.

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6004-31
DIFFERENTIAL
Removal STEP 117

appearance.
STEP 116
BD06G126-01
Fasten the axle to a stand, support the center of the

axle as shown, facing the input shaft attach suitable
lifting equipment to the left axle housing, remove the
mounting bolts and axle half.
ATTENTION: Differential can fall out of housing when
axle half is removed.
BD06G002-01
STEP 118
BD06G003-01
Remove drain plugs and drain oil from axle. BD06G127-01
Connect suitable lifting equipment to the differential

and remove the differential from axle housing.
NOTE: Make sure that the right axle stub shaft releases
from the differential.

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6004-32
Disassembly STEP 122
STEP 119
BD07N162-01
Remove the ring gear from the differential housing.

BD01F075-01
If required, remove the bearing from the housing STEP 123

cover using a suitable puller.
STEP 120
BD07N159-01
BD07N165-01

turning. Remove the bolts.
STEP 121
BD07N148-01
Remove the outer set of clutch plates, thrust washer,

BD07N163-01
Remove the housing cover from the differential

housing.

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6004-33
STEP 124 STEP 125
BD07N145-01 BD07N140-01
3
2 2
1 1
BD07N139-01
Remove the two differential half shafts, spider gears

and thrust washers from the differential housing.
4
STEP 126
BS08B044
1. ROLL PIN SET

2. DIFFERENTIAL HALF SHAFT
3. DIFFERENTIAL SHAFT
4. DIFFERENTIAL HOUSING
Drive both roll pin sets (1) out of the differential
housing (4) to remove the diferential half shafts (2).
BD07N136-01
Remove the differential shaft from the differential

housing.

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6004-34
STEP 127 STEP 129
BD07N131-01 BD07N104-01
Remove the remaining two spider gears and thrust If required, remove bearing from differential housing
washers from the differential housing. using a suitable puller and a press.
STEP 128 STEP 130
BD07N129-01 BD06G131-01
Pull the bearing cups and shims from both axle

housings.
NOTE: Make sure to identify the shims into which axle
housing they were removed.
BD07N114-01
Remove the inner set of clutch plates, thrust washer,


Copyright ©
6004-35
8
6 7
5
3
2
1
10
11
12
3
14
11
15
8
16
13
2 10
4
9
BS08A334
DIFFERENTIAL ASSEMBLY EXPLODED VIEW
1. INNER BEVEL GEAR 5. DIFFERENTIAL 9. THRUST WASHER 13. OUTER BEVEL GEAR
2. THRUST WASHER (COPPER COLOR) 6. ROLL PIN 10. SPIDER GEAR 14. RING GEAR
3. REACTION PLATE 7. ROLL PIN 11. DIFFERENTIAL HALF SHAFT 15. COVER DIFFERENTIAL
4. FRICTION PLATE 8. BEARING 12. DIFFERENTIAL SHAFT 16. BOLT

Copyright ©
6004-36
Assembly STEP 134
STEP 131
BD07N119-01
Install one reaction plate on the inner bevel gear.
BD07N105-01 STEP 135

Install bearing on differential housing using a press.
STEP 132
Check reaction plates, friction plates and thrust
washers for damage or wear, replace if necessary.
NOTE: Be sure to apply oil to all parts before assembly.
STEP 133
BD07N120-01
STEP 136
BD07N118-01
Install the (copper color) thrust washer on the inner

bevel gear.
NOTE: Clutch plates must be installed on the inner bevel
BD07N122-01
Install two reaction plates on the inner bevel gear.

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6004-37
STEP 137 STEP 140
BD07N124-01 BD07N127-01
Install two friction plates on the inner bevel gear. Install one reaction plate on the inner bevel gear.
STEP 138 STEP 141
BD07N125-01 BD07N128-01
Install one reaction plate on the inner bevel gear. Align all tabs of reaction plates on the inner bevel
gear.
STEP 139
BD07N126-01

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6004-38
STEP 142 STEP 144
BD07N129-01 BD07N136-01
BD07N130-01 BD07N137-01
Install the clutch pack and inner bevel gear assembly Install the full differential shaft into the housing
into the differential housing. through both thrust washers and spider gears
installed in the previous step. Make sure position of
STEP 143 hole in center of differential shaft is horizontal to the
differential housing.
1
STEP 145
2 1
BD07N131-01
1. THRUST WASHER 2. SPIDER GEAR

Install a thrust washer (1) and spider gear (2) into the
BD07N139-01
differential housing. Install another thrust washer (1)
and spider gear (2) directly across from the first. 1. THRUST WASHER 2. SPIDER GEAR
Make sure to install in the correct location for the full Install a thrust washer (1) and spider gear (2) into the
differential shaft. differential housing. Install another thrust washer (1)
and spider gear (2) directly across.
NOTE: The stop tab on the thrust washers must face
upwards.

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6004-39
STEP 146 STEP 148
BD07N140-01 BD07N144-01
2
3
2 2
1 1
BD07N138-01
Install both differential half shafts into housing

through thrust washers and spider gears installed in
previous step. The tapered end of half shafts (1) 4
insert into the hole in center of differential shaft.
Make sure the holes on the other end of the half
shafts (2) align with the holes in the differential
housing (3). BS08B044
1. ROLL PIN SET

2. DIFFERENTIAL HALF SHAFT
STEP 147
3. DIFFERENTIAL SHAFT
4. DIFFERENTIAL HOUSING
Drive new roll pins (1) into the differential housing to
secure half shafts.
NOTE: Use new roll pins only.
BD07N138-01
Spider gear assembly installed in differential

housing.

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6004-40
STEP 149 STEP 152
BD07N149-01 BD07N153-01
Install the (copper color) thrust washer on the outer Install two reaction plates on the outer bevel gear.
bevel gear.
NOTE: Clutch plates must be installed on the outer bevel STEP 153
STEP 150
BD07N155-01
Install two friction plates on the outer bevel gear.
BD07N150-01
STEP 154
Install one reaction plate on the outer bevel gear.
STEP 151
BD07N156-01
Install one reaction plate on the outer bevel gear.
BD07N151-01
Install one friction plate on the outer bevel gear.

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6004-41
STEP 155 STEP 158
BD07N156-01 BD07N160-01
Install one friction plate on the outer bevel gear. Clean ring gear mounting surface on differential
housing.
STEP 156
STEP 159
BD07N158-01
Align all tabs of reaction plates on the outer bevel BD07N161-01
gear. Clean mating surfaces of ring gear and differential

cover.
STEP 157 NOTE: The ring gear and the drive pinion are a matched
STEP 160
BD07N159-01
Install the clutch pack and outer bevel gear assembly

into the differential housing.
BD07N162-01
Install ring gear on differential housing.

NOTE: Make sure to align bolt holes when installing ring
gear and differential cover.
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6004-42
STEP 161 Drive Pinion Removal
NOTE: The ring gear and the drive pinion are a matched
STEP 164
Heat lock nut securing flange with a hot air blower to
loosen Loctite, approximately 120° C (248° F).
STEP 165
BD07N163-01
Install cover on differential housing.
STEP 162
BD06G132-01
Install holding wrench on input flange. Hold flange

and remove lock nut and washer. Remove holding
tool from flange.
STEP 166
BD07N166-01

turning. Install new bolts and tighten to a torque of
410 Nm (302 pound feet).
NOTE: Use new bolts only.
STEP 163
BD07N173-011
Remove the input flange from the drive pinion.
BD08B037-011
If bearing was removed from differential cover install

bearing using a press.

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6004-43
STEP 167 STEP 170
BD06G133-01 BD07N181-01
Remove the shaft seal from the axle drive housing. Drive inner bearing cup from the differential housing.
STEP 168 STEP 171
BD06G134-01 BD06G141-01
Press the input pinion out of the housing. Remove inner bearing cup and shim from differential
housing.
STEP 169 NOTE: Mark shim and bearing cup location to aid in
assembly.
STEP 172
BD07N183-01
Drive outer bearing cup from the differential housing.
BD07N175-01
Remove the spacer ring from the drive pinion.

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6004-44
STEP 173 Brake Tube Removal
STEP 174
BD07N176-01
Remove inner bearing from the drive pinion using a

suitable puller and a press. BD07N030-01
Remove the plug with the breather installed from the

axle housing.
STEP 175
BD07N001-01
Remove fitting from the brake tube on the axle

housing.

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6004-45
STEP 176 STEP 178
BD07N004-01 BD07N010-01
Remove the brake tube from the axle housing.
STEP 179
BD07N006-01
Loosen and remove the nut holding the brake tube

connector to the axle housing.
BD07N015-01
STEP 177 Loosen and remove brake tube fitting inside axle
housing.
STEP 180
BD07N008-01
Loosen the opposite end of brake tube from fitting

inside axle housing.
BD07N017-01
Remove and discard O-ring from fitting.

NOTE: Repeat steps 174 through 180 for the other side of
the axle

Copyright ©
6004-46
Brake Tube Installation
2
1 6
4 5 2
3
BS08B043
BRAKE TUBE PARTS LOCATION
1. BRAKE TUBE FITTING 36NM (27 POUND FEET) 4. AXLE HOUSING

2. O-RING 5. BRAKE TUBE
3. BRAKE TUBE THREADED NUT 100NM (74 POUND FEET) 6. HEXAGON NUT 100NM (74 POUND FEET)
STEP 181 STEP 182
BD07N017-01 BD07N018-01
Install a new O-ring on the brake tube fitting. Install the fitting in the axle and tighten to a torque of
36 Nm (27 pound feet)

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6004-47
STEP 183 STEP 185
BD00M343-01 BD07N006-01
Install a new O-ring in the groove of the brake tube.
STEP 184
BD07N005-01
Install the nut to secure the brake tube. Tighten the

nut to a torque of 100 Nm (74 pound feet).
BD07N010-01
Install the brake tube in axle housing. STEP 186
BD07N009-01
Connect the opposite end of brake tube to the fitting
installed in axle housing. Hold fitting with a wrench
and tighten brake tube to a torque of 100 Nm (74
pound feet).
NOTE: Do steps 181 through 186 for the other wheel end.

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6004-48
STEP 187 Pivot Pin Bushing Removal
STEP 189
1
2
3 A
1
BD00M347-01
BD01D499-01
BREATHER VENT EXPLODED VIEW
1. DIFFERENTIAL HOUSING PIVOT PIN BUSHING
1. O-RING 2. PLUG 3. BREATHER A. THRUST SURFACE
Remove and discard O-ring (1) from plug (2) and Inspect pivot pin bushings (1) in differential housing
install a new O-ring. Install breather (3) in plug and for cracks, breaks, deformation, or other damage.
tighten to general bolt torque specifications. Check oil splash grooves for scoring or chipping.
Check for scoring on thrust surface (A). If bushings
STEP 188 require replacement, do Steps 190 through 198.
STEP 190
BD07N003-01
BD07N193-01
Install the breather plug in axle housing and tighten Support left axle housing and wheel end with a
to general bolt torque specifications. suitable stand. Using acceptable lifting equipment to
support differential housing, remove bolts and
remove from left axle housing.
STEP 191
BD07N194-01
Remove and discard O-ring from axle housing.

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6004-49
STEP 192 STEP 194
BD08B006-01
BS08B045
Cut a slot in the pivot bushing.
STEP 193
BD08B007-01
Using a suitable length and diameter rod and spacer,

press bushing out of differential housing.
BD08B005-01 Repeat Steps 192 and 194 to remove the other pivot
Put differential housing in hydraulic press. Make sure bushing.
housing is properly supported.

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6004-50
Pivot Pin Bushing Installation STEP 196

parts.
SM118A
STEP 195
A
1 BD07N194-01
Install a new O-ring on the left axle housing.
STEP 197
2
BD01D495-01
2
A
BD07N193-01
Position differential housing with left axle housing

and install bolts.
1
STEP 198
BD01D499-01
1. DIFFERENTIAL HOUSING PIVOT PIN BUSHING

2. CENTER OF DIFFERENTIAL HOUSING
A. GROOVE
Freeze new bushing in dry ice for several hours.
Install bushing in differential housing with groove (A)
on circumference of bushing facing center of housing
Install bushing against shoulder in housing.
Repeat Step 195 to install the other pivot bushing.
BD07N197-01
Torque bolts evenly to 390 Nm (288 pound feet).

Copyright ©
6004-51
Drive Pinion Installation STEP 201
STEP 199
2
3
BD06G139-01
1. MATING NUMBER (MARKED MANUALLY)
2. PINION BASIC DIMENSION (STAMPED)
BD06G137-01
3. PINION DISTANCE DEVIATION + OR - (MARKED
Find and record the housing dimension “X”. MANUALLY)
Dimension X (Example). . . . . 205.30 mm (8.08 inch)
Distance deviation is indicated in 1/100 mm. If no
distance deviation is indicated the pinion basic
STEP 200 dimension is identical with the pinion dimension.
Record this as dimension “II”.
Dimension II (Example) 168 -0.05 mm = 167.95 mm
. . . . . . . . . (6.614 inch -0.002 inch = 6.612 inch)
STEP 202
Calculation example A:
36.13 mm
Dimension I
-------(1.422 inch)
+ 167.95 mm
Dimension II
-------(6.612 inch)
= 204.08 mm
Results in dimension Y
BD06G138-01
------(8.034 inch)
Measure the thickness of the inner bearing and Calculation example B:
record its measurement, dimension “I”.
205.30 mm
Dimension I (Example) . . . . . 36.13 mm (1.422 inch) Dimension X
-------(8.080 inch)
NOTE: Deduct the thickness of the gauge blocks being − 204.08 mm
Dimension Y
used to support the bearing from the overall measurement, -------(8.034 inch)
IE: overall measurement 106.13 mm (4.178 inch) Difference = shim = 1.22 mm
minus gauge block thickness 70 mm (2.756 inch) will equal thickness ------(0.046 inch)
dimension I.
NOTE: Shims are available in 0.10 mm (0.004 inch),

round up or down to the next available shim thickness, s =
1.20 (0.044 inch)

Copyright ©
6004-52
STEP 203 STEP 205
SM121A
BD06G140-01
Heat the bearing hole to approximately 120° C (248°

F) and install the outer bearing cup until contact is
made using a suitable diver.
STEP 204 BD07N178-01
Heat the pinion inner bearing to 120° C (248° F) in a

bearing oven. Wearing heat resistance gloves or
mittens, install the bearing on the pinion shaft until
contact.
NOTE: After installing bearing on pinion shaft, allow the
bearing to cool to ambient temperature.
BD06G141-01
BD06G142-01
Heat the inner bearing hole on the differential

housing to approximately 120° C (248° F). Install the
shim set determined in Step 202 in the bearing bore
and pull the bearing cup into to the bearing hole
using a suitable tool.

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6004-53
Drive Pinion Bearing Rolling STEP 208

Torque Adjustment
STEP 206
BD06G146-01
Press the dust shield on the input flange.
STEP 209
BD07N175-01
Install a 9.03 mm (0.35 inch) thick spacer on the

pinion shaft.
STEP 207
SM121A
BD06G147-01
Install the input flange on the pinion shaft.
STEP 210
Put the washer and nut in place on the pinion shaft.
BD06G145-01
Heat the pinion shaft outer bearing to 120° C (248°

F) in a bearing oven. Wearing heat resistance gloves
or mittens, install the bearing on the pinion shaft until
contact.
NOTE: Prior to mounting the input flange and tightening
the nut, allow the bearing to cool to ambient temperature.

Copyright ©
6004-54
STEP 211 STEP 212
BD06G132-01 BD06G148-01
Install a holding wrench on input flange. Hold flange Check the rolling torque of the drive pinion bearing.
and tighten nut to a torque of 700 Nm (516 pound The rolling torque should be 1.1 to 2.3 Nm (9.75 to
feet). Remove holding wrench. 20 lb-inch). If rolling torque is too low, install a thinner
spacer (Step 206); if rolling torque is too high, install
NOTE: When tightening rotate the pinion shaft in both
a thicker spacer (Step 206).
directions several times.
STEP 213
Remove the nut and input yoke from the drive pinion
shaft.

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6004-55
Setting Backlash and Bearing

Preload
Deviation Value -20 -10 0 +10 +20
Shim A 1.20 1.10 1.00 0.90 0.80
Shim B 0.80 0.90 1.00 1.10 1.20
STEP 214 STEP 215
1 2
A B
BD06G163-01
Record the deviation value from side of ring gear, the

value will be a + or -, use the table to determine shim
thicknesses needed.
Example: Deviation value of +10 requires the
following shims: 5 3
Shim A = 0.90 4
Shim B = 1.10 BC06G004
1. DIFFERENTIAL 5. AXLE HOUSING

2. DRIVE HOUSING A. RING GEAR SIDE
3. AXLE HOUSING B. CARRIER SIDE
4. INPUT PINION
STEP 216
BD06G164-01
Insert shim A (0.90 mm) and install the bearing cup

using a suitable driver until seated in axle housing.

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6004-56
STEP 217 STEP 220
BD06G165-01
Insert shim B (1.10 mm) and install the bearing cup BD06G168-01
using a suitable driver until seated in axle housing. Position the axle housing on the drive housing, install
4 bolts, top center, bottom center, front center, rear
center, torque bolts evenly to 390 Nm (288 pound
feet).
Contact Pattern Check
STEP 221
STEP 218
BD06G169-01
BD06G166-01 Roll the input pinion several times in both directions
Apply marking ink on several teeth of the ring gear. over the ring gear. Remove the differential and
compare the contact pattern with examples on page
STEP 219 4 and page 5.
NOTE: If the tooth contact pattern differs, the wrong shim
size was used in Step 204. Remove differential and repeat
Steps 199 though 204.
BD06G167-01
Position the differential assembly in the axle drive

housing.

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6004-57
STEP 222
BD06G171-01
Loosen and remove the nut and input flange.

BD06G167-01
Position the differential assembly in the axle drive STEP 226

housing.
STEP 223
BD06G172
Install the shaft seal with the sealing lip towards oil
sump using suitable seal installer.
BD06G170-01 NOTE: Wet the outer diameter of the seal with a solution
Install a new O-ring on the axle housing. of 50% water and 50% mineral spirits. Fill the space
between the sealing and dust lip with grease.
STEP 224
BD07N207-01
Position the axle housing on the differential housing,

install bolts and torque bolts evenly to 390 Nm (288
pound feet).

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6004-58
STEP 227 STEP 229
BD06G173-01 BD06G002-01
Install the input flange. Install holding wrench on

input flange. Apply Loctite No. 262, on the threads of
the locknut. Install the washer and locknut by hand.
Hold flange using holding tool and tighten nut to a
torque of 700 Nm (516 pound feet).
NOTE: Rotate the input pinion several times in both
directions when tightening.
STEP 228
BD06G003-01
Install axle drain plugs and torque to 50 Nm (37

pound feet).
BD08B004-01
Check optional axle pivot stop plates for wear or

damage, replace if required. Torque bolts to general
bolt torque specifications.

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6004-59
STEP 230 STEP 231
BD07N212-01 BD07N213-01
Remove dip stick from axle housing and fill with 22 To check oil level, do not screw in dip stick, but bring
Liters (23.2 U.S. Quarts) of Transaxle Fluid (SAE it into contact with the face of the axle housing.
80W-140). Remove dip stick, oil level should be between upper
and lower marks on dip stick.

Copyright ©
6004-60
NOTES

Copyright ©
Section
6005
DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL

JOINTS
6005

Italia 87728450 A - EU Issued Aprile, 2008
Copyright ©
6005-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Copyright ©
6005-3
SPECIAL TORQUES
Coupler to Flywheel Bolts......................................................................................53 to 62 Nm (39 to 46 pound feet)
Engine Drive Shaft to Coupler to Bolts ..................................................................53 to 62 Nm (39 to 46 pound feet)
Engine Drive Shaft to Transmission Bolts .............................................................34 to 41 Nm (25 to 30 pound feet)
Center, Rear and Front Drive Shaft Bolts..............................................................61 to 81 Nm (45 to 60 pound feet)
Carrier Bearing Bolts ...........................................................................................99 to 128 Nm (73 to 94 pound feet)
Lock Nut for Yoke on Front Drive Shaft.........................................................339 to 375 Nm (250 to 275 pound feet)
FRONT DRIVE SHAFT
Removal STEP 4
Use an acceptable puller and remove the yoke from
STEP 1 the end of the front drive shaft.
STEP 5
Loosen the set screws that secure the center bearing
to the front drive shaft.
STEP 6
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
STEP 7
BD03A166
Loosen and remove the bolts and straps that fasten
the center drive shaft to the yoke of the front drive
shaft.
STEP 2
BD03A167
Loosen and remove the bolts and straps that fasten

the front drive shaft to the front axle.
STEP 8
Use a prybar to disengage the front drive shaft from
BD03A183 the front axle and remove the front drive shaft from
Remove the lock nut that fastens the yoke to the front the machine.
drive shaft.
NOTE: If necessary, use a brass hammer to drive the
front drive shaft out of the center bearing.
STEP 3
Make an alignment mark on the yoke and the end of
the front drive shaft to make sure that the yoke is
installed correctly.

Copyright ©
6005-4
FRONT DRIVE SHAFT
STEP 9
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 10
Place the front drive shaft into position in the center
bearing of the machine.
STEP 11
BD03A183
Install the lock nut and washer which fastens the

yoke to the front drive shaft. Tighten the lock nut to a
torque of 339 to 375 Nm (250 to 275 pound feet).
STEP 15
Tighten the set screws that secure the center bearing
to the front drive shaft alternately until they stop
turning and the hex head socket wrench starts to
spring.
BD03A167
STEP 16
Install the bolts and straps that fasten the front drive
shaft to the front axle. Tighten the bolts to a torque of
STEP 12
Apply antiseize compound to the splines on the front
drive shaft.
STEP 13
Install the yoke to the front drive shaft, making sure
the alignment marks made during removal are
aligned.
NOTE: If a new front drive shaft has been installed, make BD03A166
sure the yoke being installed is 90° to the yoke on the other Install the bolts and straps that fasten the front drive
end of the front drive shaft. shaft to the center drive shaft. Tighten the bolts to a
torque of 61 to 81 Nm (45 to 60 pound feet).

Copyright ©
6005-5
CENTER BEARING
Removal STEP 20
Make an alignment mark on the yoke and the front
STEP 17 drive shaft to be sure that the yoke is installed
correctly.
STEP 21
Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
STEP 22
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
BD03A166
STEP 23
Loosen and remove the bolts and straps that fasten Loosen the set screws that secure the center bearing
the center drive shaft to the front drive shaft. to the front drive shaft.
STEP 18 STEP 24
BD03A183 BD03A183
Loosen and remove the lubrication hose from the Loosen and remove the bolts, washers and nuts that
center bearing fasten the bearing housing to the front frame.
STEP 19 STEP 25
Install two longer bolts, at least 3 inches, to hold the
bearing housing during removal. Use an acceptable
puller to remove the bearing housing from the front
drive shaft.
BD03A183
Loosen and remove the lock nut that fastens the
yoke to the front drive shaft.
Copyright ©
6005-6
CENTER BEARING
Apply antiseize compound to the splines on the front
NOTE: The center bearing and the bearing housing are
drive shaft. Install the yoke to the front drive shaft,
not serviced separately. If the center bearing is worn or
making sure the alignment marks made during
damaged or if the bearing housing is cracked, a new center
removal are aligned.
bearing and bearing housing must be used.
STEP 31
STEP 26
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 27
Install the bearing housing so that the lubrication
fitting is at the top.
STEP 28
BD03A183
Install the washer and lock nut that fasten the yoke to
the front drive shaft. Tighten the lock nut to a torque
of 339 to 375 Nm (250 to 275 pound feet).
STEP 32
BD03A183
Apply Loctite 242 to bolt threads. Install the bolts,

washers and nuts that fasten the bearing housing to
the front frame. Tighten the bolts to a torque of 99 to
128 Nm (73 to 94 pound feet).
STEP 29
BD03A166
Install the straps and bolts that fasten the center

drive shaft to the yoke on the front drive shaft.
Tighten the bolts to a torque of 61 to 81 Nm (45 to 60
pound feet).
STEP 33
Install the lubrication hose into the fitting on the
bearing housing.
BC05M214
Turn the set screw down to the shaft and then back it STEP 34
off 1/4th turn and lock it with the jam nut. Repeat the
Lubricate the center bearing with the grease
procedure with the other set screw.
specified in Section 1002.

Copyright ©
6005-7
CENTER DRIVE SHAFT
STEP 35 STEP 39
BD03A166 BD03A165
Loosen and remove the bolts and straps that fasten Hold the center drive shaft in position and install the
the center drive shaft to the yoke of the front drive bolts and straps that fasten the center drive shaft to
shaft. the transmission. Tighten the bolts to a torque of 61
to 81 Nm (45 to 60 pound feet).
STEP 36
Use a prybar to disengage the center drive shaft from STEP 40
the yoke of the front drive shaft.
STEP 37
BD03A166
Install the bolts and straps that fasten the center

drive shaft to the yoke of the front drive shaft. Tighten
BD03A165
the bolts to a torque of 61 to 81 Nm (45 to 60 pound
Loosen and remove the bolts and straps that fasten feet).
the center drive shaft to the transmission.
STEP 38
Hold the center drive shaft and remove from the
machine.

Copyright ©
6005-8
REAR DRIVE SHAFT
STEP 41 STEP 45
BD01D323 BD01F304
Loosen and remove the bolts and straps that fasten Hold the rear drive shaft into position and install the
the rear drive shaft to the transmission. bolts and straps that fasten the rear drive shaft to the
rear axle. Tighten the bolts to a torque of 61 to 81 Nm
STEP 42 (45 to 60 pound feet).
Use a prybar to disengage the rear drive shaft from
the transmission. STEP 46
STEP 43
BD01D323
Install the bolts and straps that fasten the rear drive
BD01F304
shaft to the transmission. Tighten the bolts to a
Loosen and remove the bolts and straps that fasten torque of 61 to 81 Nm (45 to 60 pound feet).
the rear drive shaft to the rear axle.
STEP 44
Hold the rear drive shaft and remove from the
machine.

Copyright ©
6005-9
ENGINE DRIVE SHAFT
STEP 47 STEP 50
BD01D342 BD01D342
Remove and discard the bolts and straps that fasten Place the engine drive shaft into position on the
the engine drive shaft to the transmission. transmission and install new straps and bolts.
Tighten the bolts to a torque of 34 to 41 Nm
IMPORTANT: The bolts and straps that fasten the engine
(25 to 30 pound feet).
drive shaft to the transmission must be replaced when
removed.
STEP 51
STEP 48
BD03A172
Apply Loctite 242 to bolt threads. Install the six bolts

BD03A172
that fasten the engine drive shaft to the engine.
Loosen and remove the six bolts that fasten the
Tighten the bolts to a torque of 53 to 62 Nm (39 to 46
engine drive shaft to the engine.
pound feet)
STEP 49
Remove the engine drive shaft from the machine.

Copyright ©
6005-10
UNIVERSAL JOINTS
NOTE: The bearing race and journal that make up the
STEP 52 universal joint are not serviced separately. If the bearing
Remove the drive shaft from the machine. race or journal is worn or damaged, a new universal joint
must be used.
STEP 53
STEP 55
Clean the slots in the yoke of the drive shaft.
2
1
STEP 56
Install the universal joint and install the bearings (2)
and the rings (1). Refer to the photo in Step 53.
STEP 57
Install the drive shaft.
BD01F304
1. RING 2. BEARING
Remove the ring (1) and the bearing (2) from the
drive shaft.
NOTE: The above photo shows the drive shaft on the
machine and is for reference of the ring and bearing only.
STEP 54
Remove the universal joint from the drive shaft.

Copyright ©
Section
6006
WHEELS AND TIRES
6006

Copyright ©
6006-2
TABLE OF CONTENTS
WHEELS AND BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TIRE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHANGING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLING A WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Copyright ©
6006-3
WHEELS AND BOLTS
General Information Torque Specification

The wheel bolts must be tightened after every 20 Tighten the wheel bolts to 298 Nm (220 pound-feet)
hours of operation until the wheel bolts stay tight: in the sequence shown in Figure 1. Then a final
torque of 640 to 720 Nm (475 to 530 pound-feet) in
A. If the machine is new.
the same sequence.
B. If a wheel has been removed and installed.
TIRE PRESSURES
Tire Size Tire Type Front Tire pressure Rear Tire pressure
17.5 x 25 L2 or L3 Bias Ply 3.44 bar (50 psi) 2.75 bar (40 psi)
17.5 x 25 L2 or L3 Radial 3.44 bar (50 psi) 2.75 bar (40 psi)
20.5 x 25 L2 or L3 Bias Ply 3.44 bar (50 psi) 2.75 bar (40 psi)
20.5 x 25 L2 or L3 Radial 3.44 bar (50 psi) 2.75 bar (40 psi)

Copyright ©
6006-4
CHANGING TIRES
1. Have a qualified tire mechanic service the split
WARNING: The split rim wheels used on rim wheels used on this machine.
this machine can be dangerous. When
inflating a tire on the machine, use a 2. The correct tire equipment, especially a tire
self-locking nozzle and stand at the front or inflation cage, is required. Using the wrong
rear of the tire. procedure for a split rim wheel can result in
death.
When inflating a tire off the machine, put the
wheel in a tire inflation cage. The retaining IMPORTANT: When installing a Michelin tire, lubricate
ring and rim can come off with enough force the tire with a tire mounting lubricant and inflate the tire to
to result in death to a person in front of the 551 kPa, 5.5 bar (80 psi) to make sure that the tire is seated
rim. on the rim. Then decrease the pressure to the specified
pressure.
48-44
INSTALLING A WHEEL
1. Make sure the mounting surfaces of the rim and 4. Tighten the wheel bolts to 298 Nm (220
axle flange are clean and free of dirt and grease. pound-feet) in the sequence shown in Figure 1.
Then tighten the wheel bolts in the same
2. Install the wheel, hardened washers and wheel
sequence to 640 to 720 Nm (475 to 530
bolts.
pound-feet).
3. Use a hand wrench (not an impact) to tighten the
wheel b olts to pu ll the wheel against the
planetary housing. DO NOT use an impact
wrench to tighten the wheel bolts.
1
10 8
6 12
4 3
11 5
7 9
2
B0987A88
FIGURE 1. WHEEL BOLT TORQUE SEQUENCE

Copyright ©
Section
6007
TRANSMISSION CONTROL VALVE
6007

Copyright ©
6007-2
TABLE OF CONTENTS
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Copyright ©
6007-3
CONTROL VALVE
Disassembly STEP 4
STEP 1
BD06A010
Loosen and remove the cap screws, remove the

BD06A007
cover. Remove the opposite cover.
Mark the installation position of the wiring harness to
the valve block. STEP 5
STEP 2
BD06A011
Remove the wiring harness.

BD06A008
Loosen and remove the cap screws that secure the STEP 6
distribution plate and intermediate plate to the valve
body, remove the intermediate plate and distribution
plate.
STEP 3
BD06A012
Loosen and remove the retaining plate cap screws,

remove the retaining plates and solenoids.
BD06A009
Remove the wiring harness retaining clamp.

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6007-4
STEP 7 STEP 9
BD06A013 BD06A015
Loosen and remove two cap screws, install two Remove the components.
adjusting screws. Loosen and remove the remaining
cap screws. STEP 10
STEP 8
BD06A016
Remove the opposite solenoids, housing, and

BD06A014 components.
Separate the housing from the valve body by equally
loosening the adjusting screws.

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6007-5
Inspection Assembly
1. Clean all metal parts in cleaning solvent. NOTE: Apply clean engine oil (15W-40) to pistons and
springs, orifices, new O-rings, and filter screens before
2. Immerse end housings, valve housing, valve
assembly.
plate, and distribution plate in cleaning solvent
and agitate cleaning solvent. WEAR EYE
PROTECTION WHEN USING COMPRESSED STEP 11
AIR. Use compressed air to remove foreign
matter from interior of housings and plates and to
ensure that all bores are clear of foreign matter.
3. WEAR EYE PROTECTION WHEN USING
COMPRESSED AIR. Use compressed air to
ensure that orifices are clear of foreign matter.
4. Check filter screens for blockage, rips, or tears.
Replace if any of these conditions are seen.
5. Inspect the plates, housings and covers for
corrosion, cracks, breaks, chipping or other
damage. Check bores in housings for deep BD06A017
scratches, gouges, and other damage. Replace Place the valve body on the bench with the orifices
a housing or cover if any of the above conditions up.
are seen.
6. Check pressure regulators for cracks, breaks, or STEP 12
other damage. Check connector contacts for
looseness or signs of corrosion. Replace a
pressure regulator if any of these conditions are
seen. Check resistance of pressure regulators
using a multimeter. Replace a pressure regulator
if resistance is not 17 to 21 ohms.
7. Check wiring harness connectors for signs of 3
breaks, cracks, or other damage. Check contacts
for foreign matter or corrosion. Check harness
wiring for signs of broken or cracked insulation 1 1
and broken or frayed wiring at connection to 2 2
connectors. Replace wiring harness if any of BD06A018
these conditions are seen.
1. VIBRATION DAMPER 3. PRESSURE REDUCING
8. Check springs for cracks, breaks, distortion, or 2. PISTONS VALVE
signs of permanent set. Replace a spring if any Install components in positions shown.
of these conditions are seen.
9. Inspect pistons for cracks, breaks, chipping, STEP 13
grooves, or other damage. Replace if any of
BD06A019
Preload the compression springs of the pistons,

install a roll pin of a diameter of 5.0 mm (0.20 inch).
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6007-6
STEP 14 STEP 17
BD06A020 BD06A023
Install the adjusting screws, gasket, and housing Install the cap screws and torque in a criss cross
cover. pattern to 7.5 Nm (66.3 pound-inch).
STEP 15 STEP 18
BD06A021 BD06A024
Tighten the adjusting screws equally until the cover is Install the solenoids and secure them with the
flush on the valve body. retaining plates and cap screws. Torque the cap
screws to 5.5 Nm (48.5 pound-inch).
STEP 16 NOTE: Install the retaining plate with the neck towards
valve body, install controllers with connectors as shown.
STEP 19
BD06A022
1 3
Push the pistons down through the pressure
controller wholes and remove the roll pins.
1
2 2
BD06A025
1. VIBRATION DAMPER 3. MAIN PRESSURE VALVE

2. PISTONS
Install components in positions shown.

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6007-7
STEP 20 STEP 23
BD06A026 BD06A028
Preload the compression springs of the pistons, Install the wiring harness with connector on side of
install a roll pin of a diameter of 5.0 mm (0.20 inch). valve body marking made during disassembly.
Install the adjusting screws, gasket, and housing Connect wiring harness to the solenoids.
cover.
STEP 24
STEP 21
BD06A029
BD06A023 Install the gasket, install the wiring harness plug in

Install the cap screws and torque in a criss cross the cover. Install the cap screws and torque in a criss
pattern to 7.5 Nm (66.3 pound-inch). cross pattern to 7.5 Nm (66.3 pound-inch).
STEP 22 STEP 25
BD06A027 BD06A030
Install the solenoids and secure them with the Install the wiring harness retaining clamp.
retaining plates and cap screws. Torque the cap
screws to 5.5 Nm (48.5 pound-inch).
NOTE: Install the retaining plate with the neck towards
valve body, install controllers with connectors as shown.

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6007-8
STEP 26 STEP 28
BD06A031 BD06A033
Install the screens into the bores of the intermediate Install the distribution plate, install the cap screws
plate towards the distribution plate. and torque in a criss cross pattern to 9.5 Nm (84
pound-inch).
STEP 27
STEP 29
BD06A032
Install two adjusting screws. Place the intermediate BD06A034
plate with the screens facing up. Install new o-rings on the plugs, install and torque
plugs to 6 Nm (53 pound-inch).

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SECTION INDEX
BRAKES
Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7001

Hydraulic Brake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7002
Brake Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7003
Brake Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7008

Copyright ©
Copyright ©
7001
Section
7001
REMOVAL AND INSTALLATION OF BRAKE

COMPONENTS

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7001-2
TABLE OF CONTENTS
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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7001-3
1
8
3
4
6 5
BS08A039
1. BRAKE PUMP 5. BRAKE VALVE

2. COOLING FRAME 6. PARKING BRAKE HOSE
3. REAR ACCUMULATOR (FRONT AXLE) 7. BRAKE PUMP SUCTION HOSE
4. FRONT ACCUMULATOR (REAR AXLE) 8. BRAKE PUMP PRESSURE HOSE
COMPONENT LOCATION ILLUSTRATION
3
BS08A125
1. REAR ACCUMULATOR (FRONT AXLE)

2. FRONT ACCUMULATOR (REAR AXLE)
3. PARKING BRAKE ACCUMULATOR
BRAKE ACCUMULATOR LOCATION ILLUSTRATION

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7001-4
BRAKE VALVE
1. Park the machine on a level surface and lower 1. Install the brake valve (1) in the cab or canopy.
the loader bucket to the floor. Stop the engine. Refer to the illustration on page 5.
2. Put blocks on both sides of each tire to prevent 2. Remove the plugs from the hydraulic lines and
machine movement. connect the hydraulic lines to the brake valve (1).
3. Make sure the brake accumulators are 3. Stop the vacuum pump and remove.
completely discharged. Push down and release 4. Connect all of the electrical connections.
the brake pedals at least 30 times.
5. Remove and discard tags.
4. Turn the master disconnect switch to the OFF
position. 6. Turn the master disconnect switch to the ON
position.
5. Remove the cab skirts located under the cab or
canopy. 7. Bleed the brake system. See Section 7002.
6. To release the pressure on the parking brake 8. Install the cab skirts.
accumulator, the line at the accumulator must be 9. Check the hydraulic reservoir oil level and add oil
SLOWLY cracked open. A pan will be needed to as required. See Section 1002 for the correct oil.
catch the hydraulic oil.
7. Connect a drain hose to the quick disconnect
couplings in each brake circuit to release any
pressure in the brake circuit.
8. Clean the brake valve (1) and lines, refer to the
9. Put identification tags on all electrical and
hydraulic lines that are connected to the brake
valve (1).
10. Connect a vacuum pump to the hydraulic
reservoir. Start the vacuum pump
11. Disconnect the lines from the brake valve (1) and
put plugs in each line.
12. Remove the brake valve (1).

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7001-5
1
6
2 7
9
4 10
8
5
BC05M137
1. BRAKE VALVE 6. FRONT BRAKE LINE

2. REAR ACCUMULATOR LINE (FRONT AXLE) 7. REAR BRAKE LINE
3. PARKING BRAKE LINE 8. FRONT ACCUMULATOR LINE (REAR AXLE)
4. BRAKE PUMP INPUT 9. RETURN TO TANK
5. BRAKE VALVE DISCHARGE TO FAN VALVE 10. PARKING BRAKE ACCUMULATOR
BRAKE VALVE ILLUSTRATION

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7001-6
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS

3 reservoir. Start the vacuum pump.
4
11. Tag and disconnect the accumulator hoses (1)
and (2) from brake accumulators (4) and (5).
3
2 12. Install plugs in hoses and caps on fittings.
1 13. Loosen the clamp stud on the accumulator
clamps (3).
14. Remove accumulators (4) and (5) from clamps
(3).
5 15. Disconnect hose (8) from parking brake
8 accumulator (6).
7 6 16. Remove the mounting nut on the back side of
BS08A125 bracket (7) for parking brake accumulator (6),
1. FRONT ACCUMULATOR HOSE remove the accumulator.
2. REAR ACCUMULATOR HOSE
3. MOUNTING CLAMP 17. Install a plug in the hose and cap fitting.
4. REAR ACCUMULATOR (FRONT AXLE)
5. FRONT ACCUMULATOR (REAR AXLE) Installation
6. PARKING BRAKE ACCUMULATOR
7. BRACKET 1. Mount the accumulators (4) and (5) in clamps
8. PARKING BRAKE ACCUMULATOR HOSE (3), do not tighten clamps at this time. Refer to
illustration.
Removal 2. Connect hose (1) to brake accumulator (5) and
1. Park the machine on a level surface and lower tighten.
the loader bucket to the floor. Stop the engine. 3. Connect hose (2) to brake accumulator (4) and
2. Put blocks on both sides of each tire to prevent tighten.
machine movement. 4. Tighten clamps (3) to 17Nm (13 pound feet).
3. Make sure the brake accumulators (4) and (5) 5. Install the parking brake accumulator (6) into
and the parking brake accumulator (6) are bracket (7).
completely discharged. Push down and release
the brake pedal at least 30 times. 6. Install the mounting nut and tighten.
4. Turn the master disconnect switch to the OFF 7. Connect hose (8) to the parking brake
position. accumulator (6).
5. Remove the left cab skirt located under the cab 8. Remove and discard tags.
or canopy to gain access to accumulators. 9. Stop the vacuum pump and remove.
6. To release the pressure on the parking brake 10. Install the left cab skirt.
accumulator (6), the line at the accumulator must
be SLOWLY cracked open. A pan will be needed 11. Refer to Section 7004 and check the nitrogen
to catch the hydraulic oil. charge on the accumulators.
7. Connect a drain hose to the quick disconnect 12. Turn the master disconnect switch to the ON
couplings in each brake circuit to release any position.
pressure in the brake circuit. 13. Bleed the brake system. See Section 7002.
8. Clean the brake accumulators (4) and (5), 14. Refer to Section 7008 and perform the Parking
parking brake accumulator (6) and hoses (1), (2) Brake Test Procedure.
and (8). Refer to illustration above.
15. Check the hydraulic reservoir oil level and add oil
9. Put identification tag on hose (8) that is as required. See Section 1002 for the correct oil.
connected to the parking brake accumulator (6).

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7001-7
BRAKE PUMP
1. Park the machine on a level surface and lower NOTE: DO NOT use an impact tools on the slotted nut for
the loader bucket to the floor. Stop the engine. mounting the pump drive gear.
2. Put blocks on both sides of each tire to prevent 1. Install gear (4) onto the pump shaft, install
machine movement. slotted nut (5). Torque nut to 70 to 79 Nm (52 to
58 pound feet). Refer to the illustration on page
3. Turn the master disconnect switch to the OFF
8.
position.
2. Install the cotter pin (6).
4. Clean the brake pump (1) and lines, refer to the
illustration on page 8. 3. Install the brake pump (1), mounting bolts (2)
and washers (3).
5. Put identification tags on the lines that are
connected to the brake pump (1). 4. Torque mounting bolts (2) to 57 to 65 Nm (42 to
48 pound feet).
reservoir. Start the vacuum pump. 5. Remove the plugs or caps and connect the lines
to the brake pump (1).
7. Disconnect the lines from the brake pump (1)
and put plugs in each line. 6. Stop the vacuum pump and remove.
8. Remove the mounting bolts (2) and washers (3) 7. Turn the master disconnect switch to the ON
from the brake pump (1) and remove the brake position.
pump (1).
8. Bleed the brake system. See Section 7002.
9. Remove cotter pin (6) and slotted nut (5),
9. Check the hydraulic reservoir oil level and add oil
remove drive gear (4).
as required. See Section 1002 for the correct oil.

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7001-8
5
4
3
2
3
2
8 7
BS08A038
1. BRAKE PUMP 5. SLOTTED NUT

2. MOUNTING BOLT 6. COTTER PIN
3. WASHER 7. SUCTION HOSE
4. DRIVE GEAR 8. PRESSURE HOSE
BRAKE PUMP ILLUSTRATION

Copyright ©
7002
Section
7002
HYDRAULIC BRAKE TROUBLESHOOTING

Copyright ©
7002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake Valve Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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7002-3
SPECIFICATIONS
Brake pump output ...................................................................................................28 L/min at 172 bar at 2000 rpm
7.4 gpm at 2500 psi at 2000 rpm
Accumulator nitrogen pre-charge pressure ....................................................................48 to 59 bar (700 to 850 psi)

Accumulator valve cut in pressure......................................................................... 157 to 167 bar (2280 to 2420 psi)
Accumulator valve cut out pressure ...................................................................... 190 to 196 bar (2755 to 2845 psi)
Brake warning pressure switch (normally closed) opening set point......................117 to 141 bar (1697 to 2045 psi)
Brake redundant pressure switch (normally closed) opening set point ..... 55 to 69 bar decreasing (800 to 1000 psi)
Brake light pressure switch (normally open) closing set point........................................... 4.1 bar increasing (60 psi)
Modulation pressure front brake cylinders......................................................................62 to 68 bar (900 to 986 psi)
Modulation pressure rear brake cylinders ......................................................................59 to 65 bar (856 to 943 psi)
SPECIAL TOOLS
BS06M002
BC04A001
380001676 NITROGEN REGULATOR VALVE USED TO CHECK
AND CHARGE THE ACCUMULATOR WITH NITROGEN. 380001168 ACCUMULATOR CHARGING ADAPTER
B877168V
B785789M CAS-1808 FLOW METER FITTING KIT
CAS-10280 FLOWMETER

Copyright ©
7002-4
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM

NOTE: The hydraulic brake schematic is included in the 8. Stop the engine. Turn the ignition switch to the
hydraulic schematic. Refer to the rear pocket of this ON position. Push and release the brake several
manual. times while reading the pressure on the gauges.
Each push and release of the pedal will result in
1. Check the oil level in the hydraulic reservoir; add
a slight drop in pressure, but not necessarily
oil as necessary.
equal on the two gauges.
2. Push and release the brake pedal many times
9. As the lowest pressure reaches 117 to 141 bar
with the engine stopped to remove all hydraulic
(1697 to 2045 psi) the brake warning lamp and
pressure from the brake system until there is no
alarm buzzer must actuate. If the warning lamp
pressure on the pedal.
and alarm buzzer fail to work, test the low brake
3. Install two 207 bar (3000 psi) pressure gauges to pressure warning switches and electrical circuit.
front and rear hydraulic brake accumulator test If the warning lamp and alarm buzzer actuate at
ports, refer to page 7 for the locations of the test a higher or lower pressure than specified, test
ports. the low brake pressure warning switches and
replace as needed.
4. Make sure that the pressure gauge hoses are
long enough so the gauges can be read while 10. After the low brake pressure light activates,
sitting in the operators seat. press the brake pedal eight more times.
NOTE: The gauges can not be connected to the test ports 11. Record the readings on the pressure gauges.
if hydraulic pressure remains in the system. The pressure gauges should read at or above
48 to 59 bar (700 to 850 psi).
5. Start the engine. Run the engine at low idle while
12. If the pressures are at or above 48 to 59 bar (700
reading the pressure gauges. The alarms
to 850 psi), the test is complete.
(buzzer, master warning light and brake pressure
warning light) should shut off when the 13. If the pressures are not within the required
accumulator with the lowest pressure reaches specifications, then the brake system must be
117 to 141 bar (1697 to 2045 psi), approximately bled.
40 seconds at any engine speed. 14. After bleeding the brake system, perform the
6. After the alarms stop, run the machine at high brake system check again.
idle to finish charging the accumulators. The 15. Continue to slowly push and release the brake
pressure must increase on both gauges until 190 pedal several times until the gauge pressure
to 196 bar (2757 to 2843 psi) is reached. This is suddenly drops to zero. The last pressure
the accumulator valve cut-out pressure. It is reading before the drop to zero is the nitrogen
normal for the pressure to drop slightly once the charge pressure in the accumulator. Test the
cut-out pressure is reached. pressure in both accumulators. If the pressure is
7. With the engine running at high idle, push and below 48 to 59 bar (700 to 850 psi), charge or
release the brake pedal rapidly while reading the replace the accumulator(s) (see section 7004).
drop in pressure on the gauges. The pressure NOTE: Nominal temperature of 20° C (68° F), colder
drops may not be equal, but as the lowest temperature will reduce pressure, hotter temperature will
pressure reaches 157 to 167 bar (2280 to 2420 increase pressure.
psi), the system pressure must start to increase.
This is the valve cut in pressure.
NOTE: The brake cut-in and cut-out pressures of the
brake system charge valve are factory preset and are not
adjustable.
NOTE: If the pressure on one of the pressure gauges is
lower than specified, the problem can be a bad accumulator
valve.

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7002-5
BLEEDING THE BRAKE SYSTEM

1. Check the level of hydraulic fluid in the reservoir.
Add fluid to the reservoir if necessary.
IMPORTANT: If machine is equipped with quick-attached 2
proceeding.
3
BD07N586-01
1 6. Disconnect connector C (1) and connector A (2)

from the EDC-7 controller (3).
IMPORTANT: Make sure that the master disconnect and
ignition switch are OFF before disconnecting or connecting
BD03A092 connectors on EDC-7 controller.
1. SAFETY LINK
NOTE: Disconnecting Connector A and C will prevent
engine from starting.
2. Raise loader arms and install the safety link (1).
BD07N588-01
BD03A040
7. Lossen the pressure side fitting on the brake
3. Put articulation lock in LOCKED position. pump. The pressure side of the brake pump is
4. Apply the parking brake. the top hose on the brake pump.
5. To prime pump: Turning off ignition switch and 8. Turn master disconnect ON.
master disconnect. 9. Turn the engine over, (machine will not start),
until a few drops of oil leak past the fitting. Then
tighten the fitting.
NOTE: The EDC-7 controller will only allow for 5 seconds
of cranking then it will shut down. And then you will have to
turn the ignition OFF and ON again to crank engine.
10. Turn master disconnect switch to OFF.
11. Connect connector A and connector C to the
EDC-7 controller.
12. Turn master disconnect switch to ON.

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7002-6
13. Start the engine and allow it to idle until both 17. Attach hose to the bleed screw at each wheel
brake accumulators are fully charged. end to prevent oil spillage. Submerge hoses in
fluid to prevent air from re-entering the brake
NOTE: This will be approximately 30 seconds after the
system.
low brake pressure light goes out.
18. Start the machine and allow it to idle.
19. Depress the brake pedal until the flow is clear
15. Pump the brake pedal until there is no hydraulic
(No bubbles) in each of the tubes.
pressure in the brake system (approximately 20
pumps). 20. Close all four wheel end bleed screws.
16. Remove the plastic and rubber cap from each 21. Replace all caps and plugs on wheel end.
wheel end and slowly open bleed screws.
22. Check the hydraulic fluid and add as necessary.

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7002-7
BRAKE MODULATION PRESSURE CHECK
2 3
BD06F145
1. FRONT AXLE TEST PORT 3. FRONT BRAKE ACCUMULATOR TEST PORT

2. REAR AXLE TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT
Testing the Brake Modulation 6. Start the engine.

Pressure 7. Operate the machine at low idle and watch the
pressure gauges on the brake accumulators until
1. Make sure the hydraulic accumulator cut-in and the gauges rise above 170 bar (2645 psi).
cut-out pressures are correct. Refer to page 4 of
this section. 8. Apply and hold the brakes for 10 to 15 seconds.
2. Stop the engine. Pump the brake pedal until 9. Make a note of the pressure on the gauges for
there is no pressure in the brake system. the front and rear brakes.
3. Remove the cab skirts to gain access to the 10. The front brake pressure should read 62 to 68
brake test ports. bar (900 to 986 psi). This is the modulation
pressure for the front axle.
4. Connect two 207 bar (3000 psi) pressure gauges
to the front brake test port (1) and the rear brake 11. The rear brake pressure should read 59 to 65 bar
test port (2). (856 to 943 psi).
5. Connect two 207 bar (3000 psi) pressure gauges 12. If the pressures are not within the specified
to the front brake accumulator test port (4) and range, it will be necessary to adjust the
the rear brake accumulator test port (3). modulation pressures.

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7002-8
Adjusting the Brake Modulation 1. Remove the tamper evident cover (1).
Pressure NOTE: This is a tamper evident cover and it will be
necessary to install a new cover after the modulation
NOTE: The adjusting bolt to adjust the modulation pressure is adjusted.
pressure is located in the cab, under the brake pedal.
2. Turn the adjusting bolt (2) to adjust the
modulation pressure.
NOTE: The rear brake modulation pressure cannot be
adjusted separately from the front brake modulation
pressure.
3. Repeat steps 5 through 10 in the Testing the
Brake Modulation Pressure procedure.
2 4. Repeat these steps until the brake modulation
pressure is within the specified range.
1
BD00N121
1. TAMPER RESISTANT COVER

2. ADJUSTING BOLT

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7002-9
SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY)
2 3
4
BD06F145
1. FRONT AXLE TEST PORT 3. FRONT BRAKE ACCUMULATOR TEST PORT

2. REAR AXLE TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT
NOTE: Prior to doing this procedure make sure that the 6. Start the engine and let idle until both the front
accumulator pressures are correct. and rear accumulators 3 and 4 are fully charged.
1. Check the level of the hydraulic fluid in the The accumulators are fully charged at 190 to 196
reservoir, add as needed. bar (2755 to 2842 psi).
7. Stop the engine.
8. Push the brake pedal down slowly, allowing for
full piston actuation.
NOTE: Depress the brake pedal at the rate of three
strokes per minute.
9. Continue pressing the brake pedal down. The
1 low brake pressure light should activate when
the pressure reaches 117 to 141 bar (1697 to
2045 psi). After the low brake pressure light
activates, press the brake pedal eight more
times.
10. Record the readings on the pressure gauges.
BD00M030 The pressure gauges should read at or above
1. ARTICULATION LOCK 48 to 59 bar (700 to 850 psi).
2. Install the articulation lock (1) before doing this 11. If the pressures are at or above 48 to 59 bar (700
test. to 850 psi), the test is complete.
3. Remove the left side cab skirt to gain access to 12. If the pressures are not within the required
the brake accumulator test ports. specifications, then the brake system must be
4. Pump the brake pedal until there is no hydraulic bled.
pressure in the brake system (approximately 20 13. After bleeding the brake system, perform the
pumps). brake system check again.
5. Connect two 207 bar (3000 psi) pressure gauges
to the test ports 3 and 4.

Copyright ©
7002-10
BRAKE PUMP OUTPUT TEST

1. Connect the flowmeter to the brake pump as 3. Measure the flow at 0 bar (0 psi). Record the flow
shown below. reading. Slowly close the load valve on the
flowmeter and read the flow at 170 bar (2500
2. Make sure the load control of the flowmeter is
psi). Record the flow reading.
open. Start the engine. Run the engine at full
throttle. Make sure the oil is at operating 4. Divide the flow reading at 170 bar (2500 psi) by
temperature. the reading at 0 bar (0 psi). Multiply the result by
100. This is the percent efficiency of the pump. If
the efficiency of the pump is less than 85%,
repair or replace the pump.
11
9
12 NOTE
8
10
5 6 7
1
2 12
3 4
BS02M026
1. FROM HYDRAULIC RESERVOIR 5. BRAKE PUMP 9. FILTER INLET MANIFOLD

2. ELBOW 6. FLOWMETER INLET HOSE 10. FILTER
3. PLUG 7. CAS10280 FLOWMETER 11. FILTER TO RESERVOIR HOSE
4. TO ACCUMULATOR VALVE 8. FLOWMETER OUTLET HOSE 12. O-RING
NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION
BRAKE PUMP OUTPUT TEST

Copyright ©
7002-11
2 4
30 5
31
6
32
14 5
33 21
5 30
34
2 7
35 29
5
36 8
27 15
28 10
26 15
11
16 14
24 25 12
14
17
5
23 18 19
15
2
22 5 13
5
21 20
BC05G011
BRAKE VALVE EXPLODED VIEW

Copyright ©
7002-12
1. CAP SCREW (T 22 NM (16 LB-FT)) 13. CAP (T 60 NM (44 LB-FT)) 25. CHECK VALVE
2. O-RING 14. SPOOL 26. CARTRIDGE
3. BUSHING 15. PLUG (T 10 NM (88.5 LB-IN)) 27. PLUG (T 60 NM (44 LB-FT))
4. SLEEVE 16. PLUG (T 60 NM (44 LB-FT)) 28. JET
5. SPRING 17. PLUG (T 22NM (16 LB-FT)) 29. WVI UNIT
6. SPRING RETAINER 18. VALVE SEAT 30. PLUG (T 60 NM (44 LB-FT))
7. SPRING RETAINER 19. THROTTLE SCREW 31. PLUG (T 100 NM (74 LB-FT))
8. CIRCLIP 20. PLUG (T 22NM (16 LB-FT)) 32. RV UNIT
9. SHAFT SEAL 21. CAP 33. SPRING RETAINER
10. SLEEVE LVE 22. SLEEVE 34. SLEEVE
11. GUIDE RING 23. SPRING RETAINER 35. THRUST RING
12. O-RING 24. SLEEVE 36. SLEEVE LVV

Copyright ©
Section
7003
7003
BRAKE PUMP

Copyright ©
7003-2
TABLE OF CONTENTS
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Copyright ©
7003-3
1
2 4
3
5
6
7
8
9
10
9 11
7
9 6
5 13
9
8
14
12
BS08B054
1. OUTER SHAFT SEAL 8. QUAD RING

2. RETAINING RING 9. DOWEL PIN
3. SHAFT SEAL 10. GEAR HOUSING
4. SHAFT END COVER HOUSING 11. DRIVE GEAR
5. BACKUP RING 12. DRIVEN GEAR
6. CHANNEL SEAL 13. PORT END COVER HOUSING
7. THRUST PLATE 14. BOLT
PUMP ILLUSTRATION

Copyright ©
7003-4
BRAKE PUMP
1. Secure the pump by the port end cover (13) in a 1. Install shaft seal (3) into the shaft end cover
soft jawed vise. housing (4).
2. Draw a line the length of the pump to assist 2. Install the retaining ring (2) into the shaft end
during assemble. cover housing (4).
3. Loosen and remove bolts (14). 3. Install a new outer shaft seal (1) into the shaft
4. Tap the shaft end cover housing (4) with soft end cover housing (4).
hammer to loosen it, remove the shaft end cover 4. Place the shaft end housing (4), facing down,
housing (4). into a soft jawed vise.
5. Remove the backup ring (5), channel seal (6), 5. Install new backup rings (5) and channel seals
and thrust plate (7). (6) into the thrust plates (7).
6. Remove the drive gear (11) from the gear 6. Place an assembled thrust plate (7) onto the
housing (10). shaft end cover housing (4).
7. Remove the driven gear (12) from the gear IMPORTANT: Be sure to place the thrust plate (7) onto
housing (10). the shaft end cover housing (4) in the position shown in the
8. Tap the gear housing (10) with a soft hammer to illustration on page 3.
loosen it from the port end housing cover (13) . 7. Lubricate the driven gear (12) with hydraulic oil,
9. Remove the backup ring (5), channel seal (6), slide the driven gear (12) through the thrust plate
and thrust plate (7). (7) into the shaft end cover housing (4).
10. Remove the outer shaft seal (1) from the shaft 8. Lubricate the drive gear (11) with hydraulic oil,
end cover housing (4). slide the drive gear (11) through the thrust plate
(7) into the shaft end cover housing (4).
11. Remove the retaining ring (2) from the shaft end
cover housing (4). 9. Install a new quad ring (8) into the gear housing
(10). Check that dowel pins (9) are in place either
12. Remove the shaft seal (3) from the shaft end
in the gear housing (10) or the shaft end cover
cover housing (4).
housing (4).
Inspection 10. Align the marks made during disassembly,

carefully place the gear housing (10) onto the
gears.
1. Discard all seals and quad rings. Clean all parts
11. Slide the other assembled thrust plate (7) onto
in cleaning solvent. Check all machined surfaces
the shafts of the gears.
for damage or wear.
2. Hold a straightedge across each gear housing IMPORTANT: Be sure to place the thrust plate (7) onto
and use a feeler gauge to measure the amount the gears in the position shown in the illustration on page 3.
of wear caused by the gear teeth in the gear 12. Install a new quad ring (8) into the gear housing
pocket. If the wear in any gear pocket is more (10). Check that dowel pins (9) are in place either
than 0.18 MM. (0.007 inch), use a new gear in the gear housing (10) or the port end cover
housing. housing (13).
3. Inspect the thrust plates for scoring, pitting, or 13. Align the marks made during disassembly, place
other damage. the port housing (13) onto the gear housing (10).
4. Inspect the gears for wear and damage. There 14. Install bolts (14) with clean and dry threads.
must be no scoring on the gear hubs or on the Torque bolts to 192 ± 5.5 Nm
outside edges of the gear teeth. There must be (141.5 ± 4 pound feet).
no more than 0.05 MM. (0.002 inch) wear in the
seal area of the drive shaft. If any gear must be
discarded, you must use a new hydraulic pump.

Copyright ©
Section
7004
7004
BRAKE ACCUMULATORS

Copyright ©
7004-2
TABLE OF CONTENTS
ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Copyright ©
7004-3
ACCUMULATOR SPECIAL TORQUES

Gas Charging Valve ................................................................................................................20 Nm (15 pound-feet)
SPECIAL TOOLS
BS06M002 BC04A001
380001676 NITROGEN REGULATOR VALVE 380001168 ACCUMULATOR VALVE ADAPTER
NOTE: Check your inventory of tools, if you have nitrogen
charging kit CAS10899 use it in place of the above listed
tools.
BS06M003
380001390 ACCUMULATOR CHARGING HOSE

Copyright ©
7004-4
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR
B C
A
D
G E
BS07A156
NITROGEN CHARGING KIT
1. Use the Nitrogen Charging Kit to check 7. Connect valve A to the valve stem on the adapter
accumulator pressure. (F).
2. Close valve (E). 8. Connect the accumulator to the adapter (F)
3. Adjust the regulator (D) to the minimum pressure 9. Open valve on accumulator using the adapter’s
setting by turning the knob counterclockwise. square drive (G).
4. Turn the T-handle on valve (A) fully out. 10. Turn the T-handle inward on valve (A) to engage
5. Remove the valve cap from the accumulator. the pin in the valve stem on the adapter.
6. Install adapter 380001168 (F) onto the 11. Slowly open valve (E).
accumulator. 12. Check the charge pressure on gauge (B).
WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
M253A
WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar
(450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M406
WARNING: Do not expose the accumulator to temperatures above 49° C (120° F). A charged accumulator
contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M407

Copyright ©
7004-5
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

1. Use the Nitrogen Charging Kit to discharge the 7. Connect valve A to the valve stem on the adapter
accumulator, refer to the illustration on page 4. (F).
The tool must be disconnected from the nitrogen 8. Open valve on accumulator using the adapter’s
tank. square drive (G).
2. Close valve (E). 9. Turn the T-handle inward on valve (A) to engage
3. Adjust the regulator (D) to the minimum pressure the pin in the valve stem on the adapter.
setting by turning the knob counterclockwise. 10. Slowly open valve (E).
4. Turn the T-handle on valve (A) fully out. 11. Slowly open valve (D) and allow the nitrogen to
5. Remove the valve cap from the accumulator. bleed off.
6. Install adapter 380001168 (F) onto the
accumulator.

Copyright ©
7004-6
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

IMPORTANT: The four valves A, D, and E must be in the positions noted in the procedure before connecting the Nitrogen
Accumulator Charging Kit to the machine or nitrogen, refer to illustration on page 4.
1. Close the shutoff valve (D) by turning it all the 11. Fill the accumulator to pressure according to
way to the left (counterclockwise), refer to the Temperature/Charge Pressure chart.
TEMPERATURE CHARGE PRESSURE
2. Close the gauge valve (E) by turning it all the 0° C 32° F 51.2 BAR 743 PSI
way to the right (clockwise). 5° C 41° F 52.2 BAR 757 PSI
3. Connect the charging gauges to the nitrogen 10° C 50° F 53.1 BAR 770 PSI
supply tank, open the supply tank valve. 15° C 59° F 54.1 BAR 784 PSI
20° C 68° F 55.0 BAR 798 PSI
4. Slowly turn valve (D) clockwise while watching
25° C 77° F 55.9 BAR 811 PSI
the pressure gauge (B). Stop turning valve (D)
30° C 86° F 56.9 BAR 825 PSI
when the needle on the gauge (B) reaches 10
35° C 95° F 57.8 BAR 839 PSI
bar (145 psi).
40° C 104° F 58.8 BAR 852 PSI
NOTE: If the needle goes over the needed pressure, TEMPERATURE/CHARGE PRESSURE CHART
quickly open and close valve (E) and check the pressure
12. Close valve (E) by turning to the right
again.
(clockwise). After a few minutes open valve (E)
The charging kit is now ready to be installed on the and check the accumulator for leakage.
accumulator.
13. Back off the needle valve (A) on the accumulator
5. Remove the cap from the accumulator. end of the charging hose by turning it
6. Loosen the sealing plug with an Allen wrench. counterclockwise the maximum amount. This will
prevent nitrogen from escaping from the
NOTE: Just loosen do not open to far so the gas leaks out accumulator as the hose is removed.
7. Install adapter 380001168 (F). 14. Close the valve on the nitrogen supply tank.
8. Back off the needle valve (A) on the accumulator 15. Adjust the regulator (D) to the minimum pressure
end of the charging hose by turning it setting by turning the knob counterclockwise.
counterclockwise to the maximum amount. This
16. Slowly remove the charging hose from the
prevents nitrogen from escaping from the
accumulator pressure valve.
accumulator when the charging hose is attached
to the accumulator gas charging valve. NOTE: A small amount of nitrogen will escape when
9. Install the charging hose fitting onto the adapter. disconnecting the hose.
10. Tighten the needle valve by turning it clockwise. 17. Snug the gas charging valve on the accumulator,
Slowly open the gauge valve (E) and observe the remove the adapter from the accumulator.
reading on the gauge. This reading is the 18. Torque the gas charging valve to 20 Nm
nitrogen pressure level inside the accumulator. (15 pound feet)
19. Install the cap on the accumulator.
20. Remove the charging gauges from the nitrogen
supply tank.
NOTE: A small amount of nitrogen will escape when
disconnecting the hose.

Copyright ©
Section
7008
PARKING BRAKE
7008

Copyright ©
7008-2
TABLE OF CONTENTS
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Parking Brake Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STATIC PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dynamic Parking Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parking Brake Disable Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Copyright ©
7008-3
PARKING BRAKE
Disassembly STEP 7
STEP 1
Park the machine on a hard level surface and lower
the loader bucket to the ground.
STEP 2
Place wheel chocks on each wheel to prevent 1
machine movement.
STEP 3
2
BD0CA185
Loosen the jam nut (2), turn adjusting bolt (1)

counterclockwise until the brake pads are loose.
STEP 8
BD01F143
Install the articulation lock.
STEP 4
position.
STEP 5 BD03A186
Remove the retainer pin and brake pin.
Pump the brake pedal at least 30 times to discharge
the accumulators.
STEP 9
STEP 6
BD03A187
Remove the two brake pads from the parking brake
BD03A184 assembly.
Loosen and remove the cover from the parking
brake.

Copyright ©
7008-4
Inspection STEP 14
Disengage the parking brake switch.
STEP 10 NOTE: Hydraulic pressure will not be applied to the
Clean and inspect all parts for wear and damage. parking brake until the parking brake rocker switch is
Inspect the brake disc for wear and damage. turned off, the service brakes applied and the transmission
is put into gear.
Replace all parts that are worn or damaged.
A. Place the parking brake rocker switch in the
OFF position.
Assembly
B. Apply the service brake and put the machine
STEP 11 into gear.
C. The parking brake light on the cluster will turn
off at this time.
Place the transmission back into neutral before
proceeding.
Parking Brake Adjustment

Procedure
STEP 15
BD03A187
Install the two brake pads in the parking brake

assembly.
STEP 12 1
2
BD0CA185
Turn the adjusting bolt (1) clockwise until both brake

pads contact the brake disc, then turn the adjusting
bolt (1) counterclockwise 1/2 turn. Tighten the jam
nut (2) to secure the adjusting bolt.
STEP 16
BD03A186
Install the cover on the parking brake.
Install the brake pins and retainer pins.
STEP 17
STEP 13 Perform the Parking Brake Test Procedure as
Start the machine and run the engine at low idle with described in this section.
the bucket resting on the ground.
STEP 18
IMPORTANT: It will be necessary to have an assistant
Remove the articulation lock.
help for this procedure. An operator must be present in the
cab at all times to apply the service brakes and shut down
the machine in the event of mechanical failure. STEP 19
Place the master disconnect switch to the ON
position.

Copyright ©
7008-5
STATIC PARKING BRAKE TEST PROCEDURE

STEP 20 STEP 25
While testing, the machine must be on a clear level
surface with the bucket in the travel position.
WARNING: Always know the location of all

workers in your area. Warn them before you
start working the machine. Always keep all
other persons away from your area. Serious
injury or death can result if you do not follow
these instructions.
SA015
STEP 21
Start the machine and run the engine at low idle in BD06F142
third gear neutral. Use up or down arrow and highlight config, press the
enter key to select the config menu.
STEP 22
Place the Transmission-Auto switch to the manual STEP 26
position.
STEP 23
Place the Parking Brake switch to the ON position.
STEP 24
BD06F143
Press the up or down arrow and high light brake test,

press the enter key.
BD06F141
Press and hold the enter key for 2 to 3 seconds until

the instrument cluster monitor display changes to the
select screen.

Copyright ©
7008-6
STEP 27 STEP 32
Verify that the machine does not move.
STEP 33
Reduce the engine speed to low idle and return the
transmission to neutral.
STEP 34
BD06F144
Monitor will display “Test Park Brake” if all conditions
are met to test the brake, press the enter key.
NOTE: If all conditions are not met to test the brake the
monitor will display the condition that needs corrected prior
to proceeding. BD06F141
Press the escape switch on the key pad to exit the

STEP 28 test mode.
Shift the gear selector into third gear forward, monitor
will display “Test Park Brake Ready”. Slowly increase STEP 35
the engine speed to wide open throttle. If any machine movement was detected, the parking
brake must be adjusted, see procedures this section.
STEP 29
Verify that the machine does not move.
STEP 30
Reduce the engine speed to low idle and return the
transmission neutral.
STEP 31
Shift the gear selector to third gear reverse, monitor
will display “Test Park Brake Ready”. Slowly increase
the engine speed to wide open throttle.

Copyright ©
7008-7
Dynamic Parking Brake Test Parking Brake Disable Procedure

If it becomes necessary to tow a machine, the
STEP 36 parking brake must be disabled.
Start machine and run at low idle.
STEP 43
STEP 37 Park the machine on a hard level surface and lower
the loader bucket to the ground.
STEP 44
Place wheel chocks on each wheel to prevent
machine movement.
STEP 45
BD06F141
Cycle the parking brake switch to the OFF position
STEP 38
Shift the machine into 1st gear forward.
STEP 39
The parking brake light on the cluster will turn off at
this time. BD01F143
Install the articulation lock.

STEP 40
Allow machine to roll slowly forward. STEP 46
STEP 41 position.
Engage the parking brake with the parking brake
switch. STEP 47
Pump the brake pedal at least 30 times to discharge
STEP 42 the accumulators.
If machine does not come to an immediate stop the
parking brake must be adjusted.

Copyright ©
7008-8
STEP 48 STEP 49
2
BD03A184 BD03A185
Loosen and remove the cover from the parking Loosen the jam nut (2), turn adjusting bolt (1)
brake. counterclockwise until the brake pads are loose. The
parking brake is now disabled.
NOTE: Do not replace the cover on a parking brake that
has been disabled. The cover can be severely damaged if
hydraulic pressure is applied to a disabled parking brake.

Copyright ©
SECTION INDEX
HYDRAULICS
How to Read Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8000

Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001
Hydraulic Specifications, Troubleshooting, and Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002
Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003
Loader Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8005
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006
Coupler Solenoid Locking Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8007
Ride Control Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013
Ride Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8014

Copyright ©
Copyright ©
Section
8000
HOW TO READ HYDRAULIC SCHEMATICS
8000

Copyright ©
8000-2
TABLE OF CONTENTS
HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbol Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Using Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lines, Tubes, and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crossing or Joining Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pump Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Motor Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Control Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Directional Control Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Composite Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Flow Control Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SIMPLE SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
COMMON SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Line and Line Fuctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mechanical Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pumps and Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valve Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Copyright ©
8000-3
HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC
Introduction Using Schematic Symbols

A hydraulic schematic diagram is a line drawing Reservoirs
composed of hydraulic symbols that indicate the
types of the components the hydraulic circuit
contains and how they are interconnected. Accurate
diagrams of hydraulic circuits are essential to the
service technician who must repair them. The
VENTED RESERVOIR PRESSURIZED RESERVOIR
schematic diagram is a valuable aid in diagnosing
possible causes of a problem when troubleshooting BS07B620
machinery. A rectangle with the top removed represents a

vented reservoir. A rectangle with the top in place
The purpose of this section is to show how to read
represents a pressurized reservoir.
and effectively use schematic circuit diagrams.
Circuit Diagrams
1. Cutaway Circuit Diagrams show the internal
construction of the components, as well as the
flow paths. By using colors, shades or various PRESSURIZED RESERVOIR PRESSURIZED RESERVOIR
patterns in the lines and passages, they are able
BS07B621
to show many different conditions of flow and The are other schematic diagrams that show a
pressure. Cutaway diagrams take considerably slightly different version of a pressurized reservoir,
longer to produce because of their complexity. but the symbols are similar and easily recognized. An
2. Schematic Circuit Diagrams, the “shorthand” oval with a short line on top or a rectangle with
system of the industry, are usually preferred for curved sides represents a reservoir that is
troubleshooting. A schematic diagram is made pressurized.
up of simple geometric symbols for the
components and their controls and connections.
Symbol Systems
There are several systems of symbols used when RETURN LINE ABOVE
making schematic diagrams. They are as follows: THE OIL LEVEL
BS07B622
I.S.O. - International Standards Organization Lines connected to the reservoir usually are drawn
A.N.S.I. - American National Standards Institute from the top, regardless of where the actual
connection is.
A.S.A. - American Standards Association
J.I.C. - Joint Industry Conference
A combination of these symbols is shown in this
section. There are differences between the symbols,
but there is enough similarity so that if you
understand the symbols in this section, you will be SUCTION LINE OR RETURN LINE
able to interpret other symbols as well. BELOW THE OIL LEVEL
BS07B623
If the hydraulic line terminates below the fluid level, it
is drawn all the way to the bottom of the symbol
BS07B624
RESERVOIR WITH SUCTION LINE ATTACHED AT THE
BOTTOM

Copyright ©
8000-4
A hydraulic line connected to the bottom of the Lines, Tubes, and Hoses
reservoir may be drawn from the bottom of the A hydraulic line, tube, hose, or any conductor that
symbol if the bottom connection is essential to the carries the fluid between components is shown as a
system operation. line.
BS07B626
A working line, such as an inlet pressure or return, is
shown as a solid line.
BS07B625
If the pump inlet must be charged or flooded with a BS07B627
positive head of oil above the inlet port, the reservoir OIL FLOWS ONE WAY ONLY
symbol will be above the pump symbol with a suction
line drawn out of the bottom of the reservoir symbol.
Every vehicle or system reservoir has at least two
hydraulic lines connected to it, and some may have
many more. Often the components that are BS07B628
connected to the reservoir are spread all over the OIL CAN FLOW EITHER WAY
schematic. Rather than having a number of Working lines with arrows show direction of flow.
confusing lines all over the schematic, it is customary
to draw individual reservoir symbols close to the
components. The reservoir is usually the only
component symbol pictured more than once. BS07B629
Pilot or control lines are broken into long dashes.
BS07B630
Drain lines for leakage oil are broken into short
dashes.
BS07B631
A flexible line is show as an arc between two dots
and is always represented by a solid line.
BS07B632
Quite often you will see an enclosure outline that
indicates that there are several symbols that make
up a component assembly such as a valve or a valve
stack. The enclosure outline appears like a box and
is broken with dashes on all sides.

Copyright ©
8000-5
Crossing or Joining Lines
BS07B633 Variable Displacement Variable Displacement

LINES THAT ARE NOT CONNECTED Pressure Compensated
The shortest distance between two components that BS07B636
are connected is a straight line. There are lines that A variable displacement pump is designated by
cross other lines, but are not connected. There are a drawing an arrow through the pump symbol at 45
number of ways to show crossing lines. degrees. To indicate a variable displacement
pressure compensated pump, a small box with an
arrow in it will be added to the side of the pump
symbol
BS07B634
LINES THAT ARE CONNECTED
Lines that are connected are shown with a dot that
represents the connection or shown as a tee Lever Controlled Pedal or Treadle
connection. The dot connection is the most Controlled
commonly used when drawing schematic diagrams. BS07B637
If the pump is controlled by a lever or a pedal, it will
be shown on the side of the pump.
Pump Symbols
Outlet
Inlet
Pump with Drive Shaft Pump with Drive Shaft
and Directional Arrow
Fixed Displacement
Fixed Displacement
Reversible BS07B638
A drive shaft is shown as two short parallel lines
BS07B635 extending from the side of the pump. If a curved
There are many basic pump designs. A simple fixed arrow is shown on the drive shaft, it will indicate the
displacement pump is shown as a circle with a black direction of the rotation.
triangle that is pointing outwards. The black triangle
is like an arrow head and points in the direction that
the oil will flow. If the pump is reversible or designed
to pump in either direction, it will have two black
triangles in it and they will be opposite each other.

Copyright ©
8000-6
Hydraulic Motor Symbols
Double Rod End Cylinder

BS07B643
Nonreversible Motor Reversible Motor A double rod end cylinder has a rod extending from
BS07B639 each end of the rectangle.
Hydraulic motor symbols are circles with black
triangles, but opposite a pump the triangles point
inward to show the motor is a receiver of oil. One
triangle is used for a non-reversible motor and two
triangles are used for a reversible motor.
Single Rod End Fixed Cushion Both Ends
Pump BS07B644
Motor
BS07B640
A simple schematic diagram is shown with a
hydraulic motor connected to a hydraulic pump. Single Rod End Adjustable Cushion Rod End Only
Cylinder Symbols
730LBE
SINGLE ROD END ADJUSTABLE CUSHION ROD END ONLY
Some cylinders have cushions built into them. The
Tee cushion slows down the movement of the piston as it
Rectangle nears the end of its stroke. Cylinder cushions are
shown as a smaller rectangle on the piston. If the
cushion has an adjustable orifice, a slanted arrow is
drawn at 45 degrees across the symbol.
BS07B641
A cylinder symbol is a simple rectangle representing
the barrel. The piston and rod are represented by a
tee that is inserted into the rectangle. The symbol
can be drawn in any position.
Port
Single Acting Cylinder Double Acting Cylinder

BS07B642
If the cylinder is single acting, there is only one port
shown on the symbol. The port is shown on the end
of the cylinder that receives pressurized fluid and the
opposite end of the cylinder is left open.
A double acting cylinder symbol has both ends
closed and has two ports on the symbol.

Copyright ©
8000-7
Pressure Control Symbols Relief Valve

The basic symbol is a square (which is called an
envelope) with external port connections and an Pressure Line
arrow inside to show the oil passage and direction of
flow. Usually this type of valve operates by balancing
the oil pressure against a spring, so a spring is
shown on one side of the symbol and a pilot pressure
line on the other side.
Pump Relief
Normally Closed Valve
Arrow Offset Arrow Aligned BS07B648
From Ports With Ports
A relief valve is shown as a normally closed symbol
Inlet connected between the pressure line and the
Pilot
Line reservoir. The flow direction arrow points away from
Spring the pressure line port and toward the reservoir. This
shows very graphically how a relief valve operates.
When pressure in the system overcomes the valve
Outlet Visualize square spring, flow is from the pressure line through the
Normally Closed moving toward spring relief valve to the reservoir.
BS07B646
A normally closed valve, such as a relief or sequence Pressure Reducing Valve
valve, is shown with the arrow offset from the ports High Pressure Inlet
and toward the pilot pressure line side of the square.
The spring holds the valve closed until the pilot line
oil pressure is greater than the spring pressure.
Mentally visualize a build up of pressure in the pilot Pilot
Line Drain Line to
line and the square moving over, compressing the
spring. The oil now can flow through the valve. Reservoir
Reduced Outlet Pressure

Normally open
BS07B649
A pressure reducing valve is shown as a normally
Inlet Pilot open symbol in a pressure line. This valve works
Line opposite of a relief valve, since it senses outlet
Spring
pressure versus inlet pressure. As the outlet
pressure builds, it works against a predetermined
spring force. As the spring force is overcome, flow
Outlet Visualize square
Normally Open through the valve is modulated or shut off.
moving toward spring
BS07B647
A normally open valve is shown with the arrow
connecting the two ports. It closes when the pressure
overcomes spring force. Mentally visualize a build up
of pressure in the pilot line and the square moving
over, compressing the spring. The oil flow through
the valve is now blocked.

Copyright ©
8000-8
Sequence Valve Directional Control Symbols
Supply Line Simplified Symbols
To Primary One Way Valve
Relief Cylinder
Valve Pump
No Flow
Sequence
Valve Free Flow
To Secondary
Cylinder BS07B676
A simple ball check valve is shown. When oil
BS07B650
pressure is exerted on the left side of the ball, the ball
The normally closed symbol is also used for a
is forced into the V and no oil can flow past it. When
sequence valve. The inlet port is connected to a
oil pressure is applied to the right side of the ball, the
primary cylinder and the outlet port o the secondary
ball moves away from the V and oil can flow past.
cylinder line. When the piston in the primary cylinder
reaches the end of its stroke, the pressure in the
supply line increases. The sequence valve is also By Pass Valve
connected to the supply line and also feels the
increase in pressure. As pressure increases, the
square and directional flow arrow moves over,
connecting the inlet and outlet ports, allowing fluid to Spring
flow to the secondary cylinder.
BS07B677
A by pass valve is shown as a one way valve with a
spring on the ball end of the symbol. This shows that
a pressurized flow will be necessary to overcome the
spring force and allow flow around the ball.

Copyright ©
8000-9
Composite Symbols Three - Position Valves
One - Way Valves
Free
Flow
No BS07B680
Flow Visualize a build up OPEN CENTER THREE POSITION VALVE
of pressure on the
One way valve shown right side of valve
in the closed position
BS07B678
A more complex one way valve is shown. This
directional control symbol uses a multiple envelope
(square) system that has a separate square for each
position. Remember all of the port connections are
made to the envelope that shows the neutral BS07B681
condition of the valve. Within each envelope are CLOSED CENTER THREE POSITION VALVE
arrows showing the flow paths when the valve is Three position valves will have a centered (neutral)
shifted to that position. position. The centered position can be either open or
closed to flow. The open center is usually used with a
Two - Position Valves fixed displacement pump and the closed center is
Cylinder usually used with a variable displacement pump.
Control Valve
Pump Rod End
Relief
Valve
Cylinder
Piston End
BS07B679
A simple control valve has two envelopes
(representing the spool) if it is a two position valve.
The envelopes show the flow conditions when they
are in one position. The above schematic is showing
that oil is being supplied to the rod end of the
cylinder. If we visualize the directional control valve
moved to the other position, it would be shown as
below.
BS07B710
Pressurized oil is being supplied to the piston end of
the cylinder and oil from the rod end of the cylinder is
allowed to flow to the reservoir.

Copyright ©
8000-10
Actuating Controls Flow Control Symbols
Restrictors
Lever
Pedal
Non Adjustable Adjustable
Restrictor Restrictor
BS07B682
BS07B686
The basic flow control symbol is a representation of a

restrictor. If the restrictor is adjustable, a slanted
arrow is drawn across the symbol. The restrictor
could be a special fitting with a small hole in it or a
small drilled passageway within a valve. If it is an
Two Position Controlled Two Position adjustable restriction, it could be thought of as a
by External Controlled water faucet that can be controlled by turning the
Pilot Pressure By Solenoids handle to regulate the flow. Restrictors can be
applied to meter out, meter in, and bleed off circuits.
BS07B683
Adjustable Restrictor Adjustable Restrictor

Three Position, Solenoid Controlled Pressure Pressure and
With Internal Pilot Assist Pressure Compensated Temperature
BS07B684
Compensated
Valve spools are controlled by levers, pedals, pilot BS07B687
oil, electric solenoids, etc. which are called actuating There are adjustable restrictors that are pressure
controls. These actuating controls are shown by compensated. That means that the size of the
symbols placed on the ends of the envelopes. openings in the restrictor will change with increases
and decreases in pressure. A perpendicular arrow
Solenoid Control With Internal indicates pressure compensation. If the restrictor has
Pilot Pressure both pressure and temperature compensation, the
symbol for a thermometer will also be shown.
BS07B685
THREE POSITION, SPRING CENTERED
To show that a valve is spring centered, a spring
symbol is placed at each end of the envelope. The
above schematic shows that an electrical solenoid
and pilot pressure assist are required to overcome
spring force to move the valve spool.

Copyright ©
8000-11
Accessories An oval with details inside indicates an accumulator.

The details inside will tell you what type of
Filters, strainers, and heat exchangers are
accumulator it is: spring loaded, gas charged, or
represented as squares that are turned 45 degrees
other features.
and have the port connection at the corners.
Gas Charged
Filter or Strainer
BS07B691
BS07B688
A dotted line perpendicular to the flow line indicates a The divider line indicates there is a separator
filter or strainer. between the charge and the oil. A hollow triangle
indicates gas.
Cooler
Spring Loaded
BS07B689
A solid line perpendicular to the flow with black BS07B692
triangles pointing out indicates a cooler. A spring shows that the accumulator is spring
loaded.
Heater
BS07B690
The symbol for a heater is like the symbol for a
cooler, except the black triangles point in.
Temperature Control Unit

BS07B693
Two sets of triangles pointing in and out indicates a
temperature control.
As you can see, the black triangles point in the
direction that the heat is dissipated. or in the case of
the control unit, they show that the heat can be
regulated.

Copyright ©
8000-12
SIMPLE SCHEMATIC
The illustration below has put some of the previous symbols together to form a simple hydraulic schematic. See if
you can find your way around the schematic without reading the text for each valve. The text explains the function
of each valve.
Detent
D Float
C
C
B
BS07B596

Copyright ©
8000-13
Valve A Valve C
This valve is a three position valve. The spool is lever This valve is also similar to valve A, but is designed
operated and spring centered. It is an open center to control a single acting cylinder. When you
valve. Visually place the envelopes into the center visualize placing the upper envelope in the center
position and you will see that the valve will direct oil position you will see that oil can drain back to the
into one end or the other of cylinder A. when the reservoir from cylinder C.
spool in valve A is moved out of the centered At the same time, oil from the pump can flow through
position, the valves downstream will receive no oil. valve C to the next valve.
Valve B Valve D
Valve B is similar to valve A but it is a four position Valve D is a lever operated, spring centered valve
valve. The fourth position is a float position and is and is designed to control a hydraulic motor. If a
held into that position with a detent. With this valve hydraulic motor was turning a flywheel and the oil
the cylinder B can be extended, retracted, or placed supply and return were shut off abruptly, this would
in the float position. Visualize the envelope for the cause damage to the hydraulic lines, the motor, or
float position in the inlet passageway. whatever it was powering. Therefore when the valve
You will see that oil can continue to flow to the next supplying the motor is shut off, the motor should be
valve downstream and that the rod in cylinder B able to slow down gradually. The center (neutral)
could be pushed back and forth. The oil could move position of valve D will allow that to happen by letting
from one end of the cylinder. oil from the outlet of the motor return to the inlet side.
Use this information to read hydraulic schematics.
The more experience you have reading schematics,
the easier and more comfortable it will become to
use hydraulic schematics as a troubleshooting guide.

Copyright ©
8000-14
COMMON SYMBOLS
Line and Line Fuctions Mechanical Devices
Mechanical Connections
Solid Line Two Parallel Lines
Main Line (Shafts, Levers, etc.)
Dashed Line
Pilot Line
Dotted Line
Exhaust or Drain
Variable Component
(Run arrow through
Enclosure symbol at 45°)
Outline
Lines
Crossing
Spring
Lines
Crossing
BS07B696
Lines
Joining
Liquid Direction
of Flow
Gaseous Direction
of Flow
Flexible Line
BS07B694

Copyright ©
8000-15
Pumps and Motors Reservoirs

Hydraulic Pump
Fixed Displacement Reservoir Open
to Atmospere
Hydraulic Pump
Variable Displacement Pressurized Reservoir
Pressure
Compensated Variable
Displacement Pump Line to Reservoir
Below Fluid Level
Fixed Displacement
Hydraulic Pump
(Two Directional Flow) Line to Rexervoir
Above Fluid Level
BS07B699
Hydraulic Motor
Fixed Displacement
Hydraulic Motor
Variable Displacement
Hydraulic Oscillator
BS07B695

Copyright ©
8000-16
Cylinders Valves
Single Acting
Check Valve
Pilot Operated
Double Acting
Check
Single Rod End
On-Off
Double Acting Manual Shut-off
Double Rod End
Single Rod End Pressure

Fixed Cushion Reducing Valves
Both Ends
Single Rod End
Rod End Only Non-Adjustable

Adjustable Cushion Restrictor
Differential
Cylinder
Adjustable
BS07B706
Restrictor
Adjustable
Restrictor
Pressure
Compensated
Adjustable
Restrictor
(Temperature and
Pressure
Compensated)
BS07B697

Copyright ©
8000-17
Valve Actuators
Regulating or
Selector Valves
Solenoid
2-Position
2-Way Valve
Detent
2-Position
3-Way Valve
Spring
2-Position
4-Way Valve
Manual
3-Position
4-Way Valve
Push Button
2-Position 4-Way
Open Center
Cross Over Push-Pull
Lever
Valve Capable of
Infinite Positioning
(Indicated by
Horizontal Lines
Drawn Parallel to Pedal
the Envelope)
Pressure Relief
Valve
Mechanical
BS07B698
BS07B700

Copyright ©
8000-18
Accessories
Pressure
Compensated
Filter
Cooler
Pilot Pressure
Remote Supply
Heater
Temperature
Controller
Liquid Supply
Accumulator
Hydro-Pneumatic
BS07B708
Reversing
Motor
Station or
Test Point
Pressure
Indicator
Temperature
Indicator
BS07B705

Copyright ©
8000-19
Presssure
Switch
Quick Disconnects
(Disconnected)
Quick Disconnects
(Connected)
BS07B707

Copyright ©
8000-20
NOTES

Copyright ©
8001
Section
8001
REMOVAL AND INSTALLATION OF HYDRAULIC

COMPONENTS

Copyright ©
8001-2
TABLE OF CONTENTS
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 spool line removal and installation illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 spool line removal and installation illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Joystick and 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Joystick and 1 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Joystick Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
BUCKET CYLINDER - Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Z-bar Loader Bucket Cylinder Removal And Installation Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BUCKET CYLINDERS - XT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
XT Loader Bucket Cylinder Removal And Installation Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
THERMAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Copyright ©
8001-3
LOADER CONTROL VALVE
Removal STEP 5
STEP 1 position.
Park the machine on a level surface.
STEP 6
IMPORTANT: If machine is equipped with quick-attached
proceeding.
STEP 2
BD06F213
Relieve the pressure in the ride control accumulator

with the manual bleeder valve located on the bottom
of the ride control valve. Remove the plug and turn
the valve two turns counter-clockwise.
BD03A092
Raise the lift arms and install the safety link on the lift STEP 7
arm cylinder.
Loosen the filler cap on the reservoir to release the
air pressure in the reservoir.
STEP 3
STEP 8
Drain the hydraulic reservoir.
STEP 9
BD01F143-01
Put articulation lock in the LOCKED position.
STEP 4
Stop the engine and apply the parking brake.
BD07N613-01
IMPORTANT: With the engine NOT running, pump the Loosen and remove the bolts and washers that
brake repeatedly to be sure the brake accumulators have no fasten the access cover plate for the loader control
hydraulic pressure, put the ignition switch in the ON valve. Remove the cover plate.
position then move the loader control valve back and forth
several times to release any hydraulic pressure in the pilot
control circuit, turn ignition switch OFF.

Copyright ©
8001-4
REAR OF MACHINE
5
6
2
BS07H031
1. LOADER CONTROL VALVE 4. CHECK VALVE

2. PILOT ACCUMULATOR HOSE 5. SWITCH FITTING (XT WITH RIDE CONTROL ONLY)
3. PILOT PRESSURE HOSE 6. SWITCH (XT WITH RIDE CONTROL ONLY)
4 SPOOL LINE REMOVAL AND INSTALLATION ILLUSTRATION

Copyright ©
8001-5
11
12
10
9
8
6
5
BS08A048
1. LOADER CONTROL VALVE 7. PILOT 3 SPOOL RIGHT HOSE (RED AND WHITE)
2. PILOT ACCUMULATOR HOSE 8. PILOT LIFT RIGHT HOSE (YELLOW AND BLACK)
3. PILOT PRESSURE HOSE 9. PILOT TILT RIGHT HOSE (ORANGE AND BLACK)
4. CHECK VALVE 10. PILOT TILT LEFT HOSE (GREEN AND BLACK)
5. SWITCH FITTING (XT WITH RIDE CONTROL ONLY) 11. PILOT LIFT LEFT HOSE (RED AND BLACK)
6. SWITCH (XT WITH RIDE CONTROL ONLY) 12. PILOT 3 SPOOL LEFT HOSE (YELLOW AND WHITE)

Copyright ©
8001-6
10
9
7 8
4
6
3
BS08A047
1. LOADER CONTROL VALVE 6. SWITCH (XT WITH RIDE CONTROL ONLY)


Copyright ©
8001-7
STEP 10 STEP 13
Disconnect the hoses from the remote control
valve(s) at the loader control valve one at a time and
fasten an identification tag to each hose. Refer to the 1
illustrations above. 2
STEP 11
Install a plug in each hose and a cap on each fitting.
4
STEP 12 3
2
BD01D381
1. ROD END TILT TUBE 3. HEAD END LIFT TUBE

4
3 1 2. HEAD END TILT TUBE 4. ROD END LIFT TUBE
A. Tag and disconnect the rod end tilt tube (1)
from the loader control valve and install a plug
5 in the tube and a cap on the fitting.
B. Tag and disconnect the head end tilt tube (2)
6 from the loader control valve and install a plug
in the tube and a cap on the fitting.
BD01D376
C. Tag and disconnect the head end lift tube (3)
1. VALVE RETURN HOSE
2. RIDE CONTROL TANK HOSE
from the loader control valve and install a plug
3. ACCUMULATOR DRAIN HOSE in the tube and a cap on the fitting.
4. PUMP LOAD SENSING HOSE D. Tag and disconnect the rod end lift tube (4)
5. STEERING LOAD SENSING HOSE from the loader control valve and install a plug
6. STEERING PRESSURE HOSE in the tube and a cap on the fitting.
7. PUMP PRESSURE HOSE (NOT SHOWN)
E. Tag and disconnect any auxiliary spool tubes
A. Tag and disconnect the valve return hose (1) if equipped.
at the loader control valve and install a plug in
the hose and a cap on the fitting.
B. Tag and disconnect the pump pressure hose
(7). Plug the hose and install cap on fitting.
NOTE: The pump pressure hose (7) will be connected to a
elbow at the bottom of the loader control valve.
C. Tag and disconnect the ride control tank hose
(2) and install a plug in the hose and a cap on
the fitting.
D. Tag and disconnect the accumulator drain
hose (3) and install a plug in the hose and a
cap on the fitting.
E. Tag and disconnect the pump load sensing
cap on the fitting.
F. Tag and disconnect the steering load sensing
cap on the fitting.
G. Tag and disconnect the steering pressure
cap on the fitting.

Copyright ©
8001-8
STEP 14
BS01D190
Loosen and remove the three bolts and washers that
hold the loader control valve to the valve mounting
plate.
STEP 15
Use proper lifting device to lift and remove the loader
control valve.

Copyright ©
8001-9
STEP 16
2
4
3 1
6
BD01D376
1. VALVE RETURN HOSE

2. RIDE CONTROL TANK HOSE
3. ACCUMULATOR DRAIN HOSE
4. PUMP LOAD SENSING HOSE
5. STEERING LOAD SENSING HOSE
6. STEERING PRESSURE HOSE
BS01D190
7. PUMP PRESSURE HOSE (NOT SHOWN)
A. Install and align the loader control valve with
the valve mounting plate. A. Connect the steering pressure hose (6) to the
loader control valve.
B. Install the bolts and washers that fasten the
loader control valve to the valve mounting B. Connect the steering load sensing hose (5) to
plate. Tighten the bolts. the loader control valve.
C. Before installing the fittings or connecting the C. Connect the pump load sensing hose (4) to
tubes to the fittings, install new O-rings on the the loader control valve.
fittings.
D. Connect the accumulator drain hose (3) to the
STEP 17
E. Connect the ride control tank hose (2) to the
loader control valve/
1
2 F. Connect the pump pressure hose (7) to the
bottom of the loader control valve.
G. Connect the valve return hose (1) to the
4
3
BD01D3811
1. ROD END TILT TUBE 3. HEAD END LIFT TUBE

2. HEAD END TILT TUBE 4. ROD END LIFT TUBE
A. Connect the rod end lift tube (4) to the loader
control valve.
B. Connect the head end lift tube (3) to the
C. Connect the head end tilt tube (2) to the
D. Connect the rod end tilt tube (1) to the loader
control valve.
Copyright ©
8001-10
REAR OF MACHINE
5
6
2
BS07H031
1. LOADER CONTROL VALVE 4. CHECK VALVE

2. PILOT ACCUMULATOR HOSE 5. SWITCH FITTING (XT WITH RIDE CONTROL ONLY)
3. PILOT PRESSURE HOSE 6. SWITCH (XT WITH RIDE CONTROL ONLY)

Copyright ©
8001-11
11
12
10
9
8
6
5
BS08A048
1. LOADER CONTROL VALVE 7. PILOT 3 SPOOL RIGHT HOSE (RED AND WHITE)
6. SWITCH (XT WITH RIDE CONTROL ONLY) 12. PILOT 3 SPOOL LEFT HOSE (YELLOW AND WHITE)

Copyright ©
8001-12
10
9
7 8
4
6
3
BS08A047
1. LOADER CONTROL VALVE 6. SWITCH (XT WITH RIDE CONTROL ONLY)


Copyright ©
8001-13
STEP 19 STEP 23
Connect the lines from the remote control valve to
the loader contro l valve. Refer to the ab ove
illustration.
STEP 20
BD03A092
Raise the loader arms and remove the safety link.
STEP 24
Put the articulation lock in the OPERATING position.
BD06F213
Tighten the accumulator manual bleeder valve STEP 25

located on the bottom of the ride control valve to a Start the engine and run at half throttle.
torque of 3.5 Nm (31 lb-in). Install the plug and
torque to 7 Nm (62 lb-in).
STEP 26
Slowly and completely extend and retract all
STEP 21
cylinders at least 10 times to remove any air from the
Fill the hydraulic reservoir with oil. Refer to Section circuits.
1002 for the correct oil.
STEP 27
STEP 22
Stop the engine and check for leaks.
position.
STEP 28
Install the access cover on the front of the machine.
STEP 29
Check the level of the hydraulic oil and add hydraulic
oil as required.

Copyright ©
8001-14
REMOTE CONTROL VALVE
Removal STEP 34
STEP 30
parking brake.
IMPORTANT: With the engine NOT running, pump the
brake repeatedly to be sure the brake accumulators have no
hydraulic pressure, put the ignition switch in the ON
BD06F209-01
STEP 31 Remove the front access panel.

position. STEP 35
STEP 32
BD06F210-01
Disconnect the electrical connectors for the remote

control valve.
BD06F207-01
Unlatch and open the window on the right hand side. STEP 36
Loosen the filler cap on the reservoir to release any
STEP 33 air in the reservoir. Connect a vacuum pump to the
hydraulic reservoir, turn on the pump.
STEP 37
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install
plugs in the hoses and caps on the fittings.
STEP 38
Loosen and remove the screws and washers holding
the hydraulic control tower cover. Remove the cover.
STEP 39
BD06F208-01 Loosen and remove the screws that fasten the
Open and remove the access panel. remote control valve to the hydraulic control tower.
STEP 40
Remove the remote control valve from the hydraulic
control tower.
Copyright ©
8001-15
STEP 41 position.
Install new O-rings on the adapters for the remote
control valve. STEP 48
Start the engine and run the engine at low idle.
STEP 42
Install the remote control valve and screws in the STEP 49
hydraulic control tower and tighten the screws. Check to see that the remote control valve works
correctly.
STEP 43
Install the cover over the remote control valve and STEP 50
install the screws and washers. Check for hydraulic oil leakage at the remote control
valve.
STEP 44
Remove the plugs from the hoses and the caps from STEP 51
the fittings and connect the hydraulic hoses to the Check the level of hydraulic oil in the reservoir and
fittings according to the identification tags. (Refer to add as required.
illustrations on pages 17, 18, and 19 as necessary.
STEP 52
STEP 45
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.
STEP 46
BD06F209-01
Position the access panel on the ROPS cab or the

ROPS canopy and install and tighten the screw.
BD06F210-01
Connect the electrical connectors for the remote

control valve.

Copyright ©
8001-16
STEP 53 STEP 54
BD06F208-01
Install and close the access panel. BD06F207-01
Close the right hand window.

Copyright ©
8001-17
1 2 3 4
10 5
9 7 6
8
1 9
2 8
10 7
3 6
4 5
BS07D284
1. ORANGE BLACK 5. ORANGE WHITE 8. GREEN BLACK

2. YELLOW BLACK 6. YELLOW WHITE 9. RED BLACK
3. RED WHITE 7. PILOT PRESSURE HOSE 10. PILOT TANK HOSE
4. GREEN WHITE
JOYSTICK AND 2 LEVER HOSE COLOR CODING

Copyright ©
8001-18
2
2
3
8
6
3
7 5
4
7
6 1
8
5
5 3
5 3
7
7 6
6 2
2 4
4 1
1 8
8
BS07D283
1. YELLOW WHITE 1. YELLOW WHITE

2. PILOT PRESSURE HOSE 2. PILOT PRESSURE HOSE
3. RED BLACK 3. RED BLACK
4. PILOT TANK HOSE 4. PILOT TANK HOSE
5. ORANGE BLACK 5. ORANGE BLACK
6. YELLOW BLACK 6. YELLOW BLACK
7. GREEN BLACK 7. GREEN BLACK
8. RED WHITE 8. RED WHITE
JOYSTICK AND 1 LEVER HOSE COLOR CODING 3 LEVER HOSE COLOR CODING

Copyright ©
8001-19
6 2
5 3
4
4 2
5 6
3 1
BS07D285
1. PILOT PRESSURE HOSE

2. RED BLACK
3. PILOT TANK HOSE
4. ORANGE BLACK
5. YELLOW BLACK
6. GREEN BLACK
JOYSTICK HOSE COLOR CODING

Copyright ©
8001-20
HYDRAULIC PUMP
Removal STEP 59
STEP 55
parking brake.
4
STEP 56 1
3
position.
2
STEP 57
Drain the hydraulic reservoir then refer to Section
9007 and remove the ROPS cab or ROPS canopy. BD01D308
1. PRESSURE HOSE 3. HYDRAULIC PUMP

STEP 58 2. BOLTS (4) 4. LOAD SENSING HOSE
A. Loosen and remove the four bolts (2)
connecting the pressure hose (1) to the
hydraulic pump (3).
B. Tag and disconnect the load sensing hose (4)
2 from the hydraulic pump (3).
C. Plug all lines and cap all fittings.
1
STEP 60
4 3
2
BD01D303
1. SUCTION HOSE 3. HYDRAULIC PUMP

2. BOLTS (4) 4. CASE DRAIN HOSE
A. Loosen and remove the four bolts (2)
connecting the suction hose (1) to the
hydraulic pump (3).
B. Tag and disconnect the case drain hose (4)
from the top of the hydraulic pump (3).
C. Plug all lines and cap all fittings. BD01D333
Use proper lifting device to strap and support the

hydraulic pump.

Copyright ©
8001-21
STEP 64
BD01D307
Loosen and remove the two bolts that fasten the

hydraulic pump to the transmission. BD01D335
Use proper lifting device to lift and support the

STEP 62 hydraulic pump. Install a new O-ring on the hydraulic
Remove the hydraulic pump from the machine. pump.
STEP 63 STEP 65
BD01D335 BD01D334
Remove and discard the O-ring from the hydraulic Install the hydraulic pump on the transmission.
pump.
STEP 66
BD01D3077
Install the two bolts that fasten the hydraulic pump to

the transmission. Tighten the two bolts to a torque of
335 to 375 Nm (245 to 275 lb ft).

Copyright ©
8001-22
STEP 67 STEP 69
See Section 9007 for installing the ROPS cab or
ROPS canopy.
STEP 70
Fill the hydraulic reservoir with hydraulic oil. See
4 Section 1002 for correct oil type.
1
3 STEP 71
2 position.
STEP 72
BD01D308 Start the engine and run the engine at low idle for two
1. PRESSURE HOSE 3. HYDRAULIC PUMP minutes.
2. BOLTS (4) 4. LOAD SENSING HOSE
NOTE: If any unusual vibration is heard coming from the
A. Install the pressure hose (1) to the hydraulic pump, stop the machine immediately and check for
pump (3) using four bolts (2). obstructions in the pump suction line.
B. Install the load sensing hose (4) to the
hydraulic pump (3). STEP 73
Stop the engine and check for hydraulic oil leakage
STEP 68 at the hydraulic pump.
STEP 74
Check the level of the hydraulic oil in the reservoir
and add hydraulic oil as required.
2
4 3
2
BD01D303
1. SUCTION HOSE 3. HYDRAULIC PUMP

2. BOLTS (4) 4. CASE DRAIN HOSE
A. Install the suction hose (1) to the hydraulic
pump (3) using four bolts (2).
B. Install the case drain hose (4) to the hydraulic
pump (3).

Copyright ©
8001-23
LIFT CYLINDERS
Removal STEP 79
STEP 75
parking brake.
STEP 76 BD01D709
Relieve the pressure in the ride control accumulator Loosen and remove the bolt, washer and spacer that
with the manual bleeder valve located at the rear of hold the pivot pin for the yoke.
the front chassis.
STEP 80
STEP 77
Loosen the filler cap on the hydraulic reservoir to
release any pressure.
STEP 78
BD01D711
Use a proper lifting device and secure a strap around

the lift cylinder.
STEP 81
BD01D708
Tag and disconnect the hoses on each side of the lift

cylinder. Install plugs in the hoses and caps on the
fittings.
BD01D712
Remove the pivot pin from the yoke end of the lift
cylinder.

Copyright ©
8001-24
STEP 85
Apply antiseize compound to the bores in the front
frame and the yoke on the piston rod.
STEP 86
BD01D710
Loosen and remove the bolt, washer and spacer that

hold the pivot pin at the closed end of the lift cylinder.
STEP 83
BD01D714
Use a proper lifting device and position the lift

cylinder on the machine.
STEP 87
BD01D713
Remove the pivot pin from the closed end of the lift
cylinder.
STEP 84
Remove the lift cylinder from the machine
BD01D713
Align the closed end of the lift cylinder with the front
frame and install the pivot pin.

Copyright ©
8001-25
STEP 88 STEP 91
BD01D710 BD01D712
Align the pivot pin with the front frame and install the Install the pivot pin for the yoke. Stop the engine.
spacer, washer and bolt. Tighten the bolt.
STEP 92
STEP 89
BD01D709
BD01D708 Align the pivot pin with the yoke and install the
Remove the caps and plugs and connect the hoses spacer, washer and bolt. Tighten the bolt.
to the lift cylinder.
STEP 93
STEP 90 SLOWLY extend and retract the piston rod three
If the yoke of the lift cylinder is not aligned with the times to remove any air from the lift cylinders.
loader frame, have another person start and run the
engine at low idle and use the loader control lever to STEP 94
SLOWLY move the yoke into alignment with the Lubricate the pivot pins with molydisulfide grease.
loader frame.
STEP 95
Check the level of hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the

Copyright ©
8001-26
BUCKET CYLINDER - Z-BAR LOADER
9 5
3
2 1
4
7
3 7
2
8 10
4
5
1 5
2
6
1 4
3
BS08A049
1. BOLT 6. WIPER
2. WASHER 7. WASHER
3. GREASE FITTING 8. LIFT CYLINDER
4. PIVOT PIN 9. BUCKET CYLINDER
5. SPACER 10. BELLCRANK
Z-BAR LOADER BUCKET CYLINDER REMOVAL AND INSTALLATION ILLUSTRATION

Copyright ©
8001-27
Removal STEP 100
STEP 96
parking brake.
STEP 97
With the engine stopped, move the bucket control
lever to release pressure in the bucket circuit.
STEP 98
BD01D695

mounting bracket to the machine. Remove the
mounting bracket.
STEP 101
BD01D694
Disconnect the proximity switch connector from the

wiring harness connector.
STEP 99
BD01D697

mounting bracket for the proximity switch to the
bucket cylinder. Remove the mounting bracket and
switch.
STEP 102
BD01D696

target bar to the mounting bracket. Remove the
target bar.
BD01D699
Disconnect the hoses from each side of the bucket

cylinder. Install plugs in the hoses and caps on the
fittings.
Copyright ©
8001-28
STEP 103 STEP 106
BD01D700 BD01D704
Use acceptable equipment to hold the bucket Remove the pivot pin from the head end of the
cylinder. bucket cylinder.
NOTE: It is not necessary to remove the grease line from
STEP 104 the pivot pin unless the pivot pin is to be replaced.
STEP 107
BD01D698
Loosen and remove the bolt, washer and spacer that

fasten the pivot pin from both ends of the bucket
BD01D706
cylinder.
Raise the bucket cylinder and remove the cylinder
from the machine.
STEP 105
BD01D701
Remove the pivot pin from the rod end of the bucket
cylinder.

Copyright ©
8001-29
STEP 108
Apply antisieze compound to the bores in the front
frame and the bores in the loader arm for the bucket
cylinder.
STEP 109
BD01D699
Connect the hoses to each side of the bucket

cylinder.
STEP 113
If the rod end of the bucket cylinder is not aligned
with the bellcrank, have another person start the
BD01D706
engine and run the engine at low idle and use the
Use acceptable lifting equipment to lower the bucket bucket control lever to SLOWLY move the piston rod
cylinder into position. eye into alignment with the bellcrank.
STEP 110 STEP 114

Install the pivot pin and stop the engine.
STEP 115
BD01D704
Install the pivot pin to the head end of the bucket

cylinder.
BD01D698
STEP 111 Install the spacer, washer and bolt that fasten the
Install the spacer, washer and bolt that fasten the pivot pin to the bellcrank. Tighten the bolt.
pivot pin to the front frame. Tighten the bolt.
NOTE: If a new pivot pin is being installed, connect the
grease line to the pivot pin.

Copyright ©
8001-30
STEP 116 STEP 119
BD01D697 BD01D694
Install the two bolts that fasten the mounting bracket Connect the proximity switch connector to the wiring
for the switch to the bucket cylinder. harness connector.
STEP 117 STEP 120

See Section 9006 for the adjustment procedure for
adjusting the proximity switch.
STEP 121
Start and run the engine at low idle.
STEP 122
SLOWLY extend and retract the piston rod three
times to remove any air from the bucket cylinder.
STEP 123
Lubricate the pivot pins with molydisulfide grease.
BD01D695
Install the two bolts for the mounting bracket for the STEP 124
target bar.
and add as required. Tighten the filler cap on the
STEP 118 hydraulic reservoir.
BD01D696
Install the two bolts that fasten the target bar to the
mounting bracket.

Copyright ©
8001-31
BUCKET CYLINDERS - XT LOADER
Removal STEP 128

Disconnect the hoses from the elbows at both ports
STEP 125 of the bucket cylinders. Install a plug in the tube and
Lower the bucket to the floor. With the engine a cap on the elbow.
stopped, move the bucket control lever to release
any pressure in the bucket circuit. STEP 129
Remove the roll pin (1) from the yoke (2). Remove
NOTE: The following two steps apply only to the left hand
the pivot pin (3). Refer to the illustration on page 32.
bucket cylinder.
STEP 130
STEP 126
Loosen and remove the nuts (4) and washers (5) at
the top and bottom of the cylinder bellcrank.
2
3 STEP 131
Remove the inner bellcrank (6) from the pivot pins
(7).
5 STEP 132
1 Remove the bolt (8) and the grease line (9) from the
bucket cylinder (10).
4
6 STEP 133
BS01C084
Fasten acceptable lifting equipment to the bucket
cylinder (10) and remove the bucket cylinder (10)
1. BUCKET CYLINDER (LEFT HAND SIDE)
2. PROXIMITY SWITCH MOUNTING BRACKET
from the machine.
3. TARGET MOUNTING BRACKET
4. PROXIMITY SWITCH GUARD
5. PROXIMITY SWITCH
6. TARGET BAR
Disconnect the Return-to-Dig proximity switch (5)
and remove with the mounting bracket (2) as an
assembly.
STEP 127
Remove the Return-to Dig target bar (6) with the
mounting bracket (3) from the yoke of the bucket
cylinder (1).

Copyright ©
8001-32
10 9
3
1
5
10
7
4
7
5
4
BS01C085
1. ROLL PIN 6. INNER BELLCRANK

2. YOKE 7. PIVOT PIN
3. PIVOT PIN 8. BOLT
4. NUT 9. GREASE LINE
5. WASHER 10. BUCKET CYLINDER
XT LOADER BUCKET CYLINDER REMOVAL AND INSTALLATION ILLUSTRATION

Copyright ©
8001-33

Install the Return-to Dig target bar and proximity
STEP 134 switch assembly. Connect the proximity switch
Use acceptable lifting equipment to install the bucket connector to the wiring harness connector. This step
cylinder (10) closed end on the pivot pins (7). applies only to the left hand bucket cylinder.
NOTE: See Section 9006 for Return to Dig adjustment
STEP 135 procedure.
Install the grease line (9) and the bolt (8) on the
bucket cylinder (10). STEP 141
Remove the plugs and caps and connect the hoses
STEP 136 to the elbows at the cylinder ports.
Install the inner bellcrank (6) on the pivot pins (7).
STEP 142
STEP 137 Start the engine and run the engine at low idle.
Install the washers (5) and nuts (4) on the retaining
bolts. Tighten the nuts (4). STEP 143
SLOWLY, extend and retract the piston rod three
STEP 138 times to remove any air from the bucket cylinder (10).
Align and install the pivot pin (3) in the yoke (2).
STEP 144
STEP 139 Lubricate the pivot pins with molydisulfide grease.
Install the roll pin (1) in the yoke (2) and pivot pin (3).
STEP 145
Check the level of the hydraulic oil in the hydraulic
reservoir and add as required. See Section 1002 for
the correct hydraulic oil.

Copyright ©
8001-34
OIL COOLER
Removal STEP 151
STEP 146
bucket to the ground. Stop the engine and apply the
parking brake.
STEP 147
position.
STEP 148
Raise the engine hood and remove the inner plastic
fender on the right side of the machine between the BD07N611-01
tire and the oil cooler.
STEP 149
release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.
STEP 150
BD07N612-01
Loosen and remove the two bolts and washers that

fasten the oil cooler to the cooling frame.
STEP 152
BD07N611-01
Disconnect the top hose and install a plug in the hose

and a cap on the fitting.
BD03A217
Raise oil cooler and disconnect the hose from the

bottom of the oil cooler. Install a plug in the hose and
a cap on the fitting. Remove oil cooler from the
machine.

Copyright ©
8001-35
STEP 153
BD07N611-01
Connect the hose to the top of the oil cooler.

BD03A217
Place the oil cooler in position in the cooling frame. STEP 156
Connect the lower hose to the oil cooler. Turn off the vacuum pump and disconnect from the
NOTE: Make sure that the oil cooler slides into retaining
bracket on frame.
STEP 157
STEP 154 Place the master disconnect switch in the ON
position.
STEP 158
Start the engine and run the engine at low idle for two
minutes. Stop the engine and check for hydraulic oil
leakage at the ports on the oil cooler.
STEP 159
Install the inner plastic fender between the right rear
tire and the oil cooler and tighten the two bolts
holding the shield.
STEP 160
BD07N612-01
and add hydraulic oil as required.
BD07N611-01
Install the two bolts and washers that fasten the oil
cooler to the cooling frame

Copyright ©
8001-36
RIDE CONTROL ACCUMULATOR
Removal STEP 164

STEP 161 release the air pressure in the reservoir. Connect a
Park the machine on a level surface and lower the vacuum pump to the hydraulic reservoir, turn on the
bucket to the floor. Stop the engine and apply the pump.
parking brake.
STEP 165
STEP 162
BD07N615-01
Disconnect the hose from the elbow at the bottom of
the ride control accumulator. Install a plug in the
hose and a cap on the fitting.
STEP 166
BD01F143-01
Put the articulation lock in the LOCKED position.
STEP 163
BD07N616-01
Loosen and remove the nuts and washers from the
top U-bolt. Remove the U-bolt.
BD06F213


Copyright ©
8001-37
STEP 168
Place the ride control accumulator in position on the
front frame.
STEP 169
BD07N615-01
accumulator lower bracket to the frame. Remove the
ride control accumulator from the machine.
BD07N615-01
Install the two bolts that fasten the accumulator lower

bracket to the front frame. Tighten the bolts.
STEP 170
BD07N616-01
Install the U-bolt, washers and nuts. Tighten the nuts.

Copyright ©
8001-38
STEP 171 STEP 173
BD07N615-01 BD06F213
Remove the caps and plugs and install the hose on Tighten the accumulator manual bleeder valve
the elbow at the bottom of the ride control located on the bottom of the ride control valve to a
accumulator. torque of 3.5 Nm (31 lb-in). Install the plug and
torque to 7 Nm (62 lb-in).
STEP 172
Turn off and disconnect the vacuum pump from the STEP 174
hydraulic reservoir. Refer to Section 8002 Testing the Ride Control for
the proper charging of the accumulator to check for
leaks.
STEP 175
STEP 176

Copyright ©
8001-39
RIDE CONTROL VALVE
Removal STEP 180

STEP 177 release the air pressure in the reservoir. Connect a
Park the machine on a level surface and lower the vacuum pump to the hydraulic reservoir, turn on the
bucket to the floor. Stop the engine and apply the pump.
parking brake.
STEP 181
position.
several times to release any hydraulic pressure in the pilot STEP 182
control circuit, turn ignition switch OFF. Disconnect the electrical connector from the ride
control valve.
STEP 178
STEP 183
Tag and disconnect the hoses from the ride control
valve. Install a plug in the hoses and caps on fittings.
STEP 184
Loosen and remove the two bolts and washers that
fasten the ride control valve to the frame.
STEP 185
Remove the ride control valve from the machine.
STEP 186
BD01F143-01 Remove and discard all O-rings.
Put the articulation lock in the LOCKED position.
STEP 179
BD06F213


Copyright ©
8001-40

Connect the electrical connector to the ride control
STEP 187 valve.
Install the ride control valve in position on the front
frame. STEP 193
STEP 188 hydraulic reservoir.
Install the washers and bolts through the frame and
into the ride control valve. Tighten the bolts. STEP 194
STEP 189 position.
STEP 195
Start and run the engine at low idle for two minutes.
STEP 196
at the ride control valve.
STEP 197
BD06F213
Tighten the accumulator manual bleeder valve STEP 198

located on the bottom of the ride control valve to a Put the articulation lock in the OPERATING position.
torque of 3.5 Nm (31 lb-in). Install the plug and
torque to 7 Nm (62 lb-in). STEP 199
Refer to Section 8002 and perform the Ride Control
STEP 190 Test Procedure.
Lubricate and install new O-rings.
STEP 191
Connect the hoses to the ride control valve.

Copyright ©
8001-41
FAN REVERSING VALVE
Removal STEP 204
STEP 200
parking brake.
STEP 201 BD07N614-01
BD01F143-01 BD07N604-01
Put the articulation lock in the LOCKED position. Tag and disconnect hoses from the fan reversing
valve. Install a plug in each hose and cap all fittings.
STEP 202
Loosen the filler cap on the hydraulic reservoir to STEP 205
release the air pressure in the reservoir. Connect a Loosen and remove the nuts, washers and bolts.
pump.
STEP 206
Remove the fan reversing valve from the machine.
STEP 203
STEP 207
Remove and discard all O-rings from the fittings.
BD07N610-01
Disconnect the electrical connectors from the fan

reversing valve.

Copyright ©
8001-42
STEP 208
Place the fan reversing valve into position on the
machine.
STEP 209
Lubricate and install new O-rings in the fittings.
STEP 210
Install the bolts, washers and nuts. Tighten the nuts.
BD07N610-01
Connect the electrical connectors on the fan

reversing valve.
STEP 212
STEP 213
Check the level of the hydraulic oil in the reservoir.
BD07N604-011
STEP 214
minutes.
STEP 215
at the fan reversing valve.
STEP 216
STEP 217
BD07N614-01
Remove caps from fittings and plugs from hoses.
reservoir.
Connect hoses to the fan reversing valve, remove
and discard tags.

Copyright ©
8001-43
THERMAL VALVE
STEP 218 STEP 222
Park the machine on a level surface and lower the Place the thermal valve into position on the machine.
parking brake. STEP 223
IMPORTANT: With the engine NOT running, pump the Lubricate and install new O-rings in the fittings.
hydraulic pressure, put the ignition switch in the ON STEP 224
position then move the loader control valve back and forth Install the bolts, washers and nuts. Tighten the nuts.
control circuit, turn ignition switch OFF. STEP 225
Connect the hoses to the thermal valve, remove and
STEP 219 discard tags.
release the air pressure in the reservoir. Connect a STEP 226
pump.
STEP 220 STEP 227
Check the level of the hydraulic oil in the reservoir.
STEP 228
minutes.
STEP 229
at the thermal valve.
STEP 230
BD06F211
Tag and disconnect the hoses from the thermal Check the level of the hydraulic oil in the reservoir
valve. Install a plug in the hoses and a cap on the and add as required. Tighten the filler cap on the
fittings. reservoir.
STEP 221
Remove the mounting bolts from the thermal valve,
remove the valve from the machine.

Copyright ©
8001-44
NOTES

Copyright ©
8002
Section
8002
HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING,

AND PRESSURE CHECKS

Copyright ©
8002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in all Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in all Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in the Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TESTING AND ADJUSTING THE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTING AND ADJUSTING THE MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TESTING THE PILOT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Copyright ©
8002-3
SPECIFICATIONS
Pump Output ..........................................................................................................150 L/min at 2200 rpm at 207 bar
(40 gpm at 2200 rpm at 3000 psi)
Main relief valve pressure settings .........................................................................248 to 255 bar (3596 to 3700 psi)
Differential pressure .......................................................................................................22 to 25 bar (320 to 360 psi)
Pilot pressure..................................................................................................................29 to 40 bar (420 to 580 psi)
Circuit relief valve pressure setting
Auxiliary A and B port (XT and Z Bar) ........................................................................................290 bar (4206 psi)
Bucket A and B port (Z Bar) .......................................................................................................290 bar (4206 psi)
Bucket A port (XT)......................................................................................................................183 bar (2654 psi)
Bucket B port (XT)......................................................................................................................290 bar (4206 psi)
Steering relief valve pressure setting ............................................................................................. See Section 5002
Accumulator pressure..................................................................................................................... See Section 7002

Copyright ©
8002-4
SPECIAL TOOLS
633L95 B877168V
CAS1904 PRESSURE FITTING KIT CAS1808 FLOWMETER FITTING KIT
632L95 B877895M
CAS1906 PRESSURE FITTING KIT CAS10090 HAND PUMP
B785789M B877558M
CAS10280 FLOWMETER CAS1804 PRESSURE FITTING KIT

Copyright ©
8002-5
TROUBLESHOOTING PROCEDURE
Visually check the machine for oil leakage and

damaged or missing parts. Repair or replace
any damaged or missing parts.
Check the oil level in the hydraulic reservoir. Is Fill the hydraulic reservoir with the hydraulic oil
No specified in Section 1002.
the oil level correct?.
Yes
Heat the oil in the hydraulic system to

operating temperature. Operate the
machine to find which circuits have
problems.
Problem in all Circuits

Replace the return line hydraulic filter.
See Section 2002. Do the stall test to see if
the engine is good.
See page 7. Test and adjust pump

differential pressure then proceed to Page 7
See Section 8003 and check for contaminated and do the flowmeter tests of the hydraulic
No
oil. Is the oil contaminated? p u m p . S e e p a g e 12 and t e s t t h e p i l o t
pressure.
Yes
See Section 8003 and clean or replace the

oil.
Problem in all Loader Circuits

See Page 10 and check the pressure setting
Adjust the main relief valve. See page 10 in
of the main relief valve in the loader control No this section.
valve. Is the pressure setting correct?
Problem in the Braking Circuit

See Section 7002 and check the braking
circuit.

Copyright ©
8002-6
Problem in a Single Loader Circuit

Start and run the engine at full throttle. The loader control valve is damaged. See
Operate the control for the bad circuit. Does No Section 8005 and repair the loader control
the cylinder move in both directions? valve
Yes
Check the cylinder piston packing. Is the See Section 8006 and repair the cylinder.
No
packing good?
Yes
See Page 13. Check and adjust the circuit See Section 8005. Disassemble the loader
relief valves. Then check the operation of control valve and check for worn or
No
the circuit again. Does the circuit work damaged parts.
correctly?
Yes
The problem is repaired.
Problem in the Steering Circuit

See Section 5002 and check the steering
No Repair the component as necessary.
circuit. Is the steering circuit good?
Yes
See Page 7. Do the Primary Pump Output

Test.
Problem in the Ride Control

Lift arms rapidly and continuously sink See the ride control Test Procedure page 14
towards the ground. No in this section.
Yes
Check the manual bleed valve for the ride

control accumulator to be sure that it is
closed.

Copyright ©
8002-7
TESTING AND ADJUSTING THE PUMP DIFFERENTIAL PRESSURE

NOTE: The Pump Differential Pressure must be set before attempting any other tests.
Pressure Check STEP 3
STEP 1
Make sure that the temperature of the hydraulic oil is
at least 52°C to 60°C (125°F to 140°F). The following
is the procedure for heating the hydraulic oil.
A. Apply the parking brake.
B. Start the engine.
C. To measure the oil temperature with the
instrument cluster: 1
● Press the up or down arrow key.
● Stop at the info screen with the temperatures BD00M030
that need to be monitored are on.
1. ARTICULATION LOCK
D. Run engine at full throttle. Install the articulation lock (1).
E. Hold the bucket control lever in the
ROLLBACK position while raising and STEP 4
lowering the lift arms from ground level to full
height.
F. Continue this procedure until the temperature
of the hydraulic oil is 54° to 57°C (129° to
134°F).
STEP 2
1
BD00M041
1. COVER PLATE
1 Remove the cover plate to gain access to the loader

control valve.
BD03A092
1. SAFETY LINK
Raise the loader arms and install the safety link (1).

Copyright ©
8002-8
STEP 5 STEP 9
Subtract the reading of the test port (1) from the
reading of the test port (3).
STEP 10
The difference between the two readings should be
22 to 25 bar (320 to 360 psi).
2
STEP 11
If this reading is more or less than that specified, it
1
will be necessary to adjust the pump.
Adjusting the Main Hydraulic

BD00N020 Pump
STEP 12
BD00N017
BD07H002
1. TEST PORT (LOAD SENSE)
2. TEST PORT (PILOT PRESSURE)
The delta pressure adjusting screw is the farthest
3. TEST PORT (PUMP PRESSURE) from the pump. Turn the screw clockwise to increase
t h e d i f f e r e n t i a l p r e s s u r e . T u r n in g t h e s c r e w
counterclockwise will decrease the differential
Connect two 69 bar (1000 psi) test gauges to the test
pressure.
ports (1) and (3) located on the loader control valve.
NOTE: One turn of the adjustment screw will change the
STEP 6 pressure approximately 16 bar (230 psi).
Start the engine and run at low idle.
STEP 7
Make sure all of the controls are in the neutral
position and record the readings on the test gauges
(1) and (3).
STEP 8
The pressure on test port (1) should read
approximately 29 bar (420 psi). The pressure on test
port (3) should read approximately 51 bar (740 psi).
NOTE: These readings may vary from one machine to
another. The important value is the difference between the
readings of gauges 1 and 3.

Copyright ©
8002-9
12
NOTE
11
8
4 9
10
1 2
3
BC06C158
1. CAP 1-7/16-12 ORFS 7. FILTER INLET MANIFOLD

2. LOADER CONTROL VALVE 8. INLINE NEEDLE VALVE
3. FLOWMETER INLET HOSE 9. UNION
4. LOADER CONTROL VALVE INLET HOSE 1-7/16-12 ORFS 10. “T” FITTING
5. CAS10280 FLOWMETER 11. LOAD SENSE HOSE 9/16 X 18 ORFS
6. FLOWMETER OUTLET HOSE 12. CAP 9/16 X 18 ORFS
NOTE: If unit is equipped with auxiliary steering a tee fitting will have to be used in this location.

Copyright ©
8002-10
TESTING AND ADJUSTING THE MAIN RELIEF VALVE

NOTE: The Pump Differential Pressure must be set before attempting any other tests. Refer to page 7 of this section.
STEP 1
1
BD00M041
Remove the cover plate to gain access to the loader

BD00M030
control valve.
STEP 4
Install the articulation lock (1).
STEP 2
2
1
BD00N017

2. TEST PORT
BD03A092
1. SAFETY LINK
Stop the engine and install a 345 bar (5000 psi)
pressure gauge to the test port (2) on the front of the
Raise the loader arms and install the safety link (1).
loader control valve (1).

Copyright ©
8002-11
STEP 5 Adjustment
Make sure that the temperature of the hydraulic oil is
at least 52°C to 60°C (125°F to 140°F). The following
is the procedure for heating the hydraulic oil. STEP 10
A. Apply the parking brake.
B. Start the engine.
instrument cluster:
● Press the up or down arrow key.
● Stop at the info screen with the temperatures
D. Run engine at full throttle.
E. Hold the bucket control lever in the
ROLLBACK position while raising and
lowering the lift arms from ground level to full
height.
F. Continue this procedure until the temperature
of the hydraulic oil is 54° to 57°C (129° to
134°F).
STEP 6 2
Start the engine and remove the safety link (refer to
step 2) and lower the loader arms to the ground.
1
STEP 7 BS01A046
Operate the machine at full throttle. Tilt the bucket to 1. LOADER CONTROL VALVE
a full rollback position and hold while observing the 2. RELIEF VALVE ADJUSTMENT
pressure gauge.
With the engine running and the loader on the
ground, loosen the jam nut and turn the adjustment
STEP 8 screw (2) clockwise for higher pressure or
The pressure should read between 248 and 255 bar counterclockwise for lower pressure.
(3596 to 3700 psi).
NOTE: 1/4 turn of the adjusting screw changes the
STEP 9 pressure setting approximately 35 bar (500 psi).
If the pressure is not within the specifications, it will
be necessary to adjust the main relief valve.
STEP 11
Repeat the Pressure Check Procedure.
STEP 12
If the pressure is not within the specifications, repeat
steps 10 and 11 until pressure is within the required
range.
STEP 13
Stop the engine before removing the pressure
gauge.

Copyright ©
8002-12
TESTING THE PILOT PRESSURE

STEP 1 STEP 3
BD00M030
BD00N020
Stop the engine and connect a 69 bar (1000 psi) test
Install the articulation lock (1). gauge to the pilot pressure test port located on the
STEP 2 NOTE: This can be accessed through the articulated joint
Make sure that the temperature of the hydraulic oil is area, use articulation joint lock before connecting gauge in
at least 52°C to 60°C (125°F to 140°F). The following this manner.
is the procedure for heating the hydraulic oil.
A. Apply the parking brake. STEP 4
B. Start the engine. Start and run the engine at low idle, roll the bucket
back against the stops and hold.
instrument cluster:
STEP 5
● Press the up or down arrow key. A pressure reading of 29 to 40 bar (420 to 580 psi)
● Stop at the info screen with the temperatures should be obtained.
STEP 6
D. Run engine at full throttle.
If pressure is not as specified, replace the pressure
E. Hold the bucket control lever in the reducing valve, refer to section 8005.
ROLLBACK position while raising and
lowering the lift arms from ground level to full STEP 7
height.
If pressure is correct, raise lift arms to the top and
F. Continue this procedure until the temperature turn off the engine. Turn the ignition switch to the
of the hydraulic oil is 54° to 57°C (129° to “RUN” position and disengage the controller lockout
134°F). switch.
STEP 8
Wait for the buzzer to stop then repeatedly put the
loader control lever into “FLOAT” position and back
to neutral.
STEP 9
The system should allow a minimum of 10 actuations
into float and still cause the lift arms to come down.
NOTE: If 10 full actuations cannot be made, an internal
hydraulic leak exists.

Copyright ©
8002-13
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES

Connect the hand pump to the disconnected line that
STEP 1 goes to the loader control valve.
Circuit relief valves are located as shown below.
STEP 4
6 Make sure that the hand pump is full of hydraulic oil
5 1 5 and that the temperature of the oil is approximately
1
21°C (70°F).
STEP 5
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
4 4 be sure of the reading.
STEP 6
Compare the reading to the specifications on Page 3.
STEP 7
If the pressure is not correct, adjust the circuit relief
valve.
3 Adjustment
3 1
1 STEP 1
2 Loosen the lock nut. Turn the adjustment screw
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
BS01A046
1. CIRCUIT RELIEF VALVE STEP 2

2. MAIN RELIEF VALVE Check the pressure again. Repeat the adjustment as
3. BUCKET SPOOL
necessary.
4. LIFT SPOOL
5. AUXILIARY SPOOL
Remove the cover at the front of the machine.
STEP 2
Lower the bucket to the floor. Shut off the engine.
Find an easy place to disconnect the line for the
circuit to be tested.

Copyright ©
8002-14
TESTING THE RIDE CONTROL

STEP 1 STEP 6
Move the machine to a clear level surface with Dump the bucket until it hits the dump stops. Hold the
clearance for full lift arm and bucket movement. bucket in the dump position for 5 to 10 seconds.
NOTE: This will charge the ride control accumulator.
STEP 2
STEP 7
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
their stops, place the pilot control lever in the neutral
position.
STEP 8
Set the ride control rocker switch to the “Always On”
1 position. The lift arms should rise 15 to 30 cm (6 to
12 inches) with an empty bucket.
NOTE: Test results will be for a machine with a empty
factory bucket and no attachments.
BD00M030
STEP 9
If there is little or no lift arm raise, the test may have
Install the articulation lock (1), start the machine, been done too slowly. The elapsed time between
activate the parking brake. step 6 and step 8 should not exceed six seconds.
STEP 3 NOTE: If test was done too slowly, repeat in the allotted
time.
With the pilot controller in neutral, set the ride control
rocker switch on the right side console to the “Always
On” position and observe the switch lamp, the lamp STEP 10
should illuminate. If test was completed in the allotted time and the lift
arms still do not rise, test the nitrogen charge in the
STEP 4 accumulator.
Set the ride control rocker switch to the “Off” position
and observe the switch lamp, the lamp should go out.
NOTE: This indicates that the switch is operating
correctly and has power, if the switch does not illuminate
see section 4002 and troubleshoot the electrical system for
the ride control.
STEP 5
Raise the lift arms to the top of their travel and dump
the bucket.
NOTE: Keep rocker switch in the “Off” position during
steps 5, 6, 7.

Copyright ©
8002-15
HYDRAULIC COMPONENT LOCATIONS
6 20
14 3
15
13 2
1 4
9 11
5 10
16
12
4
18
7
8 19
17
BC00N140
1.RIDE CONTROL VALVE (OPTIONAL) 11. STEERING PRESSURE DIAGNOSTIC COUPLER
2.RIDE CONTROL ACCUMULATOR 12. BRAKE ACCUMULATORS
3.RIDE CONTROL ACCUMULATOR BLEEDER VALVE 13. BRAKE AND ACCUMULATOR CHARGING VALVE
4.LIFT CYLINDERS 14. BRAKE WARNING PRESSURE SWITCH
5.BUCKET CYLINDER (TILT CYLINDER) 15. BRAKE LIGHT PRESSURE SWITCH
6.STEERING CONTROL VALVE 16. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER
7.STEERING CYLINDERS 17. REAR BRAKE CYLINDERS
8.AUXILIARY STEERING PUMP AND MOTOR (OPTION - 18. FRONT BRAKE CYLINDERS
NORTH AMERICAN MODELS) 19. PARKING BRAKE CYLINDER
9. AUXILIARY STEERING PRIORITY VALVE (OPTION - 20. FRONT AND REAR AXLE BRAKE PRESSURE DIAGNOSTIC
NORTH AMERICAN MODELS) COUPLERS
10. AUXILIARY STEERING PRESSURE SWITCH
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic schematic for
reference.

Copyright ©
8002-16
HYDRAULIC COMPONENT LOCATIONS
39
42 23 31
22 40
41
35 38
25 37
36
26 34
30 33
29
25
21
32
27
28
24
BC00N140
21. FAN DRIVE MOTOR 32. PILOT PRESSURE ACCUMULATOR

22. FAN REVERSING VALVE (OPTIONAL) 33. PILOT PRESSURE DIAGNOSTIC COUPLER
23. FAN VALVE (STANDARD) 34. FLOAT SWITCH
24. BRAKE HYDRAULIC PUMP 35. CONTROLLER
25. COUPLER LOCKING VALVE 36. LOADER CONTROL VALVE
26. COUPLER LOCKING CYLINDERS 37. PUMP PRESSURE DIAGNOSTIC COUPLER
27. IMPLEMENT HYDRAULIC PUMP 38. LOAD SENSING DIAGNOSTIC COUPLER
28. HYDRAULIC FILTER 39. BRAKE PRESSURE SWITCH (2)
29. HYDRAULIC RESERVOIR 40. AUXILIARY STEERING LOAD SENSE SOLENOID VALVE (OPTIONAL)
30. HYDRAULIC RESERVOIR BREATHER 41. PARKING BRAKE ACCUMULATOR
31. HYDRAULIC COOLER 42. PARKING BRAKE ACCUMULATOR DIAGNOSTIC COUPLER
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic schematic for
reference.

Copyright ©
Section
8003
8003
CLEANING THE HYDRAULIC SYSTEM

Copyright ©
8003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Copyright ©
8003-3
SPECIAL TOOLS
806128
CAS10508, fitting kit.
806127
CAS101162A, filter unit, portable.
TR98H032
CAS10192, vacuum pump.

Copyright ©
8003-4
GENERAL INFORMATION
Contamination in the hydraulic system is a major 1. Cylinder rod seals leak.
cause of the malfunction of hydraulic components.
2. Control valve spools do not return to neutral.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in 3. Movement of control valve spools is difficult.
several ways.
4. Hydraulic oil becomes too hot.
1. When you drain the oil or disconnect any line.
5. Pump gears, housing, and other parts wear
2. When you disassemble a component. rapidly.
3. From normal wear of the hydraulic components. 6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals. 7. Quick failure of components that have been
repaired.
5. From a damaged component in the hydraulic
system. 8. Cycle times are slow; machine does not have
enough power.
All hydraulic systems operate with some
contamination. The design of the components in this If your machine has any of these problems, check
hydraulic system permits efficient operation with a the hydraulic oil for contamination. See types of
small amount of contamination. An increase in this contamination below. If you find contamination, use
amount of contamination can cause problems in the the Portable Filter to clean the hydraulic system.
hydraulic system. The following list includes some of
these problems.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic 3. Visible contamination is foreign material that can
and visible. be found by sight, touch, or odor. Visible
contamination can cause a sudden failure of
1. Microscopic contamination occurs when very fine
components. Examples of visible contamination:
particles of foreign material are in suspension in
the hydraulic oil. A. Particles of metal or dirt in the oil.
2. These particles are too small to see or feel. B. Air in the oil
Microscopic contamination can be found by
C. The oil is dark and thick.
identification of the following problems or by
testing in a laboratory. Examples of the D. The oil has an odor of burned oil.
problems:
E. Water in the oil. See page 7.
A. Cylinder rod seal leak.
B. Control valve spools do not return to
NEUTRAL.
C. The hydraulic system has a high operating
temperature.

Copyright ©
8003-5
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter on page 3 by doing the 8. Using the fitting kit shown on page 3, install the
following steps: valve in the hole for the drain plug. Make sure
that the valve is closed.
A. Remove all the hydraulic oil from the inlet and
outlet hoses for the portable filter. 9. Stop the vacuum pump.
B. Remove the filter element from the portable 10. Connect the inlet hose for the portable filter to
filter. the valve that is installed in the hole for the drain
plug.
C. Remove all hydraulic oil from the portable
filter. 11. Disconnect the vacuum pump from the hydraulic
reservoir air breather hose. Remove the filler
D. Clean the inside of the housing for the filter
cap.
element.
12. Install the outlet hose for the portable filter in the
2. You must know whether the contamination is
hydraulic reservoir filler neck.
microscopic or visible. See types of
contamination on page 4. 13. Open the valve that is installed in the hole for the
drain plug.
3. If the contamination is microscopic:
14. Move the switch for the portable filter to the ON
A. Check the maintenance schedule for the
position. Start and run the engine at 1500 rpm
machine to learn if the hydraulic oil must be
(r/min).
changed. If needed, change the hydraulic oil.
See Section 1002 for specifications. Change 15. Run the portable filter for 10 minutes.
the hydraulic filter.
16. Continue to run the portable filter. Increase the
B. Do steps 6 through 35. engine speed to full throttle. Heat the oil to
operating temperature by doing the following
4. If the contamination is visible:
steps:
A. Change the hydraulic oil and hydraulic filter. A. Hold the blade control lever in the TILT
See Section 1002 for specifications. position for five seconds.
B. Do steps 5 through 35. B. Return the blade control lever in the
5. Check the amount of contamination in the NEUTRAL position for five seconds.
hydraulic system by doing the following steps: C. Repeat steps A and B until the oil in the
hydraulic system is at operating temperature.
A. Disassemble one cylinder in two different
circuits. Check for damage to seals, scoring of 17. Continue to run the engine at full throttle.
the cylinder wall, etc. Repair the cylinders as Continue to run the portable filter.
necessary.
18. Operate each hydraulic circuit to completely
B. If, in your judgment, the damage to the extend and retract the cylinders. Continue to
cylinders was caused by sever contamination operate each hydraulic circuit two times, one
and is not the result of normal wear, it is after the other for 45 minutes.
necessary to remove, clean and repair valves,
pump, lines, cylinders, hydraulic reservoir, etc.
in the hydraulic system. 20. Continue to run the portable filter for 10 minutes.
6. Remove the breather from the reservoir and 21. Stop the portable filter.
connect the vacuum pump to the opening. Start
the vacuum pump.
23. Remove the hose from the hydraulic reservoir.
7. Loosen and remove the drain plug from the
reservoir.

Copyright ©
8003-6
24. Close the valve that is installed in the hole for the 30. Stop the vacuum pump. Disconnect the vacuum
drain plug. pump from the opening in the reservoir and
install the breather.
25. Disconnect the inlet hose for the portable filter
from the valve. Remove the outlet hose from the 31. Remove the hydraulic filter elements from the
reservoir filler neck and replace filler cap. machine.
26. Connect a vacuum pump to the breather hose of 32. Install new hydraulic filter elements on the
the hydraulic reservoir. machine.
27. Start the vacuum pump. 33. Start the engine. Check for oil leakage around
the new hydraulic filters.
28. Remove the valve from the hole for the drain
plug. 34. Stop the engine.
29. Install the drain plug. 35. Check the oil level in the hydraulic reservoir. Add
oil as required. See Section 1002 for
specifications.

Copyright ©
8003-7
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/min). 13. Slowly move each control lever in both directions
until oil begins to flow from the open line. Hold
2. Completely retract the cylinders of all
the control lever in place until clean oil flows from
attachments on the machine. Angle the blade to
the open line.
the right, the right cylinder will be fully retracted
and the left will be fully extended. Stop the 14. Stop the engine.
engine.
15. Connect the system line to the CLOSED end of
each cylinder.
WARNING: If retracting the cylinder rods
causes the attachments to be raised, block 16. Connect a suitable drain line to the OPEN end of
the attachments in place before proceeding each cylinder and place the other end in an
to the next step! acceptable container for contaminated oil.
39-4
NOTE: Any attachment or part of an attachment that is 18. Slowly and completely extend all cylinders. As
raised must be supported with acceptable equipment to the piston rod comes in/out of the cylinder, oil will
prevent the attachment from falling. be pushed out of the OPEN end of the cylinders.
3. Move each control lever in both directions to NOTE: Any attachment or part of an attachment that is
release pressure in the hydraulic circuits. raised must be supported with acceptable equipment to
4. Loosen and remove the filler cap from the prevent the attachment from falling.
reservoir. 19. Support any attachments that will be in the
5. Drain the hydraulic oil from the reservoir. RAISED position.
A. See Section 1002 for capacity specifications. 20. Stop the engine.
B. Have available acceptable equipment to drain 21. Disconnect the drain lines and connect the
the hydraulic oil. system lines to the cylinders.
C. Remove the drain plug from the bottom of the 22. Check the oil level in the hydraulic reservoir. Add
reservoir. oil as required. See Section 1002 for
specifications.
6. Remove the hydraulic filter elements from the
machine. 23. Install the filler cap on the reservoir.
7. Install new hydraulic filter elements on the 24. Remove the hydraulic filter elements from the
machine. machine.
8. Install the drain plug in the bottom of the 25. Install new hydraulic filter elements on the
reservoir. machine.
9. Fill the hydraulic reservoir with hydraulic fluid. 26. Start and run the engine at 1500 rpm (r/min),
See Section 1002 for specifications. operate each hydraulic circuit to completely
extend and retract the cylinders.
10. Disconnect the line from the OPEN end and
CLOSED end of each cylinder. 27. Stop the engine and check for leaks. Check the
oil level in the hydraulic reservoir. Add oil as
11. Be sure all control levers are in the NEUTRAL required. See Section 1002 for specifications.
position.
12. Start and run the engine at low idle.
IMPORTANT: Check the oil level in the hydraulic
reservoir frequently while doing step 13. Have another
person hold a container under the hydraulic lines while you
do step 13.

Copyright ©
8003-8
NOTES

Copyright ©
Section
8005
8005

Copyright ©
8005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 and 4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Circuit Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Copyright ©
8005-3
SPECIFICATIONS
Special Torques
End plate mounting bolts.......................................................................... 20 to 25 Nm (177 to 221 pound-inches)
Pressure relief, flow limit, and pilot pressure reducing valves.................. 20 to 25 Nm (177 to 221 pound-inches)
Allen head plugs..................................................................................................................60 Nm (44 pound-feet)
Steering Priority Spool Cap .................................................................................................60 Nm (44 pound-feet)
Allen head cover screws (short) .................................................................................. 10.4 Nm (92 pound-inches)
Allen head cover screws (long) ........................................................................................ 6 Nm (53 pound-inches)
Anticavitation valves............................................................................................................60 Nm (44 pound-feet)
Combination anticavitation and circuit relief ........................................................................90 Nm (66 pound-feet)
Cone and plug ............................................................................................................. 10 Nm (88.5 pound-inches)
Main relief valve pressure settings .........................................................................248 to 255 bar (3596 to 3700 psi)
Circuit relief valve pressure setting
Auxiliary A and B port (XT and Z Bar) ........................................................................................290 bar (4206 psi)
Bucket A and B port (Z Bar) .......................................................................................................290 bar (4206 psi)
Bucket A port (XT)......................................................................................................................183 bar (2654 psi)
Bucket B port (XT)......................................................................................................................290 bar (4206 psi)

Copyright ©
8005-4
10 7
6 5
11
12
5A
1
7
13
8
9
BC06D160
1. HOUSING 5. LOAD CHECK VALVE 7. ANTICAVITATION AND CIRCUIT RELIEF 10. O-RINGS
2. PLATE 5A. REGENERATION CHECK VALVE 8. LS (MAIN) RELIEF VALVE 11. LS BLEED ORIFICE
3. BOLT 6. REGENERATION RELIEF VALVE 9. PILOT PRESSURE REDUCING VALVE 12. STEERING RELIEF VALVE
4. WASHER 13. LS SHUTTLE CHECK VALVE
2 SPOOL VALVE HOUSING CONFIGURATION

Copyright ©
8005-5
21 24
14 10
22
17
15
25
17
18 26
25 24
19
23
16 20 17
27
17
28
29 18
17
19
10
23
16
14
15
BC06D161
14. CAP SCREW 18. SPRING RETAINER 22. ADJUSTING NUT 26. STEERING PRIORITY SPOOL
15. THROTTLE CHECK VALVE 19. SPRING RETAINER 23. ADJUSTING ROD 27. COMPENSATION SPOOL
16. COVER 20. SPOOL 24. PLUG 28. PLUG
17. SPRING 21. JAM NUT 25. ORIFICE 29. RING
2 SPOOL VALVE SPOOL CONFIGURATION

Copyright ©
8005-6
5 31
10
10
30 27
17
24
31
BC06D162
2. PLATE 17. SPRING

3. BOLT 24. PLUG
4. WASHER 27. COMPENSATION SPOOL
5. LOAD CHECK VALVE 30. HOUSING
10. O-RING 31. ANTICAVITATION AND CIRCUIT RELIEF
3 SPOOL MOUNTING CONFIGURATION

Copyright ©
8005-7
32
33
4
5
10
30 31
10
27
17
31 24
BC06D163
2. PLATE 24. PLUG

3. BOLT 27. COMPENSATION SPOOL
4. WASHER 30. HOUSING
5. LOAD CHECK VALVE 31. ANTICAVITATION AND CIRCUIT RELIEF
10. O-RING 32. NUT
17. SPRING 33. STUD
4 SPOOL MOUNTING CONFIGURATION

Copyright ©
8005-8
15 21
22
16
23
10 10
18
17
18 14
20
16 18
15 17
10
10
23
21
22 14
BS03C037
10. O-RING 18. SPRING RETAINER

14. CAP SCREW 20. SPOOL
15. THROTTLE CHECK VALVE 21. JAM NUT
16. COVER 22. ADJUSTING NUT
17. SPRING 23. ADJUSTING ROD
3 AND 4 SPOOL VALVE SPOOL CONFIGURATION

Copyright ©
8005-9
Disassembly STEP 11
Remove the pilot pressure reducing valve (6).
STEP 1
Remove valve from machine, see section 8001. STEP 12
Remove bolts (3) and washers (4), remove plate (2)
STEP 2 from housing (1).
Remove bolts (14), covers (16), and springs (17). NOTE: For 4 spool configuration remove nut (32) from
stud (33), remove valves from housing (1).
STEP 3
Remove cap (24), spring (17), and plug (28). STEP 13
STEP 4 2
Use wooden dowel or brass drift and push spools (20
and 26) from housing (1).
IMPORTANT: Do not force spools from housing, if spool
2
binds work back and forth until spool comes out freely.
1
NOTE: Repeat steps 2 and 4 for 3 and 4 spool valve
1
configuration.
STEP 5
Remove anticavitation valves (7 and 27). BS03C026
NOTE: Repeat step 5 for 3 and 4 spool anticavitation 1. O-RINGS 2. THRUST RINGS
valves (31). Remove and discard O-rings and thrust rings from
flow limit valve (11).
STEP 6
Remove cone (13). STEP 14
STEP 7 2
Remove pressure relief valve (8 and 12).
STEP 8
Remove flow limit valve (9). 1
1
STEP 9
Remove check valves (5).
STEP 10
Remove flow limiting valve (11). BS03C025
1. O-RINGS 2. THRUST RINGS

Remove and discard O-rings and thrust rings from
pilot pressure reducing valve (9).

Copyright ©
8005-10
1
1
2
BS03C029

Remove and discard O-rings and thrust rings from pressure relief valve (8 and 12).

Copyright ©
8005-11
STEP 15
3
4
2 1
1
1
BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Remove and discard O-rings and thrust rings from anticavitation and circuit relief valves (7 and 31).

Copyright ©
8005-12
Inspection 4. Check the parts of the pressure relief valve,

anticavitation valves, and the anticavitation and
1. Discard all O-rings, thrust rings, and spool seals. circuit relief valves. Use new parts as necessary.
2. Clean all parts in cleaning solvent. 5. Inspect the other parts of the control valve. If any
3. Check the spools and the spool bores for of the parts are damaged, install new parts.
damage and wear.
Assembly
STEP 1
3
4
A
2 1
1
See Note
1
BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Install new O-rings and thrust rings on anticavitation and circuit relief valves (7 and 31). Torque relief valve (A) into
anticavitation valve to 140 Nm (103 pound-feet).
NOTE: Spool seal mounting position is critical, seal must be mounted with lip facing as shown above, pressure is in direction of
arrow.

Copyright ©
8005-13
STEP 2
1
1
2
BS03C029

Install new O-rings and thrust rings on pressure relief valve (8 and 12).
STEP 3 STEP 4
2 2
1 2
1 1
1
BS03C025 BS03C026
1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RINGS

Install new O-rings and thrust rings on flow limiting Install new O-rings and thrust rings on flow limit valve
valve (9). (11).

Copyright ©
8005-14
STEP 5 STEP 12
Install and torque regeneration check valve (14) to Install and torque check valves (5) to 40 Nm
100 Nm (73.7 pound-feet). (29.5 pound-feet).
STEP 6 STEP 13
Install new O-rings on housing (1). Install plate (2), Install and torque cone and plug (13) to 10 Nm
bolts (3) and washers (4), onto housing (1). Torque (88.5 pound-inches).
bolts to 20 to 25 Nm (177 to 221 pound-inches).
NOTE: For 4 spool configuration install new O-rings STEP 14
between housings (30) and housing (1), install nuts (32) on Install and torque plug (28) to 60 Nm (44 pound-feet).
studs (33). Torque nuts to 70 Nm (51.5 pound-feet).
STEP 15
STEP 7 Lubricate spools with hydraulic oil and push spools
Install and torque pilot pressure reducing valve (6) to (20 and 26) into housing (1).
90 Nm (66 pound-feet).
IMPORTANT: Do not force spools into housing.
STEP 8
STEP 16
Install and torque anticavitation valves (7) to 90 Nm
(66 pound-feet). Install spring retainers (18), springs (17), covers (16),
and bolts (14). Torque bolts to 6 Nm
NOTE: Repeat step for 3 and 4 spool anticavitation valves (53 pound-inches).
(31).
NOTE: Repeat steps 15 and 16 for 3 and 4 spool valve
configuration.
STEP 9
Install anticavitation valves (27), spring (17), and cap
STEP 17
(24) and torque cap to 60 Nm (44 pound-feet).
Install spring (17) and cap (24) and torque cap to
60 Nm (44 pound-feet).
STEP 10
Install and torque flow limit valve (9 and 11) to 20 to NOTE: Prior to installation in the machine, circuit reliefs
25 Nm (177 to 221 pound-inches). can be tested.
STEP 11 STEP 18
Install and torque pressure relief valves (8 and 12) to Install valve in machine, see section 8001.
20 to 25 Nm (177 to 221 pound-inches).
STEP 19
Check loader limit pressure, see section 8002.

Copyright ©
8005-15
CIRCUIT RELIEF
Pressure Test Adjustment

STEP 1 STEP 1
Connect the hand pump to the port for anticavitation Loosen the lock nut. Turn the adjustment screw
and circuit relief valves (7). clockwise to increase the pressure or
counterclockwise to decrease the pressure.
NOTE: Repeat steps for machines that are configured
with a 3 or 4 spool valve.
STEP 2
STEP 2 Check the pressure again. Repeat the adjustment as
necessary.
Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21°C (70°F).
STEP 3
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
be sure of the reading.
STEP 4
Compare the reading to the specifications on Page 3.
STEP 5
If the pressure is not correct, adjust the circuit relief
valve.

Copyright ©
8005-16
NOTES

Copyright ©
Section
8006
CYLINDERS
8006

Copyright ©
8006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BUCKET CYLINDERS Z-BAR MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BUCKET CYLINDERS FOR XT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REPLACING BUSHINGS FOR THE BUCKET CYLINDER Z-BAR MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REPLACING BUSHINGS FOR THE BUCKET CYLINDERS XT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Copyright ©
8006-3
SPECIFICATIONS
Approximate weight
Lift Cylinder - XT and Z-Bar.......................................................................................................75.7 kg (167 pounds)
Bucket Cylinder - Z-Bar Models.................................................................................................75.6 kg (167 pounds)
Bucket Cylinder - XT Models .....................................................................................................69.8 kg (154 pounds)
SPECIAL TORQUES
Screw in Gland Z-Bar Bucket Cylinder ..........................................................135 to 542 Nm (100 to 400 pound-feet)
Screw in Gland XT Bucket Cylinder ..............................................................135 to 542 Nm (100 to 400 pound-feet)
Screw in Gland for Lift Cylinders XT and Z-Bar Models ................................135 to 542 Nm (100 to 400 pound-feet)
Piston Bolt for Lift Cylinders XT and Z-Bar Models ...............................1600 to 1830 Nm (1180 to 1350 pound-feet)
Piston Bolt for Z-Bar Bucket Cylinder ....................................................2830 to 3220 Nm (2087 to 2375 pound-feet)
Piston Bolt for XT Bucket Cylinder ........................................................1600 to 1830 Nm (1180 to 1350 pound-feet)
Lock Screw for all Cylinders .............................................................................................. 2.3 Nm (20 pound-inches)
SPECIAL TOOLS
Torque Multiplier.......................................................................................................................................... CAS1039

Copyright ©
8006-4
LIFT CYLINDER
1. Clean the outside of the cylinder. If the hoses 1. Discard the parts that were removed from the
were removed with the cylinder, remove the piston and the gland.
hoses from the cylinder.
2. Clean all parts in cleaning solvent. Use only lint
2. Fasten the tube (1) in an acceptable repair stand free cloths for cleaning and drying.
or other holding equipment, refer to Figure 1. Do
3. Check to be sure that the piston rod (13) is
not damage the tube (1).
straight. If the piston rod is not straight, replace it
3. Loosen and remove the self-tapping screw (12). with a new piston rod.
4. Use a spanner wrench to loosen and remove the 4. Illuminate the inside of the tube (1) for deep
gland (4) out of the tube (1). grooves and other damage. If there is any
damage to the tube, replace it with a new tube.
5. Pull the piston rod (13) straight out of the tube (1)
to prevent damage to the tube (1). 5. Remove any small scratches on the piston rod
(13) or inside the tube (1) with emery cloth of
6. Fasten the piston rod eye or yoke in a vise and
medium grit. Use the emery cloth with a rotary
put a support under the piston rod (13) near the
motion.
piston (15). Put a shop cloth between the support
and the piston rod (13) to prevent damage to the 6. Inspect the bushings (2), (8) (in the piston rod
piston rod (13). eye or yoke and the tube. Replace as required.
7. Use a torque multiplier, CAS1039, to loosen and 7. Inspect the gland (4) for rust. Clean and remove
remove the bolt (14) that fastens the piston (15) rust as necessary.
to the piston rod (13).
8. Inspect the gland (4) end of the tube for sharp
8. Remove the piston (15) from the piston rod (13). edges that will cut the gland O-ring (10) (and
remove as necessary.
9. Inspect the piston (15) for damage and wear. If
10. Remove the seal (16), ring (17)and the wear ring
the piston is damaged or worn, replace it with a
(18) from the piston (15).
new piston.
11. Remove the O-ring (10), ring (9), O-ring (11),
wiper (5), seal (6), seal (7), and bushing (8) from
the gland (4).

Copyright ©
8006-5
13
5
6
7
4
8
11
9
10
15
17
16
18
14
1
3
2
2
3
BS03B200
1. TUBE 6. ROD SEAL 11. O-RING 16. SEAL

2. BUSHING 7. BUFFER SEAL 12. SCREW (NOT SHOWN) 17. RING
3. WIPER 8. BUSHING 13. ROD 18. WEAR RING
4. GLAND 9. BACKUP RING 14. BOLT
5. WIPER 10. O-RING 15. PISTON
FIGURE 1. LIFT CYLINDER

Copyright ©
8006-6
Assembly 15. Install the bolt (14) into the piston rod (13).
Tighten the bolt (14) to a torque of 1600 to 1830
NOTE: If a new gland is being used, put the part number Nm (1180 to 1350 pound-feet). A torque
of the cylinder on the new gland. multiplier can be used to help torque the bolt
1. Install the bushing (8) in the gland (4), refer to (14).
Figure 1. 16. Install a new wear ring (18) in the wide groove on
2. Install the seal (6) in the gland (4). The seal (6) is the outside of the piston (15), refer to Figure 1.
to be installed so that the lips of the seal (6) are 17. Install a new ring (17) in the other groove on the
toward the bushing (8). The seal (6) can be outside of the piston (15).
difficult to install.
18. Install a new seal (16) on the top of the ring (17).
3. Install the seal (7) in the gland (4). The side of
the seal (7) with the groove must be toward the 19. Fasten the tube (1) in an acceptable repair stand
bushing (8). or other holding equipment. Be careful to prevent
damage to the tube (1).
4. Install a new wiper (5) in the gland (4). The lips of
the wiper (5) must be toward the outside end of 20. Lubricate the inside of the tube (1) and the piston
the gland (4). (15) with clean oil.
5. Install a new O-ring (11) in the groove on the OD 21. Push the piston (15) straight into the tube (1).
of the gland (4). 22. When the piston (15) is in the smooth part of the
6. Install a new ring (9) in the groove on the OD of tube (1), start the gland (4) into the tube (1).
the gland (4). If both sides of the ring (9) are not 23. Lubricate the O-rings (10 and 11) on the gland
flat, the side that is not flat must be toward the (4) with clean oil.
small end of the gland (4).
24. If the original parts are being assembled:
7. Install a new O-ring (10) next to the ring (9) in the
groove on the outside of the gland (4). The A. Tighten the gland (4) to a torque of 135 to 542
O-ring (10) must be toward the small end of the Nm (100 to 400 pound-feet).
gland. B. Install and tighten the lock screw (12) to a
8. Fasten the piston rod eye or yoke in the vise. torque of 2.3 Nm (20 inch-pounds).
9. Remove any marks and sharp edges on the C. If, after tightening the gland, the lock screw
chamfer at the end of the piston rod (13). Make (12) holes are not aligned, a new hole for the
sure that the piston rod (13) is clean. lock screw (12) must be drilled. See Step 25B.
10. Lubricate the bore of the gland (4) and the piston 25. If a new gland (4) or a new tube (1) are being
rod (13) with clean oil. assembled:
11. Push the gland (4) onto the piston rod (13). If A. Tighten the gland (4) to 135 to 542 Nm (100 to
necessary, use a soft hammer to drive the gland 400 pound-feet).
(4) onto the piston rod (13). B. Use a No. 27 drill bit and drill a hole half in the
12. Put a support below and near the end of the gland (4) and half in the tube (1). Drill to a
piston rod (13). Use a shop cloth between the depth of 11 mm (7/16 inch). Do not drill within
support and the piston rod (13) to prevent 13 mm (1/2 inch) of a hole for the gland
damage to the piston rod (13). wrench.
13. Start the piston (15) onto the piston rod (13). C. Install and tighten the lock screw (12) to a
torque of 2.3 Nm (20 inch-pounds).
14. Clean the threads on the end of the piston rod
and the threads of the piston bolt using Loctite 26. If the hoses were removed with the cylinder,
cleaning solvent. Allow to dry. Apply Loctite 242 install new O-rings, if equipped, on the hose
to the piston rod threads 1/4 inch from the open fittings. Lubricate O-rings with clean oil. Install
end of the piston rod so that there is 1/2 inch of the hoses.
Loctite 242 on the piston rod threads. DO NOT
threads.

Copyright ©
8006-7
BUCKET CYLINDERS Z-BAR MODELS
were removed with the cylinder, remove the piston (16) and the gland (4).
2. Fasten the tube (1) in an acceptable repair stand free cloths for cleaning and drying.
or other holding equipment, refer to Figure 2. Do
not damage the tube (1).
3. Loosen and remove the locking screw (12) from with a new piston rod.
the gland (4) and tube (1).
4. Illuminate the inside of the tube (1) for deep
4. Use a spanner wrench to loosen and remove the grooves and other damage. If there is any
gland (4) out of the tube (1). damage to the tube, replace it with a new tube.
5. Pull the piston rod (12) straight out of the tube (1) 5. Remove any small scratches on the piston rod
to prevent damage to the tube (1). (12) or inside the tube (1) with emery cloth of
6. Fasten the piston rod eye or yoke in a vise and
motion.
put a support under the piston rod (12) near the
piston (16). Put a shop cloth between the support 6. Inspect the bushings (2), (8) and (13) in the
and the piston rod (12) to prevent damage to the piston rod eye or yoke and the tube. Replace as
piston rod (12). required.
7. Use a torque multiplier, CAS1039 to loosen and 7. Inspect the gland (4) for rust and clean and
remove the bolt (15), washer (14) that fastens remove rust as necessary.
the piston (16) to the piston rod (12).
8. Inspect the gland end of the tube (1) for sharp
8. Remove the piston (16) from the piston rod (12). edges that will cut the gland O-ring (9), (11) and
remove as necessary.
9. Inspect the piston (16) for damage and wear. If
10. Remove the seal (17), backup ring (19) and wear
ring (20) from the piston (16).
new piston.
11. Remove the O-ring (11), backup ring (10), wiper
(5), seal (6), seal (7) and bushing (8) from the
gland (4).

Copyright ©
8006-8
BC03G289
1. TUBE 6. SEAL 11. O-RING 16. PISTON

2. BUSHING 7. SEAL 12. PISTON ROD 17. SEAL
3. SCREW (NOT SHOWN) 8. BUSHING 13. BUSHING 18. BACKUP RING
4. GLAND 9. O-RING 14. WIPER 19. WEAR RING
5. WIPER 10. BACKUP RING 15. BOLT AND WASHER
FIGURE 2. BUCKET CYLINDER FOR Z-BAR MODELS

Copyright ©
8006-9
Assembly 15. Install the bolt (15) into the piston rod (12).
Tighten the bolt (15) to a torque of 2830 to 3220
NOTE: If a new gland is being used, put the part number Nm (2087 to 2375 pound-feet). A torque
of the cylinder on the new gland. multiplier can be used to help torque the bolt
1. Install the bushing (8) in the gland (4), refer to (15).
Figure 2. 16. Install a new wear ring (19) in the wide groove on
2. Install the seal (6) in the gland (4). The seal (6) is the outside of the piston (16), refer to Figure 2.
to be installed so that the lips of the seal (6) are 17. Install a new backup ring (18) in the other groove
toward the bushing (8). The wide seal (6) can be on the outside of the piston (16).
difficult to install.
18. Install a new seal (17) on the top of the backup
3. Install the seal (7) in the gland (4). The side of ring (18).
the seal (7) with the groove must be toward the
bushing (8). 19. Fasten the tube (1) in an acceptable repair stand
or other holding equipment. Be careful to prevent
4. Install a new wiper (5) in the gland (4). The lips of damage to the tube (1).
the wiper (5) must be toward the outside end of
the gland (4). 20. Lubricate the inside of the tube (1) and the piston
(16) with clean oil.
5. Install a new O-ring (9) in the groove on the
gland (4). 21. Push the piston (16) straight into the tube (1).
6. Install a new backup ring (10) in the groove on 22. When the piston (16) is in the smooth part of the
the OD of the gland (4). If both sides of the tube (1), start the gland (4) into the tube (1).
backup ring (10) are not flat, the side that is not 23. Lubricate the O-rings (9 and 11) on the gland (4)
flat must be toward the small end of the gland with clean oil.
(4).
7. Install a new O-ring (11) next to the backup ring
(10) in the groove on the outside of the gland (4). A. Tighten the gland (4) to a torque of 135 to 542
The O-ring (11) must be toward the small end of Nm (100 to 400 pound-feet).
the gland. B. Install and tighten the lock screw (3) to a
8. Fasten the piston rod eye or yoke in the vise. torque of 2.3 Nm (20 inch-pounds).
9. Remove any marks and sharp edges on the C. If, after tightening the gland, the lock screw (3)
chamfer at the end of the piston rod (12). Make holes are not aligned, a new hole for the lock
sure that the piston rod (12) is clean. screw (3) must be drilled. See Step 25B.
10. Lubricate the bore of the gland (4) and the piston 25. If a new gland (4) or a new tube (1) are being
rod (12) with clean oil. assembled:
11. Push the gland (4) onto the piston rod (12). If A. Tighten the gland (4) to a torque of 135 to 542
necessary, use a soft hammer to drive the gland Nm (100 to 400 pound-feet).
(4) onto the piston rod (12). B. Use a No. 27 drill bit and drill a hole half in the
12. Put a support below and near the end of the gland (4) and half in the tube (1). Drill to a
piston rod (12). Use a shop cloth between the depth of 11 mm (7/16 inch). Do not drill within
support and the piston rod (12) to prevent 13 mm (1/2 inch) of a hole for the gland
damage to the piston rod (12). wrench.
13. Start the piston (16) onto the piston rod (12). C. Install and tighten the lock screw (3) to a
14. Clean the threads on the end of the piston rod
and the threads of the piston bolt using Loctite 26. If the hoses were removed with the cylinder,
cleaning solvent. Allow to dry. Apply Loctite 242 install new O-rings, if equipped, on the hose
to the piston rod threads 1/4 inch from the open fittings. Lubricate O-rings with clean oil. Install
end of the piston rod so that there is 1/2 inch of the hoses.
Loctite 242 on the piston rod threads. DO NOT
threads.

Copyright ©
8006-10
BUCKET CYLINDERS FOR XT MODELS
were removed with the cylinder, remove the piston (13) and the gland (4).
2. Fasten the cylinder in a vise or other holding free cloths for cleaning and drying.
equipment. Be careful to prevent damage to the
tube (1), refer to Figure 3.
3. Loosen and remove the lock screw (3) from the with a new piston rod.
gland (4) and tube (1).
4. Illuminate the inside of the tube (1) for deep
4. Use a spanner wrench to loosen and remove the grooves and other damage. If there is any
gland (4) from the tube (1). damage to the tube, replace it with a new tube.
5. Pull the piston rod (12) straight out of the tube (1) 5. Remove any small scratches on the piston rod
to prevent damage to the tube (1). (12) or inside the tube (1) with emery cloth of
6. Fasten the rod yoke in a vise and put a support
motion.
below the piston rod (12) near the piston (13).
Use a shop cloth between the support and the 6. Inspect the bushings (2), (6) in the piston rod eye
piston rod (12) to prevent damage to the piston or yoke and the tube. Replace as required.
rod (12).
7. Inspect the gland (4) for rust and clean and
7. Use a torque multiplier, CAS-1039, to loosen and remove rust as necessary.
remove the piston bolt (17) that secures the
8. Inspect the gland end of the tube (1) for sharp
piston (13).
edges that will cut the gland O-ring (9), (10) and
8. Remove the piston (13) from the piston rod (12). remove as necessary.
9. Remove the gland (4) from the piston rod (12). 9. Inspect the piston (13) for damage and wear. If
10. Remove the backup ring (14), piston seal (15)
new piston.
and wear ring (16) from the piston (13).
11. Remove the wiper (5), seal (7), seal (8) and the
bushing (6) from the gland (4).
NOTE: Use care not to scratch the ID of gland when
removing seals.
12. Remove the O-ring (10) and backup ring (11)
from the OD of gland (4).

Copyright ©
8006-11
12
5
7
8
9 13
3
11
10 14
15
16
17
6
19
2 1
2
19
18
BS03B202
1. TUBE 6. BUSHING 11. BACKUP RING 16. WEAR RING

2. BUSHING 7. ROD SEAL 12. PISTON ROD 17. BOLT
3. SCREW 8. BUFFER SEAL 13. PISTON 18. GREASE FITTING
4. GLAND 9. O-RING 14. BACKUP RING 19. WIPER
5. WIPER 10. O-RING 15. SEAL
FIGURE 3. BUCKET CYLINDER FOR XT MODELS

Copyright ©
8006-12
Assembly 15. Install the piston bolt (17). Tighten the piston bolt
(17) to a torque of 1600 to 1830 Nm (1180 to
NOTE: If a new gland (4) is being installed, put the part 1350 pound-feet). A torque multiplier can be
number of the cylinder on the new gland (4). used to help tighten the piston bolt (17).
1. Install the bushing (6) in the gland (4), refer to 16. Install a new wear ring (16) in the groove on the
Figure 3. outer end of the piston (13).
2. Install the seal (8). The seal (8) must be installed 17. Install the piston backup ring (14) into the
with the seal lips toward the small end of the remaining groove in the piston (13).
gland (4). The seal (8) can be difficult to install.
18. Install a new piston seal (15) on top of the
3. Install the seal (7). The seal (7) must be installed backup ring (14).
with the lips toward the small end of the gland (4)
also. 19. Fasten the tube (1) in a vise or other holding
equipment. Be careful to prevent damage to the
4. Install a new wiper (5) in the gland (4). The lips of tube (1).
the wiper (5) must be toward the large end of the
gland (4). 20. Lubricate the inside of the tube (1) and the piston
(13) with clean oil.
5. Install a new O-ring (9) in the groove of the gland
(4). 21. Push the piston (13) straight into the tube (1).
6. Install a new backup ring (11) in the groove on 22. When the piston (13) is in the smooth part of the
the outside of the gland (4). If both sides of the tube (1), start the gland (4) into the tube (1).
backup ring (11) are not flat, the side that is not 23. Lubricate the O-ring (9 and 10) on the gland (4)
flat must be toward the small end of the gland with clean oil.
(4).
7. Install the O-ring (10) on the gland (4). The
O-ring (10) must be toward the small end of the A. Tighten the gland to a torque of 135 to 542
gland (4). Nm (100 to 400 pound-feet).
8. Fasten the piston rod yoke in the vise. B. Install and tighten the lock screw (3) to a
9. Remove any marks and sharpen edges on the
chamfer at the end of the piston rod (12). C. If, after tightening the gland, the lock screw (3)
holes are not aligned, a new hole for the lock
10. Lubricate the bore of the gland (4) and the piston screw (3) must be drilled. See Step 25B.
rod (12) with clean oil.
25. If a new gland (4) or a new tube (1) are being
11. Push the gland (4) onto the piston rod (12). If assembled:
necessary, use a soft hammer to drive the gland
(4) onto the piston rod (12). A. Tighten the gland (4) to 135 to 542 Nm (100 to
400 pound-feet).
12. Put a support below and near the end of the
piston rod (12). Use a shop cloth between the B. Use a No. 27 drill bit and drill a hole half in the
support and the piston rod (12) to prevent gland (4) and half in the tube (1). Drill to a
damage to the rod. depth of 11 mm (7/16 inch). Do not drill within
13 mm (1/2 inch) of a hole for the gland
13. Put the piston (13) on the end of the piston rod wrench.
(12).
C. Install and tighten the lock screw (3) to a
14. Clean the threads on the end of the piston rod torque of 2.3 Nm (20 inch-pounds).
and the threads of the piston bolt using Loctite
cleaning solvent. Allow to dry. Apply Loctite 242 26. If the hoses were removed with the cylinder,
to the piston rod threads 1/4 inch from the open install new O-rings, if equipped, on the hose
end of the piston rod so that there is 1/2 inch of fittings. Lubricate the O-rings with clean oil.
Loctite 242 on the piston rod threads. DO NOT Install the hoses.
threads.

Copyright ©
8006-13
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS
Disassembly
1. Put the piston tube (4) in a press, refer to Figure
4.
2. Use an acceptable driver to press the wipers (1)
3
and bushings (2) out of the piston tube (4).
3. Clean the bore for the bushings (2) in the tube
1
(4).
4
Assembly
1. Use an acceptable driver to press a new bushing
2
(2) into the tube (4) until the bushing (2) is
centered in the tube (4). 1
2. Use an acceptable driver to install the wipers (1) 2
in the tube (4). The lips of the wipers (1) must be
toward the outside of the bore.
BS01C003
1. WIPER 3. PISTON ROD YOKE

2. BUSHING 4. TUBE
FIGURE 4. BUSHING AND WIPER REMOVAL AND
REPLACEMENT LIFT CYLINDERS

Copyright ©
8006-14
REPLACING BUSHINGS FOR THE BUCKET CYLINDER Z-BAR MODELS
Disassembly
1
1. Put the piston rod eye (3) in a press, refer to
Figure 6.
2 3
2. Use an acceptable driver to press the wipers (1)
and bushing (2) out of the piston rod eye (3). 2
3. Put the tube (4) in a press.
1
4. Use an acceptable driver to press the bushings
(2) out of the tube (4).
5. Clean the bore for the bushings (2) in the piston
rod eye (3) and the tube (4).
4
Assembly
1. Use an acceptable driver to press new bushings
2
(2) into the piston rod eye (3). Refer to Figure 6.
2. Use an acceptable driver to install the wipers (1)
in the piston rod eye (3). The lips of the wipers
(1) must be towards the outside of the bore.
2
3. Use an acceptable driver to press new bushings
(2) into the tube (4).
BS01C004
1. WIPER 3. PISTON ROD EYE

2. BUSHING 4. TUBE
REPLACEMENT BUCKET CYLINDER

Copyright ©
8006-15
REPLACING BUSHINGS FOR THE BUCKET CYLINDERS XT MODELS
1. Put the piston tube (4) in a press, refer to Figure 1. Use an acceptable driver to press new bushings
5. (2) into the tube (4). Refer to Figure 5.
2. Use an acceptable driver to press the wipers (1) 2. Use an acceptable driver to install the wipers (1)
and bushing (2) out of the piston tube (4). in the tube (4). The lips of the wipers (1) must be
toward the outside of the bore.
3. Clean the bore for the bushings (2) in the tube
(4).
1 4
2
2
1
BS01C002
1. WIPER 3. PISTON ROD YOKE

2. BUSHING 4. TUBE
REPLACEMENT XT BUCKET CYLINDERS

Copyright ©
8006-16
NOTES

Copyright ©
Section
8007
COUPLER SOLENOID LOCKING VALVE
8007

Copyright ©
8007-2
TABLE OF CONTENTS
coupler solenoid locking valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Copyright ©
8007-3
COUPLER SOLENOID LOCKING VALVE
Disassembly STEP 11
Install solenoid (2) on valve cartridge (3).
STEP 1
Clean exterior of valve. STEP 12
Install nut (1) to secure solenoid (2).
STEP 2
Remove nut (1) and solenoid (2) from valve cartridge
(3). 1
STEP 3
Remove valve cartridge (3) from valve housing (7).
2
STEP 4
Remove and discard all O-rings (4 and 5) and
back-up rings (6).
Cleaning and Inspection

STEP 5
Immerse valve cartridge (3) and valve housing (7) in
3
cleaning solvent and agitate cleaning solvent. WEAR
EYE PROTECTION WHEN USING COMPRESSED
AIR. Use compressed air to remove foreign matter
from interior of valve cartridge and housing and to 4
ensure that all passage ways and bores are clear.
6
STEP 6 5
Check valve cartridge for (3) for cracks, breaks, 6
chipping, or other damage. Replace if any of these 6
conditions are seen.
5
6
STEP 7
6
Check bores in valve housing (7) for deep scratches, 5
gouges, and other damage. Replace valve if any of
7 6
STEP 8
Connect an ohmmeter across terminals of solenoid
(2) connector. Replace solenoid (2) and valve
cartridge (3) if ohmmeter indicates short or open
circuit.
Assembly GS98J818
1. NUT 5. O-RING
STEP 9
2. SOLENOID 6. BACKUP RING
Install new O-rings (4 and 5) and back-up rings (6) as 3. VALVE CARTRIDGE 7. VALVE HOUSING
shown. 4. O-RING
STEP 10
Lubricate O-rings (4 and 5) using clean oil then install
valve cartridge (3) in valve housing (7).
Copyright ©
8007-4
NOTES

Copyright ©
Section
8013
8013
RIDE CONTROL ACCUMULATOR

Copyright ©
8013-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TESTING RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Checking Nitrogen Charge On Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Charging Accumulator With Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Copyright ©
8013-3
SPECIFICATIONS
Ride Control Accumulator Dry Nitrogen Pressure ...................................................................... See chart on page 6
Ride Control Accumulator Fluid Capacity............................................................................. 3.79 liters (231 cu. inch)
Ride Control Accumulator Maximum Operating Pressure..............................................................280 bar (4061 psi)
ACCUMULATOR SPECIAL TORQUES

Accumulator Gas Charging Valve Cap............................................................................... Hand tighten with wrench
Gas Charging Valve ........................................................................................20 to 25 Nm (14.8 to 18.4 pound-feet)
SPECIAL TOOLS
BS06M002 BC04A001
380001676 NITROGEN REGULATOR VALVE 380001168 ACCUMULATOR VALVE ADAPTER
Check your inventory of tools, if you have nitrogen
charging kit CAS10899 use it in place of the above
listed tools.
BS06M003
380001390 ACCUMULATOR CHARGING HOSE

Copyright ©
8013-4
TESTING RIDE CONTROL

STEP 1 STEP 5
Move the machine to a clear level surface with Dump the bucket until it hits the dump stops. Hold the
clearance for full lift arm and bucket movement. bucket in the dump position for 5 to 10 seconds.
NOTE: This will charge the ride control accumulator.
STEP 2
Install the articulation lock, start the machine, STEP 6
activate the parking brake.
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
STEP 3 their stops, place the pilot control lever in the neutral
Set the ride control rocker switch to the “Off” position position.
and observe the switch lamp, the lamp should go out.
NOTE: This indicates that the switch is operating STEP 7
correctly and has power, if the switch does not With the pilot controller in neutral, set the ride control
illuminate see section 4002 and troubleshoot the rocker switch on the right side console to the “Always
electrical system for the ride control. ON” position and observe the switch lamp, the lamp
should illuminate.
STEP 4
Raise the lift arms to the top of their travel and dump STEP 8
the bucket. When the bucket reaches the fully With ride control ON. If it is working properly the lift
dumped position it will generate down-force on the lift arms should rise 15 to 30 cm (6 to 12 inches) with an
arms and cause them to sink. empty bucket.
NOTE: Keep rocker switch in the “Off” position NOTE: Test results will be for a machine with a
during this steps 4, 5, 6. empty factory bucket and no attachments.
STEP 9
If there is little or no lift arm raise, the test may have
been done too slowly. The elapsed time between
step 5 and step 8 should not exceed six seconds.
NOTE: If test was done to slowly repeat in the
allotted time.
STEP 10
If test was completed in the allotted time and the lift
arms still do not rise, test the nitrogen charge in the
accumulator.

Copyright ©
8013-5
Checking Nitrogen Charge On Accumulator
B C
A
G D
E
BS07A156
NITROGEN CHARGING KIT
1. Use the Nitrogen Charging Kit to discharge the 7. Connect valve A to the valve stem on the adapter
accumulator, refer to the illustration above. The (F).
tool must be disconnected from the nitrogen 8. Connect the accumulator to the adapter (F)
tank.
9. Open valve on accumulator using the adapter’s
2. Close valve (E). square drive (G).
3. Adjust the regulator (D) to the minimum pressure 10. Turn the T-handle inward on valve (A) to engage
setting by turning the knob counterclockwise. the pin in the valve stem on the adapter.
4. Turn the T-handle on valve (A) fully out. 11. Slowly open valve (E).
5. Remove the valve cap from the accumulator. 12. Check the charge pressure on gauge (B).
6. Install adapter 380001168 (F) onto the
accumulator.
WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
M253A
WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar
(450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M406
WARNING: Do not expose the accumulator to temperatures above 49° C (120° F). A charged accumulator
contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M407

Copyright ©
8013-6
Charging Accumulator With Nitrogen

IMPORTANT: The four valves A, D, and E must be in the positions noted in the procedure before connecting the
Nitrogen Accumulator Charging Kit to the machine or nitrogen, refer to illustration on page 5.
1. Close the shutoff valve (D) by turning it all the
TEMPERATURE CHARGE PRESSURE
way to the left (counterclockwise), refer to the
10° C 50° F 16.36 BAR 237 PSI
13° C 55° F 16.55 BAR 240 PSI
2. Close the gauge valve (E) by turning it all the 16° C 60° F 16.74 BAR 243 PSI
way to the right (clockwise). 18° C 65° F 16.87 BAR 245 PSI
3. Connect the charging gauges to the nitrogen 21° C 70° F 17.06 BAR 248 PSI
supply tank, open the supply tank valve. 24° C 75° F 17.26 BAR 250 PSI
27° C 80° F 17.45 BAR 253 PSI
4. Slowly turn valve (D) clockwise while watching
29° C 85° F 17.58 BAR 255 PSI
the pressure gauge (B). Stop turning valve (D)
32° C 90° F 17.77 BAR 258 PSI
when the needle on the gauge (B) reaches 10
35° C 95° F 17.96 BAR 261 PSI
bar (145 psi).
38° C 100° F 18.15 BAR 263 PSI
NOTE: If the needle goes over the needed pressure, TEMPERATURE/CHARGE PRESSURE CHART
quickly open and close valve (E) and check the
12. Close valve (E) by turning to the right
pressure again.
(clockwise). After a few minutes open valve (E)
The charging kit is now ready to be installed on the and check the accumulator for leakage.
accumulator.
5. Remove the cap from the accumulator. end of the charging hose by turning it
6. Loosen the sealing plug with an Allen wrench. counterclockwise the maximum amount. This will
prevent nitrogen from escaping from the
NOTE: just loosen do not open to far so the gas
accumulator as the hose is removed.
leaks out
14. Close the valve on the nitrogen supply tank.
7. Install adapter 380001168 (F).
15. Adjust the regulator (D) to the minimum pressure
setting by turning the knob counterclockwise.
end of the charging hose by turning it
counterclockwise to the maximum amount. This 16. Slowly remove the charging hose from the
prevents nitrogen from escaping from the accumulator pressure valve.
accumulator when the charging hose is attached NOTE: A small amount of nitrogen will escape when
to the accumulator gas charging valve. disconnecting the hose.
9. Install the charging hose fitting onto the adapter. 17. Snug the gas charging valve on the accumulator,
10. Tighten the needle valve by turning it clockwise. remove the adapter from the accumulator.
Slowly open the gauge valve (E) and observe the 18. Torque the gas charging valve to 20 to 25 Nm
reading on the gauge. This reading is the (14.8 to 18.4 pound feet)
nitrogen pressure level inside the accumulator.
19. Install the cap on the accumulator.
11. Fill the accumulator to pressure according to
Temperature/Charge Pressure chart. 20. Remove the charging gauges from the nitrogen
supply tank.
NOTE: A small amount of nitrogen will escape when
disconnecting the hose.

Copyright ©
Section
8014
8014
RIDE CONTROL VALVE

Copyright ©
8014-2
TABLE OF CONTENTS
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Copyright ©
8014-3
RIDE CONTROL VALVE
9 11
10
8
7 13 12
14
15
6
5
4
3 16
2
1 17
BC05B015.
1. PLUG 6. SPRING 10. ACCUMULATOR DRAIN SCREW 14. POPPET

2. CAP SCREW 7. SPOOL 11. PLUG 15. ORFICE
3. BUSHING 8. PLUG 12. SOLENOID 16. VALVE BLOCK
4. SPRING CARRIER 9. PLUG 13. ORFICE 17. RELIEF VALVE
5. SPRING
Dissasembly STEP 8
Remove the pressure relief valve (17).
STEP 1
Remove ride control valve, refer to section 8001. Inspection
1. Discard all O-rings.
STEP 2
Remove plugs (1), (8), (9), and (11). 2. Clean all parts in cleaning solvent.
3. Check the spools and the spool bores for
STEP 3 damage and wear.
Remove the solenoid (12). 4. Check the parts of the pressure relief valve.
STEP 4 If any of the parts are damaged, install new parts.

Remove the spool (7) from the valve block (16).
STEP 5
Remove cap screw (2), bushing (3), spring carrier
(4), springs (5 & 6) from spool (7).
STEP 6
Remove orifice (13), poppet (14), and orifice (15).
STEP 7
Remove accumulator drain screw (10).

Copyright ©
8014-4
Assembly STEP 6
Install springs (5 &6), spring carrier (4), bushing (3),
STEP 1 cap screw (2) onto spool (7) and torque cap screw
Install new O-rings. (2) to 5.5 Nm (48.5 lb-in).
STEP 2 STEP 7
Install and torque pressure relief valve (17) to 50 Nm Install spool (7) into valve block (16).
(37 lb-ft).
STEP 8
STEP 3 Install and torque plug (1) to 270 Nm (199 lb-ft).
Install and torque accumulator drain screw (10) to
3.5 Nm (31 lb-in). Install the plug for accumulator STEP 9
drain screw and torque to 7 Nm (62 lb-in). Install plug (8) and torque to 140 Nm (103 lb-ft), plug
(9) and torque to 30 Nm (22 lb-ft), and plug (11) and
STEP 4 torque to 90 Nm (66 lb-ft).
Install and torque orifice (15) to 15 Nm (11 lb-ft),
install poppet (14), install and torque orifice (13) to STEP 10
15 Nm (11 lb-ft). Install the ride control valve in the machine, see
section 8001.
STEP 5
Install and torque solenoid valve to 12 Nm (106 STEP 11
lb-in). Test the ride control system, see section 8002.

Copyright ©
SECTION INDEX
MOUNTED EQUIPMENT
Air Conditioning Troubleshooting and System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9002

Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9003
Removal and Installation of Air Conditioning and Heater Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9004
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9006
Roll Over Protective Structure (ROPS) Cab Structural Frame (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007
Cab Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010

Copyright ©
Copyright ©
9002
Section
9002
AIR CONDITIONING TROUBLESHOOTING

AND SYSTEM CHECKS

Copyright ©
9002-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cab Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Evaporator/Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PRESSURE-TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PROBLEM: NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of No Refrigerant or Low Refrigerant Charge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of Large Quantity of Air in System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Condenser Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PROBLEM: NOT ENOUGH COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Not Enough Refrigerant - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
High Side Restriction - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Expansion Valve Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressor Turning But Not Pumping Properly - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Expansion Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Condenser Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PROBLEM: INTERMITTENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Moisture in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PROBLEM: NOISE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Too Much Refrigerant in System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TUBE CONNECTIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Copyright ©
9002-3
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH. M171B
ATTENTION: Only authorized technicians certified 3. Keep refrigerant containers in the correct upright
by an approved training and certification organization position. Always keep refrigerant containers
may service or repair motor vehicle or mobile air away from heat and sunlight. The pressure in a
conditioning systems. It is mandatory that all container will increase with heat.
refrigerant must be RECOVERED and RECYCLED
4. Always reclaim refrigerant from the system, if
when removed from a system during servicing.
you are going to weld or steam clean near the air
Refrigerant HFC-134a is the most stable, and easiest conditioner system.
to work with of the refrigerants now used in air
5. Always check the temperature and pressure of
conditioner systems. Refrigerant HFC-134a does not
the air conditioner system before reclaiming
contain any chlorofluorocarbons (CFC’s) which are
refrigerant and when you test the system.
harmful to the earth’s ozone layer.
6. Dangerous gas can form when refrigerant comes
Safety procedures must be followed when working
in contact with an open flame. Never permit
with Refrigerant HFC-134a to prevent possible
fumes to be inhaled.
personal injury.
7. Never leak test with compressed air or flame
1. Always wear safety goggles when doing any
testers. Tests have indicated that compressed
service work near an air conditioner system.
mixtures of HFC-134a and air can form a
Liquid refrigerant getting into the eyes can cause
combustible gas.
serious injury. Do the following if you get
refrigerant near or in your eyes: 8. Always reclaim refrigerant from the system
before removing any air conditioning component.
A. Flush your eyes with water for 15 minutes.
B. See a physician immediately.
2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
frostbite or a physician must be seen if you get
refrigerant on your skin.

Copyright ©
9002-4
299L7C A22094
BELT TENSION TOOL CAS-10808 REFRIGERANT RECOVERY, RECYCLING AND CHARGING
STATION, OEM-1415
A22090
109L7
ELECTRONIC LEAK DETECTOR OEM-1437
SAFETY GOGGLES CAS-10073-3

Copyright ©
9002-5
OPERATION
The refrigerant circuit of the air conditioning system The refrigerant, still in a high pressure liquid form,
contains five major components: compressor, then flows from the receiver-drier to the expansion
condenser, receiver-drier, expansion valve and valve. The expansion valve then causes a restriction
evaporator. These components are connected by in flow of refrigerant to the evaporator core. The
tubes and hoses and operate as a closed system. evaporator meters refrigerant flow based on
The air conditioner system is charged with HFC-134a evaporator heat load.
refrigerant.
As the refrigerant flows through the evaporator core,
The compressor receives the refrigerant as a low the refrigerant is heated by the air around and
pressure gas. The compressor then compresses the flowing through the evaporator fins. The combination
refrigerant and sends it in the form of a high pressure of increased heat and decreased pressure causes
gas to the condenser. The air flow through the the air flow through the evaporator fins to become
condenser then removes the heat from the very cool and the liquid refrigerant to become a low
refrigerant. As the heat is removed the refrigerant pressure gas. The cooled air then passes from the
changes to a high pressure liquid. evaporator to the cab for the operator’s comfort.
The high pressure refrigerant liquid then flows from The electrical circuit of the air conditioning system
the condenser to the receiver-drier. The consists of a fan speed control, temperature control,
receiver-drier is a container filled with moisture one (1) relay, a blower motor, blower resistor, A.C.
removing material, which removes any moisture that compressor clutch, A.C. low pressure switch, A.C.
may have entered the air conditioner system in order high pressure switch, and A.C. warning light.
to prevent corrosion of the internal components of
the air conditioner system.
3
5
4
208L95
1. EXPANSION VALVE 3. COMPRESSOR 5. RECEIVER-DRIER

2. EVAPORATOR 4. CONDENSER

Copyright ©
9002-6
TROUBLESHOOTING
Perform a visual inspection of the machine. Check 5. - Are there heavy accumulations of oil, or oily
the following and correct as necessary: dust around the fittings, indicating refrigerant
leakage?
1. - Obtain service history if possible.
6. - Are air ducts undamaged, sealed properly and
2. - Is compressor drive belt in place and tensioned?
in position?
3. - Are grille screens, fan blades, condenser, air filter, and
7. - Condensate drain hoses and check valves
evaporator unobstructed?
present and unobstructed?
4. - Are there any sharp bends or kinks in the
hoses?
Problem: No Cooling
Mechanical - See Mechanical Compressor
Check Page 8
Compressor Runs No
Electrical - See Blower and Compressor
Clutch Check Page 9
Yes
Internal System Problem

See Pressure Testing, Page 13

Copyright ©
9002-7
Problem: Problem:
Not Enough Cooling Erratic Cooling
MECHANICAL
See Mechanical Compressor Check Page 8.

HEATER
Make sure the heater control is OFF and that there is no coolant
flow through the heater core.
ELECTRICAL
See Blower and Compressor Clutch Check - Blower Motor
Check, Blower Switch Check and Compressor Clutch Check
on Page 9.
SEAL
Make sure the sealing material is correctly in place.
INTERNAL SYSTEM PROBLEMS

See Pressure Testing, Page 13.
MECHANICAL
See Mechanical Compressor Check page 8. See Evaporator
Heater Core Check Page 12.
Problem:
System Makes Noise
ELECTRICAL
See Blower and Compressor Clutch Check on Page 9.
MECHANICAL
See Mechanical Compressor Check Page 8.

See Blower Motor Check Page 9.
REFRIGERANT
See Cab Temperature Check Page 10.

ELECTRICAL
See Compressor Clutch Check Page 9.
INTERNAL SYSTEM PROBLEM
See Pressure Testing, Page 13. INTERNAL SYSTEM PROBLEM
See Pressure Testing, Page 13.

Copyright ©
9002-8
SYSTEM CHECKS
Mechanical Compressor Check

1. Too much belt wear - replace a worn belt,
Compressor and Fan Belts because a worn belt will cause too much
slippage.
1. Loose bracket mounting bolts - tighten the

bolts to the correct torque.
Compressor Mounting Brackets 2. Bracket has cracks or breaks - replace the
bracket.
1. The compressor belt will slip on the

compressor pulley if there is compressor
seizure. Remove the compressor for
service or replacement.
2. Remove the dust cover and check the air
gap on the compressor clutch. The gap
Compressor Clutch between the front plate and pulley
assembly must be 0.41 to 0.79 mm.
3. Use a socket wrench to slowly rotate the
compressor clockwise. Compressor
rotation should be smooth and not require
much effort.
1. The compressor pulley and the

compressor drive pulley must be aligned
within 1.6 mm (1/16 inch) of each other.
Pulley and Belt Alignment Use a straight edge to check pulley
alignment. Adjust the compressor
mounting bracket if needed.

Copyright ©
9002-9
Blower and Compressor Clutch Check

NOTE: Check supply voltage with
compressor lead plugged in and engaged.
Voltage drops will not be apparent without
current flow.
Compressor Clutch
1. If there is electrical system voltage to the
clutch, check for excessive voltage drop in
the ground circuit, then see Section 9004
and replace the compressor.
1. See Section 4002 and check the high and

Low and High Pressure Switches low pressure switches.
Blower Fuse (10 amp) 1. Check for damaged blower fuse.
1. Check switch operation. Switch must give

four different blower speeds: OFF, Low,
High, and Purge.
Blower Fan Switch 2. Check for loose connections or broken
wires. Repair or replace as necessary.
3. Check resistor board.
1. Check the wiring to the blower motor.

Make repairs or replace items as
necessary.
Blower Motor 2. Check motor ground wire. Make sure
motor ground wire is making good contact
with mounting bracket.
1. With key in ON position, turn switch to

maximum cold. Compressor clutch must
engage.
NOTE: Blower must be operating, since
electrical power to temperature control switch
is received from blower switch.
Temperature Control Switch 2. Turn the blower off. Disconnect the wires
from the temperature control. Using an
ohmmeter, check the continuity between
switch terminals. If continuity is not
present when switch is on maximum cold,
replace switch.

Copyright ©
9002-10
Cab Temperature Check

1. Make sure louvers and recirculation vents are fully open
for most efficient air conditioning operation. Defrost
Air Louvers louvers must be closed.
2. Check blower; blower must be running.
ATTENTION: Use caution when feeling hoses. Hoses

become very hot. Check temperature by slowly reaching for
hose and touching briefly several times with finger tips,
increasing the duration with each touch.
Air Conditioning 1. Feel the air conditioning hoses. The high pressure hoses
(small line) must be warmer than the low pressure hose
(large line).
2. If no temperature difference, the system is low on
refrigerant, or compressor is not working correctly.
1. Put a thermometer in the air duct behind the seat and

run the compressor for five minutes to make
temperature stable. Refer to page 12.
2. Duct temperature must be below 25° C (72° F) if the
system is operating at maximum efficiency.
Duct Temperature NOTE: Ambient temperature must be 27 to 43° C (80 to
110° F).
3. If temperature is above 25° C (72° F), system is low on
refrigerant, there is a restriction in the system,
compressor is not working correctly, or air ducts are not
sealed correctly.
1. Turn the engine OFF, key switch ON, blower switch ON

and temperature control switch turned fully clockwise.
2. Remove the temperature sensing probe from the
evaporator. Refer to Section 9004.
3. Put the end of the temperature sensing probe in a
container with ice and water.
Temperature Sensing Probe Check 4. When the sensing tube has cooled to the temperature of
the ice and water mixture, the temperature control switch
should interrupt the current flow to the compressor.
Check for current at the control switch terminals as on
previous page. If current is not interrupted then replace
the control switch.

Copyright ©
9002-11
Visual and Leak Check

1. Make sure that all hose connections are
tight.
Compressor Hoses 2. Check hoses for bends or cracks. Replace
all hoses that have damage.
1. Shut off the engine.

WARNING: When refrigerant comes in
contact with an open flame, it can form
dangerous gas. Never breathe these fumes.
2. Use electronic leak detector OEM -1437
to inspect all connections. Use
instructions from manufacturer of leak
Leak Finding Check finding tool.
NOTE: When checking compressor seal for a
leak, remove the dust cover and rotate the
clutch shaft clockwise.
NOTE: To properly check the expansion valve
for leaks, remove the insulation tape.
3. Repair all leaks and recharge the system.
See Section 9003.
1. Make sure the condenser is clean and the

seals are in place. Make sure condenser
Condenser fans run when temperature control switch
is ON.

Copyright ©
9002-12
Evaporator/Heater Core Check

Make sure heater valve is closed
Evaporator/Heater Core
1. See Section 9004 for access to the
evaporator/heater core.
2. Inspect the fins on the evaporator/heater
core. All the fins that have bends or
damage must be made straight.
3. Inspect the evaporator/heater core for
restrictions. If the core is dry, use
compressed air or a brush and vacuum
cleaner. If the core is wet or filled with
Evaporator/Heater Core mud, flush the core with water using a
hose without pressure. Make sure the
water drains freely from the
evaporator/heater core. DO NOT USE
STEAM.
WARNING: Do not steam clean any air
conditioning systems parts while the system is
charged. The heat will cause the refrigerant to
rise to a pressure that could cause the system
to explode.
1. See Section 9004 for access to the

2. Make sure seals are in place so blower
Evaporator/Heater Core Sealing will pull air only through the
evaporator/heater core and not around the
Filters 1. Make sure the filters are clean.

Copyright ©
9002-13
PRESSURE TESTING
Manifold Gauge Set During normal operation the low pressure gauge
must always indicate from 10 to 35 psi (0.7 to 2.4
NOTE: The gauge set is not accurate enough to bar) after the system has run 10 to 15 minutes.
optimize an existing charge of HFC-134a. The best
use of the gauge set is to determine whether HIGH PRESSURE GAUGE - The high pressure
undercharge or overcharge exists, and then gauge is used to indicate pressures in the high side
evacuate, reclaim and recharge system with the of the system. The gauge must indicate from 0 to 400
recommended quantity (charge) of HFC-134a. psi (0 to 27.6 bar) minimum.
The manifold gauge set is the most important tool During normal operation, the high pressure gauge
used to service the air conditioning system. The will normally indicate from 120 to 310 psi (8.3 to 21.4
manifold gauge set is used to measure the high and bar). See pressure-temperature chart on page 14.
low pressures of the system, as a tool to troubleshoot
for correct refrigerant charge quantity, system Pressure Test Connection
diagnosis, and operating efficiency. The manifold
Connect the manifold gauge set into the air
gauge set can read both the high (discharge) and low
conditioning system as shown. Make sure that both
(suction) sides at the same time, since pressure must
valves in the manifold gauge set are closed.
be compared in order to make a diagnosis of system
operation.
LOW PRESSURE GAUGE - The low pressure gauge
is a compound gauge. It is best used to judge
evacuation effectiveness. A vacuum reading
indicates a system malfunction. For this reason, it is
necessary to use a compound gauge that will
indicate both pressure and vacuum.

Copyright ©
9002-14
PRESSURE-TEMPERATURE CHART
AMBIENT NORMAL LOW AIR LOUVER (BEHIND

NORMAL HIGH
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION SEAT) MAXIMUM TEMP.
°F (°C) psi (bar) psi (bar) °F (°C)
80 (27) 9 to 12 145 to 165 55 (14)

(0.62 to 0.83) (10 to 11.53)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.10 to 14.48)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.48 to 15.86)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.58)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.93 to 19.31)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.37)
The pressure-temperature chart is based on the 2. All panels and access doors installed and closed.
following conditions:
3. Cab filters clean and installed.
NOTE: High humidity will cause higher air louver
4. Heater valve at engine closed.
temperatures and dramatic increase in suction
pressure. The table shown represents readings 5. Measurements taken 15 minutes after startup.
taken in low relative humidity. Adjust the chart
according to local conditions.
1. Engine at 1500 RPM, no load, fan speed &
temperature control at max setting, A/C switch
ON, all louvers and doors open
QUICK REFERENCE TROUBLESHOOTING CHART
PROBLEM LOW PRESSURE HIGH PRESSURE SEE

GAUGE GAUGE PAGE
NO COOLING VERY LOW VERY LOW 16
NO COOLING HIGH HIGH 17
NOT ENOUGH COOLING NORMAL TO HIGH NORMAL 19
NOT ENOUGH COOLING LOW LOW 20
NOT ENOUGH COOLING HIGH LOW 22
NOT ENOUGH COOLING HIGH HIGH 23
INTERMITTENT COOLING NORMAL NORMAL 24
NOISE IN SYSTEM NORMAL TO HIGH HIGH 25

Copyright ©
9002-15
A/C RECOVERY AND CHARGING STATION CONNECTIONS

STEP 1 STEP 4
Clean the external surfaces of the compressor and Connect the hose from the high pressure gauge to
hoses. Remove the caps from the service ports on the port on the discharge hose.
the suction and pressure hoses.
WARNING: Always wear safety goggles
WARNING: Do not steam clean any air when working with liquid refrigerant. Liquid
conditioning system parts while the system is refrigerant in your eyes could cause
charged. The heat will cause the refrigerant blindness. SM105A
to rise to a pressure that could cause the
system to explode. SM104A
STEP 5
Make sure the charging station manifold gauge
STEP 2 valves are in the closed position.
Connect the hoses from the test gauges to the
service ports by turning the knurled knobs on the STEP 6
depressors. Start the engine and run at 1500 RPM maximum
speed. Operate the air conditioner system at
STEP 3 maximum cooling setting and blower speed for 15
Connect the hose from the low pressure gauge to the minutes with the cab door open. Observe the test
port on the suction hose. gauges and check the chart on page 13 against the
gauge readings.

Copyright ©
9002-16
PROBLEM: NO COOLING
VERY LOW VERY LOW
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
Indication of No Refrigerant or Low Refrigerant Charge:

1. Leak test the system, see Page 11. It may
be necessary to add refrigerant. See
Section 9003.
2. Evacuate and reclaim remaining

refrigerant from system. See Section
9003.
3. Repair system leaks as needed. Follow

the given repair procedure.
A. Discharge air from evaporator warm.
B. Compressor does not run, or cycles off 4. Check level of oil in compressor - possible
Yes
rapidly after start-up. (A/C warning light for compressor to have an oil loss.
in cab should illuminate).
5. Remove air and moisture from the
system. Replace Receiver-Drier. See
Section 9004.
6. Charge system with new refrigerant. See

Section 9003.
7. Continue performance test for other

possible problems.

Copyright ©
9002-17
HIGH HIGH
476L7
Indication of Large Quantity of Air in System:

1. Evacuate and reclaim refrigerant from
system. See Section 9003.
2. Replace receiver-drier.
Discharge air from evaporator warm Yes 3. Remove air and moisture from the
Section 9003.
Condenser Malfunctioning - Indications:

1. Check for loose or worn compressor or engine fan
belt and proper condenser fan operation.
2. Check to see that condenser is clean and

unobstructed and that the fins are straight.
3. Check system for too much refrigerant. Evacuate,
reclaim and recharge refrigerant until gauge
pressure is normal. See Section 9003.
4. Remove and check condenser for restrictions

A. Liquid line (between evaporator and
caused by oil or reduced heat transfer.
condenser) is very hot.
A. Remove refrigerant from the system. See
B. Discharge air from evaporator warm.
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9003.
5. Continue the performance test for other possible

problems.

Copyright ©
9002-18
Expansion Valve Malfunctioning - Indications:

A. Discharge air from heater/evaporator
warm.
B. Much condensation on suction hose at See Section 9004 and replace the expansion
compressor. valve.
C. Much condensation on evaporator
outlet.
Refrigerant Contamination:
1. See table below and check stable saturation pressures at
given temperature to determine if contamination exists.
A. Measure pressure from gauge on reclamation unit.
B. Measure temperature from refrigerant in reclamation
tank. If refrigerant has been in reclamation unit for some
time, use ambient temperature. The numbers in the
Refrigerant Contamination
table represent the boiling point for HFC-134a.
C. Pressure readings below range given in chart indicate
contaminated refrigerant.
IMPORTANT: Do not use contaminated refrigerant or mix
with uncontaminated refrigerant. Dispose of in accordance
with all applicable laws and local procedure.
HFC-134a Stable Saturation Pressure/ Temperature Chart
Temperature °F (° C) Pressure PSIG (Bar)
50 (10) 45 (3.1)
55 (13) 51 (3.5)
60 (16) 57 (3.9)
65 (18) 64 (4.4)
70 (21) 71 (4.9)
75 (24) 78 (5.4)
80 (27) 88 (6.1)
85 (29) 95 (6.6)
90 (32) 104 (7.2)
95 (35) 114 (7.9)
100 (38) 124 (8.6)
102 (39) 129 (8.9)
104 (40) 133 (9.2)
106 (41) 138 (9.5)
108 (42) 142 (9.8)
110 (43) 147 (10.1)
112 (44) 152 (10.5)
114 (46) 157 (10.8)
116 (47) 162 (11.2)
118 (48) 167 (11.5)
120 (49) 172 (11.9)

Copyright ©
9002-19
PROBLEM: NOT ENOUGH COOLING
NORMAL TO
SLIGHTLY HIGH NORMAL
476L7
Air in the System - Indications:

1. Test system for leaks. See page 11. Possible
leak has let air enter; check compressor seal
carefully.
2. Discharge system of refrigerant. See Section
9003.
A. Suction line warm to your hand. 3. Repair system leak as necessary.
B. Discharge air from heater/evaporator 4. Replace receiver-drier.
only a little cool.
5. Check compressor oil level.
6. Remove air and moisture from the system.
See Section 9003.
Section 9003.

Copyright ©
9002-20
LOW LO W
476L7
Not Enough Refrigerant - Indications:

1. Leak test system - system has a loss of refrigerant.
NOTE: Normally, the system will lose 1/2 to 1 ounce (14.7
to 29.5 grams) of refrigerant between seasons.
A. If leak is found, go to Step 2.
B. If no leak is found, go to Step 6.
2. Discharge refrigerant from system. See Section 9003.
A. Discharge air from evaporator 3. Repair system leaks as needed.

cool or warm - not cold.
4. Check oil level in compressor - It is possible for
compressor to lose oil.
5. Remove air and moisture from the system. Replace

Receiver-Drier. See Section 9004.
6. Charge system with new refrigerant. See Section

9003.
High Side Restriction - Indications:

A. Discharge air from heater/evaporator
1. Discharge refrigerant from system-restriction in
only a little cool.
receiver-drier or liquid line must be removed.
B. Condensation or frost on
2. Remove and replace part with restriction.
receiver-drier.
3. Remove air and moisture from the system. See
C. Liquid line to receiver-drier cool, with
Section 9003.
frost or condensation.
4. Charge system with new refrigerant. See Section
NOTE: The frost will form downstream from
9003.
or at the point of the restriction

Copyright ©
9002-21
Expansion Valve Not Operating - Indications:

1. Expansion valve outlet with condensation or frost is
A. Discharge air from evaporator warm an indication of a restriction in the expansion valve.
or cool - not cold. Replace expansion valve. See Section 9004.
B. Condensation or frost on expansion 2. Inlet end of expansion valve is warm (not hot),
valve outlet. indicating expansion valve is not completely open.
C. Inlet end of expansion valve is If the valve is stuck closed, there will be little or no
warm. flow of refrigerant through the valve. Replace
expansion valve. See Section 9004.

Copyright ©
9002-22
HIGH LOW
476L7
SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14
Compressor Turning But Not Pumping Properly - Indications:

1. Discharge refrigerant from system. See Section
9003.
2. Remove the compressor from the machine. See
Section 9004.
3. Remove and replace compressor because there is
indication of internal leak in compressor.
A. System is fully charged. 4. Replace compressor.
B. Cool discharge air from evaporator. 5. Replace receiver-drier if:
A. System has been opened before.
B. Receiver-drier has been used two or more
years. See Section 9004 for receiver-drier
replacement.
6. Charge the system with refrigerant. See Section
9003.
Expansion Valve Stuck Open

Expansion Valve Stuck Open 1. Replace expansion valve. See Section 9004.

Copyright ©
9002-23
HIGH HIGH
476L7
Condenser Not Operating - Indications:

1. Check for loose or worn compressor belt and
proper condenser fan operation.
2. Check to see that condenser is clean and that
the fins are straight.
3. Check system for too much refrigerant.
A. Remove refrigerant from system until gauge
pressure is below normal. See Section 9003.
B. Add refrigerant until gauge pressures are
A. Liquid line very hot.
normal. See Section 9003.
B. Discharge air from evaporator warm.
C. If there is still a problem, do step 4.
4. Remove and inspect condenser for restrictions
caused by oil or reduced heat transfer.
A. Discharge refrigerant from system. See
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier. See Section 9004.
Air in the System - Indications:

1. Discharge refrigerant from system. See
Section 9003.
2. Replace receiver-drier.
Warm discharge air from evaporator. 3. Remove air and moisture from the
Section 9003.

Copyright ©
9002-24
PROBLEM: INTERMITTENT COOLING
NORMAL NORMAL
476L7
Moisture in the System - Indications:

1. Discharge system of refrigerant. If too
much moisture enters the orifice of the
expansion valve, the freezing of this
moisture can stop refrigerant flow. See
Section 9003.
2. Replace receiver-drier. The moisture

removing material could be full to capacity
with moisture. See Section 9004.
Cooling is acceptable during cool part of day
but not acceptable during hot part of day. 3. Remove air and moisture from the
NOTE: The time needed to remove a large
amount of moisture will be two to three hours
minimum.

Section 9003.

Copyright ©
9002-25
PROBLEM: NOISE IN SYSTEM
NORMAL
HIGH
TO HIGH
476L7
Too Much Refrigerant in System - Indications:

1. Remove refrigerant from system until gauge
readings are below normal. See Section
A. Cool discharge air from heater/evaporator.
9003.
B. Compressor makes noise.
2. Add new refrigerant until gauge readings are
normal. See Section 9003.

Copyright ©
9002-26
TUBE CONNECTIONS TORQUE CHART
TUBING SIZE 3/8 inch 1/2 inch 5/8 inch

THREAD SIZE M10 -1.25 5/8-18 3/4-18 7/8-18 1-14
OR OR
3/4-16 7/8-14
STEEL TO STEEL 31-36 Nm 31-36 Nm 40-46 Nm 45-52 Nm 45-52 Nm
ALUMINUM TO BRASS 10-14 Nm 10-14 Nm 24-30 Nm 30-37 Nm 45-52 Nm
NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used.
IMPORTANT: Special care is required when tightening the fittings on the compressor, condenser and evaporator
since these connections are easily distorted.

Copyright ©
Section
9003
9003
AIR CONDITIONER SYSTEM SERVICE

Copyright ©
9003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Copyright ©
9003-3
SPECIFICATIONS
Air conditioning system refrigerant capacity ............................................................1670 to 1730 g (3.68 to 3.82 lbs)
(59 to 61.1 oz.)
SPECIAL TOOLS
A22094 109L7
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING SAFETY GOGGLES CAS-10073-3
STATION OEM-1415

Copyright ©
9003-4
SAFETY PROCEDURES

4. Always reclaim refrigerant from the system, if
you are going to weld or steam clean near the air
Refrigerant HFC-134a is the most stable and easiest conditioner system.
conditioning systems. Refrigerant HFC-134a does
not contain chlorofluorocarbons (CFC’s) which are
harmful to the Earth’s ozone layer.
with refrigerant HFC-134a to prevent possible
personal injury.
combustible gas.

Copyright ©
9003-5
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

Recovered refrigerant passes through an oil STEP 3
separator and a filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system off before proceeding.
STEP 1
A22114
Open the high and low valves.
STEP 4
BD08B201-01
Clean the external surfaces of the compressor and

hoses. Remove the caps from the service ports on
the suction and pressure hoses.
STEP 2
A22107
Make certain the refrigerant tank gas and liquid

valves are open.
BD08B201-01
With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports.
Connect the hose from the low pressure gauge to the
port on the suction hose. Turn in valve depressor.
Connect the hose from the high pressure gauge to
the port on the discharge hose. Turn in valve
depressor.

Copyright ©
9003-6
STEP 5 STEP 7
A22112 A22110
Connect the main power plug to a 115 volt AC outlet. Slowly open the oil drain valve and drain the oil into
Move the main power switch to the ON position and the reservoir. When the oil stops draining, close the
depress the recovery start switch. oil drain valve completely.
The compressor will shut OFF automatically when
recovery is complete. Wait for 5 minutes and observe STEP 8
the manifold pressure gauges for a pressure rise. If
pressure rises above 0 psi (0 bar), depress the
hold/cont switch. Then wait for the compressor to
automatically shut OFF.
STEP 6
A22111
Fill the A/C compressor with fresh SP-20 PAG oil

equal to the amount in the reservoir.
STEP 9
A22108
Drain the oil separator of the A/C system oil. Open

the air purge valve long enough to let some of the
compressor discharge pressure back into the
separator.
BD08B201-01
Remove the hoses from the service ports and install

the caps.

Copyright ©
9003-7
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or Air and moisture are removed from the system by a
more of the following conditions occurs before you vacuum pump. A vacuum pump is the only
remove the air and moisture from the system. equipment made to lower the pressure enough to
change the moisture to vapor that can be removed
A. The system has been opened for service
from the system.
before.
NOTE: Refer to the vacuum pump manufacturer’s
B. Receiver-drier has operated two or more
user manual for additional information.
years.
C. Disassembly of compressor shows small STEP 11
particles of moisture removing material (gold
or brown particles).
D. Large system leak (broken hose, break in
line).
E. Too much air or moisture in system.
F. Removal of compressor caused the system to
be open (uncapped) longer than 5 minutes.
STEP 10
A22113
Connect the main power plug to a 115 volt AC outlet.

Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum
of 45 minutes and press the Enter key. The display
will flash once indicating the programmed data has
been accepted.
STEP 12
BD08B201-01
With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports as follows:
1. Connect the hose from the low pressure gauge
to the port on the suction hose.
2. Connect the hose from the high pressure gauge
to the port on the discharge hose.
3. Turn in both thumbscrews to depress the service
valves.
A22115
Removal of air and moisture from the system is
necessary after the refrigerant has been removed Press the Charge key. “Program” and “Charge” will
after the system has been opened for maintenance. appear on the display.
Air enters the system when the system is opened. Air
has moisture that must be removed to prevent
damage to the system components.
NOTE: The pump on the reclamation unit will not
pull a sufficient vacuum to remove air and moisture.

Copyright ©
9003-8
STEP 13 STEP 16
A22113 A22123
Program 3.75 lbs and press the enter key. The Press the Vacuum key. “Automatic” will appear on
display will flash once indicating the programmed the display. Vacuum will appear on the display and
data has been accepted. after a slight delay, the vacuum pump will start. The
display will show the amount of time programmed
STEP 14 and begin a countdown to zero.
When the programmed time has elapsed, an
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 10 minutes. A previously charged,
leak-free system will leach refrigerant from
compressor oil and raise system pressure under
vacuum. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See Section 9002 in the manual for a leak
test.
A22114
Fully open the low and high pressure valves.

STEP 17
STEP 15
A22113
Press the charge key to begin refrigerant charging.

A22107
“Automatic” and “Charge” will appear on the display.
Open the red (vapor) and blue (liquid) valves on the The display shows the programmed amount and
tank. counts down to zero as charging proceeds. When
charging is completed, the display shows “CPL”.

Copyright ©
9003-9
STEP 18 STEP 21
A22114 BD08B201-01
Completely close the high and low pressure manifold Stop the engine, close any open valves and carefully
valves. remove the manifold gauge hoses.
ATTENTION: Check the OEM equipment manual
before performing Step 19 to avoid damaging the STEP 22
recovery unit. The pressure reading should be
obtainable with valves closed. Damage may occur if
the machine is started with the valves accidently
open or if either or both valves are opened while the
A/C system is operating.
STEP 19
Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting
and blower speed with the doors and windows open.
NOTE: The compressor will not operate if the
system pressure is too low or too high. The pressure BD08B201-01
indicator lamp will illuminate when the relay is Install the caps on the service ports on the suction
actuated by a low or high pressure and the and discharge hoses.
compressor clutch will disengage. To restart the
compressor, the air conditioner control or blower
switch must be turned to the OFF position and then
to the ON position.
STEP 20
A22117
Observe the pressure gauge readings to determine

that the correct amount of refrigerant has entered the
system. See chart on Page 9002-9 for temperature
and pressure variations.

Copyright ©
9003-10
PRESSURE - TEMPERATURE CHART
AMBIENT NORMAL LOW NORMAL HIGH AIR LOUVER

TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION MAXIMUM TEMP.
°F (°C) psi (bar) psi (bar) °F (°C)
80 (27) 9 to 12 145 to 165 55 (14)
(0.62 to 0.83) (10 to 11.5)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.1 to 14.5)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.5 to 15.8)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.6)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.9 to 19.3)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.4)
The pressure-temperature chart is based on the 5. Both cab doors open

following conditions:
6. All panels and access doors installed and closed.
1. Engine operating at 1500 RPM
7. Cab filters clean and installed.
2. No engine load
8. Heater valve at engine closed.
3. Fan speed control in maximum position and all
9. Measurements taken 15 minutes after start-up.
louvers open.
4. Cab temperature control set to maximum
cooling.

Copyright ©
Section
9004
9004
REMOVAL AND INSTALLATION OF AIR CONDITIONING
AND HEATER COMPONENTS

Copyright ©
9004-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EXPANSION VALVE, EVAPORATOR/HEATER CORE,
HEATER VALVE, BLOWERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CONDENSER AND RECIEVER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Copyright ©
9004-3
SAFETY PROCEDURES

4. Always reclaim refrigerant from the system if you
are going to weld or steam clean near the air
Refrigerant HFC-134a is the most stable, and easiest conditioner system.
conditioner systems. Refrigerant HFC-134a does not
contain any chlorofluorocarbons (CFC’s) which are
harmful to the earth’s ozone layer.
with Refrigerant HFC-134a to prevent possible
personal injury.
combustible gas.

Copyright ©
9004-4
SPECIAL TOOLS
A22094 BS03H012
REFRIGERANT RECOVERY, RECYCLING AND CHARGING SAFETY GOGGLES CAS-10073-3
STATION OEM-1415

Copyright ©
9004-5
COMPRESSOR
Removal STEP 4
STEP 1
position.
STEP 2
Discharge the air conditioning system according to
the instructions in Section 9003.
STEP 3
BD07N576-01
Remove the drive belt by releasing automatic belt

tensioner.
NOTE: Air conditioner belt is a separate belt.
STEP 5
BD07N600-01
BD08B201-01
Disconnect the low pressure line from the suction

port and the high pressure line from the discharge
p o r t o n t h e c o m p r e s s o r . I m m e d i a t e ly i n s t a l l
BD07N573-01
protective caps on the open ports and lines.
Loosen and remove the four bolts holding the
protective shield. Remove the shield.

Copyright ©
9004-6
STEP 6 Installation
STEP 9
Place the compressor into position on the machine.
STEP 10
BD07N578-01
Disconnect the compressor clutch wire from the

engine harness assembly.
STEP 7
BD07N579-01
Install the two bolts to mount the compressor.
1 STEP 11
2
BD07N579-01
Loosen and remove the two compressor mounting

bolts (1) and remove the air conditioner belt (2).
STEP 8 BD07N578-01
Remove the compressor from the machine. Connect the compressor clutch wire to the engine
harness assembly.

Copyright ©
9004-7
STEP 12 STEP 13
BD08B201-01 BD07N576-01
Carefully remove the protective cap, install a new

O-ring, and connect the high pressure line to the
discharge port on the compressor.
Carefully remove the protective cap, install a new
O-ring, and connect the low pressure line to the
suction port on the compressor.
IMPORTANT: Use caution when removing cap as
new compressors have internal pressure when
shipped.
BS08A051
Install the drive belt (1) first, then the air conditioner
belt (2).
NOTE: A/C compressor belt tension:
A. Tension for a new belt is 45 Kg (100 lb).
B. Tension for a belt used more than 20 hours is
41 Kg (90 lb).

Copyright ©
9004-8
STEP 14
BD07N600-01
BD07N573-01
Install the belt cover, install the four mounting bolts

for the belt cover.
STEP 15
Charge the air conditioning system according to the
instructions in Section 9003.

Copyright ©
9004-9
EXPANSION VALVE, EVAPORATOR/HEATER CORE,

HEATER VALVE, BLOWERS
3 6
5
7
8
9
18 10
17
12 11
14
13
16
15
BS06G118
1. EVAPORATOR 7. WASHER 13. LOWER BOX PPE

2. UPPER BOX PPE 8. GROMMET 14. EXPANSION VALVE
3. COVER PPE 9. HEATER CORE 15. BLOWER
4. SOLENOID DRIVER 10. HEATER VALVE 24V 16. RECIRCULATING VAIN
5. UPPER BOX 11. THERMOSTAT 17. RECIRCULATING MOTOR
6. BOLT 12. LOWER BOX 18. RESISTOR BLOWER MOTOR

Copyright ©
9004-10
Removal STEP 22
STEP 16
bucket to the floor.
STEP 17
If changing any air conditioning components,
discharge the air conditioning system according to
STEP 18
BD06G212
Open the cover on the cooler.
STEP 23
BD02N160
If changing the heater core, put a container capable

of holding 22.7 liter (6 gallon) container below
radiator drain. Remove radiator cap. Remove cap
and drain coolant into container. Install cap after BD06G213
coolant has drained. Install radiator cap. Remove the four screws securing the air vent,
remove the vent cover.
STEP 19
Place the master disconnect in the OFF position. STEP 24
STEP 20
Disconnect the wiring harness from the operator’s
seat (if equipped with air seat option).
STEP 21
BD06G214
Remove the three screws securing the cooler to the

cab, remove the cooler.
STEP 25
Fold the rubber mat over to gain access to the upper
box mounting bolts.
BD06G202
Remove the four bolts that fasten the operator’s seat

to the upper box, remove the seat from the machine.
Copyright ©
9004-11
STEP 26 STEP 29
BD06G215 BD06G217
Remove the six bolts securing the upper box. G o i n g t h r o u g h t h e i n s i d e f i l t er a re a f e e l t h e

recirculating vain to make sure is is in the outside air,
STEP 27 “closed”, position.
STEP 30
BD06G216
Remove two screws, one on each side of the upper

box, securing the upper box to the lower box. BD06G218
The above photo shows that the recirculating vain is

STEP 28 not in the outside air “closed” position.
Place the air selector on the control panel to outside
air. STEP 31
NOTE: In step 29 and 32 the upper box is shown
removed for clarity only, these steps must be done
prior to removing the upper box.
BD06G240
Use a screw driver and disconnect the linkage.

Copyright ©
9004-12
STEP 32 STEP 35
BD06G219
Close the vain so the upper cover can be removed. BD06G203
Disconnect the solenoid driver.

STEP 33
Remove the upper box up and rest it against the STEP 36
console.
NOTE: The wiring harness for the HVAC system
goes through the upper cover, by resting the cover
against the console the wiring harness will not need
to be removed.
STEP 34
BD06G236
Remove the upper PPE from the heater and air

conditioning cores.
NOTE: If testing on the electrical components are
required the solenoid driver can be reconnected
once the upper PPE is removed.
BD06G220
Pull the wiring harness loose from the upper PPE.

Copyright ©
9004-13
NOTE: If replacing the heater control valve, heater STEP 39
core, air conditioning expansion valve, air
conditioning evaporator core do steps 37 through 46,
if replacing electrical components go to step 47.
STEP 37
BD06G206
Remove the thermostat probe and clamp from the

evaporator core.
STEP 40
BD06G204
Remove the right side cab skirt.
STEP 38
2 3
1 BD06G237
Disconnect the electrical connectors from the

thermostat control.
STEP 41
BD06G205
1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES
3. HEATER HOSES
Fasten identification tags on the hoses. Disconnect

the hoses for the heater core and evaporator core,
install plugs in the hoses and caps on the fittings.
BD06G236
Disconnect the electrical connectors from the heater

control valve.

Copyright ©
9004-14
STEP 42 STEP 48
Pull the heater core and evaporator core from the
lower box PPE.
STEP 43
Remove the expansion valve from the evaporator
core.
STEP 44
Remove and discard the O-rings from the openings
in the expansion valve.
STEP 45
Remove the screws from the heater core and remove BD06G208
the control valve. Disconnect the electrical connector for the

recirculating vain motor, disconnect the linkage from
STEP 46 the vain. Remove the mounting screws and remove
the motor.
Remove and discard the O-rings from the heater
control valve.
STEP 49
STEP 47
1 2
3
BD06G209
1. FAN SPEED AND A/C SWITCH
BD06G207 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH
1. RESISTORS
3. THERMOSTAT
2. RESISTOR CONNECTOR
3. BLOWER MOTOR CONNECTOR Remove the switch panel from the console.
Disconnect the electrical connectors and remove
Remove the fans from the lower PPE, disconnect the
switches as required.
electrical connectors. Remove the two mounting
screws for the resistor, remove the resistor.

Copyright ©
9004-15
STEP 50
1
1 2
3
BD06G207
1. RESISTORS
2. RESISTOR CONNECTOR
BD06G209 3. BLOWER MOTOR CONNECTOR
1. FAN SPEED SWITCH
2. INSIDE/OUTSIDE AIR SELECTOR SWITCH Install the resistor, install the two mounting screws
3. THERMOSTAT and tighten. Install the fans in the lower PPE,
Replace switches and connect the electrical connect the electrical connectors.
connectors as required. Install the switch panel in the
console. STEP 53
Install new O-rings on the heater control valve.
STEP 51
STEP 54
Install the control valve, install and tighten the screws
to the heater core.
STEP 55
Install new O-rings on the openings of the expansion
valve.
STEP 56
Install the heater core and evaporator core into the
lower box PPE.
BD06G208 STEP 57
Install the motor and install the mounting screws and
tighten. Connect the electrical connector for the
recirculating vain motor, connect the linkage to the
vain.
BD06G236
Connect the electrical connectors to the heater

control valve.

Copyright ©
9004-16
STEP 58 STEP 60
2 3
BD06G237
Connect the electrical connectors to the thermostat BD06G205

1. TRANSMISSION FILTER
control.
3. HEATER HOSES
STEP 59
Remove the plugs from the hoses and the caps from
the fittings. Install new O-rings in the evaporator
fittings, connect the heater and evaporator hoses.
Remove and discard identification tags that were
used during disassemble.
STEP 61
BD06G206
Install the thermostat probe coil and clamp to the

evaporator core “cold” tube.
BD06G204
Install the right side cab skirt.
STEP 62
BD06G238
Install the upper PPE on the heater and air

conditioning cores.
Copyright ©
9004-17
STEP 63 STEP 66
BD06G210.
BD06G203 Make sure that the recirculating vain is in the closed
Connect the solenoid driver. position.
IMPORTANT: This photo shows it in the open
STEP 64 position and the upper box will not go back into
position without damaging the recirculating vain.
STEP 67
BD06G239
Push the wiring harness into the preformed notches

in the upper PPE.
BD06G241
Set the upper box into position on the heater and

STEP 65 evaporator cores.
Place the air selector on the control panel to outside
air. STEP 68
BD06G216
Install two screws, one on each side of the upper box

securing the upper box to the lower box.

Copyright ©
9004-18
STEP 69 STEP 73
BD06G242 BD06G214
Install the insolation panel in the center of the upper Install and tighten the three screws securing the
box. cooler to the cab.
STEP 70 STEP 74
BD06G215 BD06G213
Install and tighten the six bolts securing the upper Install the vent cover, install and tighten the four
box. screws securing the air vent.
STEP 71 STEP 75
BD06G243
Install the right rear floor mat into the cab, if machine BD06G202
is equipped with air ride seat make sure to pull the Install and torque the four bolts to 73 to 87 Nm (55 to
wiring up above the mat for the seat. 65 pound-feet).
STEP 72
Install the remainder of the floor mat.

Copyright ©
9004-19
STEP 76 STEP 78
Connect the wiring connector to the operator’s seat Charge the air conditioning system according to the
(if equipped with air seat option). instructions in Section 9003.
STEP 77
Ethylene Glycol and 50% water. Install the radiator
the reservoir.

Copyright ©
9004-20
CONDENSER AND RECIEVER DRIER
Removal STEP 84
STEP 79
bucket to the ground.
STEP 80
position.
STEP 81
Discharge the air conditioning system according to
BS03A107
STEP 82 Fasten identification tags on the hoses and

disconnect the hoses from the condenser.
1 STEP 85
Install plugs in the hoses and caps on the fittings.
2 STEP 86
BD01D142
1. COVER 2. CONDENSER
Open the cover (1) to gain access to the condenser
(2).
STEP 83
BS03A109
Loosen the bolts that fasten the condenser to the

bracket, pivot the condenser and remove the bolts
and condenser.
BD03A109
The condenser is connected to a bracket which

pivots on the cooling frame. Pivot the condenser to
gain access to the hoses.

Copyright ©
9004-21
STEP 90
2 Put the condenser in position on the bracket.
1
STEP 91
BD06G211
Fasten identification tags on hoses (1) and trinary

switch (2). Disconnect the hoses from the receiver
drier. Located above the rear axle under the machine
STEP 88 BS03A109
Install plugs in the hoses and caps on the fittings. Install the bolts that fasten the condenser to the
bracket, pivot the condenser down and tighten the
STEP 89 bolts.
Disconnect the trinary switch, remove the mounting
bolt, remove the receiver drier and bracket. STEP 92
BS03A107
Pivot the condenser to gain access to the hoses.
STEP 93
Remove the plugs from the hoses and the caps from
the fittings. Install new O-rings and connect the
hoses to the fittings. Remove and discard
identification tags that were used during
disassemble.
STEP 94
Pivot the condenser down and close the cover.

Copyright ©
9004-22
STEP 95 STEP 97
Charge the air conditioning system according to the
instructions in Section 9003.
STEP 98
Place the master disconnect switch to the ON
position.
BD06G211
Mount the receiver drier and bracket, install and

tighten the mounting bolt.
STEP 96
BD06G211
Remove plugs from the hoses and caps from the

fittings, install new O-rings and connect the hoses to
the fittings, connect the trinary switch. Remove and
discard identification tags that were used during
disassemble.

Copyright ©
Section
9006
LOADER
9006

Copyright ©
9006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RETURN TO DIG ADJUSTMENT (Z-BAR AND XR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RETURN TO DIG ADJUSTMENT (XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT
(Z-BAR, XT, AND XR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LOADER FRAME (Z-BAR AND XR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LOADER FRAME (XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Copyright ©
9006-3
SPECIFICATIONS
Special Torques
Bolts for the Bucket Teeth .......................................................................1315 to 1480 Nm (970 to 1090 pound-feet)
BUCKET TEETH
Replacement of the Tooth Points

1. Use a hammer and punch to drive the retaining 3 5
pin (2) for the tooth point (1) out of the tooth
4
shank (3), refer to the illustration on this page. 1 2
2. Remove the tooth point (1).
3. Install a new tooth point (1) on the tooth shank
(3).
4. Install the retaining pin (2) into the tooth point (1)
7
and tooth shank (3). Make sure the shoulder on
the retaining pin is toward the cutting edge. Use
6
8
a hammer to hit the retaining pin (2) until the 3 9
retaining pin (2) is even with the outside of the
tooth shank (3).
1 2
Replacement of the Bucket Teeth
1. Loosen and remove the nuts (4), hardened
washers (5), and bolts (6) from the bucket teeth.
NOTE: If wear of the bolt or nut makes removal 7 10
difficult, the bolt or nut can be cut off.
2. Remove the tooth.
B0740A88J
3. Install the new tooth on the bucket cutting edge 1. TOOTH POINT 6. BOLT
(7). 2. RETAINING RING 7. CUTTING EDGE
3. TOOTH SHANK 8. PLOW BOLT
4. Use new nuts (4), hardened washers (5), and
4. NUT 9. NUT
bolts (6) for the tooth being installed.
5. HARDENED WASHER 10. CORNER TOOTH
5. Tighten the nuts (4) to 1315 to 1480 Nm (970 to
1090 pound-feet). BUCKET TEETH ILLUSTRATION
Replacement of the Bucket Corner

Teeth
1. Loosen and remove the nuts (9) and bolts (8)
from the bucket corner teeth (10).
NOTE: If wear of the bolt or nut makes removal
difficult, the bolt or nut can be cut off.
2. Remove the corner tooth (10).
3. Install the new corner tooth (10) on the bucket
cutting edge (7).
4. Use new nuts (9) and bolts (8) for the corner
tooth being installed.
5. Tighten the nuts (9) to 1315 to 1480 Nm (970 to
1090 pound-feet).
Copyright ©
9006-4
RETURN TO DIG ADJUSTMENT (Z-BAR AND XR MODELS)
3
6 5 4
BS01C083
1. TARGET MOUNTING BRACKET 4. PROXIMITY SWITCH MOUNTING BRACKET

2. TILT CYLINDER 5. PROXIMITY SWITCH
3. TARGET BAR 6. PROXIMITY SWITCH GUARD
RETURN TO DIG ADJUSTMENT ILLUSTRATION Z-BAR MODELS
6. Loosen the bolts holding the target bar (3) to the

WARNING: Raised equipment on the machine target mounting bracket (1). Align the target bar
without an operator can cause injury or death. (3) parallel to the tilt cylinder (2) and tighten
Before you leave the operators compartment, bolts.
always support or lower the equipment (backhoe,
blade, boom, bucket, etc.) to the ground and stop 7. Loosen the bolts holding the proximity switch
the engine. mounting bracket (4) to the tilt cylinder (2). Adjust
CM105
the proximity switch (5) face parallel to the target
bar surface and tighten bolts.
IMPORTANT: Before adjusting the return-to-dig,
make sure that the target bar on the bucket linkage is 8. Adjust the proximity switch (5) out towards the
not damaged and all mounting bolts are tight. Slowly target bar (3), until an air gap of 3.5 to 5.0 mm
roll back and dump the bucket and make sure that (1/8 to 3/16 inch) is obtained. Torque the jam
the target bar stays the same distance from the nuts to 6 to 7.5 Nm (4.5 to 5.5 pound-feet).
switch. The switch mounting bracket protects the
NOTE: The proximity switch (5) must not protrude
switch. Make sure the target bar cannot touch the
past the proximity switch guard (6).
switch when the bucket is dumped.
9. Start the engine, position the bucket flat on the
ground and stop the engine.
2. Start the engine.
3. Raise the lift arms until they are approximately target mounting bracket (1). Slide the target bar
horizontal and fully dump the bucket. Lower the (3) towards the proximity switch (5) until the face
bucket until the bucket edge is on the ground. of the proximity switch (5) is completely covered.
4. Apply the parking brake and stop the engine. 11. Align the target bar (3) parallel to the tilt cylinder
(2) and tighten the bolts.
5. Loosen the bolts holding the target mounting
bracket (1) to the tilt cylinder eye. Align the target 12. Turn the ignition switch to the ON position (not
mounting bracket (1) parallel to the tilt cylinder the accessory position). Do NOT start the
(2). Tighten the bolts, refer to the illustration on engine.
this page.
13. Place the bucket control lever in the full
ROLLBACK position. The electromagnetic
detent should hold the lever in this position.

Copyright ©
9006-5
14. Loosen the bolts holding the target bar (3) to the 19. Place the detent switch in the ON position and
target mounting bracket (1). place the return to travel/float detent switch to
the return to TRAVEL position.
15. Slide the target bar (3) slowly away from the
proximity switch (5), until the control lever returns 20. Raise the lift arms to approximately the
to the center position. Tighten the bolts holding horizontal position. Put the bucket in the fully
the target bar (3). dumped position.
NOTE: When the proximity switch face is nearly 21. Place the loader control lever in the ROLLBACK
uncovered, the switch will be activated and the position, and verify that the electromagnet holds
control lever will return to the center position. it in that position until the end of the target bar (3)
passes in front of the proximity switch (5).
16. Check to make sure that the 3.5 to 5.0 mm (1/8
to 3/16 inch) gap is still maintained between the 22. Lower the lift arms and verify that the bucket is
target bar (3) and the proximity switch (5). flat on the ground.
17. Make sure the proximity switch (5) and all 23. Stop the engine.
mounting bolts are tight

Copyright ©
9006-6
RETURN TO DIG ADJUSTMENT (XT MODELS)
1 2
3
6 5
BS01C084
1. TILT CYLINDER (LEFT HAND SIDE) 3. TARGET MOUNTING BRACKET 5. PROXIMITY SWITCH
2. PROXIMITY SWITCH MOUNTING BRACKET 4. PROXIMITY SWITCH GUARD 6. TARGET BAR
RETURN TO DIG ADJUSTMENT ILLUSTRATION XT MODELS
7. Loosen the bolts holding the proximity switch

WARNING: Raised equipment on the machine mounting bracket (2) to the tilt cylinder (1).
without an operator can cause injury or death. Position the proximity switch (5) face parallel to
Before you leave the operators compartment, the target bar (6) and tighten the bolts.
blade, boom, bucket, etc.) to the ground and stop 8. Adjust the proximity switch (5) out towards the
the engine. target bar (6) until an air gap of 3.5 to 5.0 mm
CM105
(1/8 to 3/16 inch) is obtained. Torque the jam nut
to 6 to 7.5 Nm (4.5 to 5.5 pound-feet).
IMPORTANT: Before adjusting the return-to-dig,
make sure that the target bar on the bucket linkage is NOTE: The proximity switch (5) must not protrude
not damaged and all mounting bolts are tight. Slowly past the proximity switch guard (4).
roll back and dump the bucket and make sure that
9. Start the engine, position the bucket flat on the
the target bar stays the same distance from the
ground and stop the engine.
switch. The switch mounting bracket protects the
switch. Make sure the target bar cannot touch the 10. Loosen the bolts holding the target bar (6) to the
switch when the bucket is dumped. target mounting bracket (3). Slide the target bar
(6) away from the proximity switch (5) until the
face of the proximity switch (5) is completely
2. Start the machine. uncovered.
3. Raise the lift arms until they are approximately 11. Align the target bar (6) parallel to the tilt cylinder
horizontal and roll the bucket all the way back. (1) and tighten the bolts.
Lower the bucket until the bucket is on the
12. Turn the ignition switch to the ON position (not
ground.
the accessory position). Do NOT start the
4. Apply the parking brake and stop the engine. engine.
5. Loosen the bolts holding the target mounting 13. Place the bucket control lever in the full
bracket (3) to the tilt cylinder clevis. Align the ROLLBACK position. The electromagnetic
target mounting bracket (3) parallel to the tilt detent should hold the lever in this position.
cylinder (1) and tighten the bolts. Refer to the
illustration on this page.
target mounting bracket (3).
target mounting bracket (3). Align the target bar
(6) parallel to the tilt cylinder (1) and tighten the
bolts.

Copyright ©
9006-7
15. Slide the target bar (6) slowly towards the 19. Place the detent switch in the ON position and
proximity switch (5), until the bucket control lever set the return to travel/float detent switch to the
returns to the center position. Tighten the bolts return to travel position.
holding the target bar (6).
20. Raise the lift arms to approximately the
NOTE: When the proximity switch face is nearly horizontal position and put the bucket in the fully
covered by the target bar, the switch will be activated dumped position.
and the control lever will return to the center position.
21. Place the loader control lever in the ROLLBACK
16. Check to make sure that the 3.5 to 5.0 mm (1/8 position and verify that the electromagnet holds it
to 3/16 inch) gap is still maintained between the in that position until the end of the target bar (6)
target bar (6) and the proximity switch (5). passes in front of the proximity switch (5).
17. Make sure the proximity switch (5) and all 22. Lower the lift arms and verify that the bucket is
mounting bolts are tight flat on the ground.
18. Start the engine. 23. Stop the engine.

Copyright ©
9006-8
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT

(Z-BAR, XT, AND XR MODELS)
2
3
4
5
6
BS01C081
1. LIFT ARM 3. FRONT CHASSIS (TOP LEFT HAND SIDE) 5. HEIGHT CONTROL TARGET
2. RETURN TO TRAVEL TARGET 4. PROXIMITY SWITCH 6. TARGET MOUNTING PLATE
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION Z-BAR, XT AND XR MODELS
1. Park the machine on a level surface. 5. Position the return to travel target (2) opposite
2. Start the engine and apply the parking brake. the proximity switch (4) and tighten it to the target
mounting plate (6).
3. Lower the lift arms and place the bucket flat on
the ground. 6. Adjust the proximity switch (4) out towards the
return to travel target (2) until an air gap of 3.5 to
4. Stop the engine. 5.0 mm (1/8 to 3/16 inch) is obtained.
NOTE: To avoid damage to the proximity switch (4), 7. Lock the proximity switch (4) in this position with
it must be adjusted back to clear everything on the lift the jam nut. Torque the jam nut to 6 to 7.5 Nm
arm as it passes. Refer to the illustration on this (4.5 to 5.5 pound-feet).
page.
WARNING: Raised equipment on the machine

without an operator can cause injury or death.
Before you leave the operators compartment,
blade, boom, bucket, etc.) to the ground and stop
the engine.
CM105

Copyright ©
9006-9
2
A
B
5
BS01C082
2. RETURN TO TRAVEL TARGET 5. HEIGHT CONTROL TARGET 6. TARGET MOUNTING PLATE
APPROXIMATE APPROXIMATE
RESULTING RETURN TO RESULTING HEIGHT
MACHINE A B
TRAVEL HINGE PIN CONTROL HINGE PIN
HEIGHT HEIGHT
521E Z-BAR 57 mm (2.24 inches) 358 mm (14.10 inches) 54 mm (2.13 inches) 3302 mm (130.0 inches)
521E XT 47 mm (1.85 inches) 438 mm (17.24 inches) 48 mm (1.89 inches) 3302 mm (130.0 inches)
521E XR 59 mm (2.32 inches) 458 mm (18.03 inches) 52 mm (2.05 inches) 3500mm (137.8 inches)
TARGET ADJUSTMENT ILLUSTRATION Z-BAR, XT AND XR MODELS
8. Refer to the table and the illustration on this 14. Place the detent switch in the ON position, and
page. Position the height control target (5) on the set the return to travel/float detent switch to the
target mounting plate (6) using the table above. return to travel position.
NOTE: The higher the height control target (5) is 15. Raise the lift arms to approximately the
positioned in its slot in the target mounting plate (6), horizontal position. Place the loader control lever
the lower the lift arms will stop as they are raised. in the raise position and verify that the
electromagnet holds it in that position until the
9. Tighten the height control target (5).
height control target (5) passes in front of the
10. Position the return to travel target (2) using the proximity switch (4). Refer to the illustration on
table above. page 8.
11. Tighten the return to travel target (2). 16. With the lift arms still raised, place the loader
control lever in the lower position and verify that
NOTE: The higher the return to travel target (2) is
the electromagnet holds it in that position until
positioned in its slot in the target mounting plate (6),
the return to travel target (2) passes in front of
the lower the lift arms will stop as they are lowered.
the proximity switch (4). Refer to the illustration
12. Check to make sure the proximity switch (4) and on page 8.
all of the mounting bolts are tight. Refer to the
17. Repeat steps 8 through 16 until the desired
heights are reached.
18. Lower the bucket to the ground and stop the
engine.
Copyright ©
9006-10
LOADER FRAME (Z-BAR AND XR MODELS)
Remove 16. Connect the chain hoist to the loader frame (9).
1. Park the machine on a level surface and apply 17. Loosen and remove bolt (1), flat washer (2) and
the parking brake. Roll the bucket all the way spacer (22) that fasten the pivot pin (3) to the
forward and lower the bucket to the floor. Stop front frame.
the engine. 18. Raise the loader frame slightly. Use an
2. Loosen the filler plug in the reservoir to release acceptable driver and drive the pivot pin (3) out
the air in the reservoir. of the front frame. Do not lose the washers (4)
and wipers (5) between the front frame and the
3. Fasten a chain hoist to the cross member (23) of loader frame (9).
the loader frame (9), refer to the illustration on
page 9.
4. Loosen and remove the bolt (19), flat washer
(18), and spacer (20) that fasten the pivot pin
(17) to the piston rod yoke of the right lift cylinder
(21).
5. Use an acceptable driver and drive the pivot pin
(17) out of the piston rod yoke of the right lift
cylinder (21). Do not remove the driver.
6. Repeat Steps 4 and 5 for the left lift cylinder (6).
7. Start the engine. Roll the bucket back and lower
the bucket so that the bucket is flat on the floor
and fasten the chain hoist to a lift cylinder (6 or BD01G009
21). 19. Remove the proximity switch cover. Left-hand
8. Raise the lift cylinder (6 or 21) slightly and side of the machine only.
remove the driver, lower cylinder and let it rest on
the frame.
1
9. Repeat steps 7 and 8 for the other lift cylinder (6
or 21).
10. Connect the chain hoist to the bucket cylinder
(8).
11. Loosen and remove the bolt (14), flat washer
(13), and spacer (12) that fasten the pivot pin
(11) for the piston rod eye of the bucket cylinder
(8) to the bell crank (10).
2
(11) out of the piston rod eye of the bucket
cylinder (8). BD01G010
1. ELECTRICAL CONNECTION 2. PROXIMITY SWITCH

13. Raise the bucket cylinder (8) and use a chain or
other acceptable holding equipment to hold the 20. Disconnect the electrical connector (1), remove
bucket cylinder (8) in place. the lock nut from the proximity switch (2) and
14. If the machine is equipped with auxiliary remove the proximity switch (2) from the
hydraulics, disconnect the two hoses from the machine. Left-hand side of the machine only.
tubes at the bracket on the right side of the 21. Repeat Steps 17 and 18 for pivot pin (7).
loader frame (9). Install caps on the hoses and 22. Raise the loader frame (9) out of the front frame.
plugs in the tube fittings. Carefully move the machine out of the loader
15. If the machine is equipped with front lamps, frame (9).
loosen and remove the cap screws and lock
washers that fasten the lamp brackets to the
front frame. Put the lamp brackets on the
fenders.

Copyright ©
9006-11
6 8
5 4
2 4 13
12 14
1 3 11
9
23 10
22
15
15 21
20
19 15
17
18
16
BS01G022
1. BOLT 7. PIVOT PIN 13. WASHER 19. BOLT

2. WASHER 8. BUCKET CYLINDER 14. BOLT 20. SPACER
3. PIVOT PIN 9. LOADER FRAME 15. PIVOT PIN 21. LIFT CYLINDER
4. WASHER 10. BELL CRANK 16. DUMP LINK 22. SPACER
5. WIPER 11. PIVOT PIN 17. PIVOT PIN 23. CROSS MEMBER
6. LIFT CYLINDER 12. SPACER 18. WASHER
LOADER FRAME - Z-BAR MODELS ILLUSTRATION

Copyright ©
9006-12
Install 17. Disconnect the chain hoist from the bucket

cylinder (8).
1. Apply antiseize compound to the inner bores and
outer bores for the pivot pins of the front frame, 18. Fasten the chain hoist to one of the lift cylinders
refer to the illustration on page 11. (6 or 21).
2. Move the machine into alignment with the loader 19. Raise the piston rod yoke of the lift cylinder (6 or
frame (9). 21) so the piston rod yoke is aligned with the
loader frame (9).
3. Lower the loader frame (9) into alignment with
the front frame. 20. Install a driver in the piston rod yoke and the
loader frame (9).
4. Apply antiseize compound to the pivot pins (3
and 7) that fasten the loader frame (9) to the 21. Repeat Steps 18, 19, and 20 for the other lift
front frame. cylinder (6 or 21).
5. Start the pivot pins (3 and 7) into the front frame. 22. Disconnect the chain hoist from the lift cylinder (6
Install the washers (4) and new wipers (5) or 21).
between the loader frame (9) and the front 23. Start the engine. Raise the loader frame and roll
frame. the bucket all the way forward. Lower the bucket
6. Install the pivot pins (3 and 7) all the way. to the floor. Stop the engine.
7. Install the bolt (1), washer (2) and spacer (22) 24. Fasten the chain hoist to the cross member (23)
that fasten the pivot pins (3 and 7). Torque the of the loader frame (9).
bolt to 325 to 373 Nm (240 to 275 pound feet). 25. Start the engine and run the engine at low idle.
8. Install the proximity switch and cover. Left-hand 26. Have another person help you at this time. Move
side of the machine only. the lift control lever as required to align the piston
9. Disconnect the chain hoist from the loader frame rod yoke of one of the lift cylinders (6 or 21) with
(9). the loader frame (9).
10. If the machine is equipped with front lamps, hold WARNING: Do not use your fingers to check
the front lamps in place and install the cap the alignment of the cylinder rod. Personal injury
screws and lock washers that fasten the front can be the result.
lamps to the front frame. Tighten the cap screws. 48-88
11. If the machine is equipped with auxiliary 27. Remove the driver and install the pivot pin (17).
hydraulics, remove the plugs from the tube 28. Install the bolt (19), washer (18), and spacer(20)
fittings and the caps from the hoses. Connect the that fasten the pivot pin (17). Torque the bolt to
hoses to the tubes. 325 to 373 Nm (240 to 275 pound feet).
12. Connect the chain hoist to the bucket cylinder 29. Repeat Steps 26, 27, and 28 for the other lift
(8). cylinder (6 or 21). Stop the engine.
13. Start the engine and run the engine at low idle. 30. Lubricate the pivot pins with molydisulfide
14. Have another person help you at this time. Move grease.
the bucket control lever as required to align the 31. Disconnect the chain hoist from the cross
piston rod eye of the bucket cylinder (8) with the member (23) of the loader frame (9).
bell crank (10). Stop the engine.
32. Tighten the filler plug in the reservoir.
WARNING: Do not use your fingers to check 33. If the machine is equipped with auxiliary
the alignment of the cylinder rod. Personal injury hydraulics, start the engine and run the engine at
can be the result. low idle.
48-88 34. Slowly extend and retract the clam cylinders four
15. Install the pivot pin (11) in the bell crank (10) and times to remove air from the auxiliary circuit.
the piston rod eye of the bucket cylinder (8).
35. Stop the engine, check the level of the oil in the
16. Install the bolt (14), washer (13), and spacer (12) reservoir, and check for leaks. Add oil to the
that fasten the pivot pin (11). Torque the bolt to reservoir as required.

Copyright ©
9006-13
LOADER FRAME (XT MODELS)
Remove 13. Disconnect the hoses to the bucket cylinders.

Disconnect the hoses from the tubes at the
1. Remove all dirt and grease from the hose and bucket cylinders.
tube connections for the bucket cylinders and
clam cylinder, if equipped. 14. Install a cap on each hose and a plug in each
tube.
2. With the engine running at low idle, roll the
bucket all the way forward and lower the loader 15. If equipped, disconnect the clam hydraulic
frame until the bucket is on the floor. connections, the auxiliary hydraulic connections,
and the coupler connections as necessary. Plug
3. Stop the engine and apply the parking brake. and cap lines as needed.
4. Loosen the filler plug in the reservoir to release 16. Disconnect the wiring harnesses.
the air in the reservoir.
17. Connect the chain hoist to the loader frame (6).
5. Loosen and remove the bolt (9), washer (10),
and spacer (8) that fasten the pivot pin (7) to the 18. Loosen and remove the bolt (1), washer (2), and
piston rod yoke of the lift cylinder (11 or 15), refer spacer (14) that fasten the loader frame (6), pivot
to the illustration on page 14. pin (3) and anchor link (12) pivot pin (13) to the
machine frame.
(7) out of the piston rod yoke of the lift cylinder 19. Raise the loader frame (6) slightly. Use an
(11 or 15). Do not remove the driver. acceptable driver and drive both the pivot pins (3
and 13) from the loader frame (6) and anchor link
7. Repeat Steps 5 and 6 for the other lift cylinder (12).
(11 or 15).
20. Do not lose the washers (4) between the front
8. Start the engine. Roll the bucket back and lower frame and the loader frame (6).
the bucket so that the bucket is flat on the floor.
Fasten the chain hoist to a lift cylinder (11 or 15). 21. If equipped, remove the proximity switch cover
and the proximity switch from the left-hand side
9. Raise the lift cylinder (11 or 15) slightly and of the machine.
remove the driver, lower the cylinder and let it
rest on the frame. 22. Repeat Steps 18 and 19 on the opposite side of
the machine.
10. Repeat Steps 8 and 9 for the other lift cylinder
(11 or 15). 23. Raise the loader frame from the machine. Be
sure all the necessary hydraulic lines, wiring etc.
11. Stop the engine. are properly disconnected.
12. Move the bucket control lever to the ROLLBACK 24. Carefully move the machine out of the loader
position and the lift control lever to the LOWER frame.
position to relieve any pressure in the circuits.

Copyright ©
9006-14
4 16
5
2
1 3 4
14 13 6
12
17
11
10
8
7
BS01G021
1. BOLT (325 - 373 NM (240 - 275 LB-FT)) 7. PIVOT PIN 13. PIVOT PIN
2. WASHER 8. SPACER 14. SPACER
3. PIVOT PIN 9. BOLT 15. LIFT CYLINDER (NOT SHOWN)
4. WASHER 10. WASHER 16. LOADER LINKAGE BOLT (650 - 732 NM (480 - 540 LB-FT))
5. WIPER 11. LIFT CYLINDER 17. GUIDE LINK NUTS (240 - 305 NM (175 - 225 LB-FT))
6. LOADER FRAME 12. ANCHOR LINK
LOADER FRAME - XT MODELS ILLUSTRATION

Copyright ©
9006-15
Install 16. Disconnect the chain hoist from the lift cylinder
(11 or 15).
1. Apply antiseize compound to the inner bores and
outer bores of the front frame. 17. Start the engine. Raise the loader frame (6) and
roll the bucket all the way forward. Lower the
2. Move the machine into alignment with the loader bucket to the floor. Stop the engine.
frame (6), refer to the illustration on page 14.
18. Fasten the chain hoist to the cross member of
3. Lower the loader frame (6) into alignment with the loader frame (6).
the machine frame.
4. Apply antiseize compound to the pivot pins (3)
and (13) that fasten the loader frame (6) to the 20. Have another person help you at this time. Move
machine frame. the lift control lever as required to align the piston
rod yoke of one of the lift cylinders (11 or 15) with
5. Start the loader frame pivot pin (3), washer (4) the loader frame (6).
and wiper (5).
6. Install the loader frame pivot pin (3) and anchor WARNING: Do not use your fingers to check
link pivot pin (13) on one side of the machine. the alignment of the cylinder rod. Personal injury
can be the result.
7. Repeat Steps 5 and 6 for the opposite side of the
48-88
machine.
21. Remove the driver and install the pivot pin (7).
8. Install the bolt (1), washer (2) and spacer (14)
22. Install the bolt (9), washer (10), and spacer (8)
that secure the pivot pins (3 and 13) to the
that fasten the pivot pin (7). Torque the bolt to
machine on each side of the machine. Torque
the bolt to 325 to 373 Nm (240 to 275 pound
feet). 23. Repeat Steps 20, 21, and 22 for the other lift
cylinder (11 or 15). Stop the engine.
9. Disconnect the chain hoist from the loader frame
(6). 24. Lubricate the pivot pins with molydisulfide
grease.
10. If the machine is equipped with auxiliary
hydraulics, clam hydraulics, or coupler 25. Disconnect the chain hoist from the cross
hydraulics, remove the plugs from the tube member of the loader frame (6).
fittings and the caps from the hoses and make 26. Start the engine and run the engine at low idle.
the necessary connections.
27. Slowly extend and retract the cylinders four times
11. Connect the hoses and tubing to the bucket to remove air from the hydraulic circuit.
cylinders.
28. If equipped with auxiliary hydraulics, slowly
12. Fasten the chain hoist to one of the lift cylinders extend and retract the clam cylinders four times
(11 or 15). to remove air from the auxiliary circuit.
13. Raise the piston rod yoke of the lift cylinder (11 29. Stop the engine, check the level of the oil in the
or 15) so the piston rod yoke is aligned with the reservoir, and check for oil leaks. Add oil to the
loader frame (6). reservoir as required.
14. Install a driver in the piston rod yoke and the
loader frame (6).
15. Repeat Steps 12, 13, and 14 for the other lift
cylinder (11 or 15).

Copyright ©
9006-16
NOTES

Copyright ©
Section
9007
ROLLOVER PROTECTIVE STRUCTURE (ROPS)

CAB STRUCTURAL FRAME (CSF)
9007

Copyright ©
9007-2
TABLE OF CONTENTS
CAB STRUCTURAL FRAME (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY . . . . . . . . . . . . . . . . . . . . . . . . 3
CSF CAB AND ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Copyright ©
9007-3

CAB STRUCTURAL FRAME (CSF)
After an accident, fire or rollover, the following MUST
be performed before returning the machine to field or
Attention
job site operation:
● The ROPS or CSF structure MUST be replaced.
The Rollover Protective Structure (ROPS) or Cab ● The ROPS or CSF mounting or suspension,
Structural Frame (CSF) is a special safety operator seat and suspension, seat belts and
component of your machine. mounting components and wiring within the
DO NOT attach any device to the ROPS or CSF for operator’s protective system MUST be carefully
pulling purposes. inspected for damage.
The ROPS or CSF is a certified structural support ● All damaged parts MUST be replaced.
and any damage, fire, corrosion or modification will DO NOT WELD, ATTEMPT TO STRAIGHTEN OR
weaken the structure and reduce your protection. If REPAIR THE ROPS OR CAB STRUCTURAL
this occurs, the ROPS or CSF MUST be replaced so FRAME.
that it will provide the same protection as a new
ROPS or CSF.
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY

After every 500 hours of operation or every six
months, whichever comes first, do the following: WARNING: Do not install attachments that
will make the total weight of the machine
1. Check the torque on the CSF cab or ROPS more than the weight shown in the maximum
canopy mounting bolts; torque should be 773 to gross vehicle weight section of the ROPS
854 Nm (570 to 630 lb-ft). If necessary, tighten serial number plate. 47-26
the bolts to the correct torque.
2. Check that seat belt mounting hardware is tight WARNING: Do not change the ROPS in any
and seat belt is not cut or frayed. Check the way. Changes made to the ROPS which are
torque on operators seat mounting bolts; torque not authorized, such as welding, drilling or
should be 73 to 87 Nm (54 to 64 lb-ft). If cutting will make the ROPS weaker and
necessary, tighten the bolts to the correct torque. decrease your protection. Replace the
Replace parts that are worn or damaged. ROPS if it becomes damaged in any way.
DO NOT TRY TO MAKE REPAIRS TO THE
WARNING: Grade 8 hardware is used to ROPS. 47-25
mount and anchor the ROPS. Parts used for
replacement must be those shown in the
parts catalog. 47-27A

Copyright ©
9007-4
CSF CAB AND ROPS CANOPY
Removal STEP 5
NOTE: Procedures and photos in following steps
cover in detail removal and installation of CSF
structure. Removal and installation of ROPS is
similar to removal and installation of CSF structure.
STEP 1
floor. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in
ON position and move loader control lever back and
forth at least 30 times to release any pressure from
BD06G191-01
STEP 2 Remove skirting under each side and front of cab.
STEP 6
BD01F143-01

BD06G186-01
STEP 3 Remove the ducts from the machine.
Put battery disconnect switch in OFF position.
STEP 7
STEP 4
BD06G189-01
BD01F184-01 At RH rear, bottom of cab, disconnect ground strap

If machine is equipped with a heater, put a 25 liters from rear chassis.
(6.6 Gallons) container below radiator drain. Remove
cap and drain coolant into container. Install cap after
coolant has drained.
Copyright ©
9007-5
STEP 8 STEP 10
BD06G194-01 BD06G193-01
If machine is equipped with windshield washers, Disconnect throttle connector and the air duct.
identify, tag, and disconnect front and rear
windshield washer nozzle hoses from supply hoses. STEP 11
STEP 9
1 2
BD06G192-01
Identify, tag, and disconnect hoses from steering

BD06G205-01 control valve. Plug hoses and cap steering control
valve fittings to prevent entry of foreign matter into
2. HEATER HOSES
hydraulic system.
If machine is equipped with a heater disconnect
heater hoses (2), if machine is equipped with air STEP 12
conditioning discharge the air conditioning system,
see section 9003, and disconnect the air conditioning
hoses (1), cap and plug lines and fittings.
BD06F207-01
Unlatch and open the window on the right hand side.

Copyright ©
9007-6
STEP 13 STEP 17
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install
plugs in the hoses and caps on the fittings to prevent
entry of foreign matter into hydraulic system.
STEP 18
Push the hoses out of the bottom of the cab with the
rubber gromment.
STEP 19
BD06F208-01
Open and remove the access panel.
STEP 14
BD06G187-01
Disconnect the electrical connectors, push

connectors out of the bottom of the cab with the
rubber gromment
STEP 20
BD06F209-01
Remove the front access panel.
STEP 15
BD06G188-01
Raise floor mat up and away from brake pedal to

gain access to mounting hardware.
BD06F210-01
Disconnect the electrical connectors for the remote

control valve.
STEP 16
Loosen the filler cap on the reservoir to release any
air in the reservoir. Connect a vacuum pump to the
hydraulic reservoir, turn on the pump.

Copyright ©
9007-7
STEP 21 STEP 25
Slowly raise cab from rear chassis. Check that all tie
straps and clamps have been removed and all
hoses, tubes, and wires are disconnected and free.
Check that brake valve with hoses attached are free
and clear of cab. Remove the ROPS or CSF from the
machine. Lower ROPS or CSF onto wooden blocks
to prevent damaging cab or canopy.
BD06G185-01
Remove hardware securing brake valve to cab floor.

Let brake valve rest on the frame.
STEP 22
BD06G184-01
Install lifting eyes in threaded holes at top of the cab.
STEP 23
Connect lifting equipment to cab at lifting eyes. Take
up all slack in lifting equipment.
STEP 24
Remove nuts, bolts, and washers securing cab to
rear chassis.

Copyright ©
9007-8
2 1
4
4
5
5
6
6
BC06G031-01
1. NUT 4. RUBBER MOUNT

2. WASHER 5. WASHER
3. RUBBER MOUNT 6. BOLT

Copyright ©
9007-9
STEP 26
Check rubber mounts (3 an 4) for deterioration, tears,
deformation, or other damage; replace rubber
mounts as necessary.
STEP 27
BD06G185-01
Align mounting holes in brake valve with associated

holes in cab or canopy floor. Install hardware to
secure brake valve to floor.
STEP 32
BD01D388-01
Position cab over rear chassis then put wood blocks

under brake valve. Slowly lower cab onto rear
chassis making sure that brake valve is positioned so
that brake pedal enters into cab. Remove wood
blocks as cab is lowered onto brake valve.
STEP 28
Install washers, bolts, and nuts to secure cab to rear
chassis. Tighten bolts to a torque of 773 to 854 Nm
(570 to 630 pound feet)
BD06G188-01
STEP 29 Position floor mat.
Disconnect lifting equipment from cab.
STEP 33
STEP 30
Remove lifting eyes.
BD06G192-01
Remove plugs from hoses and caps from fittings.

Connect hoses to steering control valve following
tags installed during removal. Remove and discard
tags.

Copyright ©
9007-10
STEP 34 STEP 37
BD06G193-01 BD06G194-01
Connect throttle connector and mount air duct. If machine is equipped with windshield washers,
connect front and rear windshield washer nozzle
STEP 35 hoses following tags installed during removal.
Remove and discard tags.
STEP 38
1 2
BD06G186-01
Install the ducts on the machine.
STEP 36 1. AIR CONDITIONING HOSES

BD06G205-01
2. HEATER HOSES
If machine is equipped with a heater, remove plugs

from hoses and caps from fittings, connect heater
hoses (2), if machine is equipped with air
conditioning, remove plugs from hoses and caps
from fittings, connect air conditioning hoses (1),
charge the air conditioning system, see section 9003.
STEP 39
Remove plugs from hoses and caps from fittings.
Connect hoses to joystick and two-lever controller
and install in hose mounting grommet halves as
BD06G189-01 shown on pages 11, 12, and 13.
At RH rear, bottom of cab, connect ground strap to
rear chassis.

Copyright ©
9007-11
1 2 3 4
10 5
9 7 6
8
1 9
2
8
10 7
3 6
4 5
BS07D284-01
1. ORANGE BLACK 5. ORANGE WHITE 8. GREEN BLACK

2. YELLOW BLACK 6. YELLOW WHITE 9. RED BLACK
3. RED WHITE 7. PILOT PRESSURE HOSE 10. PILOT TANK HOSEL
4. GREEN WHITE
JOYSTICK AND 2 LEVER HOSE COLOR CODING

Copyright ©
9007-12
2
2
3
8
6
3
7 5
4
7
6 1
8
5
5 3
5 3
7
7 6
6 2
2 4
4 1
1 8
8
BS07D283-01
1. YELLOW WHITE 1. YELLOW WHITE

2. PILOT PRESSURE HOSE 2. PILOT PRESSURE HOSE
3. RED BLACK 3. RED BLACK
4. PILOT TANK HOSE 4. PILOT TANK HOSE
5. ORANGE BLACK 5. ORANGE BLACK
6. YELLOW BLACK 6. YELLOW BLACK
7. GREEN BLACK 7. GREEN BLACK
8. RED WHITE 8. RED WHITE
JOYSTICK AND 1 LEVER HOSE COLOR CODING 3 LEVER HOSE COLOR CODING

Copyright ©
9007-13
STEP 40
BD06F210-01
6 2 Connect the electrical connectors for the remote
control valve.
5 3
STEP 41
4
4 2
5 6
3 1
BS07D285-01
1. PILOT PRESSURE HOSE

2. RED BLACK BD06F209-01
3. PILOT TANK HOSE
Place the access panel into position, install and
4. ORANGE BLACK
tighten the screw.
5. YELLOW BLACK
6. GREEN BLACK
JOYSTICK HOSE COLOR CODING
STEP 42
BD06G187-01
Connect wiring harness connectors.

Copyright ©
9007-14
STEP 43 STEP 46
BD06F208-01 BD01F184-01
Install and close the access panel. If machine is equipped with a heater and coolant was
drained, check that coolant drain cap is tight.
STEP 44
STEP 47
capacity is 22 liters (5.8 U.S. Gallons). Install radiator
cap. Fill coolant reservoir up to FULL mark on
reservoir.
STEP 48
Put battery disconnect switch in ON position.
STEP 49
Start engine and run engine at low idle. Run engine
BD06F207-01 at operating temperature for approximately five
Close the right hand window. minutes to completely mix Ethylene Glycol and
water. When coolant is at operating temperature,
stop engine. When engine has cooled, check coolant
level at reservoir.
STEP 45
WARNING: Hot coolant can spray out if radiator cap
is removed. To remove radiator cap: let system cool,
turn to first notch, then wait until all pressure is
released. Scalding can result from fast removal of
radiator cap.
STEP 50
BD06G191-01
Install skirting under each side and front of cab.

Copyright ©
Section
9010
CAB GLASS INSTALLATION
9010

Copyright ©
9010-2
TABLE OF CONTENTS
PREPARATION FOR GLASS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SILICONE SEALANT APPLICATION - FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Copyright ©
9010-3
PREPARATION FOR GLASS REPLACEMENT

1. Remove all of the damaged glass section and 5. Clean the new glass section. Apply a 25 mm (1
the silicone sealant from the window frame inch) wide band of glass primer (349-110) to the
black ceramic painted edges of the window.
2. Remove all the adhesive from the window frame.
6. When replacing a front window section, a
3. The window frame recesses must be free of oil
silicone forming tool is needed, refer to Figure 2.
and dust. Clean the frame with rubbing alcohol
Use the template and instructions provided to
with a clean rag. Do not reuse the rag.
make the tool.
4. Apply a 25 mm (1 inch) wide band of metal
primer (349-108) to the window recesses.
GLASS INSTALLATION
NOTE: Once the adhesive is applied, the glass must 3. For front glass installations install a glass spacer
be installed within 5 minutes. If the glass is not 12 mm (1/2 inch) from each corner on bottom
installed within the 5 minute period, the adhesive edge of each glass section, refer to Figure 3.
must be removed and applied again.
4. Install the glass. The glass edges must not
1. Apply a 10 mm (3/8 inch) diameter bead of contact the metal frame at any point.
adhesive (345-135) to the primed surface
5. For front glass installations position the glass to
approximately 12 mm (1/2 inch) from edge.
maintain a uniform 3 mm (1/8 inch) gap between
2. The adhesive may be applied either to the front and front side glass sections.
primed glass or to the primed metal frame. DO
NOT apply the adhesive to both the glass and
the frame.
NOTE: When replacing two or more sections of the
front glass apply extra adhesive in corners, refer to
Figure 3.
SILICONE SEALANT APPLICATION - FRONT WINDOWS

1. Clean the edges of the front center and front side 6. Fill the joint with the clear silicone sealant
windows. Use glass cleaning primer. (114328A1), refer to Figure 1. The silicone must
completely penetrate and fill the gap between the
2. Apply masking tape to the inside edge of each
glass sections. The sealant must extend at least
glass section next to the gap.
1.5 mm (1/16 inch) above the outside surface of
3. Apply the polyester tape on top of the masking the glass section for the length of the gap. Be
tape across the inside side gap. Do not push the sure the sealant fills against the adhesive at
tape into the gap. each end of the joint.
4. Apply masking tape to the outside edge of each 7. Remove the polyester tape from the inside joint.
glass section. Align the edge of the tape with
8. Remove the extra silicone from the outside joint
edge of glass on both sections.
by carefully sliding the forming tool down the
5. The tape must be smooth to get the best result length of the joint. The tool must remain in
when using the silicone forming tool. contact with the glass sections during this
process. Refer to Figure 2 for forming tool
template.

Copyright ©
9010-4
9. Remove all the silicone from the forming tool
1 2 immediately after use.
10. Remove the outside tape from the glass
sections.
11. Remove the extra silicone sealant from the
inside joint by carefully sliding the forming tool
down the length of the joint.
12. Remove all the silicone from the forming tool
immediately after use.
3 13. Remove the inside joint masking tape.
4 14. If two or more glass sections are being replaced,

498L93
use the procedure on the second joint.
1. FRONT RH SIDE GLASS 3. SILICONE BEFORE 15. Apply the gray silicone sealant above the front
SMOOTHING center, front side or rear windows for additional
2. FRONT CENTER GLASS 4. SILICONE AFTER leak protection.
SMOOTHING
FIGURE 1. SILICONE APPLICATION 16. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top on
NOTE: Make the forming tool from 10 mm (3/8 inch)
each front side window replaced, refer to Figure
plexiglass, or wood. Sand all radius and edges
3.
smooth.
17. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top
edge of the rear glass, if replaced.
6 MM 120°
(1/2 INCH) R
120°
4 MM
(3/16 INCH) R
496L93
FIGURE 2. SILICONE FORMING TOOL TEMPLATE

Copyright ©
9010-5
2
1
3
4
2
1
497L93
1. SIDE GLASS ADHESIVE 4. RIGHT HAND SIDE GLASS SPACER LOCATIONS

2. CENTER GLASS ADHESIVE 5. APPLY GRAY SILICONE SEALANT DOWN 50 MM (2 INCHES)
FROM TOP OF FRONT SIDE GLASS
3. APPLY EXTRA ADHESIVE HERE WHEN REPLACING BOTH 6. APPLY GRAY SILICONE SEALANT ALONG BOTTOM EDGE OF
CENTER AND SIDE PANELS CENTER GLASS
FIGURE 3 SILICONE APPLICATION
NOTE: After completing the installation, DO NOT slam the cab door. The increased air pressure may break the
seal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and
silicone to properly set.
Copyright ©
9010-6
NOTES

Copyright ©
STARTING AND CHARGING SYSTEM POWER RELAY MODULES - COLD STARTING SYSTEM ENGINE CONTROLLER RETURN TO TRAVEL • RETURN TO DIG • PIN ENGAGE PILOT CONTROL - RIDE CONTROL - FAN CONTROL
19P-D OR-0.8
1-NC R-19.0 1-NC R-19.0 21H W-0.8 21H W-0.8 21H W-0.8 58T W-0.8 19P-E OR-0.8
1 1-Z R-8.0 1-Z R-8.0 21G W-0.8 21G W-0.8 21G W-0.8 58H-A W-0.8 37 ECB 86
75 21F W-0.8 21F W-0.8 21F W-0.8 25 SPL-BCK-LT-GD2 35 30
30 193
87 195
1-BB R-8.0 2 21E W-0.8 21E W-0.8 21E W-0.8
Not Used A ECD
86 30
7 7 0-B7 BK-0.8 K4
1-Z R-8.0 18R-A OR-2.0 18R-A OR-2.0 18R-A OR-2.0 7 7 0-B2 BK-0.8 7 7 0-B20 BK-0.8 8 8 49-Q S-0.8
215F 216F 0-B2 BK-0.8 B K4
1-NC R-19.0 18R OR-2.0 18R OR-2.0 8 8 49-K S-0.8 0-B3 BK-0.8 C 8 8 49-G S-0.8 5 5 19P-C OR-0.8 38
86
85
1
14 LG-1.0 26 26 14-A LG-0.8
19R-D OR-0.8 1-Z R-8.0 0-BN BK-0.8
28F W-0.8
0-BN BK-0.8
28F W-0.8
5 5 55B W-0.8 0-B4 BK-0.8 D 5 5 58C W-0.8 36 4 4 52J W-0.8
2 4 4 0-29 BK-0.8 53A W-0.8 3 3 0-B5 BK-0.8 4 4 58T W-0.8 10 10 Not Used
SRC-1
1 1 21C-C W-0.8 SPL-4 13C OR-1.0 13C OR-1.0 13C OR-1.0 13C OR-1.0 A A 13C-A OR-1.0 10 10 Not Used 53B-B W-0.8 4 4 27 0-B6 BK-1.0
E
F 9 9 Not Used SPL-D26 6 6 52M W-0.8 85 87A 87
21D W-1.0 15 15 21D-C W-0.8 21D-B W-0.8 13M OR-1.0 13M OR-1.0 13M OR-1.0 13M OR-1.0 B B 13M-A OR-0.8 SPL-D1 85 87A 87
0-GB BK-1.0 21H W-0.8 21H W-0.8 6 6 54B-C W-0.8 54A W-0.8 2 2 0-B26 BK-0.8 G 6 6 58-F W-0.8 1 1 Not Used 52 W-0.8
ENG CAB-E 0-BV BK-0.8 0-BV BK-0.8 0-BV BK-0.8 DISC ENG-D
21G W-0.8 21G W-0.8 1 1 55A-B W-0.8 54B-B W-0.8 5 5 Not Used H 1 1 Not Used 58-E W-0.8 9 9 Not Used 56 W-0.8 52A-A W-1.0
14 LG-1.0 F9/F10 ECB SPL-CR 28G W-1.0 28G W-1.0 28G W-1.0 9 9 Not Used 55A-A W-0.8 1 1 0-B20 BK-0.8 J 10 10 Not Used 3 3 52AU W-0.8 23 22 CAB-E
AD 21F W-0.8 21F W-0.8 SPL-RTT
58-C W-0.8
58-D W-0.8
30 30 21C-B W-0.8 21C W-0.8 21E W-0.8 21E W-0.8 3 3 55A-C W-0.8 55B W-0.8 6 6 0-29 BK-0.8 K 3 3 58C W-0.8 2 2 52J W-0.8 23 22 ENG
D+ PRM-B PRM-B1
87 87 21D-A W-0.8 13C OR-1.0 13C OR-1.0
2 2 53P-B W-0.8 EM 0-B11 BK-0.8 L 2 2 19C-D OR-1.0 SFC 56-A W-1.0 52A-B W-1.0
AB+ A Not Used 58L BK-0.8
R B+ 1-BA R-13.0 87A 87A Not Used 13M OR-1.0 13M OR-1.0 SFL 19C-C OR-0.8 0-B7 BK-0.8 M SRC
85 85 21H W-0.8 C 13H 0R-3.0 13H-D 0R-3.0 13H-D 0R-3.0 YFN YFR
18R-A OR-2.0 18R-A OR-2.0 SPL-DLY-RL 19C-B OR-1.0
3 28 0-B7 BK-0.8 0-B7 BK-0.8 43 44
13H-D 0R-3.0
A B 2 1
0-BB BK-1.0
0-BQ BK-1.0
86 86 21G W-0.8 SPL-D24
85 B 0-EA BK-0.8 C – + 0-B11 BK-0.8 0-B11 BK-0.8
26 A B 2 1
13H-C 0R-0.8
13H-B 0R-0.8
86 A 0-B20 BK-0.8 0-B20 BK-0.8
4 40 A F1
19C-D OR-1.0
PRM-B2 A B C 0-B26 BK-0.8 0-B26 BK-0.8
SPL-DLY
1A R-1.0
BUSS-PRM-E
7 7 0-B3 BK-0.8 ECD 86 30 A B C 0-B6 BK-1.0 0-B6 BK-1.0 41 29.3 AT 20°C 39.3 AT 20°C
PXT
19C-A OR-1.0
1DM R-1.0 49-M S-0.8
14 24 8 8
40 A
A2
BUSS-PRM-B P
A
K3
0-AM BK-1.0
53B-A W-1.0
9 9 Not Used 0-BS BK-1.0 SPL-FAN
30
53P-I W-1.0
10 A F2 PRBF B
13D OR-1.0 1
7 Not Used
39
21C-A W-0.8
10 10
58 W-1.0
ECD-F2
13D OR-01.0 18J-C OR-1.0 2 A
BT2 BT1 1DN R-1.0 2 6 6 54A W-0.8 SPL-PIN
SPL-EDC2 18J-B OR-1.0 3 B
0-DC BK-0.8
21F W-0.8
E 3 Not Used SPL-BCK-LGT2
5 5 19P-A OR-0.8
1-NA R-62
30 A
18R OR-2.0
PRM-A 1 2 YRC
29
1-NC R-19.0
1-ND R-62.0
ECA-L1
1-NB R-62.0
Not Used
1-BA R-13.0
0-BE BK-1.0 10 10
PXF PXM
5 A
21E W-0.8
43S-D W-0.8
58-B W-1.0
F 4 C – +
1-BB R-8.0
5 Not Used
0-BN BK-0.8
4 4 49-E S-0.8 19P OR-0.8 B
6 A
0-AD BK-1.0
A 19S1-OR-1.0 A B C 7 7 0-B1 BK-0.8 1 2
13K-A OR-1.0 13 0-BF BK-1.0 6 85 87A 87 B 58-A W-1.0
A5
28F W-0.8
G 5
B
Not Used
B2
1 1 19P-C OR-0.8
15 Not Used C
B
C BUSS-J1-ECA B
K3 ECB H Not Used 6
PRM-C
SPL-EDC4
18J-D OR-1.0
18J-E OR-1.0
8
9
3 3 Not Used SPL-D25 A B C
A B C
49-J S-0.8 C
8
1
8
1
49-N S-0.8
Not Used
42 202M Not Used D
ECA-F5
BT3 BT4 30 30 PRM-C1
SPL-PK1
18J-K OR-3.0
TDM
0-EB BK-0.8 2 2 53P-D W-0.8 53P-C W-1.0 A B C 49-M S-0.8 D 19P-D OR-0.8 E
53P-H W-1.0
22.7 AT 20°C
PXH
85 B
0-AC BK-1.0
9 9 Not Used
13K-C OR-1.0
0-BD BK-1.0
13K-B OR-1.0
87 87 ECC-F5 A SPL-HTR 10
SHC 53C-A W-0.8 49-K S-0.8 E 19P-E OR-0.8 F
53B W-1.0
13K OR-1.0
194 86 A 13K-B OR-01.0 1-GA R-3.0 SPL-EDC1 0-BC BK-1.0 5 5 Not Used
5A
Not Used C 11
0-AA BK-1.0
87A 87A
53P-J W-1.0
B S A B 1DM R-1.0 40 A F1 49-F S-0.8 F
Not Used
54B W-1.0
PRM-A1 See Note 1 28G W-1.0 12 6 6
0-NC BK-62
L1-5
85 85 10 A 49-Q S-0.8
A
L1-5 A5 G
BUSS-PRM-B 85 B 0-BN BK-0.8 13 4 4 Not Used SPL-PED-BL-GD
1-GB R-2.0
86 86
9 S-KEY
86 A 1-GC R-2.0 21H-A W-0.8 17 31 BUSS-J5-ECA
49-T S-0.8
Not Used
H 3 3 31L Y-0.8 19P OR-0.8 Not Used A
P-A1 1-C R-8.0 BUSS-L1-ECA J
8 40 A F1 BUSS-J6-ECA 19A-J OR-0.8 A7 L1-7
0-DF BK-0.8
20 A F2 PRM-C2 21F-B W-0.8 29 2 2 0-B1 BK-0.8 B

Not Used 5 10 10 Not Used 49-G S-0.8 K B A
CAB-PW CBPW B A WSH 21E-A W-0.8 32 SPC 7.5 A 0-B24 BK-0.8 C
0-BW BK-2.0
SPL-CRK BAT Not Used L
M 1A R-1.0 1 P-A3 CAN-L G-0.8 34 7 7 0-B4 BK-0.8
1-CB-A R-19.0 1 1 1CB R-19.0 B A ECA-F7 Not Used D
13K-B OR-1.0
IGN 49-S S-0.8 M
0-BX BK-2.0
DC1 13K OR-1.0 3 B A FFH 21G W-0.8 21GA W-0.8 CAN-H Y-0.8 8 8 49-J S-0.8
13D OR-1.0
ST 20 A F2 3 3 35 0-B29 BK-0.8 E
16
P-C1
BUSS-J6-ECC
BUSS-J5-ECC
0-NB BK-62 21K W-0.8 2 BUSS-PRM-PWR B A 21H W-0.8 21H-A W-0.8 9 9 Not Used
P-C2
DC2 STTR-GND ACC 4 4
SPL-EDC3 28F W-0.8 36 49-S S-0.8 49-S S-0.8 0-B11 BK-0.8 F
P-C4
12ACC W-0.8 4 1-NC R-19.0 1.9 ±0.3
21F W-0.8 21F-A W-0.8 21GA W-0.8 6 6 Not Used
P-C3
11 11 37 49-G S-0.8 49-G S-0.8
13C OR-1.0 Not Used 30 GHF4
DC3 6 1-Y R-19.0 1-E R-19.0 1-E R-19.0 18R-A OR-2.0 13 13 18R OR-2.0 13M-A OR-0.8 40 5 5 Not Used 54B-A W-0.8 11 11 54B W-1.0 49-T S-0.8 49-T S-0.8
13M OR-1.0 SPL-ACC 87 115 150 A
1-Z R-8.0 20 1.9 ±0.3
SPL-D2 Not Used 53B-B W-0.8 12 12 53B W-1.0 SPL-PED-BL
21K-A W-0.8
GHF3 GHF1 18J-G OR-2.0 14 14 18J-F OR-2.0 35W W-0.8 42 4 4 49-Q S-0.8 49-Q S-0.8
DC4
10 GHC GH FUSE
21 Not Used 16 16 Not Used 24L W-0.8 48 1 1 Not Used 53P-F W-0.8 19 19 53P-G W-1.0
SPL-A3 49-E E-0.8 49-E S-0.8 Not Used A
1-BE R-19.0
86 1BC R-19.0 3 3 53A W-0.8 57-A W-0.8 20 20 57 W-1.0 49-N S-0.8 B
K2 ECB 13D OR-1.0 1
CB1A
105 A
CB1B 18J OR-2.0 18 18 18J-A OR-2.0 0-BV BK-0.8 75 SPL-A2
85 CAB B+ 2 2 53P-E W-0.8 21 21 58-B W-1.0 49-D S-0.8 C
13K-B OR-1.0 2 13C-B OR-1.0 21 21 13C-A OR-1.0 24S W-0.8 77
30 30 21K-B W-0.8
11 87 87 21C W-0.8 12ACC-B W-0.8
28G W-1.0 19 21E W-0.8 27 27 21E-A W-0.8 24R W-0.8 78 SRTD CAB-F FRONT 58-B W-1.0 58-B W-1.0 Not Used D
49-V S-0.8 E
20G-B W-0.8 31 31 20G-A W-0.8 24B W-0.8 79 58-C W-0.8 58-C W-0.8 58-C W-0.8
87A 87A Not Used
12ACC-C W-0.8 19-1 1
0-BV BK-0.8 18 20G-A W-0.8 89 49-S S-0.8 F
13C-B OR-1.0
H 0-EQ BK-0.8 CAB-E ENG
85 85 0-DE BK-0.8 GH A
G 0-DE BK-0.8 86 86 25T LU-0.8 BUSS-J5-ECC 13-17 2 PRM-D ECA-L2 EDC7 32 19C-D OR-1.0 19C-D OR-1.0
F 0-DF BK-0.8 BUSS-J6-ECC 14-2 3 A Not Used 1 35W W-0.8
E 0-DD BK-0.8 43S-D W-0.8
19R-D OR-0.8
12-2 4
17
C BUSS-J11-ECA 22 2 0-BP BK-1.0
10 10 49-F S-0.8
D 0-EC BK-0.8 17-3 5 P 3 3 Not Used
K1 ECB 3 18J-H OR-1.0 6 6 24L W-0.8
C 0-EB BK-0.8 21D-B W-0.8 16-5 6 85 B Y 8 8 Not Used 0-AD BK-1.0 0-AD BK-1.0 49-V S-0.8 10-19 9
0-DU BK-0.8
A9
18R-A OR-2.0 GH-1 B 21F-C W-0.8 53P-A W-0.8
B
30 30 WIF 1 1
B 0-EA BK-0.8 12 87 87 13V OR-0.8
21K-A W-0.8
1-ND R-62.0
10-2 7
17-1 8 40 A F1
86 A R
5 5 24S W-0.8
7
6
7
6
Not Used
Not Used
0-AE BK-1.0
SPL-A1 BUSS-J6-ECA 9-11 2
58L BK-0.8
58-D W-0.8
7-6 1
16-4 2
49-D S-0.8 13-14 10
0-B29 BK-0.8 10-18 11
0-DC BK-0.8
ECA-F9
A G
PRM-D1
33 A B YPP
0-ES BK-19.0
87A 87A Not Used 13V OR-0.8 3 3 24B W-0.8 Not Used 58H-A W-0.8 7-2 3 0-B24 BK-0.8 13-15 12
9-3 9 BK 5 5 BUSS-J5-ECA 17-7 3
GND-CAB-SPL2
34 A B YPE
0-AB BK-2.0
85 85 0-DD BK-0.8 4 4 24R W-0.8 A B
9-2 4 16-2 13
10 A
25T-C LU-0.8 7-7 10 BUSS-PRM-PWR 13H-C 0R-0.8 8-3 1 1 1 57-B W-0.8 SPL-PINE 53C-A W-0.8 9-7 4 0-B26 BK-0.8 0-BS BK-1.0
0-B6 BK-1.0
86 86 13K-C OR-1.0 SPL-NEU 2 2 A B
0-BAC BK-2.0
31L Y-0.8 10-3 5 52 W-0.8 9-9 14
0-BW BK-2.0
25T-B LU-0.8 6-1 11 9 9 0-B5 BK-0.8 19-7 5
0-GB BK-1.0
0-EQ BK-0.8
13H-B 0R-0.8 10-4 2 0-DU Bk-0.8
0-BX BK-2.0
0-BP BK-1.0
10 A F2
L1-9
RTHP 19A-J OR-0.8 10-20 6 56 W-0.8 9-10 15
A
BUSS-J1-ECA 8-2 3 4 4 Not Used 0-AF BK-1.0 14-1 6
12ACC-B W-0.8 12ACC-B W-0.8 BUSS-L1-ECA 12-13 4 23 2 2 19P-A OR-0.8
29.9
27.4
AT 20°C (JOYSTICK)
AT 20°C (SINGLE AXIS) 28.8 AT 20°C
0-AJ BK-1.0 14-5 7 52M W-0.8 10-8 16
0-EC BK-0.8 0-EC BK-0.8 0-EC BK-0.8 0-EC BK-0.8 BUSS-J11-ECA 22-2 5 20G-B W-0.8 18-1 1 CAN-H Y-0.8 18-5 3 SPE 0-AH BK-1.0 14-4 8 49-T S-0.8 16-13 7 52AU W-0.8 10-7 17
0-EB BK-0.8 0-EB BK-0.8 0-EB BK-0.8 BUSS-PRM-E 19-2 6 BUSS-J9-ECA 13-2 2 CAN-L G-0.8 18-4 4 19P-A OR-0.8 19P-A OR-0.8 49-E S-0.8 12-22 8 BUSS-J8-ECA 13-1 18
0-EA BK-0.8 0-EA BK-0.8 0-EA BK-0.8 19S1-OR-1.0 17-4 7 57-C W-0.8 10-1 1 0-AG BK-2.0 BUSS-J7-ECA 9-12 19
FRAME 1 FRAME 2 FRAME 3 FRAME 4 FRAME 5

BC08B245-01A BC08B245-02A BC08B245-03A BC08B245-04A BC08B245-05A
TRANSMISSION-01 TRANSMISSION-02 TRANSMISSION-03 WARNING BUZZER - INSTRUMENT CLUSTER 1 - PARK BRAKE SWITCH PAD - INSTRUMENT CLUSTER 2 - PARK BRAKE BACK-UP ALARM
46
TECM
53 54 JOYSTICK ONLY F-N-R SWITCH 0-DB BK-0.8 0-DB BK-0.8
FORWARD REVERSE NEUTRAL 0-DP BK-0.8 1
SPL-D15 56
CLUTCH 1 2 3 4 1 2 3 4 1 2 3 4 0-DQ BK-0.8 2 10 10 19A-E OR-0.8 19A-F OR-0.8
36H-A P-0.8
17P-A OR-0.8
36H-A P-0.8
17P-A OR-0.8
71
25K LU-0.8 25K LU-0.8 1 K4 -- -- -- -- -- -- -- -- -- -- -- 0-DM BK-0.8 3 AIC-2
7 7 0-DAP S-0.8 2 33P-A Y-0.8 33P-A Y-0.8 ECA-F14 C4
25L LU-0.8 25L LU-0.8 2 KR -- -- -- -- -- -- -- -- -- 0-DN BK-0.8 4 13V OR-0.8 1 14 52C W-0.8 Not Used 1 14 19S-D OR-0.8 L2-4
8 8 49-H S-0.8 25Y-C LU-0.8 2 2 0-B28 BK-0.8 0-B28 BK-0.8 BUSS-J14-ECA
25M LU-0.8 25M LU-0.8 3 K1 -- -- -- -- -- -- -- -- -- 32J-D Y-0.8 5 1 1 Not Used 36F-A P-0.8 2 15 44A-B T-0.8 43S-C W-0.8 2 15 0-DB BK-0.8 A B
19A-U OR-0.8 1 1 31F-A Y-0.8 31F-A Y-0.8 5 10 0-B28 BK-0.8 BUSS-J15-ECA 5A
25N LU-0.8 25N LU-0.8 4 K3 -- -- -- -- -- -- -- 35C Y-0.8 7 6 6 Not Used 1 CAN-HG Y-0.8 3 16 Not Used 62A W-0.8 3 16 57-C W-0.8
20M 31H-A Y-0.8 4 9 17P-A OR-0.8
25P LU-0.8 25P LU-0.8 5 KV -- -- -- -- -- -- -- -- -- 58H-A W-0.8 8 5 5 Not Used CAN-LG Y-0.8 4 17 Not Used 33R Y-0.8 4 17 21K-A W-0.8
42C-E DU-1.0 3 8 CAN-LF G-0.8 19A-P BK-1.0 19H OR-1.0
25J LU-0.8 25J LU-0.8 6 K2 -- -- -- -- -- -- -- -- -- -- -- 25P-A LU-0.8 9 4 4 Not Used 36A P-0.8 5 18 Not Used 33P-A Y-0.8 5 18 31L Y-0.8
SPL-D16 41T-D K-1.0 2 7 CAN-HF Y-0.8
25S LU-0.8 25S LU-0.8 7 -- -- -- -- -- -- -- -- -- -- -- -- -- 25L-A LU-0.8 10 9 9 32J-C Y-0.8 57 0-DX BK-0.8 6 19 Not Used
41H-D OR-0.8 Not Used
33U Y-0.8 6 19 Not Used ECD 86 30
36T P-0.8 36T P-0.8 8 -- -- -- -- -- -- -- -- -- -- -- -- -- 25S-B LU-0.8 12 3 3 26E LU-0.8 P K Y N 55 SFNR 43-A DU-0.8 7 20 53C-A W-0.8
1 6
SW-PAD
52M W-0.8 7 20 19S -C OR-0.8 F9/F10
36R-C P-0.8 36R-C P-0.8 9 -- -- -- -- -- -- -- -- -- -- -- -- -- 25S-C LU-0.8 13 2 2 19A-D OR-0.8 3 4 2 1 6 5 197M 32J-A Y-0.8 7 7 36B P-0.8 8 21 Not Used
70 52AU W-0.8 8 21 19E -A OR-0.8
78
45 Not Used
Not Used
10
11
--
--
-- -- -- --
-- -- -- --
--
--
-- -- --
-- -- --
--
--
-- --
-- --
--
--
37D-A P-0.8
32F-A Y-0.8
15
STE 19A-G OR-0.8 8 8 36H-A P-0.8
Not Used
9
10
22
23
Not Used
52 W-0.8
45L-E N-0.8
45R-C N-0.8
9
10
22
23
0-DA BK-0.8
Not Used
17 19A-V OR-0.8 5 5
Not Used 12 32J-E Y-0.8 SPL-FNR 36C-A W-0.8 11 24 Not Used 35X Y-0.8 11 24 Not Used
-- -- -- -- -- -- -- -- -- -- -- -- -- 37E P-0.8 18 5 5 32J-A Y-0.8 26J LU-0.8 4 4
Not Used 13 -- -- -- -- -- -- -- -- -- -- -- -- -- 25A-A LU-0.8 19 25Y-B LU-0.8 6 6 25Y-C LU-0.8 Not Used 9 9 0-DW BK-0.8 12 25 17P-A OR-0.8 61B-B W-0.8 12 25 Not Used 85 87A 87
Not Used 14 -- -- -- -- -- -- -- -- -- -- -- -- -- 26F-B LU-0.8 20 19A-C OR-0.8 1 1 19A-B OR-0.8 26F-A LU-0.8 6 6 35B W-0.8 13 26 56 W-0.8 Not Used 13 26 31D-A Y-0.8
C B A Not Used 15 -- -- -- -- -- -- -- -- -- -- -- -- -- 52P-C W-0.8 26F-B LU-0.8 2 TRANS CAB-T 35C Y-0.8 35A-A Y-0.8
0SS 3 2 1 Not Used 16 -- -- -- -- -- -- -- -- -- -- -- -- -- 25Y-A LU-0.8
21
22
58 26R-B LU-0.8 4
2
4
26F-A LU-0.8
26R-A LU-0.8
26R-A LU-0.8
Not Used
1 1 AIC-1
TRC 19T-A OR-0.8 23 26N-B LU-0.8 3 3 26N-A LU-0.8 26N-A LU-0.8

10
3
10
3 62 72 PHF
33R-A Y-1.0
31D Y-1.0
1
2
1
2
33R Y-0.8
See Note 2 10 10 31D-A Y-0.8
Not Used 15 15 Not Used CAN-HD Y-0.8 25
7 7 0-B17 BK-0.8 197F 197M 26J LU-0.8 2 2
63 19D-B OR-0.8 31H Y-1.0 23 23 31H-A Y-0.8
0-HE BK-1.0
19A OR-1.0
25K LU-0.8 25K-A LU-0.8 25K-A LU-0.8 25K-A LU-0.8 CAN-LK G-0.8
25D LU-1.0
16 16 26 19D-C OR-1.0 30 30
SPL-D5 8 8 49S S-0.8 36H P-1.0 36H-A P-0.8 19S -C OR-0.8
25L LU-0.8 25L-A LU-0.8 25L-A LU-0.8 25L-A LU-0.8
PBD SPL-PBS 79
19E -A OR-0.8
17 17 CAN-LJ G-0.8 27 ECB 86
19D-A OR-1.0
30
25M LU-0.8 25M-A LU-0.8 25M-A LU-0.8 25M-A LU-0.8 25H LU-0.8
9 9 Not Used A A 19A-A OR-1.0 BUZ SPL-DLY3 19S-D OR-0.8
18 18 29
6 6 Not Used 25G LU-1.0 60 74
19S -B OR-0.8
B B K5
25N LU-0.8 19 19 25N-A LU-0.8 25N-A LU-0.8 25N-A LU-0.8 26R-B LU-0.8 30
5 5 Not Used SDC 35B W-0.8 1 1
64 10 10 Not Used
25P LU-0.8
25J LU-0.8
20
21
20
21
25P-A LU-0.8
25J-A LU-0.8
25P-A LU-0.8
25J-A LU-0.8
25P-A LU-0.8
25J-A LU-0.8
26E LU-0.8
25M-A LU-0.8
31
32
4 4 Not Used 59
FRONT
CAB-F
28 27
28 27 Not Used 10 10
0-B27 BK-0.8 2 2
73 10 10 Not Used
7 7 0-B21 BK-1.0
SPL-BUZ
52C W-0.8
8 8 49-L S-0.8
1 1 Not Used 0-B18 BK-0.8 7 7 7 7 0-B29 BK-0.8
25S LU-0.8 22 22 25S-A LU-0.8 36T-A P-0.8 36T-A P-0.8 36T-A P-0.8 39 9 9 Not Used
3 3 25H LU-0.8 49-R S-0.8 8 8 A A 36H P-1.0 49-V S-0.8
19A-T OR-0.8
A6
25G-A LU-0.8
8 8
A3
36T P-0.8 5 5 36T-A P-0.8 32F-A Y-0.8 32F-A Y-0.8 25C-A LU-0.8 41
B
Not Used
B
6 6
2 2 19A-Q OR-0.8 Not Used 9 9 0-B28 BK-0.8 85 87A 87 B B 0-HW BK-1.0 1 1 Not Used
32F Y-1.0 31 31 32F-A Y-0.8 0-DN BK-0.8 0-DN BK-0.8 25B-A LU-0.8 42 5 5 Not Used
Not Used 6 6 0-B26 BK-0.8
13H-C OR-0.8
ECA-F6
ECA-F3
STA
A1
B3
HOT 9 9 Not Used
47
B
0-HE BK-1.0 0-DN BK-0.8 25D-A LU-0.8 25D-A LU-0.8 25F LU-0.8
A
28 28 43 52P-B W-0.8 1 1 35R-C Y-0.8
L1-1
BUSS-J1-ECA
Not Used 5 5 5 5 Not Used
25D LU-1.0 25D-A LU-0.8 36R-E P-0.8 36R-E P-0.8 26N-B LU-0.8
A
10 10 44
BUSS-J2-ECA
4 4 Not Used
TRANS ECM DLY
7.5 A
25G-B LU-0.8
ECD-F1
ECD-F3
1 1 Not Used
TRANS ECM
3 0-DAV BK-0.8 6 6
5A
19A OR-1.0 29 29 19A-M OR-0.8 36G-A P-0.8 36G-A P-0.8 19A-K OR-0.8 45 3 3 Not Used
7.5 A
Not Used
ECA-F1
A 1 32F Y-1.0 Not Used 24 24 Not Used 25A-A LU-0.8 25A-A LU-0.8 36R-E P-0.8 46 5 Not Used SPL-DC 4 4 0-DX BK-0.8 17 17 0-BJ BK-0.8 4 4 Not Used
33R-A Y-1.0
L1-3
2 2 35A-B Y-0.8
A
7.5 A
L1-6
A
10 A
2 37D-A P-0.8 Not Used 3 3 0-DW BK-0.8 19 19 0-BG BK-0.8 3 3 33U Y-0.8
36R-B P-1.0 36R-A P-1.0 36R-E P-0.8 0-DM BK-0.8 0-DM BK-0.8 36G-A P-0.8
510
B 2
SPL-H1
36G P-1.0
12 12
36G-A P-0.8 25J-A LU-0.8
49
61 6 Not Used 19A-R OR-0.8 2 2 0-DB BK-0.8 20 20 0-BH BK-0.8 SPL-PB 2 2
SBU
A3
13 13 51
B1
A
FM
B
4 37E P-0.8 31F-A Y-0.8 28 28 31F Y-1.0 CAB-F FRONT ENG-T TRAN-E SPB 57-C W-0.8 4-1 1
Not Used Not Used
BUSS-J3-ECA
25N-A LU-0.8
BUSS-J4-ECA
A1
14 14 55
B
36A P-0.8 32 32 Not Used 21K-A W-0.8 1-7 2
19A-L OR-0.8
1 19A-W OR-0.8
48 25A LU-0.8 7 7 25A-A LU-0.8 25B-A LU-0.8 25B-A LU-0.8 25K-A LU-0.8 56 36B P-0.8 Not Used
19T-A OR-0.8
0-BK BK-1.0
BUSS-J7-ECA
BUSS-J6-ECA
8 8 2 2 0-HC BK-1.0 31L Y-0.8 5-5 3
0-HD BK-1.0 11 11 0-DM BK-0.8 58L BK-0.8 36F-A P-0.8 33 33 36F P-1.0
57 108F 0-DY BK-1.0 9 9 Not Used Not Used 3 3 Not Used
SPL-TRNS-PWR 36C-A W-0.8 34 34 36C P-1.0 13H-B OR-0.8 2-2 4
25B LU-0.8 9 9 25B-A LU-0.8 25D-A LU-0.8 62 52P-A W-0.8 24 24 52P W-1.0 Not Used 4 4 Not Used J 35A-D Y-0.8
A 2 36R-D P-1.0 19A-N OR-1.0 A CAB-E ENG
25C LU-0.8 8 8 25C-A LU-0.8 25C-A LU-0.8 25C-A LU-0.8 25Z LU-0.8 63 33P-A Y-0.8 26 26 33P Y-1.0 K 35A-B Y-0.8
B 1 36G P-1.0 19A-F OR-0.8 B
TRANS CAB-T 25R LU-0.8 64 L 35A-A Y-0.8
TCOT
25W LU-0.8 65 19A-Q OR-0.8 C SPL-PB1 BUSS-J3-ECA 8-2 5
SPL-D12 SPL-A4 M 35A-C Y-0.8
25S-A LU-0.8 25S-A LU-0.8 25S-B LU-0.8 25G-C LU-0.8 66 19A-T OR-0.8 D BUSS-J4-ECA 17-6 6
A 1 25A LU-0.8 SPL-PK1
19A-S OR-0.8
19A-W OR-0.8 SPL-TRN
19A-J OR-0.8
25S-C LU-0.8 25T-C LU-0.8 67 E
B 2 0-HF BK-0.8
66 PAF
36F P-1.0
0-AL BK-1.0
19A-C OR-0.8 F SPL-RD
33P Y-1.0
0-AK BK-1.0
0-AN BK-1.0
ESS 25W LU-0.8 25W LU-0.8 31F Y-1.0
52 25G-C LU-0.8 25G-C LU-0.8 19A-P BK-1.0 G 1 1 61B-B W-0.8 22-14 22
52P W-1.0
49 25Z LU-0.8 25Z LU-0.8 0-BY BK-1.0
0-HM BK-1.0
19A-R OR-0.8 H 2 2
0-HL BK-1.0
62A W-0.8 22-13 23 209F 209M
33R-C Y-1.0
33R-BY-1.0
TS2 SPL-D8-C1
25R LU-0.8 25R LU-0.8 19A-K OR-0.8 19A-K OR-0.8 19A-K OR-0.8 67
0-HV BK-1.0
J
SPL-H2 FORWARD REVERSE NEUTRAL BK A A
25F LU-0.8 25F LU-0.8 1 52AU W-0.8 5-17 7 35A-E Y-0.8 A A
65
31D Y-1.0
1 2 3 4 1 2 3 4 1 2 3 4 G B B 26N-B LU-0.8 26N-B LU-0.8 19A-M OR-0.8 K RFL PBW 1 2
S 52M W-0.8 5-16 8
50 A 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V U C C
25W LU-0.8
25Z LU-0.8
25Y-A LU-0.8
25Y-B LU-0.8
25Y-A LU-0.8
25Y-B LU-0.8
26E LU-0.8 26E LU-0.8 19A-S OR-0.8 L 1 2 YPB 2 1 35X Y-0.8 17-2 9
B -- -- 24V 24V -- -- 24V 24V -- -- 24V 24V 26R-B LU-0.8 26R-B LU-0.8 19A-H OR-0.8 M
2 1 See Note 3
D D 25Y LU-0.8 19A-M OR-0.8 19A-M OR-0.8 25H LU-0.8 25H LU-0.8 PRB1 A B PRB2 A B 45R-C N-0.8 13-7 10
A 2 0-HG BK-0.8 C 24V -- -- 24V 24V -- -- 24V 24V -- -- 24V SPL-D11 G 1
19A-H OR-0.8 19A-H OR-0.8 13V OR-0.8 1-9 3 A B A B 45L-E N-0.8 13-6 11
36C P-1.0
19T-A OR-0.8 19T-A OR-0.8 CLS A B
B 1 25B LU-0.8 D -- -- -- -- -- -- -- -- -- -- -- -- R A RFLG 43-A DU-0.8
A 19A-H OR-0.8 26F-B LU-0.8 26F-B LU-0.8 12-3 4 A B 43S-C W-0.8 12-1 12
Y B 40.3 AT 20°C CAN-LG Y-0.8 18-10 5
ISS B 25F LU-0.8 CAN-LF G-0.8 18-8 13
A 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V K C C 25R LU-0.8
37E P-0.8
37D-A P-0.8
37E P-0.8
37D-A P-0.8 BUSS-J2-ECA 10-5 1 69 CAN-HG Y-0.8 18-11 6 CAN-HF Y-0.8 18-9 14 35A-F Y-0.8 13-9 1
A 2 0-HH BK-0.8 B 24V 24V 24V 24V -- -- -- -- -- -- -- -- S
D D 25T-B LU-0.8 1 11-5 35C Y-0.8 32J-D Y-0.8 32J-D Y-0.8 BUSS-J1-ECA 2-3 2 53C-A W-0.8 4-4 7 41H-D OR-0.8 13-4 15 35A-C Y-0.8 13-10 2
A B
0-BAE BK-1.0
B 1 25C LU-0.8 C -- -- -- -- 24V 24V 24V 24V -- -- -- -- RECT
2 5-3 2-1 3 44A-B T-0.8 13-16 8 41T-D K-1.0 13-5 16
0-BG BK-0.8
58H-A W-0.8 13H-C OR-0.8 49-L S-0.8 12-17 3
0-BH BK-0.8
0-BU BK-1.0
0-DA BK-0.8
0-AK BK-1.0
0-BK BK-1.0
0-DY BK-1.0
0-BJ BK-0.8
0-DAV BK-0.8
TS1
0-DQ BK-0.8
0-DP BK-0.8
D -- -- -- -- -- -- -- -- 24V 24V 24V 24V A B

TSS 3 9-13 52P-C W-0.8 19A-S OR-0.8 10-21 8 52 W-0.8 5-14 9 42C-E DU-1.0 12-4 17 0-B21 BK-1.0 12-10 4
25Y-B LU-0.8 25Y-B LU-0.8 75 76 77
51 4 18-7
5 18-6
CAN-HD Y-0.8
CAN-LD G-0.8
19A-M OR-0.8 19A-M OR-0.8 0-DAP S-0.8 12-11 4
49-H S-0.8 12-16 5
19A-P BK-1.0
49-R S-0.8 12-20 10
11-6 9
68 56 W-0.8
BUSS-J6-ECA
5-15 10
4-2 11
0-B29 BK-0.8
49-V S-0.8
5-11 18
5-9 19
35C Y-0.8
19A-P BK-1.0
7-1 5
8-9 6
19A-H OR-0.8 19A-H OR-0.8
6 5-1 58L BK-0.8 0-B17 BK-0.8 12-6 6 0-B18 BK-0.8 12-7 11 0-BY BK-1.0 16-1 1 BUSS-J7-ECA 5-19 12 19A-J OR-0.8 5-6 20 BUSS-J15-ECA 22-5 7
1-11 1 7 1-10 25T-C LU-0.8 49S S-0.8 12-21 7 0-B26 BK-0.8 5-4 2 52P-C W-0.8 7-3 13 19A-S OR-0.8 8-8 21 BUSS-J14-ECA 16-8 8
FRAME 6 FRAME 7 FRAME 8 FRAME 9 FRAME 10 FRAME 11

BC08B245-09A BC08B245-09A BC08B245-08A BC08B245-09A BC08B245-10A BC08B245-11A
LIGHTS-01 LIGHTS-02 LIGHTS-03 AND HORN LIGHTS-04 AND BACKUP ALARM LIGHTS-04 AND BACKUP ALARM COMPONENT
A 42C-A DU-1.0 NORTH AMERICA EUROPE FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS
B 42C-E DU-1.0 0-MC BK-1.0 45L-C N-0.8 1 1 45L N-1.0 45L N-1.0
ECB-F8
C 42C-D DU-1.0 CAB-RF ROOF 46-D K-1.0 A 45L-E N-0.8 A8 B8 SPL-POS-R 45R-D N-0.8 3 3 45R N-1.0 45R N-1.0 1 - 1. Starting Relay 5- 37.
Fan Control Switch (Option) 10 - 73. Hydraulic Oil Temperature Sender NORTH AMERICA
D 42C-C DU-1.0 43-A DU-0.8 A A 43-B DU-0.8 B 45L-D N-0.8 41T-A K-1.0 A B 18G OR-1.0 18G-G OR-0.8 5 5 18G-A OR-1.0 18G-A OR-1.0
1 - 2. Resistor - 75 Ohm
LBEPWR
LBEGRD
SPL-PK1
B
10 A
A A
10 A
B 42R-C DU-1.0 B B 42R-F DU-1.0
1 1
A B
C 45L-C N-0.8
5A
18F-E OR-0.8 6 6 18F OR-1.0 18F OR-1.0 5- 38.
Fan Reverse Relay (Option) 10 - 74. Park Brake Switch
B1
ECB-F1
A1 A2
ECB-F2
B2 42C-A DU-1.0 C C 42C-F DU-1.0 D 45L-B N-0.8 A7
ECB-F7
B7 SPL-POS-L
18B-A OR-0.8 7 7 18B OR-1.0 18B OR-1.0
96 1 - 3. Alternator 5- 39.
Pilot Control Switch 10 - 75. Redundant Brake Pressure Switch 1 15 - 100. Right-Hand Rear Combination Lamps
19U-D OR-0.8 D D E 45R-C N-0.8 18D-A OR-0.8 18D OR-1.0 18D OR-1.0
46-C K-1.0 E E
19U-C OR-0.8
46-D K-1.0 M F 45R-E N-0.8
41T-B K-1.0 A
5A
B 18F-C OR-1.0
18E-A OR-0.8
14
15
14
15 18E OR-1.0 18E OR-1.0 100 1 - 4. Crank Control Relay 5- 40.
Ride Control Solenoid (Option) 10 - 76. Redundant Brake Pressure Switch 2 Pin 1 - Ground
80 42FS DU-1.0
0-DR BK-1.0 F F 0-MN BK-1.0 82 G 45R-D N-0.8 18F-A OR-0.8 18C-A OR-0.8 16 16 18C OR-1.0 18C OR-1.0 1 - 5. Batteries 5- Rollback Pressure Switch
41. 10 - 77. Coolant Level Sender Pin 2 - Brake Lamp
H 45R-B N-0.8 1-DR R-1.0 1-AA R-1.0 0-AJ BK-1.0 44A-E T-1.0
7 7 0-B14 BK-0.8
0-DS BK-1.0 G G 0-MK BK-1.0 18G-F OR-0.8
44-A T-0.8
22
23
22
23 44 T-1.0 18D OR-1.0
1
2
1
2 45L-A N-1.0
1
2
1
2
1 - 6. Crank Request Relay (XT with Ride Control Only) Pin 3 - Tail Lamp
SPL-PK3
8 8 49-A S-0.8 43S-A W-0.8 R R 43S-B W-0.8 19U-C OR-0.8 A B CAB-F FRONT 18B OR-1.0 3 3 18F-B OR-1.0 3 3 1 - 7. Time Delay Module 5 - 42. Rollback Jumper 11 - 78. Backup Alarm Relay Pin 4 - Turn Lamp
18F OR-1.0 35A-L K-1.0 15 - 101. Left-Hand Rear Combination Lamps
5 5 42-B R-2.0 19U-G OR-0.8 S S 19U-F BK-0.8 43-B DU-0.8
SPL-D A3
5A
B3 90 4 4 4 4
1 - 8. Master Disconnect Switch 5 - 43. Fan PWM Solenoid 11 - 79. Backup Alarm Disable Switch
41H-B OR-0.8
10 10 Not Used 0-MB BK-0.8 ECB-F3 45L N-1.0 5 5 0-BT BK-1.0 5 5

18E-A OR-0.8
CAB-RF ROOF 41T-E K-1.0 SPL-PR

PBL Not Used 6 6 Not Used 6 6 1 - 9. Starter 5 - 44. Fan Reverse Solenoid (Option) Pin 1 - Ground
LDM1
Not Used
LDM3
9 9
LDM2
6 6 42RS DU-1.0 DS
3 2 1
A
5A
B 1 1 1-AA R-1.0 LLF LLR-E
1 - 10. Ignition Switch 12 - 80. Work Lamps Switch Pin 2 - Brake Lamp
Not Used SPL-DS A4 B4 2 2 44 T-1.0
41T-C K-1.0
41T-D K-0.8
Pin 3 - Tail Lamp

41H-C OR-0.8
1 1 A A
81 ECB-F4
1 - 11. Neutral Start Relay
18D-A OR-0.8
4 4 Not Used B B
97 44A-D T-1.0 SPL-B8
101 6 - 45. Output Speed Sensor 12 - 81. Door Switch
3 3 42FS DU-1.0 83 1 - 12. Voltmeter Relay Pin 4 - Turn Lamp
43S-C W-0.8
35A-J K-1.0 6 - 46. Transmission Solenoid Valve and 12 - 82. Rotating Beacon (Optional)
43S-D W-0.8
A B
5A 44-A T-0.8 SPL-A1A
2 2 42-A R-2.0 A5 B5 SPL-FLSHR-PWR 15 - 102. Licence Plate Lamp
SPL-DR 91 Temperature Sender
41L-C OR-0.8
SPL-WL ECB-F5 1-DW R-1.0 44A-F T-1.0 1 1 12 - 83. Dome Lamp

SWL
42 R-2.0
19Z OR-1.0
0-AH BK-1.0 1 1 100 45R-A N-1.0 2 2 2- 13. Power Relay Module A 15 - 103. Backup Alarm
A B
ECC 86 30
6 - 47. Filter Maintenance Switch 12 - 84. Rotating Beacon Switch (Optional)
19U-G OR-0.8
19U-D OR-0.8
42R-F DU-1.0 5A 18E OR-1.0 2 2 SPL-J2-N 18G-J OR-1.0 3 3

2- 14. Power Relay Module B
1-KA R-1.0
1-DU R-1.0
1-DV R-2.0
K3
BUSS-J3-ECC A6 B6 K 0-JA-N BK-1.0 44A-GN T-1.0 35A-K K-1.0 6 - 48. Torque Convertor Output Temperature 12 - 85. Left-Hand Front work Lamp
41L-B OR-0.8
42C-F DU-1.0 ECB-F6 18C OR-1.0 3 3 0-BAG-N BK-1.0 1 1 44A-EN T-1.0 2 2 4 4

B
15 A
A
BUSS-J2-ECC A 0-MC BK-1.0 41H-D OR-0.8 L
BRAKE
18G-A OR-1.0 0-BR BK-1.0 2- 15. Power Relay Module C EUROPE
A2 L1-2 LIGHTS 4 4 44A-DN T-1.0 2 2 44A-EN T-1.0 18G-CN OR-1.0 3 3 5 5
Sender 12 - 86. Right-Hand Front work Lamp
0-EH BK-0.8
ECC-F2 B 0-MB BK-0.8 SPL-HB M Not Used 100. Right-Hand Rear Combination Lamps
45R N-1.0 5 5 45L-AN N-1.0 3 3 45L-BN N-1.0 45R-BN N-1.0 4 4 6 6
RELAY 2- 16. Grid heater Relay
0-EG BK-0.8
C 0-MU BK-1.0 GND-CAB-SPL2 Not Used 6 6 45R-AN N-1.0 4 4 45R-BN N-1.0

SPL-POS-NA
0-BT-N BK-1.0 1 1 LRR-E 6 - 49. Engine Speed Sensor 12 - 87. Left-Hand Rear work Lamp Pin 1 - Brake Lamp
D 0-ME BK-1.0
1 LRF 18G-HN OR-1.0 5 5 18G-JN OR-1.0 LRR-12 2- 17. Grid Heater 6 - 50. Intermediate Speed Sensor 12 - 88. Right-Hand Rear work Lamp
SPL-WRKR
1-DU R-1.0 Pin 2 - Turn Lamp

SPL-WRKF
A B 19U-B OR-1.0 85 87A 87

L1-1
7.5 A
A-1 SPL-LT
E 0-MF BK-1.0 92 2 45N-A N-0.8
SPL-LB 18F-AN OR-1.0 6 6 18F-BN OR-1.0
2- 18. Power Relay Module D 6 - 51. Turbine Speed Sensor 12 - 89. Diodes
ECC-F1 F 0-MA BK-1.0
0-EH BK-0.8
0-EF BK-0.8 35A-GN Y-1.0 7 7 35A-HN Y-1.0
101 Pin 3 - Tail Lamp
3
98
19U-H OR-1.0
G Not Used 44A-A T-0.8 Not Used 8 8 Not Used 2- 19. Circuit Breaker Cab + 6 - 52. Transmission Shifter Pin 4 - Backup Lamp
0-MU BK-1.0
42C-H DU-1.0
0-MJ BK-1.0
42C-G DU-1.0
0-ME BK-1.0
42R-H DU-1.0
0-MF BK-1.0
42R-G DU-1.0
4 0-EG BK-0.8 K4 ECC

BUSS-L1-ECC
84 H Not Used
5 Not Used 44A-C T-0.8
SPL-BRK
93
ENG-H HD-N
2- 20. Water Separator Heater 13 - 90. Brake Lamp Switch
J 0-MJ BK-1.0
6 Not Used 19Z-B OR-1.0
Not Used 10 10 30 30 19U-A OR-0.8 CAB-F FRONT 44A-FN T-1.0 2 2 Pin 5 - Ground
K Not Used 87 87 64-A OR-0.8 13 13 18F-BN OR-1.0 3 3 2- 21. Fuel Filter Heater 7 - 53. Transmission Electronic Control Module 13 - 91. Brake Lamp Relay
44A-B T-0.8
10 10 Not Used 7 45R-E N-0.8 0-B24 BK-0.8 7 7

Pin 6 - Not Used
A3
41T K-1.0
B
L 0-MN BK-1.0 49-D S-0.8 8 8 87A 87A Not Used 45L-BN N-1.0 4 4
64 OR-1.0
0-B15 BK-0.8 45L-D N-0.8

7 7 8 19Z-A OR-1.0 13 - 92. Flasher Module 101. Left-Hand Rear Combination Lamps
15 A
M 0-MK BK-1.0 Not Used 9 9 85 85 64C OR-0.8 0-JA-N BK-1.0 0-BR-N BK-1.0 1 1
ECC-F3
49-B S-0.8
LRFW
LLFW
LLRW
LRRW
8 8 B A B A B A B A 9 45A-A N-0.8
9 9 Not Used SPL-ROOF B A B A B A B A 10 45B-A N-0.8 Not Used 6 6 86 86 19U-E OR-0.8 SPL-J1 LLR-12 3 - 22. Water In Fuel Sensor 8- 54. Transmission Enable Switch 13 - 93. Hazard Switch Pin 1 - Brake Lamp
Not Used Not Used 5 5
3 - 23. Throttle Potentiometer 8- 55. FNR Switch for Joystick Controls 13 - 94. Turn Signal, High-Low Beam, and Horn Pin 2 - Turn Lamp
0-JB BK-1.0
0-JC BK-1.0
6 6 11 45H N-0.8
5 5 Not Used 12 45N-B N-0.8 1 1 Not Used 4 4 SPL-HRN 19U-E OR-0.8 SPL-POS E-HD HD-E 102 3 - 24. Engine Controller
L1-3
8- 56. Transmission Kick-Down Switch Switch Pin 3 - Tail Lamp

A
Not Used 1 1 19U-A OR-0.8 LPL

4 4 Not Used FLSHR 64M 64F 18G-D OR-1.0 A A 18G-E OR-0.8
45H N-0.8
1 1 Not Used 3 3
102 35A-H Y-1.0 8- 57. FNR Switch for Single Axis Controls 13 - 95. Driving Lamps Switch Pin 4 - Backup Lamp
45A-A N-0.8
19B OR-0.8 35A-G Y-1.0 B B 18G-E OR-0.8 A A

46-C K-1.0 1-KA R-1.0 2 2
3 3
95 0-JA BK-1.0
45B-A N-0.8
94
0-BAG BK-1.0 C C 0-JC BK-1.0 B B
4 - 25. Return-to-Travel Float Switch 8- 58. Transmission Auto Switch Pin 5 - Ground
BUSS-J4-ECA
41T-C K-1.0
2 2 19U-H OR-1.0 SHZ SPL-J1

SBE 85 86 87 88 0-B19 BK-0.8 7 7 HN1
18G-EN OR-1.0 A A 4 - 26. Height Control Switch 8- 59. Brake Declutch Pressure Switch 14 - 96. Left-Hand Front Combination Lamps Pin 6 - Not Used
0-JC BK-1.0 B B
49A 49A
L L
49-P S-0.8 8 8 64 OR-1.0
LPL
4 - 27. Electromagnetic Detents 8- 60. Declutch Switch Pin 1 - Ground 102. Licence Plate Lamp
A8
0-AF BK-1.0
103
B
19U OR-0.8
0-B13 BK-1.0
A
41T-C K-1.0 R R
19Z-B OR-1.0 5 5
HN2 Pins 3 and 4 - Return-to-Dig 8- 61. Diagnostic Connector Pin 2 - Low Beam 103. Backup Alarm
5A
Not Used 10 10
43S-C W-0.8
41J OR-1.0 103 Pins 2 and 5 - Height Control

ECA-F8
0-B14 BK-0.8 56 56
B
89 Not Used 9 9
99 Pin 3 - High Beam
43S-D W-0.8
0-B15 BK-0.8
C A 49 DU-1.0 56A 56A 41H-A OR-1.0 BU1
41J OR-1.0 6 6
Pins 1 and 6 - Return-to-Travel 9- 62. Instrument Cluster Connector 1 Pin 4 - Position
43-A DU-0.8
Not Used Not Used D-OR 56B 56B 41L-A OR-1.0 18F-A OR-0.8 5 0-JB BK-1.0
42C-E DU-1.0
D B
Not Used 1 1
1-DV R-2.0
BU1
0-B17 BK-0.8 49-C S-0.8 42C-D DU-1.0 A 56D 56D 19Z-C OR-1.0 35A-C Y-0.8 7 35A-H Y-1.0 4 - 28. Return-to-Dig Proximity Switch 9- 63. Warning Buzzer Pin 5 - Turn Signal
A6
E
L1-8
C
B
Not Used
A
4 4 0-JB BK-1.0
0-B18 BK-0.8
F 10-12 1 D 49-H S-0.8 41T-C K-1.0 B 31B 31B 64C OR-0.8 44A-C T-0.8 8 BU2
4 - 29. Pilot Control Relay ECD-K3
7.5 A
41T K-1.0 3 3
9- 64. Parking Brake Relay
0-EP BK-0.8 35A-HN Y-1.0 14 - 97. Right-Hand Front Combination Lamps
ECC-F6
0-B19 BK-0.8
G 1-4 2 E 49-L S-0.8 49 DU-1.0 C 31 31 18G-F OR-0.8 9 15-1 8
19Z-A OR-1.0 2 2 BU2
0-B8 BK-0.8
H 9-4 3 F 49A S-0.8 SRHSTLK 45L-B N-0.8 10 (ENG)
SDR 4 - 30. Height Control and Return-to-Travel 9- 65. Fuel Level Sender Pin 1 - Ground
0-B21 BK-1.0 10-17 4 0-MA BK-1.0 16-10 14 45R-B N-0.8 12 18F-AN OR-1.0 5 18F-B OR-1.0 5
A4
49-P S-0.8
J G
Proximity Switch
B
BUSS-J3-ECC 13-3 5 49-C S-0.8 16-7 15 35A-F Y-0.8 40 Not Used 7 35A-J K-1.0 7 9- 66. Air Filter Restriction Switch Pin 2 - Low Beam
ECC-F4
0-DAP S-0.8
K H 49-R S-0.8
L1-6
10 A
49-P S-0.8 12-19 12 4 - 31. Return-to-Dig Switch

0-BAG-N BK-1.0
64C OR-0.8
0-B23 BK-0.8
L 0-B17 BK-0.8 8-6 6 J 49S S-0.8 49-H S-0.8 8-5 16 BUSS-J8-ECA 5-18 1 CAB-E 44A-DN T-1.0 8 44A-D T-1.0 8
9- 67. Parking Brake Solenoid Pin 3 - High Beam
0-BAG BK-1.0
0-B13 BK-1.0
11-3 17 0-B19 BK-0.8 12-8 13 0-AF BK-1.0 4-6 1 18G-HN OR-1.0 9 18G-H OR-1.0 9 13-8 1
0-DR BK-1.0
0-B18 BK-0.8 8-11 7 49-L S-0.8 BUSS-J9-ECA 3-2 2 (CAB-E)
0-BR BK-1.0
0-DS BK-1.0
Not Used 49-E S-0.8 13-8 1 4 - 32. Pin Engage Switch (Option)
0-BT BK-1.0
M K
SPL-BCK-LT-GD 0-B19 BK-0.8 13-13 8 L 49-B S-0.8 49A S-0.8 22-1 18 BUSS J3-ECC 12-15 3 35A-F Y-0.8 11-1 9 49-D S-0.8 5-10 14 BUSS-J6-ECC 1-3 2 45L-AN N-1.0 10 45L-A N-1.0 10 (CAB-E) 9- 68. Radiator Coolant Temperature Sender Pin 4 - Position
0-B8 BK-0.8 16-11 9 M 49-A S-0.8 49-P S-0.8 13-12 19 41H-D OR-0.8 10-15 4 35A-C Y-0.8 11-2 10 0-B24 BK-0.8 5-12 15 BUSS-J7-ECC 21-2 3 45R-AN N-1.0 12 45R-A N-1.0 12 4 - 33. Pilot Pressure Solenoid 9- 69. Brake Pressure Warning Switch Pin 5 - Turn Signal
L1-4
A
0-B21 BK-1.0 11-4 10 49-R S-0.8 8-10 20 41T-D K-0.8 10-16 5 0-EP BK-0.8 19-4 11 44A-B T-0.8 9-8 16 0-AH BK-1.0 4-8 4 35A-GN Y-1.0 40 35A-G Y-1.0 40
0-DAP S-0.8 8-4 11
SPL-BCK-LGT
49S S-0.8 8-7 21 45L-E N-0.8 10-11 6 BUSS-J4-ECA BUSS-J5-ECC 1-2 17 0-AJ BK-1.0 4-7 5 ENG ENG
4 - 34. Pin Engage Solenoid (Option) 14 - 98. Horn Relay
BUSS-L1-ECC 2-4 13 0-B23 BK-0.8 16-6 12 49-E S-0.8 5-8 22 45R-C N-0.8 10-10 7 64C OR-0.8 64C OR-0.8 10 - 70. Switch Pad 14 - 99. Horn
5 - 35. Ride Control Switch (Option) 10 - 71. Instrument Cluster Connector 2
FRAME 12 FRAME 13 FRAME 14 FRAME 15-NA FRAME 15-EU 5 - 36. Ride Control Relay (Option) 10 - 72. Hydraulic Filter Restriction Switch
BC08B245-12A BC08B245-13A BC08B245-14A BC08B245-NA15A BC08B245-EU15A
CIRCUIT DIAGRAM LEGEND WIRE IDENTIFICATION NOTES

Frame and Wire Tag WIRE TAGS
FEMALE MALE BK . BLACK 702A G-1.0 NOTE 1: Electrical Center C - Power Stud ELECTRICAL SCHEMATIC
NOTE 2: Indicates Modulated and Current Controller.
SPL-00 Number where circuit
continues.
00-0 1
1 00-0 MALE FEMALE INDICATES INDICATES
CONNECTOR
1 1
CONNECTOR DU . DARK BLUE
G. . . GREEN
WIRE NUMBER
WIRE COLOR
WIRE SIZE
NOTE 3: Disconnect when Backup Alarm Disable Switch is installed. Applicable only on TUV Road Approved Machines.
521E WHEEL LOADER
TERMINAL TERMINAL EXTERNAL INTERNALLY INDICATES PARTIAL
FRAME - WIRE WIRE 54 GROUND GROUNDED
CONNECTOR 2 2
3 3 4 4
CONNECTOR K . . . PINK OR . ORANGE T . . TAN
NUMBER LG. . LIGHT GREEN P . . . PURPLE (Violet) U . . . BLUE
SHOWS CIRCUIT SHOWS COMPONENT 45E 45D
RELAY REAR
18 18 NOT ALL
Wire Tag assigned to wire in Frame. 27 27
LU . . LIGHT BLUE
CROSSING CIRCUIT SPLICE COMPONENT GROUND CONNECTOR CONNECTIONS R . . . RED W . . WHITE
NOT CONNECTED CONNECTION CIRCUIT CONTINUATION NUMBER IDENTIFICATION ARE SHOWN N . . . BROWN S . . . GREY Y . . . YELLOW
Copyright © 2008. CNH Italia S.p.A. All Rights Reserved. BC08B245-00A
Copyright ©
CAB WINDOW WASHER AND WIPER SYSTEM SECONDARY STEERING COMMUNICATION RADIO / POWER CONVERTER AIR SEAT CIGAR LIGHTER AIR-CONDITIONING COMPRESSOR
SPL-FW 0-BZ BK-1.0 1 1 0-HP BK-1.0 PRM-E PRM-E1

19J-C OR-0.8 SFWW ENG-T TRAN-E A Not Used SPL-CNV 121 128
Not Used 1
108 120 C 19L OR-2.0 19L-A OR-2.0 1
K1 ECD J
K
19J-B OR-0.8
19J OR-0.8
0-DT BK-0.8 2 114 CAB-T TRANS
CAN-HG Y-0.8 19L-B OR-2.0 2
K5 ECC
30 30 19J-E OR-0.8 63LC W-0.8 3 DM 19M OR-0.8 3 3 19M-A OR-1.0 19M-A OR-1.0 A A 19M-C OR-1.0 SPL-CAN CAN-HE Y-0.8 30 30 62A W-0.8 10-23 13
104 87 87 63H-B W-0.8
L 19J-C OR-0.8 Not Used 4 A A 19RR OR-0.8 19R-E OR-0.8
4 4 19R-A OR-1.0 19R-A OR-1.0 B B 19R-C OR-1.0 CAN-HF Y-0.8 SPL-CAN-TRANS CAN-HC Y-0.8
85
86
B
A
0-DL BK-0.8
12ACC-C W-0.8
0-EJ BK-1.0
Not Used
3
4
87 87 Not Used
M 19J-A OR-0.8 Not Used 35X Y-0.8 6 6 35X-B Y-1.0 C C 35X-C Y-1.0 CAN-HD Y-0.8 87A 87A 0-EU BK-0.8 19-10 12
87A 87A 63C2 W-0.8 19J-B OR-0.8 5 B B
35X-B Y-1.0 20 A F1 12V-C OR-2.0 5
85 85 63HC-B W-0.8 SPL-PK3 Not Used 6 C C 19R OR-0.8 SPL-2 26 26 0-HP BK-1.0 D D 0-CD BK-1.0 PRM-E2 85 85 0-ET BK-0.8 19-9 11
19S1 OR-1.0 19S1-E OR-1.0 0-ER BK-1.0 6
86 86 19J-D OR-0.8 63W W-0.8 7 19S1-E OR-1.0 E E 19S1-X R-1.0 86 86 61B-C W-0.8 61B-B W-0.8 10-22 14
BUSS-PRM-E
19R-D OR-0.8
CNV SPL-AC
49-T S-0.8 8 Not Used F F Not Used ECD-F7
SPL-HC 63HC W-0.8 20 A F2
122
61B-A W-0.8
K-WCO 9 TR-SS SS-TR 12V-G OR-1.0 A B
Not Used 10 CAN-LG G-0.8 15 A
105
30
87
30
87
63L-B W-0.8
Not Used Not Used 11 SPL-CAN-L CAN-LE G-0.8
A7 B7
PO1 A B C
A B C
129
Not Used 12 CAN-LF G-0.8 SPL-CAN-TRANS-L CAN-LC G-0.8 K5 ECD
87A 87A 63C3 W-0.8 116 CAN-LD G-0.8 12V-D OR-1.0 A B 12V OR-1.0 30 30 18M OR-0.8
85 85 63HC-A W-0.8 FWM 115 SSM
SPL-12V
A4
10 A
B4 87 87 61C OR-0.8
0-EK BK-1.0
86 86 19J-G OR-0.8 SPL-WHS ECD-F4
63H-A W-0.8 A A YSS 87A 87A Not Used
SPL-WLS
63L-A W-0.8 B B
M A 1 51-C W-1.0
SPL-SS 19R-C OR-1.0
51-A W-1.0
1
2
122 85 85 0-DJ BK-0.8
K2 ECD 19J-A OR-0.8 C C 12V-E OR-1.0 A B 86 86 61R-B W-0.8
B 2 0-CF BK-1.0 19S1-X R-1.0 3 10 A A B C
30 30 63C3 W-0.8 63C W-0.8 D D A5 B5
106 87 87 63C2 W-0.8 39.3 AT 20°C PSS
0-CE BK-1.0
Not Used
4
5 SPL-CAN-HVAC
ECD-F5 PO2 A B C
61C OR-0.8 2 2 61C-A OR-1.0
63C W-0.8 12V-A OR-1.0
87A 87A
0-B8 BK-0.8 109 N.O.
51P-A W-1.0 Not Used CAN-H Y-0.8 A A CAN-HA Y-0.8 61R-B W-0.8 29 29 61R W-1.0
0-EL BK-1.0
A A A A 6
85 85 63LC W-0.8 COM CAN-L G-0.8 B B CAN-LA G-0.8
B B 0-CC BK-1.0 19M-C OR-1.0 7 61A-B W-0.8 30 30 61A W-1.0
CAN-HM Y-0.8
86 86 19J-F OR-0.8 FWMG N.C. SPL-C3 12V-F OR-1.0 A B 12V-B OR-1.0
Not Used SPL-CAN-HVAC-L
C C 35X-A Y-1.0 35X-D Y-1.0 8 Not Used C C
127 CAB-E ENG
CAN-LN G-0.8
10 A
51P-A W-1.0 9 CAN2 CAN 123 A6
ECD-F6
B6 126
SRWP 117 Not Used
7 7 0-B23 BK-0.8
RWM 0-ND BK-62 118 0-CA BK-1.0
10
11
RAD-J3 RAD-J1 RAD 0-EN BK-0.8 M M
PR
107 Not Used A A 242F SSS 0-CB BK-1.0
1 1 Y/BK-0.8 4 4 12V-HB OR-0.8 12V-H OR-0.8 N N
0-EM BK-0.8
8 8 49-C S-0.8 0-CF BK-1.0 12 SPL-RAD 1 2 A A 61A W-1.0
Not Used H H Not Used 68L-A OR-1.0 B B 51-B W-1.0
2 2 U/BK-0.8 5 5 Not Used ROOF CAB-RF CL 1
CAN-LC G-0.8
5 5 19K-B OR-0.8 M SPL-SEC 2 B B 61R W-1.0
19K-C OR-1.0 J J 19K-D OR-1.0 19K-D OR-1.0 C C CAN-HK Y-0.8 3 3 R/BK-0.8 6 6 Not Used
4 4 Not Used 19N OR-1.0 A A 19W OR-3.0
CAN-LL G-0.8
CAN-HC Y-0.8
68C OR-1.0 K K 68C-A OR-1.0 68C-A OR-1.0 D D
1-ND R-62
4 4 W/BK-0.8 7 7 12V-HA OR-0.8
130
0-DV BK-3.0
10 10 Not Used Not Used 5 5 BK/W-0.8 8 8 0-EN BK-0.8 0-DK BK-0.8 B B
68L-B OR-1.0 L L 68L-A OR-1.0
19W OR-3.0
6 6 68W W-0.8 224F 6 6 Not Used RSPK SC
1 1 68C OR-1.0
CAB-RF ROOF 0-MA BK-1.0 A A 110 A B C HVAC-CAN1
7 7 OR/W-0.8 1 1 65R OR-0.8 1 1 61A-B W-0.8
9 9 Not Used RWMG SPL-CAN-DIAG-L 18N-A OR-0.8
8 8 Y-0.8 2 2 0-PB BK-0.8 2 2
U-0.8
3
2
3
2
19K-A OR-1.0
68L OR-1.0
SPL-3 23-1 12
SPL-CAN-DIAG
9 9 3 3 Not Used 124 49A S-0.8
10 10 R-0.8 4 4 Not Used 61B-A W-0.8
AB
B
68W W-0.8 24 24 68W-A W-1.0 11 11 W-0.8 5 5 Not Used 4 3 2 1 HVAC1
111
15 A
63W W-0.8 12 12 G/W-0.8 6 6 Not Used LSPK
25 25 63W-A W-1.0
ECC-F8
0-DH BK-0.8 A
CAB-E ENG 13 13 Not Used 7 7 65L OR-0.8 1 1
SPL-RWW RWW 18K-A OR-0.8 B 23-2 7
19K OR-1.0 14 14 Not Used 8 8 0-PA BK-0.8 2 2
CAN-HB Y-0.8 C
68W-A W-1.0 1 1
M CAN-LB G-0.8 D RAD-J2 SPK 125
C3
L1-B
0-BL BK-1.0
B
2 2 SPL-BLWR
A
20G-B W-0.8 E 18N-B OR-3.0
19J OR-0.8
10 A
ECA-F13
FWW DIA 0-ED BK-3.0

63W-A W-1.0 1 1 119 A 0-EE BK-0.8
61C-A OR-1.0
18N OR-3.0
0-BS BK-1.0 HVAC2 2 1
BUSS-J9-ECC
M
BUSS-J8-ECC
0-B BK-1.0 2 2 B 0-EM BK-0.8
A A 63H-C W-0.8 0-BY BK-1.0 0-EP BK-0.8
63L-C W-0.8 SPL-ENG C
19M OR-0.8
B B
L2-3
A
19RR OR-0.8
0-EE BK-0.8 0-ET BK-0.8
0-DK BK-0.8
D 23-3 9
18M OR-0.8
C C
112
19N OR-1.0
D D 58-D W-0.8 E 0-EU BK-0.8
BUSS-J13-ECA
C2
0-DG BK-1.0
C1
F
B
E E
B
ACT
L1-9
G 0-DT BK-0.8
10 A
F F 68L-C OR-1.0
A
ECA-F12
25 A
ECA-F11
20G-B W-0.8 3-1 1
L1-7
C7
H 0-DL BK-0.8
B
140M
10 A
A
18K-A OR-0.8 21-1 2 0-DK BK-0.8 0-DK BK-0.8
113
A4
ECC-F9
C6
C5
I
7.5 A
B
ECA-F17
75 A
0-DH BK-0.8 19-8 3 K 0-DJ BK-0.8
131
ECC-F7
7.5 A
7.5 A
10 A
ECA-F16
ECA-F15
CAN-L G-0.8 3-4 4 0-EE BK-0.8 16-3 3
ECA-F4
L 0-DU BK-0.8
L2-2
L2-1
A
A
1-ND R-62 1-8 1 CAN-H Y-0.8 3-3 5 M 0-DH BK-0.8 0-EP BK-0.8 13-11 4
A9
B
0-CE BK-1.0
35X Y-0.8 10-9 2 0-DT BK-0.8 16-12 5
0-BM BK-1.0
0-ER BK-1.0
0-BZ BK-1.0
CAN-LD G-0.8 7-5 6 49A S-0.8 12-18 1
0-ED BK-3.0
0-EK BK-1.0
0-DV BK-3.0
0-ND BK-62
0-EL BK-1.0
0-EJ BK-1.0
L2-7
GND-CAB-SPL
0-DG BK-1.0
0-BY BK-1.0 9-1 1
A7
19R-D OR-0.8 1-5 3 0-DJ BK-0.8 22-4 6
B
CAN-HD Y-0.8 7-4 7 BUSS-J11-ECA 2-5 2
L1-4
L2-6
L2-5
0-BS BK-1.0 5-13 2
A
0-B23 BK-0.8 12-12 6 10 12-14 0-MA BK-1.0 19S1-OR-1.0 2-7 4 CAN-LF G-0.8 10-13 8 0-DU BK-0.8 4-5 7 BUSS-J12-ECA 16-9 3
49-C S-0.8 12-15 7 0-EE BK-0.8 19-3 3 11 12-9 0-B8 BK-0.8 BUSS-J18-ECA 20-2 5 CAN-HF Y-0.8 10-14 9 0-DH BK-0.8 18-3 8 18K-A OR-0.8 18-2 1 0-DJ BK-0.8 19-6 4
BUSS-J14-ECA 11-8 8 58-D W-0.8 5-2 4 12 19-5 0-DT BK-0.8 BUSS-J4-ECA 10-6 6 CAN-LG G-0.8 9-5 10 12ACC-C W-0.8 1-1 1 0-ET BK-0.8 22-11 9 BUSS-J16-ECA 22-6 1 BUSS-J7-ECC 14-3 2 BUSS-J15-ECA 11-7 5
BUSS-J12-ECA 22-3 9 13 5-7 49-T S-0.8 BUSS-J5-ECA 4-3 7 CAN-HG Y-0.8 9-6 11 BUSS-PRM-E 2-6 2 0-EU BK-0.8 22-12 10 BUSS-J18-ECA 17-5 2 BUSS-J16-ECA 20-1 6
FRAME 16 FRAME 17 FRAME 18 FRAME 19 FRAME 20 FRAME 21 FRAME 22

BC08B245-16A BC08B245-17A BC08B245-18A BC08B245-19A BC08B245-20A BC08B245-21A BC08B245-22A
HEATING, VENTILATION, AND AIR-CONDITIONING GROUND CONNECTIONS

0-BA BK-5.0
RIGHT CONSOLE • GND-CAB1
133 ABOVE PEDESTAL PIVOT • GND-PDST
4 5 2 10 11 3 12 13 6 1 14 7 8 9 0-BA BK-5.0
4 5 2 10 11 3 12 13 6 1 14 7 8 9
BELOW PEDESTAL PIVOT CAB FLOOR • GND-PDST2
DNS51 ORW-0.5
DNS59 WBK-0.5
Not Used
Not Used
DNS56 WG-0.5
DNS57 WU-0.5
DNS58 WR-0.5
DNS50 OR-0.5
0-AP BK-5.0
DNS52 BK-0.5
DNS48 R-0.5
DNS53 N-0.5
DNS49 K-0.5
DNS55 U-0.5
DNS54 S-0.5
FUEL FILTER HEAD BRACKET • GND-WIF

REAR CHASSIS GROUND WELD STUD • GND-S1
134 0-AP BK-5.0
132 DNS59 WBK-0.5 6
FRONT CHASSIS GROUND WELD STUD • GND-S2
SENSOR GROUND • GND-ENG6
DNS58 WR-0.5 5 ENGINE BLOCK NEAR OIL FILTER
6 DNS49 K-0.5 DNS57 WU-0.5 4
M M
5 DNS48 R-0.5 DNS56 WG-0.5 3
Not Used 2
DNS60 OR-0.5 1 SENSOR GROUND • GND-ENG7
M. LOCK070-PF M. LOCK070-PM ENGINE BLOCK NEAR OIL FILTER
KOSTAL
135 CONNECTION NEAR MOTOR/PUMP GROUND • GND-SSCHAS

NEAR AIC (WITHIN 4 INCHES) • GND-PDST1
DNS61 S-1.0 1
DNS62 GBK-1.5 2
DNS63 LUBK-1.5 3
CONNECTION NEAR SS MODULE GROUND • GND-SSMOD
DNS64 LUR-1.5 4
REAR CHASSIS BELOW CAB • GND-FC
Not Used 5
ENGINE BLOCK NEAR STARTER • GND-ENG3
S3-S RIGHT-HAND CONSOLE • GND-CAB3D

DNS65 UR-2.5
M
DNS66 BK-2.5
DNS67 G-0.5
DNS76 OR-0.5
DNS69 YBK-0.5
S2-S 136 GND-ENG2
ENGINE BLOCK NEAR STARTER
DNS77 Y-0.5
1 2 3 4 DNS-HVAC 1-S
22-8 1 137 RIGHT CONSOLE • GND-CAB3

GND-GH1
ENGINE BLOCK
S1-S
DNS75 BK-2.5 NEAR GRID HEATER
DNS74 LU-2.5 DNS67 G-0.5
2 1 DNS-HVAC 2-S S4-S
DNS78 Y-0.5 DNS78 Y-0.5 GND-ENG4
ENGINE BLOCK NEAR STARTER GND-CAB6
DNS63 LUBK-1.5
DNS51 ORW-0.5
DNS62 GBK-1.5
DNS69 YBK-0.5
DNS72 OR-0.5
22-10 2
DNS73 UR-2.5
DNS70 BK-0.5
DNS71 BK-0.5
DNS74 LU-2.5
RIGHT-HAND CONSOLE
DNS55 U-0.5
DNS53 N-0.5
DNS54 S-0.5
DNS61 S-1.0
CLOSED ABOVE 5 ±1 C°
DNS68 Y-0.5
OPEN BELOW 0 ±1 C°
Not Used
Not Used
Not Used
Not Used
GND-ENG1
1 2 3 4 5 1 2 3 4 2 1 1 2 3 4 5 ENGINE BLOCK
0 1 2 3 4 NEAR STARTER
0-BAG-N BK-1.0
0-DAV BK-0.8
142
0-BAR BK-1.0
0-BAR BK-1.0
0-BAC BK-2.0
0-BAE BK-1.0
0-ES BK-19.0
0-BW BK-2.0
0-B13 BK-1.0
0-B10 BK-1.0
0-DQ BK-0.8
0-GB BK-1.0
0-DP BK-0.8
0-BX BK-2.0
0-DY BK-1.0
138 139
0-DR BK-1.0
0-BG BK-0.8
0-EQ BK-0.8
0-AG BK-2.0
0-BM BK-1.0
0-DG BK-1.0
0-DS BK-1.0
0-BH BK-0.8
0-ER BK-1.0
0-ED BK-3.0
0-BU BK-1.0
0-DA BK-0.8
0-BK BK-1.0
0-AB BK-1.0
0-AK BK-1.0
0-BP BK-1.0
0-CE BK-1.0
0-EK BK-1.0
0-DV BK-3.0
0-B6 BK-1.0
0-BZ BK-1.0
0-EJ BK-1.0
0-BJ BK-0.8
0-EL BK-1.0
0-ND BK-62
140
141
FRAME 23 CASE ONLY NH ONLY FRAME 24

BC08B245-23A BC08B245-24A
COMPONENTS
FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS
16 - 104. Front Wiper High Speed Relay 23 - 132. Actuator

16 - 105. Wiper Cutout Relay 23 - 133. Driver
16 - 106. Front Wiper Low Speed Relay 23 - 134. Electronic Water Valve
16 - 107. Rear Wiper and Washer Switch 23 - 135. Blower Fan Resistor
16 - 108. Front Wiper and Washer Switch 23 - 136. Blower Motor
16 - 109. Front Wiper Motor 23 - 137. Thermostat
16 - 110. Front Wiper Motor 23 - 138. Fan Speed Switch
16 - 111. Rear Washer Motor 23 - 139. Air Conditioning Switch
16 - 112. Rear Washer Motor 23 - 140. Control Panel Lamps
16 - 113. Diodes 23 - 141. Water Valve Potentiometer
23 - 142. Air Recirculating Switch
17 - 114. Secondary Steering Diodes
17 - 115. Secondary Steering Solenoid
17 - 116. Secondary Steering Module
17 - 117. Secondary Steering Motor
17 - 118. Secondary Steering Pressure Switch
18 - 119. Diagnostic Connector
19 - 120. Power Relay Module E

19 - 121. Power Converter - 24 to 12 Volt
19 - 122. 12 Volt Power Outlets (Option)
19 - 123. Radio
19 - 124. Right Speaker
19 - 125. Left Speaker
20 - 126. Air Seat
21 - 127. Cigar Lighter
22 - 128. Air Conditioning Fan Control

22 - 129. Air Conditioning Clutch Relay
22 - 130. Air Conditioning High-Low Pressure
Switch
22 - 131. Air Conditioning Compressor Clutch
CIRCUIT DIAGRAM LEGEND WIRE IDENTIFICATION NOTES

Frame and Wire Tag WIRE TAGS
FEMALE MALE BK . BLACK 702A G-1.0 NOTE 1: Electrical Center C - Power Stud ELECTRICAL SCHEMATIC
NOTE 2: Indicates Modulated and Current Controller.
SPL-00 Number where circuit
continues.
00-0 1
1 00-0 MALE FEMALE INDICATES INDICATES
CONNECTOR
1 1
CONNECTOR DU . DARK BLUE
G. . . GREEN
WIRE NUMBER
WIRE COLOR
WIRE SIZE
NOTE 3: Disconnect when Backup Alarm Disable Switch is installed. Applicable only on TUV Road Approved Machines.
521E WHEEL LOADER
TERMINAL TERMINAL EXTERNAL INTERNALLY INDICATES PARTIAL
FRAME - WIRE WIRE 54 GROUND GROUNDED
CONNECTOR 2 2
3 3 4 4
CONNECTOR K . . . PINK OR . ORANGE T . . TAN
NUMBER LG. . LIGHT GREEN P . . . PURPLE (Violet) U . . . BLUE
SHOWS CIRCUIT SHOWS COMPONENT 45E 45D
RELAY REAR
18 18 NOT ALL
Wire Tag assigned to wire in Frame. 27 27
LU . . LIGHT BLUE
CROSSING CIRCUIT SPLICE COMPONENT GROUND CONNECTOR CONNECTIONS R . . . RED W . . WHITE
NOT CONNECTED CONNECTION CIRCUIT CONTINUATION NUMBER IDENTIFICATION ARE SHOWN N . . . BROWN S . . . GREY Y . . . YELLOW
Copyright ©
MAIN HYDRAULIC PUMP AND RESERVOIR PILOT CONTROLS EQUIPMENT VALVE EQUIPMENT VALVE CYLINDERS STEERING
N.O. 47
7 F3-C7 C3
a1 BUCKET CYLINDERS - XT MODELS
7A C1 F11-C4 C9 F5-C2 C10 F2-C5 F5-C3 C11 C1 F2-C7 C2 F2-C9
C2 F1-C2 C8 F5-C1 F5-C6 C12
6 10 a2 a3 a4
C3 F11-C3 C7 F2-C3 8M 8M 8M
P 9 8N 8P 8S 15
SX LS S a1 A1 B1 A2 B2 A3 B3 A4 B4
7B 8 11
C1 F12-C1 8G 8G 8G 8G
C1 F3-C8
F3-C4 C1 12
C2 F3-C9
Ø1.8 MP
3 b1
B F3-C13 C4
T 8R
6 F3-C10 C5
F3-C6 C3
a2 8A
F6-C3 C4 P
C4 F1-C1
3A F8-C2 C5
5
F10-C1 C6 8B BUCKET CYLINDER - Z-BAR and XR MODELS L R
F11-C1 C7 7C 16
F12-C2 C8
C1 F3-C8
X C2 F3-C5
S
F3-C2 C2 4 C5 F2-C2
8F
C2 F3-C9 13
2
3B b2 8D
F3-C14 C6
8E 16A
8C
F4-C1 C7 T
3C a3 C6 F1-C3 16B
LIFT CYLINDERS
7D 8H
8H 8L
8K 8J 8J 8J 8J 14
b3 8J
3D F4-C3 C8 C3 F3-C11
SEE NOTE 1
F4-C2 C9
C4 F10-C3 16C
a4
S L1 L
b1 P LS T
1
7E C13 F2-C4 C5 F10-C2
1 b2 8M b3 8M b4 8M
C6 F3-C12 17
C1 F11-C5 F11-C2 C2
C14 F2-C6 C3 F2-C8 C4 F2-C10
b4 F4-C4 C10
F1-C4 C3
SEE NOTE 2
BRAKES HYDRAULIC OIL COOLER AND FAN DRIVE MOTOR FAN REVERSING VALVE RIDE CONTROL AUXILIARY STEERING COUPLER LOCKING CYLINDERS AND VALVE
(OPTIONAL) (OPTIONAL) (OPTIONAL) (OPTIONAL)
24 25
27 28
C3 F3-C3
44
22 23 26
S3 S1 DS2 36 F3-C1 C4
C2 F6-C2 F6-C1 C5
45
Ø0.60 39
23A
Ø1.20 23F M2 P 41 MX
F7-C1 C1
M2 42 LS EF CF
BR3 39C
P 40 41B
P 38 41C
21 39B 41A
35 39A
36A 37
LOCK
UNLOCK
23B
37A X2 A
F5-C5 C2
PP
23E
BR1 C1 F1-C6 F5-C4 C3
42A
23D 2.2 Ø= T B
20 4.5 l/m
29 41D
39D 42B
23C 39B
19
M1 T
T 46
M1 T P
BR2
34 F1-C5 C2
C1 F1-C7
DS1 37B SEE NOTE 3

43
18 S2 T N
30 31 33 F8-C1 C1
C1 F2-C1 F1-C8 C2
1 1 1
32

COMPONENTS
FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS
FRAME 1 COMPONENTS FRAME 3 COMPONENTS FRAME 5 COMPONENTS FRAME 7 COMPONENTS 7- 31. Redundant Brake Pressure Switch
1 - 1. Hydraulic Reservoir 3 - 8. Equipment Valve: 2-spool 5- 12. Bucket Cylinders 7- 1. Hydraulic Reservoir (NO, Closes at 62 Bar/900 psi) FRAME 10 COMPONENTS
1 - 2. Breather - Hydraulic Reservoir 3 - 8A. Steering Pressure Relief Bore: 101.6 mm (4.00 in) 7- 18 Rear Brakes 7- 32. Rear Axle Accumulator 10 - 40. Ride Control Accumulator
Check Valve (0.03 Bar/0.43 PSI) (217 Bar/3147 psi) Rod: 57.2 mm (2.25 in) Modulation Pressure: Pre-charge (55 Bar/800 psi) Pre-charge (14.5 Bar/210.3 psi)
Relief Valve (0.35 Bar/5.07 PSI) 3 - 8B. Pilot Pressure Reducing Valve Stroke: 758.2 mm (29.85 in) (59 to 64 Bar/855.5 to 928 psi) Capacity (2.8 liter/170.8 cu/in) Capacity (3.78 liter/231 cu/in)
1 - 3. Implement Hydraulic Pump (30 Bar/435 psi) 5- 13. Bucket Cylinder 7- 19. Rear Brake Pressure Test Port 7- 33. Rear Accumulator Test Port 10 - 41. Ride Control Valve
Displacement ( 71 cc rev/4.3 cu in rev) 3 - 8C. Pilot Pressure Relief Bore: 114.3 mm (4.5 in) 7- 20. Front Brake Pressure Test Port 7- 34. Brake and Cooling Fan Pump 10 - 41A. Pressure Relief Valve
Cutoff (280 Bar/4061 psi) (45 Bar/653 psi) Rod: 63.5 mm (2.5 in) 7- 21. Front Brake 14cc/rev (0.85 cu/in) (280 BAR/4061 psi)
Delta (21 Bar/304 psi) 3 - 8D. Steering Priority Spool Stroke: 529.2 mm (20.84 in) Modulation Pressure: 10 - 41B. Manual Bleed Valve
1 - 3A. Compensator Differential Spool 3 - 8E. Loader Main Relief 5- 14. Lift Cylinders (62 to 68 Bar/899 to 986 psi) FRAME 8 COMPONENTS 10 - 41C. Ride Control Spool Valve
1 - 3B. Compensator High Pressure Cutoff (227 Bar/3292 psi) Bore: 101.6 mm (4.0 in) 7- 22. Parking Brake Cylinder 8- 1. Hydraulic Reservoir 10 - 41D. Ride Control Solenoid
Spool Rod: 57.2 mm (2.25 in) 7- 23. Brake Valve and Accumulator 8- 35. Fan Drive Motor
3 - 8F. Load Sense Bleed Down Orifice
1 - 3C. Torque Limiter (Disabled) Stroke: 783.0 mm (30.8 in) Charging Valve Displacement: 14 cc/rev (0.85 cu/in) FRAME 11 COMPONENTS
(0.7 L/min)
1. 3D Control Piston with Spring Cut-in Pressure: 8- 36. Fan Valve 11 - 1. Hydraulic Reservoir
3 - 8G. Flow Compensator Spool FRAME 6 COMPONENTS (157 to 167 Bar/2277 to 2422 psi) Fan Speed: 1650 ± 25 rpm 11 - 42. Auxiliary Steering Priority Valve
1 - 4. Hydraulic Filter Assembly 3 - 8H. Regeneration Check Valve
Bypass (3.4 Bar/50 psi) 6- 15. Steering Cylinders Cut-out Pressure: 8- 36A. Fan Relief Relief Pressure: (241 Bar/3495 psi)
3 - 8J. Circuit Relief Valve with Anti-Cavitation Bore: 63.5 mm (2.5 in) (190 to 196 Bar/2755 to 2843 psi) (197 Bar/2857 psi) 11 - 42A. Priority Spool
Warning Switch (2.7 Bar/40psi) (290 Bar/4206 psi) Rod: 34.93 mm (1.375 in) 7- 23A. Park Brake Solenoid 8- 37. Cooler Bypass Valve (Optional) 11 - 42B. Relief Valve (240 BAR/3480 psi)
3 - 8K. Circuit Relief Valve with Anti-Cavitation Stroke: 489.2 mm (19.25 in) 7- 23B. Front Brake Valve 8- 37A. Priority Valve 11 - 43. Auxiliary Steering Pump
FRAME 2 COMPONENTS (XT Models: 183 Bar/2654 psi) 6- 16. Steering Control Valve 7- 23C. Rear Brake Valve 8- 37B Relief Valve Displacement:
2 - 1. Hydraulic Reservoir (Z-Bar Models: 290 Bar/4206 psi) Displacement: 7- 23D. Accumulator Isolation Check Valve 3.0 ± 0.6 Bar/ 43.5 ± 8.7 psi 11 cc/rev (0.671 cu/in)
2 - 5. Pilot Pressure Accumulator 3 - 8L. Regeneration Relief Valve 460 cc/rev (28.07 cu in/rev) 7- 23E. Accumulator Charging Spool 8- 38. Hydraulic Cooler 11 - 44. Auxiliary Steering Load Sense Valve
Pre-charge (13.8 Bar /200 psi) (6.7 Bar/97 psi) 6- 16A. Circuit Relief Valve 7- 23F. Priority Spool
Capacity (0.95 liter/57.9 cu in) 3 - 8M. Shuttle Check Valve (290 Bar/4206 psi) 7- 24. Parking Brake Accumulator FRAME 9 COMPONENTS FRAME 11 COMPONENTS
2 - 6. Pilot Pressure Test Port 3 - 9. Load Sense Pressure Test Port 6- 16B. Gerotor Pump Pre-charge (97 Bar/1405 psi) 9 - 39. Fan Reversing Valve 12 - 45. Coupler Locking Cylinders
2 - 7. Controller (4-Spool Valve) 3 - 10. Steering Pressure Test Port 6- 16C. Steering Spool Capacity: 0.5 liter/30.5 cu/in) Fan Speed: 1650 ± 25 rpm 12 - 46. Coupler Locking Valve
2 - 7A. Pilot ON/OFF Solenoid 3 - 47. Auxiliary Steering Pressure Switch 6- 17. Back Pressure Valve 7- 25. Front Axle Accumulator 9- 39A. Fan Crossover Relief
2 - 7B. Bucket Control Closes At: 2.0 to 2.75 Bar (30-47 psi) (8-10 Bar/115-145 psi) Pre-charge (55 Bar (800 psi) (234 BAR/3394 psi)
2 - 7C. Lift Control Capacity (2.8 liter/170.8 cu/in) 9- 39B. Reversing Spools
2 - 7D. Auxiliary Control #1 FRAME 4 COMPONENTS 7- 26. Front Accumulator Test Port 9- 39C. Pulse Width Modulator (PWM) Relief
2 - 7E. Auxiliary Control #2 3 - 8G. Flow Compensator Spool 7- 27. Redundant Brake Pressure Switch Solenoid
3 - 8J. Circuit Relief Valve with Anti-Cavitation (NO, Closes at 62 Bar/900 psi) 9- 39D. ON/OFF Reverse Solenoid
(290 Bar/4206 psi) 7- 28. Low Brake Pressure Switch
4 - 8M. Shuttle Check Valve Rising (141 Bar/2045 psi)
4 - 8N. Auxiliary Valve #1 Falling (117 Bar/1697 psi)
4 - 8P. Auxiliary Valve #2 7- 29. Brake Declutch Switch
Adjustable Factory Setting:
4 - 8R. Pressure Differential Valve
(NC, Opens at 24 Bar/350 psi)
(40 Bar/580 psi)
7- 30. Brake Lamp Switch
4 - 8S. End Cover
(NO, Closes at 4.1 Bar/60 psi)
4 - 11. Pump Pressure Test Port
HYDRAULIC SYMBOLS CIRCUIT CONTINUATION NOTES

NOTE 1. Reverse Control Check Valve.
54 PRESSURE
Frame Number and Circuit
Number where Circuit
CIRCUIT TAGS
F4-C3 C10 Used with Ride Control equipped Models ONLY. HYDRAULIC SCHEMATIC
continues.
CHECK VALVE FILTER OR SCREEN CIRCUIT LOAD SENSE
C6 F1-C3
NOTE 2. Used for XT Model Machines ONLY. 521E WHEEL LOADER
36D FRAME - CIRCUIT CIRCUIT NOTE 3. This will replace Item 36 in Frame 8 when this Option is installed on machine.
SHOWS CIRCUIT SHOWS COMPONENT PILOT PRESSURE NOTE 4. See the Repair Manual for the proper Testing and Adjustment for Hydraulic
COMPONENT CROSSING CIRCUIT
RESTRICTOR Circuit Number assigned to Circuit in Frame.
Components.
NUMBER NOT CONNECTED CONNECTED OIL COOLER DIRECTION OF FLOW LINE TYPES

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Print No. 87728450 A - EU

Use for Repair Manual

521E Wheel Loader

Fuel System Tab 3

Copyright © 2008 CNH Italia S.p.A.

521E Wheel Loader

Copyright © 2008 CNH Italia S.p.A.

521E Wheel Loader

Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear Pocket

Copyright © 2008 CNH Italia S.p.A.

Section Title Section Number

Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001

Copyright © 2008 CNH Italia S.p.A.

GENERAL TORQUE SPECIFICATIONS

Copyright © 2008 CNH Italia S.p.A.

87728450 A - EU Issued 4-08 Printed in E.C.

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Pound- Newton Pound- Newton

87728450 A - EU Issued 4-08 Printed in E.C.

TORQUE SPECIFICATIONS - METRIC HARDWARE

M6 96 to 108 11 to 12 M12 93 to 112 125 to 150

M8 228 to 276 26 to 31 M14 149 to 179 200 to 245

M10 456 to 540 52 to 61 M16 230 to 280 310 to 380

Pound- Newton M24 780 to 940 1050 to 1275

87728450 A - EU Issued 4-08 Printed in E.C.

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

37 Degree Flare Fitting Straight Threads with O-ring

Split Flange Mounting Bolts

87728450 A - EU Issued 4-08 Printed in E.C.

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

O-ring Boss End

Thread Pound- Newton

Nom. 1-1/16-12 85 to 90 115 to 122

87728450 A - EU Issued 4-08 Printed in E.C.

FLUIDS AND LUBRICANTS

Copyright © 2008 CNH Italia S.p.A.

87728450 A - EU Issued 4-08 Printed in E.C.

CAPACITIES AND LUBRICANTS

87728450 A - EU Issued 4-08 Printed in E.C.

ENGINE OIL RECOMMENDATIONS

87728450 A - EU Issued 4-08 Printed in E.C.

TRANMISSION TEMPERATURE CHART

HYDRAULIC/BRAKE SYSTEM TEMPERATURE CHART

87728450 A - EU Issued 4-08 Printed in E.C.

DIESEL FUEL SYSTEM

The diesel fuel used in this machine must meet the

Specifications for Acceptable No. 2 Diesel Fuel

87728450 A - EU Issued 4-08 Printed in E.C.

87728450 A - EU Issued 4-08 Printed in E.C.

87728450 A - EU Issued 4-08 Printed in E.C.

Copyright © 2008 CNH Italia S.p.A.

87728450 A - EU Issued 4-08 Printed in E.C.

Area: sq. meter 10.763 91 square foot

Force: newton 3.596 942 ounce force

Length: millimeter 0.039 370 inch

Mass: kilogram 2.204 622 pound

Mass/Area: kilogram/hectare 0.000 466 ton/acre

Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.