Professional Documents
Culture Documents
Models
G10-55A
G12-55A
3126019
Revised
January 5, 2011
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4 Fluid and Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5 Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Section 3
Boom ........................................................... 3-1
3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Boom System - Four Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Complete Boom Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.5 Boom Section Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.6 Extend/Retract Chain Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.7 Boom Section Separation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.8 Hose Carrier Assembly Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.9 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.10 Boom Head - Mounted Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.11 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.12 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.13 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator’s Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
G10-55A, G12-55A i
Section Subject Page
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.7 Towing a Disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Section 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Transmission Specifications And Maintenance Information. . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5 Torque Convertor Diaphragm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Section 7
Engine ........................................................... 7-1
7.1 Introduction - John Deere. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Introduction - Perkins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Introduction - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.6 Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.7 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.8 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.3 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.6 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
ii G10-55A, G12-55A
Section Subject Page
iv G10-55A, G12-55A
Section 1
Safety Practices
Contents
1.6.4 Operational Hazards PRESSURE TESTING: When conducting any test, only
use test equipment that is correctly calibrated and in good
ENGINE: Stop the engine before performing any service
condition. Use the correct equipment in the proper
unless specifically instructed otherwise.
manner, and make changes or repairs as indicated by the
VENTILATION: Avoid prolonged engine operation in test procedure to achieve the desired result.
enclosed areas without adequate ventilation.
LEAVING MACHINE: Lower the forks or attachment to
SOFT SURFACES AND SLOPES: NEVER work on a the ground before leaving the machine.
machine that is parked on a soft surface or slope. The
TIRES: Always keep tires inflated to the proper pressure
machine must be on a hard level surface, with the wheels
to help prevent tipover. DO NOT over-inflate tires.
blocked before performing any service.
NEVER use mismatched tire types, sizes or ply ratings.
FLUID TEMPERATURE: NEVER work on a machine
Always use matched sets according to machine
when the engine, cooling or hydraulic systems are hot.
specifications.
Hot components and fluids can cause severe burns.
Allow systems to cool before proceeding. MAJOR COMPONENTS: Never alter, remove, or
substitute any items such as counterweights, tires,
FLUID PRESSURE: Before loosening any hydraulic or
batteries or other items that may reduce or affect the
diesel fuel component, hose or tube, turn the engine
overall weight or stability of the machine.
OFF. Wear heavy, protective gloves and eye protection.
NEVER check for leaks using any part of your body; use BATTERY: DO NOT charge a frozen battery.Charging a
a piece of cardboard or wood instead. If injured, seek frozen battery may cause it to explode. Allow the battery
medical attention immediately. Diesel fluid leaking under to thaw before jump-starting or connecting a battery
pressure can explode. Hydraulic fluid and diesel fuel charger.
leaking under pressure can penetrate the skin, cause
infection, gangrene and other serious personal injury. 1.7 SAFETY DECALS
Relieve all pressure before disconnecting any
Check that all safety decals are present and readable on
component, part, line or hose. Slowly loosen parts and
the machine. Refer to the Operation & Safety Manual
allow release of residual pressure before removing any
supplied with machine for information.
part or component. Before starting the engine or applying
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly and are
tightened to the proper torque. Capture fluid in an
appropriate container and dispose of in accordance with
prevailing environmental regulations.
RADIATOR CAP: The cooling system is under pressure,
and escaping coolant can cause severe burns and eye
injury. To prevent personal injury, NEVER remove the
radiator cap while the cooling system is hot. Wear safety
glasses. Turn the radiator cap to the first stop and allow
pressure to escape before removing the cap completely.
Failure to follow the safety practices could result in death
or serious injury.
FLUID FLAMABILTITY: DO NOT service the fuel or
hydraulic systems near an open flame, sparks or smoking
materials.
NEVER drain or store fluids in an open container. Engine
fuel and hydraulic fluid are flammable and can cause a
fire and/or explosion.
DO NOT mix gasoline or alcohol with diesel fuel. The
mixture can cause an explosion.
Contents
1 MY1000
Torque
Torque Torque Loctite®
Tensile
Clamp Torque Loctite® 262™ 242™ or 271™
Size PITCH Stress (Dry or Loctite®
Load (Lub) OR OR
Area 263TM) Vibra-TITE™ 131 Vibra-TITE™
111 or 140
Torque
Lube OR Loctite® Torque
Tensile Torque Dry 242™ or 271™
Clamp or Loctite® 262™
Size PITCH Stress OR OR
Load Loctite® 263™
Area Vibra-TITE™ Vibra-TITE™ 131
111 or 140
K = 0.20 K= 0.18 K=0.15
Magni Coating*
Torque
Lube OR Loctite® Torque
Tensile Torque Dry 242™ or 271™ Loctite® 262™
Clamp Load or
Size PITCH Stress OR OR
See Note 4 Loctite® 263™ Vibra-TITE™ Vibra-TITE™ 131
Area
111 or 140
K = .17 K = .16 K = .15
3 0.5 5.03
3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
2.3 SPECIFICATIONS
Battery
Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free
Quantity 1
Reserve Capacity 1,000 Cold Cranking Amps @ 0° F (-18° C)
Group/Series Group 31
Alternator 12V, 95 Amps
2.3.7 Tires
Note: Standard wheel lug nut torque is 350-400 lb-ft (475-542 Nm).
Note: Pressure for foam filled tires are for initial fill ONLY.
a. G10-55A
b. G12-55A
Hydraulic System
System Capacity
G10-55A 63 gallons (238 liters)
G12-55A 65 gallons (246 liters)
Reservoir Capacity 38 gallons (144 liters)
Type of Fluid
0° to 104° F (-20° to 40° C) Mobilfluid 424® Tractor Hydraulic Fluid
-40° to 0° F (-40° to 20° C) Exon Univis HVl All Season Hyd Fluid
Auxiliary Hydraulic Circuit Max Flow 10 gpm (37,9 lpm)
Transmission
Capacity with Filter Change 4 gallons (16 liters)
Type of Fluid
0° to 104° F (-20° to 40° C) Mobilfluid 424® Tractor Hydraulic Fluid
-40° to 0° F (-40° to 20° C) Mobilfluid LT® Hydraulic Fluid (75W-80)
Transfer Case
Capacity 1.5 quarts (1,4 liters)
Type of Fluid
0° to 104° F (-20° to 40° C) Mobilfluid 424® Tractor Hydraulic Fluid
-40° to 0° F (-40° to 20° C) Mobilfluid LT® Hydraulic Fluid (75W-80)
Axles
Differential Housing Capacity
Front 15.8 quarts (15 liters)
Rear 16.9 quarts (16 liters)
Wheel End Capacity 2 quarts (1,9 liters)
Type of Fluid
0° to 104° F (-20° to 40° C) Mobilfluid 424® Tractor Hydraulic Fluid
-40° to 0° F (-40° to 20° C) Mobilfluid LT® Hydraulic Fluid (75W-80)
Air Conditioning System (if equipped)
System Capacity 2.5 lb (1134 g)
Type of Fluid Refrigerant R-134a - Tetrafluorethane
EVERY
10
Check Fuel Air Filter Check Engine Check Hydraulic Check Tire
Level Restriction Oil Level Oil Level Condition &
Indicator Pressure
1st
50
LB/F
T (N
m)
Check Wheel
Lug Nut
Torque
EVERY
50
1st
250
EVERY
250
Change Engine Oil Check Axle Check Wheel Air Filter Check
and Filter* (Before Oil Level End Oil Levels Vacuator Fan Belt
S/N 0160039451) Valve
EVERY
500
LB/F
T (N
m)
MY4750
Note: Engine oil & filter service interval can be extended. See Engine Manual for details.
EVERY
1000
EVERY
1500
a. 50 Hour
EVERY
50
OAL0450
b. 250 Hour
EVERY
250
OW1211
c. 1000 Hour
EVERY
1000
OY2080
Contents
THIRD
EXTEND
BOOM
CHAINS
SECTION
FOURTH BOOM
SECTION
SECOND BOOM
SECTION FIRST
BOOM
SECTION
AUXILIARY
HYDRAULIC
CONNECTIONS
TILT CYLINDER
QUICK SWITCH
HOSE CARRIER
ASSEMBLY
(INSIDE BOOM)
EXTEND/RETRACT RETRACT
CYLINDER CHAINS
(UNDERSIDE OF BOOM)
HOSE
PIVOT PIN SHEAVE
MY0101
WARNING
NEVER weld or drill the boom unless approved in
writing by the manufacturer. The structural integrity of
the boom will be impaired if subjected to any repair
involving welding or drilling.
3.4 COMPLETE BOOM REMOVAL/ the park brake, chock the wheels and shut the
INSTALLATION engine OFF.
2. Using suitable slings, balance the boom assembly,
lift and carefully guide the boom into place. Align the
3.4.1 Complete Boom Removal
frame pivot bore with the boom assembly pivot bore.
1. Remove any attachment from the quick switch
3. Install the boom pivot pin.
assembly. Refer to the appropriate operation and
safety manual. 4. With the sling still in place, install the compensation
cylinder, pins and bolts.
2. Remove the quick switch assembly. Refer to Section
3.9.1, “Quick Switch Removal.” 5. With the sling still in place, install the rod end of the
left lift/lower cylinder, pin and lock bolt. Repeat for
3. If equipped, remove the Boom Head Mounted
the right side lift/lower cylinder.
Winch. Refer to Section 3.10.1, “Boom Head-
Mounted Winch Removal.” Note: Raising the boom up or down with the sling may
4. Park the machine on a hard, level surface, level the be necessary so the boom, compensation and lift/lower
machine, fully retract the boom, raise the boom, cylinder bores can be aligned for easier pin installation.
place the transmission control lever in Note: Grease the boom pivot bore, compensation
(N) NEUTRAL, engage the park brake and shut the cylinder rod ends, lift/lower cylinder rod end and pins
engine OFF. before installing.
5. Place a Do Not Operate Tag on both the ignition key 6. Uncap and reconnect the previously labeled
switch and the steering wheel, stating that the hydraulic hoses to the extend/retract cylinder.
machine should not be operated.
7. Uncap and connect any remaining hydraulic fittings
6. Open the engine cover. Allow the system fluids to to their appropriate locations.
cool.
8. Recheck the wear pad gaps to ensure they meet the
7. Properly disconnect the battery. minimum gap requirement. Shim if necessary.
8. Support the front of the boom by placing a sling 9. Ensure that the boom chains are properly adjusted.
behind the boom head. Refer to Section 3.7, “Boom Section Separation
9. Label, disconnect and cap all hydraulic hoses for the Adjustment.”
extend/retract and tilt circuits. Cap all fittings and 10. Properly connect the battery.
openings to keep dirt & debris from entering the
hydraulic system. 11. Start the engine and operate all boom functions
several times. Check for leaks, and check the
10. Support the lift/lower cylinder on the left side of the hydraulic fluid level in the reservoir; add fluid if
machine. Remove the lock bolt and rod end pin. required.
Lower the lift/lower cylinder onto the frame rails.
Repeat this step for the right side lift/lower cylinder. 12. Install the quick switch assembly. Refer to Section
3.9.2, “Quick Switch Installation.”
11. Support the compensation cylinder. Remove the lock
bolt and rod end pin. Lower the compensation 13. If equipped, install the Boom Head Mounted Winch.
cylinder onto the frame rails. Refer to Section 3.10.2, “Boom Head-Mounted
Winch Installation.”
12. Lower the boom to a level position and place a
suitable support under the boom head. Reposition 14. Clean up all debris, hydraulic fluid, etc., in, on, near
the slings to each end of the boom. and around the machine.
13. Remove the bolt securing the boom pivot pin. Pull 15. Close and secure the engine cover.
out the boom pivot pin. 16. Remove the Do Not Operate Tags from both the
14. Lift the complete boom off machine and set on level ignition key switch and the steering wheel.
ground or supports. 17. Install the previously remove attachment to the quick
switch assembly. Refer to the appropriate operation
3.4.2 Complete Boom Installation and safety manual.
1. Park the machine on a hard, level surface, place the
transmission control lever in (N) NEUTRAL, engage
3.5 BOOM SECTION REMOVAL/ 8. Using a suitable lifting device, secure the tilt cylinder
INSTALLATION barrel with a nylon strap.
9. Remove both retaining clips (4) from each side of
the tilt cylinder mounting pin (5).
3.5.1 Second, Third & Fourth Boom Section
Removal 10. Remove the tilt cylinder mounting pin (5).
1. Remove any attachment from the quick switch 11. Lower tilt cylinder from the boom head.
assembly. Refer to the appropriate operation and 12. Support the front of the boom by placing a sling
safety manual. behind the boom head.
2. Remove the quick switch assembly. Refer to Section
3.9.1, “Quick Switch Removal.”
3. If equipped, remove the Boom Head Mounted
Winch. Refer to Section 3.10.1, “Boom Head-
Mounted Winch Removal.”
4. Park the machine on a hard, level surface, level the
machine, fully retract the boom, level the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF. 6 7 8 MY4130
5. Place a Do Not Operate Tag on both the ignition key 13. Loosen the jam nut and lock nut (6) to release
switch and the steering wheel, stating that the tension from the hoses on the hose take-up
machine should not be operated. weldment (7).
6. Open the engine cover. Allow the system fluids to 14. Loosen the hydraulic hoses (8) and electrical cables
cool. if equipped on the hose take-up weldment (7). Plug
3 the hose ends and tube ends to prevent dirt and
debris from entering the hydraulic system.
13 12 11 10 9
4
5
MY3580
2 15. At the top front of the boom, measure and note the
distance from the end of the three extend chain
clevises (9) to the face of the lock nut (10).
16. Loosen and remove the lock nuts (10), adjusting
nuts (11), washers (12) and springs (13) from the
three extend chain clevises (9).
MY3770
21
19
14
24
9
22
23
23
20
MY3540
MY3440
25. Remove the adjusting nut and lock nut (19), retract
17. Pull the three extend chain clevises (9) off of each chain & clevis (20), spring stop (21) and spring (22).
chain roller (14) and lay each assembly on the third Loosen bolts (23) and adjusting block (24).
and fourth boom sections respectively.
26. Properly disconnect the battery.
Note: It may be necessary to remove the extend chain
rollers to help in the removal of the top wear pads. 30 30
31 31
18. Verify all fittings, tubes and hoses are properly
capped and /or plugged. 27
26
19. Extend the second boom section to access the 28
retract chain adjusting block. 32 29
25 25
MY3420
MY4120
17 18 15 16 27. At the rear of the boom, remove both hose sheave
covers (25).
20. Remove the extend/retract cylinder support (15)
28. Unbolt the hose carrier bracket (26) from the rear of
from the front of the first boom section.
the second boom section and the hose carrier.
21. Support the extend/retract cylinder (16) with a
29. Pull the hose carrier (27) back to gain access to the
suitable sling.
tilt hose (28) and the auxiliary hose (29)
22. Remove the retaining clips (17) from each side of connections.
the extend/retract cylinder rod.
30. Disconnect the tilt hoses, auxiliary hoses and if
23. Remove the extend/retract cylinder rod mounting pin equipped, the electrical connector at the rear of the
(18). hose carrier. Label, plug and cap all hydraulic
24. Lower the front of the extend/retract cylinder to a connections to prevent dirt and debris from entering
secured block on top of the frame. Do Not use the the hydraulic system.
engine hood for support. 31. Push hose carrier (27) as far forward as possible.
Note: Tag each wear pad, spacer, shim and hardware
from each location. Note the location of any grease fitting
(if equipped) on each wear pad.
32. Remove the top rear wear pads, spacers, shims and 3.5.2 Third & Fourth Boom Section
hardware (30) from the rear of the second boom Removal
section. 1 1
33. Remove the left (or right) side rear wear pad, spacer, 2
2
shims and hardware (31) from the rear of the second
boom section.
34. Pull each boom section slightly forward to relieve the
tension in retract chain (32).
35. Remove the snap rings and pin connecting the rear
retract chain (32) from the chain clevis at the rear of
the boom. Allow chain to hang out over the rear of
the boom. 2 2
36. Place a sling around the second boom section. With
a suitable lifting device, slowly pull the second, third
and fourth boom sections approximately 25% out of MY4150
MY4140
37. With the second, third and fourth boom section still
connected to a suitable lifting device, remove all
wear pads, spacers, shims, and hardware (28) from
the front sides of the first boom section.
38. Remove both wear pads, spacers, shims, blocks
and hardware (29) from the front top of the first
boom section.
39. Remove both wear pads, spacers, shims and
hardware (30) from the front bottom of the first boom
section.
MY3590
40. Adjust sling(s) around the second boom section to
help balance the second, third and fourth boom 4. Pull each boom section slightly forward to relieve the
sections. tension on the retract chain (3).
41. Remove the remainder of the second, third and 5. Remove the snap rings and pin connecting the rear
fourth boom sections from the first boom section and retract chain (3) from the chain clevis at the rear of
set on suitable supports. the boom. Allow chain to hang out over the rear of
the boom.
6. Place a sling around the third boom section. With a 3.5.3 Fourth Boom Section Removal
suitable lifting device, slowly pull the third and fourth
1. Place a sling around the fourth boom section and
boom sections approximately 25% out of the second
slowly pull the fourth boom section approximately
boom section.
25% out of the third boom section. Lower the fourth
section boom head onto a suitable support.
5 5
9 9
4 4
8 8
4 4
8 8
6 6
7
MY3450 9 9
7. With the third and fourth boom section still 10
MY3510
connected to a suitable lifting device, remove all
wear pads, spacers, shims, and hardware (4) from 2. With the fourth boom section still connected to a
the front sides of the second boom section. suitable lifting device, remove all wear pads,
spacers, shims, and hardware (8) from the front
8. Remove both wear pads, spacers, shims, blocks
sides of the third boom section.
and hardware (5) from the front top of the second
boom section. 3. Remove top and bottom front wear pads, shims and
blocks (9) from the third boom section.
9. Remove both wear pads, spacers, shims and
hardware (6) from the front bottom of the second 4. Loosen and remove the wear pad support plate (10)
boom section. from the bottom front of the third boom section.
10. Loosen and remove the wear pad support plate (7) 5. Adjust the sling(s) around the fourth boom section
from the bottom front of the second boom section. for stability. Balance the fourth boom section and
slowly pull the fourth boom section out of the third
11. Adjust sling(s) around the third boom section to help
boom section being careful not to damage any
balance the third and fourth boom sections.
surrounding components.
12. Remove the remainder of the third and fourth boom
6. Lower the fourth boom section onto a suitable
sections from the second boom section and set on
support.
suitable supports.
11
12
13
13
MY3630
MY3470
2. Install the previously removed extend chain
1. Remove the guide bracket (11) at the front of the assembly and clevis (1) at the top rear of the fourth
hose carrier (12). Reuse the existing hardware. boom section. Allow 0.250 in (6,35 mm)(C) between
the end of the clevis (1) and the face of the lock nut
2. Loosen and remove the front two mounting bolts (13) (2). Torque lock nut to 100 lb-ft (135 Nm).
holding the hose carrier in place. Tag all hardware.
5 5
3. Remove the hose carrier through the front of the
fourth boom section.
4. When the hose carrier is approximately 25% free of 4 4
the fourth boom section, fasten the two hose carriers
together (using nylon tie-wraps or nylon straps) to
prevent separation.
5. Continue to remove the hose carrier, fastening the
hose carriers together as they are being removed.
6. When the hose carrier is approximately 75% tied
together, pull the assembly free of the boom section.
7. Lower the hose carrier onto a suitable support. 3 3
MY3490
6 MY3610
13 FRONT OF BOOM
MY3480
9. Install the previously removed hose carrier guide
1. Inspect the hose carrier track (6) for any broken or bracket (13). Torque as required.
missing clips. Repair or replace as needed.
10. Install the hose carrier (14) into the front of the fourth
2. Remove the caps from the tubes on the hose carrier. boom section. Remove each nylon tie or nylon strap
10 as the hose carrier is installed.
11
11. Align the hose carrier (14) to the hose carrier guide
bracket (13).
8
7 9
12 12
15
MY3750
MY3470
Note: Connect the tilt cylinder hoses and the auxiliary
hoses to the hose carrier bulkhead before installing the 12. Align the hose carrier mounting bracket and install
hose carrier in the fourth boom section. the previously removed hardware to mounting
bracket at the front of the fourth boom section (15).
3. Install tilt cylinder hose (7) to the bottom left fitting on Torque as required.
the hose carrier tube (8).
4. Install tilt cylinder hose (9) to the top left fitting on the
hose carrier tube (10).
5. Install adaptors (11) to each auxiliary tube at the
front right of the hose carrier.
6. Install auxiliary hoses (12) to each adaptor (11) no
the auxiliary tubes at the front right of the hose
carrier.
7. Orient each auxiliary hose (12) as shown above.
8. Torque each fitting and hose as required.
MY3630
4 4
2 2 7. Install the previously removed extend chain
assemblies and clevises (5) at the top rear of the
third boom section. Allow 0.250 in (6,35 mm)
between the end of the clevis (5) and the face of the
lock nut (6). Torque lock nut to 100 lb-ft (135 Nm).
1
3.5.8 Fourth Boom Section Installation
Note: Using a straight bar approximately 40 in
(1041 mm) long will aid in the installation of the wear
pads located on the inside front of each boom section.
3 3 1. Clean and lubricate the bottom of the fourth boom
MY3500 section where the wear pads of the third boom
2. Install the previously removed chain roller (1) at the section contact the fourth boom section.
rear of the third boom section. Insert the mounting 2. Place the sling, or two slings for better stability,
pin, retainer plate and hardware. Torque as required. around the fourth boom section and slowly insert the
3. Install the previously removed wear pads and fourth boom section into the third boom section
spacers (2) at each side rear of the third boom being careful not to damage any surrounding
section. Snug mounting bolts. Shim as needed components.
AFTER all boom sections are installed to maintain a
0.070 - 0.130 in (1,78 - 3,30 mm) gap between the
boom sections.
14 14
MY3510 15 15
0.070 - 0.130 in (1,78 - 3,30 mm) gap between the 2. Install the previously removed chain roller (13) at the
boom sections. rear of the second boom section. Insert the mounting
pin, retainer plate and hardware. Torque as required.
3. Install the previously removed wear pads and
spacers (14) at the top rear of the second boom
section. Snug mounting bolts. Shim as needed
AFTER all boom sections are installed to maintain a
0.070 - 0.130 in (1,78 - 3,30 mm) gap between the
boom sections.
9
4. Install the previously removed wear pads and
spacers (15) at each side rear of the second boom
section. Snug mounting bolts. Shim as needed
AFTER all boom sections are installed to maintain a
0.070 - 0.130 in (1,78 - 3,30 mm) gap between the
11 11 boom sections.
5. Install the previously removed wear pads and
MY3510
spacers (16) at the bottom rear of the second boom
12 10 10 12 section. Snug mounting bolts. Shim as needed
AFTER all boom sections are installed to maintain a
5. Install the previously removed wear pad support (9) 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the
at the front inside of the third boom section. Use the boom sections.
previously removed hardened washers and bolts
6. Shims may be required to maintain a 0.070 - 0.130
(10). Torque as required.
in (1,78 - 3,30 mm) gap at the top rear of the second
boom section
G10-55A, G12-55A 3-13
Boom
3.5.10 Third & Fourth Boom Section 6. Retract the second boom section pulling both retract
Installation chains at the same time.
Note: Refer to Section 2.2, “Torque Charts,” for
standard bolt torque information.
25 25
Note: Refer to Section 2.2.3, “Hydraulic Hose Torque
Chart,” for standard hose torque information.
26 26
Note: Apply Loctite® 242 to all boom assembly bolts.
Note: Using a straight bar approximately 40 in
(1041 mm) long will aid in the installation of the wear
pads located on the inside front of each boom section.
1. Place the sling or using two slings for better stability,
around the third boom section and slowly insert the
third and fourth boom sections into the second boom
section being careful not to damage any surrounding
components. MY3450
21
7. Install the previously removed wear pad support
plates and spacers (25) with existing hardware at the
22 17 inside top front of the second boom section. Snug
20 mounting bolts. Shim as needed AFTER boom
section is installed to maintain a 0.070 - 0.130 in
18 (1,78 - 3,30 mm) gap between the boom sections.
18 Note: Longer bolts may be required to fully engage the
threaded inserts in the wear pads without allowing bolts
to protrude past the chamfer on the wear pads. Refer to
19 Section 3.11.2, “Wear Pad Installation and Lubrication.”
23
MY3650 27
MY3450
30 30
MY4140
31
2. Install the previously removed wear pads, spacers
and shims at the bottom front of the first boom
section (1). Snug mounting bolts. Shim as needed
AFTER boom section is installed to maintain a
0.070 - 0.130 in (1,78 - 3,30 mm) gap between the
boom sections.
3. Install the previously removed wear pads, spacers
and shims on each side at the front of the first boom
section (2). Snug mounting bolts. Shim as needed
AFTER boom section is installed to maintain a
0.070 - 0.130 in (1,78 - 3,30 mm) gap between the
boom sections.
4. Install the previously removed wear pads, spacers
MY3590 and shims at the top front of the first boom section
12. Install the bracket and clevis assembly (31) at the (3). Snug mounting bolts. Shim as needed AFTER
rear of the fourth boom section. Torque mounting boom section is installed to maintain a
bolts. 0.070 - 0.130 in (1,78 - 3,30 mm) gap between the
boom sections.
3.5.11 Second, Third and Fourth Boom 5. Re-adjust the sling(s) and push the second, third
Section Installation and fourth boom assembly the remainder of the way
into the first boom section.
Note: Using a straight bar approximately 40 in
(1041 mm) long will aid in the installation of the wear
pads located on the inside front of each boom section.
1. Place the sling or using two slings for better stability,
around the second boom section and slowly insert
the second, third and fourth boom sections into the
first boom section being careful not to damage any
surrounding components and allowing sufficient
room to install the wear pads at the front of the first
boom section.
MY3440
MY3590 12. Connect the fourth boom section extend chain (10)
to the clevis at the top front of the third boom section
6. Connect the rear retract chain (4) to the chain clevis and adjust to the previously measured setting. Do
with the previously removed pin at the rear of the Not tighten the lock nut at this time.
third boom section. Secure the pin with the
13. Connect the third boom section extend chains (11) to
previously removed snap rings.
the clevises at the top front of the second boom
7. Pull hose carrier from the rear as far as possible to section and adjust to the previously measured
access the hydraulic and if equipped, the electrical setting. Do Not tighten the lock nut at this time.
connections.
14. Grease all wear pad at the rear of the boom using
8. If equipped, connect the electrical cable (5) to the the zerk fittings.
fitting on the hose carrier.
15. Refer to Section 3.7, “Boom Section Separation
Adjustment,” for proper boom section adjustments.
4. Attach a suitable sling to the extend/retract cylinder. 3.6.2 Retract Chain Installation
Remove the extend/retract cylinder support.
Inspect and lubricate chains thoroughly before
5. Remove the rod end pin and lower the cylinder onto installation. Articulate the chains to make sure all working
the frame rails. Lowering the extend/retract cylinder surfaces are thoroughly lubricated.
will allow access to the chains.
Note: If the inner retract chain was removed, it must be
4 installed first.
1. Fasten a rope to the end of the 3/4 in. chain in order
to pull it back into the boom.
2. Attach the chain to the chain clevis at the rear of the
MX0510 boom.
1 3 3. Carefully pull the chain into the boom until it can be
2
fastened to the chain clevis.
6. Remove tension from the chain by backing off the
4. Remove the rope.
jam nut and adjusting nut (1).
5. Fasten the chain into the clevis by installing the pin
7. Remove the four bolts (2) from the chain adjustment
and retaining ring.
block.
6. Torque the jam nuts to 100 lb-ft (135 Nm).
8. Remove the chain from the clevis (3) at the block.
To install the outer retract chain:
9. Install a nylon tie wrap through the holes of the
removed chain, making a loop with a tie wrap and tie 1. Fasten a rope to the end of the chain in order to pull
a rope to the loop. it back into the boom.
10. At the rear of the boom, pull the chain to the rear to 2. Attach the chain to the chain clevis at the rear of the
allow slack for removal. boom.
11. Remove the chain from the clevis and drop it free 3. Carefully pull the chain into the boom until it can be
from the boom. fastened to the chain clevis.
12. Holding a rope at the front adjustment block, 4. Remove the rope.
carefully pull the chain out through the back of the 5. Fastened the chain into the clevis by installing the
boom. pin and cotter pin.
13. Untie the rope and leave it in place for reinstallation 6. Install the chain adjustment block and mounting
of the chain. bolts. Torque the chain adjustment block mounting
To remove the retract chain from the fourth to second bolts to 360-390 lb-ft (475-530 Nm).
boom sections: 7. Install the extend/retract cylinder and cylinder
1. Remove the jam nut (4) from the chain clevis support.
installed in the chain adjustment block. 8. Adjust the retract chains as needed. Refer to Section
2. Back off the adjusting nut fully on the chain clevis. 3.7, “Boom Section Separation Adjustment.”
Do not remove the nut from the clevis. 9. Properly connect the battery.
3. Remove the chain from the clevis, install a nylon tie- 10. Remove the Do Not Operate Tags from both the
wrap through the holes in the chain, making a loop ignition key switch and the steering wheel.
with the tie-wrap and tie a rope to the loop.
4. Move to the back of the boom and pull the chain to 3.6.3 Extend Chain Removal
the rear to allow slack for removal. The following section explains the removal of the extend
5. Remove the chain from the clevis and drop it free chains without removing the boom assemblies.
from the boom. 1. Park the machine on level ground. Place the
6. Holding the rope at the front, carefully pull the chain transmission control lever in (N) NEUTRAL, engage
out through the back of the boom until it’s free. the parking brake switch, level the boom, extend the
7. Untie the rope and leave it in place for reinstallation boom far enough to access the chain anchor and the
of the chain. clevis through the top rear access hole, shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key 9. Remove the Do Not Operate Tags from both the
switch and the steering wheel, stating that the ignition key switch and the steering wheel.
machine should not be operated.
3. Properly disconnect the battery. 3.7 BOOM SECTION SEPARATION
4. Secure the boom sections together to prevent ADJUSTMENT
uncontrolled boom run out when the extend chains
1. Start the machine and verify the boom is in a
are removed.
horizontal (level) position.
5. On the chain being removed, loosen and remove the
2. Extend the boom 4-5 ft (1,2-1,5 m), then fully retract
jam nut from the rear chain clevis and back off the
the boom.
adjusting nut on the chain clevis to the end of the
threads. Do not completely remove the nut. 3. Shut machine OFF.
6. Remove the chain clevis pin and retaining ring to
free the chain.
7. Install the nylon tie wrap through the holes in the
chain, making a loop with the tie wrap and tie a rope
to the loop.
8. Pull the slack to the chain clevis at the front of the
boom.
9. Remove the clevis pin and the retaining ring from the
chain and chain clevis.
10. Install a nylon tie wrap through the chain holes,
forming a loop and tie a rope to the loop. D
2. Carefully pull the chain into the boom to the chain Adjust the extend chain as follows:
clevis anchor. 1. Loosen the lock nut (1) on each of the extend
3. Fasten the chain to clevis with a pin and cotter pin. chains.
4. At the other end of the chain, connect the chain to 2. Tighten the adjusting nuts on the first boom section
the clevis fastening the chain to the clevis with a pin until the gap (D) between the flat washers and boom
and retaining ring. is 0.375 in (9,52 mm) maximum. The gap must be
equal on both chains. Torque the lock nut to 100 lb-ft
5. Install the chain clevis fastening and adjusting (135 Nm).
hardware on both ends.
Note: Verify the exposed threads on both extend chain
6. Remove any clamping devises being used to keep
clevises are kept equal.
the boom sections from moving.
7. Properly connect the battery. 3. Tighten the adjusting nut on the second boom
section until the gap (D) between the washer and
8. Adjust the extend chains as needed. Refer to boom is 0.375 in (9,52 mm) maximum. Torque the
Section 3.7, “Boom Section Separation Adjustment.” lock nut to 100 lb-ft (135 Nm).
2 3
4. After adjusting, check to see that the boom sections 3. Loosen the second to third boom section retract
and access holes (2) are aligned. If they are not, the chain lock nut and adjusting nut (3) as far as
retract chain will need to be adjusted as well. possible.
Adjust the retract chain as follows: 4. Loosen the third to fourth boom section retract chain
1. Fully retract the boom. lock nut and adjusting nut (4) as far as possible.
F
5. Tighten the retract chain adjusting nut (3) until the
proper distance (E) is obtained and proper access
hole alignment (2) is obtained.
6. Torque the lock nut to 100 lb-ft (135 Nm).
7. Recheck the extend chain adjustments and readjust
if necessary.
8. Measure the distance between the third boom
section and fourth boom section (F). The dimension
should be:
G10-55A - 17.5-17.75 in (444,5-451,3 mm)
G12-55A - 18.5-18.75 in (469,9-476,7 mm)
9. Tighten the retract chain adjusting nut (4) until the
proper distance (F) is obtained and proper access
hole alignment (2) is obtained.
10. Torque the lock nuts to 100 lb-ft (135 Nm).
E MY3790
11. Re-adjust the extend chains as needed.
2. Measure the distance between the second boom
section and the third boom section (E). The
dimension should be 0.50-0.75 in (12,7-19,5 mm).
MY2720
13. When the hose carrier is pulled approximately 25% 3.8.3 Hose Carrier-Assembly Installation
out of the boom, fasten the two hydraulic carriers
1. Clean and lubricate the side surfaces where the hose
together using plastic tie wraps or nylon straps to
carrier rides.
keep them from separating.
2. Fully collapse the hose carriers and secure together
Note: Do Not wrap the hose carrier since it will not using plastic tie wraps or nylon straps to keep them
prevent the two hydraulic carriers from moving apart from separating.
sideways.
3. Install a sling around the balance point of the hose
14. Continue withdrawing the hose carrier, fastening the carrier. With a suitable lifting device, slowly insert the
two hydraulic carriers together. hose carrier into the front of the fourth boom section.
15. With the two hose assemblies tied together, remove 4. Remove the first plastic tie wrap or nylon strap as
the hose carrier and set on the ground or proper the hose carrier is being inserted into the front of the
supports. fourth boom section.
5. Continue inserting the hose carrier and removing the
3.8.2 Assembling the Hose Carrier plastic tie wraps or nylon straps until the hose carrier
Assembly is fully inserted into the boom.
The following procedure is described with the assumption
that all components have been removed and assembly
proceeding from the beginning.
MY2740
MY2730 FRONT
11. Uncap and reconnect the previously labeled tilt and 5. Verify the auxiliary hoses and/or tilt hoses are NOT
auxiliary hydraulic hoses to the proper fittings at the touching the bottom of the second boom section by
front of the fourth boom section. viewing the auxiliary hoses and/or tilt hoses through
12. If equipped, reconnect any electrical connections at the access hole (10) in each side of the second
the front and rear of the boom assembly. boom section.
12
11 MY4470
4
87 6 5
6. Verify that 4 in (101,6 mm) of slack (11) is present
9 5 MY2691
between the hose take-up bracket (5) and the first
13. Install the hose take-up compression spring (4) on hose clamp (12).
each hose take-up bracket (5) at the bottom of the 7. Verify the hose take-up bracket (5) is not bent and is
first boom section. Install the washer (6), adjusting at an 85° angle to the hose.
nut (7) and jam nut (8). Tighten the adjusting nut (7)
Note: Replace both auxiliary hoses and/or tilt hoses if
to compress the hose take-up compression spring to
the hoses are touching the bottom of the second boom
measure 3 in (76,20 mm)(9). Refer to Section 3.8.4,
section AND 4 in (101,6 mm) of slack is present between
“Boom Hose Adjustment,” if required.
the hose take-up bracket and the first hose clamp.
14. Torque the jam nut (8) against the adjusting nut (7)
to 100 ft-lbs (135,5 Nm). 8. Refer to Section 3.8.3, “Hose Carrier-Assembly
Installation,” step 13 and 14 for hose take-up bracket
15. Properly connect the battery. adjustment.
16. Remove the Do Not Operate Tags from both the 9. Measure the slack (11) at the lowest point between
ignition key switch and the steering wheel. the hose take-up bracket (5) and the first hose clamp
(12). The 4 in (101,6 mm) measurement is from the
3.8.4 Boom Hose Adjustment bottom of the first boom section to the top of the
1. Park the machine on a hard, level surface, level the hose.
machine, fully extend the boom, lower the boom 10. If necessary, loosen the hose clamp (12), pull the
head to the ground, place the transmission control auxiliary hoses and/or the tilt hoses, tighten the hose
lever in (N) NEUTRAL, engage the park brake and clamp for additional clearance.
shut the engine OFF.
11. Replace the auxiliary hoses and/or the tilt hoses if
2. Place a Do Not Operate Tag on both the ignition key the proper slack, 4 in (101,6 mm)(11) cannot be
switch and the steering wheel, stating that the achieved.
machine should not be operated.
12. Start the machine, raise the boom to level, cycle the
3. Verify any trapped hydraulic pressure in the auxiliary extend/retract cylinder, fully extend the boom.
circuit and the tilt circuit is relieved.
13. Cycle the auxiliary circuit and/or the tilt circuit,
4. Open the engine cover. Allow the system fluids to verifying the auxiliary hoses and the tilt hoses are
cool. NOT touching the bottom of the second boom
section and the proper slack, 4 in (101,6 mm) is
maintained.
14. Retract the boom and shut engine OFF.
15. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
10 MY4480
7 9
13
8
2
6
1
11
12
10 MY5090
4
5 1. Remove the lock bolt (8) holding the tilt cylinder rod
MY5080
3 end pin (9) to the quick switch assembly (10).
Remove the Tilt Cylinder pin.
1. Remove the lock bolt (1) holding the tilt cylinder rod
end pin (2) to the quick switch assembly (3). 2. Support the quick switch assembly (10).Remove the
Remove the Tilt Cylinder pin. capscrew (11) and locknut (12) securing the head
pin (13) to the boom head (14).
2. Support the quick switch assembly (3).Remove the
capscrew (4) and locknut (5) securing the head pin 3. Inspect the above pins for nicks or surface corrosion.
(6) to the boom head (7). Use fine emery cloth to fix minor nicks or corrosion.
If damaged or if it cannot be repaired the pin must be
3. Inspect the above pins for nicks or surface corrosion.
replaced.
Use fine emery cloth to fix minor nicks or corrosion.
If damaged or if it cannot be repaired the pin must be
3.9.4 Quick Switch Installation
replaced.
1. Assemble the quick switch assembly (10) to the
3.9.2 Quick Switch Installation boom head (14). Line up the quick switch between
the mounts on the boom head. The quick switch
1. Assemble the quick switch assembly (3) to the boom
should be centered in the boom head.
head (7). Line up the quick switch between the
mounts on the boom head. The quick switch should 2. Coat the quick switch head pin (13) with an anti-
be centered in the boom head. seize compound. Insert the quick switch head pin
through the quick switch and boom head. Secure
2. Coat the quick switch head pin (6) with an anti-seize
with the previous capscrew (11) and locknut (12).
compound. Insert the quick switch head pin through
the quick switch and boom head. Secure with the 3. Align the quick switch with the tilt cylinder rod end
previous capscrew (4) and locknut (5). and insert the tilt cylinder pin (9). Align the tilt
cylinder pin and screw in the locking bolt (8). Torque
3. Align the quick switch with the tilt cylinder rod end
as required.
and insert the tilt cylinder pin (2). Align the tilt
cylinder pin and screw in the locking bolt (1). Torque
as required.
Ma2070
Inspect all wear pads for wear. If the angle indicators (1)
on the ends of the wear pads are visible, the wear pads
can be reused. If the pads show uneven wear (front to
back), they should be replaced. Replace pads as a set if
MY3710 worn or damaged.
1. Using a suitable lifting device, secure the winch 3.11.2 Wear Pad Installation and Lubrication
assembly (4) with a nylon strap.
Note: Inspect all wear pads. Replace as necessary.
2. Disconnect the hydraulic hoses (5).
The following wear pad procedure must be followed to
3. Loosen and remove the mounting bolts, washers insure the proper wear pad installation:
and nuts (6)(not shown).
• The wear pad inserts and mounting bolts MUST be
4. Lower the winch assembly (4) onto a suitable skid or clean from any grease, oil or other contaminates
table. before applying Loctite® 242 and installing mounting
bolts.
3.10.2 Boom Head-Mounted Winch • Apply Loctite® 242 to all wear pad mounting bolts.
Installation
4
1. Using a suitable lifting device, secure the winch
assembly (4) with a nylon strap.
2. Raise the winch assembly (4) into position behind
the boom head. 3
2
3. Apply Loctite®
242 to the previously removed
mounting bolts.
4. Install the mounting bolts, washers and nuts (6)(not
shown). Torque to 200 lb-ft (271 Nm).
5. Connect the hydraulic hoses (5).
MAM1390
WARNING
Worn pins, stretched or cracked links or corrosive
environments can cause chain failure. A chain failure
could result in uncontrolled boom movement, loss of
MY5510 load or machine instability.
• Maintain a total boom section clearance (5) of Under normal operating conditions the boom chains will
0.070 - 0.130 in (1,78 - 3,30 mm) both the horizontal need to be inspected every 250 hours of operation. The
and vertical directions. retract chains need to be exposed and inspected every
1000 hours of operation. Environmental conditions and
A dynamic impulse/shock loads can drastically affect
normal operating conditions and require more frequent
inspection intervals.
B
Environments in which material handling vehicles
operate can vary widely from outdoor moisture to
MY3620
temperature to mildly corrosive or highly corrosive
industrial atmospheres, in addition to abrasive
• The length of the wear pad bolt depends on the exposures such as sand and grit. Some effects can be
number of shims, spacers and washers being used. as follows:
• The thickness of each threaded wear pad insert is • Moisture - Corrosive rusting reduces chain
0.312 in (7,92 mm)(A). strength by pitting and cracking.
• The bolt length should be determined by measuring
• Temperature - Low temperature reduces chain
the distance from the face of the insert to the face of
strength by embrittlement. Going in and out of
the boom (B) including any spacer, shim(s) and
cold storage results in moisture from
washer(s).
condensation.
• Bolt thread engagement in the wear pad insert
should be 0.275 ± 0.040 in (6,98 ± 1,0 mm). • Chemical Solutions or Vapors - Corrosive attack
on the chain components and/or the mechanical
• One or two hardened washers are to be used on
connections between the chain components.
each wear pad bolt except where noted otherwise.
Cracking can be (and often is) microscopic.
DO NOT use more than two hardened washers.
Going from microscopic cracking to complete
• Use only one hardened washer if mounting bolts are failure can be either abrupt or may require an
recessed. extended period of time.
• Wear Pad Bolt Torque:
• Abrasives - Accelerated wearing and scoring of
3/8 - 24 Bolt, 32 - 37 lb-ft (43 - 50 Nm)
the articulating members of the chain (pins an d
3/8 - 24 Hollow Bolt, 15 - 17 lb-ft (20 - 23 Nm)
plates), with a corresponding reduction in chain
1/2 - 20 Bolt, 76 - 86 lb-ft (103 - 116 Nm)
strength. Due to the inaccessibility of the bearing
1/2 - 20 Hollow Bolt, 45 - 50 lb-ft (61 - 68 Nm)
surfaces (pin surfaces and plate apertures),
• Torque wear pad bolts after shimming is completed. wear and scoring are not readily noticeable to
• Lubricate the face and pockets of each wear pad the naked eye.
after being installed.
Boom Section Wear Pad Pathway Lubrication:
• Clean and lightly grease all wear pad pathways with
Mystik Tetrimoly grease.
6. Clean and lightly grease the hose carrier guide bar
pathways with Mystik Tetrimoly grease.
MY1360
driving the pin(s) back into the chain. Once the press Either fractured plates (11) 12
fit integrity between outside plates and pins has or enlarged holes (12) can
been altered, it cannot be restored. occur. If either of these
MZ1470
failures occurs, the chain
Any wear pattern on the pin heads or the sides of the should be replaced immediately.
link plates indicates misalignment in the system.
This condition damages the chain as well as • Tight Joints
increases frictional loading and should be corrected. - All joints in
the chain
should flex
freely. Tight
joints (13) 13 MZ1471
resist flexing.
If the problem is caused by dirt or foreign substance
packed in the joints, clean and lubricate thoroughly
before re-installing the chain.
If the problem is caused by corrosion and rust or
bent pins, replace the chain.
3.13 FORKS
Forks should be cleaned and inspected prior to being
attached to carriage. If the following criteria is not met,
forks must be removed from service immediately.
Daily Inspection
3
6
7
5 4
2
1
9
8
11
10 MH6460
3.14 TROUBLESHOOTING
This section provides an easy reference guide covering
the most common problems that occur during operation
of the boom.
2. Boom shifts to right or left 1. Boom side wear pads 1. Shim wear pads to correct gap.
when extending. improperly shimmed or worn. Replace wear pads as needed.
Refer to Section 3.11, “Boom
Wear Pads.”
6. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s)
and/or connection leaks. or tube(s), tighten connections.
9. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8.4, “Hydraulic
operate. operating properly. Circuits.”
10. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. Refer
to Section 3.7, “Boom Section
Separation Adjustment.”-
Replace chains as needed.
Contents
FRAME LEVEL
INDICATOR
HEATER AND A/C
CONTROLS (OPTIONAL)
STEERING WHEEL
BOOM CONTROL
JOYSTICK
INSTRUMENT
PANEL SWAY CONTROL
JOYSTICK
AUXILIARY CONTROL
JOYSTICK
TRANSMISSION
CONTROL LEVER
OUTRIGGER CONTROL
JOYSTICK
IGNITION
SWITCH
FUEL TANK
SERVICE BRAKE
PEDAL
ACCELERATOR MY0930
PEDAL
WARNING 2
WARNING
DO NOT weld, grind, drill, repair or modify the cab in 4
any way. Any modification or damage to cab structural
components requires cab replacement. Refer to page
2-9 in the Operators & Safety Manual.
To help ensure optimum safety, protection and
performance, replace the cab if it is damaged. Refer to
the appropriate parts manual for ordering information.
c. Steering Test
Conduct a pressure check of the steering hydraulic 2
circuits at the main control valve. Refer to Section 8.3.1,
“Pressure Checks and Adjustments.” MY0140
4.3.2 Service Brake Pedal 5. Remove the bolt and lockwasher (1) securing the
service brake pedal pivot pin (2).
a. Brake Valve Removal 6. Pull the pivot pin from the service brake pedal
Refer to Section 8.7.3, “Service Brake Valve,” for removal bracket (3).
information. 7. Remove the service brake pedal from the cab.
7
6
MY0950
15
MY4390
16
16 14 13
11
10 13. Loose the hose clamps securing the heater hoses
(13).
MY0190 14. Label and remove both heater hoses.
15. Label and disconnect any electrical connections
10. Remove the bolts securing the front plate (10) to the
(14).
seat riser weldment (11).
16. Label and disconnect both air conditioning hoses
11. Remove the bolts securing the seat riser weldment
(15).
to the cab. Remove the riser weldment.
17. Remove the bolts (16) securing the heater assembly
to the cab. Remove the heater assembly.
4.4 CAB REMOVAL 9. Remove the necessary dash panels to gain access
to the electrical wiring connections. Label and
disconnect the harnesses. Push the harness
WARNING connectors through the opening in the cab.
10. Remove the boom joystick from is mounting
The protection offered by this ROPS/FOPS will be position. Refer to Section 4.3.4, “Boom Joystick
impaired if subjected to any modification or structural Assembly.” Label, disconnect and cap all hydraulic
damage, at which time replacement is necessary. hoses attached to the boom joystick. Cap all fittings
ROPS/FOPS must be properly installed using and openings to keep dirt and debris from entering
fasteners of correct size and grade, and torqued to the hydraulic system.
their specified value.
11. Remove the frame level and attachment tilt and
Note: To help ensure safety and optimum performance, auxiliary control joystick. Refer to Section 4.3.5,
replace the cab if it is damaged. Refer to the appropriate “Frame Sway, Auxiliary and Outrigger Control
parts manual for ordering information. Joysticks.” Label, disconnect and cap all hydraulic
hoses attached to the joystick. Cap all fittings and
Inspect the cab, its welds and mounts. If modification,
openings to keep dirt and debris from entering the
damage, a cracked weld and/or fatigued metal is
hydraulic system.
discovered, replace the cab. Contact the local distributor
with any questions about the suitability or condition of a 12. Label, disconnect and cap all hydraulic hoses
cab. attached to the steering orbitrol valve. Cap all fittings
and openings to keep dirt and debris from entering
Note: Remove and label cab components as needed the hydraulic system.
before removing the cab from the machine. Label,
disconnect and cap hydraulic hoses. Transfer cab parts 13. Label, disconnect and cap all hydraulic hoses
to the replacement cab after the replacement cab is attached to the steering orbitrol valve. Cap all fittings
securely mounted on the machine. and openings to keep dirt and debris from entering
the hydraulic system.
1. Park the machine on a firm, level surface. Allow
14. Label, disconnect and cap all hydraulic hoses
sufficient overhead and side clearance for cab
attached to the service brake valve. Cap all fittings
removal. Level the machine, fully retract the boom,
and openings to keep dirt and debris from entering
lower the boom, place the travel select lever in the
the hydraulic system.
(N) NEUTRAL position, engage the park brake and
shut the engine OFF. 15. Push all the hydraulic hoses through the opening in
the cab.
2. Block all four wheels to help prevent the machine
from moving. Assure that there is sufficient overhead 16. Disconnect the throttle cable from the throttle
and side clearance for cab removal. assembly. Refer to Section 4.3.3, “Throttle Pedal.”
3. Open the engine cover. Allow the system fluids to 17. Disconnect the engine air filter and hydraulic oil
cool. reservoir breather from their brackets at the top of
the cab. Move the air filter and breather clear from
4. Properly disconnect the battery.
the cab so they do not become damaged during cab
5. Place a funnel at the base of the radiator to channel removal.
the drained coolant into the container. Loosen the
18. Remove the fuel tank from the cab. Refer to Section
drain petcock and allow the coolant to drain.
7.6.2, “Fuel Tank.”
6. Transfer the coolant to a container with a cover, and
label as “Used Antifreeze.” Dispose of the used
coolant at an approved recycling facility.
7. Tighten the radiator drain petcock.
8. Disconnect the cab heater hoses. Refer to Section
4.3.7, “Heater/Air Conditioning System (if
equipped).”
24. Carefully begin to lift the cab. Stop and check that all
13 14 wiring, hydraulic hoses and fasteners are
disconnected or removed.
25. When all wiring, hydraulic hoses and fasteners are
disconnected or removed, carefully and slowly lift
the cab and remove it from the frame. Readjust the
position of the sling as needed to help balance the
cab during removal.
26. When the cab is completely clear of the machine,
15 carefully lower it to the ground. Block up or support
the cab so that it does not move or fall. Assure that
MY0610 no personnel enter the cab while it is being removed
from the machine.
19. Open Cab: Route a sling with a minimum lifting
27. Inspect the condition of the fittings, clamps,
capacity of 1000 lbs (453 kg) under the inner four
hydraulic hoses, etc. Replace parts as indicated by
braces (13) and behind the center cross support
their condition.
above the wind shield or install two lifting eye bolts
(14) in the threaded holes on the roof of the cab 28. Inspect and replace other machine parts that are
above the B pillars (15). exposed with the cab removed. Repair or replace as
required.
20. Enclosed Cab: Install two lifting eye bolts (14) in the
threaded holes on the roof of the cab above the B
pillars (15). Route a sling with a minimum lifting
4.5 CAB INSTALLATION
capacity of 1000 lbs (453 kg) through the lifting eye
1. Block all four wheels to help prevent the machine
bolts.
from moving. Assure that there is sufficient overhead
and side clearance for cab installation.
13 14
16 16
15
MY0610
4. Use a hoist or overhead crane and sling attached to 14. Fill the cooling system completely with coolant,
the cab. Carefully begin to align the cab with the allowing time for the coolant to fill the engine block.
mounting holes in the frame. Stop and check that The cooling system capacity is listed in Section 2.4,
wiring, hydraulic hoses, cables, etc., will not be “Fluid and Lubricant Capacities.”
pinched or damaged as the cab is positioned. 15. Properly connect the battery.
Readjust the position of the sling as needed to help
balance the cab during installation. 16. Start the engine and check the operation of all controls.
Check for hydraulic fluid leaks. Check the hydraulic
fluid level in the tank and add fluid as required.
Note: When the engine is initially started, run it briefly at
low idle and check the machine for any visual sign of
fluid leakage. STOP the engine immediately if any
leakage is noted, and make any necessary repairs
before continuing.
16 16
17. Wait for the engine to cool and check the coolant
level. Add coolant to the overflow bottle as required
to bring the coolant to the proper level.
18. Install the mirrors and all other cab components as
needed, if removed.
19. Close and secure the engine cover.
20. Unblock the wheels.
21. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
MY4170
17 17
5. Install the four cab-to-frame mount bolts, washers and
nuts (17). Torque to 280-305 lb-ft (379-414 Nm).
6. Install the two cab side mount bolts washers and
nuts (16). Torque to 680-720 lb-ft (922-976 Nm).
7. Install the engine air filter and hydraulic oil reservoir
breather to their brackets at the top of the cab.
8. Install the throttle cable to the throttle pedal
assembly. Refer to Section 4.3.3, “Throttle Pedal.”
9. Pull all the hydraulic hoses and electrical wires
through the cab.
10. Uncap and reconnect the previously labeled
hydraulic hoses to their appropriate locations.
11. Reconnect the previously labeled electrical
connections to their appropriate locations.
12. For machines equipped with the heater option,
reconnect the heater hoses to the cab heater. Refer
to Section 4.3.7, “Heater/Air Conditioning System (if
equipped).”
13. Install the fuel tank to the cab. Refer to Section
7.6.2, “Fuel Tank.”
Contents
REAR STEERING
CYLINDER
TRANSMISSION
DROP BOX
REAR AXLE
ASSEMBLY
FRONT AXLE
FRONT AXLE
WHEEL HUBS
ASSEMBLY
(2) MY0570
5.3.5 Axle Removal 9. Raise the machine using a suitable jack or hoist.
Place suitable supports under both sides of the
The front and rear axle assemblies differ in that the front
frame and lower the machine onto the supports.
axle assembly is equipped with a parking brake
Ensure that the machine will remain in place during
mechanism and a limited-slip feature; the rear axle has
axle removal.
neither. The following steps outline a typical axle removal
procedure, suitable for either the front or the rear axle 10. Support the axle that is being removed with a suitable
assembly. jack, hoist or overhead crane and sling. DO NOT
raise the axle or the machine.
Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the machine. Avoid 11. Remove both wheel and tire assemblies from the
spraying water or cleaning solution on electrical axle that is being removed. (Refer to Section 5.5.1,
components. If using a steam cleaner, seal all openings “Removing Wheel and Tire Assembly from
before steam cleaning. Machine.”)
Note: Clear the work area of all debris, unnecessary Note: The wheel and tire assemblies must be re-installed
personnel, etc. Allow sufficient space to raise the later with the directional tread pattern “arrows” facing in
machine and to remove the axle. the direction of forward travel.
1. Park the machine on a firm, level surface, level the 12. Remove the drive shaft assembly. Refer to Section
machine, fully retract the boom, lower the boom, 5.4.3, “Drive Shaft Removal.”
place the travel select lever in the (N) NEUTRAL 13. On the front axle remove the capscrew and locknuts
position, engage the parking brake, straighten all securing the lower position cylinder-mount pin to the
wheels and shut the engine OFF. front cylinder. Tap the cylinder mount pin out, and
2. Place a Do Not Operate Tag on both the ignition key move the cylinder to prevent it from interfering with
switch and steering wheel, stating that the machine axle removal.
should not be operated. 14. Remove the bolts and locknuts securing the axle to
3. Open the engine cover. Allow the system fluids to the frame.
cool. 15. Remove the axles from the machine using the jack,
4. Properly disconnect the battery. hoist or overhead crane and sling supporting the
axle. DO NOT raise or otherwise disturb the
5. Remove the optional fender assembly.
machine while removing the axle. Balance the axle
and prevent it from tipping, turning or falling while
removing it from beneath the machine. Place the
axle on a suitable support or holding stand.
3. Using a suitable jack, hoist or overhead crane and 11. Rotate wheel hubs 90 degrees so the drain plug (2)
sling, remove the axle from its support or holding becomes the fill plug (3). Refer to Section 2.4, “Fluid
stand. Balance the axle and prevent it from tipping, and Lubricant Capacities,” for proper oil and
turning or falling while positioning it beneath the capacities.
machine. DO NOT raise or otherwise disturb the 12. Install the wheel and tire assemblies. Refer to
machine while installing the axle. Keep the axle Section 5.5.2, “Installing Wheel and Tire Assembly
supported and balanced on the jack, hoist or onto Machine.”
overhead crane and sling throughout the installation
procedure. 13. Carefully remove the jack, hoist or overhead crane
and sling supporting the axle.
4. Position the axle under the frame, and align the axle
housings with the holes in the frame. 14. Carefully raise the machine using a suitable jack or
hoist. Remove the supports from beneath the frame
5. Install the four axle bolts and nuts. Tighten and and lower the machine to the ground.
torque to 530-565 lb-ft (718-766 Nm).
15. Remove the blocks from the front and rear of both
6. Move the cylinder into position on the axle cylinder tires on the other axle.
anchor. Insert a cylinder-mount pin through the
cylinder and cylinder anchor. Secure the cylinder- Note: ALWAYS use new o-rings when servicing the
mount pin with one capscrew and a new locknut. machine.
7. Apply multi-purpose grease through the self-tapping 16. Install new o-rings into the fittings. Lubricate the
lube fitting to lubricate the self-align bearing and the o-rings with clean hydraulic oil.
cylinder-mount pin. 17. Uncap and connect the steering and brake lines at
8. Install the drive shaft assemblies. (Refer to Section their axle fittings.
5.4.5, “Drive Shaft Installation.”) 18. Check the hydraulic reservoir oil level.
9. If reinstalling an axle previously removed from the 19. Start the engine. Turn the steering wheel several
machine, position the driveshaft yoke on the axle times lock to lock, operate the frame tilt function
according to the alignment marks made earlier. If several times in both directions and check the
installing a new axle, note the position of the function of the brakes. Check for hydraulic leaks,
driveshaft yoke at the transmission. Align the and tighten or repair as necessary.
driveshaft yoke on the axle in the same plane as the
yoke on the transmission. 20. Install the optional fender assembly.
21. Close and secure the engine cover.
22. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
Note: The service brake and parking brake circuits will
MY4180 need to bled after axle installation. Refer to Section
2 1 1 2 8.7.4, “Service Brake Bleeding.”
10. Tighten the axle oil drain plug, loosen and remove
the axle oil fill plug (1). (Refer to Section 2.4, “Fluid
and Lubricant Capacities,” for proper oil and
capacities.
LEVEL
MY0220
2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil level housings and fill to correct level
low. with hydraulic oil. Refer to
Section 2.4, “Fluid and
Lubricant Capacities.”
3. Vibration or intermittent noise 1. Drive shaft universal joint 1. Tighten capscrews to correct
when traveling. assembly(ies) incorrectly torque.
tightened.
5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace o-rings as needed and
housing (planet carrier). o-rings damaged or missing. tighten plugs to 96 lb-ft
(130 Nm).
2. O-ring between hub and 2. Replace o-ring.
housing (planet carrier)
damaged or missing.
8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.4, “Hydraulic
operating properly. Circuits.”
9. Slow steering response. 1. Steering (hydraulic) system not 1. Refer to Section 8.4, “Hydraulic
operating properly. Circuits.”
11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.4, “Hydraulic
operating properly. Circuits.”
12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear.
machine or braking power Refer to Section 2.4, “Fluid and
reduced. Lubricant Capacities.”
WARNING
Mismatched tire sizes, ply ratings or mixing of tire
types (radial tires with bias-ply tires) may compromise
machine stability and may cause machine to tip over.
5.5.2 Installing Wheel and Tire Assembly 6. Remove the Do Not Operate Tags from both the
onto Machine ignition key switch and the steering wheel.
Note: The wheel and tire assemblies must be installed
with the directional tread pattern “arrows” facing in the 5.6 BRAKES
direction of forward travel.
Check the brake disks for wear every 1,000 hours of
operation or yearly.
Tread “arrows” must point For more information on brake disk inspection, refer to
forward the Axle Repair Manual (P/N 31200240).
Install tires onto wheels to 5.7.1 Manually Releasing the Park Brake
rotate in proper direction
5 5
MAH0460
5 5
MZ1020
Contents
TRANSMISSION
FILTER
TORQUE CONVERTER
TRANSFER CASE
BREATHER
SHIFT SOLENOIDS
SHIFT SOLENOIDS
Note: Cleanliness is of extreme importance. Before 8. Place a suitable receptacle under the transmission
attempting to remove the transmission, thoroughly clean drain plug (2). Remove the transmission drain plug,
the exterior of the transmission to help prevent dirt from and allow the transmission oil to drain into the
entering during the replacement process. Avoid spraying receptacle. Repeat drain procedure with the drop
water or cleaning solution onto or near the transmission box (3).
shift solenoids and other electrical components.
9. Transfer the used transmission oil into a suitable, 26. Remove any external transmission components as
covered container, and label the container as “Used required, including the transmission temperature
Oil.” Dispose of used oil at an approved recycling switch, and inlet and outlet cooler hose fittings.
facility. Clean and reinstall the transmission drain Cover all transmission openings.
plug.
10. Remove the transmission-to-axle drive shafts. Refer 4
to Section 5.4.3, “Drive Shaft Removal.”
11. Remove air cleaner unit and intake tubes.
12. Remove the hydraulic pump. Refer to Section 8.6.1,
“Implement Pump Replacement.”
13. Label and disconnect the transmission temperature
switch connector and shift solenoid wiring harness
connectors.
MY0990
14. Label, disconnect and cap the transmission oil
cooler inlet and outlet hoses at the transmission. 27. Remove the transmission oil filter (4) and dispose of
15. Remove the access plug from side of the engine bell properly. Clean the filter mounting surface. Cover or
housing. This will allow access to remove the four cap the oil filter mount.
bolts holding the torque convertor diaphragm to the 28. If transmission oil is suspect to contamination or
engine flywheel. torque converter is damaged, remove the converter
16. Turn the engine over slowly by hand and align each and flex plate from the transmission.
of the four torque convertor diaphragm bolts to be 29. Remove the bolt and washers holding the converter
accessed. Remove them one at a time. to the flex plate.
17. Wipe up any spilled hydraulic and transmission oil.
6.4.2 Transmission Inspection and Internal
18. Connect a lifting strap or chain to the lifting eye at
Repair
the top of the transmission, and to a suitable hoist or
overhead crane. Operate the hoist or crane to If replacing the entire transmission, transfer the
remove slack from the chain, but DO NOT raise the transmission temperature switch to the replacement
transmission at this time. transmission. The gear shift solenoids are included with a
new transmission.
19. Place blocks under rear of engine for support
BEFORE transmission mounts are removed.
20. Place blocks under the transmission to help support
it during removal.
21. Remove both rear transmission mount bolts and
lockwashers securing the transmission mount to the
frame.
22. Remove the bolts and washers holding the
transmission to the engine.
23. Remove the capscrews and lockwashers securing
each rear transmission mount to the transmission.
24. Carefully remove the transmission from the
machine. Avoid causing damage to the transmission
or surrounding parts.
25. Lift the transmission clear of the machine, and lower
it onto suitable supports or secure it to a stand built
especially for transmission or engine service. Secure
the transmission so that it will not move or fall.
WARNING
NEVER lift a transmission alone; enlist the help of at
least one assistant or use a suitable hoist or overhead
crane and sling.
1. Install both rear transmission mounts on the
6 5
transmission. Torque capscrews to 125-140 lb-ft
(170-190 Nm).
MY0990
2. Install two guide studs near the top of the bell
housing holes. 16. Transmission oil may be added through the dipstick
tube (5). Remove the dipstick and add hydraulic oil.
3. Use a hoist or overhead crane and sling attached to
Check the oil level by taking intermittent dipstick
the lifting eye at the top of the transmission. Raise
readings as outlined in the appropriate Operation &
and position the transmission within the chassis.
Safety Manual. DO NOT overfill. Reinstall the
4. Align the torque converter, align the transmission dipstick when finished.
bolt holes with the two studs in the bell housing.
17. Transmission transfer case fluid may be added
Install the eight bolts and washers and torque to
through the fill plug (6). Remove the fill plug and add
53 lb-ft (72 Nm). Remove the two alignment studs
approximately 1.5 quarts (1,4 liters) of hydraulic oil.
and install and torque the last two transmission
Install fill plug and tighten.
mounting bolts.
18. Properly connect the battery.
5. Install the two rear transmission mounting bolts on
the frame with two capscrews and two lockwashers. 19. Install the engine cover.
Apply Loctite® 242 to the transmission mount bolts and 20. Close and secure the engine cover.
torque to 125-140 lb-ft (169-190 Nm) 21. Remove the Do Not Operate Tags from both the
6. Turn the engine over slowly by hand and align each ignition key switch and the steering wheel.
of the four torque convertor diaphragm bolts through
the access plug in the bell housing. Install them one 6.4.4 After Transmission Service or
at a time. DO NOT fully tighten until all of the Replacement
capscrews and locknuts are in place. Torque to
In general:
26-39 lb-ft (35-59 Nm). Replace access plug.
1. Check the transmission oil level and add oil as
7. Remove the hoist or overhead crane and sling.
required.
8. Connect the transmission temperature switch
2. Disconnect and clean all transmission cooler hoses.
connector and shift solenoid wiring harness
When possible, remove transmission lines from the
connectors.
machine for cleaning.
9. Secure the wiring harness to the transmission
3. Drain and flush the entire transmission cooling
housing.
system.
10. Connect the transmission oil cooler inlet and outlet
4. Thoroughly clean transmission filter screens and
hoses at the transmission.
cases, and replace transmission filter elements.
11. Install the hydraulic pump. Refer to Section 8.6.1,
5. Reassemble all components and fill the transmission
“Implement Pump Replacement.”
with clean, fresh hydraulic oil through the dipstick
12. Install the transmission-to-axle drive shafts. Refer to tube opening (5). Check the level by taking
Section 5.4.5, “Drive Shaft Installation.” intermittent dipstick readings as outlined in the
13. Install the air cleaner and tubing. appropriate Operation & Safety Manual. DO NOT
overfill. Reinstall the dipstick when finished.
14. Clean the transmission oil filter mounting surface.
15. Apply a thin film of clean hydraulic oil to the new
transmission filter gasket. Install the new filter and
torque to 20-25 lb-ft (27-34 Nm).
6. Transmission transfer case fluid may be added 6.5 TORQUE CONVERTOR DIAPHRAGM
through the fill plug (6). Remove the fill plug and add
approximately 1.5 quarts (1,4 liters) of hydraulic oil.
Install fill plug and tighten. 6.5.1 Torque Convertor Diaphragm
Removal
7. Run the engine for two minutes at idle to help prime the
torque converter and the transmission oil lines. 1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
8. Recheck the level of the fluid in the transmission place the travel select lever in the (N) NEUTRAL
with the engine running at idle. position, engage the parking brake, and shut the
9. Add hydraulic oil as necessary to bring the fluid level engine OFF.
up until it reaches the FULL mark on the dipstick.
Note: In order to remove the engine drive plates, the
Recheck the oil level when it reaches operating
engine and transmission must be separated.
temperature 180-200° F (83-94° C).
10. Recheck all drain plugs, lines, connections, etc., for 2. Refer to Section 6.4.1, “Transmission Removal,” or
leaks, and tighten where necessary. Section 7.9.1, “Engine Removal.”
8 9
6.6 TROUBLESHOOTING
This section provides an easy reference guide covering The transmission should be checked, serviced and
the most common problems that may occur during repaired only by experienced service technicians who
operation of the transmission. are aware of all safety instructions and particular
component features
Note: Contact the local distributor if internal
transmission repair is required during the warranty
period.
2. Main pressure valve stuck open. 2. Clean the valve spool and
housing.
4. Lack of power. 1. Park or service brake dragging. 1. Refer to Section 8.4, “Hydraulic
Circuits.”
6. Grinding or “clunking” noise 1. Oil level too low. 1. Fill oil to correct level. Refer to
from transmission. Section 2.4, “Fluid and
Lubricant Capacities.”
2. Repair or replace parts as
needed.
Contents
THERMOSTAT
TURBOCHARGER
FUEL INJECTOR
PUMP
ENGINE CONTROL
MODULE (ECM)
MY1011
ALTERNATOR
STARTER
IN LINE FUEL
FILTER
OIL FILTER
MY4500
THERMOSTAT
ENGINE CONTROL
MODULE (ECM)
FUEL FILTER
FUEL INJECTOR
PUMP
STARTER
OIL FILTER
MAL0260
ALTERNATOR
TURBOCHARGER
MAL0270
FUEL FILTER
(SECONDARY)
FUEL INJECTOR
PUMP
OIL FILTER
ENGINE CONTROL
MODULE (ECM)
FUEL FILTER
(PRIMARY)
TURBOCHARGER
THERMOSTAT
ALTERNATOR
STARTER
MY5530
2
2
3 MY4520
b. Thermostat Installation 5. Slowly turn the radiator cap to the first stop and allow
any pressure to escape. Remove the radiator cap.
1. Install the engine thermostat, thermostat gasket and
thermostat housing. Secure with the two capscrews 6. Place a suitable container beneath the radiator
and torque as required. drain.
2. Connect the engine water temperature sender if 7. Place a funnel at the base of the radiator to channel
connected to the thermostat housing. the drained coolant into a container. Loosen the
drain cock and slowly remove to allow the coolant to
3. Properly connect the battery.
drain. Transfer the coolant into a properly labeled
4. Open the radiator cap, and fill the radiator container. Dispose of properly if coolant needs to be
completely with coolant. Replace and tighten the replaced. Tighten the radiator drain cock.
radiator cap. Add coolant to the overflow bottle until
8. Label, disconnect and cap the hoses attached to the
the bottle is 1/4 to 1/2 full. This overfilling will
coolant recovery tank. Remove the coolant recovery
compensate for any air trapped in the cooling
tank.
system. CUMMINS RADIATOR ASSSEMBLY
5. Run the engine to operating temperature. Visually 4 6
check for leaks with the engine running. Check the 7
coolant level in the overflow bottle and fill, or drain,
as necessary.
6. Close and secure the engine cover.
7. Remove the Do Not Operate Tags from both the
5
ignition key switch and the steering wheel.
12. Loosen and remove the hoses (7) attached to the 7.5 ENGINE ELECTRICAL SYSTEM
transmission cooler. Plug and/or cap the hoses to
prevent dirt and debris from entering the The engine electrical system, including the starter,
transmission system. Position the hoses out of the alternator and primary wiring, is described in Section 9.5,
way to allow radiator removal, or remove the hoses “Electrical System Schematics.”
from the engine. Inspect the hoses, and replace if
necessary. 7.6 FUEL SYSTEM
13. Remove the radiator fan guard.
14. Remove the nuts and washers the radiator fan 7.6.1 Diesel Fuel
shroud and pull the shroud back over the fan.
Fuel represents a major portion of machine operating
15. Remove the nuts and washers from the radiator and costs and therefore must be used efficiently. ALWAYS
oil cooler mounts. use a premium brand of high-quality, clean diesel fuel.
16. Carefully lift the radiator and oil cooler out of the Low cost, inferior fuel can lead to poor performance and
engine compartment. expensive engine repair.
Note: If more clearance is needed to remove the Note: Use only diesel fuel designed for diesel engines.
radiator, the engine fan may be removed for easier Some heating fuels contain harmful chemicals that can
access. seriously affect engine efficiency and performance.
Note: Due to the precise tolerances of diesel injection
b. Radiator/Oil Cooler Installation systems, keep the fuel clean, and free of dirt and water.
1. Install the isolator mounts to the bottom of the Dirt and water in the fuel system can cause severe
radiator and oil cooler. Place the radiator and oil damage to both the injection pump and the injection
cooler in the engine compartment at their original nozzles. Use ASTM #2 diesel fuel with a minimum Cetane
orientations. Secure with the previously used rating of 40. #2 diesel fuel gives the best economy and
hardware. performance under most operating conditions. Fuels
with Cetane numbers higher than 40 may be needed in
Note: Be sure there is adequate clearance between the high altitudes or extremely low ambient temperatures to
radiator and the engine fan. help prevent misfiring and excessive smoking.
2. If necessary, install the engine fan. Inform the owner/operator of the machine to use #2
3. Install the radiator fan shroud. diesel fuel, unless ambient temperatures are below 32° F
4. Uncap and connect the previously labeled hoses to (0° C). When temperatures are below 32° F (0° C), a
the radiator, oil cooler and/or transmission cooler. blend of #1 diesel and #2 diesel fuels (known as
“winterized” #2 diesel) may be used.
5. Connect both intercooler hoses.
Note: #1 diesel fuel may be used, however, fuel
6. Install the coolant recovery tank. Uncap and connect
economy will be reduced.
the previously removed hose.
7. Open the radiator cap and fill the radiator completely Use a low-sulfur content fuel with a cloud point (the
with coolant. Replace and tighten the radiator cap. temperature at which wax crystals form in diesel fuel) at
Refer to Section 2.4, “Fluid and Lubricant least 10° below the lowest expected fuel temperature.
Capacities,” for proper capacities. The viscosity of the fuel must be kept above
1.3 centistrokes to provide adequate fuel system
8. Properly connect the battery. lubrication.
9. Run the engine to operating temperature. Visually
check for leaks with the engine running. Check the 7.6.2 Fuel Tank
coolant level in the overflow bottle and fill, or drain,
Note: The fuel tank is a one piece unit. It is located on the
as necessary.
rear of the cab. If it is determined that the fuel tank must be
10. Close and secure the engine cover. removed, the fuel must be drained before tank removal.
11. Remove the Do Not Operate Tags from both the Always dispose of fuel properly.
ignition key switch and the steering wheel.
the exterior and look for bubbles to appear at the 7.7 ENGINE EXHAUST SYSTEM
cracked or damaged area.
2. Place a Do Not Operate Tag on both the ignition key 7.9 ENGINE REPLACEMENT
switch and steering wheel, stating that the machine
should not be operated.
7.9.1 Engine Removal
3. Open the engine cover. Allow the system fluids to
cool. Note: The radiator and oil cooler must be removed from
the machine before engine removal. Refer to Section
4. Properly disconnect the battery. 7.4, “Engine Cooling System.” Several additional
15 16 components must be removed before engine removal.
17 They will be addressed in the following procedures.
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake, and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
18 switch and steering wheel, stating that the machine
should not be operated.
3. Open the engine cover. Allow the system fluids to
MY5070
cool.
5. Loosen the clamp (15) securing the air intake elbow 4. Properly disconnect and remove the battery.
(16) engine. Properly disconnect and remove the second battery
6. Loosen the capscrews securing the air cleaner if equipped.
mounting bracket (17) to the engine fire wall. 5. Remove the engine cover. Mark the position of the
7. Remove the air cleaner assembly (17 & 18). cover to help with cover adjustment when being
reinstalled.
8. Remove the air cleaner mounting bracket (17) from
the air cleaner (18). 6. Remove the oil pan cover underneath the engine
compartment.
7.8.4 Air Cleaner Assembly Installation 7. Drain and remove the radiator assembly. Refer to
(Cummins) Section 7.4.3, “Radiator/Oil Cooler and
Replacement.”
Note: Apply Loctite® 242 to the capscrew threads
before installation. 8. Remove the heater hoses attached to the engine (if
equipped).
1. Install the air cleaner (18) to the air cleaner mounting
bracket (17). Note: The engine harness is routed and attached to the
engine using hold-down clamps and plastic wire ties at
2. Install the air cleaner assembly (17 & 18) to the
various places on the engine. Before removing engine,
engine fire wall.
ensure that the harness has been completely separated
3. Tighten the previously loosened capscrews. (disconnected) from the engine. Move the harness clear
4. Install the air intake elbow (16) onto the engine. of the engine, and with the help of an observer, ensure
that the engine clears the harness during removal.
5. Adjust and tighten the clamp (15).
6. Properly connect the battery. 9. Label and disconnect all electrical wire connections
on the engine.
7. Close and secure the engine cover.
10. Label and disconnect all electrical wire connections
8. Remove the Do Not Operate Tags from both the on the Power Distribution bracket.
ignition key switch and the steering wheel.
11. Remove the Power Distribution bracket.
12. Disconnect and cap the fuel inlet line at the fuel filter
head.
13. Disconnect and cap the fuel return line from the fuel
filter head.
14. Remove the exhaust pipe from the exhaust 7.9.2 Engine Installation
manifold. Refer to Section 7.7.1, “Exhaust System
1. Secure the engine with a lifting strap or chain from
Removal.”
the appropriate lifting points (1). Use a suitable hoist
15. Loosen the clamps on the sleeve reducer at the or overhead crane.
engine and on the air suction pipe.
Note: Apply Loctite® 242 to the engine mount bracket
16. Remove the air cleaner tube assembly. Refer to capscrew threads before installation.
Section 7.8.1, “Air Cleaner Assembly Removal (John
Deere & Perkins),” or Section 7.8.3, “Air Cleaner 2. Install two guide studs in the bell housing holes.
Assembly Removal (Cummins).” 3. Lift the engine and slowly push and lower into the
17. Remove the access plug from bottom of the engine engine bay. Have an assistant ensure that the
bell housing. This will allow access to remove the engine clears the frame, hose and harness
bolts holding the torque convertor diaphragm to the components during engine installation. Position
engine flywheel. engine brackets over the front frame mounts.
18. Turn the engine over slowly by hand and align each 4. Push the engine towards the transmission aligning
of the four torque convertor diaphragm bolts to be the guide studs and the torque convertor shaft with
accessed. Remove them one at a time. the corresponding holes.
5. Push the engine against the transmission and install
eight of the ten bolts and washers. Remove both
1
guide studs and replace with the remaining two bolts
and washers. Torque bolts to 53-58 lb-ft (72-79 Nm).
6. Remove the support from under the transmission
and lower the engine the remainder of the way onto
the frame. Align the motor mount holes and install
the bolts. Apply Loctite® 242 to the motor mount
bolts and torque to 125-140 lb-ft (169-190 Nm).
7. Turn the engine over slowly by hand and align each
of the four torque convertor diaphragm bolts through
the access plug in the bell housing. Install them one
at a time. DO NOT fully tighten until all of the
capscrews and locknuts are in place. Torque to
1 26-39 lb-ft (35-59 Nm). Replace access plug.
8. Install the exhaust pipe. Refer to Section 7.7.2,
MY4270 “Exhaust System Installation.”
19. Secure the engine with a lifting strap or chain from 9. Install the complete air cleaner assembly. Refer to
the appropriate lifting points (1). Use a suitable hoist Section 7.8.2, “Air Cleaner Assembly Installation
or overhead crane. (John Deere & Perkins),” or Section 7.8.4, “Air
20. Place a support or jack under the transmission to Cleaner Assembly Installation (Cummins).”
hold the transmission in place while engine is being 10. Connect the fuel inlet line to the fuel filter head.
removed. 11. Connect the fuel return line to the fuel filter head.
21. Remove the bolts and washer securing the engine 12. Install the Power Distribution bracket.
mounts.
13. Connect all the previously labeled electrical wire
22. Remove the ten bolts holding the transmission to the connections on the Power Distribution bracket.
engine. Slightly lift and pull the engine out of the
machine. Have an assistant ensure that the engine 14. Connect all the previously labeled electrical wire
clears all frame components during removal. connections on the engine.
23. Place engine on a flat, level surface. 15. Install both heater hoses to the engine and tighten
clamps (if equipped).
16. Install the complete radiator assembly. Refer to
Section 7.4.3, “Radiator/Oil Cooler and
Replacement.”
G10-55A, G12-55A 7-15
Engine
7.10 TROUBLESHOOTING
1. Battery charge low 21. Blocked fuel tank vent 43. Faulty suction pipe
2. Bad electrical connection 22. Incorrect grade of fuel 44. Restricted oil filter
3. Faulty starter motor 23. Sticking throttle or 45. Piston seizure/pick up
4. Incorrect grade of restricted movement 46. Incorrect piston height
lubricating oil 24. Exhaust pipe restriction 47. Damaged fan
5. Low cranking speed 25. Leaking cylinder head gasket 48. Faulty engine mounting
6. Fuel tank empty 26. Overheating 49. Incorrectly aligned flywheel
7. Faulty stop control operation 27. Cold running housing or incorrectly aligned
8. Fuel inlet restricted 28. Incorrect tappet adjustment flywheel
9. Faulty fuel lift pump 29. Sticking valves 50. Faulty thermostat
10. Clogged fuel filter 30. Incorrect high pressure pipes 51. Restriction in water jacket
11. Restricted air cleaner 31. Worn cylinder bores 52. Loose fan belt
12. Air in fuel system 32. Pitted valves and seats 53. Restricted radiator
13. Faulty fuel injection pump 33. Broken, worn or sticking 54. Faulty water pump
14. Faulty fuel injectors or piston ring(s) 55. Restricted breather pipe
incorrect type 34. Worn valve stems and guides 56. Damaged valve stem oil
15. Incorrect use of cold start 35. Restricted air cleaner deflectors (if fitted)
equipment 36. Worn or damaged bearings 57. Coolant level too low
16. Faulty cold start equipment 37. Insufficient oil in sump 58. Blocked sump strainer
17. Broken fuel injection 38. Inaccurate gauge 59. Broken valve spring
pump drive 39. Oil pump worn 60. Exhauster or vacuum pipe leak
18. Incorrect fuel pump timing 40. Pressure relief valve sticking open 61. Turbo impeller damaged or dirty
19. Incorrect valve timing 41. Pressure relief valve sticking closed 62. Turbo lubricating oil seal leak
20. Poor compression 42. Broken relief valve spring 63. Induction system leaks
Contents
TILT CYLINDER
MAL0381
MAIN CONTROL STEERING STABILIZER
OUTRIGGER SWAY CYLINDER STEERING
VALVE CYLINDER(S) CYLINDER
CYLINDER(S) CYLINDER(S)
8.2 SAFETY INFORMATION Some hydraulic functions are actuated by interfacing with
electrical system components (switches, solenoids and
sensors). When the hydraulic system is not functioning
WARNING properly, check the electrical aspect of the malfunctioning
circuit also. Refer to Section 9.5, “Electrical System
DO NOT service the machine without following all Schematics,” in this manual.
safety precautions as outlined in Section 1, “Safety
Practices,” of this manual. 8.3 HYDRAULIC PRESSURE DIAGNOSIS
Petroleum-based hydraulic fluids are used in this JLG Parts Department has a kit available to use for
machine. The temperature of hydraulic fluid increases hydraulic system maintenance and troubleshooting: the
during the operation of various hydraulic functions. A JLG Pressure Test Kit. The kit is contained in a durable
heated petroleum-based hydraulic fluid presents a fire polyethylene carrying case for demanding field service
hazard, especially when an ignition source is present. conditions.
Hydraulic fluid has a flash point that ranges from
300-600° F (150-318° C) and an auto-ignition temperature Hydraulic Pressure Test Kit
of 500-750° F (262-402° C).
The hydraulic pressure test kit is used to pressure test the
Accordingly, periodically inspect all hydraulic system
various hydraulic components in the hydraulic system.
components, hoses, tubes, lines, fittings, etc. Carefully
The kit includes:
examine any deterioration and determine whether any
further use of the component would constitute a hazard. • Gauges for testing high and low pressure circuits
If in doubt, replace the component. • Fittings, couplers and hoses
Operate the hydraulic controls after the engine has
stopped to relieve trapped pressure.
Note: Residual pressure may remain in hydraulic
cylinders, hoses, valve bodies, components, etc. If the
hydraulic lines going to or coming from a component are
taut, slowly and cautiously relieve (“bleed off”) pressure.
Whenever you disconnect a hydraulic line, coupler, fitting
or other component, slowly and cautiously loosen the part
involved. A hissing sound or slow seepage of hydraulic
fluid may occur in most cases. After the hissing sound
has ceased, continue removing the part. Any escaping oil
should be directed into an appropriate container. Cap or
otherwise block off the part to prevent further fluid seepage.
Hydraulic system maintenance will, at times, require that
MZ1460
the engine be operated. Always follow safety precautions.
A major cause of hydraulic component failure is Contact JLG Parts Department Toll Free at
contamination. Keeping the hydraulic fluid as clean as 1-877-554-5438 or 717-485-6472 for ordering
possible will help avoid downtime and repairs. Sand, grit information.
and other contaminants can damage the finely machined Part Approximate Price and
Description
surfaces within hydraulic components. If operating in an Number Weight Availability
exceptionally dirty environment, change filters and Dial Hydraulic Pressure
70000652 10 lbs. Consult Factory
inspect the fluid more often. When servicing the system, Test Kit
cap or plug hydraulic fittings, hoses and tube assemblies. 70000101
Digital Hydraulic Pressure
7 lbs. Consult Factory
Plug all cylinder ports, valves and the hydraulic reservoir, Test Kit
and pump openings until installation occurs. Protect Digital Hydraulic Pressure
70027911 7 lbs. Consult Factory
Test Kit
threads from contamination and damage.
3. Tighten the jam nut and recheck the pressure at full 10. Monitor the gauge and slowly raise the boom. The
throttle. If the reading is within specification, shut the gauge should read 4100 psi (282 bar).
machine off, install the safety cap and remove the
11. If pressure is correct, proceed to step 14.
gauge from the test port.
A
4. If the proper pressure cannot be set, use the A
accompanying hydraulic schematic and/or the
electrical schematic to help troubleshoot and correct
the problem.
4. Install a tee fitting to the retract (1) port of the 17. Start the machine and if needed, warm the hydraulic
compensation cylinder. Reconnect the previously system to operating temperature.
removed retract (1) hose to the tee fitting. 18. Tilt the forks up to allow the tilt cylinder to fully
5. Slowly loosen and remove the extend (2) hose from extend.
the compensation cylinder. 19. Monitor the gauge and slowly lower the boom. The
6. Install a tee fitting to the extend (2) port of the gauge should read 4100 psi (282 bar).
compensation cylinder. Reconnect the previously 20. If pressure is correct, proceed to step 23.
removed extend (2) hose to the tee fitting and cap
the open port.
7. Install a digital or a 5000 psi (345 bar) gauge to the
retract (1) port tee fitting on the compensation
cylinder.
8. Start the machine and warm the hydraulic system to
operating temperature.
9. Tilt the forks down to allow the tilt cylinder to fully
retract.
B
B
HUSCO REXROTH
MY4490
FRONT OF MACHINE
a. Pressure Specifications
Before S/N 0160037877
E E
HYDRAULIC HYDRAULIC
MANIFOLD
3 3
MANIFOLD
1 1
4 4
2 2
D C MY1141 MY1831
B D C B
G10-55A - Before S/N 0160031864 G10-55A - S/N 0160031864 & After
G12-55A - Before S/N 0160030644 G12-55A - S/N 0160030644 & After
MY1301
7 6 5
b. Pressure Specifications
S/N 0160037877 & After
5
6
MY1831
D C B
7 9
MY4360
8.4.3
MY1170H
B1 B2
A1 A2
CYLINDER
CYLINDER
G10-55A, G12-55A
REAR STEERING
FRONT STEERING
P T STEER SELECT
VALVE
SERVICE
BRAKE VALVE
SL SR
REAR
SERVICE
BRAKES
OUTLET
RSB
Hydraulic Schematic
INLET
BV
STEERING ORBITROL
OUTLET
FSB
LOAD FRONT
PR T ST SERVICE
SENSE
BRAKES
BLS
PARK
BRAKES
TANK
BT
PR
JS TO MAIN
CONTROL
VALVE
LS
SLS
T
T2
HYDRAULIC OIL
COOLER
70 PSI
P BV BV1 JS JS1 PB
.030
BLS .030
1100 PSI
PLS
25 PSI
STABILIZER
500 PSI SLS CYLINDER
RETURN W/O LOCK
FILTER
B 8 = 75
GLS
GP
T
3.66 CID
LS 10 MICRON
3625PSI
261PSI
BREATHER
Hydraulic System
LS2
S L,L1
8-9
8-10
LEFT OUTRIGGER RIGHT OUTRIGGER
LIFT CYLINDER LIFT CYLINDER CROWD CYLINDER CYLINDER CYLINDER SWAY CYLINDER TILT CYLINDER
Before S/N 0160037877
.040 .050
COMPENSATING
SWAY CYLINDER
OUTRIGGER
P T
T
T
1 2 COMBINATION VALVE
P
P SRT SLT P
T
RTT 1 2 3 4 1 2 1 2
LOD LOU ROD ROU T SV1
LUP CIN LDN COUT
SV2 SV3
TO PUMP
2 SV4 SV5
PR
1
L R
P
JS
LS
SLS
T
T2
PR b a B A b a B A b a B A b a B A b a B A B A
X
3150 PSI
3650 PSI (-0/+25)
PLS
T2
4100 PSI
4100 PSI
4100 PSI
P2
2600 PSI
4100 PSI
4100 PSI
4100 PSI
LS LS
MY1180H
G10-55A, G12-55A
LEFT OUTRIGGER RIGHT OUTRIGGER
G10-55A, G12-55A
LIFT CYLINDER LIFT CYLINDER CROWD CYLINDER CYLINDER CYLINDER SWAY CYLINDER TILT CYLINDER
.040 .050
COMPENSATING
SWAY CYLINDER
AUX
T
8.4.3 Hydraulic Schematic (Continued)
RTT 1 2 3 4 1 2 1 2
LOD LOU ROD ROU
LUP CIN LDN COUT
TO PUMP
(SEE SHEET 1)
PR
P
"QD'S"
JS
LS
SLS
T
T2
DECOMPRESSION
VALVE
PILOT
SUMP
LS PR HPCO PPA A B PPA A B PPA A B PPA A B PPA A B PPA A B A B
4100psi 3000psi 3000psi 4100psi
2600psi 3300psi 3300psi 3300psi 4100psi 4100psi
SLS
3400psi
GAGE
INLET
GAGE
PRIORITY FLOW INLET LIFT CROWD LEFT O/R RIGHT O/R SWAY AUX TILT OUTLET
MAL0710-C
Hydraulic System
8-11
Hydraulic System
SWAY CYLINDER
.040 .050
SWAY/AUX JOYSTICKS
T
1 2 1 2
AUXILIARY
HYDRAULICS
PORTS
b B A a b B A a
DECOMPRESSION
VALVE
SWAY AUX
a. Reservoir Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
MY5300 (N) NEUTRAL, engage the park brake and shut the
engine OFF.
The hydraulic reservoir (1) is located on the frame
2. Place a Do Not Operate Tag on both the ignition key
between the engine compartment and the cab.
switch and the steering wheel, stating that the
machine should not be operated.
8.5.1 Hydraulic Oil Reservoir Draining
3. Open the engine cover. Allow the system fluids to
1. Park the machine on a firm, level surface, level the cool.
machine, fully retract the boom, lower the boom,
place the transmission control lever in 4. Properly disconnect the battery.
(N) NEUTRAL, engage the park brake and shut the 5. Drain the hydraulic oil reservoir. Refer to Section
engine OFF. 8.5.1, “Hydraulic Oil Reservoir Draining.”
2. Place a Do Not Operate Tag on both the ignition key 6. Label, disconnect and cap all hydraulic hoses
switch and the steering wheel, stating that the attached to the hydraulic oil reservoir. Cap all fittings
machine should not be operated. and openings to keep dirt & debris from entering the
3. Open the engine cover. Allow the system fluids to hydraulic system.
cool. 7. Remove the bolts securing the hydraulic oil reservoir
4. Properly disconnect the battery. to the frame.
5. Open the filler cap on the hydraulic oil reservoir. 8. Remove the hydraulic oil reservoir.
Remove the drain plug on the side of the hydraulic
oil reservoir. b. Disassembly
6. Transfer the used hydraulic oil into a suitable The hydraulic oil reservoir is a one-piece unit and cannot
covered container, and label as "Used Oil". Dispose be disassembled. The hydraulic oil level sight- glass and
of used oil at an approved recycling facility. Clean hydraulic oil filler cap can be removed and reused on the
and reinstall the drain plug. new replacement reservoir. Dispose of the old reservoir
according to local regulations concerning hazardous
7. Wipe up any hydraulic fluid spillage in, on, near and
materials disposal.
around the machine and the work area.
e. Reservoir Installation
1. Place the hydraulic oil reservoir into its original
orientation.
2. Secure the hydraulic oil reservoir to the frame with 2
the previous mounting hardware.
3. Uncap and connect the previously labeled hydraulic 2
hoses to their appropriate locations.
4. Install the hydraulic fluid level sight-glass using
special designed and drilled capscrews and gaskets.
5. Install hydraulic filter bracket and hydraulic filter.
6. Fill the hydraulic oil reservoir according to
specifications. Refer to Section 2.4, “Fluid and
Lubricant Capacities.”
7. Check the hydraulic oil reservoir for leaks.
8. Properly connect the battery.
MAL0720
9. Close and secure the engine cover.
10. Remove the Do Not Operate Tags from both the 8. Remove the four bolts and lockwashers (2) securing
ignition key switch and the steering wheel. the pump to the transmission (top bolts shown only).
Remove the o-ring located between the transmission
and the pump. Wipe up any hydraulic oil spillage.
Note: DO NOT disassemble the operating pump. The 8.7 CONTROL VALVES
pump is pre-set from the manufacturer. Any adjustments
or repairs performed by anyone other than an authorized
dealer could void the warranty. 8.7.1 Main Control Valve
The main control valve is mounted at the top of the
b. Pump Installation chassis in front of the mast supports.
1. Place the pump and a new, oiled o-ring into position The main control valve assembly consists of individual
on the transmission. Align the pump shaft with the working sections with their own valve assemblies, each
internal transmission gear, so that the machined providing a specific hydraulic function.
teeth mesh together.
a. Main Control Valve Removal
2. Align the bolt holes with the pump mount holes.
3. Apply Loctite® 242 to the previously removed bolts. 1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, raise the boom, place
4. Secure the pump to the transmission with the four the transmission control lever in (N) NEUTRAL,
bolts and washers. Torque as required. engage the park brake and shut the engine OFF.
5. Uncap and connect the previously labeled hydraulic 2. Place a Do Not Operate Tag on both the ignition key
hoses to their appropriate locations. switch and the steering wheel, stating that the
6. Fill the hydraulic reservoir. Refer to Section 8.5.2, machine should not be operated.
“Hydraulic Oil Reservoir Filling.” 3. Open the engine cover. Allow the system fluids to
7. Prime the pump by filling the case drain port with fresh, cool.
filtered hydraulic oil from a clean container before 4. Properly disconnect the battery.
installing the case drain connector and hose.
5. Close the engine cover.
8. Check all routing of hoses and tubing for sharp
bends or interference with any rotating members. All 6. Remove the main valve cover.
tube and hose clamps must be tight. 7. Thoroughly clean the main control valve and
9. Remove the 10 amp fuse from location F3 in power surrounding area, including all hoses and fittings,
distribution unit located in the engine compartment. before proceeding.
This will allow the engine to crank, but not start while 8. Drain the hydraulic fluid reservoir. Refer to Section
air is worked out of the new pump. 8.5.1, “Hydraulic Oil Reservoir Draining.”
10. Connect a hose to the “P1” port on the pump. Direct 9. Place a suitable container to catch hydraulic fluid
the open end of the hose into a fluid drip pan. drainage beneath the frame.
11. Properly connect the battery. Note: Slowly remove the hydraulic hoses attached to
12. Turn the machine ignition switch to START and back the main control valve to relieve any possible trapped
OFF in 3 to 5 second intervals. Monitor the open end pressure in the hydraulic line.
of the drain hose for a constant flow of fluid (no air) 10. Label, disconnect and cap all the hydraulic hoses,
while engine is cranking. tubes and wires at the main control valve.
13. Once a constant flow is achieved at the open end of 11. Wipe up any hydraulic fluid spillage in, on, near and
the drain hose, disconnect the hose and reinstall the around the machine and the work area.
10 amp fuse to location F3 in the power distribution
unit.
14. Inspect for leaks and check all fluid levels. The
hydraulic reservoir oil level must be to the middle of
the sight gauge.
15. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
c. Pump Test
Refer to Section 8.3.1, “Pressure Checks and
Adjustments.”
4. Using the proper o-rings and load sense shuttle, 8.7.3 Service Brake Valve
repeat step three for the remaining valve sections
and lastly the inlet end valve section. a. Service Brake Valve Removal
5. Install the three washers and nuts on the tie rods. 1. Park the machine on a firm, level surface, level the
Torque to 30 lb-ft (41 Nm). machine, fully retract the boom, lower the boom,
place the transmission control lever in (N) NEUTRAL,
e. Main Control Valve Installation engage the park brake and shut the engine OFF.
1. Install the main control valve onto the frame, aligning 2. Place a Do Not Operate Tag on both the ignition key
the bolts with the holes in the end sections of the switch and the steering wheel, stating that the
main control valve. Slide the main control valve into machine should not be operated.
position, and tighten the bolts. 3. Open the engine cover. Allow the system fluids to
2. Prime the main control valve by filling the inlet cool.
openings with fresh, filtered hydraulic oil from a 4. Properly disconnect the battery.
clean container, before attaching the hoses.
5. Label, disconnect and cap all hose attached to the
3. Use new oiled o-rings as required. Uncap and service brake valve.
connect all previously labeled hoses, clamps, etc. to
the main control valve. 6. Remove the service brake pedal. Refer to Section
4.3.2, “Service Brake Pedal.”
4. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
members, and install tie wraps and/or protective 4
conduit as required. Tighten all tube and hose
clamps.
5. Fill the hydraulic fluid reservoir. Refer to Section 3
8.5.2, “Hydraulic Oil Reservoir Filling.”
3
6. Properly connect the battery.
7. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
moving the machine or operating any hydraulic 5
functions.
8. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as needed.
9. Wipe up any hydraulic fluid spillage in, on, near and MAL0740
around the machine, work area and tools.
7. Remove the four capscrews, four nuts and four
10. Install the main control valve cover. lockwashers (3) mounting the service brake valve
11. Close and secure the engine cover. (4) to the service brake bracket (5).
12. Remove the Do Not Operate Tags from both the Note: DO NOT disassemble the service brake valve.
ignition key switch and the steering wheel. The service brake valve is not serviceable and must be
replaced in its entirety, if defective.
f. Main Control Valve Test
Conduct a pressure check of the hydraulic system in its
entirety. Adjust pressure(s) as required. Refer to Section
8.3.1, “Pressure Checks and Adjustments.”
8.7.5 Service Brake Test 4. Smoothly and controllably release the service brake.
This procedure is used in order to determine if the service 5. Smoothly and controllably depress the throttle pedal.
brake is functional. This procedure is not intended to Note: Do Not hold the accelerator pedal in the fully
measure the maximum brake performance. the brake depressed position for more than ten seconds. Damage
holding torque that is required to sustain an engine torque to the power train could occur.
at a specific engine rpm varies depending on the machine
configuration. The variations are the differences in the 6. Smoothly and controllably fully release the throttle
engine settings, power train efficiency and in the brake pedal.
holding ability, etc. 7. The machine should remain stationary during the
Conduct the following service brake test on a dry level test.
surface, clear of any personnel and/or obstacles. 8. If the machine does not remain stationary during this
1. Place the travel select lever in (N) NEUTRAL, test, contact the local distributor for proper service.
engage the park brake, and start the engine. 9. Engage the park brake, place the travel select lever
2. Raise the boom to a travel position. in (N) NEUTRAL, lower the boom and shut engine
OFF.
3. Depress the service brake, disengage the parking
brake and place the travel select lever in third gear
forward.
8.7.7 Steering Orbitrol Valve
4. Smoothly and controllably depress the throttle pedal.
Note: Do Not hold the accelerator pedal in the fully
depressed position for more than ten seconds. Damage
to the power train could occur.
5. Smoothly and controllably fully release the throttle
pedal.
6. The machine should remain stationary during the
test.
7. If the machine does not remain stationary during this
test, contact the local distributor for proper service.
8. Engage the park brake, place the travel select lever
in (N) NEUTRAL, lower the boom and shut engine
OFF.
8.7.8 Steer Select Valve b. Steer Select Manifold and Valve Disassembly,
Cleaning, Inspection and Assembly
1. Place the steer select assembly on a suitable work
surface.
2. Separate the steer select valve from the manifold by
removing the four socket head capscrews. Discard
8 the four o-rings.
3. Remove the solenoid valves and cartridges from the
steer select housing.
4. Clean all components with a suitable cleaner before
inspection.
5. Inspect the solenoid cartridges for proper operation.
MY4290
Check by shifting the spool to ensure that it is
The machine can be used in the front-wheel, four-wheel functioning properly. Check that the spring is intact.
or crab steering mode. The steer select valve (8) controls Inspect the cartridge interior for contamination.
the direction of hydraulic fluid flow to the steering cylinder 6. Inspect internal passageways of the steer select
mounted on each axle. The steer select valve is attached manifold and valve for wear, damage, etc. If inner
to a mounting plate under the frame near the left front surfaces of the manifold DO NOT display an ultra-
corner of the cab. smooth, polished finish, or components are
Verify the correct operation of the steer select valve damaged in any way, replace the manifold or
solenoids before considering replacement of the valve. appropriate part. Often, dirty hydraulic fluid causes
Refer to Section 9.5, “Electrical System Schematics,” and failure of internal seals and damage to the polished
Section 9.11, “Display Monitor and Gauges.” The housing surfaces within the secondary function manifold.
of the steer select valve is not serviceable and must be Note: ALWAYS replace seals, o-rings, gaskets, etc.,
replaced if defective. with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
a. Steer Select Manifold and Valve Removal hydraulic oil.
1. Park the machine on a firm, level surface, level the 7. Install the solenoid valves and cartridges in the steer
machine, fully retract the boom, lower the boom, select housing.
place the transmission control lever in (N) NEUTRAL,
engage the park brake and shut the engine OFF. 8. Attach the steer select valve to the manifold using
four new, oiled o-rings and the four socket head
2. Place a Do Not Operate Tag on both the ignition key capscrews.
switch and the steering wheel, stating that the
machine should not be operated. c. Steer Select Valve and Manifold Installation
3. Open the engine cover. Allow the system fluids to
1. Install the steer select valve to the mounting plate
cool.
under the left front side of the frame using the two
4. Properly disconnect the battery. bolts.
5. Label, disconnect and cap the hydraulic hoses and 2. Connect all the hydraulic hoses, fittings, solenoid
the electrical plugs connected to the steering select wire terminal leads, etc., to the steer select valve
valve.
3. Check the routing of all hoses, wiring and tubing for
6. Remove the bolts holding the steer select valve to sharp bends or interference with any rotating
the mounting plate on the frame. members, and install tie wraps and/or protective
7. Remove the steer select manifold with the attached conduit as required. Tighten all hose clamps.
steer select valve from the machine. Wipe up any 4. Properly connect the battery.
hydraulic fluid spillage in, on, near and around the
5. Start the engine and run at approximately 1/3-1/2
machine.
throttle for about one minute without moving the
machine or operating any hydraulic functions.
6. Inspect for leaks and check the level of the hydraulic a. General Cylinder Disassembly
fluid in the reservoir. Shut the engine OFF.
1. Clean the cylinder with a suitable cleaner before
Note: Check for leaks and repair as required before disassembly. Remove all dirt, debris and grease
continuing. Add hydraulic fluid to the reservoir as from the cylinder.
needed. 2. Clamp the barrel end of the cylinder in a soft-jawed
7. Wipe up any hydraulic fluid spillage in, on, near and vise or other acceptable holding equipment if
around the machine, work area and tools. possible.
8. Close and secure the engine cover.
9. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
WARNING
Significant pressure may be trapped inside the cylinder.
d. Steering Test Exercise caution when removing a counterbalance valve
or a pilot-operated check valve from a cylinder.
Refer to Section 8.4.1, “ Hydraulic Pressures.”
Note: Avoid using excessive force when clamping the
1. Conduct a pressure check of the steering hydraulic
cylinder in a vise. Apply only enough force to hold the
circuit.
cylinder securely. Excessive force can damage the
2. Check each steering mode for proper function. cylinder tube.
Note: Protect the finish of the rod at all times. Damage b. Cylinder Cleaning Instructions
to the surface of the rod can cause seal failure.
1. Discard all seals, back-up rings and o-rings. Replace
5. Using a pin spanner wrench, unscrew the head with new items from seal kit to ensure proper
gland (4) from the tube (2). A considerable amount cylinder function.
of force will be needed to remove the head gland. 2. Clean all metal parts with an approved cleaning
6. Carefully slide the head gland down along the rod solvent such as trichlorethylene. Carefully clean
toward the rod eye, away from the cylinder barrel. cavities, grooves, threads, etc.
Note: When sliding the rod and piston assembly out of Note: If a white powdery residue is present on threads
the barrel, prevent the threaded end of the barrel from or parts, it can be removed by using a soft brass wire
damaging the piston. Keep the rod centered within the brush. Wipe clean with Loctite® Cleaner prior to
barrel to help prevent binding. reassembly.
7. Carefully pull the rod assembly (3) along with the
head gland (4) out of the cylinder barrel. 8.8.2 Cylinder Inspection
8. Fasten the rod eye in a soft-jawed vise, and place a 1. Inspect internal surfaces and all parts for wear,
padded support under and near the threaded end of damage, etc. If the inner surface of the cylinder
the rod to prevent any damage to the rod. barrel does not display a smooth finish, or is scored
or damaged in any way, replace the barrel.
9. Remove the set screw from the piston head (5).
2. Remove light scratches on the piston, head gland,
10. If equipped, remove the piston head (5) mounting rod or inner surface of the cylinder barrel with a 400-
nut (6). 600 grit emery cloth. Use the emery cloth in a rotary
Note: It may be necessary to apply heat to break the motion to polish out and blend the scratch(es) into
bond of the sealant between the piston and the rod the surrounding surface.
before the piston can be removed. 3. Check the piston rod assembly for run-out. If the rod
Some cylinder parts are sealed with a special organic is bent, it must be replaced.
sealant and locking compound. Before attempting to
disassemble these parts, remove any accessible seals c. General Cylinder Assembly Instructions
from the area of the bonded parts. Wipe off any hydraulic 1. Use the proper tools for specific installation tasks.
oil, then heat the part(s) uniformly to break the bond. A Clean tools are required for installation.
temperature of 300-400° F (149-204° C) will destroy the
2. Install new seals, back-up rings and o-rings on the
bond. Avoid overheating, or the parts may become
piston and new seals, back-up rings, o-rings and
distorted or damaged. Apply sufficient torque for removal
bearing on the head gland.
while the parts are still hot. The sealant often leaves a
white, powdery residue on threads and other parts, which Note: The extend/retract cylinder has a spacer that
must be removed by brushing with a soft brass wire brush MUST be installed over the rod AFTER the head gland
prior to reassembly. and BEFORE the piston head.
11. Remove the piston head (5) from the rod (3) and 3. Fasten the rod eye in a soft-jawed vise, and place a
carefully slide the head gland (4) off the end of the padded support under and near the threaded end of
rod. the rod to prevent any damage to the rod.
12. Remove all seals, back-up rings and o-rings from the
Note: Protect the finish on the cylinder rod at all times.
piston head and all seals, back-up rings and o-rings
Damage to the surface of the rod can cause seal failure.
from the head gland.
4. Lubricate and slide the head gland over the cylinder
Note: The head gland bearing will need to be inspected
rod. Install the piston head on to the end of the
to determine if replacement is necessary.
cylinder rod. Loctite® and install the set screw in the
DO NOT attempt to salvage cylinder seals, sealing rings piston head. Refer to Section 8.8.5, “Cylinder Torque
or o-rings. ALWAYS use a new, complete seal kit when Specifications” for torque specifications for the
rebuilding hydraulic components. Consult the parts piston head and the set screw.
catalog for ordering information.
Note: Avoid using excess force when clamping the 8.8.3 Cylinder Pressure Checking
cylinder barrel in a vise. Apply only enough force to hold
Attach a 5000 psi (345 bar) gauge to the test port on the
the cylinder barrel securely. Excessive force can
P1 port on the hydraulic manifold to check the system
damage the cylinder barrel.
pressure. For more information, refer to Section 8.4.1,
5. Place the cylinder barrel in a soft-jawed vise or other “ Hydraulic Pressures.”
acceptable holding devise.
Note: If a hydraulic cylinder pressure is greater than the
Note: When sliding the rod and piston assembly into the main control valve pressure, increase the main control
cylinder barrel, prevent the threaded end of the cylinder valve pressure by adjusting the main relief. Generally,
barrel from damaging the piston head. Keep the cylinder one half turn clockwise will be adequate to check an
rod centered within the barrel to prevent binding. individual circuit. Activate the circuit and if pressure is
obtained turn the main relief counter clockwise one half
6. Carefully insert the cylinder rod assembly into the
turn. Re-check the main relief setting and adjust if
cylinder barrel.
necessary.
7. Screw the head gland into the cylinder barrel and
tighten with a spanner wrench. Refer to Section 8.8.4 Steering Cylinders
8.8.5, “Cylinder Torque Specifications” for torque
specifications for the head gland.
STEERING CYLINDER
8. If applicable, install new counter balance valve into
block on the cylinder barrel.
a. Lift/Lower Cylinder
b. Extend/Retract Cylinder
CB Valve CB Valve
Head Nut
(Large) (Small)
500-550 lb-ft 1325-1375 lb-ft 110 lb-ft 35 lb-ft
G10-55A - Before S/N 0160033661
(678-745 Nm) (1796-1864 Nm) (149 Nm) (47 Nm)
G10-55A - S/N 0160033661 thru 1400-1700 lb-ft 110 lb-ft 33 lb-ft
0160035822 (1796-1864 Nm) (149 Nm) (44 Nm)
1400-1700 lb-ft 110 lb-ft 33 lb-ft
G10-55A - S/N 0160035822 & After
(1796-1864 Nm) (149 Nm) (44 Nm)
G12-55A - Before S/N 0160033659 500-550 lb-ft 1325-1375 lb-ft 110 lb-ft (149 35 lb-ft (47
excluding 0160033452 (678-745 Nm) (1796-1864 Nm) Nm) Nm)
G12-55A - S/N 0160033659 thru 1400-1700 lb-ft 110 lb-ft 33 lb-ft
0160035879 including 0160033452 (1796-1864 Nm) (149 Nm) (44 Nm)
1400-1700 lb-ft 110 lb-ft 33 lb-ft
G12-55A - S/N 0160035879 & After
(1796-1864 Nm) (149 Nm) (44 Nm)
c. Tilt Cylinder
d. Compensation Cylinder
Head Nut
G10-55A - Before S/N 0160033659
550-600 lb-ft (745-813 Nm) 2050-2100 lb-ft (2779-2847 Nm)
excluding 0160033452
G10-55A - S/N 0160033659 thru
2200-2400 lb-ft (2982-3254 Nm)
0160037689 including 0160033452
G10-55A - S/N 0160037689 & After 2200-2400 lb-ft (2982-3254 Nm)
G12-55A - Before S/N 0160033659
600 lb-ft (813 Nm) 2250-2300 lb-ft (3050-3118 Nm)
excluding 0160033452
G12-55A - S/N 0160033659 thru
1600-2000 lb-ft (2169-2712 Nm)
0160037689 including 0160033452
G12-55A - S/N 0160037689 & After 1600-2000 lb-ft (2169-2712 Nm)
e. Sway Cylinder
f. Stabilizer Cylinder
G12-55A - Before S/N 0160033659 300-325 lb-ft 775-825 lb-ft 2.5 lb-ft
22 lb-ft (30 Nm)
excluding 0160033452 (407-441 Nm) (1050-1119 Nm) (3,3 Nm)
G12-55A - S/N 0160033659 & After 800-1000 lb-ft 2.5 lb-ft
22 lb-ft (30 Nm)
including 0160033452 (1085-1356 Nm) (3,3 Nm)
g. Outrigger Cylinder
Contents
OPTIONAL POWER
DISTRIBUTION UNIT
(behind dash panel)
OPTIONAL
HEATER/AC CONTROLS
MY5540
IGNITION
SWITCH
OIL PRESSURE
SENDER
FUEL SHUT-OFF
SOLENOID
STARTER RELAY
MY1030 MY1281
ENGINE CONTROL
MODULE (ECM)
OPTIONAL POWER
DISTRIBUTION UNIT
(behind dash panel)
OPTIONAL
HEATER/AC CONTROLS
MY4350
IGNITION
SWITCH
COOLANT
TEMPERATURE SENDER ALTERNATOR
(Below Alternator)
OIL PRESSURE
SENDER
STARTER RELAY
MAL0320
MY1850
OPTIONAL POWER
DISTRIBUTION UNIT
(behind dash panel)
OPTIONAL
HEATER/AC CONTROLS
MY4350
IGNITION
SWITCH
COOLANT
TEMPERATURE SENDER
MY4550
ALTERNATOR
ENGINE CONTROL
MODULE (ECM)
MY4540
WARNING
DO NOT service the machine without following all
safety precautions as outlined in Section 1, “Safety
Practices,” of this manual.
MY1800
CUMMINS
1 MY4550
F8 F3
IGN1
CB3 F4
CB4 CB2 CB1 F1
F9 F7
IGN3
F10
ACCY1
F11 F2
F12 F5
ACCY2
F6
MY1250
Connector Legend
No. Function Amp Rating
CB1 Options Power 3 20
CB2 Options Power 4 20
CB3 Options Power 1 20
CB4 Options Power 2 20
F1 Trans/Park Brake Power 15
F2 Alternator Excite 5
F3 Engine ECU Ignition Power 10
F4 Gauge Power 10
F5 Spare Accessory Power 15
F6 Auxiliary Electric Power 10
F7 Horn Power 15
F8 Spare Battery Power 25
F9 Engine ECU Battery Power 25
F10 Steer/Sway Power 10
F11 Rear Axle Stabilizer/Tilt Power 10
F12 Key Battery Power 15
IGN1 Ignition 1
IGN 2 Ignition 2
ACCY1 Accessory 1
ACCY2 Accessory 2
F8 F3
IGN1
F15 F4
F16 F14 F13 F1
F9 F7
IGN3
F10
ACCY1
F11 F2
F12 F5
ACCY2
F6
MY4610
Connector Legend
No. Function Amp Rating
F1 Trans/Park Brake Power 15
F2 Alternator Excite 5
F3 Engine ECU Ignition Power 10
F4 Gauge Power 10
F5 Spare Accessory Power 15
F6 Auxiliary Electric Power 10
F7 Horn Power 15
F8 Spare Battery Power 25
F9 Engine ECU Battery Power 25
F10 Steer/Sway Power 10
F11 Rear Axle Stabilizer/Tilt Power 10
F12 Key Battery Power 15
F13 Options Power 3 20
F14 Options Power 4 20
F15 Options Power 1 20
F16 Options Power 2 20
IGN1 Ignition 1
IGN 2 Ignition 2
ACCY1 Accessory 1
ACCY2 Accessory 2
F1
R1 R5
F2
F3
R2 R6
F4
F5
R3 R7
F6
F7
R4 R8
F8
MY1260
Connector Legend
No. Function Amp Rating
F1 Wiper 20
F2 Option (Roof Wiper) 5
F3 Option 15
F4 Option 25
F5 Heater 20
F6 Lights 20
F7 Beacon 10
F8 Dash Fan 10
R1 Wiper
R2 Heater Blower
R3 Aux Elec 1
R4 Aux Elec 2
R5 Option 15
R6 Option 25
R7 Lights
R8 Beacon/Fan
KEY IGN
FUL LVL (D BLU, 18 GA GXL)
I
A
DASH GND
4
1
(BLK, 18 GA GXL)
CLT TMP (D BLU, 18 GA GXL)
GAGE PWR (RED, 18 GA GXL)
G
FAULT LT/473
BEEDE GAUGE
(D BLU, 18 GA GXL)
3
2
3
2
(RED, 18 GA GXL)
TRANS TMP SW
(RED, 18 GA GXL)
ST RLY
ON
SHIFT PWR 1
OFF
ON
HORN
OFF
(BLK, 18 GA GXL)
PK BRK SOL
HR MTR
SHTDN OVR
CHECK ENG
HD34-24-31ST
OIL PSI
LEFT DASH PANEL
OVR SUP/911
STEER/SWAY PWR
OVR SGN/918 STR AW
FAULT LT/473
TRAN/BRK PWR TRAN/BRK PWR
PLUGGED
PLUGGED
3
2
1
3
2
1
PLUGGED
+
PLUGGED
OFF
CRAB
ON
ALL WHL
PLUGGED
-
6
5
4
7
PLUGGED
HR MTR
6
5
4
7
PK BRK SOL
PARK BRAKE
STEER MODE
PLUGGED ST RLY
PLUGGED PK BRK SOL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
SHIFT PWR 1
DASH GND
DASH GND
F4
F3
F2
F1
N4
N3
N2
N1
R4
R3
R2
R1
GEAR
SW3
SW1
R
F
1
4
N
TRANS SOL Y1
2
3
TRANS SOL Y3
TRANS SOL Y5
TRANS SOL Y4
SHIFT PWR 1
KEY START
Y2, Y6
Y1, Y6
TRANS SOL Y2
Y2, Y3, Y6
Y1, Y3, Y6
PK BRK SOL
3
2
HOBBS
1 2 3 4 5 6 7 8
4
1
N
R
F
TRANSMISSION LEGEND
SW4
SW2
TO CHASSIS ASSEMBLY
THR SGN/915
THR RTN/914
OVR SUP/911
PLUGGED
PLUGGED
WILLIAMS
PLUGGED
A B C D E F
(SUSPENDED)
TWIST
THROTTLE
12 TURNS
PER FOOT
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
PLUGGED PLUGGED 3 87a
KEY START TRAN/BRK PWR 1 30
SHIFT PWR 1 REVERSE 4 87
PK BRK SOL TRANS SOL Y2 5 86
RELAY
TRAN/BRK PWR
SHIFTER GND
OVR SUP/911
THR SGN/915
THR RTN/914
SP BAT PWR
SP ACCY PWR
SP CAB GND 1 PLUGGED 3 87a
SP CAB GND 2 SHIFTER GND 1 30
HD34-24-31PT
SP-1 TRANS TMP SW 4 87
SHIFTER HARNESS
SP-2 KEY START 5 86
SP-3 SHIFTER GND 2 85
TRANS TMP SW
TEST RELAY
WARN LIGHT
AC CLUTCH
STAB/TILT PWR
TILT UP
TILT DN
SP BAT PWR
STAB/TILT PWR
PLUGGED
PLUGGED STD JOY PWR
TILT
RED YEL
PLUGGED
SPEED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
STAB/TILT PWR
SHIFTER GND
TILT UP
TILT DN TILT UP RED
1 2 3 4
DT06-4S
TILT
UP
ROLLER OPTION
SHIFTER HARNESS
TILT DN BLU
TO TILT ON JOYSTICK
TILT
JOYSTICK
DOWN
PLUGGED PLUG
STANDARD
PLUGGED PLUG
1 2 3 4 5 6
SP BAT PWR
SP ACCY PWR
SP-3
SP-2
SP-1
SP CAB GND 2
SP CAB GND 1
SEE AC CLUTCH
SHEET 2
Cab Schematic - John Deere 9.5.1
ELECTRICAL SYSTEM SCHEMATICS 9.5
Electrical System
9-11 G10-55A, G12-55A
MAL0160
120 OHM
CAN TERMINATOR
B
A
KEY IGN
I
(CAN L/905, GREEN)
KEY/IGN
CABLE
STEER/SWAY PWR
STR AW
STR CRB HORN PWR
HORN HORN
FUL LVL
3
2
(RED, 18 GA GXL)
TRANS TMP SW
(RED, 18 GA GXL)
(RED, 18 GA GXL)
(RED, 18 GA GXL)
ST RLY
ON
OFF
SHIFT PWR 1
HD34-24-31ST
(BLK, 18 GA GXL)
HORN
PK BRK SOL
HR MTR
OIL PSI
ENG STOP
ENG WARN
LEFT DASH PANEL
CLT TMP
DASH PANEL HARNESS
STR CRB
TRANS TMP WRN
WAIT TO START LT
STEER/SWAY PWR
WAIT TO START
ENG WARN LT
STR AW
ENG STOP LT
TRAN/BRK PWR TRAN/BRK PWR
PLUGGED
3
2
1
3
2
1
PLUGGED
PLUGGED
+
PLUGGED
ON
OFF
CRAB
ALL WHL
PLUGGED
-
HR MTR
6
5
4
7
6
5
4
7
CAN H
PARK BRAKE
PK BRK SOL
STEER MODE
CAN L ST RLY
SHIELD SHIFT PWR 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
PK BRK SOL
DASH GND
DASH GND
F4
F3
F2
F1
N4
N3
N2
N1
R4
R3
R2
R1
GEAR
SW3
SW1
F
1
4
N
2
3
TRANS SOL Y1
TRANS SOL Y3
TRANS SOL Y5
TRANS SOL Y4
SHIFT PWR 1
HOBBS
KEY START
TRANS SOL Y2
Y2, Y6
Y1, Y6
Y2, Y3, Y6
Y1, Y3, Y6
2
3
PK BRK SOL
1 2 3 4 5 6 7 8
TRANSMISSION LEGEND
TRANSMISSION SHIFTER
TO CHASSIS ASSEMBLY
THR SGN/915
THR RTN/914
THR SUP/911
IVS
WILLIAMS
PLUGGED
(SUSPENDED)
PLUGGED
A B C D E F
THROTTLE
TWIST
12 TURNS
PER FOOT
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
PLUGGED PLUGGED 3 87a
KEY START TRAN/BRK PWR 1 30
SHIFT PWR 1 REVERSE 4 87
RELAY
HD34-24-31PT
SP ACCY PWR
SP CAB GND 1 PLUGGED 3 87a
SHIFTER HARNESS
SP CAB GND 2 SHIFTER GND 1 30
SP-1 TRANS TMP SW 4 87
SP-2 KEY START 5 86
SP-3 SHIFTER GND 2 85
TEST RELAY
WARN LIGHT
TRANS TMP SW
AC CLUTCH
STAB/TILT PWR
TILT UP
TILT DN
SP BAT PWR
IVS
PLUGGED
PLUGGED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
STAB/TILT PWR
TILT
STAB/TILT PWR
DT06-4S
SHIFTER GND
TILT UP
TILT DN
1 2 3 4
ROLLER OPTION
SHIFTER HARNESS
SP-3
SP-2
SP-1
TO TILT ON JOYSTICK
TILT UP RED
TILT
UP
AC CLUTCH
SP BAT PWR
SP CAB GND 2
SP CAB GND 1
BLK
SP ACCY PWR
STD JOY PWR
STD JOY PWR GRY
TILT
TILT DN BLU
JOYSTICK
STANDARD
DOWN
PLUGGED PLUG
PLUGGED PLUG
1 2 3 4 5 6
SEE
OPTIONS
SCHEMATIC
Cab Schematic - Perkins 9.5.2
Electrical System
9-12
MAIN DASH PANEL
9.5.3
STONERIDGE WAIT TO START REVERSE WARN LIGHT
GAUGE (RED, 18 GA GXL)
TILT TRANSMISSION SHIFTER TURNER
TRANSMISSION SHIFTER ZF RELAY TEST RELAY SPEED
THROTTLE
HOBBS
6 5 4 HOBBS WILLIAMS STANDARD
TRANS TMP WRN
(SHIELD/020) (RED, 18 GA GXL) (SUSPENDED) JOYSTICK F F
30
87
86
85
30
87
86
85
3 2
87a
87a
(CAN L/905, GREEN) 1 SW1 SW2
F F N N
(CAN H/904, YELLOW) SW1 SW2
3
1
4
5
2
3
1
4
5
2
N N TILT TILT
ENG WARN
UP DOWN R R
(RED, 18 GA GXL)
R R
YEL
RED
4 4 SW4
ENG STOP
4 4 SW3 3 3
(RED, 18 GA GXL) A B C D E F
PLUGGED
3 3 2 1
PLUGGED
SW3 SW4
REVERSE
KEY START
2 2
SHIFTER GND
SHIFTER GND
SHIFTER GND
TRAN/BRK PWR
REVERSE SOL
2 2 1 1
TRANS TMP SW
1 1
BLK
GRY
BLU
RED
PLUG
PLUG
IVS
IVR
ON-IDLE
Electrical System
1 2 3 4 5 6
THR SGN/915
THR RTN/914
THR SUP/911
STD JOY PWR
STAB/TILT PWR
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 12 TURNS
STEER MODE PER FOOT
CRAB DASH GND
7 TWIST
1 4
TILT UP
TILT DN
PLUGGED
PLUGGED
2 5
ALL WHL
PLUGGED
PLUGGED
(BLK, 18 GA GXL)
(RED, 18 GA GXL)
(ORG, 18 GA GXL)
(ORG, 18 GA GXL)
(WHT, 18 GA GXL)
PLUGGED
PK BRK SOL
SHIFT PWR 2
REVERSE SOL
KEY START
SHIFT PWR 1
TRANS SOL
TRANS SOL Y1
TRANS SOL Y6
TRANS SOL Y3
TRANS SOL Y5
(D BLU, 18 GA GXL)
(D BLU, 18 GA GXL)
KEY START
SHIFT PWR 2
HORN
SHIFT PWR 1
TRANS SOL Y1
TRANS SOL Y3
TRANS SOL Y5
TRANS SOL
REVERSE SOL
OFF
PARK BRAKE
2 OFF
Cab Schematic - Cummins
1 2 3 4 5 6 7 8 7
3
1 4
ON 2 5
3 6
ON
DASH GND
HORN
FUL LVL
STR AW
ST RLY
DASH GND
GAGE PWR
STR CRB
HORN PWR
ENG WARN LT
PK BRK SOL
ENG STOP LT
TRANS TMP SW
SHIFT PWR 1
TRAN/BRK PWR
STEER/SWAY PWR
WAIT TO START LT
TRANSMISSION LEGEND ZF SP-1
SP-2
GEAR ACTIVATED TRANS SOLENOIDS SP-3
SP BAT PWR
F1 Y1, Y3, Y4, Y6 SP ACCY PWR
SP CAB GND 1
SP CAB GND 2
F2 Y1, Y3, Y5, Y6 SEE
AC CLUTCH
SHEET 2
F3 Y1, Y3, Y6
F4 Y1, Y6
TRANSMISSION LEGEND
R1 Y2, Y3, Y4, Y6
TURNER
GEAR ACTIVATED TRANS SOLENOIDS
R2 Y2, Y3, Y5, Y6
F1 E5, E1
SHIELDED F3 E5, E3
CABLE R4 Y2, Y6
(CAN H/904, YELLOW) A F4 E6, E3
(CAN L/905,GREEN) B YEL (CAN H/904) N1 Y6 (ONLY IF PARK BRAKE OFF)
A
SP-1
SP-2
SP-3
(SHIELD/020) C
TILT UP
TILT DN
KEY START
AC CLUTCH
BRN/BLK (SHIELD/020)
SHIFTER GND
SHIFT PWR 2
SP BAT PWR
SP BAT PWR
TRANS SOL Y6
R2 E4, E2
TRANS SOL Y1
REVERSE SOL
TRANS SOL Y3
TRANS SOL
TRANS SOL Y5
TRAN/BRK PWR
SP CAB GND 1
SP CAB GND 2
TRANS TMP SW
STAB/TILT PWR
B
120 OHM C N3 Y6 (ONLY IF PARK BRAKE OFF) R3 E4, E3
CAN TERMINATOR
KEY/IGN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 N NO SOLENOIDS INGAUGED
N4 Y6 (ONLY IF PARK BRAKE OFF)
B A SHIFTER HARNESS
SHIFTER HARNESS DT06-4S
S TO TILT ON JOYSTICK
I ROLLER OPTION
TO CHASSIS ASSEMBLY
KEY ACC
KEY START
KEY IGN
STR AW
ST RLY
KEY IGN
KEY ACC
STR CRB
FUL LVL
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
YEL (CAN H)
GRN (CAN L)
BRN/BLK (CAN SHIELD)
DASH GND
GAGE PWR
HORN PWR
KEY START
PK BRK SOL
TRANS TMP SW
ENG STOP LT
TRAN/BRK PWR
STEER/SWAY PWR
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
MY4570A
G10-55A, G12-55A
9.5.4
G10-55A, G12-55A
WINDSHIELD
CAB LIGHTS WASHER DASH BLOWER HEATER M WIPER MOTOR
STOPLIGHT DOME
BEACON LEFT RIGHT MOTOR FAN MOTOR VALVE RIGHT DASH PANEL
AUX HYD PANEL OPTIONS VEC SWITCH LIGHT M
WIPER HEATER/BLOWER M M
F1 20 WIPER PWR M WORKLIGHTS BEACON WIPER
A
F5 20 HEATER PWR 1 2 3 4 5 6 7 8 9 10 OFF OFF
87a
87
86
85
30
87a
30
87
86
85
B
KEY ACC 1 4
C H
F7 10 BCN PWR 2 5 2 L
D W B
F8 10 D FAN PWR 3 6 3
AUX ELEC E P
AUX ELEC
GREEN-4
LIGHTS BCN/FAN F6 20
F
DOME LT A A B A B A B ON ON
SWING 7 MAST
7 CAB LT PWR A B A B C D
G
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
1 4 1
87a
30
87
86
85
4
87a
30
87
86
85
H
S/W LT PWR
2 5 2 5
BCN LT
AUX ELEC1
CAB LTS
WORK LT
BCN PWR
3 6 3 6
S/W LT PWR
SW1 86
CAB LT PWR
HEATER GND
HTR CNTRL B
HEATER PWR
A
EMPTY
EMPTY
87a
30
87
86
85
OPTION (15A) OPTION (25A) HEATER GND
WIPER HI
B
WASHER
WIPER HI
WIPER LO
WIPER LO
WIPER PARK
87a
30
87
86
85
87a
30
87
86
85
WIPER PARK
D
DOME/BCN GND
AUX ELEC2
AUX RLYS PWR
BLUE-3
E
STOP LT
S/W LT PWR
DOME/BCN GND
DOME LT
BCN LT
DOME/BCN GND
CAB LTS
CAB LT GND
CAB LTS
CAB LT GND
WASHER
HEATER HI
HEATER MED
HEATER LOW
HEATER GND
D FAN PWR
D FAN GND
SW1 87A
87a
30
87
86
85
F
F4
F3
F2
G
SW2 86
H
SW2 87A
25
15
15
BLACK-1 GRAY-2 HEATER HI
H G F E D C B A H G F E D C B A HEATER MED
HEATER LOW
HTR TEMP BLOWER
8K OHM
M H
L B
24 KOHM,1W
SWING
EXTRA
SW2 87A
SW2 86
MAST
SW1 87A
SIDESHIFT
SW1 86
AUX SW GND
PLUGGED
PLUGGED
PLUGGED
RESISTOR LOCATED
25A OPT
C
STOP LT
S/W LT PWR
BCN PWR
DOME LT
DOME/BCN GND
CAB LT PWR
CAB LT GND
WORK LT
PLUGGED
PLUGGED
15A OPT 2
15A OPT 1
OPT GND 1
OPT GND 2
APPROX 10" BEHIND
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
D FAN GND
AUX
AUX SW GND
25A OPT GND
WORKLIGHT/ HEATER TEMP SWITCH A B C
D FAN PWR
HEATER PWR
WIPER PWR
HEATER GND
D FAN GND
PLUGGED
OPTIONS HARNESS
FAN SW C
15A OPT 1
HEATER PWR
A OPTION 1
15A OPT 1 GND B 15 A
MAST
EXTRA
SWING
SW2 86
SW1 86
A B C D E F ENCLOSED CAB
SW2 87A
SW1 87A
HEATER GND
HTR CNTRL A
15A OPT 2
HEATER PWR
PLUGGED
PLUGGED
PLUGGED
STOP LT
A OPTION 2 OPTION
DOME LT
WORK LT
SIDESHIFT
BCN PWR
15A OPT 2 GND
(RED)
S/W LT PWR
CAB LT PWR
B 15 A
CAB LT GND
AUX SW GND
Options Schematic - John Deere/Perkins
DOME/BCN GND
25A OPT A
25A OPT GND B
OPTION
25 A
PLUGGED
D FAN GND
D FAN PWR
WIPER PWR
HEATER GND
HEATER PWR
A/C SWITCH
(BLACK)
(RED/WHITE)
OPTIONS
FUSE LEGEND
F1 20A WIPER PWR THERMOSTATIC
F2 15A 15A OPTION 1 PWR SWITCH A/C PRESSURE SWITCH
F3 15A 15A OPTION 2 PWR
PRS SW AC SW
F4 25A 25A OPTION PWR
F5 20A HEATER/BLOWER PWR
F6 20A LIGHT PWR
F7 10A BEACON PWR
F8 10A DASH FAN PWR
25A OPT GND
KEY ACC
AUX RLYS PWR
STOP LT
WORK LT
PLUGGED
PLUGGED
MAST
OPT PWR 1
SIDESHIFT
OPT PWR 2
SWING
OPT PWR 3
EXTRA
OPT PWR 4
PLUGGED
OPT GND 1
PLUGGED
OPT GND 2
PLUGGED
RLY 87
AC SW
A
RLY 87
B
25A OPT GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 86 87a 87
OPTIONS HARNESS CONDENSER FANS
A/C M 17A M
AC CLUTCH
HD36-24-19PE (ON ROOF)
RELAY
TO CHASSIS ASSEMBLY 85 30
25A OPT GND
25A OPT
MY1070
SEE SHEET 1
Electrical System
9-13
9-14
9.5.5
ROOF WIPER
AUX HYD PANEL MOTOR
STOPLIGHT WINDSHIELD
M
SWITCH WASHER DASH BLOWER HEATER
CAB LIGHTS M WIPER MOTOR
8 7 DOME MOTOR
BEACON LEFT RIGHT FAN MOTOR VALVE
OPTIONS VEC LIGHT M RIGHT DASH PANEL
1 4
WIPER HEATER/BLOWER WIPER PWR M M M
F1 20
A WORKLIGHTS BEACON WIPER
F5 20 HEATER PWR 1 2 3 4 5 6 7 8 9 10
OFF OFF
30
87
86
85
30
87
86
85
B
87a
87a
2 5 KEY ACC 1 4
C H
F7 10 BCN PWR 2 5 2 LW
D B
3 6 F8 10 D FAN PWR 3 6 3
P
E
LIGHTS BCN/FAN
F6 20 DOME LT ON ON
GREEN-4
F A A B A B A B
CAB LT PWR A B A B C D
G
30
87
86
85
30
87
86
85
87a
87a
S/W LT PWR
H
AUX ELEC1
Electrical System
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
SW1 86
BCN LT
A
CAB LTS
WORK LT
BCN PWR
30
87
86
85
87a
HEATER GND
HEATER GND
HEATER PWR
OPTION (15A) OPTION (25A)
HTR CNTRL B
B
CAB LT PWR
S/W LT PWR
CAB LT GND
EMPTY
EMPTY
WASHER
30
87
86
85
30
87
86
85
87a
87a
WIPER LO
WIPER HI
WIPER HI
WIPER LO
DOME/BCN GND
WIPER PWR
WIPER PARK
WIPER PARK
Options - Cummins
AUX ELEC2
BCN LT
WASHER
AUX RLYS PWR
STOP LT
DOME LT
CAB LTS
CAB LTS
E
SW1 87A
S/W LT PWR
CAB LT GND
CAB LT GND
BLUE-3
30
87
86
85
F
87a
DOME/BCN GND
DOME/BCN GND
F4
F3
F2
SW2 86
D FAN PWR
D FAN GND
HEATER HI
G
HEATER MED
HEATER LOW
HEATER GND
SW2 87A
H
25
15
BLACK-1 GRAY-2 HEATER HI
H G F E D C B A H G F E D C B A HEATER MED
HEATER LOW
PWR
8K OHM
GND
QC PWR
M H
QC GND
QC GND
PLUGGED
PLUGGED
PLUGGED
QC PWR
PLUGGED
PLUGGED
PWR
L B
STOP LT
BCN PWR
DOME LT
WORK LT
RESISTOR LOCATED C
S/W LT PWR
CAB LT PWR
CAB LT GND
24 KOHM,1W
DOME/BCN GND
APPROX 10" BEHIND
AUX WORKLIGHT/ HEATER TEMP SWITCH A B C
25A OPT
PLUGGED
PLUGGED
ELECTRIC
15A OPT 2
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
OPT GND 1
OPT GND 2
D FAN GND
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8
AUX SW GND
BEACON CONNECTION IN
D FAN PWR
WIPER PWR
D FAN GND
HEATER PWR
HEATER GND
OPTIONS HARNESS
ENCLOSED CAB
A B C D E F
15A OPT 2 OPTION
HTR CNTRL A
HEATER GND
A OPTION 2
HEATER PWR
QC PWR
QC PWR
B 15 A
QC GND
QC GND
STOP LT
BCN PWR
DOME LT
WORK LT
SW2 86
SW1 86
SW2 87A
SW1 87A
PLUGGED
PLUGGED
PLUGGED
S/W LT PWR
CAB LT PWR
CAB LT GND
(RED)
25A OPT
AUX SW GND
DOME/BCN GND
A
25A OPT GND
B
OPTION
25 A
A/C SWITCH
PLUGGED
D FAN PWR
WIPER PWR
D FAN GND
HEATER PWR
HEATER GND
(BLACK)
(RED/WHITE)
OPTIONS
FUSE LEGEND
QC PWR
QC GND
QC GND
KEY ACC
STOP LT
WORK LT
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
OPT PWR 1
QC PWR
OPT PWR 2
OPT PWR 3
OPT PWR 4
OPT GND 1
OPT GND 2
AC SW
AC CLUTCH
85 30
25A OPT GND
25A OPT
MY4580A
SEE SHEET 1
G10-55A, G12-55A
9.5.6
G10-55A, G12-55A
(OPT)
(OPT) (OPT) REVERSE (OPT) AUXILIARY
TAIL LIGHT ALARM TO OPTIONS HARNESS A/C TILT-ON ELECTRIC
FRONT RIGHT HORN TO DASH PANEL HARNESS TO CAB ASSEMBLY
WORKLIGHT 8-SHT3-REV BLK AND BOM COMPRESSOR JOYSTICK A S LT RT TM FUEL
BU STOP TAIL HD36-24-31PT TO SHIFTER HARNESS
VALVE SNDR
CHASSIS HARNESS HD36-24-31ST HD34-24-19SE
CHASSIS HARNESS CHASSIS HARNESS M
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
BLK
YEL
BLU
RED
ORG
POWER DISTRIBUTION
(-)
EMPTY
A B
BLK
GRN
RED
FUSE/BREAKER LEGEND A B A B PLUGGED A B
SP-1
SP-2
SP-3
A B A B C D
SP-3
SP-2
SP-1
HORN
CB2 20A OPTIONS POWER 4
MAST
HORN
ST RLY
OIL PSI
A B C D E F
SWING
EXTRA
STR AW
TILT UP
TILT DN
FUL LVL
HR MTR
KEY IGN
LT GND
CLT TMP
KEY ACC
STR CRB
CB3 20A OPTIONS POWER 1
STOP LT
KEY ACC
WORK LT
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
REVERSE
PLUGGED
PLUGGED
PLUGGED
PLUGGED
SP GND 1
SP GND 2
REVERSE
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
DASH GND
GAGE PWR
SIDESHIFT
KEY START
HORN PWR
OPT GND 1
OPT GND 2
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
CB4 20A OPTIONS POWER 2
AC CLUTCH
PK BRK SOL
KEY START
PK BRK SOL
AC CLUTCH
SP BAT PWR
SP BAT PWR
SHIFT PWR 1
OVR SUP/911
SHIFT PWR 1
THR RTN/914
OVR SGN/918
FAULT LT/473
OVR SUP/911
THR SGN/915
SP BAT PWR
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
SP ACCY PWR
TRANS TMP SW
TRAN/BRK PWR
STAB/TILT PWR
TRAN/BRK PWR
TRANS TMP SW
AUX RLYS PWR
FUL LVL
F2 5A ALTERNATOR EXCITE
FUL/STAB GND
REMOVE DIODES
STEER/SWAY PWR
LT GND
REVERSE
STOP LT
WORK LT
LT GND
WORK LT
F3 10A ENGINE ECU IGN PWR FOR OPTIONAL
ROLLER TILT NEGATIVE CABLE
ON JOYSTICK TO CAB FIREWALL
F4 10A GAGE (INST PANEL) PWR AND INSTALL
"EMPTY" PLUG
TILT DN
TILT UP
F5 15A SPARE ACCESSORY PWR
MAST
SIDESHIFT
AUX ELEC GND
SWING
EXTRA
PLUGGED
FUL/STAB GND
FUL/STAB GND
+ -
12 VDC
ALL WHEEL 1
STR AW BATTERY
STEER 2
STR/SWAY GND
MODE POSITIVE CABLE
1
STR CRB
VALVE TO STARTER
2
STR/SWAY GND
CRAB AND ALTERNATOR
NEGATIVE CABLE
Chassis Schematic - John Deere
TO ENG BLOCK
NEGATIVE CABLE
FLAG TO
12 TURNS CHASSIS FRAME
PER FOOT
TWIST ECU IGN/012 1
ECU BAT/022 2
BAT GND
BAT GND
BAT POS
BAT POS
ECU GND/050 3
ENG GND 4
CLT TMP 5
PK BRK SOL 6
POWER DIST OVR SGN/918 7
A C A C FAULT LT/473 8
BLACK-6 GRAY-5 VEC ALT EXC 9
OVR SUP/911 10
THR SGN/915 11
A
DASH GND
THR RTN/914 12
F2 5 ALT EXC
B ST RLY
ACCY-2 IGNITION-2 F5 15 SP ACCY PWR 13
C HR MTR
F6 10 AUX RLYS PWR 14
87a
30
87
86
85
87a
30
87
86
85
D OIL PSI
OPT GND 1 15
E GAGE PWR
KEY ACC 16
GREEN-4
F TRANS TMP SW
F1 15 TRAN/BRK PWR 17
HD34-24-29PE
G PLUGGED
OPT GND 2 18
IGNITION-1 ACCY-1
CHASSIS HARNESS
H TRANS SOL Y1 19
PLUGGED
87a
30
87
86
85
87a
30
87
86
85
SP CAB GND 1 20
A TRANS SOL Y2
SP CAB GND 2 21
B TRANS SOL Y3
TO POWER UNIT ASSEMBLY
SP GND 1 22
C PLUGGED
SP GND 2 23
D PLUGGED
AUX ELEC GND 24
E
CB4
F8
F3
CB3
F4
F9
CB1
F7
F10
CB2
F11
F12
TRANS SOL Y4
BLUE-3
LT GND 25
F TRANS SOL Y5
STR/SWAY GND 26
20
20
20
20
G PLUGGED
25
10
10
10
15
10
10
15
FUL/STAB GND 27
H PLUGGED 28
PLUGGED 29
BLACK-1 GRAY-2
H G F E D C B A H G F E D C B A
6A 6A
KEY IGN
ENG GND
OPT PWR 2
OPT PWR 1
GAGE PWR
OPT PWR 3
OPT PWR 4
HORN PWR
STAB/TILT PWR
STAB/TILT PWR
STAB VLV
FUL/STAB GND
ECU IGN/012
SP BAT PWR
ECU BAT/022
ECU GND/050
SHIFTER GND
KEY BAT PWR
STAB VLV
FUL/STAB GND
STAB VLV
FUL/STAB GND
STAB/TILT PWR
STEER/SWAY PWR
A B C D
STEER/SWAY PWR
STEER/SWAY PWR
SWAY ENABLE
STR/SWAY GND
SWAY ENABLE
MINUS 15
PLUG
STR/SWAY GND
SWAY ENABLE
PLUG
PLUS 15
STR/SWAY GND
SWAY LT
STR/SWAY GND
SWAY LOCK
STR/SWAY GND
SWAY LOCK
STR/SWAY GND
SWAY LOCK
STR/SWAY GND
SWAY RT
STR/SWAY GND
BLU
WHT
RED
ORG
BLK
A B C D
1 2 3 4 1 2 3 4 A B A B
STR/SWAY GND
MINUS 15
SWAY RT
STEER/SWAY PWR
STR/SWAY GND
PLUS 15
SWAY LT
STEER/SWAY PWR
1 2 1 2 1 2 1 2 1 2
BLU
BLK
RED
WHT
ORG
+
1
3
1
3
RED
YELLOW
GREEN
BLACK
RED
YELLOW
GREEN
BLACK
STABILIZER PROXIMITY
85 2
86 5
87 4
30
85 2
86 5
87 4
30
STABILIZER
87a
87a
MY1080
(-)15 DEG RLY (+)15 DEG RLY
SWAY PROXIMITY
SWITCH
Electrical System
9-15
9-16
9.5.7
(OPT)
AUXILIARY
ELECTRIC
1
2
(OPT) (OPT)
REVERSE (OPT)
FRONT RIGHT TAIL LIGHT HORN TILT-ON
ALARM TO CAB ASSEMBLY A/C QC DIVERTOR
WORKLIGHT JOYSTICK FUEL
BU STOP TAIL TO DASH PANEL HARNESS TO SHIFTER HARNESS TO OPTIONS HARNESS COMPRESSOR A B C D E F VALVE
VALVE SNDR
HD36-24-31PT HD36-24-31ST HD34-24-19SE
CHASSIS HARNESS CHASSIS HARNESS CHASSIS HARNESS M
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
POWER DISTRIBUTION
BLK
RED
YEL
BLU
ORG
A B
(-)
GRN
RED
A B A B A B
BLK
PLUGGED
FUSE/BREAKER LEGEND
CB1 20A OPTIONS POWER 3
Electrical System
A B A B C D
CB2 20A OPTIONS POWER 4 A B C D E F
CB3 20A OPTIONS POWER 1
SP-3
SP-2
SP-1
HORN
CB4 20A OPTIONS POWER 2
HORN
SP-1
SP-2
SP-3
QC PWR
LT GND
QC GND
QC GND
REVERSE
SP GND 1
SP GND 2
STR AW
ST RLY
HR MTR
AC CLUTCH
KEY IGN
KEY ACC
STR CRB
FUL LVL
OIL PSI
CLT TMP
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
CAN H
CAN L
SHIELD
PLUGGED
REVERSE
TILT UP
TILT DN
IVS
ENG GND
PLUGGED
KEY ACC
STOP LT
WORK LT
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
F1 15A TRANS/PARK BRK PWR
SP BAT PWR
DASH GND
GAGE PWR
HORN PWR
SP ACCY PWR
FUL LVL
KEY START
KEY START
AC CLUTCH
OPT PWR 1
QC PWR
OPT PWR 2
OPT PWR 3
OPT PWR 4
OPT GND 1
OPT GND 2
PK BRK SOL
PK BRK SOL
SP BAT PWR
SP BAT PWR
TRANS TMP SW
ENG STOP LT
TRAN/BRK PWR
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
TRAN/BRK PWR
SP CAB GND 1
SP CAB GND 2
TRANS TMP SW
AUX RLYS PWR
REMOVE DIODES
WAIT TO START
STAB/TILT PWR
FUL/STAB GND
STEER/SWAY PWR
F3 10A ENGINE ECU IGN PWR FOR OPTIONAL
ROLLER TILT NEGATIVE CABLE
ON JOYSTICK
LT GND
LT GND
TO CAB FIREWALL
QC GND
QC GND
WORK LT
REVERSE
STOP LT
WORK LT
F4 10A GAGE (INST PANEL) PWR
QC PWR
AND INSTALL QC PWR
PLUGGED
TILT DN
TILT UP
"EMPTY" PLUG
F5 15A SPARE ACCESSORY PWR
AUX ELEC GND
FUL/STAB GND
FUL/STAB GND
Before S/N 0160037186
+ -
12 VDC
ALL WHEEL 1
STR AW BATTERY
STEER STR/SWAY GND
MODE 2
VALVE
POSITIVE CABLE
1
STR CRB TO STARTER
CRAB
2
STR/SWAY GND AND ALTERNATOR
NEGATIVE CABLE
TO ENG BLOCK
NEGATIVE CABLE
FLAG TO
CHASSIS FRAME
12 TURNS
PER FOOT
TWIST ECU IGN/012 1
ECU BAT/022 2
ECU GND/050 3
BAT GND
BAT GND
BAT POS
BAT POS
ENG GND 4
CLT TMP 5
PK BRK SOL 6
ENG WARN LT 7
A C A C POWER DIST ENG STOP LT 8
BLACK-6 GRAY-5 VEC ALT EXC 9
THR SUP/911 10
THR SGN/915 11
A
DASH GND
THR RTN/914 12
F2 5 ALT EXC
B ST RLY
ACCY-2 IGNITION-2 F5 15 SP ACCY PWR 13
C HR MTR
F6 10 AUX RLYS PWR 14
30
87
86
85
30
87
86
85
87a
87a
D OIL PSI
OPT GND 1 15
E GAGE PWR
KEY ACC 16
GREEN-4
F TRANS TMP SW
F1 15 TRAN/BRK PWR 17
G IVS
OPT GND 2 18
IGNITION-1 ACCY-1 H TRANS SOL Y1
CHASSIS HARNESS
HD34-24-29PE
19
WAIT TO START LT
30
87
86
85
30
87
86
85
87a
87a
SP CAB GND 1 20
A TRANS SOL Y2
SP CAB GND 2 21
B TRANS SOL Y3
SP GND 1 22
C PLUGGED
SP GND 2 23
TO POWER UNIT ASSEMBLY
D PLUGGED
AUX ELEC GND 24
E TRANS SOL Y4
F8
F3
F4
F9
F7
25
BLUE-3
LT GND
CB4
CB3
CB1
F10
CB2
F11
F12
F TRANS SOL Y5
STR/SWAY GND 26
20
20
20
20
G CAN H
25
10
10
25
15
10
10
15
FUL/STAB GND 27
H CAN L 28
SHIELD 29
BLACK-1 GRAY-2
H G F E D C B A H G F E D C B A
6A 6A
STAB VLV
KEY IGN
ENG GND
GAGE PWR
HORN PWR
FUL/STAB GND
OPT PWR 2
OPT PWR 1
OPT PWR 3
OPT PWR 4
STAB/TILT PWR
STAB/TILT PWR
SP BAT PWR
SHIFTER GND
ECU IGN/012
ECU BAT/022
KEY BAT PWR
ECU GND/050
STAB/TILT PWR
STEER/SWAY PWR
STAB VLV
STAB VLV
PLUG
PLUG
A B C D
FUL/STAB GND
FUL/STAB GND
SWAY ENABLE
PLUS 15
MINUS 15
STR/SWAY GND
STEER/SWAY PWR
STEER/SWAY PWR
SWAY LT
SWAY RT
STR/SWAY GND
STR/SWAY GND
SWAY ENABLE
SWAY ENABLE
SWAY LOCK
SWAY LOCK
SWAY LOCK
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
BLK
BLU
RED
WHT
ORG
A B C D
1 2 3 4 1 2 3 4 A B A B
1 2 1 2 1 2 1 2 1 2
BLK
BLU
SWAY RT
PLUS 15
SWAY LT
RED
WHT
ORG
MINUS 15
+
STR/SWAY GND
STR/SWAY GND
RED
RED
STEER/SWAY PWR
STEER/SWAY PWR
GREEN
BLACK
GREEN
BLACK
2
5
4
1
3
2
5
4
1
3
YELLOW
YELLOW
STABILIZER
STABILIZER PROXIMITY
85
86
87
30
85
86
87
30
+
LT
SWAY PILOT RT LAT TILT LAT TILT
VALVE (-)15 DEG RLY (+)15 DEG RLY SWITCH SWITCH
SWAY PROXIMITY
MAL0180
SWITCH
G10-55A, G12-55A
9.5.8
G10-55A, G12-55A
1
2
(OPT) (OPT)
REVERSE (OPT)
FRONT RIGHT TAIL LIGHT HORN TILT-ON
ALARM TO CAB ASSEMBLY A/C QC DIVERTOR (OPT)
WORKLIGHT JOYSTICK FUEL
BU STOP TAIL TO DASH PANEL HARNESS TO SHIFTER HARNESS TO OPTIONS HARNESS COMPRESSOR A B C D E F VALVE AUXILIARY
VALVE SNDR ELECTRIC
HD36-24-31PT HD36-24-31ST HD34-24-19SE
CHASSIS HARNESS CHASSIS HARNESS CHASSIS HARNESS M
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
POWER DISTRIBUTION
A B
BLK
RED
YEL
BLU
ORG
(OPT)
(-)
A B A B A B
GRN
RED
BLK
FUSE/BREAKER LEGEND
PLUGGED
AUXILIARY
CB1 20A OPTIONS POWER 3 ELECTRIC
A B A B C D
CB2 20A OPTIONS POWER 4
A B C D E F
CB3 20A OPTIONS POWER 1 A S LT RT TM
SP-3
SP-2
SP-1
HORN
CB4 20A OPTIONS POWER 2
HORN
SP-1
SP-2
SP-3
QC PWR
LT GND
QC GND
QC GND
REVERSE
SP GND 1
SP GND 2
STR AW
ST RLY
AC CLUTCH
F1 15A TRANS/PARK BRK PWR
PLUGGED
PLUGGED
PLUGGED
KEY IGN
KEY ACC
STR CRB
FUL LVL
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
YEL (CAN H)
GRN (CAN L)
PLUGGED
REVERSE
TILT UP
TILT DN
IVS
ENG GND
PLUGGED
KEY ACC
STOP LT
WORK LT
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
SP BAT PWR
DASH GND
GAGE PWR
HORN PWR
SP ACCY PWR
FUL LVL
KEY START
KEY START
AC CLUTCH
OPT PWR 1
QC PWR
OPT PWR 2
OPT PWR 3
OPT PWR 4
OPT GND 1
OPT GND 2
PK BRK SOL
PK BRK SOL
SP BAT PWR
SP BAT PWR
F2 5A ALTERNATOR EXCITE
TRANS TMP SW
ENG STOP LT
TRAN/BRK PWR
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
TRAN/BRK PWR
SP CAB GND 1
SP CAB GND 2
TRANS TMP SW
AUX RLYS PWR
WAIT TO START
STAB/TILT PWR
FOR OPTIONAL FUL/STAB GND
STEER/SWAY PWR
F3 10A ENGINE ECU IGN PWR CABLE ROLLER TILT NEGATIVE CABLE
ON JOYSTICK TO CAB FIREWALL
LT GND
LT GND
F4 10A GAGE (INST PANEL) PWR
WORK LT
REVERSE
STOP LT
WORK LT
AND INSTALL
QC GND 7
QC GND 5
PLUGGED
"EMPTY" PLUG
QC PWR 2
TILT DN
TILT UP
BLK
YEL
BLU
QC PWR 1
RED
FUL/STAB GND
FUL/STAB GND
F6 10A AUX ELECTRIC PWR
PLUGGED
+ -
12 VDC
ALL WHEEL STR AW BATTERY
1
Chassis Schematic - Perkins
SIDESHIFT
NEGATIVE CABLE
AUX ELEC GND
TO ENG BLOCK
NEGATIVE CABLE
FLAG TO
CHASSIS FRAME
ECU IGN/012
1
ECU BAT/022
2
ECU GND/050
3
BAT GND
BAT GND
BAT POS
BAT POS
ENG GND
4
12 TURNS PER PLUGGED
5
FOOT TWIST PK BRK SOL
6
ENG WARN LT
A C A C POWER DIST 7
ENG STOP LT
8
BLACK-6 GRAY-5 VEC ALT EXC
9
THR SUP/911
10
THR SGN/915
DASH GND 11
A THR RTN/914
F2 5 ALT EXC 12
B ST RLY
ACCY-2 IGNITION-2 F5 15 SP ACCY PWR 13
C YEL (CAN H)
F6 10 AUX RLYS PWR 14
30
87
86
85
30
87
86
85
D
87a
87a
GRN (CAN L)
OPT GND 1 15
E BRN/BLK (CAN SHIELD)
KEY ACC 16
GREEN-4
F TRANS TMP SW
F1 15 TRAN/BRK PWR 17
G CABLE IVS
OPT GND 2 18
IGNITION-1 ACCY-1 H TRANS SOL Y1
19
CHASSIS HARNESS
HD34-24-29PE
WAIT TO START LT
30
87
86
85
30
87
86
85
20
87a
87a
SP CAB GND 1
A TRANS SOL Y2
SP CAB GND 2 21
B TRANS SOL Y3
SP GND 1 22
C PLUGGED
SP GND 2 23
TO POWER UNIT ASSEMBLY
D PLUGGED
AUX ELEC GND 24
E TRANS SOL Y4
25
F8
F3
F4
F9
F7
LT GND
BLUE-3
CB4
CB3
CB1
F10
CB2
F11
F12
F TRANS SOL Y5
STR/SWAY GND 26
20
20
20
20
G PLUGGED
25
10
10
25
15
10
10
15
FUL/STAB GND 27
H PLUGGED
28
PLUGGED 29
BLACK-1 GRAY-2
H G F E D C B A H G F E D C B A
6A 6A
STAB VLV
KEY IGN
ENG GND
GAGE PWR
HORN PWR
FUL/STAB GND
OPT PWR 2
OPT PWR 1
OPT PWR 3
OPT PWR 4
STAB/TILT PWR
STAB/TILT PWR
SP BAT PWR
SHIFTER GND
ECU IGN/012
ECU BAT/022
KEY BAT PWR
ECU GND/050
STAB/TILT PWR
STEER/SWAY PWR
STAB VLV
STAB VLV
PLUG
PLUG
A B C D
FUL/STAB GND
FUL/STAB GND
SWAY ENABLE
PLUS 15
MINUS 15
STR/SWAY GND
STEER/SWAY PWR
STEER/SWAY PWR
SWAY LT
SWAY RT
STR/SWAY GND
STR/SWAY GND
SWAY ENABLE
SWAY ENABLE
SWAY LOCK
SWAY LOCK
SWAY LOCK
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
BLK
BLU
RED
WHT
ORG
A B C D
1 2 3 4 1 2 3 4 A B A B
1 2 1 2 1 2 1 2 1 2
SWAY RT
PLUS 15
SWAY LT
MINUS 15
+
STR/SWAY GND
STR/SWAY GND
S/N 0160037186 Thru 0160039397 Excluding 0160039394 & 0160039397
STEER/SWAY PWR
STEER/SWAY PWR
2
5
4
1
3
2
5
4
1
3
STABILIZER
STABILIZER PROXIMITY
85
86
87
30
85
86
87
30
VALVE SWITCH
87a
87a
MY4730F
(-)15 DEG RLY (+)15 DEG RLY
Electrical System
9-17
9-18
9.5.9
1
2
(OPT) (OPT)
REVERSE (OPT)
FRONT RIGHT TAIL LIGHT HORN TILT-ON
ALARM TO CAB ASSEMBLY A/C QC DIVERTOR (OPT)
WORKLIGHT JOYSTICK FUEL
BU STOP TAIL TO DASH PANEL HARNESS TO SHIFTER HARNESS TO OPTIONS HARNESS COMPRESSOR A B C D E F VALVE AUXILIARY
VALVE SNDR ELECTRIC
HD36-24-31PT HD36-24-31ST HD34-24-19SE
CHASSIS HARNESS CHASSIS HARNESS CHASSIS HARNESS M
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
POWER DISTRIBUTION
A B
BLK
RED
YEL
BLU
ORG
(OPT)
(-)
A B A B A B
GRN
RED
BLK
FUSE/BREAKER LEGEND
PLUGGED
AUXILIARY
CB1 20A OPTIONS POWER 3 ELECTRIC
A B A B C D
CB2 20A OPTIONS POWER 4
A B C D E F
Electrical System
SP-3
SP-2
SP-1
HORN
CB4 20A OPTIONS POWER 2
HORN
SP-1
SP-2
SP-3
QC PWR
LT GND
QC GND
QC GND
REVERSE
SP GND 1
SP GND 2
STR AW
ST RLY
AC CLUTCH
F1 15A TRANS/PARK BRK PWR
PLUGGED
PLUGGED
PLUGGED
KEY IGN
KEY ACC
STR CRB
FUL LVL
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
YEL (CAN H)
GRN (CAN L)
REVERSE
TILT UP
TILT DN
IVS
ON-IDLE
IVR
KEY ACC
STOP LT
WORK LT
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
SP BAT PWR
DASH GND
GAGE PWR
HORN PWR
SP ACCY PWR
FUL LVL
KEY START
KEY START
AC CLUTCH
OPT PWR 1
QC PWR
OPT PWR 2
OPT PWR 3
OPT PWR 4
OPT GND 1
OPT GND 2
PK BRK SOL
PK BRK SOL
SP BAT PWR
SP BAT PWR
F2 5A ALTERNATOR EXCITE
TRANS TMP SW
ENG STOP LT
TRAN/BRK PWR
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
TRAN/BRK PWR
SP CAB GND 1
SP CAB GND 2
TRANS TMP SW
AUX RLYS PWR
TRANS SOL Y6
WAIT TO START
STAB/TILT PWR
FUL/STAB GND
FOR OPTIONAL
STEER/SWAY PWR
F3 10A ENGINE ECU IGN PWR CABLE ROLLER TILT NEGATIVE CABLE
ON JOYSTICK TO CAB FIREWALL
LT GND
LT GND
F4 10A GAGE (INST PANEL) PWR
WORK LT
REVERSE
STOP LT
WORK LT
AND INSTALL
QC GND 7
QC GND 5
PLUGGED
"EMPTY" PLUG
QC PWR 2
TILT DN
TILT UP
BLK
YEL
BLU
QC PWR 1
RED
FUL/STAB GND
FUL/STAB GND
F6 10A AUX ELECTRIC PWR
PLUGGED
+ -
12 VDC
ALL WHEEL STR AW BATTERY
1
STEER STR/SWAY GND
MODE 2
VALVE
POSITIVE CABLE
STR CRB TO STARTER
CRAB 1
MAST
EXTRA
SWING
PLUGGED
SIDESHIFT
NEGATIVE CABLE
AUX ELEC GND
TO ENG BLOCK
NEGATIVE CABLE
FLAG TO
CHASSIS FRAME
ECU IGN/012
1
ECU BAT/022
2
ECU GND/050
3
BAT GND
BAT GND
BAT POS
BAT POS
ENG GND
4
12 TURNS PER PLUGGED
5
FOOT TWIST PK BRK SOL
6
ENG WARN LT
A C A C POWER DIST 7
ENG STOP LT
8
BLACK-6 GRAY-5 VEC ALT EXC
9
THR SUP/911
10
THR SGN/915
DASH GND 11
A THR RTN/914
F2 5 ALT EXC 12
B ST RLY
ACCY-2 IGNITION-2 F5 15 SP ACCY PWR 13
C YEL (CAN H)
F6 10 AUX RLYS PWR 14
30
87
86
85
30
87
86
85
D
87a
87a
GRN (CAN L)
OPT GND 1 15
E BRN/BLK (CAN SHIELD)
KEY ACC 16
GREEN-4
F TRANS TMP SW
F1 15 TRAN/BRK PWR 17
G CABLE IVS
OPT GND 2 18
IGNITION-1 ACCY-1 H TRANS SOL Y1
19
CHASSIS HARNESS
HD34-24-29PE
WAIT TO START LT
30
87
86
85
30
87
86
85
20
87a
87a
SP CAB GND 1
A TRANS SOL Y2
SP CAB GND 2 21
B TRANS SOL Y3
SP GND 1 22
C ON-IDLE
SP GND 2 23
TO POWER UNIT ASSEMBLY
D IVR
AUX ELEC GND 24
E TRANS SOL Y4
25
F8
F3
F4
F9
F7
LT GND
BLUE-3
CB4
CB3
CB1
F10
CB2
F11
F12
F TRANS SOL Y5
STR/SWAY GND 26
20
20
20
20
G PLUGGED
25
10
10
25
15
10
10
15
FUL/STAB GND 27
H TRANS SOL Y6
28
PLUGGED 29
BLACK-1 GRAY-2
H G F E D C B A H G F E D C B A
6A 6A
STAB VLV
S/N 0160039451 and After Including 0160039394 & 0160039397
KEY IGN
ENG GND
GAGE PWR
HORN PWR
FUL/STAB GND
OPT PWR 2
OPT PWR 1
OPT PWR 3
OPT PWR 4
STAB/TILT PWR
STAB/TILT PWR
SP BAT PWR
SHIFTER GND
ECU IGN/012
ECU BAT/022
KEY BAT PWR
ECU GND/050
STAB/TILT PWR
STEER/SWAY PWR
STAB VLV
STAB VLV
PLUG
PLUG
A B C D
FUL/STAB GND
FUL/STAB GND
SWAY ENABLE
PLUS 15
MINUS 15
STR/SWAY GND
STEER/SWAY PWR
STEER/SWAY PWR
SWAY LT
SWAY RT
STR/SWAY GND
STR/SWAY GND
SWAY ENABLE
SWAY ENABLE
SWAY LOCK
SWAY LOCK
SWAY LOCK
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
STR/SWAY GND
BLK
BLU
RED
WHT
ORG
A B C D
1 2 3 4 1 2 3 4 A B A B
1 2 1 2 1 2 1 2 1 2
SWAY RT
PLUS 15
SWAY LT
MINUS 15
+
STR/SWAY GND
STR/SWAY GND
STEER/SWAY PWR
STEER/SWAY PWR
2
5
4
1
3
2
5
4
1
3
STABILIZER
STABILIZER PROXIMITY
85
86
87
30
85
86
87
30
VALVE SWITCH
87a
87a
MY4590A
G10-55A, G12-55A
9.5.10
G10-55A, G12-55A
TRANSMISSION LEGEND
A B A B A B A B A B C A B
F4 Y1, Y6
POSITIVE CABLE
TO BATTERY (3/0 AWG, RED)
R1 Y2, Y3, Y4, Y6
CLT/461
RELAY
INJ A/491
INJ B/493
30
R3 Y2, Y3, Y6 ST RLY PWR
OIL PRS/467
THR RTN/914
THR RTN/914
MAN TMP/463
THR RTN/914
THR RTN/914
CRANK A/447
OVR SUP/911
FUEL TMP/428
CRANK B/448
STRT SOL 87
R4 Y2, Y6 ST RLY 86
ENG GND 85
12 TURNS
PER FOOT N1 Y6 (ONLY IF PARK BRAKE OFF)
TWIST (3/0 AWG, RED)
1
ECU IGN/012
N4 Y6 (ONLY IF PARK BRAKE OFF)
2
ECU BAT/022
3
ECU GND/050 STRT SOL M
4
ENG GND
5
CLT TMP
6
PK BRK SOL
ST RLY PWR
7
OVR SGN/918
(3/0 AWG, RED)
8
FAULT LT/473
6A/400V
(4 AWG, RED)
9
ALT EXC
10
OVR SUP/911
11
THR SGN/915
12
THR RTN/914
13
ST RLY
ALTERNATOR
HR MTR (4 AWG, RED)
Power Unit Schematic - John Deere
14
OIL PSI B+
15
HD36-24-29SE
G
16
GAGE PWR ALT EXC A
TRANS TMP SW A D+
6A/400V
TO CHASSIS ASSEMBLY
19
TRANS SOL Y1
20
PLUGGED
21
TRANS SOL Y2
TRANS SOL Y3 GAGE PWR 5 PSI ENGINE OIL
22 A
PLUGGED HR MTR PRESSURE
23 B
PLUGGED SWITCH
24
25
TRANS SOL Y4
26
TRANS SOL Y5
27
PLUGGED
28
PLUGGED
29
PLUGGED CLT TMP CLT TEMP
RESISTOR LOCATED SENDER
390 OHM, 1W AT SPLIT OF CRANK
SHTDN/941 SENSOR WIRES A/447& OIL PSI OIL PRESS
B/448 IN ENGINE SENDER
SHIELDED
ECU HARNESS
CAN TERMINATOR CABLE PK BRK SOL 1 PARK
ENG GND 2 BRAKE
A
(CAN H/904, YELLOW)
(CAN L/905, GREEN) VALVE
B
120 OHM C
(SHIELD/020)
SHIELDED
CAN TERMINATOR
CABLE
A
(CAN H/904, YELLOW)
B
(CAN L/905, GREEN)
120 OHM C
(SHIELD/020)
12 TURNS
PER FOOT
TWIST
SHIELDED
CABLE
TRANS SOL Y1
ENG GND
TRANS SOL Y2
ENG GND
TRANS SOL Y3
ENG GND
TRANS SOL Y4
ENG GND
TRANS SOL Y5
ENG GND
PK BRK SOL
ENG GND
TRANS TMP SW
ENG GND
SHTDN/941
ECU IGN/012
INJ B/493
CLT/461
CRANK A/447
OVR SGN/918
HI LO/947
PLUGGED
FUEL TMP/428
MAN TMP/463
CRANK B/448
THR RTN/914
THR SGN/915
OVR SUP/911
PLUGGED
CAN L/905
PLUGGED
OIL PRS/467
CAN H/904
PLUGGED
FAULT LT/473
PLUGGED
PLUGGED
PLUGGED
PLUGGED
ECU GND/050
PLUGGED
ECU BAT/022
INJ A/491
PLUGGED
A B A B A B A B A B A B A B
J1
A1
F1
E1
C1
G1
J2
J3
A2
A3
B1
D1
K1
H1
F2
F3
E2
E3
C2
C3
G2
G3
B2
B3
D2
D3
K2
K3
H2
H3
ECU GND/050
ECU IGN/012
(CAN H/904, YELLOW)
(CAN L/905, GREEN)
(SHIELD/020)
PLUGGED
PLUGGED
PLUGGED
PLUGGED
Y1 Y2 Y3 Y4 Y5 Y6 250 F
DEERE ENGINE ECU
TRANSMISSION
A B C D E F G H J
DIAGNOSTIC
MY1090
CONNECTOR
Electrical System
9-19
9-20
9.5.11
TRANSMISSION LEGEND
GEAR ACTIVATED TRANS SOLENOIDS
MY1820
F1 Y1, Y3, Y4, Y6
F4 Y1, Y6
POSITIVE CABLE
TO BATTERY (3/0 AWG, RED)
R1 Y2, Y3, Y4, Y6
Electrical System
7
ENG WARN LT
(3/0 AWG, RED)
8
ENG STOP LT
6A/400V
(4 AWG, RED)
9
ALT EXC
10
THR SUP/911
CSA RLY PWR
11
THR SGN/915
12
THR RTN/914
13
ST RLY
ALTERNATOR
14
HR MTR
ALT PWR B+
15
OIL PSI
16
GAGE PWR G
ALT EXC A A D+
17
TRANS TMP SW
IVS 6A/400V
18
HD36-24-29SE
POWER UNIT HARNESS
19
TRANS SOL Y1
20
WAIT TO START
21
TRANS SOL Y2
5 PSI
TO CHASSIS ASSEMBLY
22
TRANS SOL Y3 GAGE PWR A ENGINE OIL
PLUGGED HR MTR PRESSURE
23 B
PLUGGED SWITCH
24
25
TRANS SOL Y4
26
TRANS SOL Y5
27
CAN H/904
28
CAN L/905
29
SHIELD/020 CLT TMP CLT TEMP
SENDER
SHIELDED
CAN TERMINATOR CABLE
RELAY
A
(CAN H/904, YELLOW)
B
(CAN L/905, GREEN) 30
(SHIELD/020) CSA RLY PWR
120 OHM C
ECU IGN/012 86
COLD START AID 85
GLOW PLUG PWR 87
ENG GND
ENG GND
ENG GND
ENG GND
ENG GND
ENG GND
ENG GND
PK BRK SOL
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
TRANS TMP SW
TO GLOW PLUGS
ECU GND/050
ECU BAT/022
CAN H/904
CAN L/905
SHIELD/020
THR RTN/914
ECU IGN/012
THR SUP/911
IVS
THR SGN/915
COLD START AID
ENG WARN LT
ENT STOP LT
WAIT TO START LT
A B A B A B A B A B A B A B
1
2
3
7
8
9
10
15
16
20
21
22
33
40
41
45
54
57
59
60
63
Y1 Y2 Y3 Y4 Y5 Y6 250 F
NOTE:
PERKINS ECM ONLY USED CONNECTIONS SHOWN TRANSMISSION
64 PIN
G10-55A, G12-55A
9-21 G10-55A, G12-55A
MY4720A
BTTY + RED 2/0AWG
1
B+ TERM
*
B- TERM
5A
TBD
5A
TBD
MAIN B+
FC208
B+ TERM
FC205
*
DIAGNOSTIC
MAIN BATTERY
MAIN B-
B- TERM
CAN H/90 YEL 18AWG
CAN L/905 GRN 18AWG
CABLE
CAN SHIELD/020 GRY 18AWG
NEG BATTERY
TO VEH GND
1
VEH GND
ST RLY ORG 16AWG
ALT EXC RED 18AWG
1
CAN L/905 GRN 18AWG
PK BRK SOL VIO 16AWG
ECU IGN/012 RED 12AWG
VEH GND
BATTERY CABLES
SPLICE 1
SPLICE 11
TO VEH GND
3
4
5
6
7
8
THR SGN/915 GRN 18AWG
9
VEH GND CABLE
10
ON-IDLE ORG 18AWG
11
12
13
POSITIVE BATTERY CABLE
14
15
SPLICE 2
BTTY - BLK 2/0AWG
16
SPLICE 3
17
18
19
TO STRT GND, F7
20
21
1
26
SPLICE 4
27
28
29 VEC POS
VEC PWR RED 8AWG
30 A
VEC PWR RED 8AWG
31 B
32
33 VEC NEG
IVR BLU 18AWG VEC GND BLK 8AWG
34 A
BTTY - BLK 2/0AWG
35 B
36
CAN SHIELD/020 GRY 18AWG
37
38
ECU IGN/012 RED 18AWG
39
HTR SIG ORG 18AWG
40
41
HTR RTN BLK 18AWG
43
ENG WARN LT VIO 18AWG
44
45
CAN H/904 YEL18AWG
46
CAN L/905 GRN 18AWG
BTTY - BLK 2/0AWG
47
48
49 30A STARTER RELAY, 12V, 75 AMP
WAIT TO START WHT 18AWG
50 TBD
FUSE HOLDER, ATO
F
1
1
TO STRT PWR, F7
TO ENG GND STUD
ENG GND
STRT PWR
2
1
87
30
86
85
FC206
4
ECU BAT/022 RED 12AWG ECU BAT/022 RED 10AWG ECU BAT/022 RED 10AWG
3
ECU GND/050 BLK 12AWG SPLICE 5
RL196
2
RL196-87
RL196-30
MOLDED DIODE
TRANS SOL Y1 BRN 16AWG 1
A
ENG GND BLK 16AWG 2
B
SOL1 DIODE 4
MOLDED DIODE
TRANS SOL Y2 BRN 16AWG 1
A
ENG GND BLK 16AWG 2
H2
H1
B
SPLICE 8
SOL2 DIODE 5 TRANS SOL Y1 BRN 16AWG TRANS SOL Y1 BRN 16AWG
1 1
TRANS SOL Y2 BRN 16AWG TRANS SOL Y2 BRN 16AWG
2 2
MOLDED DIODE TRANS SOL Y3 BRN 16AWG TRANS SOL Y3 BRN 16AWG
3 3
TRANS SOL Y4 BRN 16AWG TRANS SOL Y4 BRN 16AWG
TRANS SOL Y3 BRN 16AWG 1 4 4
A TRANS SOL Y5 BRN 16AWG TRANS SOL Y5 BRN 16AWG
ENG GND BLK 16AWG 2 5 5
B TRANS SOL Y6 BRN 16AWG
6 6
SOL3 DIOCE 6
7 7
PK BRK SOL VIO 16AWG PRK BRK SOL VIO 16AWG
8 8
MOLDED DIODE
9 9
TRANS TMP SW BLU 16AWG TRANS TMP SW BLU 16AWG
TRANS SOL Y4 BRN 16AWG 1 10 10
A ENG GND BLK 16AWG ENG GND BLK 16AWG
ENG GND BLK 16AWG 2 11 11
B SPLICE 13 ENG GND BLK 16AWG ENG GND BLK 16AWG
12 12
SOL4 DIODE 7
MOLDED DIODE
TRANS SOL Y5 BRN 16AWG 1
A
ENG GND BLK 16AWG 2
B
SOL5 DIODE 8
ZF TRANSMISSION
MOLDED DIODE
FUSIBLE LINK
PKSOL DIODE 9
SPLICE 14
2
1
SPLICE 10
MOLDED DIODE
TRANS SOL Y1 BRN 16AWG 1
1
ENG GND BLK 16AWG 2
SPLICE 16
2
SPLICE 15
SOL E1 DIODE 10
MOLDED DIODE
TRANS SOL Y2 BRN 16AWG 1
1
ENG GND BLK 16AWG 2
H3
2
FUSIBLE LINK
2
MOLDED DIODE TRANS SOL E3 BRN 16AWG
3
K3
K2
K1
TRANS SOL E2 BRN 16AWG
TRANS SOL Y3 BRN 16AWG 1 4
2
1
1
1
B
A
D
C
1 TRANS SOL E5 BRN 16AWG
ENG GND BLK 16AWG 2 5
2 TRANS SOL E6 VIO 16AWG
6
SOL E3 DIODE 12
7
8
MOLDED DIODE
9
TRANS TMP SW BLU 16AWG VALVE, PARK BRAKE
SIGNALS
TRANS SOL Y4 BRN 16AWG 1 10
1 ENG GND BLK 16AWG
ENG GND BLK 16AWG 2 11
2 SPLICE 12 ENG GND BLK 16AWG
12
SOL E4 DIODE 13
BATT GROUND
BATT POSITIVE
ALTERNATOR
STRT PWR RED 2/0AWG
1
HTR RTN BLK 18AWG
HTR SIG ORG 18AWG
GRID HTR PWR RED 2AWG
1
1
1
SOL STUD
GND STUD
PWR STUD
MOLDED DIODE
TRANS SOL Y6 BRN 16AWG 1
1
TURNER TRANSMISSION
ENG GND BLK 16AWG 2
1
1
1
2 1
RL198-4
RL198-3
RL198-2
RL198-1
SOL E6 DIODE 15
M
85
86
87
30
1
1
FC197-2
FC197-1
STARTER
ENGINE
TEMP SWITCH TEM SW
COLD START TRANS TMP SW BLU 16AWG
1
1
EC202
9.6.1 Constant Power Circuit from Battery - John Deere & Perkins
BAT POS
BAT POS NEGATIVE CABLE
TO BATTERY (3/0 AWG, BLACK)
NEGATIVE CABLE
TO CAB FIREWALL A C A C POWER DIST TO ENGINE ECU
POSITIVE CABLE
BLACK-6 GRAY-5 VEC TO BATTERY (3/0 AWG, RED)
STARTER
A RELAY
F2 5 ALT EXC
B 30
ACCY-2 IGNITION-2 ST RLY PWR
C 1 STRT SOL
GREEN-4
87
D 2
ST RLY
87a
87a
86
30
87
86
85
30
87
86
85
ECU BAT/022
E 85
KEY ACC 4
F 5
F1 15
G TRAN/BRK PWR (3/0 AWG, RED)
+ - 6
12 VDC IGNITION-1 ACCY-1 H 7
BATTERY 8 (3/0 AWG, BLACK)
9
87a
87a
A
30
87
86
85
30
87
86
85
POSITIVE CABLE 10
TO STARTER B 11 STARTER
AND ALTERNATOR C 12
ST RLY
BLUE-3
NEGATIVE CABLE 13
M
D
TO ENG BLOCK 14
CB4
CB3
CB1
CB2
STRT SOL
F12
E
F8
F9
F7
15
NEGATIVE CABLE F 16
FLAG TO G
20
20
20
20
17
25
10
15
15
H 18 ST RLY PWR
19
(3/0 AWG, RED)
20
21
(4 AWG, RED)
BLACK-1 GRAY-2 22
H G F E D C B A H G F E D C B A 23
24
25
26 ALTERNATOR
27 (4 AWG, RED)
SP BAT PWR 28
B+
G
ECU BAT/022
29 6A/400V ALT EXC A
A D+
6A/400V
SP BAT PWR
TRAN/BRK PWR
TRAN/BRK PWR
KEY BAT PWR
SP BAT PWR
SP BAT PWR
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
HORN PWR
KEY ACC
KEY ACC
ST RLY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
KEY ACC
TRAN/BRK PWR
HORN PWR
KEY ACC
KEY BAT PWR
ST RLY
SP BAT PWR
SP BAT PWR
TRAN/BRK PWR
REVERSE RELAY
SP BAT PWR
87a
OPT PWR 4
OPT PWR 3
OPT PWR 2
OPT PWR 1
30
87
86
85
3
1
4
5
2
KEY/IGN
KEY ACC
B A
A B C D E F G H
GRAY-2 BLACK-1
S SHIFTER HARNESS
I
H
G
F
E
BLUE-3
D
85
86
87
30
87a
85
86
87
30
87a
C
HORN PWR
A PARK BRAKE
HORN OFF
H
OFF 7
85
86
87
30
87a
85
86
87
30
87a
ST RLY
G
F BCN/FAN LIGHTS 1 4
GREEN-4
E 2
2 5
D 3
C 3 6
B
85
86
87
30
87a
30
85
86
87
87a
ON
A ON
HEATER/BLOWER WIPER
OPTIONS VEC
LEFT DASH PANEL
BAT POS
A B
POWER DIST
VEC OPTIONS VEC
BLACK-6 GRAY-5
WIPER HEATER/BLOWER
F1 20
F2 5 F5 20
87a
87a
30
87
86
85
30
87
86
85
ACCY-2 IGNITION-2 F5 15
GREEN-4
GREEN-4
F6 10 F7 10
87a
87a
30
87
86
85
30
87
86
85
F8 10
F6 20
LIGHTS BCN/FAN
F1 15
87a
87a
30
87
86
85
30
87
86
85
IGNITION-1 ACCY-1 1
2 AUX ELEC1
87a
87a
30
87
86
85
30
87
86
85
87a
30
87
86
85
4 OPTION (15A) OPTION (25A)
87a
87a
30
87
86
85
30
87
86
85
BLUE-3
BLUE-3
6
AUX ELEC2
7
CB4
CB3
CB1
CB2
F10
F12
F11
F8
F3
F4
F9
F7
87a
30
87
86
85
F4
F3
F2
20
20
20
20
9
25
10
10
25
15
10
10
15
10
25
15
5
11
OPT PWR 1
OPT PWR 1
12
OPT PWR 2
13
OPT PWR 2
H G F E D C B A H G F E D C B A H G F E D C B A
OPT PWR 3
15
OPT PWR 4
OPT PWR 4
16
17
18
19
KEY BAT PWR
ECU BAT/022
HORN PWR
SP BAT PWR
CHASSIS HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
KEY BAT PWR
HORN PWR
HORN
OFF
2
SP BAT PWR
SHIFTER HARNESS
KEY/IGN
B A
ON
FC197-2
GRID HEATER FUSE
2
1
FC206
85
86 ENGINE STARTER
RL196-30
1
30 ST RLY PWR RED 10AWG ALT PWR - 8AWG
1 BATT POSITIVE
K1
A
87 B
STARTER RELAY, 12V, 75 AMP
C SIGNALS
D
5A FUSE HOLDER, ATO
1 BATT GROUND
ALTERNATOR
ENGINE HARNESS MY5040
BAT POS
BAT POS NEGATIVE CABLE
TO BATTERY (3/0 AWG, BLACK)
NEGATIVE CABLE
TO CAB FIREWALL A C A C POWER DIST POSITIVE CABLE
BLACK-6 GRAY-5 VEC TO BATTERY (3/0 AWG, RED)
STARTER
A RELAY
F2 5 ALT EXC
B 30
ACCY-2 IGNITION-2 ST RLY PWR
C 1 STRT SOL
GREEN-4
87
D 2
ST RLY
87a
87a
86
30
87
86
85
30
87
86
85
3
E 85
4
F 5
F1 15
G TRAN/BRK PWR (3/0 AWG, RED)
+ - 6
12 VDC IGNITION-1 ACCY-1 H 7
BATTERY 8 (3/0 AWG, BLACK)
9
87a
87a
A
30
87
86
85
30
87
86
85
POSITIVE CABLE 10
TO STARTER B 11 STARTER
AND ALTERNATOR C 12
ST RLY
BLUE-3
NEGATIVE CABLE 13
M
D
TO ENG BLOCK 14
CB4
CB3
CB1
CB2
STRT SOL
F12
E
F8
F9
F7
15
NEGATIVE CABLE F 16
FLAG TO G
20
20
20
20
17
25
10
15
15
H 18 ST RLY PWR
19
(3/0 AWG, RED)
20
21
(4 AWG, RED)
BLACK-1 GRAY-2 22
H G F E D C B A H G F E D C B A 23
24
25
26 ALTERNATOR
(4 AWG, RED)
KEY BAT PWR
KEY IGN
27
28
B+
G
29 6A/400V ALT EXC A
A D+
6A/400V
TRAN/BRK PWR
TRAN/BRK PWR
KEY BAT PWR
KEY START
KEY START
KEY IGN
ST RLY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
KEY START
TRAN/BRK PWR
KEY START
KEY IGN
KEY BAT PWR
ST RLY
TRAN/BRK PWR
REVERSE
RELAY
3 87a
30
1
TRANSMISSION SHIFTER 4 87
5 86
HOBBS
2 85
F F
SW1 SW2
N
N
KEY/IGN
R R
B A
4 4
SW3 3 3 SW4
S
2 2
I 1 1
WARN LIGHT
TEST RELAY
KEY START
3 87a
30
1
4 87
5 86
2 85
TRAN/BRK PWR
1 2 3 4 5 6 7 8
PARK BRAKE
OFF
7
ST RLY
1 4
2 5 SHIFTER HARNESS
3 6
ON
REVERSE
ALARM
B
BAT POS
BAT POS
STOP TAIL
(-) ENG STOP LT ORG 18AWG
D 1 49
ENG WARN LT VIO 18AWG
TAIL LIGHT
BLK C 2 48
(OPT)
RED
A C GRN
B 3
ALTERNATOR 47
POWER DIST A 4
5 ALT PWR - 12AWG
46
BU
BLACK-6 GRAY-5
VEC 6 FUSIBLE LINK
1 BATT POSITIVE 45
WAIT TO START K1 44
7
ENG STOP LT A
A 8 43
F2 5 ALT EXC ALT EXC ALT EXC RED 18AWG
ACCY-2 IGNITION-2
B 9 B 42
F5 15
F6 10
D 11
87a
87a
D
30
87
86
85
30
87
86
85
40
E 12
ST RLY K2 39
F 13
F1 15 TRAN/BRK PWR 1 BATT GROUND 38
G 14
IGNITION-1 ACCY-1 H 15 K3 37
16 36
87a
87a
RL196
30
87
86
85
30
87
86
85
A 17
35
B 18 2
ST RLY ORG 16AWG 85 34
C 19 1
ENG WARN LT VIO 18AWG 86 33
BLUE-3
D 20 RL196-30
E 21 ST RLY PWR RED 10AWG 32
CB4
CB3
CB1
CB2
1
F10
F12
F11
F8
F3
F4
F9
F7
F 22 30 31
RL196-87 30
20
20
20
20
10
25
15
10
10
15
H 24 1
87 29
25
26
28
BLACK-1 GRAY-2 27 27
H G F E D C B A H G F E D C B A 28 26
STRT PWR RED 2/0AWG
29 1 M 25
PWR STUD 24
STRT SOL ORG 10AWG
REVERSE
1 23
SOL STUD 22
1 21
POSITIVE CABLE GND STUD 20
TO STARTER STARTER 19
KEY BAT PWR
GAGE PWR
17
16
15
14
13
12
11
10
9
8
7
6
5
TRANS TEMP SW
TRAN/BRK PWR
TRAN/BRK PWR
ENGINE WARN LT
WAIT TO START
TRANS TEMP SW
4
SHIFT PWR 1
KEY BAT PWR
GAGE PWR
KEY START
KEY START
REVERSE
SHIFT PWR 1
KEY IGN
3
ST RLY
2
1
CHASSIS HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
KEY START
SHIFT PWR 1
KEY IGN
KEY BAT PWR
KEY START
TRAN/BRK PWR
REVERSE
TRAN/BRK PWR
ST RLY
OFF
7
B A
1 4
+ - S 2 5
12 VDC I 3 6
BATTERY ON
TRAN/BRK PWR
KEY START
WAIT TO START
REVERSE
(RED, 18 GA GXL)
STONERIDGE
GAUGE
6 5 4 TRANS TMP WRN
(RED, 18 GA GXL) F F
3 2 1 SW1 SW2
GAGE PWR
ENG STOP LT
TRANS TMP SW
N2 N
(RED, 18 GA GXL)
3
1
4
5
2
2
5
4
1
3
ENG WARN LT
WAIT TO START LT
ENG WARN
87a
87a
30
87
86
85
30
87
85
86
R 3 R
(RED, 18 GA GXL)
4 4
ENG STOP
SW3 3 SW4
(RED, 18 GA GXL) WARN LIGHT REVERSE
TEST RELAY 2 RELAY
1
1 1
2
HOBBS
3 4 5
(ORG, 18 GA GXL)
TRANSMISSION SHIFTER ZF DASH PANEL
(D BLU, 18 GA GXL)
(ORG, 18 GA GXL)
6 7 8
(WHT, 18 GA GXL)
9.7 ENGINE START CIRCUIT 2. If a “whirring” noise is heard but the engine does not
turn over, the starter is spinning but not engaging the
flywheel. The starter drive or solenoid that pushes
9.7.1 Starter the drive forward to engage the flywheel may be
defective. Missing or damaged teeth on the flywheel
can also prevent the starter from cranking the
1 engine.
3. If the starter only “clicks” it may indicate that the
battery is discharged, or that there is a loose or
corroded battery cable connection. Check the
battery state of charge and battery condition first,
then check the cables and cable connections.
4. For additional information on the starting circuit,
refer to Section 9.5, “Electrical System Schematics.”
c. Starter Removal
Remove the starter only if it fails. To remove the starter:
MY4600
1. Place a Do Not Operate Tag on both the ignition key
The starter (1) is located on the left side of the engine (the switch and the steering wheel, stating that the
right side of the machine - John Deere). machine should not be operated.
The starter (1) is located on the right side of the engine 2. Open the engine cover.
(the right side of the machine - Perkins & Cummins).
3. Properly disconnect the battery.
a. Testing the Starter on the Engine 4. Remove the wires from the solenoid stud. Remove
the positive (+) battery cable from the starter. Label
If the starter does not engage when the ignition key and disconnect the wire from the starter solenoid
switch is turned, check the following: housing stud. Record how the wires are installed to
1. The main fuse may be blown, requiring replacement. ensure correct installation later.
Check for the cause of the blown fuse. 5. Loosen, but DO NOT remove, the three fasteners
2. There may be a defect in the ignition key switch, securing the starter to the flywheel housing. Support
ignition wiring or starter solenoid. the starter securely, as it is relatively heavy and will
3. Check battery condition. Clean the battery posts and fall if not supported.
the connectors at each end of the battery cables. 6. Support the starter and remove the fasteners
4. Check for broken wiring and damaged insulation on securing the starter to the engine. Remove the
the wiring. Replace all broken or damaged wiring. negative (-) ground cable from its starter mounting
bolt.
5. Check all connections at the starter solenoid, key
switch and wiring harness plugs. Clean and tighten 7. Remove the starter from the machine.
all connections.
d. Starter Installation
6. If the starter still does not operate after these checks
have been performed, check the starting circuit. 1. Position the starter in its mounting opening on the
flywheel housing. Position the ground cable over the
b. Starter Circuit Checks correct starter mounting bolt. Secure the starter with
the three fasteners.
1. Check wires and connections for looseness,
corrosion, damage, etc. 2. Connect the positive (+) battery cable to the upper
solenoid stud. Install the wires to the upper solenoid
stud, and secure with lock washer and nut.
3. Connect the wire to the solenoid mounting stud.
4. Properly connect the battery.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the 4. Install a drive ratchet into the square hole in the
ignition key switch and the steering wheel. serpentine belt tensioner bracket.
5. While lifting the automatic belt tensioner away from
9.7.2 Charging Circuit the belt, remove the fan serpentine belt.
Note: Record how the alternator is installed to ensure
2
correct installation later.
6. Label and disconnect the wire leads attached to the
alternator.
7. Remove the lower mounting capscrew securing the
alternator to the lower mounting hole on the engine.
8. While supporting the alternator with one hand,
remove the upper (longer) mounting hardware from
the upper alternator mount. Remove the alternator
from the machine.
b. Alternator Installation
1. Position the alternator and align with the upper
alternator mount on the engine bracket. Insert the
upper (longer) mounting hardware through the
MY0370
alternator mount. Thread the longer capscrew into
Before using a battery charger, an attempt can be made the alternator front mount. DO NOT tighten
to recharge the battery by jump-starting the machine completely at this time.
(Refer to the appropriate Operation & Safety Manual). 2. Align the lower alternator mount hole with the lower
Allow the engine to run, which will enable the mounting bracket on the engine, and insert the lower
alternator (2) to charge the battery. mounting capscrew. Tighten the lower capscrew and
If the engine alternator charging warning indicator upper capscrew securely.
illuminates, perform the following checks: 3. Place a drive ratchet into the square hole on the
1. Check all battery cable connections at the battery, serpentine belt tensioner bracket. Apply pressure
and verify that they are clean and tight. against the tensioner bracket and route the
serpentine belt onto the alternator and engine
2. Check the external alternator wiring and
pulleys. Release and check the tensioner pulley to
connections, and verify that they are in good
verify that it is pivoting freely in order to provide the
condition.
proper tension on the belt. Check for proper belt
3. Check the fan belt condition and tension. alignment. (Refer to the appropriate Operation &
4. Run the engine and check the alternator for noise. A Safety Manual.)
loose drive pulley, loose mounting hardware, worn or 4. Connect the previously labeled wire leads to the
dirty internal alternator bearings, a defective stator alternator.
or defective diodes can cause noise. Replace a worn
5. Properly connect the battery.
or defective alternator.
6. Close and secure the engine cover.
9.7.3 Alternator 7. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
a. Alternator Removal
1. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
2. Open the engine cover. Allow the system fluids to
cool.
3. Properly disconnect the battery.
MY0440
9.8.1 Windshield/Rear Window Washer 2. Connect the cab wiring harness connectors to the
Reservoir reservoir connectors.
3. Install the reservoir tank onto the mounting bracket.
4. Install the lock washers and nuts and secure.
4
5. Fill the washer fluid reservoir with washer fluid.
6. Properly connect the battery.
7. Turn the ignition key switch to the RUN position and
press the washer switch. Verify that fluid is sprayed
on both the windshield and rear glass.
8. Close and secure the engine cover.
9. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
MY1220
a. Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Remove the nuts and the lock washers from the
washer mounting bolts.
6. Pull the washer reservoir out and away from the
mounting bracket.
7. Rotate the washer reservoir, label and remove the
cab harness connectors from the washer reservoir
connectors.
8. Remove the windshield washer hoses from the
reservoir.
b. Disassembly
DO NOT disassemble the pump. The pump is not
serviceable. Replace pump if found to be defective.
4. Properly disconnect the battery. 9. Close and secure the engine cover.
10. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
5
9.10 SOLENOIDS, SENSORS AND
SENDERS
b. Disassembly
DO NOT disassemble the cab heater and fan controls.
The controls are not serviceable. Replace controls if
found to be defective.
MY1030
3. Open the engine cover. Allow the system fluids to
cool.
5. Disconnect the wiring connector at the fuel shut-off 4. Properly disconnect the battery.
solenoid (6) lead.
5. Disconnect the wiring connector at the park brake
6. Remove the fuel shut-off solenoid from the fuel solenoid lead.
injector pump.
7
b. Fuel Shut-off Solenoid Disassembly
DO NOT disassemble a fuel shut-off solenoid. Replace a
defective fuel shut-off solenoid with a new part.
2. Install the fuel shut-off solenoid on the fuel injection 6. Remove the nut on the end of the park brake coil (7).
pump. Do Not Over Tighten.
7. Remove the park brake coil.
3. Connect the wiring connector at the fuel shut-off
solenoid lead. 8. Remove the park brake solenoid (8). (Remove only if
the electrical coil is found to not be faulty.)
4. Properly connect the battery.
5. Start the engine. If the engine starts, the fuel shutoff b. Disassembly
solenoid is functioning. If the engine fails to start, the
DO NOT disassemble the solenoid. The solenoid is not
fuel shut-off run solenoid may have a poor ground
serviceable. Replace solenoid if found to be defective.
connection. Visually check the wiring at the fuel
shutoff solenoid leads and/or check for continuity
c. Park Brake Solenoid Valve Installation
with a voltmeter as required.
6. Check for fuel and/or oil leakage around the solenoid. Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
7. Close and secure the engine cover. operation. Lubricate seals and o-rings with clean
8. Remove the Do Not Operate Tags from both the hydraulic oil.
ignition key switch and the steering wheel.
1. If necessary, install the park brake solenoid in its
original orientation.
2. Slide the park brake coil over the solenoid. Tighten 1. Park the machine on a firm, level surface, level the
the nut to secure the solenoid. DO NOT overtighten. machine, fully retract the boom, lower the boom,
3. Connect the wiring connector to the park brake coil place the transmission control lever in
lead. (N) NEUTRAL, engage the park brake and shut the
engine OFF.
4. Properly connect the battery.
2. Place a Do Not Operate Tag on both the ignition key
5. Close and secure the engine cover. switch and the steering wheel, stating that the
6. Remove the Do Not Operate Tags from both the machine should not be operated.
ignition key switch and the steering wheel. 3. Open the engine cover. Allow the system fluids to
cool.
9.10.3 Transmission Solenoid Valves
4. Properly disconnect the battery.
5. Unplug the transmission temperature sender
connector from the wiring harness connector.
6. The sender is threaded into the transmission
housing. Remove the sender.
2. Place a Do Not Operate Tag on both the ignition key 4. Start the engine, allow it to reach operating
switch and the steering wheel, stating that the temperature and observe the operator’s instrument
machine should not be operated. cluster for warning indication. If the sender is not
3. Open the engine cover. Allow the system fluids to defective, the problem could be elsewhere; possibly
cool. in a shorted wire, improper-running engine, improper
or low coolant, obstructed or faulty radiator, coolant
4. Properly disconnect the battery. pump, loose fan belt, defective instrument display,
CUMMINS ENGINE SHOWN etc.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
1
ignition key switch and the steering wheel.
2
MY4620
9.10.6 Air Manifold Temperature Sensor - 4. Start the engine, allow it to reach operating
John Deere temperature and observe the operator’s instrument
cluster for warning indication. If the sensor is not
a. Air Manifold Temperature Sensor Removal defective, the problem could be elsewhere; possibly
in a shorted wire, improper-running engine, improper
1. Park the machine on a firm, level surface, level the
or low coolant, obstructed or faulty radiator, coolant
machine, fully retract the boom, lower the boom,
pump, loose fan belt, defective instrument display,
place the transmission control lever in
etc.
(N) NEUTRAL, engage the park brake and shut the
engine OFF. 5. Close and secure the engine cover.
2. Place a Do Not Operate Tag on both the ignition key 6. Remove the Do Not Operate Tags from both the
switch and the steering wheel, stating that the ignition key switch and the steering wheel.
machine should not be operated.
3. Open the engine cover. Allow the system fluids to
9.10.7 Engine Oil Pressure Sender/Switch
cool.
a. Engine Oil Pressure Sender/Switch Removal
4. Properly disconnect the battery.
1. Park the machine on a firm, level surface, level the
5. Unplug the engine coolant temperature sender/ machine, fully retract the boom, lower the boom,
switch connector from the wiring harness connector. place the transmission control lever in
6. Unplug the air manifold temperature sensor (N) NEUTRAL, engage the park brake and shut the
connector from the wiring harness connector. engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
3 switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Unplug the engine oil pressure sender connector
from the wiring harness connector.
MY1270
MY4640
9.10.10 Front and Rear Axle Proximity 3. Open the engine cover. Allow the system fluids to
Sensors cool.
The sensors used on each axle allow the steering to be 4. Properly disconnect the battery.
changed to one of three different settings. The sensors JOHN DEERE
a. Removal
1. Open engine cover. Allow system fluids to cool.
2. Properly disconnect the battery.
3. Unplug the axle proximity sensor from the wiring PERKINS
harness. BEFORE S/N 0160037186
cylinder barrel.
PERKINS
2. Connect the axle proximity sensor to the wiring S/N 0160037186 THRU 0160039451
EXCLUDUING 0160039394 & 0160039397
harness.
3. Properly connect the battery.
12
4. Close and secure engine cover. 11
5. Start the machine, select a steering mode, turn the
steering wheel until the display unit shows the
steering has been "locked" into the selected mode.
a. Gauge Removal 5. Remove the screws (11) securing the dash panel.
6. Label and disconnect the wires from the gauge,
1. Park the machine on a firm, level surface, level the
remove the gauge bracket.
machine, fully retract the boom, lower the boom,
place the transmission control lever in 7. Pull the gauge (12) out from the dash.
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
b. Disassembly b. Disassembly
DO NOT disassemble the gauge. The gauge is not DO NOT disassemble the ignition switch. Replace a
serviceable. Replace the gauge if found to be defective. defective switch with a new part.
ACC
BAT
5. Turn the ignition to the ON position to check the
gauge values. ST
6. Close and secure the engine cover.
7. Remove the Do Not Operate Tags from both the
IG
N N
ignition key switch and the steering wheel. IG
MY0830
a. Switch Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. There are three frames with three switches in each
frame.
6. Pull the frame out of the dash, disconnect the
harness connector to the switch in question and
push the switch out of the frame.
b. Disassembly
DO NOT disassemble the dash switch. Replace a
defective switch with a new part.
d. Switch Installation
1. Connect the switch to the cab harness connector.
2. Position the switch over the rectangular switch bezel
and snap into position.
3. Properly connect the battery.
4. Start the machine and check the replaced switch for
proper function.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
Warning Shutdown
Lamp State Lamp Indication Engine State
Lamp Lamp
ON ON Bulb Check When the ignition is turned on, the Key on, but engine has
EMS shall illuminate each bulb for yet to be cranked
2 seconds and extinguish them
afterwards
OFF OFF No Faults Present With both lamps off whilst engine is Engine is running with no
running then are no currently active detected faults
warnings, diagnostics or events
ON OFF Active Diagnostic Should the warning lamp illuminate Engine is running
during engine running, this normally, but has one or
indicates that an Active diagnostic more faults with engine
(Electrical fault) is present management system
ON FLASH Derate Should the warning lamp illuminate Engine is running, but has
(Invoked by Active and the shutdown lamp flash one or more Active
Diagnostic) during engine running, this diagnostic events that
indicates that an Active diagnostic have initiated engine
(Electrical fault) is present. The derate
diagnostic is sufficiently serious to
invoke engine derate
FLASH OFF Warning Should the warning lamp flash Engine is running
(Warning only) during engine running, this normally, but has one or
indicates that one or more of the more monitored engine
engine protection strategy warning parameters outside of the
values have been exceeded, but acceptable range
not to a level that will invoke Derate
or Shutdown
FLASH FLASH Derate Should both the Warning Lamp Engine is running, but
(Warning and and Shutdown Lamp flash during one or more of the
Derate) engine running, this indicates that monitored engine
one, or more of the engine parameters has gone
protection strategy values have beyond that of warning
been exceeded beyond the level only and has now
required to invoke engine derate exceeded those set for
engine derate
ON ON Engine Shutdown Should both the Warning Lamp Engine is either shutdown
and Shutdown Lamp illuminate or shutdown is imminent,
during engine running this one of more monitored
indicates that either: engine parameters have
1. One or more of the engine gone beyond that of
protection strategy shutdown warning or derate and
values has been exceeded have now exceeded
those set for engine
2. A serious Active diagnostic shutdown, or a serious
has been detected Active diagnostic has
Shortly after (time duration to be agreed) been detected
engine will shutdown
111 629 12 Red Controller #1 Engine Control Module Critical internal failure -
Bad intelligent Device or Component
115 612 2 Red System Diagnostic Engine Speed/Position Sensor Circuit lost both
Code #2 of two signals from the magnetic pickup sensor
- Data Erratic, Intermittent, or incorrect
122 102 3 Amber Boost Pressure Intake Manifold Pressure Sensor Circuit -
Voltage Above Normal, or Shorted to High
Source
123 102 4 Amber Boost Pressure Intake Manifold Pressure Sensor Circuit -
Voltage Below Normal, or Shorted to Low
Source
124 102 16 Amber Boost Pressure Intake Manifold 1 Pressure - Data Valid but
Above Normal Operational Range - Moderately
Severe Level
133 974 3 Red Remote Accelerator Remote Accelerator Pedal or Lever Position
Sensor Circuit - Voltage Above Normal, or
Shorted to High Source
134 974 4 Red Remote Accelerator Remote Accelerator Pedal or Lever Position
Sensor Circuit - Voltage Below Normal, or
Shorted to Low Source
135 100 3 Amber Engine Oil Pressure Oil Pressure Sensor Circuit - Voltage Above
Normal, or Shorted to High Source
141 100 4 Amber Engine Oil Pressure Oil Pressure Sensor Circuit - Voltage Below
Normal, or Shorted to Low Source
143 100 18 Amber Engine Oil Pressure Oil Pressure Low - Data Valid but Below Normal
Operational Range - Moderately Severe Level
144 110 3 Amber Engine Coolant Coolant Temperature Sensor Circuit - Voltage
Temperature Above Normal, or Shorted to High Source
145 110 4 Amber Engine Coolant Coolant Temperature Sensor Circuit - Voltage
Temperature Below Normal, or Shorted to Low Source
146 110 16 Amber Engine Coolant Coolant Temperature High - Data Valid but
Temperature Above Normal Operational Range - Moderately
Severe Level
153 105 3 Amber Intake Manifold #1 Intake Manifold Air Temperature Sensor Circuit
Temp - Voltage Above Normal, or Shorted to High
Source
154 105 4 Amber Intake Manifold #1 Intake Manifold Air Temperature Sensor Circuit
Temp - Voltage Below Normal, or Shorted to Low
Source
155 105 0 Red Intake Manifold #1 Intake Manifold Air Temperature High - Data
Temp Valid but Above Normal Operational Range -
Most Severe Level
187 3510 4 Amber 5 Volts DC Supply Sensor Supply Voltage #2 Circuit - Voltage
Below Normal, or Shorted to Low Source
193 520199 3 Amber Cruise Control Cruise Control (Resistive) Signal Circuit -
Voltage Above Normal, or Shorted to High
Source
194 520199 4 Amber Cruise Control Cruise Control (Resistive) Signal Circuit -
Voltage Below Normal, or Shorted to Low
Source
195 111 3 Amber Coolant Level Coolant Level Sensor Circuit - Voltage Above
Normal, or Shorted to High Source
196 111 4 Amber Coolant Level Coolant Level Sensor Circuit - Voltage Below
Normal, or Shorted to Low Source
197 111 18 Amber Coolant Level Coolant Level - Data Valid but Below Normal
Operational Range - Moderately Severe Level
199 1661 4 Amber Engine Automatic Engine Automatic Start Lamp Driver Circuit -
Start Lamp Voltage Above Normal, or Shorted to High
Source
211 1484 31 None J1939 Error Additional Auxiliary Diagnostic Codes logged -
Condition Exists
212 175 3 Amber Oil Temperature Engine Oil Temperature Sensor 1 Circuit -
Voltage Above Normal, or Shorted to High
Source
213 175 4 Amber Oil Temperature Engine Oil Temperature Sensor 1 Circuit -
Voltage Below Normal, or Shorted to Low
Source
214 175 0 Red Oil Temperature Engine Oil Temperature - Data Valid but Above
Normal Operational Range - Most Severe Level
221 108 3 Amber Barometric Pressure Barometric Pressure Sensor Circuit - Voltage
Above Normal, or Shorted to High Source
222 108 4 Amber Barometric Pressure Barometric Pressure Sensor Circuit - Voltage
Below Normal, or Shorted to Low Source
227 3510 3 Amber 5 Volts DC Supply Sensor Supply Voltage #2 Circuit - Voltage
Above Normal, or Shorted to High Source
231 109 3 Amber Coolant Pressure Coolant Pressure Sensor Circuit - Voltage
Above Normal, or Shorted to High Source
232 109 4 Amber Coolant Pressure Coolant Pressure Sensor Circuit - Voltage
Below Normal, or Shorted to Low Source
233 109 18 Amber Coolant Pressure Coolant Pressure - Data Valid but Below
Normal Operational Range - Moderately Severe
Level
234 190 0 Red Engine Speed Engine Speed High - Data Valid but Above
Normal Operational Range - Most Severe Level
235 111 1 Red Coolant Level Coolant Level Low - Data Valid but Below
Normal Operational Range - Most Severe Level
237 644 2 Amber External Speed Input External Speed Input (Multiple Unit
Synchronization) - Data Erratic, Intermittent, or
Incorrect
238 3511 4 Amber System Diagnostic Sensor Supply Voltage #3 Circuit - Voltage
code #1 Below Normal, or Shorted to Low Source
239 3511 3 Amber System Diagnostic Sensor Supply Voltage #3 Circuit - Voltage
code #2 Above Normal, or Shorted to High Source
241 84 2 Amber Wheel-based Vehicle Vehicle Speed Sensor Circuit - Data Erratic,
Speed Intermittent, or Incorrect
242 84 10 Amber Wheel-based Vehicle Vehicle Speed Sensor Circuit tampering has
Speed been detected - Abnormal Rate of Change
244 623 4 Amber Red Stop Lamp Red Stop Lamp Driver Circuit - Voltage Below
Normal, or Shorted to Low Source
245 647 4 Amber Fan Clutch Output Fan Control Circuit - Voltage Below Normal, or
Device Driver Shorted to Low Source
249 171 3 Amber Ambient Air Ambient Air Temperature Sensor Circuit -
Temperature Voltage Above Normal, or Shorted to High
Source
256 171 4 Amber Ambient Air Ambient Air Temperature Sensor Circuit -
Temperature Voltage Below Normal, or Shorted to Low
Source
261 174 16 Amber Fuel Temperature Engine Fuel Temperature - Data Valid but
Above Normal Operational Range - Moderately
Severe Level
263 174 3 Amber Fuel Temperature AEB15.60 Page 149 of 157 Engine Fuel
Temperature Sensor 1 Circuit - Voltage Above
Normal, or Shorted to High Source
265 174 4 Amber Fuel Temperature Engine Fuel Temperature Sensor 1 Circuit -
Voltage Below Normal, or Shorted to Low
Source
268 94 2 Amber Fuel Delivery Fuel Pressure Sensor Circuit - Data Erratic,
Pressure Intermittent, or Incorrect
271 1347 4 Amber Fuel Pump High Fuel Pressure Solenoid Valve Circuit -
Pressurizing Voltage Below Normal, or Shorted to Low
Assembly #1 Source
272 1347 3 Amber Fuel Pump High Fuel Pressure Solenoid Valve Circuit -
Pressurizing Voltage Above Normal, or Shorted to High
Assembly #1 Source
281 1347 7 Amber Fuel Pump High Fuel Pressure Solenoid Valve #1 -
Pressurizing Mechanical System Not Responding Properly
Assembly #1 or Out of Adjustment
285 639 9 Amber SAE J1939 Datalink SAE J1939 Multiplexing PGN Timeout Error -
Abnormal Update Rate
286 639 13 Amber SAE J1939 Datalink SAE J1939 Multiplexing Configuration Error-
Out of Calibration
288 974 19 Red Remote Accelerator SAE J1939 Multiplexing Remote Accelerator
Pedal or Lever Data Error - Received Network
Data In Error
293 441 3 Amber OEM Temperature Auxiliary Temperature Sensor Input #1 Circuit -
Voltage Above Normal, or Shorted to High
Source
294 441 4 Amber OEM Temperature Auxiliary Temperature Sensor Input #1 Circuit -
Voltage Below Normal, or Shorted to Low
Source
295 108 2 Amber Barometric Pressure Barometric Pressure Sensor Circuit - Data
Erratic, Intermittent, or Incorrect
296 1388 14 Red Auxiliary Pressure Auxiliary Pressure Sensor Input 1 - Special
Instructions
297 1388 3 Amber Auxiliary Pressure Auxiliary Pressure Sensor Input #2 Circuit -
Voltage Above Normal, or Shorted to High
Source
298 1388 4 Amber Auxiliary Pressure Auxiliary Pressure Sensor Input #2 Circuit -
Voltage Below Normal, or Shorted to Low
Source
319 251 2 Maint Real Time Clock Real Time Clock Power Interrupt - Data Erratic,
Power Intermittent, or Incorrect
322 651 5 Amber Injector Cylinder #01 Injector Solenoid Cylinder #1 Circuit - Current
Below Normal, or Open Circuit
323 655 5 Amber Injector Cylinder #05 Injector Solenoid Cylinder #5 Circuit - Current
Below Normal, or Open Circuit
324 653 5 Amber Injector Cylinder #03 Injector Solenoid Cylinder #3 Circuit - Current
Below Normal, or Open Circuit
325 656 5 Amber Injector Cylinder #06 Injector Solenoid Cylinder #6 Circuit - Current
Below Normal, or Open Circuit
331 652 5 Amber Injector Cylinder #02 Injector Solenoid Cylinder #2 Circuit - Current
Below Normal, or Open Circuit
332 654 5 Amber Injector Cylinder #04 Injector Solenoid Cylinder #4 Circuit - Current
Below Normal, or Open Circuit
334 110 2 Amber Engine Coolant Coolant Temperature Sensor Circuit - Data
Temperature Erratic, Intermittent, or Incorrect
338 1267 3 Amber Vehicle Accessories Idle Shutdown Vehicle Accessories Relay
Relay Driver Driver Circuit - Voltage Above Normal, or
Shorted to High Source
339 1267 4 Amber Vehicle Accessories Idle Shutdown Vehicle Accessories Relay
Relay Driver Driver Circuit - Voltage Below Normal, or
Shorted to Low Source
341 630 2 Amber Calibration Memory Engine Control Module data lost - Data Erratic,
Intermittent, or Incorrect
342 630 13 Red Calibration Memory Electronic Calibration Code Incompatibility - Out
of Calibration
343 629 12 Amber Controller #1 Engine Control Module Warning internal
hardware failure - Bad Intelligent Device or
Component
349 191 16 Amber Transmission Output Transmission Output Shaft Speed - Data Valid
Shaft Speed but Above Normal Operational Range -
Moderately Severe Level
351 627 12 Amber Controller #1 Injector Power Supply - Bad Intelligent Device
or Component
352 3509 4 Amber 5 Volts DC Supply Sensor Supply Voltage #1 Circuit - Voltage
Below Normal, or Shorted to Low Source
386 3509 3 Amber 5 Volts DC Supply Sensor Supply Voltage #1 Circuit - Voltage
Above Normal, or Shorted to High Source
415 100 1 Red Engine Oil Pressure Oil Pressure Low - Data Valid but Below Normal
Operational Range - Most Severe Level
418 97 15 Maint. Water in Fuel Water in Fuel Indicator High - Data Valid but
Indicator Above Normal Operational Range - Least
Severe Level
422 111 2 Amber Coolant Level Coolant Level - Data Erratic, Intermittent, or
Incorrect
425 175 2 Amber Oil Temperature Engine Oil Temperature - Data Erratic,
Intermittent, or Incorrect
428 97 3 Amber Water in Fuel Water in Fuel Sensor Circuit - Voltage Above
Indicator Normal, or Shorted to High Source
429 97 4 Amber Water in Fuel Water in Fuel Sensor Circuit - Voltage Below
Indicator Normal, or Shorted to Low Source
431 558 2 Amber Accelerator Pedal Accelerator Pedal or Lever Idle Validation
Low Idle Switch Circuit - Data Erratic, Intermittent, or Incorrect
432 558 13 Red Accelerator Pedal Accelerator Pedal or Lever Idle Validation
Low Idle Switch Circuit - Out of Calibration
435 100 2 Amber Engine Oil Pressure Oil Pressure Sensor Circuit - Data Erratic,
Intermittent, or Incorrect
441 168 18 Amber Electrical Potential Battery #1 Voltage Low - Data Valid but Below
(Voltage) Normal Operational Range - Moderately Severe
Level
442 168 16 Amber Electrical Potential Battery #1 Voltage High - Data Valid but Above
(Voltage) Normal Operational Range - Moderately Severe
Level
449 157 0 Red Injector Metering Fuel Pressure High - Data Valid but Above
Rail 1 Pressure Normal Operational Range - Moderately Severe
Level
451 157 3 Amber Injector Metering Injector Metering Rail #1 Pressure Sensor
Rail 1 Pressure Circuit - Voltage Above Normal, or Shorted to
High Source
452 157 4 Amber Injector Metering Injector Metering Rail #1 Pressure Sensor
Rail 1 Pressure Circuit - Voltage Below Normal, or Shorted to
Low Source
488 105 16 Amber Intake Manifold Intake Manifold 1 Temperature - Data Valid but
Above Normal Operational Range - Moderately
Severe Level
489 191 18 Amber Transmission Output Transmission Output Shaft Speed - Data Valid
Shaft Speed but Below Normal Operational Range -
Moderately Severe Level
497 1377 2 Amber Switch Circuit AEB15.60 Page 151 of 157 Multiple Unit
Synchronization Switch Circuit - Data Erratic,
Intermittent, or Incorrect
523 611 2 Amber System Diagnostic OEM Intermediate (PTO) Speed switch
code #1 Validation - Data Erratic, Intermittent, or
Incorrect
527 702 3 Amber Circuit - Voltage Auxiliary Input/Output 2 Circuit - Voltage Above
Normal, or Shorted to High Source
529 703 3 Amber Circuit - Voltage Auxiliary Input/Output 3 Circuit - Voltage Above
Normal, or Shorted to High Source
546 94 3 Amber Fuel Delivery Fuel Delivery Pressure Sensor Circuit - Voltage
Pressure Above Normal, or Shorted to High Source
547 94 4 Amber Fuel Delivery Fuel Delivery Pressure Sensor Circuit - Voltage
Pressure Below Normal, or Shorted to Low Source
551 558 4 Amber Accelerator Pedal Accelerator Pedal or Lever Idle Validation
Low Idle Switch Circuit - Voltage Below Normal, or Shorted to
Low Source
553 157 16 Amber Injector Metering Injector Metering Rail #1 Pressure High - Data
Rail 1 Pressure Valid but Above Normal Operational Range -
Moderately Severe Level
554 157 2 Amber Injector Metering Fuel Pressure Sensor Error - Data Erratic,
Rail 1 Pressure Intermittent, or Incorrect
559 157 18 Amber Injector Metering Injector Metering Rail #1 Pressure Low - Data
Rail 1 Pressure Valid but Below Normal Operational Range -
Moderately Severe Level
584 677 3 Amber Starter Solenoid Starter Relay Circuit - Voltage Above Normal, or
Lockout Relay Driver Shorted to High Source
Circuit
585 677 4 Amber Starter Solenoid Starter Relay Circuit - Voltage Below Normal, or
Lockout Relay Driver Shorted to Low Source
Circuit
595 103 16 Amber Turbocharger 1 Turbocharger #1 Speed High - Data Valid but
Speed Above Normal Operational Range - Moderately
Severe Level
596 167 16 Amber Alternate Potential Electrical Charging System Voltage High - Data
(voltage) Valid but Above Normal Operational Range -
Moderately Severe Level
597 167 18 Amber Alternate Potential Electrical Charging System Voltage Low - Data
(voltage) Valid but Below Normal Operational Range -
Moderately Severe Level
598 167 1 Red Alternate Potential Electrical Charging System Voltage Low - Data
(voltage) Valid but Below Normal Operational Range -
Most Severe Level
599 640 14 Red Engine External Auxiliary Commanded Dual Output Shutdown -
Protection Input Special Instructions
649 1378 31 Maint Engine Oil Change Change Lubricating Oil and Filter - Condition
Interval Exists
687 103 18 Amber Turbocharger 1 Turbocharger #1 Speed Low - Data Valid but
Speed Below Normal Operational Range - Moderately
Severe Level
689 190 2 Amber Engine Speed Primary Engine Speed Sensor Error - Data
Erratic, Intermittent, or Incorrect
691 1172 3 Amber Turbocharger #1 Turbocharger #1 Compressor Inlet Temperature
Compressor Inlet Sensor Circuit - Voltage Above Normal, or
Temperature Shorted to High Source
697 1136 3 Amber Sensor Circuit - ECM Internal Temperature Sensor Circuit -
Voltage Voltage Above Normal, or Shorted to High
Source
698 1136 4 Amber Sensor Circuit - ECM Internal Temperature Sensor Circuit -
Voltage Voltage Below Normal, or Shorted to Low
Source
757 2802 31 Amber Electronic Control Electronic Control Module data lost - Condition
Module Exists
778 723 2 Amber Engine Speed Engine Speed Sensor (Camshaft) Error - Data
Sensor #2 Erratic, Intermittent, or Incorrect
779 703 11 Amber Auxiliary Equipment Warning Auxiliary Equipment Sensor Input #3
Sensor Input (OEM Switch) - Root Cause Not Known
951 166 2 None Cylinder Power Cylinder Power Imbalance Between Cylinders -
Data Erratic, Intermittent, or Incorrect
1117 627 2 None Power Supply Power Lost With Ignition On - Data Erratic,
Intermittent, or Incorrect
1139 651 7 Amber Injector Cylinder Injector Cylinder #1 - Mechanical System Not
#01 Responding Properly or Out of Adjustment
1141 652 7 Amber Injector Cylinder Injector Cylinder #2 - Mechanical System Not
#02 Responding Properly or Out of Adjustment
1142 653 7 Amber Injector Cylinder Injector Cylinder #3 - Mechanical System Not
#03 Responding Properly or Out of Adjustment
1143 654 7 Amber Injector Cylinder Injector Cylinder #4 - Mechanical System Not
#04 Responding Properly or Out of Adjustment
1144 655 7 Amber Injector Cylinder Injector Cylinder #5 - Mechanical System Not
#05 Responding Properly or Out of Adjustment
1145 656 7 Amber Injector Cylinder Injector Cylinder #6 - Mechanical System Not
#06 Responding Properly or Out of Adjustment
1239 2623 3 Amber Accelerator Pedal Accelerator Pedal or Lever Position Sensor 2
Position Circuit - Voltage Above Normal, or Shorted to
High Source
1241 2623 4 Amber Accelerator Pedal Accelerator Pedal or Lever Position Sensor 2
Position Circuit - Voltage Below Normal, or Shorted to
Low Source
1257 1563 2 Red Control Module Control Module Identification Input State Error -
Identification Input Data Erratic, Intermittent, or Incorrect
State
1852 97 16 Amber Water in Fuel Water in Fuel Indicator - Data Valid but Above
Indicator Normal Operational Range - Moderately Severe
Level
1911 157 0 Amber Injector Metering Injector Metering Rail 1 Pressure - Data Valid
Rail but Above Normal Operational Range - Most
Severe Level
2113 52 16 Amber Coolant Temperature Coolant Temperature 2 - Data Valid but Above
Normal Operational Range - Moderately Severe
Level
2114 52 0 Red Coolant Temperature Coolant Temperature 2 - Data Valid but Above
Normal Operational Range - Most Severe Level
2115 2981 3 Amber Coolant Pressure Coolant Pressure 2 Circuit - Voltage Above
Normal, or Shorted to High Source
2116 2981 4 Amber Coolant Pressure AEB15.60 Page 153 of 157 Coolant Pressure 2
Circuit - Voltage Below Normal, or Shorted to
Low Source
2117 2981 18 Amber Coolant Pressure Coolant Pressure 2 - Data Valid but Below
Normal Operational Range - Moderately Severe
Level
2182 1072 3 Amber Engine Brake Output Engine Brake Actuator Driver 1 Circuit - Voltage
#1 Above Normal, or Shorted to High Source
2183 1072 4 Amber Engine Brake Output Engine Brake Actuator Driver 1 Circuit - Voltage
#1 Below Normal, or Shorted to Low Source
2185 3512 3 Amber System Diagnostic Sensor Supply Voltage #4 Circuit - Voltage
code #1 Above Normal, or Shorted to High Source
2186 3512 4 Amber System Diagnostic Sensor Supply Voltage #4 Circuit - Voltage
code #1 Below Normal, or Shorted to Low Source
2195 703 14 Red Auxiliary Equipment Auxiliary Equipment Sensor Input 3 Engine
Sensor Protection Critical - Special Instructions
2215 94 18 Amber Fuel Delivery Fuel Pump Delivery Pressure - Data Valid but
Pressure Below Normal Operational Range - Moderately
Severe Level
2216 94 1 Amber Fuel Delivery Fuel Pump Delivery Pressure - Data Valid but
Pressure Above Normal Operational Range - Moderately
Severe Level
2217 630 31 Amber Calibration Memory ECM Program Memory (RAM) Corruption -
Condition Exists
2249 157 1 Amber Injector Metering Injector Metering Rail 1 Pressure - Data Valid
Rail 1 Pressure but Below Normal Operational Range - Most
Severe Level
2261 94 15 Maint Fuel Delivery Fuel Pump Delivery Pressure - Data Valid but
Pressure Above Normal Operational Range - Least
Severe Level
2262 94 17 Maint Fuel Delivery Fuel Pump Delivery Pressure - Data Valid but
Pressure Below Normal Operational Range - Least
Severe Level
2263 1800 16 Amber Battery Temperature Battery Temperature - Data Valid but Above
Normal Operational Range - Moderately Severe
Level
2264 1800 18 Amber Battery Temperature Battery Temperature - Data Valid but Below
Normal Operational Range - Moderately Severe
Level
2265 1075 3 Amber Electric Lift Pump for Fuel Priming Pump Control Signal Circuit -
Engine Fuel Voltage Above Normal, or Shorted to High
Source
2266 1075 4 Amber Electric Lift Pump for Fuel Priming Pump Control Signal Circuit -
Engine Fuel Voltage Below Normal, or Shorted to Low
Source
2292 611 16 Amber Fuel Inlet Meter Fuel Inlet Meter Device - Data Valid but Above
Device Normal Operational Range - Moderately Severe
Level
2293 611 18 Amber Fuel Inlet Meter Fuel Inlet Meter Device flow demand lower than
Device expected - Data Valid but Below Normal
Operational Range - Moderately Severe Level
2311 633 31 Amber Fuel Control Valve Fueling Actuator #1 Circuit Error - Condition
#1 Exists
2321 190 2 None Engine Speed Engine Speed / Position Sensor #1 - Data
Erratic, Intermittent, or Incorrect
2322 723 2 None Engine Speed Engine Speed / Position Sensor #2 - Data
Sensor #2 Erratic, Intermittent, or Incorrect
2345 103 10 Amber Turbocharger 1 Turbocharger speed invalid rate of change
Speed detected - Abnormal Rate of Change
2363 1073 4 Amber Engine Compression Engine Brake Actuator Circuit #2 - Voltage
Brake Output #2 Below Normal, or Shorted to Low Source
2365 1112 4 Amber Engine Brake Output Engine Brake Actuator Driver Output 3 Circuit -
#3 Voltage Below Normal, or Shorted to Low
Source
2367 1073 3 Amber Engine Compression Engine Brake Actuator Circuit #2 - Voltage
Brake Output #2 Above Normal, or Shorted to High Source
2368 1112 3 Amber Engine Brake Output Engine Brake Actuator Driver 3 Circuit - Voltage
#3 Above Normal, or Shorted to High Source
2372 95 16 Amber Engine Fuel Filter Fuel Filter Differential Pressure - Data Valid but
Differential Pressure Above Normal Operational Range - Moderately
Severe Level
2373 1209 3 Amber Exhaust Gas Exhaust Gas Pressure Sensor Circuit - Voltage
Pressure Above Normal, or Shorted to High Source
2374 1209 4 Amber Exhaust Gas Exhaust Gas Pressure Sensor Circuit - Voltage
Pressure Below Normal, or Shorted to Low Source
2375 412 3 Amber Exhaust Gas Exhaust Gas Recirculation Temperature Sensor
Recirculation Circuit - Voltage Above Normal, or Shorted to
Temperature High Source
2376 412 4 Amber Exhaust Gas Exhaust Gas Recirculation Temperature Sensor
Recirculation Circuit - Voltage Below Normal, or Shorted to
Temperature Low Source
2377 647 3 Amber Fan Clutch Output Fan Control Circuit - Voltage Above Normal, or
Device Driver Shorted to High Source
2425 730 4 Intake Air Heater #2 Intake Air Heater 2 Circuit - Voltage Below
Normal, or Shorted to Low Source
2426 730 3 Intake Air Heater #2 Intake Air Heater 2 Circuit - Voltage Above
Normal, or Shorted to High Source
2555 729 3 Amber Inlet Air Heater Intake Air Heater #1 Circuit - Voltage Above
Driver #1 Normal, or Shorted to High Source
2556 729 4 Amber Inlet Air Heater Intake Air Heater #1 Circuit - Voltage Below
Driver #1 Normal, or Shorted to Low Source
2557 697 3 Amber Auxiliary PWM Auxiliary PWM Driver #1 - Voltage Above
Driver #1 Normal, or Shorted to High Source
2558 697 4 Amber Auxiliary PWM Auxiliary PWM Driver #1 - Voltage Below
Driver #1 Normal, or Shorted to Low Source
2963 110 15 None Engine Coolant Engine Coolant Temperature High - Data Valid
Temperature but Above Normal Operational Range - Least
Severe Level
2973 102 2 Amber Boost Pressure Intake Manifold Pressure Sensor Circuit - Data
Erratic, Intermittent, or Incorrect
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. JLG Europe B.V.
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Polaris Avenue 63
D - 27721 Ritterhude-lhlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 2132 JH Hoofddorp
Germany Sheung Shui N.T. Italy The Netherlands
Phone: +49 (0)421 69 350 20 Hong Kong Phone: +39 029 359 5210 Phone: +31 (0)23 565 5665
Fax: +49 (0)421 69 350 45 Phone: +852 2639 5783 Fax: +39 029 359 5845 Fax: +31 (0)23 557 2493
Fax: +852 2639 5797
www.jlg.com