JBT Manual PDF

Halvorsen Halvorsen
25 000 lb. Loader for Aircraft

627-9734-0NN
Halvorsen
GROUND SUPPORT AROUND
Halvorsen Ground THE WORLD
Support
For assistance or questions with set-up, warranty or parts, please contact your closest
JBT Sales and Service Center.
Location Warranty and Service Part Sales
Orlando
Telephones Telephones
Headquarters +1.407.850.4207 worldwide +1.407.850.4208 worldwide
John Bean Technologies Corp. 1.800.327.1686 within USA 1.800.821.3019 within USA
7300 Presidents Drive +1.407.850.4221 Fax +1.407.850.4221 Fax
Orlando, Florida 32809
USA orlando.service@jbtc.com parts.orders@jbtc.com
Madrid
John Bean Technologies +34.91.877.5880 Telephone +34.91.877.5883 Telephone
AeroTech S.L. +34.91.877.5881 Fax +34.91.877.5884 Fax
Autovía A-2, km 34,4
28805 Alcalá de Henares, madrid.parts@jbtc.com madrid.parts@jbtc.com
Madrid, Spain
London
John Bean Technologies Ltd.
Arnold Hawker House +44.208.587.0666 Telephone +44.208.831.2200 Telephone
Central Way +44.208.587.0660 Fax +44.208.587.0660 Fax
Feltham, England
london.service@jbtc.com london.parts@jbtc.com
Middlesex, United Kingdom
TW14 0XQ
Singapore
John Bean Technologies +65.6542.9255 Telephone +65.6542.9255 Telephone
Singapore Pte. Ltd. +65.6542.7493 Fax +65.6542.7493 Fax
6 Loyang Lane #03-00
Young Heng Industrial Building singapore.jbtparts@jbtc.com singapore.jbtparts@jbtc.com
Singapore 508920
JBTAeroTech.com www.JBTAeroTechDirect.com
Comments or suggestions
regarding our manuals?
Technical Publications
At JBT Technical Publications we John Bean Technologies +1.407.851.3377 Telephone
are always improving our technical 7300 Presidents Drive +1.407.850.4221 Fax
documentation. If you have any Orlando, Florida 32809 technical.publications@jbtc.com
comments or suggestions, please USA
contact us.
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INTRODUCTION
WARNING
BEFORE ATTEMPTING TO OPERATE OR MAINTAIN THE VEHICLE, COMPLETELY READ AND
UNDERSTAND THE OPERATION AND MAINTENANCE MANUAL, INCLUDING ALL DANGER,
WARNING AND CAUTION STATEMENTS. MAINTENANCE MUST BE PERFORMED
EXCLUSIVELY BY TRAINED AND QUALIFIED TECHNICIANS AND ACCORDING TO
MAINTENANCE SCHEDULES AND MANUFACTURERS’ RECOMMENDATIONS. FAILURE TO
COMPLY WITH THIS WARNING MAY RESULT IN SERIOUS BODILY INJURY, DEATH, OR
PROPERTY DAMAGE, INCLUDING DAMAGE TO THE VEHICLE! IF YOU HAVE ANY
QUESTIONS REGARDING THE SAFE OPERATION OR PROPER MAINTENANCE, PLEASE
CONTACT YOUR LOCAL JBT SERVICE CENTER BEFORE PROCEEDING.
1. PURPOSE
This technical manual presents operation, maintenance, service and parts procurement information for
the Halvorsen, 25 000 lb. Loader for Aircraft, manufactured by JBT.
2. SCOPE
This manual describes the procedures for safe operation, maintenance and repair of the Halvorsen
loader, and ordering of spare parts. This manual does not provide procedures or guidelines specific to
the operation of the vehicle on airports or the handling of aircraft. It requires that operators be aware of
all applicable rules and regulations for operating the vehicle in traffic, on the airport and with aircraft, and
that the operator has been properly trained in the operation of the vehicle. Maintenance and repairs
must only be performed by technicians skilled and experienced on heavy industrial vehicles.
3. TERMS
Throughout this manual, the Halvorsen will be referred to as the “vehicle” or “unit.” The terms “right” and
“left” in the descriptive paragraphs refer to the operator’s right and left from a normal operating position.
For additional terms and acronyms used in this manual refer to Chapter 1, Section 1, “Description”.
NOTE: MAINTENANCE IS DEFINED AS, BUT NOT LIMITED TO, INSPECTIONS, CHECKS,
ADJUSTMENTS, TROUBLESHOOTING, REPAIRS, REMOVAL, REPLACEMENT OF
COMPONENTS, MODIFICATIONS OR ANY OTHER WORK, REQUIRED FOR THE
VEHICLE TO OPERATE.
4. IMPORTANT SAFETY NOTICE
This manual contains instructions, warnings and cautions based on normal operation and maintenance
practices. In addition to the instructions in this manual, operators and maintenance personnel should
follow all locally applicable guidelines and regulations, and maintain the vehicle in optimum condition
and avoid hazardous situations. A safety conscious operator and a well cared for vehicle make a safe
and efficient combination.
Your vehicle may operate slightly different depending on specifications and optional features.
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5. VEHICLE MODIFICATIONS OR TAMPERING
Modifications, including changing of settings, replacement of parts with no OEM parts and addition of
components or features may affect the safety and operational ability of the vehicle. Do not make
modifications without prior written approval from JBT, Orlando, Florida, USA.
Tampering with emission control devices by means of removing, bypassing, defeating, damaging or in
any way rendering ineffective any vehicle emission control device or element, including diesel exhaust
fluid (DEF) to be used or installed on the vehicle is prohibited and will void all warranties and subject to
federal, state and local laws and fines.
6. TECHNICAL ADVISORIES
JBT may issue technical advisories during the life span of the vehicle. These technical advisories are
intended to improve the reliability of the vehicle or address any safety related issues that may arise.
Unless the technical advisory instructs otherwise, please insert it immediately after the list of warnings
and cautions located in the front of this manual.
To receive these important technical advisories, it is required that you inform JBT in the event the
contact information of the person responsible for this equipment has changed, the vehicle has moved to
a different location, or the vehicle has transferred ownership.
Required Information:
Equipment type
Serial number(s)
Vehicle’s operating location address
Technical Advisory mailing information (No P.O. boxes please)
Contact personnel (GSE Manager, Safety Manager)
Telephone number(s)
E-mail address(es)
Please send this information to:
Technical Publications Dept.

JBT, Ground Support Equipment
7300 Presidents Drive
Orlando, Florida 32809
USA
technical.publications@jbtc.com
7. CE COMPLIANCE
This vehicle meets or exceeds the following CE requirements:
• Machinery Directive - Annex IV . . . . . . . . . . . . . . . . . . . . . . 2006/42/EC
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Halvorsen DoC
CERTIFICATES ARE ISSUED FOR EACH VEHICLE BASED ON INDIVIDUAL CUSTOMER SPECIFICATION.
EC Declaration of Conformity
This document declares that the machinery fulfills the relevant provisions of
2006/42/EC.
EC Type Examination Certificate Number “(Pending)”

Certificate issued by SMP Svensk Maskinprovning AB
THE SWEDISH MACHINERY TESTING INSTITUTE
PO Box 7035,
SE-750 07 Uppsala, Sweden
NB No.: 0404
This Machine also fulfills the applicable requirements of the following

EC Directives:
2006/95/EC, Low Voltage Directive
2004/108/EC, EMC-directive
Standards taken into consideration:

Inspection is based on: EN 1915-1:2013 and EN 12312-9:2013.
Place of Manufacture Technical Documentation Contact

John Bean Technologies Corporation JBT AeroTech
JBT AeroTech CO: Engineering Manager
7300 Presidents Drive Autovía A-2, km 34,4
Orlando, Florida 32809 28805 Alcalá de Henares
United States of America Madrid, Spain
Phone +1.407.851.3377 Phone +34.91.877.5880
Fax +1.407.850.2839 Fax +34.91.877.5881
Type of Equipment:
25 000 lb. Loader for Aircraft Signature: ________________________
Model: Halvorsen
Serial No.: Name
Spec No.: Title
NOTE:
JBT AeroTech
Date:
2015-05-01
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8. VEHICLE IDENTIFICATION PLATE
The vehicle identification plate contains specific information about your vehicle such as model,
specification number, serial number, manufacturing date, and other pertinent information. Refer to
Figure 1 for the location of your vehicle’s identification plate.
NOTE: BE SURE TO HAVE THE INFORMATION FROM THE VEHICLE IDENTIFICATION PLATE
READILY AVAILABLE WHEN CALLING JBT FOR PARTS OR SERVICE.
LOCATION OF THE VEHICLE

IDENTIFICATION PLATE
(INSIDE OPERATOR’S DOOR)
Figure 1
VEHICLE IDENTIFICATION PLATE
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GENERAL TABLE OF CONTENTS
OPERATION AND MAINTENANCE MANUAL

WITH ILLUSTRATED PARTS LIST
Volume I – OPERATION AND MAINTENANCE
CHAPTER 1. GENERAL INFORMATION AND OPERATING INSTRUCTIONS
CHAPTER 2. MAINTENANCE
CHAPTER 3. OVERHAUL
Volume II – ILLUSTRATED PARTS LIST
CHAPTER 4. ILLUSTRATED PARTS LIST
CHAPTER 5. MANUFACTURERS’ APPENDICES
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Halvorsen
Volume I
OPERATION AND MAINTENANCE MANUAL

Original Instructions
Version 1
Edition 3, Revision 1
This volume supersedes all editions and revisions prior to:
August 2017
English Language
For use with equipment serial numbers
AN14511 and subsequent
This volume includes the following options:

DIESEL TIER 3 ENGINE
ALLISON 2100 TRANSMISSION
Refer to Volume II for

ILLUSTRATED PARTS LIST

John Bean Technologies Corporation
Orlando, Florida 32809 USA
+1-407-851-3377 Telephone
+1-407-850-4221 Fax
CONFIDENTIAL
This technical manual contains unpublished work of John Bean Technologies Corporation. All information
herein is confidential and proprietary and cannot be duplicated, used or disclosed in whole or in part, except
with written permission from John Bean Technologies Corporation, Orlando, Florida USA.
© 2011–2017 John Bean Technologies Corporation, all rights reserved.
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RECORD OF REVISIONS
All pages in this issue are original.
The following pages have had changes incorporated:
Edition /
Change Date List of Effective Pages Change Description
Revision
Aug. 2011 Edition 1 Volume I New edition.
Updated: warnings and cautions,

Chapter 1, Section 3
emergency procedures, maintenance
June 2012 Edition 2 Chapter 2, Section 3 and 5
schedules, maintenance procedures,
overhaul procedures.
Updated: warnings and cautions, general

description, controls and indicators,
Chapter 1, Section 1, 2, 4, 5
Edition 2 operation procedures, specifications,
Mar. 2013 Chapter 2, Section 3, 5, 6
Revision 1 shipping procedures, maintenance
schedules, maintenance procedures,
troubleshooting, overhaul procedures.
Updated: warnings and cautions,

Chapter 1, Section 3, 5 emergency procedures, shipping
Edition 2
June 2014 Chapter 2, Section 3, 5 procedures, maintenance schedules,
Revision 1.1
Chapter 3, Section 2 maintenance procedures, overhaul
procedures.
Updated: general format, DoC, warnings

Front matter and cautions, general description,
Chapter 1, Section 1, 2, 5 winterization system, shipping and
July 2015 Edition 3
Chapter 2, Section 3, 5 transportation, maintenance schedules,
Chapter 3, Section 2 overhaul procedures, removal and
installation.
Added: emergency stop symbol, warning

Edition 3 Front matter
Aug. 2017 and notes; fall hazard warnings.
Revision 1 Chapter 1, Section 2
Updated: Singapore office address.
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SAFETY SYMBOLS
MANDATORY ACTION PROHIBITION

REFER TO OPERATION AND STOP - AUTHORIZED ACCESS
MAINTENANCE MANUAL ONLY
INSTRUCTIONS
WARNING WARNING
NO PERSONS ON DECK NO PERSONS ON LADDER
WHEN LIFTING OR WHILE IN WHEN LOADER IS IN
MOTION OPERATION
WARNING WARNING
HAZARD - PROCEED WITH OVERHEAD CRUSH HAZARD
CAUTION
WARNING WARNING
HAND CRUSH HAZARD HAND PINCH HAZARD
WARNING WARNING
ELECTRICAL SHOCK HAZARD ELECTRICAL SHOCK HAZARD
WARNING WARNING
HOT SURFACE HAZARD HIGH PRESSURE HYDRAULIC
LINE HAZARD
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WARNING WARNING
FALL HAZARD BODY CRUSH HAZARD
WARNING WARNING
FALL HAZARD FALL FROM WING HAZARD
WARNING WARNING
OVERHEAD OBSTRUCTION FAN BLADE HAZARD
HAZARD
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EMERGENCY STOP (E-STOP) BUTTON
WARNING
IN CASE OF VEHICLE MALFUNCTION, IMPENDING ACCIDENT OR ANY UNSAFE SITUATION,
IMMEDIATELY PUSH THE EMERGENCY STOP BUTTON, APPLY BRAKES AND SET PARKING
BRAKE.
NOTE: PUSHING THE EMERGENCY STOP (E-STOP) BUTTON SHUTS DOWN THE ENGINE
AND COUPLED HYDRAULIC PUMPS. IT DOES NOT COMPLETELY CUT ELECTRICAL
POWER TO THE VEHICLE.
WHAT IS AN EMERGENCY?
• FIRE ON THE VEHICLE

• VEHICLE MALFUNCTION
• ENGINE OUT OF CONTROL
• IMPENDING ACCIDENT
• ANY UNSAFE SITUATION
WARNING
BE EXTREMELY CAREFUL WHEN STEPPING OR WALKING ON WET, SNOWY AND ICY
SURFACES. WALKING ON VEHICLE SURFACES, STEPS AND LADDERS DURING THE
WINTER OR RAINING REQUIRES SPECIAL ATTENTION TO AVOID SLIPPING AND FALLING.
EVEN AFTER REMOVING SNOW AND ICE, OR AFTER RAINING, SURFACES MAY BE VERY
SLIPPERY. WEAR APPROPRIATE GLOVES AND ANTI-SLIP BOOTS OR SHOES.
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SAFETY RELATED DECALS
LOADER REAR SECTION
WARNING: OVERHEAD CRUSH HAZARD. ALWAYS INSTALL SAFETY SUPPORT

STANDS BEFORE ACCESSING UNDER THE DECK.
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LIST OF WARNINGS AND CAUTIONS USED IN THIS MANUAL
DANGER
A DANGER STATEMENT INDICATES A SITUATION THAT MUST BE AVOIDED. FAILURE TO
COMPLY WITH THE DANGER STATEMENT WILL RESULT IN SERIOUS BODILY INJURY,
DEATH, OR PROPERTY DAMAGE, INCLUDING DAMAGE TO THE VEHICLE!
WARNING
A WARNING INDICATES A PROCEDURE THAT MUST BE FOLLOWED OR A CONDITION THAT
MUST BE OBSERVED. FAILURE TO COMPLY WITH THE WARNING MAY RESULT IN SERIOUS
BODILY INJURY, DEATH, OR PROPERTY DAMAGE, INCLUDING DAMAGE TO THE VEHICLE!
CAUTION
A CAUTION INDICATES A PROCEDURE THAT MUST BE FOLLOWED OR A CONDITION THAT

MUST BE OBSERVED. FAILURE TO COMPLY WITH THE CAUTION MAY RESULT IN DAMAGE
TO VEHICLE AND VOID WARRANTY, OR DAMAGES TO OTHER PROPERTY, INCLUDING THE
AIRCRAFT!
The following danger, warning and caution statements are used in this manual. Read all of
them and follow the instructions when performing the procedures.
DANGER
DIESEL FUELS, KEROSENE, HYDRAULIC OIL, LUBRICANTS AND GLYCOLS ARE
FLAMMABLE. USE EXTREME CAUTION TO PREVENT SPILLS AND AVOID HEAT OR OPEN
FLAMES. DO NOT OVERFILL THE FUEL TANK WHEN REFUELING. ALWAYS ALLOW ROOM
FOR EXPANSION OF FUEL.
DANGER
ELECTRICAL CURRENT FROM FACILITIES POWER, BATTERY AND LIGHTNING IS
HAZARDOUS. TO REDUCE RISK OF ELECTRICAL SHOCK: DO NOT CONNECT OR
DISCONNECT ANY ELECTRICAL CABLES DURING AN ELECTRICAL STORM, CONNECT
FACILITIES POWER UTILIZING ONLY THE PROPER CONNECTORS PROVIDED, USE ONLY
ONE HAND TO CONNECT OR DISCONNECT CABLES AND TURN OFF AND LOCK OUT ALL
ELECTRICAL POWER SOURCES BEFORE PERFORMING ANY MAINTENANCE ON THE
VEHICLE.
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WARNING
TO CALIFORNIA CUSTOMERS: CALIFORNIA PROPOSITION 65 STATES THAT DIESEL
EXHAUST AND SOME OF ITS CONSTITUENTS ARE KNOWN TO THE STATE OF CALIFORNIA
TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
WARNING
WARNING AND CAUTION STATEMENTS.
WARNING
THE DECK MUST BE FULLY LOWERED AND THE VEHICLE MUST BE PROPERLY PARKED
BEFORE BOARDING OR LEAVING THE UNIT. USE THE LADDER LOCATED BEHIND THE
OPERATOR'S CAB TO GET ON AND GET OFF THE DECK. ENSURE THE LADDER AND DECK
AREA, BOTH ON AND BELOW, ARE CLEAR OF PERSONS AND FREE OF ANY OBJECTS
WHILE OPERATING THE VEHICLE. DO NOT RELY SOLELY ON SENSORS AND WARNING
LIGHTS.
WARNING
IT IS MANDATORY THAT ALL PERSONNEL WEAR A SAFETY HARNESS, WITH THE TETHER
ATTACHED TO A DESIGNATED “D-RING” WHEN WORKING ON THE DECK IN THE AREA
IDENTIFIED AND MARKED AS “HARNESS REQUIRED AREA”.
WARNING
USE EXTREME CAUTION AT ALL TIMES WHEN WALKING ON THE DECK DO NOT STEP ON
ROLLERS OR ROLLER ASSEMBLIES.
WARNING
ENSURE THE LADDER AND DECK ARE CLEAR OF PERSONS WHILE DRIVING AND
OPERATING THE VEHICLE.
WARNING
APPLY THE PARKING BRAKE AND TURN OFF THE IGNITION SWITCH BEFORE LEAVING THE
VEHICLE UNATTENDED.
WARNING
DO NOT ALLOW PERSONS ON THE DECK WHILE IN MOTION OR IN AN ELEVATED POSITION.
DECK MAINTENANCE MAY BE PERFORMED FROM UNDERNEATH USING SAFETY
SUPPORTS.
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WARNING
NEVER EXCEED THE RECOMMENDED MAXIMUM WEIGHT LIMITS FOR THIS EQUIPMENT.
WARNING
NORMAL LOADING OPERATIONS SHOULD NOT BE PERFORMED WHILE AIRCRAFT IS BEING
REFUELED WITHOUT HAVING FACILITY AND REGULATORY APPROVAL. OPERATOR MUST
ENSURE THAT NO HYDRAULIC LEAKS OR UNSAFE CONDITIONS ARE PRESENT ON THE
VEHICLE.
WARNING
USE CAUTION WHILE REFUELING THE VEHICLE TO AVOID FUEL SPILLS. CLEAN SPILLS
PROMPTLY.
WARNING
AT THE BEGINNING OF EACH SHIFT ENSURE THAT ALL SCHEDULED SERVICES HAVE BEEN
PERFORMED, INCLUDING VERIFICATION OF TIRE CONDITION, FUEL AND FLUID LEVELS
AND OVERALL CHECK FOR LOOSE OR MISSING HARDWARE AND GENERAL CONDITION OF
THE VEHICLE.
WARNING
AN OBSERVER ON THE GROUND SHOULD BE USED TO GUIDE THE OPERATOR WHEN
DRIVING THE VEHICLE IN REVERSE.
WARNING
THE VEHICLE IS DESIGNED TO BE DRIVEN ON PAVED OR CEMENT SURFACES APPROVED
TO SUPPORT THE WEIGHT AND USE OF GROUND SUPPORT EQUIPMENT VEHICLES.
WARNING
DO NOT LIFT PERSONS WITH THE VEHICLE. THE LOADER IS NOT INTENDED FOR LIFTING
OF PERSONS OTHER THAN THE DRIVER.
WARNING
DO NOT ALLOW PERSONS UNDER THE DECK UNLESS ADEQUATE SUPPORTS ARE IN
PLACE.
WARNING
ALWAYS WEAR GLOVES TO PREVENT CONTACT WITH VERY COLD OR VERY HOT METAL
AND SURFACES WITH BARE HANDS.
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WARNING
BEFORE STARTING ANY PROCEDURE, ENSURE THE LOADER IS ON A LEVEL SURFACE
AND HAS SUFFICIENT CLEARANCE IN FRONT AND BACK. ENSURE ALL PERSONS ARE
CLEAR OF THE LOADER IN THE EVENT OF UNEXPECTED MOVEMENT. PLACE CHOCKS
APPROXIMATELY TWO (2) INCHES FROM THE FRONT AND REAR OF TIRES TO PREVENT
EXCESSIVE MOVEMENT OF THE LOADER IN EITHER FORWARD OR REVERSE DIRECTION
SHOULD THE PARKING BRAKE FAIL.
WARNING
SUPPORT THE FOLDING WALK-DECK AND HANDRAIL SECTIONS WHEN REMOVING
RETAINING PINS TO PREVENT SERIOUS PERSONAL INJURIES. PERSONNEL MUST GO
UNDER THE FOLDING DECK TO REMOVE THE RETAINING PINS.
WARNING
DO NOT ACCESS WALK-DECK WHEN NOT SECURED BY BOTH LOCKS. FULLY LOCK
TELESCOPING WALK-DECK IN PLACE BEFORE ACCESSING OR WALKING ON IT.
WARNING
ALL CARGO, PALLETS AND ROLLING STOCK MUST BE SECURED TO THE LOADER DECK
TO PREVENT MOVEMENT IN ANY DIRECTION WHEN THE LOADER IS IN MOTION.
WARNING
CAB DOORS MUST BE LATCHED CLOSED WHEN DRIVING AND OPERATING THE LOADER.
WARNING
WEAR THE SEAT BELT AT ALL TIMES WHILE OPERATING THE LOADER.
WARNING
THE OPERATOR’S VISIBILITY WILL BE IMPAIRED TOWARDS THE RIGHT WHEN A PALLET
OR CARGO IS ON THE FRONT POSITION OF THE DECK. FOR SAFE OPERATION, AN
OBSERVER SHOULD ALWAYS BE USED TO KEEP THE OPERATOR INFORMED OF
CLEARANCE, TRAFFIC OR ANY HAZARD WHEN TRANSPORTING CARGO WHEN VISIBILITY
IS IMPAIRED.
WARNING
APPLY E-STOP TO DISABLE THE VEHICLE ONLY IN CASE OF EMERGENCY. PRESSING THE
EMERGENCY STOP PUSH-BUTTON WILL COMPLETELY SHUTDOWN THE VEHICLE.
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WARNING
DECK CUT-OFF VALVE MUST BE RETURNED TO THE ON POSITION AFTER USE. LOADER
STEERING AND SERVICE BRAKES ARE DISABLED WHEN CUTOFF VALVE IS LEFT IN THE
OFF POSITION.
WARNING
BEFORE TOWING, ATTACH TOW VEHICLE WITH TOW BAR OR CHOCK WHEELS BEFORE
DISENGAGING PARK BRAKE.
WARNING
BEFORE REMOVING OR INSTALLING VEHICLE COMPONENTS, ENSURE THE VEHICLE IS ON
LEVEL GROUND, WHEELS ARE SECURELY CHOCKED AND ELECTRICAL SYSTEM IS
SWITCHED OFF.
WARNING
BEFORE PERFORMING ANY PROCEDURE THAT REQUIRES THE DECK TO BE IN AN
ELEVATED POSITION, INSTALL THE MAINTENANCE STANDS AND LOWER THE DECK FULLY
AGAINST THE MAINTENANCE STANDS.
WARNING
LIFT VEHICLE ONLY BY PROPER HOISTING POINTS AND IN ACCORDANCE WITH THE
DESCRIBED METHOD. DO NOT USE FORKLIFTS.
WARNING
BRIDLES AND CHAINS MUST HAVE EQUAL LEG LENGTH OF A MINIMUM OF 3.60 M (12 FT.)
AND HAVE THE MINIMUM RECOMMENDED CAPACITY.
WARNING
PERFORM THE RE-COMMISSIONING MAINTENANCE PROCEDURES BEFORE RETURNING
THE VEHICLE INTO SERVICE AFTER STORAGE.
WARNING
FOLLOW THE REQUIRED PROCEDURES TO PREPARE THE UNIT FOR MAINTENANCE
(LOCK-OUT AND TAG-OUT).
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WARNING
BEFORE PERFORMING ANY MAINTENANCE OR PROCEDURE, ENSURE THE VEHICLE IS ON
A CLEAN AND LEVEL SURFACE, WHEELS ARE SECURELY CHOCKED, POWER UNIT IS OFF,
HYDRAULIC PRESSURE IS DEPLETED AND BATTERIES HAVE BEEN DISCONNECTED.
PLACE A HIGHLY VISIBLE TAG ON OR NEAR VEHICLE CONTROLS TO WARN OTHER
PERSONNEL VEHICLE IS BEING WORKED ON.
WARNING
VEHICLE MAINTENANCE MUST BE PERFORMED EXCLUSIVELY BY TRAINED AND
QUALIFIED TECHNICIANS.
WARNING
LOCK OUT AND TAG OUT THE VEHICLE BEFORE PERFORMING ANY MAINTENANCE,
ADJUSTMENTS OR REPAIRS TO THE VEHICLE.
WARNING
MAINTENANCE SUPPORT STANDS MUST BE INSTALLED WHILE PERSONNEL ARE
WORKING UNDER THE RAISED DECK.
WARNING
WEAR PERSONAL PROTECTION FOR EYES, EARS, SKIN AND TOES. AVOID LOOSE
CLOTHING, HAIR AND JEWELRY WHEN PERFORMING MAINTENANCE ON THE VEHICLE.
WARNING
TURN THE BATTERY DISCONNECT SWITCH TO THE “OFF” POSITION TO AVOID
ELECTRICAL HAZARDS WHILE WORKING ON THE ELECTRICAL SYSTEM.
WARNING
BEFORE PERFORMING ANY MAINTENANCE OR PROCEDURE, START ENGINE, RAISE DECK
TO SUFFICIENT HEIGHT TO INSTALL THE MAINTENANCE STANDS, THEN LOWER THE DECK
UNTIL SCISSORS ROLLERS ARE IN CONTACT WITH THE MAINTENANCE STANDS OR
BLOCKS. CHOCK WHEELS TO PREVENT MOVEMENT OF THE LOADER IN EITHER
DIRECTION, APPLY THE PARK BRAKE AND TURN OFF THE ENGINE.
WARNING
BEFORE STARTING THE VEHICLE, ENSURE ALL PERSONS AND OBJECTS ARE CLEAR OF
THE VEHICLE AND ALL COMPARTMENT DOORS ARE CLOSED AND SECURED. TIRES AND
WHEELS CAN MOVE WITHOUT WARNING AND CRUSH PERSONS.
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WARNING
USE ONLY PROPER TOOLS AND CALIBRATED MEASUREMENT DEVICES WHEN
PERFORMING VEHICLE MAINTENANCE.
WARNING
HYDRAULIC SYSTEM OPERATES AT HIGH PRESSURE AND TEMPERATURE. BEFORE
PERFORMING MAINTENANCE, DISABLE ALL HYDRAULIC POWER SOURCES, TURN OFF
THE POWER UNIT AND DEPLETE SYSTEM PRESSURE BEFORE INSPECTING OR
LOOSENING ANY HYDRAULIC CONNECTIONS OR COMPONENTS. KEEP AWAY FROM
HYDRAULIC LEAKS. DO NOT ATTEMPT TO “FEEL” FOR THE SOURCE OF A LEAK.
PRESSURIZED HYDRAULIC OIL CAN PENETRATE THE SKIN AND CAUSE OTHER SERIOUS
INJURY.
WARNING
TORQUE LUG NUTS ACCORDING TO SPECIFICATIONS.
WARNING
OPERATE VEHICLE ONLY IN WELL VENTILATED AREAS. ENGINE EXHAUST GASES ARE
POISONOUS.
WARNING
KEEP FINGERS AND HANDS CLEAR WHEN REMOVING OIL PLUG. HOT OIL MAY CAUSE
BURNS.
WARNING
COOLANT MAY BE HOT AND CAUSE BURNS. REMOVE ENGINE COOLANT CAP ONLY WHEN
ENGINE IS COOL. CAREFULLY LOOSEN COOLANT CAP, ALLOWING PRESSURE TO
RELEASE BEFORE COMPLETELY REMOVING IT.
WARNING
INSPECT, REPLACE AND ADJUST BRAKE COMPONENTS IN ACCORDANCE WITH
MAINTENANCE SCHEDULE.
WARNING
AVOID SPARKS OR OPEN FLAMES NEAR BATTERIES. LEAD-ACID BATTERIES PRODUCE
EXPLOSIVE HYDROGEN GAS.
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WARNING
USE PROPERLY RATED JACK AND MAINTENANCE STANDS TO LIFT AND SUPPORT THE
VEHICLE (REFER TO JACKING REQUIREMENTS IN SPECIFICATIONS SECTION).
WARNING
DO NOT ALLOW ANY PERSONS UNDER THE VEHICLE UNLESS PROPERLY RATED
MAINTENANCE STANDS ARE USED FOR SAFE SUPPORT OF THE VEHICLE.
WARNING
AVOID CONTACT AND INHALATION OF DIESEL FUEL, KEROSENE, HYDRAULIC OIL,
LUBRICANTS AND GLYCOLS. WASH AFFECTED AREAS IMMEDIATELY TO AVOID SKIN
IRRITATION.
WARNING
DISCONNECT THE BATTERY BEFORE PERFORMING MAINTENANCE ON THE ELECTRICAL
SYSTEM.
WARNING
REMOVE BOTH POSITIVE AND NEGATIVE BATTERY CABLES BEFORE WELDING ON THE
VEHICLE AND TAKE PRECAUTIONS TO PREVENT DAMAGE TO ELECTRONIC EQUIPMENT.
REFER TO CHAPTER 3, OVERHAUL FOR REQUIREMENTS. ALSO, REFER TO THE ENGINE
MANUAL IN CHAPTER 5 FOR ADDITIONAL REQUIREMENTS.
WARNING
THIS IS A MANDATORY SAFETY PRECAUTION. THE NORMAL SCISSORS MAINTENANCE
STANDS CANNOT BE INSTALLED WHEN REMOVING AND REPLACING ROLLERS. ENSURE
TO PROPERLY SUPPORT THE DECK AND SCISSORS.
WARNING
HEAVY-DUTY LIFTING PROVISIONS SUCH AS SLINGS OR CHAINS USED TO SUPPORT THE
DECK PLATFORM SHALL HAVE A MINIMUM CAPACITY OF 6800 KG (15 000 LB.).
WARNING
HEAVY-LIFTING EQUIPMENT USED TO SUPPORT THE DECK PLATFORMS SHALL HAVE A
MINIMUM CAPACITY OF 6800 KG (15 000 LB.) AND BE CAPABLE OF MOVING THE DECK
PLATFORM FORWARD APPROXIMATELY 0.60 M (2 FT.) ONCE THE DECK AND SCISSORS
ARE DISCONNECTED.
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WARNING
THE DECK LINKAGE MUST BE PROPERLY SUPPORTED WHILE REMOVING THE FRONT PIN
TO AVOID PERSONAL INJURY.
WARNING
CHOCK THE BOGY WHEELS ON THE OPPOSITE SIDE OF THE LOADER, TO PREVENT
MOVEMENT IN EITHER DIRECTION, APPLY THE PARKING BRAKE AND TURN OFF THE
ENGINE.
WARNING
STORAGE OF BATTERIES GENERATE HYDROGEN GAS THAT IS EXPLOSIVE. KEEP ALL
OPEN FLAMES AND SPARKS AWAY FROM BATTERIES.
WARNING
A COMPLETELY DISCHARGED OR FROZEN BATTERY CAN EXPLODE IF POWER IS
APPLIED. FROZEN BATTERIES MUST BE ALLOWED TO WARM GRADUALLY TO NORMAL
ROOM TEMPERATURE BEFORE USING.
WARNING
WHEN REMOVING A BATTERY, ALWAYS DISCONNECT THE CABLES ON THE GROUND
TERMINALS FIRST TO PREVENT A SPARK. ALWAYS CONNECT THE GROUND CABLE LAST
WHEN CONNECTING CABLES.
WARNING
ENGINE MUST BE SHUT DOWN AND THE EXTERNAL POWER CORD MUST BE
DISCONNECTED WHEN REMOVING AND REPLACING BATTERIES.
WARNING
DO NOT REMOVE GAUGE PORT PLUGS AND GAUGES OR LOOSEN HYDRAULIC
CONNECTIONS WITH THE POWER UNIT RUNNING. HYDRAULIC PRESSURE IN THE
SYSTEMS COULD CAUSE HYDRAULIC OIL TO SPRAY ON PERSONNEL.
WARNING
THE ENGINE MUST BE TURNED OFF WHEN MAKING ANY SWITCH ADJUSTMENT TO
PREVENT AN UNCONTROLLED MOVEMENT OF THE LOADER.
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WARNING
WHEN REMOVING COMPONENTS FOR REPLACEMENT OR REPAIR, CLEAN COMPONENTS,
IDENTIFY AND MARK ALL CONNECTIONS, SUPPORT PROPERLY FOR REMOVAL AND
PLACE REMOVED COMPONENTS IN A SAFE AND SECURE LOCATION.
WARNING
ENSURE CONNECTIONS ARE CLEAN BEFORE ATTACHING BRAKE LINES. BLEED AIR
FROM BRAKE SYSTEM UPON COMPLETION OF INSTALLATION.
WARNING
TWO PERSONS WORKING TOGETHER ARE REQUIRED FOR THE REMOVAL OF THE MAIN
PANEL.
WARNING
DO NOT MOVE THE VEHICLE UNTIL A FIRM BRAKE PEDAL IS OBTAINED, AFTER BLEEDING
BRAKES.
WARNING
SECURE THE WALK-DECK SO THAT IT IS COMPLETY SUPPORTED, SO THAT WHEN IT IS
DISCONNECTED FROM THE HINGES IT WILL NOT FALL.
WARNING
THE EDGES ON THE METAL ARE SHARP AND CAN CAUSE INJURY.
WARNING
DRAIN ALL FUEL FROM THE HEATER FUEL TANK BEFORE PROCEEDING.
WARNING
FULLY LOCK TELESCOPING WALK-DECK IN PLACE TO AVOID SERIOUS INJURY OR DEATH.
CAUTION
WHEN OPERATING THE VEHICLE IN FREEZING CONDITIONS, OCCASIONALLY TURN THE

STEERING WHEEL SLOWLY TO PREVENT THERMAL SHOCK IN THE STEERING VALVE.
CAUTION
DO NOT PLACE THE EQUIPMENT INTO SERVICE WITHOUT PERFORMING ALL THE
RECOMMENDED MAINTENANCE.
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CAUTION
THE AIR CONDITIONER DOES NOT DRAW FRESH AIR INTO THE CAB. IT WILL NOT REMOVE
SMOKE OR EXHAUST FUMES. CHECK FOR PROPER VENTILATION PRIOR TO OPERATION.
CAUTION
CIRCUIT BREAKER MUST BE IN THE “OFF” POSITION WHENEVER AC POWER CABLE IS

INSTALLED OR REMOVED FROM RECEPTACLE ON WINTERIZATION BOX.
CAUTION
AC POWER CABLE MUST BE REMOVED FROM RECEPTACLE BEFORE STARTING ENGINE.
CAUTION
ENGINE CAN BE STARTED WHEN AC POWER CABLE IS NOT ENERGIZED OR CIRCUIT

BREAKER IS IN THE “OFF” POSITION.
CAUTION
DO NOT OPERATE EQUIPMENT WITH DEFECTIVE WARNING INDICATOR LIGHTS.
CAUTION
WHEN STARTING THE ENGINE, RELEASE THE IGNITION SWITCH IF THE ENGINE FAILS TO
START WITHIN 15 SECONDS. AFTER A SECOND ATTEMPT, ALLOW THE STARTER MOTOR
TO COOL DOWN FOR ONE MINUTE BEFORE ATTEMPTING TO RESTART THE ENGINE.
CAUTION
CONFIGURE THE LOADER DECK FOR THE SIZE PALLET OR ROLLING STOCK THAT WILL BE
CONVEYED.
CAUTION
ALL RETAINING QUICK RELEASE PIN HANDLES AND LANYARDS SHOULD POINT TOWARDS
GROUND.
CAUTION
THE LOADER MAY ONLY BE DRIVEN IN A STRAIGHT LINE WITH THE LEFT FOLDING WING
IN THE DOWN POSITION. THE LOADER SHOULD NEVER BE DRIVEN WITH THE RIGHT
FOLDING WING IN THE DOWN POSITION.
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CAUTION
DO NOT EXCEED 15 KM (9 MILES) OF TRAVEL IN A ONE HOUR PERIOD OF TIME. IF THAT

DISTANCE IS REACHED, TIRES MUST BE ALLOWED TO COOL FOR ONE HOUR.
CAUTION
DO NOT DRIVE THE LOADER WITH THE DIFFERENTIAL LOCK ENGAGED WHEN OPERATING
IN NORMAL CONDITIONS ON HARD SURFACES.
CAUTION
THE FRONT LOAD STOPS WILL REMAIN IN THE DOWN POSITION AND THE RED INDICATOR
LIGHT WILL BE ILLUMINATED WITH THE SWITCH IN THE DOWN POSITION. THE FRONT
LOAD STOP SWITCH MUST BE PLACED IN THE UP POSITION WHEN TRANSPORTING
CARGO, LOADING CARGO FROM THE REAR OF THE DECK OR WHENEVER THE FRONT OF
THE DECK IS LOWER THAN THE REAR OF THE DECK.
CAUTION
ROLLING STOCK MUST HAVE PARKING BRAKES APPLIED AND SECURED WITH
RESTRAINTS ATTACHED TO THE TIE DOWN RINGS ON THE DECK BEFORE DRIVING THE
LOADER.
CAUTION
DO NOT ENERGIZE HYDRAULIC EMERGENCY PUMP DURING NORMAL VEHICLE

OPERATION.
CAUTION
CONTINUOUS OPERATION OF HYDRAULIC EMERGENCY PUMP FOR MORE THAN 30

SECONDS WILL OVERHEAT THE ELECTRICAL MOTOR. IF EMERGENCY PROCEDURES
CANNOT BE COMPLETED WITHIN 30 SECONDS, PUMP MUST BE ALLOWED TO COOL FOR
AT LEAST 10 MINUTES BEFORE CONTINUING.
CAUTION
NEVER USE THE HYDRAULIC EMERGENCY PUMP FOR OPERATING THE LOADER WHILE
TOWING IT.
CAUTION
DO NOT TOW THE LOADER FOR MORE THAN 150 M (500 FT.) WITHOUT DISCONNECTING
DRIVE SHAFT FROM DIFFERENTIAL.
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CAUTION
NEVER TOW THE LOADER FROM THE REAR END WITH THE CHASSIS RAISED.
CAUTION
WHEN USING DIESEL FUELS WITH SULFUR CONTENTS GREATER THAN 500 PPM (0.05% BY
MASS) AND THE ENGINE EQUIPPED WITH AN EXTERNALLY COOLED EGR (TIER 3 ENGINES),
LARGER FILTERS WITH TIGHTER MICRON FILTRATION MUST BE USED. CONSULT THE
ENGINE MANUFACTURER FOR MODIFICATIONS NEEDED.
CAUTION
DO NOT USE DIESEL FUELS WITH SULFUR CONTENTS GREATER THAN 15 PPM (0.0015% BY
MASS) IN EPA TIER 4 ENGINES.
CAUTION
DO NOT USE JET A1 FUEL IN THIS VEHICLE. REFER TO ENGINE MANUFACTURER FOR
SPECIFIC RECOMMENDATIONS.
CAUTION
THE LOADER MUST ONLY BE DRIVEN IN AIR TRANSPORT MODE WHILE LOADING ON AND
OFF FROM SPECIFIED TRANSPORT VEHICLE OR FOR GROUND CLEARANCE, BUT NEVER
FOR MORE THAN 60 M (200 FT.).
CAUTION
IF THE ENGINE SPEEDS UP WHILE ACTIVATING THE LIFT JOYSTICK WHILE IN AIR
TRANSPORT MODE, RELEASE THE LIFT JOYSTICK IMMEDIATELY AND LOWER THE DECK.
STRUCTURAL DAMAGE WILL OCCUR, OTHERWISE
CAUTION
USE OBSERVERS WHEN DRIVING THE LOADER ONTO THE TRANSPORT VEHICLE
(AIRCRAFT OR TRAILER) FOR SAFETY AND TO ENSURE THAT THERE IS ALWAYS
ADEQUATE CLEARANCE TO PREVENT DAMAGE TO THE TRANSPORT VEHICLE AND THE
LOADER.
CAUTION
IF THE DECK IS TO BE RAISED AND LOWERED WHILE THE CAB IS IN ITS RETRACTED
SHIPPING CONFIGURATION, ENSURE ADEQUATE CLEARANCE IS AVAILABLE BENEATH
THE CAB SO THE HYDRAULIC HOSES AND ELECTRICAL CABLES UNDER THE CAB ARE NOT
PINCHED BETWEEN THE DECK AND CHASSIS.
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CAUTION
ENSURE THE CHAINS DO NOT CONTACT THE LEFT SIDE HEADLIGHT HOUSING.
CAUTION
COMPLY WITH ALL LOCAL AND GOVERNMENT REGULATIONS FOR DISPOSING OF

ENVIRONMENTALLY SENSITIVE MATERIALS SUCH AS TIRES, BELTS, BATTERIES, MOTOR
OILS, GREASE, HYDRAULIC OIL, FUELS, REFRIGERANT GASES AND GLYCOLS.
CAUTION
USE CLEAN LINT-FREE RAGS FOR CLEANING OF TANKS AND COMPONENTS.
CAUTION
DO NOT USE PLASTIC SHEETING FOR STORAGE. PLASTIC SHEETING USED FOR STORAGE
WILL CREATE CONDENSATION WHICH MAY CAUSE METAL SURFACES TO RUST OR PIT.
CAUTION
WHEN INSTALLING OR REMOVING GAUGES AND FITTINGS OR REPLACING COMPONENTS,

CAP OR PLUG ENDS OF FLUID LINES AND USE EXTREME CAUTION TO PREVENT
CONTAMINATION OF THE HYDRAULIC SYSTEM.
CAUTION
WHEN CLEANING THE VEHICLE USING A PRESSURE WASHER, CARE MUST BE TAKEN NOT
TO APPLY DIRECT PRESSURE TO ANY EXPOSED ELECTRICAL, HYDRAULIC OR ENGINE
COMPONENTS. DO NOT PRESSURE WASH INSIDE THE ENGINE OR MOTOR
COMPARTMENT.
CAUTION
WHEN WASHING OR RINSING THE LOADER, PREVENT WATER FROM INTRUDING THE
TRANSMISSION BREATHER VALVE.
CAUTION
WHEN PERFORMING A BATTERY “JUMP START” ON THE VEHICLE, ENSURE JUMP CABLES
ARE PROPERLY CONNECTED TO PREVENT DAMAGE TO THE ELECTRIC SYSTEM AND
COMPONENTS.
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CAUTION
WHEN ELECTRICALLY CHARGING BATTERIES ON THE VEHICLE, ENSURE CHARGER

CABLES ARE PROPERLY CONNECTED TO PREVENT DAMAGE TO THE ELECTRIC SYSTEM
AND COMPONENTS.
CAUTION
DO NOT CLEAN RUBBER AND PLASTIC COMPONENTS SUCH AS TIRES, LUBRICANT SEALS,
RUBBER HOSES OR ELECTRICAL COMPONENTS WITH PETROLEUM-BASED PRODUCTS
SUCH AS KEROSENE, GASOLINE OR FUEL OIL.
CAUTION
DO NOT OPERATE THE ENGINE WITH THE OIL LEVEL BELOW THE ‘MIN’ MARK OR ABOVE
THE ‘MAX’ MARK ON THE DIPSTICK.
CAUTION
ENSURE FUEL IS CLEAN AND FREE OF WATER AND DIRT.
CAUTION
ALLOW THE ENGINE TO COOL BEFORE ADDING WATER OR ANTI-FREEZE SOLUTION.
CAUTION
USE ONLY ETHYLENE-GLYCOL BASED ANTIFREEZE IN CORRECT CONCENTRATIONS TO

PREVENT FREEZING AT THE AMBIENT TEMPERATURE.
CAUTION
DO NOT USE WATER WITH SALT OR HIGH MINERAL CONTENT WHEN FILLING THE
COOLANT SYSTEM OR BATTERIES.
CAUTION
DO NOT DISCONNECT THE BATTERY OR TURN OFF OPTIONAL BATTERY DISCONNECT

SWITCH WITH THE ENGINE RUNNING. THIS WILL CAUSE A VOLTAGE SURGE IN THE
ALTERNATOR CHARGING SYSTEM.
CAUTION
DO NOT MIX HYDRAULIC OILS. WHEN CHANGING FROM ONE TYPE TO ANOTHER, THE
SYSTEM MUST BE DRAINED, CLEANED AND COMPLETELY REFILLED.
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CAUTION
BEFORE WELDING ON THE VEHICLE, DISCONNECT THE VEHICLE’S POSITIVE AND

NEGATIVE BATTERY CABLES AND ALL ELECTRONIC CONTROLLER HARNESSES.
PROTECT ELECTRONIC EQUIPMENT AND HARNESSES FROM HEAT OR SPARKS. ENSURE
THE WELDER’S GROUND CABLE IS ATTACHED TO BARE UNPAINTED METAL AS CLOSE TO
THE WELDING OPERATION AS POSSIBLE.
CAUTION
PERFORM A COMPLETE MAINTENANCE CHECK AFTER REPAIRS ARE COMPLETED.

ENSURE THE VEHICLE HAS BEEN PROPERLY SERVICED BEFORE STARTING THE POWER
UNIT.
CAUTION
AFTER REPLACING THE PUMP, FILL THE CASE DRAIN PUMP CAVITY WITH NEW HYDRAULIC
OIL BEFORE STARTING THE VEHICLE.
CAUTION
DO NOT MIX SYNTETHIC OILS WITH NON-SYNTHETIC OILS!
CAUTION
BIO-DIESEL BLENDS GREATER THAN 5% CAN REDUCE THE LIFE OF THE ENGINE IF USED.
FAILURES ATTRIBUTED TO THE USE OF BIO-DIESEL WILL NOT BE COVERED UNDER THE
WARRANTY.
CAUTION
BIO-DIESEL BLENDS CAN REDUCE THE LIFE OF THE HEATER IF LEFT IN THE FUEL SYSTEM
FOR EXTENDED PERIODS OF TIME. FAILURES ATTRIBUTED TO THE USE OF BIODIESEL
WILL NOT BE COVERED UNDER THE WARRANTY.
CAUTION
WHEN REPLACING A SPROCKET, ALWAYS REPLACE THE CHAIN. USING AN OLD CHAIN ON
NEW SPROCKETS WILL CAUSE PREMATURE WEAR OF THE SPROCKETS.
CAUTION
OVER-TIGHTENING THE CHAIN CAN CAUSE RAPID CHAIN AND SPROCKET WEAR, CHAIN
BREAKAGE, HYDRAULIC MOTOR FAILURE OR BEARING FAILURE ON THE ROLLER SHAFT.
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CAUTION
WHEN HYDRAULIC JACKS ARE USED TO RAISE THE CHASSIS, THEY MUST BE PLACED
DIRECTLY UNDER THE AXLE MOUNTING PADS.
CAUTION
AXLE HOUSING MOUNTING PAD AND FRAME PAD SURFACES MUST BE SMOOTH WITH NO
NICKS AND CLEAN OF ALL DEBRIS AND LUBRICANTS.
CAUTION
DUST CAP MUST BE REMOVED BY HAND. THE USE OF A STRAP WRENCH IS PERMITTED,
IF REQUIRED, TO INITIALLY LOOSEN THE DUST CAP.
CAUTION
PIVOT SHAFT CAP SCREWS MUST BE REMOVED OR DAMAGE TO THE CAP SCREWS OR
THE PIVOT SHAFT WILL OCCUR.
CAUTION
DO NOT PUSH PIVOT SHAFT PAST THE WELDMENT. THE SCISSORS ALSO PIVOT ON THIS
SHAFT.
CAUTION
INSTALLING MAIN LIFT CYLINDERS MAY BE POTENTIALLY HAZARDOUS DUE TO THE SIZE,
WEIGHT AND POSITION OF THE CYLINDERS. USE EXTREME CAUTION WHEN PERFORMING
THESE PROCEDURES.
CAUTION
DO NOT START ENGINE, USE THE EMERGENCY PUMP TO PROVIDE HYDRAULIC FLUID
WHEN BLEEDING AIR FROM THE MAIN LIFT CYLINDERS.
CAUTION
USE EXTREME CARE WHEN REMOVING CYLINDER WHEN PORTABLE ENGINE HOIST IS NOT
AVAILABLE. PERSONAL INJURY CAN OCCUR IF CYLINDER IS DROPPED.
CAUTION
TO PREVENT ENGINE DAMAGE AND POSSIBLE COMPLETE DESTRUCTION OF THE

TURBOCHARGER, ALWAYS COVER TURBOCHARGER INLET AND EXHAUST OPENINGS TO
PREVENT THE ENTRANCE OF ANY FOREIGN OBJECT.
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CAUTION
DO NOT ALLOW THE FRONT OF THE TRANSMISSION TO BE LOWER THAN LEVEL TO

PREVENT THE TORQUE CONVERTER FROM SLIDING FORWARD AND OUT OF THE
TRANSMISSION.
CAUTION
IF A CONDITION OCCURS THAT INTRODUCES DEBRIS INTO THE TRANSMISSION

HYDRAULIC SYSTEM, A COMPLETE CLEANUP OF THE OIL COOLER AND HYDRAULIC LINES
IS REQUIRED BEFORE REPLACEMENT TRANSMISSION IS INSTALLED.
CAUTION
CONTAINERS OR FILLERS THAT HAVE BEEN USED TO HANDLE ANTIFREEZE OR ENGINE

COOLANT SOLUTION MUST NEVER BE USED FOR TRANSMISSION FLUID. ANTIFREEZE
AND COOLANT SOLUTIONS CONTAIN ETHYLENE GLYCOL WHICH, IF INTRODUCED INTO
THE TRANSMISSION, CAN CAUSE THE CLUTCH PLATES TO FAIL.
CAUTION
DO NOT REMOVE THE FRONT SIDE SHIFT BOGY ASSEMBLY UNTIL ALL REPLACEMENT
SERVICE PARTS ARE ON HAND AND READY TO BE INSTALLED. THE FRONT SIDE SHIFT
BOGY ASSEMBLY IS A MAJOR STRUCTURAL ITEM. TO AVOID DAMAGE, THE LOADER
MUST NOT BE LEFT IN THIS DISASSEMBLED STATE FOR A LONG PERIOD OF TIME.
CAUTION
DO NOT OPERATE THE LOADER WHILE THE FRONT SIDE SHIFT BOGY IS REMOVED TO
PREVENT DAMAGING THE LOADER. THE HEAVY LIFTING EQUIPMENT SHOULD REMAIN.
CAUTION
FAILURE TO POSITION AND ORIENT THE COUPLING CORRECTLY COULD CAUSE DAMAGE
TO THE COUPLING AND PUMP.
CAUTION
DO NOT PLACE HYDRAULIC JACK UNDER THE BOWL IN THE CENTER OF THE AXLE
HOUSING.
CAUTION
USE A WHEEL CHANGING JACK OR TWO PERSONS, TO REMOVE AND INSTALL THE WHEEL
ASSEMBLY.
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CAUTION
TO PREVENT FATIGUE AND FRACTURING OF THE WHEEL BOLTS WHEN USING IMPACT
TOOLS, DO NOT ALLOW THE IMPACT TOOLS TO “HAMMER” AFTER THE NUT IS SEATED.
CAUTION
DO NOT OVERFILL THE HYDRAULIC RESERVOIR. RESERVOIR CAN BE DAMAGED IF THE

OIL LEVEL IS ABOVE THE “FULL” MARK, ON THE AFT END OF THE RESERVOIR, WHEN THE
DECK IS FULLY LOWERED.
CAUTION
WHENEVER THE COOLING SYSTEM HAS BEEN DRAINED, YOU MUST BLEED ALL AIR FROM
THE COOLING SYSTEM TO AVOID SERIOUS ENGINE DAMAGE.
CAUTION
ALL OF THE SERVICE PROCEDURES DESCRIBED ARE ONLY PERFORMED AFTER AIR
CONDITIONER SYSTEM REFRIGERANT HAS BEEN RECOVERED. NEVER USE REGULAR
SHOP OIL OR JOINT COMPOUND TO LUBRICATE OR SEAL ANY A/C CONNECTIONS.
ENSURE THE MANUFACTURER’S MANUAL IS PRESENT FOR REFERENCE.
CAUTION
EVEN WHEN TOLD OF AIR CONDITIONING SYSTEM DEFECT, ALWAYS PERFORM A VISUAL
INSPECTION PRIOR TO CONNECTING THE MANIFOLD GAUGE SET. NEVER ATTEMPT TO
ADD REFRIGERANT TO A SYSTEM UNTIL YOU HAVE MADE A COMPLETE VISUAL AND
PERFORMANCE INSPECTION OF ALL OF THE COMPONENTS.
CAUTION
BE CAREFUL NOT TO BEND PINCH-WELD WHEN REMOVING THE GLASS FROM THE
ADHESIVE.
CAUTION
DO NOT RUN ENGINE HIGHER THAN 1200 RPM DURING BRAKE FUNCTION TESTS.
CAUTION
WHEN INSTALLING BACK-UP RINGS, IT IS ESSENTIAL THAT SURFACES OF DIAGONAL

SPLICE MATCH WITH EACH OTHER AFTER BACK-UP RING IS INSTALLED IN GROOVE.
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CAUTION
ONLY SELECT PREDRILLED HOLES THAT WILL NOT ALLOW YOU TO DRILL INTO THE BLIND
CAVITIES BEHIND THE DECK BEAM, AS A NUT IS GOING TO BE INSTALLED ON THE BACK
SIDE OF THE DECK BEAM.
CAUTION
THE DECK MUST BE CENTERED AND LEVEL BEFORE ANY MODIFICATIONS ARE TO BE
PERFORMED. FAILURE TO CENTER AND LEVEL THE DECK MAY CAUSE MISALIGNMENT
ISSUES LATER IN THE PROCEDURES.
CAUTION
DO NOT CUT INTO OR REMOVE MATERIAL FROM THE DECK BUMPER WHEN REMOVING
ITEMS USING CUTTING OR GRINDING TOOLS.
CAUTION
DO NOT CONTINUE TO ENGAGE THE LIFT JOYSTICK IF THE ENGINE REVS UP WHILE THE
AIR TRANSPORT SYSTEM CLEVIS AND PIN ARE INSTALLED. STRUCTURAL DAMAGE WILL
OCCUR. TROULESHOOT THE ISSUE BEFORE PROCEEDING.
CAUTION
TO PREVENT DAMAGE TO ENCLOSURE WHEN DRILLING HOLES DO NOT PUSH ON DRILL

WITH EXCESSIVE FORCE.
CAUTION
SECURE BRACE IN REQUIRED POSITION BEFORE TIGHTENING HARDWARE. DO NOT

TORQUE UNTIL INSTRUCTED AT THE END OF THE INSTALLATION.
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TABLE OF CONTENTS
Section 1. Description
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. CAPABILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. POWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
D. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E. DRIVE AND STEER FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F. REAR AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
G. PLATFORM LIFT SCISSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
H. LOAD TRANSFER DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
I. OPERATOR’S CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
J. WINTERIZATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
K. AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Section 2. Operation
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. CONTROLS AND INDICATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. DASH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. CONVEY PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. WIPERS AND WASHERS PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
D. AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
A. PRE-OPERATION DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table 1 - OPERATOR’S DAILY INSPECTION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . 13
B. STARTING POWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
C. STOPPING LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1-Contents
TABLE OF CONTENTS
Page 1
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D. MAINTENANCE STANDS INSTALLATION AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 24
E. DECK CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
F. DRIVING THE LOADER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5. LOADING AND UNLOADING CARGO PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
A. LOADING CARGO ON THE LOADER - FRONT END OPERATION . . . . . . . . . . . . . . . . . . . 39
B. OFF LOADING CARGO ON THE LOADER - FRONT END OPERATION . . . . . . . . . . . . . . . 40
C. LOADING CARGO ON THE LOADER - BACK END OPERATION . . . . . . . . . . . . . . . . . . . . . 41
D. OFF LOADING CARGO ON THE LOADER - BACK END OPERATION. . . . . . . . . . . . . . . . . 42
E. LOADING ROLLING STOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Section 3. Emergency Procedures
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. EMERGENCY PROCEDURES‘ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. EMERGENCY SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. EMERGENCY MANOUVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C. TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
D. LIFTING AND TOWING LOADER WITH A TOW VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Section 4. Specifications
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. MODEL DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. AIRCRAFT ACCOMODATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. OPERATING CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. GENERAL DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. DIMENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. WEIGHTS AND VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table 1 - WEIGHTS AND VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 2 - ENGINE SPECIFICATIONS AND OPERATING RPM . . . . . . . . . . . . . . . . . . . . . . . 5
7. FUEL SPECIFICATIONS AND RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 3 - FUEL SPECIFICATIONS AND DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8. FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A. FUEL TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. FUEL TANK CAPACITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. FILTER TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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9. RADIATOR (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10. WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
11. BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12. AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A. FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
B. REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
13. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table 4 - TRANSMISSION RATIOS (MECHANICAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
14. HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
A. FLUID TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
C. EMERGENCY ELECTRIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
D. FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E. HOSE ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F. OPERATING PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
15. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A. BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
B. ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16. OTHER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
17. PAINT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
18. ADDITIONAL FEATURES AND EMERGENCY DEVICES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
19. VEHICLE JACKING REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A. JACK CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
B. MAINTENANCE STANDS CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
C. PRESSURE EXERTED BY VEHICLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
D. JACK AND MAINTENANCE STANDS SUPPORT SURFACE . . . . . . . . . . . . . . . . . . . . . . . . 10
20. ENVIRONMENTAL LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A. OPERATING TEMPERATURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table 5 - AMBIENT OPERATING CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
B. WINTERIZATION OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
21. OPERATOR'S VIBRATION AND SOUND LEVELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
A. SOUND LEVEL EMISSION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table 6 - SOUND LEVEL EMISSION DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
B. VIBRATION LEVEL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
22. UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Table 7 - METRIC AND STANDARD UNITS AND CONVERSIONS . . . . . . . . . . . . . . . . . . . 12
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Section 5. Shipping and Transportation
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. SHIPPING DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. PREPARATION FOR TRANSPORTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A. PREPARE DECK FOR CAB RETRACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. CAB AND WALK-DECK INTO SHIPPING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . 6
C. REMOVE THE LADDER AND STOW ON TOP OF THE DECK . . . . . . . . . . . . . . . . . . . . . . . 6
D. CONFIGURE THE FOLDING WALK-DECK AND HANDRAIL SECTIONS . . . . . . . . . . . . . . . 9
4. LOADING ONTO AIRCRAFT AND SURFACE TRANSPORT VEHICLES . . . . . . . . . . . . . . . . . . . . 9
A. SETTING INTO AIR TRANSPORT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
B. LOADING THE VEHICLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. LOADING OFF FROM AIRCRAFT AND SURFACE TRANSPORT VEHICLES. . . . . . . . . . . . . . . . 11
A. PREPARE FOR UNLOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
B. START THE ENGINE AND VERIFY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6. SLING LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A. PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
B. SECURE THE FRONT OF THE CHASSIS TO THE DECK ASSEMBLY . . . . . . . . . . . . . . . . 15
7. TIE-DOWN POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8. PREPARE THE LOADER FOR SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
A. CONFIGURE FOLDING WALK-DECK AND HANDRAIL SECTIONS . . . . . . . . . . . . . . . . . . . 18
B. INSTALL THE LADDER FOR OPERATOR ACCESS TO THE CAB . . . . . . . . . . . . . . . . . . . . 18
C. CONFIGURE THE CAB INTO OPERATIONAL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Section 6. Storage
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. STORAGE - ONE MONTH (MAXIMUM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. BATTERIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F. WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G. HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
H. GENERAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. STORAGE - INDEFINITE PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. BATTERIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
D. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F. WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
G. HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
H. GENERAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
I. EQUIPMENT SHELTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. RETURNING VEHICLE TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
A. RE-COMMISSIONING AFTER A SHORT PERIOD OF STORAGE . . . . . . . . . . . . . . . . . . . . 5
B. RE-COMMISSIONING AFTER AN EXTENDED PERIOD OF INACTIVITY . . . . . . . . . . . . . . 5
5. STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A. SHORT-TERM STORAGE - ONE MONTH MAXIMUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. LONG-TERM STORAGE - THREE YEARS MAXIMUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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LIST OF FIGURES
1-1 Figure 1 HALVORSEN LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1-1 Figure 2 VEHICLE CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-1 Figure 3 POWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-1 Figure 4 SCISSORS - LEFT SIDE VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-1 Figure 5 LOAD TRANSFER DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-1 Figure 6 OPERATOR’S CAB - EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-1 Figure 7 DASH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1-1 Figure 8 CONVEY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1-1 Figure 9 CONVEY DIRECTION AND SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 11
1-1 Figure 10 WIPERS AND WASHERS PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1-1 Figure 11 SPOTLIGHTS HANDLES AND DOOR LATCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1-1 Figure 12 CAB’S ROOF SPOTLIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1-1 Figure 13 WINTERIZATION RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1-1 Figure 14 AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1-2 Figure 2 CONVEY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-2 Figure 3 WIPERS AND WASHERS PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1-2 Figure 4 AIR CONDITIONING SYSTEM EVAPORATOR BOX. . . . . . . . . . . . . . . . . . . . . . 10
1-2 Figure 5 ENGINE OIL AND COOLANT FILL POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1-2 Figure 6 HYDRAULIC RETURN FILTER GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1-2 Figure 7 BATTERY DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1-2 Figure 8 MAIN PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1-2 Figure 9 WINTERIZATION RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1-2 Figure 11 TRANSMISSION RANGE SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1-2 Figure 12 DASH PANEL - LOWER RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1-2 Figure 13 MAINTENANCE STANDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1-2 Figure 14 RETAINING PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1-2 Figure 15 TRAY WITH SMOOTH SIDE UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1-2 Figure 16 DECK CONFIGURED FOR FORKLIFT LOADING FROM THE REAR . . . . . . . . . 27
1-2 Figure 17 CASTERS IN THE UP POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1-2 Figure 18 DECK CONFIGURED FOR FORKLIFT LOADING FROM THE SIDE . . . . . . . . . . 29
1-2 Figure 19 CASTERS IN THE UP POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1-2 Figure 20 CONVEY MODULE LATCH HANDLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1-2 Figure 21 LOWER LOBE INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1-2 Figure 22 FOLDING WINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1-2 Figure 23 RIGHT SIDE HANDRAIL AND WALK-DECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1-2 Figure 24 TRANSMISSION RANGE SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1-2 Figure 25 DASH PANEL - LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1-2 Figure 26 DASH PANEL - LOWER-RIGHT CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1-2 Figure 27 PALLET LOCK IN RELEASED POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1-2 Figure 28 PALLET LOCK IN LOCKED POSITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1-2 Figure 29 SAFETY HARNESS AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1-2 Figure 30 LOADER DECK FOR ROLLING STOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1-3 Figure 1 DASH PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1-3 Figure 2 MAIN PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-3 Figure 3 CHASSIS MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-3 Figure 4 LOADER TOW POINTS - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-4 Figure 1 GENERAL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-Figures
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Halvorsen
1-5 Figure 1. OVERALL SHIPPING DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1-5 Figure 2. RETAINING PIN AND HINGE DECK WELDMENT LOCK . . . . . . . . . . . . . . . . . . 4
1-5 Figure 3. HINGED DECK WELDMENT AND ROLLER TRAY . . . . . . . . . . . . . . . . . . . . . . . 5
1-5 Figure 4. CAB AND WALK-DECK SHIPPING CONFIGURATION. . . . . . . . . . . . . . . . . . . . 6
1-5 Figure 5. UPPER LADDER SUPPORT RETAINING PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-5 Figure 6. LOWER LADDER SUPPORT RETAINING PIN . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-5 Figure 7. LADDER STOWED ON DECK IN THE MIDDLE RIGHT SIDE. . . . . . . . . . . . . . . 8
1-5 Figure 8. LADDER SUPPORT RETAINING PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-5 Figure 9 AIR TRANSPORT CLEVIS AND PIN IN LATCHED POSITION . . . . . . . . . . . . . . 10
1-5 Figure 10 BATTERY DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1-5 Figure 11 AIR TRANSPORT PIN AND CLEVIS IN STOWING POSITION . . . . . . . . . . . . . . 13
1-5 Figure 12 HELPER CYLINDER SUPPORT CASTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1-5 Figure 13 CHASSIS TOWING EYE CHAIN ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1-5 Figure 14 LIFTING PROVISION LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1-5 Figure 15 TRANSPORT TIE-DOWN POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Section 6. Storage
1-Figures
LIST OF FIGURES
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Halvorsen
1. GENERAL
NOTE: REFER TO CHAPTER 1, SECTION 3 FOR EMERGENCY PROCEDURES.
The Halvorsen, 25 000 lb. Loader for Aircraft, is a self-propelled, hydraulically-operated and
electrically-controlled cargo loading vehicle. Refer to Figure 1.
A six-cylinder turbocharged diesel engine, coupled to a four-speed automatic transmission, provides the
power to propel the vehicle and operate the hydraulic and electrical systems. A battery-powered electric
motor drives an auxiliary hydraulic pump that is incorporated in the hydraulic system for emergency
operation in the event of a failure of the main power unit.
The automatic transmission provides precise control and inching capability for approaching aircraft and
loading docks. The loader is capable of negotiating rain, snow, sleet, sand, standing water and mud at
reduced speeds while operating on improved surfaces, as well as operating at reduced speeds on level,
semi-prepared surfaces, including gravel, perforated steel planking (PSP) and rapid runway repair
(RRR) slab.
The loader has an enclosed cab mounted on the deck that contains the driving and operating controls.
It provides comfort and safety for operating in all types of weather conditions. The cab is equipped with
an air conditioning system which gives the operator comfort during hot weather. The air conditioning
system can be used in conjunction with the heater (controlled separately) to defog windows and
dehumidify and cool the cab as required.
NOTE: REFER TO CHAPTER 2, SECTION 2, “SYSTEM OVERVIEW” FOR MORE DETAILED

INFORMATION ABOUT ASSEMBLIES AND COMPONENTS.
2. CAPABILITIES
The deck powered convey system moves palletized and platform cargo along the deck. The powered
rollers can be lowered for moving cargo by hand or for loading and off-loading cargo from forklifts on
either the right side or at the rear of the loader. Rolling stock can be driven on and off the deck from
either the front or the rear.
NOTE: REFER TO CHAPTER 1, SECTION 4, “SPECIFICATIONS” FOR DETAILED

INFORMATION ON CAPABILITIES, AIRCRAFT ACCOMMODATION, WEIGHTS AND
OTHER RELATED DATA.
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DESCRIPTION
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Halvorsen
Figure 1
HALVORSEN LOADER
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Halvorsen
3. MAJOR COMPONENTS
A. CHASSIS
The chassis assembly is a welded steel frame and provides the base for the mounting of the front
drive steer axle, rear axle, power unit and the electrical, hydraulic and fuel systems. The scissors
lifting system is attached to the chassis. Towing and tie-down points are incorporated in the
chassis frame. Refer to Figure 2.
MAIN
PANEL
DRIVE/STEER
AXLE FUEL
TANK
POWER
UNIT
RADIATOR
HELPER
CYLINDER
WINTERIZATION
PANEL & RECEPTACLE
EMERGENCY
PUMP
CHASSIS
HYDRAULIC
MANIFOLD
HYDRAULIC
RESERVOIR
REAR AXLE
ASSEMBLY
TOWING/TIE-DOWN
POINTS
Figure 2
VEHICLE CHASSIS
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DESCRIPTION
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Halvorsen
B. POWER UNIT
The power unit consists of a six-cylinder turbocharged diesel engine with an automatic
transmission coupled to the flywheel and a variable displacement hydraulic pump coupled to the
front end of the crankshaft. The power unit is mounted in the center of the chassis and the
transmission is connected to the front drive and steer axle with a drive shaft. Refer to Figure 3.
TRANSMISSION
ENGINE
HYDRAULIC
PUMP
GENERATOR
ALTERNATOR
ENGINE
AIR CLEANER
Figure 3
POWER UNIT
The diesel engine provides powers the automatic transmission to propel the loader, the pump to
operate the hydraulic systems and the alternator to keep the batteries in a fully charged state. A
compressor is powered by an hydraulic motor attached to the compressor that cools the
operator’s cab on the loader.
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Halvorsen
C. COOLING SYSTEM
The engine cooling system for dissipating heat is a closed-loop system consisting of a radiator in
a housing and a fan driven by a hydraulic motor.
The radiator is remotely mounted outside the right-side chassis frame. The fan motor has two
speeds and is controlled by sensors in the cooling system. The engine-driven water pump
circulates coolant in the system and a thermostat controls engine temperature by regulating the
flow of the coolant. A tank mounted, on top of the engine, serves as a reservoir for the fluid
volume required to maintain the cooling system temperature within the operating range. The
coolant recovery tank, mounted at the rear of the engine, allows coolant recovery to maintain a
constant fluid level and prevents the introduction of air in the closed loop system.
D. TRANSMISSION
A four-speed automatic transmission is coupled to the engine flywheel for directional control. The
torque converter provides inching capability and smooth acceleration in any range selected.
The transmission output shaft is directly connected to the differential pinion shaft with a drive
shaft. Range selection is accomplished by an electrically controlled joystick lever with digital
readout in the operator’s cab, which actuates a hydraulic cylinder mounted on the transmission,
for positioning the transmission control valve. A remote-mounted oil cooler is incorporated in the
engine coolant system to remove excessive heat from the transmission fluid and warm the
transmission fluid when operating in cold weather conditions.
E. DRIVE AND STEER FRONT AXLE

The front axle is the loader’s drive and steer axle and is rigidly attached to the chassis frame.
Incorporated in the axle are the differential assembly, planetary wheel ends and power steering
cylinders.
A brake disc is attached to the companion flange on the differential pinion shaft and the front axle
service brake and parking brake calipers react on the disc. A differential lock is provided for
positive driving of both wheels should one wheel lose traction on slippery surfaces.
F. REAR AXLE ASSEMBLY

The rear axle assembly provides support for the loader chassis at the back end and consists of a
framework that has an axle pivot shaft at the front and two attaching lugs at the back end.
A bogy assembly, consisting of an arm with two wheel assemblies attached and a telescoping
hydraulic cylinder, is assembled on each end of the axle shaft. The helper cylinders are
telescoping hydraulic cylinders used to assist the deck main lift cylinders in raising the deck when
the deck is at the lowest position and provide additional chassis clearance when driving up and
down ramps.
The bogy assemblies pivot on the axle shaft when traveling over irregular surfaces and each
wheel assembly remains on the surface to support the load. Each wheel assembly has an
external disc brake assembly incorporated in the wheel hub. The rear axle assembly is
underneath the chassis at the back end of the loader and is attached to the chassis with pivot
pins. In the normal operating configuration, the chassis rests on the axle shaft.
When the loader is to be air transported additional chassis height is required to provide clearance
at the crest of the aircraft loading ramp. To obtain the additional clearance, the airportability latch
is engaged to physically lock the deck to the chassis at rear of the loader and the DECK RAISE
switch is actuated. The helper cylinders, attached to the axle assembly shaft, will extend and
force the deck and chassis up to provide the required additional clearance.
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DESCRIPTION
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Halvorsen
G. PLATFORM LIFT SCISSORS
The scissors provide the means to raise and lower the deck and pitch the deck for alignment of
roll plane of the aircraft, loading dock and other MHE. Refer to Figure 4.
Figure 4
SCISSORS - LEFT SIDE VIEW
The forward ends of the outer scissors pivot on the main lift cylinder pivot pins and the back ends
of the inner scissors have rollers that travel on the main frame as the deck rises. The forward
ends of the inner scissors and the back ends of the outer scissors have lugs for securing the roll
cylinders.
The outer scissors legs are made in two parts to permit the rear sections to pivot on the joints for
pitching the deck up and down.
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Halvorsen
H. LOAD TRANSFER DECK
The deck is an aluminum structure that is raised and lowered by the scissors and contains the
powered convey system for moving cargo on and off the top surface. Refer to Figure 5.
Fixed rollers are in removable trays that can be removed and inverted to make a smooth surface
to accommodate the movement of rolling stock on the deck. Cargo can be conveyed fore and aft
on the deck and provision has been made for placing and removing cargo on the deck with
forklifts at the rear and right side. Adjustable pallet guides are incorporated in the deck for
conveying 88-inch or 108-inch pallets. Pallet locks are incorporated in the guides to restrain
pallets during transport. The deck includes tie-down points for securing cargo and rolling stock,
removable handrails and a ladder for operator access and safety.
HANDRAIL
FOLDING WINGS ROLLER TRAYS
PALLET GUIDE
PALLET LOCK
HANDRAIL
PALLET GUIDE
PALLET LOCK
Figure 5
LOAD TRANSFER DECK
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DESCRIPTION
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Halvorsen
I. OPERATOR’S CAB
The fully enclosed cab, mounted on the left side of the deck, provides optimum visibility, air
conditioned comfort for the operator when needed and contains all controls for driving and
operating the loader. Refer to Figure 6.
FIRE
EXTINGUISHER
FILL POINT
WINDSHIELD
WASHER FLUID
WASHER FLUID
LEVEL GAUGE
REAR DOOR
SIDE DOOR
Figure 6
OPERATOR’S CAB - EXTERIOR
NOTE: DUE TO THE CAB WINDOWS BEING TINTED IN THE LOADER, THE OPERATOR’S
VISION MAY BE LIMITED AT NIGHT. THE OPERATOR MUST REMAIN ALERT WHILE
OPERATING THE LOADER AT NIGHT.
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Halvorsen
(1) Dash Panel
This panel is located directly in front of the operator, has all switches, gauges and indicator
lights for starting and shutting down the engine and monitoring the engine and hydraulic
system conditions. Refer to Figure 7.
Figure 7
DASH PANEL
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DESCRIPTION
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Halvorsen
All panels have illumination lights with a dimmer control for lowering light intensity and
reducing glare.
(2) Deck Convey Panel
at the operator’s right side, contains the controls that activate the convey system for
moving cargo on and off the deck. Refer to Figure 8.
CONVEY JOYSTICK
CONVEY JOYSTICK
LATCH
Figure 8
CONVEY PANEL
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(3) Convey Direction and Speed Control Joystick Switch
Both located on the convey control panel to the operator’s right side is latched in the
neutral position to prevent accidental movement of the joystick handle. Refer to Figure 9.
The operator must unlatch the handle by lifting the latch with the fingers to move out of the
neutral position, then move the joystick in the direction that cargo is to be conveyed on the
deck. Convey speed is variable and is controlled by the distance the joystick handle is
moved, forward or aft, of the neutral position.
TRANSMISSION
RANGE SELECTOR
CONVEY PANEL
CONVEY DIRECTION AND

SPEED CONTROL
Figure 9
CONVEY DIRECTION AND SPEED CONTROL
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DESCRIPTION
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Halvorsen
(4) Accelerator and Brake Pedals
Both pedals are conventional and located on the floor of the cab (not shown).
(5) Wipers and Washers Panel
Located overhead in the upper-right corner of the cab enclosure. It contains the switches
and circuit breakers for the front and rear wipers and washers. Refer to Figure 10.
Figure 10
WIPERS AND WASHERS PANEL
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Halvorsen
(6) Spotlights Control Handles
Two spotlights with inside cab controls, are mounted on the cab roof for illuminating the
work area. Refer to Figure 11 and Figure 12.
FAN
INTERIOR
LIGHT
WIPER PANEL
SPOTLIGHT
CONTROL HANDLE
CAB INTERIOR, TOP FRONT
WIPER
WIPER MOTOR
DOOR LATCH
Figure 11
SPOTLIGHTS HANDLES AND DOOR LATCH
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DESCRIPTION
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Halvorsen
SPOTLIGHTS
SLIDING HANDRAIL
Figure 12
CAB’S ROOF SPOTLIGHTS
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J. WINTERIZATION SYSTEM
For operating in cold weather conditions, an external AC power source of either 120 or 240 VAC
can be connected to the winterization receptacle located on the left side of the loader. Refer to
Figure 13. The system automatically senses the voltage applied and adjusts the output voltage
for the heating elements installed for operating in cold weather. Heating elements installed warm
the engine oil, engine coolant, transmission fluid, hydraulic fluid and batteries.
When the external power source is connected, the WINTERIZATION CONNECTED indicator light
illuminates on the dash panel and the loader engine cannot be operated.
EMERGENCY PUMP
WINTERIZATION
RECEPTACLE
CIRCUIT
BREAKER
WEATHER CAP
Figure 13
WINTERIZATION RECEPTACLE
NOTE: EXTERNAL POWER CORD MUST BE ENERGIZED TO ILLUMINATE THE INDICATOR

LIGHT ON THE DRIVER’S DASH PANEL.
1-1
DESCRIPTION
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Halvorsen
K. AIR CONDITIONING SYSTEM
Heating and air conditioning systems provide temperature control inside the operator’s cab.
These systems also provide defogging of windows and humidity control. The air conditioning
system can be used to cool the cab prior to use as well as during loader operation. The air
conditioning system requires regular operator maintenance. The operator must refer any
malfunctions, damage or irregular operation to the maintenance section as soon as possible.
Operator must keep the unit clean and refrain from placing papers and other objects on the return
air inlet. Refer to Figure 14.
3 POSITION FAN SWITCH
3 POSITION A/C MODE SWITCH
POWER CONNECTIONS
DIRECTIONAL VENT LOUVERS
EVAPORATOR BOX
FILTER INLET
Figure 14
AIR CONDITIONING SYSTEM
NOTE: REFER TO THE MANUFACTURER’S MANUAL WHEN PERFORMING MAINTENANCE

ON THE AIR CONDITIONING SYSTEM.
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1. GENERAL
NOTE: REFER TO CHAPTER 1, SECTION 3 FOR EMERGENCY PROCEDURES.
This section contains operation instructions for the Halvorsen. A discussion of the principles of
operation is given to aid in understanding of its operation.
The operator must use approved procedures for approaching and departing aircraft, loading, unloading,
conveying or transferring cargo. All procedures followed should be approved by the airline and the local
aviation authority and based on the recommendations of the aircraft manufacturer.
WARNING
WARNING
THE DECK MUST BE FULLY LOWERED AND THE VEHICLE MUST BE PROPERLY PARKED
BEFORE BOARDING OR LEAVING THE UNIT. USE THE LADDER LOCATED BEHIND THE
OPERATOR'S CAB TO GET ON AND GET OFF THE DECK. ENSURE THE LADDER AND DECK
AREA, BOTH ON AND BELOW, ARE CLEAR OF PERSONS AND FREE OF ANY OBJECTS
WHILE OPERATING THE VEHICLE. DO NOT RELY SOLELY ON SENSORS AND WARNING
LIGHTS.
WARNING
WARNING
USE EXTREME CAUTION AT ALL TIMES WHEN WALKING ON THE DECK DO NOT STEP ON
ROLLERS OR ROLLER ASSEMBLIES.
WARNING
ENSURE THE LADDER AND DECK ARE CLEAR OF PERSONS WHILE DRIVING AND
OPERATING THE VEHICLE.
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OPERATION
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Halvorsen
WARNING
VEHICLE UNATTENDED.
2. SAFETY PRECAUTIONS
• Before operating the vehicle, the operator should read this manual and become completely
familiarized with the vehicle.
• Learn how your vehicle is operated. Know the location and functions of all controls, indicators,
caution instructions and warning and safety devices.
• Always perform the maintenance checks. Proper maintenance is necessary to ensure the
maximum performance of your equipment.
• Follow the correct starting, warm-up, operating, stopping and parking procedures.
• Remember that it only takes one unsafe action to cause an accident. Use the general safety
guidelines recommended by S.A.E., specification S.A.E. J153. Follow your employer’s safety
rules and instructions to develop safe working habits. A careful operator is the best safety device
there is.
WARNING
DO NOT ALLOW PERSONS ON THE DECK WHILE IN MOTION OR IN AN ELEVATED POSITION.
DECK MAINTENANCE MAY BE PERFORMED FROM UNDERNEATH USING SAFETY
SUPPORTS.
WARNING
NEVER EXCEED THE RECOMMENDED MAXIMUM WEIGHT LIMITS FOR THIS EQUIPMENT.
WARNING
NORMAL LOADING OPERATIONS SHOULD NOT BE PERFORMED WHILE AIRCRAFT IS BEING
REFUELED WITHOUT HAVING FACILITY AND REGULATORY APPROVAL. OPERATOR MUST
ENSURE THAT NO HYDRAULIC LEAKS OR UNSAFE CONDITIONS ARE PRESENT ON THE
VEHICLE.
WARNING
USE CAUTION WHILE REFUELING THE VEHICLE TO AVOID FUEL SPILLS. CLEAN SPILLS
PROMPTLY.
WARNING
AN OBSERVER ON THE GROUND SHOULD BE USED TO GUIDE THE OPERATOR WHEN
DRIVING THE VEHICLE IN REVERSE.
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WARNING
AT THE BEGINNING OF EACH SHIFT ENSURE THAT ALL SCHEDULED SERVICES HAVE BEEN
PERFORMED, INCLUDING VERIFICATION OF TIRE CONDITION, FUEL AND FLUID LEVELS
AND OVERALL CHECK FOR LOOSE OR MISSING HARDWARE AND GENERAL CONDITION OF
THE VEHICLE.
WARNING
THE VEHICLE IS DESIGNED TO BE DRIVEN ON PAVED OR CEMENT SURFACES APPROVED
TO SUPPORT THE WEIGHT AND USE OF GROUND SUPPORT EQUIPMENT VEHICLES.
WARNING
DO NOT LIFT PERSONS WITH THE VEHICLE. THE LOADER IS NOT INTENDED FOR LIFTING
OF PERSONS OTHER THAN THE DRIVER.
WARNING
DO NOT ALLOW PERSONS UNDER THE DECK UNLESS ADEQUATE SUPPORTS ARE IN
PLACE.
WARNING
ALWAYS WEAR GLOVES TO PREVENT CONTACT WITH VERY COLD OR VERY HOT METAL
AND SURFACES WITH BARE HANDS.
CAUTION
WHEN OPERATING THE VEHICLE IN FREEZING CONDITIONS, OCCASIONALLY TURN THE

STEERING WHEEL SLOWLY TO PREVENT THERMAL SHOCK IN THE STEERING VALVE.
CAUTION
DO NOT PLACE THE EQUIPMENT INTO SERVICE WITHOUT PERFORMING ALL THE
RECOMMENDED MAINTENANCE.
3. CONTROLS AND INDICATORS
A. DASH PANEL
The dash panel is located directly in front of the operator and contains all switches, gauges and
indicator lights for starting and monitoring the engine, hydraulic system conditions and shutting
down the engine. Refer to Figure 1.
At the lower-right side of the dash panel are the EMERGENCY STOP push and pull switch and
the EMERGENCY PUMP switch. The PARKING BRAKE, HYDRAULIC PREHEAT and
DIFFERENTIAL LOCK switches have indicating lights to alert the operator when these switches
are actuated and are located to the left of the engine control switches.
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OPERATION
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The deck control switches are located at the lower-left side of the panel with indicator lights
directly above at the top of the panel that indicate that the deck has been re-positioned for
alignment to the aircraft, loading dock or other material handling equipment. Directly to the right
of the deck control switches is the deck LIFT joystick.
Directional signal and headlight high beam indicator lights are at the top center of the dash panel.
(1) ENGINE PREHEAT (AMBER) - Light indicating engine glow plugs are in the heating cycle.
(2) DIFFERENTIAL LOCK ON (AMBER) - Light indicating the differential lock is engaged for
driving on slippery surfaces.
(3) HYDRAULIC FLUID COLD (AMBER) - Light indicating hydraulic fluid is below -9 ºC
(10 ºF).
(4) HYDRAULIC FLUID HOT (RED) - Light indicating hydraulic fluid is above 82 ºC (180 ºF).
Engine will shut down when illuminated.
(5) TRANSMISSION FLUID HOT (RED) - Light indicating transmission fluid is above 108 ºC
(225 ºF). Engine will shut down when illuminated.
(6) GENERATOR (RED) - Light indicating generator is not charging.
(7) ENGINE HOT (RED) - Light indicating engine coolant is above 108 ºC (225 ºF). Engine
will shut down when illuminated.
(8) ENGINE OIL PRESS (RED) - Light indicating engine oil pressure is below 27.5 kPa
(4 psi). Engine will shut down when illuminated.
(9) EMERGENCY PUMP (E-PUMP) and LOW PRESSURE (RED) - Flashing light indicating
the emergency hydraulic pump is operating.
(10) PARKING BRAKE ON (RED) - Light indicating parking brake is applied.
(11) AIR TRANSPORT (RED) - Light indicating the deck-to-chassis lock pin is installed.
(12) HIGH BEAM (BLUE) - Light indicating headlights are on high beam.
(13) WINTERIZATION CONNECTED (RED) - Light indicating an external AC power cord is
connected to the winterization receptacle and the circuit is energized.
(14) - GREEN light indicating left-turn directional signal lights are illuminated.
(15) - GREEN light indicating right-turn directional signal lights are illuminated.
(16) SHIFTED LEFT (AMBER) - Light indicating deck is shifted to the left.
(17) SHIFTED RIGHT (AMBER) - Light indicating deck is shifted to the right.
(18) ROLL LEFT (AMBER) - Light indicating the deck is raised on the right side.
(19) ROLL RIGHT (AMBER) - Light indicating the deck is raised on the left side.
(20) PITCH UP (AMBER) - Light indicating the deck is lowered at the back.
(21) PITCH DOWN (AMBER) - Light indicating the deck is higher at the back.
(22) NO PITCH (RED) - Light indicating deck cannot be pitched.
(23) PANEL LIGHT - Illuminates the dash panel.
(24) IGNITION SWITCH - Three-position switch for starting and shutting down engine. Start
position is momentary contact.
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OPERATION
20 19 23 16 17 14 12 15 11 4 9 5 6 23 8 7
22
41
18
42
HYD OIL WATER VOLT FUEL
HOUR OIL
METER PRESS TEMP METER GAUGE SPEEDOMETER TACHOMETER
21 TEMP
Figure 1
DASH PANEL
29
35
30
31
32 36 34 33 37 38 39 40 2 28 3 27 10 26 25 23 24 1 13
Halvorsen
August 2017
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(25) SHUTDOWN OVERRIDE and WARNING LIGHT TEST - Three-position momentary
contact switch, center position OFF. UP position for starting engine when engine safety
shutdown is active and DOWN position to test light bulbs in warning indicator lights.
(26) PARK BRAKE - Two-position switch for applying and releasing parking brake.
(27) HYDRAULIC PREHEAT - Two-position switch that activates the convey system to circulate
hydraulic fluid to raise the temperature of the hydraulic fluid.
(28) DIFFERENTIAL LOCK - Two-position switch that engages the front axle differential lock.
(29) EMERGENCY STOP - Two-position push and pull switch that shuts the engine down and
de-energizes all control circuits.
(30) EMERGENCY PUMP - Two-position momentary contact switch that turns on the
emergency pump when there is no fluid flow from the main hydraulic pump.
(31) PITCH AND ROLL - Four-position joystick switch with momentary contacts that raises and
lowers the rear of the deck when actuated fore and aft, as well as raises and lowers the
deck on the left or right side when actuated to the left or right.
(32) AUTO CENTER AND LEVEL - Two-position momentary contact switch that returns the
deck to the normal level position.
(33) LIFT - Two-position momentary joystick that raises the deck when pressed forward and
lowers the deck when pulled to the rear.
(34) SHIFT - Two-position momentary switch that shifts the deck to the left or right of the
centerline.
(35) HOURMETER - Indicates total accumulated hours of engine operation.
(36) HYDRAULIC OIL TEMP - Indicates temperature of hydraulic oil in degrees Fahrenheit.
(37) OIL PRESSURE - Indicates oil pressure of engine lubrication system.
(38) WATER TEMP - Indicates temperature of engine coolant in degrees Fahrenheit.
(39) VOLTMETER - Indicates voltage of the electrical system.
(40) FUEL GAUGE - Indicates quantity of fuel in fuel tank.
(41) SPEEDOMETER - Indicates speed of vehicle in miles per hour.
(42) TACHOMETER - Indicates engine revolutions per minute.
B. CONVEY PANEL
The deck convey panel at the operator’s right, contains the controls that activate the convey
system for moving cargo onto and off the deck. Refer to Figure 2.
The CONVEY MODE PALLET WIDTH switch, at the upper-right side of the panel, determines
which convey rollers will rotate as the pallet is moved over each section of the deck.
The CONVEY SECTION switches activate a section of the deck and each switch that is selected
is indicated by a GREEN indicator light to alert the operator which sections are selected to be
active during cargo movement on the deck.
The FRONT STOP LOWERED and REAR STOP LOWERED switches control the front and rear
pallet stops located on each end of the deck. The RED indicator light illuminates to alert the
operator that the stop is lowered for transfer of cargo on and off the deck.
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(1) FRONT STOP LOWERED (RED) - Light indicating front pallet stop is lowered.
(2) CONVEY FRONT SECTION (GREEN) - Light indicating front convey section is active.
(3) CONVEY MID SECTION (GREEN) - Light indicating middle convey section is active.
(4) CONVEY AFT SECTION (GREEN) - Light indicating aft convey section is active.
(5) REAR STOP LOWERED (RED) - Light indicating rear pallet stop is lowered.
(6) PANEL LIGHT - Illuminates the convey panel.
(7) CONVEY - Two-way joystick control for selecting direction to convey cargo and the speed
of the convey rollers. Joystick will latch in the center position (neutral) to prevent
accidental actuation. Convey speed increases as the joystick handle is moved farther
away from the neutral position.
Figure 2
CONVEY PANEL
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(8) CONVEY MODE PALLET WIDTH - Three-position switch that raises the convey modules
and selects the rollers in each section to rotate for the pallet width selected, 2235 or
2743 mm (88 or 108 in.). When the OFF position is selected, the convey modules are
lowered.
(9) FRONT STOP LOWERED - Two-position switch that raises and lowers the front cargo
stop.
(10) CONVEY FRONT SECTION - Two-position switch that activates the rollers on the front
convey section.
(11) CONVEY MID SECTION - Two-position switch that activates the rollers on the middle
convey section.
(12) CONVEY AFT SECTION - Two-position switch that activates the rollers on the aft convey
section.
(13) REAR STOP LOWERED - Two-position switch with a momentary contact that lowers the
rear cargo stop.
C. WIPERS AND WASHERS PANEL
The wiper panel is an overhead panel located in the upper-right corner of the cab enclosure and
contains the FRONT WIPER, REAR WIPER, FRONT WASHER and REAR WASHER switches at
the left side of the panel. The FRONT WIPER and REAR WIPER circuit breakers are adjacent to
the left of the switches. Refer to Figure 3.
The HEADLIGHTS and CAB LIGHT switches are in the center of the panel, while the DOME
LIGHT and CABIN DASH AND GAUGE LIGHTS dimmer switches are on the right side of the
panel.
(1) FRONT WIPER - Three-position switch for operating the windshield wiper motor with two
speeds.
(2) REAR WIPER - Three-position switch for operating the rear door wiper motor with two
speeds.
(3) FRONT WASHER - Two-position switch with a momentary contact that actuates the pump
for the windshield washer.
(4) REAR WASHER - Two-position switch with a momentary contact that actuates the pump
for the rear door washer.
(5) HEADLIGHTS - Three-position switch for operating the parking lights and headlights.
(6) DOME LIGHT SWITCH - Rotary switch for turning dome light OFF and ON and adjusting
the brightness.
(7) DIMMER, CABIN AND DASH - Rotary switch that adjusts the brightness of the dash panel
illumination lights and the gauge illumination lights.
(8) PANEL LIGHT - Illuminates the overhead panel.
(9) FRONT WIPER BREAKER - Resettable circuit breaker for front wipers.
(10) REAR WIPER BREAKER - Resettable circuit breaker for rear wipers.
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9 1 3 8 5
10 2 4 6 7
Figure 3
WIPERS AND WASHERS PANEL
D. AIR CONDITIONING SYSTEM
The air conditioning system evaporator box is located in the right rear of the loader’s cab behind
the operator. There are two switches located on top of the evaporator box.
Next to the switches at the top of the evaporator box, it is located a directional louver with air
vents for distribution of conditioned air for dehumidifying and defogging. Refer to Figure 4.
(1) Air Conditioning Mode Switch
This mode switch has three positions.

(a) OFF - Turns off the evaporator box fan and A/C unit.
(b) FAN - Turns on the Fan only for circulation.
(c) A/C - Turns on the air conditioning inside the loaders cab.
(2) Fan Switch
The fan speed switch controls air flow by allowing one of three fan speed selections.
(a) HIGH Speed - Fan operates at high speed.
(b) MED Speed - Fan operates at medium speed.
(c) LOW Speed - Fan operates at low speed.
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3 POSITION FAN SWITCH
3 POSITION A/C MODE SWITCH
DIRECTIONAL AIR LOUVERS
EVAPORATOR BOX
AIR FILTER INLET
Figure 4
AIR CONDITIONING SYSTEM EVAPORATOR BOX
(3) Air Conditioning Operation
(a) Conduct equipment pre-operational maintenance to ensure all associated

components are clean and serviceable prior to operation.
(b) At the A/C mode switch, select A/C position.
(c) At the fan speed switch located on the evaporator box, select the high position.
(d) Position the directional louvers for desired air distribution.
(e) Adjust the temperature by lowering or raising the fan speed switch.
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(4) Air Conditioning Shutdown
(a) Ensure the engine has cooled down.

(b) Set the fan speed switch to the low position.
(c) Switch the A/C mode switch to the OFF position.
(d) Shutdown the loader.
NOTE: WHEN COOLING IS NOT NEEDED, CIRCULATION CAN BE PROVIDED BY MOVING

THE MODE SWITCH TO THE FAN POSITION.
CAUTION
THE AIR CONDITIONER DOES NOT DRAW FRESH AIR INTO THE CAB. IT WILL NOT REMOVE
SMOKE OR EXHAUST FUMES. CHECK FOR PROPER VENTILATION PRIOR TO OPERATION.
NOTE: WHEN FIRST STARTING THE AIR CONDITIONER, IF AFTER TWO MINUTES THE
COMPRESSOR WILL NOT RUN FOR MORE THAN A FEW SECONDS, SWITCH THE
BLOWER TO “LOW” UNTIL THE COMPRESSOR CONTINUES TO RUN AND THE CAB
STARTS TO COOL. THEN SWITCH TO THE “MEDIUM” POSITION AND THEN TO THE
“HIGH” POSITION.
4. OPERATING PROCEDURES
A. PRE-OPERATION DAILY INSPECTION
Operator inspection is to be performed on a daily basis. Inspection ensures optimum loader

performance and long life for machine components. The checklist provided will assist in
performing daily operational checks.
WARNING
BEFORE STARTING ANY PROCEDURE, ENSURE THE LOADER IS ON A LEVEL SURFACE
AND HAS SUFFICIENT CLEARANCE IN FRONT AND BACK. ENSURE ALL PERSONS ARE
CLEAR OF THE LOADER IN THE EVENT OF UNEXPECTED MOVEMENT. PLACE CHOCKS
APPROXIMATELY TWO (2) INCHES FROM THE FRONT AND REAR OF TIRES TO PREVENT
EXCESSIVE MOVEMENT OF THE LOADER IN EITHER FORWARD OR REVERSE DIRECTION
SHOULD THE PARKING BRAKE FAIL.
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TABLE 1 - OPERATOR’S DAILY INSPECTION CHECKLIST
PROCEDURE CHECK ()
Deck of Loader
Check casters and rollers on deck for damage and ease of rolling.
Check rubber bumpers.
Check folding wings for damage, free movement and pin engagement.
External cab inspection.
Check heater fuel level.
Check windows and mirrors for cracks.
Check windshield washer fluid level.
Ensure cabin pin is properly installed.
Check condition on all handrails, mounting brackets and locking pins.
Check general condition power rollers.
Check condition of ladder.
Lift engine access panel on deck between power rollers 5 and 6.
Check engine oil level. Refer to Figure 5.
Close and secure engine access panel.
Turn battery on.
Start loader.
Raise loader to first maintenance stand and install maintenance stand and pins.
Shut down loader.
Chassis
Check condition of drive wheels.
Check condition of park and service brake (mounting and leaks).
Check hydraulic filter high pressure indicator.
Check coolant level in coolant recovery tank. Refer to Figure 5.
Check coolant reservoir (peephole).
Check hydraulic oil level.
Check hydraulic breather indicator.
Check belts (condition and adjustment).
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TABLE 1 - OPERATOR’S DAILY INSPECTION CHECKLIST (CONT.)
Check air filter indicator.
Check that engine and transmission dipstick tube is secured and not leaking.
Check condition of bogy wheels.
Check helper cylinders.
Check area around radiator and battery box.
Check area around fuel tank and circuit breaker box.
Check air pressure in all tires and inflate to specification 690 ± 14 kPa (100 2 psi).
NOTE: REFER TO FIGURE 5 FOR ENGINE OIL AND COOLANT FILL POINTS.
Check condition of hydraulic return filter.

NOTE: TO CHECK FILTER CONDITION, PLACE HYDRAULIC PREHEAT SWITCH
IN THE ON POSITION AND OBSERVE READING ON GAUGE. REFER TO
FIGURE 5. GAUGE IS LOCATED ON RETURN FILTER HOUSING ON THE
TOP OF THE HYDRAULIC RESERVOIR. THE FILTER ELEMENT SHOULD
BE REPLACED IF GAUGE INDICATOR IS IN RED AREA.
NOTE: REFER TO FIGURE 6 FOR HYDRAULIC RETURN FILTER GAUGE.
Underside of Deck
Check main lift cylinder.
Check pitch cylinders (wear and leaks).
Check roll cylinders (wear and leaks).
Check side shift cylinders (wear and leaks).
Check pallet stops cylinders.
Cab
Check condition cab seat and controls for adjustments.
Check condition seat belt and latch operation.
Check test warning lights.
Start loader.
Check all rear lights.
Check all front lights.
Check dome light.
Check cabin dash light.
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Check heater operation.
Check fan.
Check wipers and washers for proper operation.
Check horn.
Check operation of air conditioning system and evaporator box.
Deck Operation
Check operation of all deck position lights.
Check auto center.
Check front pallet stop.
Check rear pallet stop.
Check power rollers.
Check hydraulic filter gauge.
Check transmission fluid (with engine running).
Check case drain gauge.
Test emergency pump.
Inspect service brakes and rotors.
Inspect park brake.
Check park brake forward movement.
• Start the loader.
• Place foot pressure on the service brake foot pedal and release parking brake.
• Shift transmission to drive.
• Apply parking brake.
• Release foot brake.
• Increase engine speed slowly to verify parking brake holds (do not exceed
1200 rpm). Ensure loader does not move. If the loader moves report problem to
maintenance.
Check park brake reverse movement.
• Start the loader.
• Place foot pressure on the service brake foot pedal and release parking brake.
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• Shift transmission to reverse.
• Apply parking brake.
• Release foot brake.
• Increase engine speed slowly to verify parking brake holds (do not exceed
1200 rpm). Ensure loader does not move. If the loader moves report problem to
maintenance.
Deck Raise and lower
Deck pitch Up and down
Deck shift Left and right
Deck roll Left and right
Front pallet stop Up and down
Rear pallet stop Up and down
Power steering Left and right
Transmission shifting All ranges
Deck convey
• Front section Forward and aft
• Mid section Forward and aft
• Rear section Forward and aft
Turn battery disconnect switch to the off position after each operation.
Additional Notes or Comments
EQUIPMENT SERIAL NUMBER: HOURMETER:
DAILY CHECK PERFORMED BY: DATE:
DAILY CHECK VERIFIED BY: DATE:
NOTE: COPIES OF THIS TABLE CAN BE MADE AS PART OF A LOG.
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Figure 5
ENGINE OIL AND COOLANT FILL POINTS
Figure 6
HYDRAULIC RETURN FILTER GAUGE
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B. STARTING POWER UNIT
(1) Turn the BATTERY DISCONNECT switch on the battery box to the ON position. Refer to
Figure 7.
Figure 7
BATTERY DISCONNECT SWITCH
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(2) Ensure the EMERGENCY STOP switch on the forward end of main panel is pulled OUT.
Refer to Figure 8.
Figure 8
MAIN PANEL
NOTE: THE IGNITION START SWITCH WILL ONLY BE USED FOR MAINTENANCE PURPOSES
TO INCLUDE RAISING OF DECK TO PERFORM OPERATOR CHECKS OF THE
LOADER AND PLACEMENT OF THE MAINTENANCE STANDS.
NOTE: BEFORE USING THE IGNITION SWITCH TO START THE LOADER, ENSURE FLUID
LEVELS ARE WITHIN THE PROPER RANGE. UNDER NO CIRCUMSTANCES WILL THE
LOADER BE PLACED IN AN OPERATIONAL MODE WITH THE SWITCH IN THE “ON”
POSITION AS IT DISABLES THE CAB IGNITION SWITCH.
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(3) If operating in cold weather conditions, remove the 120/240 VAC power cord.
(a) Turn circuit breaker to the OFF position then remove power cord from the receptacle
on the winterization box on the left side of the chassis. Refer to Figure 9.
(b) Refer to ‘B. CONVEY PANEL’ for connecting power cord to winterization box after
shutting engine down.
EMERGENCY PUMP
WINTERIZATION
RECEPTACLE
CIRCUIT
BREAKER
WEATHER CAP
Figure 9
WINTERIZATION RECEPTACLE
CAUTION

CAUTION
AC POWER CABLE MUST BE REMOVED FROM RECEPTACLE BEFORE STARTING ENGINE.
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CAUTION
ENGINE CAN BE STARTED WHEN AC POWER CABLE IS NOT ENERGIZED OR CIRCUIT

BREAKER IS IN THE “OFF” POSITION.
(4) Ensure the dash panel EMERGENCY STOP switch is pulled out. Refer to Figure 10.
(5) Ensure the PARK BRAKE switch is in the ON position. Refer to Figure 10.
Figure 10
DASH PANEL
(6) Check warning lights.

(a) Move the IGNITION switch to the ON position and observe that the following
indicator lights are illuminated on the dash panel. Refer to Figure 10.
• Generator . . . . . . . . . . . . . . . . . . . RED indicator light
• Engine oil pressure. . . . . . . . . . . . RED indicator light
• Parking brake ON . . . . . . . . . . . . . RED indicator light
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(b) Hold the SHUTDOWN OVERRIDE in the down position (LIGHT TEST) and observe
that the following indicator lights illuminate. Refer to Figure 10.
• Hydraulic fluid hot . . . . . . . . . . . . . RED indicator light
• Transmission fluid hot . . . . . . . . . . RED indicator light (Only applies to
Reg. #07E00051 and below)
• Engine hot . . . . . . . . . . . . . . . . . . . RED indicator light
CAUTION
DO NOT OPERATE EQUIPMENT WITH DEFECTIVE WARNING INDICATOR LIGHTS.
(7) Select N in the digital display with the TRANSMISSION RANGE SELECTOR. Refer to
Figure 11.
TRANSMISSION RANGES
THAT CAN BE SELECTED
(DISPLAYED)
1 (RANGE 1)
DIGITAL DISPLAY 2 (RANGE 2)
3 (RANGE 3)
D (DRIVE)
N (NEUTRAL)
R (REVERSE)
LEVER
Figure 11
TRANSMISSION RANGE SELECTOR
(8) Move and hold the SHUTDOWN OVERRIDE switch to the ON position and hold while
moving the IGNITION switch to the START position until the engine starts, then release the
IGNITION and SHUTDOWN OVERRIDE switches allowing the IGNITION switch to return
to the ON position.
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CAUTION
WHEN STARTING THE ENGINE, RELEASE THE IGNITION SWITCH IF THE ENGINE FAILS TO
START WITHIN 15 SECONDS. AFTER A SECOND ATTEMPT, ALLOW THE STARTER MOTOR
TO COOL DOWN FOR ONE MINUTE BEFORE ATTEMPTING TO RESTART THE ENGINE.
NOTE: IF THE ENGINE PREHEAT INDICATOR LIGHT IS ILLUMINATED, WAIT UNTIL THE
LIGHT GOES OUT BEFORE MOVING THE IGNITION SWITCH TO THE START
POSITION.
NOTE: IF THE ENGINE STARTS THEN SHUTS DOWN WHEN THE SWITCH IS RELEASED,
MOVE AND HOLD THE SHUTDOWN OVERRIDE SWITCH IN THE ON POSITION WHEN
STARTING THE ENGINE. HOLD THE SHUTDOWN OVERRIDE SWITCH IN THE ON
POSITION AND OBSERVE THE ENGINE OIL PRESSURE GAUGE. RELEASE THE
SHUTDOWN OVERRIDE SWITCH WHEN THE OIL PRESSURE GAUGE INDICATES 5
PSI OR HIGHER.
(9) Observe all gauges and indicator lights on the dash panel for normal engine operation.
NOTE: ENGINE WILL SHUT DOWN WHENEVER THE FOLLOWING INDICATOR LIGHTS
ILLUMINATE:
• Engine oil pressure . . . . . . . . . . . . . . . . . . . . . . . . RED indicator light

• Engine hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RED indicator light
• Transmission fluid hot . . . . . . . . . . . . . . . . . . . . . . RED indicator light
• Hydraulic fluid hot . . . . . . . . . . . . . . . . . . . . . . . . . RED indicator light
(10) Allow engine to warm up before driving or operating the loader.
C. STOPPING LOADER
(1) Place the PARKING BRAKE switch on the dash panel to the ON position and observe that
the PARK BRAKE ON red indicator light is illuminated. Refer to Figure 12.
(2) Place the TRANSMISSION RANGE SELECTOR in the N position.
(3) Allow engine to idle for 3 to 4 minutes for the temperature to stabilize.
(4) Place the IGNITION switch in the OFF position to shut down the engine. Refer to
Figure 12.
(5) When the mission is completed and the loader is parked, turn the BATTERY
DISCONNECT switch on the battery box to the OFF position.
(6) When operating in cold weather, connect an AC power cord to the receptacle on the
winterization box. Refer to Figure 9.
CAUTION

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Turn circuit breaker to the ON position to energize the circuit and supply power to the
heating elements for the engine and hydraulic fluid.
The WINTERIZATION CONNECTED indicator light (RED) on the dash will be illuminated
when the circuit is energized. Refer to Figure 10.
FUEL SPEEDOMETER TACHOMETER

GAUGE
PARKING BRAKE IGNITION
Figure 12
DASH PANEL - LOWER RIGHT SIDE
D. MAINTENANCE STANDS INSTALLATION AND REMOVAL
Refer to Figure 13.
(1) Maintenance Stands Installation
(a) Raise the deck high enough to complete required work.

(b) Install both maintenance stands into the chassis and install retaining pins.
(c) Lower deck until the lower scissor rollers come into contact with the maintenance
stands.
(2) Maintenance Stands Removal
(a) Raise deck until the lower scissor roller clears the maintenance stands.
(b) Remove retaining pins.
(c) Remove both maintenance stands and stow in holders and install retaining pins.
(d) Lower the deck.
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SUPPORT BLOCK LOCATIONS
MAINTENANCE SUPPORT BLOCKS
Figure 13
MAINTENANCE STANDS
E. DECK CONFIGURATIONS
CAUTION
CONFIGURE THE LOADER DECK FOR THE SIZE PALLET OR ROLLING STOCK THAT WILL BE
CONVEYED.
CAUTION
ALL RETAINING QUICK RELEASE PIN HANDLES AND LANYARDS SHOULD POINT TOWARDS
GROUND.
(1) Deck configuration for 2235 mm (88 in.) biased pallets.
(a) Remove the two retaining pins from each pallet lock, then remove the pallet lock
assembly from the guide rail by pulling the assembly out from the cavity. There are
six pallet locks on the left side guide rails and six pallet locks on the right side guide
rails. Refer to Figure 14.
(b) Remove the two retaining pins that secure each side guide to the pivot lugs.
(c) Lift and rotate the side guides up and reinstall the retaining pins in the pivot lugs to
secure the side guide in the new position.
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(d) Install the pallet locks in the new cavities exposed and secure with the retaining pins
that were removed in the first step.
RETAINING PINS
Figure 14
RETAINING PINS
(2) Deck configuration for 2743 mm (108 in.) biased pallets.
(a) Remove the two retaining pins from each pallet lock, then remove the pallet lock
assembly from the guide rail by pulling the assembly out from the cavity. There are
six pallet locks on the left side guide rails and six pallet locks on the right side guide
rails. Refer to Figure 14.
(b) Remove the two retaining pins that secure each side guide to the pivot lugs.
(c) Lift and rotate the side guides down; reinstall the retaining pins in the pivot lugs to
secure the side guide in the new position.
(d) Install the pallet locks in the new cavities exposed and secure with the retaining pins
that were removed in the first step.
(3) Deck configuration for rolling stock, invert all caster and roller trays.
(a) The smooth side of the tray must be up. Refer to Figure 15.
(b) Release the latch retaining the tray, pick up and invert the tray, replace the tray in the
cavity and ensure the latch engages to retain the tray.
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Figure 15
TRAY WITH SMOOTH SIDE UP
(4) Deck configuration for forklift loading from the rear.
(a) Remove and stow the forklift tine trough covers when loading and off loading from
the rear. Refer to Figure 16.
(b) Invert all caster trays to have casters in the UP position. Refer to Figure 17.
REMOVE ALL FIVE

TINE TROUGH
COVERS
Figure 16
DECK CONFIGURED FOR FORKLIFT LOADING FROM THE REAR
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Figure 17
CASTERS IN THE UP POSITION
(5) Deck configuration for forklift loading from the side.
(a) Remove and stow the two handrails at the right rear of the deck when loading and
off loading from the right side of the deck.
(b) Remove and stow the forklift tine trough covers. Refer to Figure 18.
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REMOVE ALL FIVE
INE TROUGH
OVERS
Figure 18
DECK CONFIGURED FOR FORKLIFT LOADING FROM THE SIDE
(c) Invert all caster trays to have casters in the UP position. Refer to Figure 19.
Figure 19
CASTERS IN THE UP POSITION
(d) Support the walk-deck sections and remove the retaining pins.
NOTE: THERE ARE TWO WALK-DECK SECTIONS AT THE RIGHT REAR OF THE DECK THAT
ARE REQUIRED TO BE LOWERED.
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WARNING
(e) Lower the walk-decks and pallet guides to provide access for the forklift tines when
loading and unloading cargo.
(6) Deck configuration for air drop platforms.
(a) On the convey panel, place pallet width switch in the OFF position. Refer to
Figure 2.
(b) Rotate convey module latch handles to release the modules for increased height.
Refer to Figure 20.
NOTE: ALL HANDLES WILL BE “IN LINE” WITH THE DECK.
(c) To re-configure the deck for standard pallets turn the convey switch to the OFF
position and step on the convey module and rotate the latch handle. Refer to
Figure 20.
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Position handle as shown for air

drop pallet configuration
Handle as shown for standard

pallet configuration
Figure 20
CONVEY MODULE LATCH HANDLES
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(7) Deck configuration for lower lobes. Refer to Figure 21.
(a) Remove and stow front guide rail sections. Refer to Figure 23.
(b) For left folding wing:
1) Have assistant support folding wing.
2) Fully depress and hold square pin.
3) Have assistant lower folding wing to stop.
(c) For right removable wing:
1) Have assistant support wing.
2) Slide forward pin outboard to its fullest extent.
3) Remove hinge pin from the rear of wing.
4) Stow wing on hooks provided on right side walk deck.
CAB HANDRAIL
PUSHED IN
RIGHT SIDE WALKDECK/HANDRAIL

IN RETRACTED POSITION
RIGHT WING
IN STOWING LOCATION
Figure 21
LOWER LOBE INTERFACE
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CAUTION
THE LOADER MAY ONLY BE DRIVEN IN A STRAIGHT LINE WITH THE LEFT FOLDING WING
IN THE DOWN POSITION. THE LOADER SHOULD NEVER BE DRIVEN WITH THE RIGHT
FOLDING WING IN THE DOWN POSITION.
SPRING LATCH
QUICK RELEASE PIN
RIGHT SIDE
HANDRAIL/WALKDECK
FRONT GUIDE RAIL
RIGHT WING
LEFT WING
FRONT GUIDE RAIL
NORMAL OPERATING CONFIGURATION
Figure 22
FOLDING WINGS
(8) Walk-deck and right front handrail configuration for aircraft door. Refer to Figure 23.
WARNING
DO NOT ACCESS WALK-DECK WHEN NOT SECURED BY BOTH LOCKS. FULLY LOCK
TELESCOPING WALK-DECK IN PLACE BEFORE ACCESSING OR WALKING ON IT.
(a) When loading or unloading certain aircraft, the telescoping handrail and walk-deck
must be retracted to provide clearance to prevent damage to the aircraft.
NOTE: TELESCOPING HANDRAIL AND WALK-DECK HAS THREE (3) POSITIONS (FULLY
EXTENDED, FULLY RETRACTED AND MIDDLE POSITION).
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GUIDE RAILS
IN 88 MODE
STOW FRONT GUIDE
RAILS IN TOOL BOX
CAB HANDRAIL
PUSHED IN
Figure 23
SQUARE PIN
PUSHED IN
RIGHT WING
RIGHT SIDE HANDRAIL AND WALK-DECK

IN STOWING LOCATION LEFT WING
FOLDED DOWN
RIGHT SIDE HANDRAIL/WALKDECK
FULLY RETRACKED
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(b) To reposition the handrail and walk-deck, remove the lower quick release pin that is
painted yellow and is attached to a lanyard, then unlatch the upper pin that has a ball
handle.
(c) Slide the handrail and walk-deck to the required position and ensure that upper pin
latches in place.
(d) Insert the lower quick release pin fully to lock the handrail and walk-deck in position.
Yellow handle will be fully visible when pin is in place.
F. DRIVING THE LOADER
WARNING
ALL CARGO, PALLETS AND ROLLING STOCK MUST BE SECURED TO THE LOADER DECK
TO PREVENT MOVEMENT IN ANY DIRECTION WHEN THE LOADER IS IN MOTION.
WARNING
CAB DOORS MUST BE LATCHED CLOSED WHEN DRIVING AND OPERATING THE LOADER.
WARNING
WEAR THE SEAT BELT AT ALL TIMES WHILE OPERATING THE LOADER.
CAUTION
DO NOT EXCEED 15 KM (9 MILES) OF TRAVEL IN A ONE HOUR PERIOD OF TIME. IF THAT

DISTANCE IS REACHED, TIRES MUST BE ALLOWED TO COOL FOR ONE HOUR.
(1) Refer to ‘B. STARTING POWER UNIT’ for detailed procedure on starting engine.
(2) Release park brake and depress the foot brake pedal to apply the service brakes
simultaneously, then select the range for driving:
(a) To move forward, move the TRANSMISSION RANGE SELECTOR forward to select
range D in the digital display. Refer to Figure 24.
(b) To move in reverse, move the TRANSMISSION RANGE SELECTOR to the rear to
select range R in the digital display.
NOTE: FOOT BRAKE MUST BE APPLIED BEFORE THE TRANSMISSION CAN BE SHIFTED
OUT OF NEUTRAL.
NOTE: TRANSMISSION WILL SHIFT UP, AS THE SPEED INCREASES, TO RANGE 4 FOR
MAXIMUM FORWARD SPEED WHEN THE TRANSMISSION RANGE SELECTOR IS IN
RANGE D.
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TRANSMISSION RANGES
THAT CAN BE SELECTED
(DISPLAYED)
1 (RANGE 1)
DIGITAL DISPLAY 2 (RANGE 2)
3 (RANGE 3)
D (DRIVE)
N (NEUTRAL)
R (REVERSE)
LEVER
Figure 24
TRANSMISSION RANGE SELECTOR
(3) Slowly depress the accelerator pedal and as soon as the loader begins to move, release
the accelerator pedal and depress the brake pedal to check for smooth and positive brake
action.
(4) Drive the loader to within 15 feet of the aircraft or loading dock and stop the loader, using
the brake pedal, to ensure the brakes are properly operating.
NOTE: ALWAYS SELECT “RANGE 1” OR “R” FOR REVERSE, IN THE DIGITAL DISPLAY WITH
THE TRANSMISSION RANGE SELECTOR WHEN OPERATING NEAR AIRCRAFT OR
WHEN THE DECK IS ELEVATED.
Range 1 or R for reverse, will allow the foot throttle to control the engine speed for driving
and will prohibit the transmission from up-shifting to the next speed range.
NOTE: WHEN THE DECK IS ELEVATED AND RANGE D, 3 OR 2 IS SELECTED, THE FOOT
THROTTLE WILL BE INACTIVE AND THE ENGINE WILL REMAIN AT IDLE SPEED. A
NO-DRIVE CONDITION EXISTS.
(5) Select range 1 in the digital display with the TRANSMISSION RANGE SELECTOR.
(6) Raise the deck to the approximate height of the aircraft door ramp, aircraft door sill or
loading dock.
(7) Drive the loader slowly and stop when the deck is approximately four inches from the
aircraft door ramp, aircraft door sill or the loading dock.
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(8) Apply the PARKING BRAKE and select N (neutral) with the TRANSMISSION RANGE
SELECTOR.
(9) Align the deck parallel with the aircraft, loading dock or other material handling equipment
for smooth cargo transfer using the PITCH and ROLL joystick control.
NOTE: FOR THE POWERED ROLLERS TO BE EFFECTIVE ON THE CARGO CONVEY

SYSTEMS, THE LOADER DECK MUST BE ALIGNED IN ALL DIRECTIONS. THE
NON-POWERED ROLLERS MUST PROPERLY SUPPORT THE PALLET DURING
CARGO TRANSFER OPERATIONS.
(10) When cargo transfer operation is complete, actuate and hold the dash panel AUTO
CENTER AND LEVEL switch to return deck to the normal level position before lowering the
deck. Refer to Figure 25.
NOTE: WHEN THE DECK HAS RETURNED TO THE NORMAL LEVEL POSITION, THE ROLL
LEFT AND ROLL RIGHT INDICATOR LIGHTS WILL NOT BE ILLUMINATED. REFER TO
FIGURE 25.
Figure 25
DASH PANEL - LEFT SIDE
(11) When operating on slippery surfaces and a loss of traction occurs on one drive wheel,
engage the differential lock to power both wheels on the front axle.
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CAUTION
DO NOT DRIVE THE LOADER WITH THE DIFFERENTIAL LOCK ENGAGED WHEN OPERATING
IN NORMAL CONDITIONS ON HARD SURFACES.
(a) Select N with the TRANSMISSION RANGE SELECTOR.
(b) With the loader stopped, place the differential lock switch in the ON position. The
amber indicator light on the dash will be illuminated. Refer to Figure 26.
(c) Select a driving range with the TRANSMISSION RANGE SELECTOR and slowly
drive the loader until back on normal operating surfaces.
(d) Stop the loader, then disengage the differential lock by placing the switch in the OFF
position.
AMBER
INDICATOR
LIGHT
DIFFERENTIAL
LOCK
Figure 26
DASH PANEL - LOWER-RIGHT CENTER
(12) When an operation is complete, drive the loader to the assigned area, select N in the
transmission digital display and apply parking brake.
(13) Allow the engine to operate at idle speed for 3–4 minutes to stabilize the temperatures,
then shut down the engine.
(14) Chock wheels to prevent movement in either direction.
(15) When operating in arctic conditions, connect external power cord to receptacle on left side
of loader and move the circuit breaker to the ON position.
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5. LOADING AND UNLOADING CARGO PROCEDURES
WARNING
WARNING
THE OPERATOR’S VISIBILITY WILL BE IMPAIRED TOWARDS THE RIGHT WHEN A PALLET
OR CARGO IS ON THE FRONT POSITION OF THE DECK. FOR SAFE OPERATION, AN
OBSERVER SHOULD ALWAYS BE USED TO KEEP THE OPERATOR INFORMED OF
CLEARANCE, TRAFFIC OR ANY HAZARD WHEN TRANSPORTING CARGO WHEN VISIBILITY
IS IMPAIRED.
CAUTION
THE FRONT LOAD STOPS WILL REMAIN IN THE DOWN POSITION AND THE RED INDICATOR
LIGHT WILL BE ILLUMINATED WITH THE SWITCH IN THE DOWN POSITION. THE FRONT
LOAD STOP SWITCH MUST BE PLACED IN THE UP POSITION WHEN TRANSPORTING
CARGO, LOADING CARGO FROM THE REAR OF THE DECK OR WHENEVER THE FRONT OF
THE DECK IS LOWER THAN THE REAR OF THE DECK.
NOTE: PERSONS ASSISTING IN HANDLING AND SECURING OF CARGO, MUST WEAR A

SAFETY HARNESS WITH THE TETHER ATTACHED TO A DESIGNATED “D-RING” IN
THE AREA DEFINED AS “HARNESS REQUIRED AREA”. REFER TO FIGURE 29.
A. LOADING CARGO ON THE LOADER - FRONT END OPERATION
Refer to Figure 2 for convey panel.
NOTE: ENSURE ALL PALLET LOCKS ARE PULLED BACK AND ROTATED TO THE RELEASED
POSITION IN THE GUIDES BEFORE MOVING PALLETS ONTO THE DECK. REFER TO
FIGURE 27.
(1) Select pallet width of 2235 mm (88 in.) or 2743 mm (108 in.) that the deck is configured for
with the CONVEY MODE PALLET WIDTH switch on the convey panel.
(2) Place FRONT STOP switch on the convey panel in the down position to lower the forward
pallet stop. The RED indicator light will illuminate.
(3) Place the three convey section switches in the ON position. The three GREEN indicator
lights will illuminate indicating that all three convey sections are active when the CONVEY
joystick switch is moved.
(4) Hold the convey joystick towards the back as the pallet is being transferred onto the deck
to activate all the convey rollers aft and move the pallet to the rear section of the deck.
Using the convey joystick, shift the pallet fore and aft to align the pallet lock recesses with
the pallet locks.
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(5) Rotate the pallet locks and ensure they enter the pallet recesses to prevent movement of
the pallet during the transport operation. Refer to Figure 30.
(6) Place the CONVEY AFT SECTION switch in the OFF position. The GREEN indicator light
must not be illuminated.
(7) Hold the convey joystick towards the back as the second pallet is being transferred onto
the deck to activate the convey rollers aft in the front and middle sections and move the
pallet to the middle section of the deck. Using the convey joystick, shift the pallet fore and
aft to align the pallet lock recesses with the pallet locks.
the pallet during the transport operation.
(9) Place the CONVEY MID SECTION switch to the OFF position. The GREEN indicator light
(10) Hold the convey joystick towards the back as the third pallet is being transferred onto the
deck to activate the convey rollers aft in the front section and move the pallet to the front
section of the deck. Using the convey joystick, shift the pallet fore and aft to align the pallet
lock recesses with the pallet locks.
(11) Rotate the pallet locks and ensure they enter the recesses in the pallet to prevent
movement of the pallet during the transport operation.
(12) Place the CONVEY FRONT SECTION switch in the OFF position. The GREEN indicator
light must not be illuminated.
(13) Place the FRONT STOP switch in the UP position. The RED indicator light must not be
illuminated.
B. OFF LOADING CARGO ON THE LOADER - FRONT END OPERATION

(1) Pull back and rotate all pallet locks to the released position in the guides. Refer to
Figure 27.
(2) Place FRONT STOP switch on the convey panel in the down position to lower the forward
pallet stop; the RED indicator light illuminates.
(3) Place the CONVEY FRONT SECTION switch in the ON position. The GREEN indicator
light illuminates indicating that the front convey section will be active when the CONVEY
(4) Hold the CONVEY joystick forward to transfer the front pallet forward on the deck and into
the aircraft or onto the loading dock.
(5) Place the CONVEY MID SECTION switch in the ON position. The GREEN indicator light
illuminates indicating that the middle convey section will be active when the CONVEY
joystick is moved.
(6) Hold the CONVEY joystick forward to transfer the second pallet forward on the deck and
into the aircraft or onto the loading dock.
(7) Place the CONVEY AFT SECTION switch in the ON position. The GREEN indicator light
illuminates indicating that the aft convey section will be active when the CONVEY joystick
is moved.
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(8) Hold the CONVEY joystick forward to transfer the third pallet forward on the deck and into
the aircraft or onto the loading dock.
(9) Place the FRONT STOP switch in the UP position. The RED indicator light must not be
illuminated.
C. LOADING CARGO ON THE LOADER - BACK END OPERATION
NOTE: ENSURE ALL PALLET LOCKS ARE PULLED BACK AND ROTATED TO THE RELEASED
POSITION IN THE GUIDES BEFORE MOVING PALLETS ONTO THE DECK. REFER TO
FIGURE 27.
(1) Hold REAR STOP switch on the convey panel in the down position to lower the rear pallet
stop; the RED indicator light illuminates.
NOTE: THE REAR STOP SWITCH HAS A MOMENTARY CONTACT AND MUST BE HELD
ACTUATED WHEN CONVEYING CARGO ON AND OFF THE DECK.
(2) Place the three convey section switches in the ON position. The three GREEN indicator
lights illuminate indicating that all three convey sections will be active when the CONVEY
(3) Hold the convey joystick towards the front as the pallet is being transferred onto the deck to
activate all the convey rollers forward and move the pallet to the front section of the deck.
Using the convey joystick, shift the pallet fore and aft to align the pallet lock recesses with
the pallet locks.
movement of the pallet during the transport operation. Refer to Figure 28.
(5) Place the CONVEY FRONT SECTION switch in the OFF position. The GREEN indicator
(6) Hold the convey joystick towards the front as the second pallet is being transferred onto the
deck to activate the convey rollers forward in the middle and aft sections and move the
pallet to the middle section of the deck. Using the convey joystick, shift the pallet fore and
aft to align the pallet lock recesses with the pallet locks.
movement of the pallet during the transport operation.
(8) Place the CONVEY MID SECTION switch in the OFF position. The GREEN indicator light
(9) Hold the convey joystick towards the front as the third pallet is being transferred onto the
deck to activate the convey rollers forward on the aft section and move the pallet to the aft
section of the deck. Using the convey joystick, shift the pallet fore and aft to align the
recesses with the pallet locks.
the pallet during the transport operation.
(11) Place the CONVEY AFT SECTION switch in the OFF position. The GREEN indicator light
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(12) Place the REAR STOP switch in the UP position. The RED indicator light must not be
illuminated.
D. OFF LOADING CARGO ON THE LOADER - BACK END OPERATION

(1) Hold REAR STOP switch on the convey panel in the DOWN position to lower the rear pallet
stop; the RED indicator light illuminates.
NOTE: THE REAR STOP SWITCH HAS A MOMENTARY CONTACT AND REQUIRES THAT IT
BE HELD ACTUATED WHEN CONVEYING CARGO ON AND OFF THE DECK.
(2) Pull back and rotate all pallet locks to the released position in the guides. Refer to
Figure 27.
(3) Place the CONVEY AFT SECTION switch in the ON position. The GREEN indicator light
illuminates indicating that the aft convey section will be active when the CONVEY joystick
switch is moved.
(4) Hold the CONVEY joystick aft to transfer the rear pallet aft on the deck and into the aircraft
or onto the loading dock.
(5) Place the CONVEY MID SECTION switch in the ON position. The GREEN indicator light
illuminates indicating that the middle convey section will be active when the CONVEY
joystick is moved.
(6) Hold the CONVEY joystick aft to transfer the second pallet aft on the deck and into the
aircraft or onto the loading dock.
(7) Place the CONVEY FRONT SECTION switch in the ON position. The GREEN indicator
light illuminates indicating that the front convey section will be active when the CONVEY
joystick is moved.
(8) Hold the CONVEY joystick aft to transfer the third pallet aft on the deck and into the aircraft
or onto the loading dock.
• Release the REAR STOP switch and the rear stop rises fully up. The RED indicator
E. LOADING ROLLING STOCK

(1) Invert all caster and roller trays next to pallet guides, both left and right sides, for the
smooth sides to be facing up.
(2) Folding wings at the front of the deck must be in the up position when placing and
removing rolling stock on loader deck.
CAUTION
ROLLING STOCK MUST HAVE PARKING BRAKES APPLIED AND SECURED WITH
RESTRAINTS ATTACHED TO THE TIE DOWN RINGS ON THE DECK BEFORE DRIVING THE
LOADER.
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RELEASED POSITION
Figure 27
PALLET LOCK IN RELEASED POSITION
LOCKED POSITION
Figure 28
PALLET LOCK IN LOCKED POSITION
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OPERATION
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Figure 29
SAFETY HARNESS AREA
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FOLDING ROLLER TRAYS TIE DOWNS CASTER TRAYS

WING
FOLDING
WING
ROLLER TRAYS TIE DOWNS CASTER TRAYS
Figure 30
LOADER DECK FOR ROLLING STOCK
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1. GENERAL
WARNING
APPLY E-STOP TO DISABLE THE VEHICLE ONLY IN CASE OF EMERGENCY. PRESSING THE
EMERGENCY STOP PUSH-BUTTON WILL COMPLETELY SHUTDOWN THE VEHICLE.
The vehicle is equipped with an electrical-driven emergency hydraulic pump activated from the driver’s
cab actuating on a spring-loaded two-position switch. This pump allows for emergency maneuvers,
such as lowering the deck.
Also, a hand-operated emergency hydraulic pump is provided with the vehicle. This pump has a
removable handle that can be used for emergency operations when no other hydraulic source or
electrical power is available.
Emergency procedures in this section describe the necessary steps to follow, in case of mechanical
breakdown or equipment malfunctions.
NOTE: IT IS IMPORTANT TO COMPLETELY READ AND UNDERSTAND THIS EMERGENCY

PROCEDURES SECTION BEFORE OPERATING THE LOADER.
CAUTION
DO NOT ENERGIZE HYDRAULIC EMERGENCY PUMP DURING NORMAL VEHICLE

OPERATION.
2. EMERGENCY PROCEDURES‘
Should a condition arise that would require an immediate shutdown of the loader, the EMERGENCY
STOP switch can be actuated for an immediate shutdown of the power unit. Refer to Figure 1.
NOTE: WHEN THE ENGINE IS SHUTDOWN WITH THE EMERGENCY STOP SWITCH, THE
ELECTRIC DRIVEN EMERGENCY HYDRAULIC PUMP WILL AUTOMATICALLY BE
ACTUATED TO PROVIDE HYDRAULIC POWER FOR OPERATING THE POWER
STEERING, SERVICE BRAKES, PARKING BRAKES AND TRANSMISSION FOR 30
SECONDS.
CAUTION
CONTINUOUS OPERATION OF HYDRAULIC EMERGENCY PUMP FOR MORE THAN 30

SECONDS WILL OVERHEAT THE ELECTRICAL MOTOR. IF EMERGENCY PROCEDURES
CANNOT BE COMPLETED WITHIN 30 SECONDS, PUMP MUST BE ALLOWED TO COOL FOR
AT LEAST 10 MINUTES BEFORE CONTINUING.
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EMERGENCY PROCEDURES
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NOTE: THE PURPOSE OF THE HYDRAULIC EMERGENCY PUMP IS TO PROVIDE POWER
FOR STEERING, BRAKING AND PROPULSION TO GET THE LOADER TO A SAFE
PLACE.
CAUTION
NEVER USE THE HYDRAULIC EMERGENCY PUMP FOR OPERATING THE LOADER WHILE
TOWING IT.
VOLT FUEL
METER GAUGE SPEEDOMETER TACHOMETER
PARKING BRAKE IGNITION EMERGENCY PUMP

SWITCH SWITCH SWITCH
Figure 1
DASH PANEL
Follow these steps after a loader experiences an emergency (even if no mishap occurred):
• Take the loader out of service and notified maintenance as soon as possible.
• Report details of the events related to the emergency to JBT field support.
• Wait for direction and instructions from JBT GSE support office, before beginning diagnostics or
repairs.
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A. EMERGENCY SYSTEM
(1) In case of an engine or hydraulic pump failure while driving, the electrically powered
emergency hydraulic pump, incorporated in the hydraulic system, will instantly and
automatically operate for 30 seconds. This will provide hydraulic pressure for the power
steering, service brakes and parking brake. Refer to Figure 2.
NOTE: THE AUTOMATIC FEATURE IS ACTIVE ONLY WHEN THE PARKING BRAKE SWITCH
IS IN THE OFF POSITION.
AUXILIARY DECK
RAISE AND LOWER
WORK LIGHTS
EMERGENCY
PUMP SWITCH
IGNITION AND START SWITCH

(MAINTENANCE USE ONLY)
SHUTDOWN OVERRIDE
SWITCH
EMERGENCY
STOP SWITCH
Figure 2
MAIN PANEL
NOTE: THE IGNITION START SWITCH WILL ONLY BE USED FOR MAINTENANCE PURPOSES
TO INCLUDE RAISING OF DECK TO PERFORM OPERATOR CHECKS OF THE
LOADER AND PLACEMENT OF THE MAINTENANCE STANDS.
NOTE: BEFORE USING THE IGNITION SWITCH TO START THE LOADER, ENSURE FLUID
LEVELS ARE WITHIN THE PROPER RANGE. UNDER NO CIRCUMSTANCES WILL THE
LOADER BE PLACED IN AN OPERATIONAL MODE WITH THE SWITCH IN THE “ON”
POSITION AS IT DISABLES THE CAB IGNITION SWITCH.
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(2) The emergency pump switch on the dash panel can be held actuated by the operator to
provide hydraulic pressure for operating all the loader functions that are required to raise
and lower the deck, transfer cargo off the deck and release the parking brakes. A second
emergency pump switch is located on the forward end of the main panel that is used for
maintenance.
B. EMERGENCY MANOUVERS
(1) Turn the ignition switch ON and place the PARKING BRAKE switch in the ON position.
(2) Actuate and hold the EMERGENCY PUMP switch in the ON position and complete the
transfer of cargo, on or off the deck, by actuating the CONVEY switches in the normal
manner.
(3) Actuate and hold the EMERGENCY PUMP switch and the AUTO CENTER AND LEVEL
switch to return the deck to a level position.
(4) Lower the deck fully by actuating the deck LIFT switch and the EMERGENCY PUMP
switches.
(5) Raise the deck.
(a) Rotate the handle on the deck supply cutoff valve to the OFF position before raising
the deck. Refer to Figure 3.
(b) Actuate the deck LIFT switch and the EMERGENCY PUMP switch to raise the deck.
(c) Rotate the handle on the deck supply cutoff valve to the ON position after the deck
has been raised. Refer to Figure 3.
WARNING
DECK CUT-OFF VALVE MUST BE RETURNED TO THE ON POSITION AFTER USE. LOADER
STEERING AND SERVICE BRAKES ARE DISABLED WHEN CUTOFF VALVE IS LEFT IN THE
OFF POSITION.
(6) Turn the IGNITION switch to the OFF position after transferring the cargo and lowering the
deck to the full down position.
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DECK SUPPLY
CUTOFF VALVE
Figure 3
CHASSIS MANIFOLD
NOTE: REPOSITIONING OF THE DECK SUPPLY CUTOFF VALVE IS ONLY REQUIRED FOR
RAISING THE DECK WITH THE EMERGENCY PUMP.
C. TOWING
WARNING
BEFORE TOWING, ATTACH TOW VEHICLE WITH TOW BAR OR CHOCK WHEELS BEFORE
DISENGAGING PARK BRAKE.
CAUTION
DO NOT TOW THE LOADER FOR MORE THAN 150 M (500 FT.) WITHOUT DISCONNECTING
DRIVE SHAFT FROM DIFFERENTIAL.
NOTE: DRIVE SHAFT MUST BE DISCONNECTED FROM THE DIFFERENTIAL IF TOWING

DISTANCE MORE THAN 150 m (500 ft.) TO PREVENT DAMAGE TO THE
TRANSMISSION.
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(1) Connect a towing vehicle to the loader tow points on the end of the chassis frame. Refer to
Figure 4.
(2) Turn the IGNITION switch to the ON position. Refer to Figure 1.
(3) Release the parking brakes by placing the PARKING BRAKE switch in the OFF position
while holding the EMERGENCY PUMP switch actuated. Refer to Figure 1.
(4) Slowly tow the loader away from the aircraft to an area where repairs can be accomplished.
(5) Turn the IGNITION and BATTERY DISCONNECT switches to the OFF position.
(6) Chock loader wheels to prevent movement in either direction.
TOW POINT TOW POINT
Figure 4
LOADER TOW POINTS - REAR
D. LIFTING AND TOWING LOADER WITH A TOW VEHICLE
Lift the loader with the tow vehicle from the front by attaching to the tow points provided on the
front of the main frame.
NOTE: THE FRONT END OF THE DECK MAY REQUIRE PROTECTION FROM DAMAGE
DURING TOWING, DEPENDING ON THE TOWING VEHICLE AND EQUIPMENT.
CAUTION
NEVER TOW THE LOADER FROM THE REAR END WITH THE CHASSIS RAISED.
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1. GENERAL
This vehicle specification outlines the product definition of the Halvorsen, 25 000 lb. Loader for Aircraft,
offered by JBT, Ground Support Equipment. This aircraft loading and unloading vehicle is self-propelled
and air transportable.
Vehicles in this line are equipped with a diesel powered engine driving a hydraulic services pump. The
vehicle’s traction is driven by a drive shaft providing propulsion to the front wheels.
NOTE: MAINTENANCE SPECIFICATIONS ARE CONTAINED IN CHAPTER 2, SECTION 4. ALL

REFERENCES TO GALLONS ARE FOR U.S. GALLONS.
NOTE: VEHICLE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE, DUE TO

DESIGN IMPROVEMENTS AND CUSTOMERS’ SPECIFIC REQUIREMENTS.
2. MODEL DEFINITION
Vehicle name: Halvorsen, 25 000 lb. Loader for Aircraft

Designation: Halvorsen
Vehicle type: 25 000 lb. Loader for Aircraft
Power unit: Diesel (standard)
Gross vehicle weight: 14 220 kg (31 350 lb.)
Maximum cargo load: 11 340 kg (25 000 lb.)
3. AIRCRAFT ACCOMODATION
The Halvorsen can interface with lower deck aircraft, loading docks and other material handling
equipment (MHE), as well as main deck of commercial cargo aircraft.
The Halvorsen can efficiently and safely transfer and transport cargo from other MHE or a loading dock
onto aircraft and vice versa. Cargo includes pallets, platforms, containers and rolling stock. It can be
loaded and off loaded from the front end, back end and side.
The Halvorsen loader is designed for transport on rail car, ship or 96-inch wide commercial semi-trailer
and can be sling loaded. Also, for air transport on C-5, C-17 and C-130 aircraft, the loader features
drive on and drive off capabilities.
The deck can be side-shifted to the left or right of the centerline and roll to the left or right side for
alignment with aircraft doors that are not level with the loader deck. In addition, for alignment to the
aircraft roll plane when operating on irregular surfaces, the deck can also be pitched up or down from
horizontal.
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SPECIFICATIONS
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4. OPERATING CHARACTERISTICS
General Performance
• Deck lift capacity (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . 11 340 kg (25 000 lb.)
• Load capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multiple pallets, sizes and
rolling stock.
• Maximum speed (level, dry, paved surface) . . . . . . . . . . . . . . . 27 km/h (17 mph) forward
8 km/h ( 8 mph) in reverse
• Wind speed (maximum during operation). . . . . . . . . . . . . . . . . 74 km/h (46 mph / 40 knots)
• Wind speed (withstand stability) . . . . . . . . . . . . . . . . . . . . . . . . 160 km/h (100 mph)
Deck Transfer Heights
• Fully raised (maximum at roll plane). . . . . . . . . . . . . . . . . . . . . 5588 mm (220 in.)
• Fully lowered (minimum at roll plane). . . . . . . . . . . . . . . . . . . . 991 mm ( 39 in.)
• Transfer speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.48 m/s (95 fpm) maximum
Side Shift, Roll and Pitch
• Side shifting (to left or right or centerline). . . . . . . . . . . . . . . . . 76 mm (3 in.) each side
• Roll capability (to left or right side) . . . . . . . . . . . . . . . . . . . . . . 4º each side
• Pitch capability (up or down from horizontal) . . . . . . . . . . . . . . 6º up, 6º down
Folding Wing Capacity
• Per axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6800 kg (15 000 lb.)
• Per wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3400 kg ( 7500 lb.)
5. GENERAL DIMENSIONS AND WEIGHTS
A. DIMENSIONS
Refer to Figure 1.
• Overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8890 mm (350 in.)
• Overall width
- Operating configuration . . . . . . . . . . . . . . . . . . . . . 4318 mm (170 in.
- Transport configuration. . . . . . . . . . . . . . . . . . . . . . 2819 mm (111 in.)
• Overall height
- Operating configuration . . . . . . . . . . . . . . . . . . . . . 2489 mm (98 in.)
- Operating configuration (without work light) . . . . . . 2388 mm (94 in.)
- Transport configuration. . . . . . . . . . . . . . . . . . . . . . 2489 mm (98 in.)
- Transport configuration (without work light) . . . . . . 2388 mm (94 in.)
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CENTER OF GRAVITY
2896
(114)
1372 5359 787
(54) (211) (31)
8890
(350)
CENTER OF GRAVITY
2489
(98)
660
(26)
1245
(49)
2565
(101)
2819
(111)
NOTE: DIMENSIONS IN MILLIMETERS (INCHES) ARE APPROXIMATE ONLY AND

SUBJECT TO MANUFACTURING VARIANCES.
Figure 1
GENERAL DIMENSIONS
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SPECIFICATIONS
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Halvorsen
• Wheel base
- Front axle and rear bogy wheel . . . . . . . . . . . . . . . 6731 mm (265 in.)
- Front axle and forward bogy wheel . . . . . . . . . . . . 5359 mm (211 in.)
• Track width (centerline of wheels)
- Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2083 mm (82 in.)
- Forward bogy wheels . . . . . . . . . . . . . . . . . . . . . . . 2438 mm (96 in.)
- Rear bogy wheels. . . . . . . . . . . . . . . . . . . . . . . . . . 2438 mm (96 in.)
• Chassis ground clearance . . . . . . . . . . . . . . . . . . . . . . . 127 mm ( 5 in.)
• Turning diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.24 m (50 ft.)
• Turning radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.48 m (100 ft.)
NOTE: THE LOADER CAN MAKE A 3-POINT TURN ON A 15 M (50 FT.) WIDE TAXIWAY.
B. WEIGHTS AND VOLUME
TABLE 1 - WEIGHTS AND VOLUME
Description kg lb.
Shipping weight 14 220 31 350
Front axle weight 5307 11 700
Mid axle weight

4468 9850
(Forward bogy wheels)
Rear axle weight

4445 9800
(Rear bogy wheels)
Loading volume 60 m3 2120 cu.ft.
NOTE: THE SINGLE WHEEL LOAD IS 1588 kg (3500 lb.) ON THE CENTER OF THE DECK,
ON A TIRE TREAD FOOT PRINT NO SMALLER THAN 200 mm x 305 mm (8.25 in. x
12 in.). THE CENTER OF THE DECK IS 254 mm (10 in) LEFT OR RIGHT OF CENTER
AS MEASURED FROM THE CONVEY MODULE LINER.
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6. ENGINE
TABLE 2 - ENGINE SPECIFICATIONS AND OPERATING RPM
LOW IDLE
ENGINE MODEL* PEAK TORQUE** RATED POWER**
(NO LOAD)
Detroit Diesel VM Motori

R750 series, D756IE3 535 N·m (395 lbf-ft.) 121 kW (165 hp)
750 ± 50 rpm
4.5 L (272 cu.in.) @ 1350 rpm @ 3000 rpm
EPA Tier 3, EU Stage IIIA
* Engine is four-stroke turbocharged, direct injection, six cylinders in line, liquid cooling system.
**Approximate information data. Refer to specific placard on the engine and to the engine manual in
Chapter 5, MANUFACTURERS’ APPENDICES for additional information.
7. FUEL SPECIFICATIONS AND RECOMMENDATIONS
TABLE 3 - FUEL SPECIFICATIONS AND DESIGNATIONS
SULFUR % BY FUEL EPA

FUEL TYPE CONTENTS MASS DESIGNATION REQUIREMENT
Non-road Diesel fuel EPA Tier 2

< 500 ppm < 0.05% Low Sulfur Fuel
Highway Diesel fuel* EPA Tier 3
Non-road Diesel fuel** EPA Tier 3

≤ 5 ppm ≤ 0.0015% Ultra-Low Sulfur**
Highway Diesel fuel* EPA Tier 4
* EPA mandated for the U.S. that by October 2010 all on-road Diesel fuel must be 15 ppm Ultra-Low
Sulfur Diesel (ULSD) and off-road Diesel fuel must be 500 ppm. The exception was the State of
California that required all Diesel fuel to be 15 ppm ULSD since January 2007 and it applies to all
vehicles and equipment with no exceptions. EPA also required for all the U.S. that 2007 model year
and newer vehicles must use ULSD fuel, called also ‘Sulfur-free’ Diesel fuel.
**In 2004, EPA defined Tier 4 standards to be phased-in over 2008–2015, requiring substantial emission
reductions and more stringent limits through the use of control technologies.
CAUTION
WHEN USING DIESEL FUELS WITH SULFUR CONTENTS GREATER THAN 500 PPM (0.05% BY
MASS) AND THE ENGINE EQUIPPED WITH AN EXTERNALLY COOLED EGR (TIER 3 ENGINES),
LARGER FILTERS WITH TIGHTER MICRON FILTRATION MUST BE USED. CONSULT THE
ENGINE MANUFACTURER FOR MODIFICATIONS NEEDED.
CAUTION
DO NOT USE DIESEL FUELS WITH SULFUR CONTENTS GREATER THAN 15 PPM (0.0015% BY
MASS) IN EPA TIER 4 ENGINES.
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SPECIFICATIONS
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CAUTION
DO NOT USE JET A1 FUEL IN THIS VEHICLE. REFER TO ENGINE MANUFACTURER FOR
SPECIFIC RECOMMENDATIONS.
8. FUEL SYSTEM
A. FUEL TYPE
Refer to FUEL SPECIFICATIONS AND RECOMMENDATIONS and cautions above.
• Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASTM D975-07, No. 1-D and No. 2-D
• Turbine fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . JP-8 or Jet A-1 (only if fuel lubricity is
adequate; special filters required)
B. FUEL TANK CAPACITY

• Main tank fill capacity . . . . . . . . . . . . . . . . . . . . . 89.9 L (23.8 gal.)
• Cab heater fill capacity (D3). . . . . . . . . . . . . . . . 7.5 L ( 2.0 gal.)
• Cab fuel tank capacity (D4) . . . . . . . . . . . . . . . . 5.7 L ( 1.5 gal.)
C. FILTER TYPE
• Primary filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cartridge type, fuel and water
separator
• Secondary filter . . . . . . . . . . . . . . . . . . . . . . . . . Canister type
• Heated fuel and water separator . . . . . . . . . . . . Optional
NOTE: FUEL WAXING MAY OCCUR AT LOW TEMPERATURES, CLOGGING THE FUEL
SYSTEM AND REDUCING THE ENGINE EFFICIENCY. IF THE AMBIENT
TEMPERATURE IS LESS THAN 0 ºC (32 ºF), WINTER-GRADE FUEL (SUITABLE DOWN
TO -23 ºC [-10 ºF]) SHOULD BE USED. FOR TEMPERATURES BELOW -9 ºC (16 ºF)
REFER TO THE ENGINE OPERATION MANUAL IN CHAPTER 5.
NOTE: FOR OPERATION AT TEMPERATURES BELOW -23 ºC (-10 ºF), A FUEL FILTER
HEATER IS RECOMMENDED. REFER TO ENGINE MANUFACTURER’S MANUAL IN
CHAPTER 5 FOR FURTHER INFORMATION.
9. RADIATOR (COOLING)
• Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tube and fin (remote mounted)

• Fan, cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic (remote mounted)
10. WHEELS AND TIRES
• Front and rear axle wheels . . . . . . . . . . . . . . . . . . . . . . Three-piece modified, R15

381 mm (15 in.)
• Front and rear tires (standard) . . . . . . . . . . . . . . . . . . . 355/65 R15, radial tubeless
• Minimum load rating (each) . . . . . . . . . . . . . . . . . . . . . 8165 kg (18 000 lb.)
• Inflation air pressure (pneumatic tires only) . . . . . . . . . Refer to Chapter 2, Section 4,
“Maintenance Specifications”.
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11. BRAKES
• Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic
• Service brakes (all wheels) . . . . . . . . . . . . . . . . . . . . . Caliper disc type acting on front and
rear wheels, hydraulically powered,
mechanically applied with pedal.
• Parking brake (on front axle) . . . . . . . . . . . . . . . . . . . . Caliper brake, Spring-applied,
hydraulically released
• Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic oil from services system
• Front axle brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc on differential pinion shaft
(disk attached to drive flange)
- Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 mm (11.5 in.)
- Thickness, max. . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7 mm (0.50 in.)
- Thickness, min. . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13 mm (0.438 in.)
• Rear axle brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discs on all four (4) rear wheels
12. AXLES
A. FRONT AXLE
Drive and steering axle with differential lock.

• Differential gear ratio . . . . . . . . . . . . . . . . . . . . . 4.780:1
• Planetary wheel hub gear ratio . . . . . . . . . . . . . 3.103:1
• Total gear reduction of axle . . . . . . . . . . . . . . . . 14.83:1
• Steering angle . . . . . . . . . . . . . . . . . . . . . . . . . . 30º max.
• Differential lock . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic actuated
• Steering cylinders . . . . . . . . . . . . . . . . . . . . . . . Two (2)
B. REAR AXLE
Forward and rear bogy wheels, two (2) wheels on each side.
13. TRANSMISSION
• Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic, four (4) speed

• Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 SP
• Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four forward, neutral, reverse
TABLE 4 - TRANSMISSION RATIOS (MECHANICAL)
Gear First Second Third Fourth Reverse
Ratio 3.51:1 1.90:1 1.44:1 1.00:1 5.09:1
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• Auxiliary oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External spin-on
• Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote mounted
• Fluid temperature, normal operation, sump . . . . . . . . . 71 ºC to 93 ºC (160 ºF to 200 ºF)
• Max fluid temperature, sump . . . . . . . . . . . . . . . . . . . . 121 ºC (250 ºF)
14. HYDRAULIC SYSTEM
A. FLUID TYPE
NOTE: SPECIFICATIONS AND CHARACTERISTICS OF THE HYDRAULIC FLUID TO BE USED

WITH THE VEHICLE WILL DEPEND ON THE WEATHER OPERATING CONDITIONS.
This vehicle is shipped with a specified hydraulic fluid, but depending on weather operating
conditions it may be required to replace it with a fluid of the proper characteristics.
NOTE: FOR FLUID TYPES AND OIL OPERATING TEMPERATURE RANGES, REFER TO
HYDRAULIC OIL RECOMMENDATIONS IN CHAPTER 2, SECTION 4, “MAINTENANCE
SPECIFICATIONS”.
B. HYDRAULIC PUMP
• Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable displacement
C. EMERGENCY ELECTRIC PUMP
An electrical motor-driven hydraulic pump is provided for emergency operations (refer to

Chapter 1, Section 3, “Emergency Procedures”).
This pump must be manually activated by the operator when the vehicle is moving and the
braking or steering pressure drops. Also, it can be manually activated to return to zero position,
release parking brake or other emergency procedures.
D. FILTERS
• Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable, furnished with water

disposal element
• Pressure filter (optional) . . . . . . . . . . . . . . . . . . . Replaceable, 3-micron element
• Return filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable, in-tank return filter with
5-micron element
• Case drain filters . . . . . . . . . . . . . . . . . . . . . . . . Cartridge type, replaceable
E. HOSE ASSEMBLIES
Pressure Hoses
• Diameter 6.4–12.7 mm (0.25–0.50 in.) . . . . . . . SAE 100R2, SAE standard J517
• Diameter 19–31.8 mm (0.75–1.25 in.) . . . . . . . . SAE 100R12, SAE standard J517
Suction Hoses
• All diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 100R4, SAE standard J517
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F. OPERATING PRESSURES
NOTE: REFER TO CHAPTER 2, SECTION 4,.”MAINTENANCE SPECIFICATIONS” FOR

OPERATING PRESSURES.
15. ELECTRICAL SYSTEM
• Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 VDC
A. BATTERY
• Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two (2), 12 VDC

• Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance free
• Cold cranking capacity . . . . . . . . . . . . . . . . . . . 930 A @ -18 ºC (0 ºF)
• Cranking capacity . . . . . . . . . . . . . . . . . . . . . . . 1175 A @ 0 ºC (32 ºF)
• Reserve capacity. . . . . . . . . . . . . . . . . . . . . . . . 156 minutes
• Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.6 kg (58.7 lb.)
B. ALTERNATOR
• Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transistor regulator, negative ground

• Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 VDC
• Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 A
16. OTHER COMPONENTS
• Cab heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrically controlled, diesel oil fuel

• Air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . Hydraulically controlled compressor,
3 lb. 10 oz. Freon
17. PAINT SPECIFICATIONS
Color Gloss Standard Number NCP Part No.
Forest Green Semi-gloss FED-STD-595 24052 N-8891A / T-422R
Dessert Rose Semi-gloss FED-STD-595 23448 F92Y1030 / V93V28
Black Flat FED-STD-595 37038 G-4075A / T-422R
18. ADDITIONAL FEATURES AND EMERGENCY DEVICES
• Engine safety
• Emergency stop push-button switches
• Warning indicators
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19. VEHICLE JACKING REQUIREMENTS
A. JACK CAPACITY
• Minimum working capacity (each axle) . . . . . . . 10 800 kg (24 000 lb. [12 ton])
B. MAINTENANCE STANDS CAPACITY
• Minimum number of stands . . . . . . . . . . . . . . . . Four (2 front, 2 rear)

• Minimum working capacity (each) . . . . . . . . . . . 9070 kg (20 000 lb. [10 ton])
C. PRESSURE EXERTED BY VEHICLE
• Minimum at maintenance stands (unloaded) . . . 2070 kPa / 21 bar (300 psi)

• Maximum pressure exerted by vehicle. . . . . . . . 3860 kPa / 39 bar (560 psi)
D. JACK AND MAINTENANCE STANDS SUPPORT SURFACE
• Reinforced concrete surface (required) . . . . . . . 24 MPa (3500 psi) minimum
NOTE: SOME CONCRETE AND MOST ASPHALT SURFACES MAY NOT COMPLY WITH THE
MINIMUM RESISTANCE REQUIRED. INCREASING SUPPORT PAD AREA OF JACKS
AND MAINTENANCE STANDS CAN REDUCE THE STRESS ON THE GROUND
SUPPORT SURFACE.
NOTE: ENSURE THE SUPPORT SURFACE IS STRONG ENOUGH TO WITHSTAND THE

STRESS EXERTED BY THE VEHICLE WEIGHT, TRANSFERED THROUGH THE JACKS
AND MAINTENANCE STANDS.
20. ENVIRONMENTAL LIMITATIONS
A. OPERATING TEMPERATURES
TABLE 5 - AMBIENT OPERATING CONDITIONS
OPERATING AMBIENT TEMPERATURE

RECOMMENDATION
CONDITION* RANGE**
-29 ºC to +51 ºC
Normal Engine does not require assisted starts.
(-20 ºF to +123 ºF)
Requires vehicle to be pre-heated (engine

Extremely cold Below -29 ºC (-20 ºF)
block, oil pan and fuel filter).
Extremely hot Above 51 ºC (123 ºF) Refer to engine manual for requirements.
* Outside the normal operating temperature range, consider the use of an environment package
that corresponds to the extreme weather conditions in which the equipment will operate.
**Refer to Chapter 5, MANUFACTURERS’ APPENDICES for engine operating temperature
ranges and oil specifications and related information for other components. Contact JBT,
Ground Support Equipment for operating conditions in extreme weather.
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B. WINTERIZATION OPTION
The Halvorsen is designed with an engine that will start with no additional aids other than the
standard grid heater set down to -18 ºC (0 ºF). The winterization option includes battery heaters,
immersion engine block heater and hydraulic tank immersion heaters which maintain functionality
at a minimum of -40 ºC (-40 ºF).
Wiring harness connections are fitted with boot seals for harsh environments.
21. OPERATOR'S VIBRATION AND SOUND LEVELS
A. SOUND LEVEL EMISSION DATA
TABLE 6 - SOUND LEVEL EMISSION DATA
Test Locations and Conditions*
Driver’s Cab Exterior
Engine Standstill Driving Driving
R756IE3** Not available Not available Not available
* Tests performed without a hush kit installed. ** Halvorsen with Detroit engine not tested to CE
standards.
• Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EN 1915-4 and ISO 11201

• Driver or operator position. . . . . . . . . . . . . . . . . . . . . . . . Standing
• Sound power tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stationary, driving
• Test uncertainty (K = 1.6·R). . . . . . . . . . . . . . . . . . . . . . 4 dB
• Technical measures for noise reduction . . . . . . . . . . . . . Hush kit
• Possible ways to minimize noise exposure . . . . . . . . . . . Wear hearing protection
B. VIBRATION LEVEL DATA

• Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EN 1915-3
• Driver position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standing
• Vibration values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aWZF = 28.2 m/s2 (92.5 ft./s2)

• Coefficient of variation. . . . . . . . . . . . . . . . . . . . . . . . . . . CV  0.13
• Test uncertainty (K = 0.3 aWZ). . . . . . . . . . . . . . . . . . . . . 2.0 m/s2 (6.6 ft./s2)

• Technical measures for vibration reduction . . . . . . . . . . . Not applicable
• Possible ways to minimize vibration exposure . . . . . . . . Not applicable
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22. UNITS OF MEASUREMENT
Base and derived units of measurement used in this manual are in accordance to the International
System of Units (SI) of the International Bureau of Weights and Measures (BIPM).
TABLE 7 - METRIC AND STANDARD UNITS AND CONVERSIONS
Metric to Standard Standard to Metric
mm (millimeter) x 0.039 = in. x 25.4 = mm

in. (inch)
x 39.37 = in. x 0.0254 = m
m (meter) x 3.281 = ft. ft. (foot) x 0.3048 = m
x 1.094 = yd. yd. (yard) x 0.914 = m
km (kilometer) x 0.621 = mi. mi. (mile) x 1.609 = km
km/h (kilometers per
x 0.621 = mph mph (miles per hour) x 1.609 = km/h
hour)
m2 (square meter) x 10.764 = sq.ft. sq.ft. (square foot) x 0.093 = m2
m3 (cubic meter) x 35.315 = cu.ft. cu.ft. (cubic foot) x 0.028 = m3

x 61.024 = cu.in. cu.in. (cubic inch) x 0.0164 = L
x 0.264 = gal. gal. (gallon) x 3.785 = L
L (liter)
x 1.057 = qt. qt. (quart of a gallon) x 0.946 = L
x 0.035 = cu.ft. cu.ft. (cubic foot) x 28.317 = L
L/min. (liters per gpm (gallons per
x 0.264 = gpm x 3.785 = L/min.
minute) minute)
kg (kilogram) x 2.205 = lb. x 0.454 = kg
lb. (pound)
2204.6 = lb. x 0.00045 = t
t (tonne) (metric ton)
x 1.102 = tn tn (ton) (short) x 0.907 = t
bar (pressure) x 14.504 = psi psi (pounds per x 0.069 = bar
kPa (kilopascal) x 0.145 = psi square inch) x 6.895 = kPa
x 0.738 = lbf-ft. lbf-ft. (foot-pound) x 1.356 = N·m
N·m (Newton·meter)
x 8.851 = lbf-in. lbf-in. (inch-pound) x 0.113 = N·m
N (Newton) x 0.225 = lbf lbf (pound force) x 4.448 = N
kW (kilowatt) x 1.341 = hp hp (horse power) x 0.746 = kW
ºC (Celsius) x 1.8 + 32 = ºF ºF (Fahrenheit) - 32 / 1.8 = ºC
ºC (temperature ºF (temperature
x 1.8 = ºF (diff.) x 0.556 = ºC (diff.)
differential*) differential*)
* Temperature differential refers to the difference between two temperature points as opposed to a
specific temperature expressed in both ºC and ºF.
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1. GENERAL
This section contains general information on preparation of the vehicle for transportation. Check
regulations of the states and countries through which the vehicle will be transported for specific
requirements such as dimensional limitations, whether or not the vehicle can be transported with fuel,
fluids, etc.
Also, review Chapter 1, Section 6 for storage requirements and information on protection that may be
required if time enroute is expected to be more than a week.
NOTE: THE “EQUIPMENT PRE-OPERATIONAL CHECKLIST” SHOULD BE UTILIZED WHEN

COMMISSIONING NEW EQUIPMENT AND FOR RE-COMMISSIONING AFTER A
MAJOR REPAIR, OVERHAUL, RECOMMENDED ANNUAL MAINTENANCE, OVER-THE-
ROAD TRANSPORTATION AND IF THE MACHINE HAS BEEN OUT OF SERVICE FOR
MORE THAN SIX MONTHS.
NOTE: REFER TO THE “EQUIPMENT PRE-OPERATIONAL CHECKLIST” IN CHAPTER 2,

SECTION 3.
NOTE: REFER TO CHAPTER 1, SECTION 4, “SPECIFICATIONS” FOR WEIGHT, GENERAL

DIMENSIONS AND OTHER DETAILS BEFORE TRANSPORTING THE VEHICLE.
WARNING
BEFORE REMOVING OR INSTALLING VEHICLE COMPONENTS, ENSURE THE VEHICLE IS ON
LEVEL GROUND, WHEELS ARE SECURELY CHOCKED AND ELECTRICAL SYSTEM IS
SWITCHED OFF.
WARNING
WARNING
LIFT VEHICLE ONLY BY PROPER HOISTING POINTS AND IN ACCORDANCE WITH THE
DESCRIBED METHOD. DO NOT USE FORKLIFTS.
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SHIPPING AND TRANSPORTATION
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CAUTION
THE LOADER MUST ONLY BE DRIVEN IN AIR TRANSPORT MODE WHILE LOADING ON AND
OFF FROM SPECIFIED TRANSPORT VEHICLE OR FOR GROUND CLEARANCE, BUT NEVER
FOR MORE THAN 60 M (200 FT.).
CAUTION
STRUCTURAL DAMAGE WILL OCCUR, OTHERWISE.
NOTE: REPORT THIS ISSUE TO MAINTENANCE IMMEDIATELY.
CAUTION
USE OBSERVERS WHEN DRIVING THE LOADER ONTO THE TRANSPORT VEHICLE
(AIRCRAFT OR TRAILER) FOR SAFETY AND TO ENSURE THAT THERE IS ALWAYS
ADEQUATE CLEARANCE TO PREVENT DAMAGE TO THE TRANSPORT VEHICLE AND THE
LOADER.
2. SHIPPING DIMENSIONS
Refer to Chapter 1, Section 4, “Specifications” in for weight, general dimensions and other details before
transporting the vehicle. Also, refer to Figure 1.
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NOTE: DIMENSIONS IN INCHES ARE APPROXIMATE.
LOAD CAPACITY 25 000 LBS

Figure 1
OVERALL SHIPPING DIMENSIONS
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3. PREPARATION FOR TRANSPORTATION
A. PREPARE DECK FOR CAB RETRACTION
(1) Remove the retaining pin that connects the front cab side guide rail sections. Refer to
Figure 2.
(2) Invert the two roller trays adjacent to the hinged deck weldment so that the smooth side of
the roller tray is facing upwards. Refer to Figure 3.
(3) Position the hinged deck weldment in the shipping configuration.
(a) Unscrew the hinged deck weldment lock. Refer to Figure 2.
(b) Lift the hinged deck weldment and fold it onto the deck. Refer to Figure 3.
RETAINING PIN
HINGED DECK
WELDMENT LOCK
CAB RETAINING
PIN
Figure 2
RETAINING PIN AND HINGE DECK WELDMENT LOCK
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ROLLER TRAY HINGED DECK
WELDMENT
ROLLER TRAY
Figure 3
HINGED DECK WELDMENT AND ROLLER TRAY
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B. CAB AND WALK-DECK INTO SHIPPING CONFIGURATION
(1) Remove the cab retaining pin from the rear cab support beam. Refer to Figure 2.
(2) Push the cab towards the deck and into its shipping position. Refer to Figure 4.
(3) Install the cab retaining pin to retain the cab in the shipping position.
(4) Fold the rear view mirror against the cab door for clearance.
CAB SHIPPING
POSITION
REMOVE FOR FOLDING

C-130 WALKDECK/HAND
AIRCRAFT RAIL SECTION
FOLDING
WALKDECK/HAND
RAIL SECTION
Figure 4
CAB AND WALK-DECK SHIPPING CONFIGURATION
C. REMOVE THE LADDER AND STOW ON TOP OF THE DECK
(1) Remove the pin from the upper ladder support. Refer to Figure 5.
(2) Remove the pin from the lower ladder support. Refer to Figure 6.
(3) Remove and stow the ladder on top of the deck. Refer to Figure 7.
(4) Remove and stow the ladder support arm by removing the two retaining pins. Refer to
Figure 8.
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Figure 5
UPPER LADDER SUPPORT RETAINING PIN
Figure 6
LOWER LADDER SUPPORT RETAINING PIN
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Figure 7
LADDER STOWED ON DECK IN THE MIDDLE RIGHT SIDE
Figure 8
LADDER SUPPORT RETAINING PINS
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D. CONFIGURE THE FOLDING WALK-DECK AND HANDRAIL SECTIONS
This procedure allows the configuration of the folding walk-deck and handrail section into
shipping position.
(1) Remove the retaining pins on each of the folding walk-deck and handrail section on both
sides of the deck.
(2) Lift up and fold the walk-deck and handrail section on top of the deck. Refer to Figure 4.
(3) Install all of the retaining pins to secure the folding walk-deck and handrail sections during
shipment.
NOTE: WHEN SHIPPING THE HALVORSEN LOADER IN A C-130 AIRCRAFT, REMOVE THE
HANDRAIL AND THE WALK-DECK SECTION DIRECTLY BEHIND THE CAB AND STOW
THESE ITEMS ON THE DECK. THIS IS REQUIRED FOR THE OPERATOR TO EXIT THE
REAR CAB DOOR WHEN THERE IS INSUFFICIENT CLEARANCE TO OPEN THE SIDE
CAB DOOR ON A C-130 AIRCRAFT. REFER TO FIGURE 4.
WARNING
(4) Secure all loose items to the deck by using cargo straps on the cargo tie down rings on the
deck.
(5) Verify all top locks (34 places) are in the locked position.
CAUTION
IF THE DECK IS TO BE RAISED AND LOWERED WHILE THE CAB IS IN ITS RETRACTED
SHIPPING CONFIGURATION, ENSURE ADEQUATE CLEARANCE IS AVAILABLE BENEATH
THE CAB SO THE HYDRAULIC HOSES AND ELECTRICAL CABLES UNDER THE CAB ARE NOT
PINCHED BETWEEN THE DECK AND CHASSIS.
4. LOADING ONTO AIRCRAFT AND SURFACE TRANSPORT VEHICLES
A. SETTING INTO AIR TRANSPORT MODE
At the rear of the loader, rotate the air transport clevis counterclockwise and insert the air
transport pin to lock the deck and chassis frame together. Verify the following loader functions
before proceeding (ignition must be on). Refer to Figure 9.
(1) The AIR TRANSPORT indicator light (RED) on the dash panel should be flashing.
(2) The front and rear pallet stops should be inactive to the operator’s controls when their
associated toggle switches are in the “ON” position.
(3) All traction rollers lift and are inactive to the operator’s controls. Be sure all convey toggle
switches are in the “ON” position and the CONVEY MODE PALLET WIDTH toggle switch
is in the 108 or 88 position during this process.
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(4) The deck ROLL joystick is inactive to the operator’s controls.
(5) The engine speed (rpm) do not change when the LIFT joystick is in the UP position.
Immediately release the LIFT joystick if the engine speed changes during this process.
Structural damage to the deck and chassis frame will occur.
CLEVIS
PIN
Figure 9
AIR TRANSPORT CLEVIS AND PIN IN LATCHED POSITION
B. LOADING THE VEHICLE
NOTE: THE VEHICLE CAN BE LOADED IN EITHER DIRECTION. BACKING THE LOADER
ONTO THE TRANSPORT VEHICLE (AIRCRAFT OR TRAILER) IS THE PREFERRED
DIRECTION.
(1) While the deck is down and resting on the chassis frame, drive the loader to the transport
vehicle (aircraft or trailer) and align the loader with the ramp.
(2) While the loader is stationary and the park brake is engaged, move and hold the lift joystick
to the UP position until the red air transport indicator light stops flashing and becomes
constant. The chassis frame will have maximum ground clearance in air transport mode,
allowing the loader to pass over the ramp crest.
(3) Depress the brake pedal and move the park brake switch to the OFF position.
(4) Select the driving range “1” or “R” using the TRANSMISSION RANGE SELECTOR and
carefully drive the loader onto the transport vehicle.
(5) When the loader is fully onto the transport vehicle (aircraft or trailer) depress the brake
pedal, place the transmission in Neutral and move the park brake switch to the ON
position.
(6) Move the lift joystick to the DOWN position to lower the chassis frame onto the rear axle
assembly and shut down the engine.
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(7) Turn the BATTERY DISCONNECT switch on the battery box to the OFF position. Refer to
Figure 10.
(8) Restrain the loader from movement during air transport. Refer to the transport placard on
the cab side door for more information.
5. LOADING OFF FROM AIRCRAFT AND SURFACE TRANSPORT VEHICLES
A. PREPARE FOR UNLOADING
(1) Remove the tie down restraints from the loader.

(2) Turn the BATTERY DISCONNECT switch on the battery box to the ON position. Refer to
Figure 10.
(3) Verify the air transport clevis and pin is in the correct orientation for air transport
operations. Refer to Figure 9.
B. START THE ENGINE AND VERIFY
(1) The AIR TRANSPORT indicator light (RED) on the dash panel should be flashing.
(2) The front and rear pallet stops should be inactive to the operator’s controls when their
associated toggle switches are in the “ON” position.
(3) All traction rollers lift and are inactive to the operator’s controls. Be sure all convey toggle
switches are in the “ON” position and the CONVEY MODE PALLET WIDTH toggle switch
is in the 108 or 88 position during this process.
(4) The deck ROLL joystick is inactive to the operator’s controls.
(5) The engine RPM do not change when the LIFT joystick is in the UP position. Immediately
release the LIFT joystick if the engine RPM change during this process. Structural damage
to the deck and chassis frame will occur.
(6) Move and hold the lift joystick to the UP position until the red air transport indicator light
stops flashing and becomes constant. The chassis frame will have maximum ground
clearance in air transport mode allowing the loader to pass over the ramp crest.
(7) Depress the brake pedal and position the park brake switch to the OFF position.
(8) While the loader is stationary, move the differential lock switch to the ON position.
(9) Select the driving range “1” or “R” using the TRANSMISSION RANGE SELECTOR and
carefully drive the loader off of the transport vehicle.
(10) When the loader is clear of the transport vehicle, depress the brake pedal, place the
transmission in Neutral and move the park brake switch to the ON position.
(11) Move the lift joystick to the DOWN position to lower the chassis frame onto the rear axle
assembly.
(12) While the loader is stationary, position the differential lock switch to the OFF position.
(13) Remove the air transport pin and rotate the clevis clockwise. Insert the air transport pin
through the clevis and into the chassis frame. Refer to Figure 11.
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Figure 10
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PIN CLEVIS
Figure 11
AIR TRANSPORT PIN AND CLEVIS IN STOWING POSITION
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6. SLING LIFTING THE LOADER
WARNING
BRIDLES AND CHAINS MUST HAVE EQUAL LEG LENGTH OF A MINIMUM OF 3.60 M (12 FT.)
AND HAVE THE MINIMUM RECOMMENDED CAPACITY.
CAUTION
ENSURE THE CHAINS DO NOT CONTACT THE LEFT SIDE HEADLIGHT HOUSING.
A. PREPARATION
(1) Prepare the loader for “air and surface transport” as described previously.
(2) Lower the deck so it is resting on the chassis frame.
(3) Secure the rear axle assembly to the deck assembly on both sides of the loader.
(a) Route a heavy duty chain rated at 4500 kg (10 000 lb.) or greater, under the rear
axle shaft between the walking beam and helper cylinder.
(b) Secure the ends of the chain to the helper cylinder support casting. Refer to
Figure 12. The chains should be taut when installed.
Figure 12
HELPER CYLINDER SUPPORT CASTING
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B. SECURE THE FRONT OF THE CHASSIS TO THE DECK ASSEMBLY
(1) Route a heavy duty chain rated at 4500 kg (10 000 lb.) or greater, around the inner towing
eyes (2 places) on the chassis frame and through the front pallet stop housing. Refer to
Figure 13.
CHAIN ROUTING
INNER TOW EYES
Figure 13
CHASSIS TOWING EYE CHAIN ROUTING
(2) At the rear of the loader, rotate the air transport clevis counterclockwise and insert the air
transport pin to lock the deck and chassis frame together. Refer to Figure 9.
(3) Turn the BATTERY DISCONNECT switch on the battery box to the OFF position. Refer to
Figure 10.
(4) Attach the four (4) legged bridle or chains of equal length with a minimum of 3.60 m (12 ft.)
to the four (4) lifting provisions on top of the deck. Refer to Figure 14.
NOTE: REMOVE ANY HANDRAILS THAT INTERFERE WITH THE BRIDLE OR CHAINS.
SECURE HANDRAIL(S) TO THE DECK.
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LIFT POINTS
4 PLACES
Figure 14
LIFTING PROVISION LOCATIONS
(5) Attach the bridle or chains to the lifting equipment.
NOTE: LIFTING EQUIPMENT MUST HAVE A MINIMUM LIFTING CAPACITY OF 18 050 kg

(40 000 lb. / 20 tons).
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7.
FRONT AXLE REAR CHASSIS
TIE DOWN TIE DOWN
25 000 LB. 25 000 LB.
REAR CHASSIS
FRONT CHASSIS TIE DOWN
TIE DOWNS 25 000 LB.
25 000 LB.
TIE-DOWN POINTS
FRONT CHASSIS
TIE DOWNS REAR CHASSIS
25 000 LB. TIE DOWN
25 000 LB.
FRONT AXLE
TIE DOWN
25 000 LB. REAR CHASSIS

TIE DOWN
25 000 LB.
TIE DOWN STRAPS SHOWN
FOR TIE DOWN CONFIGURATION
CHASSIS BOTTOM VIEW - LOOKING UP
Figure 15
DECK TIE DOWN
25 000 LB.
DECK TIE DOWN
25 000 LB.
TRANSPORT TIE-DOWN POINTS

DECK TIE DOWN DECK TIE DOWN
25 000 LB. 25 000 LB.
DECK BOTTOM VIEW - LOOKING UP

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8. PREPARE THE LOADER FOR SERVICE
A. CONFIGURE FOLDING WALK-DECK AND HANDRAIL SECTIONS
This procedure lists the steps to configure the walk-deck into operation mode.
(1) Remove the retaining pins on each of the folding walk-deck and handrail section on both
sides of the deck.
(2) Fold the walk-deck and handrail sections so the walk-deck is horizontal.
(3) Install all of the retaining pins to secure the folding walk-deck and handrail sections during
shipment.
B. INSTALL THE LADDER FOR OPERATOR ACCESS TO THE CAB
(1) Install the ladder support arm by installing the two retaining pins. Refer to Figure 8.
(2) Install the lower ladder support and retaining pin. Refer to Figure 6.
(3) Install the upper ladder support and retaining pin. Refer to Figure 5.
C. CONFIGURE THE CAB INTO OPERATIONAL MODE
(1) Remove the cab retaining pin from the rear cab support beam. Refer to Figure 2.
(2) Pull the cab outwards and into its operation position. Refer to Figure 3.
(3) Install the cab retaining pin to retain the cab in the operation position.
(4) Pull the rear view mirror outwards.
(5) Position the hinged deck weldment in an operational configuration.
(6) Lift the hinged deck weldment and fold it into the operational position. Refer to Figure 3.
(7) Lock the hinged deck weldment by tightening the lock. Refer to Figure 2.
(8) Invert the roller tray adjacent to the hinged deck weldment so that the rollers are facing
upwards. Refer to Figure 3.
(9) Install the retaining pin that connects the front cab side guide rail sections. Refer to
Figure 2. Retaining pin and hinge deck weldment lock.
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Section 6. Storage
1. GENERAL
It is very important to properly prepare a vehicle that will be de-commissioned or removed from service
for a period of time. The main purpose of a proper preparation before storage is to avoid, or at least
minimize, potential damage due to moisture, rust and corrosion and possible component seizing.
In addition, a proper preparation of the vehicle previous to storage, as well as periodic verification during
storage, will allow to readily place the vehicle back into service with minimum effort and without major
problems.

NOTE: REFER TO THE “EQUIPMENT PRE-OPERATIONAL CHECKLIST” IN CHAPTER 2,

SECTION 3.
NOTE: MAINTENANCE SPECIFICATIONS ARE CONTAINED IN CHAPTER 2, SECTION 4.
CAUTION

2. STORAGE - ONE MONTH (MAXIMUM)
A. VEHICLE
No special action needed.
B. ENGINE
(1) Drain the engine crankcase.
(2) Fill the crankcase to the proper level with the recommended viscosity and grade oil.
(3) Fill the fuel tank with the recommended grade of fuel oil. Operate the engine for two
minutes or until the engine is warm, at 1200 rpm at no load.
(4) Check the air cleaner and service it if necessary.
(5) If freezing weather is expected during the storage period, add an ethylene-glycol based
antifreeze solution in accordance with the manufacturer’s recommendations.
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(6) Clean the outside of the engine (except the electrical system) with fuel oil. Dry it with
compressed air.
(7) Seal all of the engine openings. The material used for this purpose must be waterproof,
vapor proof and possess sufficient physical strength to resist puncture or damage from the
expansion of entrapped air.
C. BATTERIES
Disconnect and remove the two 12 VDC batteries and store them in a cool and dry location.
D. TRANSMISSION
E. AXLES
F. WHEELS AND TIRES
Chock drive wheels front and rear to prevent movement in any direction.
G. HYDRAULIC SYSTEM
Minimize exposed cylinder rods by lowering deck fully, retracting powered operator’s cab and
ensuring other cylinders are retracted.
H. GENERAL COMPONENTS
Coat all exposed unpainted metal surfaces with rust preventative. Especially important are
exposed hydraulic cylinder rods, roller chains and sprockets.
3. STORAGE - INDEFINITE PERIOD
A. VEHICLE
(1) Touch up all worn or damaged paint to prevent rust.
(2) Ensure that all points are lubricated with specified grease, oil, etc.
(3) Attach a tag to the steering wheel stating: “CAUTION: ALL LUBRICANTS HAVE BEEN
DRAINED FROM THIS VEHICLE”.
(4) Once all recommended steps are performed, refer to “EQUIPMENT SHELTER” below in
this section for recommended protection of the equipment.
B. ENGINE
(1) Drain the cooling system and flush with clean, soft water. Refill with clean, soft water and
add a rust inhibitor to the cooling system.
(2) Remove, check and recondition the injectors, if necessary, to make sure they will be ready
to operate when the engine is restored to service.
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(3) Reinstall the injectors, time them and adjust the exhaust valve clearance.
(4) Circulate the coolant by operating the engine until normal operating temperature is
reached.
(5) Turn off the engine.
(6) Drain the engine crankcase, then reinstall and tighten the drain plug. Install new lubricating
oil, filter elements and gaskets.
(7) Fill the crankcase to the proper level with a 30-weight preservative lubricating oil.
(8) Drain the fuel tank. Refill with enough clean, No. 1 diesel fuel (or pure kerosene) to permit
the engine to operate for about ten minutes. If it isn’t convenient to drain the fuel tank, use
a separate approved container to supply the recommended fuel.
(9) Drain and disassemble the fuel filter and strainer. Discard the used elements and gaskets.
Wash the shells in clean, No. 1 diesel fuel (or pure kerosene) and insert new elements.
(10) Fill the cavity between the element and shell with No. 1 diesel fuel (or pure kerosene) and
reinstall on the engine. If spin-on fuel filters and strainers are used, discard the used
cartridges, fill the new ones with No. 1 diesel fuel (or pure kerosene) and install on the
engine.
(11) Operate the engine for five minutes to circulate the clean fuel oil throughout the fuel
system.
(12) Service the air cleaner.
(13) Apply a non-friction, rust preventative compound to all exposed parts.
(14) Drain the engine cooling system.
(15) Drain the preservative oil from the engine crankcase. Reinstall and tighten the drain plug.
(16) Remove and clean batteries and battery cables with a baking soda solution and rinse them
with fresh water. Do not allow the soda solution to enter the batteries.
(17) Apply belt dressing to pulleys and belts to prevent sticking.
(18) Seal all openings in the engine, including the exhaust outlet, with moisture-resistant tape.
Use cardboard, plywood or metal covers where practical.
(19) Clean and dry the exterior, painted surfaces of the engine and spray with a suitable liquid
automotive body wax, a synthetic resin varnish or a rust preventative compound.
NOTE: REFER TO CHAPTER 5, MANUFACTURERS’ APPENDICES FOR ADDITIONAL

INFORMATION ON ENGINE MAINTENANCE AND PRESERVATION.
(20) Protect the engine with a good, weather-resistant tarpaulin and store it under cover,
preferably in a dry building which can be heated during the winter months.
(21) The stored engine should be inspected periodically. If there are any indications of rust or
corrosion, corrective steps must be taken to prevent damage to the engine parts. Perform
a complete inspection at the end of one year and apply additional treatment as required.
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C. BATTERIES
(1) After batteries have been removed from the vehicle, add distilled water to the electrolyte if
necessary and applicable. Fully charge them.
(2) Store the batteries in a cool dry place, between 0 ºC (32 ºF) and 32 ºC (90 ºF), not exposed
to direct sunlight.
(3) Keep batteries fully charged or give them a slow charge every one to two months.
(4) Check the level and the specific gravity of the electrolyte regularly.
(5) Batteries must be covered for protection against dirt and moisture.
D. TRANSMISSION
Refer to recommendations for transmissions on Manufacturers’ Data.
E. AXLES
F. WHEELS AND TIRES
The vehicle should be raised and chassis blocked so that all wheels are off ground. Tires should
be sprayed with a rubber preservative.
G. HYDRAULIC SYSTEM
CAUTION
(1) Minimize exposed cylinder rods by fully lowering deck, retracting powered operator’s cab
and ensuring other cylinders are retracted.
(2) Seal all openings with moisture-proof covers or tape.
(3) Periodically inspect the hydraulic system. If there are any indications of rust or corrosion,
corrective steps must be taken to prevent damage to the hydraulic components.
H. GENERAL COMPONENTS
Coat all exposed unpainted metal surfaces with rust preventative. Especially important are
exposed hydraulic cylinder rods, roller chains and sprockets.
I. EQUIPMENT SHELTER
Ideally, the vehicle should be stored in a shelter to protect it from the weather, since outdoor
storage of engines and transmissions is not recommended. Nevertheless, in some cases,
outdoor storage may be unavoidable. If the vehicle must be kept outdoors, follow all preparation
and storage instructions.
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(1) Protect the engine with a good, weather-resistant tarpaulin and store it under cover,
preferably in a dry building which can be heated during the winter months.
(2) Protect the vehicle with quality, weather-resistant tarpaulins (or other suitable covers)
ensuring proper air circulation.
CAUTION
DO NOT USE PLASTIC SHEETING FOR STORAGE. PLASTIC SHEETING USED FOR STORAGE
WILL CREATE CONDENSATION WHICH MAY CAUSE METAL SURFACES TO RUST OR PIT.
(3) If shelter is not available, cover deck and cab with tarpaulins or other protective material.
Cover and tape instrument panels to provide a moisture-proof seal.
(4) The stored vehicle should be inspected periodically. If there are any indications of rust or
corrosion, corrective steps must be taken to prevent further damage. Perform a complete
inspection at the end of one year and apply additional treatment as required.
4. RETURNING VEHICLE TO SERVICE
WARNING
PERFORM THE RE-COMMISSIONING MAINTENANCE PROCEDURES BEFORE RETURNING
THE VEHICLE INTO SERVICE AFTER STORAGE.
A. RE-COMMISSIONING AFTER A SHORT PERIOD OF STORAGE
When returning the equipment to service after a short time period, several items should be act
upon, as follows:
(1) Perform a general inspection of the vehicle in accordance to recommendations (refer to the
“EQUIPMENT PRE-OPERATIONAL CHECKLIST” in Chapter 2, Section 3).
(2) Replenish or replace all fluids, including oil, fuel and coolant, according to maintenance
and lubrication recommendations and guidelines. Refer to Chapter 2, Section 3,
“Preventative Maintenance”.
(3) Inspect tires for damage, cracks and dry rot. Inflate to specifications and remove chocks.
(4) As a minimum, perform the recommended daily and quarterly maintenance according to
maintenance schedules in Chapter 2, Section 3.
B. RE-COMMISSIONING AFTER AN EXTENDED PERIOD OF INACTIVITY
It is very important to properly prepare the vehicle, before placing it into service after an extended
storage period. An exhaustive inspection and a comprehensive maintenance should be
performed on the equipment to ensure proper operation and minimize breakdown and downtime.
(1) Perform a general inspection of the vehicle in accordance to recommendations (refer to the
“EQUIPMENT PRE-OPERATIONAL CHECKLIST” in Chapter 2, Section 3).
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(2) Replenish or replace all fluids, including oil, fuel and coolant, according to maintenance
and lubrication recommendations and guidelines (refer to Chapter 2, Section 3,
“Preventative Maintenance” and Chapter 5, MANUFACTURERS’ APPENDICES).
(3) Inspect tires for damage, cracks and dry rot. Inflate to specifications and remove vehicle
from raising blocks.
(4) Before placing the vehicle into operation, fully recharge the batteries before installing them
back in the vehicle.
(5) Perform ALL the recommended maintenance (daily, quarterly and annually) according to
maintenance schedules in Chapter 2, Section 3.
5. STORAGE
A. SHORT-TERM STORAGE - ONE MONTH MAXIMUM
(1) Whenever possible, the loader should be stored indoors to protect it from the weather.
(2) Perform all periodic maintenance services that are due as stated in Chapter 2, Section 3,
“Preventative Maintenance”.
(3) Chock drive wheels, front and rear, to prevent movement in either direction.
(4) Disconnect and remove the batteries and store in a cool, dry location.
(5) Coat all exposed, unpainted metal surfaces with rust preventative including all exposed
hydraulic cylinder rods and roller chains.
(6) Seal the exhaust pipe outlet with adhesive tape to prevent moisture intrusion.
(7) When the loader is stored exposed to the elements, cover the operator’s cab with a
waterproof tarpaulin to protect the cab electrical components, cab windows and windshield
wiper blades.
B. LONG-TERM STORAGE - THREE YEARS MAXIMUM
(1) When the loader is to be stored or remain inactive for an extended period (1 year or
longer), specific preservation methods are recommended to prevent damage due to rust,
corrosion and organic growth in the oils. Use a waterproof, protective material to cover the
entire loader. Place Vapor Corrosion Inhibitor (VCI) pads inside protective material before
sealing. Whenever possible, the loader should be stored indoors to protect it from the
weather.
NOTE: REFER TO THE MANUFACTURER’S MANUALS (CHAPTER 5) PERTAINING TO THE

TRANSMISSION AND ENGINE FOR DETAILED METHODS FOR PRESERVATION
WHEN THE LOADER IS TO BE STORED OR REMAIN INACTIVE, FOR AN EXTENDED
PERIOD.
(2) Perform all periodic maintenance services that are due as prescribed in Chapter 2,
MAINTENANCE, before placing loader into storage. It is recommended that no
preservatives be added to the engine oil, transmission fluid, hydraulic fluid or engine
coolant for long term storage.
(3) If the loader is equipped with air conditioning, the system should be evacuated prior to
storage.
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(4) Fill fuel tank to three quarts (¾) full with non bio-diesel fuel. Coat the chain on the filler tank
cap with approved preservation product(s). Cover filler cap with weatherproof tape.
(5) Degrease and wash entire loader. Pay specific attention to areas where rust prevention is
an issue. Let the loader completely dry before coating exposed metal surfaces and
unpainted areas using approved storage preparation methods and preservation products.
(6) Locate a level surface with adequate drainage for loader storage.
(7) Place waterproof, protective material across area for loader storage. Drive loader over
protective material.
(8) Raise the chassis with jacks and place shoring under the chassis frame to remove all
weight from the front and rear tires. Follow the corresponding procedures for CHANGING
WHEELS ON REAR AXLE in Chapter 2, Section 5, “Maintenance Procedures” for the
proper procedures on raising the loader and securing the bogy axle pivot shaft to the
chassis.
(9) Disconnect the batteries from the loader and connect an approved solar cell
trickle-charger. Secure the solar cell trickle-charger to the outside of the protective material
so as to provide maximum exposure to sunlight.
(10) Verify that all electrical boxes are clean and dry with no moisture or signs of additional rust.
Electrical boxes should contain VCI pads inside along with VCI emitters.
(11) Coat all exposed, unpainted metal surfaces with rust preventative, including all exposed
hydraulic cylinder rods, hose fittings, manifolds and roller chains on the deck, chassis and
inside the operator’s cab.
(12) Leave the cab windows and back door open when the loader is wrapped in protective
material. This will eliminate mold and galvanic rust and corrosion inside the cab by
allowing the VCI vapors to circulate inside the protective material.
(13) Seal the exhaust pipe outlet with adhesive tape to prevent moisture intrusion.
(14) Remove windshield wiper blade and arm assemblies, wrap in protective material and stow
in the operator’s cab.
(15) Use waterproof tape when prepping loader for long term storage bagging. Verify loader
disconnect switch, located on the battery box, is on the OFF position. Wrap loader in
protective material and secure the solar cell trickle-charger to the outside of the protective
material.
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TABLE OF CONTENTS
CHAPTER 2. MAINTENANCE AND REPAIR
Section 1. Safety Precautions
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. PREPARING THE UNIT FOR MAINTENANCE (LOCK-OUT AND TAG-OUT) . . . . . . . . . . . . . . . . 2
A. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. LOCK-OUT AND TAG-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. UNLOCKING AND REMOVAL OF TAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. MAINTENANCE STANDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A. MAINTENANCE STANDS INSTALLATION AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section 2. System Overview
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. POWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
D. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
E. DRIVE AND STEER FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F. REAR AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. SOLENOID VALVES, MANIFOLDS AND SWITCH LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A. SOLENOID VALVE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table 1 - SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
B. HYDRAULIC MANIFOLD LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
C. LIMIT SWITCH LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Section 3. Preventative Maintenance
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. BEFORE COMMISSIONING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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3. EQUIPMENT PRE-OPERATIONAL CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table 1 - EQUIPMENT PRE-OPERATIONAL CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. BREAK-IN PERIOD AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A. BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. BREAK-IN MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 2 - MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table 3 - AIR CONDITIONER MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . 12
6. MAINTENANCE AND FLUID KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7. HYDRAULIC OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8. OPERATIONAL CHECKS SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table 4 - OPERATIONAL CHECKS SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A. GREASE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Table 5 - GREASE POINTS - CHASSIS AND SCISSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Table 6 - FRONT AXLE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Table 7 - GREASE POINTS - DRIVE AND STEER AXLE AND DRIVE SHAFT . . . . . . . . . . . 20
B. LIMITER PIN LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
C. CHAINS LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
D. FILL POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Section 4. Maintenance Specifications
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. HYDRAULIC OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 1 - OIL OPERATING TEMPERATURE RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. OPERATING TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. FLUIDS CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. RECOMMENDED FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table 2 - ENGINE OIL, TRANSMISSION FLUID AND COOLANT . . . . . . . . . . . . . . . . . . . . . 3
Table 3 - ENGINE FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table 4 - BIODIESEL ENGINE FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table 5 - HEATER FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table 6 - HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 7 - LUBRICATING GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 8 - ELECTRICAL GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 9 - AIR CONDITIONER LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 10 - AIR CONDITIONING SYSTEM REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 11 - 1000-HOUR (ANNUAL) FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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6. EQUIPMENT ADJUSTMENT SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 12 - ADJUSTMENT SETTINGS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 13 - FRONT AXLE TORQUE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 14 - BRACE ASSEMBLY TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 6
7. HYDRAULIC PRESSURE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8. PERFORMANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table 15 - ENGINE SPECIFICATIONS AND OPERATING RPM . . . . . . . . . . . . . . . . . . . . . 7
9. BOLT IDENTIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 16 - STANDARD AND METRIC STEEL BOLTS AND NUTS . . . . . . . . . . . . . . . . . . . . 8
10. BOLT TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table 17 - STANDARD STEEL BOLTS TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . 9
Table 18 - METRIC STEEL BOLTS TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . 10
Table 19 - 18-8 AND 316 STAINLESS STEEL BOLTS TORQUE SPECIFICATIONS . . . . . . 10
Section 5. Maintenance Procedures
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. SPROCKETS AND ROLLER CHAINS INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 2
A. SPROCKETS INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. ROLLER CHAINS INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. ROLLER CHAINS ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. CONVEY MODULE CHAINS ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. FRONT AXLE REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. DRIVE AND STEER FRONT AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. DRIVE AND STEER FRONT AXLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. MAIN LIFT CYLINDERS REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A. MAIN LIFT CYLINDERS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
B. MAIN LIFT CYLINDERS INSTALLATION AND BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5. HELPER CYLINDERS REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A. HELPER CYLINDERS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
B. HELPER CYLINDERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
C. HELPER CYLINDERS BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6. SCISSORS LOWER ROLLERS REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 15
A. REMOVE LOWER ROLLERS ON INNER SCISSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
B. INSTALL LOWER ROLLER ON INNER SCISSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7. BRAKES ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
A. PARK BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
B. PARKING BRAKE FORWARD MOVEMENT FUNCTION CHECK. . . . . . . . . . . . . . . . . . . . . 18
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C. PARKING BRAKE REVERSE MOVEMENT FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . 18
D. FRONT SERVICE BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
E. FRONT SERVICE BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8. ENGINE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
A. ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
B. ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9. TRANSMISSION REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
A. TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
B. TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
10. FORWARD DECK SHIFT AND ROLL CYLINDERS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 24
A. LOADER DECK PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
B. CENTER AND LEVEL THE DECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
C. REMOVE MISCELLANEOUS ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
D. DISCONNECT THE ROLL CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
E. SECURE LIFTING PROVISIONS TO THE DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
F. REMOVE UPPER FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
G. DISCONNECT ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
H. DISCONNECT THE SIDE SHIFT CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . 29
I. REMOVE THE FRONT SIDE SHIFT BOGY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11. FORWARD DECK SHIFT AND ROLL CYLINDERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 31
A. INSTALL THE FRONT SIDE SHIFT BOGY ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
B. CONNECT THE SIDE SHIFT CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
C. CONNECT THE ROLL CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
D. CONNECT ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
E. INSTALL UPPER FASTENERS TO SECURE ROLL CYLINDERS . . . . . . . . . . . . . . . . . . . . . 34
F. INSTALL MISCELLANEOUS ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12. REAR DECK SHIFT AND ROLL CYLINDERS REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
A. CENTER AND LEVEL THE DECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
B. DISCONNECT THE REAR ROLL CYLINDER HYDRAULICS. . . . . . . . . . . . . . . . . . . . . . . . . 35
C. DISCONNECT THE SIDE SHIFT CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . 36
D. REMOVE REAR SCISSOR ROLLER TRACKS FROM THE DECK . . . . . . . . . . . . . . . . . . . . 38
13. REAR DECK SHIFT AND ROLL CYLINDERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
A. INSTALL REAR SIDE SHIFT BOGY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
B. CONNECT THE SIDE SHIFT CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
C. CONNECT THE ROLL CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
D. INSTALL REAR SCISSOR ROLLER TRACKS ON THE DECK . . . . . . . . . . . . . . . . . . . . . . . 40
14. REPLACE FAN BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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15. HYDRAULIC PUMP REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
A. HYDRAULIC PUMP REMOVAL FROM CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
B. HYDRAULIC PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
16. CHANGING WHEELS ON FRONT AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
A. FRONT AXLE WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
B. FRONT AXLE WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
17. CHANGING WHEELS ON REAR AXLE (BOGY WHEELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
A. REAR AXLE WHEEL REMOVAL (BOGY WHEELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
B. REAR AXLE WHEEL INSTALLATION (BOGY WHEELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
18. HYDRAULIC FLUID LEVEL AND REFILLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
A. CHECKING FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
B. REFILLING HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
19. BATTERY MAINTENANCE CHARGING AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
A. BATTERIES CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
B. CHARGER OUTPUT VOLTAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
C. CHARGER TYPE - AUTOMATIC OR MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
D. SELECTING BATTERY TYPE ON YOUR CHARGER OUTPUT . . . . . . . . . . . . . . . . . . . . . . 52
E. BATTERIES STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
20. BATTERY REMOVAL AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
A. REMOVE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
B. INSTALL BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
21. RADIATOR REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
A. RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
B. RADIATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
22. COOLANT SYSTEM LEVEL AND REFILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
A. COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
B. REFILL AND BLEED AIR FROM COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
C. COLD WEATHER OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
23. AIR CONDITIONER INSPECTION AND MAINTENANCE (WITHOUT GAUGES) . . . . . . . . . . . . . 58
A. CONSIDERATIONS BEFORE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
B. COMPONENTS INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
24. AIR CONDITIONING COMPONENT REPAIR OR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 59
A. HOSES AND FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
B. AIR CONDITIONING LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
C. AIR CONDITIONING EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
D. RECEIVER-DRYER AND ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
E. COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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25. LEFT SIDE SKYLIGHT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
A. LEFT SIDE SKYLIGHT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
B. LEFT SIDE SKYLIGHT CLEANING AND PREPARATION FOR INSTALLATION. . . . . . . . . . 62
C. APPLY CAB PRIMER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
D. PREPARE LEFT SKYLIGHT GLASS FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 64
E. APPLY GLASS PRIMER TO LEFT SKYLIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
F. LEFT SIDE SKYLIGHT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Table 1 - SEALANT DRYING TIMES (HOURS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
26. TOP SKYLIGHT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
A. TOP SKYLIGHT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
B. TOP SKYLIGHT CLEANING AND PREPARATION FOR INSTALLATION . . . . . . . . . . . . . . . 71
C. APPLY PRIMER TO TOP SKYLIGHT PINCHWELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
D. PREPARE TOP SKYLIGHT GLASS FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
E. APPLY GLASS PRIMER TO TOP SKYLIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
F. TOP SKYLIGHT GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Table 2 - SEALANT DRYING TIMES (HOURS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
27. HYDRAULIC SYSTEM ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
28. CHASSIS MANIFOLD ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
A. LOAD SENSE MARGIN PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
B. MAIN RELIEF VALVE AND PUMP COMPENSATOR PRESSURE . . . . . . . . . . . . . . . . . . . . 79
C. HELPER CYLINDER PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
D. PARK BRAKE RELEASE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
E. SECONDARY SERVICE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
F. THROTTLE PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
29. INNER AND OUTER SCISSORS MANIFOLD ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
A. SHIFT LEFT SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
B. SHIFT RIGHT SPEED ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
30. REAR PITCH MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
A. REAR PITCH CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
B. REAR PITCH SPEED, PITCH DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
C. REAR PITCH SPEED, PITCH UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
31. PALLET STOPS AND CONVEY LIFT MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
A. PALLET STOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
B. TRACTION ROLLER LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
32. CONVEY MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
33. ENGINE COOLANT FAN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
A. FAN MOTOR PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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34. PROXIMITY SWITCH ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
A. PROXIMITY SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
B. PROXIMITY SWITCH LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
35. ELECTRICAL SYSTEM ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
A. POTENTIOMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
B. LIMIT SWITCH ARM ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
C. DECK FULLY DOWN (2LS) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
D. FRONT OF DECK FULLY DOWN (4LS) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
E. REAR OF DECK FULLY DOWN (5LS) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
F. DECK ROLL RIGHT (14LS) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
G. DECK ROLL LEFT (15LS) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
H. DECK SHIFTED LEFT (17LS) AND DECK SHIFTED RIGHT (18LS) ADJUSTMENT . . . . . . 104
I. AIR TRANSPORT PIN (16LS) AND CLEVIS (16LS-A) ADJUSTMENTS . . . . . . . . . . . . . . . . 105
J. AIR TRANSPORT MODE (3LS-A) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
K. RPM ADJUSTMENT (TRANSMISSION ACCESSORY BOX) . . . . . . . . . . . . . . . . . . . . . . . . 108
L. PITCH UP AND DOWN (4PRS AND 5PRS) ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 111
Section 6. Troubleshooting
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. BEFORE TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. HYDRAULIC SYSTEM CLEANLINESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. PRESSURE READINGS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. MALFUNCTIONS ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. TROUBLESHOOTING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. DIAGNOSTIC TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. COMPONENTS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D. SENSORS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. TROUBLESHOOTING GUIDE TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table 1 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 2 - TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 3 - HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table 4 - ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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6. D3 AND D4 HEATER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
A. BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Table 5 - D3 AND D4 HEATER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
B. SELF DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
C. HEATER FAULT CODES, CAUSES AND ACTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Table 6 - D3 AND D4 HEATER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Section 7. System Schematics
1. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. HYDRAULIC SYSTEM CLEANLINESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL SCHEMATIC - 2100SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521-3504
INTERCONNECT DIAGRAM - 2100SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-3491-001
SP2100 HE WIRE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-9070
Table 1 - WIRE HARNESS - SP2100 - 625-9070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3. HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
HYDRAULIC SYSTEM SCHEMATIC - 2100SP. . . . . . . . . . . . . . . . . . . . . . . 623-5420-001
Table 2 - HYDRAULIC SYSTEM COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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LIST OF FIGURES
2-1 Figure 1 ENERGY SOURCES AND DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2-1 Figure 2 MAINTENANCE STANDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2 Figure 1 VEHICLE CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2-2 Figure 2 VEHICLE CHASSIS COMPONENTS - TOP VIEW. . . . . . . . . . . . . . . . . . . . . . . . 3
2-2 Figure 3 POWER UNIT COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-2 Figure 4 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2 Figure 5 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-2 Figure 6 DRIVE AND STEER FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-2 Figure 7 REAR AXLE ASSEMBLY - BOGY WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-2 Figure 8 REAR AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-2 Figure 9 HYDRAULIC MANIFOLD LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-2 Figure 10 LIMIT SWITCH LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-3 Figure 1 ENGINE OIL AND COOLANT FILL POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2-3 Figure 2 HYDRAULIC RETURN FILTER GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3 Figure 3 ENGINE OIL, COOLANT AND TRANSMISSION FLUID FILL POINTS . . . . . . . . 11
2-3 Figure 4 HELPER CYLINDER BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-3 Figure 5 GREASE POINTS - CHASSIS AND SCISSORS . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-3 Figure 6 GREASE POINTS - HELPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-3 Figure 7 GREASE POINTS - FRONT SIDE SHIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . 15
2-3 Figure 8 GREASE POINTS - REAR SIDE SHIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . 16
2-3 Figure 9 GREASE FITTINGS - IMPACT ROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-3 Figure 10 GREASE POINTS - DRIVE AND STEER AXLE AND DRIVE SHAFT . . . . . . . . . 18
2-3 Figure 11 DRIVE AND STEER AXLE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . 19
2-3 Figure 12 CHAINS LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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2-3 Figure 13 ENGINE OIL AND COOLANT FILL POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2-3 Figure 14 FILL POINT - HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2-3 Figure 15 FILL POINT - PLANETARY GEAR WHEEL END . . . . . . . . . . . . . . . . . . . . . . . . . 24
2-5 Figure 1 CONVEY MODULE CHAIN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2-5 Figure 2 WITNESS MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-5 Figure 3 DRIVE SHAFT ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-5 Figure 4 HELPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-5 Figure 5 MAIN PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-5 Figure 6 HELPER CYLINDER BLEEDER SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-5 Figure 7 LOWER ROLLER ON INNER SCISSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-5 Figure 8 PARK BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2-5 Figure 9 LOADER DECK PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2-5 Figure 10 DECK BUMPER LIMIT SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2-5 Figure 11 ROLL CYLINDER HYDRAULICS AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . 27
2-5 Figure 12 REAR VIEW OF FRONT SIDE SHIFT BOGY ASSEMBLY . . . . . . . . . . . . . . . . . . 29
2-5 Figure 13 SIDE SHIFT BOGY ASSEMBLY CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . 31
2-5 Figure 14 SIDE SHIFT CYLINDER BOGY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
2-5 Figure 15 FRONT SIDE SHIFT CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2-5 Figure 16 ROLL CYLINDER HYDRAULICS AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . 36
2-5 Figure 17 REAR SIDE SHIFT CYLINDER HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2-5 Figure 18 UPPER SCISSOR ROLLERS AND SCISSOR ROLLER TRACKS . . . . . . . . . . . . 38
2-5 Figure 19 REAR SIDE SHIFT CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2-5 Figure 20 COUPLING HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2-5 Figure 21 COUPLING ELEMENT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2-5 Figure 22 ELEMENT ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2-5 Figure 23 JACKING POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2-5 Figure 24 FLUID LEVEL MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2-5 Figure 25 BATTERY DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2-5 Figure 26 RADIATOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2-5 Figure 27 COOLANT SERVICE AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2-5 Figure 28 CLEANING URETHANE SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2-5 Figure 29 REMOVING SKYLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2-5 Figure 30 CLEANING DIRT FROM PINCHWELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2-Figures
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Halvorsen
2-5 Figure 31 CHECK FOR FLATNESS OF CAB SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2-5 Figure 32 MASKING OFF EDGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2-5 Figure 33 APPLYING PRIMER TO PINCH-WELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2-5 Figure 34 MASKING EDGE OF “FRIT” SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2-5 Figure 35 APPLYING PRESSURE TO TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2-5 Figure 36 PUNCTURING APPLICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2-5 Figure 37 WET OUT OF TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2-5 Figure 38 APPLICATION OF PRIMER TO FRIT SURFACE. . . . . . . . . . . . . . . . . . . . . . . . . 66
2-5 Figure 39 APPLICATION OF SEALANT TO PINCH-WELD . . . . . . . . . . . . . . . . . . . . . . . . . 67
2-5 Figure 40 INSTALLATION OF NEW GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2-5 Figure 41 MASKING PERIMETER OF GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2-5 Figure 42 APPLICATION OF SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2-5 Figure 43 SCRAPING OF EXCESS SEALANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2-5 Figure 44 FINISHED GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2-5 Figure 45 REMOVING PROTECTIVE GRATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2-5 Figure 46 CLEANING URETHANE SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2-5 Figure 47 CLEANING DIRT FROM PINCHWELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2-5 Figure 48 MASKING OFF EDGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2-5 Figure 49 APPLYING PRIMER TO PINCHWELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2-5 Figure 50 MASKING EDGE OF “FRIT” SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2-5 Figure 51 APPLYING PRESSURE TO TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2-5 Figure 52 PUNCTURING APPLICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2-5 Figure 53 WET OUT OF TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2-5 Figure 54 APPLICATION OF PRIMER TO FRIT SURFACE. . . . . . . . . . . . . . . . . . . . . . . . . 74
2-5 Figure 55 APPLICATION OF SEALANT TO PINCH-WELD . . . . . . . . . . . . . . . . . . . . . . . . . 75
2-5 Figure 56 INSTALLATION OF NEW GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2-5 Figure 57 APPLICATION OF SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2-5 Figure 58 SMOOTHING SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2-5 Figure 59 FINISHED SKYLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2-5 Figure 60 HYDRAULIC PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2-5 Figure 61 CHASSIS MANIFOLD - FRONT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2-5 Figure 62 CHASSIS MANIFOLD - REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2-5 Figure 63 LOAD SENSE MARGIN PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 83
2-5 Figure 64 PARK BRAKE RELEASE PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 84
2-5 Figure 65 “P” PORT, THROTTLE ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2-5 Figure 66 INNER SCISSORS MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2-5 Figure 67 OUTER SCISSORS MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2-5 Figure 68 REAR PITCH MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2-5 Figure 69 PALLET STOPS AND CONVEY LIFT MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . 92
2-Figures
LIST OF FIGURES
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Halvorsen
2-5 Figure 70 CONVEY MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2-5 Figure 71 FAN DRIVE MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2-5 Figure 72 PROXIMITY SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2-5 Figure 73 VALVE DRIVE BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2-5 Figure 74 LIMIT SWITCH ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2-5 Figure 75 LIMIT SWITCH 2LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2-5 Figure 78 LIMIT SWITCH 14LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2-5 Figure 79 LIMIT SWITCH 15LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2-5 Figure 80 LIMIT SWITCHES 17LS AND 18LS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2-5 Figure 81 LIMIT SWITCH 16LS AND 16LS-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2-5 Figure 82 AIR TRANSPORT PIN AND CLEVIS INSTALLATION . . . . . . . . . . . . . . . . . . . . . 106
2-5 Figure 83 LIMIT SWITCH 3LS-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2-5 Figure 84 TRANSMISSION ACCESSORY BOX IN MAIN PANEL . . . . . . . . . . . . . . . . . . . . 109
2-5 Figure 85 ACCESSORY BOX - PART NO. 623-7300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2-5 Figure 86 PROXIMITY SWITCHES 4PRS AND 5PRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2-6 Figure 1 HYDRAULIC SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2-6 Figure 2 FAULT CODE RETRIEVAL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2-7 Figure 1 ELECTRICAL SCHEMATIC - 2100SP - 521-3504. . . . . . . . . . . . . . . . . . . . . . . . . 5

2-7 Figure 25 INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 . . . . . . . . . . . . . . . . . . . . 29
2-7 Figure 43 WIRE HARNESS - SP2100 - 625-9070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2-7 Figure 46 HYDRAULIC SCHEMATIC - 2100SP - 623-5420-001 . . . . . . . . . . . . . . . . . . . . . . 55
2-Figures
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Halvorsen
1. INTRODUCTION
WARNING
The main purpose of this chapter is to provide all the necessary information for technicians to safely
inspect and maintain the Halvorsen, 25 000 lb. Loader for Aircraft. Before operating or maintaining the
equipment, all operating instructions should be read and completely understood. Refer to all sections in
Chapter 1.
Section 1, “Safety Precautions” presents a series of warnings and cautions for the operator and
technician to better understand the items that require especial care and attention to avoid personal
injury and property damage. Emphasis should always be placed on safety, not only for personnel
working with the equipment, but also for persons and property served with this vehicle.
Section 2, “System Overview” presents an overall review of the vehicle to allow operators and
technicians better understanding on how equipment and most components work.
Section 3, “Preventative Maintenance” presents a pre-operational check list, an operator’s daily check
and periodic maintenance schedules.
Section 4, “Maintenance Specifications” provides information required for performing regular

maintenance and procedures.
Section 5, “Maintenance Procedures” outlines the necessary procedures for mechanical, hydraulic and
electrical adjustments for the vehicle.
Section 6, “Troubleshooting” provides useful troubleshooting guidelines for locating and solving general
potential problems with the equipment, if they should arise.
Section 7, “System Schematics” presents electrical and hydraulic schematics for the vehicle to be used
in conjunction with information in Section 6, “Troubleshooting”.
It is also important to properly maintain the equipment according to maintenance schedules and
manufacturer’s recommendations to avoid potential accidents and costly mechanical breakdowns.
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SAFETY PRECAUTIONS
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2. PREPARING THE UNIT FOR MAINTENANCE (LOCK-OUT AND TAG-OUT)
A. DESCRIPTION
The lock-out and tag-out procedures, also referred to as “out-of-service notification” procedures,
must be followed before performing any maintenance on the vehicle to prevent accidental starting
of the engine, energizing of the electrical or hydraulic system, closing of any hoods and hatches
or any other operation that can injure persons or damage equipment.
Energy sources in the vehicle should be isolated and rendered inoperative prior to performing any
maintenance. The main energy sources in diesel-powered loaders are the diesel engine and
cooling system, electrical batteries, fuel tank and hydraulic system including pressure
accumulators. The engine must be switched off and allowed to cool down, prior to starting
maintenance work.
The vehicle contains many heavy components, hoods and hatches, which also contain energy in
a raised position and should be lowered, closed or properly secured when keeping them open or
in a raised position.
The lock-out and tag-out procedure also prevents accidental return of the vehicle into operation
prior to completion of all maintenance work. Refer to NFPA 70E and OSHA 29 CFR 1910.147
and 1910.333 on lock-out and tag-out procedures. Additional procedures and regulations may be
applicable at specific locations.
The vehicle ignition switch or key should not be used as the sole lock-out device, since in many
cases duplicate keys circulate and are not tightly controlled. The battery disconnect switch
should also not be used as the sole lock out device, since the switch can be easily re-actuated.
Please note that when working with movable scaffolding, cranes or jacks during maintenance
work, these also should be locked or tagged out.
WARNING
FOLLOW THE REQUIRED PROCEDURES TO PREPARE THE UNIT FOR MAINTENANCE
(LOCK-OUT AND TAG-OUT).
B. LOCK-OUT AND TAG-OUT PROCEDURE
(1) Park the vehicle in a clean and level surface. Chock wheels securely and install
maintenance supports.
(2) Ensure deck is fully lowered or if planning to work underneath, ensure the deck is fully
supported by the designated maintenance supports to prevent the deck from falling.
(3) Deplete pressure from hydraulic system. Fully retract and unload all cylinders.
(4) Turn off ignition switch.
(5) Ensure winterization systems are disconnected from external power outlets and secure
cables to prevent anybody from re-connecting them (if equipped).
(6) Turn off battery disconnect and remove handle (if equipped).
(7) Disconnect negative battery cable and secure it to avoid accidental contact with battery
posts.
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Halvorsen
Figure 1
ENERGY SOURCES AND DEVICES
2-1
SAFETY PRECAUTIONS
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Halvorsen
(8) Install an OSHA approved lock-out and tag-out tag or highly visible label on or directly
beside the ignition panel. The tag or label should clearly warn against starting, operating or
re-energizing the equipment.
(9) Install guard rails or a fall restraint system when accessing the top of the vehicle for
maintenance.
(10) Allow engine and other components sufficient time to cool down completely before starting
maintenance work. Pressure inside the cooling system will be significantly reduced after
the cool-down period.
(11) Deplete all pneumatic pressure in the tires before working on wheels, rims and tires.
(12) Open hoods and hatches and securely support them before starting any maintenance on
the vehicle.
(13) Secure the power module whenever you need to keep it open, to prevent it from swinging.
(14) Verify that all energy sources are effectively disabled.
C. UNLOCKING AND REMOVAL OF TAGS
Upon completion of maintenance, repair work and adjustments unlock and un-tag the vehicle
following the lock-out and tag-out procedure in reverse order.
3. MAINTENANCE STANDS
WARNING
The Halvorsen comes with maintenance stands (support blocks) to support the platform deck at three
different heights. The stands are stowed outside the chassis, one on each side of the vehicle.
A. MAINTENANCE STANDS INSTALLATION AND REMOVAL
Refer to Figure 2.
(1) Maintenance Stands Installation
(a) Raise the deck high enough to complete required work.

(b) Install both maintenance stands into the chassis and install retaining pins.
(c) Lower deck until the lower scissor rollers come into contact with the maintenance
stands.
(2) Maintenance Stands Removal
(a) Raise deck until the lower scissor roller clears the maintenance stands.
(b) Remove retaining pins.
(c) Remove both maintenance stands and stow in holders and install retaining pins.
(d) Lower the deck.
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Halvorsen
SUPPORT BLOCK LOCATIONS
MAINTENANCE SUPPORT BLOCKS
Figure 2
MAINTENANCE STANDS
4. WARNINGS AND CAUTIONS
DANGER
ELECTRICAL CURRENT FROM FACILITIES POWER, BATTERY AND LIGHTNING IS
HAZARDOUS. TO REDUCE RISK OF ELECTRICAL SHOCK: DO NOT CONNECT OR
DISCONNECT ANY ELECTRICAL CABLES DURING AN ELECTRICAL STORM, CONNECT
FACILITIES POWER UTILIZING ONLY THE PROPER CONNECTORS PROVIDED, USE ONLY
ONE HAND TO CONNECT OR DISCONNECT CABLES AND TURN OFF AND LOCK OUT ALL
ELECTRICAL POWER SOURCES BEFORE PERFORMING ANY MAINTENANCE ON THE
VEHICLE.
WARNING
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SAFETY PRECAUTIONS
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Halvorsen
WARNING
WARNING
WARNING
MAINTENANCE SUPPORT STANDS MUST BE INSTALLED WHILE PERSONNEL ARE
WORKING UNDER THE RAISED DECK.
WARNING
WARNING
WARNING
WARNING
BEFORE STARTING THE VEHICLE, ENSURE ALL PERSONS AND OBJECTS ARE CLEAR OF
THE VEHICLE AND ALL COMPARTMENT DOORS ARE CLOSED AND SECURED. TIRES AND
WHEELS CAN MOVE WITHOUT WARNING AND CRUSH PERSONS.
WARNING
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Halvorsen
WARNING
USE ONLY PROPER TOOLS AND CALIBRATED MEASUREMENT DEVICES WHEN
PERFORMING VEHICLE MAINTENANCE.
WARNING
INJURY.
WARNING
TORQUE LUG NUTS ACCORDING TO SPECIFICATIONS.
WARNING
OPERATE VEHICLE ONLY IN WELL VENTILATED AREAS. ENGINE EXHAUST GASES ARE
POISONOUS.
WARNING
KEEP FINGERS AND HANDS CLEAR WHEN REMOVING OIL PLUG. HOT OIL MAY CAUSE
BURNS.
WARNING
WARNING
INSPECT, REPLACE AND ADJUST BRAKE COMPONENTS IN ACCORDANCE WITH
MAINTENANCE SCHEDULE.
WARNING
AVOID SPARKS OR OPEN FLAMES NEAR BATTERIES. LEAD-ACID BATTERIES PRODUCE
EXPLOSIVE HYDROGEN GAS.
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SAFETY PRECAUTIONS
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Halvorsen
WARNING
WARNING
DO NOT ALLOW ANY PERSONS UNDER THE VEHICLE UNLESS PROPERLY RATED
MAINTENANCE STANDS ARE USED FOR SAFE SUPPORT OF THE VEHICLE.
WARNING
AVOID CONTACT AND INHALATION OF DIESEL FUEL, KEROSENE, HYDRAULIC OIL,
LUBRICANTS AND GLYCOLS. WASH AFFECTED AREAS IMMEDIATELY TO AVOID SKIN
IRRITATION.
WARNING
DISCONNECT THE BATTERY BEFORE PERFORMING MAINTENANCE ON THE ELECTRICAL
SYSTEM.
WARNING
REMOVE BOTH POSITIVE AND NEGATIVE BATTERY CABLES BEFORE WELDING ON THE
VEHICLE AND TAKE PRECAUTIONS TO PREVENT DAMAGE TO ELECTRONIC EQUIPMENT.
REFER TO CHAPTER 3, OVERHAUL FOR REQUIREMENTS. ALSO, REFER TO THE ENGINE
MANUAL IN CHAPTER 5 FOR ADDITIONAL REQUIREMENTS.
CAUTION

CAUTION
WHEN CLEANING THE VEHICLE USING A PRESSURE WASHER, CARE MUST BE TAKEN NOT
TO APPLY DIRECT PRESSURE TO ANY EXPOSED ELECTRICAL, HYDRAULIC OR ENGINE
COMPONENTS. DO NOT PRESSURE WASH INSIDE THE ENGINE OR MOTOR
COMPARTMENT.
CAUTION
WHEN WASHING OR RINSING THE LOADER, PREVENT WATER FROM INTRUDING THE
TRANSMISSION BREATHER VALVE.
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Halvorsen
CAUTION
WHEN PERFORMING A BATTERY “JUMP START” ON THE VEHICLE, ENSURE JUMP CABLES
ARE PROPERLY CONNECTED TO PREVENT DAMAGE TO THE ELECTRIC SYSTEM AND
COMPONENTS.
CAUTION
WHEN ELECTRICALLY CHARGING BATTERIES ON THE VEHICLE, ENSURE CHARGER

CABLES ARE PROPERLY CONNECTED TO PREVENT DAMAGE TO THE ELECTRIC SYSTEM
AND COMPONENTS.
CAUTION
DO NOT CLEAN RUBBER AND PLASTIC COMPONENTS SUCH AS TIRES, LUBRICANT SEALS,
RUBBER HOSES OR ELECTRICAL COMPONENTS WITH PETROLEUM-BASED PRODUCTS
SUCH AS KEROSENE, GASOLINE OR FUEL OIL.
CAUTION
DO NOT OPERATE THE ENGINE WITH THE OIL LEVEL BELOW THE ‘MIN’ MARK OR ABOVE
THE ‘MAX’ MARK ON THE DIPSTICK.
CAUTION
ENSURE FUEL IS CLEAN AND FREE OF WATER AND DIRT.
CAUTION
ALLOW THE ENGINE TO COOL BEFORE ADDING WATER OR ANTI-FREEZE SOLUTION.
CAUTION
USE ONLY ETHYLENE-GLYCOL BASED ANTIFREEZE IN CORRECT CONCENTRATIONS TO

PREVENT FREEZING AT THE AMBIENT TEMPERATURE.
CAUTION
DO NOT USE WATER WITH SALT OR HIGH MINERAL CONTENT WHEN FILLING THE
COOLANT SYSTEM OR BATTERIES.
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SAFETY PRECAUTIONS
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Halvorsen
CAUTION
DO NOT DISCONNECT THE BATTERY OR TURN OFF OPTIONAL BATTERY DISCONNECT

SWITCH WITH THE ENGINE RUNNING. THIS WILL CAUSE A VOLTAGE SURGE IN THE
ALTERNATOR CHARGING SYSTEM.
CAUTION

CAUTION
CAUTION
CAUTION

CAUTION

UNIT.
CAUTION
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1. GENERAL
NOTE: REFER TO CHAPTER 1, SECTION 1, “DESCRIPTION” AND CHAPTER 1, SECTION 4,

“SPECIFICATIONS” FOR SPECIFICATIONS AND ADDITIONAL INFORMATION ABOUT
THIS VEHICLE.
This section presents an overview of the vehicle and its system components. The Halvorsen, 25 000 lb.
Loader for Aircraft, is a self-propelled two-wheel drive vehicle, driven and operated by one person.
The vehicle is powered by a diesel engine coupled to an automatic transmission. The hydraulic system
is an open center system, powering brakes and steering.
The engine provides traction by means of a transmission with a drive shaft coupled to the front drive
axle. The parking brake disc is contained within the front axle.
The vehicle also includes a no-spin, two-wheel drive and steer axle with hydraulically operated wheel
steering, hydraulically operated brakes on the front axle input shaft and on all four rear axle wheels. The
electrical system is 24 VDC negative-grounded.
2. SYSTEM DESCRIPTION
Chassis Assemblies and Components

• Power unit (engine, transmission and hydraulic services pump)
• Radiator (cooling)
• Fuel tank
• Main electrical panel
• Hydraulic tank
• Hydraulic manifold and components
• Emergency pump
• Winterization panel and receptacle
• Front and rear axles
Platform Deck Assemblies and Components
• Lifting scissors
• Operator’s cab, including controls and indicators
• Access ladder (anchored to the chassis)
• Transfer rollers
• Walk-deck components and handrails
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SYSTEM OVERVIEW
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Halvorsen
A. CHASSIS
Refer to Figure 1 and Figure 2.

The chassis assembly is a welded steel frame and provides the base for the mounting of the front
drive steer axle, rear axle, power unit and electrical, hydraulic and fuel systems. The scissors
lifting system is attached to the chassis. Towing and tie-down points are incorporated in the
chassis frame.
MAIN
PANEL
DRIVE/STEER
AXLE FUEL
TANK
POWER
UNIT
RADIATOR
HELPER
CYLINDER
WINTERIZATION
PANEL & RECEPTACLE
EMERGENCY
PUMP
CHASSIS
HYDRAULIC
MANIFOLD
HYDRAULIC
RESERVOIR
REAR AXLE
ASSEMBLY
TOWING/TIE-DOWN
POINTS
Figure 1
VEHICLE CHASSIS
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Halvorsen
TIRE
DRIVE AXLE
PARK BRAKE
SERVICE BRAKE
2LS LIMIT SWITCH

DRIVE SHAFT
MAIN PANEL
WINTERIZATION PANEL
& RECEPTACLE
FUEL TANK
EMERGENCY PUMP
TRANSMISSION
CHASSIS MANIFOLD
HYDRAULIC FILTER BATTERIES

(HIGH PRESSURE)
BATTERY DISCONNECT
RETURN FILTER TRANSMISSION FILTER
HYDRAULIC OIL
CASE DRAIN FILTER
HYDRAULIC OIL FILLER
HYDRAULIC RESERVOIR RADIATOR
BREATHER
HYDRAULIC FLUID
SIGHT GAUGE
ENGINE
REAR AXLE ASSEMBLY

HYDRAULIC PUMP
AIR CLEANER
AIRPORTABILITY
LATCH
Figure 2
VEHICLE CHASSIS COMPONENTS - TOP VIEW
2-2
SYSTEM OVERVIEW
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Halvorsen
B. POWER UNIT
Refer to Figure 3.
The power unit consists of a six-cylinder turbocharged diesel engine with an automatic
transmission coupled to the flywheel and a variable displacement hydraulic pump coupled to the
front end of the crankshaft. The power unit is mounted in the center of the chassis and the
transmission is connected to the front drive and steer axle with a drive shaft.
TRANSMISSION
ENGINE
HYDRAULIC
PUMP
GENERATOR
ALTERNATOR
ENGINE
AIR CLEANER
Figure 3
POWER UNIT COMPONENTS
2-2
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The diesel engine provides powers the automatic transmission to propel the loader, the pump to
operate the hydraulic systems and the alternator to keep the batteries in a fully charged state. A
compressor is powered by an hydraulic motor attached to the compressor that cools the
operator’s cab on the loader.
C. COOLING SYSTEM
Refer to Figure 4.
The engine cooling system for dissipating heat is a closed-loop system consisting of a radiator in
a housing and a fan driven by a hydraulic motor.
RADIATOR
HYDRAULIC FAN MOTOR
COOLANT RECOVERY
TANK COOLANT RESERVOIR
Figure 4
COOLING SYSTEM
2-2
SYSTEM OVERVIEW
Page 5
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Halvorsen
The radiator is remotely mounted outside the right-side chassis frame. The fan motor has two
speeds and is controlled by sensors in the cooling system. The engine-driven water pump
circulates coolant in the system and a thermostat controls engine temperature by regulating the
flow of the coolant. A tank mounted, on top of the engine, serves as a reservoir for the fluid
volume required to maintain the cooling system temperature within the operating range. The
coolant recovery tank, mounted at the rear of the engine, allows coolant recovery to maintain a
constant fluid level and prevents the introduction of air in the closed loop system.
D. TRANSMISSION
Refer to Figure 5.
A four-speed automatic transmission is coupled to the engine flywheel for directional control. The
torque converter provides inching capability and smooth acceleration in any range selected.
TRANSMISSION
Figure 5
TRANSMISSION
The transmission output shaft is directly connected to the differential pinion shaft with a drive
shaft. Range selection is accomplished by an electrically controlled joystick lever with digital
readout in the operator’s cab, which actuates a hydraulic cylinder mounted on the transmission,
for positioning the transmission control valve. A remote-mounted oil cooler is incorporated in the
engine coolant system to remove excessive heat from the transmission fluid and warm the
transmission fluid when operating in cold weather conditions.
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E. DRIVE AND STEER FRONT AXLE
Refer to Figure 6.
The front axle is the loader’s drive and steer axle and is rigidly attached to the chassis frame.
Incorporated in the axle are the differential assembly, planetary wheel ends and power steering
cylinders.
A brake disc is attached to the companion flange on the differential pinion shaft and the front axle
service brake and parking brake calipers react on the disc. A differential lock is provided for
positive driving of both wheels should one wheel lose traction on slippery surfaces.
SERVICE BRAKE
DIFFERENTIAL
PLANETARY WHEEL END

PARK BRAKE
Figure 6
DRIVE AND STEER FRONT AXLE
2-2
SYSTEM OVERVIEW
Page 7
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F. REAR AXLE ASSEMBLY

The rear axle assembly provides support for the loader chassis at the back end and consists of a
framework that has an axle pivot shaft at the front and two attaching lugs at the back end.
A bogy assembly, consisting of an arm with two wheel assemblies attached and a telescoping
hydraulic cylinder, is assembled on each end of the axle shaft. The helper cylinders are
telescoping hydraulic cylinders used to assist the deck main lift cylinders in raising the deck when
the deck is at the lowest position and provide additional chassis clearance when driving up and
down ramps.
HELPER CYLINDER
(TELESCOPING
HYDRAULIC
CYLINDER)
BOGY WHEEL ARM
DISC BRAKE
BOGY
PIVOT SHAFT
Figure 7
REAR AXLE ASSEMBLY - BOGY WHEELS
The bogy assemblies pivot on the axle shaft when traveling over irregular surfaces and each
wheel assembly remains on the surface to support the load. Each wheel assembly has an
external disc brake assembly incorporated in the wheel hub.
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The rear axle assembly is underneath the chassis at the back end of the loader and is attached to
the chassis with pivot pins. In the normal operating configuration, the chassis rests on the axle
shaft.
When the loader is to be air transported additional chassis height is required to provide clearance
at the crest of the aircraft loading ramp. To obtain the additional clearance, the air portability latch
is engaged to physically lock the deck to the chassis at rear of the loader and the DECK RAISE
switch is actuated. The helper cylinders, attached to the axle assembly shaft, will extend and
force the deck and chassis up to provide the required additional clearance.
HELPER CYLINDER
AIRPORTABILITY LATCH
AXLE ASSEMBLY PIVOT
Figure 8
REAR AXLE ASSEMBLY
2-2
SYSTEM OVERVIEW
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3. SOLENOID VALVES, MANIFOLDS AND SWITCH LOCATIONS
A. SOLENOID VALVE IDENTIFICATION
TABLE 1 - SOLENOID VALVES
SOLENOID
DESCRIPTION FUNCTION
VALVE
ENGINE Fuel Solenoid 1SOL
Hydraulic Dump 1 1SOL-A
Park Brake Release 3SOL
Front Axle Differential Lock 4SOL
Lift Cylinder Lock Valve Up 7SOL
CHASSIS MANIFOLD Hydraulic Dump 2 7SOL-A
Deck Raise 8SOL
Deck Lower 9SOL
Helper Cylinder Lower 13SOL
Load Sense Pressure Limiter 47SOL
FAN MANIFOLD Fan 1 (low speed) 1SOL-B
Main Lift Cylinder Lock Valve 10SOL

ON MAIN LIFT CYLINDER
Main Lift Cylinder Lock Valve 11SOL
Front Side Shift Right 14SOL
Front Side Shift Left 16SOL
Front Left Up 21SOL

INNER SCISSORS
Front Right Down 23SOL
Front Right Up 25SOL
Front Left Down 27SOL
Rear Side Shift Right 15SOL
Rear Side Shift Left 17SOL
Rear Left Up 22SOL

OUTER SCISSORS
Rear Right Down 24SOL
Rear Right Up 26SOL
Rear Left Down 28SOL
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TABLE 1 - SOLENOID VALVES
SOLENOID
DESCRIPTION FUNCTION
VALVE
Rear Pitch Up 18SOL

REAR PITCH MANIFOLD
Rear Pitch Down 20SOL
Traction Lift Cylinders Retract 29SOL
Front Stop Retract 30SOL

DECK
Rear Stop Retract 32SOL
Pilot Traction Rollers 46SOL
Forward 1, 2, 3 33SOL
Forward 4 34SOL
Forward 5, 6 35SOL
Forward 7 36SOL
Forward 8, 9 37SOL
CONVEY MANIFOLD
Aft 1, 2, 3 38SOL
Aft 4 39SOL
Aft 5, 6 40SOL
Aft 7 41SOL
Aft 8, 9 42SOL
AIR CONDITIONING A/C Compressor Motor 51SOL
2-2
SYSTEM OVERVIEW
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B. HYDRAULIC MANIFOLD LOCATIONS
PALLET STOP & CONVEY LIFT MANIFOLD
FRONT & REAR CONVEY LIFT MANIFOLD

(MOUNTED IN SAME LOCATION
ON OPPOSITE SIDE OF DECK)
INNER SCISSORS MANIFOLD OUTER SCISSORS MANIFOLD

(LOCATED BETWEEN SCISSORS) (LOCATED BETWEEN SCISSORS)
REAR PITCH MANIFOLD

(LOCATED BETWEEN SCISSORS)
CHASSIS MANIFOLD
Figure 9
HYDRAULIC MANIFOLD LOCATIONS
2-2
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C. LIMIT SWITCH LOCATIONS
4PRS
5PRS
(LOCATED ON
OUTSIDE OF
SCISSORS)
4LS 5LS
(CENTERED 14 LS 16LS
BETWEEN 15LS 16LS-A
DECK RAILS) 17LS (LOCATED ON
18LS INSIDE REAR
(LOCATED OF DECK)
BETWEEN
SCISSORS) 2LS
(LOCATED BETWEEN
CHASSIS RAILS)
3LS-A
(LOCATED ON
INSIDE LEFT
CHASSIS RAIL)
Figure 10
LIMIT SWITCH LOCATIONS
2-2
SYSTEM OVERVIEW
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Halvorsen
1. INTRODUCTION
This section contains instructions for inspecting and maintaining the Halvorsen, 25 000 lb. Loader for
Aircraft. A periodic maintenance program is necessary to ensure the maximum performance of your
vehicle. Proper maintenance consists of complete lubrication at specified intervals, periodic inspections
and replacement of worn parts. As with any equipment, the vehicle may become hazardous if proper
service and maintenance are neglected. Therefore, it is essential to perform all described inspections,
lubrication and fault isolation on a regularly scheduled basis.
Refer to Chapter 1, Section 4, “Specifications” and Chapter 2, Section 4, “Maintenance Specifications”

for specified lubricants, reservoir volumes and other information related to lubrication and servicing.
2. BEFORE COMMISSIONING A UNIT
The following equipment pre-operational checklist allows for a comprehensive verification of the unit and
its components. It is highly recommended the checklist be followed to be sure everything is in working
condition, before putting the unit into service. If you are unsure about how to perform certain checks,
refer to Chapter 2, Section 5, “Maintenance Procedures” for mechanical adjustments and hydraulic and
electrical adjustments. For technical data and other information such as capacities or fluid amounts,
refer to Chapter 1, Section 4, “Specifications” and Chapter 2, Section 4, “Maintenance Specifications”
for more information.

NOTE: REFER TO CHAPTER 1, SECTION 4, “SPECIFICATIONS” FOR GENERAL

SPECIFICATIONS AND FLUID CAPACITIES AND CHAPTER 2, SECTION 4,
“MAINTENANCE SPECIFICATIONS” FOR RECOMMENDED LUBRICANTS AND
OPERATIONAL, PRESSURE AND ADJUSTMENT SETTINGS.
NOTE: COPIES OF THE “EQUIPMENT PRE-OPERATIONAL CHECKLIST” CAN BE MADE AS

PART OF A MAINTENANCE LOG.
NOTE: BEFORE SERVICING UNDERNEATH THE VEHICLE, BE SURE THE VEHICLE IS

SAFELY SUPPORTED ON APPROPRIATE SUPPORTING DEVICES RATED TO
HANDLE 150% (1.5 TIMES) THE GROSS VEHICLE WEIGHT.
NOTE: THE VEHICLE USES BOTH SAE AND METRIC FASTENERS (NUTS, BOLTS AND
SCREWS). BE SURE THAT THE CORRECT FASTENERS ARE USED FOR REPAIR
AND SERVICE OF THE VEHICLE.
NOTE: TO AID IN PREVENTING CORROSION, WASH AND RINSE THE LOADER ON A

REGULAR BASIS.
2-3
PREVENTATIVE MAINTENANCE
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WARNING
WARNING
NOTE: REFER TO THE SUBSECTION ‘2. PREPARING THE UNIT FOR MAINTENANCE
(LOCK-OUT AND TAG-OUT)’ IN CHAPTER 2, SECTION 1, “SAFETY PRECAUTIONS”.
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3. EQUIPMENT PRE-OPERATIONAL CHECKLIST
TABLE 1 - EQUIPMENT PRE-OPERATIONAL CHECKLIST
PROCEDURE CHECK (√)
Wash and rinse loader upon arrival.
Perform walk-around inspection and check for obvious damage, missing parts and
fluid leaks.
Verify that batteries are secure and terminals are clean.
Check level of fluid in hydraulic reservoir (deck lowered).
Check fluid level in front axle differential.
Check that the dipstick is properly installed.
Check fluid level in front axle planetary wheel hubs.
Check air pressure in all tires and inflate to specification of 6.9 ± 0.14 bar
(100 ± 2 psi).
Re-torque all wheel nuts to 271 N·m (200 lbf-ft.)
Re-torque driver axle nuts to 271 N·m (200 lbf-ft.) and mark with white line.
Check operator’s access ladder for security.
Check all handrails, mounting brackets and retaining pins.
Check power unit fluid levels, such as engine oil, coolant and transmission fluid.
Refer to Figure 1.
Check fuel level.
Check lights and turn signal operation.
Check horn operation.
Check windshield and rear door wiper and washer operation.
Check emergency pump operation.
Start power unit, observe all gauges and indicator lights for indication of proper engine operation
during engine warm-up, then
MAKE COMPLETE OPERATIONAL CHECK OF THE LOADER:
• Parking Brake Released, Applied
• Driving, transmission shifting, all ranges
• Steering Left, Right
• Service Brakes
• Deck Lift Up, Down
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TABLE 1 - EQUIPMENT PRE-OPERATIONAL CHECKLIST
PROCEDURE CHECK (√)
• Deck Pitch Up, Down
• Deck Shift Left, Right
• Deck Roll Left, Right
• Convey (all sections) Forward, Aft
• Deck Pallet Stops (front and rear) Down, Up
• Auto Center Level Operation
• Air Transportability Operation
• Inspect all hydraulic hoses and fittings for fluid leakage.
• Inspect all hydraulic motors for fluid leakage.
• Inspect steering valve for fluid leakage.
• Inspect all wiring harnesses and wires for security.
Additional Notes or Comments
EQUIPMENT SERIAL NUMBER: HOURMETER:
EQUIPMENT CHECK PERFORMED BY: DATE:
EQUIPMENT CHECK VERIFIED BY: DATE:
NOTE: COPIES OF THIS TABLE CAN BE MADE AS PART OF A MAINTENANCE LOG.
2-3
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ENGINE OIL COOLANT PRESSURE CAP
DIPSTICK COOLANT RESERVOIR
TRANSMISSION
DIPSTICK AND
FILLER PIPE
ENGINE OIL
FILLER CAP
COOLANT RECOVERY
TANK
Figure 1
Figure 2
HYDRAULIC RETURN FILTER GAUGE
2-3
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4. BREAK-IN PERIOD AND MAINTENANCE
A. BREAK-IN PERIOD
The first 200 hours of operation of the vehicle allows all components and assemblies to adjust for
what will become normal operation after the initial break-in period.
The vehicle must be thoroughly inspected after the first 200 hours of operation. The 8-hour
(daily) and 500-hour (quarterly) schedules should be used as a guide for the 200-hour
maintenance inspection.
B. BREAK-IN MAINTENANCE
An initial break-in maintenance is recommended after the first 200 hours of operation (power unit
hours). Axles, wheel hubs and transmission lubricants should be changed in accordance with
manufacturers’ recommendations.
For diesel powered vehicles, there is no need to replace the engine oil as part of the break-in
maintenance, if the manufacturer provides the engine with a high-grade lubricant and
recommends to change the oil at least every 500 hours of operation or yearly. If any other
lubricant is used after the first oil change, more frequent intervals should be observed.
NOTE: ENGINE OIL MUST BE CHANGED AND OIL FILTER CARTRIDGE REPLACED AFTER
THE FIRST 50 HOURS OF USE. FAILURE TO PERFORM THIS OPERATION
INVALIDATES THE ENGINE MANUFACTURER’S GUARANTEE.
The traction pump and drive train should be inspected for leaks and signs of potential problems,
but no oil change is required as part of the break-in maintenance.
Refer to Chapter 5, MANUFACTURERS’ APPENDICES for maintenance recommendations for
each specific component.
5. PERIODIC MAINTENANCE
Regular maintenance is required to ensure optimum loader performance and long life for machine
components. Maintain the vehicle by performing periodic maintenance at the intervals listed in the
Maintenance Schedule tables within this section.
Specific operating conditions will determine the scope and frequency of maintenance work required. If
in doubt about any service intervals or maintenance operations recommended within this manual,
please refer to the manufacturer’s recommendations for the specific component.
If the vehicle is operated under severe weather conditions such as extreme heat or cold or in sandy,
dusty or snowy areas, increase the frequency of periodic maintenance as necessary, but always refer to
specific manufacturer’s recommendations.
Maintenance records must be kept as evidence of regular and proper maintenance, an essential
requirement the manufacturer may request in the event of a warranty claim.
CAUTION

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TABLE 2 - MAINTENANCE SCHEDULE
PERIOD (HOURS)
PROCEDURE
8 50 100 OTHER
Perform walk-around inspection and check for obvious

◄
damage, missing parts and fluid leaks.
Check condition of drive wheel tires. ◄
Check condition of bogy wheel tires. ◄
Check engine oil level (refer to Figure 3). ◄
Check coolant level (refer to Figure 3). ◄
Check fuel level. ◄
Check cab heater fuel level. ◄
Check fluid level in hydraulic reservoir (deck lowered). ◄
Check fluid level in hydraulic reservoir (deck lowered).

◄
(Use fluid level marks on aft end of reservoir)
Lubricate as
Check spring plunger on impact roller and lubricate. ◄
required.
Check windshield washer fluid level. ◄
Check condition of operator’s access ladder and mounting. ◄
Check condition of all handrails, mounting brackets and

◄
lock pins.
Check all casters and rollers on deck for damage. ◄
Check folding wings on front of deck for damage, free

◄
movement and lock pin engagement.
Check all lights and turn signal operation. ◄
Check emergency pump operation. ◄
Check horn operation. ◄
Check cab ventilation fan operation. ◄
Check cab heater operation. ◄
Check windshield wiper and rear door wiper for proper

◄
operation.
Check cab doors for ease of opening and closing and door
latches for proper function. Check top and side skylights ◄
for looseness, leaking and adhesive sealant failure.
2-3
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PERIOD (HOURS)
PROCEDURE
8 50 100 OTHER
Check top and side skylights for looseness, leaking and Every 400 hours
adhesive sealant failure. or 6 months
Check all cab windows for damage and ease of opening

◄
and closing.
Check driver’s seat controls for proper operation. ◄
Check cab seat belt for damage and latch operation. ◄
Check and test warning lights on cab dashboard.

CAUTION: DO NOT OPERATE WITH DEFECTIVE ◄
WARNING LIGHTS.
Start power unit and check indicating lights and gauges for
◄
proper engine operation.
Check condition of high pressure filter.

NOTE: CHECK INDICATOR BUTTON ON HIGH
PRESSURE FILTER HOUSING. IF INDICATOR
BUTTON IS ON THE OUT POSITION, THE ◄
FILTER REQUIRES SERVICE.
CAUTION: REPLACE FILTER ELEMENT IF INDICATOR
BUTTON IS IN THE OUT POSITION.
Check condition of case drain filter.

NOTE: FILTER IS LOCATED ON THE CHASSIS FRAME
BEHIND THE HYDRAULIC FLUID RESERVOIR.
◄
CAUTION: REPLACE FILTER ELEMENT IF GAUGE
INDICATES 25 PSI OR HIGHER - RED AREA ON
GAUGE.
Check condition of hydraulic return filter condition (refer to

Figure 2).
NOTE: TO CHECK FILTER CONDITION, PLACE
HYDRAULIC PREHEAT SWITCH IN THE ON
POSITION AND OBSERVE READING ON
◄
GAGE. GUAGE IS LOCATED ON RETURN
FILTER HOUSING ON THE TOP OF THE
HYDRAULIC RESERVOIR.
CAUTION: REPLACE FILTER ELEMENT IF GAUGE
INDICATOR IS IN RED AREA.
Drain water from fuel filter. Every 400 hours.
Check air cleaner element Indicator. ◄
2-3
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PERIOD (HOURS)
PROCEDURE
8 50 100 OTHER
Check transmission fluid level at normal operating

◄
temperature (refer to Figure 3).
Every 400 hours

Verify that batteries are secure and connections are clean.
or annually.
Check condition of engine belt. ◄
Every 400 hours

Check oil level in differential.
of operation.
After first 50
hours. Then,
Change oil in differential and planetary wheel hubs. ◄
every 1000 hours
or annually.
Check oil level in planetary wheel hubs. Every 400 hours

(Front drive axle) or annually.
Clean and repack bearings in bogy wheels. Replace seals. Every 2 years.
Re-torque wheel lug nuts. ◄

After first 50 hours
Change engine oil. ◄ of operation.
Replace oil filter cartridge. ◄ Then, every 400
hours or annually.
Change primary fuel filter. ◄
Check fuel injectors. Every 400 hours

Change lubricity fuel filter. or annually.
Inspect all nine (9) traction rollers for damage and wear.
Adjust traction roller chain tension.
Replace alternator belt.

Every 1000 hours
Clean fuel tank.
or annually.
Replace air cleaner filter.
Clean radiator externally of debris.
Change oil in hydraulic reservoir.

Change all four (4) hydraulic oil filter elements: of operation.
• Return Filters Intake (2) ◄ Thereafter,
• High Pressure (1) change every 400
hours or annually.
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PERIOD (HOURS)
PROCEDURE
8 50 100 OTHER
Change engine coolant.

NOTE: USE A 50%-50% MIXTURE OF GLYCOL AND
DISTILLED WATER FOR STORAGE AND
OPERATING TEMPERATURES ABOVE -37 ºC
Every 1000 hours
(-34 ºF).
or annually.
NOTE: USE A 60%-40% MIXTURE OF GLYCOL AND
DISTILLED WATER FOR STORAGE AND
OPERATING TEMPERATURES BELOW -37 ºC
(-34 ºF).
Every 1000 hours

Change transmission fluid.
or annually.

of operation.
Thereafter,
Change transmission filter. ◄
change every
1000 hours or
annually.
Rotate tires. As needed.
Inspect condition of helper cylinder bumpers (refer to

Figure 4) and replace if deformed and not holding cylinders Every 400 hours.
in vertical position.
Every 1000 hours

Service the Espar cab heater, per instruction.
or annually.
Change all three (3) vapor corrosion inhibitors:

• Deck Box (1) Every 1000 hours
• Chassis Box (1) or annually.
• Winterization Box (1)
Air conditioner filter free of obstructions. ◄
Clean air conditioner filter. Every 400 hours

Adjust parking brake. or annually.
Check and adjust all limit switches. Refer to Chapter 2, Every 400 hours
Section 5, “Maintenance Procedures”. or annually.
2-3
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TRANSMISSION
DIPSTICK AND
FILLER PIPE
ENGINE OIL
FILLER CAP
COOLANT RECOVERY
TANK
Figure 3
ENGINE OIL, COOLANT AND TRANSMISSION FLUID FILL POINTS
Figure 4
HELPER CYLINDER BUMPERS
2-3
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TABLE 3 - AIR CONDITIONER MAINTENANCE SCHEDULE
400 HOURS OR
AIR CONDITIONING COMPONENTS ANNUALLY
ANNUALLY
COMPRESSOR NOISE ◄
RUN 5 MINUTES ◄
INSPECT SHAFT SEAL ◄
CHECK PRESSURE (RUNNING)
◄
(MAINTENANCE PERSONNEL ONLY)
CONDENSER CLEANING ◄
CHECK HOSES/MOUNTING BRACKETS ◄
FAN CYCLE ◄
DRYER SIGHT GLASS ◄
INLET AND OUTLET BOTH WARM ◄
EVAPORATOR SWITCHES FUNCTION ◄
FILTER CLEANING ◄
OUTLET TEMPERATURE
THERMOSTAT CYCLE ◄
CONDENSATE DRAIN ◄
THOROUGHLY INSPECT WIRING AND HOSES ◄
2-3
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6. MAINTENANCE AND FLUID KITS
Maintenance and fluids kits are available from JBT for the recommended maintenance intervals. Refer
to Chapter 4, ILLUSTRATED PARTS LIST for details.
7. HYDRAULIC OIL RECOMMENDATIONS
Refer to Chapter 2, Section 4, “Maintenance Specifications” for recommended hydraulic oil.
8. OPERATIONAL CHECKS SCHEDULE
TABLE 4 - OPERATIONAL CHECKS SCHEDULE
PERIOD (HOURS)
PROCEDURE
8 50 100 OTHER
Service Brake ◄
Parking Brake Release, Applied ◄
Deck Raise, Lower ◄
Deck Pitch Up, Down ◄
Deck Shift Left, Right ◄
Deck Roll Left, Right ◄
Front Pallet Stop Up, Down ◄
Rear Pallet Stop Up, Down ◄
Power Steering Left, Right ◄
Transmission Shifting All Ranges ◄
Deck Convey Forward Front, Mid, Aft Sections ◄
Deck Convey Aft Front, Mid, Aft Sections ◄
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9. LUBRICATION
The vehicle should be lubricated as required in the periodic maintenance charts. Refer to Chapter 2,
Section 4 for the fluid specifications required.
A. GREASE POINTS
Wipe grease fittings clean and apply grease. Before coating other surfaces with grease, clean
surfaces to remove dirt and foreign material. It is important to get the grease in through the
greasing nipples to avoid grease hardening and potential plugging of channels. Refer to Figure 5.
NOTE: GREASE MUST BE PUMPED INTO GREASE NIPPLES UNTIL CLEAN GREASE EXITS
FROM ALL SIDES AROUND THE CIRCUMFERENCE OF THE BEARING OR PIN.
FRONT SIDE SHIFT

CYLINDERS
Ref.er to Figure 7 8
DRIVE AND STEER AXLE 6 REAR SIDE SHIFT

Refer to Figure 9 CYLINDERS
Refer to Figure 8
DRIVE SHAFT
Refer to Figure 9
HYDRAULIC OIL
2
LEVEL GAUGE
3
Items 1 and 2
refer to Figure 6
Figure 5
GREASE POINTS - CHASSIS AND SCISSORS
2-3
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1
Figure 6
GREASE POINTS - HELPER CYLINDER
11 NOTE: ITEM 9 - TWO (2) PER BUSHING.
9
9
Figure 7
GREASE POINTS - FRONT SIDE SHIFT CYLINDERS
2-3
Page 15
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10 10
NOTE: ITEM 10 - TWO (2) PER BUSHING.
Figure 8
GREASE POINTS - REAR SIDE SHIFT CYLINDERS
12
Figure 9
GREASE FITTINGS - IMPACT ROLLERS
2-3
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GREASE POINTS
CHASSIS AND SCISSORS
Refer to Figure 5 through Figure 9.
TABLE 5 - GREASE POINTS - CHASSIS AND SCISSORS
TOTAL INTERVAL
ITEM DESCRIPTION
FITTINGS (HOURS)
1 BUSHING, WALKING BEAM 2 400
2 BUSHING, HELPER CYLINDER 2 400
3 BUSHING, REAR AXLE ASSEMBLY PIVOT 2 400
4 BUSHING, SCISSORS, LOWER, REAR* 2 400
5 BUSHING, SCISSORS, LOWER, FRONT 2 400
6 BUSHING, SCISSORS CENTER SHAFT 2 400
7 BUSHING, SCISSORS PITCH SHAFT 2 400
8 BUSHING, SCISSORS PITCH CYLINDER 4 400
9 BUSHING, SIDE SHIFT CYLINDER ROD, FRONT 4 400
10 BUSHING, SIDE SHIFT CYLINDER ROD, REAR 4 400
11 BEARING, DECK LINK 2 400
12 IMPACT ROLLER* 6 400
NOTE: *NOT ALL LOADERS HAVE THESE GREASE POINTS.
2-3
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DIFFERENTIAL
OIL LEVEL PLUG
DRIVE AND STEER AXLE
HUB OIL LEVEL, 2X
DRIVE SHAFT
Figure 10
GREASE POINTS - DRIVE AND STEER AXLE AND DRIVE SHAFT
2-3
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SOCKET,
STEERING CYLINDER
ANCHOR PIN,
SLIDERBRAKE
SERVICE PIN
SERVICECALIPER
BRAKE CALIPER
DIFFERENTIAL
OIL LEVEL PLUG
ANCHOR PIN,
SLIDER PIN
PARK
PARKBRAKE
BRAKE CALIPER
CALIPER
KNUCKLE, UPPER
SOCKET, TIE ROD

HUB OIL LEVEL, 2X
Ref. Section 2-1,
, page KNUCKLE, LOWER
Figure 11
DRIVE AND STEER AXLE LUBRICATION POINTS
TABLE 6 - FRONT AXLE LUBRICATION POINTS
TOTAL
ITEM DESCRIPTION
FITTINGS
1 KNUCKLE, UPPER 2
2 KNUCKLE, LOWER 2
3 SOCKET, STEERING CYLINDER 4
4 SOCKET, TIE ROD 2
5 PIN, SLIDER, SERVICE BRAKE CALIPER 1
6 PIN, SLIDER, PARK BRAKE CALIPER 1
2-3
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GREASE POINTS
DRIVE AND STEER FRONT AXLE AND DRIVE SHAFT
Refer to Figure 10.
TABLE 7 - GREASE POINTS - DRIVE AND STEER AXLE AND DRIVE SHAFT
TOTAL INTERVAL
ITEM DESCRIPTION
FITTINGS (HOURS)
1 KNUCKLE, UPPER 2 400
2 KNUCKLE, LOWER 2 400
3 SOCKET, STEERING CYLINDER 4 400
4 PIN, ANCHOR, SERVICE BRAKE CALIPER 1 400
5 PIN, ANCHOR, PARKING BRAKE CALIPER 1 400
6 SOCKET, TIE ROD 2 400
7 JOINT, UNIVERSAL, AXLE SHAFT 2 400
8 JOINT, UNIVERSAL, DRIVE SHAFT 3 400
9 SPLINE, DRIVE SHAFT 2 400
2-3
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B. LIMITER PIN LUBRICATION
Apply any grade motor oil with brush or oil can as appropriate.
C. CHAINS LUBRICATION
Apply any grade motor oil with brush or oil can as appropriate. Refer to Figure 12.
LUBRICATE CHAIN WITH LIMITER PIN

ANY GRADE MOTOR OIL
Figure 12
CHAINS LUBRICATION
2-3
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D. FILL POINTS
Refer to Figure 13, Figure 14 and Figure 15 for locations of fill points for drive wheel planetary
hubs and hydraulic oil reservoir.
NOTE: CHECK AT INTERVALS LISTED AND LUBRICATE AS REQUIRED. IN SEVERE

WEATHER CONDITIONS, CHECK AT MORE FREQUENT INTERVALS.
(1) Engine Fill Point

TRANSMISSION
DIPSTICK AND
FILLER PIPE
ENGINE OIL
FILLER CAP
COOLANT RECOVERY
TANK
Figure 13
2-3
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(2) Hydraulic Reservoir Fill Point
FILL POINT - HYDRAULIC RESERVOIR
Figure 14
FILL POINT - HYDRAULIC RESERVOIR
2-3
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(3) Planetary Gear Wheel End Fill Point
HUB OIL FILL AND

SPILL PLUG
HUB OIL DRAIN PLUG

HUB ORIENTED SO PLUG IS ON BOTTOM
Figure 15
FILL POINT - PLANETARY GEAR WHEEL END
2-3
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1. GENERAL
This section includes information on specifications required for performing regular maintenance and
adjustment procedures for the Halvorsen, 25 000 lb. Loader for Aircraft.
It includes recommendations for hydraulic oil fluids, recommended lubricants, mechanical adjustment
settings, pressure settings for hydraulic equipment and components and other settings necessary to
tune-up the vehicle for optimal performance. For general vehicle’s specifications and general
information, refer to Chapter 1, Section 4, “Specifications”.
2. HYDRAULIC OIL RECOMMENDATIONS
NOTE: STUDIES HAVE SHOWN THAT NEARLY 90% OF THE FAILURES OF HYDRAULIC
COMPONENTS ARE CAUSED BY HYDRAULIC FLUID CONTAMINATION.
The International Standards Organization (ISO) has established a code index system as a guideline for
machine builders and end users. This ISO code specifies different levels of oil cleanliness and is based
on the type of component used in the machine which is the most sensitive in relation to fluid borne
contaminants. According to this, the axial piston pumps and motors used on most JBT equipment
require an ISO 4406:1999 code level of 18/16/13. This code level is a means of measuring three sizes
of particles contained in 1 milliliter of fluid. The particle sizes are measured in microns, also known as
micrometers. The first number, 18 is a measurement of particles equal to or greater than 4 microns.
The second number, 16 is for particles equal to or greater than 6 microns, while the last number, 13, is
for particles equal to or greater than 14 microns.
Whether you are adding, replenishing hydraulic oil to the tank or changing the oil entirely, JBT
recommends the new oil should be filtered to meet the ISO 18/16/13 spec. Always add oil to the tank
through the in-tank filter installed in the reservoir. The fill ports are color coded, yellow with a blue bar.
JBT strongly recommends that owners work with their hydraulic oil suppliers to establish a
comprehensive sampling program to check the oil for excessive contaminants on a regular basis.
Use appropriate hydraulic oil with the viscosity grade corresponding to the operating temperature range
listed below.
TABLE 1 - OIL OPERATING TEMPERATURE RANGE
RECOMMENDED MINIMUM START-UP MAXIMUM OPERATING

HYDRAULIC OIL TEMPERATURE (OIL TANK)* TEMPERATURE (OIL TANK)
ISO VG 15 -40 ºC (-40 ºF) 66 ºC (150 ºF)
ISO VG 32 -29 ºC (-20 ºF) 74 ºC (165 ºF)
ISO VG 46 0 ºC (32 ºF) 82 ºC (180 ºF)**
ISO VG 68 10 ºC (50 ºF) 82 ºC (180 ºF)**
* In cold weather the start-up temperature can be increased by **Shutdown temperature.
using the optional heater inside the hydraulic tank.
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MAINTENANCE SPECIFICATIONS
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3. OPERATING TEMPERATURE
• Normal operating oil temperature (tank). . . . . . . . . . . . +52 ºC to +60 ºC (125 ºF to 140 ºF)
• Mission ambient temperatures range . . . . . . . . . . . . . . -40 ºC to +52 ºC (-40 ºF to +125 ºF)
For operating outside the normal weather operating temperature range, take precautions for proper
operation, such as avoiding cavitation (extremely cold weather) and overheating (hot weather).
NOTE: REFER TO COMPONENT MANUALS IN CHAPTER 5, MANUFACTURERS’

APPENDICES FOR SPECIFICATIONS ON FLUIDS AND LUBRICANTS FOR
OPERATING UNDER EXTREME WEATHER CONDITIONS.
4. FLUIDS CAPACITIES
• Engine oil (including filters). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 L ( 2.5 gal.)

• Cooling system (engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.0 L (15.0 gal.)
• Hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 L (32.0 gal.)
• Transmission including converter and filter . . . . . . . . . . . . . . . 12.3 L ( 3.3 gal.)
• Transmission Fluid Capacity
- Initial fill (new assembly). . . . . . . . . . . . . . . . . . . . . . . . . . 12.3 L (3.25 gal.)
- Refill (service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 L ( 2.0 gal.)
• Air conditioner compressor oil (empty system). . . . . . . . . . . . . 0.12 L ( 4 fl.oz.)
• Air conditioner refrigerant (freon) . . . . . . . . . . . . . . . . . . . . . . . 1.6 kg (3 lb. 10 oz.)
2-4
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5. RECOMMENDED FLUIDS AND LUBRICANTS
CAUTION
DO NOT MIX SYNTETHIC OILS WITH NON-SYNTHETIC OILS!
TABLE 2 - ENGINE OIL, TRANSMISSION FLUID AND COOLANT
JBT
ITEM RECOMMENDED OIL AND FLUIDS
PART NO.
623-5783 Engine oil Mobile Delvac 1, Synthetic 4W-40

If Mobile Delvac not available alternatives are as follows on a
temporary basis only with a reduced 200 hour oil change
interval:
• API CG-4 • ACEA-98E2

• API CF-4 • ACEA-98B4
• API CF • ACEA-98B3
• API SH • ACEA-98A2
• CCMC D5-PD2 • RVI-E2R
• MB228.1 • MIL-L2104G
• MAN271 • ALLISON CI4
• VOLVO VDS • VM 501/505
• MACK EO-L
105-0446 Transmission fluid Dexron or Mobil ATF D/M is recommended for use in
application requiring Dexron III H and Allison C-4 and Allison
TES-389. Below 0 ºF use TranSynd.
105-1301 Coolant Use a 50% / 50% mixture of glycol and distilled water for
storage and operating temperatures above -37 ºC (-34 ºF).
Use a 60% / 40% mixture of glycol and distilled water for
storage and operating temperatures below -37 ºC (-34 ºF).
NOTE: ANTIFREEZE FLUID SHALL MEET ASTM D-3306 REGARDLESS OF

MANUFACTURER.
TABLE 3 - ENGINE FUEL
ITEM RECOMMENDED FUEL
DF1 - DF2
Engine Fuel JP-5 - JP-8
2-DS15
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CAUTION
BIO-DIESEL BLENDS GREATER THAN 5% CAN REDUCE THE LIFE OF THE ENGINE IF USED.
FAILURES ATTRIBUTED TO THE USE OF BIO-DIESEL WILL NOT BE COVERED UNDER THE
WARRANTY.
TABLE 4 - BIODIESEL ENGINE FUEL
ITEM FUEL REQUIREMENTS
Bio-diesel Bio-diesel fuels meeting ASTM D 6751 specification, prior to blending can
be mixed up to 20% maximum by volume in petroleum diesel fuel. The
resulting mixture must meet the fuel properties listed in Table 5-1 of Detroit
Diesel literature 7SE270 and ASTM D-975 specification. Engine failures
attributed to the use of bio-diesel fuels will not be covered under the
manufacturer warranty.
NOTE: REFER TO MANUFACTURERS’ DATA, SECTION 12 FOR
DETROIT DIESEL LITERATURE 7SE270, LUBRICATING OIL,
FUEL AND FILTERS.
TABLE 5 - HEATER FUEL
ITEM RECOMMENDED FUEL
Diesel fuel DF1 and DF2
Diesel fuel Arctic DF-A
Heater Fuel Jet fuel JP-5 and JP-8
Kerosene
Bio-Diesel blend (5% max)
CAUTION
BIO-DIESEL BLENDS CAN REDUCE THE LIFE OF THE HEATER IF LEFT IN THE FUEL SYSTEM
FOR EXTENDED PERIODS OF TIME. FAILURES ATTRIBUTED TO THE USE OF BIODIESEL
WILL NOT BE COVERED UNDER THE WARRANTY.
2-4
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TABLE 6 - HYDRAULIC OIL
JBT PART NO. RECOMMENDED HYDRAULIC FLUID
MIL-H-83282
105-1315
NATO STD-H-537
TABLE 7 - LUBRICATING GREASE
JBT PART NO. RECOMMENDED LUBRICATING GREASE
628-0166 Grease, SYN-3001 14 oz. Cartridge
TABLE 8 - ELECTRICAL GREASE
JBT PART NO. RECOMMENDED ELECTRICAL GREASE
620-2858 Dow Corning #4 Insulating Compound MIL Spec 8660
TABLE 9 - AIR CONDITIONER LUBRICANT
JBT PART NO. RECOMMENDED AIR CONDITIOING LUBRICANT
628-0166 Sanden SP-20
TABLE 10 - AIR CONDITIONING SYSTEM REFRIGERANT
JBT PART NO. RECOMMENDED AIR CONDITIONING OIL AND REFRIGERANT
625-4992 R-134a Freon
TABLE 11 - 1000-HOUR (ANNUAL) FLUID

624-8289-1000F
ITEM PART NO. DESCRIPTION QTY. UNIT
1 105-0446 TRANSMISSION FLUID 15 qt.
2 105-0448 GEAR OIL, 75W-140 4 qt.
3 105-1301 ENGINE COOLANT FLUID 8 gal.
2-4
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6. EQUIPMENT ADJUSTMENT SETTINGS
The following adjustment settings are recommended for the properly functioning of the vehicle.
TABLE 12 - ADJUSTMENT SETTINGS CHART
ADJUSTMENT OPERATION SETTING ADJUSTMENT LOCATION
Engine idle speed 850–900 rpm Refer to Chapter 2, Section 5,

Engine high speed 1025–1050 rpm “Maintenance Procedures”.
6.9 ± 0.14 bar

Tire inflation air pressure All tires
(100 ± 2 psi)
Wheel lug nuts torque Follow a crisscross pattern and

271 N·m (200 lbf-ft.)
(front and rear) sequence.
TABLE 13 - FRONT AXLE TORQUE SETTINGS
ITEM DESCRIPTION N·m lbf-ft.
1 Drive shaft internal nut 373–441 275–325
2 Center bearing housing 108–122 80–90
3 Drive shaft and axle drive flange 122 90
4 U-joint retainer strap external nut 75–81 55–60
TABLE 14 - BRACE ASSEMBLY TORQUE SPECIFICATIONS
ORDER FASTENERS TORQUE
First Bracket connection 41 N·m (30 lbf-ft. / 360 lbf-in.)

Second Upper bracket 27 N·m (20 lbf-ft. / 240 lbf-in.)
Third Lower bracket 27 N·m (20 lbf-ft. / 240 lbf-in.)
2-4
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7. HYDRAULIC PRESSURE SETTINGS
NOTE: 1 bar = 100 kPa = 0.1 MPa = 14.5 psi.
NOTE: REFER TO “HYDRAULIC SCHEMATICS” IN CHAPTER 2, SECTION 7 FOR LOCATION

POINTS AND CHAPTER 2, SECTION 6, “TROUBLESHOOTING” FOR DP SCREENS
AND NAVIGATION.
8. PERFORMANCE SPECIFICATIONS
TABLE 15 - ENGINE SPECIFICATIONS AND OPERATING RPM
RATED POWER
ENGINE LOW IDLE HIGH IDLE
FULL LOAD
Detroit Diesel 92.5 kW (124 hp)

850 ± 30 rpm 3000–3150 rpm
D706LTE @ 3000 rpm
Driving Speeds
• Range 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 km/h ( 4.4 mph)
• range 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 km/h ( 7.1 mph)
• range 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5 km/h (11.5 mph)
• range d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.6 km/h (16.5 mph)
• range r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 km/h ( 3.3 mph)
Deck Lift Speed, Full Extension
• Deck raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 ± 4 seconds
• Deck lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 seconds
Deck Convey Speed
• Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 fpm (maximum)
2-4
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9. BOLT IDENTIFICATION CHART
TABLE 16 - STANDARD AND METRIC STEEL BOLTS AND NUTS
SAE HEX BOLTS SAE HEX NUTS
GRADE 1 OR 2 GRADE 5 GRADE 8 GRADE 1 OR 2 GRADE 5 GRADE 8
METRIC HEX BOLTS METRIC HEX NUTS
5.8 8.8 9.8 10.9 9 10
CLASS 5.8 CLASS 8.8 CLASS 9.8 CLASS 10.9 CLASS 9 CLASS 10
SAE HEX BOLTS METRIC HEX BOLTS
2 2
1 3 1 3
4 4
1. GRADE (BOLT STRENGTH) 1. GRADE (BOLT STRENGTH)

2. THREAD PITCH (THREADS PER INCH) 2. THREAD PITCH (DISTANCE BETWEEN
3. NOMINAL DIAMETER (INCHES) THREADS IN MILLIMETERS)
4. BOLT LENGTH (INCHES) 3. NOMINAL DIAMETER (MILLIMETERS)
4. BOLT LENGTH (MILLIMETERS)
2-4
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10. BOLT TORQUE SPECIFICATIONS
NOTE: THESE TORQUE VALUES ARE FOR REFERENCE ONLY. USE ONLY IF NOT
OTHERWISE GIVEN FOR A SPECIFIC MAINTENANCE PROCEDURE. IF NO TORQUE
IS PROVIDED FOR A SPECIFIC BOLT OR SCREW, REFER TO SAE, ISO OR OTHER
STANDARD FOR THE CORRESPONDING TORQUE SPECIFICATION.
TABLE 17 - STANDARD STEEL BOLTS TORQUE SPECIFICATIONS
Standard Dry Torque in Newton·meters and foot-pounds
Coarse SAE Grade 5 SAE Grade 8

Bolt Size
Threads 827 MPa (120 000 psi) 1034 MPa (150 000 psi
(in.)
per Inch Medium Carbon Heat Treated Steel Medium Carbon Alloy Steel
N·m lbf-ft. N·m lbf-ft.
1/4 (0.250) 20 13.6 10 19.0 14
5/16 (0.313) 18 25.8 19 39.3 29
3/8 (0.375) 16 44.7 33 63.7 47
7/16 (0.438) 14 73.2 54 105.8 78
1/2 (0.500) 13 105.8 78 161.3 119
9/16 (0.563) 12 154.6 114 229.1 169
5/8 (0.625) 11 208.8 154 311.8 230
3/4 (0.750) 10 348.4 257 515.2 380
7/8 (0.875) 9 517.9 382 813.5 600
1 (1.000) 8 795.9 587 1220.2 900
1-1/8 (1.125) 7 1076.5 794 1938.8 1430
1-1/4 (1.250) 7 1498.2 1105 2677.7 1975
1-3/8 (1.375) 6 2033.7 1500 3592.9 2650
1-1/2 (1.500) 6 2406.6 1775 4338.6 3200
1-5/8 (1.625) 5.5 3287.9 2425 5965.6 4400
1-3/4 (1.750) 5 4270.8 3150 7660.4 5650
1-7/8 (1.875) 5 5694.4 4200 10 304.2 7600
2 (2.000) 4.5 6169.0 4550 11 117.7 8200
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TABLE 18 - METRIC STEEL BOLTS TORQUE SPECIFICATIONS
Standard Dry Torque in Newton·meters and foot-pounds
Coarse Class 8.8 (Old 8G) Class 10.9 (Old 10K)

Bolt Size
Thread Pitch 785 MPa (113,800 psi) 980 MPa (142,200 psi)
(mm)
(mm) Medium Carbon Steel Medium Carbon Steel
N·m lbf-ft. N·m lbf-ft.
M6 1.00 8.1 6 10.8 8
M8 1.00 21.7 16 29.8 22
M10 1.25 54.2 40 61.0 45
M12 1.25 73.2 54 94.9 70
M14 1.25 120.7 89 158.6 117
M16 2.00 179.0 132 237.3 175
M18 2.00 246.8 182 320.0 236
M22 2.50 385.1 284 534.2 394
M24 3.00 568.1 419 772.8 570
TABLE 19 - 18-8 AND 316 STAINLESS STEEL BOLTS TORQUE SPECIFICATIONS
Standard Dry Torque in Newton·meters and inch-pounds

Bolt Size Threads
18-8 Stainless Steel 316 Stainless Steel
# per Inch
N·m lbf-in. N·m lbf-in.
40 0.59 5.2 0.62 5.5

#4
48 0.75 6.6 0.78 6.9
40 0.87 7.7 0.92 8.1

#5
44 1.06 9.4 1.11 9.8
32 1.08 9.6 1.14 10.1

#6
40 1.37 12.1 1.43 12.7
32 2.24 19.8 2.34 20.7

#8
36 2.49 22.0 2.60 23.0
24 2.58 22.8 2.69 23.8

#10
32 3.58 31.7 3.74 33.1
2-4
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1. GENERAL
WARNING
NOTE: REFER TO CHAPTER 2, SECTION 4, “MAINTENANCE SPECIFICATIONS”; CHAPTER 1,

SECTION 4, “SPECIFICATIONS”; AND CHAPTER 5, MANUFACTURERS’ APPENDICES
FOR SETTINGS AND ADJUSTMENT VALUES FOR ALL MAINTENANCE PROCEDURES
IN THIS SECTION.
The following procedures outline the necessary steps for adjustment of components for their proper
operation. These procedures may be necessary to be performed during regular maintenance and after
replacement or repair of components. Refer to Chapter 3, OVERHAUL for component removal and
installation.
Refer to the “LIST OF WARNINGS AND CAUTIONS USED IN THIS MANUAL” at the beginning of this
volume and to Chapter 2, Section 1, “Safety Precautions”. All warnings and cautions must be read,
understood and observed to ensure safety of operation and maintenance personnel.
NOTE: DRIVE SIDE REFERENCES ARE BASED ON U.S. AUTOMOTIVE STANDARDS, WHERE
THE DRIVER IS LOCATED ON THE LEFT HAND SIDE OF THE VEHICLE SITTING
DIRECTLY BEHIND A STEERING WHEEL FACING FORWARD.
WARNING
WARNING
VEHICLE UNATTENDED.
CAUTION

2-5
MAINTENANCE PROCEDURES
Page 1
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Halvorsen
2. SPROCKETS AND ROLLER CHAINS INSPECTION AND ADJUSTMENT
A. SPROCKETS INSPECTION
(1) Inspect sprockets for broken teeth.

(2) Inspect sprocket alignment and check for secure attachment to shafts.
CAUTION
WHEN REPLACING A SPROCKET, ALWAYS REPLACE THE CHAIN. USING AN OLD CHAIN ON
NEW SPROCKETS WILL CAUSE PREMATURE WEAR OF THE SPROCKETS.
B. ROLLER CHAINS INSPECTION
(1) Inspect chains for elongation by comparing with a new chain. If elongation is 3% or more
(3 links in 100 or about 1/2 link in 17), replace the chain.
(2) Inspect chain for discoloration. Brown or red color on chain or in the oil, indicates presence
of rust. Remove chain and inspect rollers, pins and links. If evidence of galling, excessive
wear or corrosion exists, replace chain.
(3) Inspect chain drives on convey rollers for proper adjustment.
C. ROLLER CHAINS ADJUSTMENT
Frequent adjustment of roller chains on the convey modules should not be required; however, a
check of the chain tension should be made periodically.
D. CONVEY MODULE CHAINS ADJUSTMENT
CAUTION
OVER-TIGHTENING THE CHAIN CAN CAUSE RAPID CHAIN AND SPROCKET WEAR, CHAIN
BREAKAGE, HYDRAULIC MOTOR FAILURE OR BEARING FAILURE ON THE ROLLER SHAFT.
Refer to Figure 1.
(1) Loosen the two bolts securing the hydraulic motor just enough to allow the motor to slide
when adjusting chain tension.
2-5
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JACKING SCREW
JACKING SCREW
Figure 1
CONVEY MODULE CHAIN ADJUSTMENT
(2) Loosen the outer lock nut on the motor jacking screw adjuster three or four turns.
(3) Tighten the inner nut on the motor jacking screw to move the hydraulic motor to tighten the
chain.
NOTE: UPON COMPLETION OF ADJUSTMENT, CHAIN SHOULD HAVE 12.7 MM (1/2 IN.)
DEFLECTION WHEN LIGHT THUMB PRESSURE IS APPLIED AT MID-SPAN OF THE
CHAIN.
(4) Tighten the two bolts to secure the motor and the jacking screw lock nut.
(5) Recheck the chain tension for proper deflection.
(6) Always lubricate chain with motor oil after making a chain tension adjustment.
3. FRONT AXLE REMOVAL AND INSTALLATION
CAUTION
WHEN HYDRAULIC JACKS ARE USED TO RAISE THE CHASSIS, THEY MUST BE PLACED
DIRECTLY UNDER THE AXLE MOUNTING PADS.
NOTE: BEFORE THE REMOVAL OF THE DRIVE AND STEER AXLE FOR REPLACEMENT,
CONTACT JBT FOR INSTRUCTIONS.
2-5
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A. DRIVE AND STEER FRONT AXLE REMOVAL
(1) Turn the battery disconnect switch on the battery box to the OFF position.
(2) Using a suitable lifting device or hydraulic jacks (10-ton capacity), raise the front of the
chassis until the drive wheels can be removed.
(3) Place shoring under chassis frame on both sides, then remove the hydraulic jacks or lifting
device. Drive wheels must be clear of the surface when the chassis frame is on the
shoring.
(4) Remove both drive wheels.
(5) Remove hydraulic hoses to the steering cylinders and differential lock cylinder. Mark all
hoses for location when removing. Install caps and plugs on hoses and fittings to prevent
contamination of the hydraulic system and components.
(6) Back off parking brake adjustment, without disconnecting hydraulic hoses, remove the 4
cap screws and nuts and remove parking brake assembly and lay on frame.
(7) Without removing hydraulic lines, remove 4 cap screws and remove service brake
assembly and lay on frame.
(8) Remove the drive shaft.
(9) Attach lifting straps (5-ton rating) around the axle housing on each side of the gear carrier
and remove all slack in the straps with a portable hoist.
(10) Remove the eight cap screws and nuts that secure the axle housing to the chassis frame,
then lower the axle to ground level.
NOTE: AN ALTERNATIVE METHOD TO REMOVE THE AXLE FROM UNDER THE CHASSIS
FRAME IS WITH A FORKLIFT. AXLE ASSEMBLY MUST BE SECURED TO THE
FORKLIFT TINES TO PREVENT MOVEMENT WHEN THE AXLE IS LOWERED AND
BEING MOVED.
B. DRIVE AND STEER FRONT AXLE INSTALLATION
CAUTION
AXLE HOUSING MOUNTING PAD AND FRAME PAD SURFACES MUST BE SMOOTH WITH NO
NICKS AND CLEAN OF ALL DEBRIS AND LUBRICANTS.
(1) Position the axle assembly directly under the chassis mounting pads and lift axle in
position.
(2) Install the eight axle mounting bolts, washers and nuts. Tighten the nuts just enough to
hold the axle in place. After all eight nuts are tightened, remove the lifting equipment and
slings. Tighten the mounting hardware, in a cross pattern, to 447 N·m (330 lbf-ft.).
(3) Check the connection between the drive shaft tubes from the transmission and drive axle
for alignment of “witness marks” (impression-stamped codes), then install drive shaft and
torque attaching hardware. Refer to Figure 2.
2-5
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NOTE: ALIGNMENT OF “WITNESS MARKS” MUST BE ACCURATE. ALIGNMENT OF DRIVE
SHAFT YOKES IS REQUIRED TO MAINTAIN DRIVE SHAFT BALANCE.
NOTE: APPLY THREAD LOCKING COMPOUND (LOCTITE) ON ALL SCREW THREADS.
DRIVE SHAFT SLIP YOKE DRIVE SHAFT TUBE
WITNESS MARKS - TWO PLACES

AXLE SIDE AND TRANSMISSION SIDE
Figure 2
WITNESS MARKS
(4) Connect all hydraulic hoses to the fittings.
(5) Check oil level in differential and wheel ends.
(6) Install service brake with 4 cap screws and nuts.
(7) Install parking brake assembly with 4 cap screws and nuts and adjust as outlined in
Chapter 3.
(8) Lubricate all points of the axle. Refer to Chapter 2, Section 3, “Preventative Maintenance”.
(9) Install drive wheels and torque wheel nuts to 271 N·m (200 lbf-ft.).
(10) Raise chassis, remove shoring and lower the chassis to ground level.
(11) Turn battery disconnect switch on the battery box to the ON position.
(12) With the help of an assistant, bleed the air from the park brake, service brake and
differential lock cylinder.
(13) Remove the maintenance stands and lower the deck fully. Remove the wheel chocks.
(14) Road check the loader for performance and inspect the axle assembly for oil leaks.
2-5
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Halvorsen
DIFFERENTIAL SHAFT
4
2
TRANSMISSION SHAFT
Figure 3
DRIVE SHAFT ALIGNMENT
2-5
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4. MAIN LIFT CYLINDERS REMOVAL AND INSTALLATION
NOTE: BEFORE THE REMOVAL OF THE MAIN LIFT CYLINDER FOR REPLACEMENT,
A. MAIN LIFT CYLINDERS REMOVAL
CAUTION
DUST CAP MUST BE REMOVED BY HAND. THE USE OF A STRAP WRENCH IS PERMITTED,
IF REQUIRED, TO INITIALLY LOOSEN THE DUST CAP.
CAUTION
PIVOT SHAFT CAP SCREWS MUST BE REMOVED OR DAMAGE TO THE CAP SCREWS OR
THE PIVOT SHAFT WILL OCCUR.
CAUTION
DO NOT PUSH PIVOT SHAFT PAST THE WELDMENT. THE SCISSORS ALSO PIVOT ON THIS
SHAFT.
(1) Turn the battery disconnect switch, on the battery box, to the OFF position.
(2) Disconnect the drive shaft at the transmission companion flange.
(3) Remove the four cap screws and nuts securing the drive shaft to the transmission
companion flange.
(4) Remove the two cap screws, nuts and washers, that secures the mid-ship bearing to the
chassis.
(5) At the differential end of the drive shaft assembly, remove the dust seal cover from the slip
yoke by turning it counterclockwise.
(6) Verify that the drive shaft and the slip yoke have impression stamped “witness marks” for
alignment and balance. Refer to Figure 2.
(7) Slide the splined end of the drive shaft out of the slip yoke and remove the drive shaft as a
complete assembly from the chassis.
(8) Remove the cap screws located on the left and right outside surfaces of the chassis frame,
that secure the lower pivot shafts (2, one per side) in the chassis.
NOTE: HYDRAULIC TUBES ROUTED ALONG CHASSIS FRAME WILL REQUIRE REMOVING
TO ACCESS THE RETAINING SCREWS AND FOR REMOVING THE PIVOT PIN.
INSTALL CAPS AND PLUGS ON ALL LINES AND FITTINGS THAT ARE REMOVED.
(9) On the left side of the scissors, remove the cap screw that retains the main lift cylinder
upper pivot shaft.
(10) Disconnect hydraulic lines on the cylinder to be removed. Install caps and plugs on lines
and fittings to prevent oil leakage and contamination.
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(11) Disconnect electrical wiring on hydraulic cylinder valves.
(12) Open bleeder screws on both hydraulic cylinders to remove residual pressure.
(13) To remove the right side main lift cylinder, use a dummy shaft that is slightly smaller than
the pivot shaft. Drive the upper pivot shaft towards the left side until it is clear of the
bearing in the cylinder upper clevis.
NOTE: DUMMY SHAFT MUST HAVE A SMALLER DIAMETER THAN THE CYLINDER PIVOT
SHAFT. SUGGESTED SHAFT SIZE: 66.7 mm x 1067 mm (2.625 in. x 42 in.).
NOTE: DO NOT REMOVE THE DUMMY SHAFT AT THIS TIME.
(14) To remove the left side main lift cylinder, use a dummy shaft and drive the upper pivot shaft
completely out of the scissors.
NOTE: DO NOT REMOVE THE DUMMY SHAFT AT THIS TIME.
(15) Position forklift, with side shift capability, at the side of the loader and with the tines above
the top of the cylinder barrel.
(16) Using a nylon-lifting strap around the cylinder barrel, secure the cylinder to the fork lift tine.
(17) Place a hydraulic power ram between the end of the lower pivot shafts, with the ram base
towards the cylinder that will not be removed and apply pressure to push on the pivot shaft
of the cylinder that is to be removed.
NOTE: THE BASE OF THE HYDRAULIC RAM WILL PUSH THE SHAFT ON THE CYLINDER NOT
BEING REMOVED BACK UNTIL IT IS FLUSH WITH THE WELDMENT. THE RAM WILL
THEN EXERT PRESSURE ON THE SHAFT FOR THE CYLINDER TO BE REMOVED.
(18) Place a floor jack under lower end of the cylinder and support the cylinder. Remove the
hydraulic ram.
(19) Push on the lower pivot shaft until it is just past the eye and spacers on the lower end of the
cylinder.
(20) Lift the cylinder with the forklift until it is above the chassis. This will force the cylinder to
collapse as the oil is forced out through the bleeder screws. Close the bleeder screws
when the cylinder is above the chassis.
(21) Using a nylon cargo strap around the cylinder rod, secure the top end of the cylinder to the
deck.
(22) Slide the dummy shaft, at the top of the cylinders, out of the scissors until the cylinder is
free.
(23) Remove the cylinder from the chassis.
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B. MAIN LIFT CYLINDERS INSTALLATION AND BLEEDING
CAUTION
INSTALLING MAIN LIFT CYLINDERS MAY BE POTENTIALLY HAZARDOUS DUE TO THE SIZE,
WEIGHT AND POSITION OF THE CYLINDERS. USE EXTREME CAUTION WHEN PERFORMING
THESE PROCEDURES.
(1) Attach a nylon lifting strap around the cylinder barrel, near the top end.
NOTE: CYLINDER ROD MUST BE FULLY RETRACTED WHEN INSTALLING CYLINDER IN THE
CHASSIS.
(2) Lift the cylinder into place with a forklift and lower the bottom end into the mounting bracket
on the chassis.
(3) Drive the lower pivot shaft into the spherical bearing in the eye on the bottom of the
cylinder.
NOTE: INSTALL THE SPACERS ON EACH SIDE OF THE SPHERICAL BEARING ON THE
PIVOT SHAFT AS THE SHAFT IS INSTALLED.
(4) Install and tighten the pivot shaft retaining cap screws on both sides.
(5) Reconnect the hydraulic tubes that were removed on the chassis to access the lower
cylinder pivot shafts.
(6) Connect the hydraulic hoses and wiring to the valve on the cylinder barrel.
(7) Turn the battery disconnect switch to the ON position.
(8) Turn the ignition switch to the ON position.
NOTE: DO NOT START THE ENGINE.
(9) Hold the EMERGENCY PUMP switch in the ON position.

(10) Extend cylinder rod by actuating the LIFT switch.
NOTE: POSITION CYLINDER WITH THE FORKLIFT AS THE CYLINDER IS EXTENDED TO

ALIGN THE UPPER BEARING WITH THE SCISSORS PIVOT SHAFT. DO NOT EXTEND
CYLINDER PAST THE SHAFT. IF CYLINDER ROD IS EXTENDED TOO FAR, OPEN
BLEEDER SCREW TO PUSH ROD BACK INTO CYLINDER FOR ALIGNMENT WITH THE
SHAFT.
(11) Drive upper pivot shaft through the spherical bearing and secure with the retaining screw.
(12) Install drive shaft in chassis, making sure that witness marks are aligned.
(13) Lubricate spherical bearings.
(14) Bleed air from cylinders.
CAUTION
DO NOT START ENGINE, USE THE EMERGENCY PUMP TO PROVIDE HYDRAULIC FLUID
WHEN BLEEDING AIR FROM THE MAIN LIFT CYLINDERS.
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NOTE: BLEED AIR FROM BOTH MAIN LIFT CYLINDERS AFTER REPLACING A CYLINDER.
(15) Actuate the emergency pump.

(16) Open only one (1) bleeder screw on one main lift cylinder at a time.
NOTE: EACH MAIN LIFT CYLINDER HAS THREE (3) BLEEDER SCREWS.
NOTE: THERE IS NO SEQUENCE TO OPENING THE BLEEDER SCREWS.
(17) When fluid being released from bleeder screw is clear and free of air bubbles, close
bleeder screw.
(18) Open the other bleeder screws, one at a time, on the same cylinder and when fluid being
released is clear and free of air bubbles, close bleeder screw.
(19) Bleed air from remaining main lift cylinder using procedure in steps 1 through 4.
(20) Actuate the emergency pump and raise the deck just high enough to remove the
Maintenance Stands, then lower the deck fully.
(21) Actuate the emergency pump and raise the deck to maximum height.
NOTE: CYLINDER MUST BE FULLY EXTENDED.
(22) Install Maintenance Stands in the #3 position.

(23) Leave cylinders in the fully extended position for a minimum of 20 minutes.
(24) Actuate the emergency pump and lower the deck until scissor rollers are in contact with the
Maintenance Stands.
(25) Bleed air from both main lift cylinders again using steps 1 through 5.
(26) Start engine and raise deck to remove Maintenance Stands.
(27) Lower the deck fully.
(28) Bleeding of cylinders is now complete.
5. HELPER CYLINDERS REMOVAL AND INSTALLATION
NOTE: BEFORE THE REMOVAL OF THE HELPER CYLINDER FOR REPLACEMENT,

A. HELPER CYLINDERS REMOVAL
Refer to Figure 4.
(1) Remove the nut on the bolt that retains the collar assembly on the rear axle shaft.
(2) Remove the collar assembly retaining bolt by driving it out of the axle shaft with a brass drift
punch or a punch of other soft material, to prevent damage to the retaining bolt.
(3) Remove the hydraulic hose attached to the helper cylinder and install caps and plugs on
the hose and fitting to prevent the entrance of dirt or other foreign material, that would
contaminate the hydraulic system.
(4) Place a lifting sling around the top of the cylinder rod and attach it to a portable engine
lifting hoist to support the cylinder when removing it from the axle shaft.
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NOTE: IF AN ENGINE HOIST IS NOT AVAILABLE, PLACE A PIECE OF PLYWOOD OR OTHER
SOFT MATERIAL, UNDER CYLINDER TO PROTECT THE CYLINDER FROM DAMAGE
WHEN IT IS BEING REMOVED.
CAUTION
USE EXTREME CARE WHEN REMOVING CYLINDER WHEN PORTABLE ENGINE HOIST IS NOT
AVAILABLE. PERSONAL INJURY CAN OCCUR IF CYLINDER IS DROPPED.
(5) Remove the collar assembly, outer thrust washer and hydraulic cylinder.
NOTE: ROCK THE CYLINDER FORE AND AFT, WHILE PULLING OUTWARD, TO REMOVE THE
CYLINDER FROM THE AXLE SHAFT. IF NECESSARY, APPLY PRESSURE WITH A
PRY BAR TO THE BACK SIDE OF THE CYLINDER TO FORCE THE CYLINDER
OUTWARD AS IT IS BEING ROCKED FORE AND AFT WHEN BEING REMOVED.
B. HELPER CYLINDERS INSTALLATION
Refer to Figure 4.
(1) Ensure that axle shaft is clean of all dirt and there are no nicks or other damage on the
bearing surfaces for the cylinder bushings.
(2) Install bushings in the housing on the bottom of the helper cylinder.
(3) Coat the bushings and shaft with grease to ease assembly.
(4) Lift cylinder with a portable engine hoist and install cylinder on the axle shaft.
NOTE: ENSURE THE INNER BRASS SPACER WASHER IS ON THE SHAFT AND AGAINST THE
BOGY WHEEL ASSEMBLY BEFORE INSTALLING THE CYLINDER.
(5) Install the outer collar assembly on the shaft and install the retaining bolt and nut.
NOTE: CHECK THE CONDITION OF THE TWO SPRINGS IN THE COLLAR ASSEMBLY AND
REPLACE IF DAMAGED OR DEFORMED.
(6) Remove the lifting equipment.

(7) Remove the caps and plugs from the hydraulic fittings and connect the hydraulic hose.
(8) Bleed the air from the helper cylinder. Refer to ‘C. HELPER CYLINDERS BLEEDING’.
(9) Start engine and raise the deck. Remove the scissors Maintenance Stands and lower the
deck.
(10) Shut down the engine.
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NUT
RETAINING BOLT
COLLAR ASSEMBLY
THRUST WASHER
GREASE FITTING
Figure 4
HELPER CYLINDER
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C. HELPER CYLINDERS BLEEDING
(1) Disconnect the wires on 7SOL valve. Refer to Chapter 2, Section 2, “System Overview” for
solenoid valves locations.
(2) To extend the cylinder in order to bleed air from the cylinder, actuate and hold the
EMERGENCY PUMP switch in the ON position and the AUX. DECK RAISE AND LOWER
switch in the UP position. Refer to Figure 5.
AUXILIARY DECK
RAISE/LOWER
WORK LIGHTS
EMERGENCY
PUMP SWITCH
IGNITION/START SWITCH
EMERGENCY (MAINTENANCE USE ONLY)
STOP SWITCH
SHUTDOWN OVERRIDE
SWITCH
Figure 5
MAIN PANEL
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(3) Loosen bleeder screw to bleed the air in the cylinder and tighten bleed screw securely.
Refer to Figure 6.
BLEEDER SCREW
Figure 6
HELPER CYLINDER BLEEDER SCREW
(4) Reconnect wires to 7 SOL.

(5) Start the engine and raise the deck.
(6) Remove the scissors Maintenance Stands and lower the deck.
(8) Check the fluid level in the hydraulic reservoir and refill as required.
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6. SCISSORS LOWER ROLLERS REMOVAL AND INSTALLATION
WARNING
THIS IS A MANDATORY SAFETY PRECAUTION. THE NORMAL SCISSORS MAINTENANCE
STANDS CANNOT BE INSTALLED WHEN REMOVING AND REPLACING ROLLERS. ENSURE
TO PROPERLY SUPPORT THE DECK AND SCISSORS.
Refer to Figure 7.
A. REMOVE LOWER ROLLERS ON INNER SCISSORS
(1) Chock wheels to prevent movement of the loader.

(2) Start engine, raise deck to align the center of the roller shaft horizontally with the hole in the
chassis frame. Turn off the engine.
(3) Attach a lift chain or sling to the front end of the deck and apply tension to the chain with an
overhead hoist.
(4) Remove the roller shaft retention cap screw in the scissors cross tube.
(5) Place a hydraulic jack under the scissors cross tube and raise the scissors until the roller
shaft is centered vertically with the hole in the chassis frame.
NOTE: HYDRAULIC JACK MUST BE RATED AT 10-TON OR GREATER CAPACITY.
(6) Thread a slide hammer in the end of the roller shaft and remove the shaft from the scissors
cross tube, thrust washer and roller.
(7) Roll the scissors lower roller forward on the chassis track to clear the scissors to remove
for repair or replacement.
B. INSTALL LOWER ROLLER ON INNER SCISSORS
(1) Lift roller into chassis frame forward of the scissors, then roll the roller towards the rear and
align the bore of the assembly with the hole in the chassis frame.
NOTE: THE CHASSIS ROLLER TRACK MUST BE SMOOTH, CLEAN AND FREE OF ANY
LUBRICANT.
(2) Insert the pivot shaft through the opening in the chassis frame, through the roller and thrust
washer and into the scissors cross tube. Install the shaft retention bolt.
NOTE: THE HOLE IN THE SHAFT MUST BE INDEXED WITH THE HOLE IN THE CROSS TUBE
FOR THE RETENTION BOLT.
(3) Lower the scissors onto the chassis frame and remove the hydraulic jack.
(4) Lubricate roller.
(5) Remove the hoist and lifting chain or strap, then have the assistant start the engine and
lower the deck.
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SHAFT RETENTION
CAP SCREW ROLLER
Figure 7
LOWER ROLLER ON INNER SCISSORS
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7. BRAKES ADJUSTMENTS
NOTE: REFER TO CHAPTER 3, SECTION 2, FOR PARK BRAKE OVERHAUL PROCEDURE.
A. PARK BRAKE ADJUSTMENT
Refer to Figure 8.
NOTE: THE PARK BRAKE IS SPRING APPLIED AND HYDRAULICALLY RELEASED. THE
LOADER MUST BE RUNNING TO ADJUST THE PARKING BRAKE.
(1) Start the loader. Keep the transmission selector in the neutral position. Ensure the parking
brake is disengaged (parking brake switch in the OFF position).
(2) Loosen lock nut (1) and adjusting screw (2) on brake caliper.
Figure 8
PARK BRAKE ADJUSTMENT
(3) Place a 0.30 mm (0.012 in.) thick shim between the disc and one of the linings (loader must
be running with the parking brake disengaged).
(4) Tighten the adjusting screw (2) until it is just possible to remove the shim.
(5) Torque lock nut (1) at 27–37 N·m (22–27 lbf-ft.) while holding the adjusting screw (2) with a
wrench. Remove the shim and release the hydraulic pressure by positioning the park
brake switch in the ON position (applies the brake).
(6) Raise deck off Maintenance Stands, remove Maintenance Stands and ready loader for
operation.
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B. PARKING BRAKE FORWARD MOVEMENT FUNCTION CHECK
NOTE: FORWARD MOVEMENT FUNCTION CHECK TO BE PERFORMED IN THE CAB.
(1) Start the loader.

(2) Place foot pressure on the service brake foot pedal and release parking brake.
(3) Shift transmission to drive.
(4) Apply parking brake.
(5) Release foot brake.
(6) Increase engine speed slowly to verify parking brake holds (do not exceed 1200 rpm).
Ensure loader does not move.
C. PARKING BRAKE REVERSE MOVEMENT FUNCTION CHECK
NOTE: PLACE CHOCKS APPROXIMATELY 50 MM (2 IN.) FROM THE FRONT AND REAR OF A
TIRE TO PREVENT EXCESSIVE MOVEMENT OF THE LOADER IN EITHER FORWARD
OR REVERSE DIRECTION SHOULD THE PARKING BRAKE FAIL.
NOTE: FORWARD MOVEMENT FUNCTION CHECK TO BE PERFORMED IN THE CAB.

(3) Shift transmission to reverse.
(6) Increase engine speed slowly to verify parking brake holds (do not exceed 1200 rpm).
Ensure loader does not move.
D. FRONT SERVICE BRAKE ADJUSTMENT
NOTE: REFER TO CHAPTER 3, SECTION 2, FOR FRONT SERVICE BRAKE OVERHAUL

PROCEDURE.
NOTE: REFER TO CHAPTER 5, SECTION 2, “MANUFACTURERS’ DATA” FOR REAR SERVICE

BRAKE INFORMATION.
(1) Service brake on drive axle. Drive shaft disc brake assembly does not require adjusting.
(2) Service brakes on bogy wheels. Bogy wheel disc brake assemblies do not require
adjusting.
E. FRONT SERVICE BRAKE BLEEDING
(1) Start engine and have assistant hold service brake.

(2) Attach a clear plastic tube from the bleeder to a suitable container.
(3) Loosen bleeder and observe flow of fluid.
(4) When all air is expelled close bleeder and release service brake.
(5) Bleed all remaining calipers.
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8. ENGINE REMOVAL AND INSTALLATION
NOTE: BEFORE THE REMOVAL OF THE ENGINE FOR REPLACEMENT, CONTACT JBT FOR
INSTRUCTIONS.
NOTE: WHEN IT IS NECESSARY TO REMOVE THE ENGINE FROM THE CHASSIS, THE
ENGINE AND TRANSMISSION ARE REMOVED TOGETHER AS AN ASSEMBLY.
CAUTION
TO PREVENT ENGINE DAMAGE AND POSSIBLE COMPLETE DESTRUCTION OF THE

TURBOCHARGER, ALWAYS COVER TURBOCHARGER INLET AND EXHAUST OPENINGS TO
PREVENT THE ENTRANCE OF ANY FOREIGN OBJECT.
A. ENGINE REMOVAL
(1) Turn battery disconnect switch on the battery box to the OFF position and disconnect
battery cables.
(2) Place drain pan under transmission, remove transmission oil pan drain plug and drain
transmission fluid. Replace drain plug in transmission oil pan.
(3) Disconnect all hydraulic hoses connected to transmission and install caps and plugs on
hoses and fittings to prevent the entrance of foreign material that would contaminate the
system. Mark each hose as it is removed so that it will be installed on the correct fitting
upon re-installation of engine/transmission assembly.
(4) Remove external components and wiring on transmission.
(5) Tie all cables and hoses to the chassis frame for clearance and to prevent damage when
engine/transmission assembly is removed.
(6) Disconnect drive shaft at the transmission flange.
(7) Place drain pan under engine, remove oil pan drain plug and drain engine oil. Replace
drain plug in engine oil pan.
(8) Place drain pans under the engine and coolant radiator and drain coolant system. Remove
surge tank cap to vent cooling system during draining.
(9) Disconnect fuel lines and install caps and plugs to prevent leakage and the entrance of
foreign material that could possibly contaminate the fuel system.
(10) Disconnect all electrical wiring and temporally tie back to chassis frame to prevent damage
to the harnesses and conductors.
(11) Disconnect and remove coolant pipes and hoses on engine.
(12) Remove air inlet pipe and hose from inlet on the turbocharger air pump.
(13) Remove exhaust pipe from the outlet on the turbocharger.
(14) Remove the bolt on generator belt tension adjuster and remove belts from generator
sheave. Pull generator outward to access the socket head cap screws that hold the main
hydraulic pump mounting bracket to the engine block on the right side.
(15) Place shoring under the pump mounting bracket for the pump to rest on when it is
removed.
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(16) Remove clamps and tie-wrap restraints on all hydraulic hoses that are attached to the main
pump. DO NOT disconnect any hydraulic hoses on the pump.
(17) Remove the socket head screws on each side of the engine that attach the pump mounting
bracket to the engine block.
(18) Carefully pull the pump assembly away from the engine. When clear, lower the assembly
onto the shoring.
(19) Install a lifting chain to the lifting brackets on the engine and, with an engine hoist, remove
all slack in the lifting chain. Lifting chain must be positioned to lift the engine/transmission
assembly as level as possible.
(20) Remove the eight hex head nuts and cap screws that secure the four engine and
transmission motor mounts to the chassis cross members.
(21) Lift the engine and transmission high enough to clear all fixed chassis components and
remove the assembly from the chassis.
B. ENGINE INSTALLATION
NOTE: ENGINE AND TRANSMISSION MUST BE INSTALLED IN THE LOADER AS A

COMPLETE ASSEMBLY.
(1) Install an engine lifting chain on the two engine lifting brackets on the engine.
(2) Position the lifting chain on the engine hoist to pick up the engine/transmission assembly
as level as possible before moving the assembly into the chassis.
(3) Carefully lower the engine and transmission assembly and align the motor mounts with the
holes in the chassis cross-members.
(4) Install the eight cap screws and hex head nuts in the motor mounts (two in each motor
mount) and tighten the hex head nuts to specifications.
NOTE: INSTALLATION OF THE PUMP ASSEMBLY MAY REQUIRE ROTATING THE PUMP
COUPLING TO INDEX WITH THE MATING HALF OF THE COUPLING ATTACHED TO
THE ENGINE CRANKSHAFT.
(5) Install hydraulic pump assembly on front of engine. When mounting bracket is aligned with
the threaded holes in the engine block, insert all four of the socket head screws and tighten
to specifications.
(6) Install generator drive belts on generator sheave and move generator out to tension the
belts to specifications. When the belt is tensioned, tighten cap screw securely on the
slotted tension bracket.
NOTE: FLANGES MUST BE CLEAN AND SMOOTH.
(7) Connect drive shaft to the transmission flange and tighten the four nuts on the cap screws
to specifications.
(8) Remove caps and plugs from hydraulic lines and fittings and reconnect to transmission.
(9) Install external components on transmission that were removed in order to remove the
engine and transmission from the chassis.
(10) Remove protective covers from the turbocharger inlet and exhaust openings and connect
the exhaust pipe and inlet hose.
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(11) Install the engine coolant hoses and pipes.
(12) Install the electrical harnesses and wiring. Secure the harnesses and wiring with tie wraps
to prevent chafing or mechanical damage.
(13) Refill the transmission with transmission fluid.
(14) Fill engine with lubricating oil.
(15) Remove caps and plugs on fuel lines and connect the hoses to the engine.
(16) Bleed air from the fuel system. Loosen the bleed screw on top of the secondary fuel filter.
Turn on the IGNITION switch, when a continuous flow of fuel is vented from the bleeder
screw, tighten the bleeder screw and turn off the IGNITION switch.
NOTE: IF THE STROKE OF THE LEVER ON THE FUEL PUMP APPEARS TO BE SHORT,
ROTATE THE ENGINE ONE-HALF REVOLUTION SO THAT THE FUEL PUMP LEVER IS
ON THE LOW PART OF THE CAM ON THE CAMSHAFT.
(17) Fill cooling system with coolant. Use coolant with the correct ratio of glycol and water.
(18) Connect battery cables to the batteries and turn the battery disconnect switch on the
battery box to the ON position.
NOTE: ALWAYS CONNECT THE NEGATIVE BATTERY CABLE LAST.
(19) Start engine and allow engine to warm up at the idle position.
NOTE: IMMEDIATELY CHECK INSTRUMENT GAUGES FOR ENGINE OIL PRESSURE AND
OBSERVE GAUGES DURING THE WARM-UP PERIOD FOR NORMAL OPERATION.
(20) During the warm-up period, monitor the engine for oil leaks and the coolant level. Shut
down the engine immediately if oil pressure is low or there is any abnormal noise.
(21) Once the engine has warmed up, shut the engine down and recheck all fluid levels.
9. TRANSMISSION REMOVAL AND INSTALLATION
NOTE: BEFORE THE REMOVAL OF THE TRANSMISSION FOR REPLACEMENT, CONTACT

JBT FOR INSTRUCTIONS.
A. TRANSMISSION REMOVAL
(1) Turn battery disconnect switch on the battery box to the OFF position and disconnect
battery cables.
(2) Place drain pan under transmission, remove transmission oil pan drain plug and drain
transmission fluid. Replace drain plug in transmission oil pan.
(3) Disconnect all hydraulic hoses connected to transmission and install caps and plugs on
hoses and fittings to prevent the entrance of foreign material that can contaminate the
system. Mark each hose as it is removed so that it will be installed on the correct fitting
upon re-installation of transmission.
(4) Remove external components, oil level dipstick tube and wiring on transmission.
(5) Tie all cables and hoses to the chassis frame for clearance and to prevent damage when
transmission is removed.
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(6) Disconnect drive shaft at the transmission flange.
(7) Remove access cover on bottom of engine flywheel housing and remove the six bolts that
attach the torque converter to the drive plate.
NOTE: ROTATE THE TORQUE CONVERTER FOR ACCESS TO EACH MOUNTING BOLT BY
PRYING ON THE TEETH OF THE RING GEAR THROUGH THE ACCESS HOLE.
(8) Lift engine and transmission slightly by attaching a portable engine hoist to the
transmission.
(9) Remove the two 5/8 in. cap screws on each side of the transmission that secure the
chassis mounting brackets to the transmission case.
(10) Place shoring under the engine flywheel housing to support the engine and transmission.
(11) Remove the chassis cross member under the transmission.
(12) Lower the engine and transmission onto the shoring.
NOTE: SHORING SHOULD SUPPORT THE ENGINE AND TRANSMISSION AT

APPROXIMATELY THE SAME HEIGHT AS THE CROSS MEMBER.
(13) Remove the twelve cap screws that attach the transmission to the engine flywheel housing.
(14) Carefully separate the transmission from the engine.
CAUTION
DO NOT ALLOW THE FRONT OF THE TRANSMISSION TO BE LOWER THAN LEVEL TO

PREVENT THE TORQUE CONVERTER FROM SLIDING FORWARD AND OUT OF THE
TRANSMISSION.
(15) Immediately attach a restraint strap on the converter to secure the converter on the
transmission before continuing to remove the assembly from the chassis.
(16) Remove the transmission assembly from the chassis.
B. TRANSMISSION INSTALLATION
CAUTION
IF A CONDITION OCCURS THAT INTRODUCES DEBRIS INTO THE TRANSMISSION

HYDRAULIC SYSTEM, A COMPLETE CLEANUP OF THE OIL COOLER AND HYDRAULIC LINES
IS REQUIRED BEFORE REPLACEMENT TRANSMISSION IS INSTALLED.
(1) Install lifting chain to the pads on top of the transmission case.
(2) With an engine hoist, pick up the transmission and move it into position at the back of the
engine. Transmission must be level, end to end, when it is being installed.
(3) Remove the torque converter retaining device, then rotate the converter to align the driving
lugs with the drive plate on the engine.
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(4) Carefully move the transmission forward to the engine flywheel housing and ensure that
the torque converter pilot enters the engine drive plate. Transmission must mate to the
engine housing surface without any force and the torque converter should be able to be
rotated easily by hand through the access hole.
(5) Install the twelve cap screws to secure the transmission to the engine housing.
(6) Install the six torque converter drive cap screws in the drive plate only finger-tight until they
are all in place. Tighten the cap screws to specifications. Install the cover over the access
hole.
(7) Lift the engine and transmission slightly and remove the shoring from under the engine
housing.
(8) Install the transmission cross member and bolt the support brackets to the transmission
case with the 5/8-in. bolts.
(9) Install the bolts through the frame and cross member and tighten securely.
(10) Remove lifting equipment and lifting chain.
(11) Connect drive shaft to transmission drive flange.
NOTE: FLANGES MUST BE CLEAN AND SMOOTH.
(12) Install external components, oil dipstick tube and electrical wiring.
(13) Reconnect all hydraulic hoses.
(14) Remove and replace auxiliary filter element.
(15) Refill the transmission with fluid.
CAUTION
CONTAINERS OR FILLERS THAT HAVE BEEN USED TO HANDLE ANTIFREEZE OR ENGINE

COOLANT SOLUTION MUST NEVER BE USED FOR TRANSMISSION FLUID. ANTIFREEZE
AND COOLANT SOLUTIONS CONTAIN ETHYLENE GLYCOL WHICH, IF INTRODUCED INTO
THE TRANSMISSION, CAN CAUSE THE CLUTCH PLATES TO FAIL.
(16) Start engine and allow sufficient time for warm-up of transmission fluid. Perform HOT oil
level check.
(17) Service cooling system as outlined in ‘22. COOLANT SYSTEM LEVEL AND REFILLING’.
(18) Drive the loader and check for proper shifting and fluid leaks.
(19) Recheck the transmission fluid level after driving.
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10. FORWARD DECK SHIFT AND ROLL CYLINDERS REPLACEMENT
CAUTION
DO NOT REMOVE THE FRONT SIDE SHIFT BOGY ASSEMBLY UNTIL ALL REPLACEMENT
SERVICE PARTS ARE ON HAND AND READY TO BE INSTALLED. THE FRONT SIDE SHIFT
BOGY ASSEMBLY IS A MAJOR STRUCTURAL ITEM. TO AVOID DAMAGE, THE LOADER
MUST NOT BE LEFT IN THIS DISASSEMBLED STATE FOR A LONG PERIOD OF TIME.
NOTE: THE LEFT AND RIGHT ROLL CYLINDERS ARE ATTACHED TO THE DECK SIDE SHIFT
CYLINDER ROD. TO REPLACE EITHER ROLL CYLINDER, THE SIDE SHIFT
CYLINDER BOGY ASSEMBLY MUST BE REMOVED.
NOTE: HEAVY-LIFTING EQUIPMENT IS REQUIRED. A 6800 KG (15 000 LB.) CAPACITY

FORKLIFT WITH FORK SIDE SHIFT CAPABILITIES OR AN OVERHEAD CRANE OF THE
SAME CAPACITY MUST BE USED TO SAFELY SUPPORT THE FRONT OF THE DECK
DURING THIS PROCEDURE.
NOTE: ONCE THE DECK AND SCISSORS ARE DISCONNECTED, THE DECK WILL NEED TO
BE LIFTED AND MOVED FORWARD APPROXIMATELY 0.60 M (2 FT.) TO GAIN
CLEARANCE TO SAFELY REMOVE THE FRONT SIDE SHIFT CYLINDER BOGY
ASSEMBLY. HEAVY-DUTY LIFTING SLINGS OR CHAINS WITH A MINIMUM TOTAL
CAPACITY OF 6800 KG (15 000 LB.) IS REQUIRED.
NOTE: THE LOADER MUST BE PARKED IN A LEVEL LOCATION THAT HAS SUFFICIENT
SPACE SUROUNDING THE LOADER TO ALLOW THE FORKLIFT TO SAFELY
APPROACH THE LOADER FROM ALL SIDES.
A. LOADER DECK PREPARATION
If using a forklift to support the deck, the folding walk-deck and handrails on the non-cab side of
the loader must be configured for shipping. If using an overhead crane, proceed to step (5).
(1) Remove the forward two (2) folding walk-deck and handrail sections adjacent to front deck
lifting rings. Refer to Figure 9.
(2) Remove the retaining pins on each of the folding walk-deck and handrail sections on the
non-cab side of the loader.
(3) Lift up and fold the walk-deck and handrail section on top of the deck. Refer to Figure 9.
(4) Install all of the retaining pins to secure the folding walk-deck and handrail sections.
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DECK LIFT RINGS
FOLD
WALKDECK/HANDRAIL
REMOVE TWO
HANDRAILS
DECK TIE DOWN LUGS

(BOTH SIDES)
HEADLIGHT, MARKER LIGHT,
AMBER LIGHT
Figure 9
LOADER DECK PREPARATION
(5) Start the engine. Raise the deck to a height so the inner scissor lower rollers are between
the first and second maintenance stand position.
(6) Install both maintenance stands in the FIRST maintenance stand position. DO NOT
LOWER THE DECK FROM THIS POSITION UNTIL INSTRUCTED TO DO SO.
B. CENTER AND LEVEL THE DECK
(1) From within the cab, actuate and hold the AUTO CENTER AND LEVEL switch on the cab
dash panel until the pitch, roll and shift indicator lights on the dash panel are not
illuminated.
(2) From outside of the cab, visually verify the deck platform is centered and level.
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C. REMOVE MISCELLANEOUS ITEMS
(1) At the rear of the loader, unplug and remove the three (3) limit switches located on the
inside of the deck bumper. Save hardware for re-use. Refer to Figure 10.
(2) At the front of the deck, remove the two (2) tie down lugs and backing plates located on the
deck I-beams. Discard all hardware. Refer to Figure 9.
(3) At the front of the deck, unplug the Cab side marker light, head light and amber light from
the deck electrical harness. Refer to Figure 9.
(4) Remove the headlight housing with attached lights. Save hardware for re-use.
LIMIT SWITCHES
Figure 10
DECK BUMPER LIMIT SWITCHES
D. DISCONNECT THE ROLL CYLINDER HYDRAULICS
(1) Label each of the extend and retract hydraulic hoses connected to the front roll cylinders.
These ports should be labeled on the bottom of the roll cylinders. The ports labeled “E” are
the extend ports and the ports labeled “R” are the retract ports.
(2) Disconnect the four (4) hydraulic hoses from the two front roll cylinders hydraulic ports.
Use a drain pan to collect hydraulic fluid. Install hydraulic plugs on the four (4) hydraulic
hoses to prevent contamination. Refer to Figure 11.
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UPPER FASTENERS
LOWER FASTENERS
ROLL CYLINDER
HYDRAULICS
Figure 11
ROLL CYLINDER HYDRAULICS AND FASTENERS
E. SECURE LIFTING PROVISIONS TO THE DECK
WARNING
HEAVY-DUTY LIFTING PROVISIONS SUCH AS SLINGS OR CHAINS USED TO SUPPORT THE
DECK PLATFORM SHALL HAVE A MINIMUM CAPACITY OF 6800 KG (15 000 LB.).
(1) Secure heavy-duty lifting sling or chains to the two (2) forward deck lifting rings. Refer to
Figure 9. Be sure the lifting provisions have a the minimum total capacity required.
(2) Secure the lifting provisions to an overhead crane or a set of forklift tines. Be sure the
selected lifting equipment has the minimum lifting capacity required. Leave enough slack
in the lifting provisions to allow the loader’s deck to fully side shift to each side. Deck side
shift is necessary to remove the top roll cylinder mounting fasteners.
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WARNING
HEAVY-LIFTING EQUIPMENT USED TO SUPPORT THE DECK PLATFORMS SHALL HAVE A
MINIMUM CAPACITY OF 6800 KG (15 000 LB.) AND BE CAPABLE OF MOVING THE DECK
PLATFORM FORWARD APPROXIMATELY 0.60 M (2 FT.) ONCE THE DECK AND SCISSORS
ARE DISCONNECTED.
F. REMOVE UPPER FASTENERS
Follow the instruction below to remove the upper fasteners that secure the roll cylinders to the
scissor structure.
(1) Start the engine.
(2) From within the cab, actuate and hold the SHIFT toggle switch until the deck is fully shifted
to the non-cab side.
(3) Remove and discard the upper two (2) fasteners that secure the non-cab side roll cylinder
to the scissors. Do not remove the bottom two (2) fasteners until instructed to do so. The
lifting provisions may need to be temporarily adjusted during this process to remove the
load on the roll cylinder fasteners. Refer to Figure 11.
to the Cab side.
(5) Remove and discard the top two (2) fasteners that secure the Cab side roll cylinder to the
scissors. Do not remove the bottom two (2) fasteners until instructed to do so. The lifting
provisions may need to be temporarily adjusted during this process to remove the load on
the roll cylinder fasteners. Refer to Figure 11.
(6) From within the cab, actuate and hold the AUTO CENTER/LEVEL switch until the shift
indicator lights on the dash panel are not illuminated. The deck should be centered.
(8) Shut down the engine and turn the battery disconnect OFF.
G. DISCONNECT ELECTRICAL COMPONENTS
(1) Toward the front of the scissors, unplug and remove the two (2) side shift limit switches
17LS and 18LS from their respective mounting brackets on the scissors. These limit
switches should be attached to a lanyard that is also attached to the deck I-beams. Save
hardware for re-use. Refer to Figure 12 for limit switch locations.
NOTE: THE LANYARDS ATTACHED BETWEEN THE DECK AND SIDE SHIFT CYLINDER LIMIT
SWITCHES SHOULD REMAIN ATTACHED TO THESE ITEMS. TIE WRAP THE LIMIT
SWITCHES TO THE DECK TO AVOID DAMAGING THESE ITEMS.
(2) Unplug the two twelve pin electrical connectors near the Cab side roll cylinder. This
electrical connections are located directly behind the front side shift cylinder. Some loader
functions will not operate while this electrical connection is disconnected.
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H. DISCONNECT THE SIDE SHIFT CYLINDER HYDRAULICS
(1) Label the cab side and non-cab side hydraulic hoses connected on the front side shift
cylinder. Refer to Figure 12.
DISCONNECT
ELECTRICAL
CONNECTIONS LIMIT SWITCHES
17LS AND 18LS
SIDE SHIFT CYLINDER

HYDRAULIC PORTS
Figure 12
REAR VIEW OF FRONT SIDE SHIFT BOGY ASSEMBLY
(2) Disconnect the two (2) hydraulic hoses from the front side shift cylinder. Use a drain pan to
collect hydraulic fluid. Install hydraulic plugs on the two (2) hydraulic hoses.
WARNING
(3) Remove the forward pin attaching the deck linkage to the deck. Support the deck linkage
throughout this process to prevent serious injury to personnel. The lifting provisions may
need to be temporarily adjusted during this process to remove the load on the pin. The
rear pin in the deck linkage does not need to be removed. Refer to Figure 13.
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I. REMOVE THE FRONT SIDE SHIFT BOGY ASSEMBLY
Refer to Figure 13.

(1) Adjust the tension in the lift provisions so the front portion of the deck is completely
supported.
(2) Remove and discard the four (4) remaining fasteners that secure the front roll cylinders to
the scissors.
(3) Lift the deck high enough using the heavy lifting equipment so the bottom of the side shift
cylinder is above the deck linkage attached to the front of the scissors.
(4) Move the deck forward until the side shift cylinder is in front of the deck linkage.
(5) Install two sets of wooden blocks between the scissors and the deck.
(6) Lower the deck until it is completely resting on the wooden blocks. The deck and scissors
should not be contacting each other.
(7) Position fork lift tines (using optional extensions as needed) under the center of the side
shift bogy assembly so it is completely and safely supporting the assembly. Refer to
Figure 13 for support location.
(8) Remove the two (2) pins that attach the side shift cylinder bogy assembly to the deck
structure. Save hardware for reuse.
(9) Lift the side shift cylinder bogy assembly high enough to clear the deck link and move it
forward approximately one foot. The side shift cylinder bogy assembly should be
completely and safely supported by the forklift.
(10) Rotate the side shift cylinder bogy assembly so it can be lowered out from under the deck.
CAUTION
DO NOT OPERATE THE LOADER WHILE THE FRONT SIDE SHIFT BOGY IS REMOVED TO
PREVENT DAMAGING THE LOADER. THE HEAVY LIFTING EQUIPMENT SHOULD REMAIN.
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FORK LIFT PIVOT PIN

TINE/PALLET (BOTH SIDES)
SUPPORT
LOCATION
REMOVE DECK
LINKAGE FRONT
PIN
LEAVE DECK
LINKAGE REAR
PIN
WOODEN
SUPPORT BLOCKS
Figure 13
SIDE SHIFT BOGY ASSEMBLY CYLINDER REMOVAL
11. FORWARD DECK SHIFT AND ROLL CYLINDERS INSTALLATION
A. INSTALL THE FRONT SIDE SHIFT BOGY ASSEMBLY
Refer to Figure 13.

(1) Place the side shift cylinder bogy assembly on the ends of fork lift tines so the assembly is
at a 45 degree bias to the fork lift tines. Secure the assembly to prevent it from rolling.
(2) Lift the side shift cylinder bogy assembly into the deck frame. Rotate the side shift cylinder
bogy assembly so the pivot arm assemblies, on the ends of the side shift cylinder, fit within
the deck frame I-beams.
(3) Position the side shift cylinder assembly so the two (2) pivot arm pins can be installed to
secure the side shift cylinder assembly to the deck.
(4) Secure the pivot arm pins to the deck using fasteners with thread locker applied to the
leading threads.
(5) Lift the deck high enough using the heavy lifting equipment so the bottom of the side shift
cylinder is above the deck linkage attached to the front of the scissors.
(6) Remove the wooden Maintenance Stands that are between the scissor and deck.
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(7) Move the deck backwards until the roll cylinders are aligned with the scissors. Slowly
lower the deck until the roll cylinders are within the supporting plates on the scissors.
Install the two (2) lower fasteners that secure both roll cylinders to the scissors. Do not
completely tighten the fasteners. Refer to Figure 14.
DECK LINKAGE
UPPER FASTENERS
(BOTH SIDES)
LOWER FASTENERS
(BOTH SIDES)
ROLL CYLINDER
HYDRAULICS
Figure 14
SIDE SHIFT CYLINDER BOGY INSTALLATION
WARNING
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(8) Attach the front deck linkage to the deck. Manually support the deck linkage throughout
this process to prevent serious injury to personnel. The lifting provisions may need to be
temporarily adjusted during this process to remove the load on the pin. Refer to Figure 14.
B. CONNECT THE SIDE SHIFT CYLINDER HYDRAULICS
(1) Install new hydraulic fittings with O-ring seals in the hydraulic side shift cylinder ports.
Refer to Figure 15.
(2) Connect the two (2) hydraulic hoses to the front side shift cylinder. Refer to markings on
the hydraulic hoses for correct installation locations.
(3) Tighten hydraulic connections.
SIDE SHIFT
CYLINDER
HYDRAULICS
Figure 15
FRONT SIDE SHIFT CYLINDER HYDRAULICS
C. CONNECT THE ROLL CYLINDER HYDRAULICS
(1) Install new hydraulic 45 degree hydraulic fittings with O-ring seals in the hydraulic roll
cylinder ports. Refer to Figure 14.
(2) Connect the four hydraulic hoses to the roll cylinders. Refer to markings on the hydraulic
hoses and roll cylinder for correct installation locations.
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D. CONNECT ELECTRICAL COMPONENTS
(1) Install the side shift cylinder limit switches 17LS and 18LS to their respective brackets on
the scissors. The limit switches should be adjusted to ensure the deck auto center and
level system functions correctly after these procedures are completed. Refer to Figure 12
for limit switch locations.
(2) Connect the two twelve pin electrical connectors on the scissor electrical harness to the
deck electrical harness. These electrical connectors are located directly behind the front
side shift cylinder. Refer to Figure 12.
E. INSTALL UPPER FASTENERS TO SECURE ROLL CYLINDERS
Installation of upper fasteners that secure the roll cylinders to the scissor structure.
to the non-cab side.
(3) Install the upper two (2) fasteners that secure the non-cab side roll cylinder to the scissors.
The lifting provisions may need to be temporarily adjusted during this process to remove
the load on the roll cylinder fasteners. Refer to Figure 14.
to the Cab side.
(5) Install the top two (2) fasteners that secure the Cab side roll cylinder to the scissors. The
lifting provisions may need to be temporarily adjusted during this process to remove the
load on the roll cylinder fasteners. Refer to Figure 14.
(6) From within the cab, actuate and hold the AUTO CENTER AND LEVEL switch until the
shift indicator lights on the dash panel are not illuminated. The deck should be centered.
(7) Fully tighten all eight fasteners attaching the roll cylinders to the scissor plates.
(9) Operate the deck shift and roll functions to verify no hydraulic fluid leaks exist. Be sure the
deck is center and level before proceeding.
(10) Remove the lifting provisions from the deck.
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F. INSTALL MISCELLANEOUS ITEMS
(1) At the rear of the loader, reinstall the three (3) limit switches located on the inside of the
deck bumper. Reconnect the limit switches to the deck electrical harness. Refer to
Figure 10.
(2) At the front of the deck, reinstall the two (2) tie down lugs and backing plates located on the
deck I-beams. Tighten fasteners to 542 N·m (400 lbf-ft.). Refer to Figure 9.
(3) Remove the headlight housing with attached lights. Connect all lights to the deck electrical
harness. Refer to Figure 9.
(4) Start the engine. Remove the maintenance stands and stow them in the maintenance
stand stowing locations on the chassis.
(5) Lower the deck until it is completely resting on the chassis frame.
(6) Configure the loader for normal operation.
12. REAR DECK SHIFT AND ROLL CYLINDERS REMOVAL
NOTE: THE LOADER MUST BE PARKED IN A LEVEL LOCATION THAT HAS SUFFICIENT
SPACE BEHIND THE LOADER TO ALLOW A FORKLIFT TO SAFELY APPROACH THE
LOADER FROM THE REAR.
A. CENTER AND LEVEL THE DECK
(1) Install both maintenance stands in the FIRST position.

(2) From within the cab, actuate and hold the AUTO CENTER AND LEVEL switch on the cab
dash panel until the pitch, roll and shift indicator lights on the dash panel are not
illuminated.
B. DISCONNECT THE REAR ROLL CYLINDER HYDRAULICS
(1) Label each of the extend and retract hydraulic hoses connected to the rear roll cylinders.
These ports should be labeled on the bottom of the roll cylinders. The ports labeled “E” are
the extend ports and the ports labeled “R” are the retract ports.
(2) Disconnect the four (4) hydraulic hoses from the two rear roll cylinders. Use a drain pan to
collect hydraulic fluid. Install hydraulic plugs on the four (4) hydraulic hoses to prevent
contamination. Refer to Figure 16.
(3) If the roll cylinders are being replaced, remove and discard the four (4) 45º hydraulic fittings
with O-rings on the bottom of the roll cylinders.
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FASTENERS
FASTENERS
ROLL CYLINDER
HYDRAULICS
Figure 16
ROLL CYLINDER HYDRAULICS AND FASTENERS
C. DISCONNECT THE SIDE SHIFT CYLINDER HYDRAULICS
(1) Label the cab side and non-cab side hydraulic hoses connected on the rear side shift
cylinder. Refer to Figure 17.
(2) Disconnect the two (2) hydraulic hoses from the rear side shift cylinder. Use a drain pan to
collect hydraulic fluid. Install hydraulic plugs on the two (2) hydraulic hoses.
(3) If the side shift cylinder is being replaced, remove and discard the hydraulic fittings with
O-ring seals attached to the cylinder.
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SIDE SHIFT
CYLINDER
HYDRAULICS
Figure 17
REAR SIDE SHIFT CYLINDER HYDRAULICS
(4) Start the engine. Raise the deck high enough so the upper scissor rollers on the ends of
the rear side shift cylinder are in front of the rear scissor roller tracks attached to the deck.
Refer to Figure 18.
(5) Shut down the engine, turn the battery disconnect OFF and install both maintenance
stands in the SECOND maintenance stand position.
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FORWARD
OUTER SCISSORS REAR SCISSORS ROLLER

UPPER SCISSORS TRACKS
INSIDE VIEW
Figure 18
UPPER SCISSOR ROLLERS AND SCISSOR ROLLER TRACKS
D. REMOVE REAR SCISSOR ROLLER TRACKS FROM THE DECK
(1) At the rear of the deck, remove and discard the ten (10) fasteners that secure each of the
scissor roller tracks to the deck. Refer to Figure 18.
(2) Remove the scissor roller tracks and backing plates.
(3) Remove the maintenance stands and stow them in the maintenance stand stowing
locations on the chassis.
(4) Start the engine. Slowly lower the deck until the deck saddles contact the helper cylinders.
Continue to slowly lower the deck until the rear side shift assembly rolls out from the rear of
the deck and is exposed. Refer to Figure 19.
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DECK SADDLES
REAR SIDE SHIFT

BOGY ASSEMBLY
SUPPORT LOCATION
Figure 19
REAR SIDE SHIFT CYLINDER REMOVAL
(5) Position fork lift tines under the center of the side shift bogy assembly so they are
completely and safely supporting the assembly. Refer to Figure 19.
(6) Remove and discard the four (4) fasteners that attach each rear roll cylinder to the
scissors. Refer to Figure 16. The forklift may need to be temporarily adjusted during this
process to remove the load on the roll cylinder hardware.
(7) Remove the rear roll cylinder bogy assembly.
13. REAR DECK SHIFT AND ROLL CYLINDERS INSTALLATION
A. INSTALL REAR SIDE SHIFT BOGY ASSEMBLY
(1) Place the side shift cylinder bogy assembly on the ends of fork lift tines and secure the
assembly to prevent it from rolling.
(2) Slowly position the side shift cylinder bogy assembly until the roll cylinders are within the
supporting plates on the scissors.
(3) Install the eight (8) fasteners that secure both roll cylinders to the scissors.
(4) Tighten the fasteners to standard specifications.
(5) Start the engine. Slowly raise the deck until the outer scissor upper rollers pass through
the openings in the deck and contact the upper scissor roller tracks.
(6) Continue to raise the deck past the first support block position and install both maintenance
stands in the FIRST maintenance stand position. Lower the deck until the scissor rollers
are resting on both maintenance stands.
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B. CONNECT THE SIDE SHIFT CYLINDER HYDRAULICS
(1) Install new hydraulic fittings with O-ring seals in the hydraulic side shift cylinder ports.
Refer to Figure 17.
(2) Connect the two (2) hydraulic hoses to the front side shift cylinder. Refer to markings on
the hydraulic hoses for correct installation locations.
C. CONNECT THE ROLL CYLINDER HYDRAULICS
(1) Install new hydraulic 45 degree hydraulic fittings with O-ring seals in the hydraulic roll
cylinder ports. Refer Figure 16.
(2) Connect the four hydraulic hoses to the roll cylinders. Refer to markings on the hydraulic
hoses and roll cylinder for correct installation locations.
(4) Operate the deck shift and roll functions to verify no hydraulic fluid leaks exist. Be sure the
deck is center and level before proceeding.
(5) Start the engine. Raise the deck high enough so the outer scissor upper rollers on the
ends of the rear side shift cylinder are in front of the rear scissor roller tracks attached to
the deck. Refer to Figure 18.
(6) Shut down the engine, turn the battery disconnect OFF and install both maintenance
stands in the SECOND maintenance stand position. Do not lower the deck until instructed
to do so.
D. INSTALL REAR SCISSOR ROLLER TRACKS ON THE DECK
(1) At the rear of the deck, install the rear scissor tracks and backing plate Refer to Figure 18.
(2) Torque all fasteners to 61 N·m (45 lbf-ft.) and then torque all fasteners to 88 N·m (65 lbf-ft.)
to avoid distorting the roller track.
(3) Start the engine. Remove the maintenance stands and stow them in the maintenance
stand stowing locations on the chassis.
(4) Lower the deck until it is completely resting on the chassis frame.
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14. REPLACE FAN BELTS
NOTE: APPLY THREAD LOCKING COMPOUND (LOCTITE) ON ALL SCREW THREADS.
(1) Disconnect turbo-charger air induction hose from the air cleaner.
(2) Remove the hardware that secures the air cleaner assembly to the support bracket and
remove the air cleaner as a complete assembly.
(3) Remove the cap screw and washer, on the generator belt tension adjuster.
(4) Remove the belts from the generator sheave and then pull the generator outward to access
the socket head screws that secure the main hydraulic pump-mounting bracket to the
engine block.
(5) Support the pump assembly with an engine hoist or a floor jack, then remove the four (4)
socket head screws that secure the pump bracket to the engine block.
NOTE: DO NOT REMOVE ANY HYDRAULIC LINES.
(6) Carefully pull the pump and mounting bracket, as an assembly away from the engine until
there is sufficient clearance in the coupling to remove the belts.
NOTE: IT MAY BE NECESSARY TO USE A SMALL PRY BAR TO SEPARATE THE COUPLING.
USE CARE TO PREVENT DAMAGE TO THE ELEMENT.
(7) Remove the old belts and install the new belts. Position the belts around the crankshaft
pulley and water pump sheave.
NOTE: ALWAYS INSTALL A MATCHED SET OF BELTS WHEN REPLACING BELTS.
(8) Move the pump assembly back into position. Coupling drive pins must be aligned to enter
the coupling element without force.
(9) Install the four (4) socket head screws to secure the pump assembly to the motor block.
Tighten the cap screws securely.
(10) After the socket head screws are tightened, remove the engine hoist or floor jack.
(11) Move the generator back into place and install the belts on the sheave.
(12) Install the cap screw and washer in the belt tension adjuster and generator and tighten
after the belts have been tensioned.
(13) Install the air cleaner assembly and reconnect the induction hose for the turbo-charger.
15. HYDRAULIC PUMP REMOVAL AND INSTALLATION
NOTE: BEFORE THE REMOVAL OF THE HYDRAULIC PUMP FOR REPLACEMENT, CONTACT
JBT FOR INSTRUCTIONS.
A. HYDRAULIC PUMP REMOVAL FROM CHASSIS
(1) Disconnect the turbo-charger air induction hose from the air cleaner.
(2) Remove the hardware that secures the air cleaner assembly to the support bracket and
remove the air cleaner as a complete assembly.
(3) Remove the cap screw and washer, on the generator belt tension adjuster.
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(4) Remove the belts from the generator sheave and then pull the generator outward to access
the socket head screws that secure the main hydraulic pump mounting bracket to the
engine block.
(5) On the rear of the hydraulic reservoir remove the plug on top of the elbow for the oil supply
line to the hydraulic pump. This will allow air to enter the elbow to prevent the siphon of oil
when the suction hose is removed from pump.
(6) Remove the hydraulic lines on the pump.
NOTE: THERE WILL BE A LOSS OF SOME HYDRAULIC FLUID AND THE USE OF DRAIN PANS
WILL BE REQUIRED WHEN THE FLUID HOSES ARE REMOVED.
(7) Cap or plug, all open hydraulic lines to prevent contamination of the fluid system when the
pump is removed.
(8) Support the pump assembly with an engine hoist or a floor jack, then remove the four (4)
socket head screws that secure the pump bracket to the engine block.
(9) Carefully pull the pump and mounting bracket, as an assembly away from the engine and
out of the chassis.
NOTE: IT MAY BE NECESSARY TO USE A SMALL PRY BAR TO SEPARATE THE COUPLING.
USE CARE TO PREVENT DAMAGE TO THE ELEMENT.
(10) Remove the three (3) radial socket head cap screws that hold the drive element on the
coupling hub on the pump shaft and remove the element.
(11) Loosen the two socket head set screws in the coupling hub and remove the hub from the
pump shaft.
(12) Remove the two cap screws that secure the pump to the pump bracket weldment.
B. HYDRAULIC PUMP INSTALLATION
CAUTION
FAILURE TO POSITION AND ORIENT THE COUPLING CORRECTLY COULD CAUSE DAMAGE
TO THE COUPLING AND PUMP.
NOTE: ALWAYS REPLACE HYDRAULIC FILTER ELEMENTS WHEN INSTALLING A NEW

PUMP.
NOTE: MOUNTING SURFACES MUST BE SMOOTH AND CLEAN ON THE PUMP BRACKET.
(1) Attach the pump to the pump bracket weldment with the two (2) cap screws and nuts.
(2) Slide coupling hub onto the pump shaft, noting the orientation of the internal splines. The
spline portion of the hub must be installed over the splines of the pump shaft. Refer to
Figure 20.
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DEPTH OF SHAFT FACE

TO HUB FACE TO BE ORIENT HUB SO THAT
APPROX. .93 INCHES. NONSPLINED PORTION
IS FACING OUT, AWAY
FROM PUMP.
Figure 20
COUPLING HUB
(3) The distance from the front of the hub to the face of the pump shaft should be
approximately 23 mm (0.93 in.). Refer to Figure 20.
(4) When the coupling hub has been properly positioned, torque the two (2) set screws in the
hub to 122 N·m (90 lbf-ft.).
(5) Install the coupling element on the pump hub with the side with the extended radial lugs
facing towards the coupling hub on the engine. Refer to Figure 21.
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ALIGN HOLES
FOR BOLT
INSTALLATION
CUT OUT FOR BELTS
EXTENDED
SHORTER SIDE
Figure 21
COUPLING ELEMENT INSTALLATION
(6) Apply a small amount of grease to the underside of the heads on the three (3) special
socket head cap screws and insert in the element and thread into the hub.
NOTE: THREADS ON THE RADIAL AND AXIAL CAP SCREWS ARE COATED WITH
MICRO-ENCAPSULATED ADHESIVE. DO NOT USE ANAEROBIC ADHESIVES (SUCH
AS LOCTITE). AS THEY HAVE A DETRIMENTAL EFFECT ON THE BOND BETWEEN
THE RUBBER AND THE INSERT. RECOMMENDED ADHESIVES ARE 3M MICROTITE.
SCREWS THAT ARE PROVIDED WITH THIS ADHESIVE MAY BE USED UP TO THREE
(3) TIMES.
(7) With a torque wrench, tighten the three (3) radial cap screws to 203 N·m (150 lbf-ft.).
(8) Element must not be twisted when tightening the cap screws. After tightening the radial
cap screws, inspect the element for not being twisted. Refer to Figure 22.
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Figure 22
ELEMENT ALIGNMENT
(9) Install the pump and bracket assembly on the engine.
NOTE: THIS REQUIRES THE USE OF A PORTABLE ENGINE HOIST OR A FLOOR JACK, FOR
THE SUPPORT OF THE PUMP ASSEMBLY DURING THE INSTALLATION PROCESS.
(10) Move the pump assembly into position with the fan belts in the pump bracket cut out.
Rotate the pump coupling to align the drive pins on the engine flange to match the mating
holes in the element. Refer to Figure 22.
(11) Install the four (4) socket head screws to secure the pump assembly to the motor block and
tighten the cap screws.
NOTE: APPLY THREAD LOCKING COMPOUND (LOCTITE) ON THE SCREW THREADS.
(12) Move the generator back in place and install the belts on the sheave.
(13) Install the cap screw and washer in the belt tension adjuster and generator. Tighten after
the belts have been tensioned.
(14) Remove the plugs and caps and reconnect the hydraulic hoses to the pump.
NOTE: USE NEW O-RINGS ON THE HOSE FLANGE FITTINGS.
NOTE: PUMP CAN BE DAMAGED IF IT IS NOT PRIMED.
(15) Fill pump suction hose with hydraulic fluid to prime the pump, then install the plug and
tighten securely.
NOTE: FILL THE SUCTION HOSE THROUGH THE FITTING ON THE TOP OF THE ELBOW ON
THE BACK OF THE HYDRAULIC RESERVOIR.
(16) Install the air cleaner assembly and reconnect the induction hose for the turbo-charger.
(17) Start the engine and allow engine to run a minimum of 10 minutes at idle speed.
(18) Check reservoir for correct hydraulic fluid level.
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16. CHANGING WHEELS ON FRONT AXLE
CAUTION
DO NOT PLACE HYDRAULIC JACK UNDER THE BOWL IN THE CENTER OF THE AXLE
HOUSING.
CAUTION
ASSEMBLY.
CAUTION
A. FRONT AXLE WHEEL REMOVAL
(1) Turn the battery disconnect switch on the battery box to the OFF position.
(2) Loosen lug nuts on wheel to be removed, 1/4–1/2 turn.
(3) Position a hydraulic jack (10-ton minimum capacity) directly under the axle mounting pad
and raise the chassis until the tire is off the ground.
(4) Place a fixed stand or shoring under the frame for safety, before removing the wheel
assembly.
(5) Remove all the lug nuts on the wheel assembly and then remove the wheel assembly from
the planetary hub.
B. FRONT AXLE WHEEL INSTALLATION
(1) Inspect the threads on the wheel bolts and nuts for damage. Replace all damaged
hardware before mounting the wheel assembly.
(2) Check all mounting surfaces for being smooth and clear.
NOTE: NO LUBRICANTS ARE PERMITTED ON MOUNTING SURFACES OR ON THE THREADS

OF THE WHEEL BOLTS AND WHEEL NUTS.
(3) Carefully lift the wheel assembly and install on the planetary wheel hub. Slide the
assembly into position over the wheel bolts, taking care not to damage the bolt threads.
(4) Install the wheel nuts loosely, by hand, to ensure that they are not cross threaded and turn
freely on the threads.
(5) Tighten the wheel nuts in a cross pattern to approximately 136–205 N·m (100–150 lbf-ft.) of
torque.
NOTE: MAKE SURE THAT WHEEL NUTS CENTER IN THE HOLES TO ALIGN THE WHEEL ON
THE WHEEL BOLTS.
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(6) Raise chassis slightly with the hydraulic jack and remove the safety stand or shoring.
(7) Lower the loader to ground level and remove the hydraulic jack or other lifting device.
(8) Using an accurate torque wrench, torque all wheel nuts in a cross pattern to 271 N·m
(200 lbf-ft.).
17. CHANGING WHEELS ON REAR AXLE (BOGY WHEELS)
WARNING
CHOCK THE BOGY WHEELS ON THE OPPOSITE SIDE OF THE LOADER, TO PREVENT
MOVEMENT IN EITHER DIRECTION, APPLY THE PARKING BRAKE AND TURN OFF THE
ENGINE.
CAUTION
ASSEMBLY.
CAUTION
A. REAR AXLE WHEEL REMOVAL (BOGY WHEELS)

(1) Raise the deck and install the maintenance safety blocks in the first position and lower the
deck until the scissors rollers are against the blocks.
(2) Measure the height from the bottom of the frame side rail to the ground surface just forward
of the bogy axle pivot shaft (jacking point) and the height of the hydraulic jack that will be
used to change the wheel assembly. Refer to Figure 23.
NOTE: HYDRAULIC JACK MUST HAVE A MINIMUM RATED CAPACITY OF 10 TONS.
(3) If there is insufficient clearance to place a jack under the frame side rail, due to the
condition of the tire and tread wear, it is permissible to drive the loader onto blocking
(shoring) to obtain an increase in frame height.
NOTE: DO NOT DRIVE THE DEFLATED TIRE ONTO BLOCKING.
(4) Wrap a chain or cargo straps around the bogy pivot shaft and the chassis cross members,
to secure the bogy axle pivot shaft to the chassis. Refer to Figure 23.
(5) Loosen lug nuts on wheel to be removed, 1/4–1/2 turn.
(6) Position a hydraulic jack (10-ton capacity, min.) directly under and in the center of the
chassis frame. Raise the chassis until the tires are off the ground. Refer to Figure 23.
(7) For safety place a fixed stand or shoring under the chassis at the rear. Refer to Figure 23.
(8) Remove all the lug nuts on the wheel assembly and then remove the wheel assembly from
the wheel hub.
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SAFETY STAND / SHORING
JACKING POINT
SECURE PIVOT SHAFT TO CHASSIS WITH CHAIN
Figure 23
JACKING POINT
B. REAR AXLE WHEEL INSTALLATION (BOGY WHEELS)
(1) Inspect the threads on the wheel bolts and nuts for damage. Replace all damaged
hardware before mounting the wheel assembly.
(2) Check all mounting surfaces for being smooth and clear.
NOTE: NO LUBRICANTS ARE PERMITTED ON MOUNTING SURFACES OR ON THE THREADS

OF THE WHEEL BOLTS AND WHEEL NUTS.
(3) Carefully lift the wheel assembly and install on the planetary wheel hub. Slide the
assembly into position over the wheel bolts, taking care not to damage the bolt threads.
(4) Install the wheel nuts loosely, by hand, to ensure that they are not cross threaded and turn
freely on the threads.
(5) Tighten the wheel nuts in a cross pattern to approximately 136–203 N·m (100–150 lbf-ft.) of
torque.
NOTE: MAKE SURE THAT WHEEL NUTS CENTER IN THE HOLES TO ALIGN THE WHEEL ON
THE WHEEL BOLTS.
(6) Raise chassis slightly with the hydraulic jack and remove the safety stand or shoring.
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(7) Lower the loader to ground level and remove the hydraulic jack.
(8) Using an accurate torque wrench, torque all wheel nuts in a cross pattern to 271 N·m
(200 lbf-ft.).
(9) Remove the chain or strap that is wrapped around the bogy pivot axle and chassis.
(10) Start engine and lower the deck.
18. HYDRAULIC FLUID LEVEL AND REFILLING
There are two sets of fluid level marks on the hydraulic reservoir. The marks on the aft end of the
reservoir are used to check the fluid level when the loader deck is in the fully lowered position. The fluid
level marks on the side of the tank are used to observe the fluid level when the reservoir is being filled
and the deck is elevated with the lower scissors rollers resting against the maintenance blocks that have
been placed in the first maintenance position.
CAUTION
DO NOT OVERFILL THE HYDRAULIC RESERVOIR. RESERVOIR CAN BE DAMAGED IF THE

OIL LEVEL IS ABOVE THE “FULL” MARK, ON THE AFT END OF THE RESERVOIR, WHEN THE
DECK IS FULLY LOWERED.
NOTE: MAINTAIN FLUID LEVEL IN THE HYDRAULIC RESERVOIR BETWEEN THE HIGH AND
LOW MARKS ON THE AFT END OF THE HYDRAULIC RESERVOIR WITH DECK FULLY
LOWERED.
A. CHECKING FLUID LEVEL
(1) Check fluid level in the hydraulic fluid reservoir daily by observing the fluid level in the sight
gauge and the marks on the aft end of the reservoir when the deck is fully lowered. Refer
to Figure 24.
(2) Maintain oil level between the HIGH and LOW marks.
NOTE: DO NOT OPERATE LOADER WHEN THE FLUID LEVEL IN THE SIGHT GLASS IS
BELOW THE “LOW” LEVEL MARK.
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Figure 24
FLUID LEVEL MARKS
B. REFILLING HYDRAULIC RESERVOIR
NOTE: HYDRAULIC FLUID MUST BE FILTERED TO PREVENT CONTAMINATION OF THE

HYDRAULIC SYSTEM WHEN ADDING FLUID OR REFILLING THE RESERVOIR.
(1) Start the engine and raise the deck. Insert the maintenance blocks in the first maintenance
position and then lower the deck until the scissor rollers are against the maintenance
blocks. Shut the engine down.
(2) Clean the FILL POINT cap and fitting on the suction filter located on the top of the hydraulic
fluid reservoir. Refer to Figure 24).
(3) Remove the cap on the fill point fitting.
(4) Connect the hose from the filter on the service vehicle or fluid storage tank, to the FILL
POINT fitting on the reservoir.
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(5) Add fluid to the reservoir until the fluid level in the sight glass is between the HIGH and
LOW marks on the side of the reservoir (refer to Figure 24).
NOTE: MARKS ARE IDENTIFIED AS “FIRST MX STAND”.
NOTE: DO NOT USE MARKS ON AFT END OF RESERVOIR.
(6) Remove hose from the FILL POINT fitting and install the protective cap.
(7) After adding fluid or refilling the reservoir, start the engine, remove the maintenance blocks
and lower the deck fully.
(8) Recheck fluid level when the deck is fully down. Observe the fluid level in the sight glass
and the fluid level marks on the aft end of the reservoir.
19. BATTERY MAINTENANCE CHARGING AND STORAGE
The battery box is located on the right side of the loader. The batteries used in the loader are sealed
and maintenance free. The cells do not have vent caps and no provision is made for adding electrolyte
or checking electrolyte level. Ensuring that the battery restraints are secure and that there is no
corrosion forming on the cable terminals is all that is required for service.
WARNING
STORAGE OF BATTERIES GENERATE HYDROGEN GAS THAT IS EXPLOSIVE. KEEP ALL
OPEN FLAMES AND SPARKS AWAY FROM BATTERIES.
WARNING
A COMPLETELY DISCHARGED OR FROZEN BATTERY CAN EXPLODE IF POWER IS
APPLIED. FROZEN BATTERIES MUST BE ALLOWED TO WARM GRADUALLY TO NORMAL
ROOM TEMPERATURE BEFORE USING.
WARNING
WHEN REMOVING A BATTERY, ALWAYS DISCONNECT THE CABLES ON THE GROUND
TERMINALS FIRST TO PREVENT A SPARK. ALWAYS CONNECT THE GROUND CABLE LAST
WHEN CONNECTING CABLES.
WARNING
A. BATTERIES CHARGING
To ensure proper charging of your battery, Deltran Corporation and Hawker Energy Products Inc
have developed a special charge algorithm that is designed to rapidly and safely charge these
batteries. They are available in 6 A, 10 A, 15 A and 20 A versions. Since these are automatic
chargers no manual intervention is necessary. We suggest the following Deltran chargers to get
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peak performance from your battery (charger rating 20 A charger, recommended model use on
PC 1700 or smaller battery).
As an alternative small portable automotive chargers may also be used to charge your battery.
B. CHARGER OUTPUT VOLTAGE
Determining the charger output voltage is the most important step in the charger qualification
process.
NOTE: IF THE VOLTAGE OUTPUT FROM THE CHARGER IS LESS THAN 14.2 V OR MORE
THAN 15 V FOR A 12 VDC BATTERY DO NOT USE THE CHARGER.
C. CHARGER TYPE - AUTOMATIC OR MANUAL
The two broad types of small portable charger available today are classified as either automatic
or manual. Automatic charger can be further classified as those that charge the battery up to a
certain voltage and then shut off and those that charge the battery up to a certain voltage and
then switch to a lower float (trickle) voltage. The trickle charger type of automatic charger is
preferred.
D. SELECTING BATTERY TYPE ON YOUR CHARGER OUTPUT
In general, do not use either the gel cell or maintenance free setting. If provided on your charger.
Choose the deep cycle option, should there de one on your charger. For maximum life from your
battery we recommend that you switch your charger to the 2 A trickle charger position and leave
the battery connected to the charger for a further six to eight hours. If the battery is only partially
discharged, the charge times should be appropriately reduced. The battery should however be
placed on trickle charge (2 A setting) regardless of its initial state of charge (SOC).
E. BATTERIES STORAGE
NOTE: THE BATTERY MUST BE CHARGED BEFORE STORAGE. YOUR BATTERY CAN BE
STORED AT A TEMPERATURE OF 25 ºC (77 ºF) FOR UP TO TWO YEARS. THE
LOWER THE TEMPERATURE THE LONGER THE STORAGE TIME FOR YOUR
BATTERY. IF THE TEMPERATURE RISES TO ABOUT 35 ºC (95 ºF) THE BATTERY
MAY BE STORED FOR ONLY ONE YEAR BEFORE IT NEEDS TO BE RECHARGED.
20. BATTERY REMOVAL AND REPLACEMENT
WARNING
ENGINE MUST BE SHUT DOWN AND THE EXTERNAL POWER CORD MUST BE
DISCONNECTED WHEN REMOVING AND REPLACING BATTERIES.
A. REMOVE BATTERY
(1) Turn battery disconnect switch on the battery box to the OFF position. Refer to Figure 25.
(2) Remove cover from battery box.
(3) Disconnect the ground cable from the negative (-) battery terminal first.
(4) Disconnect the cable from the positive (+) battery terminal.
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Figure 25
(5) Remove the battery hold-down restraint from the battery to be removed.
(6) Remove the battery from the box.
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B. INSTALL BATTERY
(1) Place the battery in the battery box and note that the negative (-) terminal post is oriented
in the correct position.
(2) Install the battery hold-down restraint and tighten the bolts to prevent any movement.
Over-tightening of the restraining bolts can cause distortion and damage to the battery.
(3) Coat the battery terminal posts with anti-corrosion compound.
(4) Install and tighten the cable on the positive (+) battery terminal first.
(5) Install and tighten the ground cables on the negative (-) battery terminal last.
(6) Replace the battery box cover.
21. RADIATOR REMOVAL AND INSTALLATION
WARNING
WARNING
A. RADIATOR REMOVAL
Refer to Figure 26).

(1) Drain coolant into an approved container.
(2) Remove top vent hoses and fittings (item 5)
(3) Mark, remove and cap transmission cooler lines.
(4) Remove fasteners from fuel filter (item 7) and set aside.
(5) Loosen upper and lower radiator hose clamps
(6) Loosen isolator bolts (items 2 and 3) and isolator nuts (item 4) and remove grill assembly
(item 6) from the front of the radiator.
(7) Remove isolator bolts (items 2 and 3) and isolator nuts (item 4), remove isolators (item 1)
and gaskets.
(8) Slowly slide radiator out from bracket assembly, at the same time carefully removing upper
and lower radiator hoses.
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5
6
7
1 4 EACH
2 3 8 EACH
4 4 EACH
Figure 26
RADIATOR COMPONENTS
B. RADIATOR INSTALLATION
CAUTION
Refer to Figure 26.

(1) Ensure all surfaces are clean and free of debris. Inspect isolators for any damage (cracks
or deformations to rubber), replace as necessary.
(2) Apply new sealer to fan shroud surface.
(3) Slide radiator into place, insuring upper and lower radiator hoses are placed over outlets.
(4) Install isolators (item 1) new gaskets and nuts (item 4), leave nuts loose.
(5) Install nuts and bolts (items 2 and 3), leave loose.
(6) Install grill assembly (item 6), by sliding into place under the isolators and torque nut and
bolts (items 2 and 3) to 47.5 N·m (35 lbf-ft.).
(7) Torque nuts (item 4) to 47.5 N·m (35 lbf-ft.).
(8) Install fuel filter (item 7).
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(9) Install transmission oil cooler lines.
(10) Install vent hoses and fittings, tighten upper and lower radiator hose clamps.
(11) Refill and bleed cooling system as outlined in ‘B. REFILL AND BLEED AIR FROM
COOLING SYSTEM’.
22. COOLANT SYSTEM LEVEL AND REFILLING
WARNING
WARNING
CAUTION
NOTE: THE COOLANT RESERVOIR HAS A SIGHT GLASS TO OBSERVE IF THERE IS AIR IN
THE SYSTEM.
A. COOLANT LEVEL
(1) Coolant level must be checked daily in the coolant recovery tank.
(2) Check coolant level in the coolant recovery tank and adjust fluid level as required. Refer to
Figure 27.
(3) The coolant level must be at the COLD mark when the engine is cold.
(4) If the coolant level is below the COLD mark, add fluid to bring the level to the COLD mark.
NOTE: NEVER ADD WATER TO THE COOLANT SYSTEM. USE COOLANT OF THE PROPER
MIXTURE TO PROTECT THE ENGINE FROM FREEZING. USE A HYDROMETER TO
CHECK THE COOLANT RATIO.
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Figure 27
COOLANT SERVICE AREA
B. REFILL AND BLEED AIR FROM COOLING SYSTEM
(1) Ensure drain is closed on the bottom of the radiator and all hoses are properly connected.
(2) Open petcock on the top of the radiator.
(3) Refill then system slowly with the proper mixture of coolant (50%-50% mix; 60%-40% for
arctic conditions).
(4) Allow the system to settle from time to time as it is being filled.
(5) Close the petcock when a steady stream of coolant is observed flowing from the top of the
radiator.
(6) Start the loader and allow the engine to reach normal operating temperature.
(7) With the engine running at 1500 rpm slightly open the petcock on the top of the radiator to
ensure all trapped air has been expelled.
(8) Fill surge tank and reinstall cap, fill the coolant recovery tank to the hot level.
C. COLD WEATHER OPERATIONS
NOTE: COLD WEATHER OPERATION IS DEFINED AS SUSTAINED OPERATIONS AT OR

BELOW -18 ºC (0 ºF).
Before loader is placed in a known cold weather area, perform the following steps.
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(1) Change Anti-freeze level of protection to a 60%-40% mix of glycol and distilled water.
(2) Drain and refill transmission with synthetic transmission fluid. (Recommend Allison
Transmission fluid ATF TranSynd JBT part number 624-7415).
(3) Replace engine drive belts with cold weather belts JBT part number 623-9550.
NOTE: IF THE LOADER IS PARKED DURING COLD WEATHER CONDITIONS, THE

WINTERIZATION SYSTEM SHOULD BE PLUGGED IN AND ACTIVATED AS OUTLINED
IN CHAPTER 1, SECTION 2.
NOTE: IF THE LOADER IS COLD SOAKED FOR A PERIOD OF MORE THAN 24 HOURS, THE
WINTERIZATION SYSTEM WILL NEED TO OPERATE FOR MINIMUM OF 6 HOURS,
BEFORE STARTING THE LOADER.
NOTE: WINTERIZATION CABLE FOR COLD WEATHER PART NUMBER 624-7414.
23. AIR CONDITIONER INSPECTION AND MAINTENANCE (WITHOUT GAUGES)
Inspect system for loose components, worn components, refrigerant leaks and other signs of
malfunctioning components. Follow guidelines below during system inspection and maintenance
procedures.
NOTE: FOR MAINTENANCE, SERVICE AND INSPECTION ENSURE THE MANUFACTURER’S

MANUAL IS USED FOR ALL SPECIFICATIONS, REFERENCES AND PROCEDURES.
A. CONSIDERATIONS BEFORE MAINTENANCE
Answer the following three questions while inspecting the air conditioning system:
• Has vehicle just come from operation and was A/C system used?
• Did the operator or work order explain or describe air conditioning system problems?
• If recent maintenance was performed on system, what was repaired?
Visual Inspection - System Off
With air conditioning system off, inspect the following:
(1) Inspect all system parts for obvious signs of failure.
(2) Check all hoses and fittings for indication of refrigerant leakage. Oily deposits on air
conditioning system hoses and fittings may indicate a leak.
(3) Check remaining components for signs of refrigerant leaks.
NOTE: FOR TROUBLESHOOTING THE A/C SYSTEM USING THE MANIFOLD GAUGES.
REFER TO THE VISIONAIRE INC. MANUFACTURER’S MANUAL FOR HEAVY DUTY
EQUIPMENT.
B. COMPONENTS INSPECTION
The following components must be inspected during system maintenance and inspection:
(1) Condenser - Coils must be free of all obstructions such as dirt, mud, bugs, feathers and
leaves to maintain proper air flow and heat transfer. Clean with soap and water or use an
air hose with brush.
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(2) Compressor - Ensure the compressor mounting bolts are tight. Check for refrigerant and
oil leaks. Ensure all connections are tight. The compressor must be free of dirt and
obstructions that may hamper performance.
(3) Evaporator - Ensure all drain hoses and check valves are intact and secure. Drain hoses
must be free of obstruction to ensure proper disposal of condensation from system.
(4) Air filter must be clean an intact and free of obstructions.
(5) Ensure control switches are secure and operating properly.
(6) Check all Hoses and Fittings - Inspect all hoses and fittings for leaks.
(7) Any indication of refrigerant leaks or other malfunctions must be reported to the
maintenance section as soon as possible.
NOTE: IT IS THE OPERATOR’S RESPONSIBILITY TO ENSURE ALL PROBLEMS FOUND

DURING SYSTEM OPERATION, INSPECTION AND MAINTENANCE, ARE REPORTED
TO MAINTENANCE PERSONNEL AS SOON AS POSSIBLE.
24. AIR CONDITIONING COMPONENT REPAIR OR REPLACEMENT
Service and repair procedures are similar to other vehicle service work. However, many of the A/C
system parts are made of soft metals such as copper, aluminum and brass. Caution must be taken
when removing and installing soft metal parts to avoid damage that may degrade A/C system operation
or cause premature A/C system failure.
CAUTION
ALL OF THE SERVICE PROCEDURES DESCRIBED ARE ONLY PERFORMED AFTER AIR
CONDITIONER SYSTEM REFRIGERANT HAS BEEN RECOVERED. NEVER USE REGULAR
SHOP OIL OR JOINT COMPOUND TO LUBRICATE OR SEAL ANY A/C CONNECTIONS.
ENSURE THE MANUFACTURER’S MANUAL IS PRESENT FOR REFERENCE.
NOTE: TO HELP PREVENT AIR, MOISTURE OR DEBRIS FROM ENTERING AN OPEN

SYSTEM, CAP OR PLUG OPEN LINES, FITTINGS OR COMPONENTS AS SOON AS
THEY ARE DISCONNECTED. IT’S IMPORTANT TO KEEP ALL CONNECTIONS, CAPS
AND PLUGS CLEAN TO AVOID A/C SYSTEM CONTAMINATION. DEBRIS THAT MIGHT
ENTER SYSTEM CAN CAUSE SERIOUS SYSTEM DAMAGE.
NOTE: AS A GENERAL RULE IN A/C SERVICE, ALL REMOVED GASKETS AND O-RINGS
MUST BE REPLACED DURING MAINTENANCE. NEVER REUSE GASKETS AND
O-RINGS TO PREVENT LEAKS AND FAILURE. USE FRESH REFIGERANT OIL TO
LUBRICATE CONNECTIONS, GASKETS AND O-RINGS DURING INSTALLATION.
The following components and parts should be inspected during scheduled and operator
maintenance.
• Hoses and fittings
• Lines
• Expansion valves
• Receiver-dryer and accumulator
• Compressor
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A. HOSES AND FITTINGS
When replacing hoses be sure to use the same type and ID hose as that removed. When hoses
or fittings are shielded or clamped to prevent vibration damage, ensure that these are in the
proper position and secured as necessary. On R-134a systems make sure replacement hoses
and O-rings used during reassembly are designed for use with R-134a. Use reusable fittings on
the nylon-lined hose.
B. AIR CONDITIONING LINES
Always use two wrenches when connecting or disconnecting A/C fittings attached to metal lines.
Copper and aluminum tubing used in A/C systems can kink or break easily. Tube O-ring type
fittings require only 18 foot pounds of torque for correct sealing. Ensure all grommets or clamps
used to prevent line vibration, are properly placed and secured during reassembly.
C. AIR CONDITIONING EXPANSION VALVE
To remove expansion valve from the system, remove the insulation, clean the area and
disconnect the line receiver to drier. Remove the expansion valve from the evaporator inlet.
Replace expansion valve if expansion valve failure was indicated by system operation or if debris
is detected in the valve.
D. RECEIVER-DRYER AND ACCUMULATOR
The receiver-dryer and accumulator cannot be serviced or repaired. They should be replaced
whenever the A/C system is opened for service. If the receiver-dryer or accumulator has a
pressure switch to control the compressor, remove and save for installation on new unit.
E. COMPRESSOR
The compressor can fail due to shaft seal leaks, defective valve plates, bad bearings or problems
associated with high pressure heat or lack of lubrication. Excessive heat, contaminated oil or
back pressure in the case drain line can cause compressor failure.
NOTE: AIR CONDITIONING SYSTEM AND COMPRESSOR REQUIRE ADEQUATE

REFRIGERANT OIL FOR LUBRICATION AND SAFE OPERATION. WHEN THE SYSTEM
IS OPENED FOR SERVICE, CHECK THE COMPRESSOR OIL LEVEL AND ADD CLEAN
REFRIGERATION OIL AS REQUIRED IN ACCORDANCE WITH MANUFACTURER
SPECIFICATIONS. ROTARY COMPRESSORS THAT HAVE NO OIL SUMP ARE
ESPECIALLY SUSCEPTIBLE TO FAILURE CAUSED BY INADEQUATE REFRIGERANT
OIL. ENSURE THAT THE OIL RETURN SYSTEM IS CLEAN AND OPERATIONAL WHEN
REPLACING A COMPRESSOR. WHEN ADDING OIL, USE ONLY SANDEN SP-20. ADD
OIL INTO DISCHARGE LINE OR OIL SEPARATOR. NEVER ADD OIL TO THE SUCTION
SIDE OF THE COMPRESSOR.
CAUTION
EVEN WHEN TOLD OF AIR CONDITIONING SYSTEM DEFECT, ALWAYS PERFORM A VISUAL
INSPECTION PRIOR TO CONNECTING THE MANIFOLD GAUGE SET. NEVER ATTEMPT TO
ADD REFRIGERANT TO A SYSTEM UNTIL YOU HAVE MADE A COMPLETE VISUAL AND
PERFORMANCE INSPECTION OF ALL OF THE COMPONENTS.
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With system operating, inspect system components for cycling and cab temperature levels. Refer
to the Manufacturer’s Manual for the following inspections:
• Check the Sight Glass.
• Electrical System Inspection.
• Troubleshooting and Service Procedures of the A/C System.
• Troubleshooting by Manifold Gauge Set Readings.
• Review Frequent Problem Areas.
• Performance Inspection - Engine Running.
25. LEFT SIDE SKYLIGHT REMOVAL AND INSTALLATION
A. LEFT SIDE SKYLIGHT REMOVAL
(1) Use gasket scraper or other available tool to clean urethane sealant from between the
edge of the side skylight and the cab pinch-weld of the cab. Refer to Figure 28.
Figure 28
CLEANING URETHANE SEALANT
(2) Use available tools to free the side skylight from the cab pinch-weld. Refer to Figure 28.
CAUTION
BE CAREFUL NOT TO BEND PINCH-WELD WHEN REMOVING THE GLASS FROM THE
ADHESIVE.
(3) Carefully remove the side skylight glass from the cab. Refer to Figure 29.
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Figure 29
REMOVING SKYLIGHT
B. LEFT SIDE SKYLIGHT CLEANING AND PREPARATION FOR INSTALLATION
(1) Clean dirt and debris from around the pinch-weld of cab. Using available tools, remove
any remaining sealant to achieve a flat bonding surface. Refer to Figure 30.
Figure 30
CLEANING DIRT FROM PINCHWELD
(2) Clean remaining sealant from old skylight glass and reinsert into pinch-weld to check for
flatness of cab surface. Grind and/or adjust surface as needed. If old glass is not
available, a straight edge may be used to check for flatness. Refer to Figure 31.
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Figure 31
CHECK FOR FLATNESS OF CAB SURFACE
(3) Mask off edge around the pinch-weld area of cab to avoid any overspill of primer and
sealant. Refer to Figure 32.
Figure 32
MASKING OFF EDGES
C. APPLY CAB PRIMER
(1) Read all manufacturing instructions on primers and sealants prior to the start of remaining
steps.
(2) Open K-SKYLIGHT SEALANT AND PRIMERS, part no. 627-2118. Shake can of DOW
5404 PINCHWELD PRIMER, part no. 627-2066, for a minimum of one minute.
(3) Apply primer to side of pinch-weld surface of the cab using a clean dauber, part
no. 627-2166. Refer to Figure 33.
(4) Allow to dry for a minimum of six minutes.
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Figure 33
APPLYING PRIMER TO PINCH-WELD
D. PREPARE LEFT SKYLIGHT GLASS FOR INSTALLATION
(1) Wearing clean gloves, lay WINDOW, LEFT SIDE SKYLIGHT, part no. 624-2980-002, on a
clean surface with the “frit” side of glass facing up (dark band around perimeter facing up).
(2) Clean the “frit” surface and the edge of the skylight glass with acetone or alcohol using a
lint-free cloth. Wipe clean and dry with a clean lint-free cloth.
(3) Mask off the inside edge of the “frit” area on the skylight glass. This is to avoid over spill of
primer onto the glass. Mask should be placed at the “frit” edge or slightly overlapping less
than 1/16 inch. Refer to Figure 34.
Figure 34
MASKING EDGE OF “FRIT” SURFACE
E. APPLY GLASS PRIMER TO LEFT SKYLIGHT GLASS
NOTE: READ ALL MANUFACTURING INSTRUCTIONS ON PRIMERS AND SEALANTS PRIOR

TO THE START OF REMAINING STEPS.
(1) Shake applicator stick of DOW 5500 SA GLASS/FRIT PRIMER, part no. 627-2068, for a
minimum of one minute.
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(2) While gently holding applicator stick with applicator sponge pointing up, apply pressure
with thumb and forefinger to the color band at the top of the tube. Refer to Figure 35.
Figure 35
APPLYING PRESSURE TO TUBE
(3) Screw the applicator cap down to puncture the seal on the applicator stick. Refer to
Figure 36.
Figure 36
PUNCTURING APPLICATOR
(4) Hold applicator stick on the skylight glass over the “fritted” surface (black band around the
perimeter of the glass). Press down until the tip “wets out.”
NOTE: EXCESSIVE SQUEEZING WILL NOT SPEED “WET OUT” AND CAN LEAD TO LEAKAGE
AROUND THE TUBE. REFER TO FIGURE 37.
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“WET OUT” OF TIP
Figure 37
WET OUT OF TIP
(5) Apply DOW 5500 SA GLASS/FRIT PRIMER, part no. 627-2068, to the frit surface and
glass edge of the side skylight glass. Allow to dry for a minimum of 6 minutes. Refer to
Figure 38.
Figure 38
APPLICATION OF PRIMER TO FRIT SURFACE
(6) Remove tap from frit side of the glass.
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F. LEFT SIDE SKYLIGHT INSTALLATION
(1) Apply 1/4 inch bead of DOW U-400 HV SEALANT, part no. 627-2067, around pinch-weld,
placing a bead on the center of the pinch-weld surface area. Refer to Figure 39.
Figure 39
APPLICATION OF SEALANT TO PINCH-WELD
(2) Place glass into pinch-weld area of the cab. Press down until glass is within 1/16 inch of
flush to cab surface in order to distribute sealant between the bonding surfaces. Center
glass within the pinch-weld area so that there is an even space around the glass
perimeter. Refer to Figure 40.
Figure 40
INSTALLATION OF NEW GLASS
(3) Allow sealant to set for 10 minutes before proceeding.

(4) Mask off the top surface of glass around its perimeter with tape. This is to avoid overspill of
sealant onto glass. Refer to Figure 41.
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Figure 41
MASKING PERIMETER OF GLASS
(5) Fill gap between pinch-weld and glass with DOW U-400 HV SEALANT, part no. 627-2067.
Refer to Figure 42.
Figure 42
APPLICATION OF SEALANT
(6) Smooth sealant around perimeter of glass using a scraper or other available tool. Refer to
Figure 43.
Figure 43
SCRAPING OF EXCESS SEALANT
(7) Allow to dry for 10 minutes then remove tape. Refer to Figure 44.
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Figure 44
FINISHED GLASS
(8) Allow sealant to dry. Sealant dry time depends on temperature and humidity. Use the
following table to calculate relative dry time.
TABLE 1 - SEALANT DRYING TIMES (HOURS)
Relative Ambient Temperature ºC (ºF)

Humidity
4–10 10–16 16–21 21–27 27–32 32–38 38–43 43 +
% (40–50) (50–60) (60–70) (70–80) (80–90) (90–100) (100–110) (110 +)
>90 7 5 4 3 2 2 2 2
70–90 8 6 5 3 2 2 2 2
50–70 8 7 5 4 3 2 2 2
30–50 24 12 7 5 3 3 3 2
10–30 24 24 12 7 6 5 5 4
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26. TOP SKYLIGHT REMOVAL AND INSTALLATION
A. TOP SKYLIGHT REMOVAL
(1) Remove the six bolts securing the top skylight glass protective grate to the cab. Set grate
and bolts aside, exposing the top skylight glass. Refer to Figure 45.
Figure 45
REMOVING PROTECTIVE GRATE
(2) Use gasket scraper or other available tools to clean all old urethane sealant from around
the edge of the top skylight. Refer to Figure 46.
Figure 46
CLEANING URETHANE SEALANT
(3) Carefully remove skylight glass from cab.
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B. TOP SKYLIGHT CLEANING AND PREPARATION FOR INSTALLATION
(1) Clean any dirt and debris from around surface of cab. Using available tools, remove any
remaining sealant to achieve a flat bonding surface. Refer to Figure 47.
Figure 47
CLEANING DIRT FROM PINCHWELD
(2) Mask off area around skylight opening of cab, approximately 3/4 inch from the edge, in
order to avoid any overspill of primer and sealant. Refer to Figure 48.
Figure 48
MASKING OFF EDGES
C. APPLY PRIMER TO TOP SKYLIGHT PINCHWELD

(1) Open K-SKYLIGHT SEALANT AND PRIMERS, part no. 627-2118. Shake can of DOW
5404 PINCHWELD PRIMER, part no. 627-2066, for a minimum of one minute.
(2) Apply primer to the top pinch-weld surface area of the cab using a clean dauber, part
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Figure 49
APPLYING PRIMER TO PINCHWELD
(3) Allow to dry for a minimum of six minutes.
D. PREPARE TOP SKYLIGHT GLASS FOR INSTALLATION
(1) Wearing clean gloves, lay WINDOW, SKYLIGHT, part no. 624-2980-004, on a clean
surface with the frit side of the glass facing up (dark band around perimeter facing up).
(2) Clean the frit surface and the edge of the skylight glass with acetone or alcohol using a
lint-free cloth. Wipe clean and dry with a clean lint-free cloth.
(3) Mask off the inside edge of the frit area on the skylight. This is to avoid overspill of primer
onto the glass. Mask should be placed at frit edge or slightly overlapping less than 1/16
inch. Refer to Figure 50.
Figure 50
MASKING EDGE OF “FRIT” SURFACE
E. APPLY GLASS PRIMER TO TOP SKYLIGHT GLASS

(1) Shake applicator stick of DOW 5500 SA GLASS/FRIT PRIMER, part no. 627-2068.
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(2) While gently holding applicator stick with applicator sponge pointing up, apply pressure
with thumb and forefinger to the color band at the top of the tube. Refer to Figure 51.
Figure 51
APPLYING PRESSURE TO TUBE
(3) Screw the applicator cap down to puncture the seal on the applicator stick. Refer to
Figure 52.
Figure 52
PUNCTURING APPLICATOR
(4) Hold applicator stick on the skylight glass over the fritted surface (black band around the
perimeter of the glass). Press down until the tip “wets out”.
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NOTE: EXCESSIVE SQUEEZING WILL NOT SPEED “WET OUT” AND CAN LEAD TO LEAKAGE
AROUND THE TUBE. REFER TO FIGURE 53.
“WET OUT” OF TIP
Figure 53
WET OUT OF TIP
(5) Apply DOW 5500 SA GLASS/FRIT PRIMER to the frit surface and glass edge of the top
skylight glass. Allow to dry for a minimum of six minutes. Refer to Figure 54.
Figure 54
APPLICATION OF PRIMER TO FRIT SURFACE
(6) Remove tape from frit side of the glass.
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F. TOP SKYLIGHT GLASS INSTALLATION
(1) Apply 1/4 inch bead of DOW U-400 HV SEALANT, part no. 627-2067, to the cab around
opening for top skylight glass, centering the bead within the primer area. Refer to
Figure 55.
Figure 55
APPLICATION OF SEALANT TO PINCH-WELD
(2) Place glass centered over the opening in the cab. Press down until glass is within 1/8 inch
of the cab surface in order to distribute sealant between the bonding surfaces. Refer to
Figure 56.
Figure 56
INSTALLATION OF NEW GLASS
(3) Allow sealant to set for 10 minutes. Remove tape from around the skylight opening in the
cab before proceeding.
(4) Fill gap between the surface of the cab and the glass with DOW U-400 HV SEALANT, part
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Figure 57
APPLICATION OF SEALANT
(5) Smooth sealant around perimeter of glass. Refer to Figure 58.
Figure 58
SMOOTHING SEALANT
(6) Allow to dry for 10 minutes, then replace top protective grate. Refer to Figure 59.
Figure 59
FINISHED SKYLIGHT
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(7) Allow sealant to dry. Sealant dry time depends on temperature and humidity. Use the
following table to calculate relative dry time.
TABLE 2 - SEALANT DRYING TIMES (HOURS)
Relative Ambient Temperature ºC (ºF)

Humidity
4–10 10–16 16–21 21–27 27–32 32–38 38–43 43 +
% (40–50) (50–60) (60–70) (70–80) (80–90) (90–100) (100–110) (110 +)
>90 7 5 4 3 2 2 2 2
70–90 8 6 5 3 2 2 2 2
50–70 8 7 5 4 3 2 2 2
30–50 24 12 7 5 3 3 3 2
10–30 24 24 12 7 6 5 5 4
(8) Clean up all remaining tape and tape residue. Discard old skylight glass and any
remaining sealant and primers per site regulations.
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27. HYDRAULIC SYSTEM ADJUSTMENTS
WARNING
INJURY.
WARNING
DO NOT REMOVE GAUGE PORT PLUGS AND GAUGES OR LOOSEN HYDRAULIC
CONNECTIONS WITH THE POWER UNIT RUNNING. HYDRAULIC PRESSURE IN THE
SYSTEMS COULD CAUSE HYDRAULIC OIL TO SPRAY ON PERSONNEL.
CAUTION

NOTE: THE HYDRAULIC OIL MUST BE AT NORMAL OPERATING TEMPERATURE WHEN

MAKING PERFORMANCE CHECKS, HYDRAULIC SYSTEM PRESSURE CHECKS OR
HYDRAULIC SYSTEM ADJUSTMENTS. REFER TO CHAPTER 2, SECTION 4,
“MAINTENANCE SPECIFICATIONS” FOR HYDRAULIC OIL INFORMATION.
NOTE: IN MOST CASES ‘SPECIFIED PRESSURE’ + ‘STAND-BY PRESSURE’ = ‘INDICATED

PRESSURE’.
NOTE: AN ASSISTANT IS REQUIRED TO PERFORM MOST ADJUSTMENT PROCEDURES.
NOTE: OVER-TIGHTENING THE JAM NUT WILL BREAK THE ADJUSTING SCREW.
28. CHASSIS MANIFOLD ADJUSTMENTS
A. LOAD SENSE MARGIN PRESSURE
(1) Install a differential pressure gauge on chassis manifold.
NOTE: A DIFFERENTIAL PRESSURE GAUGE RATED TO 5000 PSI MAXIMUM LINE

PRESSURE AND MAGNETICALLY COUPLED TO PREVENT DAMAGE TO THE GAUGE
IS REQUIRED WHEN MAKING THIS ADJUSTMENT (ORANGE RESEARCH INC. PART
NO. 1303PG-1C-3.5B-0-350 PSID).
(2) Remove the 5000 psi gauge that is installed on the chassis manifold. Refer to Figure 60.
(3) Connect the port marked “HI” on the differential pressure gauge to the port from which the
5000 psi gauge was removed.
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(4) Connect the port marked “LO” on the differential pressure gauge to the port marked “TP1”
on the chassis manifold. Refer to Figure 62.
5000 PSI
PRESSURE
GAUGE
REMOVE
5000 PSI GAUGE
Figure 60
HYDRAULIC PRESSURE GAUGE
(5) Start the engine and then raise the deck.

(6) Observe the differential pressure gauge when the deck is rising and record the indicated
pressure: Indicated pressure should be 290–305 psid.
(7) Stop the deck.
(8) Adjust load sense margin pressure by loosening the lock nut and turning the “A” load sense
adjusting screw clockwise to increase pressure and counterclockwise to decrease
pressure. Refer to Figure 63.
NOTE: TURNING CLOCKWISE WILL INCREASE PRESSURE 90 PSID PER TURN. TURNING
COUNTERCLOCKWISE WILL DECREASE PRESSURE 90 PSID PER TURN.
(9) Recheck pressure by repeating steps (5) through (8).

(10) Shut down engine, remove differential gauge and re-install the 5000 psi gauge that was
removed.
B. MAIN RELIEF VALVE AND PUMP COMPENSATOR PRESSURE
Refer to Figure 61, Figure 62 and Figure 63.

(1) Locate the main relief valve and pressure gauge on the chassis manifold.
(2) Loosen the lock nut on the “B” pressure compensator adjusting screw and turn the
adjusting screw 3 to 4 turns counterclockwise.
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(3) Loosen the lock nut on the main relief valve pressure adjustment screw and turn the
adjusting screw clockwise all the way in.
(4) Remove the wires from the coil on 7 SOL valve on chassis manifold.
(5) Start engine.
(6) Move and hold the deck lift switch in the UP position.
(7) Turn the pressure compensator adjusting screw slowly clockwise until a pressure of
241 bar (3500 psi) is indicated on the gauge.
NOTE: THE FOLLOWING STEPS (8) AND (9), MUST BE MADE RAPIDLY BECAUSE THE
HYDRAULIC PUMP WILL BE DELIVERING ITS MAXIMUM FLOW AT HIGH PRESSURE
AND THE ENGINE HORSEPOWER IS BEING CONVERTED TO HEAT IN THE
HYDRAULIC OIL THAT FLOWS OVER THE RELIEF VALVE.
(8) Main relief valve pressure setting - Turn the pressure adjusting screw on the main relief
valve counterclockwise to lower the pressure to 241 bar (3500 psi) and tighten the
adjusting screw lock nut. You will hear the engine “load” as the relief valve opens to
bypass the excess flow from the pump to the reservoir.
(9) Pressure compensator setting - Immediately after adjusting the main relief valve, turn the
pressure compensator adjusting screw slowly counterclockwise to an indicated pressure of
220 bar (3200 psi) on the gauge and tighten the lock nut on the adjusting screw.
(10) Release the lift switch.
(11) Reinstall the wires on 7 SOL.
(12) Remove the maintenance stands.
(13) Lower deck and shut down engine.
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PARKING BRAKE 13 SOL

RELEASE PRESSURE
5000 PSI MAIN RELIEF 7 SOL A
ADJUSTMENT
PRESSURE
(Ref. Page 10) GAUGE
47 SOL
4 SOL
3 SOL
7 SOL
1 SOL A
TP 3 VALVE IN THIS PORT

(PORT) NON-ADJUSTABLE
DECK SUPPLY CUTOFF
THROTTLE PRESSURE
REDUCING VALVE
ADJUSTMENT
FRONT VIEW
Figure 61
CHASSIS MANIFOLD - FRONT VIEW
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HELPER CYLINDER
PRESSURE
ADJUSTMENT 7 SOL A
(Ref. Page 10)
MAIN RELIEF
13 SOL
TP1
(PORT)
GAUGE PORT
TP2
(PORT)
1 SOL A
8 SOL
9 SOL
3 SOL
SECONDARY SERVICE
PRESSURE
ADJUSTMENT 47 SOL
(Ref. Page 11)
4 SOL
REAR VIEW
Figure 62
CHASSIS MANIFOLD - REAR VIEW
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Figure 63
LOAD SENSE MARGIN PRESSURE ADJUSTMENT
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C. HELPER CYLINDER PRESSURE ADJUSTMENT

(1) With engine shut down, connect a 5000 psi pressure gauge to port TP2 located on the
back side of the chassis manifold (remove the plug from the port to connect the gauge).
(2) Disconnect valve 7 SOL on chassis manifold (remove wires from coil).
(3) Actuate 13 SOL with manual override on valve.
(4) Raise deck by moving the lift switch to the UP position.
(5) Adjust the helper cylinder pressure to 172 bar (2500 psi) after the cylinder is fully extended.
(6) Loosen lock nut on the HELPER CYLINDER adjustment screw and turn the adjustment
screw clockwise to increase pressure and counterclockwise to decrease pressure. Tighten
lock nut when adjustment is complete.
(7) Return manual override to the normal position on 13 SOL.
(8) Shut down engine, remove the gauge and reinstall the plug in the manifold.
(9) Reinstall the wires on 7 SOL that were removed in step (2).
D. PARK BRAKE RELEASE PRESSURE
1500 PSI
PRESSURE GAUGE INSTALLED FOR CHECKING

PARKING BRAKE RELEASE PRESSURE
Figure 64
PARK BRAKE RELEASE PRESSURE ADJUSTMENT
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(1) With engine shut down, remove hydraulic line from park brake cylinder and install pressure
gauge on end of line.
(2) Start the engine and place the park brake switch in the OFF position.
(3) Adjust the pressure to indicate 103 bar (1500 psi). Turn the adjusting screw clockwise to
increase pressure and counterclockwise to decrease pressure.
(4) Shut down engine, remove the gauge and reconnect hydraulic line to the brake cylinder.
E. SECONDARY SERVICE PRESSURE

(1) With engine shut down, connect a 200 bar (3000 psi) pressure gauge to port TP3 located
on the left side of the chassis manifold. Remove the plug from the port in the manifold to
connect the gauge. Refer to Figure 61.
(2) Actuate 47 SOL with manual override on valve.
(3) Loosen lock nut on the SECONDARY SERVICE adjusting screw and turn clockwise to
increase pressure to 172 bar (2500 psi) or counterclockwise to decrease the pressure.
Tighten lock nut when adjustment is completed.
(4) Return manual override to the normal position on 47 SOL.
(5) Shut down engine, remove the gauge and reinstall the plug in the manifold after making the
adjustment.
F. THROTTLE PRESSURE REDUCING VALVE
(1) With engine shut down, disconnect the hydraulic pressure hose from the fitting on the
throttle actuator in the port marked “P” and place a cap on the fitting. Refer to Figure 65.
(2) Install a 40 bar (600 psi) pressure gauge on the end of the hydraulic hose that was
removed.
(3) Start engine and observe the pressure reading on the gauge.
(4) Loosen lock nut on adjusting screw and turn adjusting screw clockwise to increase
pressure and counterclockwise to decrease the pressure. Set pressure at 24 bar (350 psi)
then tighten lock nut on the adjusting screw. Refer to Figure 61, front view.
(5) Shut down engine, remove the gauge and reconnect hydraulic line to the fitting that was
capped in step (1).
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29. INNER AND OUTER SCISSORS MANIFOLD ADJUSTMENTS
NOTE: THESE PROCEDURES APPLY TO SIDE SHIFT CYLINDER FLOW CONTROL VALVES,
FRONT AND REAR.
NOTE: THE ADJUSTMENTS ON THE INNER SCISSORS MANIFOLD CONTROL THE SPEED
THAT THE FRONT END OF THE DECK WILL SHIFT. THE ADJUSTMENTS ON THE
OUTER SCISSORS MANIFOLD CONTROL THE SPEED THAT THE REAR END OF THE
DECK WILL SHIFT. ADJUSTING THE SIDE SHIFT CYLINDER FLOW CONTROL VALVES
IS A TWO-PART PROCEDURE BECAUSE THE DECK MUST SHIFT EVENLY AT THE
FRONT AND REAR IN BOTH DIRECTIONS, LEFT AND RIGHT. IF AN ADJUSTMENT IS
REQUIRED, ADJUST THE FLOW CONTROL REQUIRED TO SHIFT THE DECK FULLY
IN THE SELECTED DIRECTION IN 5 TO 6 SECONDS AS DESCRIBED IN PARAGRAPHS
A. AND B. BELOW.
A. SHIFT LEFT SPEED ADJUSTMENT

(1) Shift deck fully to the right.
(2) With a stopwatch, check the time required to side shift the deck fully to the left. Nominal
time for full shift from one side is 5 to 6 seconds.
(3) Loosen lock nut on the SHIFT LEFT speed adjustment screw and turn clockwise to slow
the speed and counterclockwise to increase the speed.
NOTE: USE THE ADJUSTING SCREW ON THE INNER SCISSORS MANIFOLD FOR THE
FRONT END OF THE DECK USE THE ADJUSTING SCREW ON THE OUTER SCISSORS
MANIFOLD FOR THE REAR OF THE DECK.
(4) Tighten lock nut upon completion of adjustment.
B. SHIFT RIGHT SPEED ADJUSTMENT

(1) Shift deck fully to the left.
(a) With a stopwatch, check the time required to side shift the deck fully to the right.
Nominal time for full shift from one side is 5 to 6 seconds.
(b) Loosen lock nut on the SHIFT RIGHT speed adjustment screw and turn clockwise to
slow the speed and counterclockwise to increase the speed.
NOTE: USE THE ADJUSTING SCREW ON THE INNER SCISSORS MANIFOLD FOR THE
FRONT END OF THE DECK. USE THE ADJUSTING SCREW ON THE OUTER
SCISSORS MANIFOLD FOR THE REAR OF THE DECK.
(c) Tighten lock nut upon completion of adjustment.
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Figure 65
“P” PORT, THROTTLE ACTUATOR
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FRONT DECK
SHIFT RIGHT
SPEED ADJUSTMENT
(Ref. Page 13)
ROLL CYLINDER
FLOW CONTROL
PRESET @ 1/2 GPM FLOW
FRONT DECK
SHIFT LEFT
SPEED ADJUSTMENT
(Ref. Page 12)
25 SOL
23 SOL
16 SOL
14 SOL
CROSSOVER RELIEF
21 SOL VALVES (6) PRESET
27 SOL @ 3000 PSI (207 BAR) (SEALED)
Figure 66
INNER SCISSORS MANIFOLD
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REAR DECK
SHIFT RIGHT
SPEED ADJUSTMENT
(Ref. Page 13)
ROLL CYLINDER
FLOW CONTROL
PRESET @ 1/2 GPM FLOW
REAR DECK
SHIFT LEFT
SPEED ADJUSTMENT
(Ref. Page 12)
24 SOL
26 SOL
17 SOL
15 SOL
CROSSOVER RELIEF
22 SOL VALVES (6) PRESET
28 SOL @ 3000 PSI (207 BAR) (SEALED)
Figure 67
OUTER SCISSORS MANIFOLD
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30. REAR PITCH MANIFOLD
A. REAR PITCH CYLINDERS
Refer to Figure 68.

(1) With engine shut down, remove hydraulic line from fitting in port marked PL2 on REAR
PITCH manifold and install a tee fitting.
(2) Connect a pressure gauge to the tee fitting and reconnect the hydraulic line to the fitting.
(3) Start engine.
(4) Move and hold, the pitch switch in the DOWN position (rear of deck raised).
(5) Adjust the pressure to indicate 103 bar (1500 psi).
(6) Loosen lock nut on the PITCH PRESSURE adjusting screw and turn clockwise to increase
pressure and counterclockwise to decrease pressure. Tighten lock nut when adjustment is
complete.
(7) Shut down engine, remove the gauge and tee fitting. Reconnect the hydraulic line to the
manifold.
B. REAR PITCH SPEED, PITCH DOWN
Refer to Figure 68.

(1) Start engine.
(2) move and hold the deck pitch switch in the UP position until the rear of deck is fully lowered
(hydraulic cylinders retracted).
(3) Using a stopwatch, check the time required to extend the cylinder rod fully. Nominal time to
extend the cylinder fully is 17 seconds.
(4) Move and hold the pitch switch in the DOWN position until the rear of the deck is fully
raised (hydraulic cylinders extended).
(5) Loosen lock nut on the pitch down adjusting screw and turn clockwise to decrease speed
and counterclockwise to increase speed. Tighten lock nut when adjustment is complete.
(6) Verify the time after each adjustment has been made and the adjustment screw lock nut
has been tightened.
C. REAR PITCH SPEED, PITCH UP
Refer to Figure 68.

(1) Start engine.
(2) Move and hold the pitch switch in the DOWN position until the rear of deck is fully raised
(hydraulic cylinders extended).
(3) Using a stopwatch, check the time required to retract the cylinder rod fully. Nominal time to
retract the cylinder fully is 22 seconds.
(4) Move and hold the pitch switch in the UP position until the rear of the deck is fully lowered
(hydraulic cylinders retracted).
(5) Loosen lock nut on the PITCH UP adjusting screw and turn clockwise to decrease speed
and counterclockwise to increase speed. Tighten lock nut when adjustment is complete.
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(6) Verify the time after each adjustment has been made and the adjustment screw lock nut
has been tightened.
18 SOL
PITCH DOWN
SPEED ADJUSTMENT
PITCH UP
SPEED ADJUSTMENT
PL2
20 SOL
COUNTERBALANCE
PITCH VALVE (PRESET)
PRESSURE
Figure 68
REAR PITCH MANIFOLD
31. PALLET STOPS AND CONVEY LIFT MANIFOLD
A. PALLET STOPS
Refer to Figure 69.

(1) With engine shut down, remove hydraulic line from fitting in port marked A2 on PALLET
STOPS AND CONVEY LIFT manifold and install a tee fitting.
(5) Loosen lock nut on the PALLET STOPS adjusting screw and turn clockwise to increase
pressure and counterclockwise to decrease pressure. Tighten lock nut when adjustment is
complete.
(6) Shut down engine, remove the gauge and tee fitting; reconnect the hydraulic line to the
manifold.
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TRACTION ROLLER
LIFT CYLINDER
ADJUSTMENT
(Ref. Page 19)
46 SOL
PALLET STOPS
ADJUSTMENT
(Ref. Page 18)
A4
A3
A2
29 SOL
GAUGE PORT
32 SOL
30 SOL
Figure 69
PALLET STOPS AND CONVEY LIFT MANIFOLD
B. TRACTION ROLLER LIFT CYLINDERS
Refer to Figure 69.

(1) With engine shut down, remove hydraulic line from fitting in port marked A4 on PALLET
STOPS AND CONVEY LIFT manifold and install a tee fitting.
(4) Actuate valve 47 SOL on the chassis manifold () using the manual override. Refer to
Figure 61.
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(6) Loosen lock nut on the TRACTION ROLLER LIFT CYLINDER adjusting screw and turn
clockwise to increase pressure and counterclockwise to decrease pressure. Tighten lock
nut when adjustment is complete.
(7) Reset the manual override on 47 SOL to the normal position.
(8) Shut down engine, remove the gauge and tee fitting; reconnect the hydraulic line to the
manifold.
32. CONVEY MANIFOLD
37 SOL 36 SOL
33 SOL
34 SOL
35 SOL
GA
42 SOL
41 SOL
38 SOL
39 SOL
40 SOL
CROSSOVER RELIEF
VALVE
10 PLACES
Figure 70
CONVEY MANIFOLD
NOTE: CROSSOVER RELIEF VALVES ARE FACTORY PRESET AND NOT ADJUSTABLE IN
THE FIELD.
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33. ENGINE COOLANT FAN MANIFOLD
NOTE: RELIEF VALVE ADJUSTMENT IS MADE WITH ENGINE SHUT DOWN.
NOTE: FAN MOTOR PRESSURE ADJUSTMENT MAY BE PRE-SET AND SEALED.
A. FAN MOTOR PRESSURE ADJUSTMENT
Refer to Figure 71.

(1) Loosen lock nut on relief valve adjusting screw.
(2) Rotate adjusting screw fully clockwise (minimum setting).
(3) Tighten lock nut.
FAN MOTOR
PRESSURE ADJUSTMENT
1 SOL-B
Figure 71
FAN DRIVE MANIFOLD
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34. PROXIMITY SWITCH ADJUSTMENT PROCEDURE
WARNING
THE ENGINE MUST BE TURNED OFF WHEN MAKING ANY SWITCH ADJUSTMENT TO
PREVENT AN UNCONTROLLED MOVEMENT OF THE LOADER.
A. PROXIMITY SWITCH ADJUSTMENT
Inductive Proximity Switch. Refer to Figure 72.

“Proximity switch” is a generic term that refers to a device capable of acting as an electronic
switch when in the presence or close proximity of a metallic object. The important distinction that
differentiates a proximity switch from a mechanical switch is that a proximity switch does not
require physical contact with anything else to operate.
Figure 72
PROXIMITY SWITCH ADJUSTMENT
B. PROXIMITY SWITCH LOCATIONS
Proximity sensors are located throughout the vehicle for different purposes. Refer to Chapter 2,
Section 4, “Maintenance Specifications” for specific locations of proximity switches.
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35. ELECTRICAL SYSTEM ADJUSTMENTS
A. POTENTIOMETERS
NOTE: POTENTIOMETERS ARE FACTORY ADJUSTED AND SEALED. DO NOT BREAK

SEALS.
(1) Deck lift, 1VC

(2) Fan controller, 2VC
(3) Throttle controller, 3VC
(4) Convey controller, 4VC
Figure 73
VALVE DRIVE BOARD
B. LIMIT SWITCH ARM ADJUSTMENTS
NOTE: REFER TO CHAPTER 2, SECTION 4, “MAINTENANCE SPECIFICATIONS” FOR

SPECIFIC LOCATIONS OF PROXIMITY SWITCHES.
Limit switches are located throughout the vehicle for different purposes.
(1) Adjust the limit switch arm so the end of the arm is aligned flush with the base as shown.
Refer to Figure 74.
(2) Apply Loctite 242 to the arm set screw on the limit switch arm and tighten to 4 N·m
(35 lbf-in.).
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SET SCREW
89 mm
3-1/2”
(3.5 in.)
Align Edge
Figure 74
LIMIT SWITCH ARM
C. DECK FULLY DOWN (2LS) ADJUSTMENT
(1) Raise the deck to the FIRST maintenance stands position and install both maintenance
stands.
(2) Level and center the deck by actuating and holding the AUTO CENTER AND LEVEL
toggle switch until the PITCH, ROLL and SHIFT indicator lights are not illuminated.
(3) Adjust the limit switch arm so it is fully extended. The end of the arm is aligned flush with
the base as shown. Refer to Figure 74. Apply Loctite 242 to the arm set screw on the limit
switch arm and tighten to 4 N·m (35 lbf-in.).
(4) Adjust the limit switch arm so the center of the roller is 54 mm (2-1/8 in.) above the limit
switch body as shown. Refer to Figure 75.
(5) Apply Loctite 242 to the switch set screw on the 2LS limit switch arm and tighten 4 N·m
(35 lbf-in.). Refer to Figure 74.
(6) Remove the maintenance stands and completely lower the deck until it is resting on the
chassis frame.
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(7) Verify the following loader functions:
(a) The deck does not shift when the SHIFT toggle switch is activated to the left or right.
(b) The engine RPM changes when the throttle pedal is actuated.
(c) The transmission can be shifted in all gears.
(8) Lift the deck 25–50 mm (1–2 in.) off the chassis frame and verify the following functions.
(a) The deck shifts when the SHIFT toggle switch is activated to the left or right.
(b) The engine rpm does not change when the throttle pedal is actuated, except for first
and reverse gear.
(c) The transmission is limited to first and reverse.
(9) This adjustment is precise and may take several small adjustments to obtain the correct
operation as stated in steps (7) and (8).
54 mm
2-1/8”
(2.125 in.)
Figure 75
LIMIT SWITCH 2LS
D. FRONT OF DECK FULLY DOWN (4LS) ADJUSTMENT
stands.
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(4) Adjust the limit switch arm so the center of the roller is 48 mm (1-7/8 in.) below the limit
(5) Apply Loctite 242 to the switch set screw on the 4LS limit switch arm and tighten to 4 N·m
chassis frame.
48 mm
1-7/8”in.)
(1.875
Figure 76
LIMIT SWITCH 4LS
(7) Verify the following loader functions while the deck is resting on the chassis frame.
(a) The NO PITCH indicator light (RED) is illuminated when the PITCH joystick is
activated in either direction.
(b) The deck pitch is inactive when the PITCH joystick is activated in either direction.
(8) Raise the deck 125–150 mm (5–6 in.) off the chassis frame. Push the PITCH joystick
forward until the NO PITCH indicator light (RED) is illuminated then release the PITCH
joystick.
(9) Verify the following loader functions while the deck is pitched DOWN.
(a) The deck and chassis structures are not contacting each other.
(b) The deck will not lower when the LIFT joystick is held in the DOWN position.
operation as stated in step (7) and (9).
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E. REAR OF DECK FULLY DOWN (5LS) ADJUSTMENT
stands.
(4) Adjust the limit switch arm so the center of the roller is 60 mm (2-3/8 in.) below the limit
60 mm
2-3/8”
(2.375 in.)
5LS
5LS
Figure 77
LIMIT SWITCH 5LS
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chassis frame.
(7) Verify the following loader functions while the deck is resting on the chassis frame:
(a) The NO PITCH indicator light (RED) is illuminated when the PITCH joystick is
activated in either direction.
(b) The deck pitch is inactive when the PITCH joystick is activated in either direction.
(8) Raise the deck 125–150 mm (5–6 in.) off the chassis frame. Pull back on the PITCH
joystick until the NO PITCH indicator light (RED) is illuminated then release the PITCH
joystick.
(9) Verify the following loader functions while the deck is pitched UP.
(a) The deck and chassis structures are not contacting each other.
(b) The deck will not lower when the LIFT joystick is held in the DOWN position.
operation as stated in steps (7) and (9).
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F. DECK ROLL RIGHT (14LS) ADJUSTMENT
(1) Raise the deck to the first Maintenance Stands position and install both Maintenance
Stands.
(2) Activate and hold the ROLL joystick to the RIGHT until the front and rear left roll cylinders
are fully extended.
(4) Adjust the limit switch arm so the center of the roller is 89 mm (3-1/2 in.) above the steel
plate on the scissors as shown. Refer to Figure 78.
(5) Apply Loctite 242 to the set screw on the 14LS limit switch arm and tighten to 4 N·m
(7) Verify the following loader functions.
(a) The ROLL RIGHT indicator light (AMBER) is not illuminated.
(b) The front and rear left roll cylinders are completely collapsed (cylinder rod not
visible).
89 mm
3-1/2”
(3.5 in.)
Figure 78
LIMIT SWITCH 14LS
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G. DECK ROLL LEFT (15LS) ADJUSTMENT
(1) Raise the deck to the first Maintenance Stands position and install both Maintenance
Stands.
(2) Activate and hold the ROLL joystick to the LEFT until the front and rear right roll cylinders
are fully extended.
(4) Adjust the limit switch arm so the center of the roller is 89 mm (3-1/2 in.) above the steel
plate on the scissors as shown. Refer to Figure 79.
(a) The ROLL LEFT indicator light (AMBER) is not illuminated.
(b) The front and rear right roll cylinders are completely collapsed (cylinder rod not
visible).
89 mm
3-1/2”
(3.5 in.)
Figure 79
LIMIT SWITCH 15LS
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H. DECK SHIFTED LEFT (17LS) AND DECK SHIFTED RIGHT (18LS) ADJUSTMENT
stands.
(2) Verify the deck is centered by measuring the distance between the front roll cylinders to the
inside of the left and right deck I-beams. Both measurements should be equal. Adjust the
deck accordingly until the measurements are equal.
(3) Adjust the limit switch arms so they are fully extended. The end of the arms is aligned flush
with the base as shown. Refer to Figure 74. Apply Loctite 242 to the arm set screw on the
limit switch arms and tighten to 4 N·m (35 lbf-in.).
(4) Adjust the limit switch arms so the attached wire rope has approximately 25 mm (1 in.) of
slack. Refer to Figure 80.
(5) Apply Loctite 242 to the set screw on the 17LS and 18LS limit switch arms and tighten to
4 N·m (35 lbf-in.). Refer to Figure 74.
OF SLACK AT FIRST
WIRE ROPE WITH SLACK
MAINTENANCE STAND AT FIRST
MAINTENANCE STAND POSITION
POSITION
Figure 80
LIMIT SWITCHES 17LS AND 18LS

(a) The SHIFT LEFT and SHIFT RIGHT indicator lights should illuminate when the
SHIFT toggle switch is activated to the appropriate direction.
(b) Actuate and hold the AUTO CENTER AND LEVEL toggle switch until the SHIFT
indicator lights are not illuminated.
(7) Raise the deck to its maximum height.
Shift the deck to either side until the appropriate shift indicator light is illuminated. Actuate
and hold the AUTO CENTER AND LEVEL toggle switch until the SHIFT indicator lights are
not illuminated.
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NOTE: THE DECK WILL JERK BACK AND FORTH WHEN APPROXIMATELY CENTERED IF
THE WIRE ROPE IS TOO TIGHT.
operation as stated in step (6) through (8).
I. AIR TRANSPORT PIN (16LS) AND CLEVIS (16LS-A) ADJUSTMENTS
(1) Raise the deck to the first maintenance stands position and install both maintenance
stands.
(2) Level and center the deck by actuating and hold the AUTO CENTER AND LEVEL toggle
switch until the PITCH, ROLL and SHIFT indicator lights are not illuminated.
(4) Adjust the limit switch arm on 16LS so the center of the roller is aligned with limit switch
guard as shown. Refer to Figure 81.
LIMIT
SWITCH
GUARD
Figure 81
LIMIT SWITCH 16LS AND 16LS-A
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(5) Apply Loctite 242 to the set screw on 16LS and tighten to 4 N·m (35 lbf-in.). Refer to
Figure 74.
(6) Adjust the limit switch arm on 16LS-A so the arm is perpendicular (90º) to the limit guard as
shown in Figure 81.
(7) Apply Loctite 242 to the set screw on 16LS-A and tighten to 4 N·m (35 lbf-in.). Refer to
Figure 74.
chassis frame.
Figure 82
AIR TRANSPORT PIN AND CLEVIS INSTALLATION
CAUTION

(a) The AIR TRANSPORT indicator light (RED) on the dash panel should be flashing.
(b) The front and rear pallet stops should be inactive to the operator’s controls when
their associated toggle switches are in the “ON” position.
(c) All traction rollers lift and are inactive to the operator’s controls. Be sure all convey
toggle switches are in the “ON” position and the CONVEY MODE PALLET WIDTH
toggle switch to 108 or 88 position during this process.
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(d) The deck ROLL joystick is inactive to the operator’s controls.
(e) The engine RPM do not change when the LIFT joystick is in the UP position.
Immediately release the LIFT joystick if the engine rpm change during this process.
J. AIR TRANSPORT MODE (3LS-A) ADJUSTMENT
CAUTION
(2) Verify the following loader functions before proceeding.
(a) The AIR TRANSPORT indicator light (RED) on the dash panel should be flashing.
(b) The front and rear pallet stops should be inactive to the operator’s controls when
their associated toggle switches are in the “ON” position.
(c) All traction rollers lift and are inactive to the operator’s controls. Be sure all convey
toggle switches are in the “ON” position and the CONVEY MODE PALLET WIDTH
toggle switch to 2743 mm (108 in.) or 2235 mm (88 in.) position during this process.
(d) The deck ROLL joystick is inactive to the operator’s controls.
(e) The engine RPM do not change when the LIFT joystick is in the UP position.
Immediately release the LIFT joystick if the engine rpm change during this process.
(3) Move the LIFT joystick to the UP position until the helper cylinders are fully extended.
(5) Position the limit switch arm so it is firmly contacting the rear axle swing arm. Refer to
Figure 83.
(6) Using a flat head screw driver, rotate the knurled shaft on the limit switch counterclockwise
while holding the limit switch arm firmly against the rear axle swing arm until the AIR
TRANSPORT indicator light (RED) on the dash panel begins to flash. Then, gently rotate
the knurled shaft clockwise until the AIR TRANSPORT indicator light (RED) on the dash
panel is solid. Apply Loctite 242 to the set screw on 3LS-A and tighten to 4 N·m (35 lbf-in.).
(a) Lower the helper cylinders a few inches by positioning the LIFT joystick in the
DOWN position. The AIR TRANSPORT red indicator should begin to flash.
(b) Move the LIFT joystick to the UP position until the helper cylinders are fully
extended. The AIR TRANSPORT red indicator should be solid.
operation as stated in step (6).
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Figure 83
LIMIT SWITCH 3LS-A
K. RPM ADJUSTMENT (TRANSMISSION ACCESSORY BOX)

(1) Place parking brake switch in the ON position and let engine run until operating
temperature is indicated on engine temperature gauge.
(2) With an accurate tachometer, check the engine idle speed. Idle speed is 850–900 rpm with
the transmission in neutral. Adjust idle speed to 850–900 rpm if required.
(3) Open the door on the main panel and check the red led lamp on side “B” of the
transmission accessory box to verify if it is illuminated.
(a) If the lamp is OFF, turn the LOW SET adjusting screw clockwise until the RED LED
lamp is illuminated.
(b) If the lamp is ON, turn the LOW SET adjusting screw counterclockwise until lamp is
not illuminated, then slowly turn the adjusting screw clockwise until the RED LED
lamp is illuminated.
NOTE: THE SHIFT-SHOCK THRESHOLD IS NOW SET AT THE CURRENT ENGINE IDLE
SPEED.
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VIEW SIDE “B” OF

TRANSMISSION
ACCESSORY BOX
Figure 84
TRANSMISSION ACCESSORY BOX IN MAIN PANEL
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LED LIGHT
ADJUSTMENT SCREW
WIRE 165 WIRE 182 WIRE 4 WIRE 15C

REV NEU RPM (POS) SHIFT PWR
(+24VDC OUT)
WIRE 15L WIRE 7 WIRE 165 WIRE 1 WIRE 1

IGNR-RED BATT-BLUE BU-RED/BLK BU-RED/BLK GND-BLK
(+24VDC IN)
Figure 85
ACCESSORY BOX - PART NO. 623-7300
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(4) Increase engine speed to 1025–1050 rpm, hold throttle steady and turn adjusting screw
clockwise until RED LED is not illuminated.
NOTE: THIS WILL BE THE SHIFT-SHOCK THRESHOLD TO RESTRICT ANY SHIFTING OUT OF
NEUTRAL TO ANY FORWARD RANGE OR TO REVERSE WHEN ENGINE RPM IS
ABOVE THRESHOLD SETTING.
(5) Allow engine to return to idle speed. The RED LED must remain ON.
(6) Select N with the transmission range selector and increase engine rpm above the
threshold setting of 1025–1050 rpm.
(a) The RED LED should not illuminate.
(b) Transmission should not shift out of NEUTRAL range.
(7) Verify rpm adjustments.
(a) With engine at idle rpm, shift transmission out of N range and increase engine speed
to above the threshold of 1025–1050 rpm. The RED LED should be illuminated.
(b) Hold the engine speed above 1025–1050 rpm and shift transmission to N. The RED
LED should go out and remain not illuminated until engine rpm falls below the
threshold setting of 1025–1050 rpm.
(c) The RED LED will illuminate when engine rpm falls below the threshold of
1025–1050 rpm.
(8) The setting of SHIFT-SHOCK is complete.
L. PITCH UP AND DOWN (4PRS AND 5PRS) ADJUSTMENTS
Refer to Figure 86.

(1) Level the deck by actuating and holding, the AUTO CENTER AND LEVEL switch on the
dash panel until the PITCH, ROLL and SHIFT indicator lights are not illuminated.
(3) Verify that the deck is level with a spirit level or by measuring from the deck to the chassis
frame.
NOTE: IF THE DECK IS NOT LEVEL, START ENGINE AND ACTUATE THE PITCH SWITCH TO
LEVEL THE DECK WITH THE CHASSIS FRAME.
(4) Turn the ignition switch to the ON position and watch the indicator lights on the dash panel.
(5) Move the upper proximity switch (4PRS), up in the slot until the indicator light just
illuminates on the dash, then carefully move the switch down until the light is not
illuminated.
(6) Secure the switch with the lock nut.
NOTE: THE 2 MM (3/32 IN.) NOMINAL GAP MUST BE MAINTAINED BETWEEN THE SWITCH
AND THE TARGET WHEN MAKING AN ADJUSTMENT.
(7) Move the lower proximity switch (5PRS) down in the slot until the indicator light just
illuminates on the dash, then carefully move the switch up until the light is not illuminated.
(8) Secure the switch with the lock nut.
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NOTE: THE 2 MM (3/32-IN.) NOMINAL GAP MUST BE MAINTAINED BETWEEN THE SWITCH
AND THE TARGET WHEN MAKING AN ADJUSTMENT.
(9) Verify adjustment of 4PRS and 5PRS by actuating pitch switch. Indicator lights on dash
panel must illuminate when deck is pitched UP or DOWN and are not illuminated when
deck is level.
TARGET
2 mm (3/32 in.) GAP

(3/32-in) GAP
4PRS
5PRS
TARGET
2 mm (3/32-in)
(3/32 in.) GAP
GAP
Figure 86
PROXIMITY SWITCHES 4PRS AND 5PRS
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1. GENERAL
The Halvorsen, 25 000 lb. Loader for Aircraft, is hydraulically operated and electrically controlled. The
hydraulic and electrical systems are complex and require a thorough understanding to determine the
cause of a malfunction or failure of a component. System diagnosis is mandatory to locate a component
that is out of adjustment or has failed, in the minimum amount of time.
The information contained in this section is provided as a guide to assist technical service personnel in
troubleshooting operational malfunctions in the vehicle hydraulic and electrical systems. The
information should be used in conjunction with the Troubleshooting section, Schematics, Reference
Designators and Maintenance Procedures incorporated in this manual.
A. BEFORE TROUBLESHOOTING
Before starting troubleshooting procedures, verify that the correct operating procedures were
used. An incorrect operating procedure can cause apparent malfunctions.
Make sure all circuit breakers and fuses have continuity. Inspect all electrical connections and
suspected defective parts to verify that there are no open circuits or defective grounding.
B. HYDRAULIC SYSTEM CLEANLINESS
A very important practice to observe when working on the hydraulic system is cleanliness.
Serious damage can result quickly from foreign material (contamination) in the hydraulic system.
When a hydraulic system is opened, cap or plug all ports and openings to keep foreign material
and moisture-laden air (contamination) from entering the system. DO NOT use Teflon tape or
pipe compound on straight threads.
2. HYDRAULIC SYSTEM
A. PRESSURE READINGS AND ADJUSTMENTS
Test ports are provided and hydraulic system diagnosis is accomplished by observing pressure
readings on a test gauge when a particular hydraulic circuit is actuated. The hydraulic
schematics and adjustment procedures indicate the correct setting for each pressure adjustment.
B. MALFUNCTIONS ISOLATION
The first step in diagnosing a malfunction is to isolate the malfunction to the hydraulic system or to
the electrical control system.
C. TROUBLESHOOTING
Refer to troubleshooting guides to assist in locating the cause of a malfunction when incorrect
pressure or incorrect flow has been determined. Also, for hydraulic components and locations,
refer to Chapter 4, ILLUSTRATED PARTS LIST.
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TROUBLESHOOTING
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INCORRECT PRESSURE
A B C D
NO PRESSURE LOW PRESSURE ERRATIC PRESSURE EXCESSIVE PRESSURE
No flow Pressure relief Air in fluid Pressure reducing or

path exists relief valve misadjusted
Pressure reducing Relief valve worn Pressure reducing or

valve set too low relief valve damaged
Pressure reducing Contamination

valve damaged in fluid
Pump, motor or Pump, motor or

cylinder damaged cylinder worn
Shuttle valve
stuck
INCORRECT FLOW
A B C
NO FLOW LOW FLOW EXCESSIVE FLOW
Pump not Flow control or relief Flow control set

receiving fluid valve set too low too high
Pump-to-drive Flow by-passing through

coupling sheared partially open valve
Directional control set External leak

in wrong position in system
Entire flow passing RPM of pump

over relief valve drive incorrect
Pump Pump, valve, motor or

damaged other component worn
Figure 1
HYDRAULIC SYSTEM TROUBLESHOOTING
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3. ELECTRICAL SYSTEM
The main electrical system components are located in the main panel. Sensors detect a specific
position of a mechanical component for the actuation and interlocking of electrical circuits.
CAUTION

4. TROUBLESHOOTING GUIDELINES
A. SCOPE
Troubleshooting guide tables list malfunctions and some possible causes of a listed malfunction.
When there is a problem or malfunction of the vehicle, read through the list on the left side of the
chart. Possible causes are listed to the right.
This guide lists the most common problems that could be encountered, but is not meant to
replace troubleshooting procedures that require diagnosing a system malfunction using the
hydraulic and electrical schematics.
B. DIAGNOSTIC TOOLS
The status panel in the cabin and an accurate voltmeter must be used to identify electrical
problems. Electrical schematics must be referred to when troubleshooting the electrical system.
Proximity switches and pressure switches must be adjusted to specifications when they are
replaced. Refer to Chapter 2, Section 5, “Maintenance Procedures”.
Hydraulic troubleshooting can be done connecting a liquid-filled pressure gauge to the test ports
in conjunction with the hydraulic schematics.
C. COMPONENTS REPLACEMENT
When a component is repaired or replaced, always check the hydraulic circuit for the correct
indicated pressure and correct actuator speeds. Refer to Chapter 2, Section 5, “Maintenance
Procedures” and Chapter 1, Section 4, “Specifications”.
The troubleshooting guides do include some obvious causes such as burned out light bulbs,
loose wire connections, physical damage to wire harnesses, components, etc., but it is assumed
that the technician will check these items before proceeding with detailed troubleshooting
procedures and adjustments.
D. SENSORS LOCATION
Refer to Chapter 2, Section 2, “System Overview” for solenoid valves and sensors location.
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TROUBLESHOOTING
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NOTE: THE HYDRAULIC AND ELECTRICAL SYSTEMS ARE COMPLEX AND REQUIRE A
THOROUGH UNDERSTANDING TO DETERMINE THE CAUSE OF A MALFUNCTION OR
FAILURE OF A COMPONENT. SYSTEM DIAGNOSIS IS MANDATORY TO LOCATE A
COMPONENT THAT HAS FAILED OR IS OUT OF ADJUSTMENT IN THE MINIMUM
AMOUNT OF TIME. THE FIRST STEP IN DIAGNOSING A MALFUNCTION IS TO
ISOLATE THE MALFUNCTION TO THE HYDRAULIC SYSTEM OR TO THE ELECTRICAL
CONTROL SYSTEM.
5. TROUBLESHOOTING GUIDE TABLES
The following pages contain the Troubleshooting Guides (Table 1 through Table 6) to assist in locating
the causes of malfunctions. Also, for components and locations, refer to “ELECTRICAL SCHEMATICS”
and “HYDRAULIC SCHEMATICS” in Chapter 2, Section 7.
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TROUBLESHOOTING GUIDE
TABLE 1 - ENGINE
SYMPTOM PROBABLE CAUSE ACTION
Engine does not Engine already running. None.

crank (turn over)
Batteries discharged or voltage output Check battery voltage; if low, charge
low. batteries.
Battery has defective cell. Replace battery.
Emergency stops pushed. Reset switch.
Transmission range selector not in N Position range selector in N.
(neutral).
Starter or starter solenoid switch Replace failed component.
failure.
Battery terminals loose or corroded. Clean and tighten.
Do not start engine until engine
Cold engine (diesel engine).
preheat light on dash panel goes out.
Circuit breaker tripped or failed. Reset circuit breaker. If circuit breaker
trips again, check for short.
Circuit breaker faulty. Replace circuit breaker.
Neutral safety switch failure. Replace switch.
Ignition or starter switch failure. Replace switch.
Engine locked up. Rotate engine by hand. If engine
cannot be rotated, check for internal
damage. Replace engine.
Low cranking Battery voltage low. Test battery voltage before and during
speed cranking. Charge or replace batteries.
Battery voltage low at starter terminal. Check battery cables for loose or
corroded terminals. Replace defective
battery cable.
Incorrect oil viscosity for temperature. Drain and refill engine sump with oil
with correct viscosity.
External power not connected (cold Check external power cord connection
weather operation). and circuit breaker.
Engine, transmission, coolant or Check elements and replace if
hydraulic reservoir heating elements defective.
not operating.
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TABLE 1 - ENGINE (CONT.)
Engine cranks, will No fuel. Check quantity of fuel in tank. Check

not run fuel gauge and sender.
Fuel filter(s) clogged. Replace fuel filter(s) element.
Air in fuel system. Check fuel lines for leaks. Bleed and
prime fuel system.
Oil pressure too low. Check engine oil level. Hold
SHUTDOWN OVERRIDE switch when
cranking and observe engine oil
pressure when engine starts.
Contaminated or incorrect grade of Drain and clean fuel tank. Refill with
fuel. fresh, clean fuel. Flush fuel lines,
replace filter elements, bleed and
prime fuel system.
Cold engine (diesel). Do not start engine until engine
preheat light on dash panel goes out.
Engine will only Check for cause of engine shutdown condition:
run with
High engine temperature. Refer to Engine overheats symptom.
SHUTDOWN
OVERRIDE switch High hydraulic oil temperature. Check fluid level in reservoir.
actuated
High transmission oil temperature. Check fluid level in transmission.
Oil pressure failure. Check engine oil level. Check
condition of engine.
Engine overheats Coolant level low. Add coolant of proper mixture to
coolant system.
Radiator fins dirty, restricted air flow. Clean radiator.
Water pump belt slipping. Adjust or replace pump drive belts.
Engine oil level low. Check engine oil level and add oil to
full mark on dipstick.
Thermostat faulty. Replace thermostat.
Water pump faulty. Replace water pump.
Cooling fan not operating. Check fan control circuit
Temperature sensor for fans. Replace temperature sensor.
Solenoid valve for fans. Replace solenoid valve.
Hydraulic motor for fan failed. Replace hydraulic motor.
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Coolant Engine thermostat faulty. Replace engine thermostat.

temperature does
not rise to normal
Move selector out of N position to a
Range selector in neutral.
forward range or the R range.
Parking brake applied. Release parking brake.
Engine runs but Engine speed (rpm) too high Check engine speed.
vehicle will not (above preset level). Engine must be below 900 rpm.
move Fill transmission to FULL mark on
Transmission fluid low.
dipstick.
Rear wheel brakes locked. Unlock brakes.
Front axle drive shaft brake locked. Unlock drive shaft brake.
Excessive loss of Coolant loss due to loose clamps on Tighten all clamps.
coolant coolant hoses.
Defective coolant hoses. Pressure check coolant system to
locate defective hoses. Replace any
hose that leaks when system is
pressurized.
Defective coolant system pressure Pressure check coolant system cap
cap. and replace as required.
Engine gaskets and/or seals. Repair or replace engine.
Loss of engine Insufficient fuel. Inspect fuel lines for air leaks and
power restriction.
Fuel filters clogged. Replace filter elements.
Fuel transfer pump defective. Replace pump.
Fuel injectors dirty or worn. Replace injectors.
Fuel injection pump defective. Replace injection pump.
Insufficient air. Clean or replace air filter element.
Restricted exhaust. Check for exhaust pipe damage.
Replace exhaust silencer.
Engine adjustments incorrect. Service engine. Check injector pump
timing.
Turbocharger faulty. Replace turbocharger.
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TROUBLESHOOTING
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Excessive black Insufficient air. Service air cleaner, replace element.

exhaust
Faulty fuel injectors. Replace injectors.
Injection pump timing. Adjust to specifications.
Turbocharger faulty. Replace turbocharger.
Contaminated or incorrect fuel. Drain and clean fuel tank, replace fuel
filter elements and refill with fuel.
Engine operating Coolant thermostat faulty. Replace coolant thermostat.
too cold
TABLE 2 - TRANSMISSION
Loader will not Range selector in neutral. Move selector out of N position to a
move forward range or the R range.
Parking brake applied. Release parking brake.
Engine rpm too high (above preset Adjust engine idle rpm to
level). specifications.
Transmission fluid low. Fill transmission with fluid.
Shifter valve not operating. Check valve for input voltage. Replace
shift valve coil.
Wire harness to shifter valve has fault. Repair or replace wire harness.
Range selector shifter defective. Replace shifter.
Broken axle. Replace axle.
Damaged differential. Repair or replace differential.
Rear wheel brakes locked. Check brake valve. Repair or replace.
Transmission shift Transmission governor malfunction. Clean or replace governor screen and
points are low governor.
(high engine rpm)
Rough shifting Governor valve malfunctioning. Clean or replace governor screen and
governor.
Control valves sticking. Rebuild or replace main control valve
body assembly.
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TABLE 2 - TRANSMISSION (CONT.)
Shifter will not Shift Engine not running. Start engine.

into forward or
reverse Parking brake in “ON” position. Turn parking brake to “OFF” position.
Service brake not applied. Apply service brake.
Engine RPM too high. Refer to the engine manual and adjust
to specifications.
Shift shock set low. Refer to Chapter 2, Section 5 for
adjusting the rpm setting on the
transmission accessory box.
Relays -16CR, -46CR or 47CR are Inspect relays and troubleshoot circuit.
inoperative.
Connector or wires in the wiring Inspect and repair as necessary.
harness going to shaft actuator
defective
Will not shift from Shorted brake pressure switch +C- Replace switch.
2nd to 1st gear PS_B.
+CP-USCR_2 failed. Replace relay.
Will not auto shift +CP-2CR_A defective. Replace relay.
to neutral
Joystick display Transmission linkage out of Adjust per vendor’s manual,
does not read adjustment. Chapter 5.
properly
Bad ground. Inspect and repair as necessary.
Transmission Fluid level low. Replace filter and or elements. Add
overheating fluid to correct level.
Fluid filters clogged. Replace filter and elements.
Aerated fluid. Improper fluid level. Adjust fluid to proper level.
Incorrect or contaminated fluid. Drain and refill with correct fluid.
Replace filter elements.
Cooler fluid flow loss due to internal Overhaul or replace transmission.
leakage.
Transmission fluid dirty, dark in color Drain and refill with new fluid, clean
and/or has odor due to failure to sump and install new filter elements.
change fluid at proper interval.
Excessive heat Refer to Transmission overheating above.
Clutch failure Damaged filter or filter elements. Overhaul or replace transmission.
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TROUBLESHOOTING
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TABLE 2 - TRANSMISSION (CONT.)
Transmission Dipstick loose. Tighten or replace cap.

throws fluid out of
fill tube or breather Fluid level too high. Drain to proper fluid level.
Fluid level too low. Fill to proper fluid level.
Fill tube is plugged or not vented. Clean vent of restriction.
Breather clogged. Clean or replace breather.
Water in transmission fluid. Drain and refill transmission with clean
fluid. Replace filter elements.
Noise (buzzing Low fluid level. Add fluid to proper level.
noise) occurring
Clogged filter or filter elements. Replace filter and elements.
intermittently
Aerated fluid or improper fluid level. Adjust fluid to proper level.
Noise (buzzing Damaged filter or filter elements. Replace filter and elements.
noise) occurring
Air leak at intake tube. Remove sump and replace intake tube
intermittently
seal and filter.
(Cont.)
Excessive engine Piston seals leaking or clutch plates Overhaul or replace transmission.
flare (slipping) on slipping in range involved.
full throttle up-shift
Sticking governor valve. Clean or replace governor screen and
governor.
TABLE 3 - HYDRAULIC SYSTEM
Parking brake does Parking brake solenoid valve 3SOL. Replace valve.
not release
Brake assembly. Repair or replace brake assembly.
Loader hard to Steering valve. Replace valve.
steer or no power
Hydraulic cylinder for steering. Repair or replace hydraulic cylinder.
steering
Loader steers in Steering valve. Replace valve.
one direction only
Hydraulic cylinder. Repair or replace hydraulic cylinder.
Loader has little or Service brake hydraulic actuating Replace valve.
no braking action valve.
when pedal
depressed
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TABLE 3 - HYDRAULIC SYSTEM (CONT.)
No steering and Deck supply cut-off valve in the off Turn to the on position.
service brakes position.
No system pressure. Check or repair main hydraulic pump.
Helper cylinder will 8SOL inoperative. Repair or replace.
not raise
Repair or replace 9SOL.
Deck will not raise 7SOL inoperative. Repair or replace.
above helper
cylinders
Repair or replace 9SOL.
Deck will not lower 10SOL or 11SOL inoperative. Repair or replace.
9SOL inoperative.
Helper cylinder will 13SOL inoperative. Repair or replace.
not lower 9SOL inoperative.
Deck will not side 14SOL or 16SOL inoperative. Repair or replace.
shift front Deck supply cut-off valve in off Turn to on position.
position.
Deck will not side 15SOL or 17SOL inoperative. Repair or replace.
shift rear Deck supply cut-off valve in off Turn to on position.
position.
Deck will not pitch 19SOL or 20SOL inoperative. Repair or replace.
Deck supply cut-off valve in off Turn to on position.
position.
9SOL inoperative.
Deck slow to side Low system pressure. Check or repair main hydraulic pump.
shift
Speed adjustment out of Adjust per specifications in Chapter 2,
specifications. Section 4.
Deck will not roll 23SOL or 24SOL inoperative. Repair or replace.
left Deck supply cut-off valve in off Turn to on position.
position.
Deck will not roll 25SOL or 26SOL inoperative. Repair or replace.
right Deck supply cut-off valve in off Turn to on position.
position.
9SOL inoperative.
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TABLE 3 - HYDRAULIC SYSTEM (CONT.)
Deck pitch speed Pressure at pitch manifold low. Set pressure at TP port to 1500 psi.
slow
Speed adjustment out of Adjust as per specifications in
specifications. Chapter 2, Section 4.
9SOL inoperative. Repair or replace.
Pallet stop 30SOL inoperative. Repair or replace.
inoperative front Deck supply cut-off valve in off Turn to on position.
position.
Pallet stop 32SOL inoperative. Repair or replace.
inoperative rear Deck supply cut-off valve in off Turn to on position.
position.
Traction rollers will 29SOL inoperative. Repair or replace.
not retract Deck supply cut-off valve in off Turn to on position.
position.
9SOL inoperative.
Emergency pump Electric motor inoperative. Repair or replace.
inoperative
Pump inoperative. Repair or replace.
Emergency pump Deck supply cut-off valve in the on Turn and hold in the off position.
will not raise deck position
above Helper
9SOL inoperative. Repair or replace.
Cylinders with a
load
Air conditioning 51SOL inoperative. Repair or replace.
system Deck supply cut-off valve in off Turn to on position.
compressor position.
inoperative
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TABLE 4 - ELECTRICAL SYSTEM
No warning lights Battery disconnect switch not turned Turn on switch.

on dash panel with on.
ignition switch in
Battery 1BAT or 2BAT discharged. Recharge or replace battery.
the ON position
Circuit breaker 4CB tripped. Reset circuit breaker.
Oil pressure gauge Oil pressure sending unit (1POT). Replace oil pressure sending unit.
does not indicate
Oil pressure gauge (1GA). Replace oil pressure gauge.
pressure (engine
has oil pressure)
Coolant Engine temperature sending unit Replace engine temperature sending
temperature gauge (2POT). unit.
does not indicate
Engine temperature gauge (2GA). Replace engine temperature gauge.
temperature
Fuel gauge does Fuel sending unit (3POT). Replace fuel sending unit.
not indicate fuel
Fuel gauge (3GA). Replace fuel gauge.
level
Voltmeter does not V-belt loose. Tighten belt.
indicate
Voltmeter. Replace voltmeter.
Generator regulator. Replace generator.
Generator failure V-belt loose. Tighten belt.
light does not go
1CR relay. Replace relay.
out when engine is
running Generator Repair or replace generator.
Oil pressure Oil pressure switch. Replace switch.
warning light does
Oil pressure low. Check engine condition.
not go out when
engine is running
(oil pressure is 4
psi or higher)
Engine coolant Low coolant level. Add coolant.
temperature
Engine thermostat. Replace thermostat.
warning light
illuminates
Hydraulic oil Hydraulic oil temperature switch. Replace switch.
temperature
Hydraulic oil temperature above Check oil level in reservoir.
warning light
180 ºF.
illuminates
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TROUBLESHOOTING
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TABLE 4 - ELECTRICAL SYSTEM (CONT.)
Headlamps and Circuit breaker 9CB tripped. Reset circuit breaker.

parking lights do
not illuminate
Stoplights do not Stoplight switch. Replace switch.
illuminate
Turn signals do not Circuit breaker 8CB tripped. Reset circuit breaker.
function
Flasher. Replace flasher.
Turn signal switch. Replace switch.
Backup lights do 43CR relay. Replace relay.
not illuminate when
loader is in reverse
Horns do not sound Horn switch. Replace switch.
Circuit breaker 1CB, 15CR relay. Reset circuit breaker and/or relay.
Emergency pump Circuit breaker 1CB tripped, 7TGS, Reset circuit breaker. Replace
8TGS switches. switches.
Electric pump motor or contactor. Repair or replace.
Deck does not Circuit breaker 13CB tripped. Reset circuit breaker.
convey in any
direction
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6. D3 AND D4 HEATER TROUBLESHOOTING
A. BASIC TROUBLESHOOTING
TABLE 5 - D3 AND D4 HEATER TROUBLESHOOTING
Heater does not Heater switch is OFF. Turn switch to ON.

ignite
Blower motor does not run. Check: fuse in power harness, power
to control unit, electrical connections
and power into and from switch.
Blower motor runs approximately 20 Ensure voltage at control unit remains

seconds and then shuts off. above 10 volts during start-up with
glow pin circuit on.
Blower motor runs and fuel metering Check fuel lines and fuel filter and fuel
pump starts and then shuts down after level in tank.
two start-up attempts. Check combustion air or exhaust tube
blockage.
Blower motor runs but there is no fuel Verify electrical pulses at fuel metering
flow. pump.
Check for pump freeze and fuel line
blockage.
Heater ignites, but No fuel flow. Check fuel metering pump flow.
shut downs at
random. Overheating. Check for possible overheat.
No proper voltage to control unit. Verify control unit input voltage.
Heater smokes and Exhaust pipe blocked. Inspect for exhaust blockage.
builds up carbon
Combustion air intake blocked. Inspect for air intake blockage.
Exhaust gases entering air intake Inspect for cracks or leaks from
pipe. exhaust and air intake pipes.
Short cycling on rapid ON-OFF

operation.
Fuel system failing. Verify fuel system proper operation.
Fuel flow incorrect. Fuel metering pump flow.
Blower motor speed incorrect. Verify motor speed (rpm).
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TROUBLESHOOTING
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B. SELF DIAGNOSTICS
The heater is equipped with self diagnostic capability. To retrieve information on the heater's last
five (5) faults, a retrieval device is required (part no. 624-8951). There is a pig tail to
accommodate the connector on the main harness from heater.
Connect the fault code retrieval device as shown.
(1) Self-diagnostics Device Functions
(a) Access the current fault which is affecting the heater.
(b) Access the five previous faults which affected the heater.
(c) Clear the fault memory to erase previous fault history.
(d) Unlock “Lockout Features” which exist for some control units.
(e) Start heater.
(2) Device Face and Controls
Symbols that are seen on the display face are as follows.
AF ACTUAL FAULT
Up to five stored faults can be accessed.

F1 through F5
The AF and F1 are the same number.
This symbol is displayed when the heater is in

operation.
The word ‘dIA’ for diagnostic will come on when the

DIAG
unit is connected.
000 Three digit diagnostic fault code number.
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1. DELETE FAULT MEMORY 4. BACKWARDS, FAULT F5

2. DELETE FAULT MEMORY THROUGH F1, AF
3. SWITCH HEATER ON-OFF 5. FORWARD AF, F1 THROUGH F5

(REQUEST DIAGNOSTIC FAULT 6. DISPLAY SCREEN
CODES)
Figure 2
FAULT CODE RETRIEVAL DEVICE
NOTE: IF THERE ARE NO HEATER FAULTS, THE HEATER WILL GO THROUGH A NORMAL
START CYCLE AND REGULATE BASED ON THERMOSTAT SETTING.
(a) Turn ON the fault code retrieval device and wait 10 seconds.
(b) Press the “D” button.
(c) Wait 3 to 5 seconds for the current fault code to appear (AF).
(d) To review the previous faults use the arrow buttons (F1 = most recent, F5 = oldest).
(e) Consult the fault code chart for code number descriptions.
(f) To erase the faults stored in the memory press both “L” keys at the same time for 5
seconds. This will also unlock the control unit in the case of an operational lockout.
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C. HEATER FAULT CODES, CAUSES AND ACTIONS
TABLE 6 - D3 AND D4 HEATER FAULT CODES
FAULT CODE AND DESCRIPTION FAULT CAUSE AND ACTION
000 Normal Operation
Disconnect connection S1-B1 at AIRTRONIC at

Warning - short circuit in control
004 connector 81, pin 16 check for short between pin and
unit, fresh air outlet
blower relay. If no short exists replace control unit.
Disconnect connection S1-B1 at AIRTRONIC at

Warning - short circuit at control connector 81, pin 16 check the line through to the relay
005
unit anti-theft alarm output isolating switch or theft warning in line for short circuit to
chassis. If no short exists replace control unit.
Switch oft due to signal change. Check for change of

009 TRS - shut down signal from (+) to (-) at pin 13 (S1) or a (+) signal at pin
14 (S1).
Start vehicle motor. Check voltage at (B1) between

terminals 1 and 10. This must be less than 16 volts
010 Over voltage (15.2 volts with glow pin on). Check vehicle charging
system.
AIRTRONIC 24 V - voltage must be less than 32 volts
Start vehicle motor. Check voltage at connector (B1)

between terminals 1 and 10. This must be more than 10
011 Under voltage shut down volts. Check vehicle charging system. Check batteries
and connections.
AIRTRONIC 24 V - voltage must be more than 21 volts.
Sensor has detected excessive temperatures.

Check for clogged hot air ducting.
012 Overheat at overheating sensor Check that the total number of ducting pieces in unison
is not too large. Re-route if necessary. Check overheat
sensor resistance values. If OK measure fuel flow.
Flame sensor detects excessive temperature at heat

exchanger Check for clogged hot air ducting. Check
that the total number 01 ducting pieces in unison is not
013 Overheat at flame sensor
too large. Re-route if necessary. Measure fuel quantity.
Check flame sensor resistance (refer to component
value chart).
Check for clogged hot air ducting. Check that the total
number of ducting pieces in unison is not too large.
Temperature difference between
Check flame sensor, if OK, check overheat sensor. If
014 flame sensor and overheat sensor
over-heat sensor is defective replace COMB sensor. If
too large
over-heat sensor is OK measure fuel quantity. If fuel
flow amount is OK replace control unit.
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TABLE 6 - D3 AND D4 HEATER FAULT CODES (CONT.)
Fault code 015 is shown when the AIRTRONIC is

switched on again alter fault code 017. The hardware
Overheat with excessive
015 limit value for the overheat sensor, has been exceeded
temperatures
control unit is locked. Check sensor. Unlock control
unit.
The hardware limit value for the overheat sensor, has

been exceeded, because the control unit has not
Overheat with excessive
017 detected fault code 012, 013. The control unit is locked.
temperature
If AIRTRONIC is switched on again, fault code 015 is
displayed. Unlock control unit. Check sensor.
Power consumed by glow pin is too low (glow pin

019 Glow Pin Resistance
resistance is too high). Replace the glow pin.
Check continuity of glow pin.

020 Open circuit - glow pin AIRTRONIC 12 V - approx. 0.5  ± 0.05 
AIRTRONIC 24 V - approx. 2.0  ± 0.20 
Check functions 01 glow pin in installed condition,

Short circuit - glow pin disconnecting connector from controller.
CAUTION! AIRTRONIC 12 VDC and 24 VDC.
For AIRTRONIC 12 V - Check Apply voltage of 8 V and 18 V to glow pin respectively
functions with max. 8 volts. and measure current intensity after 40 seconds.
For AIRTRONIC 24 V - Check Glow pin is OK for the following values:
021
functions with max. 18 volts. • Glow pin 8 V, current = 9 A +1.5/-1.2 A
If voltage values are exceeded the • Glow pin 18 V, current = 4 A ± 0.5 A
component is destroyed. If the values differ, replace glow pin. If the values of the
Check short-circuit resistance of continuity test and function test are OK, check glow pin
main unit: 20 A minimum. cable harness for damage and continuity. If OK replace
control unit.
Glow plug, output (+) - short circuit Check glow plug lead harness for correct laying and
022
after UB (battery voltage) damage and continuity, if OK → replace control box.
This fault code cannot be displayed as the diagnostics

Diagnostics cable B1-WS - short
025 cable is probably defective. Check diagnostics cable for
circuit - after UB (battery voltage)
correct laying and possible damage.
Check blower motor cable harness for correct routing

and damage. If OK, disconnect cable harness from
031 Blower motor interrupted
control unit and check for continuity, if OK, replace
control unit.
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TROUBLESHOOTING
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Blower motor, short circuit

CAUTION!
For AIRTRONIC 12 V check Check functions of blower motor, disconnecting
functions with 8 volts maximum! connector from control unit.
For AIRTRONIC 24 V check Apply voltage of 8 volts or 18 volts ± 0.1 to blower motor
032 and measure current intensity after 40 seconds.
functions with 18 volts maximum!
If voltage values are exceeded the Current < 6.5 A - blower motor OK, replace controller.
component is destroyed. Current > 6.5 A - replace blower.
Check short-circuit resistance of
main unit: 20 A minimum.
Motor speed varies from specification by more than 10%

for longer than 30 seconds. If too slow, check for
restriction and check for short in motor circuit or control
033 Blower motor does not turn unit. If none found, replace blower. If too fast, check for
damage or missing magnetic sensor on control unit.
Replace blower motor if damaged. Replace control unit
otherwise.
Disconnect connector from fuel metering pump, if fault

code 048 (interruption) is displayed then the fuel
metering pump is defective, replace FMP.
047 Short circuit - fuel metering pump If fault code 047 is still displayed, then disconnect
connection S1-B1. At connector B1, Pin 5, check line1
(green-red) through to FMP for short circuit to pin 10, if
OK replace control unit.
Disconnect connector from fuel pump and measure

resistance value of fuel pump (refer to values). If
resistance values OK, then reconnect cable harness to
048 Open circuit - fuel metering pump
the fuel pump. Disconnect connection S1-81 and
measure the resistance value between pin 5 and pin 10.
If OK, replace control unit.
Check that the lead harness of the metering pump has

Metering pump outlet (+) Short been correctly laid and check for damage, if OK →
049
circuit - after UB (battery voltage) remove lead harness and check for continuity, if OK →
replace control box.
Control unit is locked after too many unsuccessful start

attempts. (Maximum 255 start attempts). Check fuel,
glow pin, combustion air and exhaust flow. Unlock the
050 Too many no start attempts
control box by deleting the fault memory with the timer,
diagnostic unit, Edith costumer service program or
diagnostic tool.
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If the resistance value of flame sensor is 1274  after

switching on (> 70 ºC [> 158 ºF]), then the blower or the
AIRTRONIC runs for approx. 15 minutes to cool down.
051 Faulty flame recognition If resistance does not fall below the above value within
15 min., this is followed by fault shut down.
Check flame sensor, diagrams and values. If OK,
replace control unit.
No flame detected on start attempt. Check exhaust and

combustion air lines. Check fuel supply and measure
fuel flow (refer to following pages).
052 No start safety time exceeded
Check glow pin (refer to fault code 020 and 021).
Check flame sensor, diagram and values table on
following pages, if OK, replace control unit.
053 Flame cutout in boost mode Heater has started successfully but the flame has
extinguished.
054 Flame cutout in high mode
Check exhaust and combustion air lines. Check fuel
055 Flame cutout in medium mode supply and measure fuel flow, refer to values.
Check flame sensor, diagram and values table on
056 Flame cutout in low mode following pages, if OK, replace control unit.
Temperature sensor detects a value beyond it's range

sensor.
Disconnect connection S1-B1 (main harness), measure
060 Open circuit - external temperature resistance value at connector B1, pins 6 and 12. If there
is an open circuit, the ohmic value between the pins is >
7175. If the resistance value is OK, then the control unit
is defective. Replace control unit.
Disconnect connection S1-B1 (main harness). Measure

resistance value at connector B1, between pins 6 and
12. If there is a short circuit, the ohmic value between
061 Short circuit - external temperature
the pins is < 486 . If fault 061 continues to be
displayed, then the control unit is detective. Replace
control unit.
Potentiometer values outside of range on thermostat

(switch).
Check resistance between pins 6 and 7 at B1.
Thermostat - rheostat - timer, open Resistance value for interruption between pins
062 > 7175 
circuit
Normal value: 1740  through 2180  (± 80 ).
If resistance value is OK, replace control unit. If not
replace thermostat switch.
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If a ventilating switch has been built-in, disconnect and

check function. If faulty, replace switch.
Switch control short circuit Disconnect wires from thermostat or switch. If fault code
Fault recognition only works in 062 is displayed, replace switch. If switch is OK, check
heating mode. However, if a short connection lines gray and red and brown and white for
063 circuit already exists and the short-circuit. If OK, reconnect wires to thermostat or
AIRTRONIC is subsequently switch.
switched on, ventilating mode will Disconnect connection B1. If fault 063 is still displayed,
be active (no fault code). replace control unit. Resistance value for short circuit
between pins 6 and 7 < 486 .
Normal value: 1740  to 2180  (± 80 ).
Sensor is detecting value outside of range. Open

AIRTRONIC shell and remove control unit from casing.
Disconnect green connector from control unit. At
connector measure resistance value between green
064 Open circuit - flame sensor wire and brown-white wire.
Check flame sensor, diagram and values. If flame
sensor is OK, replace control unit.
Resistance value for interruption > 7175 
Open AIRTRONIC shell and remove control unit from

casing.
Disconnect green connector from control unit. If fault
064 is displayed, replace combination sensor
065 Short circuit - flame sensor
(flame-temperature). If fault 065 is still displayed,
Resistance value for short circuit < 486 , refer to
values on following pages.

casing.
Disconnect blue and green connectors from control
unit. Measure the resistance value at blue connector pin
071 Open circuit - overheat sensor
1 (blue wire) and at green connector pin 2 (brown-white
wire). Refer to values on following pages. If OK,
Resistance value for interruption > 223 

casing. Disconnect blue connector from control unit. If
fault 071 displayed, replace combination sensor
072 Short circuit - overheat sensor (flame-temperature). If fault 072 is still displayed,
Resistance value for short circuit < 183 . Refer to the
following pages for values.
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090 Control unit defect Internal failure. Replace control unit.
Check vehicle charging system. Poor battery, battery

091 External voltage disturbance
charger, eliminate fault.
092 Control unit defective (ROM fault)
093 Control unit defective (ROM fault) Disconnect heater from power for 10 seconds by
disconnecting it from harness or pull out the fuses.
Control unit defective (EEPROM Reconnect and test again. If the problem persists,
094
fault) replace ECU.
095 Control unit defective (ROM fault)
Replace control unit or use external temperature sensor

096 Internal temperature sensor defect
if possible.
Control unit defective (power

097 Internal failure. Replace control unit.
failure)
Voltage short-term < 5 6 volt (for 12 volt) or < 7 8 volt (for

24 volt).
099 Too many resets in sequence In case of a voltage drop, check the fuses, the supply
cables, the negative connections and the positive
support point on the battery for corrosion and correct
contact.
Test control box with testing device, if OK → check lead

harness of the external components has been correctly
Transistor error in control box
laid and check for damage, if OK → check lead harness
for continuity, if OK → replace control box.
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1. GENERAL INFORMATION
The schematics contained in this section are provided as a guide to assist technical service personnel in
troubleshooting operational malfunctions in the vehicle hydraulic and electrical systems. These
schematics should be used in conjunction with the troubleshooting, reference designators and
maintenance procedures sections incorporated in this manual.
A. BEFORE TROUBLESHOOTING
Before starting troubleshooting procedures, verify that the correct operating procedures were
used. An incorrect operating procedure can cause apparent malfunctions.
Make sure all circuit breakers and fuses have continuity. Inspect all electrical connections and
suspected defective parts to verify that there are no open circuits or defective grounding.
B. HYDRAULIC SYSTEM CLEANLINESS
A very important practice to observe when working on the hydraulic system is cleanliness.
Serious damage can result quickly from foreign material (contamination) in the hydraulic system.
When a hydraulic system is opened, cap or plug all ports and openings to keep foreign material
and moisture laden air (contamination) from entering the system. DO NOT use Teflon tape or
pipe compound on straight threads.
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2. ELECTRICAL SCHEMATICS
NOTE: THIS SECTION MAY NOT CONTAIN ALL SCHEMATICS LISTED. REFER TO THE
PRODUCT SPECIFICATION AT THE FRONT OF THE MANUAL FOR THE APPLICABLE
SCHEMATICS FOR YOUR EQUIPMENT.
• ELECTRICAL SCHEMATIC - 2100SP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521-3504
• INTERCONNECT DIAGRAM - 2100SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-3491-001
• SP2100 HE WIRE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-9070
Electrical Option Schematics
NOTE: OPTION SCHEMATICS ARE PART OF A CUSTOM OPTION. COMPONENTS CAN BE

LOCATED IN CHAPTER 4, ILLUSTRATED PARTS LIST.
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Figure 1
ELECTRICAL SCHEMATIC - 2100SP - 521-3504
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Figure 2
ELECTRICAL SCHEMATIC - 2100SP - 521-3504 (CONT.)
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Figure 3
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Figure 4
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Figure 5
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Figure 6
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Figure 7
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Figure 8
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Figure 9
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Figure 10
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Figure 11
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Figure 12
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Figure 13
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Figure 14
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Figure 15
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Figure 16
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Figure 17
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Figure 18
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Figure 19
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Figure 20
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Figure 21
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Figure 22
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Figure 23
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Figure 24
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Figure 25
INTERCONNECT DIAGRAM - 2100SP - 624-3491-001
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Figure 26
INTERCONNECT DIAGRAM - 2100SP - 624-3491-001 (CONT.)
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Figure 27
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Figure 28
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Figure 29
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Figure 30
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Figure 31
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Figure 32
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Figure 33
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Figure 34
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Figure 35
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Figure 36
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Figure 37
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Figure 38
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Figure 39
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Figure 40
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Figure 41
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Figure 42
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Figure 43
WIRE HARNESS - SP2100 - 625-9070
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Figure 44
WIRE HARNESS - SP2100 - 625-9070 (CONT.)
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Figure 45
WIRE HARNESS - SP2100 - 625-9070 (CONT.)
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TABLE 1 - WIRE HARNESS - SP2100 - 625-9070
ITEM PART NO. DESCRIPTION QTY.
1 DWG-623-9526 ELECT FABRICATION PRACTICES 1

2 620-1317-003 FLEX-GARD, NYLON:SLIT 1/2” 3
3 620-1317-004 FLEX-GARD, NYLON:SLIT 5/8” 1
4 620-1317-006 FLEX-GARD, NYLON:SLIT 1” 12
5 620-3900-018 WIRE STRD YEL 18GA GXL 364
6 622-2962-009 CONN, SEALING PLUG 7
7 622-2967-006 CONN, PLUG 4POS (FEMALE) 2
8 622-2967-008 CONN, PLUG 8POS (FEMALE) 2
9 622-2967-009 CONN, RECP 8POS (MALE) 1
10 622-2967-013 CONN, PIN 16-18AWG SOLID 7
11 622-2967-015 CONN, SOCKET (16-18AWG) SOLID 18
12 622-2967-022 CONN, WEDGE 4POS PLUG 2
13 622-2967-024 CONN, WEDGE 6POS PLUG 2
14 622-2967-025 CONN, WEDGE 8POS RECP 1
15 622-2967-042 CONN, BOOT 4 POS. PLUG 2
16 622-2967-043 CONN, BOOT 6 POS. PLUG 2
17 622-2967-050 CONN, BOOT 8 POS. RECP 1
18 622-2967-054 RECEPTACLE, 6 POS. W/BUSSED PINS 1
19 622-2967-055 RECEPTACLE, 6 POS. W/BUSSED PINS 2
20 623-4929-005 CONDUIT, FLEXIBLE NYLON 0.75” 2
21 623-4929-008 CONDUIT, FLEXIBLE NYLON 1” 1
22 625-9092-024 CONN ASSY, 24F TWIST LOCK 1
23 625-9092-025 GROMMET COVER, 24-WAY 1
24 625-9092-026 WIRE DRESS, 24-WAY 1
25 625-9092-027 CONVOLUTE CAPTR, WIRE DRESS 1
26 625-9092-080 CONN ASSEMBLY, 80F BOLT 1
27 625-9092-081 GROMMET COVER, 80-WAY 1
28 625-9092-082 BACKSHELL, 90 DEG. DIR A 1
29 625-9092-083 WIRE DRESS, LOWER 80-WAY 90 DEG 1
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TABLE 1 - WIRE HARNESS - SP2100 - 625-9070 (CONT.)
30 625-9093-001 CONN ASSY, GT150 HALF SHROUD 3

31 625-9093-002 CPA LOCK, GRAY 3
32 625-9093-003 TERMINAL, F GT150 6
33 625-9093-004 SEAL ASSY, CABLE 1-WAY, YELLOW 6
34 625-9093-005 TPA LOCK, BLACK, CONVOLUTE CAPT 3
35 625-9093-006 CONN ASSY, 3-WAY W/P TWR BLK 1
36 625-9093-007 TERMINAL, M W/P PIN 3
37 625-9093-008 SEAL ASSY, CABLE 1-WAY W/P PPL 3
38 625-9093-009 PLUG, CAVITY SEAL 44
39 625-9116 CABLE, TWISTED PAIR, 18AWG 41
40 625-9121-031 CONN, REC., 9-WAY, J9139 1
41 625-9121-046 COVER, HDC16-9, RECPT 1
42 625-9121-050 CONN, STRAIN RELIEF, HD 1
43 625-9121-051 PIN, SIZE 16, GOLD 5
44 626-3024-200 TERM, FEMALE CRIMP 60
45 622-2967-064 RECEPTACLE, BUS PINS 6POS SPLIT 1
46 625-7012-120 AE-RESISTOR, 120:OHM 1
47 623-4929-001 CONDUIT, FLEXIBLE NYLON 0.312” 3
48 623-4995 TY-RAP LARGE 14.5” 50# 10
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3. HYDRAULIC SCHEMATICS
NOTE: THIS SECTION MAY NOT CONTAIN ALL SCHEMATICS LISTED. REFER TO THE
PRODUCT SPECIFICATION AT THE FRONT OF THE MANUAL FOR THE APPLICABLE
SCHEMATICS FOR YOUR EQUIPMENT.
• HYDRAULIC SYSTEM SCHEMATIC - 2100SP . . . . . . . . . . . . . . . . . . . . . . . 623-5420-001
Hydraulic Option Schematics
NOTE: OPTION SCHEMATICS ARE PART OF A CUSTOM OPTION. COMPONENTS CAN BE

LOCATED IN CHAPTER 4, ILLUSTRATED PARTS LIST.
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Figure 46
HYDRAULIC SCHEMATIC - 2100SP - 623-5420-001
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Figure 47
HYDRAULIC SCHEMATIC - 2100SP - 623-5420-001 (CONT.)
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Figure 48
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Figure 49
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Figure 50
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Figure 51
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TABLE 2 - HYDRAULIC SYSTEM COMPONENTS
1 623-5410 MANIFOLD, ASSEMBLY - CHASSIS 1

2 623-5411 MANIFOLD, ASSEMBLY - PITCH 1
3 620-2565 GAUGE, PRESSURE 1
4 623-5413 MANIFOLD, ASSEMBLY 2
5 623-8652 PUMP, PISTON ASSEMBLY 1
6 623-5415 MANIFOLD, ASSEMBLY - STOPS/TR. LIFT 1
8 623-8653 VALVEPAC - FAN DRIVE 1
9 623-5403 VALVE, STEERING CONTROL 1
10 624-0330 PUMP, 2-SECTION - EMERGENCY 1
11 623-5393 CYLINDER, FRONT SIDE SHIFT 1
12 623-5394 CYLINDER, REAR SIDE SHIFT 1
13 623-5930 RESERVOIR, ASSEMBLY 1
14 623-5396 CYLINDER, MAIN LIFT 2
15 623-5397 CYLINDER, HELPER 2
16 623-8650 CYLINDER, PITCH 2
17 623-5399-001 CYLINDER, ROLL - FRONT 2
18 623-5639-001 CYLINDER, PALLET STOP 2
19 623-6556 CYLINDER, TRACTION WHEEL LIFT 18
20 514-8244 FILTER, HIGH PRESSURE 1
21 514-8244-002 ELEMENT, HIGH PRESSURE REF.
22 620-0128 VALVE, SHUTTLE 2
24 623-2906-003 SWITCH, PRESSURE 1
25 623-5460 VALVE, BRAKE, TANDEM 1
26 621-5556 FILTER, RETURN - CASE DRAIN 1
27 621-5556-002 ELEMENT, FILTER - CASE DRAIN REF.
28 620-1428-001 MOTOR, HYDRAULIC 9
29 623-5399-002 CYLINDER, ROLL - REAR 2
30 623-6380 SWITCH - PRESSURE - STOP LIGHTS 1
31 621-5556-001 INDICATOR, GAUGE 1
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TABLE 2 - HYDRAULIC SYSTEM COMPONENTS (CONT.)
32 232-7645 HEAT EXCHANGER 1

33 623-6703 BREATHER, RESERVOIR REF.
34 621-5724 FILTER, RETURN - RESERVOIR REF.
35 620-0461 ELEMENT, RETURN - 5 MICRON REF.
36 623-6774 MOTOR, HYDRAULIC 1
37 623-5416 MANIFOLD, CONVEY 1
38 623-8712 ACTUATOR, THROTTLE 1
39 624-4218 SWITCH, BRAKE PRESSURE DIFFERENTIAL 1
40 624-8907 VALVE, PRESSURE REDUCER 1
41 624-7180 SWITCH ASSY, PRESSURE 1
42 625-4073 MANIFOLD, AC-MOTOR 1
43 625-3089-005 MOTOR, AC COMP HYD 1
44 623-7300-001 ACTUATOR, STONE BENNETT SHFTR 1
45 625-4427 PLUG, CAVITY 1
46 625-4428 VALVE, CHECK IN-LINE 1908F 1
- 623-7300-006 ACTUATOR, STONE BENNETT SHFTR 1
- 623-8717 VALVE, PROPORTIONAL 2
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TABLE OF CONTENTS
CHAPTER 3. OVERHAUL
Section 1. Overhaul Procedures
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. EQUIPMENT RE-COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. ADJUSTMENTS AFTER REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. PRECAUTIONS BEFORE WELDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Section 2. Removal and Installation
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. BRAKES ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. SERVICE BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. PARKING BRAKE FUNCTION TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A. PARKING BRAKE FORWARD MOVEMENT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. PARKING BRAKE REVERSE MOVEMENT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. PARKING BRAKE LINING REPLACEMENT AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . 4
A. REPLACE PARKING BRAKE LINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. PARKING BRAKE, INSTALL REPAIR KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. CHANGE SEAL KIT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7. FRONT AXLE BRAKE, REPLACE BRAKE LININGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8. FRONT AXLE BRAKE, INSTALL REPAIR KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9. REAR BRAKE OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
A. PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
B. REMOVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
C. DISASSEMBLY OF CALIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
D. ASSEMBLY OF CALIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
E. HOUSING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10. BOLT-ON DECK HINGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
A. DAMAGED WALK-DECK WELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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B. REPLACEMENT PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Table 1 - BOLT-ON DECK HINGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11. D4 CAB HEATER KIT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
A. INSTALLATION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12. CAB SUSPENSION SHOCK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
13. BOLT-ON DECK BUMPER DOUBLE PLATE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table 2 - DECK BUMPER DOUBLER BOLT-ON KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
A. VEHICLE AND DECK PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
B. DAMAGED ITEM REMOVAL PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
C. RECIPROCATING SAW CUTTING METHOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
D. CARBIDE BUR CUTTING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
E. PRIME AND PAINT AFFECTED AREAS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
F. KIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
14. SEAT SUSPENSION KIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Table 3 - SEAT SUSPENSION KIT (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Table 4 - 628-8712. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
A. SEAT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
B. SLIDE THE SEAT OFF THE TRACKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
C. DISASSEMBLE THE SEAT FROM THE CAB FLOOR WITH TRACKS ATTACHED . . . . . . . 58
D. SEAT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
E. SEAT SUSPENSION INSERT SUBASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
F. SEAT SUSPENSION INSERT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
G. SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
H. INSTALL THE NEW SEAT ASSEMBLY IN THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
I. OPERATIONAL CHECKOUT REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
J. SEAT SUSPENSION KIT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
15. MAIN PANEL CONVERTER KIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Table 5 - CONVERTER KIT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Table 6 - TOOLS LIST FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
B. LOADER PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
C. CONVERTER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
D. MAIN PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
E. DRILL NEW HOLES IN THE MAIN PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
F. REINSTALL THE MAIN PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
G. CONVERTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
H. MAIN PANEL CABLE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
I. CLOSE DOOR ON MAIN PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
J. OPERATIONAL CHECKOUT REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
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16. RIGHT FRONT HANDRAIL BRACE KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Table 7 - HALVORSEN BRACE KIT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Table 8 - TOOLS LIST FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
B. LOADER PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
C. INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
D. ASSEMBLE BRACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
E. FIT THE BRACE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
F. TIGHTENING THE BRACE ASSEMBLY IN POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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LIST OF FIGURES
CHAPTER 3. OVERHAUL
3-2 Figure 1 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3-2 Figure 2 PARKING BRAKE SEALS, REPAIR AND LINING KITS. . . . . . . . . . . . . . . . . . . . 5
3-2 Figure 3 COVER CAP SCREWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-2 Figure 4 BELLEVILLE SPRINGS STACKING SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . 8
3-2 Figure 5 FRONT AXLE BRAKE SEALS, REPAIR AND LINING KITS . . . . . . . . . . . . . . . . 12
3-2 Figure 6 CALIPER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-2 Figure 7 BOLT-ON DECK HINGE - PART 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-2 Figure 17 BOLT-ON DECK HINGE - PART 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3-2 Figure 18 SIDE CONSOLE PANEL AND HEATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3-2 Figure 19 INTAKE, EXHAUST AND FUEL LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3-2 Figure 20 WIRING SPLICE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3-2 Figure 21 FUEL PUMP INSTALLATION REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3-2 Figure 22 D4 CUSTOM HEATER REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3-2 Figure 23 CUBE RELAY REFERENCE SCHEMATIC AND VIEW . . . . . . . . . . . . . . . . . . . . 35
3-2 Figure 24 THERMOSTAT WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3-2 Figure 25 AUTO LUBRICATION PUSH BUTTON WIRING . . . . . . . . . . . . . . . . . . . . . . . . . 35
3-2 Figure 26 CAB LEFT SHOCK TOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3-2 Figure 27 CAB LEFT SHOCK TOWER WITH CAP REMOVED . . . . . . . . . . . . . . . . . . . . . . 37
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3-2 Figure 28 RIGHT SIDE CONSOLE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3-2 Figure 29 RIGHT SIDE CAB SHOCK TOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3-2 Figure 30 TEMPLATE POSITIONING STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3-2 Figure 31 TEMPLATE HOLE MARKINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3-2 Figure 32 LIMIT SWITCH REMOVAL STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3-2 Figure 33 LIMIT SWITCH GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3-2 Figure 34 LIMIT SWITCH GUARD REMOVAL USING RECIPROCATING SAW . . . . . . . . . 43
3-2 Figure 35 LIMIT SWITCH GUARD REMOVAL USING CYLINDRICAL CARBIDE
BUR STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3-2 Figure 36 LIMIT SWITCH GUARD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3-2 Figure 37 REMAINDER OF C-CHANNEL REMOVAL STEPS . . . . . . . . . . . . . . . . . . . . . . . 45
3-2 Figure 38 BUMPER GRINDING STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3-2 Figure 39 GRIND WELD FROM BOTTOM OF DOUBLER PLATE . . . . . . . . . . . . . . . . . . . . 46
3-2 Figure 40 CUT THE BOTTOM WELD ON THE DECK DOUBLER PLATE STEPS . . . . . . . . 46
3-2 Figure 41 GRIND DOWN WELD FROM AROUND DECK DOUBLER PLATE STEPS . . . . . 47
3-2 Figure 42 DOUBLER PLATE WELD RELIEF CUT STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3-2 Figure 43 DOUBLER PLATE REMOVAL STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3-2 Figure 44 GRIND AREA SMOOTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3-2 Figure 45 PRIME AND PAINT AFFECTED AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3-2 Figure 46 DRILL SIX HOLES IN DECK BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3-2 Figure 47 LUBRICATE FASTENER BEFORE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 50
3-2 Figure 48 DOUBLER PLATE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3-2 Figure 49 TORQUE FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3-2 Figure 50 LIMIT SWITCH GUARD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3-2 Figure 51 LIMIT SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3-2 Figure 52 DECAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3-2 Figure 53 AGED CLEVIS REMOVAL STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3-2 Figure 54 REPLACEMENT CLEVIS AND COLLAR INSTALLATION STEPS . . . . . . . . . . . . 54
3-2 Figure 55 CHECK AIR TRANSPORT SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . 55
3-2 Figure 56 OPERATOR’S SEAT MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3-2 Figure 57 STOP AND BENT TAB RIGHT SLIDE RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3-2 Figure 58 REAR TAB ON UPPER SLIDE RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3-2 Figure 59 UPPER LEFT SLIDE RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3-2 Figure 60 UPPER SLIDE RAILS AND S-BRACKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3-2 Figure 61 SEAT SUSPENSION INSERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3-2 Figure 62 SEAT SUSPENSION INSERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3-2 Figure 63 SEAT SUSPENSION ALIGNMENT WITH SLIDE RAILS . . . . . . . . . . . . . . . . . . . 61
3-2 Figure 64 SLIDE RAILS FASTENED TO SEAT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 62
3-2 Figure 65 SEAT SUSPENSION INSERT ADAPTER PLATE . . . . . . . . . . . . . . . . . . . . . . . . . 63
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3-2 Figure 66 FASTEN ADAPTER PLATE TO SEAT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 64
3-2 Figure 67 INSERT FASTENERS INTO ADAPTERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3-2 Figure 68 FASTEN ADAPTERS TO SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3-2 Figure 69 TIGHTEN ADAPTERS TO SUSPENSION INSERT . . . . . . . . . . . . . . . . . . . . . . . 66
3-2 Figure 70 REMOVE SUSPENSION INSERT SUBASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 67
3-2 Figure 71 TORQUE FASTENERS ON SUSPENSION SUBASSEMBLY . . . . . . . . . . . . . . . 67
3-2 Figure 72 SEAT SUSPENSION ASSEMBLY ATTACHMENT. . . . . . . . . . . . . . . . . . . . . . . . 68
3-2 Figure 73 SEAT INSTALLATION - RAILS ATTACHED TO CAB FLOOR. . . . . . . . . . . . . . . 69
3-2 Figure 74 SEAT INSTALLATION - RAILS NOT ATTACHED TO CAB FLOOR . . . . . . . . . . 70
3-2 Figure 75 TORQUE SEAT MOUNTING FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3-2 Figure 76 MAIN PANEL LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3-2 Figure 77 POSITIVE AND NEGATIVE CABLES INSIDE MAIN PANEL . . . . . . . . . . . . . . . . 74
3-2 Figure 78 CONVERTER PART NO. 624-8698-030. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3-2 Figure 79 CONVERTER PART NO. 624-7172 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3-2 Figure 80 REMOVE BATTERY CABLES FROM MAIN PANEL . . . . . . . . . . . . . . . . . . . . . . 76
3-2 Figure 81 COVER PLATE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3-2 Figure 82 LOWER MOUNTING FASTENERS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3-2 Figure 83 UPPER MOUNTING FASTENERS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3-2 Figure 84 MAIN PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3-2 Figure 85 NEW HOLE PATTERN ON BOTTOM OF MAIN PANEL . . . . . . . . . . . . . . . . . . . 80
3-2 Figure 86 MAIN PANEL RE-INSTALLATION ON LOADER . . . . . . . . . . . . . . . . . . . . . . . . . 81
3-2 Figure 87 CHASSIS HARNESS PLATE RE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 81
3-2 Figure 88 CONVERTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3-2 Figure 89 CABLE-RETAINING CLAMP TIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3-2 Figure 90 CABLE-RETAINING CLAMP HAND TIGHTENING . . . . . . . . . . . . . . . . . . . . . . . 83
3-2 Figure 91 ELECTRICAL BOX DOOR CLAMPS TIGHTENING . . . . . . . . . . . . . . . . . . . . . . . 84
3-2 Figure 92 HANDRAIL AND WALK-DECK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3-2 Figure 93 HANDRAIL AND WALK-DECK ASSEMBLY (CONT.) . . . . . . . . . . . . . . . . . . . . . 88
3-2 Figure 94 BRACE KIT INSTALLED ON RIGHT FRONT HANDRAIL . . . . . . . . . . . . . . . . . . 89
3-2 Figure 95 PAIRING BRACKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3-2 Figure 96 LOOSELY CONNECTING BRACKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3-2 Figure 97 ATTACHING BRACKETS TO HANDRAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3-2 Figure 98 FITTING UPPER BRACKET TO VERTICAL RAIL . . . . . . . . . . . . . . . . . . . . . . . . 92
3-2 Figure 99 ATTACHING CLAMPING U-BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3-2 Figure 100 TIGHTENING TO TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3-2 Figure 101 TIGHTENING ALL OTHER FASTENERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3-Figures
LIST OF FIGURES
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CHAPTER 3. OVERHAUL
1. GENERAL
If an overhaul or a system component is required, refer to Chapter 5, MANUFACTURERS’

APPENDICES for pertinent information. The section or sections that cover the component or system
should be read in full and understand completely before attempting any part of an overhaul.
Units operating in extreme conditions (such as high or low temperatures, long periods of sustained
operation, continued operation in sand or dust, or continued exposure to sea air moisture) need regular
inspection. Overhaul periods can be set as necessary.
WARNING
WARNING
INJURY.
CAUTION

UNIT.
NOTE: FOR THE ADJUSTMENT OF COMPONENTS, REFER TO CHAPTER 2, SECTION 5,

“MAINTENANCE PROCEDURES”.
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2. EQUIPMENT RE-COMMISSIONING
After and overhaul or major repair, the equipment must be thoroughly inspected and serviced as stated
in the corresponding maintenance schedules in Chapter 2, Section 3, “Preventative Maintenance”.
Also, before placing the vehicle back into service, it must be re-commissioned utilizing the
“EQUIPMENT PRE-OPERATIONAL CHECKLIST” in Chapter 2, Section 3, “Preventative Maintenance”.

MAJOR OVERHAUL, RECOMMENDED ANNUAL MAINTENANCE, OVER-THE-ROAD
TRANSPORTATION AND IF THE MACHINE HAS BEEN OUT OF SERVICE FOR MORE
THAN SIX MONTHS.
CAUTION

ENVIRONMENTALLY SENSITIVE MATERIALS, SUCH AS TIRES, BELTS, BATTERIES, MOTOR
3. REMOVAL AND INSTALLATION
Main components may be necessary to be removed and replaced during overhaul procedures. The
sections on removal and installation within this manual include the main assemblies and sub-assemblies
and it is not intended to cover all components that could possibly be removed or repaired.
Refer to Chapter 4, ILLUSTRATED PARTS LIST and Chapter 5, MANUFACTURERS’ APPENDICES
for information on specific components and for the list of spare parts.
For safety and reliability use only JBT replacement parts.
4. ADJUSTMENTS AFTER REPAIRS
To ensure proper operation of assemblies and overall components, it is necessary to follow the
corresponding adjustment procedures stated in this manual and perform the recommended tests.
Refer to Chapter 2, Section 5, “Maintenance Procedures” for the adjustment of components and
Chapter 5, MANUFACTURERS’ APPENDICES for additional information.
5. PRECAUTIONS BEFORE WELDING
Proper precautions must be taken to prevent damage to electronic equipment.
CAUTION

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1. GENERAL
The following procedures for removal, installation and overhaul of vehicle components outline the steps
and precautions to take when removing items for replacement and repair. Make sure to read and
understand each procedure before attempting to perform it.
In addition, after removing and replacing components, adjustments must be performed. Refer to
Chapter 2, Section 5, “Maintenance Procedures” for this purpose.
WARNING
PERSONNEL THAT THE VEHICLE IS BEING WORKED ON.
WARNING
WARNING
WARNING
WARNING
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WARNING
WARNING
WHEN REMOVING COMPONENTS FOR REPLACEMENT OR REPAIR, CLEAN COMPONENTS,
IDENTIFY AND MARK ALL CONNECTIONS, SUPPORT PROPERLY FOR REMOVAL AND
PLACE REMOVED COMPONENTS IN A SAFE AND SECURE LOCATION.
WARNING
WARNING
ENSURE CONNECTIONS ARE CLEAN BEFORE ATTACHING BRAKE LINES. BLEED AIR
FROM BRAKE SYSTEM UPON COMPLETION OF INSTALLATION.
WARNING
TWO PERSONS WORKING TOGETHER ARE REQUIRED FOR THE REMOVAL OF THE MAIN
PANEL.
CAUTION

CAUTION
CAUTION

UNIT.
CAUTION
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2. BRAKES ADJUSTMENTS
A. PARKING BRAKE ADJUSTMENT
NOTE: THE PARKING BRAKE IS SPRING APPLIED AND HYDRAULICALLY RELEASED. THE
LOADER MUST BE RUNNING IN ORDER TO ADJUST THE PARKING BRAKE.
Refer to Figure 1.
(1) Start the loader. Keep the transmission selector in the neutral position. Ensure the parking
brake is disengaged (parking brake switch in the OFF position).
(2) To adjust the parking brake, loosen the lock nut (1) and adjusting screw (2) on brake
caliper.
(3) Place a 0.30 mm (0.012 in.) thick shim (3) between the disc and one of the linings (loader
must be running with the parking brake disengaged).
(4) Tighten the adjusting screw (2) until it is just possible to remove the shim.
(5) Torque lock nut (1) at 30 to 37 N·m (22 to 27 lbf-ft.) while holding the adjusting screw (2)
with a wrench. Remove the shim and release the hydraulic pressure by positioning the
parking brake switch in the ON position (applies the brake).
(6) Remove the maintenance safety blocks and lower the deck fully. Remove wheel chocks.
For parking brake overhaul, refer to ‘5. PARKING BRAKE, INSTALL REPAIR KIT’.
Figure 1
PARKING BRAKE
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B. SERVICE BRAKE ADJUSTMENT
(1) Drive Axle Service Brakes

Drive shaft disc brake assembly does not require adjusting.
For service brake overhaul, refer to ‘8. FRONT AXLE BRAKE, INSTALL REPAIR KIT’.
(2) Bogy Wheels Service Brakes
Bogy wheels have internal wet disc brake assemblies and do not require adjusting.
3. PARKING BRAKE FUNCTION TESTS
CAUTION
DO NOT RUN ENGINE HIGHER THAN 1200 RPM DURING BRAKE FUNCTION TESTS.
NOTE: PERFORM PARKING BRAKE FUNCTION CHECK FROM THE CAB.
A. PARKING BRAKE FORWARD MOVEMENT TEST

(6) Increase engine speed slowly to verify parking brake holds. Ensure loader does not move.
B. PARKING BRAKE REVERSE MOVEMENT TEST

(6) Increase engine speed slowly to verify parking brake holds. Ensure loader does not move.
4. PARKING BRAKE LINING REPLACEMENT AND ADJUSTMENT
NOTE: NEW LININGS MUST BE KEPT FREE OF OIL, GREASE AND OTHER CONTAMINANTS.
A. REPLACE PARKING BRAKE LINING
(1) Position the parking brake switch in the OFF position to apply hydraulic pressure to release
the brake.
(2) Loosen lock nut (1) and back off adjusting screw (2). Refer to Figure 1).
(3) Disconnect fluid line from the brake. Cap end of fluid line to prevent entry of dirt into the
hydraulic system.
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(4) Remove bolts used to fasten the brake assembly to the drive axle. Remove brake
assembly.
(5) Place brake in a soft-jawed vise with disc clearance slot facing up.
NOTE: CLAMPING SHOULD BE DONE ON THE SIDES OF THE BRAKE ON MACHINED

SURFACES.
NOTE: REFER TO FIGURE 2 FOR (6) THROUGH (9).
(6) Remove screws (28) and bushings (25). Using a thin-blade tool, pry lining (26) from
housing (27) and remove through disc clearance slot.
(7) Rotate lining assembly (23) until screws (22) are aligned with access holes in housing
(27). Remove flat head screws (22). Pry lining (21) from piston (20) and remove through
disc clearance slot.
(8) Install new lining (21) into piston (20) through disc clearance slot. Install new flat head
screws (22) and torque to 3.4 to 4.5 N·m (30 to 40 lbf-in.).
(9) Insert new bushings (25) into new lining (26). Install new lining into housing through disc
clearance slot. Align the holes with the housing and fasten with new screws (28). Torque
screws (28) 2.5 to 3.2 N·m (22 to 28 lbf-in.).
Figure 2
PARKING BRAKE SEALS, REPAIR AND LINING KITS
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(10) Reinstall brake on axle and connect hydraulic line.
(11) Have assistant start engine and place the parking brake switch in the OFF position to apply
hydraulic pressure to release the brake.
(12) Bleed all air from the brake assembly.
NOTE: PERFORM PARKING BRAKE ADJUSTMENT AS PER ‘A. PARKING BRAKE

ADJUSTMENT’.
NOTE: PERFORM PARKING BRAKE FUNCTION CHECK AS PER ‘3. PARKING BRAKE
FUNCTION TESTS’.
5. PARKING BRAKE, INSTALL REPAIR KIT
NOTE: WHEN REMOVING SEALS AND BACK-UP RINGS, BE CAREFUL NOT TO SCRATCH OR
MAR PISTONS. WHEN INSTALLING NEW SEALS IN THE BRAKE, ENSURE THE KIT IS
THE PROPER ONE FOR HYDRAULIC FLUID.
(1) Position the parking brake switch in the OFF position to apply hydraulic pressure to release
the brake.
(2) Loosen lock nut (1) and back off adjusting screw (2). Refer to Figure 1.
(3) Disconnect fluid line from brake.
(4) Disconnect fluid line from the brake. Cap end of fluid line to prevent entry of dirt into
hydraulic system.
(5) Remove bolts used to fasten the brake assembly to the drive axle. Remove brake
assembly.
NOTE: REFER TO FIGURE 2 FOR STEPS (6) THROUGH (31).
(6) Place brake in a soft-jawed vise with cover (3) in a vertical position.

SURFACES.
(7) Remove bleeder screw (30).

(8) Using a sharp-bladed tool, carefully remove two seals (29) from housing (27). Note
direction of seals.
(9) To remove cover (3), loosen four cap screws (1).
NOTE: LOOSEN CAP SCREWS EVENLY AND IN A-B-C-D ORDER UNTIL SPRING PRE-LOAD
IS RELEASED. REFER TO FIGURE 3.
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Figure 3
COVER CAP SCREWS
(10) Remove cap screws (1), lock washers (2), cover (3) and gasket (24). Using a thin-blade
tool, remove seal (4) from cover.
(11) Remove Belleville springs (6) and washer (7). Note the stacking sequence of Belleville
springs.
(12) Remove piston (10) from housing (27) bore. Remove O-ring (12) and back-up ring (11)
from piston. Push rod (13) should also come out with the piston.
(13) Remove piston (16) from housing (27) bore. Remove O-rings (14 and 17) and back-up
rings (15 and 18) from piston.
(14) Remove lining assembly (23) from housing (27) bore. Hold assembly on a flat surface and
separate lining (21) and piston (20) by removing flat head screws (22). Remove O-rings
(19) from piston (20).
(15) Loosen vise jaws and rotate brake so that disc clearance slot is facing upward. Remove
pan head screws (28), lining (26) and bushings (25) from housing (27).
(16) Lubricate all rubber components from kit with clean hydraulic fluid used in the system.
(17) Clean all parts and housing bore thoroughly with clean hydraulic fluid used in the system
and keep free of all contaminants, dirt and debris.
NOTE: USE A HEAVY, WATERPROOF GREASE TO LUBRICATE SURFACES AS SHOWN IN

FIGURE 2.
(18) Install new lining (26) in housing (27) using new bushings (25) and new pan head screws
(28). Torque screws (28) at 2.5 to 3.2 N·m (22 to 28 lbf-in.).
(19) Install new lining (21) on piston (20) using new flat head screws (22). Torque screws (22)
at 2.7 to 3.4 N·m (24 to 30 lbf-in.). Install new O-rings (19) on piston (20) and insert lining
assembly (23) into housing (27) bore.
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(20) Carefully install two new seals (29) in housing (27). Be sure to install seals (29) in the
same direction as they were removed.
(21) Install new bleeder screw (30). Torque bleeder screw 12.2 to 20.3 N·m (9 to 15 lbf-ft.).
(22) Install new O-rings (14 and 17) and new back-up rings (15 and 18) on piston (16). Note
order of components.
(23) Install piston (16) into housing (27) bore. Note direction of piston.
NOTE: WHEN INSERTING PISTON, BE SURE NOT TO PINCH O-RING ON INLET PORTS.
(24) Install new back-up ring (11) and new O-ring (12) on piston (10). Note order of
components. Install push rod (13) in bore of piston. Install piston into housing (27) bore.
(25) Fully lubricate threads of adjusting screw (8) and lock nut (9); install into piston (10).
(26) Install washer (7), spacer (5) and Belleville springs (6) over end of piston (9). Follow the
stacking sequence shown in Figure 4.
NOTE: NOT ALL MODELS USE SPACER (5) OR WASHER (7). SOME MODELS USE TWO
WASHERS (7).
Figure 4
BELLEVILLE SPRINGS STACKING SEQUENCE
NOTE: IF SEAL KIT IS BEING INSTALLED, USE EXISTING BELLEVILLE SPRINGS AFTER
COMPLETELY LUBRICATING WITH A LIGHT COAT OF HEAVY, WATERPROOF
GREASE. REFER TO FIGURE 2. IF REPAIR KIT IS BEING INSTALLED, USE NEW
BELLEVILLE SPRINGS, ALREADY GREASED. NOTE THAT THE BELLEVILLE SPRING
NEAREST THE COVER (3) WILL CONTACT THE COVER WITH ITS OUTSIDE
DIAMETER.
(27) Install new seal (4) in cover (3).

(28) Install new gasket (24), cover (3), lock washers (2) and cap screws (1). Torque cap screws
at 29.8 to 36.6 N·m (22 to 27 lbf-ft.).
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NOTE: TIGHTEN CAP SCREWS EVENLY AND IN A-B-C-D ORDER. REFER TO FIGURE 3.


ADJUSTMENT’.
NOTE: PERFORM PARKING BRAKE FUNCTION CHECK AS PER ‘3. PARKING BRAKE
FUNCTION TESTS’.
6. CHANGE SEAL KIT PROCEDURE
(1) Loosen lock nut (9) and back off adjusting screw (8). Refer to Figure 1.
(3) Remove bolts used to fasten the mounting bracket assembly to vehicle. Remove brake
and mounting bracket assembly from vehicle and remove mounting bracket assembly from
brake.
NOTE: FOR STEPS (4) THROUGH (26), REFER TO FIGURE 2.
(4) Place brake in a soft-jawed vise with cover (3) in a vertical position.

SURFACES.

(6) Using a sharp bladed tool, carefully remove two seals (29) from housing (27). Note
direction of seals.
(7) To remove cover (3), loosen four cap screws (1).
NOTE: LOOSEN CAP SCREWS EVENLY AND IN A-B-C-D ORDER UNTIL SPRING PRE-LOAD
IS RELEASED. REFER TO FIGURE 3.
(8) Remove cap screws (1), lock washers (2), cover (3) and gasket (24). Using a thin blade
tool, remove seal (4) from cover.
(9) Remove spacer (5), Belleville springs (6) and washer (7). Note the stacking sequence of
Belleville springs.
NOTE: NOT ALL MODELS USE SPACER (5) OR WASHER (7). SOME MODELS USE TWO
WASHERS (7).
(10) Remove piston (10) from housing (27) bore. Remove O-ring (12) and back-up ring (11)
from piston. Push rod (13) should also come out with piston.
(11) Remove piston (16) from housing (27) bore. Remove O-rings (14 and 17) and back-up
rings (15 and 18) from piston.
(12) Remove lining assembly (23) from housing (27) bore. Remove O-rings (19) from lining
assembly.
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(13) Lubricate all rubber components from kit with clean type fluid used in the system.
(14) Clean all parts and housing bore thoroughly with clean type fluid used in the system and
keep free of all contaminants, dirt and debris.
NOTE: USE A HEAVY, WATERPROOF GREASE TO LUBRICATE SURFACES. REFER TO

FIGURE 2.
(15) Carefully install two new seals (29) in housing (27). Be sure to install seals (29) the same
direction as they were removed.
(16) Install new O-rings (19) on lining assembly (23). Install lining assembly (23) in housing
(27) bore.
(17) Install new O-rings (14 and 17) and new back-up rings (15 and 18) on piston (16). Note
order of components.
(18) Install piston (16) into housing (27) bore. Note direction of piston.
NOTE: WHEN INSERTING PISTON, BE SURE NOT TO PUNCH O-RING ON INLET PORTS.
(19) Install new back-up ring (11) and new O-ring (12) on piston (10). Note order of
components. Install push rod (14) in bore of piston. Install piston into housing (27) bore.
(20) Fully lubricate threads of adjusting screw (8) and lock nut (9) and install into piston (10).
(21) Install washer (7), spacer (5) and Belleville springs (6) over end of piston (10). Follow the
stacking sequence shown in Figure 4. Not all models use spacer (5) or washer (7).
NOTE: COMPLETELY LUBRICATE BELLEVILLE SPRINGS (6) WITH A LIGHT COAST OF

HEAVY, WATERPROOF GREASE. REFER TO FIGURE 2.
(22) Install new seal (4) in cover (3).

(23) Install new gasket (24), cover (3), lock washers (2) and cap screws (1). Torque cap screws
at 30 to 37 N·m (22 to 27 lbf-ft.).
NOTE: TIGHTEN CAP SCREWS EVENLY AND IN A-B-C-D ORDER. REFER TO FIGURE 3.


ADJUSTMENT’.
NOTE: PERFORM PARKING BRAKE CHECK AS PER ‘3. PARKING BRAKE FUNCTION TESTS’.
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7. FRONT AXLE BRAKE, REPLACE BRAKE LININGS
Refer to Figure 5.
(2) Remove bolts used to fasten the brake assembly to axle. Remove brake assembly from
vehicle.
(3) Place brake in a soft-jawed vise with end plug (6) in a vertical position.
NOTE: CLAMPING SHOULD BE DONE AT THE SIDES OF THE CALIPER ON THE MACHINED
SURFACES.
(4) Remove hex nut (1) from compensator assembly (9).

(5) Remove Belleville spring (2), wedge ring (3), washer (4) and O-ring (5) from compensator
assembly (9). Do not discard, save for reassembly.
(6) Using a spanner wrench, remove end plug (6) from housing (18).
(7) Remove piston (10) and lining (11) assembly from housing bore.
NOTE: DO NOT REMOVE COMPENSATOR ASSEMBLY (9) FROM PISTON (10).
(8) Remove flat head screws (12) to separate lining (11) and piston (10).
(9) Install new lining (11) on piston (10) using new flat head screws (12).
(10) Loosen vise jaws and rotate caliper so that disc clearance slot is facing up.
(11) Remove flat head screws (16) and lining (17) from housing (18).
(12) Install new lining (17) in housing (18) using new flat head screws (16).
(13) Rotate caliper to original position in vise.
(14) Remove seal (15) from housing bore.
(15) Lubricate new seal (15) from lining kit in clean hydraulic fluid.
(16) Install new seal (15) into groove of housing bore through the disc clearance slot end of
bore. Note the direction of seal.
(17) Carefully assemble piston (10) and lining (11) assembly to end plug (6).
(18) Install O-ring (5), washer (4), wedge ring (3), Belleville spring (2) and hex nut (1) on
compensator assembly (9).
NOTE: ENSURE THAT WEDGE RING (3) AND BELLEVILLE SPRING (2) ARE INSTALLED IN
PROPER DIRECTION.
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Figure 5
FRONT AXLE BRAKE SEALS, REPAIR AND LINING KITS
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(19) Tighten hex nut (1) securely.
NOTE: ASSEMBLY CREATED FROM STEPS (17) AND (18) IS THE END PLUG AND PISTON
ASSEMBLY.
(20) Lightly lubricate housing bore and piston (10) with clean hydraulic fluid.
(21) Carefully reinstall end plug and piston assembly into housing bore keeping lining face free
of hydraulic fluid and contamination. Tighten end plug (6) with a spanner wrench until it
bottoms out on housing (18).
(22) Install brake on axle and bleed brake to remove all air.
WARNING
BRAKES.
8. FRONT AXLE BRAKE, INSTALL REPAIR KIT
NOTE: WHEN REMOVING SEALS AND BACK-UP RINGS, BE CAREFUL NOT TO SCRATCH OR
MAR PISTONS. WHEN INSTALLING NEW SEALS IN THE BRAKE, ENSURE THAT THE
REPAIR KIT USED IS THE PROPER ONE FOR THE SYSTEM FLUID USED.
Refer to Figure 5.
(2) Remove bolts used to fasten the brake assembly to axle. Remove brake assembly from
vehicle.
(3) Place brake in a soft-jawed vise with end plug (6) in a vertical position.
NOTE: CLAMPING SHOULD BE DONE AT THE SIDES OF THE CALIPER ON THE MACHINED
SURFACES.

(5) Remove hex nut (1) from compensator assembly (9).
(6) Remove Belleville spring (2), wedge ring (3), washer (4) and O-ring (5) from compensator
assembly (9). Do not discard, save for reassembly.
(7) Using a spanner wrench, remove end plug (6) from housing (18).
(8) Remove piston (10) and lining (11) assembly from housing bore.
(9) Remove flat head screws (12) to separate lining (11) and piston (10).
(10) Remove compensator assembly (9) from piston (10).
(11) Loosen vise jaws and rotate caliper so that disc clearance slot is facing up.
(12) Remove O-ring (8) and back-up ring (7) from end plug (6).
(13) Using a thin-blade tool, remove back-up ring (14), O-ring (13) and seal (15) from housing
bore.
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(14) Remove flat head screws (16) and lining (17) from housing.
(15) Install new lining (17) in housing (18) using new flat head screws (16).
(16) Rotate caliper to original position.
(17) Lubricate all seals, O-rings and back-up rings from repair kit in clean hydraulic fluid.
(18) Carefully install new back-up ring (7) and O-ring (8) over non-threaded end of end plug (6)
and into groove. Ensure they are installed in proper position in groove.
CAUTION
WHEN INSTALLING BACK-UP RINGS, IT IS ESSENTIAL THAT SURFACES OF DIAGONAL

SPLICE MATCH WITH EACH OTHER AFTER BACK-UP RING IS INSTALLED IN GROOVE.
(19) Install new O-ring (13) and new back-up ring (14) in housing bore. Ensure they are
installed in proper position in groove.
(20) Install new seal (15) into groove of housing bore through the disc clearance slot end of
bore. Note the direction of seal.
(21) Install new compensator assembly (9) in piston (10) and tighten.
(22) Install new lining (11) on piston (10) using new flat head screws (12).
(23) Carefully assemble piston (10) and lining (11) assembly to end plug (6).
(24) Install new O-ring (5), new washer (4), new wedge ring (3), new Belleville spring (2) and
new hex nut (1) on compensator assembly (9).
NOTE: ENSURE THAT WEDGE RING (3) AND BELLEVILLE SPRING (2) ARE INSTALLED IN
THE PROPER DIRECTION.
(25) Tighten hex nut (1) securely.
NOTE: THE END PLUG AND PISTON ASSEMBLY CREATED FROM STEPS (25), (26) AND (27).
(26) Lightly lubricate housing bore and piston (10) with clean hydraulic fluid.
(27) Carefully reinstall end plug and piston assembly into housing bore keeping lining face free
of hydraulic fluid and contamination. Tighten end plug (6) with a spanner wrench until it
bottoms out on housing (18).
(28) Install new bleeder screw (19). Torque approximately 13.6 N·m (10 lbf-ft.).
(29) Install brake on axle and bleed brake to remove all air.
WARNING
BRAKES.
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9. REAR BRAKE OVERHAUL PROCEDURES
A. PREPARATION
(1) Raise deck to sufficient height to perform all maintenance and install maintenance stands.
(2) Raise the loader and remove each rear wheel assembly as outlined in Chapter 2,
Section 5, “Maintenance Procedures”.
(3) Relieve pressure from the caliper by loosening the bleeder screw. Remove and cap
hydraulic line.
(4) Remove the two outermost bolts from the caliper assembly and remove caliper and the two
brake pad assemblies (make note of all washers and their position for reassembly).
B. REMOVE HUB ASSEMBLY
(1) Remove the snap ring and cover and cover assembly.
(2) Remove the outer Timken bearing nut, lock washer and inner nut.
(3) Remove outer wheel bearing.
(4) Remove hub.
(5) Unscrew the 18 button head hex screws and remove the rotor assembly.
(6) Inspect rotor for any bluing and heat cracks. Rotor should be resurfaced whenever pads
are replaced, do not allow less than 10 mm (0.40 in.) minimum thickness. If there are
any signs of abnormal wear discard and replace with a new rotor assembly.
C. DISASSEMBLY OF CALIPER
(1) Detach boot from the pistons.

(2) Remove the pistons.
(3) Remove the boot from the housing groove.
(4) Remove the O-ring.
(5) Remove the bleeder screw.
(6) Clean and inspect all components for abnormal wear.
D. ASSEMBLY OF CALIPER
(1) Internal grooves in housing must be free of sand, dirt, chips and particle contaminants.
(2) Lubricate O-rings and the housing grooves with hydraulic fluid (MIL-H-32282).
(3) Install bleeder screw.
(4) Install O-rings into the second groove of the housing bores.
(5) Install Piston assemblies.
(6) Expand small end of the boot and install this end first over the closed end of the piston.
(7) Push the piston all of the way into the cavity depth and engage the small end of the boot
into the groove of the piston.
(8) Push the piston in slowly until it bottoms out in the bore.
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E. HOUSING ASSEMBLY
(1) Assemble the housing with the pistons fully retracted, the spacer, secondary plate and four
center bolts with the washers under the heads of the bolts and lock nuts. Refer to Figure 6.
(2) Torque the four center bolts to 108 to 122 N·m (80 to 90 lbf-ft.).
(3) Repack wheel bearings and install new wheel seal.
(4) Install new or resurfaced rotor to the hub assembly. Install rotor screws with a
non-permanent thread locking compound. Torque the screws to 39 N·m (29 lbf-ft.).
(5) Install hub assembly, outer wheel bearing and inner wheel bearing nut.
(6) Tighten inner wheel bearing nut while rotating the hub assembly, keep tightening the inner
wheel bearing nut until the rotating hub begins to drag. Then loosen the nut slightly to free
up the hub assembly.
(7) Install the lock washer and outer wheel bearing nut and torque to 68 to 81 N·m (50 to 60
lbf-ft.). Recheck that the hub rotates freely.
ONE WASHER BETWEEN

CALIPER AND MOUNTING ONE NUT ON
BRACKET CALIPER BOLT
P/N: 624-8920-003 P/N: 624-8970-006
TWO WASHERS ONE OUTER CALIPER

ONE SPACER BETWEEN
UNDER EACH HEAD BOLT POINTED TOWARDS
CALIPER AND MOUNTING
P/N: 624-8970-003 TIRE/WHEEL ASSEMBLY
BRACKET
P/N: 624-8970-005
P/N: 624-8970-004
Figure 6
CALIPER ASSEMBLY
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(8) Install the caliper assembly and new brake pads to the bracket and install the two end
bolts, placing the two washers under the head of the bolts and one spacer between the
calipers and mounting bracket.
NOTE: THE BOLT THREAD ENDS SHOULD POINT TOWARD THE WHEEL.
(9) Install the locking nut and torque to 20 to 27 N·m (15 to 20 lbf-ft.).
(10) Reinstall tire and wheel assembly as per procedure in Chapter 2, Section 5.
10. BOLT-ON DECK HINGE
WARNING
SECURE THE WALK-DECK SO THAT IT IS COMPLETY SUPPORTED, SO THAT WHEN IT IS
DISCONNECTED FROM THE HINGES IT WILL NOT FALL.
WARNING
THE EDGES ON THE METAL ARE SHARP AND CAN CAUSE INJURY.
A. DAMAGED WALK-DECK WELD
A damaged weld walk-deck or guide hinge is to be replaced by the following steps.

(1) Remove the walk-deck and guide that is attached to the damaged hinge in such a way as
to leave other walk-decks and guides still attached to the adjacent hinges.
(2) Remove the welds and the damaged hinge from the deck beam Using a plasma cutter or
die grinder.
(3) Attach a new bolt-on hinge using a variable thickness (“peelable”) shims and supplied
hardware by match drilling the deck beam.
B. REPLACEMENT PROCEDURE
NOTE: THE INSTRUCTIONS ARE WRITTEN FOR A WALK-DECK HINGE REPLACEMENT;

REPLACEMENT OF A GUIDE WOULD BE SIMILAR.
(1) Gain access to the damaged hinge by placing the loader deck at working height. The
hinge damage may vary. Refer to Figure 7.
(2) Pull out the quick release pins to allow the deck to hinge upward freely.
(3) Empty all compartments of the walk-deck to be removed. Attach the lifting straps to the
walk-deck and support with the overhead lift.
(4) Ensure the spacers between the sections of the walk-decks and the guide arms that are
going to be removed. They must be replaced in the same location when reinstalling the
walk-deck if they fall out. The spacers and washers maintain the proper relationships
(gaps) between the adjacent walk-deck and guides.
(5) The walk-deck containing the broken hinge is to be removed at this point. It must be
removed from the adjacent undamaged hinges in such a way as not to disturb the other
walk-decks and guides attached to the same hinges. In order to do this, loosen the center
pivot nut on the undamaged hinge on the side facing the damaged hinge.
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(6) With a hammer, tap the pivot bolt into the hinge until it is flush with the hinge. While using
a drift pin, continue tapping the pivot bolt into the hinge until the inserted pin takes up the
support of the guide that is also in the hinge (if present).
(7) From the other side, continue to pull out the center hinge bolt to the point where it still
supports the guides and walk-deck that are not to be removed. Take care not to remove
the bolt too far. Repeat steps (3) through (7) for the adjacent undamaged hinge, if
required.
(8) Using a lifting device capable of 340kg (750 lb.) remove the walk-deck to gain access to
the damaged hinge.
(9) Using a plasma cutter or a die grinder, remove the welds on the broken hinge. Remove as
little material as possible from the deck beam.
(10) Using a hammer, remove the hinge from the deck beam. If the hinge does not come loose,
repeat step (8), do not remove too much material from the deck beam.
(11) Using a grinder, clean the remaining welds from the beam surfaces so that they are smooth
and flat.
(12) Place the replacement hinge part number (part no. 624-8935) into the beam approximately
where the broken hinge was removed.
NOTE: THERE IS A TOP AND A BOTTOM ORIENTATION. THE TOP HOLE IN THE SIDE
PLATES IS HIGHER THAN THE FLANGE, WHILE THE LOWER HOLE IS LEVEL WITH
THE FLANGE.
(13) Reinstall the walk-deck tap the center threaded rod back into place, driving out the
temporary drift pin installed in step (6), ensure all spacers (if present) remain in place.
Tighten locking nuts until SNUG against hinge.
(14) Attach the replacement hinge to the walk-deck using the original hardware and spacers (if
there are any). While holding the hinge straight, measure the gap between the back of the
hinge and the deck beam. Using the supplied “peelable” aluminum shim (part
no. 624-8925), remove enough laminates, so that the resulting shim thickness matches the
measurement of the gap. Peel back small layers at a time, using a knife on the corner to
expose enough material to grab and pull back with pliers.
(15) Holding the hinge and the shim in place, match drill at least two holes on each side of the
hinge. Attach the hinge (part no. 624-8935) and the back shim (part no. 624-8925) using
the supplied hardware. Finish drilling all of the other usable holes and attach the hardware
inserting the bolt from the hinge side.
CAUTION
ONLY SELECT PREDRILLED HOLES THAT WILL NOT ALLOW YOU TO DRILL INTO THE BLIND
CAVITIES BEHIND THE DECK BEAM, AS A NUT IS GOING TO BE INSTALLED ON THE BACK
SIDE OF THE DECK BEAM.
(16) Ensure to use the supplied “peelable” aluminum shims (part no. 624-8920) to fill the spaces
between the top and bottom of the hinge and the deck beam. Tap in place of steel flat
stock.
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TYPICAL DAMAGED WALK-DECK HINGE
ADJACENT HINGE DAMAGED HINGE ADJACENT HINGE
BOLT-IN REPLACEMENT HINGE AND SHIMS INSTALLED
Figure 7
BOLT-ON DECK HINGE - PART 1
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(17) Using a right angle drill, match drill the holes on the top of the deck beam at the bottom.
NOTE: IF A RIGHT ANGLE DRILL IS NOT AVAILABLE, MEASURE THE DISTANCE FROM THE
HOLE IN THE OUTSIDE OF THE BEAM AND TRANSFER THIS DISTANCE TO THE
OTHER SIDE OF THE BEAM TO LOCATE THE DRILL POINT. INSERT BOLTS FROM
THE OUTSIDE OF THE DECK BEAM, SO THAT THE NUT ENDS UP ON THE NEW
HINGE.
(18) Tighten all hardware to 34 N·m (25 lbf-ft.). Touch up exposed unpainted surfaces with
paint.
(19) Ensure to check for correct movement of the walk-deck.
TYPICAL DAMAGED HINGE
PULL OUT TOP RELEASE PINS
ATTACH LIFTING STRAPS TO WALK DECK
Figure 8
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REMOVE BROKEN HINGE SPACERS AND WASHERS (IF PRESENT)
LOOSEN CENTER PIVOT NUT ON UNDAMAGED HINGE
NUT REMOVED ON UNDAMAGED ADJACENT HINGE

CLOSEST TO THE DAMAGED HINGE SIDE
Figure 9
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TAP IN CENTER BOLT FLUSH WITH INSERT A DRIFT PIN, INTILL

OUTSIDE HINGE FACE. SUPPORTS THE GUIDE.
CONTINUE TO PULL OUT THE CENTER HINGE BOLT TO THE POINT WHERE IT STILL SUPPORTS
THE GUIDES. DECK HAS BEEN REMOVED SPACERS REMAIN IN THEIR ORGINAL LOCATIONS.
Figure 10
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SUITABLE LIFTING DEVICE CAPABLE OF DAMAGED HINGE TO BE REMOVED

LIFTING 340 kg (750 lb.)
GRIND OUT WELDS ONLY ON BOTH SIDES OF THE HINGE
Figure 11
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SOAPY WATER WILL HELP GRINDER FROM REMOVE WELDS, USING DYE GRINDER.
JAMMING WITH ALUMINUM FILLINGS.
REMOVE THE HINGE FROM THE DECK BEAM. IF THE HINGE DOES NOT
COME LOOSE, REPEAT STEP 1.
Figure 12
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USING THE DYE GRINDER, CLEAN ALL REMAINING WELDS; BEAM SURFACES MUST BE
SMOOTH AND FLAT.
REST ALL THE WALK-DECK. TAP THE CENTER THREADED ROD BACK INTO PLACE DRIVING
OUT THE TEMPORARY DRIFT PIN. ENSURE ALL SPACERS REMAIN IN PLACE.
Figure 13
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TAP THE CENTER THREADED ROD BACK USE A KNIFE OR OTHER SHARP EDGE TO
INTO PLACE. LIFT THE LAMINAT ON ONE CORNER.
TYPICAL “PEELABLE” ALUMINUM SHIM, WARNING:

PART NO. 624-8920 SHOWN (STEP 13) EDGES OF METAL ARE VERY SHARP.
USES PART NO. 624-8925.
Figure 14
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CHECK FOR CORRECT MOVEMENT OF THE WALK-DECK
Figure 15
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624-8935 624-8925
SHIM, LAMINATED BACK
M-HINGE SUPPORT NGSL

624-8959
625-4369
SHIM, LAMINATED BACK-REAR

SHIM, LAMINATED BACK-DOUBLE
624-8956
624-8960
SHIM, LAMINATED DOUBLE
M-HINGE SUPPORT, DOUBLE

625-4123
625-4370
SHIM-LAMINATED REAR M-HINGE REAR SUPPORT, NGSL
Figure 16
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USE 624-8955
USE 624-8955 USE 624-8971 USE 624-8955 USE 624-8971 USE 625-4258

Figure 17
USE 624-8971
USE 624-8955 USE 625-4459 USE 625-4258
USE 624-8955 USE 624-8955 USE 625-4459
USE 624-8971
Halvorsen
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TABLE 1 - BOLT-ON DECK HINGE

624-8954
1 107-9307 SCR, HHC-F 10.9 M8 x 1.25 x 50 MG 18

2 107-9259 NUT PTH 10.9 x 1.25 MG 18
3 107-9275 WASHER FLAT STD HD M8 MG 36
4 107-9307 SCR, HHC-F 10.9 M8 x 1.25 x 50 MG 20
5 107-9259 NUT PTH 10.9 M8 x 1.25 MG 20
7 107-9307 SCR, HHC-F 10.9 M8 x 1.25 x 50 MG 12
8 107-9259 NUT PTH 10.9 M8 x 1.25 MG 12
9 107-9275 WASER FLAT STD HD M8 MG 24
10 107-9307 SCR, HHC-F 10.9 M8 x 1.25 x 50 MG 10
11 107-9259 NUT PTH 10.9 M8 x 1.25 MG 10
13 624-8953 M-HINGE SUPPORT NGSL 1
14 624-8925 SHIM, LAMINATED BACK 1
15 624-8920 SHIM, LAMINATED TOP AND BOTTOM 2
16 624-8955 K-HINGE, BOLT-ON DECK, SINGLE
17 624-8971 K-HINGE, BOLT-ON DECK, DOUBLE
18 624-8956 M-HINGE SUPPOPRT, DOUBLE 1
19 624-8959 SHIM, LAMINATED BACK-DOUBLE 1
20 624-8960 SHIM, LAMINATED DOUBLE 2
21 625-4258 K-HINGE REAR NGSL
22 625-4123 M-HINGE REAR SUPPORT, NGSL 1
23 625-4369 SHIM, LAMINATED BACK-REAR 1
24 625-4370 SHIM, LAMINATED REAR 2
25 625-4459 K-HINGE SUPPORT, REAR GUIDERAIL
26 625-4446 M-HINGE SUPPORT, REAR GUIDERAIL 1
27 624-4369 SHIM, LAMINATED BACK-REAR 1
28 625-4370 SHIM, LAMINATED TOP-BACK 2
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11. D4 CAB HEATER KIT REPLACEMENT
WARNING
DRAIN ALL FUEL FROM THE HEATER FUEL TANK BEFORE PROCEEDING.
NOTE: BEFORE BEGINNING PROCEDURES, VERIFY THAT THE FAULTY HEATER THAT IS
BEING REPLACED IS A D3LC HEATER BY CHECKING THE ID DECAL.
NOTE: TURN THE BATTERY DISCONNECT SWITCH, LOCATED ON THE BATTERY BOX, TO
THE OFF POSITION AND INSTALL CHOCKS BEFORE WORK IS PERMITTED ON THE
LOADER.
NOTE: INSTALLATION INSTRUCTIONS REQUIRE ONE TECHNICIAN AND ONE ASSISTANT.
A. INSTALLATION PROCEDURES
Refer to Figure 18.
(1) Turn the battery disconnect switch, located on the battery box, to the OFF position and
install wheel chocks.
(2) Pull the cab all the way out to safely drain all fuel from the heater fuel tank before
proceeding.
(3) Completely remove the side console panel from the cab to fully access the heater. The
convey panel, auto lubrication push button, transmission joystick and heater thermostat
must be unplugged and removed during this step. Save all removed hardware for
reassembly later.
Figure 18
SIDE CONSOLE PANEL AND HEATER
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(4) Completely remove the heater and heater hood from the cab by removing the four (4)
mounting nuts and washers securing the heater to the cab. The intake and exhaust hoses,
intake fuel line, hot air duct and heater electrical harness must also be disconnected from
the heater during this step. Refer to Figure 19. Keep all removed hardware and clamps for
installation of new heater.
Figure 19
INTAKE, EXHAUST AND FUEL LINE
(5) Completely remove and discard the heater fuel pump. Keep fuel pump hose and clamps
for installation of new heater fuel pump.
(6) Completely remove the heater electrical harness from the cab by cutting wire number 1
and wire number 14 on the cab electrical harness.
NOTE: CUT BOTH WIRES LABELED WIRE NUMBER 1 DURING THIS STEP. SOME LOADER
MAY BE CONFIGURED WITH A BROWN WIRE (NUMBER 1) AND A RED WIRE
(NUMBER 13).
(7) Remove the splices from wire number 1 and wire number 13, leaving as much wire on the
cab electrical harness as possible. Disconnect the red wire from 3CR-A (30). The wire
splices and 3CR-A are located under the dash pane. Refer to Figure 20.
(8) Strip both wires labeled wire number 1 and the single wire labeled wire number 13
approximately 0.25 inches.
(9) Crimp the supplied female spade (part no. 239-3650-001) to the single wire labeled wire
number 13.
(10) Crimp the supplied female spade (part no. 239-3650-002) to both wires labeled wire
number 1.
(11) Place a 19 mm (0.75 in.) long piece of heat shrink tubing (part no. 624-8942-004) over both
crimped connections on female spades referenced in steps (9) and (10). Refer to
Figure 22.
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Figure 20
WIRING SPLICE REMOVAL
(12) Install D4 24 VDC Heater (part no. 627-5930-001) and hood (part no. 627-5930-003) in the
locations of the previously removed heater, heater hood and fuel pump using all the
previously removed hardware. The heater fuel pump must be fastened to the cab at a 15º
to 35º angle from the horizontal. Refer to Figure 21.
(13) Next, connect the intake and exhaust hoses, intake fuel line, fuel tank line and hot air duct
to D4 24 VDC Heater (part no. 627-5930-001) and hood (part no. 627-5930-003) using the
previously removed clamps.
(14) Install D4 Custom Heater (part no. 627-5930-002) by following the routing of the previously
removed heater harness.
(15) Route the two (2) loose green wires through the fuel pump access hole. Insert both wires
in the black fuel pump connector that is provided with D4 Custom Heater (part
no. 627-5930-002) and then connect it to the fuel pump. Refer to Figure 21. The fuel
pump is not affected by wire polarity.
(16) Connect the red wire with red male spade from item number 2 to 3CR-A (30). Refer to
Figure 22 that shows 3CR-A (cube relay) schematic for reference. Next, connect the red
wire with blue female spade to wire number 13 on the cab electrical harness and connect
the brown wire with the blue female spade to wire number 1 on the cab electrical harness.
(17) Reinstall the side console panel and all previously removed electrical components. Verify
that the heater thermostat and the auto lubrication push button are wired properly before
proceeding. Refer to Figure 22.
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(18) Fill the heater fuel tank with one of the following fuels listed in table below. Turn the battery
disconnect switch to the ON position then verify that the heater thermostat and all other
components are operating correctly. It may take a few minutes for the heater to reach full
output capabilities.
Figure 21
FUEL PUMP INSTALLATION REFERENCE
627-5930-002
Figure 22
D4 CUSTOM HEATER REFERENCE
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Figure 23
CUBE RELAY REFERENCE SCHEMATIC AND VIEW
Figure 24
THERMOSTAT WIRING DIAGRAM
Figure 25
AUTO LUBRICATION PUSH BUTTON WIRING
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12. CAB SUSPENSION SHOCK ADJUSTMENT
(1) Shut off the engine and turn off the battery disconnect switch.
(2) Open the cab door.
(3) Remove the black shock tower cap from the left shock tower. Refer to Figure 26 and
Figure 27.
Cab Left Shock Tower

with Cap
625-4873
Figure 26
CAB LEFT SHOCK TOWER
(4) Starting from the complete unscrewed position, screw the dampening adjustment screw
clockwise 13 detent clicks.
(5) Re-install the black tower cap on the shock tower. Refer To Figure 26.
(6) Sitting in the cab, remove and electrically disconnect the transmission shifter joystick panel
from the right side console.
(7) Remove the electrically disconnect the convey panel from the right side console.
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Cab Left
Shock Tower
Shock SDAS
Figure 27
CAB LEFT SHOCK TOWER WITH CAP REMOVED
(8) Remove the right side console by unscrewing the seven (7) M10 bolts. Three (3) bolts are
on the inside of the panel and four (4) bolts are on the outside along the bottom. Refer to
Figure 28.
Transmission Shifter
Joystick Panel Convey Panel
Four (4) M10

Outside Bolts
Figure 28
RIGHT SIDE CONSOLE PANEL
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(9) Lift the right side console out of the way and remove the black shock tower cap from the
shock tower at the right of the seat. Refer to Figure 29.
Right Side
Convey Console
Right Shock
Tower with Cap
Figure 29
RIGHT SIDE CAB SHOCK TOWER
(10) Rotate the red SDAS counter clockwise until fully unscrewed position.
(11) Starting from the complete unscrewed position, screw the dampening adjustment screw
clockwise 13 detent clicks.
(12) Re-install the black shock tower cap on the shock tower.
(13) Re-install the right side console and the seven (7) bolts to their locations.
(14) Electrically re-connect and re-install the transmission shifter joystick and convey panel to
the right side console.
(15) Ensure the loader transmission is shifting properly and that the convey functions are
completely restored. Refer to the operator and maintenance manuals if necessary.
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13. BOLT-ON DECK BUMPER DOUBLE PLATE INSTALLATION
TABLE 2 - DECK BUMPER DOUBLER BOLT-ON KIT

628-1494
1 105-0327-901 LOCTITE 242 (24205) 0.5ML 1
2 107-9084 SCR,HHC 8.8 M10X1.5X50 MG 2
3 107-9214 SCR,SFH-F 10.9 M12X1.75X50 MG 4
4 107-9260 NUT,PTH 8 M10X1.50 MG 2
5 107-9276 WSHR,FLAT STD HD M10 MG 4
6 628-1805 W-CLEVIS, AIR TRANSPORT 1
7 625-8097 GUARD, LIMIT SW BOLT-ON 1
8 627-6384-001 STEP BIT, 1/8–1/2, 1/4 SHANK 1
9 628-1512 PLATE, DECK BUMPER OUTER DOUBLER 1
10 628-1516 PLATE, DECK BUMPER INNER DOUBLER 1
12 628-1774 DECAL, ATS CLEVIS AND PIN INSTAL 1
13 628-4094 W-TEMPLATE, ATS DOUBLER BOLT-ON 1
14 DWG-628-1595 PROCEDURES, ATS DOUBLER BOLT-ON 1
15 107-9302 SCR,HHC 10.9 M8X1.25X25 MG 1
16 628-2891-002 CYLINDRICAL END CARBIDE BUR 1
17 628-2561 ALUMINUM GRINDING WHEEL 2
18 628-2557 ALUMINUM CUTOFF WHEEL 2
A. VEHICLE AND DECK PREPARATION
CAUTION
THE DECK MUST BE CENTERED AND LEVEL BEFORE ANY MODIFICATIONS ARE TO BE
PERFORMED. FAILURE TO CENTER AND LEVEL THE DECK MAY CAUSE MISALIGNMENT
ISSUES LATER IN THE PROCEDURES.
(1) Apply the park brake and chock wheels to prevent movement of the loader in either
direction.
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(2) Raise deck past the FIRST maintenance stand position and install both maintenance
stands, then lower the deck until the scissor rollers rest on both maintenance stands.
(3) Verify the deck is level and centered by actuating and holding, the auto center and level
switch on the cab dash panel until the pitch, roll and shift indicator lights are not illuminated.
(4) From outside the loader, visually verify the side shift cylinders are centered, all four roll
cylinders are completely lowered and the pitch arm is in the correct position for a level
deck. Refer to Chapter 2, Section 5, “Maintenance Procedures” for more information.
(5) Shut down the engine and turn the battery disconnect switch, located on the battery box, to
the OFF position.
(6) Install item number 13 (part no. 628-4094 W-TEMPLATE, ATS DOUBLER BOLT-ON) as
shown in Figure 30, step 1.
(7) Push item number 13 (part no. 628-4094 TEMPLATE, ATS DOUBLER BOLT-ON) upwards
so that the top of the template keyway is contacting the top surface of the slotted hole in the
deck bumper. Align the bottom edge of item number 13 (part no. 628-4094 TEMPLATE,
ATS DOUBLER BOLT-ON) horizontally with the bottom edge of the deck bumper. Refer to
Figure 30, step 2.
Figure 30
TEMPLATE POSITIONING STEPS
(8) The template keyway should fit inside the slotted hole in the deck bumper and the template
should fit flush against the deck bumper. The template may be held in position using a
locking welding clamp or suitable clamping device. Refer to Figure 31.
(9) Mark the center of the six (6) holes on item number 13 (part no. 628-4094 TEMPLATE,
ATS DOUBLER BOLT-ON) with a center punch or suitable marking device. Refer to
Figure 31. The markings will be used to drill six holes in the deck bumper later in these
procedures.
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Figure 31
TEMPLATE HOLE MARKINGS
(10) Remove item number 13 (part no. 628-2841 TEMPLATE, ATS DOUBLER BOLT-ON).
(11) Label the three (3) limit switches shown in Figure 32, step 1. This will help identify these
items during the reassembly portion of these procedures.
(12) Remove the three (3) limit switches from the limit switch guard. Save all hardware for later
reuse. Refer to Figure 32, step 2. As a note, it will not be possible to lower the deck after
these limit switches have been removed.
Figure 32
LIMIT SWITCH REMOVAL STEPS
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B. DAMAGED ITEM REMOVAL PROCEDURES
Remove the limit switch guard from the inside of the deck bumper. Use caution to avoid
damaging surrounding electrical harnesses while removing this item. Refer to Figure 33. Two
different cutting methods can be used to accomplish this task. The limit switch guard may be
removed with a reciprocating saw or a die grinder with suitable cutting attachments. Please
select one of these methods depending upon the available tools and refer to the corresponding
section.
LIMIT SWITCH GUARD ELECTRICAL HARNESS
Figure 33
LIMIT SWITCH GUARD
CAUTION
DO NOT CUT INTO OR REMOVE MATERIAL FROM THE DECK BUMPER WHEN REMOVING
ITEMS USING CUTTING OR GRINDING TOOLS.
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C. RECIPROCATING SAW CUTTING METHOD
Remove the limit switch guard by cutting the C-channel with a reciprocating saw and a cutting
blade suitable for cutting aluminum. Refer to Figure 34 for before and after images.
BEFORE AFTER
Figure 34
LIMIT SWITCH GUARD REMOVAL USING RECIPROCATING SAW
D. CARBIDE BUR CUTTING METHOD

(1) Weaken the weld around the C-channel and the limit switch guard using a die grinder and
the item number 16 (part no. 628-2891-002 CYLINDRICAL END CARBIDE BUR). Refer to
Figure 35. Before and throughout the cutting process apply WD-40 or liquid soap to the
carbide bur to reduce clogging issues.
Figure 35
LIMIT SWITCH GUARD REMOVAL USING CYLINDRICAL CARBIDE BUR STEPS
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(2) Break the weld around the C-channel to remove the limit switch guard using a medium
sized sledge hammer. Refer to Figure 36.
Figure 36
LIMIT SWITCH GUARD REMOVAL
(3) Weaken the weld around the C-channel using a 4 inch angle grinder and item number 18
(part no. 628-2557 ALUMINUM CUT-OFF WHEEL). Do not cut into or remove material
from the deck bumper when performing this task. Refer to Figure 37.
(4) Remove the remainder of the C-channel using a medium sized sledge hammer. Refer to
Figure 37, step 3.
(5) The remainder of the C-channel and weld material should be removed and ground flat
using a 4 inch angle grinder and item number 17 (part no. 628-2561 ALUMINUM
GRINDING WHEEL). Refer to Figure 38.
(6) Grind down the weld on the bottom of the deck bumper doubler plate using a 4 inch angle
grinder and item number 17 (part no. 628-2561 ALUMINUM GRINDING WHEEL). This
process will reduce the profile of the weld so it may be accurately cut out later in these
procedures. Do not cut into or remove material from the deck bumper when performing
this task. Refer to Figure 39.
(7) Cut through the bottom weld on the deck bumper doubler plate using a 4 inch angle grinder
and item number 18 (part no. 628-2557 ALUMINUM CUT-OFF WHEEL). Do not cut into or
remove material from the deck bumper when performing this task. Refer to Figure 40.
(8) Grind the remainder of the weld around deck doubler plate using a die grinder and item
number 16 (part no. 628-2891-002 CYLINDRICAL END CARBIDE BUR). Be sure to keep
the cutting tool perpendicular to the doubler plate. Throughout the cutting process apply
WD-40 or liquid soap to the carbide bur to reduce clogging issues. Do not cut into or
remove material from the deck bumper when performing this task. Refer to Figure 41.
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(9) Cut two small openings in the doubler plate top left and right corners using a 4 inch angle
grinder and item number 18 (part no. 628-2557 ALUMINUM CUT-OFF WHEEL). These
openings should be large enough so a steel chisel can be inserted and used to pry the
doubler plate away from the deck. Do not cut into or remove material from the deck
bumper when performing this task. Refer to Figure 42.
(10) Insert a steel chisel in each of the openings in the doubler plate. Break the welds around
the doubler plate by driving the chisel into the openings using a small sledge hammer.
Refer Figure 43, steps 1 and 2. Additional weld grinding may be required in some
circumstances.
STEP 1 STEP 2 STEP 3
Figure 37
REMAINDER OF C-CHANNEL REMOVAL STEPS
Figure 38
BUMPER GRINDING STEPS
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Figure 39
GRIND WELD FROM BOTTOM OF DOUBLER PLATE

Figure 40
CUT THE BOTTOM WELD ON THE DECK DOUBLER PLATE STEPS
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Figure 41
GRIND DOWN WELD FROM AROUND DECK DOUBLER PLATE STEPS
Figure 42
DOUBLER PLATE WELD RELIEF CUT STEPS
(11) 3.12 Use a large crowbar to pry the doubler plate from the deck bumper. Refer to
Figure 43, step 3.
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Figure 43
DOUBLER PLATE REMOVAL STEPS
(12) Grind the area around the slotted hole on the deck bumper flat using a 4 inch angle grinder
and item number 17 (part no. 628-2561 ALUMINUM GRINDING WHEEL). Periodically
use a straight edge to verify the area is flat. Refer to Figure 44.
STEP 1 STEP 2
Figure 44
GRIND AREA SMOOTH
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E. PRIME AND PAINT AFFECTED AREAS
(1) Apply a coat of primer to the areas that require paint. A fast-drying, gray spray primer for
aluminum is recommended. Allow primer to fully dry before proceeding. Refer to
Figure 45, step 1.
(2) 4.2 Apply a coat of green paint over the primed area. A fast drying OD green spray paint is
recommended. Allow paint to fully dry before proceeding. Refer to Figure 45, step 2.
STEP 1 STEP 2
Figure 45
PRIME AND PAINT AFFECTED AREA
F. KIT INSTALLATION
(1) Drill six (6) 0.5 inch holes in the deck bumper at the locations of the six (6) previously
marked locations using a hand-held drill and item number 8 (part no. 627-6384-001 STEP
BIT, 1/8-1/2, 1/4 SHANK). Throughout the drilling process apply WD-40 or liquid soap to
the drill bit to reduce clogging issues. Refer to Figure 46. Remove all burrs and sharp
edges afterwards.
(2) Lubricate the heads on item number 3 (part no. 107-9214, SCR-SFH-F 10.9 M12 X 1.75 X
50 MG) with WD-40. Refer to Figure 47. This will reduce friction during installation so the
desired torque can be achieved without damaging the fasteners.
(3) Position item number 9 (part no. 628-1512, PLATE, DECK BUMPER OUTER DOUBLER)
and item number 3 (part no. 107-9214, SCR-SFH-F 10.9 M12 X 1.75 X 50 MG) as shown
in Figure 48, step 1.
(4) Apply several drops of item number 1 (part no. 105-0327-901, LOCTITE 242 (24205)
0.5 ml) to the leading threads on item number 3 (part no. 107-9214, SCR-SFH-F 10.9 M12
X 1.75 X 50 MG). Refer to Figure 48, step 2.
(5) Position item number 10 (part no. 628-1516, PLATE, DECK BUMPER INNER DOUBLER)
as shown in Figure 48, step 3. Finger tighten item number 3 (part no. 107-9214, SCR-
SFH-F 10.9 M12 X 1.75 X 50 MG).
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(6) Tighten the four fasteners in a cross pattern to approximately 41 N·m (30 lbf-ft.) using an
8 mm or 5/16 inch Allen head socket and torque wrench. Then, torque the four fasteners in
a cross pattern to 95 N·m (70 lbf-ft.). Refer to Figure 49.
Figure 46
DRILL SIX HOLES IN DECK BUMPER
Figure 47
LUBRICATE FASTENER BEFORE INSTALLATION
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Figure 48
DOUBLER PLATE INSTALLATION
Figure 49
TORQUE FASTENERS
(7) Install item number 7 (part no. 625-8097, GUARD, LIMIT SW BOLT-ON) using item
number 2 (part no. 107-9084, SCR, HHC 8.8 M10 X 1.5 X 50 MG), item number 4 (part
no. 107-9260, NUT,PTH 8 M10 X 1.50 MG) and item number 5 (part no. 107-9276, WSHR,
FLAT STD HD M10 MG). Refer to Figure 50.
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Figure 50
LIMIT SWITCH GUARD INSTALLATION
(8) Reinstall the three limit switches in their appropriate locations using the previously
removed hardware. Refer to Figure 51.
Figure 51
LIMIT SWITCH INSTALLATION
(9) Clean the surface of the deck bumper shown in Figure 60 with isopropylic alcohol and
install item number 12 (part no. 628-1774, DECAL, ATS CLEVIS AND PIN INSTAL) as
shown in Figure 52.
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Figure 52
DECAL INSTALLATION
(10) Loosen the socket head set screw on the clevis collar shown in Figure 53, step 1.
(11) Remove and discard of the hex head cap screw that retains the clevis collar to the chassis
bumper. Refer to Figure 53, step 2.
(12) Remove the clevis collar and air transport clevis. The air transport clevis will be replaced
during this modification and can be discarded.
STEP 1 STEP 2
Figure 53
AGED CLEVIS REMOVAL STEPS
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(13) Install item number 6 (part no. 628-1805 W-CLEVIS, AIR TRANSPORT), the previously
removed clevis collar and item number 15 (part no. 107-9302 SCR, HHC 10.9 M8 X 1.25 X
25 MG) as shown in Figure 54, step 1. Be sure to align the access hole in clevis collar to
the threaded hole on the chassis bumper.
(14) Tighten the socket head set screw on the clevis collar to secure the collar to the chassis
frame. Refer to Figure 54, step 2.
(15) Torque item number 15 (part no. 107-9302 SCR,HHC 10.9 M8 X 1.25 X 25 MG) to
approximately 20 to 27 N·m (15 to 20 lbf-ft.). Refer to Figure 54, step 3.

Figure 54
REPLACEMENT CLEVIS AND COLLAR INSTALLATION STEPS
(16) Turn the battery disconnect switch, located on the battery box, to the ON position. Start the
loader and lift the deck enough so the maintenance stands can be removed.
(17) Remove the maintenance stands and stow them in the maintenance stand holders. Lower
the deck to rest on the chassis frame.
(18) Install the air transport system pin and clevis as shown in Figure 55, step 1. The traction
modules should lift automatically when this step is performed.
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(19) From inside the cab, perform the following functionality checks before proceeding.
Troubleshoot any functionality issues. Refer to Chapter 2, Section 6 for troubleshooting
guidance:
• The red air transport indicator light should be flashing.
• Deck roll, pitch and side shift should be inactive.
CAUTION
DO NOT CONTINUE TO ENGAGE THE LIFT JOYSTICK IF THE ENGINE REVS UP WHILE THE
AIR TRANSPORT SYSTEM CLEVIS AND PIN ARE INSTALLED. STRUCTURAL DAMAGE WILL
OCCUR. TROULESHOOT THE ISSUE BEFORE PROCEEDING.
• Move the lift joystick to the RAISE position. The engine RPM should not change
during this task.
• When the helper cylinders are fully extended the red air transport indicator light
should become solid.
Figure 55
CHECK AIR TRANSPORT SYSTEM OPERATION
(20) Lower the deck completely to rest on the chassis frame. Remove the air transport clevis
and pin and stow these items appropriately in the chassis frame.
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14. SEAT SUSPENSION KIT INSTALLATION
The optional Seat Suspension Kit improves comfort for operators.
TABLE 3 - SEAT SUSPENSION KIT (OPTIONAL)

TABLE 4 - 628-8712
- 628-8712 K-SEAT SUSPENSION REF
1 107-1111 NUT, PTH A2 TH 0.31-18 SS 4
2 107-1339 WASHER, FLAT 5/16 304 SS 4
3 107-1341 WASHER, FLAT A2 TH 0.38 SS 8
4 107-0364 NUT, PTH A2 TH 0.38-16 4
5 107-2979 SCREW, SBH A2 0.31-18X1 SS 4
6 107-9017 SCREW, HHC-F 8.8 M6X1X20 MG 4
7 107-9450 WASHER, FNDR STD HD M6 MG 4
8 110-2213 SCREW, HHC A2 0.38-16X1 SS 4
9 629-1390 M-INSERT, SEAT SUSPENSION 1
10 628-8714 ADAPTER, SEAT INSERT 2
11 DWG-628-8803 SEAT SUSPENSION KIT INSTALLATION PROCEDURE 1
A. SEAT REMOVAL
Remove Seat from Cab

The seat normally slides on tracks mounted to the cab floor. The tracks consist of upper and
lower slide rails which slide back and forth on each other. The upper slide rails are mounted on
two S-brackets attached to the bottom of the seat with four screws. Refer to Figure 56.
The upper right slide rail has two tabs bent down at both ends of the travel. The bent tabs
interfere with a stop in the middle of the lower right slide rail. This intentional interference
prevents the seat from sliding off the tracks.
One of two methods may be used to remove the seat from the cab:
(1) Slide the seat off the tracks (preferred).
(2) Disassemble the seat from the cab floor with tracks attached.
If unable to slide the seat off the tracks, then it must be removed by disassembling the
bolted connections to the cab floor.
Main components of the seat as removed from cab are shown in the following illustration.
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S-brackets
Seat
Side lever
on right Seat
slide rail tracks
SEAT REMOVED FROM CAB
Figure 56
OPERATOR’S SEAT MAIN COMPONENTS
B. SLIDE THE SEAT OFF THE TRACKS
(1) Operate side lever to allow the seat to slide on the tracks. Push seat forward until it slides
against the stop.
(2) View right slide rails under the seat from the front.
(3) Locate the bent tab restricting travel at the rear of the upper right slide rail. The bent rear
tab contacts the stop in the middle of the lower right slide rail when the seat is pushed
forward. Refer to Figure 57.
Tab bent
down at
the rear of
upper right
slide rail
Stop in
middle of the
lower right
slide rail
VIEW UNDER SEAT
Figure 57
STOP AND BENT TAB RIGHT SLIDE RAIL
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(4) Place the blade of a screwdriver under the bent rear tab. Push the tab up with the
screwdriver to clear the height of the stop on the lower right slide rail. Refer to Figure 58.
Push tab up
over the
stop with
screwdriver
BEND REAR TAB UP TO SLIDE THE SEAT FORWARD.
Figure 58
REAR TAB ON UPPER SLIDE RAIL
(5) Push seat forward until it slides of the tracks.

(6) Leave lower slide rails bolted to the cab floor.
C. DISASSEMBLE THE SEAT FROM THE CAB FLOOR WITH TRACKS ATTACHED
(1) Perform steps in this section only if unable to remove the seat in the previous section.
(2) Operate side lever to allow the sea to slide on the tracks Push seat forward or backward to
access four screws securing the tracks to the cab floor.
(3) Remove the four screws, nuts and washers attaching the seat lower slide rails to the cab
floor. Access the screws from inside the cab and the washers from the outside. Use a
13-mm socket wrench and a 13-mm end-box combination wrench.
(4) Save all fasteners for reassembly. Replace with new fasteners if deemed necessary.
(5) Remove seat from the cab with all slide rails attached.
D. SEAT DISASSEMBLY
(1) Remove and discard the S-brackets from the bottom of the seat.
(2) Place seat on a flat surface to make the bottom accessible. The bottom of the slide rails
should face up.
(3) If still attached, slide the lower slide rails off the upper slide rails. Save the lover slide rails
for reassembly.
(4) Disassemble the upper slide rails from the S-brackets and save them for reassemble. Use
a 3/16-inch Allen wrench and a 1/2-inch end-box combination wrench. Discard spacers,
screws, nuts and washers removed. Refer to Figure 59.
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Remove
and discard Upper left
M6 screws slide rail
and
washers
Remove
and
discard
button
head
screws
and related
washers,
nuts, and
S-bracket spacers
VIEW AT SEAT BOTTOM
Figure 59
UPPER LEFT SLIDE RAIL
(5) Remove the four M6 screws and washers securing the S-brackets to the seat using a
10-mm socket wrench. Discard the screws and washers removed. Discard the
S-brackets. Refer to Figure 60.
Upper left
Upper right
slide rail
slide rail
has no
with side
side lever
lever
attached
Remove
and discard
four M6
screws and Remove
washers and
discard the
S-brackets
VIEW AT SEAT BOTTOM
Figure 60
UPPER SLIDE RAILS AND S-BRACKETS
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(6) Mark the location of the four holes through the seat fabric as you remove screws.
(7) Enlarge holes in the fabric with a utility knife, as needed. This will help locate the threaded
holes in the seat during reassembly.
E. SEAT SUSPENSION INSERT SUBASSEMBLY
(1) Place the part no. 629-1390, M-INSERT, SEAT SUSPENSION (item number 9) on a flat
working surface. The bottom of part no. 629-1390, M-INSERT, SEAT SUSPENSION (item
number 9) must be face up.
(2) Mark a line on part no. 629-1390, M-INSERT, SEAT SUSPENSION (item number 9)
passing through the center of one of the rear slide rail mounting holes. The line must be
parallel to the sides of the part. Refer to Figure 61.
(3) Mark a parallel line 11 inches from the first line. This line should pass through the center of
the opposite rear slide rail mounting hole.
(4) These lines will be used to align the centers of the upper slide rails.
REAR
Rear slide
rail mounting Mark parallel
holes lines on each
side of the
suspension
insert
Front slide
rail mounting
slots
FRONT
279 mm (11 in.)
MARK LINES ON BOTTOM OF SUSPENSION INSERT

TO ALIGN UPPER SLIDE RAILS.
Figure 61
SEAT SUSPENSION INSERT
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(5) Set the upper slide rails on the lines marked on part no. 629-1390, M-INSERT, SEAT
SUSPENSION (item number 9). The slide lever on the upper right slide rail must be
oriented toward the front of part no. 629-1390, M-INSERT, SEAT SUSPENSION (item
number 9). Refer to Figure 61 and Figure 62.
Upper left Large

slide rail slots on
(Shown bottom
not yet plate
installed)
Ride
adjustment
knob Upper
right
slide rail
Side
lever
SEAT SUSPENSION UPSIDE DOWN
Figure 62
SEAT SUSPENSION INSERT
(6) Align the rear mounting holes on the slide rails with the rear mounting holes on part
no. 629-1390, M-INSERT, SEAT SUSPENSION (item number 9).
(7) Insert a part no. 107-2979, SCREW (item number 5) through each hole aligned. Refer to
Figure 63.
Button
head
Button
screw
head
screw
ALIGN UPPER SLIDE RAILS CENTER WITH LINES ON SEAT SUSPENSION.
Figure 63
SEAT SUSPENSION ALIGNMENT WITH SLIDE RAILS
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(8) Thread a part no. 107-1111, NUT (item number 1) and part no. 107-1339, Washer (item
number 2) on each screw from below.
(9) Align the front mounting holes on the slide rails with the front mounting slots on part
no. 629-1390, M-INSERT, SEAT SUSPENSION (item number 9).
(10) Insert a part no. 107-2979, SCREW (item number 5) through each hole aligned.
(11) Thread a part no. 107-1111, NUT (item number 1) and part no. 107-1339, Washer (item
(12) Tighten the four bolted joints snug. Use a 3/16-inch Allen wrench and a 1/2-inch end-box
combination wrench. Be sure to keep the center of the slide rails aligned to the lines
marked on 629-1390, M-INSERT, SEAT SUSPENSION (item number 9).
(13) Use torque wrench and 1/2-inch end/combination wrench to tighten to 15 N·m (11 lbf-ft. or
132 lbf-in.) maximum. Refer to Figure 64.
NOTE: AFTER THE SLIDE RAILS ARE ATTACHED TO part no. 629-1390, M-INSERT, SEAT
SUSPENSION (item number 9), IT IS IDENTIFIED AS THE SEAT SUSPENSION INSERT
SUBASSEMBLY.
INSTALL FASTENERS AND TORQUE TO SPECIFICATIONS.
Figure 64
SLIDE RAILS FASTENED TO SEAT SUSPENSION
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F. SEAT SUSPENSION INSERT ASSEMBLY
(1) Install adapters on the seat suspension insert subassembly

(2) The kit includes two steel part no. 628-8714, ADAPTER, SEAT INSERT (item number 10)
to secure the seat to the top of the seat suspension insert subassembly. Each part
no. 628-8714, ADAPTER, SEAT INSERT (item number 10) is a black strip with four holes.
Notice the larger holes are offset from the centerline.
(3) Place two part no. 628-8714, ADAPTER, SEAT INSERT (item number 10) across the top
of the seat suspension insert subassembly. The inner holes should be offset outward to
the front and rear on each end. Align the inner holes with matching holes in the seat
suspension insert subassembly. Refer to Figure 65.
FRONT
Inner holes
offset from Adapters
centerline
outward
Insert 3/8-16
screws with
washers
through each
inner hole
(4 places)
REAR
ADAPTER PLATE TO FIT SEAT SUSPENSION INSERT TO SEAT
Figure 65
SEAT SUSPENSION INSERT ADAPTER PLATE
(4) Insert four part no. 110-2213, SCREW (item number 8) with part no. 107-1341, WASHER
(item number 3) through the aligned holes.
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(5) Thread part no. 107-0364, NUT (item number 4) and part no. 107-1341, WASHER (item
(6) Use 9/16-inch end-box combination wrench to tighten these joints. However, leave loose
enough to allow the part no. 628-8714, ADAPTER, SEAT BINSERT (item number 10) to
move. Refer to Figure 66.
NOTE: AFTER PART NO. 628-8714, ADAPTER, SEAT INSERT (ITEM NUMBER 10) ARE
ATTACHED TO THE SEAT SUSPENSION INSERT SUBASSEMBLY, IT IS IDENTIFIED
AS THE SEAT SUSPENSION INSERT ASSEMBLY.
FASTEN SCREWS AND NUTS LOOSELY TO ALLOW

ADAPTER MOVEMENT AS NEEDED.
Figure 66
FASTEN ADAPTER PLATE TO SEAT SUSPENSION
(7) Place seat suspension insert assembly on the bottom of the seat with the adapters
touching the seat. The ride adjustment knob must face toward the front of the seat.
(8) Insert four part no. 107-9017, SCREW (item number 6) and part no. 107-9450, WASHER
(item number 7) through the outer holes of the adapters. Refer to Figure 67.
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INSERT M6 SCREWS AND WASHERS THROUGH APAPTERS.
Figure 67
INSERT FASTENERS INTO ADAPTERS
(9) Allow parts to move around, as needed, to locate the matching holes in the seat through
the fabric.
(10) Thread four part no. 107-9017, SCREW (item number 6) into the seat by hand. Do not
tighten them. Refer to Figure 68.
THREAD M6 SCREWS INTO SEAT TO PIN SUSPENSION INSERT IN POSITION.
Figure 68
FASTEN ADAPTERS TO SEAT
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(11) The adapters are now pinned to the seat by the four part no. 107-9017, SCREW (item
number 6).
(12) Securely tighten all fasteners attaching adapters to the seat suspension insert
subassembly to prevent and motion. Use a 9/16-inch socket wrench and 9/16-inch
end-box combination wrench. Refer to Figure 69.
TIGHTEN ADAPTERS TO SUSPENSION INSERT TO PREVENT MOTION AND

MAKE THE SUSPENSION INSERT AND ADAPTERS INTO A SUBASSEMBLY.
Figure 69
TIGHTEN ADAPTERS TO SUSPENSION INSERT
(13) Remove the four (4) SCREWS, part no. 107-9017 (item 6) and four (4) WASHERS, part
no. 107-9450 (item 7). Refer to Figure 70.
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REMOVE PREVIOUSLY INSTALLED M6 SCREWS FROM SEAT.
Figure 70
REMOVE SUSPENSION INSERT SUBASSEMBLY
(14) Place the seat suspension insert assembly on a flat surface to access the screws on top of
the adapters.
(15) Use a torque wrench with a 9/16-inch socket and a 9/16-inch end-box combination wrench
to tighten the four bolted joints to 27 N·m (20 lbf-ft. or 240 lbf-in.) maximum. Refer to
Figure 71.
TORQUE SCREWS FASTEN ADAPTERS TO SUSPENSION INSERT.
Figure 71
TORQUE FASTENERS ON SUSPENSION SUBASSEMBLY
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G. SEAT ASSEMBLY
(1) Place the seat suspension insert assembly on the bottom of the seat with the adapters
touching the seat. The ride adjustment knob must face toward the front of the seat.
(2) Thread four part no. 107-9017, SCREW (item number 6) and part no. 107-9450, WASHER
(item number 7) through the adapters and the seat fabric into the seat.
(3) Use a torque wrench with a 10 mm socket and tighten the four part no. 107-9017, SCREW
(item number 6) to 11 N·m (8 lbf-ft. or 96 lbf-in.) maximum. Use extension bar and deep
socket, if necessary. Refer to Figure 72.
(4) This is now the new seat assembly and is ready for installation in the cab.
Ride
adjustment
knob
TORQUE SEAT SUSPENSION SUBASSEMBLY TO THE SEAT.
Figure 72
SEAT SUSPENSION ASSEMBLY ATTACHMENT
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H. INSTALL THE NEW SEAT ASSEMBLY IN THE CAB
Install the new seat assembly in the cab using the appropriate of the following sections.
If lower slide rails are already attached to the cab floor:
(1) Slide the seat assembly onto the lower slide rails. Be sure the bent tab clears the stop.
Refer to Figure 73.
(2) Use a screwdriver to reach and bend the rear tab down again to prevent the seat from
sliding off the tracks.
CONSTRAIN SEAT TO TRACK BY BENDING REAR TAB DOWN.
Figure 73
SEAT INSTALLATION - RAILS ATTACHED TO CAB FLOOR
If lower slide rails are not attached to the cab floor:

(3) Slide the lower slide rails on the upper slide rails on the seat assembly.
(4) Ensure the rear tab on the upper right slide rail is bent down to prevent the seat from sliding
forward off the tracks.
(5) Place the seat assembly with the lower slide rails on the cab floor.
(6) Insert the fasteners that were removed in subsection ‘C. DISASSEMBLE THE SEAT
FROM THE CAB FLOOR WITH TRACKS ATTACHED’, through the cab floor.
(7) Tighten all fasteners using 13-mm sockets and 13-mm end-box combination wrench. Slide
the seat on the tracks to gain clearance for the wrench as needed.
(8) Use a torque wrench with a 13-mm sockets to tighten fasteners to 37 N·m (27 lbf-ft. or 324
lbf-in.) maximum. Refer to Figure 74.
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Re-use
mounting
hardware
that was
previously
removed
SEAT FRONT VIEW
Figure 74
SEAT INSTALLATION - RAILS NOT ATTACHED TO CAB FLOOR
TORQUE SEAT MOUNTING FASTENERS THROUGH THE CAB FLOOR.
Figure 75
TORQUE SEAT MOUNTING FASTENERS
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I. OPERATIONAL CHECKOUT REQUIREMENTS
Verify seat travel

(1) Sit on the seat inside the cab.
(2) Operate the side lever and push and pull the seat forward and backward between the
stops.
(3) Rotate the ride adjustment knob in the seat suspension as needed. This will minimize
bottoming and topping out during driving operation.
(4) Ensure all parts are properly secured to prevent them fro loosening.
J. SEAT SUSPENSION KIT OPERATION
The ride of the seat can be adjusted to accommodate an operator’s weight and preferences by
turning the adjustment knob on the front of the seat assembly. Turning the knob clockwise (while
viewing it from the front) will create a “stiffer” ride with less movement, while turning the knob
counter clockwise will create a “looser” ride with more movement. An optimal adjustment should
prevent topping out or bottoming out of the seat suspension during operations.
15. MAIN PANEL CONVERTER KIT INSTALLATION
A. GENERAL
(1) Purpose
This document provides instructions for safely replacing the voltage converter in the Main
Panel for the Halvorsen, 25 000 lb. Loader for Aircraft.
(2) Manpower Requirements
Estimated time to accomplish: 1 hour

Suggested personnel needed: One (1) 5-skilled level
Vehicle and Vehicular Equipment Maintenance
Journeyman
One (1) 1-skilled level
Vehicle and Vehicular Equipment Maintenance Helper
(3) References
Halvorsen Technical Manual - OPERATOR INSTRUCTIONS, Change 10, 31 March 2013.
Halvorsen Technical Manual - OPERATION AND MAINTENANCE INSTRUCTIONS,
Change 10, 31 March 2013.
Halvorsen Technical Manual - ILLUSTRATED PARTS LIST, Change 10, 31 March 2013.
(4) Safety Precautions
Adhere to all local standard shop safety practices when working to these instructions.
Warnings and cautions will precede the text to which they apply. The following warnings
and cautions are used in this document. Read all of them and follow the instructions when
performing the procedures. The symbols shown below are used to call your attention to
some procedures that may cause death or injury to personnel and damage to equipment.
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CAUTION
TO PREVENT DAMAGE TO ENCLOSURE WHEN DRILLING HOLES DO NOT PUSH ON DRILL

WITH EXCESSIVE FORCE.
NOTE: TWO PERSONS WORKING TOGETHER ARE REQUIRED FOR THE REMOVAL OF THE
MAIN PANEL.
(5) Parts List

Inspect and inventory the kit per Table 5, before performing the installation.
Report any missing kit items promptly to a Halvorsen Technical Support Representative.
Refer to the OEM Point of Contact (POC) information section in this document.
TABLE 5 - CONVERTER KIT PARTS LIST
- 629-0560 K - Main Panel 24V/12V Converter REF

1-1 107-2091 . Washer, Flat #10 SS 4
1-2 107-2324 . Nut, PTH A2 #10-32 SS 4
1-3 107-2873 . Screw, PPAN A2 #10-32X1 SS 4
1-4 624-8698-030 . Converter, 24V/12V 30A 1
1-5 DWG-628-8577 . Kit Installation Procedure REF
(6) Tool List

Common hand tools and general supplies listed in Table 6 are necessary for
accomplishing this installation. Ensure that these tools and supplies are available before
starting any work.
TABLE 6 - TOOLS LIST FOR INSTALLATION
TOOLS AND SUPPLIES QUANTITY
General purpose drill bit, 7/32-inch 1

Drill stop, 7/32-inch drill size 1
Power drill 1
Pen, pencil or marking device 1
Combination adjustable square ruler 1
Tape measure 1
Center punch 1
Adjustable pliers 1
Ratcheting socket wrench (with extension) 1
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TABLE 6 - TOOLS LIST FOR INSTALLATION (CONT.)
Sockets, various sizes As required

Combination wrenches, various sizes As required
Flat blade screwdrivers, various sizes As required
Phillips screwdrivers, various sizes As required
Wood block, approximately 2 in. x 4 in. x 6 in. to protect components when
As required
drilling
B. LOADER PREPARATION
(1) Raise the deck to gain access to the main panel electrical boxes.
(2) Install both maintenance stands in the FIRST maintenance position on the chassis. Lower
the deck until the scissor rollers are against the blocks.
(3) Turn the battery disconnect switch, located on the battery box, to the OFF position.
C. CONVERTER INSPECTION
(1) Locate the main panel enclosure on the Halvorsen, 25 000 lb. Loader for Aircraft, as shown
in Figure 76.
MAIN PANEL
Figure 76
MAIN PANEL LOCATION
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(2) Disconnect the positive cable from the lower left corner of the Main Panel. Disconnect the
negative cable from inside the bottom of the Main Panel. Refer to Figure 77.
(3) Remove the cables by pulling them gently out of the panel.
Disconnect Disconnect
Positive Cable Negative Cable
Figure 77
POSITIVE AND NEGATIVE CABLES INSIDE MAIN PANEL
(4) Remove both the 4-pin and 6-pin receptacles from the converter as shown in Figure 78 and
Figure 79.
(5) Determine which model of the converter is in the main panel enclosure.
(a) If the converter installed resembles Figure 78 (part no. 624-8698-030,

CONVERTER, 24V/12V 30A), remove all hardware and the converter from the main
panel. Proceed to ‘G. CONVERTER INSTALLATION’, Figure 88 to replace the
converter.
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CONVERTER #1-2 INSIDE OF
P/N: 624-8698-030 MAIN PANEL
#1-4
4-PIN
(1 DCDC)
RECEPTACLE #1-1
6-PIN
(2 DCDC)
RECEPTACLE #1-3
#1-3
Figure 78
CONVERTER PART NO. 624-8698-030
(b) If the converter installed resembles Figure 79 (part no. 624-7172, Converter, 24/
13.5V), remove all hardware and the converter from the Main Panel. Proceed to
complete all steps in this instruction.
Converter
P/N: 624-7172
Main Panel
4-pin and 6-pin
Receptacles
Figure 79
CONVERTER PART NO. 624-7172
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D. MAIN PANEL REMOVAL
It is preferred to modify the Main Panel Assembly without having to dismount it from its location
on the chassis. However, in order to accomplish this safely, the proper equipment must be
available at the local shop.
To modify the Main Panel without removing it from the loader:
• Raise the right front side of the loader off the ground following procedures for removing the
front axle wheel. Refer to Chapter 2, Section 5, “Maintenance Procedures”.
• Raise the loader enough to allow marking and drilling the converter mounting holes on the
bottom of the Main Panel Assembly.
• Skip ahead to ‘E. DRILL NEW HOLES IN THE MAIN PANEL’, Figure 85 to mark and drill
the converter mounting holes in the Main Panel.
NOTE: IF THE APPROPRIATE EQUIPMENT IS NOT AVAILABLE TO SAFELY PERFORM THE

PREVIOUS PROCEDURES AT THE LOCAL SHOP, FOLLOW THE INSTRUCTIONS IN
THIS SECTION FOR REMOVING AND MODIFYING THE MAIN PANEL.
(1) Remove the negative electrical cable from the rear single-hole connector and the positive
electrical cable through the front single-hole connector on the left side of the Main Panel.
Figure 80
REMOVE BATTERY CABLES FROM MAIN PANEL
(2) Remove the part no. 623-6744 PLATE, COVER located on the chassis behind the main
panel. Use a ratchet wrench to loosen the nuts and save the hardware for re-installation.
Refer to Figure 81.
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Figure 81
COVER PLATE REMOVAL
(3) Loosen and remove the two lower fastener sets from the panel mounting ears using a
ratchet wrench and a box wrench and save the hardware for re-installation. The view
shown in Figure 82 is of the lower right mounting ear seen from the top of the panel.
Figure 82
LOWER MOUNTING FASTENERS REMOVAL
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(4) Loosen the upper two fastener sets in preparation for removing the main panel from the
chassis. Refer to Figure 83.
Figure 83
UPPER MOUNTING FASTENERS REMOVAL
(5) Place a piece of cardboard or protective mat on the ground in front of the main panel.
NOTE: TWO PERSONS WORKING TOGETHER ARE REQUIRED FOR THE REMOVAL OF THE
MAIN PANEL.
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(6) Remove the upper two fastener sets while supporting the Main Panel and save the
hardware for re-installation. Swing the Main Panel away from the loader and carefully set it
flat on the mat. Be careful not to put tension on the connected harnesses on the right side
of the enclosure. Cut cable ties as necessary to remove any tension. Place a wood block
under the Main Panel, if necessary, to provide better access to the bottom of the
enclosure. Refer to Figure 84.
Do not disconnect
these cables from
right side of
Main Panel
Mounting
Bracket Bottom of
Main Panel
Wooden Block
Cardboard
Figure 84
MAIN PANEL REMOVAL
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E. DRILL NEW HOLES IN THE MAIN PANEL
(1) Mark the center of each drill hole on the bottom of the Main Panel part no. 624-2903
ME-ENCL (30 x 24 x 10) according to Figure 85.
(2) Punch the four marked centers using a center punch.
Drill Holes
Figure 85
NEW HOLE PATTERN ON BOTTOM OF MAIN PANEL
(3) Place a drill stop on a 7/32-inch diameter drill bit. Allow end of drill bit to protrude
approximately 1/4-inch from the drill stop.
(4) Open the enclosure and make sure all wiring and other components are cleared from the
area to be drilled.
(5) Drill a 7/32-inch diameter hole at each of the four locations noted in Figure 85 from the
outside of the bottom of the main panel.
(6) Use a deburring tool to remove burrs around the drilled holes inside and outside the box.
Clean any debris that may have accumulated inside the box.
(7) Test fit the new electrical converter in the bottom of the main panel. Check that the new
holes align with the mounting holes in the new converter.
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F. REINSTALL THE MAIN PANEL
(1) Reinstall the Main Panel to its chassis-mounting bracket using previously removed
hardware.
Figure 86
MAIN PANEL RE-INSTALLATION ON LOADER
(2) Reinstall the chassis electrical harness cover plate using previously removed hardware.
Figure 87
CHASSIS HARNESS PLATE RE-INSTALLATION
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G. CONVERTER INSTALLATION
Refer to the steps below to install the new converter (part no. 624-8698-030) in the main panel.
Installation
(1) Place the converter (#1-4) into the bottom of the main panel.
(2) From outside the bottom of the panel insert four screws (#1-3) upward through the newly
drilled holes and the converter.
(3) Tighten one nut (#1-2) and one washer (#1-1) at each screw location as shown below in
Figure 88.
(4) Re-connect both the 4-pin and 6-pin receptacles to the new converter.
#1-2
#1-4
4-PIN
(1 DCDC)
RECEPTACLE #1-1
6-PIN
(2 DCDC)
RECEPTACLE #1-3
#1-3
Figure 88
CONVERTER INSTALLATION
H. MAIN PANEL CABLE CONNECTION
(1) Reinstall the negative electrical cable through the rear single-hole connector and reconnect
the terminal ring to the left contact post on the bottom of the main panel. Refer to
Figure 89.
(2) Tighten the cable-retaining clamp on the outside of the Main Panel using adjustable pliers.
(3) Reinstall the positive electrical cable through the front single-hole connector on the left side
of the main panel. Re-attach the ring terminal to the electrical positive contact post inside
the left side of the main panel. Refer to Figure 90.
(4) Tighten the cable-retaining clamp on the outside of the main panel. Refer to Figure 90.
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Figure 89
CABLE-RETAINING CLAMP TIGHTENING
Figure 90
CABLE-RETAINING CLAMP HAND TIGHTENING
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I. CLOSE DOOR ON MAIN PANEL
(1) Tighten all door clamps.

(2) Use a screwdriver of appropriate size to tighten all door clamps on the electrical box. Refer
to Figure 91.
Figure 91
ELECTRICAL BOX DOOR CLAMPS TIGHTENING
J. OPERATIONAL CHECKOUT REQUIREMENTS
Perform loader functional tests and exercise the loader per the following functional tests:
(1) Turn the battery disconnect switch to the ON position.
(2) Ensure transmission shift selector is in NEUTRAL.
(4) Perform all checks for cab and deck operation. Refer to the “EQUIPMENT
PRE-OPERATIONAL CHECKLIST” in Chapter 2, Section 3.
(6) Turn the battery disconnect switch to the OFF position.
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16. RIGHT FRONT HANDRAIL BRACE KIT
A. GENERAL
(1) Purpose
This document provides instructions for safely installing a brace kit on the right front
handrail of the loader.
SUMMARY: Cracks in the lower channel of part no. 623-6070 Right Front Handrail,
requires installation of a brace kit to reduce the stress.
(2) Manpower Requirements
Estimated time to accomplish: 1 hour

Suggested personnel needed: One (1) 5-skilled level
Vehicle and Vehicular Equipment Maintenance
Journeyman
One (1) 3-skilled level
Vehicle and Vehicular Equipment Maintenance Helper
(3) OEM Point of Contact (POC)

JBT Corp.
Ground Support Equipment
Orlando, FL 32809
Halvorsen Technical Support Representative
Telephone CONUS: 1-866-444-6475
Telephone OCONUS: 1-407-888-8284
Email: NGSL.Halvorsen@jbtc.com
Website: www.myjbtaerotech.com
(4) References
Halvorsen Technical Manual - OPERATOR INSTRUCTIONS, Change 11, 31 March 2014.
Halvorsen Technical Manual - OPERATION AND MAINTENANCE INSTRUCTIONS,
Change 11, 31 March 2014.
Halvorsen Technical Manual - ILLUSTRATED PARTS LIST, Change 11, 31 March 2014.
(5) Definitions and Conventions Used in these Instructions
The following Halvorsen loader orientation conventions are used throughout this
document:
Left side from the point of view of the operator sitting in the cab (i.e., cab side).
Right side from the point of view of the operator sitting in the cab (i.e., no-cab side).
(6) Safety Precautions
Adhere to all local standard shop safety practices when working to these instructions.
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(7) Parts List
Inspect and inventory the kit per Table 7, before performing the installation.
Report any missing kit items promptly to a Halvorsen Technical Support Representative.
Refer to the OEM Point of Contact (POC) information section in this document.
TABLE 7 - HALVORSEN BRACE KIT PARTS LIST
- 629-0480 K - BRACE REF

1 107-0364 NUT, PTH A2 0.38-16 SS 8
2 107-1932 WASHER, FLAT NAR A2 0.38 SS 8
3 107-2360 SCREW, HHC GR8 0.38-16 X1.5 MG 2
4 110-0194 NUT, PTH GR5 TH 0.38-16 ZP 1
5 238-0704 WASHER, BEARING 1
6 628-7874 U-BOLT, 0.38-16 X1.5 X2P CLAMPING SS 2
7 628-9702 U-BOLT, 0.38-16 X1.5 X2P SQUARE BEND SS 2
8 629-0478 BRACKET, UPPER 1
9 629-0479 BRACKET, LOWER 1
10 629-0804 CLAMP, SADDLE SS 2
11 DWG-628-9907 BRACE KIT INSTALLATION PROCEDURE REF
(8) Tool List

Common hand tools and general supplies listed in Table 8 are necessary for
accomplishing this installation. Ensure that these tools and supplies are available before
starting any work.
TABLE 8 - TOOLS LIST FOR INSTALLATION
Open end-box combination wrench, 9/16 inches 1
Socket wrench 1
Socket, 9/16 inches 1
Torque wrench calibrated in N·m (or lbf-ft. or lbf-in.) 1
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B. LOADER PREPARATION
(1) Park the loader to be modified on a flat level surface.

(2) Position the loader in a well illuminated work area.
(3) Allow clear access for working on the right side of the loader.
(4) Lower the deck until it is completely resting on the chassis (if not already lowered).
(5) Apply the parking brake and shut down the engine.
(6) Place chocks approximately 50 mm (2 in.) from the front and rear of any tire.
(7) Turn the battery disconnect switch, located on the battery box, to the OFF position.
(8) Place the part no. 623-6100 handrail and walk-deck assembly in the fully retracted
position. Refer to Figure 92.
W-Handrail, RF
P/N 623-6070
Brace kit will

be installed
here
W-Handrail, Pivoting
P/N 623-6918
W-Handrail,
Telescoping
P/N 623-6095
Handrail and W alkdeck Assembly

RETRACTED P/N 623-6100
HANDRAIL AND WALK-DECK FULLY RETRACTED
Figure 92
HANDRAIL AND WALK-DECK ASSEMBLY
(9) Secure the part no. 623-6918 pivoting handrail weldment into its folded position.
(10) Rotate the fully retracted part no. 623-6100 handrail and walk-deck assembly 90 degrees.
The handrail should be suspended horizontally above the deck. Refer to Figure 93.
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Handrail
horizontal
Rotated above deck
walkdeck
Install
quick Pivoting
release handrail
pins securely
folded
Rotated
guide
rails
HANDRAIL AND WALK-DECK TILTED 90º INWARDS
Figure 93
HANDRAIL AND WALK-DECK ASSEMBLY (CONT.)
WARNING
FULLY LOCK TELESCOPING WALK-DECK IN PLACE TO AVOID SERIOUS INJURY OR DEATH.
(11) Install quick release pins to secure the part no. 623-6100 right front handrail and walk-deck
assembly in this rotated position.
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C. INSTALLATION INSTRUCTIONS
The part no. 629-0480, K-BRACE must be installed by fastening it to part no. 623-6070,
W-HANDRAIL, RF. The location of the brace kit as it will be installed on the handrail is shown in
Figure 96.
NOTE: IT IS NOT NECESSARY TO REMOVE THE HANDRAIL FROM THE WALK-DECK IN

ORDER TO INSTALL THE BRACE KIT. THE TELESCOPING SLIDING HANDRAIL,
WALK-DECK AND OTHER HANDRAIL PARTS ARE NOT SHOWN IN FIGURE 94 FOR
CLARITY.
W-Handrail, RF
P/N 623-6070
Vertical
square rail
Brace kit
P/N 629-0480
Lower
channel
Upright
round rail
Figure 94
BRACE KIT INSTALLED ON RIGHT FRONT HANDRAIL
D. ASSEMBLE BRACE
(1) Connect the upper and lower brackets.
(2) Position the brackets side by side on a flat working surface.
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(3) Align slots in part no. 629-0479, LOWER BRACKET (item number 9) with corresponding
holes in part no. 629-0478, UPPER BRACKET (item number 8).
(4) Insert part no. 107-2360, SCREW (item number 3) and part no. 238-0704, WASHER (item
number 5) through each slot in the lower bracket. The screw heads must be on the side of
the lower bracket. Refer to Figure 95.
Upper
bracket
Lower
bracket
INSTALL SCREWS AND WASHERS THROUGH SLOTS AND HOLES ON BRACKETS.
Figure 95
PAIRING BRACKETS
(5) Thread a part no. 110-0194, NUT (item number 4) and part no. 238-0704, WASHER (item
number 5) on each screw from the side of the upper bracket. Use a 9/16-inch socket and
end-box combination wrench to thread nuts most of the way. Do not tighten them. Allow
the connected brackets to move. Refer to Figure 96.
CONNECT BOTH BRACKET LOOSELY ALLOWING MOTION.
Figure 96
LOOSELY CONNECTING BRACKETS
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E. FIT THE BRACE ASSEMBLY
(1) Loosely attach brace assembly to the handrail.

(2) Hold the connected brackets in position on the handrail. Place the part no. 629-0478,
UPPER BRACKET (item number 8) on the vertical square rail and rest the part
no. 629-0479, LOWER BRACKET (item number 9) on the upright round rail. Refer to
Figure 97.
Upper
Lower
bracket
bracket
Handrail
HOLD CONNECTED BRACKETS IN POSITION ON HANDRAIL.
Figure 97
ATTACHING BRACKETS TO HANDRAIL
(3) Insert two part no. 628-9702, SQUARE U-BOLT, (item number 7) from below to hold the
upper bracket to the vertical square rail. Refer to Figure 98.
number 2) on the ends of each part no. 628-9702, SQUARE U-BOLT, (item number 7).
Refer to Figure 98.
(5) Use a socket wrench with a 9/16-inch socket to tighten the nuts evenly. However, leave
them loose enough to allow the part no. 629-0478, UPPER BRACKET (item number 8) to
slide on the vertical square rail.
CAUTION
SECURE BRACE IN REQUIRED POSITION BEFORE TIGHTENING HARDWARE. DO NOT

TORQUE UNTIL INSTRUCTED AT THE END OF THE INSTALLATION.
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FIT THE UPPER BRACKET LOOSELY TO VERTICAL SQUARE RAIL.
Figure 98
FITTING UPPER BRACKET TO VERTICAL RAIL
(6) Place two part no. 629-0804, SADDLE CLAMP (item number 10) between the part
no. 629-0479, LOWER BRACKET (item number 9) and the upright round rail. Align holes
in bracket with holes in part no. 629-0804, SADDLE CLAMP (item number 10). Refer to
Figure 101.
(7) Insert two part no. 628-7874, CLAMPING U-BOLT (item number 6) from below through
each part no. 629-0804, SADDLE CLAMP (item number 10) and part no. 629-0479,
LOWER BRACKET (item number 9) around the upright round rail. Refer to Figure 99.
Gap
between Saddle
Brackets Clamps
Upright
Round Rail
Square
U-bolts
Clamping
U-bolts
ATTACH CLAMPING U-BOLTS ON LOWER BRACKET.
Figure 99
ATTACHING CLAMPING U-BOLTS
number 2) on the ends of each part no. 628-7874, CLAMPING U-BOLT (item number 6).
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(9) Use a socket wrench with a 9/16-inch socket to tighten the nuts evenly. However, leave
them loose enough to allow the part no. 629-0479, LOWER BRACKET (item number 9) to
slide on the upright round rail. Refer to Figure 99.
NOTE: TO TIGHTEN NUTS EVENLY ON ALL U-BOLTS, MAKE SURE A SIMILAR NUMBER OF
THREADS PROTRUDE PAST THE NUTS ON EACH THREADED END AT ALL TIMES.
(10) Adjust the position of the brackets to maintain a uniform gap between brackets around the
handrail channel. Be sure the channel is not in contact with any part of the brace assembly
to prevent rubbing. Refer to Figure 99.
(11) Securely tighten all fasteners to prevent any motion of the brace assembly. Tighten
fasteners on the upper bracket first, then tighten the lower bracket and last tighten the
connection between brackets. Do not over tighten.
F. TIGHTENING THE BRACE ASSEMBLY IN POSITION
(1) With all fasteners firmly in place apply the final torque using a torque wrench with a
9/16-inch socket. Refer to Figure 100.
(2) Torque all nuts evenly per the sequence in the corresponding table in Chapter 2, Section 4,
“Maintenance Specifications”. Refer to Figure 101.
TORQUE CONNECTING NUTS EVENLY.
Figure 100
TIGHTENING TO TORQUE SPECIFICATIONS
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TORQUE ALL OTHER NUTS EVENLY.
Figure 101
TIGHTENING ALL OTHER FASTENERS
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Volume II

Original Instructions
Version 1
Edition 3
This volume supersedes all editions and revisions prior to:
December 2015
English Language
For use with equipment serial numbers
AN14511 and subsequent
This volume includes the following options:

DIESEL TIER 3 ENGINE
ALLISON 2100 TRANSMISSION
Refer to Volume I for

Operation and Maintenance

John Bean Technologies Corporation
+1-407-851-3377 Telephone
+1-407-850-4221 Fax
CONFIDENTIAL
This technical manual contains unpublished work of John Bean Technologies Corporation. All information
herein is confidential and proprietary and cannot be duplicated, used or disclosed in whole or in part, except
with written permission from John Bean Technologies Corporation, Orlando, Florida USA.
© 2011–2015 John Bean Technologies Corporation, all rights reserved.
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RECORD OF REVISIONS
All pages in this issue are original.
The following pages have had changes incorporated:
Edition /
Change Date List of Effective Pages Change Description
Revision
Aug. 2011 Edition 1 Volume II New edition.
June 2012 Edition 2 Volume II Updated: chapters 4 and 5.
Edition 2
Mar. 2013 Volume II Updated: chapters 4 and 5.
Revision 1
Edition 2
June 2014 Volume II Updated: chapters 4 and 5.
Revision 1.1
Dec. 2015 Edition 3 Volume II Updated: chapters 4 and 5.
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Section 1. Introduction
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. HOW TO ORDER PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. PARTS RETURNED FOR CREDIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. STANDARD WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. ITEMS JBT DOES NOT WARRANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. NORMAL WEAR ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. SHOP SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. ROUTINE ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 2. Manufacturer CAGE Codes
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. METHOD OF LISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 3. Numerical Parts List
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. EXPLANATION OF COLUMNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. NUMERICAL ARRANGEMENT SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. SAMPLE APPLICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 4. Explanation of Parts List Columns
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. PARTS LIST COLUMNS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. ITEM NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. PART NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. PART DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. QUANTITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Section 5. Engine and Transmission Assembly
ACTUATOR, STONE BENNET SHIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . 623-7300-006 . . . . . . . . . 2

ENGINE INSTALLATION, MLK25K3P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9627 . . . . . . . . . . . . . 3
POWER MODULE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9583 . . . . . . . . . . . . 14
ENGINE AND TRANSMISSION WITH WINTERIZATION . . . . . . . . . . . . . . 627-9582 . . . . . . . . . . . . 21
DIPSTICK ASSEMBLY, 2100 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . 624-8309 . . . . . . . . . . . . 24
SURGE OVERFLOW TANK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . 627-4426 . . . . . . . . . . . . 25
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9581 . . . . . . . . . . . . 27
Section 6. Chassis Assembly
CHASSIS ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9676 . . . . . . . . . . . . . 2

BATTERY TRAY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-6451 . . . . . . . . . . . . . 6
FUEL SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-3926 . . . . . . . . . . . . . 9
FUEL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-6157 . . . . . . . . . . . . 14
SHROUD AND SUPPORT ASSEMBLY, RADIATOR . . . . . . . . . . . . . . . . . 627-5618 . . . . . . . . . . . . 16
MAINTENANCE SUPPORT BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . 623-8468 . . . . . . . . . . . . 19
PLACARD INSTALLATION, CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-7183 . . . . . . . . . . . . 20
Section 7. Drive Train Assembly
FRONT AXLE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-8791 . . . . . . . . . . . . . 2

FRONT AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-8792 . . . . . . . . . . . . . 4
DRIVE AND STEER AXLE - KESSLER LT41-PL58. . . . . . . . . . . . . . . . . . . 627-8476 . . . . . . . . . . . . . 7
DRIVE SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9920 . . . . . . . . . . . . 10
Section 8. Rear Axle Assembly
REAR AXLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1225 . . . . . . . . . . . . . 2

REAR AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1226 . . . . . . . . . . . . . 4
HELPER CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628-1509 . . . . . . . . . . . . . 7
WALKBEAM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-5133 . . . . . . . . . . . . . 9
WALKBEAM MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1224 . . . . . . . . . . . . 10
HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1240 . . . . . . . . . . . . 12
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Section 9. Tires and Wheels
TIRE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1450. . . . . . . . . . . . . . 2

TIRE AND RIM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1451. . . . . . . . . . . . . . 3
TUBELESS BEAD SEAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-8708. . . . . . . . . . . . . . 4
Section 10. Scissors Assembly
SCISSORS ASSEMBLY, INNER AND OUTER. . . . . . . . . . . . . . . . . . . . . . 627-9635. . . . . . . . . . . . . . 2

SCISSORS SUB-ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-0300. . . . . . . . . . . . . . 5
SIDE SHIFT ASSEMBLY, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-4640. . . . . . . . . . . . . 11
ROLL CYLINDER ASSEMBLY, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-6612. . . . . . . . . . . . . 13
PIVOT ARM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-7421. . . . . . . . . . . . . 15
SIDE SHIFT ASSEMBLY, REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-6220. . . . . . . . . . . . . 16
ROLL CYLINDER ASSEMBLY, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-6613. . . . . . . . . . . . . 18
LINK / PIVOT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-7273. . . . . . . . . . . . . 20
LINK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-7272. . . . . . . . . . . . . 23
Section 11. Deck Assembly
DECK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9636. . . . . . . . . . . . . . 2

FOLDING WINGS / CAB AND ENGINE HATCH. . . . . . . . . . . . . . . . . . . . . 623-6920. . . . . . . . . . . . . . 6
FOLDING WING ASSEMBLY, LEFT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . 624-6644. . . . . . . . . . . . . 11
FOLDING WING ASSEMBLY, RIGHT SIDE . . . . . . . . . . . . . . . . . . . . . . . . 623-6956. . . . . . . . . . . . . 13
SCISSOR TRACKS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-7214. . . . . . . . . . . . . 14
SCISSOR TRACKS INSTALLATION, REAR. . . . . . . . . . . . . . . . . . . . . . . . 623-7215. . . . . . . . . . . . . 17
TRACTION ROLLER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-4020. . . . . . . . . . . . . 19
TRACTION ROLLER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628-4088. . . . . . . . . . . . . 21
BUMPERS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1400. . . . . . . . . . . . . 24
CASTER AND ROLLER TRAY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 623-6900. . . . . . . . . . . . . 28
CASTER TRAY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-3077. . . . . . . . . . . . . 30
ROLLER TRAY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-3078. . . . . . . . . . . . . 32
IMPACT ROLLERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-6895. . . . . . . . . . . . . 35
IMPACT ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-7250. . . . . . . . . . . . . 37
PALLET STOP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-6911. . . . . . . . . . . . . 38
PALLET STOP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-1211. . . . . . . . . . . . . 44
TINE WAY COVERS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-6820. . . . . . . . . . . . . 46
TINE WAY COVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-3075. . . . . . . . . . . . . 47
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TIE DOWN / LIFT PROVISION INSTALLATION, DECK . . . . . . . . . . . . . . . 624-3115 . . . . . . . . . . . . 48
MUD FLAP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-9632 . . . . . . . . . . . . 52
PLACARD INSTALLATION, DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-7168 . . . . . . . . . . . . 54
CARGO TIE DOWN KIT, DECK PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . 628-1270 . . . . . . . . . . . . 56
Section 12. Walk-deck and Handrail Assembly
HANDRAIL, WALKDECK AND GUIDE INSTALLATION . . . . . . . . . . . . . . . 623-6700 . . . . . . . . . . . . . 2

HANDRAIL AND WALKDECK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 623-4705 . . . . . . . . . . . . 10
HANDRAIL AND WALKDECK ASSEMBLY, TOOL BOX . . . . . . . . . . . . . . . 623-6850 . . . . . . . . . . . . 12
HANDRAIL AND WALKDECK ASSEMBLY, LEFT REAR . . . . . . . . . . . . . . 623-6860 . . . . . . . . . . . . 14
HANDRAIL AND WALKDECK ASSEMBLY, TOOL BOX . . . . . . . . . . . . . . . 623-6880 . . . . . . . . . . . . 16
HANDRAIL AND WALKDECK ASSEMBLY, RIGHT REAR . . . . . . . . . . . . . 623-6890 . . . . . . . . . . . . 18
HANDRAIL AND WALKDECK ASSEMBLY, RIGHT FRONT . . . . . . . . . . . . 623-6100 . . . . . . . . . . . . 20
HANDRAIL AND WALKDECK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 623-8710 . . . . . . . . . . . . 25
GUIDE AND PALLET LOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 623-7330 . . . . . . . . . . . . 27
PALLET LOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-4251 . . . . . . . . . . . . 29
Section 13. Ladder Assembly
LADDER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-3125 . . . . . . . . . . . . . 2

LADDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-3126 . . . . . . . . . . . . . 5
LADDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-4190 . . . . . . . . . . . . . 8
SUPPORT ASSEMBLY, LOWER LADDER . . . . . . . . . . . . . . . . . . . . . . . . . 624-3127 . . . . . . . . . . . . 11
Section 14. Cab Assembly
CAB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9637 . . . . . . . . . . . . . 2

SUPPORT BEAM ASSEMBLY, CAB FRONT . . . . . . . . . . . . . . . . . . . . . . . 624-4038 . . . . . . . . . . . . 10
SUPPORT BEAM ASSEMBLY, CAB REAR. . . . . . . . . . . . . . . . . . . . . . . . . 624-4039 . . . . . . . . . . . . 11
CAB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9639 . . . . . . . . . . . . 12
CAB SHELL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-4753 . . . . . . . . . . . . 19
SIDE DOOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-2994 . . . . . . . . . . . . 25
REAR DOOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-2995 . . . . . . . . . . . . 28
HEATER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-1146 . . . . . . . . . . . . 30
HEATER ASSEMBLY, D4 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-5930 . . . . . . . . . . . . 32
HANDRAIL ASSEMBLY, CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-4041 . . . . . . . . . . . . 34
MIRROR ASSEMBLY, CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-6080 . . . . . . . . . . . . 36
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WIPER INSTALLATION, CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-3956. . . . . . . . . . . . . 38
ELECTRICAL PANEL ASSEMBLY, CONVEY . . . . . . . . . . . . . . . . . . . . . . 624-2915. . . . . . . . . . . . . 42
CAB INSULATION, THERMAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-3093. . . . . . . . . . . . . 46
CAB INSULATION INSTALLATION, ACOUSTIC . . . . . . . . . . . . . . . . . . . . 625-3967. . . . . . . . . . . . . 48
PANEL ASSEMBLY, FLOOR MAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-3964. . . . . . . . . . . . . 50
Section 15. Hydraulic System
CHASSIS HYDRAULIC INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9669. . . . . . . . . . . . . . 2

HOSE ASSEMBLY KIT, CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9669-001 . . . . . . . . . 22
TUBE ASSEMBLY KIT, CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9669-002 . . . . . . . . . 35
EMERGENCY PUMP HYDRAULIC ASSEMBLY . . . . . . . . . . . . . . . . . . . . 624-0330. . . . . . . . . . . . . 47
MANIFOLD ASSEMBLY, CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5410. . . . . . . . . . . . . 49
MANIFOLD SUB-ASSEMBLY, CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 623-6681. . . . . . . . . . . . . 51
MANIFOLD, FAN DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-8653. . . . . . . . . . . . . 54
HYDRAULIC RESERVOIR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5930. . . . . . . . . . . . . 55
SCISSOR HYDRAULIC INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 625-9350. . . . . . . . . . . . . 58
HOSE ASSEMBLY KIT, SCISSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5945-003 . . . . . . . . . 75
TUBE ASSEMBLY KIT, SCISSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-9350-002 . . . . . . . . . 86
MANIFOLD ASSEMBLY, REAR PITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5411. . . . . . . . . . . . . 97
MANIFOLD ASSEMBLY, INNER AND OUTER SCISSORS . . . . . . . . . . . . 623-5413. . . . . . . . . . . . . 99
DECK HYDRAULIC INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628-0452. . . . . . . . . . . . 101
HOSE ASSEMBLY KIT, DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5952-003 . . . . . . . . 111
TUBE ASSEMBLY KIT, DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-6080-002 . . . . . . . . 117
MANIFOLD ASSEMBLY, STOPS AND LIFT. . . . . . . . . . . . . . . . . . . . . . . . 623-5415. . . . . . . . . . . . 124
MANIFOLD ASSEMBLY, FIVE STATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 623-5416. . . . . . . . . . . . 126
CAB HYDRAULIC INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5949. . . . . . . . . . . . 128
HOSE ASSEMBLY KIT, CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5949-003 . . . . . . . . 132
HYDRAULIC INSTALLATION, FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . 623-7170. . . . . . . . . . . . 137
HYDRAULIC INSTALLATION, FINAL ASSEMBLY HOSE KIT . . . . . . . . . . 623-7170-003 . . . . . . . . 141
VALVE BLOCK ASSEMBLY A/C MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 625-4073. . . . . . . . . . . . 146
Section 16. Electrical System
CHASSIS ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 627-9621-001 . . . . . . . . . . 2

WINTERIZATION ELECTRICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . 624-3490. . . . . . . . . . . . . 23
ELECTRICAL INSTALLATION, POWER MODULE . . . . . . . . . . . . . . . . . . 628-5469. . . . . . . . . . . . . 34
ELECTRICAL ASSEMBLY, MAIN PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . 628-0554-001 . . . . . . . . . 44
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SCISSOR ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 628-0414 . . . . . . . . . . . . 58
DECK ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624-3249 . . . . . . . . . . . . 67
DECK PANEL ELECTRICAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 624-2911 . . . . . . . . . . . . 78
TAIL LIGHT ASSEMBLY, 24V LEFT TURN . . . . . . . . . . . . . . . . . . . . . . . . . 624-5754 . . . . . . . . . . . . 88
TAIL LIGHT ASSEMBLY, 24V RIGHT TURN. . . . . . . . . . . . . . . . . . . . . . . . 624-5756 . . . . . . . . . . . . 90
CAB ELECTRICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628-0563-001 . . . . . . . . 92
DASH PANEL ELECTRICAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 628-0600-001 . . . . . . . 103
WIPER PANEL ELECTRICAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 624-3258 . . . . . . . . . . . 109
CONVEY PANEL ELECTRICAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 624-2915 . . . . . . . . . . . 112
A/C CONNECTOR ELECTRICAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 627-7214 . . . . . . . . . . . 116
PROXIMITY SWITCH ELECTRICAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . 622-6730 . . . . . . . . . . . 117
ACCELERATOR PEDAL ELECTRICAL ASSEMBLY. . . . . . . . . . . . . . . . . . 627-7150 . . . . . . . . . . . 118
Section 17. Identification
IDENTIFICATION INSTALLATION, CHASSIS . . . . . . . . . . . . . . . . . . . . . . . 623-5500-001 . . . . . . . . . 2

IDENTIFICATION INSTALLATION, CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . 623-5500-002 . . . . . . . . . 7
IDENTIFICATION INSTALLATION, DECK. . . . . . . . . . . . . . . . . . . . . . . . . . 623-5500-003 . . . . . . . . 12
MAINTENANCE STANDARD DECAL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . 627-4879 . . . . . . . . . . . . 18
Section 18. Air Conditioning System
AIR CONDITIONER CONDENSER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-3088 . . . . . . . . . . . . . 2

AIR CONDITIONER COMPRESSOR MOTOR . . . . . . . . . . . . . . . . . . . . . . 625-3089-500 . . . . . . . . . 4
A/C EVAPORATOR, LOUVER BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-3091 . . . . . . . . . . . . . 6
REFRIGERANT HOSES KIT, A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-4728 . . . . . . . . . . . . . 9
AIR CONDITIONING SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . 627-8134 . . . . . . . . . . . . 13
AIR CONDITIONING ELECTRICAL INSTALLATION. . . . . . . . . . . . . . . . . . 627-8136 . . . . . . . . . . . . 18
AIR CONDITIONING HYDRAULIC INSTALLATION . . . . . . . . . . . . . . . . . . 627-8135 . . . . . . . . . . . . 24
MANIFOLD, A/C MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-4073 . . . . . . . . . . . . 32
DRIER ASSEMBLY, A/C RECEIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625-3864 . . . . . . . . . . . . 35
AIR CONDITIONING SYSTEM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . 625-4534 . . . . . . . . . . . . 36
A/C HYDRAULIC HOSE KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-8135-001 . . . . . . . . 39
A/C HYDRAULIC TUBE KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627-8135-002 . . . . . . . . 48
A/C LOW PRESSURE SWITCH ELECTRICAL ASSEMBLY . . . . . . . . . . . . 625-4887 . . . . . . . . . . . . 54
A/C FAN OVERRIDE SWITCH ELECTRICAL ASSEMBLY . . . . . . . . . . . . . 625-4132 . . . . . . . . . . . . 55
A/C HIGH PRESSURE SWITCH ELECTRICAL ASSEMBLY . . . . . . . . . . . 625-4130 . . . . . . . . . . . . 56
4-Contents
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1. GENERAL
Chapter 4 includes the parts lists and illustrations. Parts lists are grouped by function and subdivided by
assembly.
A table of contents lists the various assemblies and sub-assemblies of the equipment. Instructions for
ordering and returning parts, and the standard JBT warranty, are included in this section. Review the
warranty before ordering and/or returning parts.
Manufacturer CAGE Codes, listed in alphabetical order in Section 2, are provided for items not modified
by JBT. In addition, an explanation of columns assists in using the parts lists.
For safety and reliability use only JBT replacement parts.
2. HOW TO ORDER PARTS
Orders will receive prompt attention and errors will be minimized if the customer follows the suggestions
listed below:
• Write order legibly (preferably typewritten). Date the order and show a requested shipping
date. Give the full name, address, and telephone number (if in the USA) of the person
ordering the parts. Give the full name and address of the person who is to receive the parts.
NOTE: GIVE THE BILLING ADDRESS IF DIFFERENT FROM THE SHIPPING ADDRESS.
• Specify shipping mode, i.e., Air Freight, Motor Freight, United Parcel Service, Parcel Post, etc.
• Indicate the quantity of each item required, starting with units of measure (“each,” “feet,” etc.)
as required.
• State the JBT part number, followed by a complete description. Check to be sure the part
number and description agree. Parts not assigned a JBT part number should be ordered by
manufacturer's name and part number.
• If possible, include the model and serial number of the unit for which parts are required.
• Assign a number to the order and sign it legibly.
• Immediately confirm all fax and telephone orders with purchase orders.
• Address orders as follows:
JBT - Ground Support Equipment

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INTRODUCTION
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3. PARTS RETURNED FOR CREDIT
• Before returning any part, write a letter to JBT, Ground Support Equipment, Orlando, Florida
USA requesting permission. Give an exact list, descriptions, and part numbers. Explain why
you wish to return parts and what action is desired: repair, credit, or replacement. Include
model and serial number of the unit from which the parts were removed.
• If authority is granted, transportation charges must be prepaid, the sender's name must be
marked on the outside of the container, and a return order must be enclosed with the returned
parts.
• Only parts purchased from JBT may be returned for credit consideration.
• If a replacement part is desired before returning a defective part, a separate purchase order
must accompany this request. When credit is approved, your account will be credited with the
proper amount.
4. STANDARD WARRANTY
John Bean Technologies Corporation, warrants that new equipment (product) of its own manufacture
is of good workmanship and is free from mechanical defects, provided that (1) the equipment is
operated in accordance with the printed instructions of JBT, (2) the equipment is used under the normal
operating conditions for which it is designed, (3) the equipment is not subjected to misuse, negligence or
accident, and (4) the equipment receives proper care, lubrication, protection, and maintenance in
accordance with the printed instructions of JBT by qualified personnel.
This warranty expires 12 months from time of commissioning of unit into service or 1000 hours,
whichever first occurs. JBT obligations under this warranty being limited to the repair or replacement, at
JBT election, of defective parts, provided that such defect is reported to JBT promptly or within 30 days
after the defect is discovered, or by reasonable diligence should have been discovered by the
customer. JBT will not be liable under this warranty for labor to remove or reinstall the defective part, for
down time or for any other costs. Any parts replaced under this warranty shall become the property of
and upon request be returned to and at the expense of JBT. Under this warranty JBT may, at its
discretion, require the first user to purchase replacement components and make warranty coverage
dependent upon a failure analysis.
5. ITEMS JBT DOES NOT WARRANT
Engines, engine components, transmissions, axles, commercial truck chassis, storage batteries, tires,
equipment lighting, normal wear items (A.), shop supplies (B.), routine adjustments (C.), maintenance
items, cleaning, preparation and towing. Many of the foregoing components are warranted directly by
the non-JBT manufacturer to the first user and serviced by a worldwide network of distributors and
others authorized to handle warranty claims. A first user's warranty claim should be presented directly
to such an authorized service entity. In the event any component manufacturer will not deal directly with
a first user then JBT will cooperate with the first user in the presentation of a claim to such non-JBT
manufacturer. Under NO circumstances does JBT assume any liability for any warranty claims against
or warranty work done by or in behalf of any non-JBT manufacturer of the foregoing components.
JBT reserves the right to make changes in design and changes or improvements upon its products
without any obligation upon itself to notify a first user or to install the same upon its products theretofore
manufactured.
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A. NORMAL WEAR ITEMS
Tires, chains, sprockets, bearings, bushings, engine belts and hoses, brake pads and discs,
lagged rollers and etc. are not covered for wear and tear. Should the first user suspect a
manufacturing defect as the cause for failure of one of these components the first user may, after
purchasing and installing a replacement component, return the failed component to JBT for
warranty analysis. Should JBT or the component manufacturer determine the failure was due to
a manufacturing defect the first user will receive warranty credit for the failure. Should JBT or the
component manufacturer determine the component failed due to simple wear or abuse the first
user will be liable for all service fees.
B. SHOP SUPPLIES
All lubricants, hydraulic system fluid, engine coolant and additives, all filters, and items used
during normal maintenance of equipment are not covered under this warranty.
C. ROUTINE ADJUSTMENTS
Any hydraulic or mechanical adjustment made to enhance or continue the operation of a piece of
equipment and having been made after 50 hours from time of commissioning of the unit into
service.
THERE ARE NO UNDERSTANDINGS, REPRESENTATIONS OR WARRANTIES OF ANY KIND,

EXPRESS, IMPLIED, STATUTORY, OR OTHERWISE (INCLUDING, BUT WITHOUT LIMITATION, THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE),
NOT EXPRESSLY SET FORTH HEREIN.
Except as expressly provided herein, JBT shall not be liable to buyer for damages of any kind or nature
occasioned by or arising out of the installation, operation, use, misuse, non-use, repair, or replacement
of said equipment, or out of the use of any method of process for which the same may be employed.
In the event, notwithstanding the terms of this agreement, it is determined by a court of competent
jurisdiction that an express warranty has been given by JBT to Buyer with respect to the speed,
capacity, or other like performance characteristics of said equipment. JBT liability for breach of the
same shall be limited to accepting return of such equipment f.o.b. plant of manufacture, refunding any
amounts paid thereon by Buyer (less depreciation at the rate of 15% per year if Buyer has used
equipment for more than 30 days) and canceling any balance still owing on the equipment.
DISCLAIMER OF CONSEQUENTIAL DAMAGES. JBT IN NO EVENT SHALL BE LIABLE FOR

CONSEQUENTIAL DAMAGES ARISING OUT OF OR IN CONNECTION WITH THIS AGREEMENT.
CONSEQUENTIAL DAMAGES FOR PURPOSES HEREOF SHALL INCLUDE, WITHOUT LIMITATION,
LOSS OF USE, INCOME OR PROFIT, OR LOSSES SUSTAINED AS THE RESULT OF INJURY
(INCLUDING DEATH) TO ANY PERSON, OR LOSS OF OR DAMAGE TO PROPERTY (INCLUDING,
WITHOUT LIMITATION, PROPERTY HANDLED OR PROCESSED BY THE USE OF SAID
EQUIPMENT).
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Section 2. Manufacturer CAGE Codes
1. GENERAL
The CAGE Code (Commercial And Government Entity Code) is assigned as a unique identifier for
suppliers of goods and services to government defense agencies. A CAGE code identifies a specific
supplier facility and its location. Many suppliers use the CAGE code as a prefix to their part numbers for
identification of the item and its origin.
CAGE Codes are used internationally as part of the NATO Codification System (NCS). CAGE codes
are issued in the U.S. by the Defense Logistics Information Service (DLIS). Other countries, such as the
United Kingdom and France, also issue CAGE codes.
2. METHOD OF LISTING
This list is arranged in alphabetic order by vendor, while the CAGE codes are shown at the right side of
each manufacturer’s name.
CAGE codes below correspond to the suppliers of the major components used to manufacture the
equipment (refer to Manufacturers’ Appendices, Chapter 5). The Business Identification Number Cross-
reference System, or BINCS, at the Defense Logistics Information Service website was used as a
reference for these CAGE codes.
Additional information can be requested from the Defense Logistics Information Service, 74 Washington
Ave. N STE 7, Battle Creek, MI 49017-3084.
MANUFACTURER CAGE CODES
Eaton Mfg. Co. Reliance Div.

73330
Massillon, OH 44646
General Motor Corp. Allison Transmission Division

73342
4700 Www. 10th St. P.O. Box 894 Indianapolis, IN 46206-0894
Sauer - Sundstrand Co.

14120
2800 E. 13th St. Ames, IA 50010
Dana Corp. Spicer Heavy Axle Div.

97271
2100 W. State Blvd. P.O. Box 750 Fort Wayne, IN 46801
Detroit Diesel Corp.

72582
13400 Outer Drive West Detroit MI 48239-4001
4-2
MANUFACTURER CAGE CODES
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Section 3. Numerical Parts List
1. INTRODUCTION
The numerical listing comprises part numbers of the equipment. Included in this list are references to
Section, Figure, and Item numbers of the parts located in Chapter 4.
When a part number is known and item description or illustration is desired, the number should be
located in the numerical index. In this list, Section, Figure and Item number is shown for each part
number. By consulting the respective parts list or illustration, the part can be located by reference to the
corresponding item number.
2. EXPLANATION OF COLUMNS
• The first column contains the JBT part numbers. The part numbers are in numerical order.
• The second column identifies the section.
• The third column identifies the figure number which illustrates each item.
• The fourth column identifies the item number.
3. NUMERICAL ARRANGEMENT SEQUENCE
Part number arrangement begins at the extreme left-hand position and continues to the right, one
position at a time. The first position arrangement of the part number is as follows:
Numerals 0 through 9
4. SAMPLE APPLICATION
The following list of numbers is in correct numeric sequence:
102-0001
102-0020
102-0031
102-0035
102-0043
102-0059
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NUMERICAL PARTS LIST
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Section 4. Explanation of Parts List Columns
1. INTRODUCTION
The parts listed in each section are organized in order of their numerical part number. The aids in
locating parts via their part number.
Electrical and hydraulic components are located in the section of the manual where the component
resides on the product. In cases where multiple components comprise a system and that system
resides throughout the product (i.e.,: fuel system, hydraulic system), then those components can be
located in the section of the manual where the main component of that system resides on the product.
2. PARTS LIST COLUMNS
A. ITEM NUMBER
The first column provides a cross reference between the parts listed and the illustrations. To find
a view of the part listed and its visual relationship to the assembly, locate the figure and item
number in the list, then refer to the illustration and locate the part by item number. To find a part
number and description in the parts list, locate the part on an illustration, note the item number,
then refer to the parts list and locate the applicable part number and description.
B. PART NUMBER
The second column lists the part number necessary for reordering repair parts. Refer to the
Description column for description and additional identifying information. Standard commercial
hardware can be ordered from JBT or obtained locally. Vendor parts can be obtained from JBT or
directly from the vendor.
C. PART DESCRIPTION
The third column lists the description of each item in the parts list. The identifying noun or key
word is the first word in the description column. The remainder of this column contains the rest of
the description to assist in completely identifying the item.
D. QUANTITY
The final column indicates the quantity of each part required to complete the next higher
assembly. The abbreviation REF indicates that a part number is referenced to another list; this
practice insures that the quantity shown on the list does not exceed the quantity used on the
equipment.
4-4
EXPLANATION OF PARTS LIST COLUMNS
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Section 5. Engine and Transmission Assembly
Assembly Assy. No. Figure Page
1. ACTUATOR, STONE BENNET SHIFTER 623-7300-006 Figure 1 2
2. ENGINE INSTALLATION, ML25K3P 627-9627 Figure 2 Sheet 1 3
3. POWER MODULE ASSEMBLY 627-9583 Figure 3 Sheet 1 14
4. ENGINE AND TRANSMISSION WITH

WINTERIZATION 627-9582 Figure 4 Sheet 1 21
5. DIPSTICK ASSEMBLY, 2100 TRANSMISSION 624-8309 Figure 5 24
6. SURGE OVERFLOW TANK ASSEMBLY 627-4426 Figure 6 25
7. ENGINE ASSEMBLY 627-9581 Figure 7 Sheet 1 27
ENGINE AND TRANSMISSION ASSEMBLY 4-5

The Illustrated Parts List includes alternate parts which may not be used with your configuration. Page 1
For applicable parts refer to the product specification at the front of the manual. December 2015
Halvorsen
Figure 1
ACTUATOR, STONE BENNET SHIFTER
623-7300-006
4-5 ILLUSTRATED PARTS LIST

Page 2 The Illustrated Parts List includes alternate parts which may not be used with your configuration.
December 2015 For applicable parts refer to the product specification at the front of the manual.
Halvorsen
DETAIL A
BOTH SIDES
DETAIL C
1 35 36
38
DETAIL B
DETAIL F
109 DETAIL A
112
140 139
DETAIL C
Figure 2 Sheet 1
ENGINE INSTALLATION, MLK25K3P
627-9627

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133
110
39
116
52
5
115
88
138
55
5
88
89 109
89
111 116
60
61
108
21 16 99 39
DETAIL B
Figure 2 Sheet 2
627-9627

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34
56 59
16 21 14
5
3
3
63
5
3
5
23 18 24
32
5
59 57
55 59
86 51
DETAIL F
SOME ITEMS REMOVED
FOR CLARITY
Figure 2 Sheet 3
627-9627

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133
64
62
106
110 61
116
103
102
SECTION H-H 45
ROTATED 180 DEG. 135
Figure 2 Sheet 4
627-9627

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98 20 94
112
77
DETAIL G
Figure 2 Sheet 5
627-9627

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100 22
113
SECTION E-E
82
84
83
DETAIL G
Figure 2 Sheet 6
627-9627

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137 136 DETAIL L
133 64 1
42
26 30 7 4
45
1
135
64
132
24 23
125
86 33
20 93 122 18 23 24
39
124
64
1 2
137 54
39
SECTION K-K
SOME ITEMS REMOVED
SECTION J-J FOR CLARITY
Figure 2 Sheet 7
627-9627

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106
109
117 15 19 97
89
44
77
89
94 98 20
16 21
DETAIL L
39
49
39
SECTION D-D
SOME ITEMS REMOVED
FOR CLARITY
Figure 2 Sheet 8
627-9627

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627-9627
1 102-0512 BARB, HOSE 04 X 1/4 MNPT BR 3
2 102-1202 ELB. 1/4 NPT-BRASS WH3500X4 1
3 105-0014 CLAMP, MUFFLER 3.00 WITH SADDLE 5
4 105-0075 CLAMP, MUFFLER 2.00 WITH SADDLE 2
5 105-0091 CLAMP HOSE 54-44 14
7 105-1089 BARB, HOSE 10 X 1/2 MNPT BR 1
14 107-9081 SCREW. HHC-F 8.8 M10 X 1.5 X 35 MG 2
15 107-9258 NUT, PTH 8 M6 X 1.00 MG 8
16 107-9260 NUT, PTH 8 M10 X 1.50 MG 12
18 107-9262 NUT, PTH 8 M16 X 2.00 MG 10
19 107-9274 WASHER, FLAT STD. HD M6 MG 12
24 107-9340 SCREW, HHC 10.9 M16 X 2 X 55 MG 12
26 118-2678-002 CROSS - 1/4 NPT 1
30 620-1952 COCK, DRAIN 04 MNPT 1
32 627-1508 W-TRANSMISSION MOUNT 1
33 627-5709 W-ENGINE MOUNT 1
34 623-5392 MUFFLER, DONALDSON-M085207 1
35 627-9920 A-SHAFT, DRIVE 1
36 627-3926 I-FUEL SYSTEM, HEATED, ML44K 1
38 627-9583 A-POWER MOD, ML44K 1
39 623-7258 CLAMP, HOSE-CT-250L 10
42 627-5618 A-SHROUD / SUPPORT-RADIATOR 1
44 623-8706 ELBOW, RUBBER REDUCER 3.5/3.0 1

Halvorsen
627-9627
45 623-9551 CLAMP, HOSE-SILICONE 0.625 2
49 623-9555 M-HOSE, STRAIGHT SILICONE 2.001 1
51 623-9639 BRACKET, EXHAUST PIPE-TURBO 1
52 624-0270 HOSE, ENGINE-PRESSURE 1
54 624-0276 HOSE, ELBOW SILICONE 2.00 I.D. 1
55 627-4273 W-EXHAUST PIPE TURBO 1
56 624-0281 EXHAUST PIPE, MUFFLER INLET 1
57 624-0282 EXHAUST PIPE, MUFFLER OUTLET 1
59 624-0314 WRAP, HIGH TEMP-CLOTH 2
60 627-9768 PIPE, AIR INTAKE 1
61 627-3395 W-TUBE RADIATOR OUTLET 1
62 627-3394 W-TUBE RADIATOR INLET 1
63 624-1409 EXHAUST SYSTEM BELLOW, NGSL 1
64 624-1447 CLAMP, HOSE-FUEL INJ. 0.25 4
77 627-9880 W-CAC CROSSBEAM 1
82 107-2281 SCREW, HHC GR8 0.5-20 X 1.5 MG 4
83 107-2283 NUT, PTHM GRC 0.5-20 MG 4
84 107-9455 WASHER, FLAT NAR HD 0.5 MG 4
86 624-8968 PLATE, SHIM ENGINE MOUNT 4
87 105-0103 CLAMP, HOSE 1.50-3.50 SS 1
88 105-0106 CLAMP, HOSE 0.88-2.75 SS 2
89 105-0117 CLAMP, HOSE 2.125-4.00 SS 1
90 107-9018 SCREW, HHC-F 8.8 M6 X 1 X 25 MG 4
93 107-9046 SCREW, HHC 8.8 M8 X 1.25 X 25 MG 1
94 107-9047 SCREW, HHC-F 8.8 M8 X 1.25 X 30 MG 4
97 107-9168 SCREW, SFH-F 10.9 M6 X 1 X 20 MG 4

98 107-9259 NUT, PTH 8 M8 X 1.25 MG 4
99 107-9316 SCREW, HHC-F 10.9 M10 X 1.5 X 35 MG 8

Halvorsen
627-9627
100 107-9388 SCREW, HFLNG 10.9 M12 X 1.75 X 30 MG 2
102 REF-623-5384-014 HOUSING, AIR CLEANER 1
103 REF-623-5384-018 BANDS, AIR CLEANER MOUNT 2
106 623-8271 PRE-CLEANER, DONALDSON-H000821 1
108 627-0650 M-HOSE, 1.88 I.D. ELBOW 1
109 627-7214 AE-CAC 1
110 627-9766 W-TUBE, CAC RETURN 1
111 627-9764 TUBE, CAC INTAKE 1
112 627-9649 W-CAC BRACKET, NGSL 1
113 107-2181 NUT, PTH 10 M12 X 1.75 MG 2
115 627-5899 COUPLING, SILICONE ELBOW, TURBO 1
116 627-5901 COUPLING, SILICONE 3
117 627-9601 W-COUPLING, INTAKE ELBOW 1
118 628-5832 REDUCER, 2.50 X 3.00 DIA., SILICONE 1
119 627-6173 GASKET, CAC MOUNT 1
120 627-6174 GASKET, CAC MOUNT 2
122 239-8852-024 CLAMP, SUPPORT 2.62 NC 1
124 627-5218 TUBE, RAD. INLET, ML44K 1
125 627-6383 HOSE, RAD. INLET, RUBBER, ML44K 1
132 623-9552-032 HOSE, COOLANT 0.25 X 32 SAE 20R3 1
136 102-0701 ELBOW, ST 90 0.25 BR STD. 1
137 118-2658-003 NIPPLE, HEX 0.25 X 0.25 2
138 105-0135 CLAMP, HOSE 2.63-3.50 S.S. 1
139 107-2933 WASHER, LOCK M10 MG 4
140 107-9320 SCREW, HHC 10.9 M10 X 1.5 X 60 MG 4

Halvorsen
29
11 22
58 62 64 61
49
60 68 66 67 57
11 22
72
76
51
93
70
Figure 3 Sheet 1
POWER MODULE ASSEMBLY
627-9583

Halvorsen
78
78 96
94
69
10 21
75
98
84 88 86
88 86 83
61 62 81
63 97
73
59 62
43
100 89 21 82
70
88 86 83
50
87 99 21 10
51
92
85 88 86
91
Figure 3 Sheet 2
627-9583

Halvorsen
70
77
35
25
24
41
84
34
41
28 43
HYDRAULIC PUMP
41
23
15
74
8
SOME ITEMS REMOVED
FOR CLARITY
Figure 3 Sheet 3
627-9583

Halvorsen
SECTION A-A
SOME ITEMS REMOVED
FOR CLARITY
93
80
95
79
94
96 73
74
93
57 67 66 68 60
71
SECTION B-B
Figure 3 Sheet 4
627-9583

Halvorsen
627-9583
8 107-2182 NUT, PTH 10 M16 X 2.00 MG 2
10 107-9045 SCREW, HHC-F 8.8 M8 X 1.25 X 20 MG 4
11 107-9078 SCREW, HHC-F 8.8 M10 X 1.5 X 20 MG 6
15 107-9117 SCREW, HHC 8.8 M16 X 2 X 60 MG 2
22 107-9276 WASHER, FLAT STD HD M10 MG 9
23 107-9279 WASHER, FLAT HD M16 MG 2
24 107-9321 SCREW, HHC 10.9 M10 X 1.5 X 70 MG 6
25 107-9429 SCREW, SHCSLO 10.9 M8 X 1.25 X 20 MG 4
28 107-9458 SCREW, SFH-F 10.9 M14 X 2 X 40 MG 4
29 107-9388 SCREW, KFLNG 10.9 M12 X 1.75 X 30 MG 8
34 627-4872 MOUNT, LH PUMP BRACKET 1
35 627-4869 MOUNT, RH PUMP BRACKET 1
41 627-4853 COUPLING, CENTAFLEX CFA 50-2-S 1
43 627-7302 BRACKET, ALTERNATOR-UPPER, ML44K 1
49 627-7502 W-RH TRANS ADAPTER 1
50 627-7619 W-LH TRANS ADAPTER 1
51 627-9582 ENGINE/TRANS. W/WNTZ 1
57 107-2181 NUT, PTH 10 M12 X 1.75 MG 4
58 107-9014 SCREW, HHC-F 8.8 M6 X 1 X 10 MG 4
59 107-9038 SCREW, HHC 8.8 M6 X 1 X 90 MG 4
60 107-9093 SCREW, HHC-F 8.8 M12 X 1.75 X 45 MG 4
61 107-9258 NUT, PTH 8 M6 X 1.00 MG 6
63 620-7183 KIT, RADIATOR COOLANT OVERFLOW 1
64 623-6870 MOUNT, FLEX BOLT M6 X 1.0 4
65 624-0301 SPACER-SURGE TANK - HEAVY DUTY 4

Halvorsen
627-9583
66 624-5155 ISOLATOR, SURGE TANK - HEAVY DUTY 4
67 624-5157 PLATE, SPACER-SURGE ISOLATORS 2
68 624-5158 WASHER, MOUNT-SPACER 4
69 627-9820 W-OVERLOW BRACKET, TIER3 1
70 REF-627-3290-201 BELT, -35 TO 125 F 1
71 627-4422 W-MOUNT, SURGE TANK 1
72 627-4425 W-MOUNT, SURGE TANK 1
73 627-4426 A-TANK, SURGE-OVERFLOW 1
74 627-4876 M-HYD PUMP BRACKET 1
75 627-7307 W-MOUNT, ALTERNATOR 1
76 627-5955 PLATE, ECU MOUNT BRACKET 1
77 627-5448 SPACER, DAMPER PULLEY 1
78 102-0512 BARB. HOSE 04 X 1/4 MNPT BR 2
79 103-1719 ADAPTER, S90 1/2 FNPT X 1/2 MNPT BR 1
80 105-1089 BARB. HOSE 10 X 1/2 MNPT BR 1
81 107-9018 SCREW, HHC-F 8.8 M6 X 1 X 25 MG 2
82 107-9044 SCREW, HHC-F 8.8 M8 X 1.25 X 16 MG 1
83 107-9104 SCREW, HHC-F 8.8 M16 X 2 X 35 MG 2
84 107-9120 SCREW, HHC 8.8 M16 X 2 X 80 MG 1
85 107-9121 SCREW, HHC 8.8 M16 X 2 X 90 MG 1
86 107-9662 NUT, PTH 8 M16 X 2.00 MG 4
87 107-9267 NUT, HEX 8 M8 X 1.25 MG 1
89 239-8852-004 CLAMP, SUPPORT 1.00 NC 1
90 239-8852-005 CLAMP, SUPPORT 1.12 NC 1
91 REF-623-5384-060 ISOLATOR, ENGINE MOUNT 4
92 623-8221 FRONT, MOTOR MOUNT 1
93 623-9551 CLAMP, HOSE-SILICONE 0.625 2

Halvorsen
627-9583
96 624-1447 CLAMP, HOSE-FUEL INJ. 0.25 2
97 624-8309 A-DIPSTICK 2100 TRANSMISSION 1
98 627-7151 SPACER, MOTOR MOUNT 1
99 239-8852-002 CLAMP, SUPPORT 0.75 NC 1
100 628-5713 NEOPRENE, 0.13 X 1.0 X 2.50 1
* NOT SHOWN

Halvorsen
15
Figure 4 Sheet 1
ENGINE AND TRANSMISSION WITH WINTERIZATION
627-9582

Halvorsen
8
8
10
6
ENGINE
SIDE
REF 623-5384-103
FLYWHEEL W/RING
SECTION THRU
COVER CONNECTING
ENGINE WITH TRANSMISSION
NOT TO SCALE
Figure 4 Sheet 2
627-9582

Halvorsen
627-9582
1 627-9581 ENGINE, VM D756IE3 1
2 627-8774 TRANSMISSION, ALLISON 2100SP 1
3 623-5386-001 FLEXPLATE, ALLISON TRANSMISSION 1
5 623-5386-003 PILOT ADAPTER - FLEXPLATE 1
6 623-5386-004 BOLT, PILOT ADAPTER 8
7 623-5386-005 RING, ATTACHING - FLEXPLATE 1
8 623-5386-007 KIT, BOLT ATTACHING RING 2
9 623-5386-008 COVER, HOUSING 2
10 623-5386-009 PLATE, SCUFF 1
14 623-5384-061 MOUNT, ENGINE FRONT LH 1
15 623-5386-015 BOLT, FLEXPLATE HOUSING COVER 4
17 625-5699 STARTER MOTOR, 24V ISKRA 1
18 625-5699-002 CAP SCREW 2
19 625-5699-003 WASHER, SPRING 2

Halvorsen
1
Figure 5
DIPSTICK ASSEMBLY, 2100 TRANSMISSION
624-8309
DIPSTICK ASSEMBLY, 2100 TRANSMISSION

624-8309
1 624-8309-001 DIPSTICK, 2100 TRANSMISSION 1
2 624-8309-002 TUBE, TRANSMISSION DIPSTICK 1

Halvorsen
4
1 2
3
5
Figure 6
SURGE OVERFLOW TANK ASSEMBLY
627-4426

Halvorsen
SURGE OVERFLOW TANK ASSEMBLY
627-4426
1 107-1482 NUT, PTH A2 #8-32 S.S. 1
2 111-5755 SCREW, PRND GR 2 #8-32 X 0.5 ZP 1
3 118-7293 WASHER, FLAT NARROW #8 ZP 1
4 623-8707 LANYARD - 20.00 WITH TAB 1
5 623-7159 M-CAP, RADIATOR 1 BAR 1
6 623-7338 SIGHT, WINDOW - LIQUID LEVEL 1
7 627-4397 W-TANK, SURGE / OVERFLOW 1

Halvorsen
14 PLUG, CLAMP, AND FITTING

SUPPLIED WITH ASSEMBLY
143
110
95 DETAIL A
88
105
113 121
144
SEE DETAIL A
26
104
155 158 162
89
154 159 157 152
33
159 156 161 160
124
138
139
Figure 7 Sheet 1
ENGINE ASSEMBLY
627-9581

Halvorsen
DETROIT DIESEL
VM MOTORI
VM MOTORI S.p.A. - 44042 CENTO (FE) via Ferrarese, 29 - Made in Italy -
MATRICOLA PESO
Serial XXX/X-XXXXX Weight Kg XXX
MOTORE TIPO
Engine type XXX/1
MODELLO
Engine Type XXXXXXX
VERSIONE POT MAX GIRI/MIN
Eng. Version XXX Max power Kw XX.X r.p.m. XXXX
OMOLOGAZIONE XX*XX/XXXX*XX/XXX*XXXX*XX
Homologation
XX XX X - XXXXXX
SERIAL PLATE MUST BE ATTACHED HERE

(SAMPLE PLATE SHOWN)
10 98 136 94
112
103 108
132
150
142 96
119 114 115 116 117 118 120

102
122
100
111
95
129
14
1
93
99
106
97 18 141
20
109 149
107 126
Figure 7 Sheet 2
ENGINE ASSEMBLY
627-9581

Halvorsen
ENGINE ASSEMBLY
627-9581
1 623-3544 HEATER, TANK, COOL, 1000W, 120V 1
2 623-3548 HE-OIL PAN HEATER 1
3 623-5384-009 BANJO FITTING, BARB FUEL LINE 1
4 623-5384-011 WASHER, SEAL - BANJO BOLT 5
5 623-5384-013 FILTER, AIR CLEANER 1
6 623-5384-014 HOUSING, AIR CLEANER 1
7 623-5384-015 ELBOW, AIR INTAKE-TURBO 1
8 623-5384-016 CLAMP, AIR ELBOW SMALL - TURBO 1
9 623-5384-017 CLAMP, AIR ELBOW LARGE - TURBO 1
10 623-5384-018 BANDS, AIR CLEANER MOUNT 2
11 623-5384-019 INDICATOR, AIR RESTRICTION 1
12 623-5384-021 THERMOSTAT 1
13 623-5384-022 THERMOSTAT HOUSING 1
14 623-5384-025 PULLEY, WATER PUMP 1:1.56 1
15 623-5384-032 FITTING, BLEED - WATER MANIFOLD 1
16 623-5384-033 BANJO, WATER BLEED FITTING 7
17 623-5384-034 WASHER, SEALING - WATER FITTING 15
18 623-5384-035 OIL FILTER 1
19 623-5384-036 O-RING, OIL FILTER 2
20 623-5384-039 OIL COOLER ASSEMBLY 1
21 623-5384-045 CONNECTOR, INTAKE MANIFOLD 1
22 623-5384-046 FUEL INJECTION TIMER SWITCH 1
23 623-5384-047 SWITCH, WATER TEMP. SHUTDOWN 1
24 623-5384-048 CAP, OIL FILLER 2
26 627-9581-034 MANIFOLD, EXHAUST MIDDLE 1
28 623-5384-054 EXPANSION RINGS, EXHAUST MANIFOLD 4
29 623-5384-057 INTAKE, MANIFOLD, REAR 1

Halvorsen
ENGINE ASSEMBLY
627-9581
30 623-5384-060 ISOLATOR, ENGINE MOUNT 4
31 6232-5384-061 MOUNT, ENGINE FRONT, LEFT SIDE 1
32 623-5384-064 EJECTION VALVE, AIR FILTER 1
33 627-9581-091 TURBOCHARGER 1
36 623-5384-084 OIL SEPERATOR 1
37 623-5384-090 FUEL SOLENOID 1
38 623-5384-094 GASKET, EXHAUST 6
39 623-5384-095 GASKET, COOLANT 6
40 623-5384-096 GASKET, COOLANT CONNECTION 1
41 623-5384-099 LUBRICATION LINE, HEAD 1
42 623-5384-101 REPAIR KIT, FUEL INJECTOR 1
43 623-5384-102 RELAY-COLDSTART 1
45 623-5384-104 BLOCK-OUT PLATE, PUMP 1
46 623-5384-105 HOSE, FUEL-.3125 1
47 623-5384-106 GASKET, PUMP BLOCK - OFF PLATE 1
48 623-5384-108 BARB-STR 0.38 X 0.25 NPT 2
49 623-5384-109 EL 90 0.25 NPT-STREET 3
50 623-5384-110 ADAPTER 0.25 X 0.375 NPT 2
51 623-5384-111 COUPLING 0.25 NPT 1
52 623-5384-112 CLAMP, FUEL HOSE 4
53 623-5384-113 EL 90 0.25 NPT 1
54 623-5384-114 BARB-STR 0.3125H X 0.25 NPT 2
55 623-5384-115 HARNESS, ENGINE 1
56 623-5384-116 HARNESS, GLOW PLUGS 1
57 623-5384-117 HARNESS, KSB GLOW PLUGS 1
58 623-5384-118 SEALANT, OIL PAN 1
59 623-5384-121 GASKET, CRUSH DRAINBACK 706LTE 6
60 623-5384-124 SOLENOID, STARTER - NGSL 1

Halvorsen
ENGINE ASSEMBLY
627-9581
61 623-5384-125 KEY, FRONT PULLEY 1
62 623-5384-126 KEY, OIL PUMP GEAR 1
63 623-5384-127 O-RING 1
64 623-5384-128 FRONT SEAL 1
65 623-5384-129 NUT 1
66 623-5384-131 GASKET, EXHAUST 1
67 623-5384-132 GASKET SET 1
68 623-5384-133 TAPPET 1
69 623-5384-134 UNION, FUEL INJECTOR 6
70 623-5384-135 GASKET, TURBO MOUNTING 2
71 623-5384-136 GASKET SET, CYLINDER HEAD 1
72 623-5384-137 O-RING, REAR CAMSHAFT SEAL 2
73 623-5384-138 REAR MAIN BEARING W/CARRIER 1
74 623-5384-139 SEAL, REAR MAIN 1
75 623-5384-140 WASHER, THRUST 2
76 623-5384-141 O-RING 1
77 623-5384-142 BOLT, FLYWHEEL 12
78 623-5384-143 BOLT, BELL HOUSING 9
79 623-5384-144 BOLTS, TRANSMISSION 11
80 623-5384-145 STUD, CARRIER BEARING 6
81 623-5384-146 SCREW, HEAD 6
82 623-5384-147 SCREW, HEAD 6
83 623-5384-148 SCREW, HEAD 14
84 623-5384-152 O-RING, FLYWHEEL 2
85 623-5384-153 PLUG, TOP ROCKER COVER 8
86 623-5384-154 BOLT, ROCKER COVER 27
87 623-5384-155 PLUG, OIL BREATHER 3
88 623-5384-156 ELBOW, OIL BREATHER 1

Halvorsen
ENGINE ASSEMBLY
627-9581
89 623-5391-003 FITTING, WATER HEATER 1
90 623-5391-006 GLOW PLUGS 6
91 623-5391-007 CONTROLLER, GLOW PLUG 1
92 623-7312 HEATER, 150W, 120V IMMERSON 1
93 623-7369 BRACKET, HEATER 1
94 627-3290-004 TUBE ASSEMBLY, FUEL RETURN 1
95 627-3290-006 PUMP, WATER 1
96 627-3290-014 COVER, ROCKER ARM 2
97 627-3290-026 CRANKSHAFT PULLEY 1
98 627-3290-031 DIP STICK, OIL SUMP 1
99 627-3290-041 PIPE. OIL DRAIN 1
100 627-3290-045 HOSE, BYPASS 1
101 627-9581-049 NIPPLE, TURBO OIL 1
102 627-3290-051 TUBE, FUEL PUMP RETURN 1
103 627-3290-055 CLAMP, INJECTOR HOLD DOWN 6
104 627-3290-067 ADAPTER 1
105 627-3290-083 GASKET, INTAKE THROTTLE 1
106 627-3290-086 VIBRATION BALANCER 1
107 627-3290-089 PUMP, FUEL INJECTION KIT 1
108 627-3290-115 SCREW, INJECTOR HOLD DOWN 6
109 627-3290-131 BOLT, OIL PAN 43
110 627-3290-159 INJECTOR 6
111 627-3290-162 BLOCK, FUEL REFUSE 1
112 627-9581-058 MANIFOLD, FRONT INTAKE 1
113 627-3290-168 MANIFOLD, COOLANT, REAR 1
114 627-3290-169 PIPE, HIGH PRESSURE FUEL 1

Halvorsen
ENGINE ASSEMBLY
627-9581
120 627-3290-175 PIPE, INJECTION 1
121 627-3290-176 MANIFOLD, COOLANT, FRONT 1
122 627-3290-178 HOSE, FUEL RAIL RETURN 1
124 627-9581-180 HOSE, OIL RETURN 1
125 627-3290-186 GASKET, ROCKER COVER 2
126 627-3290-199 M-OIL PAN, TIER3 1
127 627-3290-201 BELT, -35 TO 125 F 2
128 627-3290-202 K-CONNECTOR, VEHICLE, R756IE3, VM 1
129 627-3290-221 ECU, ENIGINE TIER3 1
130 627-3290-222 FILTER, FUEL AND HEATER 1
131 627-3290-223 FLANGE, EXHAUST 2.000, TIER3 1
132 627-3290-225 ELBOW, INLET 1
133 627-3290-226 PRIM FUEL FILTER, TIER3 2
134 627-3290-227 O-RING, OIL FILTER BASE 2
135 627-3290-228 GASKET, WATER PUMP 2
136 627-3290-229 TUBE, DIPSTICK, TIER3 1
137 627-3290-230 O-RING, DIPSTICK, TIER3 1
138 627-3290-231 CLAMP, HOSE 6
139 627-3290-234 PLUG, PIL PAN DRAIN 2
141 627-3290-236 WATER PIPE RETURN 1
142 627-3290-237 WATER RETURN PIPE 1
143 627-3290-238 CLAMP, SPRINGBAND 1
144 627-3290-246 GASKET, INTAKE MANIFOLD 6
145 627-3290-248 PUMP, OIL ASSEMBLY 1
146 627-3290-251 STUD, OIL FILTER 1

Halvorsen
ENGINE ASSEMBLY
627-9581
147 627-3290-252 GASKET, INJECTOR 6
148 627-3290-253 O-RING 6
149 627-3290-254 VALVE 1
150 627-3290-255 RAIL, FUEL ASSY. 1
151 627-7307 W-MOUNT, ALTERNATOR 1
152 627-9581-037 CONTROL FLANGE, TURBO 1
154 627-9581-079 GASKET, TURBO OUTLET 1
155 623-5384-166 STUD 8
156 627-3290-109 STUD 4
157 627-3290-110 STUD, M8 X 22 3
158 623-5384-165 NUT, M8 20
159 627-3290-129 NUT, M8 7
160 627-9581-167 FLANGE, TURBO OUTLET 1
161 627-9581-184 GASKET, TURBO OUTLET FLANGE 1
162 627-9581-197 ELBOW, TURBO RELOCATION 1
163* 627-3290-029 HUB, CRANKSHAFT 1
* NOT SHOWN

Halvorsen
Section 6. Chassis Assembly
1. CHASSIS ASSEMBLY 627-9676 Figure 1 Sheet 1 2
2. BATTERY TRAY INSTALLATION 627-6451 Figure 2 Sheet 1 6
3. FUEL SYSTEM INSTALLATION 627-3926 Figure 3 Sheet 1 9
4. FUEL TANK ASSEMBLY 623-6157 Figure 4 14
5. SHROUD AND SUPPORT ASSEMBLY, RADIATOR 627-5618 Figure 5 Sheet 1 16
6. MAINTENANCE SUPPORT BLOCK ASSEMBLY 623-8468 Figure 6 19
7. PLACARD INSTALLATION, CHASSIS 624-7183 Figure 7 20
CHASSIS ASSEMBLY 4-6

Halvorsen
27
9
8 1
18
20
3
21
3
30
Figure 1 Sheet 1
CHASSIS ASSEMBLY
627-9676

Halvorsen
26
3
12
25
13
14
15
17
11 6 2
28
5 16
Figure 1 Sheet 2
CHASSIS ASSEMBLY
627-9676

Halvorsen
19
11
29
23
29
10
Figure 1 Sheet 3
CHASSIS ASSEMBLY
627-9676

Halvorsen
CHASSIS ASSEMBLY
627-9676
1 107-2231 SCREW, HHC 8.8 M12 X 1.75 X 20 MG 6
2 107-9014 SCREW, HHC-F 8.8 M6 X 1 X 10 MG 1
3 107-9045 SCREW, HHC-F 8.8 M8 X 1.25 X 20 MG 7
6 107-9302 SCREW, HHC 10.9 M8 X 1.25 X 25 MG 1
7 107-9416 BOLT, HFLNG 8.8 M10 X 1.5 X 20 MG 24
8 107-9447 WASHER, FLAT NAR HD M12 MG 6
9 627-9626 W-CHASSIS ML24K3P 1
10 627-8791 I-FRONT AXLE, KESSLER LT41 1
11 623-8468 A-MAINTENANCE STAND 2
12 623-8469 PAD, RUBBER 6
13 628-1805 W-CLEVIS, AIR TRANSPORT 1
14 623-8692 W-PIN, AIRTRANSPORTABILITY 1
15 623-8695 PIN, QUICK RELEASE 5/8 IN. 1
16 623-8697 LANYARD-12.00 WITH SPLIT RING 1
17 623-8698 LANYARD-12.00 WITH TAB 1
18 623-8734 PAD, FRONT SUB FRAME 2
19 624-1225 I-REAR AXLE, NGSL 1
20 624-1450 I-TIRES, NGSL 1
21 624-3140 W-HYD. MANIFOLD COVER 1
23 627-6451 I-BATTERY BOX, ML44K 1
25 624-6070 SHIM, DECK REST THICK 4
26 624-6593 BUMPER, PLATFORM 2
27 624-7183 I-PLACARD, CHASSIS 1
28 624-8941 M-SHAFT COLLAR 1
29 627-9627 I-POWER MOD, ML25K3P 1
30 627-9669 IH-CHASSIS 1

Halvorsen
10
8
17 2
Figure 2 Sheet 1
BATTERY TRAY INSTALLATION
627-6451

Halvorsen
B B
7 6
TOP VIEW
SOME ITEMS REMOVED
8 FOR CLARITY
17
15 16 15 16
11 11
SECTION B-B
Figure 2 Sheet 2
627-6451

Halvorsen
627-6451
2 107-9046 SCREW, HHC-F 8.8 M8 X 1.25 X 25 MG 2
7 107-9316 SCREW, HHC-F 10.9 M10 X 1.5 X 35 MG 6
8 627-1447 W-TRAY, BATTERY ML44K 1
10 627-1504 W-COVER, BATTERY ML44K 1
11 623-7289 THREADED SHAFT, M8 X 1.25 4
12 627-1505 BATTERY STRAP, HEAT SHRINK 2
15 107-9259 NUT, PTH 10 M8 X 1.25 MG 8
17 107-2185 NUT, INSERT, AVK-AHS7812579 2

Halvorsen
28
14
16
15
TO FEED TUBE
BLOCK
42
FUEL
SOME ITEMS REMOVED

3
FOR CLARITY
4
45
46
43
44
4
INJECTOR 3
PUMP
Figure 3 Sheet 1
FUEL SYSTEM INSTALLATION
627-3926

Halvorsen
DETAIL C 11 10 9 8 17 DETAIL D
SOME ITEMS REMOVED

FOR CLARITY
FEED TUBE
DETAIL H
47
22
38 7 19
SECTION A-A
ROTATED 90 DEG. CCW
44
SECTION B-B
43
SOME ITEMS REMOVED
FOR CLARITY
Figure 3 Sheet 2
627-3926

Halvorsen
4 46
TIE WRAP 42
HOSES
27” LONG
29 3 18 21 20
VENT LINE
TO BOTTOM
TANK
25
31 7 6
30
23 4
140” LONG 14” LONG
44
29 3 29 3 19 7 38
TO FUEL BLOCK
DETAIL C 4
33” LONG
29 3
TO FEED HOSE
48
80” LONG
16 29 3 37 21 37
4
TO INJECTOR
PUMP
43 DETAIL D
31 7 6 SOME ITEMS
REMOVED FOR CLARITY
DETAIL H
ROTATED 90 DEG. CCW
Figure 3 Sheet 3
627-3926

Halvorsen
627-3926
3 105-1190 HOSE, FUEL 3/8 I.D. DSL / GAD, J1527 24.5 ft.
4 105-1262 CLAMP, HOSE 0.44-0.67 S.S. 9
6 107-2180 NUT, PTH 10 M10 X 1.50 MG 10
8 107-2858 SCREW, PPAN A2 #10-32 X 0.75 S.S. 5
9 231-5027-003 GASKET 1
10 231-5027-004 WASHER, FLAT SD 0.203 I.D. 0.38 O.D. X 0.06 NYLON 5
11 628-4434 M-SENDER, FUEL LEVEL 1
14 623-6157 A-FUEL TANK 1
15 623-6158 ISOLATOR STRIP, FUEL TANK 2
16 625-6640 W-STRAP, FUEL TANK - ASSEMBLY 2
17 DWG-514-6319 DWG-SENDING UNIT INSTALL INSTRUCTIONS 1
18 107-9310 SCREW, HHC-F 10.9 M8 X 1.25 X 65 MG 2
19 107-9081 SCREW, HHC-F 8.8 M10 X 1.5 X 35 MG 4
20 107-9259 NUT, PYH 8 M8 X 1.25 MG 4
22 103-1714 PLUG, HEX CS 06 MNPT BR 1
23 105-1096 BARB, 90 06 X 06 MNPT BR 1
25 625-6695 W-FUEL TANK BRACKET, SUPPORT 2
28 625-6987 A-FUEL TANK BRACKET, SUPPORT 1
29 620-1317-004 FLEX-GARD, NYLON SLIT 5/8 IN. 24.5 ft.
30 625-9437 PLATE, SPACER, FUEL TANK 2
31 107-9084 SCREW, HHC 8.8 M10 X 1.5 X 50 MG 10
37 107-9062 SCREW, HHC 8.8 M8 X 1.25 X 40 MG 2
38 107-9260 NUT, PTH 8 M10 X 1.5 MG 4
42 519-7339-001 HEATED FUEL HOSE - 24VDC 1
43 REF-627-3290-222 FILTER, FUEL AND HEATER 0

Halvorsen
627-3926
44 627-3729 A-FILTER, FS20022, LUB. 1
45 105-1289 BARB, HOSE 0.31 I.D. HOSE X 6FNPT 1
46 102-1625 ADAPTER, STRAIGHT 10M SAE (45) X 3/8 IN. MNPT BR 2
47 627-5562 PLATE, FILTER 1
48 628-5890 K-BANJO FITTING M14 2
* NOT SHOWN

Halvorsen
10
5
13 1
4
13
12
13 5
13
1
14
9 10
11 3
SECTION A-A
Figure 4
FUEL TANK ASSEMBLY
623-6157

Halvorsen
FUEL TANK ASSEMBLY
623-6157
1 623-6157-001 CAP, FUEL TANK 1
2 624-8922 TUBE, RD 4.50 X 0.250 W AL 1
3 624-8923 FITTING, 0.500 X 0.375 NPTF AL 1
4 624-8924 FITTING, 0.500 X 0.500 NPTF AL 1
5 624-8926 VALVE, ROLLOVER 1
6 624-8927 CAP, SHIPPING 5 HOLE FLG 1
7 624-8928 CAP, SHIPPING PLASTIC 3
8 624-8929 CAP, SHIPPING VINYL 1
9 624-8939 SHELL, FRONT FUEL TANK NGSL 1
10 624-8931 SIDE, FUEL TANK NGSL 2
11 624-8932 SUPPORT, WITHDRAW NGSL 1
12 624-8933 FLANGE, GUAGE #10-32 NGSL 1
13 624-8934 A-WITHDRAW TUBE NGSL 2
14 624-8940 SHELL, REAR FUEL TANK NGSL 1

Halvorsen
20 21
13
15
5
DETAIL A
DETAIL B
1
SOME ITEMS REMOVED
EXPLODED VIEW
FOR CLARITY
12
5
2
14
3
DETAIL A
DETAIL B
8
25
26
22
22
26
5
Figure 5 Sheet 1
SHROUD AND SUPPORT ASSEMBLY, RADIATOR
627-5618

Halvorsen
24
13
RADIATOR MOUNT 20
22 22
22 9
7 3
18
16
19
11
14
13
Figure 5 Sheet 2
627-5618

Halvorsen
627-5618
1 107-2035 SCREW, SOCKET HEAD SET, M5 X 0.8 X 10 ZP 2
2 107-9078 SCREW, HEX HEAD CAP, FULL THREAD 8.8 M10 X 1.50 4
X 20 MG
X 30 MG
5 107-9260 NUT, PTH 8 M10 X 1.50 MG 18
7 107-9460 NUT, HEX GR 8 0.38 X 16 MG 4
*8 623-6774 MOTOR, HYDRAULIC F11-5 1
9 623-7129 ISOLATOR, LF 1.5 SERIES 4
11 623-8150 W-RADIATOR GRILL 1
12 628-1668 W-HOUSING, RADATOR FAN 1
13 624-3101 W-PLENUM, RADIATOR SUPPORT 1
14 623-8490 FAN, 20 IN. O.D. FLANGE 4Z-37.5/37.5 1
15 623-8493 HUB, ROTATING, FAN 1
16 627-5130 RADIATOR, ALUMINUM W/OIL COOL, ML44K 1
18 623-8581 GASKET, ADH FOAM RADIATOR 2
19 623-8582 GASKET, ADH FOAM RADIATOR 2
20 107-9047 SCREW, HEX HEAD CAP, FULL THREAD 8.8 M8 X 1.25 X 10

30 MG
21 5150138 WASHER, FLAT 5/16 IN. 10
22 107-9276 WASHER, FLAT STD HARD M10 MG 28
24 107-2168 NUT, INSERT, AL, M8 X 1.25, GRIP 3.8 1
25 628-1667 W-MOUNT, RADIATOR FAN SHROUD 1
26 107-9081 SCREW, HHC-F 8.8 M10 X 1.5 X 35 MG 6

Halvorsen
(HANDLE)
(KEYRING)
Figure 6
MAINTENANCE SUPPORT BLOCK ASSEMBLY
623-8468
MAINTENANCE SUPPORT BLOCK ASSEMBLY

623-8468
1 623-8461 MAINTENANCE STAND WELDMENT 1
2 623-8466 PIN, QUICK RELEASE L 7/16 IN. 1
3 623-8467 LANYARD-20.00 WITH SPLIT RING 1
4 627-8288 DE-MAINTENANCE STAND 1

Halvorsen
Figure 7
PLACARD INSTALLATION, CHASSIS
624-7183

Halvorsen
PLACARD INSTALLATION, CHASSIS
624-7183
1 624-7149 A-PLACARD, DOT FLIP HAZARD 1
2 107-9017 SCREW, HEX HEAD CAP-F 10.9 M6 X 1 X 20 MG 4
3 107-9450 WASHER, FENDER STD HARD M6 MG 4
4 624-7175 INSERT, GRIP M6 X 1.0 CS 4

Halvorsen
Section 7. Drive Train Assembly
1. FRONT AXLE INSTALLATION 627-8791 Figure 1 2
2. FRONT AXLE ASSEMBLY 627-8792 Figure 2 Sheet 1 4
3. DRIVE AND STEER AXLE - KESSLER LT41-PL58 627-8476 Figure 3 Sheet 1 7
4. DRIVE SHAFT ASSEMBLY 627-9920 Figure 4 Sheet 1 10
DRIVE TRAIN ASSEMBLY 4-7

Halvorsen
REF: 627-8543
SECTION A-A 3
Figure 1
FRONT AXLE INSTALLATION
627-8791

Halvorsen
FRONT AXLE INSTALLATION
627-8791
1 107-2831 SCREW, HHC GR 8 0.75-16 X 14 MG 8
2 107-9501 NUT, PTH 0.75-16 UNC MG 8
4 627-8792 A-AXLE, FRONT, KESSLER 1

Halvorsen
11 13
15
14 4 5 6
10
5 6 8
2
DETAIL B
6 5 4 1
Figure 2 Sheet 1
FRONT AXLE ASSEMBLY
627-8792

Halvorsen
SECTION A-A
SOME ITEMS REMOVED
FOR CLARITY
12 6 5
DETAIL B
SOME ITEMS REMOVED
FOR CLARITY
Figure 2 Sheet 2
FRONT AXLE ASSEMBLY
627-8792

Halvorsen
FRONT AXLE ASSEMBLY
627-8792
1 623-5427 CALIPER, PARKING BRAKE 1
2 625-8642 CALIPER, SERVICE BRAKE 1
4 107-9095 SCREW, HHC 8.8 M12 X 1.75 X 60 MG 6
5 107-2181 NUT, PTH 10 M12 X 1.75 MG 9
6 107-9447 WASHER, FLAT NAR HD M12 MG 18
7 628-5485 M-KESSLER AXLE LT41-PL58 1
8 107-9096 SCREW, HHC 8.8 M12 X 1.75 X 70 MG 2
10 107-2934 NUT, U, M6 X 1, 0.8-4 PLATE, MG 4
11 107-9018 SCREW, HHC-F 8.8 M6 X 1 X 25 MG 4
12 107-9094 SCREW, HHC-F 8.8 M12 X 1.75 X 50 MG 1
14 628-5319 W-AXLE LS CONTACT 1
15 628-5329 W-AXLE LIMIT SWITCH CONTACT MOUNT 1

Halvorsen
3
2
4 1
4
Figure 3 Sheet 1
DRIVE AND STEER AXLE - KESSLER LT41-PL58
627-8476

Halvorsen
DO NOT PAINT
CHROME CYLINDER
4 DO NOT PAINT
4 CHROME CYLINDER
7
2
3
1
4
SOME COMPONENTS REMOVED

3 FOR CLARITY
Figure 3 Sheet 2
627-8476

Halvorsen
627-8476
1 627-8476-001 SPACER, WHEEL, KESSLER 2
2 627-8476-002 MOUNT, BRAKE CALIPER 1
3 627-8476-003 DISC, LARGE-WHEEL BRAKE, KESSLER 1
4 627-8476-004 STEERING CYLINDER 2
7 627-8476-070 CONNECTOR ROD ASSEMBLY, ML42K4P 1

Halvorsen
DRIVE AXLE
TRANSMISSION
REV. D
Figure 4 Sheet 1
DRIVE SHAFT ASSEMBLY
627-9920

Halvorsen
DRIVE AXLE
TRANSMISSION
Figure 4 Sheet 2
627-9920

Halvorsen
627-9920
1 623-5447-001 FLANGE 2
2 623-5447-002 YOKE, SLIP 2
3 623-5447-003 STUB, SLIP 2
4 623-5447-004 BEARING, CENTER 1
5 623-5447-005 YOKE, TUBE 1
6 623-5447-006 YOKE, END 1
7 623-5447-007 SHAFT, TUBE 1
8 624-8966 UNIVERSAL JOINT, MAINTENANCE FREE 3
9 623-5447-009 FLANGE, DRIVE 1
10 623-5447-010 WASHER, SHAFT 1
11 623-5447-011 NUT, SHAFT 1
12* 623-5447-012 TUBE 1
13 623-5447-013 TUBE 1
14* 623-5447-014 WASHER, LOCK 0.50 4
15* 623-5447-015 BOLT, 0.50-20 X 1.75 4
16* 623-5447-016 NUT, HEX 0.50-20 4
17 624-4055 RETAINER, WASHER, DRIVE FLANGE 1
18* 623-5447-017 KIT, BEARING STRAP C3-70-38X 1
19 627-1994 A-TOOL, 3 PIN SPANNER WRENCH 1
* 107-9032 SCREW, HHC 8.8 M6 X 1 X 45 MG 6
* 107-9035 SCREW, HHC 8.8 M6 X 1 X 60 MG 2
* NOT SHOWN

Halvorsen
Section 8. Rear Axle Assembly
1. REAR AXLE INSTALLATION 624-1225 Figure 1 2
2. REAR AXLE ASSEMBLY 624-1226 Figure 2 Sheet 1 4
3. HELPER CYLINDER ASSEMBLY 628-1509 Figure 3 7
4. WALKBEAM ASSEMBLY 624-5133 Figure 4 9
5. WALKBEAM MODIFICATION 624-1224 Figure 5 10
6. HUB ASSEMBLY 624-1240 Figure 6 12
REAR AXLE ASSEMBLY 4-8

Halvorsen
REV. E
Figure 1
REAR AXLE INSTALLATION
624-1225

Page 2
The Illustrated Parts List includes alternate parts which may not be used with your configuration.
December 2015
For applicable parts refer to the product specification at the front of the manual.
Halvorsen
REAR AXLE INSTALLATION
624-1225

20 MG
X 25 MG
3 107-2309 WASHER, FLAT NARROW HARD M8 MG 16
5 623-5449 W-PIN, REAR AXLE 2
6 623-8732 TRAY, HOSE 2
7* 624-3246 CHASSIS, ELECTRICAL (REF. SEC. 4-16) 1
8 623-9637 SPACER, BRONZE, REAR AXLE 8
9** 624-1226 A-REAR AXLE, NGSL (REF. FIG. 2) 1
10 625-3193 GREASE FITTING, STRAIGHT. 5/16-24 SHORT 2
* NOT SHOWN
**NOTE: Contact JBT for appropriate IUID label when replacing rear axle assembly 624-1225

Halvorsen
REV. C
Figure 2 Sheet 1
REAR AXLE ASSEMBLY
624-1226

Page 4
December 2015
Halvorsen
Figure 2 Sheet 2
REAR AXLE ASSEMBLY
624-1226

Halvorsen
REAR AXLE ASSEMBLY
624-1226
1 103-0744 PIN, COTTER 0.156 X 1.75 SS 4
2 107-2181 NUT, PTH 10 M12 X 1.75 MG 6
3* 107-2182 NUT, PTH 10 M16 X 2.00 MG 32
4 107-9263 NUT, PTH 8 M20 X 2.50 MG 2
6 107-9348 SCREW, HEX HEAD CAP, 10.9 M16 X 2.00 X 130 MG 32
8 107-9396 SCREW, HEX FLANGE, 10.9 M12 X 1.75 X 120 MG 8
10 107-9454 WASHER, FLAT THICK HARD M12 MG 8
11 628-1509 A-HELPER CYLINDER (REF. FIG. 4) 2
13 625-4019 BUSHING, REAR AXLE PIVOT 2
14 624-0268 SPACER, HELPER CYLINDER 2
15 624-0327 MACHINING, REAR AXLE 1
16 624-5133 A-WALKBEAM NGSL (REF. FIG. 5) 2
17 624-1240- HUB ASSEMBLY (REF. FIG. 7) 4
18 624-3092 SPACER, WALKBEAM 2
19 624-3093 SPACER, WALKBEAM OUTER 2
20 624-3095 BRACKET WELDMENT, HELPER CYLINDER UPRIGHT 2
21 624-3098 ROD, HELPER CYLINDER SPRING 2
22 624-3099 SPRING, HELPER CYLINDER UPRIGHT 4
23 624-3100 COVER, SPRING, HELPER CYLINDER UPRIGHT 4
* NOT SHOWN

Page 6
December 2015
Halvorsen
5
SEE DETAIL B 3 5
2
1
SECTION A-A
6 7
A A
9
10
DETAIL B
Figure 3
HELPER CYLINDER ASSEMBLY
628-1509

Halvorsen
HELPER CYLINDER ASSEMBLY
628-1509
1 623-4647 BRACKET, MOUNTING, HELPER CYLINDER WHEEL 1
2 623-6149 WHEEL ASSEMBLY, HELPER CYLINDER 2
3 625-3996 BUSHING, HELPER CYL WHEEL PIN 1
4 623-9568 BUSHING, HELPER CYLINDER FIBER BACKE 2
5 625-4508 W-BRACKET, HELPER CYLINDER WHEELS 1
6 624-0322 CIRCLIP, HELPER CYLINDER 0.625 2
7 624-0323 CIRCLIP, HELPER CYLINDER 1.00 1
9 628-1404 CYLINDER, HELPER 1
10 623-9560 FITTING, GREASE, STRAIGHT 0.25-28 SHORT ZP 1
NOTE: CONTACT JBT FOR APPROPRIATE IUID LABEL WHEN REPLACING HELPER
CYLINDER ASSEMBLY 628-1509.

Page 8
December 2015
Halvorsen
Figure 4
WALKBEAM ASSEMBLY
624-5133
WALKBEAM ASSEMBLY
624-5133
1 623-9568 BUSHING, HELPER CYLINDER PIVOT 2
2 624-1224 WALKBEAM MODIFICATION 1
3 623-9560 GREASE FITTING 1
NOTE: CONTACT JBT FOR APPROPRIATE IUID LABEL WHEN REPLACING REAR AXLE.

Halvorsen
REV. D
Figure 5
WALKBEAM MODIFICATION
624-1224

Page 10
December 2015
Halvorsen
WALKBEAM MODIFICATION
624-1224
1 624-1221 WALKBEAM 1
2 624-1222 FLANGE, WALKBEAM, INNER 1
3 624-1223 FLANGE, WALKBEAM, OUTER 1
4 107-1030 SCREW, HEX HEAD CAP, GR 8 0.50 - 13 X 1.25 ZP 6
5 107-2171 SCREW, SOCKET FLAT HEAD, GR 8 0.50 -13 X 1.25 ZP 4
6 107-2172 PIN, DOWEL 0.625 X 1.25 51200 6
7 107-2173 PIN, DOWEL 0.625 X 1.75 51200 6

Halvorsen
REV. H
Figure 6
HUB ASSEMBLY
624-1240

Page 12
December 2015
Halvorsen
HUB ASSEMBLY
624-1240
1 107-2360 SCREW, HHC GR 8 0.38-16 X 1.5 MG 18

10 MG
3 623-9560 FITTING, GREASE 1
4 624-0335 BEARING, TIMKEN 2.8125 BORE 1
5 624-0336 BEARING, 2.75 BORE 1
6 624-0337 SEAL, 3.25 SHAFT 1
7 624-0338 SNAP RING, 6.25 BORE 1
8 624-0339 O-RING, 6.102 O.D. 1
9 624-8970 BRAKE CALIPER, REAR 1
* 624-0341-001 SEAL 1
* 624-0341-002 OVERHAUL 1
* 624-0341-004 KIT, DISC BRAKE, REAR 1
* 624-8970-001 SERVICE KIT, SERVICE BRAKE, RR-LIN 1
* 624-8970-002 BACKING PLATE 1
* 624-8970-003 WASHER 1
* 624-8970-004 SLEEVE, AUSCO BRAKE 1
* 624-8970-005 SCREW, HEX HD, GR 8, 0.5-13 X 5.5 1
* 624-8970-006 NUT, PTHM, GR 8 0.5-13 1
10 624-0343 BRAKE DISC 1
11 624-0345 COVER 1
12 624-0352 NUT, 2.548-18 2
13 624-0353 WASHER, LOCK 1
14 624-0358 BOLT, WHEEL STUD 12
15 624-0360 SPINDLE WELDMENT, BRAKE MOUNT 1
16 624-0363 HUB, MACHINED 1
* 624-0362 HUB, CASTING 1
* 105-0351 LOCTITE, THREADLOCKER - 242, 10 ML 1
* 624-0362 HUB, CASTING 1
17 624-8564 BRACKET, HOSE NGSL 1
* NOT SHOWN

Halvorsen
Section 9. Tires and Wheels
1. TIRES INSTALLATION 624-1450 Figure 1 2
2. TIRE AND RIM ASSEMBLY 624-1451 Figure 2 3
3. TUBELESS BEAD SEAL SYSTEM 623-8708 Figure 3 4
TIRES AND WHEELS 4-9

Halvorsen
REV. C
Figure 1
TIRE INSTALLATION
624-1450
TIRES INSTALLATION
624-1450
1 624-1227 NUT, WHEEL 48
2 624-1451 A-TIRE AND RIM ASSEMBLY (REF. FIG. 2) 6

Halvorsen
Figure 2
TIRE AND RIM ASSEMBLY
624-1451
TIRE AND RIM ASSEMBLY

624-1451
1 624-0346 RIM, MODIFIED R15 (3 PIECE) 1
2 623-5388 TIRE, 355/65 R15 MICHELIN 1
4 624-1451-001 VALVE EXTENSION 1
TIRES AND WHEELS 4-9

Halvorsen
Figure 3
TUBELESS BEAD SEAL SYSTEM
623-8708
TUBELESS BEAD SEAL SYSTEM

623-8708
1 623-8708-001 SEAL, TUBELESS BEAD 250TL15 1
2 623-8708-002 VALVE 2102, 52412 1
3 623-8708-003 PLUG 2110, 46701 1

Halvorsen
Section 10. Scissors Assembly
1. SCISSORS ASSEMBLY, INNER AND OUTER 627-9635 Figure 1 Sheet 1 2
2. SCISSORS SUB-ASSEMBLY 624-0300 Figure 2 Sheet 1 5
3. SIDE SHIFT ASSEMBLY, FRONT 623-4640 Figure 3 11
4. ROLL CYLINDER ASSEMBLY, FRONT 624-6612 Figure 4 13
5. PIVOT ARM ASSEMBLY 623-7421 Figure 5 15
6. SIDE SHIFT ASSEMBLY, REAR 623-6220 Figure 6 16
7. ROLL CYLINDER ASSEMBLY, REAR 624-6613 Figure 7 18
8. LINK / PIVOT INSTALLATION 623-7273 Figure 8 Sheet 1 20
9. LINK ASSEMBLY 623-7272 Figure 9 23
SCISSORS ASSEMBLY 4-10

Halvorsen
REV. U
Figure 1 Sheet 1
SCISSORS ASSEMBLY, INNER AND OUTER
627-9635

Halvorsen
Figure 1 Sheet 2
627-9635

Halvorsen
627-9635
2 107-9259 NUT, PTH 10 M8 X 1.25 MG 4
4* 622-6913 BUMPER, PLATFORM 2
7 623-4640 SIDE SHIFT ASSEMBLY, FRONT 1
8 624-3248 SCISSORS ELECTRICAL (REF. SEC. 4-16) 1
9 625-9350 SCISSORS HYDRAULICS (REF. SEC. 4-15) 1
10 623-6220 A-BOGY (SIDE SHIFT) REAR (REF. FIG. 3-6) 1
11 107-2272 SCREW, SOCKET FLAT HEAD, GR 8 0.75 - 16 X 6 MG 12
12 624-0300-500 A-SUBASSEMBLY, SCISSORS (REF. FIG. 3-6) 1
13 107-2232 NUT, PTH LT THIN 0.75-16 MG 16
14 624-8917 SCREW, MOD., SOCKET FLAT HEAD, GR 8 0.75-16 X 4

5.75 MG
* NOT SHOWN

Halvorsen
REV. E
Figure 2 Sheet 1
SCISSORS SUB-ASSEMBLY
624-0300

Halvorsen
Figure 2 Sheet 2
624-0300

Halvorsen
Figure 2 Sheet 3
624-0300

Halvorsen
Figure 2 Sheet 4
624-0300

Halvorsen
624-0300
1 107-1050 SCREW, HEX HEAD CAP, 8.8 M10 X 1.50 X 35 ZP 2
2 107-1912 WASHER, LOCK M10 ZP 5
X 20 MG
5 624-6597 SPACER, SCISSOR PITCH CYLINDER 4
6* 625- 4519 SHAFT, LOWER REAR ROLLER PIVOT 2
7 623-4598 SPACER, LOWER PITCH CYLINDER 4
8 623-4622 PIVOT SHAFT, SCISSORS MAIN 2
9 623-4629 PIVOT SHAFT WELDMENT, UPPER SCISSOR CYLINDER 1
10 623-7422 A-ROLLER ASSEMBLY, LOWER SCISSOR 2
* 623-7367 ROLLER, FLANGED 1
* 625- 4012-001 BUSHING, LOWER ROLLER 1
11 623- 9560 FITTING, GREASE, STRAIGHT 0.25-28 SHORT 10
12 624-1403 BUSHING, LOWER FRONT 4
13 624-1404 BUSHING, MAIN CONNECTION 4
14 624-1405 BUSHING, PITCH ARM 4
15 624-1406 BUSHING, LOWER PITCH CYLINDER 2
16 624-1415 KEEPER PLATE 2
17 624-1453 TUBE, LIFT CYLINDER, SPACER 4
18 624-1454 TUBE, LIFT CYLINDER, SPACER 4
19 624-1997 SPACER, PITCH ARM 4
20 624-1998 SPACER, MAIN OUTER CONNECTION 2
21 624-1999 SPACER, MAIN INNER CONNECTION 2
22 624-2000 SCISSOR MOD., INNER 1
23 624-2001 WASHER, THRUST 2
24 624-2002 SPACER, SCISSORS 2
25 624-2003 PIVOT SHAFT WELDMENT, SCISSORS OUTER 2

Halvorsen
624-0300
26 624-2005 PIVOT SHAFT WELDMENT, PITCH ARM UPPER 2
27 624-2008 PIVOT SHAFT WELDMENT, PITCH CYLINDER 2
28 624-2011 PIVOT SHAFT WELDMENT, PITCH ARM LOWER 2
29 625- 4519 SHAFT, LOWER REAR ROLLER PIVOT 2
30 624-2030-500 PITCH ARM MOD., OUTER SCISSOR 1
31 624-2031 WASHER, THRUST 2
32 624-2040 OUTER SCISSOR MOD., LEFT 1
33** 624-2050 OUTER SCISSOR MOD., RIGHT 1
* NOT SHOWN
**Contact JBT for appropriate IUID label when replacing this part.
NOTE: Contact JBT for appropriate IUID label when replacing part 624-0300.

Halvorsen
REV. F
Figure 3
SIDE SHIFT ASSEMBLY, FRONT
623-4640

Halvorsen
SIDE SHIFT ASSEMBLY, FRONT
623-4640
1 104-1587 CIRCLIP, ROLLER, D1400-0500 2
5 623-4624 SPACER, SIDE SHIFT 2
6 623-5393-500 CYLINDER, FRONT SIDE SHIFT 1
* 623-5393-090 SEAL KIT 1
8 623-7421 PIVOT ARM ASSEMBLY (REF. FIG. 9) 2
9 623-8275 SUPPORT WELDMENT, CYLINDER SHORT 1
10 623-8282 SLEEVE, SIDE SHIFT CYLINDER 2
17 624-6612-500 ROLL CYLINDER ASSEMBLY, FRONT (REF. FIG. 8) 2
* NOT SHOWN
**Contact JBT for appropriate IUID label when replacing 623-4640.

Halvorsen
6 4
2
A 3
1
A SECTION A-A
3-D REF VIEW
Figure 4
ROLL CYLINDER ASSEMBLY, FRONT
624-6612

Halvorsen
ROLL CYLINDER ASSEMBLY, FRONT
624-6612
1 104-1589 CIRCLIP, ROLLER, D1400-1100-B 1
3 623-4623 BUSHING, SIDE SHIFT 1
4 623-6271 BEARING, SPHERICAL PLAIN 110 MM BORE 1
6** 624-1991 ROLL CYLINDER, FRONT 1
* 624-1991-090 SEAL KIT 1
7 623-9561 ROD WIPER, 3.5 SHAFT DIAMETER 2
* NOT SHOWN

Halvorsen
REV. D
Figure 5
PIVOT ARM ASSEMBLY
623-7421
PIVOT ARM ASSEMBLY

623-7421
1 623-4599 PIVOT ARM 1
2 623-4636 BEARING, SELF-LUBRICATING 1
3 623-6272 BEARING, SPHERICAL PLAIN 50 MM BORE 1

Halvorsen
REV. E
Figure 6
SIDE SHIFT ASSEMBLY, REAR
623-6220

Halvorsen
SIDE SHIFT ASSEMBLY, REAR
623-6220
1 104-1588 CIRCLIP, ROLLER, D1400-0550 2
2* 107-9419 SCREW, HEX FLANGE, 8.8 M10 X 1.50 X 35 MG 4
6 623-4624 SPACER, SIDE SHIFT 2
7 623-4632 ROLLER, FLANGED 2
8 623-5394-500 CYLINDER, REAR SIDE SHIFT 1
* 623-5393-090 SEAL KIT 1
10 625- 4016 BEARING, SPHERE-ROL - WITH PHYMET 2
11 623-8279 SUPPORT WELDMENT, CYLINDER LONG 1
12 623-8282 SLEEVE, SIDE SHIFT CYLINDER 2
16 104-1584 CIRCLIP, ROLLER, D1300-1000 2
17 624-6613-500 ROLL CYLINDER ASSEMBLY, REAR (REF. FIG. 11) 2
* NOT SHOWN
NOTE: CONTACT JBT FOR APPROPRIATE IUID LABEL WHEN REPLACING SIDE SHIFT
ASSEMBLY REAR 623-6220.

Halvorsen
1
6 3
A
4 5
A SECTION A-A
3-D REF VIEW
Figure 7
ROLL CYLINDER ASSEMBLY, REAR
624-6613

Halvorsen
ROLL CYLINDER ASSEMBLY, REAR
624-6613
1** 624-1992 ROLL CYLINDER, REAR 1
* 624-1991-090 SEAL KIT 1
3 623-6271 BEARING, SPHERIC PLAIN 110 MM BORE 1
4 623-4623 BUSHING, SIDE SHIFT 1
5 104-1589 CIRCLIP, ROLLER, D1400-1100 1
6 104-1590 CIRCLIP, ROLLER, D1300-1600 1
7 623-9561 ROD WIPER, 3.5 SHAFT DIAMETER 2
* NOT SHOWN
**Contact JBT for appropriate IUID label when replacing 623-6220.

Halvorsen
REV. F
Figure 8 Sheet 1
LINK / PIVOT INSTALLATION
623-7273

Halvorsen
Figure 8 Sheet 2
623-7273

Halvorsen
623-7273
1 623-7272 LINK ASSEMBLY (REF. FIG. 14) 1
2 623-7265 PIPE 4
3 623-7271 PIN WELDMENT 2
7 623-4637 PIN WELDMENT, PIVOT 2

Halvorsen
REV. B
Figure 9
LINK ASSEMBLY
623-7272
LINK ASSEMBLY
623-7272
1 623-7266 SNAP RING 2
2 623-7268 BEARING 2
3 623-7269 LINK WELDMENT 1
4 623-9560 GREASE FITTING 1

Halvorsen
Section 11. Deck Assembly
1. DECK ASSEMBLY 627-9636 Figure 1 Sheet 1 2
2. FOLDING WINGS / CAB AND ENGINE HATCH 623-6920 Figure 2 Sheet 1 6
3. FOLDING WING ASSEMBLY, LEFT SIDE 624-6644 Figure 3 11
4. FOLDING WING ASSEMBLY, RIGHT SIDE 623-6956 Figure 4 13
5. SCISSOR TRACKS INSTALLATION 623-7214 Figure 5 Sheet 1 14
6. SCISSOR TRACKS INSTALLATION, REAR 623-7215 Figure 6 17
7. TRACTION ROLLER INSTALLATION 624-4020 Figure 7 19
8. TRACTION ROLLER ASSEMBLY 628-4088 Figure 8 Sheet 1 21
9. BUMPERS INSTALLATION 624-1400 Figure 9 Sheet 1 24
10. CASTER AND ROLLER TRAY ASSEMBLY 623-6900 Figure 10 28
11. CASTER TRAY ASSEMBLY 624-3077 Figure 11 30
12. ROLLER TRAY ASSEMBLY 624-3078 Figure 12 32
13. IMPACT ROLLERS INSTALLATION 623-6895 Figure 13 35
14. IMPACT ROLLER ASSEMBLY 623-7250 Figure 14 37
15. PALLET STOP INSTALLATION 623-6911 Figure 15 Sheet 1 38
16. PALLET STOP ASSEMBLY 624-1211 Figure 16 44
17. TINE WAY COVERS INSTALLATION 623-6820 Figure 17 46
18. TINE WAY COVER ASSEMBLY 624-3075 Figure 18 47
19. TIE DOWN / LIFT PROVISION INSTALLATION, DECK 624-3115 Figure 19 Sheet 1 48
20. MUD FLAP ASSEMBLY 623-9632 Figure 20 52
21. PLACARD INSTALLATION, DECK 624-7168 Figure 21 54
22. CARGO TIE DOWN KIT, DECK PLATFORM 628-1270 Figure 22 Sheet 1 56
DECK ASSEMBLY 4-11

Halvorsen
30 27 28 29 34
26 29
17
DETAIL A
1
31 27 28 29 34
2
26 29
33
33
25
16
33
35
3
35
DETAIL A
15
14
13
Figure 1 Sheet 1
DECK ASSEMBLY
627-9636

Halvorsen
11
18
6
5
4
24
12
35
Figure 1 Sheet 2
DECK ASSEMBLY
627-9636
DECK ASSEMBLY 4-11

4-11
Page 4
December 2015
USE 624-8955 USE 624-8971 USE 624-8955 USE 624-8971 USE 624-8955
USE 625-4258
627-9636
Figure 1 Sheet 3
DECK ASSEMBLY
USE 624-8971 USE 625-4459 USE 624-8955 USE 625-4258
USE 625-4459
USE 624-8955 USE 624-8955 USE 624-8971
TOP VIEW
SOME COMPONENTS REMOVED FOR CLARITY
REPLACEMENT HINGE DIAGRAM (SERVICE PARTS ONLY)
REF: 624-8954 FOR INSTALLATION INSTRUCTIONS
Halvorsen
Halvorsen
DECK ASSEMBLY
627-9636
1 623-7350 W-DECK, PLATFORM 1

2 623-6820 I-TINE WAY COVER 1
3 623-6900 I-CASTER/ROLLER TRAY 1
4 107-9062 SCREW, HHC 8.8 M8 X 1.25 X 40 MG 4
5 107-9259 NUT, PTH 8 M8 X 1.25 MG 4
11 624-1400 I-BUMPERS, NGSL 1
12 623-7214 I-SCISSOR TRACKS, ALUMINUM DECK 1
13 623-6920 I-FOLDING WINGS, CAB AND ENGINE HATCH 1
14 623-6911 I-PALLET STOP 1
15 624-4020 I-TRACTION ROLLER 1
16 623-6700 I-HANDRAIL / WALKDECK / GUIDE 1
17 623-6895 I-IMPACT ROLLERS 1
18 628-0452 IH-DECK 1
24 623-9632 A-MUD FLAP 2
25 624-3115 I-TIE DOWN / LIFT PROVISION, DECK 1
26 107-9092 SCREW, HHC-F 8.8 M12 X 1.75 X 35 MG 2
27 107-9095 SCREW, HHC 8.8 M12 X 1.75 X 60 MG 4
28 107-9261 NUT, PTH 8 M12 X 1.75 MG 4
30 624-5162 W-PLATE, TINEWAY GUARD, RIGHT 1
31 624-5163 W-PLATE, TINEWAY GUARD, LEFT 1
32 624-6065 GASKET, TINEWAY GUARD 2
33 624-7168 I-PLACARD, DECK 1
34 107-9447 WASHER, FLAT NARROW HD M12 MG 4
35 628-1512 PLATE, DECK BUMPER OUTER DOUBLER 1
36 628-1516 PLATE, DECK BUMPER INNER DOUBLER 1
37 107-9214 SCREW, SFH-F 10.9 M12 X 1.75 X 50 MG 4
DECK ASSEMBLY 4-11

Halvorsen
REV. N
Figure 2 Sheet 1
FOLDING WINGS / CAB AND ENGINE HATCH
623-6920

Halvorsen
Figure 2 Sheet 2
623-6920
DECK ASSEMBLY 4-11

Halvorsen
28
Figure 2 Sheet 3
623-6920

Halvorsen
Figure 2 Sheet 4
623-6920
DECK ASSEMBLY 4-11

Halvorsen
623-6920
1 624-6644 FOLDING WING ASSEMBLY, LEFT (REF. FIG. 7) 1

2 623-6956 FOLDING WING ASSEMBLY, RIGHT (REF. FIG. 8) 1
3 623-8466 PIN, QUICK RELEASE L-HANDLE, 7/16 IN. 1
4 623-8697 GASKET, TIE DOWN 1
5 624-6056 PIN WELDMENT, FOLDING WING 1
6 623-7164 SPRING, LEFT SIDE WING 1
7 623-7161 PIN, SQUARE 1
8 623-6616 GUIDE, SPRING TUBE 1
9 624-3130 DECK WELDMENT, HINGED 1
11 107-9180 SCREW, SOCKET FLAT HEAD, 10.9 M8 X 1.25 X 30 MG 4
12 107-9259 NUT, PTH 10 M8 X 1.25 MG 18
13 623-8212 GASKET, HINGE 8
15 624-4026 HINGE, SS 4
18 623-7344 ENGINE HATCH 1
19 623-7104 TOP WELDMENT, LOCK 2
* 623-7104-001 KIT, TOP LOCK
21 623-7121 SPRING, LOCK 2
26 HFS0178 NUT, JAM GR 5 0.50 -13 SS 2
27 624-4182 HANDLE, CAB LOCKDOWN 1
28 624-4185 LOCKDOWN, CAB LOCATOR 1
29 624-4186 ROD, THREADED 1
30 624-4187 RAM, CAB LOCKDOWN 1
30 MG
* NOT SHOWN

Halvorsen
REV. C
Figure 3
FOLDING WING ASSEMBLY, LEFT SIDE
624-6644
DECK ASSEMBLY 4-11

Halvorsen
FOLDING WING ASSEMBLY, LEFT SIDE
624-6644
1 107-9181 SCREW, HH C, 8.8 M8 X 1.25 X 35 MG 2
3 107-2168 NUT, INSERT, ALUMINUM, M8 X 1.25 GRIP 3.8 4
5 623-4350 W-WING, LEFT 1
6 624-6643 SKID PLATE, LEFT SIDE FOLDING WING 1
7 107-9259 NUT, PTH 10 M8 X 1.25 MG 1
9 623-7104 WELDMENT, TOP, LOCK 1
10 623-7121 SPRING, LOCK 1

Halvorsen
REV. F
Figure 4
FOLDING WING ASSEMBLY, RIGHT SIDE
623-6956
FOLDING WING ASSEMBLY, RIGHT SIDE

623-6956
1 623-7158 FOLDING WING, MACHINED 1
2 623-4368 BAR, ROUND RETRACT PIN 1
3 623-4369 BAR, ROUND RETRACT PIN HANDLE 1
5 107-9258 NUT, PTH 8 M6 X 1.00 MG 1
DECK ASSEMBLY 4-11

Halvorsen
DECK WELDMENT REF
SECTION A-A
Figure 5 Sheet 1
SCISSOR TRACKS INSTALLATION
623-7214

Halvorsen
DETAIL C
5
3
1
5
DETAIL C
SECTION B-B
Figure 5 Sheet 2
623-7214
DECK ASSEMBLY 4-11

Halvorsen
623-7214
1 623-7195 TRACK, ROLLER RAIL, LONG 2
3 623-7197 TRACK, ROLLER RAIL, SHORT 2
5 107-9193 SCREW, SOCKET FLAT HEAD, FULL THREAD 10.9 M10 50

X 1.5 X 25 MG

Halvorsen
REV. D
Figure 6
SCISSOR TRACKS INSTALLATION, REAR
623-7215
DECK ASSEMBLY 4-11

Halvorsen
SCISSOR TRACKS INSTALLATION, REAR
623-7215
1 623-8562 TRACK, ROLLER RAIL, REAR 2
2 623-8561 PLATE, REAR ROLLER TRACK 2
5 107-2181 NUT, PTH 10 M12 X 1.75 MG 20

Halvorsen
REV. A
Figure 7
TRACTION ROLLER INSTALLATION
624-4020
DECK ASSEMBLY 4-11

Halvorsen
TRACTION ROLLER INSTALLATION
624-4020
1 107-9259 NUT, PTH 10 M8 X 1.25 MG 36
4 623-4088 TRACTION ROLLER ASSEMBLY (REF. FIG. 13) 9

Halvorsen
1
21
22
14
17
24
10
22
9
FOR CLARITY
14
15 14 18 19
Figure 8 Sheet 1
TRACTION ROLLER ASSEMBLY
628-4088
DECK ASSEMBLY 4-11

Halvorsen
12
16
6
4
20
12
2 13
11
7
8 23
5
25
13
Figure 8 Sheet 2
628-4088

Halvorsen
628-4088
1 623-6557 W-HOUSING, TRACTION ROLLER 1
2 628-4060 TRACTION ROLLER, GROOVED 1
3 623-6562 SPRING, LIMITER 1
5 620-0085 BEARING, 30 MM SELF ALIGNING 2
6 620-1591 SPROCKET, 12T 1.00 IN. BORE SINGLE 1
7 622-0463 SHIM, MOTOR MOUNT 1
9 623-6593 W-ARM, ADJUSTING, TRACTION ROLLER 1
10 623-6559 PLATE, MOUNTING 2
11 107-9260 NUT, PTH 8 M10 X 1.50 MG 4
12 107-9196 SCREW, SFH-F 10.9 M10 X 1.5 X 40 MG 4
13 107-9329 SCREW, HHC 10.9 M12 X 1.75 X 50 MG 2
15 624-4026 HINGE, STAINLESS STEEL 2
16 107-2181 NUT, PTH 10 M12 X 1.75 MG 2
17 107-9079 SCREW, HHC-F 8.8 M10 X 1.5 X 25 MG 4
18 107-9259 NUT, PTH 8 M8 X 1.25 MG 4
19 107-9303 SCREW, HHC 10.9 M8 X 1.25 X 30 MG 4
20 623-5473 A-CONVEY CHAIN, LOW STRETCH 1
21 107-2081 PIN, ROLL 302 0.5 X 3 STAINLESS STEEL 1
22 107-9267 NUT, HEX 8 M8 X 1.25 MG 2
23 104-0977 RING, SNAP EXT 1.00 SHAFT 1
24 624-6073 W-LIMITER, TRACTION ROLLER 1
25 620-1428 MOTOR, HYDRAULIC 1
DECK ASSEMBLY 4-11

Halvorsen
7 15 2 6 12 6 7 1 2 15 3 15
15 3 5
2 1 1 2
8
8
FRONT VIEW OF DECK
W-DECK (REF)
15 3 12
5 2 13
REAR VIEW OF DECK
Figure 9 Sheet 1
BUMPERS INSTALLATION
624-1400

Halvorsen
15
SECTION A-A
Figure 9 Sheet 2
624-1400
DECK ASSEMBLY 4-11

Halvorsen
BOTTOM VIEW
10
11
Figure 9 Sheet 3
624-1400

Halvorsen
624-1400
2 107-2181 NUT, PTH 10 M12 X 1.75 MG 18
3 107-9278 WASHER, FLAT STD. HARD M12 MG 30
5 623-5488 BUMPER, RUBBER 6
6 623-7192 BUMPER, FRONT 6
7 624-3136 SPACER, BUMPER 6
10 624-5173 STRIP, DECK, RUB 4
11 107-2233 SCREW, SOCKET FLAT HEAD, #8-32 X 0.38 S.S. 16
13 624-7192 EXTENSION, REAR BUMPER 2
DECK ASSEMBLY 4-11

Halvorsen
REV. G
Figure 10
CASTER AND ROLLER TRAY ASSEMBLY
623-6900

Halvorsen
CASTER AND ROLLER TRAY ASSEMBLY
623-6900
1 624-3077 CASTER TRAY ASSEMBLY 1
2 624-3078 ROLLER TRAY ASSEMBLY 1
3 623-7104 TOP WELDMENT, LOCK 31
* 623-7104-001 KIT, TOP LOCK
4 623-7121 SPRING, LOCK 31
7 107-9259 NUT, PTH 10 M8 X 1.25 MG 31
* NOT SHOWN
DECK ASSEMBLY 4-11

Halvorsen
Figure 11
CASTER TRAY ASSEMBLY
624-3077

Halvorsen
CASTER TRAY ASSEMBLY
624-3077
1 107-2310 SCREW, SOCKET FLAT HEAD, A2 M5 X 0.08 X 25 S.S. 144
2 107-1975 WASHER, FLAT STD A2 M5 S.S. 144
3 107-1976 NUT, PTH A2 M5 X 0.80 S.S. 144
4 624-8299 CASTER, LOW PROFILE 36
6 624-3080 TRAY, 31.50 IN., CASTER 3
7 624-3081 TRAY, 27.80 IN., CASTER 3
8 624-3082 TRAY, 19.34 IN., CASTER 3
* 624-3077-003 TRAY WITH CASTERS - 3082 (3 CASTERS) 1
* NOT SHOWN
NOTE: PART NO. 623-8460, SPACER, CASTER, USED UNDER ORIGINAL SPLIT-ROLLER
CASTER IS OBSOLETE. DO NOT USE UNDER SINGLE-ROLLER LOW PROFILE
CASTER, PART NO. 624-8299 (ITEM 4).
DECK ASSEMBLY 4-11

Halvorsen
REV. B
Figure 12
ROLLER TRAY ASSEMBLY
624-3078

Halvorsen
624-3078
1 107-2310 SCREW, SOCKET FLAT HEAD, A2 M5 X 0.8 X 25 S.S. 48
3 107-1976 NUT, PTH GR A2 M5 X 0.8 S.S. 48
4 624-6626 NUT, RETAINING GR 8 STEEL, 7/16-20 220
5 624-8299 CASTER, LOW PROFILE 12
7 624-3079 TRAY, 27.74 IN., CABIN HATCH 1
8 624-3083 TRAY, 37.92 IN., COMBINED 4
9 624-3084 TRAY, 37.92 IN., ROLLER 6
10 624-3085 TRAY, 29.29 IN., ROLLER 6
11 624-3086 TRAY, 24.29 IN., ROLLER 1
12 624-3087 TRAY, 30.42 IN., ROLLER 1
13 624-3088 TRAY, 15.30 IN., ROLLER 2
14 624-3089 TRAY, 10.30 IN., LEFT WING 1
15 624-3090 TRAY, 37.92 IN., KNUCKLE 2
16 624-4021 WASHER, GRAVITY ROLLER 220
17 624-4022 SHAFT, GRAVITY ROLLER 110
18 624-4025 TUBE ASSEMBLY, GRAVITY ROLLER 110
* 624-4023 BEARING, GRAVITY ROLLER 2
* 624-4024 TUBE, GRAVITY ROLLER 1
* 624-8964 K-RETAINER, TRAYS FULL DECK 1
* 107-9450 WASHER, FENDER STD HARD M6 MG 4
* 624-8899 K-RETAINER, TRAYS 1
* 107-9450 WASHER, FENDER STD HARD M6 MG 4
* 624-3078-002 TRAY WITH ROLLERS - 3089 (2 ROLLERS) 1
DECK ASSEMBLY 4-11

Halvorsen
624-3078
* 624-3078-033 TRAY WITH ROLLERS AND CASTERS - 3083 1

(3 CASTERS AND ROLLERS)
* NOT SHOWN
NOTE: PART NO. 623-8460, SPACER, CASTER, USED UNDER ORIGINAL SPLIT-ROLLER
CASTER IS OBSOLETE. DO NOT USE UNDER SINGLE-ROLLER LOW PROFILE
CASTER, PART NO. 624-8299 (ITEM 5).

Halvorsen
REV. B
Figure 13
IMPACT ROLLERS INSTALLATION
623-6895
DECK ASSEMBLY 4-11

Halvorsen
IMPACT ROLLERS INSTALLATION
623-6895
2 107-9261 NUT, PTH 8 M12 X 1.75 MG 7
4 623-7250 A-IMPACT ROLLER (REF. FIG. 20) 7

Halvorsen
2
4
3-D REF VIEW
Figure 14
IMPACT ROLLER ASSEMBLY
623-7250
IMPACT ROLLER ASSEMBLY

623-7250
1 107-2084 SCREW, SOCKET HEAD SET, C 45H M6 X 1.00 X 6 ZP 2
2 112-1555 NUT, JAM HEX 5/8-11 CP 2
3 624-8967 SPRING PLUNGER 2
4 623-7239 BAR, ROLLER SHAFT 1
5 625-4504 A- ROLLER 1
6 623-7246 SUPPORT WELDMENT, #1 IMPACT ROLLER 1
DECK ASSEMBLY 4-11

Halvorsen
REV. H
Figure 15 Sheet 1
PALLET STOP INSTALLATION
623-6911

Halvorsen
Figure 15 Sheet 2
623-6911
DECK ASSEMBLY 4-11

Halvorsen
Figure 15 Sheet 3
623-6911

Halvorsen
Figure 15 Sheet 4
623-6911
DECK ASSEMBLY 4-11

Halvorsen
Figure 15 Sheet 5
623-6911

Halvorsen
623-6911
1 624-1211 A -PALLET STOP (REF. FIG. 26) 2
3 107-2181 NUT, PTH 10 M12 X 1.75 MG 40

25 MG
6 107-9258 NUT, PTH 8 M6 X 1.00 MG 8
7 623-6957 HOUSING WELDMENT, HEADLIGHT 2
8 623-7285 GASKET, HEADLIGHT 1
9 623-7286 GASKET, HEADLIGHT 1
12* 107-9019 SCREW, HEX HEAD CAP, 8.8 M6 X 1.00 X 30 MG 2
13 624-8307 SHIM, PALLET STOP 4
* NOT SHOWN
DECK ASSEMBLY 4-11

Halvorsen
REF: HYD. CYL. GUIDE/STOP
REV. B
Figure 16
PALLET STOP ASSEMBLY
624-1211

Halvorsen
PALLET STOP ASSEMBLY
624-1211
1 103-0751 PIN, CLEVIS 0.50 X 1.75 PL 3
2 107-9263 NUT, PTH 8 M20 X 2.50 MG 3
4 110-0350 PIN, COTTER 0.13 X 1.00 ZP 3
5 623-7172 BRACKET, LINK PALLET STOP, MACHINED 1
6 624-1216 BRACKET WELDMENT, PALLET STOP 1
7 624-1219 STOP, PALLET, MACHINED 3
DECK ASSEMBLY 4-11

Halvorsen
REV. D
Figure 17
TINE WAY COVERS INSTALLATION
623-6820
TINE WAY COVERS INSTALLATION

623-6820
1 624-3075 COVER ASSEMBLY, TINE WAY (REF. FIG. 28) 1

Halvorsen
REV. C
Figure 18
TINE WAY COVER ASSEMBLY
624-3075
TINE WAY COVER ASSEMBLY

624-3075
1 107-2315 SCREW, SOCKET HEAD SET, 12.9 12/M 10 X 20 MG 8
2 624-3070 COVER ASSY, TINE WAY, LARGE 3
3 624-3071 COVER ASSY, TINE WAY, MEDIUM 1
4 624-3072 COVER ASSY, TINE WAY, SMALL 1
DECK ASSEMBLY 4-11

Halvorsen
3
4
33
16
9
12
DETAIL B
DETAIL K
DETAIL B DETAIL A
DETAIL A
8
30
32 31
DETAIL K
Figure 19 Sheet 1
TIE DOWN / LIFT PROVISION INSTALLATION, DECK
624-3115

Halvorsen
22 19
16 34
17 7
26
7 17
DETAIL C
BOTH SIDES
DETAIL F
DETAIL E BOTH SIDES
BOTH SIDES
FRONT AND REAR
DETAIL J
DETAIL D
DETAIL N
DETAIL H
DETAIL C
DETAIL E
32 31
DETAIL F DETAIL G
17 7
31 32
REFER TO I-AC OPTION
DETAIL D
FOR CLARITY
33
Figure 19 Sheet 2
624-3115
DECK ASSEMBLY 4-11

Halvorsen
20 16
REFER TO I-AC OPTION 32 31
33
26
DETAIL J
BOTH SIDES
DETAIL N
FOR CLARITY
27
7 21
18 19
16 17 17 7
7 17
DETAIL H
25
BOTH SIDES
FOR CLARITY
DETAIL G
BOTH SIDES
Figure 19 Sheet 3
624-3115

Halvorsen
624-3115
8 623-6818 BRACKET, TIE DOWN RING 26
9 623-6937 D-RING 26
12 624-3105 PROVISION, LIFT-DECK 4
17 107-2181 NUT, PTH 10 M12 X 1.75 MG 30
18 107-2183 NUT, PTH 10 M20 X 2.50 MG 8
25 624-7152 PLATE, BACKING, DECK TIE DOWN 2
26 624-7155 RESTRAINT, 25K TIE DOWN 2
27 624-7157 ADAPTER, RESTRAINT, 25K TIE DOWN 4
30 107-2880 SCREW, SHC, 12.9 M10 X 1.5 X 45 MG 4
31 107-9456 WASHR, FLAT NARROW HARD M10 MG 52
32 107-9260 NUT, PTH 8 M10 X 1.50 MG 52
33 107-2899 SCREW, SHC 12.9 M10 X 1.5 X 190 MG 48
34 107-9331 SCREW, HHC 10.9 M12 X 1.75 X 70 MG 8
DECK ASSEMBLY 4-11

Halvorsen
Figure 20
MUD FLAP ASSEMBLY
623-9632

Halvorsen
MUD FLAP ASSEMBLY
623-9632
2 623-9634 CLAMP, MUD FLAP 2
3 623-9635 MUD FLAP 1
5 107-9259 NUT, PTH 10 M8 X 1.25 MG 6
7 624-4197 SUPPORT WELDMENT, MUD FLAP 1
DECK ASSEMBLY 4-11

Halvorsen
REF - WALKDECK/HANDRAILS
1 2 3 4
REF - WALKDECK/HANDRAILS
1 2 3 4
REF - DECK
WELDMENT
6
VIEW A
1 2 5 6
VIEW A
VIEW FROM REAR
NOTE ORIENTATION
OF ITEM 6
ITEMS REMOVED
FOR CLARITY
Figure 21
PLACARD INSTALLATION, DECK
624-7168

Halvorsen
PLACARD INSTALLATION, DECK
624-7168
1 624-7149 A-PLACARD, DOT FLIP HAZARD 3
3 107-9258 NUT, PTH 8 M6 X 1.00 MG 5
4 107-9168 SCREW, SFH-F 10.9 M6 X 1 X 20 MG 6
5 107-9018 SCREW, HHC-F 10.9 M6 X 1 X 25 MG 12
6 624-7156 SPACER, DOT FLIP HAZARD 1
DECK ASSEMBLY 4-11

Halvorsen
B
B
A
A
Figure 22 Sheet 1
CARGO TIE DOWN KIT, DECK PLATFORM
628-1270

Halvorsen
Figure 22 Sheet 2
628-1270
DECK ASSEMBLY 4-11

Halvorsen
628-1270
1 107-2880 SCREW, SHC 12.9 M10 X 1.5 X 45 MG 2
2 623-6818 BRACKET, D-RING CARGO TIE DOWN 1
4 107-9260 NUT, PTH 8 M10 X 1.50 MG 2
5 623-6937 D-RING, CARGO TIE DOWN 10,000 LB 1
6 105-0327-901 LOCTITE 242 (24205) 0.5 ML 1
7 107-2899 SCREW, SHC 12.9 M10 X 1.5 X 190 MG 2
8 DWG-628-1270 K-CARGO TIE DOWN, DECK PLATFORM 1

Halvorsen
Section 12. Walk-deck and Handrail Assembly
1. HANDRAIL, WALKDECK AND GUIDE

INSTALLATION 623-6700 Figure 1 Sheet 1 2
2. HANDRAIL AND WALKDECK ASSEMBLY 623-4705 Figure 2 10
3. HANDRAIL AND WALKDECK ASSEMBLY,

TOOL BOX 623-6850 Figure 3 12

LEFT REAR 623-6860 Figure 4 14

TOOL BOX 623-6880 Figure 5 16

RIGHT REAR 623-6890 Figure 6 18

RIGHT FRONT 623-6100 Figure 7 Sheet 1 20
8. HANDRAIL AND WALKDECK ASSEMBLY 623-8710 Figure 8 25
9. GUIDE AND PALLET LOCK ASSEMBLY 623-7330 Figure 9 27
10. PALLET LOCK ASSEMBLY 623-4251 Figure 10 29
WALK-DECK AND HANDRAIL ASSEMBLY 4-12

Halvorsen
REF - DECK WELDMENT
REV. H
Figure 1 Sheet 1
HANDRAIL, WALKDECK AND GUIDE INSTALLATION
623-6700

Halvorsen
Figure 1 Sheet 2
623-6700

Halvorsen
Figure 1 Sheet 3
623-6700

Halvorsen
Figure 1 Sheet 4
623-6700

Halvorsen
Figure 1 Sheet 5
623-6700

Halvorsen
Figure 1 Sheet 6
623-6700

Halvorsen
Figure 1 Sheet 7
623-6700

Halvorsen
623-6700
1 107-2217 NUT, PTH GR 8 0.88-9 MG 8

2 107-2216 NUT, PTH GR 8 0.63-11 MG 46
3 107-9279 WASHER, FLAT HARD M16 MG 30
4* 107-9450 WASHER, FENDER STD HARD M6 MG 4
5 623-4705 HANDRAIL AND WALKDECK ASSEMBLY (REF. FIG. 8) 1
6 624-5028 SHAFT, WALKDECK PIN 6
10 623-7330 GUIDE AND PALLET LOCK ASSEMBLY (REF. FIG. 17) 1
14 623-8707 LANYARD, 20 WITH TAB 25
16* 107-9258 NUT, PTH 8 M6 X 1.00 MG 19
17* 107-9450 WASHER, FENDER STD HARD M6 MG 19
22* 107-9018 SCREW, HEX HEAD CAP, FULL THREAD 10.9 M6 X 1 X 3
25 MG
23* 107-9259 NUT, PTH 10 M8 X 1.25 MG 2
24* 107-9046 SCREW, HEX HEAD CAP, FULL THREAD 10.9 M8 X 1.25 2
X 25 MG
25* 107-9275 WASHER, FLAT STD HARD M8 MG 4
26 624-8893 TUBE, SS 1.0 IN. X 0.049 X 1.00 2
27 624-8895 TUBE, SS 0.75 IN. X 0.049 X 2.00 4
28 624-8894 TUBE, SS 0.75 IN. X 0.049 X 1.00 2
* 624-7401 KIT-FIELD FIX, NGSL 1
* 625-4258 K-HINGE REAR NGSL 1
* 625-4459 K-HINGE SUPPORT, REAR GUIDE RAIL 1
* NOT SHOWN

Halvorsen
REV. D
Figure 2
HANDRAIL AND WALKDECK ASSEMBLY
623-4705

Halvorsen
623-4705
1 623-6850 HANDRAIL AND WALKDECK, TOOL BOX 1
2 623-6860 HANDRAIL AND WALKDECK, LEFT REAR 1
4 623-6880 HANDRAIL AND WALKDECK, TOOL BOX 1
5 623-6890 HANDRAIL AND WALKDECK, RIGHT REAR 1
6 623-6100 HANDRAIL AND WALKDECK, RIGHT FRONT 1
7 623-8710 HANDRAIL AND WALKDECK 1
8* 104-1607 LINK, CONNECTING PAIR 0.25 S.S. 4
9 627-6439 CHAIN, STRAIGHT LINK 2 ft.
10 107-2780 BOLT, EYE SH 0.75-0.38-16 X 2.5 S.S. 4
12 107-2763 NUT, PTH A2 TH 0.38-16 S.S. 4
13 623-7275 HOOK, SLIDE BOLT / SWIVEL SNAP S.S. 2
* NOT SHOWN

Halvorsen
REV. D
Figure 3
HANDRAIL AND WALKDECK ASSEMBLY, TOOL BOX
623-6850

Halvorsen
623-6850
1 104-0815 LINK, CONNECTING WIDE 0.13 S.S. 4
4 107-2308 NUT, PTH A2 M6 X 1.00 S.S. 4
5 107-1782 SCREW, HEX HEAD CAP, FULL THREAD A2 M6 X 1.00 X 4

25 S.S.
6 620-6376 LANYARD 4
7 623-6851 WALK DECK WELDMENT, FRONT LEFT 1
8 623-6852 HANDRAIL WELDMENT, CENTER 1
9 623-6855 HANDRAIL WELDMENT, FRONT LEFT 1
14 624-2047 LATCH, DECK 1

Halvorsen
Figure 4
HANDRAIL AND WALKDECK ASSEMBLY, LEFT REAR
623-6860

Halvorsen
HANDRAIL AND WALKDECK ASSEMBLY, LEFT REAR
623-6860
2 620-6376 LANYARD 3
3 623-6856 HANDRAIL WELDMENT, REAR 1
4 623-6861 WALK DECK WELDMENT 1
7 623-8593 PIN, QUICK RELEASE L, 5/8 IN. 2

Halvorsen
REV. D
Figure 5
623-6880

Halvorsen
623-6880
2 107-2308 NUT, PTH A2 M6 X 1.00 S.S. 8
3 107-1782 SCREW, HEX HEAD CAP, FULL THREAD A2 M6 X 1.00 X 8

25 S.S.
4 620-6376 LANYARD 3
6 623-6881 WALK DECK WELDMENT, RIGHT CENTER 1
9 624-2047 LATCH, DECK 2

Halvorsen
Figure 6
HANDRAIL AND WALKDECK ASSEMBLY, RIGHT REAR
623-6890

Halvorsen
HANDRAIL AND WALKDECK ASSEMBLY, RIGHT REAR
623-6890
2 620-6376 LANYARD 3
4 623-6856 HANDRAIL WELDMENT, REAR 1
5 623-6916 WALK DECK WELDMENT, REAR 1

Halvorsen
REV. K
Figure 7 Sheet 1
HANDRAIL AND WALKDECK ASSEMBLY, RIGHT FRONT
623-6100

Halvorsen
16
Figure 7 Sheet 2
623-6100

Halvorsen
Figure 7 Sheet 3
623-6100

Halvorsen
623-6100
1* 104-0815 LINK, CONNECTING WIDE 0.13 S.S. 3
3 107-1747 PIN, COTTER 18-8 5/32 DIAMETER S.S. 1
4 107-1748 PIN, ROLL A2 M4 X 26 S.S. 1

X 1.50 X 25 MG

X 1.50 X 30 MG

X 1.50 X 35 MG
9 107-9260 NUT, PTH 8 M10 X 1.50 MG 11
13 107-9418 SCREW, HEX FLANGE 8.8 M10 X 1.50 X 30 MG 2
14 107-9421 SCREW, HEX FLANGE 8.8 M10 X 1.50 X 50 MG 4
15 107-9446 NUT, ACORN 6 M10 X 1.50 MG 16
19 107-9453 NUT, JAM 4 M12 X 1.75 MG 2
21 107-9455 WASHER, FLAT NARROW HARD 0.50 MG 5
23 107-9500 NUT, JAM 4 M10 X 1.50 MG 18
24 107-2274 NUT, JAM GR 8 0.75-16 MG 12
25 107-2728 WASHER, DIN 125A - TP200 M20 MG 24
26 515-1889 KNOB, HANDRAIL LOCK 1
28 623-6070 HANDRAIL WELDMENT, RIGHT FRONT 1
29 623-6095 HANDRAIL WELDMENT, TELESCOPING 1
30 623-6101 ROLLER, TRACK 6
31 623-6217 WALKDECK WELDMENT, TELESCOPING 1
32 623-6218 BUMPER, HANDRAIL 3

Halvorsen
623-6100
33 623-6235 PIN, HANDRAIL LOCK 1
34 623-6237 SPRING, COMPRESSION 1
35 623-6241 ROLLER, PLASTIC GROOVED 3 IN. O.D. 1
36 623-6244 ROLLER ASSEMBLY, CUBE 3
* RETAINER CLIP 1
37 623-6918 HANDRAIL WELDMENT, PIVOTING 1
38 623-6921 STRIP, WEAR 4
39 623-7006 WELDMENT, KICKPLATE AND HANDRAIL MOUNT 1
40 623-7404 STRIP, BUMPER MOUNT 3
41 623-7405 WELDMENT, WALKDECK AND KICKPLATE 1
42 623-7406 STRIP, WEAR 1
45 620-6376 LANYARD 3
48 623-6868 STOP, SLEEVE 1
49 623-8707 LANYARD, 20 WITH TAB 1
50 624-5747 SPACER, HANDRAIL PIN 1
51 624-6052 PIN, YELLOW, QUICK RELEASE 5/8 IN. 1
52 107-2255 PIN, CLEVIS, 0.50 X 1.75 S.S. 1
53 107-1554 SCREW, HEX HEAD TAP B, C1 #10-16 X 0.5 S.S. 1
* NOT SHOWN

Halvorsen
REV. B
Figure 8
623-8710

Halvorsen
623-8710
4 620-6376 LANYARD 2
6 624-2025 WALK DECK WELDMENT, LEFT 1
7 624-2044 HANDRAIL WELDMENT, CAB 1

Halvorsen
REV. D
Figure 9
GUIDE AND PALLET LOCK ASSEMBLY
623-7330

Halvorsen
GUIDE AND PALLET LOCK ASSEMBLY
623-7330
1 623-4251 PALLET LOCK ASSEMBLY 12
2 624-2052 GUIDE WELDMENT, FIRST RIGHT 1
3 624-2053 GUIDE WELDMENT, FIRST LEFT 1
4 624-2054 GUIDE WELDMENT, SECOND LEFT 1
5 624-2055 GUIDE WELDMENT, SECOND RIGHT 1
6 624-2056 GUIDE WELDMENT, THIRD LEFT 1
8 624-4744 GUIDE WELDMENT, FRONT LEFT 1
9 624-4745 GUIDE WELDMENT, FRONT RIGHT 1

Halvorsen
REV. B
Figure 10
PALLET LOCK ASSEMBLY
623-4251

Halvorsen
PALLET LOCK ASSEMBLY
623-4251
1 623-4248 HANDLE WELDMENT, PALLET LOCK 1
2 623-4249 FRAME WELDMENT, PALLET LOCK 1
3 623-6843 SPRING 1
4 623-6844 PIN, ROLL 1
5 623-6848 BLOCK, PALLET LOCK PISTON 1
6 623-8667 PIN ASSEMBLY 1
- 623-7233 LANYARD, PALLET LOCK PINS 1
* NOT SHOWN

Halvorsen
Section 13. Ladder Assembly
1. LADDER INSTALLATION 624-3125 Figure 1 Sheet 1 2
2. LADDER ASSEMBLY 624-3126 Figure 2 Sheet 1 5
3. LADDER 624-4190 Figure 3 Sheet 1 8
4. SUPPORT ASSEMBLY, LOWER LADDER 624-3127 Figure 4 11
LADDER ASSEMBLY 4-13

Halvorsen
Figure 1 Sheet 1
LADDER INSTALLATION
624-3125

Halvorsen
Figure 1 Sheet 2
LADDER INSTALLATION
624-3125

Halvorsen
LADDER INSTALLATION
624-3125
1 107-9017 SCREW, HEX HEAD CAP, FULL THREAD 8.8 M6 X 1 X 20 2

MG
2 107-9258 NUT, PTH 8 M6 X 1.00 MG 2
4 623-8697 GAKET, TIE DOWN 2
5 624-0308 PIN, HITCH 0.75 X 4.0 2
6 624-0309 PIN, LYNCH WIRE LOCK 0.38 X 2.5 2
7 624-3126 LADDER ASSEMBLY 1
8 624-3127 SUPPORT ASSEMBLY, LOWER LADDER 1
9 624-5019 LANYARD, 9.00 WITH TAB AND KEY RING 2

Halvorsen
REV. C
Figure 2 Sheet 1
LADDER ASSEMBLY
624-3126

Halvorsen
Figure 2 Sheet 2
LADDER ASSEMBLY
624-3126

Halvorsen
LADDER ASSEMBLY
624-3126

25 MG
2 107-9260 NUT, PTH 8 M10 X 1.50 MG 2
3 107-9258 NUT, PTH 8 M6 X 1.00 MG 8
7 624-5743 WELDMENT, CHANNEL, LADDER ATTACH 2
8 623-9618 COUPLER, LADDER 1
10 624-4190 LADDER 1
11 624-5753 COUPLER, LADDER UPPER 1

Halvorsen
REV. E
Figure 3 Sheet 1
LADDER
624-4190

Halvorsen
Figure 3 Sheet 2
LADDER
624-4190

Halvorsen
LADDER
624-4190
1 624-5755 LADDER SLIDE, DOUBLE C 16
2 624-3104 RIVETS, LADDER 64
3 624-4169 BLOCKS, STOP, LADDER 16
4 624-4193 LADDER, SECTION 5
5 624-6053 RIVETS, 1/4 LADDER 64
6 624-7439 END CAP, LADDER, BLACK 10
7 624-7439-001 RIVET, FLAT, 0.188 X 0.375, ALUMINUM 41027 20

Halvorsen
Figure 4
SUPPORT ASSEMBLY, LOWER LADDER
624-3127
SUPPORT ASSEMBLY, LOWER LADDER

624-3127
1 624-4191 WELDMENT, SUPPORT, LOWER LADDER 1
2 624-0310 BUSHING, LADDER 1

Halvorsen
Section 14. Cab Assembly
1. CAB INSTALLATION 627-9637 Figure 1 Sheet 1 2
2. SUPPORT BEAM ASSEMBLY, CAB FRONT 624-4038 Figure 2 10
3. SUPPORT BEAM ASSEMBLY, CAB REAR 624-4039 Figure 3 11
4. CAB ASSEMBLY 627-9639 Figure 4 Sheet 1 12
5. CAB SHELL ASSEMBLY 625-4753 Figure 5 Sheet 1 19
6. SIDE DOOR ASSEMBLY 624-2994 Figure 6 Sheet 1 25
7. REAR DOOR ASSEMBLY 624-2995 Figure 7 28
8. HEATER INSTALLATION 627-1146 Figure 8 30
9. HEATER ASSEMBLY, D4 CAB 627-5930 Figure 9 32
10. HANDRAIL ASSEMBLY, CAB 624-4041 Figure 10 34
11. MIRROR ASSEMBLY, CAB 624-6080 Figure 11 36
12. WIPER INSTALLATION, CAB 625-3956 Figure 12 Sheet 1 38
13. ELECTRICAL PANEL ASSEMBLY, CONVEY 624-2915 Figure 13 Sheet 1 42
14. CAB INSULATION, THERMAL 625-3093 Figure 14 46
15. CAB INSULATION INSTALLATION, ACOUSTIC 625-3967 Figure 15 48
16. PANEL ASSEMBLY, FLOOR MAT 625-3964 Figure 16 50
CAB ASSEMBLY 4-14

Halvorsen
CAB BEAM INSTALLATION VIEW

FOR CLARITY
DETAIL A
15
11
23
24
29
Figure 1 Sheet 1
CAB INSTALLATION
627-9637

Halvorsen
41
44 4
26
39
43
45
52
49 40
50 51
DETAIL A
SOME COMPONENTS NEED REMOVED
FOR CLARITY
Figure 1 Sheet 2
CAB INSTALLATION
627-9637
CAB ASSEMBLY 4-14

Halvorsen
17
DETAIL B
13
19
DETAIL C
CAB SUB-ASSEMBLY VIEW

FOR CLARITY
19
DETAIL C
Figure 1 Sheet 3
CAB INSTALLATION
627-9637

Halvorsen
26
10
30
53
22
32
10
20
21
14
9
25
DETAIL B
FOR CLARITY
Figure 1 Sheet 4
CAB INSTALLATION
627-9637
CAB ASSEMBLY 4-14

Halvorsen
8 17
34
18
33
12
5
CAB INSTALLATION VIEW
Figure 1 Sheet 5
CAB INSTALLATION
627-9637

Halvorsen
DETAIL D
CAB INSTALLATION VIEW
28
27
24
41 51
49
50
DETAIL D
Figure 1 Sheet 6
CAB INSTALLATION
627-9637
CAB ASSEMBLY 4-14

Halvorsen
CAB INSTALLATION
627-9637
2 107-2258 SCREW, SOCKET FLAT HEAD, FULL THREAD 2

GR8 0.5-13 X 3.50 MG
3 107-9261 NUT, PTH 8 M12 X 1.75 MG 9
5 107-9259 NUT, PTH 10 M8 X 1.25 MG 13
6 107-9266 NUT, HEX 8 M6 X 1.00 MG 1
9 107-1746 PIN, CLEVIS 18-8 1/2 DIA. SS 2
11 107-9260 NUT, PTH 8 M10 X 1.50 MG 1
12 107-9177 SCREW, SOCKET FLAT HEAD, FULL THREAD 10.9 M8 X 4

1.25 X 16 MG
14 107-2336 PIN, COTTER 0.125 X 1 SS 2
17 627-9639 A-CAB 1
18 623-6987 PIN WELDMENT, CAB 1
19 624-6055 HINGE WELDMENT, 0.5 IN. PIN 1
20 624-1402 SHOCK 2
21 624-4028 SPACER, SHOCK 4
22 624-4029 BACKING PLATE, CAB 1
23 624-4038 A-SUPPORT BEAM ASSY, CAB FRONT 1
24 624-4039 A-SUPPORT BEAM ASSY, CAB REAR 1
25 624-6598 CLEVIS 2
26 107-9094 SCREW, HHC-F 8.8 M12 X 1.75 X 50 MG 8
28 107-9453 NUT, JAM 4 M12 X 1.75 MG 1

Halvorsen
CAB INSTALLATION
627-9637
29 624-6596 BUSHING, CAB BEAM SLEEVE 2
30 624-6594 W-PLATE, CAB REAR BEAM 2
32 107-2257 NUT, PTH GR5 TH 0.5-13 MG 2
33 623-8707 LANYARD, 20 W/TAB 1
34 624-7419 PLATE, BACKING 2
39 107-1930 WASHER, FLAT STD. A2 M8 SS 1
40 107-1780 SCREW, HEX HEAD CAP, FULL THD. A2 M8 X 1.25 X 30 1

SS
41 624-7431 SHIM, CAB 1
43 624-7442 WELDMENT, PLATE, SHIM ADJUSTER 1
44 624-7445 WELDMENT, PLATE, SHIM 1
45 3616479 WASHER, LOCK M8 SS 1
49 107-2296 NUT, JAM A270 M20 X 2.5 SS 1
50 107-2293 SCREW, HHC-F, A270 M20 X 2.5 X 90 SS 1
51 625-3185 LANYARD, 12 W/TAB AND KEYRING 1
53* 625-4873 CAP, SHOCK TOWER 2
* NOT SHOWN
CAB ASSEMBLY 4-14

Halvorsen
REV. A
Figure 2
SUPPORT BEAM ASSEMBLY, CAB FRONT
624-4038
SUPPORT BEAM ASSEMBLY, CAB FRONT

624-4038
1 104-1591 CIRCLIP, ROLLER 3

2 624-4031 ROLLER ASSY, CAB 3
- 623-4607 BEARING, CAB ROLLER 1
- 624-4027 ROLLER, CAB 1
3 624-4036 SUPPORT BEAM WELDMENT, FRONT CAB 1
* NOT SHOWN

Halvorsen
REV. A
Figure 3
SUPPORT BEAM ASSEMBLY, CAB REAR
624-4039
SUPPORT BEAM ASSEMBLY, CAB REAR

624-4039
1 104-1591 CIRCLIP, ROLLER 4

2 624-4031 ROLLER ASSY, CAB 4
* 623-4607 BEARING, CAB ROLLER 1
* 624-4027 ROLLER, CAB 1
3 624-4037 SUPPORT BEAM WELDMENT, REAR CAB 1
* NOT SHOWN
CAB ASSEMBLY 4-14

Halvorsen
REV. L
Figure 4 Sheet 1
CAB ASSEMBLY
627-9639

Halvorsen
12
Figure 4 Sheet 2
CAB ASSEMBLY
627-9639
CAB ASSEMBLY 4-14

Halvorsen
Figure 4 Sheet 3
CAB ASSEMBLY
627-9639

Halvorsen
Figure 4 Sheet 4
CAB ASSEMBLY
627-9639
CAB ASSEMBLY 4-14

Halvorsen
Figure 4 Sheet 5
CAB ASSEMBLY
627-9639

Halvorsen
CAB ASSEMBLY
627-9639
X 30 MG
2 107-9045 SCREW, HEX HEAD CAP, FULL THREAD 8.8 6
3 107-9259 NUT, PTH 10 M8 X 1.25 MG 4
7 622-5108 CLAMP, MUFFLER 3.50 HEAVY DUTY 1
8 622-5153 COLUMN, STEERING 10 IN. 1
9 623-2675 WHEEL HUB, STEERING, 7/8-16 SPLINES 1
10 623-2676 HORN BUTTON 1
12 624-5738 SEAT, T1 1
* 624-5738-001 SEAT COVER 1
* 624-5738-002 SEAT CUSHION 1
* 624-5738-003 BACK COVER 1
* 624-5738-004 BACK CUSHION 1
* 624-5738-005 SEAT BELT 1
14* 624-2980-500 A-CAB SHELL 1
15 624-4040 I-HEATER 1
16 624-4175 FIRE EXTINGUISHER ASSY 1
* 624-4176 FIRE EXTINGUISHER 1
* 624-4177 BRACKET, FIRE EXTINGUISHER 1
17 624-4041 HANDRAIL ASSY 1
20* 623-5949 CAB HYDRAULICS 1
21* 624-3250 IE-CAB (REF. SEC. 4-16) 1
23 624-4061 FAN, CAB 1
24 624-4062 DOME LIGHT, CAB 1
25 624-6080 MIRROR ASSY 1
CAB ASSEMBLY 4-14

Halvorsen
CAB ASSEMBLY
627-9639
27 107-9258 NUT, PTH 8 M6 X 1.00 MG 3
29 624-5751 STOP, HANDRAIL 1
30 107-9017 SCREW, HEX HEAD CAP, FULL THD. 10.9 M6 X 1.00 X 20 1

MG
31 519-0198 TRIM, QUICKEDGE 2 ft.
32 623-8707 LANYARD, 20 W/TAB 1
33 624-6052 PIN, YELLOW, QUICK RELEASE 5/8 IN. 1
34 624-4060 WIPER INSTALLATION, CAB 1
35 107-0808 RIVET, FLAT GR30 44 PL 6
36 623-9636* PLACARD, LOADER/TRANSPORTER, DATA PLATE 1
37 624-5208 MOUNTING PLATE, PLACARD 1
38 624-5209* DECAL, TRANS. SHIFT NOTE 1

MG
* NOT SHOWN

Halvorsen
20 36
37 40
23
43
33
DETAIL H
15
24
34 25
46
DETAIL G
44 39
DETAIL H
26 38
4 45 2 10 25
DETAIL G 26 10 2 45 4
47
Figure 5 Sheet 1
CAB SHELL ASSEMBLY
625-4753
CAB ASSEMBLY 4-14

Halvorsen
4 10 27
10 4 2
27
4 10 2
10 4
27
27
DETAIL B
DETAIL A
21
DETAIL B
DETAIL A
9 6 11
DETAIL E
28
4 10 2
17
2
4 10 2
18 2 10 4
SOME ITEMS REMOVED FOR CLARITY
Figure 5 Sheet 2
CAB SHELL ASSEMBLY
625-4753

Halvorsen
27
4 10 2
27
4 10
DETAIL C
27
27
4 10 2
4 10
DETAIL D
DETAIL E
SOME ITEMS REMOVED
FOR CLARITY
Figure 5 Sheet 3
CAB SHELL ASSEMBLY
625-4753
CAB ASSEMBLY 4-14

Halvorsen
8 11 1
1 11 7
DETAIL C
35 48
21 22 49
DETAIL F
50
31
DETAIL D DETAIL F
2 10 4 41
10 2 4
29
32
1 11 6
14 5 13 13 5 14 12
30
16
7 9 11
Figure 5 Sheet 4
CAB SHELL ASSEMBLY
625-4753

Halvorsen
CAB SHELL ASSEMBLY
625-4753
4 107-9017 SCREW, HHC-F 8.8 M6 X 1 X 20 MG 43
5 107-2180 NUT, PTH 10 M10 X 1.50 MG 4
6 107-9045 SCREW, HHC-F 8.8 M8 X 1.25 X 20 MG 6
7 107-9047 SCREW, HHC-F 8.8 M8 X 1.25 X 30 MG 5
8 107-9066 SCREW, HHC 8.8 M8 X 1.25 X 60 MG 4
9 107-9259 NUT, PTH 8 M8 X 1.25 MG 5
13 107-9321 SCREW, HHC 10.9 M10 X 1.5 X 70 MG 4
14 107-9456 WASHER, FLAT NAR. HD M10 MG 8
15 623-7338 SIGHT, WINDOW-LIQUID LEVEL 1
16 623-9610 W-STEP, CAB 1
17 624-1231 PLATE, FLOOR 1
18 624-1232 PLATE, FLOOR 1
19 624-2980-002 WINDOW, LEFT SIDE SKYLIGHT 1
20 624-2980-003 WINDOW, FRONT 1
21 624-2980-004 WINDOW, SKYLIGHT 1
22 624-2987 GRATE, TIE DOWN 4
23 624-2990 W-CAB 1
24 624-2991 W-FUEL TANK 1
25 624-2994 A-SIDE DOOR 1
26 624-2995 A-REAR DOOR 1
27 624-3003 MOUNT, DOOR STRAP 8
CAB ASSEMBLY 4-14

Halvorsen
CAB SHELL ASSEMBLY
625-4753
28 624-3004 W-FOOT REST 1
29 627-1146 I-HEATER, D4 CAB 1
30 624-4050 BULKHEAD, CAB 1
31 624-4061 FAN, CAB 1
32 624-4062 DOME LIGHT, CAB 1
33 624-4063 CAP, FUEL TANK, HEATER 1
34 624-4068 GASKET, SIDE DOOR 1
35 624-5730 W-GRATE 1
36 624-5873-001 GASKET, FRONT WINDSHIELD 1
37 624-5873-003 GASKET, RH SLIDING WINDOW 1
38 624-6604 GASKET, REAR DOOR 1
39 624-7176 A-VENTILATOR, CAB 1
40 624-7181 SLIDING WINDOW, RIGHT SIDE 1
41 628-1156 A-PANEL, SIDE CONSOLE 1
42 625-3922 I-INSULATION, AC CAB 1
43 625-3956 I-WIPER, AC CAB 1
44 HFS0058 RIVET, BLIND 0.188 X 0.38 ALUMINUM 12
45 107-2466 WASHER, LCKINT A2 M6 S.S. 10
46 627-6923 K-PLATE, STRIKER REAR DOOR 1
47 627-6917 K-PLATE, STRIKER SIDE DOOR 1
48 107-2846 WASHER, FLAT NARROW #8 S.S. 4
49 107-2845 NUT, PTH GR 5 #8-32 S.S. 4
50 107-2844 SCREW, PRND GR 2 #8-32 X 0.75 S.S. 4

Halvorsen
REV. D
Figure 6 Sheet 1
SIDE DOOR ASSEMBLY
624-2994
CAB ASSEMBLY 4-14

Halvorsen
Figure 6 Sheet 2
SIDE DOOR ASSEMBLY
624-2994

Halvorsen
SIDE DOOR ASSEMBLY
624-2994
1 107-2175 NUT, INSERT, ALUMINUM, M6 X 1.00, GRIP 4.2 20

MG
3 107-9258 NUT, PTH 8 M6 X 1.00 MG 14
8 624-2992 WELDMENT, SIDE DOOR 1
9 624-2994-002 WELDMENT, COVER 1
10 624-2994-005 POCKET, DOOR 1
11 624-2996 LATCH, SIDE DOOR 2
12 624-7182 SLIDING WINDOW, SIDE DOOR, ASSY. 1
* 624-7181-001 HANDLE, SLIDING WINDOW 1
* 624-5873 GASKET, RUBBER **
13 624-2994-001 HINGE, SIDE DOOR 1
15 624-5024 HANDLE, DOOR GRAB 1
16 107-2809 NUT, INSERT, ALS4, M8 X 1.25, GRIP 3.8 6
18 624-6627 LATCH, INSIDE, SIDE DOOR 1
19 624-6628 ROD, LATCH, SIDE DOOR 1
20 107-2466 WASHER, LCKINT A2 M6 SS 5
* NOT SHOWN
**AS REQUIRED
CAB ASSEMBLY 4-14

Halvorsen
11 8
1
4
LA
TAI
DE
5 2
1 7 3 12
DETAIL A
Figure 7
REAR DOOR ASSEMBLY
624-2995

Halvorsen
REAR DOOR ASSEMBLY
624-2995
1 107-2175 NUT, INSERT, ALUMINUM, M6 X 1.00 GRIP 4.2 17

MG
4 624-2982 LATCH, OUTSIDE, REAR DOOR 1
5 624-2983 LATCH, INSIDE, REAR DOOR 1
6 624-2993 WELDMENT, REAR DOOR 1
7 624-2995-001 HINGE, REAR DOOR 1
8 624-2998 WINDOW, REAR DOOR 1
11 624-5873-002 GASKET, REAR DOOR WINDOW 1
12 107-2466 WASHER, LOCK INT A2 M6 S.S. 5
CAB ASSEMBLY 4-14

Halvorsen
Figure 8
HEATER INSTALLATION
627-1146

Halvorsen
HEATER INSTALLATION
627-1146
4 107-1975 WASHER, FLAT STD. A2 M5 MG 18
5 107-1976 NUT, PTH 8 M5 X 0.80 SS 9
6 107-2170 SCREW, HEX HEAD CAP, A2 M5 X 0.08 X 20 SS 9
8 237-1382-004 NUT, PTH GR 5 #6-32 ZP 4
11 239-9076-010 CLAMP, P 1.625 STEEL CUSHIONED 1
12 627-5930 A-HEATER, D4 CAB 1
CAB ASSEMBLY 4-14

Halvorsen
Figure 9
HEATER ASSEMBLY, D4 CAB
627-5930

Halvorsen
HEATER ASSEMBLY, D4 CAB
627-5930
3 624-1234-003 CLAMP, HOSE 59 MM–83 MM 2
4 624-1234-004 NUT, INSERT, AL M4 X 0.7, GRIP 3.3 1
6 624-1234-006 FLEXI EXHAUST 24 MM-50 IN. 1
7 624-1234-007 CLAMP, HOSE 0.55-1.25 SS 2
8 624-1234-008 COMBUSTION AIR HOSE - 13 IN. 1
10 624-1234-010 11MM FUEL CLAMPS 2
11 624-1234-011 THERMOSTAT, HEATER 24V 1
13 624-1234-013 HOSE, FUEL 3.5MM I.D. 7 IN. 1
14 624-1234-014 HOSE, FUEL 5.0MM I.D.-7 IN. 1
23 624-1234-023 M6 WASHER 4
24 624-1234-024 M6 NUT PTH 4
25 624-1234-025 DUCT, 90 DEG. X 75 MM 1
26 624-1234-026 CLAMP, FUEL 9 MM 2
27 624-1234-027 CAP, HOSE INTAKE 1
28 624-1234-028 CAP, HOSE EXHAUST 1
29 627-5930-001 HEATER, D4 24 VOLT WITH PUMP 1
* 627-5930-004 D4 FUEL PUMP 1
30 627-5930-002 HE-HEATER, D4 CUSTOM 1
31 627-5930-003 HOOD, D4 75 MM 90 DEGREE BEND 1
33 624-8942-004 TUBING, SHRINK 1
34 239-3650-001 TERMINAL SLIP-ON FEMALE 14-AWG INS 1
36* 624-8951 DIAGNOSTIC UNIT, ESPAR HEATER 1
* NOT SHOWN
CAB ASSEMBLY 4-14

Halvorsen
VIEW A
REV. D
Figure 10
HANDRAIL ASSEMBLY, CAB
624-4041

Halvorsen
HANDRAIL ASSEMBLY, CAB
624-4041
1 107-1748 PIN, ROLL A2 M4 X 26 SS 1
2 107-9260 NUT, PTH 8 M10 X 1.50 MG 2
6 515-1899 KNOB, PLASTIC 1
7 623-6218 BUMPER, HANDRAIL 1
8 623-6237 SPRING, COMPRESSION 1
9 623-7404 STRIP, BUMPER MOUNT 1
10 624-4042 HANDRAIL WELDMENT, CAB 1
11 624-4051 PIN, HANDRAIL, CAB 1
12 107-0806 RIVET, BLIND, WEAR, HANDRAIL, CAB, PRO GR41 64 33

SS
13 624-4047 STRIP, WEAR, HANDRAIL, CAB 2
14 624-4048 STRIP, WEAR, HANDRAIL, CAB 1
15 624-5747 SPACER, HANDRAIL PIN 1
CAB ASSEMBLY 4-14

Halvorsen
REV. A
Figure 11
MIRROR ASSEMBLY, CAB
624-6080

Halvorsen
MIRROR ASSEMBLY, CAB
624-6080
2 107-9259 NUT, PTH 10 M8 X 1.25 MG 3
4 624-6076 WELDMENT, MIRROR MOUNT 3
5 624-6079 WELDMENT, MIRROR BRACKET 1
6 624-6081 MIRROR, HEAD 1
7 107-1492 NUT, ACORN 6 M8 X 1.25 ZP 2
8 107-2262 WASHER, CONICAL SPRING, M8 MG 3
CAB ASSEMBLY 4-14

Halvorsen
10 13
16
3
13 9
ISO VIEW
Figure 12 Sheet 1
WIPER INSTALLATION, CAB
625-3956

Halvorsen
12
18
15
3 1
21
11
Figure 12 Sheet 2
625-3956
CAB ASSEMBLY 4-14

Halvorsen
1 2 3
19
SEE DETAIL A
20
21
12
14
22
17
20
18
7
DETAIL A
Figure 12 Sheet 3
625-3956

Halvorsen
625-3956
2 107-9284 NUT, HEX 10 M8 X 1.25 MG 4
3 107-9409 SCREW, HFLING 8.8 M8 X 1.25 X 20 MG 6
4 237-2308-002 GROMMET, 0.688 ID X 0.188 GW 1
6 622-0746-009 WIPER BLADE, REAR 1
7 624-1252 MOTOR, WIPER FRONT 1
8 624-1253 AE-MOTOR, WIPER REAR 1
9 624-4060-001 DRY ARM, FRONT 1
10 624-4060-002 DRY ARM, REAR 1
11 624-4060-003 ELBOW 1
12 624-4060-005 TUBING, WIPER ARM 2 ft.
13 624-4060-008 WET ARM KIT, WIPER 2
14 624-0746-006 SHAFT, PIVOT 1
15 624-5023 FILL CAP 1
16 624-5030 WIPER BLADE, FRONT 1
17 624-6082 SPACER WIPER 3
18 622-1035-011 FITTING COWL 2
19 625-3954 A- RESERVOIR, WIPER 1
20 624-4060-006 TUBING, 1.8 ID X 1/16 W X 20 FT. 1
21 624-4060-007 TUBING, FILL 4 FT. LONG 1
22 622-0746-007 WIPER ADAPTER KIT-UTA48519 1
CAB ASSEMBLY 4-14

Halvorsen
Figure 13 Sheet 1
ELECTRICAL PANEL ASSEMBLY, CONVEY
624-2915

Halvorsen
Figure 13 Sheet 2
624-2915
CAB ASSEMBLY 4-14

Halvorsen
624-2915
1 624-2917 JOYSTICK AND CARD, CONVEY 1
2 622-2967-013 CONNECTOR, PIN 16-18 AWG SOLID 12
3 622-2967-011 CONNECTOR, RECP 12 POS (MALE) 1
4 622-2967-027 CONNECTOR, WEDGE 12 POS RECP 1
5 624-3245 DE-CONVEY PANEL 1
6 DWG-623-9526 ELECT FABRICATION PRACTICES 1
7 620-0764 LAMP, 24V 6
8 519-2207 AE-LIGHT, PANEL ILLUMINATOR 1/2 X 1/2 1
9 620-0763-001 LIGHT, PILOT, BASE 5
10 620-0763-003 LIGHT, PILOT, LENS, GREEN 3
11 620-0763-002 LIGHT, PILOT, LENS, RED 2
12 111-7576 NUT, PTH GR 5 #10-24 ZP 2
13 107-0730 SCREW, SBIND GR 2 #10-24X.75 ZP 2
14 238-6221 SWITCH, TOGGLE SPDT 4
15 237-5490 SWITCH, TOGGLE DPDT 1
16 515-3065 SWITCH, TOGGLE SPST 1
18 622-2962-009 CONNECTOR, SEALING PLUG 1
19 239-3646-001 TERMINAL, RING #4 14-AWG 5
24 621-5215-001 TUBING, HEAT SHRINK 0.12/0.25 3 ft.
25 620-3900-018 WIRE STRANDED YELLOW 18 GA GXL 18 ft.
26 110-3959 WASHER, FLAT NARROW #10 ZP 2
27 624-2914 PE-PANEL CONVEY 1

Halvorsen
624-2915
28 622-7278-001 SPLICE, PARALLEL (14-12 AWG) 1
30 622-2967-001 CONNECTOR, RECEPTACLE 2 POS (MALE) 1
33 624-2920 CONNECTOR, 9 POS (FEMALE) 1
34 624-2921 CONNECTOR, PIN (FEMALE) 9
35 624-6609 VARISTOR, METAL OXID 31 VDC 1
36 622-6481 SWITCH, TOGGLE GUARD 5
37 620-3900-014 WIRE, 14-AWG, GXL, YELLOW 4 ft.
CAB ASSEMBLY 4-14

Halvorsen
Figure 14
CAB INSULATION, THERMAL
625-3093

Halvorsen
CAB INSULATION, THERMAL
625-3093
1 625-3093-001 PANEL, THERMAL INSULATION 1

CAB ASSEMBLY 4-14

Halvorsen
Figure 15
CAB INSULATION INSTALLATION, ACOUSTIC
625-3967

Halvorsen
CAB INSULATION INSTALLATION, ACOUSTIC
625-3967
1 625-3967-001 PANEL, ACOUSTIC INSULATION 1
CAB ASSEMBLY 4-14

Halvorsen
Figure 16
PANEL ASSEMBLY, FLOOR MAT
625-3964

Halvorsen
PANEL ASSEMBLY, FLOOR MAT
625-3964
1 625-3964-001 PANEL, FLOOR MAT 1
2 625-3964-002 PANEL, FLOOR MAT 1
3 625-3984-003 PANEL, FLOOR MAT 1
CAB ASSEMBLY 4-14

Halvorsen
Section 15. Hydraulic System
1. CHASSIS HYDRAULIC INSTALLATION 627-9669 Figure 1 Sheet 1 2
2. HOSE ASSEMBLY KIT, CHASSIS 627-9669-001 Figure 2 Sheet 1 22
3. TUBE ASSEMBLY KIT, CHASSIS 627-9669-002 Figure 3 Sheet 1 35
4. EMERGENCY PUMP HYDRAULIC ASSEMBLY 624-0330 Figure 4 47
5. MANIFOLD ASSEMBLY, CHASSIS 623-5410 Figure 5 49
6. MANIFOLD SUB-ASSEMBLY, CHASSIS 623-6681 Figure 6 Sheet 1 51
7. MANIFOLD, FAN DRIVE 623-8653 Figure 7 54
8. HYDRAULIC RESERVOIR ASSEMBLY 623-5930 Figure 8 Sheet 1 55
9. SCISSOR HYDRAULIC INSTALLATION 625-9350 Figure 9 Sheet 1 58
10. HOSE ASSEMBLY KIT, SCISSOR 623-5945-003 Figure 10 Sheet 1 75
11. TUBE ASSEMBLY KIT, SCISSOR 625-9350-002 Figure 11 Sheet 1 86
12. MANIFOLD ASSEMBLY, REAR PITCH 623-5411 Figure 12 97
13. MANIFOLD ASSEMBLY, INNER AND OUTER

SCISSORS 623-5413 Figure 13 99
14. DECK HYDRAULIC INSTALLATION 628-0452 Figure 14 Sheet 1 101
15. HOSE ASSEMBLY KIT, DECK 623-5952-003 Figure 15 Sheet 1 117
16. TUBE ASSEMBLY KIT, DECK 627-6080-002 Figure 16 Sheet 1 117
17. MANIFOLD ASSEMBLY, STOPS AND LIFT 623-5415 Figure 17 124
18. MANIFOLD ASSEMBLY, FIVE STATIONS 623-5416 Figure 18 126
19. CAB HYDRAULIC INSTALLATION 623-5949 Figure 19 Sheet 1 128
20. HOSE ASSEMBLY KIT, CAB 623-5949-003 Figure 20 Sheet 1 132
21. HYDRAULIC INSTALLATION, FINAL ASSEMBLY 623-7170 Figure 21 Sheet 1 137
22. HYDRAULIC INSTALLATION, FINAL ASSEMBLY

HOSE KIT 623-7170-003 Figure 22 Sheet 1 141
23. VALVE BLOCK ASSEMBLY A/C MANIFOLD 625-4073 Figure 23 146
HYDRAULIC SYSTEM 4-15

Halvorsen
SEE DETAIL A
135
93 80 83
SEE DETAIL E
SEE DETAIL D
91 R
34 SEE DETAIL U
91
SEE DETAIL B
34
135
93
SEE DETAIL C DETAIL U

SOME ITEMS REMOVED
FOR CLARITY
Figure 1 Sheet 1
CHASSIS HYDRAULIC INSTALLATION
627-9669

Halvorsen
57 31 20
31
8
21 60
56 TP2
11 PB
3 108
59 G
60
TP1 56
H 60
P 17
40 12 LS
16 DETAIL E
8
SOME ITEMS REMOVED
FOR CLARITY
146
74 83
134
135
82 71
150
66
135
144 84
102 139 84
136 79
111
DETAIL D 142 83
SOME ITEMS REMOVED
FOR CLARITY
Figure 1 Sheet 2
627-9669

Halvorsen
94 83 73
123
136
94 83 73
61
135
61
29
100 68
31
DETAILC
SOME ITEMS REMOVED 135
FOR CLARITY
(BOTH SIDES)
31
113
112
99 96
B
DETAIL
SOME ITEMS REMOVED
FOR CLARITY
Figure 1 Sheet 3
627-9669

Halvorsen
93 83 80
151
151 36
135
36
DETAIL A
SOME ITEMS REMOVED
FOR CLARITY
Figure 1 Sheet 4
627-9669

Halvorsen
9
135
DETAIL T
SOME ITEMS REMOVED SEE DETAIL H
91
FOR CLARITY 34 SEE DETAIL J 34
91
SEE DETAIL K
SEE DETAIL L
80 83 93
SEE DETAIL G
SEE DETAIL N
SEE DETAIL M
SEE DETAIL T SEE DETAIL F
116
135
80 83
83
DETAIL F
SOME ITEMS REMOVED
FOR CLARITY
Figure 1 Sheet 5
627-9669

Halvorsen
81 84
81 77 84 120
138
115
28
28 48
125 129
126
50
128
48
DETAIL G DETAIL J
SOME PARTS REMOVED BOTH SIDES
FOR CLARITY
62
37
24
102
35
62
36
R 15
M 15
2
118 29
135
96 99
12 LSO
T 15 15 P
DETAIL K
SOME ITEMS REMOVED
FOR CLARITY
Figure 1 Sheet 6
627-9669

Halvorsen
54
22
22
53
47
40
39
136
DETAIL H
SOME ITEMS REMOVED
FOR CLARITY 135
(BOTH SIDES) 45
39
146
19 34
131
80 83 75
10 35
PORT 2 35
PORT 1 64
PORT 3 10 135
42
DETAIL L
SOME ITEMS REMOVED
FOR CLARITY
Figure 1 Sheet 7
627-9669

Halvorsen
135
45
136
121
52
45
45
46
109 46
122 DETAIL M
90 76
145 144 84 145 74 83
ADL 137 LSF 26
135
114 101 89
135
35
56 LS1
119 56 TP3
14 P3
38 14 P4
80 83 86 DETAIL N
T 17 15 P1 SOME ITEMS REMOVED
P2 133 12 P5 FOR CLARITY
Figure 1 Sheet 8
627-9669

Halvorsen
48
52
135
34 55
48 SEE DETAIL R
DETAIL P 49 SEE DETAIL P

SOME ITEMS REMOVED SEE DETAIL Y
FOR CLARITY
SEE DETAIL AC
SEE DETAIL W
SEE DETAIL AB
9
SEE DETAIL AD
146
135
ACTUATOR
JAM NUT
CLEVIS
DETAIL R
SELECTOR ARM LINKAGE
DETAIL W
Figure 1 Sheet 9
627-9669

Halvorsen
115
SECTION AA-AA 51 48
FOR CLARITY
132
92
63
80 88 83
36
63
98 83 70
63
135
92
SECTION AB
SOME ITEMS REMOVED
132
FOR CLARITY
Figure 1 Sheet 10
627-9669

Halvorsen
35
97 LS
117 7 L
5 P
65
T 6
104
67 4
DETAIL AC
SOME ITEMS REMOVED
FOR CLARITY
79 82 141 82 79 71
122
111
136
149
122
140 82 79
122
147
122
111
122
DETAIL AD
111
Figure 1 Sheet 11
627-9669

Halvorsen
41
DETAIL Y
SOME ITEMS REMOVED
FOR CLARITY
152 83 80
153
153
135
DETAIL V-V
SOME ITEMS REMOVED
FOR CLARITY
Figure 1 Sheet 12
627-9669

Halvorsen
SEE DETAIL X
SEE DETAIL AG
SEE DETAIL AE
Figure 1 Sheet 13
627-9669

Halvorsen
31 OUTLET
DRAIN 26
119 60 INLET
DETAIL X
SOME ITEMS REMOVED
FOR CLARITY
83 73
34
120
123
34
72 79 82
103 DETAIL AE
BOTH SIDES
Figure 1 Sheet 14
627-9669

Halvorsen
38 38 78 85 69
18
38
124
121
114
33 LFT 95
DETAIL AG 127
SOME ITEMS REMOVED
FOR CLARITY
135
102
32 32 134
SECTION AF-AF
Figure 1 Sheet 15
627-9669

Halvorsen
627-9669
2 102-0193 O-RING CONNECTOR 90 1

3 102-1071 FITTING SWIVEL 04 SAEF X 04 FNPT 1
4 102-1757 ADAPTER, 90 -32BARB X -24FLG CD61 1
5 102-1758 ADAPTER, KIT -12FLG CD62 1
6 102-1759 ADAPTER, KIT -24FLG CD61 1
7 102-1761 ADAPTER, 90 M22 X 1.5 X -08MJIC 1
8 102-1774-1616 ADAPTER, STRAIGHT -16MJIC X -16MJIC 2
9 102-1775-0404 ADAPTER, STRAIGHT -04MORB X -04MJIC 2
19 102-1776-0604 ADAPTER, REDUCER 06MJIC X 04FJIC 1
20 102-1776-0806 ADAPTER, REDUCER 08FJIC X 06MJIC 1
24 102-1777-0406 ADAPTER, 90 -04MORB X -06MJIC 1

Halvorsen
627-9669
34 102-1778-0404 ADAPTER, 90 -06FJIC X -06MJIC 10

35 102-1778-0606 ADAPTER, 90 SW -06FJIC X -06MJIC 4
41 102-1780-0008 ADAPTER, TEE UNION -08JIC 1
45 102-1783-0404 ADAPTER, BH -04MJIC X -04MJIC 7
48 102-1784-0004 ADAPTER, BH 90 -02MJIC 8
49 102-1784-0006 ADAPTER, BH 90 -02MJIC 2
50 102-1784-0008 ADAPTER, BH 90 -02MJIC 2
51 102-1784-0012 ADAPTER, BH 90 -12MJIC 1
52 102-1785-0016 ADAPTER, BH 45 -XXMJIC 2
53 102-1786-0004 ADAPTER, BH RN -02MJIC 2
55 102-1787-0004 ADAPTER, BH BR -02MJIC 1
56 102-1788-0004 ADAPTER, PLUG -04ORB 3
57 102-1788-0012 ADAPTER, PLUG -12ORB 1
59 102-1790-0404 ADAPTER, 45 04MORB X 04MJIC 1
60 102-1790-1212 ADAPTER, 45 12MORB X 12MJIC 4
61 102-1796-0404 ADAPTER, 90 UNION -04JIC 4
62 102-1801-1212 ADAPTER, STRAIGHT -12MNPT X -12MJIC 2
63 102-1802-1208 ADAPTER, 90 -12MNPT X -08MJIC 4

Halvorsen
627-9669
65 102-1816 ADAPTER, 90 -16MJIC X -12FLG CD62 1

66 102-1871-1212 ADAPTER, TEE RN-12MJIC X 12FNPT 1
67 105-0136-004 CLAMP, T-BOLT FOR 2.00 I.D. HOSE 2
68 107-1922 WASHER, LOCK A4 0.25 S.S. 2
69 107-2181 NUT, PYH 10 M12 X 1.75 MG 2
70 107-2314 BOLT, CARRIAGE GR 6.8 M8 X 1.25 X 65 MG 4
71 107-9024 SCREW, HHC-F 8.8 M6 X 1 X 60 MG 4
72 107-9036 SCREW, HHC 8.8 M6 X 1 X 70 MG 4
73 107-9042 SCREW, HHC-F 8.8 M8 X 1.25 X 10 MG 8
74 107-9044 SCREW, HHC-F 8.8 M8 X 1.25 X 16 MG 2
75 107-9063 SCREW, HHC 8.8 M8 X 1.25 X 45 MG 1
76 110-1617 SCREW, HHC GR 5 0.44-14 X 1 ZP 4
77 107-9086 SCREW, HHC 8.8 M10 X 1.5 X 70 MG 2
78 107-9092 SCREW, HHC-F 8.8 M12 X 1.75 X 35 MG 2
79 107-9258 NUT, PTH 8 M6 X 1.00 MG 11
80 107-9259 NUT, PTH 8 M8 X 1.25 MG 16
81 107-9260 NUT, PTH 8 M10 X 1.50 MG 4
86 107-9302 SCREW, HHC 10.9 M8 X 1.25 X 25 MG 4
87 107-9303 SCREW, HHC 10.9 M8 X 1.25 X 30 MG 2
88 107-9310 SCREW, HHC-F 10.9 M8 X 1.25 X 65 MG 4
89 107-9455 WASHER, FLAT NARROW HARD 0.5 MG 4
90 110-0244 WASHER, LOCK, 44 ZP 4
91 118-2679-003 ADAPTER, STRAIGHT -02MNPT X -04MJIC 4
92 232-7645 HEAT EXCHANGER 2
93 239-8852-004 CLAMP, SUPPORT 1.00 NC 4

Halvorsen
627-9669
94 239-8852-017 CLAMP, SUPPORT 0.25 NC 4

95 514-8244 FILTER, HIGH PRESSURE 100 GPM 1
96 5150007 WASHER, FLAT STD 0.31 MG 2
97 519-4529-001 ADAPTER, STRAIGHT M14 X 1.5 X -06MJIC 1
98 5250185 NUT GR 5 5/16-18 HEX NYLON LOCK MG 4
99 600681 SCREW, HHC GR 5 0.31-18 X 0.75 MG 2
100 600682 SCREW, HHC GR 5 0.25-20 X 0.75 MG 2
101 600756 SCREW, HHC GR 5 0.5-13 X 1 MG 4
102 620-0925 ADAPTER, 45 -12FJIC X -12MJIC 2
103 620-0927 ADAPTER, 90 08MJIC X 08FJIC SW HP 2
104 620-0929 ADAPTER, 90 16MJIC X 16FJIC SW HP 1
105 620-1317-002 FLEX-GARD, NYLON SLIT 3/8 IN. 29
106 620-1317-006 FLEX-GARD, NYLON SLIT 1 IN. 6
108 620-2565 GAUGE, PRESSURE 1
109 620-4440 CLAMP, TWIN TUBE 3/8 IN. 1
111 620-4447 CLAMP, SINGLE TUBE 3/4 IN. 4
112 621-5556 SPIN ON FILTER ASSEMBLY 1
113 621-5556-001 GAUGE, INDICATOR 1
114 623-5410 MANIFOLD, CHASSIS 1
115 623-5930 AH-RESERVOIR 1
116 623-6744 PLATE, COVER 1
117 623-8652 PUMP, HYDRAULIC 1
118 623-8653 MANIFOLD, FAN DRIVE 1
119 624-0330 AH-E-PUMP NGSL 1
120 624-1228 BULKHEAD, WALKBEAM 2
121 624-3128 TUBE CLAMP SINGLE 1.00 2
122 624-3129 TUBE CLAMP DOUBLE 1/4 IN. 7
123 624-5171 PAD, WALKING BEAM - NGSL 2

Halvorsen
627-9669
124 624-5719 BRACE, HYDRAULIC TANK ASSEMBLY 1

125 624-5722 TOP BAR, HYDRAULIC TANK ASSEMBLY 2
126 624-5725 STRAP, HYDRAULIC TANK ASSEMBLY 2
127 624-5726 PAD, HYDRAULIC TANK 2
128 624-5727 PAD, BOTTOM, HYDRAULIC TANK 2
129 624-5728 PAD, TOP, HYDRAULIC TANK 2
131 624-8907 VALVE, PRESUURE REDUCER 1
132 624-8908 ISOLATOR, HEAT EXCHANGER NGSL 8
133 625-4428 VALVE, CHECK IN-LINE 1908F 1
134 627-9652 BRKT, TRANSMISSION HYDRAULIC TUBE 1
135 627-9669-001 IH-CHASSIS HOSE ASSEMBLY KIT 1
136 627-9669-002 IH-CHASSIS TUBE ASSEMBLY KIT 1
137 102-1788-0006 ADAPTER, PLUG -06ORB 1
138 102-1788-0008 ADAPTER, PLUG -08ORB 1
139 107-2180 NUT, PTH 10 M10 X 1.50 MG 1
140 107-9018 SCREW, HHC-F 8.8 M6 X 1 X 25 MG 2
141 107-9031 SCREW, HHC 8.8 M6 X 1 X 40 MG 1
142 107-9045 SCREW, HHC-F 8.8 M8 X 1.25 X 20 MG 1
143 107-9078 SCREW, HHC-F 8.8 M10 X 1.5 X 20 MG 1
144 107-9080 SCREW, HHC-F 8.8 M10 X 1.5 X 30 MG 2
145 239-8852-006 CLAMP, SUPPORT 1.25 NC 2
146 623-7300-006 ACTUATOR, STONE BENNETT SHIFTER 1
147 627-9912 BRKT, CAC CROSSBEAM 1
149 102-1951 ADAPTER, 90 UNION 12JIC X 12JIC 1
150 118-2659-008 ADAPTER, BUSHING 3/4 MNPT X 3/8 FNPT 1
152 107-9047 SCREW, HHC-F 8.8 M8 X 1.25 X 30 MG 2
153 102-1189 CLAMP COATED 11/16 I.D. SUPPORT 4

Halvorsen
26
27
SEE DETAIL AD
53
DETAIL A
2
K
3
U
R
42
43
53
SEE DETAIL H 14
R
SEE DETAIL J
DETAIL B
SEE DETAIL V
SEE DETAIL A
SEE DETAIL B
SEE DETAIL N
Figure 2 Sheet 1
HOSE ASSEMBLY KIT, CHASSIS
627-9669-001

Halvorsen
35
12
12
35
48 DETAIL AD
24 47 BOTH SIDES
24 11
47 11
24
36
48 36
47
48
SECTION D-D
Figure 2 Sheet 2
627-9669-001

Halvorsen
PORT 2
8
PORT 3
46
PORT 1
23
7 LS
PORT 3
6
22 L
DETAIL J
T 34
34 P
SECTION K-K
SOME ITEMS REMOVED
FOR CLARITY
49
31
49
50
SECTION M-M
Figure 2 Sheet 3
627-9669-001

Halvorsen
43 37
42
3
2
SECTION C-C
SOME ITEMS REMOVED
FOR CLARITY
54
53
54
SECTION N
SOME ITEMS REMOVED
FOR CLARITY
Figure 2 Sheet 4
627-9669-001

Halvorsen
41
54
37 41
54
DETAIL P
Figure 2 Sheet 5
627-9669-001

Halvorsen
10
21
M 21
T 21
P 28
16 15
51 SECTION U-U
SOME ITEMS REMOVED
FOR CLARITY
29
14
25
SECTION R-R
13
SOME ITEMS REMOVED
FOR CLARITY
Figure 2 Sheet 6
627-9669-001

Halvorsen
13
R 16
LSO 9
22
DETAIL H
SOME ITEMS REMOVED
FOR CLARITY
Figure 2 Sheet 7
627-9669-001

Halvorsen
33 30 INLET 9 LSF 45 TP2 31 H
34
32
DRAIN
1
P3 26
DETAIL V
P1 27 P4 28 FOR CLARITY
LS1 4
Figure 2 Sheet 8
627-9669-001

Halvorsen
29
10
30
SECTION W-W
SOME ITEMS REMOVED
FOR CLARITY
Figure 2 Sheet 9
627-9669-001

Halvorsen
14 19
25
DETAIL Y
SOME ITEMS REMOVED
FOR CLARITY
21
DETAIL X
DETAIL AB
DETAIL Y
51
DETAIL P
DETAIL AB
SOME ITEMS REMOVED
FOR CLARITY
Figure 2 Sheet 10
627-9669-001

Halvorsen
46
40
DETAIL AA-AA
SOME ITEMS REMOVED
OR CLARITY
P5 8
19 T1
LS 7 DETAIL X
SOME ITEMS REMOVED
OR CLARITY
Figure 2 Sheet 11
627-9669-001

Halvorsen
627-9669-001
1 519-0196-048-S HOSE, ASSEMBLY FJIC SW-06 X 48 SLVD 1
6 519-0196-110 HOSE, ASSEMBLY FJIC SW-06 X 110 LG 1
15 519-0197-040 HOSE, ASSEMBLY FJIX SW-08 X 40 LG 1
16 519-0197-041 HOSE, ASSEMBLY FJIX SW-08 X 41 LG 1
21 627-9713-096 HOSE, ASSEMBLY FJIC SW-12 X 96 1
28 519-0197-196-S HOSE, ASSEMBLY FJIX SW-08 X 196 LG 11
29 519-0197-232-S HOSE, ASSEMBLY FJIX SW-08 X 232 LG 1

Halvorsen
627-9669-001
32 620-1848-028 HOSE, ASSEMBLY -16 X 28 LG 100R12 1
33 620-1848-049 HOSE, ASSEMBLY -16 X 49 LG 100R12 1
49 620-2013-140-S HOSE, ASSEMBLY FJIC SW-04 X 140 SLV 2
50 623-0419-032 HOSE, SUCTION 2.00 ID X 32.00 1
51 627-9713-038 HOSE, ASSEMBLY FJIC SW-12 X 38 1
54 620-1850-020 A-HOSE, -06 ORFS TO -08 JIC, 20 4

Halvorsen
DETAIL B
Figure 3 Sheet 1
TUBE ASSEMBLY KIT, CHASSIS
627-9669-002

Halvorsen
3
5
5
4 DETAIL H
SECTION A-A
4
1
DETAIL H
SOME ITEMS REMOVED
FOR CLARITY
17 17
17 DETAIL B 17
BOTH SIDES
Figure 3 Sheet 2
627-9669-002

Halvorsen
DETAIL D
DETAIL F
DETAIL G
DETAIL C
Figure 3 Sheet 3
627-9669-002

Halvorsen
18
11
10
6
9
DETAIL C 8 2
1
20
20
1
19
DETAIL D
19
DETAIL G
Figure 3 Sheet 4
627-9669-002

Halvorsen
6 8 9 10
SECTION E-E 18 11
12 LFT
P 13
P2 14 15
T 15
OUTLET 14
13
12
DETAIL F
SOME ITEMS REMOVED
FOR CLARITY
Figure 3 Sheet 5
627-9669-002

Halvorsen
12
14 15
15
13
14
17 12
13
DETAIL F
SOME ITEMS REMOVED
FOR CLARITY
17
19
16
16
19
DETAIL B DETAIL G
SOME ITEMS REMOVED
FOR CLARITY
Figure 3 Sheet 6
627-9669-002

Halvorsen
17
16 DETAIL H
DETAIL G
DETAIL K
DETAIL G
DETAIL V
DETAIL J
DETAIL H
Figure 3 Sheet 7
627-9669-002

Halvorsen
10
11
18
DETAIL J
16
17
DETAIL K
FOR CLARITY
Figure 3 Sheet 8
627-9669-002

Halvorsen
DETAIL L
20
REF
2
20
3
DETAIL L
FOR CLARITY
Figure 3 Sheet 9
627-9669-002

Halvorsen
DETAIL U
DETAIL S
19
“TO COOLER” PORT ON TRANSMISSION

DETAIL S
Figure 3 Sheet 10
627-9669-002

Halvorsen
13
12
15
14
DETAIL V
FOR CLARITY
9 6
10
11
18
DETAIL U
FOR CLARITY
Figure 3 Sheet 11
627-9669-002

Halvorsen
627-9669-002
1 627-9696 A-TUBE, 0.25 SST 1
2 627-9697 A-TUBE, 0.25 SST 1
3 627-9695 A-TUBE, 0.75 SST 1
4 623-6723 A-TUBE, 0.25 SST 2
5 623-6725 A-TUBE, 0.50 SST 1
6 623-6731 A-TUBE, 1.00 SST 1
8 623-6733 A-TUBE, 0.25 SST 1
9 623-6734 A-TUBE, 0.25 SST 1
10 623-6735 A-TUBE, 0.25 SST 1
11 623-6736 A-TUBE, 0.375 SST 1
12 623-8175 A-TUBE, 1.00 SST 1
13 623-8176 A-TUBE, 1.00 SST 1
14 623-8177 A-TUBE, 0.50 SST 1
15 624-3137 A-TUBE, 0.375 SST 1
16 624-6059 A-TUBE, 0.25 SST 2
17 624-6060 A-TUBE, 0.25 SST 2
18 623-6737 A-TUBE, 0.375 SST 1
19 627-9668 A-TUBE, 0.75 SST 1
20 628-4630 A-TUBE, 0.75 SST 1

Halvorsen
REV. B
Figure 4
EMERGENCY PUMP HYDRAULIC ASSEMBLY
624-0330

Halvorsen
EMERGENCY PUMP HYDRAULIC ASSEMBLY
624-0330
1 5060008 SCREW, HEX HEAD CAP, GR 5 0.38-16 X 1.25 MG 2
2 5060010 WASHER, LOCK 3/8 MG 2
3 5060031 WASHER, FLAT 3/8 MG 2
4 624-0320 PUMP, EMERGENCY 1
5** 624-0329 MOTOR, EMERGENCY PUMP DRIVE 1

Halvorsen
REV. D
Figure 5
MANIFOLD ASSEMBLY, CHASSIS
623-5410

Halvorsen
MANIFOLD ASSEMBLY, CHASSIS
623-5410
1** 623-6681 MANIFOLD SUB-ASSEMBLY (REF. FIG. 35) 1
2 623-8717 VALVE, PROPORTIONAL (REF. FIG. 37) 2
3 623-2906-004 SWITCH, PRESSURE 200 PSI 0.25 NPT 1
* NOT SHOWN

Halvorsen
REV. E
Figure 6 Sheet 1
MANIFOLD SUB-ASSEMBLY, CHASSIS
623-6681

Halvorsen
Figure 6 Sheet 2
623-6681

Halvorsen
623-6681
1 623-5410-002 VALVE, SOLENOID 2
2 623-5410-003 VALVE, 2 POSITION 2 WAY 1
3 623-5938 VALVE, N.O. MOD. ELEMENT 2
4 623-5940 VALVE, CHECK 1
5 623-6681-014 VALVE 3
6 623-6681-007 VALVE, 350 PSI 1
7 623-6681-008 VALVE, 1500 PSI 1
8 623-6681-009 VALVE, 2500 PSI 1
9 623-6681-010 VALVE 4
10 623-6681-011 VALVE 1
11** 623-5410-001 BODY 1
12 623-5410-005 PLUG, ORIFICE 1
13 623-5410-004 COIL 2
14 623-6681-001 VALVE, PRESSURE REDUCING 1
15 625-4427 PLUG, CAVITY 1
16 623-6681-003 VALVE, 2500 PSI 1
17 624-0297 VALVE, HIGH PRESSURE BALL 1
* 624-0297-090 SEAL KIT 1
18 623-6681-004 VALVE 1
19 623-6681-005 VALVE 1
20 623-6681-006 VALVE, 4000 PSI 1
21 623-6681-012 VALVE, 3500 PSI 1
22 623-6681-013 VALVE, 3500 PSI 1
23 623-6681-015 COIL 5
24 624-0297-001 BOLT KIT 1
* NOT SHOWN

Halvorsen
REV. B
Figure 7
MANIFOLD, FAN DRIVE
623-8653
MANIFOLD, FAN DRIVE

623-8653
1 623-8653-001 VALVE, PROPORTIONAL CONTROL 1

2 623-8653-002 COIL 1
3 623-8653-004 PRESSURE COMPENSATOR 1
4 623-8653-005 CHECK VALVE 1
5 623-8653-006 BODY, MANIFOLD 1

Halvorsen
15
SECTION A-A
Figure 8 Sheet 1
HYDRAULIC RESERVOIR ASSEMBLY
623-5930

Halvorsen
3 12 13
2
14
9
4 10 8 11 12
6 6
Figure 8 Sheet 2
623-5930

Halvorsen
623-5930
1 623-5931 RESERVOIR - WELDMENT 1
2 623-6703 BREATHER 1
3 621-5724 FILTER, RETURN 1
4 620-1736 ADAPTER, 90, -24M ORB X -20M JIC 1
5 102-1775-2416 ADAPTER, STRAIGHT., -24M ORB X -16M JIC 1
6 620-0889 ADAPTER, PLUG, -16 ORB 2
7 620-0884 ADAPTER, PLUG, -4 ORB 1
8 519-4244-002 GASKET, FILTER 1
9 624-3043 GAUGE, HYDRAULIC FLUID LEVEL 1
10 621-5093-001 CAP, HYDRAULIC TANK 1
11 110-0046 SCREW, HEX HEAD CAP, GR 5 0.38-16 X 1.00 ZP 4
12 110-0243 WASHER, LOCK 0.38 ZP 8
13 110-0043 SCREW, HEX HEAD CAP, GR 5 0.38-16 X 1.25 ZP 4
14 102-0922 ADAPTER, CAP -20F JIC 1
15 624-3042 DIFFUSER 1

Halvorsen
EXTEND
50
11
51
1
37
40
41
38
44
13
40
37
RETRACT
1 39
12
7
DETAIL F
DETAIL G
52
42
44
52
45
45
33
19
26
27
27
26
44
3
17
2
20
8
16
Figure 9 Sheet 1
SCISSOR HYDRAULIC INSTALLATION
625-9350

Halvorsen
DETAIL D
PITCHARM REAR VIEW

FOR CLARITY
Figure 9 Sheet 2
625-9350

Halvorsen
10
24
23
24
23
22 28
22
57
29
56 37
48
17
DETAIL G
Figure 9 Sheet 3
625-9350

Halvorsen
22
22
23
23
40
37
22
40
25
22
23
23
52
42
52
24
43
DETAIL E
2
43
43
43
2
2
43
2
38
16
16
24
43
2
46
P
38 720 34
6
24
46
8
B2 6
16
16
16
19
21
Figure 9 Sheet 4
625-9350

Halvorsen
39
12
11
41
39
37
41
38
51
50
53
54
30
FOR CLARITY
49
10
37
40
40
49
12
12
Figure 9 Sheet 5
625-9350

Halvorsen
11
SOME COMPOENETS REMOVED

4
46
55
6
4
18
FOR CLARITY
15
23
23
6
18
22
16
12
16
28
22
31
8
47
12
40
40
24
37
12
24
Figure 9 Sheet 6
625-9350

Halvorsen
32
32
32
32
15
6
11
18 11 11
11
6
SECTION A-A
Figure 9 Sheet 7
625-9350

Halvorsen
32
32
32
32
6
30
12
16
11
5 15 55
SOME COMPONENTS REMOVED 4

FOR CLARITY
Figure 9 Sheet 8
625-9350

Halvorsen
53 SOME COMPONENTS REMOVED
FOR CLARITY
6
4
30
5 15
8 16
6 18
12
45
44
43
31
31
SECTION B-B
11
11
15
31
15
30 8
8
11
31
11
6
SOME COMPONENTS REMOVED 6
FOR CLARITY
Figure 9 Sheet 9
625-9350

Halvorsen
55
55 12
4
46
38 36 34
6
PITCHARM REAR VIEW

MANIFOLD ASSEMBLY
FOR CLARITY
18 6
8 16
12
16 8
Figure 9 Sheet 10
625-9350

Halvorsen
12
55
16
16 12
18
DETAIL D
FOR CLARITY
Figure 9 Sheet 11
625-9350

Halvorsen
18 8
11
11
11
11
15 6
31 8
8
31
35 38 36
DETAIL E
FOR CLARITY
Figure 9 Sheet 12
625-9350

Halvorsen
13
40
37
13
11
40
35 38 36
T 31
47
P 8
DETAIL E
FOR CLARITY
Figure 9 Sheet 13
625-9350

Halvorsen
31
31
35 38 36
11 11
15 6
6 15
11

FOR CLARITY
11
8
Figure 9 Sheet 14
625-9350

Halvorsen
47
35 38 36
8 T
P 8
DETAIL F
FOR CLARITY
Figure 9 Sheet 15
625-9350

Halvorsen
625-9350
1 102-1277 ADAPTER, REDUCER 12FJIC X 08MJIC 1

20 102-1780-081212 ADAPTER, TEE UNION -08-12-12JIC 1
26 102-1784-0004 ADAPTER, BH 90 -02MJIC 2
27 102-1784-0006 ADAPTER, BH 90 -02MJIC 2
30 102-1788-0004 ADAPTER, PLUG -04ORB 3

Halvorsen
625-9350
31 102-1788-0010 ADAPTER, PLUG -10MORB 4

33 102-1791-1212 FITTING, STRAIGHT SWIVEL, 12 O-RING X 12 JIC 1
34 107-2259 SCREW, HHC GR 5 0.38-16-4.5MG 3
35 107-2260 SCREW, HHC GR 5 0.38-16-5 MG 4
36 107-2261 NUT, PYH GR 5 0.38-16 MG 7
37 107-9259 NUT, PTH 8 M8 X 1.25 MG 9
38 107-9276 WASHER, FLAT STD HARD M10 NG 16
39 107-9313 SCREW, HHC-F 10.9 M10 X 1.5 X 20 MG 2
40 239-8852-003 CLAMP, SUPPORT 0.88 NC 10
41 239-8852-004 CLAMP, SUPPORT 1.00 NC 3
44 620-4443 TUBE CLAMP SINGLE 1/2 IN. 4
45 620-4447 CLAMP, SINGLE TUBE 3/4 IN. 3
46 623-5411 MANIFOLD, REAR PITCH 1
47 623-5413 MANIFOLD, INNER / OUTER SCISSORS 2
48 627-9548 BULKHEAD 1
49 623-8650 CYLINDER, PITCH 2
50 623-8658 ADAPTER, 90 SW-12ORB X -12 JIC 2
51 623-8659 ADAPTER, 90 SW-100RB X -08 JIC 2
53 623-5945-003 HOSE ASSEMBLY KIT 1
54 625-9350-002 IH-SCISSOR TUBE ASSEMBLY KIT 1
55 102-1329 ADAPTER, 06MORB X 06MJIC 1
57 628-4456 PLATE, SPACER SCISSOR BULKHEAD 2
* NOT SHOWN

Halvorsen
REV. A
Figure 10 Sheet 1
HOSE ASSEMBLY KIT, SCISSOR
623-5945-003

Halvorsen
A
Figure 10 Sheet 2
623-5945-003

Halvorsen
A
Figure 10 Sheet 3
623-5945-003

Halvorsen
Figure 10 Sheet 4
623-5945-003

Halvorsen
B P
Figure 10 Sheet 5
623-5945-003

Halvorsen
Figure 10 Sheet 6
623-5945-003

Halvorsen
Figure 10 Sheet 7
623-5945-003

Halvorsen
Figure 10 Sheet 8
623-5945-003

Halvorsen
Figure 10 Sheet 9
623-5945-003

Halvorsen
Figure 10 Sheet 10
623-5945-003

Halvorsen
623-5945-003
1 620-2013-045-S HOSE ASSEMBLY, -4 X 45 IN. LG SLVD 1

3 519-0196-020 HOSE ASSEMBLY, -6 X 20 IN. LG 1
24 519-0196-042 HOSE ASSEMBLY, -6 X 42 IN. LG PRIMARY 1
24 519-0196-041 HOSE ASSEMBLY, -6 X 41 IN. LG ALTERNATE 1
30 519-0196-018-S HOSE ASSEMBLY, -6 X 18 IN. LG SLVD PRIMARY 1
30 519-0196-017-S HOSE ASSEMBLY, -6 X 17 IN. LG SLVD ALTERNATE 1

Halvorsen
DETAIL D
DETAIL A
DETAIL B
DETAIL C
DETAIL E
ML25K3P SCISSORS
Figure 11 Sheet 1
TUBE ASSEMBLY KIT, SCISSOR
625-9350-002

Halvorsen
16
4
17
5
7
18
6
19
DETAIL A
20
3
DETAIL B
20
DETAIL C
Figure 11 Sheet 2
625-9350-002

Halvorsen
23
24
22
19
18
21
17
16
DETAIL D
DETAIL E
Figure 11 Sheet 3
625-9350-002

Halvorsen
DETAIL K
DETAIL J
DETAIL H
DETAIL N
DETAIL F
DETAIL G
DETAIL L
DETAIL M
ML25K3P SCISSORS
Figure 11 Sheet 4
625-9350-002

Halvorsen
11
DETAIL F
13
12
14
8
2
15
DETAIL G
DETAIL H
Figure 11 Sheet 5
625-9350-022

Halvorsen
10
DETAIL J
10
12
DETAIL K
11
DETAIL L
Figure 11 Sheet 6
625-9350-022

Halvorsen
2 15
14
13
DETAIL M
24
23
DETAIL N
Figure 11 Sheet 7
625-9350-022

Halvorsen
DETAIL V
DETAIL R
DETAIL T
DETAIL U
ML25K3P SCISSORS
Figure 11 Sheet 8
625-9350-022

Halvorsen
9
DETAIL R
21
22
DETAIL T
Figure 11 Sheet 9
625-9350-022

Halvorsen
4
DETAIL U
DETAIL V
Figure 11 Sheet 10
625-9350-022

Halvorsen
625-9350-002
1 623-6707 A-TUBE 0.75 SST 1
2 623-6708 A-TUBE 0.38 SST 1
3 623-6709 A-TUBE 0.50 SST 2
4 623-6710 A-TUBE 0.25 SST 1
5 623-6711 A-TUBE 0.25 SST 1
6 623-6712 A-TUBE 0.38 SST 1
7 623-6713 A-TUBE 0.38 SST 1
8 623-6714 A-TUBE 0.50 SST 1
9 623-6746 A-TUBE 0.50 SST 1
10 623-6747 A-TUBE 0.50 SST 1
11 623-6750 A-TUBE 0.50 SST 1
12 623-6751 A-TUBE 0.50 SST 1
13 623-6753 A-TUBE 0.25 SST 1
14 623-6754 A-TUBE 0.25 SST 1
15 623-6755 A-TUBE 0.38 SST 1
16 623-6756 A-TUBE 0.25 SST 1
17 623-6757 A-TUBE 0.25 SST 1
18 623-6758 A-TUBE 0.38 SST 1
19 623-6759 A-TUBE 0.38 SST 1
20 623-6879 A-TUBE 0.50 SST 1
21 624-8566 A-TUBE 0.50 SST 1
22 624-8567 A-TUBE 0.50 SST 1
23 624-8568 A-TUBE 0.50 SST 1
24 624-8569 A-TUBE 0.75 SST 1

Halvorsen
REV. B
Figure 12
MANIFOLD ASSEMBLY, REAR PITCH
623-5411

Halvorsen
MANIFOLD ASSEMBLY, REAR PITCH
623-5411
1 623-5411-001 BODY 1
2 624-0296 VALVE, 3 POSITION DO3 DIRECTIONAL 1
* 620-6451-090 SEAL KIT 1
* 620-6451-092 BOOT REPLACEMENT 1
* 620-6451-093 COIL REPLACEMENT 1
3 111-2282 SCREW, SOCKET HEAD CAP, GR 8 10-24 X 1.25 4
4 623-5411-002 VALVE, COUNTER BALANCE 1
5 620-0110-001 VALVE, SHUTTLE 1
6 620-0123-001 VALVE, NEEDLE 2
7 620-1664-001 VALVE PRESSURE COMP. FLOW CONTROL 1
8 620-1326-001 VALVE, SHUTTLE 1
9 623-5411-003 VALVE, PRESSURE REDUCING 1
* NOT SHOWN

Halvorsen
REV. B
Figure 13
MANIFOLD ASSEMBLY, INNER AND OUTER SCISSORS
623-5413

Halvorsen
MANIFOLD ASSEMBLY, INNER AND OUTER SCISSORS
623-5413
1 623-5413-001 BODY 1
2 625-6345 VALVE, DIRECTIONAL 3
3 623-5413-002 VALVE, CHECK 6
4 623-5413-003 VALVE, NEEDLE W/CHECK 2
5 623-5413-004 VALVE 4
* NOT SHOWN

Halvorsen
VIEW C
VIEW E
Figure 14 Sheet 1
DECK HYDRAULIC INSTALLATION
628-0452

Halvorsen
DETAIL C
DETAIL B
Figure 14 Sheet 2
628-0452

Halvorsen
K
23
K
13 25
20 32 34 49
51 47 36 19
10
40
15 41
51 47 36 19 20 49 34 32
13 25
12
51 47 36 19
40
3 47 50
17
39 35 48
48 35 39
27
59 4 59 58
39
54 35 33 55 8
BOTTOM VIEW
FRONT OF LOADER
Figure 14 Sheet 3
628-0452

Halvorsen
48 35
9
18
18
61
14
14
DETAIL B
FOR CLARITY
Figure 14 Sheet 4
628-0452

Halvorsen
59 58
27 4
8
40
59
19 36 51 47
10
13 7
46 36 47 51
19 36 51 47
10
13 25
19 36 51 47 20 32 34 49
40 45 36 47 53
24
40 21
17 6 36 47 50
50 47 36 6
21
17
19 36 51 47
53 47 36 45
47 51 36 19
25 13
49 34 32 20
47 51 36 19
3
61
BOTTOM VIEW
REAR OF LOADER
SOME COMPONENTS REMOVED 49 34 32 20
FOR CLARITY
Figure 14 Sheet 5
628-0452

Halvorsen
19 36 51 47
40
9 T
13 7
42 TP
40
9 P
17
1 57 34 32
DETAIL C
FOR CLARITY
Figure 14 Sheet 6
628-0452

Halvorsen
9 P
43
12
T 9
P 44
22
12
62 34 32 2
DETAIL D
FOR CLARITY
Figure 14 Sheet 7
628-0452

Halvorsen
16 9
T1 11
P1 9
17
DETAIL E
FOR CLARITY
P 44 9 P
SECTION K-K
Figure 14 Sheet 8
628-0452

Halvorsen
628-0452
1 623-5415 MANIFOLD, ASSEMBLY STOPS AND LIFT 1
2 623-5416 MANIFOLD, 5 STATION 1
3 623-8170 CUSTOM MANIFOLD 1
4 621-5639-001 CYLINDER, PALLET STOP-NGSL 2
5 623-6556 CYLINDER ASSEMBLY 18
6 623-2474 MANIFOLD, HEADER 2
10 102-1796-0808 ADAPTER, 90 -08MJIC X -08MJIC 4
13 102-1780-0006 ADAPTER, TEE UNION -06JIC 11
23 623-5952-003 IH-DECK HOSE ASSEMBLY KIT 1
24 627-6080-002 IH-DECK TUBE ASSEMBLY KIT 1
27 102-1329 ADAPTER, 06MORB X 06MJIC 2
32 107-9259 NUT, PTH 8 M8 X 1.25 MG 14

Halvorsen
628-0452
33 107-9260 NUT, PTH 8 M10 X 1.50 MG 1
36 107-9258 NUT, PTH 8 M6 X 1.00 MG 24
39 239-8852-008 CLAMP, SUPPORT 2.00 NC 3
42 102-1788-0004 ADAPTER, PLUG -04ORB 1
43 102-1788-0006 ADAPTER, PLUG -06ORB 1
44 102-1788-0010 ADAPTER, PLUG -10MORB 2
48 107-9317 SCREW, HHC 10.9 M10 X 1.5 X 40 MG 36
49 107-9309 SCREW, HHC-F 10.9 M8 X 1.25 X 60 MG 7
50 107-9036 SCREW, HHC 8.8 M6 X 1 X 70 MG 6
51 107-9034 SCREW, HHC 8.8 M6 X 1 X 55 MG 16
53 107-9033 SCREW, HHC 8.8 M6 X 1 X 50 MG 4
54 107-9316 SCREW, HHC-F 10.9 X 1.5 X 35 MG 1
55 239-8852-007 CLAMP, SUPPORT 1.50 NC 1
57 107-2225 SCREW, SHCSLO 10.9 M8 X 1.25 X 20 MG 3
58 103-0725 PIN, CLEVIS 0.75 X 2.00 11-285Z 2
59 103-0693 PIN, COTTER 0.094 X 1.75 S.S. 4
61 102-0031 ADAPTER, 90 SWIVEL -06FJIC X -06MJIC 1
62 107-9303 SCREW, HHC 10.9 M8 X 1.25 X 30 MG 4
* NOT SHOWN

Halvorsen
VIEW C
VIEW E
Figure 15 Sheet 1
HOSE ASSEMBLY KIT, DECK
623-5952-003

Halvorsen
FROM ‘B’ PORT
20 MODULE 7
TO A2 OF MANIFOLD
FROM ‘B’ PORT

MODULE 6 19 FROM ‘A’ PORT
TO B5 OF MANIFOLD 22 MODULE 7
TO B2 OF MANIFOLD
FROM ‘A’ PORT

VIEW A
MODULES 19
TO A5 OF MANIFOLD
FROM ‘B’ PORT

T0 ‘A’ PORT 19
MODULE 6
TO ‘A’ PORT
VIEW B 11
MODULE 4
30 TO ‘B’ PORT
MODULE 4
TO PORT OPP.
1
ROD END
TO ‘A’ PORT
13
MODULE 1
FROM ‘A’ PORT

T0 ‘B’ PORT 15
MODULE 1 TO ‘A’ PORT
27
MODULE 2
FROM ‘A’ PORT
T0 ‘B’ PORT 18
MODULE 2
4
28
6 8
Figure 15 Sheet 2
623-5952-003

Halvorsen
12 TO B4
13 TO A4
TO B1 13
13 TO A3
12 TO B3

MANIFOLD
TO A1 10
STOP/LIFT
FOR CLARITY
21 TO P1 OF
VIEW A
A1 P PORT
B1
A2
B2
A3
B3
A4
B4
A5
B5
24
TO T1
STOP/LIFT
MANIFOLD
T PORT
Figure 15 Sheet 3
623-5952-003

Halvorsen
A2
A3
4 TO B2
B2
A4
SOME COMPNENTS REMOVED

5 TO A2
B3
FOR CLARITY
B4
VIEW B
3
7 TO A3
CONNECT TO
POINT A
23
CONNECT TO
POINT B
7TO B3
TO A4 4
POINT B
POINT A
4
TO B4
Figure 15 Sheet 4
623-5952-003

Halvorsen
TO ‘A’ PORT
MODULE 9
1
10
VIEW E
FROM ‘B’ PORT 23
TO ‘B’ PORT 13
TO ‘A’ PORT
MODULE 9
MODULE 8
Figure 15 Sheet 5
623-5952-003

Halvorsen
623-5952-003
2* 519-0197-027-S HOSE ASSEMBLY, -8 X 27 IN. LG SLVD 2
29 519-0196-025-S HOSE ASSEMBLY, -6 X 25 IN. SLVD 1
30 519-0197-064-S HOSE ASSEMBLY, -08 X 64 IN. SLVD 1
* NOT SHOWN

Halvorsen
VIEW A
VIEW B
VIEW C
VIEW D
Figure 16 Sheet 1
TUBE ASSEMBLY KIT, DECK
627-6080-002

Halvorsen
8
10
48
6 47
49
50
VIEW SHOWN
LOOKING FROM
BOTTOM TO TOP
5 9
VIEW A
Figure 16 Sheet 2
627-6080-002

Halvorsen
37 38 39 40 44 43
41 42
18
16
21
19
17
20
15
22
51 51 1 1 46 2
VIEW SHOWN
LOOKING FROM
BOTTOM TO TOP VIEW B
Figure 16 Sheet 3
627-6080-002

Halvorsen
27 34 33
31
36
11
12 35
29
VIEW SHOWN
32 28 30 LOOKING FROM
VIEW C BOTTOM TO TOP
Figure 16 Sheet 4
627-6080-002

Halvorsen
13
14
25 45
26
45
24 26
25
24
23
VIEW SHOWN
LOOKING FROM VIEW D
BOTTOM TO TOP
Figure 16 Sheet 5
627-6080-002

Halvorsen
627-6080-002
1 623-8180 TUBE ASSEMBLY -08 2
10 623-8190 TUBE ASSEMBLY -06 1
11 623-8195 TUBE ASSEMBLY -06 1
12 627-1550 TUBE ASSEMBLY -06 1
13 628-4191 A-TUBE, 0.38 SST 1
14 628-4189 A-TUBE, 0.38 SST 1
15 623-8617 A-TUBE, 0.375 SST 1
16 623-8618 TUBE ASSEMBLY -06 1
17 623-8619 A-TUBE, 0.375 SST 1
18 623-8620 TUBE ASSEMBLY -06 1
19 627-1532 TUBE ASSEMBLY -06 1
20 627-1534 TUBE ASSEMBLY -06 1
21 623-8623 TUBE ASSEMBLY -06 1
22 623-8624 A-TUBE, 0.375 SST 1
23 623-8625 A-TUBE, 0.375 SST 2
24 623-8626 TUBE ASSEMBLY -06 2
25 623-8627 A-TUBE, 0.375 SST 2
26 623-8628 TUBE ASSEMBLY -06 2
27 623-8629 TUBE ASSEMBLY -06 1

Halvorsen
627-6080-002
28 623-8630 A-TUBE, 0.375 SST 1
29 623-8631 A-TUBE, 0.375 SST 1
30 623-8632 TUBE, 0.38 SST 1
31 623-8633 TUBE ASSEMBLY -06 1
32 623-8634 A-TUBE, 0.375 SST 1
33 623-8635 TUBE ASSEMBLY -06 1
34 623-8636 TUBE ASSEMBLY -06 1
35 623-8637 TUBE ASSEMBLY -06 1
36 623-8638 TUBE ASSEMBLY -06 1
37 623-8640 A-TUBE, 0.375 SST 1
38 623-8641 TUBE ASSEMBLY -06 1
39 623-8642 TUBE ASSEMBLY -06 1
40 623-8643 TUBE ASSEMBLY -06 1
41 623-8644 TUBE ASSEMBLY -06 1
42 623-8645 TUBE ASSEMBLY -06 1
43 623-8646 TUBE ASSEMBLY -06 1
44 623-8647 TUBE ASSEMBLY -06 1
45 623-8648 TUBE ASSEMBLY -06 2
46 623-8651 TUBE ASSEMBLY -08 1
47 624-3050 TUBE ASSEMBLY -06 1
48 624-3051 TUBE ASSEMBLY -06 1
49 624-3052 TUBE ASSEMBLY -06 1
50 624-3053 TUBE ASSEMBLY -06 1
51 624-3054 TUBE ASSEMBLY -08 2

Halvorsen
REV. B
Figure 17
MANIFOLD ASSEMBLY, STOPS AND LIFT
623-5415

Halvorsen
MANIFOLD ASSEMBLY, STOPS AND LIFT
623-5415
1 623-5415-004 VALVE, PARKER 1
* 622-6094-091 REPLACEMENT COIL 1
2 623-5954 VALVE, SOLENOID, 2 POS. 4 WAY 3
* 622-6094-091 REPLACEMENT COIL 1
3 623-5415-001 BODY 1
4 623-5415-003 VALVE, 2500 PSI 1
5 623-5415-005 VALVE, 1500 PSI 1
6 620-6157-001 VALVE 2
7 623-5415-002 VALVE, SHUTTLE 1
8 623-5415-006 VALVE, 800 PSI 1
* NOT SHOWN

Halvorsen
REV. B
Figure 18
MANIFOLD ASSEMBLY, FIVE STATIONS
623-5416

Halvorsen
MANIFOLD ASSEMBLY, FIVE STATIONS
623-5416
1 623-8163 MANIFOLD, FIVE STATIONS 1
2 627-3126 VALVE, 3 POSITION DO3 DIRECTIONAL 5
* 620-6452-090 SEAL KIT 1
* 620-6451-092 BOOT REPLACEMENT 2
3 623-8654 RELIEF MODULE, CROSS OVER 5
* 620-8654-001 CARTRIDGE, 1850 PSI 2
* 620-0132-002 BODY, WITH BUNA N SEALS 1
4 107-1162 SCREW, SOCKET HEAD CAP, GR 8 10-24 X 3 20
* NOT SHOWN

Halvorsen
Figure 19 Sheet 1
CAB HYDRAULIC INSTALLATION
623-5949

Halvorsen
Figure 19 Sheet 2
623-5949

Halvorsen
623-5949
1* 624-4309 PLATE, SPACER 1
2 624-0340 VALVE, BRAKE, TANDEM 1
3* 620-0128 VALVE, SHUTTLE 2
4* 624-5212 VALVE, STEERING 1
5 623-5949-003 HOSE ASSEMBLY KIT (REF. FIG. 87) 1
6* 102-1814-0608 ADAPTER, STRAIGHT SWIVEL, -6M ORB X -8F JIC 1
7 102-1781-0606 ADAPTER, TEE, -6M ORB X -6M JIC 4
8 102-1775-0606 ADAPTER, STRAIGHT, -6M ORB X -6M JIC 4
9* 102-1775-0608 ADAPTER, STRAIGHT, -6M ORB X -8M JIC 1
10 102-1786-0008 ADAPTER, B.H. RUN, -8M JIC 1
11 102-1776-0806 ADAPTER, REDUCER, -8F JIC X -6M JIC 1
12* 102-1775-0604 ADAPTER, STRAIGHT, -6M ORB X -4M JIC 1
14 102-1783-0808 ADAPTER, B.H., -8M JIC X -8M JIC 3
16* 102-1789-0808 ADAPTER, CONNECTOR 90º 2
17* 102-1777-0808 ADAPTER, 90, -8M ORB X -8M JIC 2
21 102-1778-0606 ADAPTER, 90 SWIVEL, -6F JIC X -6M JIC 5
22 102-1775-0406 ADAPTER, STRAIGHT, -4M ORB X -6M JIC 2
23* 624-4218 SWITCH, BRAKE PRESSURE DIFFERENTIAL 1
24* 118-2677-002 TEE, 0.25 -18 NPT, STEEL 1
25* 102-1782-0006 ADAPTER, TEE RUN SWIVEL, -6M JIC 1
26* 102-1243 ADAPTER, STRAIGHT, -4M NPT X -6F JIC 1
27* 624-4215 TUBE ASSEMBLY, -6 1
28* 624-4216 TUBE ASSEMBLY, -6 1

Halvorsen
623-5949
29 107-9267 NUT, HEX 8 M8 X 1.25 MG 2
32* 624-5126 SPACER, BRAKE 2
33 107-9259 NUT, PTH 8 M8 X 1.25 MG 6
35* 118-2659-001 ADAPTER, STRAIGHT, -4M NPT X -2 FNPT 2
* NOT SHOWN

Halvorsen
Figure 20 Sheet 1
HOSE ASSEMBLY KIT, CAB
623-5949-003

Halvorsen
T
SOME HOSES REMOVED

FOR CLARITY
SOME HOSES REMOVED

FOR CLARITY
P
R T
Figure 20 Sheet 2
623-5949-003

Halvorsen
LS
SOME HOSES REMOVED

FOR CLARITY
B1
B2
Figure 20 Sheet 3
623-5949-003

Halvorsen
Figure 20 Sheet 4
623-5949-003

Halvorsen
623-5949-003

Halvorsen
REV. A
Figure 21 Sheet 1
HYDRAULIC INSTALLATION, FINAL ASSEMBLY
623-7170

Halvorsen
Figure 21 Sheet 2
623-7170

Halvorsen
Figure 21 Sheet 3
623-7170

Halvorsen
623-7170
1 624-4314 TUBE ASSEMBLY, -12 2
2 623-9590 WELDMENT, CLAMP, LIFT CYLINDER 2
3 623-7170-003 HYDRAULIC INSTALLATION, FINAL ASSEMBLY HOSE 1

KIT (REF. Figure 21 Sheet 1)
4 623-5396-500 CYLINDER, MAIN LIFT 2
* 623-5397-001 REPLACEMENT BLEEDER SCREW 1
* 623-5396-090 SEAL KIT, MAIN LIFT CYLINDER 1
* 623-4468 BEARING, SPHERICAL 1
* 104-1585 RETAINING RINGS, BEARING 1
* 623-5925 VALVE WITH COIL 1
* 623-5410-004 COIL 1
8 102-1778-1212 ADAPTER, 90 SW., -12F JIC X -12M JIC 1
9 102-1780-0008 ADAPTER, TEE UNION, -8 JIC 2
10 102-1777-1212 ADAPTER, 90, -12M ORB X -12M JIC 2
11 102-1777-0606 ADAPTER, 90, -6M ORB X -6M JIC 1
14 624-8900 SLEEVE, WEAR TRIP MAIN CYLINDER 2
15* 107-2271 TIE, CABLE 32 IN. HD BLACK PLT 8H-CO 6
* NOT SHOWN

Halvorsen
Figure 22 Sheet 1
HYDRAULIC INSTALLATION, FINAL ASSEMBLY HOSE KIT
623-7170-003

Halvorsen
Figure 22 Sheet 2
623-7170-003

Halvorsen
Figure 22 Sheet 3
623-7170-003

Halvorsen
Figure 22 Sheet 4
623-7170-003

Halvorsen
623-7170-003
3 519-0196-145-S HOSE ASSEMBLY FJIC SW-06 X 145 SLVD 1
9 519-0197-144-S HOSE, ASSEMBLY FJIC SW-08 X 144 SLVD
12 620-1848-065-S HOSE, ASSEMBLY, 16 X 65 SLVD 1

Halvorsen
Figure 23
VALVE BLOCK ASSEMBLY A/C MANIFOLD
625-4073
VALVE BLOCK ASSEMBLY A/C MANIFOLD

625-4073
3 623-6681-010 VALVE, SUN 1
5 623-6681-015 COIL, 24 VDC, SUN 1

Halvorsen
Section 16. Electrical System
1. CHASSIS ELECTRICAL INSTALLATION 627-9621-001 Figure 1 Sheet 1 2
2. WINTERIZATION ELECTRICAL INSTALLATION 624-3490 Figure 2 Sheet 1 23
3. WINTERIZATION BOX ELECTRICAL INSTALLATION 623-5459 Figure 3 Sheet 1 29
4. ELECTRICAL INSTALLATION, POWER MODULE 628-5469 Figure 4 Sheet 1 34
5. ELECTRICAL ASSEMBLY, MAIN PANEL 628-0554-001 Figure 5 Sheet 1 44
6. SCISSOR ELECTRICAL INSTALLATION 628-0414 Figure 6 Sheet 1 58
7. DECK ELECTRICAL INSTALLATION 624-3249 Figure 7 Sheet 1 67
8. DECK PANEL ELECTRICAL ASSEMBLY 624-2911 Figure 8 Sheet 1 78
9. TAIL LIGHT ASSEMBLY, 24V LEFT TURN 624-5754 Figure 9 88
10. TAIL LIGHT ASSEMBLY, 24V RIGHT TURN 624-5756 Figure 10 90
11. CAB ELECTRICAL INSTALLATION 628-0563-001 Figure 11 Sheet 1 92
12. DASH PANEL ELECTRICAL ASSEMBLY 628-0600-001 Figure 12 Sheet 1 103
13. WIPER PANEL ELECTRICAL ASSEMBLY 624-3258 Figure 13 Sheet 1 109
14. CONVEY PANEL ELECTRICAL ASSEMBLY 624-2915 Figure 14 Sheet 1 112
15. A/C CONNECTOR ELECTRICAL ASSEMBLY 627-7214 Figure 15 116
16. PROXIMITY SWITCH ELECTRICAL ASSEMBLY 622-6730 Figure 16 117
17. ACCELERATOR PEDAL ELECTRICAL ASSEMBLY 627-7150 Figure 17 118
ELECTRICAL SYSTEM 4-16

Halvorsen
DETAIL A
HARNESS CONTINUED
ONTO SCISSORS TO
PROXIMITY SWITCH
13
DETAIL BG
RIGHT SIDE
ISOMETRIC VIEW
Figure 1 Sheet 1
CHASSIS ELECTRICAL INSTALLATION
627-9621-001

Halvorsen
21
17 38 25 19
DETAIL A
SOME COMPONENTS
REMOVED FOR CLARITY
7
71
REF
56
DETAIL BG
SOME COMPONENTS
REMOVED FOR CLARITY
Figure 1 Sheet 2
627-9621-001

Halvorsen
DETAIL B
LEFT SIDE
ISOMETRIC VIEW
21
38 25 19 17
DETAIL B
SOME COMPONENTS
REMOVED FOR CLARITY
Figure 1 Sheet 3
627-9621-001

Halvorsen
25 17 19
P
DETAIL K
V
P
4" - 8 THD
VELVAC
DETAIL AD
U
DETAIL J
DETAIL H
N
Figure 1 Sheet 4
627-9621-001

Halvorsen
DETAIL AE
49
48
51
47
41
39
50
52
DETAIL AD
49
DETAIL AE
SOME COMPONENTS
REMOVED FOR CLARITY
Figure 1 Sheet 5
627-9621-001

Halvorsen
DETAIL C
ALTERNATOR
67
POS (+) POST
G
DETAIL H
DETAIL W
F
DETAIL AL
4" - 8 THD
VELVAC
DETAIL E
G
DETAIL D
F
Figure 1 Sheet 6
627-9621-001

Halvorsen
28
17 25 38
3LS-A
12 26 29 43
DETAIL C
27 25 38
10SOL
22
11SOL
DETAIL D
Figure 1 Sheet 7
627-9621-001

Halvorsen
7
13
DETAIL E
FOR CLARITY
24 16 37
SECTION F-F
FOR CLARITY 19 25 38
21
SECTION G-G 2LS
Figure 1 Sheet 8
627-9621-001

Halvorsen
25 380
60.0
23
1 14
DETAIL J
SECTION M-M
18 25 38
23 22
SECTION N-N
Figure 1 Sheet 9
627-9621-001

Halvorsen
R SECTION P-P 6
STARTER
SECTION R-R
Figure 1 Sheet 10
627-9621-001

Halvorsen
63
50
22
21 SECTION U-U
ROTATED 90 & 86
FOR CLARITY
4 SECTION V-V
ROTATED 90
FOR CLARITY
Figure 1 Sheet 11
627-9621-001

Halvorsen
AB
AB
DETAIL AA
DETAIL X
WIRES 17, 18 AND 176
DETAIL Y
DETAIL W
Figure 1 Sheet 12
627-9621-001

Halvorsen
47SOL 9SOL
8SOL
4SOL
21
3SOL
1SOL
13SOL
MANIFOLD
ASSEMBLY
7SOL-A
7SOL 3PS
DETAIL AA
Figure 1 Sheet 13
627-9621-001

Halvorsen
31
1TAS-A 7TAS
53 32
11 26 29 43
2LS
33
21
4POT
SECTION AB-AB
21
5CON
DETAIL X
5
40 39 41 21
E-PUMP
20 4
8
WIRE #6
DETAIL Y
Figure 1 Sheet 14
627-9621-001

Halvorsen
42 14
14 57
45
44 43 46
1 58
14 54
41 61 62 59
62 61 470
40 39 41
69
55
68 56
58 41 61 62
64
58
70
71
66 65
Figure 1 Sheet 15
627-9621-001

Halvorsen
INSTALL GLOW
50 PLUG WIRE
FROM ENGINE
WIRE 404
WIRE 2
FROM STARTER
WIRE 477
DETAIL AL
60
GROUND
+12VDC
+24VDC
SECTION BJ-BJ
Figure 1 Sheet 16
627-9621-001

Halvorsen
15 58
68
59
1SOL-B
M
8
60
L
30
BJ BJ
21
L
2
57
DETAIL K
FOR CLARITY
Figure 1 Sheet 17
627-9621-001

Halvorsen
6
(BEHIND 14
ITEM 7) 58
SW (+)
7 71
BATT (+)
14
38 25 17
9 2
BATT (-)
69
71
67
1
SW (-)
5
SECTION L-L
ROTATED 90
FOR CLARITY
Figure 1 Sheet 18
627-9621-001

Halvorsen
627-9621-001
1 621-4966-018 AE-CABLE 2/0 BLK 0.375 - 0.375 W/L 1
2 621-4966-012 AE-CABLE 2/0 BLK 0.375 - 0.375 W/L 2
3 621-4966-066 AE-CABLE 2/0 BLK 0.375 - 0.375 W/L 1
4 624-3481-096 AE-CABLE 2/0 NEG (BLK) 1
5 624-8875-140 AE-CABLE 2/0 RED 0.38 - 0.38, W/L 1
6 621-5428-078 AE-CABLE 2/0 RED 0.312 - 0.375 W/L 1
7 625-4823-096 AE-CABLE 2/0 RED 0.312 - 0.375 W/L 1
8 621-5428-012 AE-CABLE 2/0 RED 0.312 - 0.375 W/L 1
9 519-9424-102 AE-CABLE 4-AWG BLACK 0.25 - 0.375 W/L 1
11 623-8524 AE-LIMIT SWITCH, DPDT 1
12 623-8523 AE-LIMIT SWITCH, SPDT 1
13 628-0554-001 AE-MAIN PANEL, NGSL, ENG 1
14 624-8875-018 AE-CABLE 2/0 RED 0.38 - 0.38, 18 IN. 2
15 623-7304 BATTERY, OPTIMA (12 VOLTS DC) 2
18 239-8852-001 CLAMP, SUPPORT 0.50 N.C. 3
19 239-8852-002 CLAMP, SUPPORT 0.75 N.C. 8
20 623-2326 RELAY, POWER 300A, 28 VDC 1
21 628-0553 HE-CHASSIS, NGSL, T3 1
22 624-3262 HE-CHASSIS FRONT 1
23 6223-8831 HORN, 108 DB 335 HZ 24V, SEALED 1
24 107-2180 NUT, PTCH 10 M10 X 1.50 MG 4
25 107-9259 NUT, PTH 8 M8 X 1.25 MG 18
26 117-7576 NUT, PTH A2 TH #10-24 S.S. 4
27 623-6744 PLATE, COVER 1
28 624-1436 PLATE, PROXIMITY SWITCH REAR 1

Halvorsen
627-9621-001
29 107-0780 SCREW, SPAN GR 2 #10-24 X 2 ZP 4
30 620-9056 SW DISCONNECT 2 CIRCUITS 1
31 623-5009 SWITCH, LOW TEMPERATURE 32 F 1
32 514-4745 SWITCH, TEMP. NO ABOVE 180F 1
33 514-3086-004 SENDER, TEMP. WATER 100230 F 1
34 105-0210 NYLON CABLE WRAP, 7.3 IN. - 50 LB 20
35 623-4995 NYLON CABLE WRAP, LARGE 14.5 IN. 50 LB 20
39 107-9258 NUT, PTH 8 M6 X 1.00 MG 11
40 107-9017 SCREW, HHC-F 8.8 M6 X 1 X 20 MG 6
42 624-5019 LANYARD - 9.00 WITH TAB AND SPLIT RING 1
44 107-1976 NUT, PTH GR A2 M5 X 0.8 S.S. 4
45 624-6252 CONNECTOR, NATO 1
46 107-2512 SCREW, PPAN A2 M5 X 0.8 X 25 S.S. 4
47 107-9018 SCREW, HHC-F 8.8 M6 X 1 X 25 MG 3
48 1079019 SCREW, HHC-F 8.8 M6 X 1 X 30 MG 2
49 627-8774-001 TCM, AL2100SP TRANSMISSION 1
50 627-6036 HE-AL2100SP TCM, ML44K 1
51 625-9209 BRACKET, TCM 1
52 625-9582 W-SHIELD, TCM WEATHER 1
53 106-1197 BUSHING, HEX 08 MPT X 06 FNPT BR 1
54 624-7821-030 BREAKER, MANUAL HIGH AMP 1
56 627-8723-130 AE-CABLE 8-AWG RED #10-0.31, W/L 1

Halvorsen
627-9621-001
57 627-1136-036 AE-CABLE 8-AWG BLK 0.38-0.38, W/L 1
58 627-1281-024 AE-CABLE 8-AWG RED 0.25-0.38, W/L 3
60 627-6326 CONVERTER, EQUALIZER 1
61 107-1107 NUT, PTH A2 0.25-20 S.S 6
62 107-1522 SCREW, PPAN GR 2 0.25-20 X 1 S.S. 6
63 627-5817 AE-CAN, ML44K 1
64 620-0757 CONTACTOR, 24V SPNO 50 AMP 1
65 620-2983-001 DIODE, 3 AMP (400V) 1
66 627-7180-012 AE-CABLE 8-AWG RED 0.25-.32, W/L 1
67 625-4823-078 AE-CABLE 1/0 RED 0.312 - 0.375 W/L 1
68 627-8729 AE-CABLE, 12V INTERLOCK 1
69 627-7189-032 AE-CABLE 18-AWG YEL #10 - 0.375, W/L 1
70 627-8702 AE-DIODE, 6A, WITH TERMINAL 1
71 627-8742 HE-12V CONTROL, ML44K 1
* NOT SHOWN

Halvorsen
28
30
18 14 12
SECTION B-B
Figure 2 Sheet 1
WINTERIZATION ELECTRICAL INSTALLATION
624-3490

Halvorsen
7
3 4 6
27
SECTION F-F
FROM HYDRAULIC 7
TANK 137”
17 15 23
7 FROM ENGINE
112” GANG BOX
28
SECTION A-A
Figure 2 Sheet 2
624-3490

Halvorsen
TRANSMISSION DETAIL D
HEATER PAD
DETAIL E
OIL PAN
HEATER
TO WINTERIZATION 7 8 4
BOX
TANK HEATER
31 20 19 25 16
4 5
4 9 5 4
8 FROM BATTERY
DETAIL D 31”
GANGBOX
SOME ITEMS REMOVED
FOR CLARITY
Figure 2 Sheet 3
624-3490

Halvorsen
6 4
TO ENGINE
7
GANGBOX
31 19 25 16
13 10 11
8 4
29
DETAIL E
SOME ITEMS REMOVED
FOR CLARITY
28
22
21 4AC
3AC
26 SECTION C-C
SOME ITEMS REMOVED
FOR CLARITY
Figure 2 Sheet 4
624-3490

Halvorsen
624-3490
3 106-0024 ADAPTER, BUSHING 16 MNPT X 08 FNPT 1
4 106-0125 SEALING RING, 0.50 8
5 106-0135 CONNECTOR, CORD 0.38 LIQUID TIGHT 2
6 106-0142 CONNECTOR, CORD 0.38 90 DEG. LIQUID TIGHT 2
7 106-0517 CONDUIT 0.38 LIQUID TIGHT 24 ft.
8 106-0941 CONNECTOR, CORD 0.50 WATERTIGHT OVAL 3
9 106-0945 CORD, CONNECTOR, 0.5 IN. ST (0.125 - 0.25) 1
11 107-1976 NUT, PTH A2 M5 X 0.8 S.S. 1
12 107-2071 WASHER, SEALING 0.375 BONDED S.S. 4
13 107-2268 SCREW, PPAN A2 #10-24 X 0.75 S.S. 1
14 107-9081 SCREW, HHC-F 8.8 M10 X 1.5 X 35 MG 4
15 107-9259 NUT, PTH 10 M8 X 1.25 MG 1
18 107-9285 NUT, HEX 10 M10 X 1.5 MG 4
19 239-3648-002 TERMINAL MEDIUM PIGTAIL SPLICE 5
20 239-3648-003 TERMINAL LARGE PIGTAIL SPLICE 3
23 239-8852-007 CLAMP, SUPPORT 1.50 NC 1
24 515-3000-014 WIRE 14-AWG (THHN) 135 ft.
25 600682 SCREW, HHC GR 5 0.25-20 X 0.75 MG 8
27 620-9390 HEATER, 1500W 120V IMMERSION 1

Halvorsen
624-3490
28 623-5459-001 AE-WINTERIZATION BOX 1
29 623-7310 HEATER, BATTERY 50W 2
30 623-7313 GASKET, M-ENCLOSURE 1
31 623-7321 M-GANG BOX 5 OUTLETS WITH COVER 2
32 624-8942-004 TUBING, SHRINK 3/8 IN. 0.6 ft.

Halvorsen
3 1 4
3 1 4
26
42
2 1 3 SOME ITEMS REMOVED

36 35 34 33 FOR CLARITY
Figure 3 Sheet 1
WINTERIZATION BOX ELECTRICAL ASSEMBLY
623-5459

Halvorsen
44
38
44
40 37
7
44
28
42
DETAIL E
27
5
DETAIL G 44 43
15
7
40
14 28 32
18 45 20 32
SECTION A-A
42
30
42
31
16 45 19
27
23 22 43
39
18 45 10 9 8 21 SECTION B-B
SECTION C-C
Figure 3 Sheet 2
623-5459

Halvorsen
20 41
12 11 13
21
42
43
SECTION D-D
38
39
SECTION F-F
31
31
DETAIL E
DETAIL G
Figure 3 Sheet 3
623-5459

Halvorsen
623-5459
1 106-0006 LOCKNUT, #141 1/2 IN. CONDUIT 3
2 106-0078 CORD CONNECTOR, 0.5 IN. ST (0.25-0.375) 1
3 106-0125 SEALING - 1/2 IN. O-RING 3
4 106-0142 CONNECTOR, CORD 0.38 90º LIQUID TIGHT 2
5 107-0806 RIVET - CHERRY SST 2
6 107-1073 SCREW, HHC A2 0.31-18 X 1 S.S. 4
7 107-1111 NUT, PTH A2 0.31-18 S.S. 4
8 107-1382 SCREW, SPAN A2 #8-32 X 0.75 S.S. 2
9 107-1482 NUT, PTH A2 #8-32 S.S. 2
10 107-1919 WASHER, FLAT NARROW A2 #10 S.S. 4
11 107-2006 NUT, PTH A2 M4 X 0.7 S.S. 4
12 107-2063 SCREW, SPAN A2 M4 X 0.7 X 20 S.S. 4
13 107-2074 WASHER, SEAL A2 M4 S.S. 4
14 107-2203 WASHER, SEALING 0.312 BONDED S.S. 4
15 107-2871 WASHER, FLAT STD 0.31 S.S. 4
16 107-2872 SCREW, PPAN A2 #6-32 X 0.25 S.S. 4
17 239-3646-013 TERMINAL, RING 0.375 10-AWG 1
20 239-8418 RELAY, 120V 50/60 HZ DPDT 1
21 514-2056-006 RELAY, SOCKET 8 PIN OCTAL (DIN) 1
22 515-1210-003 CIRCUIT BREAKER (MINI-MAG) 15A 1
23 515-1420 CIRCUIT BREAKER, BOOT 1
24 515-3000-010 WIRE 10-AWG (THHN) 1 ft.
25 515-3000-014 WIRE 14-AWG (THHN) 30 ft.
26 620-1049-003 CONTROL CABLE 18-AWG, 3 COND. 2 ft.
27 622-0244-001 MOUNTING TRACK, 2M DIN 1

Halvorsen
623-5459
28 622-0244-003 END PLATE COVER (USK) 1
29 622-0244-005 MARKER STRIP (USK) 10 BLANKS 1
30 622-0244-007 TERMINAL BLOCK, 26-8 AWG USK10 5
31 622-0244-009 TERMINAL BLOCK, GROUND 20-8 AWG 2
32 622-0244-023 INSERTION BRIDGE 10 POS USK10 1
33 622-2967-003 CONNECTOR, RECEPTACLE 3 POS (MALE) 1
35 622-2967-019 CONNECTOR, WEDGE 3 POS RECEPTACLE 1
36 622-2967-047 CONNECTOR, BOOT 3 POS RECEPTACLE 1
37 622-7277-001 VAPOR CORROSION INHIBITOR 5CU 1
38 623-7306 PLUG, MALE 3 PRONG 30A WITH COVER 1
39 623-7307 RELAY, 240V 50/60 HZ SPDT 1
40 623-7308 TRANSFORMER, AUTO 3 KVA 50/60 HZ 1
41 623-7309-001 PLACARD, HIGH VOLTAGE CAUTION 1
42 623-7314 M-ENCLOSURE WINTERIZATION BOX 1
43 623-7315 M-INNER PANEL WINTERIZATION 1
44 623-7316 DECAL, WINTERIZATION BOX 1
45 624-8942-003 TUBING, SHRINK 3:3, BLACK 1/4 IN. 5 ft.
* NOT SHOWN

Halvorsen
DETAIL C
DETAIL A
DETAIL B
NON-CAB SIDE
ISOMETRIC VIEW
REF 628-0554-001
ENG-R 32
Figure 4 Sheet 1
ELECTRICAL INSTALLATION, POWER MODULE
628-5469

Halvorsen
32 7POT-B
22
DETAIL A
32 SB-1
REF 623-3700-006
DETAIL B
SOME ITEMS REMOVED
FOR CLARITY
Figure 4 Sheet 2
628-5469

Halvorsen
32 WIRE #404
32 WIRE #477
32 12BUS1
6CON
6CON
23
REF 627-6211
29
34 ECAN-P
6 19
7
24 20
5
REF 627-3290-087
REF 627-3290-221
34 ECUK-P
27 30 TO GROUND
BLACK WIRE
TERMINAL
DETAIL C
12 10 4
ALTERNATOR 32
27
28
ORANGE WIRE
BLUE &
TO POSITIVE 27
STATOR HOUSING
TERMINAL
RED WIRE
17 16 18
26
Figure 4 Sheet 3
628-5469

Halvorsen
REF 627-3958
32 9MTR-P
REF 627-3958
DETAIL E
10MTR-P 32
32 WIRE #474 TO “NO”

WIRE #1 TO “G”
ITAS
22
31
7POT 32
7POT-A 32
22
Figure 4 Sheet 4
628-5469

Halvorsen
DETAIL E
DETAIL F
TOP VIEW
DETAIL H
Figure 4 Sheet 5
628-5469

Halvorsen
IPS
32 WIRE #57 TO “NO”
29 WIRE #1 TO “G”
21
1 CON
WIRE #8 32
REF 625-5699
SECTION D-D
SOME ITEMS REMOVED
FOR CLARITY
3POT
WIRE #53 32
REF 232-8790-011
3POT
WIRE #1 32
DETAIL F
Figure 4 Sheet 6
628-5469

Halvorsen
EXTERNAL
32 REG-P
27
25
32 PFTEMP-P
8 9 11
32 2HTR-P
32 WNF-P
15 14 13
REF 627-3290-222
30
27
SECTION J-J
SOME ITEMS REMOVED
FOR CLARITY
Figure 4 Sheet 7
628-5469

Halvorsen
REF 627-6036
SOME ITEMS REMOVED

TCMENG-P 32
FOR CLARITY
DETAIL H
REF 627-2969
DCAN-R 32
PCAN-P 32
REF 627-6149
BUS477 32
Figure 4 Sheet 8
628-5469

Halvorsen
628-5469
4 107-0015 SCREW, HHC GR 5 0.5-13 X 6.5 ZP 1
5 107-1107 NUT, PTH A2 0.25-20 S.S. 2
6 107-1522 SCREW, PPAN GR 2 0.25-20 X 1 S.S. 2
7 107-1927 WASHER, FLAT STD A2 0.25 S.S 4
9 107-1976 NUT, PTH GR A2 M5 X 0.8 S.S. 4
10 107-2125 WASHER, FLAT NARROW 0.56 MG 2
11 107-2170 SCREW, HHC A2 M5-0.8 X 20 4
12 107-2257 NUT, PTH GR 5 TH 0.5-13 MG 1
13 107-9018 SCREW, HHC-F 8.8 M6 X 1 X 25 MG 2
14 107-9258 NUT, PTH 8 M6 X 1.00 MG 2
17 110-0065 SCREW, HHC GR 5 0.5-13 X 1.75 ZP 1
18 110-0237 NUT, PTH GR 5 0.5-13 ZP 1
19 238-8421 RELAY, SOLENOID 1
21 621-1874 SWITCH, OIL PRESSURE 1
22 623-8537 SENSOR, TEMPERATURE FAN DRIVE CONT. 3
23 623-9915 AE-DIODE WITH RING TERMINALS 1
24 624-8942-004 TUBING, SHRINK 3:1, BLACK 3/8 IN. 1
25 625-4112-001 REGULATOR, EXTERNAL 1
26 625-4112-004 ALTERNATOR, 24 VDC, 120A, T3 1
27 625-4112-005 HE-EXT REGULATOR, T3 1

Halvorsen
628-5469
28 625-4828 CABLE, GROUND 1/0, 16 IN. 1
30 627-5536 PLATE, EXTERNAL REGULATOR 1
31 627-7213 SWITCH, TEMPERATURE, 125 ºF 1
32 628-5454 HE-POWER MOD 1

Halvorsen
13 12 41 13 12 149
CUT 19.75 65 66
65 66 CUT 17.25
CUT 22.50 61 13 12 41
13 12 41
CUT 15.38 65 66 66 65 CUT 9.25
5 61
65 66 CUT 17.10
5 61
65 66 5
CUT 18.00 65 66 61 17 11 67 13
CUT 19.83 65 66
CUT 15.00 61
102
123
Figure 5 Sheet 1
ELECTRICAL ASSEMBLY, MAIN PANEL
628-0554-001

Halvorsen
74 78 84 69 FDC-RB
75 80 69 85 FDC-PB
72 78 82 FDC-RC
72 78 82 FDC-RA
73 80 83 FDC-PA
105 MAIN STUD

13 17 2 45
13 17 11 35
13 17 18
100
94
98
137
3
B
4
3
113
117
118
FDC-RA
FDC-RB
FDC-PC
FDC-PA
FDC-PB
C
108
SECTION A-A
125
13 12 41
19.50 66 65
19.50 61
13 17 11
5
66 65
19.50 61
67
67
19.50 61
13 17 11
5
CUT
CUT
CUT
CUT
19.50
CUT
Figure 5 Sheet 2
628-0554-001

Halvorsen
11
13
17
126
127
REV
NEU
13 RPM (NEG)
98
RPM (POS)
12
LAMP POWER
41 SHIFT POWER
PTO IN
SECTION B-B
PTO OUT
98
GRN-BLK S/S ORG

BLU-RED/BLK INGR-RED
BLU-RED/BLK BATT-BLUE
HI-GRN/BLK IGNS-GRN
HI-GRN/BLK SSOL-WHT
SECTION C-C
Figure 5 Sheet 3
628-0554-001

Halvorsen
32-SOL
WIRE #127
30-SOL 29-SOL
WIRE #127 WIRE #125
12
46-SOL
WIRE #153
PALLET STOP AND

CONVEY MODULE
LIFT MANIFOLD
37 38 39
DETAIL F
31 FOR CLARITY
REFER TO 624-3263
12FT HE-MAIN PANEL
16 TO DECK BOX
12 34-SOL
27 WIRE #135 35-SOL
WIRE #136
33-SOL
22 1 WIRE #133
DETAIL E 40-SOL
36-SOL
SOME COMPONENTS REMOVED WIRE #138
WIRE #140
FOR CLARITY
41-SOL
37-SOL WIRE #143
WIRE #139
38-SOL
CONVEY MODULE
WIRE #134
CONVEYING MANIFOLD
39-SOL
WIRE #144
42-SOL
WIRE #142
DETAIL G 12
FOR CLARITY
Figure 5 Sheet 4
628-0554-001

Halvorsen
108
42 21 114
23 21 114
7 15
130 8
114 29 20
114 43 22
88
93
108
129
108
108
122
DETAIL G
39 38 7
8
92
122
60
59
91
129
122
89
129
58
90
60
52
55
131
108
39
57
56
Figure 5 Sheet 5
628-0554-001

Halvorsen
143
138 13RES
138 14RES
12RES 135 143
136 11RES 138 17RES
138 19RES
15RES 138
8RES 136 138 16RES
10RES 138 138 18RES
9RES 135
143
60
91
59
DETAIL G
Figure 5 Sheet 6
628-0554-001

Halvorsen
30 45
45
28 45 108
2PB-1
WL-TGS 15TGS
45
30 45
7TGS 1TGS-A 2TGS-A
7 8 15
71 78 69 70
128
MP-RB
MP-RA
71 78 69 68 68 69 78 71
MP-RC
ENG-R
120 121 69 78 79
CHAS-R
128
CHS-FRT
113
3
140 121 69 78
3
SECTION D-D
115
Figure 5 Sheet 7
628-0554-001

Halvorsen
11 13
17
128
10
9
15 8 7
99
108
31
46
SECTION E-E
Figure 5 Sheet 8
628-0554-001

Halvorsen
9 10
145
7 38 39
36 40
112 6
92
89
8
7 124 8 15
108
129
17 2 13
119 47
31 95 46 11 17 34 24 26 25 27
17 2 13
44 47 48
145
49
37 40
35
96
32
97 47
145
17 2 13
Figure 5 Sheet 9
628-0554-001

Halvorsen
628-0554-001
1 DWG-623-9526 DWG-ELECT FABRICATION PRACTICES 1
2 HFS0148 SCREW, SRND A2 #10-32 X 0.75 S.S. 8
5 107-0811 RIVET, PRO 0.188 X 0.25 ALUMINUM 27
6 107-1107 NUT, PTH A2 0.25-20 S.S. 2
7 107-1382 SCREW, SPAN A2 #8-32 X 0.75 S.S. 56
8 107-1482 NUT, PTH A2 #8-32 S.S. 56
9 107-1522 SCREW, PPAN GR 2 0.25-20 X 1 S.S. 4
10 107-1927 WASHER, FLAT STD A2 0.25 S.S. 4
11 107-2061 SCREW, SPAN A2 #10-32 X 1 S.S. 77
12 107-2090 NUT, HEX A2 #10-24 S.S. 24
13 107-2091 WASHER, FLAT A2 #10 S.S. 69
15 107-2322 WASHER, FLAT A2 #8 S.S. 30
17 107-2324 NUT, PTH A2 #10-32 S.S. 89
18 107-2325 SCREW, SRND A2 #10-32 X 1.75 S.S. 4
20 237-5752-001 SWITCH GUARD, RED 1
21 237-5752-005 SWITCH GUARD, RED (ALT KEYWAY) 3
22 237-7505 SWITCH, DPDT TOGGLE (ON) OFF (ON) 1
23 239-0854 SWITCH, DPDT TOGGLE ON ON (ON) 1
24 239-2601-005 CIRCUIT BREAKER, 5A, #8 TERMINAL 3
28 239-3121 JUMPER, TOGGLE SWITCH 1
29 239-3327 SWITCH, SPST TOGGLE OFF - ON 1
30 239-3646-022 TERMINAL, RING 3

Halvorsen
628-0554-001
31 239-3646-003 TERMINAL, RING 20
34 239-3646-009 TERMINAL, RING 27
35 239-3646-012 TERMINAL, RING 5
40 239-8101-008 WIRE, INSULATED, AUTO, 8-AWG RED THHN 3
41 3616387 SCREW, PPAN A2 #10-24 X 0.5 S.S. 24
42 515-3065 SWITCH, SPDT TOGGLE (ON) ON 2
43 519-8841 SWITCH GUARD, 3 POSITIONS 1
44 620-0757 CONTACTOR, 24V SPNO 50 AMP 2
45 620-1240-002 TERMINAL, RING 18
48 620-1240-006 TERMINAL, RING 2
49 620-2983-001 DIODE, 3 AMP, 400V 3
50 620-3900-014 WIRE, 14-AWG, GXL, YELLOW 60
51 620-3900-018 WIRE STRANDED YELLOW 18 GA GXL 520
52 620-4478-004 RESISTOR, 300K 0.5W 5% 1
55 620-9546 MOUNT, TIME DELAY 3
56 621-1033-002 TIME DELAY MOD. (1-100 SEC.) 1
57 621-1034 FLASHER-24V S.S. 2
58 621-2736 RELAY, SOCKET LY2 14
59 621-2737 TRACK MOUNTED SOCKET PTF14 12
60 621-2738 RELAY HOLD-DOWN CLIP 52

Halvorsen
628-0554-001
61 622-0244-001 MOUNTING TRACK, 2 M DIN 2
62 622-0244-002 TERMNAL BLOCK, 22-12 AWG 83
63 622-0244-004 TERMINAL BLOCK, END CAP 4
64 622-1345-001 RELAY, LY2 12 VDC WITH LED 1
65 622-1358-011 DUCT, WIRING (2 IN. X 2 IN.) 16
66 622-1358-012 DUCT, WIRING, COVER (2 IN.) 16
67 622-1560 STANDOFF, 0.5 IN. DELRIN 12
68 622-2962-005 CONNECTOR, RECP, DRC FLANGE 40 “A” 2
70 622-2962-010 CONNECTOR, RECP, DRC FLANGE 40 “B” 1
71 622-2962-020 CONNECTOR, GASKET, DRC, RECP 40 POS 3
73 622-2967-002 CONNECTOR, PLUG 2 POS (FEMALE) 1
80 622-2967-015 CONNECTOR, SOCKET 16-18 AWG SOLID 4
83 622-2967-018 CONNECTOR, WEDGE 2 POS PLUG 1
88 622-5906 SWITCH, PUSH-BUTTON, N.C., RED 1
89 622-6214-004 RELAY 24V SPDT WITH DIODE, BRACKET 19
90 622-6328 RELAY, LY2 24VDC WITH DIODE 13
91 622-6328-001 RELAY, LY4 24VDC WITH DIODE 12
92 622-7161 M-MOUNT, MODULE DIN 14
93 622-7165 E-STOP GUARD WITH FINGER HOLES 1

Halvorsen
628-0554-001
95 623-1506 GASKET, CDM CIRCUIT BREAKER 27
96 623-1513-012 AE-CABLE 12.0 IN. (4-AWG / RED) 1
97 623-1513-048 AE-CABLE 48.0 IN. (4-AWG / RED) 1
98 623-7300-002 STONE BENNETT ACCESSORY BOX 1
99 623-7848 BUSS BAR, GROUND 20 POSITION 1
100 627-0334 AE-CONTROLLER, FAN DRIVE ML44K 1
102 624-2907 ME-PNL FOR (624-2903) 1
105 624-2919 TERMINAL BLOCK, SINGLE STUD 0.31 IN. 1
108 624-3244 DE-MAIN PANEL 1
113 625-4733 M-CORD CONNECTOR, 0.5 IN. ST (0.125-0.25) 2
114 625-8370 SEAL, PANEL BUSHING 5
115 625-8413 CORD CONNECTOR, 5 HOLE, 4X 0.12, 1X 0.20 1
117 106-0007 LOCKNUT CONDUIT 3/4 IN. 1
118 106-0086 CONNECTOR CORD 0.75 (0.50-0.625) 1
119 238-8421 RELAY, SOLENOID 1
120 622-2962-001 CONNECTOR, RECP, DRC FLANGE 70 “A” 1
121 622-2962-035 CONNECTOR, GASKET, DRC, RECP 70 POS 2
122 622-6214-003 RELAY, CUBE 12V WITH DIODE 7
123 627-6055 ME-ENCL (30 X 24 X 10), ML44K 1
124 627-6467-001 PE-MAIN PANEL CB’S, ML44K, ENG 1
125 627-6471 PLATE, SUB-PANEL, MEP 1
126 627-6474 PLATE, SUB-PANEL, MEP 1
127 627-6475 HINGE, CONT., 2.0 W, 0.187 PIN 1
128 627-6478 A-BRKT, SUB-PANE, STOP 2
129 627-1539 DE-MAIN PANEL, ML44K 1
130 624-7170 PE-MAIN PANEL E-STOP 1

Halvorsen
628-0554-001
132 620-3900-010 WIRE, STRANDED YELLOW 10 GA GXL 15
134 621-5215-001 TUBING, HEAT SHRINK 0.12/0.25 1 FT. 4
135 625-6920-475 RESISTOR, MF 475 0.4W 1% 2
136 625-6920-590 RESISTOR, MF 590 0.4W 1% 2
137 627-6540 CORD CONNECTOR, 2 HOLE, 2X 0.20 1
138 625-6920-003 RESISTOR, MF 1.00K 0.4W 1% 8
139 622-0244-007 TERMINAL BLOCK, 18-8 AWG USK10 1
140 622-2962-022 CONNECTOR, RECP, DRC FLANGE 70 “B” 1
141 622-0244-005 MARKER STRIP (USK) 10 BLANKS 8.1
142 622-0244-003 END PLATE COVER (USK) 2
143 624-8942-205 TUBING, SHRINK 3:1, CLEAR 1/2 IN. 1
144 624-8942-206 TUBING, SHRINK 3:1, CLEAR 3/4 IN. 0.5
146 622-0244-022 INSERTION BRIDGE 10 POS USK4 1
147 515-5917-004 TUBING 1/2 SPIRAL WRAP 10
148 624-8942-055 TUBING, SHRINK 3:1, BLACK 1/2 IN. 0.3
149 107-2874 SCREW, PPAN A2 #10-24 X 0.375 S.S. 6

Halvorsen
TOP VIEW
DETAIL B
Figure 6 Sheet 1
SCISSOR ELECTRICAL INSTALLATION
628-0414

Halvorsen
17
16 31
14
30
297
CONNECTS
TO 16CB
29 28 32
SECTION A-A
ROTATED 90 FOR CLARITY
8 7 1 11
6 3 18
9 3 5 6
28 29
DETAIL B
Figure 6 Sheet 2
628-0414

Halvorsen
DETAIL C
31 TO 627-6423
30
297
CONNECTS
17CB
LOCATED IN
DECK BOX
DETAIL D
DETAIL E
LEFT SIDE
ISO VIEW
Figure 6 Sheet 3
628-0414

Halvorsen
23SOL
14SOL
25SOL
16SOL
27SOL
21SOL
15
DETAIL C
15
20SOL
18SOL
DETAIL E
10
4 2 13
12 2 4
10
DETAIL D
Figure 6 Sheet 4
628-0414

Halvorsen
DETAIL F
DETAIL G
DETAIL M
DETAIL H
28 29
DETAIL M
3 27
Figure 6 Sheet 5
628-0414

Halvorsen
17SOL
24SOL
15SOL 26SOL
28SOL
22SOL
15
DETAIL F
15
10
10
DETAIL G
DETAIL H
Figure 6 Sheet 6
628-0414

Halvorsen
DETAIL K DETAIL J
22 23 24 4
15
DETAIL J
BOOT SUPPLIED WITH LIGHT

ITEM 22
25 26
DETAIL K
NTS REAR VIEW
Figure 6 Sheet 7
628-0414

Halvorsen
628-0414
1 107-0780 SCREW, SPAN GR 2 #10-24 X 2 ZP 8
2 107-9017 SCREW, HHC-F 8.8 M6 X 1 X 20 MG 4
3 107-9259 NUT, PTH 8 M8 X 1.25 MG 11
7 110-0253 WASHER, FLAT STD #10 ZP 8
8 117-7576 NUT, PTH A2 TH #10-24 S.S. 8
9 239-8852-019 CLAMP, SUPPORT 1.31 NC 1
10 622-6730 A-PROXIMITY SWITCH, 18 MM 2
11 623-8523 AE-LIMIT SWITCH, SPDT 4
12 623-9529 W-PROXY SWITCH 1
13 624-1419 W-PROXY SWITCH 1
14 624-3263 HE-MAIN BOX TO CABIN (C) 1
15 624-3264 HE-SCISSORS 1
16 624-3267 HE-MAIN BOX TO CABIN (A) 1
17 624-3268 HE-MAIN BOX TO CABIN (B) 1
18 624-4057 BRACKET, LIMIT SWITCH, SCISSOR 4
22 624-7167 ULTRA BEAM, LT WORK 2
23 624-7175 INSERT, M6 X 1.0 CLOSED END, BLIND 8
24 107-9016 SCREW, HHC-F 8.8 M6 X 16 MG 8
26 621-5215-001 TUBING, HEAT SHRINK 0.12/0.25 1
27 239-8852-001 CLAMP, SUPPORT 0.5 N.C. 2

Halvorsen
628-0414
28 HX0006 ROPE, WIRE 1/16 IN. S.S. 4
29 624-7434 CONNECTOR 4
30 625-4961-480 AE-CABLE 8-AWG RED #10-0.25, W/L 1
31 627-6418 HE-ECAB 1
32 627-2969 HE-SPEEDOMETER LONG 1
* NOT SHOWN

Halvorsen
DETAIL G
DETAIL F
DETAIL E
Figure 7 Sheet 1
DECK ELECTRICAL INSTALLATION
624-3249

Halvorsen
32-SOL
WIRE #127
30-SOL 29-SOL
WIRE #127 WIRE #125
12
46-SOL
WIRE #153
PALLET STOP AND

CONVEY MODULE
LIFT MANIFOLD
37 38 39
DETAIL F
31 FOR CLARITY
REFER TO 624-3263
12FT HE-MAIN PANEL
16 TO DECK BOX
12 34-SOL
27 WIRE #135 35-SOL
WIRE #136
33-SOL
22 1 WIRE #133
DETAIL E 40-SOL
36-SOL
SOME COMPONENTS REMOVED WIRE #138
WIRE #140
FOR CLARITY
41-SOL
37-SOL WIRE #143
WIRE #139
38-SOL
CONVEY MODULE
WIRE #134
CONVEYING MANIFOLD
39-SOL
WIRE #144
42-SOL
WIRE #142
DETAIL G 12
FOR CLARITY
Figure 7 Sheet 2
624-3249

Halvorsen
57 48 36 8
8
8 36 48 56
52
53 56 48 36 8
DETAIL N
DETAIL P
54
48 47 36 8 18 54 8 36 47 48
18
52
36 47 48
46
53 48 47 36
0.5 FT 46
SECTION U-U 0.5 FT SECTION V-V
Figure 7 Sheet 3
624-3249

Halvorsen
52
18
52
0.5 FT
20 28 33
46
12
36
DETAIL P
8
4
29 32
6
9
20 28 40
12
29 32
20 28 40
3
6
9

2
29 32
SECTION B-B
FOR CLARITY
20 28 33
12
6
8
5
DETAIL N
36
8
53
53
12
18
0.5 FT
46
Figure 7 Sheet 4
624-3249

Halvorsen
17
50
DETAIL C 60 44 43
59
DETAIL M
DETAIL H
DETAIL K
DETAIL J
REFER TO 624-3267
HE-MAIN PANEL
TO CABIN (A)
REFER TO 624-3268
HE-MAIN PANEL
TO CABIN (B)
13 DETAIL M
49 48 36 23
27
DETAIL C
6.5 FT
Figure 7 Sheet 5
624-3249

Halvorsen
0.5 FT
46
17
50
12
DETAIL K
7
2
11
40 28 20
50
12
11
Figure 7 Sheet 6
624-3249

Halvorsen
61
DETAIL J
11
12
11
Figure 7 Sheet 7
624-3249

Halvorsen
DETAIL W
56 48 36 8 55
SECTION AA-AA
55
17
17
46 46
0.5 FT 0.5 FT
9 36 47 48 12 8
34 28 20 14
48 47 36 9
34 28 15 20 46 46
14 20 28 34
0.5 FT 0.5 FT
SECTION A-A
34 28 20 15
Figure 7 Sheet 8
624-3249

Halvorsen
46
0.5 FT 17
8 36 47 48
48 47 36 8
8 36 48 57
51
55
57 48 36 8
DETAIL W
27
4.5 FT
42 44 43 23
1
DETAIL H
Figure 7 Sheet 9
624-3249

Halvorsen
624-3249
1 624-2911 AE-DECK PANEL NGSL 1

2 623-8524 LIMIT SWITCH ASSEMBLY, DPDT 2
3 623-8523 LIMIT SWITCH ASSEMBLY, SPDT 2
4 624-5754 24V LEFT TURN ASSEMBLY 1
5 624-5756 24V RIGHT TURN ASSEMBLY 1
6 107-9063 SCREW, HHC, 8.8 M8 X 1.25 X 45 MG 5
7 624-3485 BRACKET, FRONT LIMIT SWITCH 1
8 239-8852-001 CLAMP, SUPPORT 0.50 NC 22
9 239-8852-002 CLAMP, SUPPORT 0.75 NC 6
11 239-8852-004 CLAMP, SUPPORT 1.00 NC 7
12 624-3265 HE-DECK 1
13 624-3478 HE-DECK BOX TO CABIN 1
14 627-5110 AE-HEADLIGHT, 24V ADJUSTABLE 2
15 623-7323 LIGHT, AMBER 24V 2
16 620-1317-001 FLEX -GARD, NYLON SPLIT 5/16 IN. 12
17 623-7324 AE-MARKER LIGHT, AMBER 4
18 623-7325 AE-MARKER LIGHT, RED 4
20 117-7576 NUT, PTH A2 TH #10-24 S.S. 32
23 239-3646-013 TERMINAL RING 0.375 10-AWG 2
27 519-8558-010 WIRE, STRANDED BLACK 10 GA GXL 11
31 627-8859 W-BRACKET, COMPRESSOR A/C 1
32 107-9259 NUT, PTH 8 M8 X 1.25 MG 5

Halvorsen
624-3249
33 107-2220 SCREW, PAN HEAD PHILLIPS, A2 #10-24 X 1.5 S.S. 12

34 107-2268 SCREW, PAN HEAD PHILLIPS, A2 #10-24 X 0.75 S.S. 12
37 107-9261 NUT, PTH 8 M12 X 1.75 MG 4
40 107-2265 SCREW, SOCKET PAN HEAD, GR 2 #10-24 X 2.25 S.S. 8
42 107-9418 SCREW, HHC 8.8 M10 X 1.5 X 30 MG 4
43 107-9276 WASHER, FLAT STD HARD, M10 MG 8
44 107-9260 NUT, PTH 8 M10 X 1.50 MG 6
47 107-9018 SCREW, HEX HEAD CAP - FULL THREAD 8.8 M6 X 1 X 10
25 MG
48 107-9258 NUT, PTH 8 M6 X 1.00 MG 17
20 MG
50 625-5670 HE-LEFT FRONT EXT MARKER LIGHT 1
51 625-5671 HE-RIGHT FRONT EXT MARKER LIGHT 1
52 625-5672 HE-LEFT REAR EXT MARKER LIGHT 1
53 625-5673 HE-RIGHT REAR EXT MARKER LIGHT 1
54 625-5741 BRACKET, REAR MARKER LIGHT 2
55 625-6115 HE-RIGHT FRONT DECK EXTENSION 1
30
57 107-9031 SCREW, HEX HEAD CAP 8.8 M6 X 1 X 40 3
59 625-8097 GUARD, LIMIT SW BOLT-ON 1
60 107-9084 SCREW, HEX HEAD CAP 8.8 M10 X 1.5 X 50 MG 2
61 239-8852-003 CLAMP, SUPPORT 0.88 NC 2
* NOT SHOWN

Halvorsen
COVER REMOVED 9
FOR CLARITY
29 18 20
28
14 12
11 8
4
LY-4
34CR
24V
10
7 3
13 9
6 2
5 1
14 12
11 8
4
LY-4
33CR
24V
10
7 3
13 9
6 2
5 1
6
4
8
LY-2
39CR
24V
7
2
5
1
3
6
4
8
LY-2
38CR
24V
7
2
5
1
3
6
4
8
LY-2
37CR
24V
7
2
5
1
3
6
4
8
LY-2
36CR
24V
7
2
5
1
3
27 67
6
4
8
LY-2
24V
31CR
7
2
5
1
3
6
4
8
LY-2
30CR
24V
7
2
5
1
3
26CR
19 18 21
57 68
25 41 8 39 17
58
AC-P4
60 56 55 54 52 64 53 59
AC-P3
Figure 8 Sheet 1
DECK PANEL ELECTRICAL ASSEMBLY
624-2911

Halvorsen
11 39 25 26 41
11 39 25 26 41
22
6
5
B
B
C
COVER REMOVED
FOR CLARITY
9
22
22
6
6
5
5
A
C
A
A
5
5
6
6
22
22
Figure 8 Sheet 2
624-2911

Halvorsen
DBOX-RA
DBOX-RC
15
15
2
2
35 46 23 14 45
34 46 23 14 45
45 14 23 46 34
2
15
DBOX-RB
AC-P3
AC-P4
Figure 8 Sheet 3
624-2911

Halvorsen
4
DBOX-RA
DBOX-RC
SECTION B-B
9
10
47 61
65
SECTION A-A
DBOX-RB
61 47
49
3
30
61 47
61 47
48
Figure 8 Sheet 4
624-2911

Halvorsen
BUS
SECTION C-C
1
51 36 46 23 45
Figure 8 Sheet 5
624-2911

Halvorsen
39
42
41
38
51
42
39
41
17CB
38
51
18CB
4
51
62
19CB
SECTION D-D
41
37
39
42
44 46 45
D
Figure 8 Sheet 6
624-2911

Halvorsen
40
40
43
40
Figure 8 Sheet 7
624-2911

Halvorsen
624-2911
1 623-7848 BUSS BAR, GROUND 20 POS 1
3 624-8297 CONNECTOR, CORD, 0.5 IN. ST, 2 WIRE 1
4 623-9135 DECAL, DECK BOX 1
5 622-1358-011 DUCT, WIRING, 2 IN. X 2 IN. 7 ft.
6 622-1358-012 DUCT, WIRING COVER 2 IN. 7 ft.
7 DWG-623-9526 DWG-ELECTRICAL FABRICATION PRACTICES 1
8 622-7161 M-MOUNT, MODULE DIN 1
9 624-2905 ME-ENCL (24 X 20 X 8) 1
10 624-2929 ME-PNL FOR (624-2905) 1
11 622-0244-001 MOUNTING TRACK, 2M DIN 1
14 622-2962-009 PLUG, SEALING CONNECTOR 25
15 622-2962-005 CONNECTOR, RECEPTACLE, DRC 40 “A” 2
16 622-2962-001 CONNECTOR, RECEPTACLE, DRC FLANGE 70 “A” 1
17 622-6214-004 RELAY, 24V SPDT WITH DIODE, BRACKET 1
18 621-2738 RELAY, HOLD-DOWNS CLIP 16
19 622-6328 RELAY, LY2 24 VDC WITH DIODE 6
20 622-6328-001 RELAY, LY4 24 VDC WITH DIODE 2
21 621-2736 RELAY, SOCKET LY2 6
22 107-0811 RIVET, PRO, 0.188 X 0.25 ALUMINUM 12
23 107-2875 SCREW, PPAN ROUND GR 2 #8-32 X 0.75 ZP 12
25 107-2858 SCREW, PPAN A2 #10-32 X 0.75 S.S. 7
26 622-1560 STANDOFF, 0.5 IN. DELRIN 6
27 622-0244-002 TERMINAL BLOCK, 22-12 AWG 67
28 622-0244-004 END CAP 2
29 621-2737 TRACK MOUNTED SOCKET PTF 14 2

Halvorsen
624-2911
34 622-2962-020 CONNECTOR, GASKET, DRC, RECEP. 40 POS 2
35 622-2962-035 CONNECTOR, GASKET, DRC, RECEP. 70 POS 1
39 107-2324 NUT, PTH A2 #10-32 S.S. 13
40 107-2873 SCREW, PPAN A2 #10-32 X 1 S.S. 6
41 107-2091 WASHER, FLAT A2 #10 S.S. 13
42 623-1506 GASKET, CDM CIRCUIT BREAKER 3
43 625-4950 PE-DECK PANEL CB’S 1
44 107-2867 SCREW, PPAN A2 #8-32 X.5 S.S. 4
45 107-1482 NUT, PTH A2 #8-32 S.S. 18
46 107-2322 WASHER, FLAT A2 #8 S.S. 18
49 625-4733 M-CORD CONNECTOR, 0.5 IN. ST (0.125-0.25) 1
55 625-4919-016 CONNECTOR, SOCKET (12-14 AWG) SOLID 4
57 239-1754 CORD, 16-AWG 4 COND TYPE SJTO 5 ft.
58 HEW0056 CORD, ELECTRICAL 12/4 SO 5 ft.
59 624-8942-006 TUBING, SHRINK 3 in.
60 624-8942-007 TUBING, SHRINK 1.0 3 in.
61 106-0125 SEALING - 1/2 IN. O-RING 4
62 620-3900-010 WIRE, STRANDED YELLOW 10 GA GXL 2 ft.

Halvorsen
624-2911
63 620-3900-018 WIRE, STRANDED YELOW 18 GA GXL 200 ft.
67 622-0244-005 MARKER STRIP (USK) 10 BLANKS 7
68 623-4929-003 CONDUIT, FLEXIBLE NYLON 0.5 IN. 0.83 ft.
69 621-5215-001 TUBING, HEATSHRINK 0.12/0.25 2

Halvorsen
REV. A
Figure 9
TAIL LIGHT ASSEMBLY, 24V LEFT TURN
624-5754

Halvorsen
TAIL LIGHT ASSEMBLY, 24V LEFT TURN
624-5754
1 622-7682 TAIL LIGHT ASSEMBLY 1
2 620-0231-001 LENS, YELLOW TAIL LIGHT 1
5* 620-4710 LAMP, 24V, STOP / TAIL 1
6* 620-0796 LAMP, 28V, #1683 1
7 622-2967-007 CONNECTOR, RECEP. 6 POS MALE 1
9* 622-2967-049 BOOT, 6 POS RECEPTACLE 1
10* 620-0231-002 LENS, RED / WHITE 1
11* 620-0231-003 LENS, RED 2
* NOT SHOWN

Halvorsen
REV. A
Figure 10
TAIL LIGHT ASSEMBLY, 24V RIGHT TURN
624-5756

Halvorsen
TAIL LIGHT ASSEMBLY, 24V RIGHT TURN
624-5756
1 622-7682 TAIL LIGHT ASSEMBLY 1
2 620-0231-001 LENS, YELLOW TAIL LIGHT 1
5* 620-4710 LAMP, 24V, STOP / TAIL 1
6* 620-0796 LAMP, 28V, #1638 1
7 622-2967-007 CONNECTOR, RECEPTACLE 6 POS MALE 1
9* 622-2967-049 BOOT, 6 POS RECEPTACLE 1
10* 620-0231-002 LENS, RED / WHITE 1
11* 620-0231-003 LENS, RED 2
* NOT SHOWN

Halvorsen
9 13
14 9
24
DETAIL D
4
18 4 5 6
DETAIL F 30
DETAIL F
DETAIL D
LEFT SIDE
ISO VIEW
Figure 11 Sheet 1
CAB ELECTRICAL INSTALLATION
628-0563-001

Halvorsen
DETAIL E 16 9
DETAIL E
RIGHT SIDE
ISO VIEW
Figure 11 Sheet 2
628-0563-001

Halvorsen
3MTR-A
CABIN RA
23
CABIN RB
BACK VIEW
REAR WIPER MOTOR
CABIN RC
23
DETAIL K DETAIL G
DETAIL J
DETAIL L
DETAIL H
SECTION A-A
DETAIL K
LEFT VIEW
Figure 11 Sheet 3
628-0563-001

Halvorsen
23 8 3
21
23
3 7
DETAIL B
DETAIL G REAR WIPER MOTOR

REFERENCE ONLY
DOME LIGHT 7
REFERENCE ONLY
3 7
23
DETAIL H
DETAIL J
Figure 11 Sheet 4
628-0563-001

Halvorsen
DETAIL L
8 3
23
DETAIL M
SECTION D-D
BACK VIEW
Figure 11 Sheet 5
628-0563-001

Halvorsen
23
DETAIL L 15 9
1 40
TSIG-R
23
TSIG-P
17
DETAIL M
Figure 11 Sheet 6
628-0563-001

Halvorsen
17
FLASHER SWITCH
10
DETAIL S
28
29 DETAIL R
19 BRAKE SWITCH
22 PRESSURE SWITCH
ISO VIEW
CAB REMOVED FOR CLARITY
Figure 11 Sheet 7
628-0563-001

Halvorsen
13 M
20
41A
70
11 ALARM
2PS-A
DETAIL R
4MTR-A
SHOWN ON DRAWING
624-3486
4MTR
DETAIL N
DETAIL S
Figure 11 Sheet 8
628-0563-001

Halvorsen
23
DETAIL N
ISO VIEW
COMPLETE INSTALLATION
CAB REMOVED FOR CLARITY
Figure 11 Sheet 9
628-0563-001

Halvorsen
84D
CONNECT TO L
3MTR 84C
CONNECT TO H
84E
CONNECT TO P
FRONT WIPER MOTOR
VIEW FROM INSIDE CAB
UNDER DASH PANEL
UPPER RUBBER SEAL
LOWER RUBBER SEAL
INSTALL SPOT LIGHTS

AS SHOWN
ALL PARTS SHOWN ARE
INCLUDED WITH LIGHT
Figure 11 Sheet 10
628-0563-001

Halvorsen
628-0563-001

3 107-0047 SCREW, SHWTAP F #10-24 X 0.5 ZP 15
4 107-9046 SCREW, HHC 8.8 M8 X 1.25 X 25 MG 7
5 107-9259 NUT, PTH 8 M8 X 1.25 MG 7
7 239-9076-004 CLAMP, 0 0.50 STEEL CUSHIONED 6
9 620-0805-003 SCREW, SPAN 4.8 M4 X 0.7 X 20 ZP 26
10 622-6214-004 RELAY, 24V SPDT WITH DIODE, BRACKET 3
11 622-7926-001 ALARM, SONEALERT 65DB 1
12 623-4995 NYLON CABLE WRAP, LARGE 14.5 IN. - 50 LB 10
* 624-6624-001 BULB, H3 24V 70W 1
13 623-7300-003 SHIFTER, JOYSTICK STONE BENNETT 1
14 624-2915 AE-CONVEY PANEL 1
15 624-3258 AE-WIPER PANEL 1
16 628-0600-001 AE-PANEL DASH, ML25K3P, ENG 1
17 624-3486 AE-TURN SIGNAL 1
18 627-7150 AE-PEDAL, TIER 3 1
19 624-3943 SWITCH, LOW PRESSURE 1
20 624-5018 BRACKET, HARNESS 1
21 624-6625 AE-LIGHT, SPOT 24 VDC 2
22 624-7180 AE-SWITCH, PRESSURE 1
23 625-4055 HE-CAB 1
24 520-1001-004 SEAL, PLUG BUTTON 0.875 IN. WHITE 1
27 627-6423 HE-ECAB2 1
28 627-5730 HE-CAN, CAB, SHORT 1
29 627-2971 HE-SPEEDOMETER, SHORT 1
30 627-7122 W-ACCELERATOR PEDAL STAND 1
* NOT SHOWN

Halvorsen
75 39
40
80
73
37
76
35
38 41
25 9
36
71
25 54
87
74
22 18 20 77
23 18 20
71
14 25
71
55 33 15
39
19 18
35
24 18 20
6
21 18 20
16 26 33 55
12
Figure 12 Sheet 1
DASH PANEL ELECTRICAL ASSEMBLY
628-0600-001

Halvorsen
Figure 12 Sheet 2
628-0600-001

Halvorsen
2TACH-P1
83 84 29
69
67
2GA-P
70 68
67
1GA-P
70 68
67
FROM CCAN-P (REF)
CAN GAUGE DETAIL

NOT TO SCALE
Figure 12 Sheet 3
628-0600-001

Halvorsen
628-0600-001
1 622-2962-018 CONNECTOR, BOOT 70 POS PLUG OR RECEPTACLE 1
8 623-9137 DE-DASH PANEL 1
9 623-5913-006 GAUGE, FUEL LEVEL 24V 1
12 623-5913-008 GAUGE, HOURMETER 1
14 623-5913-007 GAUGE, HYDRAULIC TEMPERATURE 1
15 624-3252 AE-JOYSTICK AND CARD, RAISE / LOWER 1
16 519-6725 JOYSTICK, 4 WAY 1
18 620-0764 LAMP, 24V #1864 (T3 1/4) 24
19 519-2207 AE-LIGHT, PANEL ILLUMINATION 1/2 X 1/2 3
20 620-0763-001 LIGHT, PILOT, BASE 22
21 620-0763-004 LIGHT, PILOT, LENS, AMBER 8
22 620-0763-007 LIGHT, PILOT, LENS, BLUE 1
25 623-5913-009 LIGHT KIT, 24 VDC 3
26 107-1482 NUT, PTH A2 #8-32 S.S. 4
30 622-2967-052 RECEPTACLE, 12 POS WITH BUSSED PINS 1
31 622-2967-054 RECEPTACLE, 6 POS WITH BUSSED PINS 3
32 622-2962-003 CONNECTOR, PLUG, DRC, 70 “A” KEY 1

Halvorsen
628-0600-001
33 107-2844 SCREW, PRND GR 2 #8-32 X 0.75 S.S. 6
35 238-1579 SWITCH, SPDT TOGGLE (ON) OFF (ON) 2
36 238-6221 SWITCH, SPDT TOGGLE ON ON 1
37 239-0854 SWITCH, DPDT TOGGLE ON ON (ON) 1
38 232-8790-101 SWITCH, DPST TOGGLE ON ON 1
39 515-3065 SWITCH, SPDT TOGGLE (ON) ON 2
40 622-5906 SWITCH, PUSH-BUTTON, N.C., RED 1
41 622-6481 GUARD, TOGGLE SWITCH 1
43 519-5559-009 TERMINAL FEMALE SLIP-ON 18-AWG X 0.187 8
50 239-3646-008 TERMINAL, RING 1
54 623-5913-003 GAUGE, VOLTS, 24 VDC 1
55 107-2322 WASHER, FLAT A2 #8 S.S. 6
59 624-2920 CONNECTOR, 9 POS (FEMALE) 1
60 624-2921 CONNECTOR, PIN (FEMALE) 8
62 624-6609 VARISTOR, METAL OXID 31 VDC 1

Halvorsen
628-0600-001
67 622-2967-062 CONNECTOR, RECP 3 WAY Y 3
68 627-1824 HE-CAN, CAB GAUGE 2
69 627-1854 HE-CAN, CAB GAUGE W/RES. 1
70 627-1862 HE-CAN, INTERCONNECT 2
71 520-1001-006 SEAL, PLUG BUTTON 0.5 IN. BLACK 3
72 625-6920-002 RESISTOR, MF 2.61K 0.4 1% 1
73 627-6033-001 PE-PANEL DASH, ML44K, ENG 1
74 627-6469 GAUGE, COOLANT TEMPERATURE 280 F 1
75 627-6468 GAUGE, TACHOMETER 3500 RPM 1
76 627-7141-001 AE-GAUGE, SPEEDOMETER, ENG 1
77 627-6470 GAUGE, OIL PRESSURE 100 PSI 1
80 627-2005 LAMP, 12 VDC BA9S RED LED 1
81 623-4929-007 CONDUIT, FLEXIBLE NYLON 1-3/16 IN. 2
82 620-3900-014 WIRE STRANDED YELLOW 14 GA GXL 1
87 520-1001-007 SEAL, PLUG BUTTON 0.687 IN. 1
88 624-2913-001 CONTROL CARD, DECK RAISE / LOWER 1
* NOT SHOWN

Halvorsen
REV. A
Figure 13 Sheet 1
WIPER PANEL ELECTRICAL ASSEMBLY
624-3258

Halvorsen
Figure 13 Sheet 2
624-3258

Halvorsen
624-3258
1 239-5109-005 CIRCUIT BREAKER, 3 AMP 2

4 622-2967-010 CONNECTOR, PLUG 8 POS FEMALE 1
8 622-2967-027 CONNECTOR, WEDGE 12 POS RECEP 1
10 623-9136* DECAL, PANEL WIPER 1
11 624-0786 DIMMER SWITCH 2
12 625-3469 A-DIMMER SWITCH BEZEL 1
* 624-0786-003 SWITCH, DIMMER BEZEL 1
15 620-0764 LAMP, 24V 1
16 519-2207 AE-LIGHT, PANEL ILLUMINATOR 1/2 X 1/2 1
17 624-3259* PE-PANEL WIPER 1
18 622-7278-002 SPLICE PARALLEL, 10-09 AWG 1
21 239-3650-003 TERMINAL, SLIP-ON FEMALE 18-AWG INS 4
22 622-7278-001 TERMINAL, SPLICE PARALLEL 14-AWG 2
26 621-5215-001 TUBING, HEAT SHRINK 1 FT. 1
27 621-5215-002 TUBING, HEAT SHRINK 1 FT. 2
28* 620-3900-014 WIRE, STRANDED YELLOW 14 GA GXL 18 ft.
29* 620-3900-018 WIRE, STRANDED YELLOW 18 GA GXL 17 ft.
* NOT SHOWN

Halvorsen
Figure 14 Sheet 1
CONVEY PANEL ELECTRICAL ASSEMBLY
624-2915

Halvorsen
Figure 14 Sheet 2
624-2915

Halvorsen
624-2915
1 624-2917 JOYSTICK AND CARD, CONVEY 1
4 622-2967-027 CONNECTOR, WEDGE 12 POS RECEP. 1
5 624-3245* DECAL, CONVEY PANEL 1
6* DWG-623-9526 ELECTRICAL FABRICATION PRACTICES 1
7 620-0764 LAMP, 24V 6
8 237-5418 LIGHT, PANEL ILLUMINATOR 1
9 620-0763-001 LIGHT, PILOT, BASE 5
12 118-5262 NUT, PTH GR 5 #10-32 ZP 2
13 111-7119 SCREW, PAN ROUND GR 2 #10-32 X 1.50 ZP 2
16 515-3065 SWITCH, TOGGLE SPST 1
17 622-2967-017 CONNECTOR, WEDGE 2 POS RECEP. 1
24 621-5215-001 TUBING, HEATSHRINK 0.12/0.25 1 FT. 3 ft.
25 620-3900-018 WIRE, STRANDED YELLOW 18 GA GXL 18 ft.
26* 107-1919 WASHER, FLAT NARROW A2 #10 S.S. 2
27 624-2914* PLACARD, CONVEY PANEL 1

Halvorsen
624-2915
28 622-7278-001 TERMINAL, SPLICE PARALLEL 14-AWG 1
33 624-2920 CONNECTOR, 9 POS FEMALE 1
34 624-2921 CONNECTOR, PIN FEMALE 9
35 624-6609 VARISTOR, METAL OXIDE 31 VDC 1
36 622-6481 SWITCH, TOGGLE GUARD 5
37 624-2913-002 CONTROL CARD, CONVEY 5
* NOT SHOWN

Halvorsen
5 4 3 2 2 3 4 5
9MTR-R 10MTR-R
Figure 15
A/C CONNECTOR ELECTRICAL ASSEMBLY
627-7214
A/C CONNECTOR ELECTRICAL ASSEMBLY

627-7214
1 627-4404 A-CAC 1
5 622-2967-046 CONNECTOR, BOOT 2 POS RECP 2

Halvorsen
12.00
304.8
A (BLUE)
C (BLACK)
1 6
5 2 3 4 B (BROWN)
WIRE PIN BODY
STRIP WIRE BACK FAR ENOUGH TO BE ABLE

TO BE DOUBLED OVER. THIS IS NECESSARY
TO INSURE PROPER CRIMPING OF PIN BODIES.
Figure 16
PROXIMITY SWITCH ELECTRICAL ASSEMBLY
622-6730
PROXIMITY SWITCH ELECTRICAL ASSEMBLY

622-6730
1 622-6729 PROXIMITY SWITCH 18 MM 1

5 621-5215-004 TUBING, HEATSHRINK 0.38/0.75 1 FT. 0.2 ft.
6 621-5215-002 TUBING, HEATSHRINK 0.18/0.38 1 FT. 0.2 ft.
7 DWG-623-9526 ELECTRICAL FABRICATION PRACTICES 1

Halvorsen
3-D REF VIEW

32.0 AT IDLE
17.0 AT WIDE OPEN
THROTTLE
8.22
208.8
B
BLACK ORANGE
1 GREEN
1 6
VIOLET
2 5
3 4
RED WHITE
6.17
REAR VIEW OF
CONNECTOR
156.7
3
2
4
6
13.1 5
1.90 0.78
48.3 19.8
0.97
2.87 1.94 24.7
72.9 49.3
0.46
11.8
Figure 17
ACCELERATOR PEDAL ELECTRICAL ASSEMBLY
627-7150

Halvorsen
ACCELERATOR PEDAL ELECTRICAL ASSEMBLY
627-7150
1 627-4095 PEDAL, ACCELERATOR, TIER3, NSS 1
6 623-4929-002 CONDUIT, FLEXIBLE NYLON 0.38 IN. 2

Halvorsen
Section 17. Identification
1. IDENTIFICATION INSTALLATION, CHASSIS 623-5500-001 Figure 1 Sheet 1 2
2. IDENTIFICATION INSTALLATION, CAB 623-5500-002 Figure 2 Sheet 1 7
3. IDENTIFICATION INSTALLATION, DECK 623-5500-003 Figure 3 Sheet 1 12
4. MAINTENANCE STANDARD DECAL KIT 627-4879 Figure 4 Sheet 1 18
IDENTIFICATION 4-17
Halvorsen
REV. E
Figure 1 Sheet 1
IDENTIFICATION INSTALLATION, CHASSIS
623-5500-001

Halvorsen
Figure 1 Sheet 2
623-5500-001
IDENTIFICATION 4-17
Halvorsen
Figure 1 Sheet 3
623-5500-001

Halvorsen
17
Figure 1 Sheet 4
623-5500-001
IDENTIFICATION 4-17
Halvorsen
IDENTIFICATION INSTALLATION
623-5500-001
1 515-8930 DECAL, NO STEP WARNING 10
2 515-8933 DECAL, HOT EXHAUST 2
3 515-9904 DECAL, DIESEL 1
4 519-2556 DECAL, DANGER, HIGH VOLTAGE 1
5 622-7213 DECAL, BRIDGE WARNING 1
6 622-7902 DECAL, HOT EXHAUST WARNING 3
7 623-0350 REFLECTIVE STRIP, 2 X 10 SILVER 12
8 624-1204 DECAL, NATO PLUG 1
9 624-5139 STENSIL, TIE DOWN 2
10 624-5141 STENSIL, T.P. 100 PSI 2
11 624-5143 STENSIL, HYDRAULIC OIL 1
12 624-5145 DECAL, BATTERY DISCONNECT 1
13 624-6063 DECAL, HYDRAULIC LEVEL MX STAND 1
14 624-6064 DECAL, DECK FULLY DOWN 1
15 624-5144 STENSIL, TOW POINT 1
16 624-6607 DECAL, DANGER 120 VOLTS 3
17 624-0313 PLACARD, DOT FLIP HAZARD 1
18 624-7169 STENSIL, 25 000 LB 2

Halvorsen
REV. A
Figure 2 Sheet 1
IDENTIFICATION INSTALLATION, CAB
623-5500-002
IDENTIFICATION 4-17
Halvorsen
Figure 2 Sheet 2
623-5500-002

Halvorsen
Figure 2 Sheet 3
623-5500-002
IDENTIFICATION 4-17
Halvorsen
Figure 2 Sheet 4
623-5500-002

Halvorsen
623-5500-002
1 515-9904 DECAL, DIESEL 1
2 622-7883 DECAL, HAND PINCHPOINT WARNING 3
4 624-5149 DECAL, MAINTENANCE SUPPORT WARNING 2
5 624-5148 DECAL, WASHER RESERVOIR 1
-6 625-4852 DECAL, WASHER FLUID 1
IDENTIFICATION 4-17
Halvorsen
REV. C
Figure 3 Sheet 1
IDENTIFICATION INSTALLATION, DECK
623-5500-003

Halvorsen
Figure 3 Sheet 2
623-5500-003
IDENTIFICATION 4-17
Halvorsen
Figure 3 Sheet 3
623-5500-003

Halvorsen
Figure 3 Sheet 4
623-5500-003
IDENTIFICATION 4-17
Halvorsen
Figure 3 Sheet 5
623-5500-003

Halvorsen
623-5500-003
1 622-7883 DECAL, HAND PINCH POINT WARNING 1
3* 624-0313 PLACARD, DOT FLIP HAZARD 3
4 624-5137 STENSIL, HARNESS REQUIRED 1
5 624-5140 DECAL, SLING POINT 1
6 624-5139 STENCIL, TIE DOWN 1
7 624-7169 STENCIL, 25 000 LB. 1
* NOT SHOWN
IDENTIFICATION 4-17
Halvorsen
Figure 4 Sheet 1
MAINTENANCE STANDARD DECAL KIT
627-4879

Halvorsen
Figure 4 Sheet 2
627-4879
IDENTIFICATION 4-17
Halvorsen
Figure 4 Sheet 3
627-4879

Halvorsen
Figure 4 Sheet 4
627-4879
IDENTIFICATION 4-17
Halvorsen
627-4879
1 627-8696 DE-RIGHT SIDE, MAINTENANCE STAND 1
2 627-8698 DE-LEFT SIDE, MAINTENANCE STAND 1
3 627-8288 DE-MAINTENANCE STAND 2

Halvorsen
Section 18. Air Conditioning System
1. AIR CONDITIONER CONDENSER FAN 625-3088 Figure 1 2
2. AIR CONDITIONER COMPRESSOR MOTOR 625-3089-500 Figure 2 4
3. A/C EVAPORATOR, LOUVER BOX 625-3091 Figure 3 Sheet 1 6
4. REFRIGERANT HOSES KIT, A/C 625-4728 Figure 4 Sheet 1 9
5. AIR CONDITIONING SYSTEM INSTALLATION 627-8134 Figure 5 Sheet 1 13
6. AIR CONDITIONING ELECTRICAL INSTALLATION 627-8136 Figure 6 Sheet 1 18
7. AIR CONDITIONING HYDRAULIC INSTALLATION 627-8135 Figure 7 Sheet 1 18
8. MANIFOLD, A/C MOTOR 625-4073 Figure 8 Sheet 1 32
9. DRIER ASSEMBLY, A/C RECEIVER 625-3864 Figure 9 35
10. AIR CONDITIONING SYSTEM ASSEMBLY 625-4534 Figure 10 Sheet 1 36
11. A/C HYDRAULIC HOSE KIT 627-8135-001 Figure 11 Sheet 1 39
12. A/C HYDRAULIC TUBE KIT 627-8135-002 Figure 12 Sheet 1 48
13. A/C LOW PRESSURE SWITCH ELECTRICAL

ASSEMBLY 625-4887 Figure 13 54
14. A/C FAN OVERRIDE SWITCH ELECTRICAL

15. A/C HIGH PRESSURE SWITCH ELECTRICAL

AIR CONDITIONING SYSTEM 4-18

Halvorsen
Figure 1
AIR CONDITIONER CONDENSER FAN
625-3088

Halvorsen
AIR CONDITIONER CONDENSER FAN
625-3088
1* 625-3088-001 A-BOX, A/C BOND CHASSIS 1
2 625-3088-002 A-COIL, A/C BOND 1
3* 625-3088-003 FAN, A/C CONDENSER 1
4* 625-3088-004 BULKHEAD, #6 A/C BOND 1
5* 625-3088-005 BULKHEAD, #8 A/C BOND 1
* 625-3088-006 COVER, A/C BOND 1
* 625-3088-007 HARDWARE, A/C BOND 1
* 625-3088-008 O-RING, A/C #8 HBNR 1
* 625-3088-009 O-RING, A/C #6 HBNR 1
* NOT SHOWN

Halvorsen
Figure 2
AIR CONDITIONER COMPRESSOR MOTOR
625-3089-500

Halvorsen
AIR CONDITIONER COMPRESSOR MOTOR
625-3089-500
1 625-3089-001 BASE, A/C COMPRESSOR 1
2 625-3089-002 COMPRESSOR, A/C 1
3 625-3089-003 HOUSING, A/C COMPRESSOR BELL 1
4 625-3089-004 COUPLING, A/C COMPRESSOR 1
5 625-3089-005 MOTOR, A/C COMPRESSOR HYDRAULIC 1
6* 625-3089-006 HARDWARE, A/C COMPRESSOR 1
* NOT SHOWN
**NOTE: CONTACT JBT FOR APPROPRIATE IUID LABEL WHEN REPLACING P/N 625-3089-500.

Halvorsen
10
Figure 3 Sheet 1
A/C EVAPORATOR, LOUVER BOX
625-3091

Halvorsen
Figure 3 Sheet 2
625-3091

Halvorsen
625-3091
1 625-3091-001 A-BOX, A/C EVAPORATOR CHASSIS 1
2 625-3091-002 A-BOX, A/C EVAPORATOR LOUVER BOX 1
3 625-3091-003 RESISTOR, A/C EVAPORATOR BLOWER MOTOR 1
4 625-3091-004 THERMOSTAT, A/C EVAPORATOR PRESET 1
5 625-3091-005 RELAY, A/C EVAPORATOR FAN OVERRIDE 1
6 625-3091-006 BRACKET, A/C EVAPORATOR EXP VALVE 1
7 625-3091-007 VALVE, A/C EVAPORATOR EXPANSION VALVE 1
8 625-3091-008 A-COIL, A/C EVAPORATOR 1
9* 625-3091-009 FILTER, A/C EVAPORATOR RETURN AIR 1
10 625-3091-010 KNOB, A/C EVAPORATOR RETURN AIR FILTER 2
11 625-3091-011 VALVE, A/C EVAPORATOR RUBBER CHECK 2
12 625-3091-012 BLOWER, A/C EVAPORATOR 1
13 625-3091-013 SWITCH, A/C EVAPORATOR MODE TOGGLE 1
14 625-3091-014 SWITCH, A/C EVAPORATOR FAN SPD TOGGLE 1
-16 625-3091-016 HE-EVAPORATOR, A/C 1
* NOT SHOWN

Halvorsen
Figure 4 Sheet 1
REFRIGERANT HOSES KIT, A/C
625-4728

Halvorsen
Figure 4 Sheet 2
625-4728
Figure 4 Sheet 3
625-4728

Halvorsen
Figure 4 Sheet 4
REFRIGERANT HOSES, KIT A/C
625-4728
Figure 4 Sheet 5
K-REFRIGERANT HOSES, A/C
625-4728

Halvorsen
625-4728
1 625-4610 A-HOSE, REFRIGERANT SUCTION 1
2 625-4611 A-HOSE, REFRIGERANT COMPRESSOR DISCHARGE 1
3 625-4612 A-HOSE REFRIGERANT CONDITIONER LIQUID 1
4 625-4766 A-HOSE, REFRIGERANT DRIER LIQUID 1
5 625-4771 A-HOSE, REFRIGERANT OIL SEPARATOR DISCHARGE 1
6 625-4777 A-HOSE, REFRIGERANT OIL SEPARATOR 1
7 625-4832 A-VALVE, A/C #10 SUCTION SERVICE 1
8 625-4833 A-VALVE, A/C #8 DISCHARGE SERVICE 1
* 625-4833-001 O-RING, A/C COMPRESSOR 1
9 625-4918 ADAPTER, A/C 45 FLARE FITTING 1
* NOT SHOWN

Halvorsen
DETAIL A
ML25K3P CHASSIS
DETAIL B
ML25K3P CHASSIS DECK
ML25K3P CHASSIS HYD

ML25K3P SCISSORS
DETAIL C
G
DETAIL D
G
DETAIL E
23
23
23
CHASSIS CAB
20
ML25K3P
Figure 5 Sheet 1
AIR CONDITIONING SYSTEM INSTALLATION
627-8134

Halvorsen
2.2 FT
29 30
22
33
28
6
33
25 9
DETAIL C
9
23
6
17
1
2.3 FT
34
30 29
33
DETAIL B
27
23

1.5 FT
30 29
SECTION G-G
FOR CLARITY
22
15
20
Figure 5 Sheet 2
627-8134

Halvorsen
11 8 5
7 10 32
F
18
16
22
31 F 18 24 9 6
23
20
20
J
DETAIL A
24 9 6
19
J
10 7 4 10 13
H H 23
DETAIL D
FOR CLARITY
22
COVER REMOVED
20
7 4 10
DETAIL E
FOR CLARITY
Figure 5 Sheet 3
627-8134

Halvorsen
7 10 32 2 11
31
20
86
11 2
SECTION F-F
26
20
SECTION H-H
20
SECTION F-F
FOR CLARITY
Figure 5 Sheet 4
627-8134

Halvorsen
627-8134
1 107-9031 SCREW, HHC 8.8 M6 X 1 X 40 MG 1

2 107-2704 SCREW, HHC GR5 0.38-16 X 0.5 MG 4
5 107-9084 SCREW, HHC 8.8 M10 X 1.5 X 50 MG 2
6 107-9258 NUT, PTH 8 M6 X 1.00 MG 6
7 107-9259 NUT, PTH 8 M8 X 1.25 MG 13
8 107-9260 NUT, PTH 8 M10 X 1.50 MG 2
13 600681 SCREW, HHC GR 5 0.31-18 X 0.75 MG 4
15 239-8852-007 CLAMP, SUPPORT 1.50 NC 3
16 625-4154 W-BRACKET, CONDENSOR A//C 1
17 625-4235 BRACKET, REF-HOSE, A/C 1
18 625-4501 MOUNT, 3/8-16 X 3/8-16F 4
19 625-4502 MOUNT, CAPTURED 4
20 625-4534 A-A/C SYSTEM 1
22 627-8136 IE-A/C SYSTEM OPTION 1
23 627-8135 IH-A/C SYSTEM OPTION 1
24 107-9018 SCREW, HHC-F 8.8 M6 X 1 X 25 MG 4
25 107-9030 SCREW, HHC 8.8 M6 X 1 X 30 MG 1
26 625-4001 DECAL, A/C MODE 1
27 625-5918 GUARD, FRONT, A/C REFRIGERANT HOSE 1
28 625-5920 GUARD, REAR, A/C REFRIGERANT HOSE 1
30 620-1317-007 FLEX-GARD, NYLON SLIT 1-1/4 IN. 9
31 623-9632 A-MUD FLAP 1

Halvorsen
DETAIL B
5
ML25K3P DECK
DETAIL H
ML25K3P CAB
DETAIL E
DETAIL A
3-D REF VIEW
Figure 6 Sheet 1
AIR CONDITIONING ELECTRICAL INSTALLATION
627-8136

Halvorsen
8
AC1A-P
AC2A-P
REF
624-2911
4 AE-DECK PANEL
AC1A-R NGSL
AC2A-R
DETAIL A
REF
625-3088
A-CONDENSER,
AC ACCOND
DETAIL B
FOR CLARITY
Figure 6 Sheet 2
627-8136

Halvorsen
4
AC1-P REF 625-3091
AC2-P A-EVAPORATOR, AC
DETAIL E
FOR CLARITY
REF 625-4073
MANIFOLD, AC-MOTOR
ACSOL
DETAIL H
Figure 6 Sheet 3
627-8136

Halvorsen
3-D REF VIEW

DETAIL G
DETAIL F
Figure 6 Sheet 4
627-8136

Halvorsen
REF 625-4132
5
AE-SWITCH, AC FAN OVERRIDE
ACF-R
REF 625-4130
AE-SWITCH, HIGH PRES AC
ACH-P
REF 625-3864
A-DRIER, AC RECEIVER DETAIL F
FOR CLARITY
REF 625-4887
REF 625-3089 AE-SWITCH, LOW PRES AC
A-COMPRESSOR, AC ACL-P
DETAIL G
FOR CLARITY
Figure 6 Sheet 5
627-8136

Halvorsen
627-8136
2 623-4995 NYLON CABLE WRAP LARGE 14.5 IN. 50 LB 5
3 105-0210 NYLON CABLE WRAP, 7.3 IN. 50 LB 10
4 628-4448 HE-AC-SYSTEM OPTION, CAB 1
5 628-4449 HE-AC SYSTEM OPTION, DECK 1

Halvorsen
DETAIL D
DETAIL D DETAIL B
ML25K3P DECK
DETAIL B
ML25K3P DECK
F
F
F
F
DETAIL A
DETAIL A
6
6 14
16
14
REF 625-308916
A-COMPRESSOR, AC
REF 625-3089
A-COMPRESSOR, AC
3
16
12 16
AO 6
1 12
AO 6
P DETAIL A
4 DETAIL A
P FOR CLARITY
FOR CLARITY
LS
14
11
LS
14
11
AR LS
4 5
AR LS
4 5
DETAIL B
DETAIL
FOR B
CLARITY
FOR CLARITY
Figure 7 Sheet 1
AIR CONDITIONING HYDRAULIC INSTALLATION
627-8135

Halvorsen
REF 623-5415
MANIFOLD, ASSY STOPS/LIFT
14
19
DETAIL D
4 13
9 10
17 10
12 3
19 REF 623-5415
MANIFOLD, ASSY STOPS/LIFT
P
16
SECTION F-F
FOR CLARITY
Figure 7 Sheet 2
627-8135

Halvorsen
DETAIL H
ML25K3P SCISSORS
DETAIL K
DETAIL J
ML25K3P
CHASSIS
ML25K3P CHASSIS HYD

DETAIL R
3-D REF VIEW DETAIL G
DETAIL E
Figure 7 Sheet 3
627-8135

Halvorsen
21
14
25
22
DETAIL E
REF 623-5930
AH-RESERVIOR
REF 514-8244
FILTER, HIGH
PRESSURE 100 GPM 18
27 14
14
25
23
20
DETAIL G
FOR CLARITY
25
DETAIL H
Figure 7 Sheet 4
627-8135

Halvorsen
25
22
25
21
14 24
DETAIL K
DETAIL J
REF 620-4440
CLAMP, TWIN
TUBE 3/8"
26
25
24
DETAIL R
Figure 7 Sheet 5
627-8135

Halvorsen
DETAIL C
ML25K3P SCISSORS
DETAIL L
DETAIL M
DETAIL P
DETAIL N
3-D REF VIEW

ML25K3P CHASSIS
Figure 7 Sheet 6
627-8135

Halvorsen
14 14
21
23
22
21
25
DETAIL C 25
FOR CLARITY
25
DETAIL L
24
14
20
DETAIL M
25
23
DETAIL N
FOR CLARITY
21
22
14
DETAIL P
Figure 7 Sheet 7
627-8135

Halvorsen
627-8135
1 102-1775-0808 ADAPTER, STRAIGHT - 08MORB X -08MJIC 1
7 102-1782-0016 ADAPTER, TEE RN SWIVEL -16JIC 1
9 107-9259 NUT, PTH 8 M8 X 1.25 MG 2
12 625-4073 MANIFOLD, A/C MOTOR 1
13 625-4264 PLATE, MANIFOLD A/C 1
14 627-8135-001 IH-HOSE ASSEMBLY KIT, A/C SYSTEM OPTION 1
17 5060064 SCREW, HHC GR 5 0.38-16 X 0.75 MG 2
19 102-1795-0008 ADAPTER, TEE SWIVEL BR -08JIC 1
20 102-0200 ADAPTER, BH 90 -08MJIC 2
23 102-1784-0006 ADAPTER, BH 90 -02MJIC 2
24 628-4499 A-CLAMP, TWIN TUBE 3/8 IN. AND 1/2 IN. 3
25 627-8135-002 IH-TUBE ASSEMBLY KIT, A/C SYSTEM OPTION 1
26 3613557 SCREW, HHC GR 5 0.25-20 X 2.5 MG 1
27 102-1778-1616 ADAPTER, 90 SWIVEL -16FJIC X -16MJIC 1

Halvorsen
Figure 8 Sheet 1
MANIFOLD, A/C MOTOR
625-4073

Halvorsen
Figure 8 Sheet 2
MANIFOLD, A/C MOTOR
625-4073

Halvorsen
MANIFOLD, A/C MOTOR
625-4073
1 620-1326-001 VALVE SHUTTLE CSAB XXN 1
2 622-6079-001 COIL, 24 VDC, SUN 1
3 623-6681-010 MANIFOLD BODY, A/C REFRIGERANT 1
4 625-4073-001 VALVE, SUN DMDA-MNN 1
5 624-7796-001 COIL, 24 VDC, SUN 1
6 102-1788-0006 ADAPTER, PLUG -060RB 1

Halvorsen
Figure 9
DRIER ASSEMBLY, A/C RECEIVER
625-3864

Halvorsen
DETAIL D
DETAIL A
FOR CLARITY
7
DETAIL C 8
1
DETAIL A
DETAIL B
DETAIL B
FOR CLARITY
Figure 10 Sheet 1
AIR CONDITIONING SYSTEM ASSEMBLY
625-4534

Halvorsen
4 6
DETAIL C
FOR CLARITY
DETAIL D
Figure 10 Sheet 2
625-4534

Halvorsen
625-4534
1 625-3864 A-DRIER, A/C RECEIVER 1
2 625-3797 SEPERATOR, AC/ OIL 1
3 625-3088 A-CONDENSOR, A/C 1
4 625-3089 A-COMPRESSOR, A/C 1
5 625-3091 A-EVAPORATOR, A/C 1
6 625-4728 K-REFRIGERANT HOSES, A/C 1
7 625-4130 AE-SWITCH, HIGH PRESSURE A/C 1
8 625-4132 AE-SWITCH, A/C FAN OVERRIDE 1
9 625-4887 AE-SWITCH, LOW PRESSURE A/C 1

Halvorsen
DETAIL F ML25K3P DECK
DETAIL D
DETAIL H
ML25K3P SCISSORS
ML25K3P CHASSIS
DETAIL L
ML25K3P CHASSIS HYD
Figure 11 Sheet 1
A/C HYDRAULIC HOSE KIT
627-8135-001

Halvorsen
11 8
DETAIL D
REF 625-4073
MANIFOLD, AC MOTOR
8
P
1
LSO
LS1
REF 519-0196-124
HOSE, ASSY FJIC
AR SW-06 X 124LG
4
DETAIL F
Figure 11 Sheet 2
627-8135-001

Halvorsen
10
13
DETAIL H
FOR CLARITY
DETAIL L
Figure 11 Sheet 3
627-8135-001

Halvorsen
DETAIL A
ML25K3P DECK
T
DETAIL B
3
T
7
AO
REF 625-4073
MANIFOLD, AC-MOTOR
DETAIL A
Figure 11 Sheet 4
627-8135-001

Halvorsen
REF 625-3089
7 A-COMPRESSOR, AC
11
DETAIL B
FOR CLARITY
REF 623-5415 1
MANIFOLD, ASSY STOPS/LIFT LS1
3
P
SECTION T-T
Figure 11 Sheet 5
627-8135-001

Halvorsen
ML25K3P SCISSORS
DETAIL M
ML25K3P
CHASSIS HYD DETAIL N
DETAIL R DETAIL P
ML25K3P
CHASSIS
3-D REF VIEW
Figure 11 Sheet 6
627-8135-001

Halvorsen
10
13
DETAIL M
12
DETAIL N
FOR CLARITY
Figure 11 Sheet 7
627-8135-001

Halvorsen
12
9
DETAIL P
FOR CLARITY
REF 514-8244
FILTER, HIGH PRESSURE
100 GPM
6
DETAIL R
FOR CLARITY
Figure 11 Sheet 8
627-8135-001

Halvorsen
627-8135-001
3 519-0197-025-S HOSE, ASSEMBLY FJIX SW-08 X 25 SLVD 1

Halvorsen
DETAIL E
DETAIL F
ML25K39 SCISSORS
DETAIL G
ML25K39
DETAIL H ML25K39
DETAIL J CHASSIS
CHASSIS HYD
3-D REF VIEW
Figure 12 Sheet 1
A/C HYDRAULIC TUBE KIT
627-8135-002

Halvorsen
5 6
DETAIL F
DETAIL E
Figure 12 Sheet 2
627-8135-002

Halvorsen
4
3
DETAIL G
1
DETAIL H
2
1
DETAIL J
FOR CLARITY
Figure 12 Sheet 3
627-8135-002

Halvorsen
DETAIL B
DETAIL C
ML25K3P SCISSORS
ML25K3P CHASSIS HYD
ML25K3P CHASSIS
3-D REF VIEW
Figure 12 Sheet 4
627-8135-002

Halvorsen
7
DETAIL B
DETAIL C
Figure 12 Sheet 5
627-8135-002

Halvorsen
627-8135-002
1 628-0918 A-TUBE, 0.38 SST 1
2 628-0919 A-TUBE, 0.38 SST 1
3 628-0943 A-TUBE, 0.38 SST 1
4 628-0944 A-TUBE, 0.50 SST 1
5 628-0945 A-TUBE, 0.38 SST 1
6 628-0946 A-TUBE, 0.50 SST 1
7 628-0948 A-TUBE, 0.38 SST 1
8 628-0949 A-TUBE, 0.50 SST 1

Halvorsen
501-1-0-4
NO 8 35 PSIG
HS200-121-0002 YY-WW-E
BLACK HOUSING
1 2 4 3
.55
1/4" FEMALE FLARE
14.0
(7/16-20 UNF-2B) EPOXY SEAL 5
DEFLATOR
WIRE LEADS (2) 18 AWG,
.92 600V PVC INSULATION, 1/32",
.50 BLUE, 105 C, UL 1015
23.4 12.7
1.75 12.00
44.4 304.8
Figure 13
A/C LOW PRESSURE SWITCH ELECTRICAL ASSEMBLY
625-4887
A/C LOW PRESSURE SWITCH ELECTRICAL ASSEMBLY

625-4887
4 622-2967-046 CONNECTOR, BOOT 2 POS RECEPTACLE 1

Halvorsen
501-1-0-6
NO 180 240 PSIG
BLACK HOUSING HS400-121-0001 YY-WW-E
1/4" FEMALE FLARE

(7/16-20 UNF-2B)
.55 EPOXY SEAL
4 3 2 1
14.0 DEFLATOR
5
WIRE LEADS (2) 18 AWG,

.92 .50
600V PVC INSULATION, 1/32",
1.80 BLUE, 105 C, UL 1015
23.4 12.8
45.7 12.00
304.8
Figure 14
A/C FAN OVERRIDE SWITCH ELECTRICAL ASSEMBLY
625-4132
A/C FAN OVERRIDE SWITCH ELECTRICAL ASSEMBLY

625-4132
4 622-2967-040 CONNECTOR, BOOT 2 POS PLUG 1

Halvorsen
501-1-0-5
NC 350 250 PSIG
HS200-121-0003 YY-WW-E
GREEN HOUSING WIRE LEADS (2) 18 AWG,
600V PVC INSULATION, 1/32",
BLACK, 105 C, UL 1015
1/4" FEMALE FLARE

(7/16-20 UNF-2B) EPOXY SEAL
.55
5
14.0 DEFLATOR 1 2 4 3
.92 .50
23.4 12.7 1.80 12.00

304.8
45.7
Figure 15
A/C HIGH PRESSURE SWITCH ELECTRICAL ASSEMBLY
625-4130
A/C HIGH PRESSURE SWITCH ELECTRICAL ASSEMBLY

625-4130
3 622-2967-001 CONNECTOR, RECEPTACLE P 2 POS (MALE) 1
5 620-1317-009 FLEX-GARD, NYLON SLIT 1/4 IN. 1 ft.

Halvorsen
GENERAL
Section 2. Engine
VM MOTORS
WORKSHOP MANUAL, ENGINE FAMILY R750
Section 3. Transmission
ALLISON TRANSMISSION
OPERATOR’S MANUAL (OM3063EN)
SERVICE MANUAL (SM319EN)
TRANSMISSION TROUBLESHOOTING MANUAL (TS319EN)
MECHANIC’S TIPS (MT3190EN)
STONE BENNETT CORP.
DESCRIPTION AND INSTALLATION BULLETINS
PARTS LIST MANUAL
Section 4. Axles and Steering
KESSLER & CO., OFF-HIGHWAY AXLE DIVISION

SERVICE MANUAL - JBT ML 42K4P (41.3485.3)
DANFOSS HYDRAULICS
SERVICE MANUAL (HN.21.AD.02)
SPARE PARTS (HN.21.UA.52)
Section 5. Hydraulic Pumps and Motors
LINDE HYDRAULICS CORP.

HPR-75-02 PUMP INSTALLATION AND ADJUSTMENT INSTRUCTIONS
SPARE PARTS LIST (REF. 253 804 91 11)
SERVICE TRAINING, MAINTENANCE AND PARTS LIST
5-Contents
Page 1
December 2015
Halvorsen
PARKER HANNIFIN CORP.
INTRODUCTION AND CONTROL OPTIONS CATALOG (2600-102-1/USA)
PARKER PUMPS PARTS AND SERVICE (Bulletin PM 1620-12-M1/USA)
ROSS OPERATION
SERVICE MANUAL (2704)
Section 6. Hydraulic Cylinders
PARKER HANNIFIN CORP.

CYLINDER INFORMATION DRAWINGS
CLOVER HYDRAULICS & ENGINEERING, INC.
SPECIFICATIONS AND PARTS LIST DRAWINGS
CYLINDER SEAL REPLACEMENT PROCEDURES
TEXAS HYDRAULICS, INC.
MAINTENANCE MANUAL
Section 7. Brakes
AUSCO PRODUCTS
SERVICE NOTES
MICO, INC.
PRODUCT CATALOG
INSTALLATION AND SERVICE INSTRUCTIONS
SERVICE INSTRUCTIONS
Section 8. Air Conditioner and Heater
ESPAR HEATER SYSTEMS

OPERATION AND MAINTENANCE MANUAL WITH PARTS LIST
VISIONAIRE, INC.
MAINTENANCE GUIDE
5-Contents
Page 2
December 2015
Halvorsen
WARNING
WARNING AND CAUTION STATEMENTS. MAINTENANCE MUST BE PERFORMED
EXCLUSIVELY BY TRAINED AND QUALIFIED TECHNICIANS AND ACCORDING TO
MAINTENANCE SCHEDULES AND MANUFACTURERS’ RECOMMENDATIONS. FAILURE TO
COMPLY WITH THIS WARNING MAY RESULT IN SERIOUS BODILY INJURY, DEATH OR
PROPERTY DAMAGE, INCLUDING DAMAGE TO THE VEHICLE! IF YOU HAVE ANY
QUESTIONS REGARDING THE SAFE OPERATION OR PROPER MAINTENANCE, PLEASE
CONTACT YOUR LOCAL JBT SERVICE CENTER BEFORE PROCEEDING.
GENERAL
This chapter contains instruction bulletins, parts lists, service manuals, etc., issued by major
manufacturers’ appendices of the Halvorsen aircraft loader.
Information is included only for components that are considered repairable.
A list of manufacturers and their CAGE codes is included for those major components in Chapter 4,
Section 2.
5-1
INTRODUCTION
Page 1
December 2015
Halvorsen
Section 2. Engine
VM MOTORS
Florida Detroit Diesel-Allison
WORKSHOP MANUAL, ENGINE FAMILY R750

R756IE3 Diesel Engine, Tier 3
5-2
ENGINE
Page 1
December 2015
R 750
Workshop Manual
Engine Family R750
R754EU4 R756EU4 R756IE3 R754EU5 R756EU5
R Common Rail Injection System
750 Unitary Displacement
4 (no. of cylinders) 4 x x 4 x
6 (no. of cylinders) x 6 6 x 6
Turbocharged yes yes yes yes yes
I (Intercooler) yes yes yes yes yes
EU4 - Emissions EURO 4 EURO 4

x x x
Certification EC/EPA Stage3A EC/EPA Stage3A
E3 - Emissions
x x EC/EPA Stage3A x x
Certification
EU5 - Emissions EURO 5 EURO 5
x x x
Certification EC/EPA Stage3B EC/EPA Stage3B
VM Order Number 42431133F

Edition 9 - 10/2010

R 750
sections

R 750
SUMMARY
INTRODUCTION....................................................................................................................... 6
Models Covered........................................................................................................................................ 6
R 754 and 756 EU4/EU5 common rail industrial engines are applied to vehicles of the
road, such as road sweepers and trucks. R 756 IE3 are applied to vehicles not of the
road, agricultural and lifting application................................................................................... 6
Notice To Users Of This Manual.......................................................................................................... 6
Replacement Parts................................................................................................................................... 7
Cleanliness And Care Of Product..................................................................................................... 7
Handling Precautions for Electric Circuits....................................................... 8
ENGINE electronic control unit ....................................................................................................... 8
Precautions for Arc Welding.............................................................................................................. 12
service manual - Updating........................................................................................... 13
General Information...................................................................................................... 17
Introduction............................................................................................................................................... 17
How To Order This Manual..................................................................................................................... 17
Engine Serial Number and engine plate identification.............................................................. 17
Maintenance....................................................................................................................... 19
Engine Specifications.............................................................................................................................. 19
Maintenance Intervals........................................................................................................................... 25
Maintenance Schedule - R750 EURO 4 - IE3........................................................................................ 25
Maintenance Schedule - R750 EURO 5................................................................................................. 26
Engine External Views............................................................................................................................ 27
Engine Oil ..................................................................................................................................................... 31
Coolant......................................................................................................................................................... 36
Air Filter Element..................................................................................................................................... 39
Fuel System................................................................................................................................................. 42
Fuel Filter.................................................................................................................................................... 43
alternator Belt / Poly - V (Serpentine) ............................................................................................ 45
Diesel Particulate Filter (DPF) - r 750 euro 4.................................................................................. 47
Diesel Particulate Filter (DPF) - r 750 euro 5.................................................................................. 50
Extended Storage.................................................................................................................................... 51
REMOVAL AND INSTALLATION............................................................................................ 52
FASTENER TIGHTENING SPECIFICATIONS........................................................................ 53
special tools..................................................................................................................... 54
Timing Side............................................................................................................................ 58
Timing Gears................................................................................................................................................ 59
Oil pump......................................................................................................................................................... 62
Crankshaft gear....................................................................................................................................... 67
Hydraulic pump Idler gear (between the crankshaft and camshaft gears).................. 68
injection pump Idler gear (between the camshaft and injection pump gears).............. 71
hydraulic pump gear assembly........................................................................................................... 72
belt tensioner - (automatic type)....................................................................................................... 76
belt tensioner bracket.......................................................................................................................... 77
idler pulleys............................................................................................................................................... 78
crankshaft hub and pulley.................................................................................................................. 79
water pump and pulley........................................................................................................................... 82
timing gear cover..................................................................................................................................... 83
front oil seal............................................................................................................................................. 84
ExHaust Side....................................................................................................................... 85
turbocharger............................................................................................................................................ 85
egr cooler.................................................................................................................................................. 86
intake Throttle / EGR valve & PROPER actuators....................................................................... 88
exhaust manifold...................................................................................................................................... 91
intake manifold.......................................................................................................................................... 92

R 750
Flywheel Side..................................................................................................................... 93
Crankshaft End Play (Axial Clearance)........................................................................................... 93
Flywheel....................................................................................................................................................... 94
FLYWHEEL RING GEAR.................................................................................................................................. 97
Flywhell housing...................................................................................................................................... 98
rear main bearing carrier.................................................................................................................... 100
THRUST WASHERS......................................................................................................................................... 100
REAR MAIN BEARING .................................................................................................................................... 101
Rear oil seal................................................................................................................................................ 101
cps target wheel bolt............................................................................................................................ 101
BASIc ENGINE....................................................................................................................... 102
cylinder head GASKET.............................................................................................................................. 102
cylinder head............................................................................................................................................. 103
Torque Procedure After the First 20‑30 Minutes of Operation............................................ 106
EXPANSION PLUGS........................................................................................................................................ 107
Cylinder Head End spacer..................................................................................................................... 107
VALVE GUIDES................................................................................................................................................ 108
VALVE SEATS................................................................................................................................................... 110
Valve Seat Reconditioning.................................................................................................................... 111
Valves............................................................................................................................................................. 112
Valve Springs.............................................................................................................................................. 114
Rocker ARM.................................................................................................................................................. 115
Valve Lifters............................................................................................................................................... 117
Valve Push Rods......................................................................................................................................... 119
fractured Connecting Rod.................................................................................................................. 120
removal......................................................................................................................................................... 120
BROACHED Connecting Rod.................................................................................................................... 124
removal......................................................................................................................................................... 124
piston............................................................................................................................................................. 128
Oil Pan & Oil Pickup.................................................................................................................................... 133
Oil Pickup...................................................................................................................................................... 133
Oil Pressure Relief Valve...................................................................................................................... 134
engine block..................................................................................................................... 136
crankcase.................................................................................................................................................... 136
engine block..................................................................................................................... 137
Liner................................................................................................................................................................ 137
camshaft....................................................................................................................................................... 140
Camshaft bearings .................................................................................................................................. 143
front journal Camshaft bushing...................................................................................................... 144
Piston Cooling Jets (Oil Spray Nozzles).......................................................................................... 145
crankshaft.................................................................................................................................................. 146
Crankshaft front main bearing......................................................................................................... 152
INJECTION SIDE.................................................................................................................... 153
INJECTION FUEL SYSTEM............................................................................................................................. 153
electrical sensors . ............................................................................................................................... 154
low pressure system requirements................................................................................................ 158
high pressure pump................................................................................................................................. 159
injector........................................................................................................................................................ 162
rail.................................................................................................................................................................. 164
HIGH PRESSURE fuel COMPONENTS TIGHTENING PROCEDURE........................................................ 165
oil filter HOUSING...................................................................................................................................... 166
oil delivery pipe to rocker arm.......................................................................................................... 167
rocker arm cover.................................................................................................................................... 168
coolant manifold..................................................................................................................................... 168
thermostatic valve ................................................................................................................................. 169
vacuum pump................................................................................................................................................ 170
ENGINE ELECTRICAL........................................................................................................... 171
Alternator................................................................................................................................................... 171
Alternator pulley.................................................................................................................................... 171
voltage regulator................................................................................................................................... 174
Alternator Bracket................................................................................................................................. 174
Starter.......................................................................................................................................................... 174

R 750
ENGINE CONTROL................................................................................................................ 175
DIAGNOSTIC TROUBLE CODES “euro 4”................................................................................................... 175
DIAGNOSTIC TROUBLE CODES “euro 5”................................................................................................... 181
labour time guide........................................................................................................... 192
KEY TO DEFINITIONS...................................................................................................................................... 192
electrical system.......................................................................................................... 201
Electrical Schematic Diagrams - “A” SIDE - Engine . ..................................................................... 201
engine Wiring harness............................................................................................................................ 203
installation electric diagram - “k” side - vehicle......................................................................... 207
Introduction
R 750
INTRODUCTION
Models Covered
R 754 and 756 EU4/EU5 common rail industrial engines are applied to vehicles of the road, such as road swee-
pers and trucks. R 756 IE3 are applied to vehicles not of the road, agricultural and lifting application.
Notice To Users Of This Manual
Throughout this publication, Dangers, Warnings and Cautions (accompanied by the International HAZARD Sym-
bol ) are used to alert the mechanic to special instructions concerning a particular service or operation that
may be hazardous if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY!
These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instruc-
tions when performing the service, plus common sense operation, are major accident prevention measures.
DANGER
DANGER—indicates an imminently hazardous situation that, if not avoided, will result in death or serious
injury.
WARNING
WARNING—indicates a potentially hazardous situation that, if not avoided, could result in death or se-
rious injury.
CAUTION
CAUTION—indicates a potentially hazardous situation that, if not avoided, may result in minor or modera-
te injury or property damage. It may also be used to alert against unsafe practices.
This manual has been written and published by the Service Department of VM Motori to aid our dealers’ mechani-
cs and company service personnel when servicing the products described herein. We reserve the right to make
changes to this manual at any time and without prior notice in accordance with the Company’s policy of
constant product improvement.
COPYRIGHT © 2007 July, VM Motori S.p.A.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system or transmitted, in any form, whether electronic or mechanical, or by photocopying, recording or other
means without prior permission in writing of VM Motori.
Published by VM Motori, from whom further copies may be obtained through your normal literature ordering pro-
cedure (refer to front page to identify the order number).
A copy of this manual is available from VM Motori web site Customer Reserved Area “Extranet”
VM Motori S.p.A. - Service Department, Via Ferrarese 29 - 44042 Cento (FE) ITALY
Every reasonable effort is made to ensure that the VM Motori’s publications are accurate, but nothing
shown, described or referred to herein should be regarded as an infallible guide to the procedures, mate-
rials, specifications, dimensions, design or availability of any particular engine, nor does this publication
constitute an offer for the sale of any particular engine. No liability can be accepted by the VM Motori or
any Distributor or Dealer for any malfunction, damage, loss, injury or death caused by the use of incorrect
or misinterpreted information, omissions or errors that may have arisen during the preparation of this
workbook.
It is assumed that these personnel are familiar with industrial product servicing procedures.
Furthermore, it is assumed that they have been trained in the recommended service
procedures of VM Motori Products, including the use of mechanics’ common hand tools and the special VM Motori
or recommended tools from other suppliers.
We could not possibly know of and advise the industrial trade of all conceivable procedures and of the possible
hazards and/or results of each method. Therefore, anyone who uses a service procedure and/or tool, which is not
recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety
will be endangered.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication. As required, revisions to this manual will be sent to
all dealers contracted by us to service these products.
Refer to dealer service bulletins, warranty, owner manuals and installation manuals for other pertinent information
concerning the products described in this manual.
Extranet area contained in VM Motori web site is another source of information.
Introduction
R 750
Replacement Parts
Use of parts other than the recommended service re-
placement parts, will avoid the warranty on those parts
that are damaged as a result.
WARNING
When servicing the electrical, ignition and fuel sy-
stems, it is extremely important that all
components are properly installed and tightened. If
not, any electrical or ignition
component opening would permit sparks to ignite fuel
vapors from fuel system leaks, if
they existed.
Cleanliness And Care Of Pro-
duct
A VM Motori Product is a combination of many machi-
ned, honed, polished and lapped surfaces with tole-
rances that are measured in the thousands of a mm.
When any product component is serviced, care and
cleanliness are important.
Throughout this manual, it should be understood that
proper cleaning and protection of
machined surfaces and friction areas is a part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.
Whenever components are removed for service, they
should be retained in order. At the
time of installation, they should be installed in the
same locations and with the same mating surfaces as
when removed.
Any time the intake or exhaust openings are expo-

sed during service they should be covered to protect
against accidental entrance of foreign material which
could enter the cylinders and cause extensive internal
damage when the engine is started.
It is important to note, during any maintenance proce-
dure replacement fasteners must have the same mea-
surements and strength as those removed. Numbers
on the heads of the metric bolts and on the surfaces of
metric nuts indicate their strength. American bolts use
radial lines for this purpose, while most American nuts
do not have strength markings.
Mismatched or incorrect fasteners can result in dama-
ge or malfunction, or possibly personal injury. There-
fore, fasteners removed should be saved for reuse
in the same locations whenever possible. Where the
fasteners are not satisfactory for reuse, care should be
taken to select a replacement that matches the origi-
nal.
Personnel should not work on or under an engine that

is suspended. Engines should be attached to work
stands, or lowered to ground as soon as possible.
Introduction
R 750
Handling Precautions for Electric Circuits
ENGINE electronic control unit
WARNING
IN ORDER TO AVOID ECU DAMAGE PAY ATTENTION TO

THE FOLLOWING INSTRUCTIONS:
• DO NOT CUT ENGINE VOLTAGE OFF DURING ENGINE

OPERATION
• before cut engine voltage off through elet-

trical devices (breakers, switch, etc.) wait
for 30 sec. at least so that the ECU can be
carried out the “after-run” procedure
• do not use start booster to let start the en-

gine
Introduction
R 750
It should be kept in mind, while working on the product,

that the electrical systems are capable of violent and
damaging short circuits or severe electrical shocks.
When performing any work where electrical terminals
could possibly be grounded or touched by the mecha-
nic, the battery cables should be disconnected at the
battery.
Before working on the electrical system, disconnect

the (–) battery cable to prevent short circuits.
CAUTION
Make sure the starter switch and lighting switches are
OFF before disconnecting or connecting battery cable.
Semiconductor components may otherwise be dama-
ged.
When separating connectors, grasp the connectors

themselves rather than the harnesses.To separate
locking connectors, first push them in the direction of
the arrows. To reconnect locking connectors, push
them together until they click.
Before washing the engine, cover electrical parts to

keep them dry. (Use plastic sheets or the like.) Keep
water away from harness connectors and sensors and
immediately wipe off any water that gets on them.
When applying a voltage to a part for inspection pur-

poses, check that the (+) and (–) cables are connected
properly then gradually increase the voltage from zero.
Do not exceed the specified voltage.
Remember that control units and sensors do not ne-
cessarily operate on the battery voltage.
CAUTION
Introduction
R 750
• Do not pierce wire insulation with test probes or
alligator clips when performing electrical inspections.
Doing so can, particularly with the chassis harness,
hasten corrosion.
Inspection of harnesses
Inspections with connectors fitted to-

gether
Waterproof connectors
• Connect an inspection harness and connector A
between the connectors B of the circuit to be ins-
pected. Perform the inspection by applying a test
probe C to the connectors of the inspection harness.
Do not insert the test probe C into the wire-entry sides
of the waterproof connectors since this would damage
their waterproof seals and lead to rust.
Non-waterproof connectors
Perform the inspection by inserting a test probe C into
the wireentry sides of the connectors. An extra-narrow
probe is required for control unit connectors, which are
smaller than other types of connector. Do not force a
regular-size probe into control unit connectors since
this would cause damage.
Inspections with connectors separated

Inspections on female terminals
Perform the inspection by carefully inserting a test pro-

be into the terminals. Do not force the test probe into
the terminals since this could deform them and cause
poor connections.
Inspections on male terminals

Perform the inspection by applying test probes directly
to the pins.
CAUTION .
• Be careful not to short-circuit pins together with the
test probes. With control unit connectors, short-cir-
cuiting of pins can cause damage to the control unit’s
internal circuitry.
When using a multimeter to check continuity, do not
10 Introduction
R 750
allow the test probes to touch the wrong terminals
Inspection of connectors
Visual inspection
Check that the connectors are fitted together securely
Check whether wires have been separated from their

terminals due to pulling of the harness
Check that male and female terminals fit together

tightly
Check for defective connections caused by loose

terminals, by rust on terminals, or by contamination of
terminals by foreign substances.
Checking for loose terminals

• If connector terminal retainers become damaged,
male and female terminals may not mate with each
other when the connector bodies are fitted together.
To check for such terminals, gently pull each wire and
see whether any terminals slip out of their connector
housings.
Introduction 11
R 750
Precautions for Arc Welding
When arc welding is performed, current from the
welder flows to ground via the vehicle’s metal parts.
Unless appropriate steps are taken, this current can
damage engine control units, other electrical devices
and wiring harnesses.
And any electrical device near the point on the vehi-
cle to which the (–) cable of the welder is connected,
might be largely damaged.
REMOVE THE ELCTRONIC ENGINE CON-

TROL UNIT FROM THE VEHICLE
Current flows backward as shown nearby
From battery (–) cable

To prevent damage to the battery and to electrical
devices that are connected directly to the battery, it is
essential to disconnect the battery’s (–) cable.
Procedure
Turn the starter switch to the LOCK position.
Disconnect the battery’s (–) cable.
Cover all parts of the vehicle that may be damaged by
welding sparks.
Connect the welder’s (–) cable to the vehicle as close
as possible to the area being welded. Do not connect
the welder’s (–) cable to the cab if the frame is being
welded, and vice versa.
Set the welding current in accordance with the part
being welded.
12 Introduction
R 750
service manual - Updating
Edition 0 _ 07 - 2007
Date Chapter / Paragraph Action Description
dd/mm/yyyy
04/07/2007 First Issue
Edition 1 _ 11 - 2007
gg/mm/aaaa
28/11/2007 Maintenance / Engine Specifications updating: API and ACEA engine oil specifications
regarding all engine models of R750 family
modification: engine oil change quantity (oil filter
cartridge included), concerning all engine versions,
with counter balancer shaft and oil pan with major
capacity
Insertion: new DPF particulate filter cleaning proce-
dure using an electrical oven
Engine Block / Crankshaft Insertion: crankshaft tech drawing about R756
Edition 2 _ 03 - 2008
DATE Chapter / Paragraph Action Description
gg/mm/aaaa
14/03/2008 Maintenance / Engine Oil Added important note about 2 different oil pan capa-
cities on R750 engines. Take care during engine oil
change and filling.
Basic Engine / Fractured connecting Rod New paragraph “Fractured Connecting Rod”
Specia Tools Added spare parts code about socket for removal
alternator pulley
Labour Time Guide Added labour time for cleaning DPF filter with com-
pressed air
Exhaust Side / Turbocharger Added note about failure of turcharger: with an
important oil leakage into exhaust side evaluate a
cleaning of DPF Filter
Edition 3 _ 04 - 2008
dd/mm/yyyy
23/04/2008 Special Tools Inserted: Electrical Owen for DPF Filter
cleaning, Engine test harness.
Updated the Diagnostic Tool P/N
Introduction Inserted: Handling Precautions for Electric
Circuits, Precautions for Arc Welding
Introduction 13
R 750
Edition 4 _ 07- 2008
dd/mm/yyyy
23/07/2008 Special Tools Inserted: Compression Tester Adapter Tool.
Inserted: Break out Box Tool.
Timing Side / Crankshaft gear Heating of crankshaft gear before installing

it on crankshaft
Introduction Warning about ECU safeguard
Edition 5_ 09 - 2008
dd/mm/yyyy
08/09/2008 Engine Block Inserted: new chapter “Crankcase”,
inspection procedure of balance shaft
assembly plugs and their caulking.
Edition 6 _ 12- 2008

dd/mm/yyyy
17/12/2008 Introduction Inserted: indication DO NOT use START-
BOOSTERS to let start the engine
17/12/2008 Maintenance Inserted: required conditions about:

• DPF filter cleaning with electrical oven
• service regeneration through diagno-
stic tool
14 Introduction
R 750
Edition 7 _ 03- 2010
dd/mm/yyyy
22/01/2010 General Information Updating of engine codes about R750 EURO5 engines family
Maintenance ENGINE SPECIFICATIONS: updating of R754EU5 R756EU5 engine

models
MAINTENANCE SCHEDULE: updating of maintenance chart about engi-
nes model EURO5
ENGINE OIL:
• updating of ACEA oil specifications about engines EURO 5
• added delete procedure about ENGINE OIL DILUTION function
AIR FILTER: maintenance procedure about engines EURO5
DPF DIESEL PARTICULATE FILTER : description of DPF filter about
engines EURO 5.
Timing Side “PTO” IDLER GEAR: updating of Loctite 572 on PTO cover gears bolt
threads
OIL PUMP: updating of dimensions about R750 EURO 5 engine models
Basic Engine CYLINDER HEAD VALVE SEAT: updating of dimensions about R750
EURO 5 engine models
Injection Side low pressure system requirements: updating of specifications
as from installation manual
Electrical System Electrical Schematic Diagrams , engine Wiring harness,
installation electric diagram: updating in relation to EURO 5
engine models
Special Tools updating of injector extractor fork for R750 EURO 5 engine models, VM
code 68400045G
Engine Block CRANKCASE: updating installation plugs for closing counter balance shaft
oil lubrication passages
Basic Engine HYDRAULIC TAPPET: insert new tappet 40432003F
Timing Side IDLER GEAR (between crankshaft and camshaft gear): insert new idler
gear
Edition 8 _ 04- 2010

dd/mm/yyyy
07/04/2010 Maintenance OIL CHANGE/OIL DILUTION CALULATION: updating of reset pro-
cedure
Maintenance DPF FILTER EURO 5: updating of cleaning procudure through com-

pressed dry air
Electrical System INSTALLATION ELECTRICAL DIAGRAM “K SIDE”: updating
electrical diagram R750EU5 engines
INSTALLATION ELECTRICAL DIAGRAM “K SIDE”: new electrical
diagram R750IE3 engines
Labout Time Guide Insert ECU diagnosis time
General Information 15
R 750
Edition 9 _ 10 - 2010
dd/mm/yyyy
08/10/2010 Maintenance ENGINE SPECIFICATIONS: updating of exhaust back pressure
about R750IE3 - EU4 - EU5 engine models
DPF FILTER EURO 4: cleaning procedure of pressure lines (from

pressure sensor and DPF filter) every time the DPF filter comes
cleaned
ENGINE SPECIFICATIONS, ENGINE OIL: updating of engine oil
specifications and oil pan capacities
16 General Information
R 750
General Information
Introduction
This comprehensive overhaul and repair manual is designed as a service guide for the
VM common rail diesel engines belonging to R750 family models. It provides specific
information, including procedures for disassembly, inspection, assembly and adjustment,
to enable dealers and service mechanics to repair these products. Before attempting
repairs, read through the procedures to understand the methods and tools used and the
cautions and warnings required for safety.
How To Order This Manual
This manual can be order through your normal literature ordering procedure (refer to
front page to identify the order number).
A copy of this manual is available from VM Motori web site Customer Reserved Area “Extranet”
Engine Serial Number and engine plate identification

Engine Serial Number
1 - VM serial number stamped in the crankcase P

2 - VM serial number and specification plate
q r
P) Engine serial number (punched on the crankcase)
q) Engine code
XXC 01001
r) Consecutive number
The table helps you to identify the model through the engine
code.
1
Engine code Engine model
56C R754EU4
79C R756EU4
80C R756IE3
05D R754EU5
06D R756EU5
General Information 17
R 750
engine plate identification
FLYWHEEL
SIDE
A) Manufacturer identification G) Version

B) Serial number H) Maximum power (kW)
C) Weight L) Maximum number of
2 revolutions
D) Type
M) Homologation number
E) Family
N) Lubricating oil features
F) Model
TIMIMG SIDE
18 General Information
R 750
Maintenance
Engine Specifications
r 754 eu4, r 756 eu4, r 756 ie3
GENERAL SPECIFICATIONS
Engine Model R754 IE3/EU4 R756 IE3/EU4
Engine Type In–line 4 cylinder In–line 6 cylinder
Engine
Bore 94 mm
Cylinder
Stroke 107 mm
Firing order 1‑3‑4‑2 1-5-3-6-2-4
Displacement 2.970 liters 4.455 liters
Compression Ratio 17,5 ± 0.5 : 1 17,5 ± 0.5 : 1
Injection System Type Direct - Common Rail
Cooling System Type Forced Water Cooling
Intake System Type Turbocharger/Intercooler
Maximum Power (Ratings are
based upon ECE Directive R120) 74 (100) @ 3000 rpm 121 (165) @ 3000 rpm
Nm (CV)
Maximum Torque 340 Nm @ 1350 rpm 535 Nm @ 1350rpm
Engine Rotation (Looking at
counterclockwise
flywheel)
Idle Speed 800 ± 50 rpm 750 ± 50 rpm
Weight (Dry) 269 kg 335 kg
Maximum permanent lengthwise
inclination 35° 30°
(with flywheel up)
inclination 35°
(with flywheel down)
Maximum permanent
30°
crosswise inclination
Valve clearance ‑ intake and

Hydraulic
exhaust
Maximum pressure difference
500 kPa ( 72 PSI)
between cylinders
Maintenance 19
R 750
The engine has been designed to be powered by
standard fuels (conforms to specifications DIN EN 590)
available on the European market. If it is to be powered
by BIODIESEL fuels (conforms to specifications UNI EN
Fuel Specifications
14214), it can be mixed, up to 5%, with fuel (conforms to
specifications DIN EN 590) available on the European
market. About R750 engine models use only fuel with low
sulphur content (not above 10-50 ppm)
Fuel Pump Type Gerotor Type
Fuel System
Fuel Flow Rate
Low Fuel Pressure Fuel Flow Pressure
Line filtering area filtrante 6300 ± 200 cm2 /
Fuel Filter Type
filtration efficiency 5 micron @ 95%
Fuel Pump Type 3 – cylinder radial plunger
Delivery/Pump
Fuel System
Rotation
High Fuel Pressure Common Rail Pressure max 1400 bar
Line
Injection Pressure max 1350 bar
Injector Type solenoid type
SAE 10W 40
Standard API CI-4
Oil Change
(Including Filter) MAX 8.7 Kg MAX 12 kg
Engine STANDARD OIL PAN
Systems
Oil Change
(Including Filter)
/ /
more OIL PAN
CAPACITY
Oil Change
Engine Oil (Including Filter)
COUNTER MAX 7.9 Kg /
BALANCER SHAFT
IN OIL PAN
Oil Pump Type Internal Rotor
Thermostat
Consumption 0.5 - 1 (gr/CVh)
Oil temperature (alarm) 128°C
1.2 bar (idle 800±50
Oil pressure (with hot 1.2 bar (idle 750±50 rpm) / 3.2
rpm) / 3.2 bar (rating
engine) bar (rating 3000 rpm)
3000 rpm)
Normal operating
80‑85° C
temperature
start opening 80 ± 2 °C start opening 80 ± 2 °C / 90°C

Thermostat
/ 90°C fully open fully open
Coolant System
5 liters (without radia- 7.5 liters (without radiator and
Capacity
tor and pipes) pipes)
Water Circuit Pressure 0.9 - 1.1 bar

Standard ASTM D 3306
20 Maintenance
R 750
Engine Battery 12 V 12 V
Systems Electric System Alternator 2.3 Kw - 105 A 2.3 Kw - 110 A
Starter 12V, 2.4 kW
MAX 70 mbar -
Admittable depressure
with new air filter <35mbar
Intake System
Air Cosumption m3/h 365 @ 3000 rpm 673 @ 3000 rpm
(R750EU4) 350 mbar

with DPF (Diesel Particulate Filter) new, clean or
Max. Exhaust
Engine regenerated
backpressure
Systems
(R750IE3) 250 mbar
Exhaust System
Exhaust Gas
Temperature (in
625°C @ 3000 rpm 637°C @ 3000 rpm
accordance with ECE
Regulation R120)
Maintenance 21
R 750
r 754 eu5, r 756 eu5
GENERAL SPECIFICATIONS
Engine Model R754 EU5 R756 EU5
Engine Type In–line 4 cylinder In–line 6 cylinder
Engine
Bore 94 mm
Cylinder
Stroke 107 mm
Firing order 1‑3‑4‑2 1-5-3-6-2-4
Displacement 2.970 liters 4.455 liters
Compression Ratio 17,8 ± 0.5 : 1 17,8 ± 0.5 : 1
Injection System Type Direct - Common Rail
Cooling System Type Forced Water Cooling
Intake System Type Turbocharger/Intercooler
Maximum Power - Nm (CV) 74 (100) @ 3000 rpm 121 (165) @ 3000 rpm
Maximum Torque 340 Nm @ 1400 rpm 500 Nm @ 1400 rpm

Engine Rotation (Looking at
counterclockwise
flywheel)
Idle Speed 800 ± 50 rpm 750 ± 50 rpm
Weight (Dry) 260 kg 335 kg
inclination 30°/57% 30°
(with flywheel up)
inclination 35°/70%
(with flywheel down)
Maximum permanent
30°/57%
crosswise inclination
Valve clearance ‑ intake and

Hydraulic
exhaust
Maximum pressure difference
500 kPa ( 72 PSI)
between cylinders
22 Maintenance
R 750
The engine has been designed to be powered by stan-
dard fuels (conforms to specifications DIN EN 590/2004)
available on the European market. If it is to be powered
by BIODIESEL fuels (conforms to specifications UNI EN
Fuel Specifications
14214), it can be mixed, up to 5%, with fuel (conforms to
specifications DIN EN 590) available on the European
market. About R750E engine models use only fuel with
low sulphur content (not above 10-50 ppm)
Fuel Pump Type Gerotor Type
Fuel System Fuel Flow Rate
Fuel Flow Pressure
Low Fuel Pressure
Line Filter efficiency in according Bosch std KM 45 110 004_
Fuel Filter Type en /
Water separation in according ISO 16332
Fuel Pump Type 3 – cylinder radial plunger
Delivery/Pump
Fuel System
Rotation
High Fuel Pressure Common Rail Pressure max 1600 bar
Line
Injection Pressure
Injector Type solenoid type
SAE 10W 40
Standard
ACEA E6 - API CJ4
Oil Pan Capacity
8.7 Kg 12 kg
Engine STANDARD OIL PAN
Systems Oil Change
(Including Filter)
/ /
more OIL PAN
CAPACITY
Oil Pan Capacity

Engine Oil COUNTER
7.9 kg /
BALANCER SHAFT
IN OIL PAN
Oil Pump Type Internal Rotor

Thermostat
Consumption 0.2 (gr/KWh)
Oil temperature (alarm) 135°C
Oil pressure (with hot > 1.5 bar / 120°C (rpm engine idle)
engine) 4 - 4.5 bar / 80°C (max 3000 rpm)
Normal operating
80‑85° C
temperature
start opening 80 ± 2 °C start opening 80 ± 2 °C / 90°C

Thermostat
/ 90°C fully open fully open
Coolant System
5 liters (without radia- 7.5 liters (without radiator and
Capacity
tor and pipes) pipes)
Water Circuit Pressure 0.9 - 1.1 bar

Standard ASTM D 3306
Maintenance 23
R 750
12 V
Engine Battery
Cold Cranking Amps (CCA) 950 A EN
Systems
Electric System Capacity 140 Ah
Alternator 14V - 2.3 Kw - 105 A

Starter 12V, 2.5kW
max 40 mbar -
Admittable depressure
with new air filter
Intake System
Air Cosumption m3/h
(R754EU5 350 mbar) - (R756EU5 - 450 mbar)

Max. Exhaust
Engine with DPF (Diesel Particulate Filter) new, clean or
backpressure
Systems regenerated
Exhaust System
Exhaust Gas
Temperature after 569 °C
turbocharger
24 Maintenance
R 750
Maintenance Intervals
WARNING
Avoid injury or death, product damage, fire or explosion. The electrical system is capable of violent and
damaging short circuits or severe electrical shocks. When performing any activity where any electrical
terminals could possibly be grounded or touched, the battery cables should be disconnected at the batte-
ry.
Always disconnect battery cables from the battery before working around electrical system components
to prevent injury to yourself and damage to the electrical system should a wire be accidentally shorted.
Maintenance Schedule - R750 EURO 4 - IE3
AFTER FIRST 50 HOURS
• Replace the engine oil filter (If the engine has not been in operation, the filter must be replaced once
every 12 months)
EVERY 10 HOURS or every day

• Check the engine oil level. (This task interval can be extended based on operator experience with the
product.)
• Check the coolant level
• Check the air filter element cleaning and possible replacement if dirty
• Check the radiator cleaning
EVERY 300 HOURS

• Change the engine oil. (Or every year, whichever occurs first.)
In particulary severe operating conditions, in dusty environments and when operating under extreme loads,
the engine oil must be replaced every 150 working hours.
• Replace the engine oil filter (Or every year, whichever occurs first.)
• Replace the fuel filter (every 300 hours or 30.000 km.) (Or every year, whichever occurs first.)
EVERY 900 HOURS

• Replace the Poly-V alternator belt (Or every 2 years, whichever occurs first.)
EVERY 1200 HOURS

• Replace engine coolant (Or every 2 years, whichever occurs first.)
EVERY 1500 HOURS or 50.000 km

• Diesel particulate filter cleaning
EVERY 4000 HOURS

• Partial engine overhaul
EVERY 8000 HOURS

• Total engine overhaul
Maintenance 25
R 750
Maintenance Schedule - R750 EURO 5
AFTER FIRST 50 HOURS
• Replace the engine oil filter (If the engine has not been in operation, the filter must be replaced once
every 12 months)
EVERY 10 HOURS or every day

• Check the engine oil level. (This task interval can be extended based on operator experience with the
product.)
• Check the coolant level
• Check the air filter element cleaning and possible replacement if dirty
• Check the radiator cleaning
EVERY 300 HOURS

• Change the engine oil. (Or every year, whichever occurs first.)
IMPORTANT: Whenever the engine oil is changed it is necessary to reset the OIL DILUTION CALCU-
LATION function (refer to paragraph OIL DILUTION CALCULATION).
In particulary severe operating conditions, in dusty environments and when operating under extreme loads,
the engine oil must be replaced every 150 working hours.
• Replace the engine oil filter (Or every year, whichever occurs first.)
• Replace the fuel filter (every 300 hours or 30.000 km.) (Or every year, whichever occurs first.)
• REPLACE AIR FILTER CARTRIDGE
• CHECK THE CLEANING OF Air intake circuit
• CHECK THE CLEANING AND TIGHTNESS OF intercooler pipeS
• CHECK THE TIGHTNESS OF OIL SEPARATOR PIPES AND RELATED SYSTEM
• CHECK THE TIGHTNESS OF VACUUM PUMP PIPES AND RELATED SYSTEM
• CHECK THE CLEANING OF EXHAUST circuit FROM DUST
EVERY 900 HOURS

• Replace the Poly-V alternator belt (Or every 2 years, whichever occurs first.)
• CHECK THE CLEANING OF FUEL TANK AND RELATED FILLING PLUG
• REPLACE THE SERVICE INDICATOR ON AIR FILTER
EVERY 1200 HOURS

• Replace engine coolant (Or every 2 years, whichever occurs first.)
EVERY 4000 HOURS

• Partial engine overhaul
• Diesel particulate filter REGENERATION
EVERY 8000 HOURS

• Total engine overhaul
26 Maintenance
R 750
Engine External Views
Exhaust Side View
10
3
6
9
5
8 2
11
. Oil pan
. Hydraulic pump
3. EGR valve and Intake Throttle
4. Turbocharger
5. Exhaust manifold
6. Intake manifold
7. Rear Engine lifting eye
. EGR cooler
9. Water pump pulley
0. Injector
. Crankshaft speed sensor / crankshaft position sensor
Maintenance 27
R 750
Timing Side View
10 9
3
7
5
2
. Crankshaft pulley
. Timing cover
3. Turbocharger
4. Oil filter
5. Automatic belt tensioner
6. Alternator Poly V Belt
7. Water pump pulley
. Alternator
9. Injector
0. Coolant manifold (thermostatic valve housing)
28 Maintenance
R 750
Injection Side View
9
10 8
7
12
11
2 3
. High pressure pump

. Oil filter
3. Oil heat exchanger
4. Starter
5. Rail
6. Oil separator
7. Oil dipstick tube
. Injector
9. Alternator
0. Vacuum pump
. Camshaft sensor
. Oil pressure & temperature sensor
Maintenance 29
R 750
Top Side View
2 1
4 3 14 13
12
11
6
10
8 9
. Intake temperature & pressure sensor

. Intake manifold
3. Oil filler cap
4. Coolant temperature sensor
5. Thermostatic valve housing
6. Poly V belt alternator
7. Alternator
. Vacuumm pump
9. Oil filter housing
0. Oil separator
. Oil dipstick tube
. Injector
3. Rocker arm valve cover
4. Coolant manifold
30 Maintenance
R 750
Engine Oil
Specifications
To help obtain optimum engine performance and to provide maximum protection, the
engine requires engine oil with a rating of ACEA-SAE‑API.
We strongly recommend the use of the following engine oil specifications:
SAE 10W - 40
This oil exceeds requirements for
R750 EURO 4
ACEA
API CI-4
R750 EURO 5
ACEA E6
API CJ-4
IMPORTANT: the engine oil used on R750 EURO 5 engine models is valid on engines EURO 4 too.
Oil Level
IMPORTANT
Two (2) different oil pans, with different oil capacity, are installed on R750
engines.(Refert to Section “Engine Specifications” to determine oil pans capaci-
ties”).
During oil change use the lowest oil quantity for filling the engine until the MIN
level is reached, indicated by oil dipstick MIN mark. If the MIN oil level is not rea-
ched, add oil, 100 - 200 ml at a time for reaching the MIN oil level. Add further oil
quantity (100 - 200 ml at a time) for reaching the MAX oil level.
CAUTION
ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is
restricted by law. Do not spill oil or oil waste into the environment when using or
servicing your engine. Contain and dispose of oil or oil waste as directed by local
authorities.
An overfilled engine crankcase or block can cause a fluctuation or drop in oil pressure.
The over‑full condition results in the engine crankshaft splashing and agitating the oil,
causing it to become aerated. The aerated oil causes a loss of engine performance and
an increase in crankcase back pressure. An extreme overfill condition could result in
large amounts of oil being drawn into the intake.
Checking engine oil level must be done carefully. The oil level must be maintained
between the minimum and the maximum oil level mark on the dipstick. To ensure that
you are not getting a false reading, observe the following before checking the oil level.
• Ensure that the vehicle or the engine at rest in a flat surface.
• Allow five minutes for the oil to drain into the oil pan if the engine has just been opera-
ted or oil has just been added.
Maintenance 31
R 750
Checking
IMPORTANT: Engine crankcase oil must be checked at intervals specified in Maintenance Schedules.
1. Check the engine oil daily before the first start‑up.
CAUTION
Avoid possible injury or damage to the crankcase oil dipstick and internal engine
components. Do not remove the oil dipstick when the engine is running. Stop the engine completely befo-
re removing or inserting the dipstick.
2. If the engine is operating, stop the engine. Allow approximately 5 minutes for the oil to
drain into the oil pan.
3. Remove the dipstick. Wipe the dipstick clean and reinstall it fully into the dipstick tube.
a - Dipstick a
b - dipstick tube
4. Remove the dipstick and observe the oil level. Oil level must be between the marks on the dipstick.
5. Add specified oil to bring the level up to, but not over, the maximum mark on the dipstick.
Refer to “Engine Specifications - Engine oil Capacities” for the oil quantity and oil specifications for qua-
lity.
IMPORTANT
Two (2) different oil pans, with different oil capacity, are installed on R750 engines.(Refert to Section “En-
gine Specifications” to determine oil pans capacities”).
During oil change use the lowest oil quantity for filling the engine until the MIN level is reached, indicated
by oil dipstick MIN mark. If the MIN oil level is not reached, add oil, 100 - 200 ml at a time for reaching the
MIN oil level. Add further oil quantity (100 - 200 ml at a time) for reaching the MAX oil level.
32 Maintenance
R 750
Filling
IMPORTANT: Do not overfill. Refer to “Engine Specifications - Engine oil Capacities” for the oil quanti-
ty and oil specifications for quality.
Two (2) different oil pans, with different oil capacity, are installed on R750 engines.(Refert to Section “Engi-
ne Specifications” to determine oil pans capacities”).
During oil change use the lowest oil quantity for filling the engine until the MIN level is reached, indicated
by oil dipstick MIN mark. If the MIN oil level is not reached, add oil, 100 - 200 ml at a time for reaching the
MIN oil level. Add further oil quantity (100 - 200 ml at a time) for reaching the MAX oil level.
1. Remove the oil filler cap.
a - Oil filler cap

a
NOTE: Always use the dipstick to determine the exact quantity of oil or fluid required.
2. Add the specified oil to bring the level up to, but not over, the maximum mark on the
dipstick.
3. Install the oil filler cap.
Maintenance 33
R 750
Changing—Oil and Filter
Refer to the Maintenance schedule for the change interval.
IMPORTANT: Whenever the engine oil is changed it is necessary to reset the OIL DILUTION CALCU-
LATION function (refer to following paragraph OIL DILUTION CALCULATION).
IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows more
freely, carrying away more impurities. Use only specified engine oil (refer to Engine Specifications - Engi-
ne Oil Specifications).
1. Start the engine and allow it to reach normal operating temperature.

2. Stop the engine and allow approximately 10 minutes for the oil to drain into the oil pan.
3. remove the oil dipstick and remove oil filler cap
4. Remove the threaded plug from the oil pan.
CAUTION
ENVIRONMENTAL HAZARD! Discharge of oil or
oil waste into the environment is restricted by law.
Do not spill or discharge oil or oil waste into the
environment when using or servicing your boat.
Contain and dispose of oil or oil waste as defined
by local authorities.
a - Oil filler cap b

b - Threaded plug
oil dilution calculation

Whenever you change the engine oil, you must reset the “Oil dilution calculation” function.
Important: The Oil Dilution Calculation function can be reset with the Diagnostic Tool
To reset of Oil dilution calculation function resto- use the potentiometer accelerator.
red is necessary to use the diagnostic tool. VERIFICATION: if the procedure has been correctly car-
In the absence of diagnostic tool it is possible to reset ried out the engine oil low pressure pilotlight blinks
the function through the following procedure: 3 times by 1 second spaced by 0.5 seconds. On some
. With engine turned off bring the engine start key to vehicles the verification is not feasible.
ON position
. Fully press the accelerator pedal (from 0% to 100%)
3. Wait for 3 secs before leaving it
4. Leave the accelerator pedal up to original position
(0 %) and wait for 3 secs before pressing it again.
The above procedure to points 2, 3, 4 must be carried
out 5 times. On some vehicles the accelerator pedal
procedure is not feasible: in place of pedal accelerator
34 Maintenance
R 750
5 Install the plug with the washer in the oil pan.
Oil sump threaded plug 78.5 Nm
6 Use an appropriate device to loosen the oil filter cartridge.

7 Remove the oil filter cartridge.
8 Disconnect and properly dispose of the old oil filter a - Device
element. Discard the old O‑ring from the oil filter. b - O‑ring
c - Filter element
9. Install the new O‑ring. Apply lubricant engine oil to
the O‑ring.
10. Thread the new filter element into the oil filter
housing.
IMPORTANT: Over tightening the oil filter will

cause deformation resulting in oil leakage. b
Oil filter cartridge 12.7 Nm
c
11. Turn the oil filter until the sealing surface contacts
the housing.
12. Torque the oil filter using an appropriate socket.
13. Refill the engine with new engine oil.
a
Refer to Filling.
14. Start the engine and check for leaks
Maintenance 35
R 750
Coolant
Specifications
CAUTION
Propylene glycol, alcohol or methanol based antifreeze is not recommended for
use in the closed cooling system.
Use only de‑ionized or distilled water to dilute the antifreeze if it is not pre‑diluted.
Diesel engines are high compression engines and create higher engine operating
temperatures. The closed cooling system and engine must remain as clean as possible to
provide adequate engine cooling. Adequate engine cooling can only be assured by using
the proper antifreeze and water. VM Motori recommends that the closed cooled section
of the closed cooling system must be filled with a low‑silicate formula of ethylene glycol
antifreeze in solution with deionized or distilled water. A low‑silicate formula prevents anti-
freeze separation, which causes a silicate gelatin to form.
This gelatin will block engine and heat exchanger passages causing the engine to ove-
rheat.
The coolant, if not premixed, should be mixed, using antifreeze and deionized water, be-
fore being added to the closed cooling system. Common tap water or softened water con-
tains unwanted minerals, which can leave deposits in the system that reduce the efficien-
cy of the cooling system. The closed cooled section of the closed cooling system should
be kept filled year‑round with an approved antifreeze‑coolant solution. Do not drain the
closed cooled section for storage because draining will promote rusting of internal surfa-
ces. If the engine will be exposed to freezing temperatures, ensure that the closed cooled
section is filled with a properly mixed antifreeze‑coolant solution to protect the engine and
the closed cooling system to the lowest temperature to which they will be exposed.
IMPORTANT: The antifreeze‑coolant used in these engines must be a low‑si-

licate ethylene glycol, containing deionized, purified water. Using other types of
engine coolant may cause fouling of the heat exchangers and overheating of the
engine. Do not combine different types of coolants without knowing that they are
compatible. Refer also to the coolant manufacturer’s instructions.
VM Motori approves this type of antifreeze-coolant solution:
Solution 50% Antifreeze + 50% Antifreeze meets the following industry

de‑ionized or distilled specifications: ASTM D 3306
water

Refer to Maintenance Schedules for change intervals.

Refer to Engine Specifications - Coolant System/Capacities for capacity
36 Maintenance
R 750
Checking the level
CAUTION
Avoid serious injury from burns. Do not remove the
coolant cap when the engine is hot. Coolant may
discharge violently.
IMPORTANT: Check engine coolant before star-

ting the engine, when the engine is cold.
1. Allow the engine to cool.
2. Remove the pressure cap from the coolant expansion
tank or radiator and observe the coolant level.
3. The coolant level in the radiator should be kept at a - Pressure cap
the bottom side of the pressure cap neck. If the vehicle d - Radiator
is equipped with an expansion tank the coolant level
should be kept between the upper (MAX) and lower
(MIN) marks.Please refer to the user manual of the
vehicle.
4. If the coolant level is correct, install the pressure cap.
a
5. If the coolant level is low, add the specified coolant.
Refer to Filling or Capacities for coolant quantity.
6. Install the pressure cap.
Filling the Closed Cooling System

1. Remove the pressure cap with the engine is cold.
IMPORTANT: Use only the specified coolant. (Refer to Coolant specifications)

2. If the coolant is being replaced or the level is low, slowly add the specified coolant to the level indicated in sec-
tion “Checking Level”.
CAUTION
Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there
is sufficient coolant always available before operating the engine every day.
3. Do not install the pressure cap. Start and operate the engine at fast idle (1500‑1800 RPM). Add coolant if neces-
sary to maintain the coolant at the level specified previously.
IMPORTANT: When installing the pressure cap, be sure to tighten it securely to avoid coolant loss.
4. Install the pressure cap after the engine has reached normal operating temperature (thermostat fully open), and
the coolant level remains constant, as specified previously (Refer to Engine Specifications).
5. Test the engine operation. Observe the temperature gauge and check the engine for coolant leaks. If the tempe-
rature gauge indicates excessive temperature or coolant leaks exist, stop the engine immediately and inspect for
the cause.
6. After the first operation, allow the engine to cool.

7. Remove the pressure cap and add the specified coolant to the level indicated in section “Checking Level” .
8. Install and securely tighten the pressure cap.
Maintenance 37
R 750
Draining the Closed Cooling System
CAUTION
ENVIRONMENTAL HAZARD! Discharge or oil, coolant, and other engine and drive
fluids into the environment is restricted by law. Do not spill or discharge oil, coo-
lant, and other engine and drive fluids into the environment when using or servi-
cing your vehicle. Contain and dispose of oil, coolant, and other engine and drive
fluids as defined by local authorities.
WARNING
Avoid personal injury and burns from hot engine coolant. Allow the engine to cool
down before removing the coolant pressure cap. A sudden loss of pressure could
cause hot coolant to boil and discharge violently.
1. Allow the engine to cool.

2. Remove the pressure cap from the coolant expansion tank or radiator.
NOTE: Drain coolant into a suitable container. Dispose of old coolant properly.
3. Loosen the radiator drain plug or tap. If the plug/tap is not present, remove lower rub-
ber pipe from radiator.
a - Coolant pressure cap

b - Drain plug/tap
4 After the coolant has drained completely, close the radiator drain valve or install the
rubber pipe in the radiator. Tighten all drain plugs and drain valves securely.
5. If required, clean the closed cooling system. Refer to Cleaning the Closed Cooling
System.
6. Fill the system with the specified coolant. Refer to Filling.
Cleaning the Closed Cooling System

Closed cooling section of closed cooling system must be cleaned in accordance with the
maintenance scheduled intervals or whenever decreased cooling efficiency is experien-
ced.
38 Maintenance
R 750
Air Filter Element
r 750 eu4
NOTE: To remove the air filter element, refer to the vehicle manufacturer’s
instructions.
r 750 eu5
A air filter box a

B air mass flow meter
Slacken the clamps C.
Remove the cover D.
Maintenance 39
R 750
Replace the main air filter cartridge A.
R 754 EU5
On R 756 EU5 engine model it is needed to pull the

orange handle as shown in the picture. Remove the air R 756 EU5
filter cartdridge from the box.
UNLOCK
R 756 EU5 a
Replace the main air filter cartdridge A.
40 Maintenance
R 750
Replace the secondary (pre-filter) air filter cartridge B.
b
NOTE: After having replaced the main cartrid-
ge (A) two or three times, it is important to replace
the cartridge (B), as well.
Clean the CYCLON area.
CYCLON area
Maintenance 41
R 750
Fuel System
General Information
WARNING
Always disconnect battery cables from battery before working on fuel system to
prevent fire or explosion.
WARNING
FIRE AND EXPLOSION HAZARD: Fuel leakage from any part of the fuel system
can be a fire and explosion hazard which can cause serious bodily injury or death.
Careful periodic inspection of entire fuel system is mandatory, particularly after
storage. All fuel components should be inspected for leakage, softening, harde-
ning, swelling or corrosion.
Any sign of leakage or deterioration requires replacement before further engine
operation.
WARNING
IMPORTANT: Use of improper or water‑contaminated diesel fuel can cause
serious engine damage. Use of improper fuel is considered misuse of the engine,
and the resulting damage will not be covered by warranty.
specifiCations
The engine has been designed to be powered by standard fuel (conforms to
specifications DIN EN 590) available on the European market. If it is to be powe-
red by BIODIESEL fuels (conforms to specifications UNI EN 14214), it can be
mixed, up to 5%, with fuel (conforms to specifications DIN EN 590) available on
the European market. About R750 engine models use only fuel with low content
of sulphur (not above 10-50ppm)
Diesel Fuel in Cold Weather

Unaltered diesel fuels thicken and gel in cold temperatures unless they are treated. Vir-
tually all diesel fuels are climatized to allow their use in a particular region for that time
of the year. If it becomes necessary to treat the diesel fuel further, it is the owner’s and
operator’s responsibility to add a commercial standard brand anti‑gel diesel fuel additive
according to product directions.
No liability can be accepted by the VM Motori for any malfunction or engine dama-
ge, caused by the use of diesel fuel additive and the resulting damage will not be
covered by warranty.
42 Maintenance
R 750
Fuel Filter
Draining
The water‑separating fuel filter can be drained of water and small dirt particles by opening the water drain cap
(bleed valve).
IMPORTANT: To ensure complete draining in warm weather, open the water drain cap before starting
daily operations. In cold weather, when there is a possibility that the condensed water will freeze, drain
the filter shortly after the end of daily operations.
NOTE: Place a suitable container under the fuel filter to catch contaminated fuel or water.
1. Using a suitable container to catch contaminated fuel or water, open the drain cap at
bottom of the filter.
2. Drain the fuel filter until the fuel is clear in appearance.
3. Close the drain cap
4. Fill the water‑separating fuel filter if the fuel has heen completely drained from the filter. Refer to Filling.
a - Fuel filter
b - Drain cap
Filling & air bleeding

Follow this procedure after installing a new filter or after the fuel has been completely
drained from the filter when checking for water.
1. Loosen the air vent (bleed) screw on fuel filter header assembly.
NOTE: The fuel filter is equipped with a primer plunger on the fuel filter header to assist in filling the
fuel filter.
2. Move the primer plunger up and down repeatedly. The filter is
full when an air‑free stream of fuel flows from the air vent screw.
3. Securely tighten the air vent screw. b
4. Start the engine and check for fuel leaks. Stop the engine
immediately if a fuel leaks
exist. Recheck the installation of the fuel filter.
a
WARNING
Ensure that no fuel leaks exist before closing the engine
hatch.
a - Air vent (bleed) screw

b - Primer Plunger
Maintenance 43
R 750
Removal
CAUTION
Absolute cleanliness is required for work on the fuel system, since the injection pump and fuel injectors
have very close tolerances. Even minute particles of dirt or small amounts of water can impair the func-
tion of the fuel injection system.
1. Disconnect both battery cables from the battery.

2. Unplug the Water In Fuel ( WIF) sensor wire from the drain cap.
a - Drain cap
b - WIF sensor wire
IMPORTANT: The water‑separating fuel filter must be replaced; it cannot be cleaned and reused.
3. If the locking ring is present, loosen it and remove the filter. If is not present, remove by hand or using a com-
mercial device the water‑separating fuel filter.
a - Water separating fuel filter

b - Locking ring a
Installation
1. Lubricate the fuel filter seal with engine oil.

2. Fill the new water‑separating fuel filter pouring new fuel.
3. Align the fuel filter to the fuel filter header assembly.

Hand tighten the filter to secure the filter to the header assembly.
Do not use a filter wrench. Continue with Filling and Air Bleeding of fuel Filter.
4. Connect the water in the fuel sensor connector and the battery cables.
5. Start the engine and check for fuel leaks.
Stop the engine immediately if fuel leaks exist .

Recheck the fuel filter installation.
44 Maintenance
R 750
alternator Belt / Poly - V (Serpentine)
Inspection
1. Inspect the belt for proper tension and for the following:
• Excessive wear
• Cracks
• Fraying
• Glazed surfaces
NOTE: Minor, transverse cracks (across the belt width) may be acceptable.
Longitudinal cracks (in the direction of belt length) that join transverse cracks
are NOT acceptable.
2. Check the operation of the automatic tensioner and

associated components.
a. Position a suitable tool in the automatic tensioner
release slot.
b. Rotate the automatic tensioner, in the direction of
the arrow.
c. Release the automatic tensioner and allow it to glide
back slowly.
d. The automatic tensioner must return to the initial
position and hold tension on the
serpentine belt.
b
a - Automatic tensioner
b - Release slot a
Maintenance 45
R 750
Replacement - Installation b
IMPORTANT: If a belt is to be reused, it should
be installed in the same direction of rotation as
when first used.
1. Position a suitable tool in the automatic tensioner

release slot.
2. Rotate the automatic tensioner, in the direction of c
the arrow, to remove the tension on the serpentine
belt.
a - Serpentine belt
b - Tensioner release slot a
c - Hole
d - pin
3. Install a pin into the tensioner hole to block the

tensioner rotation.
4. Before removing the serpentine belt note its position
on the alternator, and idler pulleys.
5. Replace the serpentine belt.
6. Install a new belt if required.
IMPORTANT:Carefully remove the pin and re-

lease the automatic tensioner with the breaker bar,
ensuring that the belt stays positioned properly on
the alternator and idler pulleys races.
a
IMPORTANT: For a correct alignment of the
serpentine belt it must be stay positioned on the a1
inner races of the alternator and idler pulleys
a - alternator pulley
b - idler pulley
a1 - alternator pulley outer races remaining
b1 - idler pulley outer race remaining
a1
b
b1 b1
46 Maintenance
R 750
Diesel Particulate Filter (DPF) - r 750 euro 4
Introduction
Diesel particular filters remove particulate matter and inorganic ash from diesel exhaust. Under normal operating conditions the
filters collect and burn particulate matter. However, inorganic ash, from the oil does not burn, so it slowly accumulates in the
filter. This necessitates periodic ash removal from the filter.
This document provides guidelines for ash removal from DPF particulate filter. Following these guidelines maintains filter per-
formance, and trouble free operation.
Cleaning Interval
Refer to Maintenance scheduled intervals. Some applications, including older higher emission engines, may require more
frequent cleaning.
Customers utilizing a backpressure monitor / dashboard MIL will be notified by the alarm system that cleaning of a DPF filter is
required.
Service Record
Customers are required to maintain proper record of the DPF filter service and cleaning. This record should include the fol-
lowing information:
- Date of installation of filter
- Vehicle operating hours at the time of installation
- DPF filter part number and serial number
- Date and vehicle operating hours for each filter cleaning
IMPORTANT: every time the DPF filter comes cleaned it is necessary to clean the pressure sensor
lines (lines between pressure sensor and DPF filter).
Clean the lines as follows:

1. mark each line (the pressure lines have different diameter)
2. disconnect the lines
3. blow with compressed aria in the lines (blow towards DPF filter, see arrows for orientation)
Maintenance 47
R 750
Cleaning Process through “dry com-
pressed air”
safety Equipment Required
- A source of compressed dry air (80-100 psi / 5.5-7 bar) with
a standard shop air-gun
- Dust mask, gloves, safety glasses should be worn during
the cleaning.
- An industrial vacuum cleaner or a dust/ash collecting device
Cleaning Process through “heating in electrical

oven”:
- Electrical Oven (see specific technical procedure)
Before removing the DPF filter centerbody for cleaning, mark

the exhaust side (outlet) of the filter. Remove the centerbody.
Using compressed dry air on the outlet side and a vacuum
on the inlet side, from a distance approximately of 10 cm
blow air (5.5-7 bar) through the filter allowing the vacuum
cleaner to collect the ash. Alternatively, connect the inlet
side of the filter to a dust/ashcollecting device. Make sure to
move the gun slowly, directing air into each individual cell for
better results.
Continue this process for approximately 30-40 min. Avoid
direct contact of the air nozzle with the filter surface. Larger
filters generally require longer cleaning time.
Install the DPF filter centerbody on the vehicle in the rever-
sed flow direction from which it was removed.
The side with the mark should become the inlet side.
It is not recommended cleaning of DPF filters with steam and
/ or other detergents. Use of these products may damage
and / or deactivate the filters.
CLAMP CLAMP
CENTER BODY
INLET
OUTLET
CENTER BODY CORPO CENTRALE

INLET CENTER BODY
OUTLET
CENTER BODY
30 Nm
~ 10 cm
48 Maintenance
R 750
Cleaning Process using an “electri-
cal oven”
WARNING
Before removing the DPF filter centerbody for cleaning, mark
In certain conditions it could be necessary to clean the filter
the exhaust side (outlet) of the filter.
earlier than normal scheduled maintenance interval filter
Put the DPF center body into the electrical oven.
cleaning, as in event of faster soot accumulation with con-
Follow the heating steps, shown in this chart:
sequent clogging of the filter. This higher soot accumulation
can happen in case of failure of some engine component
STEP TEMPERATURE DURATION RAMP SHAPE (i.e. EGR locked open) or in case of engine particular use:
°C (min) always very low load duty cycle, low idle for very long time,
start ambient into oven / / increasing etc. In this case the MIL lamp will switch on.
1 0 - 200 60 min linear 10°C / min The DPF diesel particulate filter may result in a faster clog-
ging and higher soot accumulation if the outlet pneumatic
2 200 - 500 120 min linear 5°C / min
connections or actuators electrical connections of the intake
3 500 - 600 30 min linear 2°C / min throttle valve and EGR valve are exchanged (see “Intake
4 600 360 min constant Throttle Valve Section”). Before removing any connections
5 600 - 500 30 min linear from above mentioned components, it is recommended to
apply a label on them.
6 500 - 200 120 min linear
7 200 - 120 60 min linear
Ash Removal
8 120 60 min constant
Disposal of ash should be in accordance with all local laws
9 switch off / / and regulations.
Remove the DPF center body from the oven.

Install the DPF filter centerbody on the vehicle in the rever-
sed flow direction from which it was removed.
The side with the mark should become the inlet side.
It is not recommended cleaning of DPF filters with steam and
/ or other detergents. Use of these products may damage
and / or deactivate the filters.
IMPORTANT
The DPF filter cleaning carried out by electrical oven is
deeper that compressed air cleaning.
On engine models EURO 4, at the end of every DPF
cleaning process (compressed air or electrical oven), is
necessary to let start the process “service self regene-
ratio” through the diagnostic tool (Refer to the Special
Tools section).
Whenever exist:
• un evident damage of the turbocharger with conse-
quent engine oil at the exhaust
or
• engine oil in intake system
it is required to clean the DPF filter with electrical oven.
IMPORTANT
DPF Diesel Particulate Filter does not require any
additional maintenance other than routine cleaning. If
the unit does become plugged, the centerbody can be
removed and cleaned or replaced.
Engine maintenance procedures must be followed to
ensure proper DPF filter operation.
Oil consumption that exceeds engine specification will
increase the required cleaning frequency.
Whenever the DPF is disassembled replace the clamps
and ring spacers.
DPF Filter Clamp torque screws 30 Nm
Maintenance 49
R 750
Diesel Particulate Filter (DPF) - r 750 euro 5
IMPORTANT: the DPF filter is not serviceable.
It is necessary to launch the service regeneration through the diagnostic tool in order to clean the DPF filter. It is pos-
sible to clean the DPF filter also through compressed air: refer to Section DIESEL PARTICULATE FILTER R 750 EURO
4 - CLEANING PROCESS USING COMPRESSED DRY AIR
R 754 EU5
delta p sensor point
SENSORE DIFFERENZIALE DI PRESSIONE SCARICO
GAS INLET
ENTRATA GAS
Exhaust gas tempemperature sensor point GAS OUTLET

SENSORE TEMPERATURA GAS SCARICO USCITA GAS SCARICO
R 756 EU5
delta p sensor point

SENSORE DIFFERENZIALE DI PRESSIONE SCARICO
GAS INLET
ENTRATA GAS
Exhaust gas tempemperature sensor point GAS OUTLET

SENSORE TEMPERATURA GAS SCARICO USCITA GAS SCARICO
50 Maintenance
R 750
Extended Storage
Storage Information
VM Motori engines are shipped from the factory with a sufficient preservation for a 6 (six) months shelf life.
Each time the storage procedure is performed the “shelf life” will be extended for six months. The procedure should
be performed 30 days of the expiration of VM Motori’s preservation or the current protection.
When the engine is being not operated for short periods of time, less than one month, it is advisable to start the
engine and operate until it reaches normal operating temperature at least once per month.
The engine must always be started and operated until it reaches normal operating temperature once per month if it
is installed for emergency purposes.
When the engine is being not operated for long periods of time, such as one month or more, up to six months, it is
needed to carry out a specific treatment to protect it for 6 months.
If the engine remains not operating for a further period of time, check the need to repeat the protective treatment to
extend the protection for other 6 months. (Refer to Preparing the Engine for Extended Storage - Engine Protective
Treatment)
Preparing Engine For Extended Storage *

To prepare the engine for extended storage, follow this procedure:
1. Check for external damages.
2. Remove any cap or protection tape.
3. Check alternator belt tension.
4. Check the air cleaner.
5. Fill the engine to the proper level with preservative lubricating oil MIL-L-21260C, Grade 2.
6. Connect the engine (not for air cooled type *) to an auxiliary radiator, if not existing, and fill with specific solution,
water and antifreeze (see coolant specification).
7. Prepare in a portable container a mixture of regular fuel and 10 % preservative oil type Castrol Safecoat DW30X
or Rustilo 181 or DWX31
8. Prepare an auxiliary battery and connect to the engine.
9. Start the engine.
10. Operate the engine for five minutes at idle and then at about ⅓ of max rpm until normal temperature is reached
(70°C ÷ 80°C or 158°F ÷ 176°F) for water cooled engines; in the case of air cooled engine operation, perform the
same test for twenty minutes.
11. Stop the engine.
12. Drain the cooling system.
13. Drain the preservative oil from the engine.
14. Drain the fuel system.
15. Loosen the v-belt driving the alternator.
16. Disconnect the engine from all auxiliary devices useful to the test.
17. Seal all engine openings including the exhaust outlet, with moisture resistant tape. Use cardboard, plywood or
metal cover where practical.
18. Clean and dry the exterior painted surfaces of the engine and spray with a suitable liquid automobile body wax,
a synthetic resin varnish or rust preventive compound.
19. Apply a rust preventive compound to all exposed engine part and to the flywheel.
20. Protect the engine with a good weather-resistant tarpaulin and store under cover, in a dry building.
NOTE: Plastic may be used for indoor storage.

Moisture absorbing chemicals are available commercially for use when dampness prevails in the storage area.
Outdoor storage of engines is not recommended.
*) Coolant related procedures not to be applied for air-cooled engines.
Restoring An Extended Storage Engine

Use the following procedure to restore an engine that has been in extended storage.
1. Remove the covers and tape from all of the openings of the engine and electrical equipment.
2. Remove the plugs from the inlet and outlet fuel lines and connect the lines to their proper position.
3. Wash the exterior of the engine with fuel oil to remove the rust preventive. (Do NOT wash the electrical components.)
4. Remove the rust preventive from the flywheel.
5. Tighten the belt to proper tension.
6. For fluid filling, installation and preparing the engine for the use, refer to herein instruction.
7. Check for any coolant or oil leakage at the first running in.
Maintenance 51
R 750
ENGINE lifting eye bracket
Place the lifting device as shown in the figure.

Loosen the screws (A) and disassemble the side supports
(B).
Move the engine to the installation area.
Further information are available inside the owner manual or
installation manual.
A
B
a - lifting eye bracket screw (front side)
lifting eye bracket (front side) 27.5 Nm
b - lifting eye bracket nut (rear side) b

lifting eye bracket (rear side) 32.4 Nm
a
52 Removal and Installation

R 750
FASTENER TIGHTENING SPECIFICATIONS

COMPONENT Nm SYSTEM
center main bearing carrieRs - bolts 44,1 ENGINE BLOCK
OIL DELIVERY TO main bearing carrieRs - SPECIAL SCREW ON BLOCK 53,9 ENGINE BLOCK
CAMSHAFT FLANGE - SCREW 27,5 ENGINE BLOCK
OIL PISTON COOLING JET - SCREW 12,7 ENGINE BLOCK
IDLER GEAR (BEETWEN CAMSHAFT AND CRANKSHAFT GEARS) - BOLT 32,4 TIMING SIDE
IDLER GEAR (BEETWEN CAMSHAFT AND INJECTION PUMP GEARS) - SCREW 35 TIMING SIDE
OIL PUMP - SCREW 27,5 TIMING SIDE
COOLANT PUMP - SCREW 32,4 TIMING SIDE
CRANKSHAFT FRONT HUB - NUT SEE PROCEDURE TIMING SIDE
CRANKSHAFT FRONT PULLEY - SCREW 45,1 TIMING SIDE
RAIL - SCREW SEE PROCEDURE INJECTION SIDE
RAIL BRACKET - SCREW SEE PROCEDURE INJECTION SIDE
INJECTOR - CLAMP SCREW SEE PROCEDURE INJECTION SIDE
HIGH PRESSURE INJECTION PUMP - FLANGE NUT 27,5 INJECTION SIDE
HIGH PRESSURE INJECTION PUMP GEAR - NUT 86,3 INJECTION SIDE
ENGINE OIL HEAT EXCHANGER (MODINE) - BOLT 60 INJECTION SIDE
OIL FILTER HOUSING - BOLT 39,2 INJECTION SIDE
COOLANT MANIFOLD - SCREW 11,8 INJECTION SIDE
OIL DELIVERY PIPE TO ROCKER ARM - HOLLOW BOLT ON CYL. HEAD 14 INJECTION SIDE
OIL DELIVERY PIPE TO ROCKER ARM - HOLLOW BOLT ON CRANCASE 23,5 INJECTION SIDE
EXHAUST MANIFOLD - NUT 32,4 EXHAUST SIDE
INTAKE MANIFOLD - NUT 27,5 EXHAUST SIDE
TURBOCHARGER - NUT 32,4 EXHAUST SIDE
OIL DELIVERY PIPE TO TURBOCHARGER- HOLLOW BOLT ON TURBO FLANGE 24,5 EXHAUST SIDE
OIL DELIVERY PIPE TO TURBOCHARGER - NUT ON BLOCK 32,4 EXHAUST SIDE
EGR HEAT EXCHANGER (INSTALLED ON HOUSING) - SCREW 10,8 EXHAUST SIDE
EGR HEAT EXCHANGER (INSTALLED ON BLOCK) - SCREW 32,4 EXHAUST SIDE
EGR HOUSING HEAT EXCHANGER (INSTALLED ON EXHAUST MANIFOLD) - NUT 32,4 EXHAUST SIDE
ASSEMBLY EGR & INTAKE THROTTLE VALVE - SCREW 10,8 EXHAUST SIDE
ELBOW ASSEMBLY EGR & INTAKE THROTTLE VALVE - SCREW 10,8 EXHAUST SIDE
VACUUM PUMP OIL DELIVERY PIPE - HOLLOW BOLT (ON BLOCK) 27,5 ENGINE ELECTRICAL
ALTERNATOR - NUT 45,1 ENGINE ELECTRICAL
ALTERNATOR IDLE PULLEY 80 ± 5 ENGINE ELECTRICAL
STARTER MOTOR - BOLT 83,4 ENGINE ELECTRICAL
VACUUM PUMP OIL DELIVERY PIPE - HOLLOW BOLT (ON VACCUM PUMP) 24,5 ENGINE ELECTRICAL
REAR MAIN BEARING CARRIER - NUT 24,5 FLYWHEEL SIDE
FLYWHEEL HOUSING - SCREW 68,6 FLYWHEEL SIDE
FLYWHEEL SEE PROCEDURE FLYWHEEL SIDE
OIL FILTER 12,7 MAINTENANCE
CONNECTING ROD - SCREW SEE PROCEDURE BASIC ENGINE
CYLINDER HEAD SEE PROCEDURE BASIC ENGINE
ROCKER ARM - NUT 29 BASIC ENGINE
GLOW PLUG OR PLUG 14,2 BASIC ENGINE
ALTERNATOR BRACKET - SCREW 68,6 REMOVAL & INSTALLATION
FRONT ENGINE LIFTING BRACKET (INSTALLED ON ALTERNATOR BRACKET) 27,5 REMOVAL & INSTALLATION
REAR ENGINE LIFTING BRACKET (INSTALLED ON EXHAUST MANIFOLD) 32,4 EXHAUST SIDE
Fastener Tightening Specifications 53

R 750
special tools
VM code Description Picture
68400012A Cylinder liner extractor
68400015A Crankshaft and camshaft

bearing remover/installer
68410006A Crankshaft
assembly tool
68410012F Assembly/disassembly
Hydraulic tappets tool
68420016F XZN wrench for cylinder

head bolt (12 mm)
68420015F XZN wrench for cylinder
head bolt (14 mm)
68420019F Angular torque wrench
68460003A Cylinder head assembly

dowels
54 Special Tools
R 750
68480003A Flywheel ring gear clamp (to
be installed in place of starter
motor)
68490007A Cylinder liner protusion

gauge
68460005F Pins for flywheel assembly
68400038F Crankshaft gear extractor for

engines with cylindrical
crankshaft end
68500010F R750 EURO 4

R750 EURO 5
R750 IE3
Diagnostic tool
---------------------------------------
The software updating

is available on VM Motori
web site, Customer Reser-
ved Area “EXTRANET”
Special Tools 55
R 750
68410013G Front Oil Seal Installer
68400040F Injector Remover (Complete)

68400046F Body
68400044F Stud
68400045F Fork R750 EURO 4 / IE3
68400045G Fork R750 EURO 5
68410010F Rear Oil Seal Installer
68480013F Counter balancing crankshaft

pins (only for engines where
the counter weight balance is
installed)
6844009F Cylinder head seal hydraulic

68440010F test
Cylinder head seal test with
hydraulic O-rings
56 Special Tools
R 750
68420022F Alternator idle pulley remover
68490038F
ONLY FOR R750
EURO 4
Owen for DPF Filter cleaning

3kW - 220V
Test Engine harness
68490035F (without potentiometer acce-

lerator and ECU)
68490036F (with potentiometer accelera-

tor and without ECU)
68490037F (with potentiometer accelera-

tor and with ECU)
68490034F engine compression adapter
tester tool
Break out box
68500017F (without jumpers)

68500016F (complete of jumpers)
Special Tools 57
R 750
Timing Side
. Timing cover (metal sheet)

. Crankshaft pulley
3. Belt Tensioner
4. Plastic Idler pulley
5. Coolant pump pulley
6. Metal idler pulley
7. Alternator 7
. Poly - V alternator belt 8
6
5
2 3
4
58 Timing Side
R 750
Timing Gears
. Crankshaft gear
. Oil pump gear
6
3. Idler gear
4. Camshaft gear
5. Idler gear
5
6. Injection pump gear
7. Hydraulic pump gear
7 4
. Gear driving oil pump

gear (crankshaft gear
not visible)
6
. Oil pump gear
3. Idler gear
4. Camshaft gear
5. Idler gear 5
7
6. Injection pump gear 4
7. Hydraulic pump gear
Timing Side 59
R 750
Timing gears with cylinder number 1 piston is at compression stroke TDC.
Timing reference punched dots
camshft gear
hydraulic pump
gear
idler gear
crankshaft gear
camshft gear
idler gear
idler gear
crankshaft
gear
60 Timing Side
R 750
1 - Oil pump gear

2 - Crankshaft gear
3 - Idler gear
4 - Camshaft gear
5 - Idler gear
6 - High pressure injection pump gear
timing reference marks - punched dots on the gears

segni di riferimento per la fase - punti punzonati sugli ingranaggi
5
4
Timing Side 61
R 750
Oil pump
Removal
• Remove the gear driving the oil pump gear.

• Remove the 3 screws with washers (Note bolts
position).
• a - gear driving the oil pump gear

• b - oil pump and its gear
• c - screws with washers
a
Cleaning
1. Disassemble and wash all parts in cleaning solvent. b
2. Put on safety glasses and dry parts with compressed air.
c
Inspection
1. Inspect the oil pump shaft, rotors, and housing for
excessive wear or damage. Replace the oil pump assembly
if excessive wear or damage is found. a
2. Check clearance between the inner and outer oil pump

rotors.
3. Check clearance between the outer rotor and housing.
4. Check the outer and inner rotor end float (reentering of
outer rotor from oil pump body).
b
5. If the measured values are greater than specified, the
pump is faulty and must be replaced as a complete unit.
6. Check the rotor and gear coupling rolling torque.
c
62 Timing Side
R 750
Specifications
a - Shaft f - Difference between height of inner rotor and outer rotor
seat (Reentering of outer rotor from pump body - see picture
b - Inner rotor
below)
c - Outer rotor
g - Rotor housing
d - Clearance between rotors (see outer rotor)
e - Clearance between housing and outer rotor (see pump
housing)
0.030 - 0.087
mm
1 - Oil pump gear
2 - Rotor housing
3 - Outer rotor
4 - Inner rotor
5 - Shaft
Axial clearance between gear and pump body 0.150 ‑ 0.250 mm

Rotor and gear coupling rolling torque resistance 9 kgm
Difference between height of inner rotor and outer rotor seat 0.030 - 0.087 mm
Timing Side 63
R 750
Outer rotor
R754 EURO 4-5
a- 57.95 - 58 mm
b- 49.3 - 49.4 mm
Heigh of outer rotor: 32.483 - 32.5 mm b
R756 EURO 4-5
a- 57.95 - 58 mm
b- 49.3 - 49.4 mm
Heigh of outer rotor: 37.983 - 38 mm
c - Clearance between rotors 0.07 - 0.20 mm

c
Inner rotor
a
a 25.92 - 25.97 mm
b 41.12 - 41.15 mm
c 32.045 - 32.075 mm
Heigh of inner rotor:
R754 32.483 - 32.5 mm b
R756 37.983 - 38 mm
64 Timing Side
R 750
oil Pump body
R754 EURO 4-5
a - Inside diameter of rotor housing 58.13 - 58.18 mm

Clearance between housing and 0.13 - 0.23 mm
outer rotor
b - Rotor seat depth in housing 32.53 - 32.57 mm
c - depth 22.06 - 22.10 mm
R756 EURO 4-5
a - Inside diameter of rotor housing 58.13 - 58.18 mm a

Clearance between housing and 0.13 - 0.23 mm
outer rotor
b - Rotor seat depth in housing 38.03 - 38.07 mm
c - depth 22.06 - 22.10 mm
oil Pump housing into crankcase
Timing Side 65
R 750
Installation
• Lubricate the oil pump rotor housing and the inner and outer rotor surfaces with engine oil.
• Install the bevelled (chamfered) end of the outer rotor towards the seat (the inside) of the rotor housing.
• Install the 3 screws and spring washers into the mounting holes in the oil pump. Install the oil pump in the cylinder block.
• Torque the 3 oil pump screws evenly in a diagonal pattern.
Oil pump screws 27.5 Nm

• Install the gear driving the oil pump gear by aligning the keyway gear with the crankshaft key and the side with flange must
be pointed toward the crankshaft gear. The flat surface of the gear must be pointed towards outside.
• Check that the oil pump gear is not in a bind by ensuring that there is some clearance (backlash) between the crankshaft
sprocket and oil pump gear. Verify the installation if no backlash exists between the gears.
• Install the timing gear cover.
• Complete the engine assembly.
• Verify oil pressure and check for leaks when you start the engine.
a - Bevelled (chamfered) end

b - Rotor housing
c - Oil pump screws
flange keyway gear
flange
66 Timing Side
R 750
Crankshaft gear
Removal a
NOTE: Replace the timing gear only if worn or

damaged.
Before removing the gear make the reference marks
on it and idler gear, so that its installation results easier
in order to mantain the gears timing.
Take the oil pump driving gear off.
Remove the oil pump and the idler gear if nedeed. b
Install the Crankshaft Gear Puller onto the gear.
Tighten the four clamping screws securely.
Turn the Crankshaft Gear Puller screw and remove the
timing gear.
a - Crankshaft gear puller with clamping screws

b - crankshaft gear
INStallation
Install the gear by aligning the keyway sprocket with
the crankshaft spline.
Remark new gear making the same reference pre-
viously made on replaced gear and align the reference
marks on the gear with idler gear reference marks, or if
necessary, time the crankshaft gear with the idler gear
and camshaft gear (Refer to Timing gears with cylinder
number 1 piston is at compression stroke TDC.).
NOTE: Before installing the crankshaft gear

on the crankshaft, heat the gear at 70°C and istall it
against crankshaft shoulder keeping it in position
for 10 seconds.
Timing Side 67
R 750
Hydraulic pump Idler gear (between the crankshaft and
camshaft gears)
removal
Remove the 2 idler gear bushing screws.. d - crankshaft gear and idler gear assembly timing
Before removing the gear make a reference mark on all dots aligned (dots punched on the gear)
3 gears, crankshaft, idler and camshaft gear or align the e - Idler gear assembly and camshaft gear timing
3 gears as shown in the picture so that the timing dots dots aligned (dots punched on the gears)
(punched on each gear) are properly aligned, timed. f - timing reference dots punched on the gears (fa-
Remove the idler gear bushing and idler gear assembly. cing outside)
a - Idler gear bushing
b - Idler gear assembly Separate the idler gear bushing from the idler gear
c - Idler gear bushing screw assembly.
Timing gears with cylinder number 1 piston is

e at compression stroke TDC.
timing reference punched dots on the gears
a coated by a dot of felt-tip pen, carried out
during assembling process.
a
c
68 Timing Side
R 750
Installation
Lubricate the idler gear assembly (bearing and idler a
gear bushing and pin shim C).
Install the idler gear bushing into the idler gear assem- b
bly. Verify that the bushing rotates freely.
Ensure that the timing reference dots on the gear are
facing outside, not towards the block.
Install the idler gear assembly. Ensure the timing dots
on the adjacent gears (crankshaft and camshaft gear)
are properly aligned or that the reference marks car-
ried out previously are properly aligned.
Verify that the cut area of the bushing is towards the
crankshaft sprocket so that the oil pump driving gear
fits properly.
Ensure that the tapered side C1 of pin shim ring
C faces the gear, inside engine (only on EURO 5
engine model).
Torque the 2 idler gear bushing screws

X = Idler gear bushing screws 32.4 Nm
c1
specifications c
Inner diameter - Idler gear 53.465 - 53.480 mm

bushing
Inner diameter - Idler gear 53.500 - 53.519 mm
Clerance - Installation 0.02 - 0.054 mm
Wear Limit 0.2 mm a
x - idler gear bushing screws b

b - Idler gear
c - pin shim ring for idle gear (on EURO 5)
c1 - tapered side of pin shim ring
f - timing reference dots punched on the gear (fa-

cing outside)
g - cut area of the bushing is towards the
crankshaft sprocket.
h - oil pump driving gear
Timing Side 69
R 750
x - idler gear bushing screws
b - Idler gear
c - pin shim ring for idle gear (on EURO 5)
c1 - tapered side of pin shim ring
f - timing reference dots punched on the gear (fa-

cing outside)
g - cut area of the bushing is towards the
crankshaft sprocket.
h - oil pump driving gear
h
g f
70 Timing Side
R 750
injection pump Idler gear (between the camshaft and injec-
tion pump gears)
removal
Remove the idler gear fixing screw, at the bottom of
c
the injection pump.
a - Idler gear (between the camshaft and injection b

pump gears) a
b - camshaft gear
c - injection pump gear
d - injection pump
e - idler gear fixing screw
installation
Install the gear between the camshaft gear and injec-
tion pump gear. d
This gear must not to be timed.
Thread the bolt with a new O-ring, grease it with Mo-
liykote 111 grease, and torque the bolt as follows:
1st Step - tightening 35 Nm e

Loosen the bolt by an angle 30° ÷ 90°
between
2nd Step - re-tightening 35 Nm
f - O-ring
g - screw
a
a
f
g g
Timing Side 71
R 750
hydraulic pump gear assembly
removal
Loosen the rear allen screws and remove the rear

flange.
Loosen the front allen screws and remove the cover.
72 Timing Side
R 750
Remove the hydraulic pump sprocket assembly (dri-
ving gear + ball bearing)
Remove the hydraulic pump idler gear
Timing Side 73
R 750
installation
Install the idler gear into the block.
Oil the idle gear shaft
Ensure that the grooves are towards the block
a - groove
Install the hydraulic pump sprocket assembly (gear +

ball bearing) into the block bore.
Oil the outer surface of ball bearing.
Install the front cover by aligning the pins with block

holes.
a - pin
b - Hydraulic pump cover fixing screws
Apply Loctite 572 on the allen screws thread and

torque them.
Hydraulic pump cover 24.5 Nm

fixing screws
a
74 Timing Side
R 750
Install rear flange.
Apply Loctite 572 on threads bolts and torque them.
Rear flange Fixing 19.6 Nm

Screws
Note: install the gasket with the

cut side as showed in the picture
Timing Side 75
R 750
belt tensioner - (automatic type)
removal
b
Remove the alternator belt (Refer to Altenator Belt)
Position a suitable tool in the automatic tensioner
release slot. Move (rotate) in direction of the arrow the
tensioner and align 2 holes.
Insert a pin into to 2 holes to block the tensioner.
Remove the tensioner bolt.
a - Serpentine belt c
b - Tensioner release slot
c - Hole
d - pin
Installation a
b
Align the pin with the drilling in the bracket and install
the automatic tensioner assembly. Torque the automa-
tic tensioner mounting screw.
Tensioner bolt 78.5 Nm
a - drilling
b - pin
c - screw
76 Timing Side
R 750
belt tensioner bracket
removal
Remove the alternator belt and belt tensioner (Refer to

proper section). b
Remove the bolts from the bracket.
installation
Install and torque the bolt at:
a 78.5 Nm
b 44.1 Nm
Timing Side 77
R 750
idler pulleys
removal
Remove the alternator belt. (Refer to alternator belt

section)
Remove the left-hand therad bolt.
a - metal pulley
Installation
Install the bolt (left-hand therad) and torque it
Idler pulley screw 53 Nm
Remove the right-hand therad bolt.
Install the bolt and torque it.
b - Plastic Pulley
b
Idler pulley screw 53 Nm
78 Timing Side
R 750
crankshaft hub and pulley
removal
Remove the alternator belt (Refer to Alternator Belt

section).
a
Install the Flywheel ring gear clamp tool in place of
starter to block the crankshft rotation.
Remove the 6 crankshaft pulley bolts and take the

b
pulley off.
Using a suitable 46 mm socket, remove the left‑hand c

thread crankshaft hub nut.
IMPORTANT: It is also possible take the

crankshaft pulley and hub off as assembly without
removing crankshaft pulley from the hub.
a - crankshaft hub nut d

b - crankshaft pulley
c - crankshaft hub
d - Flywheel ring gear clamp tool
crankshaft hub and pulley as assembly
Timing Side 79
R 750
installation
If the pulley has been removed from the hub, install the
hub on the pulley as shown in the picture.
Make sure that the pulley rim is towards outside. a
a - crankshaft pulley
b - crankshaft hub
c - pulley rim b
80 Timing Side
R 750
Clean contact surfaces between the crankshaft hub
and crankshaft nut with cleaning solvent and dry with
compressed air. c a
Clean the crankshaft threads.
Clean the crankshaft hub surface in contact with the oil
pump gear driving.
If the timing gear cover oil seal has been removed for
replacement, clean the seating surface in the cover.
Front Oil seal and the sealing lip of an oil seal can be
damaged by grease on your hands or the dirt from
gloves. A damaged oil seal or oil seal lip could result in
an oil leak. When fitting or replacing crankshaft hub, do
not touch inside the oil seal or touch the oil seal lip with
your bare hands or with dirty gloves.
Install the Flywheel Holder Tool in place of the starter

motor to block the crankshaft rotation.
a
Apply lubricant “Molykote G Rapid Plus Paste” to
the left‑hand thread crankshaft hub nut threads and on
the crankshaft hub contact side.
Align the keyway of crankshaft hub with crankshaft

spline and finger tighten the left‑hand thread
crankshaft hub nut.
WARNING: the left‑hand thread crankshaft

hub nut must be installed with flange-side towards
crankshaft gear (the inside of engine).
b
TIGHTENING PROCEDURE
Torque the nut at 400 Nm.
Loosen and retorque it at 600 Nm
a - crankshaft hub contact surface (oil pump gear

driving)
b - crankshaft hub keyway
c - crankshaft spline
d - crankshaft hub contact surface (crankshaft nut)
e - left‑hand thread crankshaft hub - flange-side
Install fixing pulley bolts with proper washers and

torque them.
Crankshaft pulley bolt 45.1 Nm
d
Remove the Flywheel Holder Tool.
x - identification mark for left-hand thread nut e
Timing Side 81
R 750
water pump and pulley a
removal
Remove any pipes or rubber hoses from the pump.

Remove the alternator belt (Refer to Alternator Belt
Section).
Remove the water pump pulley screws or water pump b
housing screws to take the water pump assembly off.
a - water pump housing

b - water pump housing screws c
c - water pump pulley screws
Remove the old gasket from the pump housing and

block. Be careful not to gouge or nick the sealing
surfaces.
installation
Inspect the water circulating pump body for blockage,
cracks, sand holes, corrosion or other damage.
Inspect the impeller for cracks, corrosion, or damage.
Inspect the impeller shaft and bearings for excessive
side play, abnormal noise when turning, or wear.
Inspect the pulley for bends, cracks, corrosion, impro-
per runout, or other damage.
Apply sealant Loctite to both sides of the new water

circulating pump gasket.
Install the new water circulating pump gasket on the
engine block.
Torque the 6 water circulating pump flange screws as
shown in the picture.
Torque 3 water pump pulley screws.
water circulating pump flange 32.4 Nm

screws
water circulating pump flanged sup- 32.4 Nm x
port (upper position) fixing screws
water pump pulley screws 27.5 Nm x
x - water pump - upper position
82 Timing Side
R 750
timing gear cover
metal sheet cover
removal
Remove any component that hinder the cover removal.
Remove the fixing bolts around the cover perimeter.
Use a knife to cut the sealant silicon. Detach the cover from crankcase by ensuring do not bend it.
installation
Check the front oil seal for wear or damage. Replace the oil seal if needed. (Refer to Front Oil Seal section).
Remove the old silicon material from the cylinder block and timing gear cover. Be careful not to gouge or nick the
sealing surfaces.
Apply a continuous bead of sealant (silicon type Dow Corning 7091) (as shown in the pictures) along the cover
perimeter, following the races and on the inside of hole bolts as shown.
Align the cover with the pins installed in the block.
Torque the timing gear cover flange screws evenly, in a cross pattern to:
timing gear cover flange screws 12.7 Nm
a - holes
b - races
c - bead of sealant
c
a
Timing Side 83
R 750
front oil seal
removal
IMPORTANT: Oil seals and the sealing lip of an oil seal can be damaged by grease on your hands or the dirt
from gloves. A damaged oil seal or oil seal lip could result in an oil leak. When fitting or replacing an oil seal, do
not touch inside the oil seal or touch the oil seal lip with your bare hands or with dirty gloves.
The seal is made of special compounds; do not touch or handle the lips of the seal. Do not attempt to install front
main seal using a hammer or mallet. Damage to the seal or timing cover could result.
Lubricate the oil seal outer surfaces. Do not touch or handle the lips of the seal.
Install the new front oil seal in the Front Oil Seal Installer.
Torque the screw and the seal will stop when seated.
84 Timing Side
R 750
ExHaust Side
turbocharger
removal
IMPORTANT: In case of failure of turbocharger (seized

bearings, broken shaft, etc.) with consequent oil leakage
from turbocharger exhaust side, evaluate the DPF filter clea-
ning (Refer to Section “Maintenance - DPF Filter”)..
d
Loosen the hollow bolt and hex nut of the oil delivery pipe a
and remove oil delivery pipe.
Loosen the clamp of the oil drain pipe and take it off.
Remove mounting nuts.
Remove the old gasket.
c
a - oil delivery pipe b

b - oil drain pipe (clamp)
c - mounting nuts
d - hollow bolt
e - hex nut
a
Installation
Install a new gasket on the exhaust manifold.
Install the turbo and torque the nuts evenly, in a diagonal e
pattern.
Turbocharger flange nuts 32.4 Nm

Install the oil drain pipe.
Finger tighten the hollow bolt with new washers on the turbo
and hex nut on the block.
Torque the hollow bolt and the hex nut.
Oil delivery pipe hollow bolt 24.5 Nm

Oil delivery pipe hex nut 32.4 Nm
Exhaust Side 85
R 750
egr cooler
removal
Loosen the clamps of the rubber hoses and remove them
from EGR cooler.
Loosen the clamps of the pipe connected to EGR cooler
b
housing and throttle valve.
Remove the pipe.
a - rubber hose (clamp)

b - pipe (clamp)
c
c - EGR cooler
d - EGR cooler housing
e - bolts fixing the EGR cooler assembly to cranckcase a
f - nuts fixing EGR housing to exhaust manifold and the old
gasket.
g - spacer between EGR cooler and crankcase
Loosen and remove the bolts fixing the EGR cooler assem-
bly to cranckcase.
IMPORTANT: Between the EGR cooler and crankcase

a spacer is inserted. Do not forget it during assembling.
Remove nuts fixing EGR housing to exhaust manifold and
old gasket.
d
e
d
d e
86 Exhaust Side
R 750
Loosen the 5 fixing screws and remove the housing from
EGR cooler.
c
IMPORTANT: Never use a caustic cleaning solution,
as it may attack aluminum. Also, never use a wire brush
which could damage blade or mating surfaces.
c - EGR cooler
d - EGR cooler housing with gasket.
Installation
Assemble the EGR cooler assembly by using a new gasket.
x - EGR cooler fixing screw to housing
x = EGR cooler fixing screw to 10.8 Nm x

housing a
Install a new gasket on mating surface of EGR housing coo-
ler and install it in the exhaust manifold studs.
Finger tighten 2 nuts fixing the EGR cooler assembly to
exhaust manifold and bolt fixing EGR cooler assembly to
crankcase.
IMPORTANT: Mind to install the spacer between the

EGR cooler and crankcase.
b
a - nuts fixing EGR cooler assembly to exhaust manifold

with new gasket.
b - bolts fixing the EGR cooler assembly to cranckcase
Torque nuts and bolts as indicate in the table.
a = nuts fixing EGR cooler assembly to 32.4 Nm

exhaust manifold
b = bolts fixing the EGR cooler assembly 32.4 Nm
to crankcase
e
Install a new washers in the collars of the metal pipe clamps.
Install the pipe and torque the screw of the clamps.
e - washer
Install the rubber hoses and proper clamps.
Exhaust Side 87
R 750
intake Throttle / EGR valve & PROPER actuators
removal
WARNING
The DPF diesel antiparticulate filter may result in a FIRE
HAZARD if the inlet/outlet pneumatic connections or actua-
tors electrical connections of the intake throttle valve and
EGR valve are exchanged. Before removing any connec-
tions from above mentioned components, it is recommended
a
to apply a label on them.
Label the pneumatic rubber pipes connected to outlet of

throttle valve and EGR valve.
a - EGR valve (pneumatic oulet)
b
b - Throttle valve (pneumatic oulet) d
These 2 outles are connected to 2 identical modulator va-
cuum sensors and it results very simple to exchange them.
Loosen the bolts fixing throttle valve to intake manifold.
Remove the intake throttle valve and old gasket.
Loosen bolts fixing the throttle valve to elbow and separate
the valve from elbow.
c - bolts fixing the throttle valve to elbow
d - bolts fixing throttle valve to intake manifold
Installation
Take a new gasket and install the throttle valve on the elbow.
Torque the bolts at:
c = bolts fixing the throttle valve to elbow 10.8 Nm

Install a new gasket on elbow mating surface and torque the
bolts at:
d = bolts fixing the elbow to intake manifold 10.8 Nm
88 Exhaust Side
R 750
a - Vacuum pump
c b - Pnuematic outlet from vacuum pump
c - Actuators (c1: EGR valve / c2: Intake throttle valve)
d - Actuators electrical connection (d1: EGR valve / d2:

a Intake throttle valve
e - Intake Throttle valve

e1 - Intake Throttle valve - Pneumatic Inlet (in the valve)
e2 - Intake Throttle valve Pneumatic Outlet from proper
Actuator
f - EGR valve
b f1 - EGR valve - Pneumatic Inlet (NOT VISIBLE)
f2 - EGR valve Pneumatic Outlet from proper Actuator
x - Actuators Pnuematic Inlet from vacuum pump

(VAC=vacuump)
c1 d1 y - OUT=pnuematic outlet from actuator to Intake Throttle
c2 d2 valve or EGR valve
f
e b
e2 f2
y
b
f x
e e1
Exhaust Side 89
R 750
EGR & INTAKE THROTTLE VALVE CONNECTIONS TEST
EGR VALVE - VALVOLA EGR
INTAKE THROTTLE
VALVE
VALVOLA ASPIRA-
ZIONE A FARFALLA
INTAKE THROTTLE VALVE

ACTUATOR
EGR VALVE ACTUATOR MODULATORE DEL VUOTO

MODULATORE DEL VUOTO VALVOLA EGR VALVOLA ASPIRAZIONE A
FARFALLA
vehicle wiring harness

connector
Connettore cablaggio
veicolo
2
2
1
2 1 1
engine wiring harness

+ 12 V from Main
connector Relay
Connettore cablaggio + 12 volt da Relé
motore
principale
VACUUM PUMP
POMPA DEL
VUOTO
90 Exhaust Side
R 750
INSTRUCTIONS
Measure with a tester the continuity between pin 2 of one of two the vehicle wiring harness connectors (con-
nectors that will be connected to proper modulators) and pin 1 of engine wiring harness connector. Once verified
the continuity, the electrical connection is related to Intake Throttle valve.
Measure with a tester the continuity between pin 2 of remaining engine wiring harness connector and pin 2 of the
vehicle wiring harness connector, to establish the electrical connection related to EGR valve.
Once verified the electrical connections, carry on with pneumatic hoses connection to proper component.
FINAL ENGINE TEST

Operate the engine
Run the engine at idle RPM for several minutes to allow the vacuum system charges.
Stop the engine
Verify Intake Throttle Valve drive rod moves, so that it closes intake inlet.
exhaust manifold
removal
Loosen the 2 bolts fixing the heat shield and remove it.
a - heat shield
Remove any component wich hinders the turbocharger
removal.
b b
Loosen and remove fixing flange nuts. a
b - flange nuts fixing exhaust manifold
Remove all spacers if present from the studs and remove the
exhaust manifold and old single gaskets.
c - spacer
Installation
Install new single gaskets on the studs if necessary.
Install the exhaust manifold and proper spacers.
Install flange nuts and torque them evenly in a cross pattern.
Exhaust flange nut 32.4 Nm
b c
Exhaust Side 91
R 750
intake manifold
removal
Remove the exhaust manifold and any component wich
hinders the intake manifold removal.
If nedeed remove the Intake Throttle Valve and proper elbow
fixed to intake manifold.
Remove fixing flange nuts and take the intake manifold off.
a - flange nut
If necessary replace the gaskets. a
Installation
Install new gaskets on studs if nedeed.
Install the flange nuts and torque them evenly in a cross
pattern.
Intake flange nut 27.5 Nm
92 Exhaust Side
R 750
Flywheel Side
Crankshaft End Play (Axial Clearance)
Install the Flywheel. Refer to Flywheel.
Attach the Dial Indicator to the cylinder block to check the installed crankshaft end play (axial clearance).
Measurement can be made from the crankshaft counter weight or flywheel outer surface..
Firmly force the crankshaft rearward. Record the measurement.
Firmly force the crankshaft forward. Record the measurement.
Subtract the measurements to determine the crankshaft end play (axial clearance).
crankshaft end play 0.080 - 0.230 mm
If the end play (axial clearance) is incorrect, calculate the necessary thickness of the thrust washers needed.
Install different thickness thrust washers in rear main carrier and recheck the end play (axial clearance).
Refer to Rear Main Bearing Carrier to determine thickness thrust washers.
Repeat the steps until the proper end play (axial clearance) is obtained.
Flywheel Side 93
R 750
Flywheel
Removal
• Measure and record the crankshaft End Play (Axial

Clearance) before removing the flywheel. (Refer
Crankshaft End Play - Axial Clearance).
• Remove the starter and install the special tool, flywheel
holder tool, to block the crankshaft rotation.
• Remove 2 of the flywheel bolts and install the Flywheel
Assembly Guide Pins (Refer to special tools).
• Remove the remaining flywheel bolts and remove the
flywheel.
• a - Flywheel bolts
• b - Flywheel
• b
• Take the flywheel off and remove the special tool,
flywheel holder tool, blocking the crankshaft rotation
94 Flywheel Side
R 750
When taking the flywheel off a crankshaft thrust plate could be • c - thrust plate o-ring groove
installed. • d - engine without crankshaft thrust plate
If not present, it is melted with the flywheel. In this case verify • e - thrust washers
the O-ring presence. • f - rear oil seal
• a - cranckshaft thrust plate (NOT melted with flywheel)
• b - cranckshaft thrust plate (melted with flywheel)
e
d
f
a f
Flywheel Side 95
R 750
Installation
Install a new O-ring in thrust plate groove. A small amount of grease, such as Molykote, may be used to hold the O‑-ring in
position during installation. Whenever the flywheel is removed, replace the O‑ring.
Install the thrust plate with O-ring towards the crankshaft.
Ensure that there are no scratches, nicks, cracks, or seizure marks on the flywheel mating surface. Only minor scratches,
nicks, or seizure marks can be removed. Replace the flywheel if damaged.
When installing the flywheel, do not touch or handle the lips of the rear oil seal. Ensure that the rear oil seal is in good condi-
tions. Replace it if any doubt exists. (Refer to Rear Main Bearing Carrier).
Ensure that thrust washers are not damaged or worn and are properly seated into the rear main bearing carrier. Replace them
if any doubt exists (Refer to Rear Main Bearing Carrier).
Install the 2 Flywheel Assembly Guide Pins in the crankshaft..
Install the flywheel with O‑ring (if the cranckshaft thrust plate is melted with flywheel ) onto the crankshaft using the Flywheel
Assembly Guide Pins.
Lubricate the threads and underside of the head of the flywheel bolts.
NOTE: The flywheel bolts may be installed as many as three times, and then must be replaced with new bolts. Replace
the bolts if any doubt exists about reuse. New bolts must not be lubricated.
Install and hand tighten four of the flywheel bolts.
Remove the Flywheel Assembly Guide Pins and install the remaining flywheel bolts.
Remove the starter and install the special tool, flywheel holder tool, to block the crankshaft rotation.
Torque the flywheel bolts evenly in a clockwise direction, cross pattern at 50 Nm..
Loosen completely one flywheel bolt at a time, and tighten the bolts evenly in a clockwise direction, cross pattern at 20 Nm +
75° .
NOTE:Verify the Crankshaft End Play (Axial Clearance).

Refer to Crankshaft End Play (Axial Clearance) to set the crankshaft end play.
Remove the special tool, flywheel holder tool, to block the crankshaft rotation and install the starter.
Bolt specifications
a 70 mm
b 58.75 - 60.25 mm
a
b
96 Flywheel Side
R 750
FLYWHEEL RING GEAR
1. Heat the ring gear with a torch on the engine side of the ring gear.
2. Once heated, knock the ring gear off the flywheel. Do not strike the flywheel when removing the ring gear.
CAUTION
Some components are made of steel that has been heat treated to increase hardness.
Applying excessive heat to the hardened steel will alter the hardness and make the steel weaker. Do not heat any portion of
these hardened steel components, such as a flywheel ring gear, to a temperature higher than 210 °C.
3. Heat the new ring gear for 20 minutes in an oven preheated to 190 - 210° C , or heat evenly until the gear expands enough to
slip onto the flywheel. Do not overheat the ring gear.
IMPORTANT: The ring gear must be installed so the bevel on the teeth is toward the crankshaft side of the flywheel.
4. Install the ring gear. Ensure that the ring gear is seated properly against the flywheel shoulder. The ring gear can move away
from the flywheel shoulder no more than 0.50 mm.
Flywheel Side 97
R 750
Flywhell housing
Removal a
Remove the flywheel (refer to Flywheel).
Remove the crankshaft thrust plate if fitted.
Remove the flywheel housing bolts.
c
Using a rubber mallet, tap evenly around the housing. The
flywheel housing with rear main bearing carrier, will be pulled
from the cylinder block.
When removing the flywheel housing, do not touch or handle b
the lips of the rear oil seal and do not damage the rear main
bearing carrier O-ring.
a - flywheel housing bolts
b - rear oil seal
c - thrust washers
a - O‑ring into the groove of the flywheel housing a - Rear main bearing carrier flange nuts
b - Groove b - Flywheel housing with detached rear main bearing
c - Flywheel housing carrier
c - Rear main bearing carrier
98 Flywheel Side
R 750
Installation
A O-ring
IMPORTANT: Whenever the flywheel and flywheel
housing are removed, replace all installed O‑-rings.
Ensure that thrust washers are not damaged or worn

and are properly seated into the rear main bearing
carrier. Replace them if any doubt exists (Refer to Rear
Main Bearing Carrier).
Apply silicon Dow Corning 7091 on flywheel housing
groove where the O-ring seats. PHOTO A.
Install a new O‑-ring into the groove of the flywheel
housing.
Apply a bead of sealant (thickness 2 mm) around the
O-ring as shown in the photo B.
Install a new O-ring into the groove around the rear

main bearing carrier. B O-ring
Apply a bead of sealant (thickness 2 mm) around the
O-ring as shown in the photo C.
Lubricate the rear crankshaft journal and rear main

bearing.
Install the flywheel housing.
Install and torque the flywheel housing bolts evenly in a
diagonal pattern.
flywheel housing bolts 68.6 Nm cordone di silicone

- bead of silicon
Flywheel Side 99
R 750
rear main bearing carrier
Removal
Remove the flywheel and flywheel housing. (Refer to proper section).

Disassemble the rear main bearing carrier from the flywheel housing by removing the flange nuts
Installation
Check the thrust washers condition and that they are properly seated into the rear main bearing carrier.
Replace them if any doubt exists.
Install a new O‑ring around the groove of the carrier. and apply silicon (Refer to Flywheel Housing).
Align the flywheel housing with the rolled pin installed in the rear carrier.
Install the flange nut and torque them.
Rear Main Bearing Carrier fixing flange nut 24.5 Nm
a - Rear main bearing carrier flange nuts

b- Rolled pin install in the rear carrier a b
THRUST WASHERS a
removal
b
Using a suitable device, carefully pry out the washer c d
halves. Do not damage the rear main bearing carrier or
rear oil seal.
INSTALLATION
Ensure that the washer halves are properly seated
in the rear main carrier and that the oil passages are
towards outside as shown in the picture.
Align the tab of a washer half with the notch in the rear
main bearing carrier
Press the washer halves simultaneously into the car-
rier.
a - tab
b / c - washer halves
d - oil passages (grooves)
Specifications
Thrust Washer
Standard 2.310 ‑ 2.360 mm
First oversized (+0.10) 2.410 ‑ 2.460 mm
Second oversized (+0.20) 2.510 ‑ 2.560 mm
100 Flywheel Side

R 750
REAR MAIN BEARING
Removal
a - hole - oil passage
Using a suitable mandrel, press the rear main bearing
out of the carrier.
Installation
Align the hole of a new rear main bearing with the oil
passage in the rear main bearing carrier and press the
new bearing into the carrier.
Specifications a
Rear main bearing inner 80.045 - 80.07
diameter (installed into the mm
carrier)
First oversized bearing 0.25 mm
IMPORTANT: Refer to Crankshaft Section to

determine the Rear Main Bearing Crankshaft Jour-
nal Outside Diameter and Rear Main Bearing
Clearance.
Rear oil seal

removal
Using a suitable device, carefully pry out the old seal. Do not damage the rear main bearing carrier or thrust
washers.
INSTALLATION
IMPORTANT: The seal is made of special compounds; do not touch or handle the lips of the seal. Do not
attempt to install rear main seal using a hammer or mallet. Damage to the seal or rear main bearing carrier could
result.
Lubricate the rear oil seal outer surfaces. Do not touch or handle the lips of the seal.
Install the new rear oil seal in the bearing carrier using the Flywheel Seal Installer. The seal will stop when seated.
cps target wheel bolt

removal
Remove the flywheel, flywheel housing with rear main bea-
ring carrier. a
Slacken and remove no. 3 bolts retaining the CPS
(Crankshaft Position Sensor) target wheel.
a - CPS (Crankshaft Position Sensor) target wheel bolts
installation
Usually replace the old bolts.
Replace the old bolts and apply loctite 510 on the bolt
thread.
Install the bolts and torque them.
CPS (Crankshaft Position 14.7 Nm

Sensor) target wheel bolts
Flywheel Side 101

R 750
BASIc ENGINE
cylinder head GASKET
IMPORTANT: When cylinder heads are removed for service but pistons and cylinder liners are not disturbed,use
the same thickness gaskets that were removed. Refer to Head Gasket Identification.
Refer to the following procedures during a complete engine rebuild or when pistons and liners are being replaced.
1. Use the dial indicator and Support Block tool (liner gauge bar) (refer to Special Tools) to measure piston height above the
cylinder block with the piston at Top Dead Center (TDC ).
2. Place Support Block on cylinder block surface and set the dial indicator to zero 0.
3. Move the Support Block tool to the piston surface with the piston at TDC point as shown.Record the measurement.
4. Measure the piston protrusion (height) of all pistons. Use the average measurement to determine the gasket thickness
required for all cylinders.
a - Support Block tool

b - Dial indicator
c - piston
Piston protrusion (height) above Gasket thickness

cylinder block - average required
0.60 - 0.72 mm 1.42 mm
0.73 - 0.82 mm 1.52 mm
0.83 - 0.95 mm 1.62 mm
5. After determining the head gasket thickness required,

identify and select the proper the cylinder head gasket. Two notches gasket shown
Note the identification marks (holes or notches) in the lower a - Notches

right hand corner.
No mark indicates a thickness of 1.42 mm

Two marks indicate a thickness of 1.52 mm
One mark indicates a thickness of 1.62 mm
102 Basic Engine

R 750
cylinder head
INSTALLATION
• Clean out bolt holes in cylinder block. Be certain no contaminants (dirt, old oil or coolant) remain in the holes.
• Clean the gasket surfaces on block and heads.
• IMPORTANT: Cylinder head bolts may be installed as many as three times, and then must be replaced with new
bolts. Replace if any doubt exists or the thread is stretched.
• NOTE: New cylinder head bolts must not be lubricated. They are already lubricated with an anti‑seizing lubricant
from the manufacturer, and do not require additional lubrication.
• Thoroughly clean all existing cylinder head bolts and washers, including all formed spacer‑washers (terminal bridges,
three types) and cylinder head spacers (for ends of first and last cylinder heads).
• If the bolts are reusable lubricate with Molykote G Rapid Plus Paste the bolt threads and underside of bolt heads of all
12M (12 mm) cylinder head bolts (side bolts) and 14M (14 mm) cylinder head bolts (center bolts)
• IMPORTANT: Cylinder head gasket must be installed dry. Do not use any sealant or adhesive on the gasket.
• Position the cylinder head gasket on the cylinder block.
• Install the Cylinder Head Guide Pins (refer to Special Tools) into the 12 mm bolt holes in the gasket and cylinder block at
each cylinder location. These pins will align the gasket and cylinder heads.
• Beginning with cylinder number 1, install the cylinder heads over the guide pins.
a - Cylinder head gasket

b - Guide pin locations (two at each cylinder)
c - Cylinder head
Center bolts Side bolts (injection side) Side bolts (intake/exhaust side)
Basic Engine 103

R 750
• One at a time, remove the Cylinder Head Guide Pins and install the 12M cylinder head side bolts previously lubricated is
reused, finger tight. Do not disturb the cylinder head placement.
• Install and finger tighten all lubricated 14M cylinder head center bolts, including the proper formed spacer washers (ter-
minal bridges, three types) and cylinder head spacers, for the ends of the first and last cylinder heads, as shown in the
following.
a - Spacer, first and last cylinder head ends
b - (b1,b2,b3) - Formed spacer washers (terminal bridges, three types)
b1 and b1* have the same shape but b1 is overturned than b1*, the edge is upwards.
b1* b1 b1 b1 b1*
a a
b3 b2 b2 b3
b2
b1 b3
b2
b3
b1*
a
b1 x y
b1 and b1* have the same shape but b1 is overturned than b1*, the edge is upwards.
x - edge upwards
y - edge downwards
104 Basic Engine

R 750
• Using the appropriate tools (refer to Special Tools), lightly hand tighten all bolts.
15 16 17 18
1
9 7
3 5
2 8 4 6
10
11 12 13 14
• Correctly align the cylinder heads by temporarily instal- SIDE BOLTS

ling the exhaust or intake (or both) manifold with gaskets
and finger tighten each flange nuts. a. First pass and sequence:
Torque value - 30 Nm
• Slightly loosen the 12M and 14M bolts as needed, to
allow the cylinder heads to align. Sequence
11, 12, 13, and 14 (4 cylinder heads engine)
Max disalignement 0.2 mm (measured on intake/exhaust
flanges manifold) 15, 16, 17, 18, 19 and 20 (6 cylinder heads engine)
b. Second pass and sequence:
• Hand tighten the exhaust manifold nuts sufficiently to
align the cylinder heads to the exhaust manifold. Torque angle + 85°
Sequence
• Using the appropriate tools (refer to Special Tools), hand
tighten all 14M and 12M cylinder head bolts. 11, 12, 13, and 14 (4 cylinder heads engine)
15, 16, 17, 18, 19 and 20 (6 cylinder heads engine)
• Torque the center bolt 14M set as specified and in the
sequence shown, following steps a, b, and c. Do not
torque the side bolt set at this time. c. Third pass and sequence:
CENTER BOLTS Torque value 30 Nm

Sequence
a. First pass torque and sequence:
15, 16, 17, and 18 (4 cylinder heads engine)
Torque Value - 30 Nm
21, 22, 23, 24, 25 and 26 (6 cylinder heads engine)
Sequence
d. Final pass and sequence:
3‑2‑1‑4‑5‑8‑9‑10‑7‑6 (4 cylinder heads engine)
Torque angle + 85°
11, 12, 13, 14, 10, 9, 8, 4, 3, 2, 1, 5, 6, 7 (6 cylinder heads
engine) Sequence
b. Second pass torque and sequence: 15, 16, 17, and 18 (4 cylinder heads engine)
Torque Angle + 65° 21, 22, 23, 24, 25 and 26 (6 cylinder heads engine)
Sequence
1‑2‑3‑4‑5‑6‑7‑8‑9‑10-11-12-13-14 (6 cylinder heads engine)
c. Final pass and sequence:
Torque Angle + 65°
Sequence
• Now, torque the side bolt numbered sets as specified

and in the sequence shown, following steps a, b, c and
d.
Basic Engine 105

R 750
Torque Procedure After the First 20‑30 Minutes of Operation
IMPORTANT
When the cylinder heads are replaced or disassembled an additional angular torque and conventional torque must be
applied. Torque the cylinder head mounting bolts as specified after the first 20‑30 minutes of operation and with engine
cold..
1. Operate the engine at a fast idle for few minutes. Then operate the engine at 1/3 RPM of the rated RPM for approximately
20‑30 minutes until water temperature reaches 70-80 degrees °C, normal operating temperature.
2. Let the engine cool down completely, at least less than 40° C, temperature measured on 1st cylinder head..
3. Follow the sequence one at a time, completely loosen each M14 center bolt and torque as indicated in steps a and b.
a. First pass:
center Bolts - M14
Slacken completely one bolt at a time and retorque it at 30 Nm + 120° (or 60°+60°) by following the sequence indicated
here below.
Slackening Sequence
1‑2‑3‑4‑5‑6‑7‑8‑9‑10 (4 cylinder heads engine) / 1‑2‑3‑4‑5‑6‑7‑8‑9‑10-11-12-13-14 (6 cylinder heads engine)
Torque Value 30 Nm + Torque Angle 120° (or 60°+60°)
Torque Sequence
SIDE Bolts - M12
NOTE: The 12M side bolts numbered 11 ÷ 18 (4 cylinder heads engine) or 15 ÷ 26 (6 cylinder heads engine) do not require
tightening again.
If necessary, check the 12M side bolts with a conventional torque wrench, checking the torque on each side bolt as indicated.
Torque Value 90 Nm
Torque Sequence
11-12-13-14-15-16-17-18 (4 cylinder heads engine)
15-16-17-18-19-20-21-22-23-24-25-26 (6 cylinder heads engine)
106 Basic Engine

R 750
Disassembly
Using a valve spring compressor, remove the valve locks,
the retainers, the springs, and the spring plates.
Remove the valves from the cylinder head and place in a
rack or label the parts in order for reassembly in their original
locations.
1 Rocker pedestal nut

2 Valve cone (valve keeper)
3 Valve spring retainer
4 Valve spring
5 Plate washer
6 Valve Guide
7 Cylinder head
8 Expansion plugs
10 Intake valve seat

11 Intake valve
12 Exhaust valve
13 Exhaust valve seat
16 Rocker arm support stud
17 Strap
18 Rocker arm
19 Rocker arm
20 Rocker arm bushing
21 12M cylinder head bolt, injector side
22 12M cylinder head bolt, manifold side
23 14M cylinder head center bolt
24 Formed spacer washer (manifold side clamp)
25 Formed spacer washer (intermediate clamp)
26 Formed spacer washer (front and rear, end
spacer)
27 End spacer
28 Oil pipe
29 Hollow bolt and sealing washers
30 Injector side of cylinder head
31 Plug, glow plug hole (or glow plug if equipped)
EXPANSION PLUGS
Removal
1. Remove expansion plugs if leaking or damaged.
NOTE: These plugs may be removed with a sharp punch
or they may be drilled and pried out.
Repair
1. Apply sealant (Loctite 290) to the outer diameter of the
expansion plugs.
Cylinder Head End spacer

Repair
End spacer 89.92 - 90 mm a - Expansion plugs
Basic Engine 107

R 750
VALVE GUIDES
1. Inspect the valve guides for cracks or chips.
2. Inspect the valve guide bores for seizure marks, carbon
deposits or scoring.
3. Inspect the valve guide height.
4. Remove the valve stem seals.
5. Insert a new valve into guide.
6. Measure the valve stem clearance as follows:
a. Attach a dial indicator to cylinder head. Position it against
the valve stem and close to the valve guide.
b. While holding the valve head off of the seat by about 2
mm move valve stem back and forth in directions shown.
Compare stem clearance with specifications.
Valve guidestem diameter - See chapter “Valves”
Exhaust 7.921 - 7.939 mm
Intake 7.94 - 7.96 mm
Valve guide clearance - production

Exhaust (0.061 - 0.094 ) mm
Intake (0.04 - 0.075) mm
c. Measure the valve guide inner diameter with a valve guide

bore gauge. If measured value of stem clearance is not
within specifications, replace the valve guide.
Valve guide inner diameter
Exhaust 8 - 8.015 mm
Intake
Valve guide height

Exhaust 54.75 - 55.25 mm
Intake
108 Basic Engine

R 750
Replacement
CAUTION: Aluminum cylinder heads can be distorted or a
melted when heated improperly or unevenly.
A torch will improperly and unevenly heat an aluminum
cylinder head. Do not use a torch to heat an aluminum
cylinder head. To heat an aluminum cylinder head during
valve seat or valve guide replacement, use an oven ap-
propriately designed and constructed for the purpose.
1. Remove the valve stem seals.
2. Heat the cylinder head in an oven to 85 degrees C (185
degrees F).
3. Using a suitable drift, drive out the old guide from the
underside of the cylinder head.
4. With the cylinder head temperature at 85 degrees C (185
degrees F), press the new guide in to obtain measurement
as shown.
a - Guide height measurement (above cylinder head

upper surface) (EXHAUST/INTAKE)
a 1.5 - 2 mm
IMPORTANT: If the valve guide has been removed, both

the valve and the valve guide must be replaced as a set.
Basic Engine 109

R 750
VALVE SEATS
1. Inspect the valve seats for cracks, excessive wear, and looseness in counterbore.
2. Measure exhaust and intake valve seats. Refer to valve seat specifications.
3. If measured values are not as specified, recondition the valve seat. If the valve seats cannot be repaired, it will
be necessary to replace the cylinder head. Refer to Repair ‑ Valve Seat Reconditioning.
Measurements
a - Valve recession
b - Counterbore inner diameter
Valve recession (service limit) (a)

Exhaust 0.3 mm
Intake
Counterbore inner diameter (b)
Exhaust 38.964 - 38.988 mm
Intake 41.962 - 41.985 mm
Counterbore inner height (b1)
Exhaust 10 - 10.01 mm
Intake
a a
b1
110 Basic Engine

R 750
INTAKE
f d
45°
g 45°
exhaust
f d
30°
Measurements
d - Seat outer diameter
60° g e - Seat height
f - Seat width
g - Seat angle
Seat outer diameter (d)
Seat width (f)
Exhaust 39.050 - 39.066 mm
R750 EU4 1.6 ‑ 1.8 mm
Intake 42.070 - 42.086 mm Exhaust
Seat height (e) Intake
Exhaust / Intake 7.85 - 7.95 / 7.73 ‑ 7.83 mm R750 EU5 1.6 ‑ 1.8 mm
Exhaust 2 - 2.2 mm
Intake
Valve Seat Reconditioning If during seats valve reconditioning excessively lowers

valve recess or if the seat widht is wider than above
NOTE: Several different types of equipment are availa-
specified measures, replace valve seat insert. During
ble for reconditioning valve seats.
replacement operation, special care should be taken
Equipment manufacturer’s recommendations should be
not to damage seat insert counterbore.
followed carefully to attain proper results.
IMPORTANT: Regardless of type of equipment, it is
Install seat valve inserts after heating cylinder head in
essential that valve guide bores be free of carbon or dirt
an oven at 150°C or cooling them down at -170°C in
to achieve proper centering of pilot in valve guide, ensu-
liquid nytrogen athmosphere.
ring concentricity when reconditioning valve seats.
Seat installation into head bore must be free, no re-
Recondition pitted or worn valve seats to the specified
quiring pressure for installation if above conditions are
angles.
maintained.
Basic Engine 111

R 750
Valves
1. I nspect valves for damage, warpage, or both. Replace if necessary.
2. Measure the valve. If measured values are not as specified, repair the valve. Refer to Valve Refacing. Replace the valve
if it cannot be repaired.
INTAKE (mm) EXHAUST (mm)

A - Stem diameter (production, new) 7.94 - 7.96 7.921 - 7.939
F - Face width (production, new) 3.57 - 3.85 2.640 - 2.992
D - Margin thickness (Production, new) 1.82 1.73
Service limit 1.30
E - Face angle (production, new) 29 degrees 30 minutes 44 degrees 30 minutes
B - Head diameter (production, new) 40.8 - 41 37.9 - 38.1
112 Basic Engine

R 750
Valve Refacing
Pitted valves can be refaced to proper angle on a valve grin-
der, that ensuring the correct relation between the cylinder
head seat and the valve mating surface.
Replace valves with excessive wear on stems or valves that
are warped excessively. When an excessively‑-warped valve
head is refaced, a knife edge will be ground on part or all
of the valve head due to the amount of metal that must be
removed to completely reface. Knife edges lead to breakage
or burning.
NOTE: Various equipment is available for refacing valves.
Manufacturer’s recommendations should be carefully fol-
lowed to attain proper results.
After refacing, measure the valves and replace if out of
specifications.
1. Recondition the valve face to the proper angle if the valve
face is pitted or worn.
NOTE: When refacing do not thin the valve margin thickness

less than 1.30 mm.
After reconditioning, measure the valve margin. If the valve

margin is less than the specified amount, replace the valve.
Assembly
NOTE: Valve stem seals are used on intake and
exhaust valves. a
1. Lubricate valve guides and valve stems with engine
oil.
2. Install each valve in the port from which it was remo-
ved or for which it has been fitted.
3. I nstall the valve guide seal onto the valve stem and
push down until seated against the guide. b
a - Valve stem seal
b - Seal installed on guide
4. Install the plate washer, the valve spring, and the

retainer on valve stem.
5. Compress the valve spring using valve spring com-
pressor.
NOTE: Lubricant may be used to hold valve locks in
place while releasing compressor tool
6. Coat the valve stem locks with lubricant to hold in
place.
7. Install the valve stem locks.
b
a - Plate washer c d
b - Valve spring a
c - Retainer
d - Valve locks
8. Slowly release the valve spring compressor, ensuring

that the valve locks seat properly
in the valve stem groove.
Basic Engine 113

R 750
Valve Springs
1. Inspect the valve springs for discoloration due to excessive heat.
2. Inspect the valve spring valve locks, the retainers, and the washer for wear, distortion, or cracks.
3. Measure the free standing height of each spring. Replace the spring if measured value is other than specified.
4. Measure the spring inclination (distortion). If the measured value exceeds the specified limit, the valve spring
must be replaced.
a - Free standing height

b - Spring inclination
Free standing height

Exhaust - Intake 48 mm
Spring Inclination
Exhaust - Intake Service limit 2 mm
Valve open
a - Applied pressure
b - Height
Applied pressure 294 N ± 6%

Height 38.5 mm
Valve closed
a - Applied pressure
b - Height
Applied pressure 635 N ± 4%

Height 28.2 mm
114 Basic Engine

R 750
Rocker ARM
removal
1. Remove the rocker arm covers.
IMPORTANT: Mark or store the components during re-
moval for reassembly in their original location.
2. Remove the rocker arm assemblies and valve push rods.
Place the components in a numbered rack according to their
position in the engine or mark the parts in order for reassem-
bly to the original location.
Cleaning
1. Wash the components in cleaning solvent.
2. Put on safety glasses and dry the components with com-
pressed air.
Inspection
1. Inspect components for excessive wear, cracks or dama-
ge.
NOTE: The push rods are hollow and serve as oil galle-
ries to lubricate each individual rocker arm assembly.
2. Visually inspect each pushrod for wear and deposits. En-
sure the valve pushrod oil passage is not restricted.
3. Roll each valve pushrod on a flat surface and inspect the a - Rocker arm support
shaft for bends. journal outside diameter
4. Replace all damaged parts.
5. Using a micrometer, measure the outside diameter of
rocker arm support journals.
Replace the rocker arm support if the journal outside diame-
ter is less than specified.
Outside diameter 24.97‑25.00 mm
6. Using an inside micrometer, measure inside diameter of

the rocker arm bushing.
a - Rocker arm bushing
Inside diameter (Produc- 25.020 ‑ 25.041 mm
inside diameter
tion)
Assembly clearance 0.020 - 0.071 mm
Wear limit 0.2 mm
7. Replace the rocker arm assembly if wear limit is greater

than specified.
Basic Engine 115

R 750
Assembly
IMPORTANT: Before assembling the rocker arms

assembly drain all of the residual oil in the valve lifter
out of the drain hole in the valve lifter, by compressing
the valve lifter, using the Valve Lifter Tool (Refer to Valve
lifter section).
Lubricate with engine oil the rocker arm bushings and rocker
arm support journals.
Install the rocker arms on the rocker arm support journals.
Position as shown.
Install the strap around the rocker arm assembly. Ensure that
the strap is not spread open or the valve cover will not fit.
Lubricate the outer surfaces and ends of the valve pushrods. a - Rocker arm
Lubricate the valve lifter contact surfaces. b - Rocker arm support
Install the valve pushrods in their original locations. Ensure c - Strap
that the valve pushrods seat in the lifter sockets.
Lubricate the rocker arm and rocker arm contact surfaces.
Lubricate the threads of the rocker arm support studs.
Install the rocker arm assembly onto the rocker arm support
studs. Simultaneously align the valve pushrods with the
rocker arm sockets.
Install both rocker arm support nuts on the rocker arm sup-
port. Torque the rocker arm support nuts evenly.
Rocker arm support nut 29 Nm
x - rocker arm support nut

y - Rocker arm support
d
IMPORTANT: Valve lash adjustment, or valve clea- a - Rocker arm assembly

rance, is hydraulically controlled and automatically set b - Pushrod
when the rocker arm support flanged nuts are properly c - Rocker arm socket
torqued. d -Valve pushrod seat in
the lifter socket
Repeat the steps for the rocker arm assembly on each
cylinder.
No valve lash adjustment is required.
x
y
116 Basic Engine

R 750
Valve Lifters
CAUTION: Camshafts and valve lifters develop
matched wear patterns during engine operation.
Mismatching worn camshafts and valve lifters or using
worn components with new components can cause
rapid and excessive wear resulting in engine component
failure. Always use new camshafts and valve lifters whe-
never any of the components are replaced.
The hydraulic roller valve lifters are held in position and
prevented from rotation by special retainers. There is one
retainer for each cylinder head. Care should be exercised
when installing the retainers to ensure that the flat portions of
the lifters are properly positioned in the retainers.
Removal
1. Remove the valve covers.
IMPORTANT: Place rocker arm assemblies, pushrods
and valve lifters in a rack for reassembly in their original
locations.
2. Remove the rocker arm assemblies and the valve pushro-
ds. Keep parts in matched sets.
IMPORTANT: Lifters must be reassembled in the exact
same position on the camshaft lobes so that the roller
will operate in the same direction on the same lobe, if
reused.
3. Make matching marks on all retainers and valve lifters
showing the location and orientation in the bores.
4. Lift the retainer piece away from around the top of the
valve lifters. Do not disturb the valve lifters at this time.
5. Insert the Valve Lifter Tool firmly into the valve lifter. Press
downward on the internal spring until the top of the tool is
lower than the stop. Turn the tool 90° and remove the valve
lifter.
6. Remove the remaining valve lifters while keeping them in
order for reassembly. a - Drain hole
Cleaning b - Valve Lifter Tool
1. Except for the valve lifters, clean the parts with cleaning
solvent.
2. Put on safety glasses and dry parts with compressed air.
3. While holding upright wipe the valve lifters with a clean, oil a - Push rod
saturated, lint free cloth. b - Retainer
Store lifters in the upright position. c - Valve lifter
Inspection d - Roller
1. Inspect the valve push rod seat A. If the valve push rod
seat is scuffed or worn, inspect the valve push rod. Check
that valve push rod seat surfaces show no signs of dents,
scoring and/or damage.
2. Inspect the outer valve lifter body wall. If wall is scuffed or
worn, inspect engine block
valve lifter bore.
3. Inspect the roller of the valve lifter. If the roller is scuffed or
worn, inspect camshaft lobe.
4. Measure the outer diameter B of the valve lifter. If the
measured value is less than specified, replace the valve
lifter.
Outer diameter 22.195 ‑ 22.212 mm
5. Inspect all parts carefully. If any parts are damaged or

worn, the entire valve lifter
assembly must be replaced.
Basic Engine 117

R 750
Installation
CAUTION: Camshafts and valve lifters develop

matched wear patterns during engine operation.
Mismatching worn camshafts and valve lifters or using
worn components with new components can cause
rapid and excessive wear resulting in engine component
failure. a
Always use new camshafts and valve lifters whenever
any of the components are replaced.
IMPORTANT: Before installation, coat the entire valve lif-
ter with engine oil. If installing a new camshaft and valve
b
lifters, engine oil has to be poured over valve lifters and
camshaft lobes.
IMPORTANT: Before assembling the valve lifters

drain all of the residual oil in the valve lifter out of the
drain hole in the valve lifter, by compressing the valve
lifter, using the Valve Lifter Tool (Refer to Valve lifter
section).
c
Drain all of the residual oil in the valve lifter out of the drain
hole in the valve lifter, by compressing the valve lifter, using
the Valve Lifter Tool. a - retainer
Before installing the valve lifters, coat the entire valve lifter b - square top or flat portion
with engine oil. c - lifter
Install the valve lifters in the bores in order of removal, using
the Valve Lifter Tool. Align the matching marks made prior
to disassembly. Ensure the valve lifter drain hole is pointing
towards the crankshaft.
Install the retainers around the square top of the lifters to
prevent them from rotating.
Lubricate and install the valve push rods. Ensure the valve
push rods seat in the valve lifter sockets.
NEW HYDRAULIC TAPPET VM PN 40432003F INSTAL-

LED SINCE NOVEMBER 2009 IN PLACE OF VM CODE b
40432001F.
THE LASTEST TAPPET VM PN 40432003F SUPERSEDES
THE PREVIOUS ONE.
BOTH TAPPEST ARE INTERCHANGEABLES
118 Basic Engine

R 750
Valve Push Rods
Removal
1. Remove the valve covers.
IMPORTANT: Organize rocker arm assemblies and valve push
rods in a rack for reassembly in their original locations.
2. Remove the rocker arm assemblies.
3. Lift the valve push rods from their seat in the valve lifter.
a - Valve push rod
b -‑ Valve lifter seat (not visible here)
Cleaning
1. Clean the rocker arm assemblies and push rods.
2. Clean the valve push rod oil passages.
3. Put on safety glasses and dry the components with com-
pressed air.
Inspection
1. Inspect all contact surfaces for excessive wear or scoring.
2. Ensure that the valve push rod oil passage is not restricted.
3. Roll the valve push rods on a flat surface and inspect them
for bends.
4. Replace all damaged parts.
Installation
IMPORTANT: Before assembling the valve push

rods drain all of the residual oil in the valve lifter out
of the drain hole in the valve lifter, by compressing the
valve lifter, using the Valve Lifter Tool (Refer to Valve lifter
section).
1. Lubricate the outer surfaces and ends of valve push rods.
2. Install the valve push rods in their original locations. Ensure
that the push rods seat in the valve lifter seat.
3. Install the rocker arms.
Basic Engine 119

R 750
fractured Connecting Rod
Disassembly
removal
1. Clamp the connecting rod in a soft‑-jawed vise.
IMPORTANT: Each connecting rod assembly must
2. Use the Piston Ring Expander Tool to remove the
be reassembled in the same original location.
first and second compression rings and the oil control
Mark or identify each connecting rod assembly to
ring with spring.
ensure placement in the original cylinder number
3. Remove the snap rings retaining the piston pin.
location during reassembly. Retain the rod cap
Push the piston pin out of the connecting rod and
and bearings with the connecting rod and piston
piston.
assembly. Do not mix the components.
4. Note the orientation of the piston combustion cham-
Remove the connecting rod bearings. Keep the
ber recess in relation to the casting node, paint mark
bearings, with the original connecting rod and con-
on con rod shaft, and the connecting rod number.
necting rod cap, together as a matched set.
IMPORTANT: The connecting rod can damage the

crankshaft journal, the cylinder bore, and piston
cooling jet. Ensure no components are damaged
during connecting rod removal.
While protecting the crankshaft journal, cylinder bore,

and piston cooling jets from damage, push the piston
and connecting rod out of the cylinder.
IMPORTANT: The mating surfaces of the connec-

ting rods and the connecting rod bearing caps
form an individual fit and as a result must not be
interchanged or damaged under any circumstan-
ces. To avoid damage, do not lay connecting rods
or connecting rod bearing caps on their mating x
surfaces. x - piston cooling jet
FRACTURED CONNECTING RODS a - Combustion chamber recess orientation

b - Connecting rod number
a c - Casting Node
d - Paint mark (for weight classification)
e - matching marks on the connecting rod cap
and connecting rod shaft
FRACTURE
d
b c
b
e c
120 Basic Engine

R 750
Inspection (fractured Connecting Rod)
IMPORTANT: Measurements should be taken when
components are at room temperature.
Coloured paint marks on the connecting rods
shaft identify the weight classification. Ensure all
connecting rods have the same color paint mark.
Replace connecting rods that are not the same
weight classification and do not have the same co-
lor paint mark. If only one connecting is replaced,
replace however all connecting rods.
Check for twisted or bent connecting rods.

Peform Magnaflux inspection of all rods and caps if
any doubts exixst.
Torque temporarirly the bolts at 88 Nm (Refer to

Connecting Rod Assembly for the correct tighte-
ning procedure and torque value)
Parallelism deviation between 0.15 mm

piston pin end and bearing end
x - Lenght 162.975 - 163.025
mm
x
Use an inside dial indicator to measure the connec-
ting rod crankshaft journal bore inside diameter, out of
round and taper.
a - Connecting rod crankshaft journal bore
Inner diameter (without 57.563 ‑ 57.582 mm

bearings)
Maximum allowable wear 0.02 mm
or taper

determine the Connecting Rod Crankshaft Jour-
nal Outer Diameter and Connecting Rod Bearing
Clearance.
Inspect for damage to the bearing cap and bolt threa-

ds.
Measure connecting rod bushing inner diameter and
piston pin outer diameter.
Replace the connecting rod bushing if clearance
exceeds specification.
a - Rod bushing inner diameter
b - Piston pin outer diameter
IMPORTANT: In service when replacing the

rod bushing it must be bored once that is instal-
led into its rod. Install the bushing by aligning the
lubrication oil hole with the rod hole.
Bushing inner diameter 30.035 - 30.050 mm
Piston pin outer diameter 29.992 - 29.996 mm
Piston pin bore 34 - 34.025 mm
or taper
Mounting Clearance 0.039 - 0.058 mm
Basic Engine 121

R 750
Assembly (fractured Connecting Rod )
Lubricate with engine oil the inside of the connecting
rod bushing, piston pin bore, and piston pin.
Assemble the piston to the connecting rod with the
combustion chamber recess, paint mark on con ros
shaft, and the connecting rod number all oriented as
noted during disassembly, or refer to the picture.
combustion chamber recess orientated towards intake
& exhaust side and the connecting rod number positio-
ned as shown in the picture.
Insert the piston pin and install the snap ring.
Install the piston-connecting rod assembly into the
cylinder block bore by taking care do not damage the
liner surface and crankshaft journal.
IMPORTANT: The connecting rod can damage x x - piston cooling jet

the crankshaft journal, the cylinder bore, and the
piston cooling jet. Ensure no components are da-
maged during connecting rod installation.
Align the connecting rod with the crankshaft journal

and tap on the piston top until the connecting rod
bearing contacts the journal. Do not scratch or nick the
crankshaft journal.
Ensure that the matching marks on the connecting rod
cap and the connecting rod shaft are the same and
that the rod cap numbers point toward the camshaft/
injection side. .
FRACTURED CONNECTING RODS
a - Combustion chamber recess orientation

c - Casting Node
a d - Paint mark (for weight classification)
FRACTURE
d
b c
b
e c
122 Basic Engine

R 750
IMPORTANT: New connecting rod screw threads and the screw head do not generally require lubrication.
An anti‑friction product has been applied by the factory.
Usually the bolts are replaced: if the screw threads are not stretched, and the top or bottom of the bolt
head does not show damage, the connecting rod screws may be reused. When reusing a connecting rod
screw, lubricate the threads and bottom of the screw head with engine oil.
Lubricate the connecting rod screw threads and the underside of the screw head, unless the screws are being
replaced with new screws that are pre‑lubricated.
Apply engine oil to the crankshaft journal and connecting rod bearing surfaces.
Install the connecting rod cap.
Install and finger tighten the connecting rod screws and torque them as specified :
Connecting rod screw - Fractured Connecting Rod

First pass 10 Nm
Connecting rod screw - Fractured Connecting Rod

Second pass 30 Nm
Final pass (Angle Torque) + 40
Verify that proper torque was achieved by testing the torque setting of each connecting rod screw to be at least as
specified in the following table. Do not apply more than this specified amount during the validation test.
Connecting rod screw validation test torque 88 Nm
Ensure that the connecting rod assembly and the crankshaft journal are not binding and that there is proper side‑-
to‑-side movement.
IMPORTANT: Refer to Crankshaft Section to determine Connecting Rod Bearing Clearance between
the bearings and crankshaft journal when the connecting rod is installed on crankshaft..
Install the remaining piston and connecting rod assemblies.
Connecting rod bolt specification - connecting rod broached
Basic Engine 123

R 750
BROACHED Connecting Rod Disassembly
1. Clamp the connecting rod in a soft‑-jawed vise.
removal 2. Use the Piston Ring Expander Tool to remove the
IMPORTANT: Each connecting rod assembly must first and second compression rings and the oil control
be reassembled in the same original location. ring with spring.
Mark or identify each connecting rod assembly to 3. Remove the snap rings retaining the piston pin.
ensure placement in the original cylinder number Push the piston pin out of the connecting rod and
location during reassembly. Retain the rod cap piston.
and bearings with the connecting rod and piston 4. Note the orientation of the piston combustion cham-
assembly. Do not mix the components. ber recess in relation to paint mark on con rod shaft,
Remove the connecting rod bearings. Keep the and the connecting rod number.
bearings, with the original connecting rod and con-
necting rod cap, together as a matched set.
IMPORTANT: The connecting rod can damage the

crankshaft journal, the cylinder bore, and piston
cooling jet. Ensure no components are damaged
during connecting rod removal.
While protecting the crankshaft journal, cylinder bore,

and piston cooling jets from damage, push the piston
and connecting rod out of the cylinder.
IMPORTANT: The mating surfaces of the connec-

ting rods and the connecting rod bearing caps
form an individual fit and as a result must not be x x - piston cooling jet
interchanged or damaged under any circumstan-
ces. To avoid damage, do not lay connecting rods
or connecting rod bearing caps on their mating
surfaces.
BROACH
d
b
b

c-
124 Basic Engine

R 750
Inspection (Connecting Rod - BROACHED)
IMPORTANT: Measurements should be taken when
components are at room temperature.
Coloured paint marks on the connecting rods
shaft identify the weight classification. Ensure all
connecting rods have the same color paint mark.
Replace connecting rods that are not the same
weight classification and do not have the same co-
lor paint mark. If only one connecting is replaced,
replace however all connecting rods.
Check for twisted or bent connecting rods.

Peform Magnaflux inspection of all rods and caps if
any doubts exixst.
Torque temporarirly the bolts at 88 Nm (Refer to

Connecting Rod Assembly for the correct tighte-
ning procedure and torque value)
Parallelism deviation between 0.15 mm

piston pin end and bearing end
x - Lenght 162.975 - 163.025
mm x
Use an inside dial indicator to measure the connec-
ting rod crankshaft journal bore inside diameter, out of
round and taper.
a - Connecting rod crankshaft journal bore
Inner diameter (without 57.563 ‑ 57.582 mm

bearings)
or taper

determine the Connecting Rod Crankshaft Jour-
nal Outer Diameter and Connecting Rod Bearing
Clearance.
Inspect for damage to the bearing cap and bolt threa-
ds.
Measure connecting rod bushing inner diameter and
piston pin outer diameter.
Replace the connecting rod bushing if clearance
exceeds specification.
a - Rod bushing inner diameter

b - Piston pin outer diameter
IMPORTANT: In service when replacing the

rod bushing it must be bored once that is instal-
led into its rod. Install the bushing by aligning the
lubrication oil hole with the rod hole.
Bushing inner diameter 30.035 - 30.050 mm
Piston pin outer diameter 29.992 - 29.996 mm
Piston pin bore 34 - 34.025 mm
or taper
Mounting Clearance 0.039 - 0.058 mm
Basic Engine 125

R 750
Assembly (Connecting Rod - BROACHED)
Lubricate with engine oil the inside of the connecting

rod bushing, piston pin bore, and piston pin.
combustion chamber recess, paint mark on con ros
shaft, and the connecting rod number all oriented as
noted during disassembly, or refer to the picture.
combustion chamber recess orientated towards intake
& exhaust side and the connecting rod number positio-
ned as shown in the picture.
Insert the piston pin and install the snap ring.
Install the piston-connecting rod assembly into the
cylinder block bore by taking care do not damage the
liner surface and crankshaft journal.
IMPORTANT: The connecting rod can damage

the crankshaft journal, the cylinder bore, and the
piston cooling jet. Ensure no components are da-
maged during connecting rod installation.
Align the connecting rod with the crankshaft journal

and tap on the piston top until the connecting rod
bearing contacts the journal. Do not scratch or nick the
crankshaft journal.
Ensure that the matching marks on the connecting rod x x - piston cooling jet
cap and the connecting rod shaft are the same and
that the rod cap numbers point toward the camshaft/
injection side. .
BROACHED CONNECTING RODS
BROACH
d
b
d

c-
e - matching marks on the connecting rod cap and
connecting rod shaft
b
126 Basic Engine

R 750
IMPORTANT: New connecting rod screw threads and the screw head do not generally require lubrication.
An anti‑friction product has been applied by the factory.
Usually the bolts are replaced: if the screw threads are not stretched, and the top or bottom of the bolt
head does not show damage, the connecting rod screws may be reused. When reusing a connecting rod
screw, lubricate the threads and bottom of the screw head with engine oil.
Lubricate the connecting rod screw threads and the underside of the screw head, unless the screws are being
replaced with new screws that are pre‑lubricated.
Apply engine oil to the crankshaft journal and connecting rod bearing surfaces.
Install the connecting rod cap.
Install and finger tighten the connecting rod screws and torque them as specified :
Connecting rod screw - Broached Connecting Rod

First pass 30 Nm
Final pass (Angle Torque) + 60°
Verify that proper torque was achieved by testing the torque setting of each connecting rod screw to be at least as
specified in the following table. Do not apply more than this specified amount during the validation test.
Connecting rod screw validation test torque 88 Nm
Ensure that the connecting rod assembly and the crankshaft journal are not binding and that there is proper side‑-
to‑-side movement.
IMPORTANT: Refer to Crankshaft Section to determine Connecting Rod Bearing Clearance between
the bearings and crankshaft journal when the connecting rod is installed on crankshaft..
Install the remaining piston and connecting rod assemblies.
Connecting rod bolt specification - connecting rod broached
Basic Engine 127

R 750
piston
Disassembly
1. Clamp the connecting rod in a soft‑jawed vise.
2. Use the Piston Ring Expander Tool to remove the first and second compression rings and the oil control ring
with spring.
3. Remove the snap rings retaining the piston pin. Push the piston pin out of the connecting rod and piston.
4. Note the orientation of the piston combustion chamber recess in relation to the paint mark, the casting node
(only for fractured connnecting rods), and the connecting rod number. (Refer to Connecting Rods Section)
CLEANING
IMPORTANT: Do not wire brush on any part of a piston.
1. Wash the components in cleaning solvent.
2. Clean varnish from piston skirts and pins with a suitable cleaning solvent.
3. Clean the ring grooves.
4. Clean the piston oil lubrication holes and slots.
5. Put on safety glasses and dry the components with compressed air.
Inspection
Inspect the piston for cracked ring lands, skirts or pin bosses, wavy worn ring lands, scuffed or damaged skirts or
eroded areas at top of piston. Replace pistons that are damaged or show signs of excessive wear.
NOTE: Do not mistake tapered or different ring design characteristics for unusual wear patterns. The first (upper)
compression ring is trapezoidal (tapered) in design. That is, it has a taper on both upper and lower surfaces. Cor-
respondingly, the first compression ring groove is tapered on top and bottom. The second (scraper) compression
ring and the oil control ring are more typical in design.
a - First compression ring ‑ trapezoidal (tapered)

b - First compression ring groove ‑ (tapered)
c - Outer edge of first compression ring
b
128 Basic Engine

R 750
Measure the piston outer diameter 17 mm from the
bottom and 90 degrees to the piston pin . Replace the
piston if measurement is less than specified.
a - Outer diameter measurement point

Outer diameter 93.930 - 93.950 mm
Wear limit 0.10 mm
Inspect the piston ring grooves for nicks or burrs that

might cause the rings to bind.
Except on the upper piston ring groove, insert the edge
of the rings into respective piston ring groove and roll
the ring entirely around the groove to make sure that 17 mm
ring does not bind. If resistance or binding occurs at
any point, determine the cause.
a. If binding is caused by a distorted ring, recheck with
another ring.
IMPORTANT: When using a fine cut file, do not
remove excess material. Verify with a feeler gauge
and compare to specifications.
b. If binding is caused by ring groove, remove the ma-
terial causing the binding by dressing the ring groove
with a fine cut file.
Measure the thickness of the rings. Replace piston

rings as a set if out of specification. First compression ring
Piston Ring Thickness (Production)

First compression (tapered ‑ outer 2.568 ‑2.597 mm
edge)
Second compression 1.970 - 1.995 mm
2.568 ‑2.597 mm
Oil control 2.97 ‑ 2.99 mm
First compression ring
1.5 mm
Second compression ring

Second compression ring
2° + or ‑ 30 minutes
Basic Engine 129

R 750
Measure the piston ring groove width.
Piston Ring Groove Width (Production)

First compression (tapered 3 mm (nominal)
‑ outer edge)
Second compression 2.06 ‑ 2.08 mm
Oil control 3.03 ‑ 3.05 mm
Using a feeler gauge, measure the clearance between

the serviceable, or new, second compression and oil
control piston rings and ring groove at several points
around the piston. Replace the piston if the measured
values exceed the specification.
Piston Ring Groove

Clearance
First compression Not applicable (tapered)
2 - Not applicable ‑ first compression ring and groove
Oil control 0.04 - 0.08 mm tapered
3 - Second compression ring and groove
4 - Oil control ring and groove
Check the piston ring end gap:
a. Position the selected ring in the cylinder bore.
NOTE: The ring must be level (at right angles to the

bore surface) for measurement. Push the ring 6 mm
into the bore with the crown of the piston.
b. Measure the gap between the ends of the ring with

a feeler gauge as shown.
Piston Ring End Gap (Production)
First compression 0.30 - 0.42 mm
Oil control 0.30 - 0.60 mm
Piston Ring End Gap

First compression 0.5 mm maximum
Second compression 0.9 mm maximum
Oil control 0.7 mm maximum
c. If the gap between the ends of the piston ring is less

than specified, remove the
ring and try to fit another. Check the cylinder bore if the
specification cannot be met with new rings. Refer to
Cylinder Liners.
d. Fit each ring to the cylinder in which it is going to be
installed.
130 Basic Engine

R 750
assembly
1. Lubricate the inside of the connecting rod bushing,
piston pin bore, and piston pin.
2. Assemble the piston to the connecting rod (Refer to
connecting Rod Section). First compression ring
3. Insert the piston pin and install the snap ring. ‑ trapezoidal (tapered)
4. Clamp the connecting rod in a soft‑jawed vise
IMPORTANT: Always install rings with ring markin- a

gs (“CTOP”, “PIP” or a dot) facing the top of
piston.
a - ring markings
5. Install the oil control ring spring in lower piston

groove.
6. Using the Piston Ring Expander Tool, install the oil
control ring. Second compression ring
7. By hand, squeeze the ring into the groove to seat
the spring and check for binding.
8.Using the tool, install the second compression ring in
the center piston groove. The inner taper is toward the
bottom of the piston.
9. By hand, squeeze the ring into the groove and che-
ck for binding. a
10. Using the tool, install the first compression ring in
upper piston groove.
11. By hand, squeeze the ring into the groove and
check for binding.
Oil control ring
Basic Engine 131

R 750
Installation
1. Before installing pistons into cylinders, ring gaps must be positioned as show in the picture:
a. First compression ring (trapezoidal) gap, 20° to the right of combustion chamber recess.
b. Second compression ring gap, centered on the combustion chamber recess.
c. Oil control ring gap, 20° to the left of combustion chamber recess.
a - First compression ring (trapezoidal) gap

b - Second compression ring gap
c - Oil control ring gap
2. Lubricate the cylinder bores and piston rings. IMPORTANT: The connecting rod can damage the
3. Each piston and connecting rod assembly must be crankshaft journal, the cylinder bore, and the piston
installed in the cylinder from which it was removed. cooling jet. Ensure no components are damaged during
connecting rod installation.
4. Turn the crankshaft to position the crank pin away 7. Align the connecting rod with the crankshaft jour-
from the cylinder so the connecting rod will not damage nal and tap on the piston top until the connecting rod
it during installation. bearing contacts the journal. Do not scratch or nick the
5. Using a ring compressor, install the piston by tapping crankshaft journal.
on the piston‑top with a suitable device. 8.Install the connecting rod cap.
6. Insert the connecting rod bearings into the connec- 9. Install and torque the connecting rod screws. (Refer
ting rod and matching connecting rod cap. Lubricate the to Connecting Rod Section)
bearings and crankshaft journal with engine oil.
x - Combustion chamber recess

y - Camshaft/Injection side
x
132 Basic Engine

R 750
Oil Pan & Oil Pickup
Removal
Drain the oil out of the engine. Refer to the Maintenan-
ce section.
Remove the oil pan screws.
Cut through oil pan sealant on pan rails using a suita-
ble tool. Ensure do not bend the pan rails.
Remove the oil pan. a
c
b
a - Sealant cutting tool
b - Hammer
c - Oil pan
Oil Pickup
Removal
1. Remove the oil pick‑up tube and strainer mounting
screws.
2. Remove the oil pickup tube and strainer and spa-
cers. b1 a
d
a - Oil pickup tube
b - Oil pickup tube screw
c - Oil strainer
d - Spacers
b
3. Remove the old oil pickup tube O‑ring.
Installation
1. Replace the oil pickup tube O‑ring.
2. Lubricate the oil pickup tube O‑ring.
3. Install the oil pick‑up tube and strainer on the engine c
block.
4. Install the oil pick‑up tube and strainer screws. Tor-
que the screws.
oil pick‑up tube and strainer (b) 12.7 Nm

screws b1
(b1) 32.4 Nm a
1. Wipe off all excess oil and foreign matter from
sealing surface on crankcase and oil pan. Thoroughly
de‑grease all sealing surfaces prior to application of b
sealant.
CAUTION
Excessive amounts of sealant could loosen and
become lodged on the oil pickup strainer resulting
in a restricted oil flow. Do not apply excessive
amounts of sealant.
2. Apply a continuous bead of sealant (silicon type

Dow Corning 7091) around the oil pan flange on the
inside of the bolt holes as shown.
3. Install the oil pan.
4. Install oil pan screws finger tight. Torque the oil pan
screws evenly, in a diagonal pattern.
a
Oil pan screw 12.7 Nm
b
a - Oil pan flange
b - Continuous bead of sealant
Basic Engine 133

R 750
Oil Pressure Relief Valve
The oil pressure relief valve (oil pressure regulator val-
ve) is installed vertically in the underside of the crankca-
se.
Removal
1. Remove the oil pan.
2. Clean old gasket material from the area around the
relief valve.
3. If removing only the relief valve and spring, or sprin-
gs: proceed to Disassembly.
a - Example of suitable tool
Observe all precautions and perform all steps except
b - Valve assembly
step 1.
c - Slots
4. If removing the complete pressure relief valve assem-
bly:
a. Unscrew the oil pressure relief valve assembly from

the crankcase using a suitable tool. The tool should en-
gage the 2 slots opposite each other on the edge of the
valve assembly.
NOTE: Locking compound is used during installation of

the oil pressure relief valve assembly. Area around the
assembly may need to be heated to aid in removal.
b. Remove the pressure relief valve assembly from the

crankcase.
c. Proceed to Disassembly.
Disassembly
1. Lock the pressure relief valve assembly in a
soft‑jawed vise, if the complete assembly was removed.
CAUTION
The oil pressure relief valve cap and high pressu-
re spring are retained by a snap‑ring. If released
suddenly the spring could propel the valve cap with
enough force to cause injury.
Use caution when removing or installing the
snap‑ring. Wear safety glasses.
2. Push the cap in against the high pressure spring and

hold. Remove snap‑ring.
3. Release spring pressure slowly.
b
a
a - Cap
b - Snap‑ring
c - Valve body
134 Basic Engine

R 750
4. Remove cap, springs and relief valve from bore of a - Cap
the valve body. b - Spring (inner ‑ if dual spring equipped)
NOTE: Some oil pressure relief valves have only one c - Spring (outer ‑ if dual spring equipped)
spring. d - Relief valve
Cleaning
1. Clean gasket sealing material from cylinder block
and pan flanges.
2. Wash all parts in cleaning solvent.
3. Put on safety glasses and dry parts with compres-
sed air.
Inspection
1. Replace the complete oil pressure valve assembly if
the spring is broken.
2. Replace the complete valve assembly if the valve is
badly worn or sticking in the bore.
3. The valve can be lapped into it the seat using a grin-
ding paste, if necessary to restore pressure.
4. Ensure that the valve slides freely in the valve seat
and valve body when coated with oil.
Assembly
1. Coat the inside of the oil pressure relief valve seat
and body bore with engine oil.
Liberally coat the remaining components. a - Relief valve
2. Assemble the valve, springs, and cap. Install parts b - Spring (inner ‑ if dual spring equipped)
into valve seat and body. c - Spring (outer ‑ if dual spring equipped)
3. Push the cap in against the high pressure spring d - Cap
and hold. e - Snap‑ring
4. Install the snap‑ring. f - Valve seat and body
Installation
1. If installing only the oil pressure relief valve and
spring, or springs: refer to Assembly.
Observe all precautions and perform all steps with the
valve body still in the crankcase.
2. If installing the complete oil pressure relief valve
assembly:
a. Apply sealant Loctite 510 to the threads when repla-

cing the complete oil pressure relief valve assembly.
Screw the complete assembly into the crankcase.
b. Using a suitable tool, torque the oil pressure relief
valve assembly into the crankcase.
Oil pressure relief valve assembly 53.9 Nm
a - Oil pressure relief valve assembly

b - Threads
Basic Engine 135

R 750
engine block
crankcase
In case of engine overhaul or oil pan removal verify a
the installation and related caulking of plugs that close
the balance shaft assembly lubricating oil gallery, on
engine whit balance shaft assembly installed.
a - plugs
inspection
On some engine versions is possible the balance shaft as- Figura 1
Photo 1
sembly is not installed. The balance shaft assembly lube oil b
gallery on the block are close by plugs.
a - Plugs
In case of engine overhaul verify if the plugs (A) are caulked

(see photo 2-3)
In case of photo 1 the plug “B” comes out of block or is not

correctly installed. The plug is NOT properly seated. The
plug must be correctly installed and caulked. (see photo 2-3)
B - plug comes out of crankcase
IMPORTANT: carry out always the Figura 2

Photo 2
caulking on all plugs: install the plug at
the same level of the block surface as
shown in the photo 2-3 and carry out
the caulking by 180°.
Figura 3
Photo 3
136 Engine Block

R 750
engine block
Liner
removal
Remove the liners by using the special tool
Remove engine components as needed, including pistons. a
Remove the piston cooling jets (oil spray nozzles).
Remove the plate from Cylinder Liner Puller Tool.
a - Cylinder Liner Puller Tool
b - Plate
IMPORTANT: To avoid mismatching cylinder liners and pi-
stons upon reassembly, mark the liners in a suitable fashion
as to the cylinder number and orientation in the cylinder
block.
b
Install the Cylinder Liner Puller Tool into the cylinder liner and
attach the plate to the tool at bottom of the cylinder liner.
Screw the nut of the tool and remove the cylinder liners. Note
the O‑rings on the cylinder liner lower part.
c
specifications
Remove old sealant from the cylinder liners.
Clean the cylinder liners, especially at areas where shown,
and in the areas where the O‑rings fit.
c - Areas for special cleanliness
Wash the liners in cleaning solvent.
Put on safety glasses and dry the components with compres-
sed air.
Inspect the cylinder liners for abnormal wear or cracks.
Inspect the cylinder liners for a ridge at the top of the ring
travel. Remove the ridge if the cylinder liners are within
specification.
Measure the cylinder liners for taper and out of round using a
dial indicator or inside micrometer. If wear exceeds specifica-
tion replace the cylinder liners.
NOTE: Carefully move the gauge up and down in the cylin-
der liner bore to determine taper.
Measure the taper at three different vertical positions and at
opposite sides of the cylinder liner bore. Turn the gauge to
different points around the cylinder liner wall to determine the
out of round condition.
Maximum measurement depth is 108 mm down from the
top edge of the cylinder liner.
Cylinder Liner
Production diameter - inner 93.995 ‑ 94.015 mm
Wear limit 0.10 mm
Production out of round or taper 0.008 mm
Maximum out of round or taper 0.10 mm
Engine Block 137

R 750
Installation a - Cylinder liner recess
Cylinder liners on all engines are required to protrude, or rise b - Cylinder liner
above, the surface of the cylinder block. c - Cylinder block
d - Cylinder head mounting
CAUTION :Cylinder liner protrusion can only be surface
correctly measured with the cylinder liners fully seated in the
cylinder block.
Incorrect measurements will result in engine performance
problems or severe engine damage. Ensure the cylinder
liners are fully seated in the cylinder block before measuring
cylinder liner protrusion.
NOTE: The cylinder liners will rotate freely in the bore when
the cylinder block and cylinder liner are completely clean and
ready for measuring cylinder liner protrusion.
a. Unless being replaced, install the cylinder liners in the
same cylinder block bore without O‑rings as marked or a - Support Block tool
noted upon disassembly. b - dial indicator
b. Using a precision depth gauge measure and record the
amount of cylinder liner recess (the depth below the cylinder
head mounting surface of the cylinder block) of each liner.
a
1. Use the dial indicator and Support Block tool (liner gauge
bar) (Refer to Special Tools Section) to measure the liner
protrusion above the cylinder block.
2. Place Support Block with the dial indicator feeler gauge on
the cylinder block.
3. Set the dial indicator to zero (0).
b
4. Move the dial indicator to the liner on the liner neck. Re-
cord the measurement.
5. Measure the liner protrusion of all liners.
6. Verify the amount of liner protrusion for each liner as
specified:
Cylinder liner protrusion - 0.01 ÷ + 0.07 mm
If the amount is incorrect, replace the liner and install another

x
one.
If the amount is correct to procede with the installation of all
liners as follows:
7. Install two coloured O‑ rings (same colour) in the liner y
grooves lower part and another O‑ ring (different colour than
previous 2 O-rings) in liner groove lower part. (see picture).
IMPORTANT: The first two O-rings have a different thickness
and colour than the second one. Do not mix O-rings one
another.
8. Lubricate with lubricant lower centering collars in cylinder

block (those areas where lower liner O‑ rings seal against
the bore).
IMPORTANT: Do not lubricate upper bore area where sea- x - two coloured O‑ rings in the liner grooves lower part
lant (LOCTITE 986) will be applied later.(see next step 9). (same colour)
9. Select and apply the specified sealant (LOCTITE 986) to y - O‑ ring in liner groove lower part. (different colour than
the liner surfaces, as shown in the picture. other 2 o-rings with same colour)
LOCTITE 986
138 Engine Block

R 750
10. Install the cylinder liners in the cylinder block, being care-
ful not to damage the O‑ rings.
11. Once the liners are installed, hold the liners securely in
position with the bolts and formed spacer‑washers.
Temporarily torque the bolts and allow the sealant to get dry.
a - Cylinder liner
b - Suitable bolt
c - Formed spacer washer
IMPORTANT: If the cylinder heads are not installed

within 1 hour, the cylinder liners must remain clamped by the
spacer washers and bolts for roughly 8 hours, so that the
sealant can properly cure. After 8 hours the spacer washers
and bolts can be removed and the cylinder heads can be
installed.
12. After the sealant is dry, verify the cylinder liner protrusion
as stated before.
13. If the cylinder liner protrusion is correct, continue the
engine assembling.
Engine Block 139

R 750
camshaft
Testing ‑ Measuring Lobe Lift
1. Remove the rocker arm assemblies.
2. Secure the dial indicator to the cylinder head so the dial indicator plunger rests inside the push rod cup.
3. Turn the crankshaft so that the camshaft lobe is at the bottom of its travel.
4. Set the dial indicator to “0” (zero).
5. Turn the crankshaft 2 (two) complete revolutions while reading the dial indicator.
6. Measure all lobes of camshaft in the same manner.
IMPORTANT: Camshaft replacement will be necessary if lobe dimensions are less than 0.05 mm of the
values specified.
Camshaft - Lobe lift

Exhaust 7.303 mm
Intake 6.850 mm
Wear Limit 0.05 mm
CAMSHAFT lobe diameter

1. Measure the total camshaft height with a micrometer. Subtract the lobe diameter. The difference is lobe lift.
If the lobe lift is less than specified, the camshaft must be replaced.
Camshaft - Lobe diameter

Exhaust 38.550 ‑ 38.650 mm
Intake 39.450 ‑ 39.550 mm
Wear Limit 0.05 mm
a - Total camshaft height

b - Lobe diameter
c - Lobe lift
CAMSHAFT JOURNAL DIAMETER

1. Use a micrometer to measure each camshaft journal
diameter in two directions (“X‑X”)
and (“Y‑Y”). If the measured value is less than speci-
fied, the camshaft must be replaced.
NOTE: Camshaft bearings are available in

0.250 mm undersized. Clerance between camshaft
journal and camshaft bearings, refert to “Camshaft
Bearings” section.
Camshaft Journal diameter

Front 53.495 ‑ 53.510 mm
Center 53.450 ‑ 53.470 mm
Rear 53.480 ‑ 53.500 mm
Wear limit 0.200 mm
140 Engine Block

R 750
CLEARANCE BETWEEN THRUST PLATE AND CAMSHAFT
1. Measure clearance between thrust plate and camshaft.
Camshaft
Thrust plate and camshaft clearance 0.030‑0.095 mm
IMPORTANT: Camshaft gear is a press fit on shaft. If removal is needed, upon reassembly gear must be heated
in an oven to 180‑200 degrees °C (360‑390 degrees °F) for 10 minutes and pressed on the shaft. After installing
the proper thrust plate and positioning the key, press the gear until it is tight against the shoulder.
2. If the measured value exceeds specification, remove and inspect the thrust plate thickness at four opposite
points. Replace the plate if assembly clearance is less than specified at any point.
Camshaft thrust plate thickness (S) 3.95 ‑ 4.05 mm
s - Camshaft thrust plate thickness

a,b,c,d - Thickness dimension at four opposite points
e - Camshaft thrust plate
f - camshaft gear
Engine Block 141

R 750
Removal
Turn crankshaft to cylinder number 1 TDC of its com-
pression stroke so that the timing marks on camshaft
gear and idler gear are aligned as shown.
IMPORTANT: Place rocker arm assemblies, valve push

rods and lifters in a rack for reassembly in their original
locations.
Remove the rocker arm assemblies and valve push

rods. Remove the valve roller lifters.
Remove the cylinder heads.
Remove the oil level dipstick.
Remove camshaft thrust plate mounting screws and timing reference marks
lock washers.
Carefully withdraw the camshaft. Take care not to da-
mage the camshaft bearings.
a - Camshaft thrust plate mounting screw

b - Camshaft thrust plate
c - camshaft gear
c c
a
a
Installation
Lubricate the camshaft lobes with engine oil
Lubricate the camshaft bearings.
Install the camshaft. Be careful not to damage the bea-
rings.
Align the timing marks on camshaft gear and idler gear
as shown previously.
Install the thrust plate mounting screws using the
lockwashers. Torque the screws.
Camshaft thrust plate mounting screw 27.5 Nm
142 Engine Block

R 750
Camshaft bearings
Inspection
1. Remove the camshaft.
2. Inspect the camshaft bearings. Replace the bearings if they are worn or damaged.
3. Measure the inner diameter of the camshaft bearings and compare to the camshaft journal dimensions. Calcu-
late the bearing clearance.
IMPORTANT: In service when replacing the front camshaft bushing it must be bored once that is
installed into its cranckcase seat. Install the front bushing by aligning the lubrication oil hole in the block
with the bushing hole. Refer to the picture to identify the inclination angle.
specifications
Camshaft Front Bushing
Bushing inner diameter (Bushing bored into the block) 53.59 - 53.62 mm
Clearance (bushing - journal) 0.08 - 0.125
Camshaft Rear and Center Bearing

Bearing inner diameter (bearings installed in the block) 53.550 - 53.600 mm
Clearance (Center Bearing) 0.08 - 0.15
Clearance (Rear Bearing) 0.05 - 0.12
First oversized Bushing 0.25 mm
20°
sede albero camme

- camshaft seat
sede ingranaggio rinvio

- idler gear seat
sede albero motore

- crankshaft seat
sede pompa olio

- oil pump seat
Engine Block 143

R 750
front journal Camshaft bushing
Install a new bearing on bearing puller tool.

Align the oil passage in the engine block with the hole of
the new bearing.
NOTE: To aid installation retain bearing halves on tool
with a rubber band or similar. a b a
Assemble the Front Main Bearing and Camshaft Bea-
ring Puller into front main bearing.
a - Bearing puller tool

b - Front main bearing (new bushing)
Apply Loctite 601 on the bearing outer surface.

Using two wrenches, hold the puller screw and then,
turn the nut until the old bearing has been pulled out
from proper seat.
The Front Main Bearing and Camshaft Bearing Tool will
install the bearing to the correct depth.
IMPORTANT: While removing/install a new bea-

ring (Crankshaft Front Main Bearing or Camshaft
Bearing) ensure that the oil hole in the bearing is
positioned correctly. The oil hole in the bearing
must be aligned with the oil passage in the engine
block for proper lubrication.
a - Oil passage (in crankcase)

b - Bearing hole
c - Front Main Bearing and Camshaft
Bearing Puller Tool
d - Bearing halves (on tool)
e - Bearing bore
144 Engine Block

R 750
Piston Cooling Jets (Oil Spray
Nozzles) a b
Oil spray from the piston cooling jet nozzles cools
and lubricates the piston and other engine com-
ponents. Inadequate or improper oil spray could
result in engine damage.
Ensure the oil spray nozzles are clean and the pi-
ston cooling jet assemblies are correctly installed
to allow proper oil spray distribution.
Remove the piston cooling jet assembly from near the

cylinder bore. d
Remove and discard the O‑ring seal on the piston
cooling jet.
a - Cooling jet assembly

b - Nozzle
c - Plate
d - Bolt
Clean the passages of the piston cooling jet and cylin-

der block.
Put on safety glasses.
Blow out any debris from cleaning, using compressed
air. c
Ensure the check valve ball moves freely against the
spring in the bore. b
x - Spring
y - Check valve ball
2. Check for a cracked, bent or damaged tube or a d

nozzle.
x y
Install a new O‑ring in the piston cooling jet groove.

Lubricate the piston cooling jet O‑ring.
Insert the piston cooling jet assembly into the cylinder
block.
Ensure that the piston cooling jet assembly is correctly
seated.
Position the tube and nozzle as shown.
Apply sealant to the piston cooling jet assembly screw
threads.
Install and torque the piston cooling jet assembly screw.
Piston cooling jet assembly screw 12.7 Nm
Engine Block 145

R 750
crankshaft
removal
1. Remove the main bearing locating screws and spe-
cial locating screws that hold the main bearing carriers
in cylinder block and supply lubricating engine oil to
main bearings carriers and front / rear main bearings. c
a - Locating screw ‑ standard
b a
b - Special locating screw (for oil supply hose to turbo- a
charger)
c - Oil supply pipe ‑ rocker arms
2. Install the Crankshaft Installer Tool over the timing

gear to protect front main bearing.
d - Crankshaft Installer Tool

e - Crankshaft gear
IMPORTANT: Before removing the crankshaft from the e

block, number or mark the bearing carriers according
to the journal upon which they are fitted. Also make
matching marks on both bearing carrier halves for
correct reassembly.
IMPORTANT: When removing the crankshaft do not

damage the piston cooling jet. Ensure to remove
the oil piston cooling jet. (Refer to Oil Piston coo-
ling Jets Section) d
x - matching marks on both bearing carrier halves

y - matching marks on all main bearing carriers
(between carrier and block)
z - number all main center bearing carrier according to
the journal upon which they are fitted
3. Withdraw the crankshaft so that the main bearing z

carries can be disassembled.
Disassemble all main bearing carriers.
Take crankshaft off from the cylinder block.
w - main bearing carriers removed proper block bore

x
y
146 Engine Block

R 750
Inspection
1. Inspect crankshaft for deep grooves, scratches, pitted
surfaces or uneven wear.
2. Inspect crankshaft rear oil seal surface for scoring or
damage.
3. Inspect crankshaft oil passages for restrictions.
4. Inspect the crankshaft threaded bolt holes for dama-
ge.
5. Inspect the crankshaft balancer keyway for damage.
6. After a seizure, overheating or grinding, crankshaft

must be Magnafluxed to verify no surface cracks are
present.
After grinding perform “SURSULF” treatment (hardness
HV 587 with load of 500 gr. corresponding to HRc 53).
After treatment “SURSULF” perform lapping o n all sur-
faces with roughness Ra 0.18 / 0.22.
IMPORTANT: It is forbidden the crankshaft straightening

after SURSULF treatment. No material may be remo-
ved, either by hand or machine grinding, from
thrust faces of crankshaft. Replace crankshaft if machi-
ned surfaces on front and rear ends or threaded areas
of crankshaft ends are out-of-round, worn or damaged.
7. Measure the journals of the crankshaft to determine if

replacement or grinding is necessary.
specifications
Lenght (4 cylinders) 595.1 mm

Lenght (6 cylinders) 819.1 mm
Crankshaft Front Main Bearing Journal Outer diameter 62.985 - 63.005 mm
First Oversized Bearing 0.25 mm
Center Main Bearing Crankshaft Journal Outer diameter 63.005 - 63.02 mm
Rear Main Bearing Crankshaft Journal Outer diameter 79.985 - 80 mm
Crankshaft Connecting Rod Journal Outer diameter 53.940 - 53.955 mm
Wear limit 0.10 mm
Front Main Bearing Clearance (between crankshaft Front Main Bea- 0.023 - 0.083 mm
ring Journal Outer diameter and crankshaft Front Main Bearing inner
diameter)
Center Main Bearing Clearance (between Center Main Bearing 0.008 - 0.051 mm
Crankshaft Journal Outer diameter and main bearings carrier inner
diameter)
Rear Main Bearing Clerance (between Rear Main Bearing 0.045 - 0.085 mm
Crankshaft Journal Outer diameter and Rear Main Bearing carrier
inner diameter)
Connecting Rod Bearing Clerance (between Crankshaft Connec- 0.012 ‑ 0.066 mm
ting Rod Journal Outer diameter and connecting ros bearings inner
diameter)
Engine Block 147

R 750
20172140F_1
148 Engine Block

R 750
20172136G_1
Engine Block 149

R 750
installation a - Brush dipped in lubricant
Lubricate with grease the main bearing bores in the b - Main bearing bore
cylinder block.
Install the matching main bearing carrier halves on
crankshaft journals in their original locations (marked
during disassembly) or by referencing the factory paint
marks on the side.
Ensure that all carriers were positioned so that the front
of the carrier halve is toward the crankshaft gear after
installing them on the journal.
Lubricate with MOLYguard LMP 180 grease the bearing
carrier underside bolts and thread and torque them.
Bearing carrier bolt 44.1 Nm
a- Reference paint marks made by factory or operator

during disassembly
b-‑ Reference that identifies the front of the carrier, it
must be pointed toward the crankshaft gear.
c- crankshaft gear
Install the Crankshaft Installer Tool over the timing

gear to protect the front main bearing.
Position the engine cylinder block horizontal with the
oil pan flange facing up.
Carefully insert the crankshaft with the main bearing
carriers attached into the cylinder block.
a - Crankshaft assembly
b - Main bearing carrier entering cylinder block
150 Engine Block

R 750
Rotate the bearing carriers to align with marks made
during disassembly. If no marks are present, position z
the bearing carriers with the round hole through the
casting pointing toward the oil pan flange.
x - matching marks on both bearing carrier halves

y - matching marks on all main bearing carriers
(between carrier and block) x
z - Round holes through the castings
y
Install new sealing washers on all main bearing loca-
ting screws and special locating screws.
To avoid damaging the threads,hand thread the main
bearing locating screws and special locating screws
into the bearing carriers.
Torque all main bearing locating screws and special
locating screws.
a - Locating screw ‑ standard

b - Special locating screw (for oil supply hose to turbo-
charger)
Locating screw 53.9 Nm
b a
a
Engine Block 151

R 750
Crankshaft front main bearing
Install a new bearing on bearing puller tool.
Align the oil passage in the engine block with the hole of
the new bearing.
NOTE: To aid installation retain bearing halves on tool
with a rubber band or similar.
a b a
Assemble the Front Main Bearing and Camshaft Bea-
ring Puller into front main bearing.
a - Bearing puller tool

b - Front main bearing
Apply Loctite 601 on the bearing outer surface.

Using two wrenches, hold the puller screw and then,
turn the nut until the old bearing has been pulled out
from proper seat.
The Front Main Bearing and Camshaft Bearing Tool will
install the bearing to the correct depth.
IMPORTANT: While removing/install a new bea-

ring (Crankshaft Front Main Bearing or Camshaft
Bearing) ensure that the oil hole in the bearing is
positioned correctly. The oil hole in the bearing
must be aligned with the oil passage in the engine
block for proper lubrication.
a - Oil passage
b - Bearing hole
c - Front Main Bearing and Camshaft
Bearing Puller Tool
d - Bearing halves (on tool)
e - Bearing bore
152 Engine Block

R 750
INJECTION SIDE
INJECTION FUEL SYSTEM
DIAGRAM
al veicolo
10a
. Serbatoio combustibile 1. Tank

. Filtro combustibile 2. Fuel Filter Assembly
3. Blocchetto di rifiuto nafta 3. Fuel refuses collecting block
4. Pompe iniezione alta pressione 4. High Pressure Pump
5. Valvola di regolazione pressione combustibile 5. Fuel metering Valve
6. Valvola regolazione pressione nel rail 6. Rail Pressure Regulator Valve
7. Accumulatore di pressione (Rail) 7. Rail
. Sensore pressione rail 8. Rail Pressure Sensor
9. Iniettori 9. Injectors
0. Filtro Aria - 10a. Debimetro (solo per motori EURO 5) 10. Air Filter
. Turbocompressore 10a. Air Mass Flow meter - only for EURO 5 engine models
. Intercooler 11. Compressor
3. Valvola aspirazione a farfalla 12. Intercooler
4. Valvola EGR 13. Electronic Throttle Body
5. Scambiatore di calore EGR 14. EGR Pneumatic Valve
6. Collettore EGR 15. EGR Cooler
7. Collettore aspirazione/ sensore pressione aria comburente 16. EGR Distributor
. Sensore di posizione albero motore/sensore giri 17. Intake Manifold Pressure + Temperature Sensor
9. Sensore da fase albero camme 18. Crankshaft Position / Engine Speed Sensor
0. Sensore temperatura liquido di raffreddamento 19. Camshaft Position Sensor
. Sensore pressione e temperatura olio motore 20. Coolant Temperature Sensor
. Candelette 21. Oil temp & Pressure sensor
3. Pedale acceleratore 22. Glow Plugs
4. Centralina motore 23. Pedal Assembly
24. Engine Control Unit
Injection Side 153

R 750
electrical sensors
location
Engine Coolant temperature Intake - air temperature and pressure sensor
154 Injection Side

R 750
Camshaft / Phase sensor
Fuel pressure regulator valve
Injection Side 155

R 750
Crankshaft position sensor / engine RPM sensor
156 Injection Side

R 750
Pressure sensor - Rail Lube Engine oil Temperature and Pressure sensor
Injection Side 157

R 750
low pressure system requirements
A Inlet fuel filter - 0.4 bar

B Outlet fuel filter/Inlet low pressure pump
B max vacuum pressure
Difference between A - B (max. bar)
C fuel pump return
C ≤ 0.6 bar
158 Injection Side

R 750
high pressure pump
removal
Release the clamp and disconnect the fuel delivery rubber
hose from the pump.
Loosen and remove the fuel return hose hollow bolt and
proper washers from the pump.
Loosen and remove the fuel delivery pipe nut from high
pressure pump to rail.
Loosen and remove the 3 fixing flange screws.
Take the pump off. Replace the gasket install on the studs.
b
a - fuel delivery rubber hose clamp
d
b - fuel return rubber hose hollow bolt and proper washers
c - fuel delivery pipe from high pressure pump to rail.
a
d - fixing flange nut
d
c
Loosen the flange nut and use a normal gear extractor to

remove the injection pump gear.
Remove the collar out without damaging the body flange of
the pump. At the spare parts the pump will supply as assem-
bly: pump and collar.
e - collar
Injection Side 159

R 750
Installation
Install the collar with bevelled side towards outside.

Press the collar till it goes in contact with body flange pump.
a - bevel
Install the gear on the pump shaft.
IMPORTANT: The spline is not installed on the

pump shaft keyway.
b - keyway
Install the nut and torque it.
High pressure pump gear nut 86.4 Nm
160 Injection Side

R 750
Install a new gasket on the studs.
c - gasket
Install the high pressure pump on studs, thread the flange
nuts and torque them.
d - flange nut
High pressure pump flange nut 27.5 Nm
NOTE: The pump must not be timed.
Install with proper clamp the fuel return rubber hose to the
pump.
Install the fuel delivery hose hollow bolt with proper washers
x
to the body pump and torque it.
x - fuel delivery hose hollow bolt
y - fuel return hose hollow bolt
y
fuel delivery hose hollow bolt 27.5 Nm
fuel return hose hollow bolt
WARNING: When the pump is removed a specific

procedure must be performed to install correctly high
pressure fuel delivery pipes.
Before installing the high pressure pipe from pump
to rail and high pressure pipes from rail to injectors a
specific procedure must be observed. (Refer to High d
Pressure fuel components Tightening Procedure)
NOTE: Whenever each of these components such

as the high pressure pump, injectors, rail and any high
pressure fuel pipe (pipe from pump to rail and pipes
from rail to injectors) are loose and/or removed, a spe-
cific procedure must be performed in order to avoid fuel
leakage in the high pressure fuel system, high pressure
fuel delivery pipes.
(REFER TO HIGH PRESSURE FUEL COMPONENTS

TIGHTENING PROCEDURE)
Injection Side 161

R 750
injector
Removal
IMPORTANT: Whenever injectors are removed for

service, they must be retained in order. At the time of
installation, they must be installed in the same locations
as when removed, because each injector has a proper
IMA code. a
Loosen the injector fixing screw and remove the clamp. c
Loosen the high pressure fuel pipe nut.
IMPORTANT: When loosing high pressure pipe

nut on injector retain injector feed connector with a
wrench 13 mm.
b
Push the fuel return hose clamp to remove it.
Take the injector off by hand.
a - injector fixing screw and the clamp

b - fuel return hose clamp
c - high pressure fuel pipe nut
d - IMA code
e - injector feed connector
b
e
IMPORTANT:
R750EURO 4 IMA code is composed by number 6 digit
R750EURO 5 IMA code is composed by number 7 digit
162 Injection Side

R 750
Installation
Verify the cleaning into cylinder head bore where the injector
is located. d
Install a new O-ring in proper groove in the injector and apply
Molykote P 1500 paste as shown in the photo.
Verify that the washer is installed at the end of the injector.
Install the injector into the cylinder head.
Verify the presence of the plaque on rocker arm cover.
Install the injector clamp and fixing screw with spherical
washer, to be installed as shown in the photos.
f
a - injector clamp
b - injector washer
c - injector fixing screw and proper spherical washer
d - plaque on rocker arm cover a c
e - injector O-ring with Molikote P 1500 paste
f - cylinder head bore where the injector is located.
g - IMA code
Finger tighten completely the injector fixing screws and

torque them.
injector fixing screw 21 - 25 Nm
c a
WARNING: When the injector is removed a speci-
fic procedure must be performed to install correctly high
pressure fuel delivery pipes. d
Before installing the injector high pressure fuel pipes
from rail to injectors a specific procedure must be
observed. (Refer to High Pressure fuel components
Tightening Procedure)

b e
IMPORTANT: Whenever one or all injectors are

replaced, new IMA code must be re-written inside ECU
by diagnostic tool.
g
Injection Side 163

R 750
rail
Removal
Remove any component wich hinders the rail removal.
Remove high pressure pipes from the rail: from rail to injector
and from high pressure pump to rail.
a
Remove the bolts fixing to rail bracket.
Remove the rail. c
a - high pressure pipes (from rail to injectors)
b - high pressure pipes (from rail to high pressure pump)
c - rail fixing bolt to rail bracket b
Installation
WARNING: When the rail is removed a specific

procedure must be performed to install correctly high
pressure fuel delivery pipes.
Before installing the high pressure pipe from pump
to rail and high pressure pipes from rail to injectors a
specific procedure must be observed. (Refer to High
Pressure fuel components Tightening Procedure)
c
164 Injection Side

R 750 - Draft
R 750
HIGH PRESSURE fuel COMPONENTS TIGHTENING PROCEDURE
NOTE: Whenever each of these components such as the high pressure pump, injectors, rail and any high pres-
sure fuel pipe (pipe from pump to rail and pipes from rail to injectors) are loose and/or removed, a specific procedure
must be performed in order to avoid fuel leakage in the high pressure fuel system, high pressure fuel delivery pipes.
If this procedure is observed, a correct alignment of high fuel pressure pipes is carried out so that the fuel leakage in
high pressure fuel system is avoided.
IMPORTANT: Whenever any high pressure fuel delivery pipe (pipe from pump to rail and pipes from rail to
injectors) is loose and/or removed, it must be replaced in order to avoid fuel leakage in the high pressure fuel system.
1 - Verify that the injectors are properly tight. (Refer to Injector Section).
2 - Verify that the high pressure pump is properly tight. (Refer to High pressure Pump Section).
3 - Even if the following screws are tight, therefore loosen them:
• the screws fixing the rail to the bracket
• the screws fixing the rail bracket to crankcase.
4 - Finger tighten completely and simultaneously every high pressure pipes nuts.
5 - Install the clamp on the high pressure pipe from pump to rail and finger tighten proper screw.
6 - Torque the high pressure pipe nut no. 3 (for engine with 4 cylinders) no. 4 (for engine with 6 cylinders) at RAIL SIDE 19 ± 2
Nm
7 - Torque the high pressure pipe remaining nuts at RAIL SIDE (no. 1,2,4,5 for engine with 4 cylinders and 1,2,3,5,6,7 for engi-
ne with 6 cylinder.) 19 ± 2 Nm
8 - Torque the high pressure pipe nuts at INJECTOR SIDE (no.1,2,3,4 for engine with 4 cylinders and 1,2,3,4,5,6 for engine
with 6 cylinder.) 27 ± 2 Nm
9 - Torque the high pressure pipe nut at HIGH PRESSURE PUMP 20.5 ± 2 .5 Nm
10 - Torque the screw of the clamp fixing the high pressure pipe from pump to rail to rail bracket 14.7 ± 2 Nm
11 - Torque the screws fixing the rail to the bracket and the screws fixing the rail bracket to crankcase 33 ± 2 Nm
b e b
a
c
e
d
e
a - high pressure pipe nuts at RAIL SIDE (no. 3 for engine with 4 cylinders) (no.4 for engine with 6 cylinder)
b - high pressure pipe nuts at INJECTION SIDE
c - high pressure pipe nut at HIGH PRESSURE PUMP
d - screw of the clamp fixing the high pressure pipe from pump to rail to rail bracket
e - screws fixing the rail to the bracket and the screws fixing the rail bracket to crankcase
Injection Side 165

R 750
oil filter HOUSING
Removal
To remove the oil filter cartridge, refer to Maintenance Sec-
tion.
Loosen the bolt fixing the oil filter assembly (oil filter cartridge
and oil filter housing) to oil heat exchanger.
Remove the oil filter assembly.
Loosen the special bolt fixing the oil heat exchanger to
crankcase. Loosen the clamp fixing the rubber hoses to oil
heat exchanger and remove it. a
a - bolt fixing the oil filter assembly (oil filter cartridge
and oil filter housing) to oil heat exchanger.
b - special bolt fixing the oil heat exchanger to crankca-
se.
installation b
Replace the old O-ring into the groove of oil heat exchanger a
and install a new one. Grease the O-ring with Molykote 111.
Install the oil heat exchanger and torque the special bolt
fixing the oil heat exchanger to crankcase.
“b” special bolt fixing the oil heat exchan- 60 Nm

ger to crankcase. d
Replace the old O-ring into the groove of oil filter assembly
c
and install a new one. Grease the O-ring with Molykote 111.
Replace the O-ring into the groove bolt fixing the oil filter
assembly and grease it with Molykote 111.
Finger tighten and torque it.
“a” bolt fixing the oil filter assembly 39.2 Nm e

c - O-ring into the groove of oil heat exchanger
d
d - O-ring into the groove of oil filter assembly a
e - O-ring into the groove bolt fixing the oil filter assem-
bly to oil heat exchanger.
c
b
166 Injection Side

R 750
oil delivery pipe to rocker arm
Removal
Loosen and remove the hollow bolts (injection and exhaust
side) and proper washers. Loosen also the clamp fixing the
pipe to cylinder head end spacer).
a - hollow bolts (injection side)
b - hollow bolt (exhaust side)
c - clamp fixing pipe to cylinder head spacer
Installation
Install the hollow bolts with new washers. Lubricate with
engine oil the hollow bolts thread.
Install the clamp and tighten securely it.
a c
hollow fixing bolt (cylinder head side) 14 Nm
hollow fixing bolt (exhaust side) 23.5 Nm
Injection Side 167

R 750
rocker arm cover
Removal
Remove any component that hinders the rocker arm cover
removal.
Loosen and remove the fixing screws. a
Remove the gasket.
a - rocker arm fixing screw
Installation
Install a new gasket if necessary.
Install the cover and torque the fixing screws in a cross
pattern (see picture)
rocker arm fixing screws 11.8 Nm
coolant manifold
Removal
Remove any component that hinder the coolant manifold
removal.
Rocker arms cover - tightening procedure
Remove the fixing screws and take the manifold off.
Replace the old gasket.
x - coolant manifold fixing screw
x
Installation
Inspect the sealing surfaces for deep nicks and scratches.
Inspect the castings for cracks or corrosion that might pre-
vent a proper seal.
Replace or repair components as needed.
IMPORTANT: The end cover and the coolant manifold
gasket flanges must align for proper sealing on the cylinder
heads. Align the flanges using a straight edge as shown.
Align the coolant manifold end cover and the coolant mani-
fold using a straight edge device and then, torque the coolant
manifold end cover screws evenly in a diagonal pattern.
Insert a new gasket between Coolant manifold and Coolant
manifold end cover, by applying Loctite 510 on both surfa-
ces.
coolant manifold screws 11.8 Nm

coolant manifold end cover screws 10.8 Nm
a - Coolant manifold end cover
b - Gasket
c - Coolant manifold
d - Typical straight edge device
e - Coolant manifold end cover screw and washer
168 Injection Side

R 750
thermostatic valve
Removal
Remove the no. 4 thermostat cover screws. x
Remove the cover and take the thermostat off.
x - thermostat cover screws
installation
Install the cover and torque the fixing screws.
thermostat cover screws 10.8 Nm
Injection Side 169

R 750
vacuum pump
removal
If needed remove the alternator from the engine.
Disconnect oil feed pipe and oil return pipe from vacuum
pump.
c
Loosen the vacuum pump fixing screws.
Installation
Ensure that the O-ring is properly seated.
Replace it if needed. a
Install the vacuum pump on the alternator.
Torque the vacuum pump fixing screws to alternator.
x - oil feed pipe to vacuum pump

y - oil return pipe from vacuum pump
a - vacuum pump
b - O-ring
c - vacuum pump fixing screw
Refer to section “Alternator” to identify the torque value

of vacuum pump oil supply hollow bolt
y x
170 Injection Side

R 750
ENGINE ELECTRICAL
Alternator
Removal a
• Remove Poly-V belt.
• Disconnect wiring electrical connections from the
alternator.
• Detach from the vacuum pump any oil feeding and c
draining hose
• Loosen and remove the alternator fixing bolt.
• a - Alternator
• b - Vacuum pump
• c - alternator fixing bolt
• d1 - Vacuum pump oil feeding
• d2 - Vacuum pump oil draining hose
Installation
Position the alternator on the bracket. b
Thread the bolts in the alternator and torque the nuts.
Alternator fixing bolt 45.1 Nm

Install vacuum pump oil feeding hollow bolt with proper
washers and draining hoses .
vacuum pump oil feeding hollow bolt (on 24.5 Nm d1

vacuum pump)
vacuum pump oil feeding hollow bolt (on 27.5 Nm
crankcase)
c d2
Alternator pulley
Removal
The alternator pulley could be idle type: it can be identified
if the front cover is present or the special tool 68420022F
installs on the pulley.
Remove the cover and install the special tool 68420022F
and dissamble the pulley.
installation
Thread the pulley on the alternator shaft.
Tighten the pulley.
Alternator idle pulley 80 ± 5 Nm
IMPORTANT: Install alternator fan with the arrow

rinted on it as shown in the photo.
Engine Electrical 171

R 750
testing
W
TERMINALE W - corrente in uscita
D+
TERMINALE D+ - per carica /

lampada carica batteria
schema per controllo alternatore
WL: Lampada carica alternatore da

2 a 4 watts, 12 V
IS: Interuttore accensione
172 Engine Electrical

R 750
Constant Ampere RPM Alternator

Voltage
13.5 V 0 amp 1000 rpm
23 amp 1500 rpm
105 amp 6000 rpm
Volt Costanti Ampere giri/min Alternatore

13.5 V 0 amp 1000 giri/min
23 amp 1500 giri/min
105 amp 6000 giri/min
corrente in
uscita
alternatore
giri/min.
Rapporto puleggia albero motore / puleggia alternatore 2.63

crankshaft pulley / alternator pulley ratio 2.63
Engine Electrical 173

R 750
voltage regulator
removal
• Remove the alternator from the engine.
• Remove the vacuum pump if needed and loosen the voltage regulator fixing screws.
• a - vacuum pump
• b - voltage regulator fixing screws
• c - voltage regulator
b
c
Alternator Bracket
Removal
a
• Unscrew the alternator bracket bolts.
• Remove the bracket
a - alternator fixing bracket bolts
Assembling
• Position the bracket on the cranckcase
• Thread the bolts and torque them.
Alternator bracket bolt 68.6 Nm
Starter
Removal
• Unscrew the starter fixing bolts.

• Remove the starter
a - starter fixing bolts
a
Assembling
• Position the starter on the flywheel housing
• Thread the bolts and torque them.
Starter fixing bolt 83.4 Nm
174 Engine Electrical

R 750
ENGINE CONTROL
DIAGNOSTIC TROUBLE CODES “euro 4”
NOTE: In VM Motori internet web site Customer Reserved Area “EXTRANET”, section “Diagnostic Tool & Trouble-
shooting Common Rail Engines R750 MR700-500” are available:
• the lastest Diagnostic Tool Software Release for Common Rail Engine Models
• Industrial and Marine Common Rail engine troubleshooting symptoms charts
ENGLISH ITALIANO DTC

Crankshaft/Camshaft Position Sensor Offset Errore di Posizione Sensore Albero a Camme/Al- P0016
Error bero Motore
BPA Boost Pressure Actuator Solenoid Circuit Malfunzionamento Circuito Solenoide Attuatore P0046
Malfunction di Controllo Pressione di Sovralimentazione BPA
Air Temperature Signal Duty Cycle Error Errore Duty Cycle Segnale Temperatura Aria P0070
Fuel Rail Pressure Monitoring Error for Active Errore Pressione Rail durante Controllo Pressio- P0087
Pressure Control by Metering Unit Governor ne Rail da Regolatore di Pressione
Raw Air Mass Signal Plausability Error Errore di Plausibilità Segnale Portata Aria P0100
Raw Air Mass Signal Plausability Error Errore di Plausibilità Segnale Portata Aria P0101
Battery Voltage Signal Range Check Error Errore Intervallo di Controllo Segnale Tensione P0103
Batteria
Air Mass Signal Range Check Error of Reference Errore Segnale Portata Aria di Riferimento P0104
Signal
Intake Air Temperature Sensor Error Errore Sensore Temperatura Aria in Aspirazione P0110
Intake Air Temperature Sensor Warning Allarme Sensore Temperatura Aria in Aspirazione P0113
Engine Coolant Sensor Error Errore Sensore Acqua Motore P0115
Engine Coolant Temperature Warning Allarme Temperatura acqua Motore P0118
Accelerator Pedal Position Sensor 1 Error Errore Posizione Pedale Acceleratore - Sensore P0120
1
Fuel Temperature Sensor Error Errore Sensore Temperatura Gasolio P0180
Fuel Rail Pressure Signal Error Errore Segnale Pressione Rail P0190
Fuel Rail Pressure Sensor Offset Monitoring Errore Controllo Scostamento Segnale Pressione P0191
Error Rail
Oil Temperature Sensor Signal Error Errore Segnale da Sensore Temperatura Olio P0195
Motore
Engine Oil Temperature Warning Allarme Temperatura Olio Motore P0198
Engine Control 175

R 750
Cylinder 1 - Injector Circuit Malfunction Warning Cilindro 1 - Allarme di Malfunzionamento Circuito P0201
Iniettore
Iniettore
Iniettore
Iniettore
Iniettore
Iniettore
Accelerator Pedal Position Sensor 2 Error Errore Posizione Pedale Acceleratore - Sensore P0220
2
Accelerator Pedal Position Sensors Synchroniza- Errore di Sincronizzazione Sensori di Posizione P0221
tion Error Pedale Acceleratore
Turbo/Super Charger Overboost Condition Condizioni di Alta Pressione di Sovralimentazio- P0234
ne
Boost Pressure Sensor Error Errore Sensore Pressione di Sovralimentazione P0235
Boost Pressure Warning Allarme Pressione di Sovralimentazione P0238
Metering Unit Solenoid PWM Control Circuit Malfunzionamento Circuito di Controllo PWM P0252
Malfunction Solenoide Regolatore di Pressione
PCV Pressure Control Valve Analogic/Digital Errore Canale Analogico/Digitale di Controllo P0256
Channel Error Valvola Regolazione Portata Combustibile PCV
PCV Pressure Control Valve PWM Circuit Mal- Malfunzionamento Circuito PWM di Controllo Val- P0257
function vola Regolazione Portata Combustibile PCV
Cylinder 1 - Injector Circuit Malfunction Specific Cilindro 1 - Errore Specifico di Malfunzionamento P0262
Error Circuito Iniettore
Turbo/Super Charger Underboost Condition Condizioni di Bassa Pressione di Sovralimenta- P0299
zione
Crankshaft Position Sensor Error Errore Sensore di Giri Albero Motore P0335
Engine Overspeed Warning Allarme Fuorigiri Motore P0338
Camshaft Position Sensor Error Errore Sensore di Fase Albero a Camme P0340
GCU-R Glow Control Unit - Standard Voltage GCU Unità di Controllo Candelette Malfunziona- P0380
System Relay Circuit Malfunction mento Relè
Glow Lamp Indicator Malfunction Malfunzionamento Spia Candelette P0381
176 Engine Control

R 750
EGR Exhaust Gas Recirculation Flow Insufficient Portata Insufficiente del Ricircolo dei Gas di P0401
Detected Scarico EGR
EGR Exhaust Gas Recirculation Flow Excessive Portata Eccessiva del Ricircolo dei Gas di Scari- P0402
or Inlet Air Circuit Malfunction Detected co EGR o Malfunzionamento Impianto di Ingres-
so Aria
EGR Exhaust Gas Recirculation Actuator Malfun- Malfunzionamento Attuatore Ricircolo Gas di P0404
ction Scarico EGR
Fan 1 Control Relay Malfunction Malfunzionamento Circuito Relè Ventola 1 P0480
TVA Throttle Valve Actuator Monitoring Error Errore Attuatore Valvola Parzializzatrice Aspira- P0487
Indicated by Digital Status Signal zione TVA Indicato da Segnale Digitale di Stato
TVA Throttle Valve Actuator Circuit Malfunction Malfunzionamento Circuito Attuatore Valvola P0488
Parzializzatrice Aspirazione TVA
ction Scarico EGR
ction Scarico EGR
Vehicle Speed Sensor Malfunction Malfunzionamento Sensore di Velocità Veicolo P0500
Brake Signal Error Errore Segnale Freno P0504
Incorrect Immobilizer Key Chiave Immobilizer non Corretta P0513
Engine Oil Pressure Sensor/Switch Signal Error Errore Segnale da Sensore Pressione Olio Mo- P0520
tore
Engine Oil Pressure Lamp Malfunction Malfunzionamento Spia Pressione Olio Motore P0521
Critical Engine Oil Pressure Warning Allarme Pressione Olio Motore Critica P0522
Low Engine Oil Pressure Warning Allarme Pressione Olio Motore Bassa P0524
Battery Voltage Error Errore Tensione Batteria P0560
Cruise Control Multi-Function Input “A”/”B” Malfunzionamento Circuito di Controllo Cruise P0585
Correlation Error (Invalid Switch Combination Control (Controllo Dati di Input non Valido)
Detected)
Add-on heater Circuit Malfunction Malfunzionamento Circuito Riscaldatore Ausilia- P0597
rio
ECU Internal Communication Error - SPI ECU Errore di Comunicazione Interna - SPI P0600
ECU Internal EEPROM Memory Error ECU Errore Interno Memoria EEPROM P0601
TPU Time Processing Unit Monitoring Error Errore di Verifica Tempo di Attivazione Processo- P0606
re TPU
ECU Internal Watchdog/Controller Error Errore Interno Controllore/Processore ECU P0607
Energizing Time Calibration Error Errore Calibrazione Tempo di Apertura Iniettore P0611
Starter Relay Circuit Malfunction Malfunzionamento Circuito Relè Comando Moto- P0615
rino di Avviamento
Starter Relay Circuit Malfunction (Low Side Malfunzionamento Circuito Relè Comando Moto- P0616
Power Stage) rino di Avviamento (Low Side Power Stage)
Starter Relay Circuit Malfunction (high Side Malfunzionamento Circuito Relè Comando Moto- P0617
Power Stage) rino di Avviamento (high Side Power Stage)
Sensor Supply Voltage 1 Check Error Errore Verifica Tensione di Alimentazione Sensori P0641
1
Air Conditioning Relay Circuit Malfunction Malfunzionamento Circuito Relè Aria Condizio- P0645
nata
MIL Lamp Circuit Malfunction Malfunzionamento Circuito Spia MIL P0650
2
GCU Glow Control Unit - Glow Plug GSK Dia- GCU Unità di Controllo Candelette - Errore Tra- P0670
gnosis Transmission Error smissione Diagnosi GSK
Engine Control 177

R 750
Glow Plug Circuit Malfunction Cylinder 1 Malfunzionamento Circuito Candeletta Cilindro 1 P0671
Main Relay Control Error Errore Controllo Main Relè P0685
3
Transmission Controller Unit TCU Generic Error Errore Generico Centralina Cambio TCU P0700
Main Clutch Signal Error Errore Segnale Frizione P0704
Transmission Controller Unit TCU Torque Con- Centralina Cambio TCU Valore di Coppia da P0740
verted Clutch out of Tolerance Convertitore Fuori Tolleranza
Reverse Gear Switch Error Errore Commutatore Inversione di Marcia Cam- P0812
bio
Transmission Controller Unit TCU Neutral Lamp Centralina Cambio TCU Malfunzionamento Spia P1000
Error Cambio in Neutro
Transmission Controller Unit TCU Internal Error Errore Interno Centralina Cambio TCU P1601
E.C.U. Analogic/Digital Converter Error Errore Convertitore Analogico/Digitale E.C.U. P1602
Engine Coolant Sensor Malfunction Malfunzionamento Sensore Acqua Motore P1603
T15 Terminal Signal Plausibility Error Errore di Plausibilità Segnale Terminale T15 P1605
T50 Terminal Signal Plausibility Error Errore di Plausibilità Segnale Terminale T50 P1606
ECU Processor Recovery Locked ECU Ripristino Processore Bloccato P1612
ECU Internal Supply Voltage Error ECU Errore Tensione di Alimentazione Interna P1613
ECU Internal Supply Voltage Error ECU Errore Tensione di Alimentazione Interna P1614
Plausibility Error on Base Map for Torque to Errore di Plausibilità nella Mappa di Conversione P1615
Quantity Conversion Coppia/Introduzioni
ECU - Fuel Injector Control Module A Performan- ECU - Errore Prestazione Modulo A di Controllo P1616
ce Error Iniezioni
ECU - Fuel Injector Control Module B Performan- ECU - Errore Prestazione Modulo B di Controllo P1617
ce Error Iniezioni
ECU Overrun Monitoring Error ECU Errore Contollo Limiti Tempo di Attivazione P1619
Iniettori
ECU Redundant Engine Speed Monitoring Error ECU Errore Controllo di Ridondanza Segnale P161A
Giri Motore
ECU Processor Recovery Suppressed ECU Ripristino Processore Abolito P161B
ECU Redundant Shut Off Test Error during Initia- ECU Errore Test di Ridondanza Disattivazione P1620
lization Iniettori durante Inizializzazione
ECU Internal Communication Error Between Errore Interno di Comunicazione tra Processore P1627
Function Computer and Monitoring Module e Modulo di Controllo
Dataset Variant Coding Plausibility Error Errore di Plausibilità della Codifica Variante P1628
Dataset
System Lamp Circuit Malfunction Malfunzionamento Circuito Spia di Sistema P1650
Transmission Controller Unit TCU Gear Incorrect Errore Interno Centralina Cambio TCU Rapporto P1701
Ratio Marcia Errato
Transmission Controller Unit TCU Solenoid Cir- Centralina Cambio TCU Errore Circuito Solenoidi P1702
cuit Error
Transmission Controller Unit TCU Engine/Turbi- Centralina Cambio TCU Errore Sensore Velocità P1703
ne Speed Sensor Error Turbina
178 Engine Control

R 750
Transmission Controller Unit TCU Solenoid Centralina Cambio TCU Valvola Commutatrice P1704
Switch Valve Latched Bloccata
Transmission Controller Unit TCU Relay Error Centralina Cambio TCU Errore Relay P1801
Transmission Controller Unit TCU Pressure Centralina Cambio TCU Errore nella Verifica P1802
Switch Check Error Commutatore di Pressione
Transmission Controller Unit TCU Pressure Centralina Cambio TCU Test Funzionamento P1803
Switch Test Failed Commutatore di Pressione Fallito
DPF Particulate Filter - Filter Dismounted or DPF Filtro Particolato - Filtro Smontato o Difetto- P2002
Defective so
Fuel Filter Heating Relay Circuit Malfunction Malfunzionamento Circuito Relè Riscaldatore P2030
Filtro Gasolio
Exhaust Gas Temperature Sensor Error - Bank 1 Errore Sensore di Temperatura Gas di Scarico P2031
- Position 1 - Bancata 1 - Posizione 1
- Position 2 - Bank 1 - Posizione 2
Exhaust Gas Temperature Sensor Plausibility Errore nella Verifica di Plausibilità Sensore di P2080
Check Error - Position 1 Temperatura Gas di Scarico - Posizione 1
Exhaust Gas Temperature Sensor Plausibility Errore nella Verifica di Plausibilità Sensore di P2084
Check Error - Position 2 Temperatura Gas di Scarico - Posizione 2
Injector Bank 1 Circuit Malfunction Warning Allarme di Malfunzionamento Circuito Iniettori P2147
Bancata 1
Injector Bank 1 Circuit Malfunction Specific Error Errore Specifico di Malfunzionamento Circuito P2148
Iniettori Bancata 1
Injector Bank 2 Circuit Malfunction Warning Allarme di Malfunzionamento Circuito Iniettori P2150
Bancata 2
Injector Bank 2 Circuit Malfunction Specific Error Errore Specifico di Malfunzionamento Circuito P2151
Iniettori Bancata 2
Barometric Pressure Sensor Error Errore Sensore Pressione Atmosferica P2226
Water in Fuel Sensor Circuit Malfunction Malfunzionamento Circuito Sensore Acqua nel P2266
Gasolio
Water in Fuel Sensor Circuit Malfunction Malfunzionamento Circuito Sensore Acqua nel P2267
Gasolio
Water in Fuel Detection Rilevamento Acqua nel Gasolio P2269
PRV Rail Pressure Relief Valve Error Errore Valvola di Limitazione Pressione Massima P2293
Rail PRV
PRV Rail Pressure Relief Valve Error Errore Valvola di Limitazione Pressione Massima P2294
Rail PRV
Accelerator Pedal Position/Brake not plausible Posizione Acceleratore/Freno non plausibile P2299
EGR Cooler By-pass Valve Actuator Malfunction Malfunzionamento Attuatore By-pass Radiatore P2425
EGR
EGR
EGR
- Position 1 - Bancata 1 - Posizione 1
DPF Particulate Filter - Engine Protection Active DPF Filtro Particolato - Protezione Motore Attiva P242F
DPF Particulate Filter - Differential Pressure DPF Filtro Particolato - Sensore Pressione Diffe- P2452
Sensor Defective renziale Difettoso
Engine Control 179

R 750
DPF Particulate Filter - Differential Pressure not DPF Filtro Particolato - Pressione Differenziale P2453
Plausible non Plausibile
DPF Particulate Filter - Low System Efficiency DPF Filtro Particolato - Efficienza Sistema Bassa P2458
PTO Enable Switch Circuit Malfunction Malfunzionamento Commutatore PTO P251C
Water Level in Fuel Actuator Malfunction Malfunzionamento Attuatore Livello di Acqua nel P3200
Gasolio
CAN Messages Error from Communication Ma- Errore Messaggi CAN da Gestore Comunicazioni U0001
nager CAN
CAN A Controller Error Errore Controllo Linea CAN A U0028
CAN B Controller Error Errore Controllo Linea CAN B U0037
CAN C Controller Error Errore Controllo Linea CAN C U0046
CAN Message Timeout Error from Transmission Errore Messaggio CAN da Centralina Cambio U0101
Controller Unit TCU TCU
CCVS CAN Error on Cruise Control CCVS Errore Messaggio CAN da Cruise Control U0104
RXEEC2 CAN Message Timeout Error RXEEC2 Errore Messaggio CAN U0107
PTO CAN Message Timeout Error PTO Errore Messaggio CAN U0117
TSC1-VE Speed Override Vehicle Dynamic Con- TSC1-VE Errore Messaggio da Controllo Veicolo U0122
trol Module VC Error Message VC
EBC1 CAN Message Timeout Error EBC1 Errore Messaggio CAN U0129
TSC1-PE Torque/Speed Override Control Module TSC1-PE Errore Messaggio da Controllo Esterno U0140
PTO Error Message di Coppia/Velocità PTO
Lost Communication with Vehicle Immobilizer Comunicazione con Centralina Immobilizer U0167
Control Module Interrotta
Invalid Data Received from Transmission Con- Dati Ricevuti da Centralina Cambio TCU non U0402
troller Unit TCU Coerenti
RXEEC2 CAN Message Out of Range RXEEC2 Messaggio CAN oltre i limiti U0408
Invalid Data Received from Vehicle Immobilizer Dati Ricevuti da Centralina Immobilizer non Coe- U0426
Control Module (EEPROM Error) renti (Errore EEPROM)
EEC2 Message or Accelerator Pedal not Present EEC2 Errore Messaggio CAN o Pedale Accelera- U1001
tore non presente
Accelerator Pedal Signal Above Threshold Value Segnale Pedale Acceleratore Eccede Limite U1002
Superiore
180 Engine Control

R 750
DIAGNOSTIC TROUBLE CODES “euro 5”
NOTE: In VM Motori internet web site Customer Reserved Area “EXTRANET”, section “Diagnostic Tool & Trouble-
shooting Common Rail Engines R750 MR700-500” are available:
• the lastest Diagnostic Tool Software Release for Common Rail Engine Models
• Industrial and Marine Common Rail engine troubleshooting symptoms charts
DTC SPN Description FMI FMI FMI FMI FMI Max FMI Min FMI Sig FMI Npl
Max Min Sig Npl
16 228 Crankshaft/ 1 FF FF FF offset
Camshaft Position between
Sensor Offset Error camshaft and
crankshaft
87 157 Error Fuel Low Rail 1 FF FF FF maximum
Pressure positive
deviation of
rail pressure
exceeded
87 157 Error Fuel Low Rail 5 FF FF FF maximum
Pressure positive
deviation of
rail pressure
exceeded
concerning
set flow of
fuel
87 157 Error Fuel Low Rail 9 FF FF FF minimum
Pressure rail pressure
exceeded
88 157 Error Fuel High Rail 1 FF FF FF maximum
Pressure negative rail
pressure de-
viation with
metering unit
on lower limit
is exceeded
88 157 Error Fuel High Rail 5 FF FF FF maximum
Pressure rail pressure
exceeded
89 157 Fuel Rail Pressure 5 FF FF FF setpoint of
Monitoring Error metering unit
for Active Pressure in overrun
Control by Metering mode not
Unit Governor plausible
96 172 Air mass temperatu- 1 2 FF FF Voltage abo- Voltage
re signal error ve upper limit below
lower limit
100 132 Raw Air Mass Si- 9 A B FF Signal range Signal ran- signal
gnal Error check high ge check cutoff
error low error or short
circuit
to either
battery or
ground
101 132 Raw Air Mass 1 2 FF FF airmass ratio airmass
Signal Plausability is higher than ratio is
Error threshold lower than
high threshold
low
Engine Control 181

R 750
102 132 Error path excee- 5 6 FF FF If the upper If values
ding the maximum limit is excee- fall below
drift limit in low-idle ded when the the lower
mode correction when the
value cal- correction
culation is value cal-
released culation is
released
102 132 Error path excee- 9 A FF FF If the upper If values
ding the maximum limit is excee- fall below
drift limit in the load ded when the the lower
range correction when the
value cal- correction
culation is value cal-
released culation is
released
103 132 Battery Voltage Si- 1 2 FF FF Voltage Voltage
gnal Range Check above upper below
Error Limit lower Limit
110 105 Intake Air Tempera- 1 2 FF FF Voltage abo- Voltage
ture Sensor Error ve upper limit below
lower limit
113 105 Intake Air Tempera- 1 FF FF FF air tempera-
ture Sensor Warning ture above
upper Limit
115 110 Engine Coolant 1 2 3 4 Voltage abo- Voltage Can Msg. plausibili-
Sensor Error ve upper limit below value ty defect
lower limit defect between
OTS and
CTS
118 110 Engine Coolant 1 FF FF FF Coolant
Temperature War- temperature
ning above upper
limit
120 91 Accelerator Pedal 1 2 FF 4 Voltage abo- Voltage Unplausi-
Position Sensor 1 ve upper limit above up- ble voltage
Error per limit
168 174 Fuel over temp 1 FF FF FF Over temp
180 174 Fuel Temperature 1 2 FF FF Voltage abo- Voltage
Sensor Error ve upper limit below
lower limit
190 164 Fuel Rail Pressure 1 2 FF FF Voltage abo- Voltage
Signal Error ve upper limit below
lower limit
195 175 Oil Temperature 1 2 3 4 Voltage abo- Voltage signal Plausibi-
Sensor Signal Error ve upper limit below error for lity error
lower limit CAN between
OTS and
CTS
198 175 Engine Oil Tempera- 1 FF FF FF Oil Tempe-
ture Warning rature above
upper limit
201 651 Cylinder 1 - Injector FF FF 3 FF Open load
Circuit Malfunction
Warning
Circuit Malfunction
Warning
182 Engine Control

R 750
Circuit Malfunction
Warning
Circuit Malfunction
Warning
216 629 ECU Overrun Moni- 1 FF FF FF Energising
toring Error time exceeds
limit of over-
run monito-
ring (ECU
Overrun
monitoring
error)
216 629 ECU Redundant 5 FF FF FF Plausibili-
Engine Speed Moni- ty error in
toring Error engine speed
check (ECU
Redundant
engine speed
monitoring
error)
220 91 Accelerator Pedal 1 2 FF FF Voltage abo- Voltage
Position Sensor 2 ve upper limit above up-
Error per limit
221 91 Accelerator Pedal FF FF FF 4 deviation
Position Sensors between
Synchronization APP1 and
Error APP2 vol-
tage too
high
234 641 Turbo/Super FF 2 FF FF negative
Charger Overboost governor
Condition deviation
below limit
235 102 Boost Pressure 1 2 3 4 Voltage abo- Voltage CAN Not plausi-
Sensor Error ve upper limit below signal ble with at-
lower limit defect mospheric
pressure
sensor
238 102 Boost Pressure 1 FF FF FF Boost pres-
Warning sure above
upper limit
252 1347 Metering Unit Sole- FF FF 3 4 open load excess
noid PWM Control of mete- tempera-
Circuit Malfunction ring unit ture of me-
output tering unit
powersta-
ge
253 1347 Metering Unit Sole- FF 2 FF FF short
noid PWM Control circuit to
Circuit Malfunction ground of
metering
unit output
254 1347 Metering Unit Sole- 1 FF FF FF short circuit
noid PWM Control to battery of
Circuit Malfunction metering unit
output
Engine Control 183

R 750
262 651 Cylinder 1 - Injector 1 2 3 4 short circuit general short not-classif-
Circuit Malfunction on Low Side short circuit Low yable error
Specific Error to battery circuit Side to
High Side
263 651 Energizing Time 1 2 FF FF above upper below
Calibration Error limit of ener- lower limit
gizing time of energi-
zing time
High Side
zing time
High Side
zing time
High Side
zing time
299 641 Turbo/Super Char- 1 FF FF FF positive
ger Underboost governor de-
Condition viation above
limit
335 190 Crankshaft Position 1 2 FF FF no crankshaft wrong
Sensor Error signal crankshaft
signal
338 190 Engine Overspeed 1 FF FF FF engine speed
Warning above upper
limit
340 723 Camshaft Position 1 2 FF FF no camshaft wrong
Sensor Error signal camshaft
signal
380 676 GCU-R Glow Con- 1 2 3 4 Short Circuit Short No Load Excess
trol Unit - Standard to Battery Circuit to Tempera-
Voltage System Ground ture
Relay Circuit Mal-
function
381 675 Glow Lamp Indica- 1 2 3 4 Short Circuit Short No Load Excess
tor Malfunction to Battery Circuit to Tempera-
Ground ture
401 27 EGR Exhaust Gas FF 2 FF FF negative
Recirculation Flow governor
Insufficient Detected deviation
below limit
184 Labour Time Guide

R 750
402 27 EGR Exhaust Gas 1 FF FF FF Positive
Recirculation Flow governor de-
Excessive or Inlet viation above
Air Circuit Malfunc- limit
tion Detected
403 27 EGR Exhaust Gas FF FF 3 4 No Load Excess
Recirculation Actua- Tempera-
tor Malfunction ture
405 27 EGR Exhaust Gas FF 2 FF FF negative
Recirculation Flow governor
Insufficient Detected deviation
During DPF Rege- below limit
neration
489 27 EGR Exhaust Gas FF 2 FF FF Short
Recirculation Actua- Circuit to
tor Malfunction Ground
490 27 EGR Exhaust Gas 1 FF FF FF Short Circuit
Recirculation Actua- to Battery
tor Malfunction
500 84 Vehicle Speed Sen- 1 FF 3 4 exceeding of HW signal vehicle
sor Malfunction the maximum for vehicle speed not
vehicle speed speed not plausi-
valid ble with
injection
mass and
engine
speed
520 100 Engine Oil Pressu- 1 2 3 FF Voltage abo- Voltage Voltage
re Sensor/Switch ve upper limit below signal
Signal Error lower limit absent
521 835 Engine Oil Pressure 1 2 3 4 short circuit short No Load excess
Lamp Malfunction to battery circuit to tempera-
ground ture
522 100 Critical Engine Oil 1 FF FF FF Oil Pressure
Pressure Warning below lower
limit
524 100 Low Engine Oil 1 FF FF FF Oil Pressure
Pressure Warning below lower
limit
544 173 DPF Particulate 5 6 FF FF Voltage abo- Voltage
Filter - Exhaust Gas ve upper limit below
Temperature Sensor lower limit
Error
560 168 Battery Voltage 1 2 FF FF Voltage abo- Voltage
Error ve upper limit above up-
per limit
571 597 Brake Signal Error FF FF 3 4 brake brake
signal is signal not
defective plausible
585 527 Cruise Control FF FF FF 4 Eeprom
Multi-Function Input error
“A”/”B” Correlation
Error (Invalid Switch
Combination De-
tected)
Labour Time Guide 185

R 750
600 629 ECU Internal Com- 1 FF FF FF communica-
munication Error tion error of
- SPI CJ940 (ECU
Internal Com-
munication
Malfunction)
600 627 ECU Internal Com- FF FF FF 4 Set, if
munication Error SPI-com-
Between Function munication
Computer and Moni- failed
toring Module
601 629 ECU Processor FF FF FF 4 A recovery
Recovery Locked has occur-
red
602 629 ECU Processor Re- FF FF FF 4 a recovery
covery Suppressed has occur-
red
606 625 Plausibility Error FF FF FF 4 Not plausi-
on Base Map for ble fault
Torque to Quantity
Conversion
606 629 TPU Time Proces- FF FF FF 8 Deviation
sing Unit Monitoring between
Error TPU and
system
time
607 629 ECU Internal Wa- FF FF FF 8 Set, if
tchdog/Controller error-
Error counter of
Watchdog
or control-
ler are not
plausible
or the sy-
stem must
shut down
(ECU
Internal
Watchdog
error)
615 677 T50 Terminal Signal 1 FF FF FF Terminal 50
Plausibility Error always Pres-
sed
616 677 Starter Relay Circuit 1 2 3 4 Short Circuit Short No load Overhea-
Malfunction (Low to Battery Circuit to ted
Side Power Stage) Ground
617 677 Starter Relay Circuit FF 2 FF FF Short
Malfunction (high Circuit to
Side Power Stage) Ground
641 1079 Sensor Supply Vol- 1 2 FF FF Voltage abo- Voltage
tage 1 Check Error ve upper limit below
lower limit
645 1351 Air Conditioning 1 2 3 4 Short Circuit Short No load Excess
Relay Circuit Mal- to Battery Circuit to Tempera-
function Ground ture
650 1213 MIL Lamp Circuit 1 2 3 4 Short Circuit Short No load Unplaus-
Malfunction to Battery Circuit to ble
Ground

R 750
lower limit
685 1485 Main Relay Control 1 2 FF FF main relay main relay
Error does not opens too
open in time early
lower limit
1620 629 ECU Redundant FF 2 3 4 Watch dog Voltage Voltage
Shut Off Test Error switch off monitoring monitoring
during Initialization path de- upper limit lower limit
fect ECU shut off shut off
Internal path de- path de-
Shut-off fect ECU fect ECU
Path Wa- Internal Internal
tchdog Shut-off Shut-off
Path High Path Low
Voltage Voltage
1628 628 Dataset Variant FF FF 3 4 Signal Not plausi-
Coding Plausibility fault ble fault
Error
2002 131 DPF Particulate Fil- FF A FF FF Corrected
ter - Filter Dismoun- maximum
ted or Defective differential
pressure
is lower
than the
threshold
2102 634 TVA Throttle Valve FF 2 FF FF Short
Actuator Circuit Circuit to
Malfunction Ground
2103 634 TVA Throttle Valve 1 FF FF FF Short Circuit
Actuator Circuit to Battery
Malfunction
2146 657 Injector Bank 1 1 2 FF 4 general short short not-classif-
Circuit Malfunction circuit circuit on yable error
Specific Error Low Side
to ground
2149 658 Injector Bank 2 1 2 FF 4 general short short not-classif-
Circuit Malfunction circuit circuit on yable error
Specific Error Low Side
to ground
2226 108 Barometric Pressure 1 2 FF 4 Voltage abo- Voltage Not
Sensor Error ve upper limit above up- plausiple
per limit with boost
pressure
sensor
2264 97 Water Level in Fuel 1 2 3 4 Short Circuit Short No Load Excess
Actuator Malfunction to Battery Circuit to Tempera-
Ground ture
2269 97 Water in Fuel Detec- 1 FF FF FF Water in fuel
tion detected
2293 157 PRV Rail Pressure 1 2 3 FF PRV was pressure PRV did
Relief Valve Error recognised shock re- not open
as OPEN quested after pres-
sure shock

R 750
2452 131 DPF Particulate 1 2 FF FF Voltage abo- Voltage
Filter - Differential ve upper limit below
Pressure Sensor lower limit
Defective
2453 81 DPF Particulate FF FF FF 1C hose line
Filter - Differential defective
Pressure not Plau- or signal
sible not plausi-
ble
2454 81 Soot mass over limit 1 FF FF FF Over limit
2533 677 T15 Terminal Signal FF FF 3 FF No Ter-
Plausibility Error minal 15
signals
detected
2687 859 Fuel Filter Heating 1 2 3 4 Short Circuit Short No Load Excess
Relay Circuit Mal- to Battery Circuit to Tempera-
function Ground ture
242F 131 DPF Particulate Fil- 1 FF FF FF Differential
ter - Engine Protec- pressure
tion Active above limit
242F 81 DPF Particulate Fil- 5 FF FF FF Soot mass
ter - Engine Protec- greater than
tion Active the threshold
251C 979 PTO Enable Switch 1 2 FF 4 short circuit short Multiple
Circuit Malfunction to battery circuit to State
ground Switch not
Plausible
252F 98 Critical Oil Mass 1 2 FF FF Max Error Min Error
Check Error path for criti- path for
cal engine oil critical
mass engine oil
mass
60B 629 Analog digital con- 1 2 3 4 Voltage abo- Voltage Check si- Time out
verter error ve upper limit below gnal error conversion
lower limit
60C 627 ECU Internal Supply 1 FF FF FF ECU internal
Voltage Error supply vol-
tage above
upper limit
60C 627 ECU Internal Supply FF 6 FF FF ECU
Voltage Error internal
supply vol-
tage below
lower limit
61F 634 TVA Throttle Valve FF FF 7 8 No Load Excess
Actuator Circuit Tempera-
Malfunction ture
62B 629 ECU - Fuel Injector 1 2 3 4 CY33X CY33X is CY33X is CY33X
Control Module A internal reset unlocked / in Testmo- SPI com-
Performance Error / clockloss / CY33X init de munication
undervoltage error error /che-
cksum/
readback
62B 629 ECU - Fuel Injector 5 6 7 8 CY33X CY33X CY33X CY33X
Control Module B internal parity internal check of ON ti-
Performance Error error program inv. YSEL meout for
flow error during ON at least 1
failed cylinder

R 750
62F 628 ECU Internal FF 2 3 4 error error default va-
EEPROM Memory during during lue used
Error last read last write
operation operation
C001 639 CAN Messages FF FF 3 FF Timeout in
Error from Commu- CAN send
nication Manager messages
C028 639 CAN A Controller 1 FF FF FF Bus off in
Error CAN A
C037 639 CAN B Controller 1 FF FF FF Bus off in
Error CAN B
C046 639 CAN C Controller 1 FF FF FF Bus off in
Error CAN C
C101 898 TSC1-TE CAN Mes- 15 FF 17 FF timeout for timeout
sage Timeout Error TSC1-TE, for TSC1-
from Transmission when active TE, when
Controller Unit TCU inactive
C107 91 RXEEC2 CAN Mes- FF FF 3 FF Timeout
sage Timeout Error of CAN
message
EEC2
C122 898 TSC1-VE Speed 1 FF 3 FF timeout for timeout
Override Vehicle TSC1-VE, for TSC1-
Dynamic Control when active VE, when
Module VC Error inactive
Message
C140 898 TSC1-PE Torque/ 1 2 FF FF timeout for timeout
Speed Override TSC1-PE, for TSC1-
Control Module PTO when active PE, when
Error Message inactive
C408 91 RXEEC2 CAN Mes- 1 FF FF FF Out of range
sage Out of Range data in CAN
message
RxEEC2

R 750

R 750

R 750
labour time guide
KEY TO DEFINITIONS
R/R = removal and re-installation
INTERPRETING THE CODE OF THE OPERATION

Cod. 3Z - EAA / 4
The first code group identifies the operation performed (ex: 3Z = replacement)
The second group separated by a dash, identifies the component (ex: EAA = camshaft)
The number after the slash, identifies the quantity of components involved in the operation, this number can be
omitted if there are no other similar components on the engine.
This type of code is used when there are no other similar components or multiple components on the
engine.
3Z - EAA
3Z = Replacement
EAA= Camshaft
This type of code is used when there are other similar components or multiple components on the engine.
10Z - OAA / 6
10Z = Test
OAA = Injector
/6 = no.6 injectors
OPERATION Time
0.125 = 7.30 minutes
0.25 = 15 minutes
0.50 = 30 minutes
0.75 = 45 minutes
1 = 1 hour
COMPONENTs groups
A - SYSTEM (ENGINE - CRANKCASE - LINER)
b - SYSTEM (CRANKSHAFT - MAIN REAR CARRIER )
c - SYSTEM (piston - connecting rods )
D - SYSTEM (CYLINDER HEAD - ROCKER ARM )
e - SYSTEM (camshaft - hydraulic tappet - push rods)
g - SYSTEM (lubrication)
H - SYSTEM (cooling)
j - SYSTEM (BELT - PULLEY - TENSIONER)
k - SYSTEM (intake and exhaust, DPF FILTER)
M - SYSTEM (flywheel housing - oil pan - timing cover)
o - SYSTEM (FUEL)
p - SYSTEM (injection pump )
q - SYSTEM (crankshaft main bearings )
s - SYSTEM (electrical)

R 750
ECU diagnosis
Operazione Ore
ECU diagnosis + download engine collect data (log file) 1
ECU calibration - updating 0.50
Engine idle RPM - RPM modification 0.50
IMA injector code writing 0.50
EGR-TVA Test 0.50
DPF filter Regeneration 1
Compression cylinder Test 0.50
Dash Board light/lamps Test 0.50
Injector test 0.50
Engine serial number writing 0.50
Electrical measurement through break out box 1

R 750
A - SYSTEM (ENGINE - CRANKCASE - LINER)
Operation SYSTEM No. Cyl. Hours
14Z - AAA ENGINE REMOVAL AND REINSTALLATION 4
(ENGINE INSTALLED ON THE VEHICLE)
3Z - AAA SHORT BLOCK REPLACEMENT 4 11
6 11.50
7Z - AAA MAJOR ENGINE OVERHAUL 4 25
Steam clean and completely dismantle; clean all parts; flush all oil and 6 32.50
water passages and replace plugs; check crankshaft for size and wear
and inspect all parts.
Check the liner wear and if necessary replace them.
Replace, or renew where necessary, camshaft and auxiliary drive bushes,
main and big end bearings and thrust washers.
Inspect and replace timing gears, as necessary.
Replace water pump, oil pump.
Overhaul turbochargeR
Clean head and disassemble completely; inspect all parts and magnaflux
head (Magnaflux crack detector); and Hydraulic test with special tool
(pressure the cylinder
head at ~ 2 bar ( 29 psi) dip it in a hot water +50-60°C (+122-140°F) for
two
minutes and check for air bubble.)
Check longitudinal and horizontal warpage on head surface; replace valve
guides or ream as needed. Grind valves and seats; replace valves and/or
seats, as required. Check springs, keepers and retainers and replace as
required. Lap valves and reassemble. Final test bench.
8Z - AAA Partial engine overhaul 4 10
Steam clean parts and partial dismantle (cylinder heads and pistons). 6 12
Clean the disassembled parts, replace plug (only if worn), check liners
dimension and wear.
Hone cylinder liners and replace the compression rings.
Check or replace, valves, guide valves and seats grind.
Inspect and replace timing gears, as necessary. Inspect and renew, as
required water pump, oil pump and turbocharger.
Engine reassembly and test bech.
2I - AAA Oil consumption rectification 4 10.25
Remove cylinder head, lube oil pan and oil pump. 6 15.50
Remove all pistons and connecting rods.
Deglaze all cylinder bores.
Clean and check pistons for wear, renewing as necessary and replace all
piston rings.
Check condition of oil pump and renew if necessary.
Reassemble all parts using new gaskets.
1N - AAA ENGINE FLYWHEEL SIDE - OIL LEAKAGE 1.50
R&R flywheel and flywheel housing
Rear crankshaft seal - replacement
Rear main carrier o-ring - replacement
Camshaft o-ring
Flywheel o-ring

R 750
Operation SYSTEM No. Hours
Cyl.
3Z - ABA Cylinder Block - Replacement 4 11
Steam clean complete engine, dismantle, clean and inspect all component 6 16.50
parts.
Reassemble engine complete into new bare block with same or new
pistons, using new rings main and big end bearings and thrust washers,
gaskets and seals, and torque to specifications.
Run engine and check for leaks.
3Z - AIA/1 LINER - REPLACEMENT (ONE) 4 6.75
3Z - AIA/1 LINER - REPLACEMENT (ONE) 6 9.25
3Z - AIA/4 LINER - REPLACEMENT (ALL) 4 7.75
3Z - AIA/6 LINER - REPLACEMENT (ALL) 6 10.25
b - SYSTEM (CRANKSHAFT - MAIN REAR & CeNTER CARRIER - flywheel - timing gears)
Cyl.
3Z - BAA CRANKSHAFT - Replacement 4 13
– rear crankshaft seal & o-ring, camshaft o-ring, flywheel o-ring replacement. 6 15
– R&R flywheel housing.
– R&R oil pan and strainer.
– R&R oil pump.
– R&R vibration damper.
– R&R thrust washers, replace if necessary.
– R&R timing gear cover.
– R&R head.
– R&R main center bearing carriers.
– R&R pistons and connecting rods.
3Z - BIA Replace main rear bearing carrier 1.25
R&R Flywheel and flywheel housing
3Z - BHA CENTER MAIN BEARING CARRIERS 4 12.50

R&R oil pan and strainer 6 14.50
3Z - BLA CRANKSHAFT FRONT HUB 0.75
3Z - BFA FLYWHEEL (WITH FLYWHEEL GEAR) 0.50
3Z - BFE FLYWHEEL GEAR 0.75
3Z - BAF CRANKSHAFT FRONT GEAR 1.75
3Z - EAC TIMING GEARS 2.50
3Z - BAF EAC (CAMSHAFT GEAR)
3Z - LCA BAF (CRANKSHAFT FRONT GEAR)
3Z - PAC LCA (IDLER GEAR)
PAC (INJECTION DRIVE GEAR)

R 750
c - SYSTEM (piston - connecting rods )
Cyl.
3Z - CAA/1 Piston and Connecting Rod (one) 4 6.50
3Z - CAA/1 Piston and Connecting Rod (one) 6 9
3Z - CAA/4 Piston and Connecting Rod (all) 4 7.50
3Z - CAA/6 Piston and Connecting Rod (all) 6 10
3Z - CAD PISTON RINGS (ALL PISTONS) 4 7.75
6 10.25
D - SYSTEM (CYLINDER HEAD - ROCKER ARMS )

Cyl.
8Z - DAA Top overhaul (cylinder heads and/or gaskets) 4 8.50
Remove cylinder head(s) and gasket(s). 6 10.50
Remove all traces of jointing compound and old gasket.
Check cylinder head(s) and reseat valves.
Fit new gasket and replace head(s) if necessary, Check injector atomisers and
service as necessary.
Torque head.
Engine bench test
3Z - DAA Cylinder Head AND GASKET ReplaceMENT (all cyl.heads) 4 4.50
R&R and renew rocker arm assembly 6 6
R&R intake manifold
R&R exhaust manifold
R&R water manifold from heads
R&R rocker arm lubricating pipe
Installation new gaskets
10Z - DFA rocker arm assembly - check (ALL) 4 1.25
Clean and disassemble rocker arm assembly. 6 1.50
Inspect all parts and renew or replace as necessary.
Reassemble head assembly.
3Z - DGG INTAKE & EXHAUST VALVE GUIDES - REPLACEMENT (ALL) 4 7.50
3Z - DGF Includes: R&R cylinder head 6 9
3Z - DGH/1 VALVE SPRING - REPLACEMENT (ONE) 1
3Z - DGI/1
3Z - DGH/4/6 VALVE SPRING - REPLACEMENT (ALL) 2
3Z - DGI/4/6
e - SYSTEM (camshaft - hydraulic tappet - push rods)

Cyl.
3Z - EAA CAMSHAFT - REPLACEMENT 4 6.50
6 8.50
3Z - ECA PUSH RODS 1.75
3Z - EBB HYDRAULIC TAPPET 4 5
6 6.50
3Z - EFA VALVE COVER 1.50

R 750
g - SYSTEM (lubrication)
Cyl.
3Z - GEA OIL HEAT EXCHANGER (MODINE) 0.50
3Z - GAA OIL PUMP 1.25
3Z - GGA oil pressure relief valve 1
3Z - GAQ rocker arm oil feed pipe 0.50
3Z - GBA OIL FILTER 0.25
H - SYSTEM (cooling)
Cyl.
3Z - HAA COOLANT PUMP 0.50
3Z - HAL COOLANT PUMP PULLEY 0.25
3Z - HDA THERMOSTATIC VALVE 0.25
3Z - HHA RADIATOR 1
j - SYSTEM (BELT - PULLEY - TENSIONER)

Cyl.
3Z - JBA COOLANT PUMP BELT - 0.25
AUTOMATIC BELT TENSIONER
k - SYSTEM (intake and exhaust, DPF FILTER)
Cyl.
3Z - KAA INTAKE MANIFOLD 0.75
3Z - KDA TURBOCHARGER 0.50
3Z - KBA EXHAUST MANIFOLD 0.75
3Z - KCH EGR COOLER 0.75
3Z - KCA EGR VALVE & INTAKE THROTTLE VALVE ASS.BY 0.25
5E - KGB DPF FILTER (cleaning by compressed air and replacement DPF filter 0.90
clamps
M - SYSTEM (flywheel housing - oil pan - timing cover)

Cyl.
3Z - MAA FLYWHEEL HOUSING 1.50
Rear crankshaft seal - replacement
Ream main carrier o-ring - replacement
Camshaft o-ring
Flywheel o-ring
3Z - MCA TIMING COVER 1
R&R alternator belt
R&R crankshaft front hub
cleaning of silicon from timing cover
3Z - MCE TIMING COVER - FRONT OIL SEAL 0.75
3Z - MBA OIL PAN 0.75

R 750
o - SYSTEM (FUEL)
3Z - OAA/1 INJECTOR (ONE) 0.50
3Z - OAA INJECTOR (ALL) 4 1
6 1.25
10Z - OAA FUEL RETURN QUANTITY FROM INJECTOR - TEST 0.25
12Z - OEL AIR BLEEDING FROM INJECTION SYSTEM 0.25
3Z - OEC FUEL FILTER 0.25
3Z - OHB FUEL PRESSURE ACCUMULATOR (RAIL) 0.50
p - SYSTEM (injection pump )

3Z - PAC fuel pump drive gear 0.75
3Z - PAA INJECTION PUMP - REPLACEMENT 0.75
3Z - PCA FUEL PRESSURE CONTROL VALVE (MPROP) 0.25
q - SYSTEM (crankshaft main bearings AND CONNNECTING ROD BEARINGS )

3Z - QAA CRANKSHAFT FRONT MAIN BEARING 4 13.50
6 15.50
3Z - QBB CONNECTING ROD BEARINGS (ALL CON-RODS) 4 2
R&R oil pan and strainer 6 3
Cleaning of silicon from oil pan
Engine test for oil leakage
3Z - QAD CRANKSHAFT REAR MAIN BEARING 1.75
(REAR MAIN BEARING CARRIER)
Replace also:
• Rear crankshaft seal - replacement
• Rear main carrier o-ring - replacement
• Camshaft o-ring
• Flywheel o-ring

R 750
s - SySTEM (electrical)
Cyl.
3Z - SEA ALTERNATOR 0.50
3Z - SEF ALTERNATOR VOLTAGE REGULATOR 0.50
3Z - SGA STARTER MOTOR 0.25
3Z - SGD STARTER MOTOR - SOLENOID 0.50
3Z - SAA ENGINE WIRING HARNESS 1

R 750

electrical system
Electrical Schematic Diagrams - “A” SIDE - Engine
r754 EURO4 - euro 5
201 Electrical System

r756 EURO4 - EURO5

engine Wiring harness
r754 euro 4

r754 euro5

r756 euro4

r756 euro5

installation electric diagram - “k” side - vehicle
r754 - r756 euro4 - R756IE3 Disegno nr. 16662041F_Ed 1 - 03/2007
Drawing no. 16662041F_Ed 1 - 03/2007
15
50

r750 euro4 - R750IE3
Disegno nr. 16662041F_Ed 2 - 11/2008

Drawing no. 16662041F_Ed 2 - 11/2008

R750IE3 Disegno nr. 16662056F_Ed1_04_2010
Drawing no. 16662056F_Ed1_04_2010

r754 - r756 euro5 ed.2
Disegno nr. 16662051F_Ed_2
Drawing no. 16662051F_Ed_2
15
50

r754 - r756 euro5 ed.3
Disegno nr. 16662051F_Ed_3
Drawing no. 16662051F_Ed_3

Halvorsen
Section 3. Transmission
ALLISON TRANSMISSION
Division of General Motors Corp.
OPERATOR’S MANUAL (OM3063EN)

1000/2000/2400 Series Allison On-highway Transmissions
SERVICE MANUAL (SM319EN)

1000, 2000, 2000mh, 2400 Series On-highway Transmissions
TRANSMISSION TROUBLESHOOTING MANUAL (TS319EN)

1000 And 2000 Product Families Electronic Controls
MECHANIC’S TIPS (MT3190EN)

1000 and 2000 Product Family Transmission
STONE BENNETT CORP.
DESCRIPTION AND INSTALLATION BULLETINS

Transmission Shift Controls
PARTS LIST MANUAL

SNS-01 Bennett Shift System
5-3
TRANSMISSION
Page 1
December 2015
OM3063EN_200306.pdf 8/19/04 8:57:52 AM
CM
MY
CY
CMY
Operator’s Manual
1000/2000/2400 Series
Allison On-Highway Transmissions
OM3063EN
OM3063EN
Operator’s
Manual
Allison On-Highway
1000 SeriesTM
2000 SeriesTM
2400 SeriesTM
June 2003
Division of General Motors Corporation

P.O. Box 894 Indianapolis, Indiana 46206-0894
www.allisontransmission.com
Printed in the USA Copyright © 2003 General Motors Corp.

NOTES
2
TABLE OF CONTENTS
INTRODUCTION
KEEPING THAT ALLISON ADVANTAGE . . . . . . . . . . . . . . . . . . . . . . . . 7
A BRIEF DESCRIPTION OF THE ALLISON 1000/2000/2400 SERIES
TRANSMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECTRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PLANETARY GEARS AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . . 11
COOLER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SHIFT SELECTORS
DESCRIPTION OF AVAILABLE TYPES . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION OF THE SHIFT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . 17
RANGE SELECTION—ALL 1000 SERIES™ AND 2400 SERIES™
TRANSMISSIONS WITH P (PARK) POSITIONS . . . . . . . . . . . . . . . . . . . 20
RANGE SELECTION—ALL 1000 SERIES™ AND 2400 SERIES™
TRANSMISSIONS WITHOUT P (PARK) POSITIONS . . . . . . . . . . . . . . . . 24
RANGE SELECTION—ALL 2000 SERIES™ TRANSMISSIONS WITH
AUTO-APPLY PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
RANGE SELECTION—ALL 2000 SERIES™ TRANSMISSIONS WITHOUT
AUTO-APPLY PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DRIVING TIPS
MAXIMUM VEHICLE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
PREVENT MAJOR PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
TURNING ON/OFF THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ACCELERATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
PRIMARY/SECONDARY SHIFT SCHEDULES . . . . . . . . . . . . . . . . . . . . 37
KICKDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
OUTPUT SPEED INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
RANGE INHIBIT(ED) LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CHECK TRANS OR MALFUNCTION INDICATOR LIGHT . . . . . . . . . . . . 38
SHIFT INHIBITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
USING THE ENGINE TO SLOW THE VEHICLE . . . . . . . . . . . . . . . . . . . 41
RANGE PRESELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REFUSE PACKER STEP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
TWO-SPEED AXLE (Some 1000/2000/2400 Series Applications) . . . . . . . . . . 43
DRIVING ON SNOW OR ICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ROCKING OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATING TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
HIGH FLUID TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
PARK PAWL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
PARKING/LEAVING VEHICLE WITH ENGINE RUNNING . . . . . . . . . . . . 47
TOWING OR PUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
SURGING NATURAL GAS ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . 49
POWER TAKEOFF
POWER TAKEOFF (PTO) SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 50
CONVERTER-DRIVEN POWER TAKEOFF (PTO) . . . . . . . . . . . . . . . . . . 50
SPLIT-SHAFT POWER TAKEOFF (PTO) . . . . . . . . . . . . . . . . . . . . . . . . 53
CARE AND MAINTENANCE

PERIODIC INSPECTIONS AND CARE . . . . . . . . . . . . . . . . . . . . . . . . . 55
IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL . . . . . . . . . . . 56
TRANSMISSION FLUID CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
KEEPING FLUID CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
FLUID RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
TRANSMISSION FLUID AND FILTER CHANGE INTERVALS . . . . . . . . . . 62
TRANSMISSION FLUID CONTAMINATION . . . . . . . . . . . . . . . . . . . . . 64
COOLER FLUSHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE . . . . . . . . . 66
VENT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
DIAGNOSTICS
DIAGNOSTIC CODES AND TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
CUSTOMER SERVICE
OWNER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
ALLISON TRANSMISSION DISTRIBUTORS . . . . . . . . . . . . . . . . . . . . . 73
ALLISON TRANSMISSION REGIONAL OFFICES . . . . . . . . . . . . . . . . . . 76
4
TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
• 1000 Series™ is a trademark of the General Motors Corporation.
• DEXRON® is a registered trademark of the General Motors Corporation.
• TranSynd™ is a trademark of Castrol Ltd.
5
WARNINGS, CAUTIONS, NOTES
IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings

and cautions described in this handbook. It is, however, important to understand
that these warnings and cautions are not exhaustive. Allison Transmission could
not possibly know, evaluate, and advise the service trade of all conceivable ways
in which service might be done or of the possible hazardous consequences of each
way. The vehicle manufacturer is responsible for providing information related to
the operation of vehicle systems (including appropriate warnings, cautions, and
notes). Consequently, Allison Transmission has not undertaken any such broad
evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE
OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON
TRANSMISSION OR THE VEHICLE MANUFACTURER MUST first be
thoroughly satisfied that neither personal safety nor equipment safety will be
jeopardized by the service methods selected.
Proper service and repair is important to the safe, reliable operation of the
equipment. The service procedures recommended by Allison Transmission (or the
vehicle manufacturer) and described in this handbook are effective methods for
performing service operations. Some of these service operations require the use of
tools specially designed for the purpose. The special tools should be used when
and as recommended.
Three types of headings are used in this manual to attract your attention. These
warnings and cautions advise of specific methods or actions that can result in
personal injury, damage to the equipment, or cause the equipment to become
unsafe.
WARNING: A warning is used when an operating procedure, practice,

etc., if not correctly followed, could result in personal injury or loss of
life.
CAUTION: A caution is used when an operating procedure, practice,

etc., if not strictly observed, could result in damage to or destruction of
equipment.
NOTE: A note is used when an operating procedure, practice, etc., is

essential to highlight.
6
INTRODUCTION
KEEPING THAT ALLISON ADVANTAGE
STOP
R R
YIELD SPEED
ZONE
HILL
V01724
Allison 1000/2000/2400 Series provide many advantages for the driver who must
“stop and go” or change speeds frequently. Driving is easier, safer, and more
efficient.
The 1000/2000/2400 Series transmissions are rugged and designed to provide
long, trouble-free service. This handbook will help you gain maximum benefits
from your ALLISON-equipped vehicle.
7
Figure 1. 1000/2000/2400 Series Transmission—Left-Front View
OIL VENT
(BREATHER) PARKING BRAKE
MOUNTING PROVISION
TURBINE SPEED
SENSOR
ENGINE SPEED
SENSOR
OUTPUT SPEED SENSOR
8
NSBU SWITCH
SELECTOR SHAFT
SAE 6-BOLT
PTO PAD
(DRIVE GEAR OPTIONAL)
AVAILABLE
OIL FILL TUBE
LOCATION
CONTROL MAIN OIL FILTER
1000 / 2000 / 2400 SERIES TRANSMISSION — LEFT-FRONT VIEW V06692.00.00

Figure 2. 1000/2000/2400 Series Transmission—Right-Rear View
ENGINE SPEED
SENSOR
TURBINE SPEED
SENSOR
OIL VENT
(BREATHER)
OUTPUT SPEED
SENSOR
9
MOUNTING PAD
(SAE #3 HOUSING ONLY)
COOLER PORTS
AVAILABLE
OIL FILL TUBE
LOCATION
OPTIONAL SAE 6-BOLT

TACHOGRAPH PTO PAD
PROVISION (DRIVE GEAR OPTIONAL)
MAIN ELECTRICAL
CONNECTOR
1000 / 2000 / 2400 SERIES TRANSMISSION — RIGHT-REAR VIEW
V06693
A BRIEF DESCRIPTION OF THE ALLISON 1000/2000/2400
SERIES TRANSMISSIONS
The 1000/2000/2400 Series transmissions are fully automatic, torque-converter
driven, electronically controlled transmissions best suited for light-medium duty,
on-highway applications. Each transmission series contains features which have
been designed for specific vocational needs.
• 1000 Series™—These models are best suited for light duty on-highway
applications. The 1000 Series™ transmissions have park pawls.
• 2000 Series™ and 2400 Series™—These models are best suited for
single-axle medium duty on-highway applications. The 2400 Series™
transmissions have park pawls; the 2000 Series™ transmissions do not have
park pawls.
The park pawl exists but cannot be engaged in some vehicle configurations using
1000 Series™ and 2400 Series™ transmissions (e.g., some rear engine vehicles
with air brakes). For these configurations, the P (Park) position is not used.
A provision to mount a Power Takeoff (PTO) is available on all models. The PTO
drive gear is optional.
All models have up to five forward ranges and one reverse. All clutches are
hydraulically-actuated, spring-released, and have automatic compensation for wear.
Gearing is helical type, arranged in planetary sets. Electronic controls provide
automatic gear selection in each drive range and automatic engagement of the
torque converter (lockup) clutch.
ELECTRONIC CONTROL SYSTEM

The 1000/2000/2400 Series control system consists of five major components
connected by customer-furnished wiring harnesses. These components are:
• Transmission Control Module (TCM)
• Engine throttle position sensor or direct electronic communication of
throttle information
• Engine, turbine, and output speed sensors
• NSBU switch
• Control valve module
The control valve module contains solenoids and a pressure switch module to
position and monitor control valve operation. The pressure switch module also
contains a thermistor to monitor sump fluid temperature. The throttle position
sensor (or engine-to-transmission communication link), speed sensors, pressure
switch module, and NSBU switch transmit information to the TCM. The TCM
processes this information and then sends signals to actuate specific solenoids
located on the control valve module in the transmission. These solenoids control
10
both oncoming and offgoing clutch pressures to provide closed-loop shift control
by matching rpm during a shift to a previously established desired profile that is
programmed into the TCM.
The 1000/2000/2400 Series electronic control system has the “adaptive shifting”
feature. Adaptive shifting helps optimize shift quality by monitoring critical
characteristics of clutch engagement and making on-going adjustments to improve
subsequent shifts. The transmission shift calibration is based on several different
types of shifts, e.g., full throttle, part throttle, closed throttle—upshifts, downshifts,
etc. Each shift is associated with specific speed and throttle position parameters. In
order to optimize each type of shift for normal driving, shift controls must
experience operation and shifting in a wide variety of operating conditions.
A “drive in” period under varied driving conditions is required before the
Adaptive Controls can be expected to optimize each and every shift. In general,
shift quality will begin to converge to their “adapted” level after five typical shifts
of a particular shift type.
TORQUE CONVERTER
The torque converter consists of three elements—pump, turbine, and stator. The
pump is the input element and is driven directly by the engine. The turbine is the
output element and is hydraulically driven by the pump. The stator is the reaction
(torque multiplying) element. When the pump turns faster than the turbine, the
torque converter is multiplying torque. When the turbine approaches the speed of
the pump, the stator starts to rotate with the pump and turbine. When this occurs,
torque multiplication stops and the torque converter functions as a fluid coupling.
All 1000/2000/2400 Series torque converters contain a torque converter (lockup)
clutch. When engaged, this clutch causes the torque converter pump and turbine to
be locked together, thus enabling them to rotate in unison at engine speed. This
condition, commonly referred to as “torque converter clutch operation,” thus
provides direct drive through the transmission. This type of operation maximizes
engine braking and enhances fuel economy. The torque converter (lockup) clutch
is regulated by the shift controls to engage automatically. The torque converter
clutch releases at lower speeds or when the TCM detects conditions requiring it to
be released. The torque converter clutch contains a damping mechanism which
reduces the transmittal of engine-induced torsional vibrations into and beyond the
transmission.
PLANETARY GEARS AND CLUTCHES

A series of three helical planetary gear sets and shafts provides the mechanical
gear ratios and direction of travel for the vehicle. The planetary gear sets are
controlled by five multiplate clutches that work in pairs to produce up to five
11
forward speeds and one reverse speed. The clutches are applied and released
hydraulically in response to electronic signals from the TCM to the appropriate
solenoids.
COOLER CIRCUIT
The transmission fluid is cooled by a remote-mounted oil cooler. The bottom of
the transmission torque converter housing provides for the direct mounting of a
control main filter and includes two ports to facilitate the attachment of the oil
cooler lines.
12
CONVERTER HOUSING/FRONT SUPPORT MODULE
• CONVERTER HOUSING MAIN HOUSING MODULE
• INPUT SPEED SENSOR • MAIN HOUSING
• OIL PUMP • C3 CLUTCH
TORQUE • FRONT SUPPORT TURBINE • C4 CLUTCH
CONVERTER SPEED • C5 CLUTCH
ASSEMBLY SENSOR
MAIN SHAFT
OUTPUT YOKE
13
REAR COVER MODULE
• REAR COVER
• OUTPUT SPEED SENSOR
• OUTPUT SHAFT
• P3 PLANETARY
• PARK PAWL
P2 PLANETARY
P1 PLANETARY
SHALLOW OIL PAN (OPTIONAL)
CONTROL MAIN FILTER CONTROL VALVE MODULE
ROTATING CLUTCH MODULE SUCTION FILTER
• TONE WHEEL OR OPTIONAL PTO DRIVE GEAR
• C2 CLUTCH
Figure 3. 1000 Series™ Transmission Cross Section

• C1 CLUTCH
• TURBINE SHAFT V06630.00.02
CONVERTER HOUSING
PTO DRIVE GEAR (OPTIONAL)
14
REAR COVER MODULE
• REAR COVER
• C5 PISTON
• P3 PLANETARY
NO PARK PAWL
COOLER MANIFOLD

DEEP OIL PAN
Same as 1000 Series™ except as shown SUCTION FILTER
TONE WHEEL
V06631.00.02
CONVERTER HOUSING
PTO DRIVE GEAR (OPTIONAL)
15
REAR COVER MODULE
• REAR COVER
• C5 PISTON
• P3 PLANETARY
COOLER MANIFOLD

DEEP OIL PAN
Same as 1000 Series™ except as shown SUCTION FILTER
TONE WHEEL
V06632.00.02
V06633.00.02
REAR COVER MODULE
• REAR COVER
CONVERTER HOUSING
Figure 6. 1000 Series™ Transmission Cross Section With Optional

Converter Housing and Rear Cover
16
SHIFT SELECTORS
DESCRIPTION OF AVAILABLE TYPES

The 1000/2000/2400 Series transmissions use lever-type shift selectors. The shift
positions on the shift selector can vary according to the shift selector installed.
OPERATION OF THE SHIFT SELECTOR

The shift selector is used by the operator to select the following ranges.
• Park (P) for transmissions with park pawls
• Auto-Apply Parking Brake (PB) for vehicles with automatically engaged
parking brakes
• Reverse (R)
• Neutral (N)
• Drive (D)*
• Fourth Range (4)**
• Third Range (3)**
• Second Range (2)**
• First Range (1)
* The shift selector position representing this gear range may be labeled “5” (for
the highest gear in the range), “OD” (for Overdrive), “D” (for the normal Drive
position), or “1–5” (for the complete gear range).
** In calibrations with five forward ranges, one of these selector positions will not
be available.
Ranges are selected by moving the lever to the desired selector position (P, PB,
R, N, D, 4, 3, 2, or 1). Five speed transmission models have five forward ranges,
first through fifth. Four speed models have four forward ranges, first through
fourth. When a forward range has been selected, the transmission automatically
upshifts through each range. As the vehicle slows, the transmission will downshift
automatically through each range.
17
The following tables list the shift selector positions and corresponding ranges for
all 1000/2000/2400 Series models.
All 1000 Series™ and 2400 Series™ Transmissions

With P (Park) Position
Shift Shift Shift

Selector Selector Selector
Position Range Position Range Position Range
P (Park) Neutral* P (Park) Neutral* P (Park) Neutral*
R (Reverse) Reverse R (Reverse) Reverse R (Reverse) Reverse
N (Neutral) Neutral N (Neutral) Neutral N (Neutral) Neutral
D (Drive)** 1–5 D (Drive)** 1–5 D (Drive)** 1–5
(1–4)***
4 (Fourth) 1–4 4 (Fourth) 1–4 3 (Third) 1–3
3 (Third) 1–3 2 (Second) 1–2 2 (Second) 1–2
1 (First) 1 1 (First) 1 1 (First) 1
* With Park Pawl engaged
** The shift selector position representing this gear range may be labeled “5” (for the highest gear
in the range), “OD” (for Overdrive), “D” (for the normal Drive position), or “1–5” (for the
complete gear range)
*** 1–4 in Trailering Mode or 4 Speed Calibration
All 1000 Series™ and 2400 Series™ Transmissions

Without P (Park) Position
Shift Shift Shift

(1–4)***
complete gear range)
18
All 2000 Series™ Transmissions With Auto-Apply Parking Brake
Shift Selector Shift Selector Shift Selector

PB Neutral* PB Neutral* PB Neutral*
(Auto-Apply (Auto-Apply (Auto-Apply
Parking Brake) Parking Brake) Parking Brake)
(1–4)***
* With Auto-Apply Parking Brake engaged
complete gear range).
All 2000 Series™ Transmissions Without Auto-Apply Parking Brake
Shift Shift Shift

(1–4)***
There are several features of the 1000/2000/2400 Series transmissions that can
inhibit transmission shifting. See the SHIFT INHIBITS paragraph of this manual.
With an Allison-equipped vehicle, selecting the right moment to upshift or
downshift during changing road and traffic conditions is not necessary. The Allison
1000/2000/2400 Series transmission does it for you. However, knowledge of the
ranges and when to select them will make vehicle control and your job even
easier.
19
RANGE SELECTION—ALL 1000 SERIES™ AND
2400 SERIES™ TRANSMISSIONS WITH P (PARK)
POSITIONS
ALL TRANSMISSIONS WITH P (PARK) POSITION
WARNING: For vehicles containing 1000 Series™ and
2400 Series™ transmissions, follow this procedure each time the
operator’s station will be unoccupied with the engine running.
• Bring the vehicle to a complete stop using the service brake.
• Make sure the engine is at low idle rpm.
• Put the transmission in P (Park).
• Engage the park pawl by slowly releasing the service brake.
• If a parking brake is present, apply the parking brake. Make
sure the parking brake is properly engaged.
• Apply the emergency brakes and make sure they are properly
engaged.
• Chock the wheels and take any other steps necessary to keep
the vehicle from moving.
If this procedure is not followed, the vehicle can move
unexpectedly and cause injury and/or property damage.
P Use P (Park) for the following.

• to turn on or turn off the engine
• to check vehicle accessories
• to operate the engine at idle for longer than five minutes
• for stationary operation of the power takeoff (if your vehicle
is equipped with a PTO)
This position places the transmission in N (Neutral) and engages
the park pawl.
WARNING: R (Reverse) may not be obtained due to an active
inhibitor. Always apply the service brakes when selecting
R (Reverse) to prevent unexpected vehicle movement and
because a service brake inhibit can be present. Always be sure
that “R” is not flashing whenever R (Reverse) is selected.
Check for active diagnostic codes if R (Reverse) is not attained.
20
WARNING: To help avoid injury and/or property damage
caused by unexpected vehicle movement, do not make shifts
from R (Reverse) to N (Neutral) without applying the service
brakes, parking brake, or emergency brake. Selecting N (Neutral)
does not apply vehicle brakes unless an auxiliary system to apply
a parking brake is installed.
CAUTION: Do not idle in R (Reverse) for more than

five minutes. Extended idling in R (Reverse) can cause
transmission overheating and damage. Always select P (Park)
whenever time at idle exceeds five minutes.
R R (Reverse) is used to back the vehicle. Completely stop the vehicle

and let the engine return to idle before shifting from a forward
range to R (Reverse) or from R (Reverse) to a forward range. The
reverse warning signal is activated when the shift selector is in this
position.
WARNING: To help avoid injury or property damage caused by
unexpected vehicle movement, do not make shifts to or from
N (Neutral) without manually or automatically applying an
appropriate vehicle brake.
WARNING: DO NOT allow the vehicle to “coast” in

N (Neutral). There is no engine braking in N (Neutral). You
could lose control of the vehicle, causing property damage or
personal injury. Coasting in neutral can cause severe transmission
damage.
N This position places the transmission in N (Neutral). Used for

starting the engine and stationary operation.
WARNING: D (Drive) and other forward ranges can not be
obtained due to an active inhibitor. The range selected can not be
obtained, resulting in unexpected vehicle movement. To help
avoid injury and/or property damage, always apply the service
brakes when selecting D (Drive) or other forward ranges. Check
for the RANGE INHIBIT(ED) light or the CHECK TRANS
light.
21
from a forward range to N (Neutral) without applying the service
CAUTION: Do not idle in D (Drive) or any forward range for

more than five minutes. Extended idling in D (Drive) can cause
transmission overheating and damage. Always select P (Park)
NOTE: Turn off the vehicle HIGH IDLE switch, if present, before
shifting from N (Neutral) to D (Drive) or R (Reverse). D (Drive) or
R (Reverse) will not be attained unless the shift is made with the
engine at idle.
D* Use D (Drive) for normal driving. The transmission will initially
attain first range when D (Drive) is selected. As vehicle speed
increases, the transmission will upshift automatically through each
available range up to 4 (FOURTH) or 5 (FIFTH). As the vehicle
slows, the transmission will downshift automatically.
* The shift selector position representing this gear range may be
labeled “5” (for the highest gear in the range), “OD” (for
Overdrive), “D” (for the normal Drive position), or “1–5” (for the
WARNING: The transmission incorporates a hold feature to
prohibit upshifting above the range selected during normal
driving. For downhill operation, select a lower transmission
range. If the engine governed speed is exceeded in the held
range, however, the transmission will upshift to the next higher
range to prevent engine damage. To avoid injury and/or property
damage due to loss of vehicle control, use the vehicle brakes to
prevent exceeding engine governed speed in the held range.
22
WARNING: To avoid loss of control, use a combination of
downshifting, braking, and other retarding devices. Downshifting
to a lower transmission range increases engine braking and can
help you maintain control. The transmission has a feature to
prevent automatic upshifting above the lower range selected.
However, during downhill operation, if engine governed speed is
exceeded in the lower range, the transmission will upshift to the
next higher range to prevent engine damage. This will reduce
engine braking and could cause a loss of control. Apply the
vehicle brakes or other retarding device to prevent exceeding
engine governed speed in the lower range selected.
4* Use 4 (FOURTH) or 3 (THIRD) for city traffic and braking on

3* steep downgrades.
* 3 for shift selectors with P,R,N,D,3,2,1
Actual ranges available depend on programming by vehicle
manufacturer.
3* Use 3 (THIRD) or 2 (SECOND) for heavy city traffic and braking
2* on steeper downgrades.
* 3 for shift selectors with P,R,N,D,4,3,1
manufacturer.
1 Use 1 (FIRST) range for the following.
• when pulling through mud and deep snow
• when maneuvering in tight spaces
• while driving up or down very steep grades
First range provides the vehicle with its maximum driving torque
and maximum engine braking effect.
23
RANGE SELECTION—ALL 1000 SERIES™ AND
2400 SERIES™ TRANSMISSIONS WITHOUT P (PARK)
POSITIONS
1000 SERIES™ AND 2400 SERIES™ TRANSMISSIONS WITHOUT
P (PARK) POSITION
WARNING: For vehicles containing 1000 Series™ and
2400 Series™ models without P (Park) positions, each time you
park the vehicle or leave the operator’s station with the engine
running, do the following.
• Ensure that the engine is at low idle rpm.
• Put the transmission in N (Neutral).
• Apply the emergency brake and/or parking brake and make
sure they are properly engaged.
• If the operator’s station will be unoccupied with the engine
running, chock the wheels and take any other steps necessary
to keep the vehicle from moving.
If the procedure is not followed, the vehicle may move suddenly
and cause injury and/or property damage.



transmission overheating and damage. Always select N (Neutral)
24
P (PARK) POSITION
position.

damage.
N Use N (Neutral) for the following.


obtained due to an active inhibitor. The range selected can not
be obtained, resulting in unexpected vehicle movement. To help
light.
25
P (PARK) POSITION

engine at idle.
26
P (PARK) POSITION

* 3 for shift selectors with R,N,D,3,2,1
manufacturer.
manufacturer.
27
RANGE SELECTION—ALL 2000 SERIES™
TRANSMISSIONS WITH AUTO-APPLY PARKING BRAKE
2000 SERIES™ TRANSMISSIONS WITH AUTO-APPLY PARKING
BRAKE
WARNING: For vehicles containing 2000 Series™ transmissions
without PB (Auto-Apply Parking Brake) selector position, follow
this procedure each time the operator’s station will be
unoccupied with the engine running.
• Put the transmission in PB (Auto-Apply Parking Brake).
Make sure the parking brake is porperly engaged.
• Apply the emergency brake and make sure it is properly
engaged.
unexpectedly and cause injury and/or property dmage.
PB Use PB (Auto-Apply Parking Brake) for the following.

This position places the transmission in N (Neutral) and engages
the parking brake.
28
BRAKE

transmission overheating and damage. Always select
PB (Auto-Apply Parking Brake) whenever time at idle exceeds
five minutes.

position.

damage.
N This position places the transmission in N (Neutral). Used for

starting the engine and stationary operation.
29
BRAKE
obtained due to an active inhibitor. The range selected can not be
obtained, resulting in unexpected vehicle movement. To help
light.


transmission overheating and damage. Always select
PB (Auto-Apply Parking Brake) whenever time at idle exceeds
five minutes.
engine at idle.
30
BRAKE


* 3 for shift selectors with PB,R,N,D,3,2,1
manufacturer.
* 3 for shift selectors with PB,R,N,D,4,3,1
manufacturer.
31
RANGE SELECTION—ALL 2000 SERIES™
TRANSMISSIONS WITHOUT AUTO-APPLY PARKING
BRAKE
2000 SERIES™ TRANSMISSIONS WITHOUT AUTO-APPLY PARKING
BRAKE
WARNING: For vehicles containing 2000 Series™ transmissions
without PB (Auto-Apply Parking Brake) selector position, follow
this procedure each time the operator’s station will be
unoccupied with the engine running.
• Put the transmission in N (Neutral), apply the parking brake,
emergency brake, and make sure they are properly engaged.
unexpectedly and cause injury and/or property damage.



32
BRAKE
position.

damage.
N Use N (Neutral) for the following.


obtained due to an active inhibitor. The range selected can not
be obtained, resulting in unexpected vehicle movement. To help
light.
33
BRAKE

engine at idle.
34
BRAKE
4*3* Use 4 (FOURTH) or 3 (THIRD) for city traffic and braking on

steep downgrades.
manufacturer.
3*2* Use 3 (THIRD) or 2 (SECOND) for heavy city traffic and braking
on steeper downgrades.
manufacturer.
35
DRIVING TIPS
MAXIMUM VEHICLE LOADING

WARNING: Operation with excessive loads can cause transmission
damage and unexpected vehicle movement. To help avoid injury,
property damage and/or transmission damage, do not exceed the
following.
• For 1000 Series™ and 2400 Series™ transmissions, do not exceed
11 800 kg (26,000 lb) GCW or the OEM vehicle rating, whichever
is less.
• For 2000 Series™ transmissions, do not exceed 13 600 kg
(30,000 lb) GCW or the OEM rating, whichever is less.
PREVENT MAJOR PROBLEMS

Minor problems can be kept from becoming major problems if you notify an
Allison Transmission distributor or dealer when any of these conditions occur.
• Shifting feels abnormal
• Transmission leaks fluid
• Unusual transmission-related sounds (changes in sound caused by normal
engine thermostatic fan cycling, while climbing a long grade with a heavy
load, have been mistaken for transmission-related sounds)
• CHECK TRANS light or RANGE INHIBIT(ED) light comes on
frequently
TURNING ON/OFF THE VEHICLE

Before turning on or off the engine, the driver must verify that one of the
following ranges has been selected and engaged.
• P (Park)
• PB (Auto-Apply Parking Brake)
• N (Neutral) if P (Park) or PB (Auto-Apply Parking Brake) is not available
The vehicle should not start unless these ranges have been selected. If the vehicle
starts in any other range, seek service immediately.
36
Transmission operation at cold ambient temperatures may require preheating or
the use of a lower viscosity transmission fluid. See the FLUID RECOMMENDA-
TIONS paragraph in this manual.
Even when the engine is warm and capable of full-throttle output, the transmission
should not be taken out of P (Park), PB (Auto-Apply Parking Brake), or
N (Neutral) for at least thirty seconds to allow for buildup of transmission fluid
pressure.
ACCELERATOR CONTROL
WARNING: To avoid injury or property damage caused by sudden
movement of the vehicle, do not make shifts from N (Neutral) to a
forward range or R (Reverse) when the throttle is open. The vehicle will
lurch forward or rearward and the transmission can be damaged. Avoid
this condition by making shifts from N (Neutral) to a forward range or
R (Reverse) only when the throttle is closed and service brakes are
applied.
The position of the accelerator pedal influences the timing at which automatic
shifting occurs. When the pedal is fully depressed, upshifts will occur
automatically at high engine speeds. A partially depressed position of the pedal
will cause the upshifts to occur at lower engine speeds. An electronic throttle
position signal tells the TCM how much the operator has depressed the pedal.
Excessive throttle position may inhibit the directional shift.
PRIMARY/SECONDARY SHIFT SCHEDULES

The points at which shifts occur depend upon predetermined speeds and other
operating conditions. A transmission “shift calibration” includes several sets of
shift points which may be used according to current or anticipated operating
conditions. Some shift schedules may be inhibited as a result of operating
conditions, such as engine or transmission fluid temperature. Shift schedules may
be changed through selection of a remote (usually dash-mounted) switch—which
is typically associated with a change in anticipated vehicle operation.
The TCM includes the capacity for two separate and distinct shift calibrations
(customer-selectable), one for use in “Primary Mode” of operation and one in
“Secondary Mode.”
• Primary—This shift schedule is typically used for all normal vehicle
operations.
• Secondary—This is an alternate shift schedule that the TCM uses upon
request. Not all vehicles will be equipped with a secondary shift. The
request can be interlocked with a vehicle component, or be
operator-controlled via a dash-mounted switch.
37
Your vehicle may have a dash-mounted light that illuminates when the secondary
mode is active.
KICKDOWN
Some vehicles have a “kickdown” feature that allows the operator to choose
between an “Economy” primary shift schedule and “Performance” secondary shift
schedule. The throttle pedal will have a detent feel when full-throttle is achieved
using “Economy” shift points. When the operator “steps through” this detent, the
function is activated and “Performance” shift points are achieved.
OUTPUT SPEED INDICATOR

Your vehicle may contain a light or other indicator that is activated when a preset
output speed has been exceeded in the vehicle, transmission, or auxiliary
equipment. The output speed may occur in either the forward or reverse direction.
This indicator may be used to alert the operator that a specific overspeed condition
has occurred or to indicate the attainment of a minimum or maximum operating
speed.
RANGE INHIBIT(ED) LIGHT

The red or amber RANGE INHIBIT(ED) warning light is located on or near the
shift selector. The purpose of this indicator is to alert the operator that
transmission operation is being inhibited and that range shifts being requested by
the operator may not occur. When certain operating conditions are detected by the
TCM, the controls will command the transmission to be locked in the range
currently in use. If the torque converter clutch is applied when the condition is
detected, the clutch will be disengaged concurrently with the activation of the
RANGE INHIBIT(ED) light.
Each time the engine is started, the RANGE INHIBIT(ED) light will illuminate,
then turn off after two seconds. If the light does not illuminate during ignition, or
if the light remains on after ignition, the transmission system should be checked
immediately.
For the conditions under which shift inhibits occur, see the SHIFT INHIBITS
paragraph in this manual.
CHECK TRANS OR MALFUNCTION INDICATOR LIGHT

The red or amber CHECK TRANS light or Malfunction Indicator Light (MIL) of
some type is located on the dash panel. For vehicles which are compliant to
industry On Board Diagnostics II (OBD II) requirements, an MIL Light will be
present. For vehicles which are not compliant to industry OBD II requirements, a
CHECK TRANS light will be present.
38
Each time the engine is started, the CHECK TRANS or MIL light will
illuminate, then turn off after two seconds. If the light does not illuminate during
ignition, or if the light remains on after ignition, the transmission system should
be checked immediately.
Illumination of the CHECK TRANS light at any time after start-up indicates that
a problem has been detected. The TCM will register a diagnostic code and shifts
may be restricted. Depending upon the severity of the problem, operation may
continue in order to reach service assistance. The TCM may not respond to shift
selector requests since upshifts and downshifts may be restricted and direction
changes may not occur.
Illumination of the MIL Light at any time after start-up may indicate a problem
with the engine or transmission.
SHIFT INHIBITS
The transmission control system will inhibit shifting to protect the transmission
from some types of abusive operation, in response to diagnostic trouble codes, and
to satisfy transmission feature/option requirements. These shift inhibits fall within
the following types.
• Above-idle neutral-to-range shifts
• Forward/reverse directional shifts
• Transmission problems
• Auxiliary equipment operation
Above-Idle Neutral-to-Range Shifts.

applied.
Above-idle (greater than 900 rpm) shifts from N (Neutral) to R (Reverse) or

N (Neutral) to a forward range are normally inhibited (except in emergency
vehicles or some other type of specialized equipment).
When these shifts are inhibited, the RANGE INHIBIT(ED) light will illuminate.
See the RANGE INHIBIT(ED) LIGHT paragraph in this manual for further
information.
39
Forward/Reverse Directional Shifts.

applied.
Forward/reverse directional changes are typically not permitted if appreciable

output shaft speed is detected.
When these shifts are inhibited, the RANGE INHIBIT(ED) light will illuminate.
See the RANGE INHIBIT(ED) LIGHT paragraph in this manual for further
information.
Transmission Problems. Lights such as a RANGE INHIBIT(ED), CHECK

TRANS, and a flashing PRNDL display will be illuminated when the
transmission detects a problem. An illuminated RANGE INHIBIT(ED) light or a
flashing PRNDL display indicates that the TCM has locked the transmission into
a forward range or R (Reverse). Shifts from N (Neutral)-to-D (Drive),
N (Neutral)-to-R (Reverse) and directional shifts will be inhibited. The locked
range allows the vehicle to reach service assistance. The transmission will remain
locked until the problem has been corrected. With the exception of diagnostic
trouble code (DTC) U2105, the CHECK TRANS light will be illuminated when
the TCM has registered a DTC. When a U2105 is registered, the CHECK
TRANS light may not be illuminated in earlier models. Depending upon the
severity of the problem, operation may continue to allow the vehicle to reach
service assistance by locking the transmission in the range currently in use. The
TCM may inhibit upshifts, downshifts and directional change shifts. See the
DIAGNOSTIC CODES AND TOOLS paragraph in this manual for further
information.
An illuminated Malfunction Indicator Light (MIL) may indicate a problem with
the transmission or engine.
See the RANGE INHIBIT(ED) LIGHT and CHECK TRANS OR
MALFUNCTION INDICATOR LIGHT paragraphs in this manual for further
information.
Auxiliary Equipment Operation. The TCM will prevent shifts from P (Park),
PB (Auto-Apply Parking Brake), or N (Neutral)-to-range when auxiliary
equipment is in operation (e.g., a wheelchair lift). For some vehicles such as
buses, shifts from P (Park), PB (Auto-Apply Parking Brake), or
N (Neutral)-to-range will be prevented unless the brake pedal is depressed.
40
USING THE ENGINE TO SLOW THE VEHICLE
WARNING: The transmission incorporates a hold feature to prohibit
upshifting above the range selected during normal driving. For downhill
operation, select a lower transmission range. If the engine governed
speed is exceeded in the held range, however, the transmission will
upshift to the next higher range to prevent engine damage. To avoid
injury and/or property damage due to loss of vehicle control, use the
vehicle brakes to prevent exceeding engine governed speed in the held
range.

downshifting, braking, and other retarding devices. Downshifting to a
lower transmission range increases engine braking and can help you
maintain control. The transmission has a feature to prevent automatic
upshifting above the lower range selected. However, during downhill
operation, if engine governed speed is exceeded in the lower range, the
transmission will upshift to the next higher range to prevent engine
damage. This will reduce engine braking and could cause a loss of
control. Apply the vehicle brakes or other retarding device to prevent
exceeding engine governed speed in the lower range selected.
To use the engine as a braking force, select the next lower range. If the vehicle is
exceeding the maximum speed for this range, use the service brakes and/or other
retarding devices to slow the vehicle. When a lower speed is reached, the TCM
will automatically downshift the transmission. Engine braking provides good
speed control for going down grades. When the vehicle is heavily loaded, or the
grade is steep, it may be desirable to preselect a lower range before reaching the
grade. If engine-governed speed is exceeded, the transmission will upshift
automatically to the next range.
CAUTION: Using the retarder or engine brake on wet or slippery roads

may cause loss of traction on the drive wheels — your vehicle may
slide out of control. To help avoid injury or property damage, turn the
retarder or engine brake enable to OFF when driving on wet or slippery
roads.
RANGE PRESELECTION
Range preselection means selecting a lower range to match driving conditions you
encounter or expect to encounter. Learning to take advantage of preselected shifts
will give you better control on slick or icy roads and on downgrades.
41
Downshifting to a lower range increases engine braking. The selection of a lower
range often prevents cycling between that range and the next higher range on a
series of short up-and-down hills.
NOTE: Preselecting during normal operation may result in reduced fuel

economy.
Manual range downshifts will not occur until a calibration value of output speed is
reached. When a range downshift is manually selected and the transmission output
speed is above the calibration value, the transmission will stay in the range it was
in even though a lower range was requested. Apply the vehicle service brakes or
some retarding device to reduce the transmission output speed to the calibration
value and then the shift to the lower range will occur.
Two shift schedules are used with range preselection: hold upshift and preselect
downshift.
Hold Upshift. This shift schedule keeps the transmission from shifting above the
selected range. This shift schedule permits upshifts to occur if an engine
overspeed condition could result by the transmission remaining (by operator
selection) in a range lower than its highest range. When the hold feature is
activated, transmission upshift points occur at engine speeds which are higher than
normal upshifts in order to “hold” the transmission from upshifting beyond the
current range.
WARNING: The transmission incorporates a hold feature to prohibit

upshifting above the range selected during normal driving. For downhill
operation, select a lower transmission range. If the engine governed
speed is exceeded in the held range, however, the transmission will
upshift to the next higher range to prevent engine damage. To avoid
injury and/or property damage due to loss of vehicle control, use the
vehicle brakes to prevent exceeding engine governed speed in the held
range.
Preselect Downshift. This shift schedule is used when the driver preselects a
lower range. The operator may preselect any range below D (Drive) on the shift
selector at any time. When a range has been “preselected” in this manner, shift
points to and from ranges above the preselected range are higher than the normal
shift points. The transmission will downshift when an engine overspeed condition
will not result after the shift. Shifts below the preselected range are not affected.
42
REVERSE
Putting the transmission into R (Reverse) may activate vehicle back-up lights
and/or reverse warning devices.
To achieve REVERSE range in some European transit and tour buses, an
instrument panel-mounted switch must be pressed simultaneously with the
R (Reverse) shift selector button.
REFUSE PACKER STEP SWITCH

When personnel are on the rear step of a refuse packer, the transmission will
operate in FIRST and NEUTRAL only.
• An operator request to upshift beyond FIRST or to shift to R (reverse) is
ignored by the TCM.
• If the transmission is in R (reverse), the TCM will cause the transmission to
shift to NEUTRAL.
• If the transmission is in a forward range higher than 1 (FIRST), the TCM
will invoke “preselect downshifts” until FIRST is attained.
TWO-SPEED AXLE (Some 1000/2000/2400 Series

Applications)
The two-speed axle may be shifted while the vehicle is moving. However, the
axle or vehicle manufacturer’s recommendations should be followed for shifting
the axle. It is recommended that axle shifts be made with the transmission in the
highest range, or vehicle stopped, to prevent a transmission shift from coinciding
with an axle shift.
DRIVING ON SNOW OR ICE

Here is where all of your ability as a professional driver comes into focus
regardless of what transmission you have. If possible, reduce your speed and
select a lower range before you lose traction. Select the range that will not exceed
the speed you expect to maintain. Accelerate or decelerate very gradually to
prevent losing traction. It is very important to slow gradually when a lower range
is selected. It is important that you reach the lower range selected before
attempting to accelerate. This will avoid an unexpected downshift during
acceleration.
NOTE: If ABS is activated, the lockup clutch is automatically

disengaged.
43
ROCKING OUT
applied.
CAUTION: If the wheels are stuck and not turning, do not apply full
power for more than 30 seconds in either D (Drive) or R (Reverse). Full
power for more than 30 seconds under these conditions will cause the
transmission to overheat. If the transmission overheats, shift to
N (Neutral) and operate the engine at 1200–1500 rpm until it cools
(2–3 minutes).
If the vehicle is stuck in deep sand, snow, or mud, it may be possible to rock it
out. Shift to D (Drive) and apply steady, light throttle (never full throttle). When
the vehicle has rocked forward as far as it will go, apply and hold the vehicle
service brakes. Allow the engine to return to idle; then select R (Reverse). Release
the brakes and apply a steady, light throttle and allow the vehicle to rock in
R (Reverse) as far as it will go. Again, apply and hold the service brakes and
allow the engine to return to idle. This procedure may be repeated in D (Drive)
and R (Reverse) if each directional shift continues to move the vehicle a greater
distance. Never make N (Neutral)-to-D (Drive) or directional shift changes when
the engine rpm is above idle.
OPERATING TEMPERATURES
To ensure proper operation of the transmission, adhere to the following minimum
and maximum transmission operating temperatures.
Sump, minimum continuous 40°C (100°F)

Sump, maximum intermittent 121°C (250°F)
To cooler, maximum intermittent 149°C (300°F)
Your transmission may have a converter-out transmission temperature gauge near

the “to-cooler” port on the transmission converter housing.
44
HIGH FLUID TEMPERATURE
CAUTION: Always select P (Park), PB (Auto-Apply Parking Brake),
or N (Neutral) whenever time at idle exceeds five minutes. Extended
idling in any other ranges can cause transmission overheating and
damage.
CAUTION: Sustained use of the parking brake with the engine running
and the transmission in range can cause an overheating failure of the
transmission. The vehicle can contain a buzzer or dash-mounted light to
alert the operator when the ignition switch is “ON”, the parking brake is
applied, and the transmission selector is in range.
CAUTION: The engine should never be operated for more than

30 seconds at full throttle with the transmission in range and the output
stalled. Prolonged operation of this type will cause the transmission fluid
temperature to become excessively high and will cause severe overheat
damage to the transmission.
Your vehicle may have a dash indicator or other alarm that turns on when the
transmission sump temperature or to-cooler temperature exceeds specified limits.
If the transmission overheats during normal operations, do the following.
• Check the fluid level in the transmission. See the CARE AND
MAINTENANCE section of this manual.
• Safely stop the vehicle and check the cooling system. If it appears to be
functioning properly, run the engine at 1200–1500 rpm with the
transmission in N (Neutral). This should reduce the transmission and engine
temperatures to normal operating levels in 2 or 3 minutes. If temperatures
do not decrease, reduce the engine rpm.
• If high temperature in either the engine or transmission persists, stop the
engine and have the overheating condition investigated by maintenance
personnel.
PARKING BRAKE
For shift selectors with a PB (Auto-Apply Parking Brake) position, selecting
PB (Auto-Apply Parking Brake) places the transmission in NEUTRAL and
automatically engages the parking brake. For shift selectors without a
PB (Auto-Apply Parking Brake) position, the parking brake must be manually
engaged. Your vehicle may have an indicator light that illuminates when the
parking brake is applied.
45
CAUTION: Do not apply the transmission-mounted parking brake with
the vehicle in motion. Transmission and/or driveline damage can result.
In the event of a dynamic brake apply, recheck the torque of all brake
mounting bolts to verify the integrity of the mount.
CAUTION: Sustained use of the parking brake with the engine running
and the transmission in range can cause an overheating failure of the
transmission. The vehicle can contain a buzzer or dash-mounted light to
alert the operator when the ignition switch is “ON”, the parking brake is
applied, and the transmission selector is in range.
PARK PAWL
A park pawl is standard on 1000 Series™ and 2400 Series™ transmissions and is
not available on 2000 Series™ transmissions. The park pawl effectively grounds
the transmission output shaft, thereby preventing rotation of the driveline.
Provided the vehicle is stationary, selecting P (Park) on the shift selector places
the transmission in NEUTRAL and engages the park pawl. The park pawl exists
but cannot be engaged in some vehicle configurations using 1000 Series™ and
2400 Series™ transmissions (e.g., some rear engine vehicles with air brakes). For
these configurations, the P (Park) position is not used.
WARNING: To help avoid injury and/or property damage caused by

unexpected vehicle movement, do not attempt to engage P (Park) with
the vehicle in motion (2 km/hr (1 mph) or higher). If you attempt to
engage P (Park) with the vehicle in motion (2 km/hr (1 mph) or higher),
the park pawl will ratchet, will not engage, and will not hold the
vehicle. Repeated park pawl ratcheting can cause transmission damage.
WARNING: If the vehicle has four-wheel-drive and the transfer case is

in Neutral, the vehicle can be free to roll even if the P (Park) position is
selected. To avoid injury and/or property damage caused by unexpected
movement of the vehicle, be certain that the transfer case is in “high”
drive range, not Neutral, whenever the vehicle is parked.
46
WARNING: If the vehicle is equipped with a two-speed axle or
two-speed transfer case which is engaged in “low”, even very low
vehicle speeds can produce appreciable transmission output shaft speed.
Even the slightest vehicle motion can deter engagement of the park pawl
in such cases. To help avoid injury and/or property damage caused by
unexpected vehicle movement, be certain that the axle or transfer case is
in “high” drive range whenever the vehicle is parked and the park pawl
is engaged.
Torque Lock. If the vehicle is parked on an incline and P (Park) is properly

engaged, the weight of the vehicle may generate an excessive amount of torque on
the park pawl in the transmission. In this situation, it may be difficult to shift the
transmission out of the P (Park) position. This condition is commonly called
“torque lock.”
To drive a vehicle with torque lock, do the following.
1. Push the vehicle uphill a small amount to release the pressure on the park
pawl and permit the shift out of P (Park).
2. Shift the transmission out of P (Park) while applying the service brakes.
3. Release the parking brake.
PARKING/LEAVING VEHICLE WITH ENGINE RUNNING

WARNING: For vehicles containing 1000 Series™ and 2400 Series™
transmissions, follow this procedure each time the operator’s staton will
be unoccupied with the engine running.
• If a parking brake is present, apply the parking brake. Make sure
the parking brake is properly engaged.
engaged.
• Chock the wheels and take any other steps necessary to keep the
vehicle from moving.
If this procedure is not followed, the vehicle can move unexpectedly
47
transmissions without P (Park) positions, each time you park the vehicle
or leave the operator’s station with the engine running, do the following.
• Apply the emergency brakes and/or parking brake and make sure
they are properly engaged.
running, chock the wheels and take any other steps necessary to
keep the vehicle from moving.
WARNING: For vehicles containing 2000 Series™ transmission with

PB (Auto-Apply Parking Brake) selector position, follow this procedure
each time the operator’s station will be unoccupied with the engine
running.
• Put the transmission in PB (Auto-Apply Parking Brake). Make
engaged.
WARNING: For vehicles containing 2000 Series™ transmission

without PB (Auto-Apply Parking Brake) selector position, follow this
procedure each time the operator’s station will be unoccupied with the
engine running.
48
TOWING OR PUSHING
CAUTION: Failure to lift the driving wheels off the road, disconnect
the driveline, or remove the axle shafts before pushing or towing can
cause serious transmission damage.
The engine cannot be started by pushing or towing. Before pushing or towing a

vehicle, lift the drive wheels off the road, disconnect the driveline, or remove the
axle shafts from the drive wheels. When the axle shafts are removed, be sure to
cover the wheel openings to prevent loss of lubricant and entry of dust and dirt.
An auxiliary air supply will usually be required to release the vehicle brake
system.
SURGING NATURAL GAS ENGINES

NOTE: Engine surging or engine speed cycling may occur on natural
gas powered equipment. This condition typically occurs when the
transmission is being operated in a hold position with throttle applied
and the engine speed above full load engine governed speed. Surging
may also occur at closed and part throttle. This condition is an engine
characteristic and NOT a transmission concern.
49
POWER TAKEOFF
POWER TAKEOFF (PTO) SYSTEMS

Three types of PTO systems may be used with the 1000/2000/2400 Series
transmissions.
• Transmission-Mounted Converter-Driven PTO—A transmission-mounted
converter-driven PTO drive provides both an infinitely-variable PTO drive
ratio and a protective hydraulic cushion against abrupt loading/unloading
(during “converter mode” operation) and engine-driven PTO speed control
(during “torque converter clutch mode” operation).
• Split-Shaft PTO—A split-shaft PTO, a chassis-mounted component, is
typically used in applications which require full engine power being
available to either propel the vehicle or to power auxiliary equipment
through the PTO drive—but not both simultaneously. In both cases, the
transmission output shaft delivers power to the split-shaft transfer case. The
split-shaft transfer case is then shifted to deliver this power to either the
driveline or PTO drive.
• Flywheel-Driven PTO—A flywheel-driven PTO, often called a “sandwich
PTO,” mounts between the engine and transmission. The PTO is normally
driven directly by the engine.
CONVERTER-DRIVEN POWER TAKEOFF (PTO)

The following pertains to Transmission-Mounted Converter-Driven PTOs only.
PTO Configuration. The PTO is mounted on the left and/or right side of the
transmission housing. The PTO drivetrain consists of a large drive gear in the
transmission, an idler gear arrangement, and a smaller driven gear in the PTO.
The drive gear is integral to the transmission rotating clutch housing, which
rotates at the same speed as the torque converter turbine. With this drive
configuration, the PTO rotates in the same direction as the engine.
Two types of transmission-mounted PTOs may be used with these transmission
models.
• A constant-drive PTO is used in applications which require full-time PTO
operation. The PTO driven gear is in constant mesh with the drive gear and
cannot be disengaged.
• A clutch drive PTO is used in applications which require only part-time
operation of the PTO. For clutch drive PTOs, the following applies: 1) the
50
engagement/disengagement provision is facilitated by a hydraulic clutch
mechanism in the PTO assembly; 2) the PTO can be engaged or disengaged
at any time (except at engine speeds that exceed drive speed limits imposed
on the driven equipment).
PTO Engagement — Sliding Gear PTOs.
CAUTION: Do not use or install a sliding gear PTO where the sliding
gear meshes directly with the PTO drive gear. The PTO drive gear can
be damaged when the sliding gear slides into the PTO drive gear,
producing metal particles that can cause transmission damage.
NOTE: “Manual shift PTOs”—units which are engaged/disengaged to

the PTO drive gear in the transmission through use of a manual
(“sliding gear”) mechanism—are not compatible with the design of these
transmission models.
PTO Engagement — Manual Shift PTO. Manually shifted (Cable, Electrical,

Air shifted) PTOs that engage internally inside the PTO can be used.
WARNING: If you leave the vehicle and the engine is running, the
vehicle can move unexpectedly and you or others could be injured. DO
NOT leave the vehicle with the engine running unless you have taken
all of the following precautions:
• Shift the transmission to N (Neutral) or P (Park)
• Make sure that the engine is at low idle (500–800 rpm)
• Apply the park brake or emergency brake and make sure it is
properly engaged
vehicle from moving
On automatic transmissions, the gears in the transmission turn when the

transmission is in neutral, therefore, gears clashing will occur if the PTO is shifted
into range or out of range at this time.
With Converter Driven Gear:
1. Engine idle. With the operator seated in the driver’s seat and while
activating the vehicle’s brake, shift transmission level into any of the drive
positions. (This will stop transmission gear from turning.)
2. Shift PTO into or out of range.
3. If the PTO does not engage release the PTO to the disengage position, shift
the transmission to neutral and repeat the above steps from step A.
51
4. Shift the transmission into park or neutral. (This will start transmission
gears turning.) If you hear a grinding or ratcheting sound turn PTO off and
repeat these procedures from step A.
PTO Engagement — Clutch Driven. The PTO will engage only when the PTO
switch is on, the throttle position is low, and engine speed and output speed are
within user-specified limits. Your vehicle may have a light on the dash that
illuminates when the PTO is engaged.
CAUTION: Do not exceed the engagement and operational speed limits

imposed on the driven equipment during the operation of the PTO.
Exceeding the speed limits produces high hydraulic pressure in the PTO
that can damage the PTO components. Consult the vehicle
manufacturer’s literature for these speed limits.
CAUTION: Some vehicles “creep” in range at low vehicle speeds while

maintaining a specified engine speed for PTO operation (e.g., paint
stripers and feedlot trucks). DO NOT use the vehicle brakes to control
vehicle speed during PTO operation. Use ONLY throttle to control both
engine and vehicle speed when the transmission is in reverse or a
forward range. Applying BOTH brakes and throttle will cause the
transmission to overheat. Extended operation at elevated temperatures
will damage the transmission.
PTO Operation. The transmission operates in either converter mode or torque

converter clutch mode. In converter mode, the torque converter (lockup) clutch is
not engaged and the PTO is driven through the torque converter, producing a
torque at the PTO drive gear that is always greater than the input torque. In torque
converter clutch mode, the torque converter (lockup) clutch is engaged, the PTO
drivetrain is driven at a speed proportional to the engine speed.
The PTO drive is normally in continuous converter mode operation when the
transmission is in P (Park), PB (Auto-Apply Parking Brake), and R (Reverse).
Torque converter clutch operation in N (Neutral) is available for some
applications. If the PTO is used with the transmission in D (Drive) or another
forward range, transmission shifts (both converter/torque converter clutch mode
shifts and shifts between gears) are based on the automatic shift sequence of the
transmission shift controls. PTO drive gear speed will be affected each time a shift
occurs.
With the vehicle stopped and the engine at idle, PTO output speed is dependent
upon the transmission gear selection.
• If the transmission is in D (Drive) or R (Reverse), the PTO output speed is
zero.
52
• If the transmission is in N (Neutral), P (Park), or PB (Auto-Apply Parking
Brake), the PTO output will rotate slowly.
In some vehicles, the transmission will shift into N (Neutral) regardless of the
shift selector position under the following conditions.
• the PTO is enabled
• the transmission output speed is near zero
• the throttle position is near zero
To reselect a range, the operator must shift into N (Neutral), then shift to the
desired range.
CAUTION: Do not exceed the engagement and operational speed limits

imposed on the driven equipment during the operation of the PTO.
Exceeding the speed limits produces high hydraulic pressure in the PTO
that can damage the PTO components. Consult the vehicle
manufacturer’s literature for these speed limits.
CAUTION: When the PTO disengages due to overspeed, the PTO will
automatically re-engage at a user-specified speed, which is typically
relatively low. The resultant re-engagement shock could cause damage
to a high-inertia PTO system.
PTO Overspeed Protection. All 1000/2000/2400 Series-equipped vehicles with

PTO enable have engagement and operational speed limits programmed into the
TCM to help protect PTO equipment. The PTO will deactivate when operational
speeds (either engine or transmission output) are exceeded. When the PTO is
disengaged due to overspeed, the PTO will be automatically re-engaged at a user
specified speed, which is typically relatively low. After the speed has been
reduced, the operator may manually engage the PTO by repeating the engagement
process.
SPLIT-SHAFT POWER TAKEOFF (PTO)

For many split-shaft PTOs, holding the transmission in direct drive at all engine
speeds is desirable. In this manner, the automatic range shifts are eliminated,
thereby eliminating rapid torque changes which would occur at the driven
equipment during a shift in the transmission. Such a condition, for instance, could
create an undesirable pressure surge (and directional control problem) at the
nozzle-end of a fire hose.
53
NOTE: Unlike most Allison on-highway transmission models, the
1000/2000/2400 Series transmission models do not have a controls
provision which supports this type of split-shaft PTO application. The
output of a split-shaft PTO driven by these models will, therefore, be
subjected to transmission range shifts and will experience rapid speed
and torque changes with each occurrence.
54
CARE AND MAINTENANCE
PERIODIC INSPECTIONS AND CARE

Transmission Inspection.
CAUTION: Do not spray steam, water, or cleaning solution directly at

the vent assembly (breather). Spraying steam, water, or cleaning solution
at the vent assembly can force the water or cleaning solution into the
transmission and contaminate the transmission fluid. Seal all openings
and the vent assembly (breather) before spraying steam, water, or
cleaning solutions on the transmission.
Clean and inspect the exterior of the transmission at regular intervals. Severity of
service and operating conditions determine the frequency of these inspections.
Inspect the transmission for:.
• loose bolts — transmission and mounting components
• fluid leaks — repair immediately
• loose, dirty, or improperly adjusted throttle sensor or shift selector linkage
• damaged or loose hoses
• worn, frayed, or improperly routed electrical harnesses
• worn or frayed electrical connections
• worn or out-of-phase driveline U-joints and slip fittings
• clogged or dirty vent assembly
Vehicle Inspection. Check the vehicle cooling system occasionally for evidence of
transmission fluid which would indicate a faulty oil cooler.
55
Welding.
CAUTION: When welding on the vehicle:

• DO NOT WELD on the vehicle without disconnecting all control
system wiring harness connectors from the TCM.
• DO NOT WELD on the vehicle without disconnecting TCM
battery power and ground leads.
• DO NOT WELD on any control components.
• DO NOT CONNECT welding cables to any control components.
• PROTECT CONTROL COMPONENTS FROM SPARKS AND
HEAT DURING WELDING.
A label describing on-vehicle welding precautions is available from your

authorized Allison service dealer and should be installed in a conspicuous place. A
vehicle used in a vocation that requires frequent modifications or repairs involving
welding must have an on-vehicle welding label. Refer to SA2607.
IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL

Transmission fluid cools, lubricates, and transmits hydraulic power. Always
maintain proper fluid level. If fluid level is too low, the torque converter and
clutches do not receive an adequate supply of fluid and the transmission overheats.
If the level is too high, the fluid aerates—causing the transmission to shift
erratically and overheat. Fluid may be expelled through the vent assembly or
dipstick tube when the fluid level is too high.
TRANSMISSION FLUID CHECK

transmissions, follow this procedure each time the operator’s staton will
be unoccupied with the engine running.
• If a parking brake is present, apply the parking brake. Make sure
engaged.
56
transmissions without P (Park) positions, each time you park the vehicle
or leave the operator’s station with the engine running, do the following.
• Apply the emergency brakes and/or parking brake and make sure
WARNING: For vehicles containing 2000 Series™ transmission with

PB (Auto-Apply Parking Brake) selector position, follow this procedure
each time the operator’s station will be unoccupied with the engine
running.
engaged.
WARNING: For vehicles containing 2000 Series™ transmission

without PB (Auto-Apply Parking Brake) selector position, follow this
procedure each time the operator’s station will be unoccupied with the
engine running.
57
Fluid Check Procedure. Clean all dirt from around the end of the fluid fill tube
before removing the dipstick. Do not allow dirt or foreign matter to enter the
transmission. Dirt or foreign matter in the hydraulic system may cause undue wear
of transmission parts, make valves stick, and clog passages. Check the fluid level
using the following procedure and report any abnormal fluid levels to your
maintenance persons.
Cold Check Procedure. The purpose of the cold check is to determine if the
transmission has enough fluid to be operated safely until a hot check can be made.
CAUTION: The fluid level rises as fluid temperature rises. DO NOT fill
the transmission above the “COLD CHECK” band if the transmission
fluid is below normal operating temperatures. During operation, an
overfull transmission can become overheated, leading to transmission
damage.
Check the fluid level as follows:

1. Bring the vehicle to a complete stop on a level surface using the service
brake.
2. Make sure the engine is at low idle rpm.
3. Put the transmission in P (Park), PB (Auto-Apply Parking Brake), or
N (Neutral).
4. Apply any other parking brake, if present, and make sure it is properly
engaged.
5. Chock the wheels and take any other steps necessary to keep the vehicle
from moving.
6. Run the engine at 1000–1500 rpm for at least one minute to purge air from
the system. Apply the service brakes and shift to D (Drive), then to
N (Neutral), and then shift to R (Reverse) to fill the hydraulic system.
Finally, shift to P (Park) or PB (Auto-Apply Parking Brake), if available,
or N (Neutral) and allow the engine to idle (500–800 rpm). Slowly release
the service brakes.
7. With the engine running, remove the dipstick from the tube and wipe the
dipstick clean.
8. Insert the dipstick into the tube and remove. Check the fluid level reading.
Repeat the check procedure to verify the reading.
9. If the fluid level is within the “COLD CHECK” band (Figure entitled
Typical Dipstick Markings), the transmission may be operated until the
fluid is hot enough to perform a “HOT RUN” check. If the fluid level is
not within the “COLD CHECK” band, add or drain as necessary to bring it
to the middle of the “COLD CHECK” band.
58
10. Perform a hot check at the first opportunity after the normal operating
sump temperature of 71°C–93°C (160°F–200°F) is reached.
Hot Check Procedure.
CAUTION: When performing the Hot Check procedure, the fluid must
be hot to ensure an accurate check and help prevent transmission
damage. The fluid level rises as temperature increases. During operation,
an overfull transmission can become overheated, leading to transmission
damage.
Operate the transmission in D (Drive) until normal operating temperature is

reached:
• sump temperature 71°C–93°C (160°F–200°F)
• converter-out temperature 82°C–104°C (180°F–220°F)
• If a transmission temperature gauge is not present, check fluid level when
the engine water temperature gauge has stabilized and the transmission has
been operated under load for at least one hour.
HOT RUN
BAND
COLD CHECK
BAND
V06713
Figure 7. Typical Dipstick Markings

Check the fluid level as follows:
1. Bring the vehicle to a complete stop on a level surface using the service
brake.
2. Make sure the engine is at low idle rpm.
3. Put the transmission in P (Park), PB (Auto-Apply Parking Brake), or
N (Neutral).
59
4. Apply any other parking brake, if present, and make sure it is properly
engaged.
5. Chock the wheels and take any other steps necessary to keep the vehicle
from moving.
6. With the engine running, remove the dipstick from the tube and wipe the
dipstick clean.
7. Insert the dipstick into the tube and remove. Check the fluid level reading.
NOTE: Safe operating level is within the “HOT RUN” band on the
dipstick. See Figure entitled Typical Dipstick Markings. The width of
the “HOT RUN” band represents approximately 1.0 liter (1.06 quart) of
fluid at normal opeating sump temperature.
8. If the fluid level is not within the “HOT RUN” band, add or drain as
necessary to bring the fluid level to within the “HOT RUN” band.
Consistency of Readings. Always check the fluid level at least twice using the
procedure described above. Consistency (repeatable readings) is important to
maintaining proper fluid level. If inconsistent readings persist, check the
transmission vent assembly (breather) to be sure it is clean and unclogged. If
readings are still inconsistent, contact your nearest Allison distributor or dealer.
KEEPING FLUID CLEAN

Prevent foreign material from entering the transmission by using clean containers,
fillers, etc. Lay the dipstick in a clean place while filling the transmission.
CAUTION: Containers or fillers that have been used for antifreeze

solution or engine coolant must NEVER be used for transmission fluid.
Antifreeze and coolant solutions contain ethylene glycol which, if put
into the transmission, can cause the clutch plates and some seals to fail.
FLUID RECOMMENDATIONS
Hydraulic fluids (oils) used in the transmission are important influences on
transmission performance, reliability, and durability. Any fluids meeting
DEXRON®-III specifications are acceptable for use in the 1000, 2000, and 2400
Series transmissions. TranSynd™ fluids fully meet the DEXRON®-III
specifications.
60
To ensure the fluid is qualified for use in Allison transmissions, check for a
DEXRON®-III fluid license or approval numbers on the container, or consult the
lubricant manufacturer. Consult your Allison Transmission dealer or distributor
before using other fluid types.
CAUTION: Disregarding minimum fluid temperature limits can result

in transmission malfunction or reduced transmission life.
When choosing the optimum viscosity grade of fluid to use, duty cycle, preheat
capabilities, and/or geographical location must be taken into consideration. The
table below lists the minimum fluid temperatures at which the transmission may
be safely operated without preheating the fluid. Preheat with auxiliary heating
equipment or by running the equipment or vehicle with the transmission in
P (Park) or PB (Auto-Apply Parking Brake), if available, or N (Neutral) for a
minimum of 20 minutes before attempting range operation.
Transmission Fluid Operating Temperature Requirements
Ambient Temperature Below Which Preheat is

Required
Viscosity Grade Celsius Fahrenheit
DEXRON®-III –25° –13°
TranSynd™ –30° –22°
(Ref. SIL 13-TR-90)
Some shift ranges and the torque converter clutch mode may not be reached
during cold weather operation. As the transmission reaches normal operating
temperature, all shift ranges and the torque converter clutch mode will begin to
function.
61
TRANSMISSION FLUID AND FILTER CHANGE INTERVALS
CAUTION: Transmission fluid and filter change frequency is
determined by the severity of transmission service. To help avoid
transmission damage, more frequent changes can be necessary than
recommended in the general guidelines when operating conditions create
high levels of contamination or overheating.
Frequency. New vehicles delivered from the OEM with a mixture of TranSynd™
and non TranSynd™ fluid must follow fluid/filter change recommendations
outlined in Schedule 1 of the Transmission and Fluid Change table. If the
customer fills the transmission with TranSynd™ or TES-295 equivalent, the
change recommendations of Schedule 1 must be followed.
Upon the next oil change, if the customer reinstalls TranSynd™ or TES 295
equivalent, the fluid/filter change recommendations outlined in Schedule 2 may be
used. The recommendations in Schedule 2 are based upon Allison fluid change
procedures and the transmission containing 100% of TranSynd™ fluid.
For transmissions that contain a mixture of TranSynd™ and non-TranSynd™
fluids, refer to Schedule 3.
NOTE: Flushing Machines are not recommended or recognized due to

variation and inconsistencies with ensuring removal of 100 percent of
the used fluid.
Allison Transmission requires an initial filter change for the Spin-On Control
Main Filter during the first 8000 km (5000 miles) or 200 hrs of service, whichever
comes first. Following the initial filter change, change fluid/filters after
recommended mileage, months, or hours have elapsed, whichever occurs first. See
Transmission and Fluid Change table for recomendations. The transmission sump
filter is permanent and does not require replacement except at overhaul.
Severe Vocations include On/Off Highway, Refuse, City Transit, Shuttle, and
Motorhomes. General Vocations includes all other vocations. Local conditions,
severity of operation or duty cycle may require more or less frequent fluid change
intervals that differ from the published recommended fluid change intervals of
Allision Transmission. Transmission protection and fluid change intervals can be
optimized by the use of fluid analysis.
The following tables are given only as a general guide for fluid and filter change
intervals.
62
Schedule 1. Recommended Fluid and Filter Change Intervals
(Non-TranSynd™ /Non- TES 295 Fluid)
Filters
Lube/
Vocation Fluid Control Main Internal Auxiliary
80 000 km 80 000 km 80 000 km
General (50,000 miles) (50,000 miles) Overhaul (50,000 miles)
24 months 24 months 24 months
40 000 km 40 000 km 40 000 km
Severe (25,000 miles) (25,000 miles) Overhaul (25,000 miles)
Schedule 2. Recommended Fluid and Filter Change Intervals

(TranSynd™ /TES 295 Fluid)
Filters
Lube/
Vocation Fluid Control Main Internal Auxiliary
160 000 km 80 000 km 80 000 km
80 000 km 80 000 km 80 000 km
Schedule 3. Modified Fluid and Filter Change Intervals With a Mixture*

of TranSynd™ and Non-TranSynd™ Fluids
Filters
Vocation Fluid Control Main Internal Lube/Auxillary
80 000 km 80 000 km 80 000 km
40 000 km 40 000 km 40 000 km
* Mixture is defined as the quantity of oil remaining in the transmission after a standard fluid
change combined with the quantity of TranSynd™ that is required to fill the transmission to the
proper level. A mixture of TranSynd™ or TES 295 equivalent vs. non-TranSynd™ other than as
defined in this paragraph does not meet the requirements that permit the eligibility for the
recommendations given in Schedule 3.
63
Abnormal Conditions. Transmissions used in high cycle rate applications should
use fluid analysis to be certain that a proper fluid change interval is established.
Transmission fluid must be changed whenever there is evidence of dirt or a high
temperature condition. A high temperature condition is indicated by the
transmission fluid being discolored or having a strong odor, or by fluid analysis.
Local conditions, severity of operation, or duty cycle may require more or less
frequent fluid or filter change intervals.
Fluid Analysis. Transmission protection and fluid change intervals can be

optimized by monitoring fluid oxidation according to the tests and limits shown in
the following table. Fluid oxidation can be monitored through a fluid analysis firm
and/or by using an oil analysis kit.
• Fluid analysis firms—Consult your local telephone directory for fluid
analysis firms. To ensure consistent and accurate fluid analysis, use only
one fluid analysis firm. Refer to the Technician’s Guide for Automatic
Transmission Fluid, GN2055EN, for additional information.
• Oil analysis kits, part number 29537805, are available through your normal
Allison Transmission parts source.
Refer to the Technician’s Guide for Automatic Transmission Fluid, GN2055EN,
for additional information.
Fluid Oxidation Measurement Limits
Test Limit
Viscosity ±25% change from new fluid
Total Acid Number +3.0* change from new fluid
* mg of KOH required to neutralize a gram of fluid.
TRANSMISSION FLUID CONTAMINATION

Fluid Examination. At each fluid change, examine the drained fluid for evidence
of dirt or water. A normal amount of condensation will appear in the fluid during
operation.
Water. Obvious water contamination of the transmission fluid or transmission

fluid in the cooler water (in heat exchanger) indicates a leak between the water
and fluid areas of the cooler. Inspect and pressure test the cooler to confirm the
leak. Replace leaking coolers.
NOTE: Cooler water can also be contaminated by engine oil; be sure to

locate the correct source of cooler water contamination.
64
Engine Coolant.
CAUTION: If the transmission fluid is contained by water, 0.2 percent

by volume, or any trace of ethylene glycol, disassemble the transmission
and replace the following:
• Seals
• Gaskets
• Clutch plates
• Bearings
• Torque converters that cannot be disassembled
• Components that have rusted
• Solenoids that do not meet resistance specifications
Remove all traces of ethylene glycol and varnish deposits. Failure to
follow this procedure decreases transmission reliability and durability.
Metal. Metal particles in the fluid (except for the minute particles normally
trapped in the oil filter) indicate internal transmission damage. If these particles
are found in the sump, the transmission must be disassembled and closely
inspected to find their source. Metal contamination requires complete transmission
disassembly. Clean all internal and external hydraulic circuits, cooler, and all other
areas where the particles could lodge.
COOLER FLUSHING PROCEDURE

Metal contamination requires complete transmission disassembly and cleaning.
Clean all internal and external hydraulic circuits, transmission cooler, and all areas
where metal and other particles could lodge. Special tool J 46550 Transmission
Cooler Kiwk-Flsuh Cart is now an essential tool for all overhaul and maintenance
service outlets, J 46550 or an approved cooler flushing device that meets Allison
cooler flushing requirements and procedures.
1. Flush contaminated fluid from the cooler by flowing transmission fluid
through the cooler in the reverse direction of normal flow. Use a flushing
pump that pumps fluid in a pulsating flow at a minimum mean rate of
0.5 liters/sec (8.0 gpm) and 275–345 kPa (40–50 psi). The J 46550
Transmission Cooler Kwik-Flush Cart meets these requirements.
2. After flushing the contaminated fluid, use the flushing pump to circulate
clean transmission fluid through the cooler in a closed loop back to a
10–micron filter. Circulate fluid in the closed loop for a minimum of five
minutes.
CAUTION: After flushing the cooler, be sure to check the external

cooler circuit restriction. If circuit pressure drop is above specification,
the cooler has excessive trapped particles and must be replaced.
65
NOTE: When equipment to flush the oil cooler is not available, install a
filter in the cooler line between the oil cooler and the transmission
“from cooler” port. The cooler circuit pressure drop specifications must
still be met (see AS64–071 or AS64–072 in the Allison Sales Tech Data
book). Frequent initial changes of this filter element may be required as
debris is flushed out of the oil cooler circuit. Closely monitoring change
in cooler circuit pressure drop will indicate when a filter change is
needed.
TRANSMISSION FLUID AND FILTER CHANGE

PROCEDURE
Drain Fluid.
1. Drain the fluid when the transmission is at normal operating sump
temperature of 71–93°C (160–200°F). Hot fluid flows quicker and drains
more completely.
2. Remove the drain plug from the oil pan and allow the fluid to drain into a
suitable container.
3. Examine the fluid as described in the TRANSMISSION FLUID
CONTAMINATION paragraph in this Section.
Replace Control-Main Filter (refer to Figure 8).

1. Using a standard strap-type filter wrench or the J 45023, remove the
control-main filter by rotating it in the counterclockwise direction.
2. Remove the magnet from the filter attachment tube or from the top of the
filter element.
3. Clean any metal debris from the magnet. Report any metal pieces larger
than dust to your maintenance personnel.
4. Reinstall the magnet onto the filter attachment tube.
5. Lubricate the gasket on the control-main filter with transmission fluid.
6. Install, by hand, the control-main filter until the gasket on the control-main
filter touches the converter housing or cooler manifold.
CAUTION: Turning the control-main filter more than ONE FULL

TURN after gasket contact will damage the filter.
7. Using the J 45023 or by hand, turn the filter ONE FULL TURN ONLY
after gasket contact.
8. Reinstall the drain plug and sealing washer. Tighten the drain plug to
30–40 N·m (22–30 lb ft).
66
MAGNET
TE
V06712.01.00
Figure 8. Replacing the Control-Main Filter

Refill Transmission. The amount of refill fluid is less than the amount used for
the initial fill. Fluid remains in the external circuits and transmission cavities after
draining the transmission.
After refill, check the fluid level using the TRANSMISSION FLUID CHECK
paragraph of this Manual.
67
OM3063EN_200306.pdf 8/18/04 4:04:40 PM
Transmission Fluid Capacity
Initial Fill * Refill*

Transmission Sump Liters Quarts Liters Quarts
Standard 14 14.8 10 10.6
1000/2000/2400
Shallow 12 12.7 7 7.4
* Approximate quantities, do not include external lines and cooler hose.
VENT ASSEMBLY
Location and Purpose. The vent assembly is located at the top left-rear of the
transmission main housing. The vent assembly prevents air pressure buildup
within the transmission and its passage must be kept clean and open.
CAUTION: Do not spray steam, water, or cleaning solution directly at

the vent assembly (breather). Spraying steam, water, or cleaning solution
at the vent assembly can force the water or cleaning solution into the
C
transmission and contaminate the transmission fluid. Seal all openings
and the vent assembly (breather) before spraying steam, water, or
M
cleaning solutions on the transmission.
Y
CM
Maintenance. The amount of dust and dirt encountered will determine the
frequency of vent assembly cleaning. Use care when cleaning the transmission.
MY
CY
CMY
68
DIAGNOSTICS
DIAGNOSTIC CODES AND TOOLS

Diagnostic features are provided with the transmission control system to assist in
the troubleshooting of malfunctions. These features include a red or amber
CHECK TRANS light or some type of Malfunction Indicator Light (MIL), a
PC-based diagnostic program, and an optional hand-held scan tool. The CHECK
TRANS and MIL lights are located on the dash panel. For vehicles which are
compliant to industry On Board Diagnostics II (OBD II) requirements, an MIL
Light will be present. For vehicles which are not compliant to industry OBD II
requirements, a CHECK TRANS light will be present. The PC-based diagnostic
program can troubleshoot all transmissions. The hand-held scan tool can
troubleshoot only some transmissions.
Illumination of the CHECK TRANS light at any time after start-up indicates that
the TCM has registered a diagnostic trouble code (DTC). Diagnostic codes are
used to identify and clarify the nature of the malfunction. Diagnostic codes are
read and cleared through the PC-based diagnostic program or the hand-held scan
tool.
Illumination of the MIL Light at any time after start-up may indicate a problem
with the engine or transmission.
For further information, consult an authorized Allison Transmission distributor or
service dealer or the website www.allisontransmission.com. Reference the Sales
and Service Directory (SA2229) for the current listing of Allison Transmission
authorized distributor and service dealers.
69
CUSTOMER SERVICE
OWNER ASSISTANCE
The satisfaction and goodwill of the owners of Allison transmissions are of
primary concern to Allison Transmission Division (ATD), its distributors, and their
dealers.
As an owner of an Allison transmission, you have service locations throughout the
world that are eager to meet your parts and service needs with:
• Expert service by trained personnel
• Emergency service 24 hours a day in many areas
• Complete parts support
• Sales teams to help determine your transmission requirements
• Product information and literature
Normally, any situation that arises in connection with the sale, operation, or
service of your transmission will be handled by the distributor or dealer in your
area (check the telephone directory for the Allison Transmission service outlet
nearest you).
Refer to Worldwide Sales and Service Directory (SA2229EN) for the current
listing of Allison Transmission authorized distributor and service dealers. This
directory is available from SGI, Inc.
We recognize, however, that despite the best intentions of everyone concerned,
misunderstandings may occur. To further assure your complete satisfaction, we
have developed the following three-step procedure to be followed in the event a
problem has not been handled satisfactorily.
Step One—Discuss the problem with a member of management from the
distributorship or dealership. Frequently, complaints are the result of a
breakdown in communication and can quickly be resolved by a member of
management. If you have already discussed the problem with the Sales or Service
Manager, contact the General Manager. All ATD dealers are associated with an
ATD distributor. If the problem originates with a dealer, explain the matter to a
management member of the distributorship with whom the dealer has his service
agreement. The dealer will provide his ATD distributor’s name, address, and
telephone number on request.
70
Step Two—When it appears the problem cannot be resolved readily at the
distributor level without additional assistance, contact the Allison Transmission
Regional Office responsible for the local distributor. You will be assisted by a
member of the Regional Service Manager’s staff, depending on the nature of your
problem.
For prompt assistance, please have the following information available.
• Name and location of authorized distributor or dealer
• Type and make of equipment
• Transmission model number, serial number, and assembly number (if
equipped with electronic controls, also provide the TCM assembly number)
• Transmission delivery date and accumulated miles and/or hours of operation
• Nature of problem
• Chronological summary of unit’s history
Step Three—If you contacted a regional office and you are still not satisfied,
present the entire matter to the Home Office by writing to the following
address or calling the phone number below:
Allison Transmission
Manager, Warranty Administration – PF9
P.O. Box 894
Indianapolis, IN 46206-0894
800–252–5283
The inclusion of all pertinent information will assist the Home Office in
expediting the matter. If an additional review by the Home Office of all the facts
involved indicates that some further action can be taken, the Regional Office will
be advised.
When contacting the Regional or Home Office, please keep in mind that
ultimately the problem will likely be resolved at the distributorship or dealership
utilizing their facilities, equipment, and personnel. Therefore, it is suggested the
above steps be followed in sequence when experiencing a problem.
Your purchase of an Allison Transmission product is greatly appreciated, and it is
our sincere desire to assure complete satisfaction.
71
SERVICE LITERATURE
Additional service literature is available. This service literature provides fully
illustrated instructions for the operation, maintenance, service, overhaul, and parts
support of your transmission. To ensure that you get maximum performance and
service life from your unit, you may order publications from:
SGI, Inc.
Attn: Allison Literature Fulfillment Desk
8350 Allison Avenue
Indianapolis, IN 46268
TOLL FREE: 888–666–5799
INTERNATIONAL: 317–471–4995
1000/2000/2400 Series Service Literature
Automatic Transmission Fluid Technician’s Guide GN2055EN

*Mechanic’s Tips MT3190EN
*Operator’s Manual OM3063EN
Parts Catalog PC3062EN
Parts Catalog CD-ROM CD3062EN
Principles of Operation PO3065EN
Retail Literature Catalog GN2798EN
Service Manual SM3191EN
Troubleshooting Manual TS3192EN
Worldwide Sales & Service Directory SA2229EN
* Also available on the internet at www.allisontransmission.com
72
ALLISON TRANSMISSION DISTRIBUTORS
EASTERN REGION
Atlantic Detroit Diesel-Allison, LLC Penn Detroit Diesel-Allison, Inc.
180 Route 17 South 8330 State Road
Lodi, NJ 07644 Philadelphia, PA 19136-2986
201-489-5800 215-335-0500
Covington Detroit Diesel-Allison Western Branch Diesel, Inc.
8015 Piedmont Triad Parkway 3504 Shipwright Street
Greensboro, NC 27409 Portsmouth, VA 23703
336-292-9240 757-673-7000
Johnson & Towers, Inc. Williams Detroit Diesel-Allison
2021 Briggs Road Mount Southeast, Inc.
Laurel, NJ 08054 2849 Moreland Avenue, S.E
856-234-6990 Atlanta, GA 30315-0037
404-366-1070
New England Detroit Diesel-Allison, Inc.
90 Bay State Road
Wakefield, MA 01880-1095
781-246-1810
73
CENTRAL REGION
Caribe Detroit Diesel-Allison Inland Detroit Diesel-Allison, Inc.
Division of GT Corporation 210 Alexandra Way
Ceramic Ind. Park, Campo Rico Ave., Carol Stream, IL 60188
Block C 630-871-1111
Carolina, Puerto Rico 00982
787-750-5000
Central Detroit Diesel-Allison, Inc. Inland Diesel, Inc.
9200 Liberty Drive 13015 West Custer Avenue
Liberty, MO 64068 Butler, WI 53007-0916
816-781-8070 262-781-7100
Clarke Detroit Diesel-Allison, Inc. Interstate Detroit Diesel
3133 East Kemper Road 2501 East 80th Street
Cincinnati, OH 45241 Minneapolis, MN 55425
513-771-2200 952-854-5511
Florida Detroit Diesel-Allison, Inc. Williams Detroit Diesel-Allison
5105 Bowden Road Midwest, Inc.
Jacksonville, FL 32216 1176 Industrial Parkway
904-737-7330 North Brunswick, OH 44212-2342
330-225-7751
SOUTHWESTERN REGION
Detroit Diesel-Allison De Mexico S.A. Stewart & Stevenson Services, Inc.
de C.V. 2707 North Loop West
Av. Santa Rosa No. 58 Houston, TX 77008
Col. Ampliacion Norte 713-868-7700
Tlalnepantla, Estado de Mexico
C.P. 54160
(525)6-333-1800
Stewart & Stevenson Power, Inc. United Engines, LLC
5840 Dahlia Street 5555 West Reno Avenue
Commerce City, CO 80022 Oklahoma City, OK 73127
303-287-7441 405-947-3321
74
WESTERN REGION
Pacific Detroit Diesel-Allison Company Valley Detroit Diesel-Allison, Inc.
7215 South 228th Street 425 South Hacienda Boulevard
Kent, WA 98032 City of Industry, CA 91745-1123
253-854-0505 626-333-1243
Smith Detroit Diesel-Allison, Inc. Williams Detroit Diesel-Allison
250 West 3900 South Southwest, Inc.
Salt Lake City, UT 84107 2602 S. 19th Avenue
801-415-5000 Phoenix, AZ 85009
602-257-0561
Stewart & Stevenson
1755 Adams Avenue
San Leandro, CA 94577-1001
510-635-8991
CANADIAN REGION
Detroit Diesel-Allison Midwest Detroit Diesel-Allison Ltd.
British Columbia Ltd. 1460 Waverley Street
9300 192nd Street Winnipeg, Manitoba R3T OP6
Surrey, British Columbia V4N 3R8 204-452-8244
604-888-1211
Detroit Diesel-Allison Canada East Waterous Detroit Diesel-Allison (Div.
Div. of Integrated Power Systems Corp of Integrated Power Systems Corp)
2997 Rue Watt 10025 51st Avenue
Ste. Foy, Quebec G1X 3W1 Edmonton, Alberta T6E OA8
418-651-5371 780-437-3550
Harper Detroit Diesel Ltd.
10 Diesel Drive
Toronto, Ontario M8W 2T8
416-259-3281
75
ALLISON TRANSMISSION REGIONAL OFFICES
EASTERN REGION WESTERN REGION
P. O. Box 400 39465 Paseo Padre Parkway Suite 3500
Columbus , NJ 08022-0400 Fremont, CA 94538
609-298-2541 510-498-5208
CENTRAL REGION CANADIAN REGION
P. O. Box 894, Speed Code PF06 P. O. Box 5160 Station A
Indianapolis, IN 46206-0894 London, Ontario N6A 4N5
317-242-2327 519-452-5256
SOUTHWESTERN REGION
Av. Ejercito Nacional No. 843
Colonia Granada
Mexico, D.F. C.P. 11520
525-901-3057
Texas Office: 936-321-4248
936-321-4278
To find the closest authorized distributor or dealer of Allison Transmission product

and services visit the sale and service locator on the Allison Transmission web
site—www.allisontransmission.com.
76
OM3063EN 200306 www.allisontransmission.com Printed in USA 200309
SM3191EN_200305.pdf 8/19/04 9:40:06 AM
CM
MY
CY
CMY
Service Manual
1000, 2000, 2000MH, 2400 Series
On-Highway Transmissions
SM3191EN
SM3191EN
Service
Manual
1000 Series™
2000 Series™
2000MH Series
2400 Series™
2003 MAY
Allison Transmission, General Motors Corporation

Printed in the U.S.A. Copyright © 2003 General Motors Corp.

INTRODUCTION
TRADEMARK USAGE
• Biobor JF® is the registered trademark for a biological inhibitor manufactured by Hammonds
Fuel Additives Company.
• DEXRON® is a registered trademark of General Motors Corporation.
• Loctite® is a registered trademark of the Loctite Corporation.
• Spiralock® is a registered trademark of Spiralock of Michigan.
• Teflon® is a registered trademark of the DuPont Corporation.
• TranSynd™ is a trademark of Castrol Ltd.
• 1000 Series™ is a trademark of General Motors Corporation.
• Windows™ is a trademark of Microsoft Corporation.
• Allison DOC™ and Allison Diagnostic Optimized Connection™ are trademarks of General
Motors Corporation.
NOTE:
This publication is revised periodically to include improvements,
new models, special tools, and procedures. A revision is indicated
by the date on the title page. Check with your Allison
Transmission service outlet for the currently applicable
publication. Additional copies of this publication may be
purchased from authorized Allison Transmission service outlets.
Look in your telephone directory under the heading of
Transmissions — Truck, Tractor, etc.
ii Copyright © 2003 General Motors Corp.

IMPORTANT SAFETY NOTICE
IT IS YOUR RESPONSIBILITY to be completely familiar with the Warnings and

Cautions described in this Service Manual. These Warnings and Cautions advise against
the use of specific service methods that can result in personal injury, damage to the
equipment, or cause the equipment to become unsafe. It is, however, important to
understand that these Warnings and Cautions are not exhaustive. Allison Transmission
could not possibly know, evaluate, and advise the service trade of all conceivable ways in
which service might be done or of the possible hazardous consequences of each way.
Consequently, Allison Transmission has not undertaken any such broad evaluation.
Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS
NOT RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly
satisfied that neither personal safety nor equipment safety will be jeopardized by the
service methods selected.
Proper service and repair are important to the safe, reliable operation of the equipment.
The service procedures recommended by Allison Transmission and described in this
Service Manual are effective methods for performing service operations. Some of these
service operations require the use of tools specifically designed for the purpose. The
special tools should be used when and as recommended.
WARNINGS, CAUTIONS, AND NOTES

Three types of headings are used in this manual to attract your attention:
WARNING!
is used when an operating procedure, practice,
etc., which, if not correctly followed, could result
in personal injury or loss of life.
CAUTION:
is used when an operating procedure, practice,
etc., which, if not strictly observed, could result
in damage to or destruction of equipment.
NOTE:
is used when an operating procedure, practice, etc.,
is essential to highlight.
Copyright © 2003 General Motors Corp. iii

LIST OF WARNINGS
This manual contains the following Warnings —
IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.
Operation with excessive loads can cause transmission damage and unexpected vehicle movement.
To help avoid injury, property damage, and/or transmission damage, do not exceed 11 800 kg
(26,000 lbs) GCW or the OEM vehicle rating, whichever is less.
If ignition is turned “OFF” and then “ON” while the CHECK TRANS light is displayed, the
transmission may remain in neutral until the code is cleared. Leave ignition “ON” until you are in
a safe place to stop.
For vehicles containing 1000 and 2400 models, each time you park the vehicle or leave the
operator’s station with the engine running, do the following.
• Engage the P (Park) range by slowly releasing the service brake.
• Apply the emergency brake and/or parking brake, if present, and make sure it is properly
engaged.
• If the operator’s station will be unoccupied with the engine running, chock the wheels and
take any other steps necessary to keep the vehicle from moving.
If this procedure is not followed, the vehicle can move suddenly and you or others could be injured.
For vehicles containing 2000 models with auto-apply parking brakes, each time you park the
vehicle or leave the operator’s station with the engine running, do the following.
• Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the parking brake is
properly engaged.
• Apply the emergency brake, if present, and make sure it is properly engaged.
For vehicles containing 2000 models without auto-apply parking brakes, each time you park the
vehicle or leave the operator’s station with the engine running, do the following.
• Apply the emergency brake and/or parking brake and make sure they are properly engaged.
Observe safety precautions during hydraulic pressure check procedures. All personnel must stand
clear of the vehicle. Take precautions against movement of the vehicle. Be sure that gauges
(vacuum, pressure, tachometer) have extended lines so that they can be read from inside the
vehicle.
iv Copyright © 2003 General Motors Corp.

LIST OF WARNINGS
To help avoid injury or property damage caused by sudden and unexpected vehicle movement, do
not start a stationary stall test until you:
• Put the transmission in P (Park) or N (Neutral)…and
• Apply the parking brake and service brake…and
• Chock the vehicle wheels and take any other steps necessary to keep the vehicle from
moving…and
• Warn personnel to keep clear of the vehicle and its path.
Use appropriate safety equipment such as safety glasses, safety shoes, and gloves.
Do not burn discarded Teflon® seals; toxic gases are produced by burning Teflon®.
Never dry bearings by spinning them with compressed air. A spinning bearing can disintegrate,
allowing balls or rollers to become lethal flying projectiles. Also, spinning a bearing without
lubrication can damage the bearing.
Avoid contact with the hot fluid or the sump when draining transmission fluid. Direct contact with
the hot fluid or the hot sump may result in bodily injury.
Chock wheels to prevent vehicle from moving when driveline is disconnected. This is not necessary
if vehicle is on a lift or jackstands.
Be sure the torque converter is moving rearward with the transmission as it is removed. Do not
allow the torque converter to become disengaged from the oil pump or to fall and injure yourself
or others.
The torque converter must be held to the torque converter housing by a retaining device such as
shipping brackets. Without the retaining device, the torque converter may slide forward,
disengaging the oil pump, or may fall completely out of the transmission causing personal injury
and/or property damage. NEVER tilt the converter end down unless a torque converter retaining
device is installed.
The 1000/2000/2400 Series transmission dry weights are approximately 150 kg (330 lb). To help
avoid personal injury and/or property damage:
• Use caution when installing, removing, or moving the transmission.
• Get help when lifting the transmission. Assistance from a hoist or another person may be
required.
• Make sure that the lifting equipment can properly support the transmission.
If the transmission is not secured properly to the adapter plate, it could fall. To help avoid personal
injury and/or property damage:
• Use at least 5 bolts to support the transmission.
• Use M10 x 1.5 bolts with 19-25 mm (3⁄4-1 inch) thread engagement. If the proper bolt is not
used, the PTO bolt holes may be damaged.
Copyright © 2003 General Motors Corp. v

LIST OF WARNINGS
The 1000/2000/2400 Series torque converter dry weights are approximately 29 kg (63 lb). To help
• Use caution when installing, removing, or moving the torque converter.
• Get help when lifting the torque converter. Assistance from a hoist or another person may be
required.
• Make sure that the lifting equipment can properly support the torque converter.
The 1000/2000/2400 Series converter housing/front support module dry weights are approximately
27 kg (60 lb). To help avoid personal injury and/or property damage:
• Use caution when installing, removing, or moving the converter housing/front support
module.
• Get help when lifting the converter housing/front support module. Assistance from a hoist or
another person may be required.
• Make sure that the lifting equipment can properly support the converter housing/front
support module.
Always remove or install the P3 planetary carrier assembly by holding onto the output shaft.
Holding onto the P3 carrier assembly instead of the output shaft may allow the output shaft to fall
causing personal injury and/or property damage.
All pressure from the torque converter must be exhausted before loosening the test fixture nut.
Failure to relieve the pressure could cause personal injury and/or property damage.
The rotating clutch housing and turbine shaft are held together by a retaining ring. Removal of the
retaining ring will allow the turbine shaft and the rotating clutch housing to move freely. Ensure
that the rotating clutch housing and the turbine shaft are restrained from moving when removing
the retaining ring. Personal injury and/or property damage may result from the movement of the
rotating clutch housing or the turbine shaft.
Pressing the P3 planetary carrier from the bearing race requires the P3 carrier to fall from the
bearing race. Ensure that the P3 carrier is safely caught when freed from the bearing race. An
uncontrolled fall of the P3 carrier could cause personal injury and/or property damage.
vi Copyright © 2003 General Motors Corp.

TABLE OF CONTENTS
Paragraph Page Paragraph Page
Section 1. GENERAL INFORMATION Section 2. PREVENTIVE MAINTENANCE

1–1. SCOPE OF MANUAL 2–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
a. Content and Organization . . . . . . . . . . . . 1–1 2–2. PERIODIC INSPECTION AND CARE
b. Illustrations. . . . . . . . . . . . . . . . . . . . . . . . 1–1 a. Transmission Inspection . . . . . . . . . . . . . 2–1
c. Maintenance Information . . . . . . . . . . . . 1–1 b. Vehicle Inspection . . . . . . . . . . . . . . . . . . 2–1
c. Welding . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
1–2. SUPPLEMENTARY INFORMATION . . . . 1–1
2–3. IMPORTANCE OF PROPER
1–3. ORDERING PARTS TRANSMISSION FLUID LEVEL . . . . . . . . 2–1
a. Transmission Nameplate . . . . . . . . . . . . . 1–1
2–4. TRANSMISSION FLUID CHECK
b. Parts Catalog . . . . . . . . . . . . . . . . . . . . . . 1–1
a. Fluid Check Procedure . . . . . . . . . . . . . . 2–2
1–4. GENERAL DESCRIPTION b. Cold Check Procedure . . . . . . . . . . . . . . . 2–4
a. Transmission Design Features. . . . . . . . . 1–4 c. Hot Check Procedure . . . . . . . . . . . . . . . . 2–4
b. Model Nomenclature. . . . . . . . . . . . . . . . 1–6 d. Consistency of Readings . . . . . . . . . . . . . 2–5
1–5. DIAGNOSIS 2–5. KEEPING FLUID CLEAN. . . . . . . . . . . . . . 2–5
a. Before Starting . . . . . . . . . . . . . . . . . . . . . 1–6 2–6. FLUID RECOMMENDATIONS . . . . . . . . . 2–5
b. CHECK TRANS Light . . . . . . . . . . . . . . 1–6 2–7. TRANSMISSION FLUID AND FILTER
c. Range Inhibit Indicator . . . . . . . . . . . . . . 1–6 CHANGE INTERVALS
d. Personal Computer (PC)-Based a. Frequency. . . . . . . . . . . . . . . . . . . . . . . . . 2–6
Diagnostic System . . . . . . . . . . . . . . . . . . 1–7 b. Abnormal Conditions. . . . . . . . . . . . . . . . 2–6
e. Troubleshooting When No Diagnostic c. Fluid Analysis . . . . . . . . . . . . . . . . . . . . . 2–6
Codes are Present. . . . . . . . . . . . . . . . . . . 1–7 d. Fluid and Filter Change Intervals . . . . . . 2–6
f. Troubleshooting Intermittent
2–8. TRANSMISSION FLUID CONTAMINATION
Diagnostic Codes . . . . . . . . . . . . . . . . . . . 1–7
a. Fluid Examination . . . . . . . . . . . . . . . . . . 2–6
1–6. PRESERVATION AND STORAGE b. Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
a. Storage (New Transmissions, c. Engine Coolant. . . . . . . . . . . . . . . . . . . . . 2–9
Before Installation) . . . . . . . . . . . . . . . . . 1–8 d. Flush Oil Cooler. . . . . . . . . . . . . . . . . . . . 2–9
b. Preservation Methods . . . . . . . . . . . . . . . 1–8
2–9. TRANSISSION FLUID AND FILTER
c. One Year Storage (Without Fluid). . . . . . 1–8 CHANGE PROCEDURE
d. One Year Storage (With Fluid) . . . . . . . . 1–8 a. Drain Fluid . . . . . . . . . . . . . . . . . . . . . . . . 2–9
1–7. RESTORING TRANSMISSION b. Replace Control-Main Filter . . . . . . . . . . 2–9
TO SERVICE c. Refill Transmission . . . . . . . . . . . . . . . . . 2–9
a. Transmission Exterior . . . . . . . . . . . . . . . 1–9 2–10. VENT ASSEMBLY
b. Sealed Vent Assembly and Openings . . . 1–9 a. Location and Purpose. . . . . . . . . . . . . . . 2–10
c. New Transmissions . . . . . . . . . . . . . . . . . 1–9 b. Maintenance . . . . . . . . . . . . . . . . . . . . . . 2–10
d. Stored Without Fluid . . . . . . . . . . . . . . . . 1–9 2–11. MAIN PRESSURE CHECK
e. Stored With Fluid. . . . . . . . . . . . . . . . . . . 1–9 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 2–10
1–8. OPERATING INSTRUCTIONS . . . . . . . . . 1–9 2–12. TRANSMISSION STALL TEST AND
NEUTRAL COOL-DOWN CHECK
1–9. SPECIFICATIONS AND DATA . . . . . . . . . 1–9 a. Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
1–10. ELECTROMAGNETIC/RADIO b. Stall Test Results . . . . . . . . . . . . . . . . . . 2–12
FREQUENCY INTERFERENCE . . . . . . . 1–18 c. Neutral Cool-Down Check Procedure. . 2–13
Copyright © 2003 General Motors Corp. vii

1000/2000/2400 SERIES TRANSMISSIONS
2–13. FLUID LEAK DIAGNOSIS 3–6. ASSEMBLY PROCEDURES

a. Finding the Leak . . . . . . . . . . . . . . . . . . 2–13 a. Parts Lubrication . . . . . . . . . . . . . . . . . . 3–12
b. Powder Method . . . . . . . . . . . . . . . . . . . 2–14 b. Grease Used for Assembly . . . . . . . . . . 3–12
c. Sealing Compounds and
c. Black Light and Dye Method . . . . . . . . 2–14
Nonsoluble Greases . . . . . . . . . . . . . . . 3–12
d. Repairing the Leak . . . . . . . . . . . . . . . . 2–14 d. Clutches and Pistons . . . . . . . . . . . . . . 3–12
2–14. ON-VEHICLE MAINTENANCE . . . . . . . 2–14 e. Threaded Plugs and Hydraulic
Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
f. Lip-Type Seals . . . . . . . . . . . . . . . . . . . 3–12
Section 3. GENERAL OVERHAUL
g. Butt-Joint Sealrings . . . . . . . . . . . . . . . 3–13
INFORMATION
h. Bearings. . . . . . . . . . . . . . . . . . . . . . . . . 3–13
3–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 i. Electrical Components . . . . . . . . . . . . . 3–13
3–2. TOOLS AND EQUIPMENT 3–7. REMOVING (OR INSTALLING)
a. Improvised Equipment . . . . . . . . . . . . . 3–1 TRANSMISSION
a. Draining Transmission . . . . . . . . . . . . . 3–13
b. Special Tools . . . . . . . . . . . . . . . . . . . . . 3–1
b. Disconnecting Controls . . . . . . . . . . . . 3–14
c. Mechanic’s Tools and c. Uncoupling From Driveline,
Shop Equipment . . . . . . . . . . . . . . . . . . . 3–1 Engine, and Vehicle . . . . . . . . . . . . . . . 3–14
3–3. REPLACEMENT PARTS d. Removing the Transmission. . . . . . . . . 3–14
a. Ordering Information . . . . . . . . . . . . . . . 3–9 e. Transmission Installation . . . . . . . . . . . 3–14
b. Parts Normally Replaced 3–8. WEAR LIMITS. . . . . . . . . . . . . . . . . . . . . . 3–15
at Overhaul . . . . . . . . . . . . . . . . . . . . . . . 3–9 3–9. SPRING SPECIFICATIONS . . . . . . . . . . . 3–15
3–4. CAREFUL HANDLING . . . . . . . . . . . . . . . 3–9 3–10. TORQUE SPECIFICATIONS . . . . . . . . . . 3–15
3–5. CLEANING AND INSPECTION
a. Dirt Causes Malfunction . . . . . . . . . . . . . 3–9 Section 4. TRANSMISSION DISASSEMBLY
b. Cleaning Parts . . . . . . . . . . . . . . . . . . . . 3–9 4–1. INSTALLATION OF TRANSMISSION
c. Cleaning Bearings . . . . . . . . . . . . . . . . . 3–9 INTO REPAIR STAND . . . . . . . . . . . . . . . . 4–1
d. Keeping Bearings Clean. . . . . . . . . . . . . 3–9 4–2. INPUT SPEED SENSOR REMOVAL
e. Inspecting Bearings . . . . . . . . . . . . . . . . 3–10 (IF PRESENT) . . . . . . . . . . . . . . . . . . . . . . . 4–2
f. Inspecting Cast Parts and 4–3. TURBINE SPEED SENSOR REMOVAL . 4–3
Machined Surfaces . . . . . . . . . . . . . . . . 3–10
4–4. OUTPUT SPEED SENSOR REMOVAL
g. Inspecting Bushings and (2WD TRANSMISSIONS ONLY) . . . . . . . 4–3
Thrust Washers . . . . . . . . . . . . . . . . . . . 3–10
4–5. NSBU SWITCH REMOVAL
h. Inspecting Sealrings and Gaskets. . . . . 3–10
(IF PRESENT) . . . . . . . . . . . . . . . . . . . . . . . 4–3
i. Inspecting Gears. . . . . . . . . . . . . . . . . . 3–11
4–6. VENT HOSE REMOVAL (IF PRESENT) . 4–4
j. Inspecting Splined Parts. . . . . . . . . . . . 3–11
k. Inspecting Threaded Parts . . . . . . . . . . 3–11 4–7. TORQUE CONVERTER REMOVAL . . . . 4–5
l. Inspecting Retaining Rings . . . . . . . . . . 3–11 4–8. CONVERTER HOUSING/FRONT
m. Inspecting Springs. . . . . . . . . . . . . . . . . 3–11 SUPPORT MODULE REMOVAL . . . . . . . 4–6
n. Inspecting Clutch Plates . . . . . . . . . . . . 3–11 4–9. ROTATING CLUTCH ASSEMBLY
o. Inspecting Swaged and REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
Interference-Fit Parts . . . . . . . . . . . . . . 3–12 4–10. OIL PAN AND SUCTION FILTER
p. Inspecting Sealing Surfaces . . . . . . . . . 3–12 REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
viii Copyright © 2003 General Motors Corp.

TABLE OF CONTENTS
4–11. WIRING HARNESS ASSEMBLY 5–7. MAIN PUMP ASSEMBLY

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9 a. Main Pump Disassembly. . . . . . . . . . . . 5–15
4–12. CONTROL VALVE ASSEMBLY b. Main Pump Inspection . . . . . . . . . . . . . . 5–16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 4–10 c. Main Pump Bushing Replacement . . . . 5–19
d. Main Pump Dowel Pin Replacement. . . 5–20
4–13. REAR BALL BEARING REMOVAL . . . . 4–12
e. Wear Plate Inspection . . . . . . . . . . . . . . 5–21
4–14. REAR COMPONENTS REMOVAL . . . . . 4–14 f. Main Pump Assembly . . . . . . . . . . . . . . 5–21
4–15. PARK PAWL REMOVAL . . . . . . . . . . . . . 4–16 5–8. FRONT SUPPORT ASSEMBLY
4–16. P2 PLANETARY MODULE AND MAIN a. Front Support Disassembly . . . . . . . . . . 5–22
SHAFT REMOVAL . . . . . . . . . . . . . . . . . . 4–16 b. Ground Sleeve Inspection . . . . . . . . . . . 5–27
4–17. C5 CLUTCH REMOVAL. . . . . . . . . . . . . . 4–17 c. Ground Sleeve Replacement . . . . . . . . . 5–28
d. Ground Sleeve Needle Bearing
4–18. P1 PLANETARY MODULE . . . . . . . . . . . 4–17 Replacement. . . . . . . . . . . . . . . . . . . . . . 5–30
4–19. C4 CLUTCH REMOVAL. . . . . . . . . . . . . . 4–18 e. Ground Sleeve Bushing Replacement . . 5–31
f. Front Support Thrust Washer
4–20. C4 CLUTCH PISTON ASSEMBLY
Inspection . . . . . . . . . . . . . . . . . . . . . . . . 5–32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 4–20
g. Front Support Assembly . . . . . . . . . . . . 5–32
4–21. C3 CLUTCH REMOVAL. . . . . . . . . . . . . . 4–21
5–9. CONVERTER HOUSING/FRONT
4–22. C3 CLUTCH PISTON ASSEMBLY SUPPORT MODULE ASSEMBLY. . . . . . 5–37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 4–23
5–10. ROTATING CLUTCH MODULE
a. Disassembly of Rotating Clutch
Section 5. MODULE REBUILD
Module . . . . . . . . . . . . . . . . . . . . . . . . . . 5–40
5–1. TORQUE CONVERTER ASSEMBLY b. Turbine Shaft Inspection . . . . . . . . . . . . 5–47
a. Preliminary Inspection . . . . . . . . . . . . . . 5–1 c. Turbine Shaft Bushing Replacement . . . 5–48
b. End Play Check . . . . . . . . . . . . . . . . . . . . 5–1 d. Rotating Clutch Housing Inspection . . . 5–49
c. Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 e. Rotating Clutch Housing Bushing
d. Inspection of Torque Converter. . . . . . . . 5–3 Replacement. . . . . . . . . . . . . . . . . . . . . . 5–50
5–2. ELECTRONIC COMPONENT f. Rotating Clutch Housing Tone Wheel
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 5–5 Replacement. . . . . . . . . . . . . . . . . . . . . . 5–51
g. C1 Clutch Friction Plate Inspection. . . . 5–53
h. C1 Clutch Reaction Plate Inspection . . . 5–54
SUPPORT MODULE DISASSEMBLY . . . 5–6
i. C1 Clutch Backplate Inspection . . . . . . 5–55
5–4. TORQUE CONVERTER HOUSING j. C2 Clutch Friction Plate Inspection. . . . 5–56
(WITHOUT COOLER MANIFOLD) k. C2 Clutch Reaction Plate Inspection . . . 5–56
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5–9 l. C1 Piston Housing Inspection . . . . . . . . 5–57
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–10 m. Rotating Clutch Thrust Washer
5–5. TORQUE CONVERTER HOUSING (DIRECT Inspection . . . . . . . . . . . . . . . . . . . . . . . . 5–57
MOUNT; WITHOUT COOLER MANIFOLD) n. Assembly of Rotating Clutch Module . . 5–58
a. Disassembly. . . . . . . . . . . . . . . . . . . . . . 5–11 5–11. MAIN HOUSING ASSEMBLY
b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 5–11
a. Disassembly of Selector Shaft
5–6. TORQUE CONVERTER HOUSING and Detent Lever . . . . . . . . . . . . . . . . . . 5–66
(WITH COOLER MANIFOLD) b. Assembly of Selector Shaft and
a. Disassembly. . . . . . . . . . . . . . . . . . . . . . 5–12 Detent Lever. . . . . . . . . . . . . . . . . . . . . . 5–68
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–13 c. Nameplate Replacement . . . . . . . . . . . . 5–70
Copyright © 2003 General Motors Corp. ix

d. Main Housing Dowel Pin d. Output Shaft Bushing Inspection

Replacement . . . . . . . . . . . . . . . . . . . . . 5–70 (4WD Transmissions Only) . . . . . . . . . 5–91
e. Replacement of Fill Tube Plug . . . . . . . 5–71 e. Output Shaft Bushing Replacement . . . 5–92
f. Replacement of Vent Assembly . . . . . . 5–71 f. Assembly of Rear Cover . . . . . . . . . . . . 5–93
5–12. RING GEAR AND CLUTCH COMPONENT 5–18. OUTPUT YOKE INSPECTION . . . . . . . . 5–94
INSPECTIONS 5–19. CONTROL VALVE MODULE
a. C3 Clutch Component Inspection . . . . 5–71 a. Disassembly of Control
b. C3 Clutch Backplate Assembly Valve Assembly . . . . . . . . . . . . . . . . . . 5–95
Thrust Plate Replacement . . . . . . . . . . . 5–75 b. Disassembly of Shift Valve Body. . . . . 5–99
c. C4 Clutch Component Inspection . . . . . 5–76 c. Disassembly of Modulated Main Valve
d. C5 Clutch Component Inspection . . . . . 5–78 Body . . . . . . . . . . . . . . . . . . . . . . . . . . 5–102
e. P1 Planetary Gear Inspection . . . . . . . . 5–80 d. A/B Solenoid Bracket Inspection . . . . 5–103
e. Assembly of Shift Valve Body . . . . . . 5–103
5–13. MAIN SHAFT INSPECTION . . . . . . . . . . 5–80
f. Disassembly of the Main Valve
5–14. P1 PLANETARY MODULE Body . . . . . . . . . . . . . . . . . . . . . . . . . . 5–106
a. P1 Planetary Module Disassembly . . . . 5–81 g. Dowel Pin Replacement . . . . . . . . . . . 5–108
b. P1 Planetary Carrier Assembly h. Assembly of the Main Valve Body. . . 5–109
Inspection . . . . . . . . . . . . . . . . . . . . . . . 5–81 i. Assembly of Control Valve
c. P2 Planetary Ring Gear Inspection . . . . 5–82 Assembly . . . . . . . . . . . . . . . . . . . . . . . 5–110
d. P1 Planetary Carrier Bushing j. Assembly of Modulated Man Valve
Replacement . . . . . . . . . . . . . . . . . . . . . 5–82 Body . . . . . . . . . . . . . . . . . . . . . . . . . . 5–115
e. P1 Planetary Carrier Thrust Washer
Inspection . . . . . . . . . . . . . . . . . . . . . . . 5–83 Section 6. TRANSMISSION ASSEMBLY
f. P1 Planetary Module Assembly . . . . . . 5–83
6–1. C3 CLUTCH INSTALLATION. . . . . . . . . . 6–1
5–15. P2 PLANETARY MODULE
6–2. P1 PLANETARY MODULE AND
a. P2 Planetary Module Disassembly . . . 5–84
C4 CLUTCH INSTALLATION. . . . . . . . . . 6–3
b. P2 Planetary Carrier Assembly
Inspection . . . . . . . . . . . . . . . . . . . . . . . 5–84 6–3. C5 CLUTCH REACTION PLATE
c. P3 Planetary Ring Gear Inspection . . . . 5–85 SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6–6
d. P2 Planetary Carrier Bushing 6–4. P2 PLANETARY MODULE AND
Replacement . . . . . . . . . . . . . . . . . . . . . 5–85 MAIN SHAFT INSTALLATION . . . . . . . . 6–8
e. P2 Planetary Module Assembly . . . . . . 5–86 6–5. C5 CLUTCH INSTALLATION. . . . . . . . . . 6–9
5–16. P3 PLANETARY CARRIER ASSEMBLY 6–6. PARK PAWL INSTALLATION . . . . . . . . 6–10
a. P3 Planetary Carrier Assembly
Inspection . . . . . . . . . . . . . . . . . . . . . . . 5–86 6–7. OUTPUT SHAFT AND P3 PLANETARY
CARRIER ASSEMBLY
b. P3 Planetary Carrier Bearing Race
INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–11
Replacement . . . . . . . . . . . . . . . . . . . . . 5–87
6–8. REAR COVER ASSEMBLY
INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–11
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–88
b. Rear Cover Housing Retaining Ring 6–9. CONTROL VALVE ASSEMBLY
Replacement . . . . . . . . . . . . . . . . . . . . . 5–90 INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–14
c. Output Shaft Bushing Inspection 6–10. WIRING HARNESS ASSEMBLY
(2WD Transmissions Only) . . . . . . . . . 5–91 INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–16
x Copyright © 2003 General Motors Corp.

TABLE OF CONTENTS
6–11. OIL PAN AND SUCTION FILTER 6–22, INPUT SPEED SENSOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–17 INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–31
6–12. ROTATING CLUTCH ASSEMBLY 6–23. TURBINE SPEED SENSOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–18 INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–32
6–13. CONVERTER HOUSING/FRONT 6–24. OUTPUT SPEED SENSOR
SUPPORT MODULE INSTALLATION . . 6–19 INSTALLATION
(2WD TRANSMISSIONS ONLY). . . . . . . 6–32
6–14. REAR COVER SELECTIVE
SPACER INSTALLATION 6–25. REMOVAL OF TRANSMISSION FROM
(2WD TRANSMISSIONS ONLY). . . . . . . 6–21 REPAIR STAND. . . . . . . . . . . . . . . . . . . . . 6–33
SPACER INSTALLATION Section 7. WEAR LIMITS AND
(4WD TRANSMISSIONS ONLY). . . . . . . 6–22 SPRING DATA
6–16. TRANSMISSION END PLAY CHECK . . 6–23 7–1. WEAR LIMITS DATA
6–17. TORQUE CONVERTER a. Maximum Variations . . . . . . . . . . . . . . . . 7–1
INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–24 b. Cleaning and Inspection. . . . . . . . . . . . . . 7–1
6–18. NSBU SWITCH INSTALLATION
7–2. SPRING DATA
(IF PRESENT). . . . . . . . . . . . . . . . . . . . . . . 6–26
a. Spring Replacement . . . . . . . . . . . . . . . . . 7–1
6–19. REAR SEAL INSTALLATION b. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
(2WD TRANSMISSIONS ONLY). . . . . . . 6–29
6–20. OUTPUT NUT INSTALLATION Section 8. CUSTOMER SERVICE
(1000 SERIES™ 4WD
TRANSMISSIONS ONLY) . . . . . . . . . . . . 6–29 8–1. OWNER ASSISTANCE . . . . . . . . . . . . . . . . 8–1
6–21. VENT HOSE INSTALLATION. . . . . . . . . 6–31 8–2. SERVICE LITERATURE. . . . . . . . . . . . . . . 8–2
Copyright © 2003 General Motors Corp. xi

LIST OF FOLDOUT ILLUSTRATIONS

(Back of Service Manual)
CROSS-SECTION VIEWS
Foldout
1 1000 Series™
2 2000 Series™
3 2400 Series™
4 1000 Series™ Direct Mount
EXPLODED VIEWS
5,A SAE No. 3 Torque Converter Housing with Integral Cooling Ports
5,B SAE No. 2 Torque Converter Housing with Manifold
5,C SAE No. 3 Torque Converter Housing with Manifold
5,D Direct Mount — Torque Converter Housing
6 Converter Housing/Front Support Module, Rotating Clutch Housing, and C3 Clutch Components
6,A Converter Housing/Front Support Module Components
7 Front Support Module Components
8 Main Pump Assembly Components
9 Front Support Assembly Components
10 Rotating Clutch Assembly Components
11 Oil Pan and Suction Filter Components
12 Main Housing Components
13 C4 and C5 Clutch Components
14,A P1 Planetary Module, P2 Planetary Module, and Main Shaft Components
14,B P2 Planetary Module Components
14,C P3 Planetary Module
15,A P1 Planetary Carrier Assembly Components
15,B P2 Planetary Carrier Assembly Components
16,A P3 Planetary Assembly, Output Shaft, C5 Piston Return Assembly, and Park Pawl Components
16,B Rear Cover Assemblies
17 P3 Planetary Carrier Assembly
18,A Rear Cover Assembly Components, 10 x 3
18,B Rear Cover Assembly Components, Non-Park Brake
18,C Rear Cover Assembly Components, Transfer Case
18,D Rear Cover Assembly Components, 9 x 3
19,A Control Valve Assembly Components
19,B Shift Valve Body Assembly Components
19,C Main Valve Body Assembly Components
19,D Modulated Main Valve Body
20 Vent Hose and Yokes/Flanges
21 1000/2000/2400 Series Hydraulic Schematic — Neutral/Park
22 1000/2000/2400 Series Hydraulic Schematic — First Range
23 1000/2000/2400 Series Hydraulic Schematic — Second Range
24 1000/2000/2400 Series Hydraulic Schematic — Third Range
25 1000/2000/2400 Series Hydraulic Schematic — Fourth Range
26 1000/2000/2400 Series Hydraulic Schematic — Fifth Range
27 1000/2000/2400 Series Hydraulic Schematic — Reverse (With N04 Software and Later)
28 1000/2000/2400 Series Hydraulic Schematic — Reverse (Prior to and Including N04 Software)
29 1000/2000/2400 Series Hydraulic Schematic — Default Reverse (“Limp Home”)
30 1000/2000/2400 Series Hydraulic Schematic — Default Forward (3rd Range “Limp Home”)
xii Copyright © 2003 General Motors Corp.
SECTION 1 — GENERAL INFORMATION
1–1. SCOPE OF MANUAL 3. The required tools and fixtures, listed in
Table 3–1 (Section 3 of this manual), are avail-
a. Content and Organization. This Service Manual able.
describes overhaul procedures for 1000/2000/2400 Series
4. Reasonable and prudent maintenance prac-
automatic transmissions (Figures 1–1 and 1–2).
tices are used.
• Major transmission components are described
and their functions explained.
NOTE:
• Detailed instructions are provided for
Service organizations and individuals are
disassembly, rebuild, and re-assembly.
encouraged to contact their local ATD Distributor
• Part inspection instructions are in Section 3. for information and guidance on any task outlined
• Wear limits and spring data are in Section 7. in this manual.
b. Illustrations
1. The text is supported with line drawings, ex-
ploded, and cross-sectional views. Overhaul 1–2. SUPPLEMENTARY
procedures are illustrated by line drawings. INFORMATION
Cross-sections show the relationship of assem-
Supplementary information will be issued, as required,
bled parts. Cross-sections and exploded views
if any changes occur after publication of this manual.
are on foldout pages in the back of the manual.
Check with your dealer or distributor to be sure you
2. Illustrations show correct procedures for all have the latest information.
models — including models not illustrated.
c. Maintenance Information. Each task described 1–3. ORDERING PARTS

in this manual has been successfully completed by
service organizations and individuals. Not every a. Transmission Nameplate. The nameplate (1)
service organization or individual possesses the (Figure 1–3) is located on the right side of the
required special tooling, training, or experience to transmission. The nameplate will be one of two styles
perform all described tasks. However, any task may be (Figures 1–4 and 1–5). Both nameplates are imprinted
performed if the following conditions are met: with the transmission model, serial number,
transmission identification number, engineering group
1. The organization or individual has the required number, engineering feature configuration number,
knowledge of the task through: and date of manufacture. Use all of these numbers
• Formal instruction at Allison Transmission when ordering replacement parts or requesting service
Division (ATD) or a Distributor training information.
facility. b. Parts Catalog. Replacement parts are listed in
• On-the-job instruction by an ATD or Parts Catalog PC3062EN. Do not order by the item
Distributor representative. numbers used on exploded views in this manual. Use
the Parts Catalog to determine the correct part number.
• Experience in performing the task.
Order all replacement parts from your distributor or
2. The work environment is suitable to prevent authorized dealer. Check the Yellow Pages for your
contamination or damage to transmission parts nearest authorized service outlet. Listings are under
or assemblies. Transmission — Truck, Tractor, Etc.
Copyright © 2003 General Motors Corp. 1–1

1000/2000/2400 SERIES SERVICE MANUAL
OIL VENT
MOUNTING PROVISION
TURBINE SPEED
SENSOR
INPUT SPEED
SENSOR
OUTPUT SPEED SENSOR
NSBU SWITCH
SELECTOR SHAFT
SAE 6-BOLT
PTO PAD
AVAILABLE
OIL FILL TUBE
LOCATION
1000 / 2000 / 2400 SERIES™ TRANSMISSION – LEFT-FRONT VIEW V04779.03.00
Figure 1–1. 1000/2000/2400 Series Transmission — Left-Front View
INPUT SPEED
SENSOR
TURBINE SPEED
SENSOR
OIL VENT
(BREATHER)
OUTPUT SPEED
SENSOR
MOUNTING PAD
COOLER PORTS
AVAILABLE
OIL FILL TUBE
LOCATION
PROVISION FOR SAE 6-BOLT
CUSTOMER-SUPPLIED PTO PAD
SPEED SENSOR OR (DRIVE GEAR OPTIONAL)
TACHOGRAPH
(OPRIONAL) MAIN ELECTRICAL
CONNECTOR
1000 / 2000 / 2400 SERIES™ TRANSMISSION – RIGHT-REAR VIEW V04780.01.04
Figure 1–2. 1000/2000/2400 Series Transmission — Right-Rear View
1–2 Copyright © 2003 General Motors Corp.

GENERAL INFORMATION
DIV. OF GENERAL MOTORS CORP.

INDIANAPOLIS, INDIANA, USA
MODEL DATE
XXXXXXXXXX XXXXX
SERIAL NO. EFCN TID
XXXXXXXXXX XXXXXXXX XX
XX–XXXX XX–XXXX XX–XXXX
V06183
Figure 1–3. 1000/2000/2400 Series Transmission Nameplate Location
DIV. OF GENERAL MOTORS CORP.

INDIANAPOLIS, INDIANA, USA
MODEL DATE
XXXXXXXXXX XXXXX
SERIAL NO. EFCN TID
XXXXXXXXXX XXXXXXXX XX
V06533
Legend
(1) Model (Series) (4) Transmission Identification Number
(2) Date of Manufacture (5) Engineering Group Number
(3) Engineering Feature Configuration Number (6) Serial Number
Figure 1–4. 1000/2000/2400 Series Transmission Nameplate Components

ICULTURA
AGR L
D IM
AN
PL
E
EM
ILE AEROSPAC
UAW
ENT
WORKERS
933
OB
OM
OF
UT AM
DA ERI
UNITE CA
DIVISION OF GENERAL MOTORS CORP.

INDIANAPOLIS, INDIANA
MODEL XX–XXXX XX–XXXX

1000SERIES
DATE TID XX–XXXX XX–XXXX
XXXXX XX XX–XXXX XX–XXXX
SERIAL NO.
XXXXXXXXXX XX–XXXX XX–XXXX
EFCN
XXXXXXX XX–XXXX XX–XXXX
Legend
(1) Model (Series) (4) Engineering Feature Configuration Number
(2) Engineering Group Number (5) Serial Number
(3) Transmission Identification Number (6) Date of Manufacture
Figure 1–5. 1000/2000/2400 Series Transmission Nameplate Components
1–4. GENERAL DESCRIPTION higher speeds, the torque converter clutch

(TCC) is automatically engaged to provide di-
rect drive from the engine to the transmission.
a. Transmission Design Features. Allison 1000/
Hydraulic fluid for converter charging pressure
2000/2400 Series transmissions (Figures 1–1 and 1–2)
comes from the sump and is supplied by the in-
are torque-converter driven, fully automatic transmis-
put pump. The torque converter clutch is ap-
sion systems. The 1000/2000/2400 Series transmis-
plied or released by changing direction of fluid
sions have up to five forward speeds, neutral, and re-
in the torque converter. An integral converter
verse. The fifth range has an overdrive gear ratio. The
damper minimizes the need for additional en-
1000/2000/2400 Series incorporates a variety of stan-
gine vibration control.
dard and optional design features.
1. Transmission-to-Engine Coupling. The con- 3. Planetary Gearing. The planetary gear train in-
verter housings of 1000/2000/2400 Series cludes three constant-mesh, helical gear plane-
transmissions mate directly to SAE No. 2 or tary sets. By the engagement of the clutches in
No. 3 flywheel housings or to the engine block various combinations, the planetary sets act
in some cases. Flexplate drive is used for en- singly or together to provide five forward
gine-to-transmission torque transfer. ranges, neutral, and reverse.
2. Torque Converter. Several torque converters 4. Clutches. Five clutches (two rotating and three
are available to match the transmissions to a stationary) direct the flow of torque through
wide variety of diesel and gasoline engines. the transmission. All range clutches are hy-
The torque converter is a single-stage, draulically-actuated and spring-released, with
polyphase, three-element unit, consisting of a automatic wear compensation. Clutches are
pump, stator, and turbine. At lower output cooled by the transmission fluid. The transmis-
speeds, the torque converter multiplies torque sion electronic control module signals solenoid
and provides a fluid coupling to the engine. At valves to apply and release clutches based on

GENERAL INFORMATION
speed and power combinations and the range transmission fluid to either water or air
selected by the operator. depending upon the cooler type used.
5. Hydraulic System. A common hydraulic sys- 9. Oil Fill Tube/Dipstick Provisions. All 1000/
tem serves the torque converter and the trans- 2000/2400 Series models have a fill tube/
mission. Transmission fluid for all hydraulic dipstick provision on both sides of the
operations, lubrication, and cooling comes transmission. The fill tube and dipstick are
from the sump and is supplied by the charging OEM-installed and adapted as specified by the
pump. vehicle manufacturer. A plug is installed in the
unused location.
6. Transmission Fluid Filtration. Fluid filtration
is provided by two filter systems. A suction fil- 10. Parking Pawl/Parking Brake
ter, located in the sump, provides general pro-
• All 1000 Series™ and 2400 Series™
tection to the entire hydraulic system by
transmissions have a PARK pawl. The
filtering large particulates. A spin-on filter pro-
internal parking pawl is engaged by
vides full-time protection for the control sole-
selection of the PARK position on the shift
noids and multipass protection for the entire
selector. The parking pawl is not available
system. The spin-on filter is externally located
on 2000 Series™ models.
on the converter housing at the lower left front
of the transmission. • Some 1000/2000/2400 Series models are
available with an optional rear cover that
7. Electronic Controls accommodates an OEM-installed two-shoe,
expanding-type drum brake. All parking brake
• A microcomputer provides electronically- controls and linkages are OEM-supplied.
controlled automatic gear selection and
automatic engagement of the torque 11. Power Takeoff. The 1000/2000/2400 Series
converter clutch. The microcomputer is an transmissions have a provision to mount and
independent controller and is referred to as drive a power takeoff (PTO) unit on the left
a Transmission Control Module, or TCM. and/or right side of the transmission housing.
The optional PTO drive gear is driven by the
• The electronic control system uses adaptive transmission torque converter turbine, with
logic to provide optimum shift quality. speed and torque reflecting engine input and
Driving efficiency is improved by shifting characteristics of the torque converter. PTO
at the exact programmed transmission shift units and associated controls are provided by
point for every engine/transmission/vehicle the vehicle manufacturer and/or body builder.
combination. The electronic controls can be
customized for four-speed or five-speed 12. Output Yokes/Flanges. A variety of output
yokes or flanges are available to meet vehicle
operation to meet vocational requirements.
driveline requirements. Yokes or flanges are
OEM-installed and are adapted as specified by
8. Remote Oil Cooler. Ports for remote-mount oil the vehicle manufacturer.
cooler lines are located on the bottom surface
of the converter housing near the converter
housing/main housing splitline or on the right WARNING!
side of the direct-mount converter housing. Operation with excessive loads can cause trans-
Remote oil-to-water coolers require plumbing mission damage and unexpected vehicle move-
for transmission fluid and engine-cooling ment. To help avoid injury, property damage,
water. Remote oil-to-air coolers may also be and/or transmission damage, do not exceed
used and only transmission fluid lines need to 11 800 kg (26,000 lbs) GCW or the OEM vehicle
be provided. Heat is transferred from the rating, whichever is less.

b. Model Nomenclature. Several transmission
configurations are available within the 1000/2000/ NOTE:
2400 Series. Models are identified as follows: The CHECK ENGINE light may serve the CHECK
TRANS function for vehicles which are compliant
1000* Heavy-duty automatic transmission with to industry On Board Diagnostics II (OBD-II) re-
parking pawl quirements.
Maximum GVW 22,000 lb (motor home
only)
3. When the CHECK TRANS light is “ON”,
Maximum GVW 19,850 lb shifts may be restricted by the Transmission
Maximum GCW 26,000 lb Control Module (TCM) as follows:
2000* Heavy-duty automatic transmission
without parking pawl
WARNING!
Maximum GVW 30,000 lb
Maximum GCW 30,000 lb If ignition is turned “OFF” and then “ON” while
the CHECK TRANS light is displayed, the trans-
2000MH* Heavy-duty automatic transmission with- mission may remain in neutral until the code is
out parking pawl cleared. Leave ignition “ON” until you are in a
Limited release in motor home safe place to stop.
applications only
Maximum GVW 28,000 lb • When the TCM senses abnormal conditions.
Maximum GCW 28,000 lb • The transmission may be locked in the range it
2400* Heavy-duty automatic transmission with was in when the problem was detected.
parking pawl
• The transmission may continue to operate with
Maximum GVW 26,000 lb inhibited shifting.
Maximum GCW 26,000 lb
• The TCM may not respond to shift selector
* GVW rating, GCW rating, or OEM axle rating, whichever is less.
requests.
• Direction changes and shifts from neutral-to-
range may not occur.
1–5. DIAGNOSIS
• Whenever the CHECK TRANS light is
displayed, the TCM logs a diagnostic code in
NOTE: memory. These diagnostic codes can be
accessed through the PC-based Allison DOC™
Refer to the TS3192EN 1000/2000/2400 Series
diagnostic systems.
Troubleshooting Manual for in-depth troubleshoot-
ing procedures.
NOTE:
Diagnostic codes can be logged without illuminating
a. Before Starting. Before attempting to repair the the CHECK TRANS light. This occurs when the
transmission, the faulty condition and its probable TCM senses a problem, but determines the problem
cause should be identified. won’t cause immediate transmission damage or
dangerous performance.
b. CHECK TRANS Light
1. The CHECK TRANS light is original equip- c. Range Inhibit Indicator
ment manufacturer (OEM)-supplied and usu- 1. Some conditions detected by the TCM cause
ally located on the vehicle’s instrument panel. the transmission to be locked in one range.
When this occurs, the torque converter clutch
2. The CHECK TRANS light is illuminated is automatically disengaged. Shifts out of
briefly during vehicle start-up as a bulb check. N (Neutral) may be inhibited.

GENERAL INFORMATION
2. At the same time these events occur, a required — Make sure batteries are properly connected
OEM-supplied RANGE INHIBITED light, and charged.
mounted on the dash or near the shift selector, — Make sure throttle is closed and engine
is illuminated. This notifies the driver that speed is below 900 rpm.
shifting is inhibited and the shift selector may
not respond to shifts requested. — Make sure electrical connections are
properly made.
d. Personal Computer (PC)-Based Diagnostic
— Check support equipment for proper
System
installation and operation.
1. Control system diagnostics are done using a
• If the shifting process is rough, give the shifts
“Windows” PC operating system and interface/
time to adapt to “converged” state before
software which is available through Allison
assuming there is a problem.
Transmission tool sources. The PC is a re-
ceiver/transmitter/display medium that allows • Refer to Section 7 “General Troubleshooting of
the service technician to communicate with the Performance Complaints” in the 1000/2000/2400
TCM. Typical troubleshooting activities per- Series Troubleshooting Manual TS3192EN.
formed are installation checkout and diagnos- — These troubleshooting charts list a variety
tic code retrieval. of conditions that may or may not relate to
the TCM.
2. Allison Diagnostic Optimized Connection™
(Allison DOC™) provides tabular, graphical, — Some conditions and suggested checks
and chart displays of real-time and recorded include mechanical and hydraulic items.
TCM data. A Help system is incorporated into • If the troubleshooting charts refer you to a
the Allison DOC™ software and a printed TCM check, use the diagnostic code
User Guide is shipped with each Allison troubleshooting information that best applies
DOC™ Installation CD-ROM. to the situation.
3. The User Guide and User’s Manual contains f. Troubleshooting Intermittent
information for performing the following: Diagnostic Codes
• Display (retrieve) diagnostic trouble codes 1. Intermittent codes are a result of conditions
(DTCs). Transmission diagnostic codes which are not always present.
begin with P0, P1, U1, or U2 followed
immediately by three additional numbers. 2. When conditions causing the code exist, the
For a complete list of codes and more code is logged in memory. The code stays in
detailed information, refer to TS3192EN, memory until it is manually cleared or cycled
Electronic Troubleshooting Manual. out by forty code-free warm-up cycles.
• Clear diagnostic codes 3. When intermittently occurring codes exist,
• Obtain transmission data such as input check for the following items:
speed or sump fluid temperature
• Dirty, damaged or corroded harness
• A solenoid test
connectors and terminals
• Clutch diagnostics (including torque
converter clutch) • Terminals not fully seated in connectors
• Damaged harnesses (due to poor routing,
e. Troubleshooting When No Diagnostic Codes
chafing, excessive heat, tight bends, etc.)
Are Present
• Always start with the basics: • Improperly mounted electronic control
components
— Make sure the shifter is in the appropriate
range. • Poor connector seals (where applicable)
— Check the fluid level. • Exposed harness wires

• EMI generating components and • Remove all tape from openings and the vent
accessories assembly.
• Loose ground connections • Repeat Steps (2) through (6).
4. To help locate intermittents, it sometimes helps d. One Year Storage (With Fluid)
to place the appropriate tester on the suspect 1. Drain the fluid and replace the oil filter elements.
component or circuit and simulate operating 2. Fill the transmission to operating level with a
conditions — wiggle, pull, bump, and bend mixture of one part VCI #10 (or equivalent) to
while watching the tester. 30 parts TranSynd™ or DEXRON®-III
transmission fluid. Add 3 ml of Biobor® JF (or
1–6. PRESERVATION AND STORAGE equivalent) for every 10 liters (1⁄4 teaspoon per
gallon) of fluid in the system.
a. Storage (New Transmissions, Before Installa-
tion). New transmissions are filled with transmission NOTE:
fluid and drained before shipment. The residual fluid When calculating the amount of Biobor® JF
in the transmission provides adequate protection to required, use the total volume of the system, not just
safely store the transmission without further treatment the quantity required to fill the transmission.
for one full year if stored indoors, in conditions of nor- Include external lines, filters, and the cooler.
mal climate, and with all shipping plugs installed.
3. Operate the transmission for approximately
b. Preservation Methods. When the transmission is
five minutes at 1500 rpm with the transmission
stored or inactive for an extended period (one or more
in neutral.
years), specific preservation methods are required to
prevent damage from rust, corrosion, and organic 4. Make sure the transmission shifts through all
growth in the transmission fluid. Preservation methods ranges and that the lockup clutch is also activated.
described are for storage with or without transmission 5. Continue operating the transmission in neutral
fluid. The methods are the same whether a transmis- at 1500 rpm until normal operating tempera-
sion is in or out of a vehicle.
ture is reached.
c. One Year Storage (Without Fluid)
1. Drain the fluid.
CAUTION:
If the unit does not have a converter-out temper-
2. Remove the vent assembly per Paragraph 5–11f. ature gauge, do not stall the converter.
3. Spray 30 ml (one ounce) of VCI #10 (or equiva-
6. If normal operating temperature is less than
lent) into the transmission through the vent as-
107°C (225°F), shift the transmission to for-
sembly hole. Also, spray 30 ml (one ounce)
ward range and stall the converter. Do not ex-
through the fill tube hole.
ceed 107°C (225°F).
4. Install the vent assembly per Paragraph 5–11f. 7. As soon as the transmission is cool enough to
5. Seal all openings and the vent assembly with touch, seal all openings and the vent assembly
moisture-proof tape. with moisture-proof tape.
6. Coat all exposed, unpainted surfaces with pre- 8. Coat all exposed, unpainted surfaces with pre-
servative grease such as petrolatum (MIL-C- servative grease such as petrolatum (MIL-C-
11796, Class 2). 11796), Class 2.
9. If additional storage time is required, repeat
7. If additional storage time is required, do the
Steps 2 through 8 at yearly intervals, except, it
following at yearly intervals.
is not necessary to drain the transmission each
• Wash all external grease from the year. Just add VCI #10 and Biobor® JF (or
transmission with mineral spirits. equivalents).

GENERAL INFORMATION
1–7. RESTORING TRANSMISSION Check for proper fluid level. Add or drain transmission
TO SERVICE fluid, as required, to obtain the proper level.
a. Transmission Exterior. Wash all external grease

from the transmission with mineral spirits.
1–8. OPERATING INSTRUCTIONS
b. Sealed Vent Assembly and Openings. Remove
all tape from openings and the vent assembly.
c. New Transmissions. If the transmission is new, WARNING!
drain the residual preservative oil. Refill the Operation with excessive loads can cause trans-
transmission to the proper level with DEXRON®-III. mission damage and unexpected vehicle move-
ment. To help avoid injury, property damage,
d. Stored Without Fluid. If the transmission was and/or transmission damage, do not exceed
prepared for storage without fluid, drain the residual 11 800 kg (26,000 lbs) GCW or the OEM vehicle
fluid and replace the oil filter elements. Refill the rating, whichever is less.
transmission to the proper level with DEXRON®-III or
an Allison approved C-4 transmission fluid.
Detailed transmission operation information is in the
CAUTION: 1000/2000/2400 Series Principles of Operation Man-
When a transmission has been stored, the TCM ual, PO3065EN or 1000/2000/2400 Series Operator’s
must be reset to unadapted shifts. Resetting to Manual, OM3063EN. Refer to the latest edition.
unadapted shifts erases previous shift adapta-
tions and allows the transmission to begin using
Fast Adaptive mode to regain adapted shifts. Use 1–9. SPECIFICATIONS AND DATA
Allison DOC™ to reset to unadapted shifts.
The following specifications and data provide a quick
e. Stored With Fluid. If the transmission was pre- reference to the major characteristics of the transmis-
pared for storage with fluid, it is not necessary to drain sion. More detailed information may be obtained from
and refill the transmission with new transmission fluid. Tech Data Book SA3018EN.

Table 1–1. Specifications And Data Chart*
INPUT/OUTPUT RATINGS (1000 SERIES™):

Refuse
Input Speed** General*** (On-Highway) Motor Home Transit Bus
Max Full Load Gov. Speed 4600 rpm 4600 rpm 4600 rpm 4600 rpm
Min Full Load Gov. Speed 2200 rpm 2200 rpm 2200 rpm 2200 rpm
Max Idle Speed in Drive 900 rpm 900 rpm 900 rpm 900 rpm
Min Idle Speed in Drive 500 rpm 500 rpm 500 rpm 500 rpm
Input Power
254 kW 254 kW 254 kW 134 kW
Maximum Net
(340 hp) (340 hp) (340 hp) (180 hp)
Input Torque
705 N·m 705 N·m 705 N·m 603 N·m
Maximum Net
(520 lb ft) (520 lb ft) (520 lb ft) (445 lb ft)
Turbine Torque
1152 N·m 1152 N·m 1152 N·m 1017 N·m
Maximum Net
Output Shaft Speed
Maximum Speed 5000 rpm 5000 rpm 5000 rpm 5000 rpm
Other
9000 kg 7500 kg 9980 kg 7500 kg
Gross Vehicle Weight (GVW)
(19,850 lbs) (16,540 lbs) (22,000 lbs) (16,540 lbs)
11 800 kg 11 800 kg
Gross Combined Weight (GCW) N/A N/A
(26,000 lbs) (26,000 lbs)
Min Vehicle N/V Ratio
Output rpm/kmph 24 24 24 24
(Output rpm/mph) (38) (38) (38) (38)
Max Vehicle N/V Ratio
(Output rpm/mph) (62) (62) (62) (62)
Max Angular Rotation of Output
Shaft After Static Apply of Park 18.5 Degrees 18.5 Degrees 18.5 Degrees 18.5 Degrees
Provision
* All data and specifications are subject to change without notice.

** Engines with full load governed speed greater than 3800 rpm require Shift Energy Management (SEM) and additional calibration development.
*** Includes truck, school buses, one-way rental trucks, and road sweepers.
NOTE: Values with English units shown in parentheses ( ) are for reference purposes only. Conversions between Metric and English units are not
necessarily equivalent.

GENERAL INFORMATION
Table 1–1. Specifications And Data Chart* (cont’d)
INPUT/OUTPUT RATINGS (2000 SERIES™ — All models except the 2000MH Series):
Refuse
Input Speed** General*** (On-Highway) Road Sweeper Transit Bus
Max Full Load Gov Speed 4500 rpm 4500 rpm 4500 rpm 4500 rpm
Min Full Load Gov Speed 2200 rpm 2200 rpm 2200 rpm 2200 rpm
Max Idle Speed in Drive 900 rpm 900 rpm 900 rpm 900 rpm
Min Idle Speed in Drive 500 rpm 500 rpm 500 rpm 500 rpm
Input Power
224 kW 224 kW 224 kW 134 kW
Maximum Net
(300 hp) (300 hp) (300 hp) (180 hp)
Input Torque
705 N·m 705 N·m 705 N·m 603 N·m
Maximum Net
Turbine Torque
1152 N·m 1152 N·m 1152 N·m 1017 N·m
Maximum Net
Output Shaft Speed
Maximum Speed 4500 rpm 4500 rpm 4500 rpm 4500 rpm
Other
13 600 kg 10 550 kg 14 515 kg 12 000 kg
(30,000 lbs) (23,250 lbs) (32,000 lbs) (26,500 lbs)
13 600 kg
Gross Combined Weight (GCW) N/A N/A N/A
(30,000 lbs)
Min Vehicle N/V Ratio***
(Output rpm/mph) (38) (38) (38) (38)
Max Vehicle N/V Ratio***
(Output rpm/mph) (62) (62) (62) (62)


INPUT/OUTPUT RATINGS (2000MH SERIES):

Input Speed Motor Home
Max Full Load Gov Speed 2800 rpm
Min Full Load Gov Speed 2200 rpm
Max Idle Speed in Drive 900 rpm
Min Idle Speed in Drive 500 rpm
Input Power
205 kW
Maximum Net
(275 hp)
Input Torque
813 N·m***
Maximum Net
(600 lb ft)
Turbine Torque
1152 N·m
Maximum Net
(850 lb ft)
Output Shaft Speed
Maximum Speed 4500 rpm
Other
12 700 kg
(28,000 lbs)
12 700 kg
Gross Combined Weight (GCW)
(28,000 lbs)
Min Vehicle N/V Ratio**
Output rpm/kmph 24
(Output rpm/mph) (38)
Max Vehicle N/V Ratio**
Output rpm/kmph 38
(Output rpm/mph) (62)

** Min/Max N/V ratio values for the 2000 Series™ are guidelines only.
*** With Shift Energy Management.

GENERAL INFORMATION
INPUT/OUTPUT RATINGS (2400 SERIES™):

Refuse
Input Speed** General*** (On-Highway) Transit Bus
Max Full Load Gov Speed 4500 rpm 4500 rpm 4500 rpm
Min Full Load Gov Speed 2200 rpm 2200 rpm 2200 rpm
Max Idle Speed in Drive 900 rpm 900 rpm 900 rpm
Min Idle Speed in Drive 500 rpm 500 rpm 500 rpm
Input Power
224 kW 224 kW 134 kW
Maximum Net
(300 hp) (300 hp) (180 hp)
Input Torque
705 N·m 705 N·m 603 N·m
Maximum Net
(520 lb ft) (520 lb ft) (445 lb ft)
Turbine Torque
1152 N·m 1152 N·m 1017 N·m
Maximum Net
(850 lb ft) (850 lb ft) (750 lb ft)
Output Shaft Speed
Maximum Speed 4500 rpm 4500 rpm 4500 rpm
Other
11 800 kg 10 550 kg 11 800 kg
(26,000 lbs) (23,250 lbs) (26,000 lbs)
11 800 kg
Gross Combined Weight (GCW) N/A N/A
(26,000 lbs)
Min Vehicle N/V Ratio
Output rpm/kmph 24 24 24
(Output rpm/mph) (38) (38) (38)
Max Vehicle N/V Ratio
Output rpm/kmph 38 38 38
(Output rpm/mph) (62) (62) (62)
Max Angular Rotation of Output
Shaft After Static Apply of Park 18.5 Degrees 18.5 Degrees 18.5 Degrees
Provision


MAIN PRESSURE SCHEDULES✝:

Pressure During Normal Operation
Main Pressure @ 600 rpm Main Pressure @ 2100 rpm
Forward/Rev Converter w/ G solenoid active 590–720 kPa (85–105 psi) 634–758 kPa (92–110 psi)
Forward Converter w/ G inactive 700–1380 kPa (101–200 psi) 1515–1795 kPa (220–260 psi)
*Forward Lock-up w/G active N/A 510–627 kPa (74–91psi)
Forward Lock-up w/G inactive N/A 1000–1170 kPa (145–170 psi)
Neutral/ Park w/G solenoid active 590–720 kPa (85–105 psi) N/A
Neutral/Park 800–1655 kPa (130–240 psi) 1515–1795 kPa (220–260 psi)
✝ With modulated main pressure. Refer to Table 2–5 Main pressure Test Conditions for main pressure schedules for
transmissions prior to and starting with S/N 6310004116.
* Medium duty gasoline engines only.
FITTINGS — METRIC AND ENGLISH:

The cooler ports and main pressure tap are the only non-metric fittings on the transmission.
DRY WEIGHTS: 1000 Series™ 2000 Series™ 2400 Series™
150 kg 150 kg 150 kg
(330 lb) (330 lb) (330 lb)
DRIVE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flexplate
DRIVE RANGE AND SHIFT CONTROL: . . . . . . . . . . . . Mechanical (external)
ROTATION (viewed from input):

Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
CLUTCHES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil-cooled, hydraulically-actuated, spring-

released, self-compensating for wear


GENERAL INFORMATION
DRIVE RANGE AND SEQUENCES — ALL 1000 AND 2400 MODELS:

Shift Selector Shift Selector
Shift Selector Position Range Position Range Position Range
P (Park) Neutral† P (Park) Neutral† P (Park) Neutral†
D (Drive) 1–5 D (Drive) 1–5 D (Drive) 1–5 (1–4)††
† with Park Pawl engaged
†† 1–4 in Trailering Mode or 4 Speed Calibration
DRIVE RANGE AND SEQUENCES — ALL 2000 MODELS WITH AUTO-APPLY PARKING BRAKE:
PB (Auto-Apply Parking PB (Auto-Apply PB (Auto-Apply
Neutral† Neutral† Neutral†
Brake) Parking Brake) Parking Brake)
† with Auto-Apply Parking Brake engaged
DRIVE RANGE AND SEQUENCES — ALL 2000 MODELS WITHOUT AUTO-APPLY PARKING BRAKE:

GEAR DATA:
Type . . . . . . . . . . . . . . . . Planetary, constant mesh, helical
1000 2000 2400
Range
Series™*** Series™*** Series™***
First 3.10:1 3.51:1 3.51:1
Second 1.81:1 1.90:1 1.90:1
Third 1.41:1 1.44:1 1.44:1
Fourth 1.00:1 1.00:1 1.00:1
Fifth 0.71:1 0.74:1 0.74:1
Reverse –4.49:1 –5.09:1 –5.09:1
*** The ratios shown do not include the torque multiplication characteristics of the transmission torque converter.
HYDRAULIC SYSTEM:
2000MH Series models must use a TES-295 fluid such as TranSynd™; all other
Fluid type . . . . . . . . . . . .
models may use TranSynd™ or DEXRON®-III.
Filters . . . . . . . . . . . . . . . Internal suction filter in the sump; Control main spin-on multipass filter externally
mounted to the converter housing.
Temperature
Oil Temperature Limits . . . . . . . . . . . . . . Location
Limit
Minimum Start-up, DEXRON®-III –27C (–17ºF)
Minimum start-up, TranSynd™ –30ºC (–22ºF)
Minimum continuous sump 40ºC (100ºF)
Typical continuous sump 93ºC (200ºF)
Maximum intermittent sump 121ºC (250ºF)
Typical continuous converter-out 121ºC (250ºF)
Maximum intermittent converter-out 149ºC (300ºF)
Initial Transmission Fill Quantities (Transmission Only)** Sump Fill Quantity
Standard 14 liters (15 qts)
Shallow 12 liters (13 qts)
Refill Transmission Fill Quantities (Transmission Only)** Sump Fill Quantity
Standard 10 liters (10.5 qts)
Shallow 7 liters (7.5 qts)

** Quantities are approximate and do not include external lines and cooler hose.

GENERAL INFORMATION
OPERATIONAL EQUIPMENT:
Engine Adaptation . . . . . . . . . . . . . . . . . Adaptation 1000 2000 2400
SAE No. 2 X X X
SAE No. 3 X X X
Direct Mount X
Throttle Position Input Signal . . . . . . . . . . . . . . . . . . . . . . . . Throttle position sensor
Pulse-width-modulated (PWM) signal
Throttle position signal from an SAE J1850 or
SAE J1939 serial communication link
Range Shift Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable, air actuation, electric, electronic
Output Yokes and Flanges (customer supplied) . . . . . . . . . . . 1000/2000
2WD/Fixed yoke
2WD/Slip yoke
4WD/Slide together
REGULATION EQUIPMENT:
Tachograph Provision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 tooth tone wheel
Neutral Start/ Back-Up Switch (NSBU)
Parking Brake (customer supplied) . . . . . . . . . . . . . . . . . . . . 9 inch x 3 inch; 10 inch x 3 inch
ASSOCIATED EQUIPMENT:
POWER TAKEOFFS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbine Driven
Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional for 1000/2000/2400 Series
Pad Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 6 Bolt
Pad Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:00 and 9:00
Power Takeoff Drive Gear Ratings: Transmission Configuration Rating
With PTO on One Side 339 N·m (250 lb ft)
With PTO on Both Sides — Each 271 N·m (200 lb ft)
TORQUE CONVERTERS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . One stage, three element, polyphase
Stall torque ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TC210–2.05:1; TC211–2.00:1; TC221–1.73:1;
TC222–1.58:1
PARK PAWL
Maximum GVW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 818 kg (26,000 lb)
Static Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4067 N·m (3000 ft lb)
Disengagement Effort at Static Capacity . . . . . . . . . . . . . . . . <34 N•m (<25 ft lb)
Impact Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 kph (2.5 mph)
Engagement speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6–4.8 kph (1–3 mph) during deceleration
N/V Range** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24–38 output rpm/kmph (38–62 output rpm/mph)
Maximum Vehicle Roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 mm (5.91 inches) when engaged on a
10 percent grade
** Min/Max N/V ratio values for the 2000 Series™ are guidelines only.
1–10. ELECTROMAGNETIC/RADIO concerning emitted radio frequency interference for
FREQUENCY INTERFERENCE transportation electronics.
Some radio-telephone or two-way communication ra-

All electrical and electronic systems generate dios (land-mobile radio), or the manner in which they
electromagnetic fields that can interfere with other are installed, can adversely affect vehicle operation or
electronic systems. Allison Transmission electronic be affected by other vehicle components. Expenses in-
transmission controls comply with Federal curred to protect vehicle-related systems from EMI/
Communications Commission (FCC) regulations and RFI emissions by radio-telephone or two-way commu-
other guidelines concerning emitted radio frequency nications radios (land-mobile radio) or to integrate
interference for transportation electronics. The such devices into vehicles are not the responsibility of
position of Allison Transmission Division of General Allison Transmission.
Motors is that manufacturers and installers of
Electromagnetic Interference (EMI)/Radio Frequency Refer to the latest edition of the TS3192EN 1000/
Interference (RFI) emitting equipment are responsible 2000/2400 Series Troubleshooting Manual for detailed
for adhering to FCC regulations and other guidelines instructions regarding EMI problems.

SECTION 2 — PREVENTIVE MAINTENANCE
2–1. SCOPE b. Vehicle Inspection. Check the vehicle cooling
system occasionally for evidence of transmission fluid
Proper care and regular maintenance enables the
which would indicate a faulty oil cooler.
transmission to meet its duty requirements. Perform
the maintenance procedures described in this section
on a regular basis to prevent premature transmission or c. Welding
support equipment failure. Allison transmissions are
manufactured to provide long term, efficient service in
their designed applications. CAUTION:
When welding on the vehicle:
• DO NOT WELD on the vehicle without dis-
2–2. PERIODIC INSPECTIONS
connecting from the TCM all control system
AND CARE wiring harness connectors.
a. Transmission Inspection • DO NOT WELD on the vehicle without dis-
connecting TCM battery power and ground
leads.
CAUTION:
When cleaning the transmission, do not spray
DO NOT CONNECT welding cables to any con-
steam, water, or cleaning solution directly at the
trol components.
vent assembly. Spraying steam, water, or clean-
ing solution at the vent assembly can force the
water or cleaning solution into the transmission
and contaminate the transmission fluid. A label describing on-vehicle welding precautions is
available from your authorized Allison service dealer
Clean and inspect the exterior of the transmission at and should be installed in a conspicuous place. A
regular intervals. Severity of service and operating vehicle used in a vocation that requires frequent
conditions determine the frequency of these inspec- modifications or repairs involving welding must have
tions. Inspect the transmission for: an on-vehicle welding label (ST2067EN).
• loose bolts—transmission and mounting

components 2–3. IMPORTANCE OF PROPER
• fluid leaks—repair immediately TRANSMISSION FLUID LEVEL
• loose, dirty, or improperly adjusted throttle
sensor or shift selector linkage Transmission fluid cools, lubricates, and transmits hy-
• damaged or loose hoses draulic power. Always maintain proper fluid level. If
fluid level is too low, the torque converter and clutches
• worn, frayed, or improperly routed electrical
do not receive an adequate supply of fluid and the
harnesses
transmission overheats. If the level is too high, the
• worn or frayed electrical connections fluid aerates—causing the transmission to shift errati-
• dented, worn, or out-of-phase driveline cally and overheat. Fluid may be expelled through the
U-joints and slip fittings vent assembly or dipstick tube when the fluid level is
• clogged or dirty vent assembly too high.

WARNING!
For vehicles containing 2000 models without
WARNING! auto-apply parking brakes, each time you park
For vehicles containing 1000 and 2400 models, the vehicle or leave the operator’s station with the
each time you park the vehicle or leave the engine running, do the following.
operator’s station with the engine running, do the • Bring the vehicle to a complete stop using the
following. service brake.
• Bring the vehicle to a complete stop using the • Make sure the engine is at low idle rpm.
service brake.
• Apply the emergency brake and/or parking
• Put the transmission in P (Park). brake and make sure they are properly en-
• Engage the P (Park) range by slowly releasing gaged.
the service brake. • If the operator’s station will be unoccupied
• Apply the emergency brake and/or parking with the engine running, chock the wheels
brake, if present, and make sure it is properly and take any other steps necessary to keep the
engaged. vehicle from moving.
• If the operator’s station will be unoccupied If this procedure is not followed, the vehicle can
with the engine running, chock the wheels move suddenly and you or others could be in-
and take any other steps necessary to keep the jured.
If this procedure is not followed, the vehicle can
move suddenly and you or others could be in- NOTE:
jured. Be sure that the fill tube and dipstick meet Allison
Transmission specifications. Requirements for the
standard oil pan are shown in Figure 2–1 and
requirements for the shallow oil pan are shown in
WARNING! Figure 2–2. Refer to Tech Data Book SA3018EN for
For vehicles containing 2000 models with auto- relevant AS drawings.
apply parking brakes, each time you park the
vehicle or leave the operator’s station with the When checking a long dipstick calibration:
engine running, do the following. • Be sure the dipstick contacts the oil pan surface
• Bring the vehicle to a complete stop using the as shown in Figures 2–1 and 2–2.
service brake. • Take measurements from the end of the dipstick.
• Make sure the engine is at low idle rpm. When checking a short dipstick calibration:
• Put the transmission in PB (Auto-Apply Park- • Remove the oil pan.
ing Brake). Make sure that the parking brake
• Take measurements from the oil pan splitline.
is properly engaged.
• Apply the emergency brake, if present, and
make sure it is properly engaged. a. Fluid Check Procedure. Clean all dirt from
• If the operator’s station will be unoccupied around the end of the fluid fill tube before removing
with the engine running, chock the wheels the dipstick. Do not allow dirt or foreign matter to
and take any other steps necessary to keep the enter the transmission. Dirt or foreign matter in the
vehicle from moving. hydraulic system may cause undue wear of
transmission parts, make valves stick, and clog
If this procedure is not followed, the vehicle can passages. Check the fluid level using the following
move suddenly and you or others could be in-
procedure and report any abnormal fluid levels to
jured.
your maintenance persons.

PREVENTIVE MAINTENANCE
TRANSMISSION 5.0 mm TRANSMISSION 5.0 mm

CENTERLINE (0.20 in) CENTERLINE (0.20 in)
Fill tube to be Fill tube to be

98.9 mm straight in all 98.9 mm straight in all
(3.89 in) vertical planes (3.89 in) vertical planes
for this distance for this distance
72.6 mm 72.6 mm
10.0 mm (2.86 in) 10.0 mm (2.86 in)
(0.39 in) (0.39 in)
30.0 mm 30.0 mm
(1.18 in) HOT RUN (1.18 in) HOT RUN
OIL PAN OIL PAN
SPLIT LINE SPLIT LINE
(Ref. only) TYPICAL TYPICAL
COLD CHECK COLD CHECK
BAND BAND
101.9 mm
(4.01 in)
Dipstick must
contact oil pan
LONG FILL TUBE AND DIPSTICK* SHORT FILL TUBE AND DIPSTICK
*Check measurements from end of dipstick
V05803
Figure 2–1. Fill Tube And Dipstick Requirements (Standard Oil Pan)


72.6 mm 72.6 mm
10.0 mm (2.86 in) 10.0 mm (2.86 in)
(0.39 in) (0.39 in)
30.0 mm 30.0 mm
OIL PAN OIL PAN
BAND BAND
88.5 mm
(3.48 in)
Dipstick must
contact oil pan
V05804
Figure 2–2. Fill Tube And Dipstick Requirements (Shallow Oil Pan)

b. Cold Check Procedure. The purpose of the cold the hydraulic system. Finally, shift to P (Park)
check is to determine if the transmission has enough or PB (Auto-Apply Parking Brake), if available,
fluid to be operated safely until a hot check can be or N (Neutral) and allow the engine to idle
made. (500–800 rpm). Slowly release the service
brakes.
CAUTION: • With the engine running, remove the dipstick
The fluid level rises as fluid temperature in- from the tube and wipe the dipstick clean.
creases.
• Insert the dipstick into the tube and remove.
DO NOT fill above the “COLD CHECK” band if Check the fluid level reading. Repeat the check
the transmission fluid is below normal operating procedure to verify the reading.
temperatures.
• If the fluid level is within the “COLD CHECK”
• Park vehicles containing 1000 and 2400 models band, the transmission may be operated until the
as follows: fluid is hot enough to perform a “HOT RUN”
— Bring the vehicle to a complete stop on a check. If the fluid level is not within the “COLD
level surface using the service brake. CHECK” band, add or drain as necessary to bring
it to the middle of the “COLD CHECK” band.
— Make sure the engine is at low idle rpm.
— Put the transmission in P (Park). • Perform a hot check at the first opportunity
after the normal operating sump temperature of
— Engage the P (Park) range by slowly
71˚C–93˚C (160˚F–200˚F) is reached.
releasing the service brake.
— Apply the emergency brake and/or parking c. Hot Check Procedure
brake, if present, and make sure it is properly
engaged. CAUTION:
• Park vehicles containing 2000 models with auto- The fluid must be hot for an accurate check. The
apply parking brakes as follows: fluid level rises as temperature increases.
— Bring the vehicle to a complete stop on a
level surface using the service brake. • Operate the transmission in D (Drive) range until
normal operating temperature is reached:
— Put the transmission in PB (Auto-Apply — Sump temperature 71˚C–93˚C (160˚F–200˚F)
Parking Brake). Make sure that the parking — Converter-out temperature 82˚C–104˚C
brake is properly engaged. (180˚F–220˚F)
— Apply the emergency brake, if present, and — If a transmission temperature gauge is not
make sure it is properly engaged. present, check fluid level when the engine
water temperature gauge has stabilized and
• Park vehicles containing 2000 models without
the transmission has been operated under
auto-apply parking brakes as follows:
load for at least one hour.
— Bring the vehicle to a complete stop on a
level surface using the service brake. • Park vehicles containing 1000 and 2400 models
— Make sure the engine is at low idle rpm. as follows:
— Put the transmission in N (Neutral). — Bring the vehicle to a complete stop on a
— Apply the emergency brake and/or parking level surface using the service brake.
brake and make sure they are properly — Make sure the engine is at low idle rpm.
engaged. — Put the transmission in P (Park).
• Chock the wheels and take any other steps — Engage the P (Park) range by slowly
necessary to keep the vehicle from moving. releasing the service brake.
• Run the engine for at least one minute. Apply — Apply the emergency brake and/or parking
the service brakes and shift to D (Drive), then to brake, if present, and make sure it is properly
N (Neutral), and then shift to R (Reverse) to fill engaged.

• Park vehicles containing 2000 models with auto- 2–5. KEEPING FLUID CLEAN
apply parking brakes as follows:
Prevent foreign material from entering the transmis-
— Bring the vehicle to a complete stop on a sion by using clean containers, fillers, etc. Lay the dip-
level surface using the service brake. stick in a clean place while filling the transmission.
— Put the transmission in PB (Auto-Apply CAUTION:
Parking Brake). Make sure that the parking Containers or fillers that have been used for
brake is properly engaged. antifreeze solution or engine coolant must
NEVER be used for transmission fluid.
— Apply the emergency brake, if present, and Antifreeze and coolant solutions contain ethylene
make sure it is properly engaged. glycol which, if put into the transmission, can
cause the clutch plates to fail.
• Park vehicles containing 2000 models without
auto-apply parking brakes as follows: 2–6. FLUID RECOMMENDATIONS
— Bring the vehicle to a complete stop on a Hydraulic fluids (oils) used in the transmission are
level surface using the service brake. important influences on transmission performance,
— Make sure the engine is at low idle rpm. reliability, and durability. Only TranSynd™ or a TES-295
fluid is acceptable for use in the 2000MH transmissions.
— Put the transmission in N (Neutral). For all other models, only fluids meeting DEXRON®-III
— Apply the emergency brake and/or parking specifications are acceptable. TranSynd™ fluids fully
brake and make sure they are properly meet the DEXRON®-III specifications.
engaged. To make sure the fluid is qualified for use in Allison
• Chock the wheels and take any other steps transmissions, check for a DEXRON®-III fluid license
or approval numbers on the container, or consult the
necessary to keep the vehicle from moving.
lubricant manufacturer. Consult your Allison
• With the engine running, remove the dipstick Transmission dealer or distributor before using other
from the tube and wipe the dipstick clean. fluid types.
• Insert the dipstick into the tube and remove. CAUTION:

Check fluid level reading. Repeat the check
procedure to verify the reading. Disregarding minimum fluid temperature limits
can result in transmission malfunction or re-
duced transmission life.
NOTE:
When choosing the optimum viscosity grade of
Safe operating level is within the “HOT RUN” band
fluid to use, duty cycle, preheat capabilities, and/or
on the dipstick. See Figures 2–1 and 2–2. The width geographical location must be taken into
of the “HOT RUN” band represents approximately consideration. Table 2–1 lists the minimum fluid
1.0 liter (1.06 quart) of fluid at normal operating temperatures at which the transmission may be safely
sump temperature. operated without preheating the fluid. Preheat with
auxiliary heating equipment or by running the
equipment or vehicle with the transmission in P (Park)
• If the fluid level is not within the “HOT RUN” or PB (Auto-Apply Parking Brake), if available, or
band, add or drain as necessary to bring the fluid N (Neutral) for a minimum of 20 minutes before
level to within the “HOT RUN” band. attempting range operation.
Table 2–1. Transmission Fluid Operating
d. Consistency of Readings. Always check the fluid Temperature Requirements
level at least twice using the procedure described
above. Consistency (repeatable readings) is important Ambient Temperature Below
to maintaining proper fluid level. If inconsistent read- Which Preheat is Required
ings persist, check the transmission vent assembly to Viscosity Grade Celsius Fahrenheit
be sure it is clean and unclogged. If readings are still DEXRON®-III –27 –17
inconsistent, contact your nearest Allison distribution TranSynd™ –30 –22
or dealer. (Ref. SIL 13-TR-90)

2–7. TRANSMISSION FLUID AND • Oil analysis kits, part number 29537805, are
FILTER CHANGE INTERVALS available through your normal Allison
Transmission parts source.
Refer to the Technician’s Guide for Automatic
CAUTION: Transmission Fluid, GN2055EN, for additional
Transmission fluid and filter change frequency is information.
determined by the severity of transmission ser-
Table 2–2. Fluid Oxidation Measurement Limits
vice. More frequent changes may be necessary
than recommended in the general guidelines Test Limit
when operating conditions create high levels of Viscosity ±25% change from new fluid
contamination or overheating.
Total Acid Number +3.0* change from new fluid
Water 0.2% by volume maximum
a. Frequency. Table 2–3 is given only as a general * mg of KOH required to neutralize a gram of fluid.
guide for fluid and filter change interval.
d. Fluid and Filter Change Intervals. Change the
b. Abnormal Conditions. Transmissions used in control main filter at the first 8000 km (5000 miles)
high cycle rate applications should use fluid analysis to then follow the appropriate schedule in Table 2–3.
be certain that a proper fluid change interval is estab-
lished. Transmission fluid must be changed whenever 2–8. TRANSMISSION FLUID
there is evidence of dirt or a high temperature condition. CONTAMINATION
A high temperature condition is indicated by the trans-
mission fluid being discolored or having a strong odor, a. Fluid Examination. At each fluid change, exam-
or by fluid analysis. Local conditions, severity of opera- ine the drained fluid for evidence of excessive dirt or
tion, or duty cycle may require more or less frequent water. A normal amount of condensation will appear in
fluid or filter change intervals. the fluid during operation.
c. Fluid Analysis. Transmission protection and fluid b. Water. Obvious water contamination of the
change intervals can be optimized by monitoring fluid transmission fluid or transmission fluid in the cooler
oxidation according to the tests and limits shown in water (in heat exchanger) indicates a leak between the
Table 2–2. Fluid oxidation can be monitored through a water and fluid areas of the cooler. Inspect and
fluid analysis firm or by using an oil analysis kit. pressure test the cooler to confirm the leak. Replace
leaking coolers.
• Fluid analysis firms—Consult your local
telephone directory for fluid analysis firms. For
consistent and accurate fluid analysis, use only NOTE:
one fluid analysis firm. Refer to the Cooler water can also be contaminated by engine
Technician’s Guide for Automatic oil; be sure to locate the correct source of cooler
Transmission Fluid, GN2055EN, for additional water contamination.
information.

Table 2–3. Transmission Fluid and Filter Change
1000/2000/2400/2000MH Series
Schedule 1. Recommended Fluid and Filter Change Intervals (Non-TranSynd™/Non-TES 295 Fluid)
SEVERE VOCATION GENERAL VOCATION

Filters Filters
Fluid Control Main Internal Lube/Auxiliary Fluid Control Main Internal Lube/Auxiliary
25,000 Miles 25,000 Miles Overhaul 25,000 Miles 50,000 Miles 50,000 Miles Overhaul 50,000 Miles
(40 000 km) (40 000 km) (40 000 km) (80 000 km) (80 000 km) (80 000 km)
12 Months 12 Months 12 Months 24 Months 24 Months 24 Months
NOTE: The following recommendations in Schedule 2 are based upon the transmission containing 100 percent of
TranSynd™ fluid. For transmissions that contain a mixture of TranSynd™ and non-TranSynd™ fluids, refer to
Schedule 3.
Flushing Machines are not recommended or recognized due to variation and inconsistencies with ensuring removal
of 100 percent of the used fluid. Recommendations in Schedule 2 are based upon standard Allison fluid change
procedures.
Schedule 2. Recommended Fluid and Filter Change Intervals (TranSynd™/TES 295 Fluid)

Filters Filters
Copyright © 2003 General Motors Corp.

(80 000 km) (80 000 km) (80 000 km) (160 000 km) (80 000 km) (80 000 km)
NOTE: Change fluid/filters after recommended mileage, months, or hours have elapsed, whichever occurs first.
Severe Vocation: On/Off Highway, Refuse, City Transit, Shuttle Transit, and 2000MH models.
General Vocation: All other vocations.
2–7
Table 2–3. Transmission Fluid and Filter Change (cont’d)
2–8
1000/2000/2400/2000MH Series
Schedule 3. Modified Fluid and Filter Change Intervals With a Mixture* of TranSynd™ and Non-TranSynd™ Fluids

Filters Filters
(40 000 km) (40 000 km) (40 000 km) (80 000 km) (80 000 km) (80 000 km)
* Mixture is defined as the quantity of oil remaining in the transmission after a standard fluid change combined with the quantity of
TranSynd™ that is required to fill the transmission to the proper level. A mixture of TranSynd™ or TES 295 equivalent vs. non-
TranSynd™ other than as defined in this paragraph does not meet the requirements that permit the eligibility for the recommendations
given in Schedule 3.
Severe Vocation: On/Off Highway, Refuse, City Transit, Shuttle Transit, and 2000MH models.
Local conditions, severity of operation or duty cycle may require more or less frequent fluid change intervals that differ from the published
recommended fluid change intervals of Allison Transmission. Transmission protection and fluid change intervals can be optimized by the use of fluid analysis.
Filters must be changed at or before recommended intervals.

c. Engine Coolant • Remove the drain plug from the oil pan and al-
low the fluid to drain into a suitable container.
CAUTION: • Examine the fluid as described in Paragraph 2–8.
Engine coolant in the transmission hydraulic
system requires immediate action to prevent b. Replace Control-Main Filter (Figure 2–3)
malfunction and possible serious damage. 1. Remove the control-main filter by rotating it in
Completely disassemble, inspect, and clean the the counterclockwise direction. Use a standard
transmission. Remove all traces of the coolant, strap-type filter wrench or the J 45023.
and varnish deposits resulting from engine
coolant contamination. Replace the torque 2. Remove the magnet from the filter attachment
converter, all seals, gaskets, bearings, friction tube or from the top of the filter element.
clutch plates, solenoids, and all rusted parts.
3. Clean any metal debris from the magnet. Re-
d. Flush Oil Cooler. Transmission failures can port any metal pieces larger than dust to your
cause the oil cooler to become restricted or plugged. maintenance personnel.
Flush the oil cooler whenever the transmission is re- 4. Reinstall the magnet onto the filter attachment
moved for repair. Using the J 46550 Transmission tube.
Cooler Flush Cart or an approved flushing device that 5. Lubricate the gasket on the control-main filter
can perform the following: with transmission fluid.
1. Flow clean transmission fluid through the 6. Install, by hand, the control-main filter until
cooler and hoses in the opposite direction of the gasket on the control-main filter touches
normal flow. Use a minimum pulsating flow the converter housing or cooler manifold.
rate of 0.5 liter/sec (8.0 gpm), at 275–345 kPa
(40–50 psi). Flush the cooler and hoses thor-
oughly to remove all contaminated fluid.
CAUTION:
Turning the control-main filter more than ONE
2. After thoroughly flushing contaminated fluid, FULL TURN after gasket contact will damage
circulate clean transmission fluid through the the filter.
cooler in a closed loop that includes a 10 mi-
cron filter. 7. Using the J 45023 or by hand, turn the filter
3. Circulate clean transmission fluid through the ONE FULL TURN ONLY after gasket contact.
filter for 5 minuets or more, the longer the fil- 8. Reinstall the drain plug and sealing washer.
tering process the cleaner the fluid. Tighten the drain plug to 30–40 N·m (22–
30 lb ft).
4. Determine the pressure drop in the external
cooler.
c. Refill Transmission. The amount of refill fluid is
5. If the pressure drop is above specification, the less than the amount used for the initial fill. Fluid remains
cooler has excessive trapped particles and must in the external circuits and transmission cavities after
be repaired or replaced. draining the transmission. After refill, check the fluid
level using the procedure described in Paragraph 2–4.
2–9. TRANSMISSION FLUID AND Table 2–4. Transmission Fluid Capacity

FILTER CHANGE PROCEDURE Initial Fill* Refill*
a. Drain Fluid Transmission Sump Liters Qts Liters Qts
• Drain the fluid when the transmission is at nor- Standard 14 14.8 10 10.6
mal operating sump temperature—71˚C–93˚C 1000/2000/2400
Shallow 12 12.7 7 7.4
(160˚F–200˚F). Hot fluid flows quicker and
drains more completely. * Approximate quantities, do not include external lines and cooler hose.

MAGNET
FILTER
V06694.01.00
Figure 2–3. Control-Main Filter
2–10. VENT ASSEMBLY stand) preparation, recording of data, and comparing

recorded data against specifications provided.
a. Location and Purpose. The vent assembly is lo-
cated at the top left-rear of the transmission main WARNING!
housing. The vent assembly prevents air pressure
Observe safety precautions during hydraulic
buildup within the transmission and its passage must pressure check procedures. All personnel must
be kept clean and open. stand clear of the vehicle. Take precautions
against movement of the vehicle. Be sure that
b. Maintenance. The amount of dust and dirt en-
gauges (vacuum, pressure, tachometer) have ex-
countered will determine the frequency of vent assem- tended lines so that they can be read from inside
bly cleaning. Use care when cleaning the transmission. the vehicle.
CAUTION: 1. All transmission fluid level and pressure

When cleaning the transmission, do not spray checks must be made at normal operating
steam, water, or cleaning solution directly at the temperatures 71–93ºC (160–200ºF) sump;
vent assembly. Spraying steam, water, or clean- 82–104ºC (180–220ºF) converter-out. Check
ing solution at the vent assembly can force the transmission fluid level.
water or cleaning solution into the transmission 2. Connect a 0–300 psi (0–2070 kPa),
and contaminate the transmission fluid. 0.4375-20 UNF-2B inch series oil pressure
gauge at the main pressure tap (Figure 2–4). Use
2–11. MAIN PRESSURE CHECK Allison DOC™ to check engine rpm. See
PROCEDURE Table 2–5 for main pressure levels.
3. Disconnect the driveshaft.
Checking main pressures helps to determine if a
transmission malfunction is due to a mechanical or an 4. With brakes applied, check main pressure with
electrical problem. Properly making these pressure the engine running at 2100 rpm and 600 rpm.
checks requires transmission and vehicle (or test 5. Continue the procedure for all ranges.

MAIN PRESSURE TAP
BOTTOM VIEW
V05742
Figure 2–4. Main Pressure Check Point
Table 2–5. Main Pressure Test Conditions

(Used Prior To S/N 6310004116)
Range Main Pressure @ 600 rpm Main Pressure @ 2100 rpm
Forward (Converter) 800–1380 kPa (115–200 psi) 1515–1795 kPa (220–260 psi)
Forward (Torque Converter
— 1000–1170 kPa (145–170 psi)
Clutch Applied)
Reverse 800–1380 kPa (115–200 psi) 1515–1795 kPa (220–260 psi)
(Used Starting With S/N 6310004116)

— 1000–1170 kPa (145–170 psi)
Clutch Applied)
(Transmissions with Modulated Main “G” solenoid)

Main Pressure @ 600 rpm Main Pressure @ 2100 rpm
Forward/Rev Converter w/ G
590–720 kPa (85–105 psi) 634–758 kPa (92–110 psi)
solenoid active
Forward Converter w/ G inactive 700–1380 kPa (101–200 psi) 1515–1795 kPa (220–260 psi)
*Forward Lock-up w/G active N/A 510–627 kPa (74–91psi)
Forward Lock-up w/G inactive N/A 1000–1170 kPa (145–170 psi)
Neutral/ Park w/G solenoid active 590–720 kPa (85–105 psi) N/A

2–12. TRANSMISSION STALL TEST AND
CAUTION:
NEUTRAL COOL-DOWN CHECK
DO NOT conduct a stall test in R (Reverse)
a. Purpose. When a vehicle is performing unsatisfac- range. The torque produced in reverse range can
torily, use the stall test to determine if the malfunction is damage the vehicle driveline or axle.
in the engine or in the transmission. The neutral cool-
down check uses a two minute cooling period after the
CAUTION:
stall to gather fluid temperature data for troubleshooting.
The stall condition causes a rapid rise in fluid tem-
NOTE: perature; never maintain the stall for more than 30
seconds at any one time. Do not let the converter-
The stall test should only be performed by a quali- out fluid temperature exceed 149˚C (300˚F). Dur-
fied service technician. ing stall conditions, converter-out temperatures
rise much faster than internal temperatures. Do
not use internal fluid temperature to determine the
NOTE: length of the stall condition. If the stall test is re-
peated, do not let the engine overheat.
The engine manufacturer’s test data must be avail-
able for the stall test. This data can be obtained • Shift the transmission into a forward range.
from the engine manufacturer or from the equip-
ment dealer or distributor or from SCAAN. • With the vehicle blocked and wheels chocked,
parking and service brakes applied, hold the
engine at wide-open throttle and record the
• The engine stall rpm under load is compared to
maximum engine speed reached. This is the
the engine manufacturer’s specified rpm for the
stall speed.
stall test.
• Reduce engine rpm to idle and shift to
NOTE: N (Neutral).
Allison DOC™ can read sump temperature to show • Raise engine speed to 1200–1500 rpm for 2–3
when normal operating temperatures have been minutes to allow the transmission to cool
reached and the temperature has stabilized. down.
• Monitor converter-out temperature.
• Connect a tachometer (Allison DOC™ can read
engine rpm) of known accuracy to the engine b. Stall Test Results
and install a temperature probe into the
converter-out (to cooler) hose. Bring the
transmission to the normal operating NOTE:
temperature range of 71˚C–93˚C (160˚F–200˚F). Environmental conditions, such as ambient temper-
ature, altitude, engine accessory loss variations, etc.,
WARNING! affect the power input to the converter. Under such
To help avoid injury or property damage caused conditions, stall speed can vary from specification
by sudden and unexpected vehicle movement, do by ±150 rpm and still be accepted as within normal
not start a stationary stall test until you: range.
• Put the transmission in P (Park) or
N (Neutral)…and
• Apply the parking brake and service • If engine stall speed is more than 150 rpm be-
brake…and low the stall speed specified by the engine
• Chock the vehicle wheels and take any other manufacturer, an engine problem is indicated.
steps necessary to keep the vehicle from mov- If engine stall speed is more than 150 rpm
ing…and above specification, a transmission problem is
• Warn personnel to keep clear of the vehicle indicated, such as slipping clutches, cavitation,
and its path. aeration, or torque converter failure.

• An extremely low stall speed (such as 33 per- to the following list for possible points of fluid
cent of the specified engine stall rpm), during leaks and their causes.
which the engine does not smoke, could indi- • Transmission mating surfaces:
cate a freewheeling stator in the converter.
— Attaching bolts not correctly tightened
• Perform a neutral cool-down check if engine
— Improperly installed or damaged gasket
stall-speed tests meet specifications, but cause
the transmission fluid to overheat. — Mounting face damaged
• If the engine stall speed meets the specification • Housing leak:
and the cool-down check shows that transmis- — Filler pipe or plug seal damaged or
sion fluid cools properly, an electronic control missing
problem may exist. Refer to the 1000/2000/ — Filler pipe bracket dislocated
2400 Series Electronic Control Troubleshoot-
— Oil cooler connector fittings loose or
ing Manual TS3192EN.
damaged
c. Neutral Cool-Down Check Procedure — Output shaft seals worn-out or damaged
— Pressure port plug loose
• The neutral cool-down check determines if the
transmission fluid cools following an engine — Porous casting
load condition. Perform this check immediate- • Leak at converter end:
ly after the maximum engine rpm has been re- — Converter seal damaged
corded in the stall test.
— Seal lip cut (check converter hub for
• Record the converter-out fluid temperature. damage)
• Reduce the engine rpm to idle and shift to — Garter spring missing from seal
N (Neutral). Run the engine at 1200–1500 rpm
— Converter leak in weld area
for two minutes to cool the fluid.
— Porous casting
• At the end of two minutes, record the convert-
er-out fluid temperature. Converter-out fluid • Fluid comes out of fill tube:
temperature should return to within the normal — Overfilled—incorrect dipstick calibration
operating temperature range. — Plugged vent (breather)
• If the fluid does not cool during the two minute — Water or coolant in fluid—fluid will
cool-down check, a stuck stator may be the appear milky
source of the problem. — Drain-back holes plugged
NOTE: 3. Visually inspect the suspected area. Inspect all

the gasket mating surfaces for leaks.
You may use Allison DOC™ to perform stall test
and clutch test procedures. Refer to the diagnostic
tool’s user manual for specific instructions. CAUTION:
When cleaning the transmission, do not spray
steam, water, or cleaning solution directly at the
vent assembly. Spraying steam, water, or clean-
2–13. FLUID LEAK DIAGNOSIS ing solution at the vent assembly can force the
water or cleaning solution into the transmission
a. Finding the Leak and contaminate the transmission fluid.
1. Identify the fluid. Determine whether it is
engine oil, automatic transmission fluid, or 4. If the leak still cannot be identified, then clean
hydraulic fluid from a specific vehicle system. the suspected area with a degreaser, steam, or
spray solvent. Clean and dry the area. Operate
2. Operate the vehicle to reach normal operating the vehicle for several miles at varying speeds.
temperature and park the vehicle. Inspect the Inspect the vehicle for leaks. If the source of
vehicle to identify the source of the leak. Refer the leak is still not identified, use the powder

method, and/or black light and dye method as — Improperly tightened fasteners or dirty/
explained below. damaged threads
— Warped flanges or sealing surfaces
b. Powder Method
— Scratches, burrs, or other damage to a
• Clean the suspected area.
sealing surface
• Apply an aerosol-type white powder.
— Damaged or worn-out gasket
• Operate the vehicle under normal operating
— Cracked or porous casting adjacent to the
conditions.
gasket
• Visually inspect the suspected area and trace
— Improper sealant used (where applicable)
the leak path over the white powder surface to
the source. • Seals:
— Fluid level/pressure is too high
NOTE: — Plugged vent or drain-back holes
Dye and black light kits are available for finding
leaks. Refer to the manufacturer’s directions when — Damaged seal bore
using the kits. See kit directions for the color of the — Damaged or worn-out seal
fluid dye mix.
— Improper installation
— Cracks in component
c. Black Light and Dye Method
— Output shaft surface scratched, nicked, or
• Pour the specified amount of dye into the trans- damaged
mission fill tube.
— Loose or worn-out bearing causing excess
• Operate the vehicle in normal operating condi- seal wear
tions.
• Sealing Flange:
• Direct the black light toward the suspected
area. The dyed fluid will appear as a brightly — Inspect the sealing flange for bends;
colored path leading to the source. replace the part with the damaged flange.
d. Repairing the Leak. Once the leak has been

traced back to its source, inspect the leaking part for 2–14. ON-VEHICLE MAINTENANCE
the following conditions, and repair the leaking part.
For service procedures performed with the
• Gaskets:
transmission mounted in the vehicle, refer to 1000/
— Fluid level/pressure is too high 2000/2400 Series In-chassis Maintenance job aid
— Plugged vent or drain-back holes booklet, JA3664EN.

SECTION 3 — GENERAL OVERHAUL INFORMATION
3–1. SCOPE 3–2. TOOLS AND EQUIPMENT
This section provides general information for trans- a. Improvised Tools and Equipment. The follow-
mission overhaul. The information provided includes: ing items may be improvised.
• Tools and equipment required for overhaul • Work Table — 500 kg (1000 lb) capacity
(Figure 3–1)
• Replacement parts information
• Overhaul Stand — J 29109 or equivalent
• Cleanliness and careful handling (Table 3–1)
• Cleaning and inspection
b. Special Tools. Special tools are illustrated and
• Assembly procedures identified in Table 3–1.
• Transmission removal and installation c. Mechanic’s Tools and Shop Equipment. The
following tools, in addition to the common tools ordi-
• Locating wear data narily required, should be available.
• Locating spring specifications • Common hand tools, metric where required
• Locating torque specifications for plugs, bolts, • Metric wrench set (sockets, box-end
and nuts wrenches, and Allen wrenches)
120 cm
(48 in.)
200 cm
(78 in.) OIL DRAIN STEEL TOP
TROUGH
60 cm 16-GAUGE SHEET STEEL
(24 in.) 35 mm (11⁄ 2 in.) DEEP
35 mm (11⁄ 2 in.) WIDE
OIL DRAIN
(BOTH SIDES) 5x15 cm
(2x6 in. BOARD)
FOR TOP FRAME
AND LEG BRACKETS
10x10 cm
(4x4 in. LEGS)
V00660.02
Figure 3–1. Work Table

• Snapring pliers • Clean, lint-free shop cloths (do not use waste
cloths)
• Micrometer (metric preferred)
• Containers for parts
• Depth micrometer (metric preferred)
• Supply of wood blocks
• Dial indicator set (metric preferred)
• Petrolatum
• Metric headless guide bolts set
• Container of water for leak testing the torque
converter
• M10 eye bolt
• Container of mineral spirits for cleaning parts
• M16 eye bolt
• Suitable hoist — 500 kg (1000 lb) capacity CAUTION:

Caustic cleaning compounds will damage some
• A 12 N·m (100 lb in.) torque wrench transmission parts. Use only mineral spirits to
clean transmission parts.
• A 350 N·m (250 lb ft) torque wrench
WARNING!
• A press for disassembly and assembly of
spring-loaded clutches and interference-fit Use appropriate safety equipment such as safety
parts glasses, safety shoes, and gloves.

GENERAL OVERHAUL INFORMATION
Table 3–1. Special Tools and Equipment*
Kent-Moore Tool No.**/ Kent-Moore Tool No.**/
Illustration Description Illustration Description
J 5959 J 24204-2
Dial Indicator Set Bar and Stud Assembly
J 5959 J 24204-2
J 7872 J 24420-B
Dial Indicator Clamp Universal Puller
and Adapter
J 7872 J 24420-B
J 8092 J 24446
Universal Driver Rear Bearing Installer
J 8092 J 24446
J 21369-F J 24459-5
Torque Converter Leak Spring Compressor Adapter
Test Fixture
J 24459-5
J 21369-F

Table 3–1. Special Tools and Equipment* (cont’d)
J 26941 J 41364-A
Front Support Needle NSBU Switch
Bearing Remover Adjusting Tool
J 26941 J 41364-A
J 43763
J 29109
Torque Converter Leak Test
Repair Stand
Plug
J 29109 J 43763
J 43764
J 33163
Torque Converter
Valve Tray Set
End Play Gauge
J 33163
J 43764
J 43765
J 39354
Ground Sleeve
Rivet Installer
Installer/Remover
J 39354
J 43765

J 43770
J 43766
Main, Lube, Converter
Selector Shaft Spring Pin
Relief Valve Spring
Installer
Compressor
J 43766 J 43770
J 43771
J 43767
Pump Bushing
Tone Wheel Staker
Installer/Remover
J 43767 J 43771
J 43768 J 43772
Tone Wheel Driver Oil Pump Seal Installer
J 43768
J 43772
J 43769
J 43773
Spanner Nut
Valve Spring Compressor
Wrench — 4WD
J 43769 J 43773

J 43774 J 43778
Ground Sleeve Bushing Rotating Clutch Bushing
Installer Installer
J 43774 J 43778
J 43775
J 43779
Front Support Needle
Dowel Pin Installer
Bearing Installer
J 43775 J 43779
J 43776 J 43780
C2 Piston Return Spring Main Housing Dowel Pin
Compressor Installer
J 43776 J 43780
J 43777 J 43781
C1 Piston Return Spring P1 Bushing Remover/
Spring Compressor Installer
J 43777 J 43781

J 43782 J 43909
Output Shaft Seal Installer Selector Shaft Seal Installer
J 43782 J 43909
J 43910
J 43783
Output Bearing Puller Leg
Output Shaft Seal Installer
Set
J 43783 J 43910
J 43785 J 43911
P2 Bushing Remover/ Selector Shaft Seal
Installer Remover
J 43785 J 43911
J 43791 J 44247
Output/Turbine Shaft Wiring Harness Connector
Bushing Installer Installer
J 43791 J 44247
J 43797 J 44525
P3 Carrier Bearing Race C1 Clutch Backplate
Installer Selector
J 43797 J 44525


J 44526
J 44587
Output/Turbine Shaft
Main Shaft Holder
Bushing Remover
J 44587
J 44526
J 44528 J 44723
P3 Carrier Bearing Race Transmission/Stand
Remover Adapter Plate
J 44528 J 44723
J 44529 J 45023
Ground Sleeve Bushing Control Main Filter
Remover Wrench
J 44529 J 45023
J 44530 J 46550
C3/C4 Piston Spring Transmission Cooler
Compressor Flush Cart
J 44530
J 46550
* We believe this source and its tools to be reliable. These tools may be
available from other manufacturers. General Motors does not en-
dorse, indicate any preference for, or assume any responsibility for
the products or tools from these firms, or for any such items that may
be available from other sources.
** Kent-Moore Tool Division, 29784 Little Mack,
Roseville, Michigan 48066

3–3. REPLACEMENT PARTS steam-cleaning or with volatile mineral spirits.
Do not use caustic soda solution for steam-
a. Ordering Information. Refer to the latest cleaning. Clean friction-faced clutch plates and
version of Parts Catalog PC3062EN for parts bearings with mineral spirits only.
information. Do not order replacement parts using the
reference numbers in this service manual. 2. Dry all parts, except bearing assemblies, with
compressed air. To prevent rust, lubricate
b. Parts Normally Replaced at Overhaul. The steam-cleaned parts as soon as they are dry.
following parts are normally replaced at each
transmission overhaul: 3. Clean fluid passages by working a piece of soft
wire through the passages and flushing them
• Gaskets
with mineral spirits. Dry the passages with
• Lockstrips compressed air.
• Washers or retaining rings damaged by 4. Examine parts, especially fluid passages, after
removal or abnormal wear cleaning to make certain they are entirely
clean. Re-clean parts if necessary.
• Oil seals and piston sealrings
c. Cleaning Bearings
• Suction filters
1. Bearings that have been in service should be
WARNING! thoroughly cleaned in volatile mineral spirits.
Do not burn discarded Teflon® seals; toxic gases 2. Soak particularly dirty bearings or ones filled
are produced by burning Teflon®. with hardened grease in mineral spirits before
trying to clean them.
3–4. CAREFUL HANDLING

WARNING!
Handle parts and subassemblies carefully to prevent Never dry bearings by spinning them with
nicking, scratching, and denting. Parts that fit together compressed air. A spinning bearing can
closely and have a specific operating clearance can disintegrate, allowing balls or rollers to become
bind if damaged. Parts that depend upon smooth sur- lethal flying projectiles. Also, spinning a bearing
faces for sealing may leak if scratched. Control valve without lubrication can damage the bearing.
body assembly parts are especially susceptible to leak-
ing if scratched. Valves, when dry, must move freely
3. Before inspection, lubricate the bearings with
by their own weight. Handle these parts carefully and
transmission fluid.
protect them during removal, cleaning, inspection, and
installation. Keep control valve body assembly parts in d. Keeping Bearings Clean. Ball or roller bearing
clean containers until installation. failures are usually caused by dirt or grit in the bear-
ing. Keep bearings clean during removal and installa-
tion. Observe the following rules for maximum bear-
3–5. CLEANING AND INSPECTION ing life:
a. Dirt Causes Malfunction. All parts must be • Do not unwrap new bearings until they are to
clean to permit effective inspection. Do not allow dirt be installed.
or foreign material to enter the transmission during as-
sembly. Even minute particles can cause close-fit • Do not remove the grease in which new
parts, such as valves, to malfunction. bearings are packed until they are to be
installed.
b. Cleaning Parts
1. Clean all metallic transmission parts, except • Do not lay bearings on a dirty bench. Place
bearings and friction-faced clutch plates, by bearings on clean, lint-free paper.

• If a bearing is not installed immediately, wrap
or cover the lubricated bearing with clean CAUTION:
paper or lint-free cloth to keep out dust. The output shaft has Spiralock® threaded holes.
If the Spiralock® threads are damaged, replace
e. Inspecting Bearings the output shaft.
1. Inspect bearings for rough rotation. Replace a
bearing if its rotation is still rough after clean- 5. Inspect the ribs inside the main housing for
ing and lubrication. reaction plate wear grooves in the side of the
ribs.
2. Inspect bearings for scored, pitted, scratched,
6. Replace housings or other cast parts that are
cracked, or chipped races, and for excessive
cracked.
roller or ball wear. Replace the bearing if any
defects are found. 7. Inspect all machined surfaces for damage that
could cause fluid leakage or other malfunction.
3. Inspect a defective bearing’s bore and mating Rework or replace defective parts.
shaft for grooved, burred, or galled conditions
that indicate the bearing has been turning in the 8. Inspect the oil tracks of the control module and
bore or on the shaft. If the damage cannot be main housing for porosity, broken lands,
repaired with crocus cloth, replace the defec- cracks, dirt, and land surface imperfections.
tive part. These imperfections will cause severe fluid
leakage leading to transmission failure.
4. When removing a bearing, do not apply pres-
sure across the balls. This can cause brinelling g. Inspecting Bushings and Thrust Washers
and bearing failure.
1. Inspect bushings for scores, burrs, sharp edges,
5. If a bearing must be removed or installed with- and evidence of overheating. Remove scores
out the proper tool, press only on the race with crocus cloth. Remove burrs and sharp
which is adjacent to the mounting surface. If a edges with a scraper or knife blade. Before
press is not available, carefully seat the bearing reinstalling, carefully check bushings for signs
with a drift and hammer. of distress.
f. Inspecting Cast Parts CAUTION:

and Machined Surfaces
When removing a defective bushing do not
1. Inspect bores for wear, scratches, grooves, and damage the bushing bore.
dirt. Remove scratches and burrs with crocus
cloth. Clean the part. Replace parts that are 2. Replace bushings that are out-of-round, deeply
deeply scratched or grooved. scored, or excessively worn. Inspect parts
mated to bushings to make sure they are not
2. Inspect all fluid passages for obstructions. If an
damaged or worn beyond use.
obstruction is found, remove it with com-
pressed air, or by working a soft wire back and 3. Inspect thrust washers for distortion, scores,
forth through the passage and flushing it out burrs, and wear. Replace a thrust washer if de-
with mineral spirits. fective or worn.
3. Inspect mounting faces for nicks, burrs, h. Inspecting Sealrings and Gaskets
scratches, and foreign matter. Remove any de-
fects with crocus cloth or a soft stone. Clean 1. Inspect piston sealrings and lip-type seals for
the part. If scratches are deep, replace the de- nicks, cuts, tears, splits, and pattern damage. A
fective part. damaged seal can indicate rough or sharp
edges in piston grooves or on a mating surface
4. Inspect threaded openings for damaged that could damage a new seal.
threads. Clean damaged threads with the cor-
rect size tap. 2. Replace all composition gaskets.

3. Inspect hook-type sealrings for wear, broken 2. Spline wear is determined by comparing feeler
hooks, and distortion. gauge thickness with the thickness of the worn
area on the spline. Replace parts having
4. Install a new hook-type sealring if the old ring excessive spline wear. (Refer to Wear Limits,
shows any wear on its outside diameter, or if Section 7.)
there is excessive side wear.
3. Backlash cannot be used to establish critical
5. Inspect clutch housing sealing surfaces for spline wear. Accurate backlash measurement
nicks, burrs, dents, or displaced metal that requires the mating parts to be concentrically
could interfere with mating parts or damage located.
the piston seal. Remove raised metal, sharp
edges, burrs, or nicks with a soft stone and cro-
cus cloth. Thoroughly clean all residue from k. Inspecting Threaded Parts. Inspect threaded
the housing before assembly. parts for burred or damaged threads. Remove burrs
with a soft stone or fine file. Replace damaged parts.
6. Inspect piston sealring grooves for nicks, burrs,
dents, or displaced metal that could damage
l. Inspecting Retaining Rings. Inspect all retaining
the seal. Remove raised metal, sharp edges,
rings for nicks, distortion, or excessive wear. Replace the
burrs, or nicks with a soft stone and crocus
retaining ring if any defects are found. The retaining ring
cloth. Thoroughly clean all residue from the
must snap tightly into its groove to function properly.
piston before assembly.
i. Inspecting Gears m. Inspecting Springs. Inspect springs for signs of

1. Inspect gears for scuffed, nicked, burred, or overheating, permanent set, or wear due to rubbing
broken teeth. If a defect cannot be removed adjacent parts. Replace the spring if any one of these
with a soft stone, replace the gear. defects are found. (Refer to Spring Data, Table 7–2 in
Section 7.)
2. Inspect gear teeth for wear that has changed
the original tooth shape. If this condition is n. Inspecting Clutch Plates (Figure 3–2)
found, replace the gear. 1. Inspect friction-faced clutch plates (C1 clutch
plates are externally tanged; all other clutch
3. Inspect the thrust face of gears for scores,
plates are internally splined) for burrs, embed-
scratches, and burrs. Remove such defects with
ded metal particles, severely pitted faces, loose
a soft stone. If scratches and scores cannot be
faces, excessive wear, cone, cracks, distortion,
removed with a soft stone, replace the gear.
shallow oil groove depth, or damaged spline
4. Inspect gears for load pattern and signs of dis- teeth. Remove burrs using a soft honing stone.
tress. Any sign of distress indicates that a gear Replace plates which have any defects.
failure during operation is possible. Reusing
distressed gears is an individual customer deci- 2. Inspect steel plates (C1 clutch plates are inter-
sion based on experience. Backlash cannot be nally splined; all other clutch plates are exter-
used to establish critical gear wear. Backlash nally tanged) for burrs, scoring, excessive
tolerances are of such nature that a gear usually wear, excessive cone, distortion, imbedded
pits, scuffs, scores, or galls long before gear metal, galling, cracks, breaks, or damaged
wear becomes critical. tangs. Remove burrs and minor surface irregu-
larities using a soft stone. Replace plates which
j. Inspecting Splined Parts have any defects.
1. Inspect splined parts for stripped, twisted, 3. The amount of clutch plate cone is determined
chipped, or burred splines. Remove burrs with a by measuring the distance between the inside
soft stone. Replace the part if other defects are diameter of the plate and a level surface
found. Spline wear is not considered harmful ex- (Figure 3–2). Discard plates having excessive
cept where it affects the fit of the splined parts. cone (refer to Wear Limits, Section 7).

b. Grease Used for Assembly. During assembly use
oil-soluble grease with a low melting point (petrola-
tum) to temporarily retain parts, butt-joint sealrings,
CLUTCH PLATE
LEVEL SURFACE scarf-cut sealrings, and hook-type sealrings.
c. Sealing Compounds and Nonsoluble Greases.

Do not use gasket-type sealing compounds, fibrous
Measure here for cone greases, or nonsoluble vegetable-base cooking com-
V00493.01 pounds inside the transmission or where they could be
flushed into the transmission hydraulic system.
Figure 3–2. Method of Measuring Clutch Plate Cone d. Clutches and Pistons
4. Determine oil groove depth with a depth 1. Soak each friction-faced clutch plate (two-
micrometer by measuring from the smooth minute minimum) in transmission fluid before
surface to the bottom of the oil groove. final assembly.
Replace plates not having the minimum oil
groove depth (refer to Wear Limits, Section 7). 2. Apply a generous amount of transmission fluid
o. Inspecting Swaged and Interference-Fit Parts. to the piston cavity before final assembly.
If there is evidence of looseness, the assembly should 3. Assemble clutch plates so that the cone of each
be replaced. plate faces the same direction.
p. Inspecting Sealing Surfaces e. Threaded Plugs and Hydraulic Fittings
1. Inspect surfaces in contact with hook-type,
scarf-cut, and butt-joint sealrings for step- CAUTION:
wear, nicks, scratches, and scoring. Use a soft • Do not use Teflon® tape on threaded parts. Sliv-
stone or crocus cloth to remove only the raised ers can cause the transmission to malfunction.
metal portion of these defects. Polishing the • Improperly installed plugs or fittings can
area to remove a defect is neither necessary nor cause leakage and cracked housings.
desirable. If the defects are too severe to cor-
rect, replace the defective part.
Tighten all pipe plugs to the specified torque in the as-
2. Inspect surfaces in contact with spring-loaded, sembly procedure and on the exploded views. Tighten
lip-type seals for nicks, scratches, roughness, other fittings sufficiently to prevent leakage.
or other surface irregularities. Inspect for em-
bedded particles, step-wear, and dirt on flanges f. Lip-Type Seals
or other components exposed to external con- 1. When replacing lip-type seals, make sure the
tamination. Remove the defects and restore the spring-loaded lip is toward the fluid to be
finish. Replace the part if scores or scratches sealed (toward the inside of the unit). Coat the
permit fluid leakage. inside of the seal with petrolatum to protect the
seal during shaft installation and to provide lu-
brication during initial operation.
3–6. ASSEMBLY PROCEDURES
2. The circumference of some seals is precoated
a. Parts Lubrication. During final assembly, with a dry sealant. The sealant is usually col-
lubricate all moving parts with transmission fluid. The ored for easy identification. Precoated seals do
fluid will help protect friction surfaces and ferrous not require any additional sealant before instal-
metals until the unit is in service. lation.

g. Butt-Joint Sealrings i. Electrical Components. For inspection and
repair of electrical components, refer to the Allison
CAUTION: Transmission 1000/2000/2400 Series Troubleshooting
Manual TS3192EN.
If humidity is allowed to penetrate and expand a
butt-joint sealring, the sealring can be damaged
during installation. A damaged sealring will leak 3–7. REMOVING (OR INSTALLING)
fluid from the clutch piston cavity and cause TRANSMISSION
clutch slippage. Do not open the sealed package
until you are ready to install the sealring.
WARNING!
1. Butt-joint sealrings require special handling Avoid contact with the hot fluid or the sump
during assembly. The sealrings contain materi- when draining transmission fluid. Direct contact
als that absorb moisture from the atmosphere with the hot fluid or the hot sump may result in
causing the sealring to expand. The sealrings bodily injury.
are shipped in airtight packages. Do not open
the sealed package until the butt-joint sealring
is ready to be installed into the transmission. CAUTION:
Check sealring end clearance before installa- Whenever a transmission is overhauled,
tion to make sure the sealring has not ex- exchanged, or has undergone repairs, the
panded. Transmission Control Module (TCM) must be
“RESET TO UNADAPTED SHIFTS.” This will
2. Remove the sealring from its package and cause the TCM to erase previous adaptive
place it in its operational position inside the information and begin to adapt in Fast Adaptive
bore that it will be sealing. Mode from the base calibration. Use Allison
DOC™ to reset the TCM to fast adaptive mode.
Refer to the appropriate user guide for “Reset To
3. Using a feeler gauge, check the end clearance
Fast Adaptive” instructions.
of the sealring. The end clearance must be
greater than 0.38 mm (0.015 inch).
a. Draining Transmission
4. If the end clearance is less than minimum specifi- Drain the transmission fluid before removing the
cations, bake the sealring in an oven at 93–149°C transmission from the vehicle.
(200–300°F) for 24 hours or get a new seal-
ring. Repeat Steps (2) and (3). • Remove the drain plug from the oil pan. Examine
the drained fluid for evidence of contamination
5. Pack the sealring and its groove with a liberal (refer to Paragraph 2–8). Reinstall the drain plug.
amount of oil-soluble grease.
• Remove the transmission fill tube if it interferes
with transmission removal. Plug the fill tube hole
6. Roll up the sealring to about half its free diam-
in the main housing to keep dirt from entering the
eter and hold it for about 10 seconds. Being
transmission.
careful not to spread the sealring more than
necessary, slide it onto the hub. Place one end
of the sealring into the groove and gradually NOTE:
work the seal into the groove.
A significant amount of fluid may drain from the
hydraulic lines when they are disconnected from the
h. Bearings. If a bearing must be removed or transmission.
installed without an installation sleeve, drive or press
only on the race which is adjacent to the mounting
surface. If a press is not available, carefully seat the • Disconnect all hydraulic lines from the
bearing with a drift and a hammer, driving against the transmission. Remove the lines from the vehicle
supported race. if they interfere with transmission removal. Plug

all openings to keep dirt from entering the • Securely support the transmission with a hoist,
hydraulic system. jack, or other suitable removal equipment.
b. Disconnecting Controls • Remove all bolts, nuts, washers, spacers, and

supports that attach the transmission to the
• Disconnect the external wiring harness from vehicle and the engine.
the main electrical connector, three speed
sensors and the NSBU switch. Prevent dirt or
moisture from entering a disconnected NOTE:
connector. Position the wiring harness so it It may be necessary to remove an engine flywheel
does not interfere with transmission removal. housing access cover to remove flexplate or
flexplate adapter bolts. This is the engine to
• Disconnect linkage from the customer- transmission connection.
furnished transmission shift lever. Position the
disconnected linkage so it does not interfere
with transmission removal. Leave the shift d. Removing The Transmission
lever and NSBU switch on the transmission.
CAUTION:
• If PTO(s) is (are) used, disconnect the PTO(s)
Do not pull the transmission away from the
wiring harness(es).
torque converter assembly. The torque converter
• If a parking brake is present, disconnect drive cover must be entirely free of any restraint
by the flexplate drive or crankshaft pilot when
linkage.
the transmission separates from the engine.
c. Uncoupling From Driveline,
Engine, And Vehicle WARNING!
Be sure the torque converter is moving rearward
WARNING! with the transmission as it is removed. Do not
Chock wheels to prevent vehicle from moving allow the torque converter to become disengaged
when driveline is disconnected. This is not from the oil pump or to fall and injure yourself or
necessary if all wheels are off the ground. others.
• Move the transmission away from the engine,

• Disconnect the vehicle drive shaft from the
approximately 34.6 mm (1.36 inch) for a
transmission output flange or yoke. Position
number 2 flywheel housing or 44.2 mm
the disconnected shaft to avoid interference
(1.74 inch) for a number 3 flywheel housing,
when removing the transmission.
until it is completely clear of the engine. If
• If PTO equipped, disconnect PTO connections used, remove the adapter ring and/or gasket.
such as: • Raise or lower the transmission as necessary
— PTO hydraulic hoses to remove it from the vehicle.
— PTO-powered equipment drive shaft e. Transmission Installation
• If transmission mountings support the rear of

CAUTION:
the engine, place a jack or other support under
the engine. To avoid damage to the NSBU switch, make sure
the transmission jack safety strap or chain does
not bear on the NSBU switch.
CAUTION:
To avoid damage to the NSBU switch, make sure 1. Use a transmission jack to raise the
the transmission jack safety strap or chain does transmission into mounting position. Mount
not bear on the NSBU switch. the transmission.

2. Make all connections from vehicle to transmis- 3–9. SPRING SPECIFICATIONS
sion.
Refer to Spring Data Table 7–2 for spring identifica-
3. Verify all mechanical and electrical connection and specifications.
tions.
4. Fill the transmission with transmission fluid 3–10. TORQUE SPECIFICATIONS

(Paragraphs 2–4 through 2–9) and road test Assembly procedures in Sections 5 and 6 specify the
after installation. torque requirements for all plugs, bolts, and nuts.
Torque values are also presented with the foldout illus-
3–8. WEAR LIMITS trations in the back of this manual. Torque values spec-
ified are for dry assembly, except when otherwise
Refer to Wear Limits Data Table 7–1, for information noted. Bolts and washers should be washed and dried
covering parts fits, clearances, and wear limits. before assembly.

SECTION 4 — TRANSMISSION DISASSEMBLY
4–1. INSTALLATION OF
TRANSMISSION INTO
REPAIR STAND
Tools Required
• J 44723 Transmission/Stand Adapter Plate

• J 29109 Repair Stand
WARNING!
The torque converter must be held to the torque
converter housing by a retaining device such as
shipping brackets. Without the retaining device,
the torque converter may slide forward,
disengaging the oil pump, or may fall completely
out of the transmission causing personal injury
and/or property damage.
WARNING!
The 1000/2000/2400 Series transmission dry
weights are approximately 150 kg (330 lb). To
help avoid personal injury and/or property
damage:
• Use caution when installing, removing, or
moving the transmission.
• Get help when lifting the transmission. Assis-
tance from a hoist or another person may be
required.
• Make sure that the lifting equipment can prop-
erly support the transmission.
1. Position the transmission on the work table so

that the oil pan is facing down. 3
1 2
2. If present, remove the PTO(s).
3. If present, remove twelve PTO cover bolts (3).
4. If present, remove two PTO covers (2).
NOTE:
PTO Cover Gasket (2) has been redesigned. The 1
former and current designs are interchangeable. 2
The former design may be reused unless 3
replacement is necessary or the design is no longer
available. DO NOT use a PTO cover gasket to
mount a PTO.
V07702.02.00
5. If present, remove two PTO gaskets (1).

6. Install adapter plate J 44723 (2) onto repair

1 stand J 29109 (1).
D2
7. Attach a sling to the transmission (2).

8. Attach a hoist to the sling. Raise the
1 transmission to adapter plate J 44723 (1).
2
WARNING!
If the transmission is not secured properly to the
adapter plate, it could fall. To help avoid
personal injury and/or property damage:
• Use at least 5 bolts to support the transmission.
• Use M10 x 1.5 bolts with 19-25 mm (3⁄4-1 inch)
thread engagement. If the proper bolt is not
used, the PTO bolt holes may be damaged.
9. Secure transmission (2) to the adapter plate

J 44723 (1) using the PTO mounting pad as the
attachment point.
V08141.01.00
10. Remove the sling from the transmission.
1 2 4–2. INPUT SPEED SENSOR

REMOVAL (IF PRESENT)
3
1. Position the main housing so that the oil pan is
facing down.
2. If present, remove sensor shipping cover (4).
4 3. Remove bolt (1) that holds speed sensor (2) to
the converter housing.
4. Remove speed sensor (2).
5. Remove O-ring (3) from the speed sensor.
D4b

TRANSMISSION DISASSEMBLY
4–3. TURBINE SPEED

SENSOR REMOVAL 1
2
1. If present, remove sensor shipping cover (4).
3
2. Remove bolt (1) that holds speed sensor (2) to
the main housing.
4
D4a
4–4. OUTPUT SPEED

SENSOR REMOVAL
1
(2WD TRANSMISSIONS ONLY)
2
1. If present, remove sensor shipping cover (4). 3
2. Remove bolt (1) that holds speed sensor (2) to

the rear cover.
4 D4
4–5. NSBU SWITCH REMOVAL

(IF PRESENT)
1. With a wrench keeping selector lever (1) from
rotating, turn nut (3) counter-clockwise and
remove from the selector shaft (2).
2. Inspect the selector shaft for a shoulder or a
burr. Remove any shoulder or burr with a file
before removing the NSBU switch.
3. Remove the selector lever from the selector
®
shaft.
6 5
4 3 2
1
V08085.00.00

4. Remove front splash shield (4) from the

selector shaft.
5. Inspect selector shaft (3) for burrs or a
shoulder. Remove burr or shoulder with a file.
6. Remove two bolts (2).
7. Remove NSBU switch (1) from the main
housing and selector shaft.
1
3
2
4
2 V07746.02.00
4–6. VENT REMOVAL

1. Gently pry on the shoulder below the cap and
1
remove vent (1).
V07744.00.00

4–7. TORQUE CONVERTER

REMOVAL 1
1
WARNING! 2
2
The 1000/2000/2400 Series torque converter dry
weights are approximately 29 kg (63 lb). To help
moving the torque converter.
• Get help when lifting the torque converter. As- 1
sistance from a hoist or another person may be
required. 1
• Make sure that the lifting equipment can prop-
erly support the torque converter.
D9
1. Position the transmission so that the front of
the converter housing is facing up.
2. If present, remove four bolts (1) and two
shipping brackets (2).
3. If present, remove one bolt (2), two nuts (4), 1

2
two bolts (1), and shipping bracket (3).
1 3
D9a

4. Attach a sling to torque converter (1).

5. Attach a hoist to the sling and raise torque
converter (1) from converter housing (2).
1 6. Place torque converter (1) on the work table.
Remove the sling.

SUPPORT MODULE REMOVAL
2
WARNING!
The 1000/2000/2400 Series converter housing/
front support module dry weights are
approximately 27 kg (60 lb). To help avoid
D9b
moving the converter housing/front support
module.
• Get help when lifting the converter housing/
front support module. Assistance from a hoist
or another person may be required.
Make sure that the lifting equipment can
properly support the converter housing/front
support module.
CAUTION:
The bolts used to install the torque converter
housing and rear cover to the main housing are
similar in size and color. The rear cover bolts are,
however, shorter than the torque converter
housing bolts. Installing torque converter
housing bolts into the rear cover may damage the
main housing. To help avoid torque converter
housing bolts from being installed into the rear
cover and vice versa, store the bolts separately.
These bolts must be installed into their correct
locations to help avoid main housing damage.
1 1
1 1. For SAE No. 2 or No. 3 torque converter
1
housings, remove the following.
1 1
• 15 bolts (1)
1 1 • 5 bolts (2)
1
1
1 1
2
1
2 2 2 2 1
1
D10

2. For direct mount torque converter housings,

remove the following.
• 18 bolts (1)
• 1 bolt (2) 1 1
1 1
• 1 bolt (3)
1 1
1 1
1
1
1 1
1 1 1 1 2
1
1
3
D10a
3. Attach a sling to converter housing (1).

4. Attach a hoist to the sling. 1
5. Remove converter housing/front support

module (1) from main housing (4) and turbine
shaft (2).
6. Place the converter housing/front support
module on the work table. 2
7. Remove the sling.
3
8. Remove and discard main housing/separator
plate gasket (3).
4
D12
4–9. ROTATING CLUTCH

ASSEMBLY REMOVAL
1. Remove rotating clutch module (1). 1
D17a

NOTE:
The thrust bearing assembly may be attached to the
rotating clutch module or the P1 planetary module.
1
2. Remove thrust bearing assembly (1) from
rotating clutch assembly or P1 planetary
module.
V07725.00.00.eps
1 4–10. OIL PAN AND SUCTION

7 2 FILTER REMOVAL
1. Position the main housing so that the oil pan is
3
facing up.
4 2. Remove drain plug (1).
3. Remove drain plug seal (2) from drain
plug (1).
5 4. Remove twelve oil pan bolts (7).

5. Remove oil pan (3).
6 6. Remove oil pan gasket (4).
7. Remove suction filter (5).
8. Remove suction filter seal (6).
V07773.01.00
9. Inspect and clean magnet (1) in oil pan (2).
1 2
V07726.00.00.eps

4–11. WIRING HARNESS

ASSEMBLY REMOVAL
1. If present, remove connector shipping
cover (1).
V07819.02.00
2. Using a 30–32 mm (13⁄16 inch) deepwell socket

or box end wrench, depress the four tabs on
internal wiring harness connector (1).
3. With the tabs depressed, gently pop the
connector into and through main housing (2)
with the palm of the hand.
V07820.02.00
4. Disconnect internal wiring harness (2) from

1
the following components.
2
• A trim solenoid (8)
• B trim solenoid (6) 11
• E ON/OFF shift solenoid (5)

• D ON/OFF shift solenoid (4) 10
• F trim solenoid (3)
• C ON/OFF shift solenoid (7)
• Pressure switch assembly (9)
• The G ON/OFF modulated main solenoid (11)
5. Remove solenoid retainers (1) from
solenoids (4) and (5). 9 3
4
6. Remove internal wiring harness (2) from main 5
6
valve body (10). 8
7 V07821.01.00
7. Install solenoid retainers (1).

4–12. CONTROL VALVE

1 1 ASSEMBLY REMOVAL
4 2 1. Remove two detent spring bolts (1).
2. Remove detent spring assembly (2).
V08120.00.00
3. Remove 15 control valve assembly bolts (1).
2
1
2
1 1
1 1
1 1
1
1
1 1
1
V08121.00.00
NOTE:
Installing a lint-free cloth into the park pawl apply
1
assembly guide hole prevents the selector valve pin
2 from falling into the transmission.
4. Install a lint-free cloth (1) in the park pawl

apply assembly guide hole in main
housing (2).
V08122.00.00

CAUTION:
The main selector valve can be easily damaged. 1 2
Do not drop the main selector valve when
removing or installing the control valve assembly
onto or from the main housing.
NOTE:
Putting an index finger over the end of the manual
selector valve hole during the removal of the control
valve module from the main housing is highly rec-
ommended.
5. Lift control valve assembly (2) until two dowel

pins (1) of the control valve assembly are V08123.00.00
disengaged from the main housing.
6. Slide the control valve assembly to the side and

disengage selector valve pin (3) from detent
lever (1).
7. Remove the control valve assembly from the
main housing. 1
2
D23a
8. Remove, as a unit, manual selector valve (2)

and selector valve pin (3) from shift valve
body (1).
9. Remove selector valve pin (3) from manual
selector valve (2).
1
2
3
V08124.00.00

10. Remove the lint free cloth from the park pawl
apply assembly guide hole.
1
2
D21d
4–13. REAR BALL BEARING REMOVAL

1 Tools Required
• J 43910 Output Shaft Bearing Puller Leg Set
• J 24420-B Universal Puller
2 • J 43769 Spanner Nut Wrench—4WD
1. Position the transmission so that the rear of the
transmission is facing up.
2. If present, remove oil seal assembly (1).
R105
20.9° NOTE:
1 The fullest clockwise position of the selector shaft is
P (Park), which engages the park pawl.
3. For 1000 Series™ 4WD transmissions only,

1 use a wrench on selector shaft flats (1) to rotate
2 the selector shaft to its fullest clockwise
D position.
P OD
R N
23.2°
34.3°
45.5°
56.2° 67.0°
77.8°
R63d

4. For 1000 Series™ 4WD transmissions only, do

the following.
• Install J 43769 (1) onto output nut (2).
• Remove output nut (2).
1
V08031.00.00
5. Remove retaining ring (1).

1
A24f
6. Assemble three J 43910 legs with puller

4
J 24420-B.
1
7. Place the foot of each leg between two bearing 2
balls. 3
8. Twist each leg until the foot of the leg is forced
under the bearing races.
9. Adjust center screw (4) and each leg nut (1) until
the body of J 24420-B is perpendicular to the
rear face of the main housing.
10. Tighten center screw (4) until ball bearing
assembly (3) is dislodged.
11. Remove the J tools from the ball bearing

assembly.
R106

12. Remove selective spacer (1).

1
R107
4–14. REAR COMPONENTS REMOVAL

2 3
1 1. If a park brake cable bracket is present, do the
3
following.
2
CAUTION:
3
3
3 however, shorter than the torque converter
3 housing bolts into the rear cover may damage the
3 3 main housing. To help avoid torque converter
housing bolts from being installed into the rear
cover and vice versa, store the bolts separately.
3 3 3 3 3 locations to help avoid main housing damage.
D24f
• Remove three bolts (2).

• Remove bracket (1) from the rear cover.
• Remove thirteen bolts (3).

2. If a park brake cable bracket is not present, do

2 1
the following.
1
CAUTION: 2
housing and rear cover to the main housing are 2 2
however, shorter than the torque converter 2
housing bolts into the rear cover may damage the 2
main housing. To help avoid torque converter
housing bolts from being installed into the rear 2
cover and vice versa, store the bolts separately. 1 2
locations to help avoid main housing damage.
• Remove four bolts (1).
1 2 2 2 2
• Remove twelve bolts (2). V08023.00.00
3. Disengage rear cover module (1) from main

housing dowel pin (4) and pawl support 1
pin (5).
4. Remove rear cover module (1).
5. Remove and discard rear cover gasket (2). 2
WARNING! 4
Always remove or install the P3 planetary

carrier assembly by holding onto the output
D24
shaft. Holding onto the P3 carrier assembly
instead of the output shaft may allow the output
shaft to fall causing personal injury and/or 1
property damage. 3 2
6. Remove, as a unit, output shaft (2) and P3 4

planetary carrier assembly (1).
7. Remove output shaft (2) from P3 planetary
carrier (1).
8. Remove P3 sun gear (4).
NOTE:
The thrust bearing assembly may be attached to the
output shaft or the P3 sun gear.
9. Remove thrust bearing (3) from output

D25
shaft (2) or P3 sun gear (4).

4–15. PARK PAWL REMOVAL

1 1. For transmissions with park pawls, do the
2 following.
• Disengage pawl return spring (2) from main
4 housing (4).
• Remove, as a unit, park pawl (1) and pawl
return spring (2) from pawl support pin (3).
• Remove the pawl return spring from the
3 park pawl.
D26
2. Remove pawl support pin (2) from the main

1 housing.
3. If present, remove apply assembly guide (3).
2
3 4. Remove C5 piston return spring assembly (1).
D27

MAIN SHAFT REMOVAL
1
3 1. Remove, as a unit, main shaft (3), P2 sun
gear (2), and sun gear spacer (1).
2
2. Remove sun gear spacer (1) and P2 sun
gear (2) from the main shaft.
D28

3. Remove P2 planetary module (2).

1
NOTE:
The thrust bearing assembly may be attached to P2
planetary module or the P2 sun gear. 2
4. Remove thrust bearing assembly (1) from P2

planetary module (2) or the P2 sun gear.
D29
4–17. C5 CLUTCH REMOVAL

1
1. Remove selective reaction plate (1).
2. Remove six C5 clutch friction plates (2) and
2
five C5 clutch reaction plates (3).
3
3. Remove C5 clutch backplate (4).
D30

1
1. Remove P1 planetary module (2).
NOTE:
The thrust bearing assembly may be attached to the 2
P1 planetary module or the P2 planetary module.
2. Remove thrust bearing assembly (1) from P1

planetary module (2) or the P2 planetary
module.
D31

1
2 Tools Required
3
• J 24204-2 Bar and Stud Assembly
4
5 • J 44530 C3/C4 Piston Spring Compressor
CAUTION:
DO NOT install special tools (J tools) onto the
6 gear thrust plate rivets of the C3 clutch
6 backplate assembly. The special tools could
damage the gear thrust plate rivets.
1. Install J 24204-2 (1) and J 44530 (2) into the

main housing. Make sure that J 24204-2 does
D32 not touch gear thrust plate rivets (6) on the C3
clutch backplate assembly.
2. Compress piston return spring assemblies (5)
until a gap is visible below retaining rings (3)
and (4).
4. Remove spiral retaining ring (4).
5. Remove J 24204-2 (1) and J 44530 (2) from
the main housing.
6. Remove C4 clutch backplate (1).

1
D33a

7. Remove five C4 clutch friction plates (1) and

four C4 clutch reaction plates (2).
8. Remove, as a unit, C4 spring plate (4) and 3
three piston return spring assemblies (3).
1
4 2
D33
NOTE: 1
The piston return spring assemblies snap off.
1 2
9. Remove three piston return spring assemblies (1)

from C4 spring plate (2).
D34
10. Remove P1 ring gear (1).
D35

4–20. C4 CLUTCH PISTON

ASSEMBLY REMOVAL
NOTE:
The preferred method of dislodging the C4 clutch pis-
1 ton is with compressed air. If compressed air is not
available, remove the C4 clutch piston assembly using
pliers. If compressed air is used, note the following.
• Use a 3⁄8 inch rubber hose on the air connection
to reach into the C4 clutch annulus port.
• When shooting air into the annulus port, make
sure that the rubber hose covers both of the C4
clutch annulus port holes.
D39a 1. Position the air connection rubber hose so that

the hose covers both C4 clutch annulus
holes (1).
2. Shoot air into the C4 clutch annulus port until

C4 clutch piston assembly (1) is dislodged.
3. Remove C4 clutch piston assembly (1).
1
D35a


1
Tools Required
2
3
• J 44530 C3/C4 Piston Spring Compressor
4
1. Position the main housing so that the front of 5
the main housing is facing up.
CAUTION:
gear thrust plate rivets of the C3 clutch
backplate assembly. The special tools could
D36
main housing. Make sure that J 44530 does not
touch gear thrust plate rivets (3) on the C3
2. Compress piston return spring assemblies (5)
until a gap is visible below retaining ring (4).
4. Remove J 24204-2 and J 44530 from the main
housing.
5. Remove C3 clutch backplate assembly (1).

1
D37a

6. Remove four C3 clutch friction plates (1) and

3 three C3 clutch reaction plates (2).
1
2 7. Remove, as a unit, C3 spring plate (4) and
three piston return spring assemblies (3).
D37
1 NOTE:
The piston return spring assemblies snap off.
1 2
8. Remove three piston return spring

assemblies (1) from C3 spring plate (2).
D38

4–22. C3 CLUTCH PISTON

ASSEMBLY REMOVAL
NOTE:
The preferred method of dislodging the C3 clutch pis-
ton is with compressed air. If compressed air is not
available, remove the C3 clutch piston assembly using
pliers. If compressed air is used, note the following. 1
• Use a 3⁄8 inch rubber hose on the air connection
to reach into the C3 clutch annulus port.
• When shooting air into the annulus port, make
sure that the rubber hose covers both of the C3
clutch annulus port holes.
D39b
1. Position the air connection rubber hose so that
the hose covers both C3 clutch annulus
holes (1).
2. Shoot air into the C3 clutch annulus port until

C3 clutch piston assembly (1) is dislodged.
1
3. Remove C3 clutch piston assembly (1).
D39

NOTES

SECTION 5 — MODULE REBUILD

1
ASSEMBLY
CAUTION:
Allison Transmission Division GM recommends
using only genuine Allison torque converters
with 1000/2000/2400 Series Allison transmis-
sions. Any transmission damage that may occur
as a result of using a converter other than a new
Allison converter or a genuine Allison replace-
ment is the responsibility of the owner and will
not be covered by Allison warranty.
a. Preliminary Inspection
R0
1. Remove the transmission fluid from torque
converter (1).
2. Examine the transmission fluid for the
following.
• Evidence of foreign matter
• Metal particles
3. If the torque converter is damaged, replace the
torque converter.
b. End Play Check
Tools Required 1
• J 43764 Torque Converter End Play Gauge 7 6

• J 5959-1 Dial Indicator
2
• J 5959-3 Rod 1⁄4 x 101⁄2 inches 5
3
• J 5959-7 Lug Attachment 4
• J 7872-2 Magnetic Clamp

• J 7872-3 Swivel Adapter
1. Position torque converter (3) on the work table
so that the pump hub is facing up.
2. Install J 43764 (2) into the torque converter
hub. V07740.00.00.eps
3. While holding J 43764 (2) in the converter

hub, rotate the center screw until J 43764 is
locked into the converter hub. Do not over
tighten J 43764.

4. Assemble the following tools and install the

tools onto the torque converter as shown.
1
• J 5959-1 (1)
7 6 • J 5959-3 (7)
• J 5959-7 (6)
2
5 • J 7872-2 (4)
3
4 • J 7872-3 (5)
5. Adjust J 5959-7 (6) so that J 5959-1 (1) firmly
contacts the top of J 43764 (2).
6. Set J 5959-1 (1) to read zero. Lift J 43764 (2)
up as far as possible.
7. Read J 5959-1 (1) (torque converter end play).
V07740.00.00.eps
8. Compare the measured end play with the
allowable end play.
Table 5–1. Allowable Torque Converter End Play
Converter Max End Play

New 0.762 mm (0.0300 inch)
Used 1.015 mm (0.0400 inch)
9. If the measured torque converter end play

exceeds the value listed in Table 5–1, replace
the torque converter.
10. Remove the J tools from the converter housing.
c. Leak Test
1
Tools Required
2
3
• J 43763 Torque Converter Leak Test Plug
4 • J 21369-F Torque Convert Leak Test Fixture
5
6
NOTE:
The torque converter leak test requires a large
container of water in order to submerge the torque
converter.
1. Position torque converter (6) on the work table

so that the pump hub is facing up.
2. Move nut (3) to the middle of the center
V07741.00.00.eps
body (1) of J 43763.
3. Install J 43763 into the torque converter hub.

MODULE REBUILD
4. Install torque converter (8) with J 43763 (1)

2
into J 21369-F (3). 1 3
5. Firmly tighten nut (6) in order to seal J 43763
into the torque converter.
4
6. Firmly tighten nut (5) in order to securely 5
attach the torque converter to J 21369-F (3). 6
7
7. Connect an air hose to air fitting (1) of J 43763.
8
8. Pressurize the converter to 517 kPa (75 psi)
maximum. Disconnect the air hose.
9. Submerge the torque converter in water.
10. Closely observe the torque converter for
bubbles that indicate leakage. If the torque
converter leaks, replace the torque converter.
R2a
WARNING!
All pressure from the torque converter must be
exhausted before loosening the test fixture nut.
Failure to relieve the pressure could cause
personal injury and/or property damage.
11. Push on pressure relief valve (2) of J 43763

and release the air from the torque converter.
12. Remove the J tools from the torque converter.
d. Inspection of Torque Converter
1
NOTE:
Replace the torque converter if it does not meet
specifications.
1. Measure the OD of torque converter hub (1) in

the bushing wear area (Dimension A).
Dimension A must equal or exceed 58.250 mm
(2.2933 inch).
R3

2. Measure the distance between the flats of the

1 torque converter hub (Dimension A).
Dimension A must equal or exceed 51.816 mm
(2.040 inch).
R3a
3. Measure the OD of the torque converter cover

1 pilot (Dimension A). Dimension A must equal
or exceed 43.080 mm (1.696 inch).
R4

MODULE REBUILD
5–2. ELECTRONIC COMPONENT

INSPECTION
1. Perform the following steps for the input,
turbine, and output speed sensors.
• Replace speed sensor (1) if the speed sensor
shows signs of cracking and/or oil leakage.
• Replace the speed sensor if the attachment
bracket is bent or damaged or the speed
sensor is loose in its bore.
60°
• Make sure the speed sensor connection is
oriented as shown.
• Measure the resistance of the speed sensor.
If the resistance does not meet the following
specifications, replace the speed sensor. R4a
Ambient Temperature Resistance

(ºC) (ºF) (Ohms)
0 32 2157–2637
25 77 2340–2860
50 122 2614–3195
2. Measure the resistance of A trim and B trim

solenoids (1). If the resistance does not meet the
following specifications, replace the solenoid. 1
Sump Temperature Resistance

(ºC) (ºF) (Ohms)
0 32 4.5
20 68 5.5
40 104 6.5
R4b

3. Measure the resistance of C, D, G, and E ON/

1 OFF shift solenoids (1). If the resistance does
not meet the following specifications, replace
the solenoid.

(ºC) (ºF) (Ohms)
0 32 20.0
20 68 22.0
40 104 24.5
4. Measure the resistance of F trim solenoid (1).

If the resistance does not meet the following
specifications, replace the solenoid.

R4c
(ºC) (ºF) (Ohms)
0 32 9.5
20 68 10.5
40 104 11.5

SUPPORT MODULE
1
DISASSEMBLY
1. Position converter housing/front support
module (2) on the work table so that the torque
2 converter housing is facing up.
2. Remove oil seal assembly (1).
D10c

MODULE REBUILD
3. Remove 10 bolts (1).
1 1
1 1
1
1
1
1
1
1
V07728.00.00.eps
4. Remove seals (2) from bolts (1).

1
V07727.00.00.eps
CAUTION:
Do not damage the separator plate when
separating the torque converter housing from the
front support module.
1
5. Remove converter housing (1) from front
support module (3).
2
NOTE:
Separator Plate Gasket (2) has been redesigned. The 3
former and current designs are interchangeable. The
former design may be reused unless replacement is 4
necessary or the design is no longer available.
5
6. Remove converter housing/separator plate
gasket (2) from separator plate (4). D14

7. Remove two butt joint sealrings (1 and 2) from

1 ground sleeve (3).
8. Remove three butt joint sealrings (6) from the
2
rear hub of the front support assembly.
9. Remove thrust washer (5).
3
D15
10. Remove five bolts (4) retaining main pump

1 assembly (1) to front support assembly (3).
CAUTION:
Do not damage the separator plate when
2 separating the front support assembly, separator
plate, and main pump assembly.
11. Separate front support assembly (3), separator

plate (2), and main pump assembly (1).
3
D16

MODULE REBUILD

HOUSING (WITHOUT
COOLER MANIFOLD)
a. Disassembly 1
Tools Required
• J 45023 Control Main Filter Wrench
8 6
1. Remove pressure tap plug (7).
5 2
2. Remove O-ring (6) from pressure tap plug (7). 9 7 3
3. Using J 45023 (11) or a filter strap wrench, 4
10
remove control main filter (10).
4. Remove magnet (9) from filter attachment 11
tube (8) or from filter (10). R5
5. Remove filter attachment tube (8).

6. If present, remove two hydraulic connector
assemblies (4). Remove O-rings (5) from the
connector assemblies.
7. If present, remove two shipping plugs (3).
Remove O-rings (2) from the shipping plugs.

b. Assembly
Tools Required
1
CAUTION:
Install the short-threaded end of the filter
attachment tube into the converter housing. If
8 6 the long-threaded end of the filter attachment
5 2 tube is installed, the threads of the converter
9 7 3 housing will be damaged.
4
10 1. Install filter attachment tube (8) by hand.
Tighten the tube to 25–35 N·m (18–26 lb ft).
11
2. Install magnet (9) onto the filter attachment
R5
tube.
3. Lubricate gasket on control main filter (10)
with transmission fluid.
4. Install the control main filter by hand until the
gasket on the control main filter touches the
converter housing.
CAUTION:
Turning the control main filter more than ONE
FULL TURN after gasket contact will damage
the filter.
5. Using J 45023 (11) or by hand, turn the filter

ONE FULL TURN ONLY.
6. Install O-ring (6) onto pressure tap plug (7).
Install the plug. Tighten the plug to 10–13 N·m
(7–10 lb ft).
7. If present, install O-rings (5) onto hydraulic
connector assemblies (4). Install two hydraulic
connector assemblies (4). Tighten the connector
assemblies to 20–30 N·m (15–22 lb ft).
8. If present, install O-rings (2) onto two shipping
plugs (3).
9. Install plugs (3). Tighten the plugs to 2.5–3.5 N·m
(2–3 lb ft).

MODULE REBUILD
5–5. TORQUE CONVERTER HOUSING

1
(DIRECT MOUNT; WITHOUT
3 2
COOLER MANIFOLD)
a. Disassembly
Tools Required
• J 45023 Control Main Filter Wrench R0X
1. Remove pressure tap plug (5). Remove
O-ring (4) from the pressure tap plug. 10
4
2. Using J 45023 (9) or a filter strap wrench, 6
5
remove control main filter (8). 7
8
3. Remove magnet (7) from filter attachment
tube (6) or from filter (8). 9
R5a
4. Remove filter attachment tube (6).
5. Remove bolt access cover (10).
6. If present, remove two hydraulic connector
assemblies (2). Remove O-rings (3) from the
connector assemblies.
b. Assembly
Tools Required
CAUTION:
the long-threaded end of the filter attachment
tube is installed, the threads of the converter
housing will be damaged.
1. Install filter attachment tube (6) by hand.

Tighten the tube to 25–35 N·m (18–26 lb ft). 1
2. Install magnet (7) onto the filter attachment 3 2

tube.
3. Lubricate the gasket on control main filter (8)
4. Install the control main filter by hand until the
R0X
converter housing.
10
CAUTION:
4
6
Turning the control main filter more than ONE 5
7
8
the filter.
5. Using J 45023 (9) or by hand, turn the filter 9

R5a
ONE FULL TURN ONLY.


1
7. Install plug (5). Tighten the plug to 10–13 N·m
3 2 (7–10 lb ft).
8. Install bolt access cover (10).
9. If present, install O-rings (3) onto hydraulic
connector assemblies (2). Install two hydraulic
connector assemblies (2). Tighten the connector
assemblies to 20–30 N·m (15–22 lb ft).
R0X
10
4
6
5
7
8
9
R5a
5–6. TORQUE CONVERTER HOUSING

(WITH COOLER MANIFOLD)
a. Disassembly
Tools Required
1. Remove pressure tap plug (4). Remove

O-ring (3) from the pressure tap plug.
2. Using J 45023 (10) or a filter strap wrench,
5 remove control main filter (7).
3 9
6 4 3. Remove magnet (6) from filter attachment
tube (5) or from filter (7).
7 1 4. Remove filter attachment tube (5).
2 8 5. If present, remove two shipping plugs (2).
10 Remove O-rings (1) from the shipping plugs.
V07730.00.00
6. If present, remove two elbow adapters
(90 degree) (8) as follows.
• Mark the orientation of the elbow adapters
on the manifold.
• Loosen the lock nuts on the elbow adapters.
• Remove the elbow adapters from the
manifold.
• Remove O-rings (9) from elbow
adapters (8).

MODULE REBUILD
7. Remove four manifold bolts (2).

8. Remove eight manifold bolts (1).
1 1 1 1 2 2
1 1 1 1 2 2
R7
9. Remove cooler manifold (4), gasket (3),

channel plate (2), and gasket (1).
R9
b. Assembly
Tools Required
• J 45023 Control Main Filter Wrench 1
1. Install gasket (1), channel plate (2), gasket (3),

and cooler manifold (4). 2
R9

2. Install four manifold bolts (2).

3. Install eight manifold bolts (1). Tighten
1 1 1 1 2 2
bolts (1) and (2) to 24–29 N·m (18–21 lb ft).
1 1 1 1 2 2
R7
CAUTION:
the long-threaded end of the filter attachment
tube is installed, the threads of the converter
housing will be damaged.
4. Install filter attachment tube (5) by hand.

5 3 9
Tighten the tube to 24–29 N·m (18–21 lb ft).
6 4
5. Install magnet (6) onto the filter attachment
tube.
7 1
6. Lubricate the gasket on control main filter (7)
2 8
10
R6 7. Install the control main filter by hand until the
converter housing.
CAUTION:
Turning the control main filter more than ONE
the filter.
8. Using J 45023 (10) or by hand, turn the filter

ONE FULL TURN ONLY.
10. Install plug (4). Tighten the plug to 10–13 N·m
(7–10 lb ft).

MODULE REBUILD
11. If present, install O-rings (1) onto two shipping

plugs (2). Install the shipping plugs. Tighten
the plugs to 2.5–3.5 N·m (2–3 lb ft).
12. If present, install two elbow adapters

(90 degree) (8) as follows.
• Install O-rings (9) onto elbow adapters (8).
• Install the elbow adapters so that they align
with the orientation marks made on the 5 3 9
manifold. 6 4
• Tighten the elbow adapters to 20–30 N·m
(15–22 lb ft). 1
7
2 8
10
R6
5–7. MAIN PUMP ASSEMBLY

1
a. Main Pump Disassembly
NOTE: 2
The Main Pump Assembly and Wear Plate have
been redesigned. The former and current designs
3
are interchangeable. The former design may be re-
used unless replacement is indicated by wear mea- 4
surements or the design is no longer available. 5
5
6
1. Remove wear plate (1).
NOTE: V07777.00.00.eps
The main pump drive gear and driven gear have a
punch mark on one side. Before the gears are
removed from the main pump, the presence or
absence of the punch marks on the gears must be
noted so that the gears can be reinstalled in their
original orientation.
2. Note the presence or absence of punch marks

on the drive gear and driven gear. If punch
marks are absent, move the drive and driven
gears for re-alignment.
3. Remove drive gear (2) and driven gear (3) from
main pump body (4).
4. Remove O-ring (6).

b. Main Pump Inspection
A NOTE:
1 • Make the measurements described below at sev-
eral locations.
• Replace the main pump body, driven gear, and
drive gear if any of the following specifications
are not met.
1. Measure the depth of the main pump body gear

cavity (Dimension A). The maximum depth of
the gear cavity is 24.940 mm (0.9819 inch).
V07774.00.00
2. Measure the ID of the main pump body gear

cavity (Dimension A). The maximum ID of the
gear cavity is 109.191 mm (4.2989 inch).
1
V07775.00.00.eps
3. Measure the OD of the driven gear (Dimension

A). The minimum OD of the driven gear is
108.987 mm (4.2908 inch).
V07729.00.00.eps

MODULE REBUILD
4. Measure the distance between the flats of the

drive gear (Dimension A). The maximum
distance between the flats is 52.165 mm
(2.0537 inch). 1
V07711.00.00.eps
5. Align the drive gear and driven gear with the

main pump so that their punch marks are in the 1
same position as when they were originally
removed.
6. Install the gears into main pump body (3).
2
V07776.00.00.eps
7. Measure the clearance between driven gear (1)

and main pump body (2) (Driven Gear
Diametral Clearance). The maximum Driven
Gear Diametral Clearance is 0.204 mm
(0.0080 inch).
V07712.00.00.eps

8. Measure the clearance between driven gear (1)

and main pump body crescent (2) (Driven
Gear/Crescent Tooth Clearance). The
maximum Driven Gear/Crescent Tooth
Clearance is 0.455 mm (0.0179 inch).
R17
9. Hold a straight edge across main pump

body (1) and drive gear (3). Measure the
clearance between the drive gear and the
straight edge (Drive Gear Side Clearance). The
maximum Drive Gear Side Clearance is
2 0.066 mm (0.0026 inch).
1
3 10. Hold a straight edge across main pump
body (1) and driven gear (2). Measure the
clearance between the driven gear and the
straight edge (Driven Gear Side Clearance).
The maximum Driven Gear Side Clearance is
0.066 mm (0.0026 inch).
R18
11. Remove drive gear (1) and driven gear (2) from
1
main pump body (3).
V07776.00.00.eps

MODULE REBUILD
c. Main Pump Bushing Replacement

Tools Required
1
• J 43771 Pump Bushing Removal and
Installation Tool 2
• J 8092 Universal Driver
NOTE:
The Main Pump Bushing has been redesigned.
The current bushing can only be used in units with
S/N 6310144856 (Indianapolis) or S/N 6320047965
(Baltimore) and later. Pump Assemblies that can
use the current bushing have casting number
29539582 cast into the pump body. Service the
bushing in pumps not marked with casting number V07713.00.00.eps
29539582 by replacing the pump assembly.
1. Inspect the bushing for damage and wear. The

bushing must not be damaged or worn.
2. Measure the ID of the bushing. The ID of the
pump bushing must not exceed 58.458 mm
(2.3015 inch). The pump bushing must have a
complete burnt-orange Teflon® coating. If any
portion of the Teflon® coating is worn and
bronze material is visible, replace the pump.
3. Remove all gears from pump body (1).
J 43771 PUMP BUSHING
4. Remove the front seal from pump body (1). REMOVAL AND
INSTALLATION TOOL
NOTE:
The preferred method for removing or installing
the bushing is to use tool J 43771 and a press. If a
press is not available, use J 43771 and universal 1
driver J 8092.
2
5. Support pump body (1), machined surface up,
on two wooden blocks so that bushing (2) can
be removed from the back.
6. Install the longer end of J 43771 into the WOOD BLOCKS
bushing.
INSTALLATION V07474.01.01
7. Press, or drive, bushing (2) from pump
body (1).
8. Clean the bushing bore of all residues. Parts
must be dry before installing the bushing.

J 43771 PUMP BUSHING NOTE:

REMOVAL AND
INSTALLATION TOOL The bushing may be oriented in any position, but
the preferred orientation is with the bushing split
2
joint aligned with the casting numbers and the cen-
terline of the boss opposite the numbers. Position
APPLY LOCTITE® the split joint away from the boss.
1
9. Support pump body (1), machined surface
down, on two wooden blocks.
10. Install bushing (2) onto the shorter end of
WOOD BLOCKS
J 43771.
11. Apply Loctite® #620 to the bushing bore.
INSTALLATION V07505.01.01 12. Using J 43771, press or drive the pushing into
the pump body until J 43771 seats.
d. Main Pump Dowel Pin Replacement

1 Tools Required
2
• J 43779 Dowel Pin Installer
NOTE:
Do not replace the main pump dowel pin(s) unless
the dowel pin(s) are damaged.
3
1. Remove dowel pin (2) from main pump
body (3).
CAUTION:
V07745.00.00.eps DO NOT mar the main pump body surface when
installing the dowel pin(s). Tap gently on the
J 43779 dowel pin installer tool. Heavy or
continued hammering on the J 43779 will
damage the main pump body surface.
2. Using J 43779 (1), install dowel pin (2).

3. Make sure the dowel pin is installed to a height
of 10.7–11.3 mm (0.42–0.44 inch) above the
main pump body surface.

MODULE REBUILD
e. Wear Plate Inspection
NOTE:
If any of the following specifications are not met, re-
place the main pump wear plate.
1
1. Inspect wear plate (1) for damage. The wear

plate must not be scored, nicked, or grooved.
2. Measure the thickness of the wear plate in the
gear wear area. The thickness of the wear plate
must not be less than 2.950 mm (0.1161 inch).
V07778.00.00.eps
f. Main Pump Assembly

1
1. Install O-ring (6) onto pump body (4).
2. Position main pump body (4) on the work table
so that the pump body hub is facing down.
3. Lubricate pump drive gear (2) and driven 2
gear (3).
3
CAUTION:
4
When the drive gear and driven gear are 5
installed into the main pump, the gears must be 5
installed in their original orientation by having 6
their punch marks in the same position as when
they were originally removed. Failure to install
the drive and driven gears in their original
orientation may damage the transmission. V07777.00.00.eps
4. Align the drive gear and driven gear with the

main pump so that their punch marks are in the
same position as when they were originally
removed.
5. Install the gears into pump body (4).
6. Align the dowel pin holes in wear plate (1)
with dowel pins (5) in the pump body. Make
sure the bolt holes in pump wear plate (1) align
with the bolt holes on main pump body (4).
7. Install wear plate (1) onto dowel pins (5) and
main pump body (4).

5–8. FRONT SUPPORT ASSEMBLY

a. Front Support Disassembly
Tools Required
2 • J 24459-5 Spring Compressor Adapter

• J 43770 Main, Lube, Converter Relief
1
• J 43773 Valve Spring Compressor
1. Install J 24459-5 (1) onto J 43770 (2).
V07709.00.00.eps
2. Position front support assembly (1) on the

work table so that the rear of the front support
1
assembly is facing down.
3. Align J 43770 (5) and J 24459-5 (4) with the
front support so that:
2 • The threaded rod of J 43770 is facing down.
• Two bolt holes of J 43770 align with the
3 bolt holes of the front support.
4 4. Install J 43770 (5) onto the front support
assembly.
2 5 5. Install two front support retaining bolts (2).
6. Align the slot of J 24459-5 (4) with retainer
pin (3).
V07732.00.00.eps 7. Turn the front support so that pin (3) is
accessible and using J 24459-5 (4) and
J 43770 (5), compress the main regulator valve
spring until retainer pin (3) is loose.
8. Using a pick, push the pin through front
support (1).
9. Turn front support (1) so that the rear is facing
down.
10. Relieve main regulator valve spring tension
and remove the J tools.

MODULE REBUILD
11. Remove stop (3), spring (2), and main

regulator valve (1).
1
2
3
V07779.00.00.eps
12. Using J 43773 (2), compress the C1 clutch

backfill valve spring until retaining clip (1) is
loose. Remove the clip.
1
2
V07780.00.00.eps
13. Remove spring (2) and C1 clutch backfill

valve (1).
1
2
V07781.00.00.eps

14. Align the slot of J 24459-5 (2) with retainer

1
pin (1).
15. Using J 24459-5 (2), compress the lube

regulator valve spring until retainer pin (1) is
loose. Remove the pin.
2
V07798.00.00.eps
16. Remove stop (4), spring (2), and lube regulator

valve (1).
17. Remove O-ring (3) from stop (4).
1 4
2
3
V07797.00.00 .eps
18. Using J 43773 (2), compress the converter

relief valve spring until retaining clip (1) is
1 loose. Remove the clip.
2
V07796.00.00.eps

MODULE REBUILD
19. Remove spring (2) and converter relief

valve (1).
2
1
V07795.00.00.eps
20. Install J 24459-5 (1) onto J 43770 (2).
V07709.00.00.eps


1
• Threaded rod of J 43770 is facing down.
• Two J 43770 bolt holes align with two bolt
holes in the front support.
22. Install J 43770 (5) onto front support
2
assembly (1).
3 23. Install two front support retaining bolts (2).

4 24. Align the slot in J 24459-5 (4) with retainer
2
pin (3).
5 25. Using J 24459-5 (4) and J 43770 (5), compress
the converter flow valve spring until retainer
pin (3) is loose.
R21k
26. Turn the front support so that pin (3) is

accessible using a pick, push the pin through
front support (1).
27. Turn front support (1) so that the rear is facing

down.
28. Relieve converter flow valve spring pressure

and remove the J tools.
29. Remove stop (4), spring (3), and converter flow

valve (2).
4 2
3
V07719.00.00.eps

MODULE REBUILD
b. Ground Sleeve Inspection
NOTE:
• The ground sleeve bushing and bearing are re-
placed with the ground sleeve installed in the
front support.
— Replace the needle bearing if the bearing
is damaged. 1
— Replace the bushing if the bushing is
damaged or the ID specification is not
met.
• The only time the ground sleeve is pressed from
the front support is to replace the ground sleeve.
— The new ground sleeve comes with a
pre-installed bushing.
— Replace the ground sleeve if the ground
sleeve splines or sealring bore R22
specification is not met.

• The bearing must be removed to replace the
ground sleeve. If the ground sleeve and the bear-
ing both need replacing, replace the ground
sleeve first.
• Replace the ground sleeve if it does not meet
specifications.
1. Inspect the splines of ground sleeve (1) for

damage and wear. No visible wear is allowed.
2. Measure the ID of ground sleeve (2) at the

1
turbine shaft sealring bore (Dimension A).
Maximum ID is 45.450 mm (1.7894 inch). B
3. Measure the ID of ground sleeve bushing (1)

(Dimension B). Maximum ID is 33.820 mm
(1.3315 inch). 2
R23

c. Ground Sleeve Replacement

1 Tools Required
• J 43765 Ground Sleeve Installer/Remover

1. Remove the bearing per Paragraph 5–8d.
2. Position front support (2) on a press bed so that
2
it is supported by wooden blocks and the
ground sleeve is facing down.
3. Install the short end of J 43765-2 (1) into the
rear of the front support.
4. Press the ground sleeve from front support (2).
V07710.00.00.eps
5. Position front support (2) on the work table so

that the rear hub is facing down.
6. Align the ground sleeve with the front support
1 so that the sleeve is centered over the front
support and the rear of the sleeve is facing
down.
V07782.00.00.eps
7. Rotate ground sleeve (1) until the lowest (and

smallest) hole in the ground sleeve is aligned
2
1 with fluid passage (2). Arrows indicate the
holes that must align.
8. Gently tap the ground sleeve into the front
support until the front support holds the ground
18° sleeve in a vertical position.
V07783.00.00.eps

MODULE REBUILD
9. Align J 43765-1 (1) so that the lip of the tool is 1

down.
10. Install J 43765-1 (1) onto the ground sleeve.
R26b
11. While holding J 43765-1 (3) in place, turn over

the front support/ground sleeve and place 1
J 43765-1 on a press.
12. Install J 43765-3 (1) into the rear hub of front

support (2).
2
13. Press on J 43765-3 until the ground sleeve
seats.
R26c
14. Check the Total Indicated Runout (TIR) of the

ground sleeve as follows.
C
• Install the OD (D) of front support (1) in a 1
lathe.
• Using a dial indicator, make sure front
support (1) surface (C) is square with the 2
OD (D) of the front support.
• Check the TIR along ground sleeve axis (B) B D
at the ground sleeve pitch diameter (A). The
TIR must not exceed 0.20 mm (0.008 inch). A
15. If the bearing does not need replacing, install
the bearing per Paragraph 8–5d.
R26e

d. Ground Sleeve Needle Bearing Replacement

Tools Required
2
• J 26941 Front Support Needle Bearing
Remover
1 3 • J 8092 Universal Driver
• J 43775 Front Support Needle Bearing
Installer
NOTE:
If the bearing has been removed, skip Steps 1
through 5.
R25
1. Position front support (3) so that it is supported
by wooden blocks and the ground sleeve is
facing down.
2. Install J 26941 (1) into bearing (2) so that the
lips of the tool engage the bottom lip of the
needle bearing race.
3. Tighten the screw of J 26941 finger tight.
4. Install a slide hammer onto the end of J 26941.
5. Remove needle bearing (2).
6. Install the large end of J 43775 (2) onto

J 8092 (1).
3 7. Install a new needle bearing (3) onto J 43775
1
(either side up).
4 8. Drive needle bearing (3) into front support (4)

until J 43775 seats.
9. Make sure the bearing is installed flush to
2
0.25 mm (0.010 inch) below ground sleeve
surface.
R25a

MODULE REBUILD
e. Ground Sleeve Bushing Replacement

Tools Required 1
7
• J 44529 Ground Sleeve Bushing Remover 2
• J 8092 Universal Driver 3

• J 43774 Ground Sleeve Bushing Installer
9
4
8
CAUTION: 10
Always use J 44529 when removing the ground
sleeve bushing to help avoid damage to the
5
ground sleeve sealing surface.
6
1. Position front support (10) so that it is
supported by wooden blocks and the ground
sleeve is facing up. V07742.01.00.eps
2. Install J 44529-2 (8) into J 44529-1 (7).

3. Install J 44529-2 (8) and J 44529-1 (7) into
bushing (9).
4. Install washer (6) and nut (5) onto
J 44529-2 (8).
5. While holding the top of J 44529-2 (8) with a
wrench, tighten nut (5) until J 44529-1 (7)
engages bushing (9).
6. Install J 44529-3 (4) onto J 44529-2 (8).
7. Install bearing (3), washer (2), and nut (1) onto
J 44529-2 (8).
wrench, tighten nut (1) until the bushing is
dislodged.
9. Remove the J tools from the ground sleeve.
10. Remove the bushing from the J tools.

NOTE:
1
The preferred method for installing the ground
3 sleeve bushing is to use J 43774 and a press. If a
press is not available, use J 43774 and J 8092 uni-
versal driver.
11. If the bushing will be installed by hand, install

4
the large end of J 43774 (2) onto J 8092 (1).
2 12. Install new bushing (3) onto J 43774.
13. Drive the bushing into ground sleeve (4) until
the bushing is seated.
14. Make sure the bushing is installed flush to
0.25 mm (0.010 inch) below the ground sleeve
surface.
R27a
f. Front Support Thrust Washer Inspection
1
NOTE:
Replace the thrust washer if any of the following
specifications are not met.
1. Measure the thickness of thrust washer (1)

(Dimension A).
2. Minimum thrust washer thickness is 1.49 mm
(0.059 inches).
A
V07718.00.00.eps
g. Front Support Assembly

Tools Required
1 • J 24459-5 Spring Compressor Adapter

• J 43770 Main, Lube, Converter Relief
work table so that the rear of the assembly is
facing down.
2. Install converter flow valve (2).
4 2 3. Install converter flow valve spring (3) and
3 stop (4).
V07719.00.00.eps

MODULE REBUILD
4. Install J 24459-5 (1) onto J 43770 (2).
V07709.00.00.eps

1
• The threaded rod of J 43770 is facing down.
holes of the front support.
6. Install J 43770 (5) onto the front support
assembly. 2
7. Install two bolts (2).

3
8. Align J 24459-5 (4) slot with the pin (3). 4
9. Using J 24459-5 (4) and J 43770 (5), compress
2
the spring until the stop is past the pin hole.
5
10. Install retainer pin (3). Make sure the pin is
below the front support surface.
R21k
11. Remove the J tools.

12. Install converter relief valve (1).
NOTE:
The Converter Relief valve spring has been rede-
signed. The new valve spring is 44.85 mm
(1.766 inch) in free length and has 12.18 coils. The
new spring is not marked with color striping. Re-
place the former valve spring with the current valve
spring, P/N 29541296. The converter relief valve
spring P/N 29541296 and lube regulator valve
spring P/N 29540523 must be replaced at the same
time. Refer to SIL 29-1K2K-02.
2
1
13. Install converter relief valve spring (2).
V07795.00.00.eps
14. Using J 43773 (2), compress the spring.
1 15. Install retaining clip (1). Make sure the

retaining clip is below the front support
surface.
2
V07796.00.00.eps
16. Install lube regulator valve (1).
NOTE:
The Lube Regulator valve spring has been rede-
signed. The new valve spring is colored light blue, is
31.43 mm (1.237 inch) in free length, and has 6.79
coils. Replace the former valve spring with the cur-
rent valve spring, P/N 29540523. Lube regulator
valve spring P/N 29540523 and converter relief
valve spring P/N 29541296 must be replaced at the
same time. Refer to SIL 29-1K2K-02.
1 4 17. Install lube regulator valve spring (2).

2 18. Install O-ring (3) onto lube regulator stop (4).
3
19. Install the lube regulator stop.
V07797.00.00 .eps

MODULE REBUILD
20. Align J 24459-5 (2) slot with retainer pin (1).

1
21. Using J 24459-5 (2), compress the spring until
the stop is past the pin hole.

below the surface of the front support.
2
V07798.00.00.eps
23. Install C1 clutch backfill valve (1).
24. Install C1 clutch backfill valve spring (2).
1
2
V07781.00.00.eps
25. Using J 43773 (2), compress the spring.
26. Install retaining clip (1). Make sure the

retaining clip is below the surface of the front 1
support.
2
V07780.00.00.eps

27. Install main regulator valve (1).
28. Install main regulator valve spring (2) and

stop (3).
1
2
3
V07779.00.00.eps
29. Install J 24459-5 (1) onto J 43770 (2).
V07709.00.00.eps

MODULE REBUILD

front support so that: 1
• The J 43770 threaded rod faces down.
holes in the front support.
2
31. Install J 43770 (5) onto the front support
assembly.
3
32. Install two bolts (2).
4
33. Align J 24459-5 (4) slot with retainer pin (3).
2 5
34. Using J 24459-5 (2) and J 43770 (5), compress
the spring until the stop is past the pin hole.

V07732.00.00.eps
below the front support surface.

SUPPORT MODULE ASSEMBLY
1
Tools Required
• J 43772 Oil Pump Seal Installer

1. Position main pump assembly (2) on the work
table so that the rear of the pump is facing up.
2. Align the dowel pin holes in separator plate (1)
with dowel pins (3) in the pump body. Align 3
the bolt holes in separator plate (1) with the
bolt holes in main pump body (2). 2
3. Install separator plate (1) onto main pump

3
assembly (2).
A16


1 work table so that ground sleeve (4) is facing
up.
2
5. Align, as a unit, main pump assembly (1) and
separator plate (3) so that:
3
• Align main pump dowel pins (2) with their
holes in the front support assembly.
• Align the main pump assembly bolt holes
with the bolt holes of the front support
4 assembly.
6. Install, as a unit, main pump assembly (1) and
5 separator plate (3) onto front support
assembly (5).
6 7. Install five bolts (6). Tighten the bolts to
A16a 24–29 N·m (18–21 lb ft).
8. Align the tangs of thrust washer (5) with the

1 slots at the base of the front support assembly
rear hub.
2 9. Install thrust washer (5) onto the front support
assembly. The thrust washer should snap into
3 place.
4 NOTE:
The three butt joint sealrings on the rear hub have
been replaced with three double lap joint sealrings.
The butt joint and double lap joint sealrings are in-
5 terchangeable for all medium duty applications re-
gardless of transmission serial number.
6
10. Install three new butt joint or double lap joint
D15
sealrings (6) onto the front support assembly
rear hub.
CAUTION:
Interchanging the ground sleeve butt joint
sealrings on the ground sleeve may result in
transmission damage. Install the correct sealring
at the correct ground sleeve location.
• P/N 29538158 (1) is installed on the front end
of the ground sleeve.
• P/N 29531038 (2) is installed on the middle of
the ground sleeve.
11. Install a new butt joint sealring (2) onto the

middle of ground sleeve (3).
12. Install a new butt joint sealring (1) onto the

front of ground sleeve (3).

MODULE REBUILD
13. Position front support module (5) on the work

table so that the ground sleeve is facing up.
14. Align the bolt holes of converter housing/

separator plate gasket (2) with the bolt holes in
separator plate (4).
1
15. To assist in retaining gasket, apply petrolatum
in spots to the gasket face nearest the separator 2
plate.
16. Install the gasket onto the separator plate. 3
17. Apply petrolatum onto the OD of main pump 4

assembly (3).
5
D14
18. Install two M10 x 1.5 guide bolts (2) into front
support module (3).
19. Align the converter housing bolt holes with the

bolt holes in the front support module.
20. Install the converter housing onto the guide

bolts and onto the front support module.
1
21. Remove the guide bolts from the front support
module.
A14
22. Install seals (2) onto ten bolts (1).
5
D14

23. Install ten bolts (1) into the converter housing

to retain the front support module. In a criss-
cross pattern, tighten the bolts to 51–61 N·m
(38–45 lb ft).
1 1
1 1
1
1
1
1
1
1
V07728.00.00.eps
24. Align oil seal assembly (2) with main pump

body (3) so that the double edges face the
pump body hub.
1
25. Using J 43772, install the oil seal assembly
into the pump body hub.
2 26. Make sure the seal is installed flush to
0.25 mm (0.010 inch) below the main pump
body surface.
3
D10d
5–10. ROTATING CLUTCH MODULE

3
a. Disassembly of Rotating Clutch Module
1 Tools Required
4
• J 43776 C2 Piston Return Spring Compressor
• J 43777 C1 Piston Return Compressor
2
1. Position rotating clutch assembly (4) on the
work table so that the rear of the assembly is up.
2. Remove retaining ring (1) from the rotating
clutch assembly.
3. Remove P1 sun gear (3) with P1 drive
flange (2). Remove the P1 sun gear from the
R46
drive flange.

MODULE REBUILD
4. Remove bronze thrust washer (1) from C2

drive hub (2). 1
R45
5. Remove C2 drive hub (1).

5 1
NOTE:
The thrust bearing assembly may stick to the C1
drive hub or the C2 drive hub.
2
6. Remove thrust bearing assembly (2) from the
rear of C1 drive hub (3) or the front of C2 drive 3
hub (1).
7. Remove C1 drive hub (3). 4
NOTE:
The thrust bearing assembly may stick to the rear of
R43a
the turbine shaft or the front of the C1 drive hub.
8. Remove thrust bearing assembly (4) from the

rear of turbine shaft (5) or the front of the C1
drive hub.

9. Remove seven C2 clutch reaction plates (1)

3 and six C2 clutch friction plates (2) from
rotating clutch housing (3).
1
R44
10. Remove internal spiral retaining ring (1) from

1
C1 clutch backplate (3).
2
11. Remove retaining ring (2) from turbine
shaft (4).
3
12. Remove C1 clutch backplate (3) from turbine
4 shaft (4).
R41

six C1 reaction clutch plates (2) from turbine
1 shaft (3).
3
2
R39

MODULE REBUILD
WARNING!
1
The rotating clutch housing and turbine shaft are
held together by a retaining ring. Removing the
retaining ring allows the turbine shaft and the
rotating clutch housing to move freely. Make sure 2
the rotating clutch housing and the turbine shaft 3
are restrained from moving when removing the
retaining ring. Personal injury and/or property
damage may result from the movement of the
rotating clutch housing or the turbine shaft.
14. Remove retaining ring (1) from turbine

shaft (3).
15. Remove rotating clutch housing (2) from the
4
rear of the turbine shaft.
16. Remove two butt joint sealrings (4) from the R38
turbine shaft.
17. Position rotating clutch housing (2) on the
work table so that the rear of the housing is
facing up. 1
18. Remove retaining ring (1) from C1 piston

housing (3).
3
2
R37a
19. Position rotating clutch housing (7) on the base

of J 24204-2 (8) so that the rear of the housing 1
is facing up. 6
20. Install J 43777 (5) onto the C1 piston return 2

spring assembly.
3
21. Align J 43777 (5) notch with the gap in
retaining ring (6). 4 7
22. Install J 43777 (4) extension onto the shaft of
J 24204-2 (8). 5
23. Install the J 24204-2 ball bearing (3) and
washer (2) onto the shaft of J 24204-2.
8
24. Install the J 24204-2 wing nut (1) onto the
shaft of J 24204-2. R36

25. Compress the return spring assembly until

1
retaining ring (6) can be removed.
6
26. Remove retaining ring (6) from its groove in
2 the rotating clutch housing inner hub.
3 27. Remove all J tools.
28. Remove retaining ring (6) from rotating clutch

4 7 housing (7).
R36
29. Remove C1 piston return spring assembly (1)

1 from C1 clutch piston (3).
30. Remove C1 clutch piston (3), with C1 balance

2 piston (2) attached, from the rotating clutch
housing.
31. Remove C1 balance piston (2) from C1 clutch

3 piston (3).
R35a
32. Remove sealrings (1) and (2) from C1 clutch

1 piston (3).
2
R34

MODULE REBUILD

of J 24204-2 (10) so that the rear of the 1
housing is facing up.
2 7
34. Align J 43776-2 (7) so that the bowl is facing 3
down.
35. Install J 43776-1 (7) onto the shaft of 4
J 24204-2 and onto the C2 piston return spring
assembly. Make sure the rim of the J 43776-2 8
almost touches the retaining ring. 9
5
36. Install J 43776 spring (5) onto the shaft of
J 24204-2.
6
NOTE: 10
J 43776-1 has two notches. Either notch can fit over
R33
the ball of the C1 piston housing, but only one notch
also leaves the holes in the retaining ring easily ac-
cessible.
37. Align J 43776-2 (4) so that:

• One notch fits over the ball of C1 piston
housing (9).
• The holes in retaining ring (6) are easily
accessible.
38. Install J 43776-1 (4) onto the shaft of
J 24202-2.
39. Install J 24204-2 ball bearing (3) and washer (2)
onto the shaft of J 24204-2.
40. Install J 24204-2 wing nut (1) onto the shaft of
J 24204-2.
NOTE:
Make sure the J 43776-1 notch remains over the
ball of the C1 piston housing while the return spring
assembly is being compressed.
41. Compress the return spring assembly until

retaining ring (6) can be removed.
42. Remove retaining ring (6) from its groove in
the rotating clutch housing inner hub and move
the retaining ring over the top of J 43776-2 (7).
43. Remove all J tools from the rotating clutch
housing.
clutch housing.

45. Remove C1 piston housing (1) from rotating

clutch housing (3).
1 46. Remove C2 piston return spring assembly (2)
from C2 clutch piston (4).
4 3
R32b

1 clutch housing.
48. Remove C2 clutch piston (3) with C2 balance

2 piston (2) attached.
49. Remove C2 balance piston (2) from C2 clutch

piston (3).
3
R31
50. Remove O-ring (1) from the inner hub of

1
R32a

MODULE REBUILD
51. Remove three piston sealrings (1), (2), and (3)

from C2 clutch piston (4).
1
2
3
R30
b. Turbine Shaft Inspection
NOTE: 1 2
Replace the turbine shaft bushing if any of the fol-

lowing specifications are not met.
1. Inspect bushing (2) inside the end of turbine A

shaft (1) for damage.
2. Measure the ID of the turbine shaft bushing
(Dimension A). Maximum ID is 20.117 mm
(0.7920 inch).
R47

c. Turbine Shaft Bushing Replacement

1
Tools Required
2 7
9 • J 44526 Output/Turbine Shaft Bushing
3 Remover
10 • J 43791 Output/Turbine Shaft Bushing

Installer
4
8
CAUTION:
Always use J 44526 when removing the turbine
5 shaft bushing to help avoid damage to the turbine
shaft.
6
1. Install J 44526-2 (8) into J 44526-1 (7).
R48 2. Install J 44526-2 (8) and J 44526-1 (7) into
bushing (9).
3. Install washer (6) and nut (5) onto J 44526-2 (8).
engages bushing (9).
5. Install J 44526-3 (4) onto J 44526-2 (8).
J 44526-2 (8).
dislodged.
8. Remove the J tools from the turbine shaft.

MODULE REBUILD
9. Install a new bushing (2) onto J 43791 (1).

10. Drive the bushing into turbine shaft (3) until 1
the bushing is seated.

0.25 mm (0.010 inch) below the inner turbine 2
shaft surface.
3
R48a
d. Rotating Clutch Housing Inspection

3
1
NOTE:
PTO gears are permanently staked to the rotating 2
clutch housing and are not serviceable. Turbine
tone wheels are serviceable.
B A
1. Inspect the turbine tone wheel or PTO Gear (3)
for damage. Make sure a tone wheel is not
dented or out-of-round.
2. If the PTO gear is damaged, replace the
rotating clutch housing. If the tone wheel is
damaged, replace the tone wheel.
3. Measure the ID of the rotating seal bore of
R49
rotating clutch housing (1) (Dimension A). If
the ID exceeds 74.050 mm (2.9154 inch),
replace the rotating clutch housing.
NOTE:
Replace the rotating clutch housing bushing if any
of the following specifications are not met.
4. Inspect bushing (2) inside the front of rotating

clutch housing (1) for damage.
5. Measure the ID of the bushing (Dimension B).
The maximum ID is 78.170 mm (3.0776 inch).

e. Rotating Clutch Housing

1 Bushing Replacement
Tools Required
• J 43778 Rotating Clutch Bushing Installer

CAUTION:
2
DO NOT score the rotating clutch housing bore
when removing the clutch housing bushing.
1. Gently tap the bushing through the inside of

the rotating clutch housing until the bushing
becomes dislodged.
R50 2. Remove bushing (2) from rotating clutch
housing (1).
3. Remove any nicks or burrs with crocus cloth.
4. Position rotating clutch housing (4) on a press

1 so that the front of the housing is facing up.
2
NOTE:
3 The preferred method for installing the rotating
clutch housing bushing is to use J 43778 and a press.
4
If a press is not available, use J 43778 and J 8092
universal driver.

the large end of J 43778 (2) onto J 8092 (1).
7. Using J 43778, press the new bushing into the
R50a
clutch housing.
0.25 mm (0.010 inch) below the rotating clutch
housing surface.

MODULE REBUILD
f. Rotating Clutch Housing

Tone Wheel Replacement
1
Tools Required
• J 43768 Tone Wheel Driver
• J 43767 Tone Wheel Staker
1. Grind the stakes from rotating clutch
housing (1).
R50b

so that the front of the housing is down. 1
3. Install J 43768 (1) onto tone wheel (3).

4. Using J 43768 (1), press tone wheel (3) from
R50c

1
so that the front of the housing is facing up.
6. Align tone wheel (2) so that the outside edge is
facing up.
7. Install tone wheel (2) onto the rotating clutch
2
housing.
8. Install J 43768 (1) onto the tone wheel.
9. Using J 43768 (1), press the tone wheel onto
the rotating clutch housing.
3
R50d

10. Locate four positions on rotating clutch

1
housing (3), 90 degrees apart, that have not
been previously staked.
11. Align J 43767 (2) so that the staking prongs

are down at two of the staking locations.
2
12. Install J 43767 (2) onto the rotating clutch
housing.
3
13. Install J 43768 (1) onto J 43767 (2).
CAUTION:
Stake the tone wheel to 9 tons. The accuracy of
the pressure gauges on presses varies. Start at a
lower pressure and increase to 9 tons. Too great a
R50e pressure will distort the tone wheel. Too little
pressure will result in stakes that will not hold.
14. Using J 43767 (2) and J 43768 (1), stake the

turbine tone wheel to the rotating clutch
housing.
NOTE:
Tapping J 43768 and J 43767 may be required to
remove J 43768 and J 43767 from the rotating
clutch housing.
15. Remove J 43768 (1) and J 43767 (2).

MODULE REBUILD
16. Align J 43767 (2) so that the staking prongs

are down at the other two 2 staking locations. 1
17. Install J 43767 (2) onto the tone wheel.
18. Install J 43768 (1) onto J 43767 (2).

2
CAUTION:
Stake the rotating clutch housing to 9 tons. The 3
accuracy of the pressure gauges on presses
varies. Start at a lower pressure and increase to
9 tons. Too great a pressure will distort the tone
wheel. Too little pressure will result in stakes that
will not hold.
19. Using J 43767 (2) and J 43768 (1), stake the

R50e
turbine tone wheel to the rotating clutch
housing.
NOTE:
Tapping J 43768 and J 43767 may be required to
remove J 43768 and J 43767 from the rotating
clutch housing.
20. Remove J 43768 (1) and J 43767 (2).
g. C1 Clutch Friction Plate Inspection
1
NOTE:
• Measure as described below at three or more lo-
cations.
• Replace any C1 clutch friction plate that does
not meet specifications.
1. Measure the thickness of each C1 clutch

friction plate (1) (Dimension A). Minimum
thickness is 2.375 mm (0.0935 inch).
2. Measure the oil groove depth of each plate A
(Dimension B). Minimum groove depth is
0.200 mm (0.0079 inch). B
V07802.00.00.eps

NOTE:
Check the plates for coning on a level surface.
3. Measure the cone of each plate (1)

A 1 (Dimension A). Maximum cone is 0.255 mm
(0.0100 inch).
R52
h. C1 Clutch Reaction Plate Inspection

1
NOTE:
cations.
• Replace any C1 clutch reaction plate that does

reaction plate (1) (Dimension A). Minimum
A
R53
NOTE:

A 1
(Dimension A). Maximum cone is 0.200 mm
(0.0079 inch).
R54

MODULE REBUILD
i. C1 Clutch Backplate Inspection

1
NOTE:
cations.
• Replace the C1 clutch backplate if it does not
meet specifications.
1. Measure the wear surface thickness of C1

clutch backplate (1) (Dimension A). Minimum
thickness is shown in the table. A
ID Minimum Thickness
6221 11.840 mm (0.4661 inch)
R55
6222 12.280 mm (0.4835 inch)

6223 12.730 mm (0.5012 inch)
6224 13.180 mm (0.5189 inch)
6225 13.630 mm (0.5366 inch)
NOTE:
2. Measure the cone of backplate (1)

(Dimension A). Replace backplate (1) if any A
cone is present. 1
R56

j. C2 Clutch Friction Plate Inspection

1
NOTE:
cations.
• Replace any C2 clutch friction plate that does

A
2. Measure the oil groove depth of each plate
(Dimension B). Minimum groove depth is
B 0.200 mm (0.0079 inch).
R57
NOTE:

(0.0089 inch).
A 1
R58
k. C2 Clutch Reaction Plate Inspection

1
NOTE:
cations.
• Replace any C2 clutch reaction plate that does

A
R59

MODULE REBUILD
NOTE:
2. Measure the cone of plate (1) (Dimension A).

Maximum cone is 0.240 mm (0.0094 inch).
A 1
R60
l. C1 Piston Housing Inspection
1
NOTE:
• Measure as described below at three or more lo- 2
cations.
• Replace the C1 piston housing if it does not meet
specifications.
1. Inspect C1 piston housing (1) for damage.

2. Make sure ball (2) moves freely and has a
minimum of 1.0 mm (0.04 inch) travel parallel
to the centerline of the C1 piston housing.
R60b
m. Rotating Clutch Thrust Washer Inspection
1
NOTE:

(Dimension A).
2. The minimum thickness is 2.59 mm
(0.102 inches).
A
R60a

n. Assembly of Rotating Clutch Module

Tools Required
1
2
3 • J 43776 C2 Piston Return Spring Compressor
4 • J 43777 C1 Piston Return Compressor
• J 44525 C1 Clutch Backplate Selector
NOTE:
The C2 clutch piston has been redesigned to elimi-
nate the 1 mm (0.040 in.) bleed hole. For medium
duty applications the current and former C2 Clutch
pistons are interchangeable regardless of transmis-
R30
sion serial number.
1. Install three piston sealrings (1), (2), and (3)

onto C2 clutch piston (4).
2. Lubricate C2 balance piston seal (3), the piston
ID and OD, and sealrings (1) and (2) with
petrolatum.

1 facing up.
4. Install O-ring (1) into the bottom groove on the
inner hub of rotating clutch housing (2).
R32a

MODULE REBUILD
5. Position C2 clutch piston (3) on the work table

so that the rear of the piston is facing up. 1
6. Align C2 balance piston (2) so that the rubber

seal is facing down. 2
7. Install C2 balance piston (2) onto C2 clutch

piston (3).
8. Lubricate the rubber seals on C2 balance 3
piston (2) with petrolatum.
9. Install C2 clutch piston (3) with C2 balance
piston (2) attached into rotating clutch
4
housing (4). Make sure the C2 clutch piston is
seated on the rotating clutch housing.
10. Push C2 balance piston (2) below the retaining
ring groove on rotating clutch housing (4). R31
11. Install retaining ring (1) into rotating clutch

housing (4). Make sure the retaining ring is
seated completely around the rotating clutch
housing.
12. Align C2 piston return spring assembly (2) so

that the notches of the spring assemblies are
facing and aligned with the tangs of C2 clutch 1
piston (4).
13. Install C2 piston return spring assembly (2)

into C2 clutch piston (4). 2
14. Align C1 piston housing (1) so that the rear of
the housing is facing up.
15. Install C1 piston housing (1) into C2 clutch

4 3
piston (4).
R32b


1 of J 24204-2 (10) so that the rear of the
2 7
3 17. Install J 43776-1 (7) onto the shaft of
J 24204-2 with the bowl down.
4 18. Install retaining ring (6) onto the surface of
J 43776-2 (7).
8
9 19. Install J 43776 spring (5) onto the shaft of
5 J 24204-2.
20. Install J 43776-2 (4) onto the shaft of

6 J 24204-2.
10
21. Align a notch of J 43776-2 (4) with the ball of
R33 the C1 piston housing.
22. Install J 24204-2 ball bearing (3) and

washer (2) onto the J 24204-2 shaft.
23. Install J 24204-2 wing nut (1) of onto the shaft

of J 24204-2.
24. Compress the C2 piston return spring assembly

until the retaining ring groove on the inner hub
of the rotating clutch housing is visible.
25. Install retaining ring (6) onto the rotating

clutch housing inner hub. Make sure the
retaining ring is seated all around the clutch
housing.
26. Remove all J tools except for the base of

J 24204-2.
27. Install C1 piston ID sealring (1) and C1 piston
1 OD sealring (2) onto C1 clutch piston (3).
Lubricate the sealrings with petrolatum.
2
R34

MODULE REBUILD

facing up. 1
29. Align C1 clutch piston (2) so that the spring

indents are facing up.
2
30. Install C1 clutch piston (2) into C1 piston
housing (4). Make sure the C1 clutch piston is
seated in the C1 piston housing.
3
31. Align C1 piston return spring assembly (1) so 4
that the springs are facing and aligned with the
spring pockets of C1 clutch piston (2).
32. Install C1 piston return spring assembly (1)

into C1 clutch piston (2). R35

of J 24204-2 (8) so that the rear of the housing 1
is facing up. 6
34. Place retaining ring (6) into the inner hub of 2

the rotating clutch housing.
3
35. Install J 43777 (5) onto the shaft of J 24204-2 (8).
36. Center J 43777 on the C1 piston return spring 4 7

assembly.
5
37. Install J 43777 extension (4) onto the shaft of
J 24204-2.
38. Install J 24202-2 ball bearing (3) and 8

washer (2) onto the shaft of J 24204-2.
R36
39. Install J 24204-2 wing nut (1) on the shaft of
J 24204-2.
40. Compress the C1 piston return spring assembly

until the retaining ring groove on the rotating
clutch housing inner hub is visible.
41. Install retaining ring (6) onto the rotating

clutch housing inner hub.
42. Remove all J tools.


1 work table so that the rear of the housing is
facing up.
44. Lubricate the rubber seals on C1 balance
piston (2) with petrolatum.
2
45. Align C1 balance piston (2) so that the rubber
seal is facing down.
46. Install the C1 balance piston between the C1
clutch piston and the C1 piston housing.
3
47. Press C1 balance piston (2) into the C1 piston
housing until the C1 balance piston is below
the retaining ring groove on the C1 piston
housing.
48. Install retaining ring (1). Make sure the
R37 retaining ring is seated in its groove.
49. Install two butt joint sealrings (4) onto turbine

1 shaft (3).
50. Position turbine shaft (3) on the work table so

that the rear of the shaft is facing up.
2
3 51. Align rotating clutch housing (2) with the rear
of turbine shaft (3) so that the rear of the clutch
52. Install rotating clutch housing (2) onto the

larger splined diameter of turbine shaft (3).
53. Install retaining ring (1) onto the turbine shaft.

Make sure the retaining ring is seated
4 completely around the turbine shaft.
R38
54. Starting with a C1 clutch reaction plate,

alternately install six C1 clutch reaction
1 plates (2) and six C1 clutch friction plates (1)
3 onto turbine shaft (3).
2
R39

MODULE REBUILD
55. Align J 44525-2 (3) with the turbine shaft so

that the countersunk holes of J 44525-2 are 1
facing up.
2
56. Install J 44525-2 (3) onto the turbine shaft.
57. Align J 44525-1 (2) with the turbine shaft so 3

that the inner ridge of J 44525-1 is facing
down.
4
58. Slide the inner ridge of J 44525-1 (2) into the
turbine shaft retaining ring groove.
59. Align the holes in J 44525-1 (2) with the

countersunk holes of J 44525-2 (3).
60. Hand install two J 44525 bolts (1) into the

holes of the J 44525-1 (2). R40
61. Torque J 44525-1 bolts (1) to 5.4 N·m (48 lb in.).
NOTE:
The shift quality of the transmission depends heavi-
ly on selecting the correct C1 clutch backplate.
62. Do the following for each tab of J 44525-3 (1).
• Place the flat surface (tabbed end) of 1

J 44525-3 (1) onto the top surface of
J 44525-2 (3). 2
• Try to slide a tab of J 44525-3 (1) into the 3
retaining ring groove on the turbine shaft.
4
NOTE:
At most, two of the different tabs will fit into the re-
taining ring groove.
• If a tab fits into the retaining ring groove,

record the four digit ID number, located on
the stem of J 44525-3, associated with the
R40a
tab.
63. Select a C1 clutch backplate so that:
• If no tab of J 44525-3 fits into the retaining

ring groove, select the C1 clutch backplate
with ID No. 6221 or 8521.

• If one or more tabs of J 45525-3 fit into the

retaining ring groove, select the C1 clutch
backplate with an ID No. corresponding to
the highest number recorded in the previous
step.
C1 Clutch Backplate
ID No. Part Number
6221 29536221 or 29538521
6222 29536222 or 29538522
6223 29536223 or 29538523
6224 29536224 or 29538524
6225 29536225 or 29538525
64. Remove all J tools from the turbine shaft.
65. Align C1 clutch backplate (3) so that the

1
beveled edge of the backplate is facing up.
2 66. Install the C1 clutch backplate onto turbine
shaft (4).
3 67. Install retaining ring (2) onto turbine shaft (4).
4 68. Lift C1 clutch backplate (3) and install spiral
retaining ring (1) into C1 clutch backplate (3).
5
CAUTION:
Installing the thrust bearing assembly into the
rear of the turbine shaft in the wrong direction—
blue stripe not showing—could result in
destruction of the transmission.
R41
69. Align thrust bearing assembly (2) so that the

blue stripe on the thrust bearing assembly is
facing away from turbine shaft (3).
1 70. Install thrust bearing assembly (2) into turbine
shaft (3). Make sure the blue stripe on the
2 thrust bearing assembly is visible.
3 71. Center C1 clutch plates (4).
4 72. Install C1 drive hub (1) over C1 clutch

plates (4). Make sure C1 drive hub (1) has
seated on thrust bearing assembly (2).
R43

MODULE REBUILD
CAUTION:
1
Installing the thrust bearing assembly onto the
rear of the C1 drive hub in the wrong direction—
blue stripe not showing—could result in
destruction of the transmission. 2

blue stripe on the thrust bearing assembly is 3
facing away from C1 drive hub (3).
74. Install thrust bearing assembly (2) onto rear of
C1 drive hub (3). Make sure the blue stripe on
the thrust bearing assembly is visible.
75. Align C2 drive hub (1) so that the small end is
facing up.
R43b
76. Install C2 drive hub (1).
77. Starting with a C2 clutch reaction plate,
alternately install seven C2 clutch reaction 3
plates (2) and six C2 clutch friction plates (1)
into the rotating clutch housing.
R44a
78. Align the tangs of bronze thrust washer (1)

with the holes in C2 drive hub (2). 1
79. Install bronze thrust washer (1) onto C2 drive

hub (2). 2
R45

80. Align P1 sun gear (3) so that the gear teeth of

3 the sun gear face the concave face of P1 drive
flange (2).
1
4 81. Install P1 sun gear (3) into P1 drive flange (2).
Make sure the splines are engaged.
82. While holding the sun gear, align the double

2 wide splines of P1 drive flange (2) with the
double wide spaces on rotating clutch
housing (4).
83. Install P1 sun gear (3) with P1 drive flange (2)

into rotating clutch housing (4).
84. Install retaining ring (1) into rotating clutch

housing (4). Make sure the retaining ring is
R46
seated all the way around the rotating clutch
housing.
5–11. MAIN HOUSING ASSEMBLY

a. Disassembly of Selector Shaft and
Detent Lever
Tools Required
• J 43911 Selector Shaft Seal Remover
NOTE:
Do not remove the selector shaft unless replacing
one or more of the following:
• selector shaft
• selector shaft nut
• detent lever
• park pawl apply assembly
1. Position the transmission so that the valve

body face of the main housing is facing up.
2. Remove screw (3) from the body of
J 43911-1 (2).
1
3. Screw the body of J 43911-1 into selector shaft
seal (1).
4. Install screw (3) into the body of J 43911-1 (2).
5. Tighten screw (3) against shaft (4) until
seal (1) becomes dislodged.
6. Remove selector shaft seal (1) from
J 43911-1 (2).
2 3 R67

MODULE REBUILD
7. While holding the flats of selector shaft (1),

loosen selector shaft nut (2) so that the nut
slides freely on the selector shaft.
8. Remove detent lever (2) from the flats of the
selector shaft.
2
1
R64
CAUTION:
DO NOT mar the main housing surface around
the spring pin when removing the spring pin. An
unmarred surface is required to maintain the 1
seal between the control valve assembly and the 2
main housing.
9. Place a protective plate (2) on the main

housing surface around spring pin (3). 3
10. Place a drill bit (1) into the spring pin to
prevent cutting or collapsing the pin while
removing the pin.
11. Remove spring pin (3) from the main housing.

R64a
12. While holding the detent lever (3) and nut (4),
carefully slide selector shaft (1) through the
following.
• selector shaft nut (4)
• detent lever (3)
• selector shaft seal hole (2)
13. Remove nut (4), detent lever (3), and park pawl 4 3
apply assembly (5) (if present) from the main 2 1
housing.
R65

14. If park pawl apply assembly (1) is present, do

the following.
• Rotate park pawl apply assembly (1) 180
degrees.
• Remove the nib of park pawl apply
assembly through the keyhole in detent
1 lever (2).
2
b. Assembly of Selector Shaft and Detent Lever
Tools Required
R66a
• J 43909 Selector Shaft Seal Installer
• J 43766 Selector Shaft Spring Pin Installer
1. Install a new selector shaft seal (1) onto
J 43909 (2).
2. Using J 43909, drive selector shaft seal (1) into
the main housing.
1 3. Make sure the selector shaft seal is seated in

2
the bottom of the bore.
R67a
4. If the transmission has park pawl apply

assembly (1), do the following.
• Install the nib of park pawl apply
assembly (1) through the keyhole in detent
lever (2).
• Rotate the park pawl apply assembly 180
1 degrees.
R66b

MODULE REBUILD
5. If present, place the roller end of park pawl

apply assembly (5) into the main housing.
6. Align detent lever (3) so that:
• The cockscomb of the detent lever is facing
up.
• The guide hole for the manual selector
valve pin is facing forward.
• The selector shaft hole in the detent lever is
aligned with selector shaft seal (2). 4 3
7. Slide selector shaft (1) through the following 2 1
components.
• selector shaft seal (2)
• detent lever (3) 5
• selector shaft nut (4)
8. Install the selector shaft into the main housing.
R65
9. Install detent lever (2) onto the flats of selector

shaft (1).
10. Install selector shaft nut (3) onto selector
shaft (1).
11. Install a crowsfoot with a torque wrench onto

nut (3).
12. While holding the flats of selector shaft (1), 2

tighten nut (3) to 24–34 N·m (18–25 ft lb). 1
R64
CAUTION:
DO NOT mar the main housing surface when
installing the spring pin. Use only gentle tapping
on the J 43766 selector shaft spring pin installer
tool. Heavy or continued hammering on the 1
J 43766 will damage the main housing surface.
13. Install spring pin (2) into J 43766.

2
14. Using J 43766, drive spring pin (2) into the
main housing.
15. Make sure the spring pin is installed to a height

of 8.50–9.00 mm (0.335–0.354 inch).
R64b

c. Nameplate Replacement
NOTE:
When replacing a nameplate, keep the original
nameplate. Stamp the information from the original
nameplate onto the replacement nameplate.
M
1 0 OD
SE 0 S
6 3 RIA
–
E
XX L RIE
N
0 1 X X XO. S
X
DIV
.
0 EL INDIANOFAP GE
OL NE
IS, RA
L
IND MO
IAN TO
DAT A, US
X E
RS
A CO RP
CAUTION:
1 0 X X X X X EFX X .
– X X
14 XXX X XCN X X
–
16 XXX
X 21– X X X
–1 X 34– XXX X X X
7 24
–
X
X
35 XX
37 XXX
–X X
XX
X
X
39
–
TID
50 XXX X X
–
XX XXX
X
DO NOT drill through the main housing when
X
–
XX XXX
–X X
XX
X
X drilling out the nameplate rivets.
1. Using a 3⁄16 inch drill bit, drill through

1 2
rivet (1). Remove rivet (1) and nameplate (2).
2. Place a new nameplate (2) and a new rivet (1)
onto the main housing.
R68
3. Using a pop rivet gun, install the rivet into the
main housing.
d. Main Housing Dowel Pin Replacement

Tools Required
• J 43780 Main Housing Dowel Pin Installer
1
2 NOTE:
Do not replace the main housing dowel pin unless
the dowel pin is damaged.
CAUTION:
removing the dowel pin. An unmarred surface is
required to maintain the seal between the rear
cover assembly and the main housing.
R69
1. Remove dowel pin (1) from the rear surface of

the main housing.
2. Install a new dowel pin (1) into J 43780 (2).
CAUTION:
installing the dowel pin. Use only gentle tapping
on the J 43780 dowel pin installer tool. Heavy or
continued hammering on the J 43780 will
damage the main housing surface.
3. Using J 43780 (2), drive the dowel pin until

seated.
of 20.80–21.20 mm (0.819–0.835 inch) above
the main housing rear surface.

MODULE REBUILD
e. Replacement of Fill Tube Plug

1
1. Remove fill tube plug (1).
2. Remove fill tube seal (2). 2
3. Install fill tube seal (2) into the main housing.

4. Align the tab on fill plug (1) with the tang on
the main housing.
NOTE:
The fill plug should click into place.
5. Install fill plug (1) into fill tube seal (2) and the
plug tab into the main housing tang.
D5
f. Replacement of Vent Assembly

1
1. Pry off vent cap (1).
2. If vent (2) remains, gently pry the vent from
2
the main housing.
3. Gently tap a new vent assembly into the main
housing until the vent is seated.
D6
5–12. RING GEAR AND CLUTCH

COMPONENT INSPECTIONS 1
a. C3 Clutch Component Inspection
NOTE:
• Make the measurements described below at
three or more locations.
• Replace any parts not meeting specifications.

friction plate (1) (Dimension A). Minimum A
2. Measure the oil groove depth of each C3 clutch
friction plate (Dimension B). Minimum groove B
depth is 0.200 mm (0.0079 inch). R71

NOTE:
3. Measure the cone of each C3 clutch friction

A 1 plate (1). Maximum cone is 0.225 mm
(0.0089 inch).
R72

1 thickness is 2.440 mm (0.0961 inch).
R73
NOTE:
5. Measure the cone of each C3 clutch reaction

plate (1) (Dimension A). Maximum cone is
A 1 0.400 mm (0.0157 inch).
R74

MODULE REBUILD
6. Measure the thickness of C3 spring plate (1)

(Dimension A). Minimum thickness is
3.110 mm (0.1224 inch). 1
R145
7. Measure the cone of C3 spring plate (1)

(0.0157 inch).
A 1
R146

8. Measure the thickness of C3 clutch

backplate (1) (Dimension C). Minimum
9. Measure the distance from the top of thrust

2 plate (2) to the bottom of the C3 clutch plate
inner rim (Dimension A). Measure the
thickness of the C3 clutch plate inner rim
(Dimension B). Calculate the thickness of the
thrust plate (Dimension D) by subtracting
Dimension B from Dimension A (Dimension
D = Dimension A – Dimension B). Minimum
A B C thrust plate thickness is 3.000 mm
(0.1181 inch).
NOTE:
R85
10. Measure the cone of C3 clutch backplate (1).

Replace backplate (1) if any cone is present.

MODULE REBUILD
b. C3 Clutch Backplate Assembly Thrust

Plate Replacement
Tools Required
• J 39354 Rivet Installer
CAUTION:
Use care when drilling through the backplate
rivets. Once the rivet has been drilled through,
the drill bit may catch on the backplate causing
damage to the drill bit and/or the backplate.
NOTE:
Replace all three thrust plates if one thrust plate
needs replacing.
1. Using a 9⁄64 inch drill bit, drill through the

heads of six rivets (1). 1
2. Remove the rivets and three gear thrust plates (2).

2
NOTE:
Set the gap of the rivet installer to 4.45 mm
(0.175 inch). If the rivet connection is too loose, use 3
a smaller gap.
3. Using J 39354, install three new gear thrust

plates (2) and six rivets (1) so that the rivets are
flush or below the surface of the thrust plates.
4. Make sure rivets (1) and thrust plates (2) are
not loose. R87

c. C4 Clutch Component Inspection

1
NOTE:
cations.
• Check the plates for coning on a level surface.

A thickness is 2.375 mm (0.0935 inch).
friction plate (1) (Dimension B). Minimum
B groove depth is 0.200 mm (0.0079 inch).
R71

0.225 mm (0.0089 inch).
A 1
R72

reaction plate (1) (Dimensions A). Minimum
R73

MODULE REBUILD

0.400 mm (0.0157 inch).
A 1
R74
6. Measure the thickness of C4 spring plate (1)

(Dimension A). Minimum thickness is
3.110 mm (0.1224 inch). 1
R145
7. Measure the cone of C4 spring plate (1)

(0.0157 inch).
A 1
R146

8. Measure the thickness of the C4 clutch

backplate (Dimensions A). Minimum thickness
1 is 15.400 mm (0.6063 inch).
9. Measure the cone of the C4 clutch backplate.
Replace backplate (1) if any cone is present.
V07716.00.00.eps
d. C5 Clutch Component Inspection
1
NOTE:
cations.
• Check the plates for coning on a level surface.
NOTE:
A Starting with S/N 631013648, C5 Clutch Friction
Plates and the P3 Ring Gear have been redesigned.
The former and current designs are interchange-
B able only if the current C5 Friction Plates are used
V07802.00.00.eps with the current P3 Ring Gear. Do not mix current
and former designs. The former design may be re-
used unless replacement is indicated by wear mea-
surements or the design is no longer available.

friction plate (1). Minimum thickness is
2.375 mm (0.0935 inch).
friction plate (1). Minimum groove depth is
0.200 mm (0.0079 inch).

MODULE REBUILD

plate (1). Maximum cone is 0.225 mm
(0.0089 inch).
A 1
V07717.00.00.eps

reaction plate (1). Minimum thickness is given
1
in the following table. The clutch pack will
contain five ID number 2 plates and an ID
number 1, 2, or 3 selective plate. A clutch may
contain six ID number 2 plates if build
measurements require an ID number 2 plate as
the selective plate.
Part ID
Number Minimum Thickness Number
29536481 1.935 mm (0.0762 inch) 1 A
29536482 2.435 mm (0.0959 inch) 2
29536483 2.935 mm (0.1156 inch) 3
R81

0.295 mm (0.0116 inch).
A 1
R82

6. Measure the thickness of C5 clutch

backplate (1) (Dimension A). Minimum
7. Measure the cone of C5 clutch backplate (1)
(Dimension A). Replace backplate (1) if any
cone is present.
R147
e. P1 Ring Gear Inspection
1
NOTE:
Clutch plate movement can cause notching on the
external splines of P1 ring gear.
1. Inspect the external splines of P1 planetary

ring gear (1) for notching. Replace the ring
gear if detectable notching has occurred.
V07803.00.00.eps
5–13. MAIN SHAFT INSPECTION
NOTE:
Replace the main shaft if it does not meet specifica-
tions.
A
B
1. Inspect the main shaft pilots for damage.
1
2. Measure the main shaft pilots (Dimension A).
Minimum pilot OD is 19.987 mm (0.7869 inch).
3. Inspect the main shaft journal contact area for
damage.
4. Measure the main shaft journal contact area for
A
the P2 planetary bushing (Dimension B).
Minimum main-shaft journal diameter is
36.405 mm (1.4333 inch).
V07707.00.00.eps

MODULE REBUILD

1
a. P1 Planetary Module Disassembly
1. Remove thrust washer (1) from P2 ring 2
gear (4).
2. Remove retaining ring (2) from P2 ring
gear (4). 3
3. Separate P1 planetary carrier assembly (3)
from P2 ring gear (4).
V07708.00.00.eps
b. P1 Planetary Carrier Assembly Inspection

1. Check the end play between P1 planetary
carrier (1) and thrust washer (2) at each pinion
gear (3). 1
2. If the end play exceeds 1.010 mm

(0.0040 inch), replace the P1 planetary carrier 2
assembly.
V07705.00.00.eps
3. Inspect the bushing for wear or damage.

4. Measure the ID of the bushing. If the ID of the
bushing exceeds 50.690 mm (1.9957 inch),
replace the bushing. A 1
V07706.00.00.eps

c. P2 Planetary Ring Gear Inspection

1 A
NOTE:
Clutch plate movement can cause notching on the

R90b
d. P1 Planetary Carrier Bushing Replacement

1 Tools Required
• J 43781 P1 Bushing Remover/Installer
3
NOTE:
2 The preferred method for removing/installing the
P1 carrier bushing is to use J 43781 and a press. If
a press is not available, use J 43781 and J 8092 uni-
versal driver.
4 1. Position P1 planetary carrier (3) on the press

with the external splines facing up.
2. If the bushing will be removed by hand, install
R99a the short end of J 43781 (2) onto J 8092 (1).
3. Using J 43781, press bushing (4) out of the
carrier.

MODULE REBUILD

the long end of J 43781 (2) onto J 8092 (1).
1
6. Using J 43781, press or drive the bushing into 3
the carrier until J 43781 (2) seats.
2
4
R99
e. P1 Planetary Carrier Thrust Washer

Inspection 1
NOTE:

(Dimension A).
2. The minimum thickness is 1.49 mm A
(0.059 inches).
R60c
f. P1 Planetary Module Assembly

1
1. Position P2 ring gear (4) on the work table so
that the tang holes are facing up.
2
2. Install P1 planetary carrier assembly (3) into
P2 ring gear (4). Make sure the splines are
engaged.
3. Install retaining ring (2) into the P2 ring gear 3
so that the P1 planetary carrier assembly is
retained.
4. Align the tangs of thrust washer (1) with the
4
tang holes in the P2 ring gear.
5. Install the thrust washer onto the P2 ring gear.
R89

1
a. P2 Planetary Module Disassembly
1. Remove retaining ring (1) from P3 ring
gear (3).
2
2. Separate P2 planetary carrier assembly (2)
from P3 ring gear (3).
V07804.00.00.eps
b. P2 Planetary Carrier Assembly Inspection

1 gear (3).
2 (0.0417 inch), replace the P2 planetary carrier
assembly.
V07703.00.00.eps
3. Inspect bushing (1) for wear and damage.

A 4. Measure the ID of the bushing (Dimension A).
If the bushing ID exceeds 36.575 mm
(1.4400 inch), replace the bushing.
1
V07704.00.00.eps

MODULE REBUILD
c. P3 Planetary Ring Gear Inspection

1
NOTE:
Starting with S/N 631013648, C5 Clutch Friction
Plates and the P3 Ring Gear have been redesigned.
The former and current designs are interchange-
able only if the current C5 Friction Plates are used
with the current P3 Ring Gear. Do not mix current
and former designs. The former design may be re-
used unless replacement is indicated by wear mea-
surements or the design is no longer available.
NOTE:
Clutch plate movement can cause notching on the V07785.00.00.eps

d. P2 Planetary Carrier Bushing Replacement

Tools Required 1
3
• J 43785 P2 Bushing Remover/Installer
NOTE: 2
The preferred method for removing/installing the
P2 carrier bushing is to use J 43785 and a press. If
a press is not available, use J 43785 and J 8092 uni-
versal driver.
4
1. Position P2 planetary carrier (3) on wooden blocks

on the press with the external splines facing up.
R102a
2. If the bushing will be removed by hand, install
the short end of J 43785 (2) onto J 8092 (1).
3. Using J 43785 (2), press or drive bushing (4)
out of carrier (3).
4. Position P2 planetary carrier (4) on wooden
blocks on the press with the external splines
facing down.


1 the long end of J 43785 (2) into J 8092 (1).
3 6. Install a new bushing (3) onto J 43785 (2).
7. Using J 43785 (2), press or drive the bushing
into the carrier until J 43785 (2) seats.
4
2
R102
e. P2 Planetary Module Assembly

1
1. Position P3 ring gear (3) on the work table so
that the outer splines are facing down.
2. Install P2 planetary carrier assembly (2) into
P3 ring gear. Make sure the splines are
2
engaged.
3. Install retaining ring (1) into the P3 ring gear
so that the P2 planetary carrier assembly is
retained.
3
V07804.00.00.eps
5–16. P3 PLANETARY CARRIER

1 ASSEMBLY
2 a. P3 Planetary Carrier Assembly Inspection

3
gear (3).
(0.0040 inch), replace the P3 planetary carrier
assembly.
V07714.00.00.eps

MODULE REBUILD
3. If the transmission has a parking pawl, do the

following for each P3 carrier assembly tooth.
• Place straight edge (3) against the side of 1
carrier assembly tooth (2). Measure the
wear on the carrier assembly tooth
(Dimension A).
• If measurable wear exists, replace the P3
planetary carrier assembly.
2 3
V07715.00.00.eps
b. P3 Planetary Carrier Bearing

Race Replacement
Tools Required 4
1
• J 44528 P3 Carrier Bearing Race Remover
• J 43797 P3 Carrier Bearing Race Installer 4
1. Position P3 planetary carrier (2) on the work

table so that the rear of the carrier is facing up.
2. Install J 44528-1 (1) over the hub of the carrier 3 2
and onto bearing race (3).
3. Tighten J 44528-1 screws (4) wrench tight.
R98
4. Place two wooden blocks (3) on the press.

5. Position carrier (4) so that J 44528-1 (2) spans 1
the wooden blocks and the front of the carrier
is facing down.
6. Install J 44528-2 (1) into the carrier. 2
WARNING!
Pressing the P3 planetary carrier from the 3
bearing race causes the P3 carrier to fall from the
bearing race. Make sure the P3 carrier is safely
caught when freed from the bearing race. An
4
uncontrolled fall of the P3 carrier could cause
personal injury and/or property damage.
R98a

7. Using J 44528-2 (1), press P3 planetary

carrier (4) from J 44528-1 (2).
8. Remove the bearing race from J 44528-1.
9. Remove J 44528-2 (1) from the carrier.
10. Position P3 planetary carrier (3) on the press so
1 that the rear of the carrier is facing up.
11. Install a new bearing race into J 43797 (1).

2
12. Using J 43797 (1), press bearing race (2) onto
P3 planetary carrier (3) until J 43797 seats.
3
R98b

1
a. Disassembly
1. Position rear cover (2) on the work table so that
the rear of the cover is facing down.
2
R108

MODULE REBUILD
3. If the rear cover needle bearing assembly needs

replacing and the transmission is not a 3
1000 Series™ 4WD, perform the following.
• Position rear cover (1) on the press so that
2
the rear of the cover is facing up.
• Press output tone wheel (2) and needle
bearing assembly (3) from the rear cover.
1
R108a
4. If the rear cover needle bearing assembly needs

replacing and the transmission is a
1000 Series™ 4WD, perform the following. 1
• Position rear cover (1) on the work table so
that the rear of the cover is facing up.
• Using a drift, tap needle bearing
assembly (2) from the rear cover.
R108b

the rear of the cover is facing down.
6. Gently pry C5 clutch piston (2) from rear 2
cover (1).
R109

7. Remove sealrings (1) and (2) from C5 clutch

1 piston (3).
R110
8. If tachograph plug (2) is present do the

following.
1 2
• Position the rear cover on the work table so
• Remove tachograph plug (2).
3
• Remove washer (3).
R105a
b. Rear Cover Retaining Ring Replacement

1
NOTE:
DO NOT replace the retaining ring in the rear cover
except for the following conditions.
• The retaining ring is damaged
2 • The rear cover is replaced

the rear of the cover is facing up.
3. Install a new retaining ring (1).
4. Make sure the retaining ring is seated.
R108c

MODULE REBUILD
c. Output Shaft Bushing Inspection

(2WD Transmissions Only)
A
1. Inspect output shaft bushing (2) for wear and
1
damage.
2. Measure the ID of bushing (2) (Dimension A). 2
If the ID of the bushing exceeds 20.070 mm
3. Measure the OD of the bearing surface (Di-
mension B). If the OD of the bearing surface is
less than 44.978 mm (1.7708 inch), replace the B
output shaft.
R111
d. Output Shaft Bushing Inspection

(4WD Transmissions Only)
A
1. Inspect output shaft bushing (2) for wear and 1
damage.
2. Measure the ID of bushing (2) (Dimension A). 2
If the ID of the bushing exceeds 20.070 mm
3. Measure the OD of the bearing surface
B
(Dimension B). If the OD of the bearing
surface is less than 44.978 mm (1.7708 inch),
replace the output shaft.
R111a

e. Output Shaft Bushing Replacement

Tools Required
• J 44526 Output/Turbine Shaft Bushing

Remover
• J 43791 Output/Turbine Shaft Bushing
Installer
CAUTION:
Always use J 44526 when removing the output
shaft bushing to help avoid damage to the output
shaft.
1. Install J 44526-2 (8) into J 44526-1 (7).

1
2. Install J 44526-2 (8) and J 44526-1 (7) into
2 7
bushing (9).
9
3 3. Install washer (6) and nut (5) onto J 44526-2 (8).
10
4 engages bushing (9).
8
5. Install J 44526-3 (4) onto J 44526-2 (8).
5 J 44526-2 (8).
6 7. While holding the top of J 44526-2 (8) with a
dislodged.
R112
9. Remove the bushing from the J tools.

1 11. Using J 43791, drive the bushing into output
shaft (3) until J 43791 (1) is seated.
2 12. Make sure the bushing is pressed flush to
0.25 mm (0.010 inch) below the output shaft
3 surface.
R112a

MODULE REBUILD
f. Assembly of Rear Cover

3
1. Position the rear cover so that the rear of the
cover is facing down.
2. If present, install output tone wheel (2). 2
3. Gently tap needle bearing assembly (3) into the

rear cover.
1
R108a
4. Install retaining ring (1).

1
R108
5. Install sealrings (1) and (2) onto C5 clutch

piston (3). Lubricate the sealrings with 1
petrolatum.
2
R110

6. Position the rear cover so that the rear of the

cover is facing down.
2 7. Align the tang on C5 clutch piston (2) with the
tang hole in rear cover (1).
8. Install C5 clutch piston (2) into rear cover (1).
R109
9. If tachograph plug (2) is present do the

following.
1 2
• Position rear cover (1) on the work table so
• Install washer (3) onto tachograph plug (2).
3
• Install tachograph plug (2) and washer (3)
into rear cover (1).
• Tighten the tachograph plug to 60–67 N·m
(44–49 lb ft).
R105a
5–18. OUTPUT YOKE INSPECTION

A
NOTE:
cations.
• Replace the output yoke if it does not meet speci-
fications.
1. Inspect output yoke (1) for damage.

2. Measure the OD of the output yoke oil seal
surface. Minimum surface OD is 65.080 mm
(2.5622 inch).
R138

MODULE REBUILD
5–19. CONTROL VALVE MODULE
CAUTION:
• Transmission damage may occur when control
valve springs and other parts are mistakenly
interchanged. Interchanging parts can be
avoided by:
— Tagging each part as the part is
removed.
— Using Valve Tray Set J 33163 to
simplify correct valve body reassembly.
• Protect the control valve assembly parts from
damage by:
— Handling all valves carefully.
— Protecting the control valve assembly
parts during removal, cleaning,
inspection, and installation.
— Keeping the parts in clean containers
until the parts are installed.
• When the valves are installed dry, the weight of
the valves must be sufficient to move the valves
through the valve bores. If the valves do not
move freely, the transmission may be damaged.
a. Disassembly of Control Valve Assembly

Tools Required
• J 33163 Valve Tray Set

1. Position the control valve assembly on the
work table so that the main valve body
assembly is facing up.
2. Remove the six bolts (1) and one bolt (2)
retaining the reverse signal tube and pressure
switch assembly to the main valve body.
1
1
1 2
1
1 1
1
V08125.00.00

3. Remove reverse signal tube (2) from main

2
valve body (3).
4. Remove pressure switch assembly (1) from
main valve body (3).
1
R114
5. Remove two bolts (1) retaining modulated

1
main valve body (2) to valve body (3).
6. Remove modulated main valve body (2).
2
V08126.00.00 (R116).eps
V08176.00.00
7. Remove F trim solenoid retainer (1).

5
8. Remove F trim solenoid (7), sleeve (4),
1 valve (3), and spring (2).
9. Remove O-rings (5) and (6) from F trim
2 solenoid (7).
3
4
5
6
7
V08126.00.00

MODULE REBUILD
10. Remove D ON/OFF shift solenoid retainer (1).

5
11. Remove D ON/OFF shift solenoid (4).
1
12. Remove O-rings (2) and (3) from D ON/OFF
shift solenoid (4).
2 3
4
V08127.00.00
13. Remove E ON/OFF shift solenoid retainer (1).

5
14. Remove E ON/OFF shift solenoid (4).
1
15. Remove O-rings (2) and (3) from E ON/OFF
shift solenoid (4).
2 3 4
V08128.00.00
16. Remove three bolts (1) that retain A/B solenoid 1

bracket (2) to main valve body (3).
V08129.00.00

17. Remove A/B solenoid bracket (1), two

1 accumulator springs (2), and two accumulator
2 plugs (3).
3 3 2
16 18. Remove A trim solenoid (15), valve (13),
spring (12) if present, valve (11), and
spring (10).
19. Remove B trim solenoid (9), valve (7),

valve (6), and spring (5).
20. Remove O-ring (14) from A trim solenoid (15).

4
21. Remove O-ring (8) from B trim solenoid (9).
5
6
10 7
11 8
12 9
13
14
15
V08130.00.00
CAUTION:
2 Do not damage the solenoid(s) when turning over
1 the control valve assembly.

work table so that shift valve body (1) is facing
4 up.
23. Remove C ON/OFF shift solenoid retainer (2).
24. Remove C ON/OFF shift solenoid (5).

3 5
25. Remove O-rings (3) and (4) from C ON/OFF
shift solenoid (5).
V08131.00.00

MODULE REBUILD

work table so that the main valve body is
facing up.
1
1
27. Remove fourteen bolts (1) retaining the shift 1 1
valve body and the main valve body together.
28. Position the control valve assembly on the 1 1

work table so that the assembly is on edge 1
(sideways).
1 1
29. Reinstall four bolts (1) so that the bolts are 1 1 1
partially threaded into the shift valve body and
protrude from the main valve body. 1
1
30. Gently tap the bolts until the assembly
separates.
V08132.00.00

work table so that shift valve body (1) is facing 1
up.
32. Separate shift valve body assembly (1),

separator plate (2), and main valve body
assembly (4).
2
3 4
3
V08135.00.00
b. Disassembly of Shift Valve Body

1
Tools Required
• J 43773 Valve Spring Compressor 3
1. Using J 43773 (2), compress the C shift spring

until retaining clip (1) is loose. Remove the
clip.
2
R130

2. Remove spring (2) and C shift valve (1).
R131
3. Using J 43773 (2), compress the E shift spring

1 until retaining clip (1) is loose. Remove the
clip.
R132
4. Remove plug (3), spring (2), and E shift

valve (1).
2
3
R133

MODULE REBUILD
5. Using J 43773 (2), compress the D shift valve

spring until retaining clip (1) is loose. Remove 1
the clip.
R134
6. Remove plug (3), spring (2), and D shift

valve (1).
2
3
R135
7. Using J 43773 (2), compress the control main

valve spring until retaining clip (1) is loose. 1
Remove the clip.
R136

8. Remove spring (2) and control main valve (1).
R137
9. Remove solenoid screen (1).
V08137.00.00
c. Disassembly of Modulated Main Valve Body

1
1. Remove G ON/OFF solenoid (4) retainer.
2 2. Remove G ON/OFF solenoid (3) from
3 modulated main valve body (1).
3. Remove two O-rings (2) from the G ON/OFF
solenoid.
4 V08177.00.00

MODULE REBUILD
d. A/B Solenoid Bracket Inspection

1. Measure the angle between the surfaces of A/B 1
solenoid bracket (1) (Angle A).
2. Adjust the bracket surfaces until the angle
between the surfaces is approximately
82.84 degrees.
R148
e. Assembly of Shift Valve Body

Tools Required
1. Install solenoid screen (1).
2. Make sure the screen is installed to a depth of 1
0.50–1.00 mm (0.020–0.039 inch)
(Dimension A) below the shift valve body sur-
A
face as shown.
V08137.00.00
3. Install control main valve (1) and spring (2).
R137

4. Compress the spring with J 43773 (2).

1
retaining clip is below the valve body surface.
R136
6. Install D shift valve (1), spring (2), and

plug (3).
2
3
R135

1 8. Install retaining clip (1). Make sure the
R134

MODULE REBUILD
9. Install E shift valve (1), spring (2), and

plug (3).
2
3
R133

1
R132
12. Install C shift valve (1) and spring (2).
R131


1
R130
f. Disassembly of the Main Valve Body

1
Tools Required
3 • J 33163 Valve Tray Set
1. Using J 43773 (2), compress the control relief
spring until retaining clip (1) is loose. Remove
the clip.
R126
2. Remove spring (2) and control relief valve (1).
1
2
R127

MODULE REBUILD
3. Using J 43773 (2), compress the exhaust

backfill spring until retaining clip (1) is loose. 1
Remove the clip.
R128
4. Remove spring (2) and exhaust backfill

valve (1).
1 2
R129

g. Dowel Pin Replacement

Tools Required
• J 43779 Dowel Pin Installer
CAUTION:
DO NOT mar the main valve body surface when
installing the dowel pin(s). Use only gentle
tapping on dowel pin installer tool J 43779.
Heavy or continued hammering on J 43779 will
damage the main housing surface.
NOTE:
The main valve body has five dowel pins that can be
replaced. Do not replace a dowel pin unless the
dowel pin is damaged. Use the following procedure
to replace a dowel pin.
1. Remove the dowel pin from the main valve

body.
1
1 2. Place a new dowel pin into J 43779 (3).
3. Install J 43779 with the dowel pin into the
dowel pin hole.
4. Gently tap J 43779 until J 43779 touches the
main valve body surface.
1
of 10.7–11.3 mm (0.42–0.44 inch) above the
1 2 main valve body surface.
R125

MODULE REBUILD
h. Assembly of the Main Valve Body

Tools Required

1. Install exhaust backfill valve (1) and spring (2).
1 2
R129

1
R128
4. Install control relief valve (1) and spring (2).
1
2
R127


1
3
R126
i. Assembly of Control Valve Assembly

1 Tools Required
1. Position main valve body assembly (4) on the
work table so that the worm-track side is
facing up.
2
2. Align separator plate (2) with main valve body
dowel pins (3).
3 3. Install the separator plate.
4. Align shift valve body assembly (1) with main
valve body dowel pins (3).
3 4 5. Install the shift valve body assembly onto the
3
separator plate.
V08135.00.00

work table so that the main valve body is
facing up.
1
1 7. Install fourteen bolts (1) retaining the valve
1 1
bodies together. Tighten the bolts to 10–13 N·m
(7–10 lb ft).
1 1
1
1 1
1 1 1
1 1
V08132.00.00

MODULE REBUILD

work table so that the shift valve body is facing
up.
2
1
NOTE:
• O-ring (4) is slightly larger than O-ring (3).
• ON/OFF shift solenoid (5) has P/N 29536833
4
printed on the solenoid.
9. Install solenoid O-ring (4) onto C ON/OFF

shift solenoid (5). 3 5
10. Install solenoid O-ring (3) onto C ON/OFF
shift solenoid (5).
11. Align C ON/OFF shift solenoid (5) so that the V08131.00.00
electrical connector points away from the
nearest dowel pin and is parallel to the
separator plate.
12. Push the solenoid into the valve body until the
solenoid seats.
13. Install solenoid retainer (2).

CAUTION:
Do not damage the solenoid(s) when turning over
1
the control valve assembly.
2
3 3 2
16
work table so that main valve body (16) is
facing up.
NOTE:
A trim solenoid (15) has P/N 29533074 printed on
the solenoid.
4
5
6
15. Install solenoid O-ring (14) onto A trim
10 7
11 8 solenoid (15).
12 9
13
14
15 NOTE:
The B trim solenoid (9) has P/N 29533075 printed
on the solenoid.
V08130.00.00
16. Install solenoid O-ring (8) onto B trim

solenoid (9).
17. Install spring (10), A trim valve (11),
spring (12) if present, and trim gain valve (13).
18. Install spring (5), B trim valve (6), and trim
gain valve (7).
19. Install A trim solenoid (15) so that the
electrical connector faces up.
20. Install B trim solenoid (9) so that the electrical
connector faces up.
21. Align two accumulator plugs (3) so that their
spring bores are facing up.
22. Install two accumulator plugs (3) and

two accumulator springs (2).
23. Push the A and B trim solenoids into their

bores until the solenoids seat.
24. Align A/B solenoid bracket (1) with main
valve body dowel pin (4).
25. Install A/B solenoid bracket (1) so that the A
and B trim solenoids and the accumulator
plugs and springs are retained in the valve
body.

MODULE REBUILD
26. Install three bolts (1) through A/B solenoid

bracket (2). Tighten the bolts to 10–13 N·m 1
(7–10 lb ft).
V08129.00.00
NOTE:
5
• The solenoid O-rings are brown in color.
O-ring (3) is slightly larger than O-ring (2). 1

27. Install solenoid O-ring (3) onto E ON/OFF shift

solenoid (4).
28. Install solenoid O-ring (2) onto E ON/OFF shift

solenoid (4).
2 3 4
29. Install E ON/OFF shift solenoid (4) so that the
solenoid electrical connector faces up.
30. Install solenoid retainer (1). V08128.00.00
NOTE: 5
• The solenoid O-rings are brown in color.
O-ring (3) is slightly larger than O-ring (2). 1

31. Install solenoid O-ring (3) onto D ON/OFF shift

solenoid (4).
32. Install solenoid O-ring (2) onto D ON/OFF shift
solenoid (4).
2 3
33. Install D ON/OFF shift solenoid (4) so that the 4
solenoid electrical connector faces up.
V08127.00.00

5 NOTE:
The solenoid O-rings are brown in color. O-ring (6)
1
is slightly larger than O-ring (5).
2 35. Install solenoid O-ring (6) onto F trim

3 solenoid (7).
36. Install solenoid O-ring (5) onto F trim
solenoid (7).
37. Install F trim spring (2).
4
5 38. Install F trim valve (3).
6 39. Install F trim sleeve (4).
7
V08126.00.00 40. Align F trim solenoid (7) so that the electrical
connector faces up.
41. Push the solenoid into the valve body until the
solenoid seats.
43. Align the bolt holes and alignment tab of

pressure switch assembly (1) with the pressure
2
switch assembly holes in main valve body (3).
44. Install pressure switch assembly (1) onto main

1
valve body (3).
45. Install reverse signal tube (2) into the main

valve body.
3
R114

MODULE REBUILD
NOTE:
Seven bolts retain the reverse signal tube and the
pressure switch assembly.
• One bolt (2) is slightly longer than the other six
bolts (1).
• The pressure switch assembly is retained by five
bolts (1) and bolt (2). 1
1
• The reverse signal tube is retained by one
1 2
bolt (1) and bolt (2).
1
46. Install six bolts (1) and one bolt (2) retaining 1 1
1
the reverse signal tube and pressure switch
R114a
assembly to the main valve body.
47. Tighten the bolts (1) and (2) to 10–13 N·m
(7–10 lb ft).
j. Assembly of Modulated Main Valve Body
1
1. Install two O-rings (2) onto G ON/OFF
solenoid (3). 2
2. Install G ON/OFF solenoid (3) into its bore in 3
modulated main valve body (1).
3. Install solenoid retainer (4) into the valve body.
4 V08177.00.00
4. Align modulated main valve body (2) with its 1

bolt holes in main valve body (3).
NOTE: 2
The modulated main valve body retaining bolts,
M6 x 1.0 x 65, are slightly longer and gold colored.
5. Install two bolts (1) retaining modulated main

valve body (2) to main valve body (3). 3
6. Tighten bolts to 10–13 N·m (7–10 lb ft)

V08126.00.00 (R116).eps
V08176.00.00

NOTES
5–116 Copyright © 2003 General Motors Corp..

SECTION 6 — TRANSMISSION ASSEMBLY
6–1. C3 CLUTCH INSTALLATION

Tools Required
1
1. Position the main housing so that the front of
NOTE:
Do not reuse the old C3 clutch piston assembly. In-
stall a new C3 clutch piston assembly.
2. Apply petrolatum to the ID and OD of new C3

D39
clutch piston assembly (1).
3. Align new C3 clutch piston assembly (1) with
the main housing so that the seal is facing
down and the 1.016 mm (0.040 inch)
lubrication/cooling orifice positioned at the top
of the main housing.
4. Install the C3 clutch piston assembly. Gently
tap the piston until the piston seats.
NOTE: 1
• The spring assemblies can be reused. If required,
squeeze the spring assembly tabs with pliers to 1 2
make sure the spring assemblies are retained to
the spring plate.
• The piston return spring assemblies should snap
into place.
5. Install three piston return spring assemblies (1)

onto spring plate (2).
D38

6. Align spring plate (4) and piston return spring

3 assemblies (3) so that the spring assemblies
1
2
face up.
7. Install spring plate (4) into the main housing.
8. Starting with a C3 clutch friction plate,
4 alternately install four C3 clutch friction
plates (1) and three C3 clutch reaction plates (2)
into the main housing.
D37
9. Align C3 clutch backplate assembly (1) with

1 gear thrust plates (2) down.
10. Install C3 clutch backplate assembly (1) into
the main housing.
D37a
CAUTION:
1
2
gear thrust plate rivets of the C3 clutch
backplate assembly. The special tools could
3
4
5 11. Install J 24204-2 (1) and J 44530 (2) into the
main housing. Make sure J 44530 does not
12. Compress C3 piston return spring assemblies (5)
until the retaining ring groove is visible.
13. Install retaining ring (4). Make sure the
retaining ring is seated.
D36 14. Remove J 24204-2 and J 44530.

TRANSMISSION ASSEMBLY

C4 CLUTCH INSTALLATION
1
Tools Required
1. Position the main housing so that the rear of
NOTE:
Do not reuse the old C4 clutch piston assembly. In-
stall a new C4 clutch piston assembly.
D35a
2. Apply petrolatum to the ID and OD of new C4

clutch piston assembly (1).
3. Align C4 clutch piston assembly (1) so that the
seal is facing down and the 1.016 mm
(0.040 inch) lubrication/cooling orifice
positioned at the top of the main housing.
4. Install C4 clutch piston assembly (1). Gently
tap the piston until the piston seats.
5. Align P1 ring gear (1) so that the outside

splines are facing down.
6. Install P1 ring gear (1). Rotate the ring gear
1
until the C3 friction plates are engaged.
7. Make sure P1 ring gear (1) is seated against the
thrust plates of the C3 clutch backplate
assembly.
D35

8. Install P1 planetary module (2). Rotate the

1 module until the module drops into place.
CAUTION:
Installing the thrust bearing incorrectly could
destroy the transmission.
2
9. Align thrust bearing (1) so that the blue stripe

on the thrust bearing is facing away from P1
planetary module (2).
10. Install thrust bearing (1) onto P1 planetary
module (2).
D31a
1
NOTE:
• The spring assemblies can be reused. If
1 2 necessary, squeeze the spring assembly tabs with
pliers to make sure the spring assemblies are
retained to the spring plate.
• The piston return spring assemblies should snap
into place.
11. Install three piston return spring assemblies (1)

onto C4 spring plate (2).
D34
12. Align spring plate (4) and piston return spring

assemblies (3) with the spring assemblies up.
3 13. Install spring plate (4) into the main housing.
1 14. Starting with a C4 clutch friction plate,
alternately install five C4 clutch friction
4 2
plates (1) and four C4 clutch reaction plates (2).
D33

15. Install C4 clutch backplate (1).

1
CAUTION:
• DO NOT install special tools (J tools) onto the
gear thrust plate rivets of the C3 clutch back- D33a
plate assembly. The special tools could damage
the gear thrust plate rivets.
• DO NOT damage the P1 planetary carrier
bushing when installing J 24204-2 into the
main housing. The threaded rod of J 24204-2
must pass through but not touch the bushing.

main housing. Make sure J 24204-2 does not 1
touch gear thrust plate rivets (6) on the C3 2
clutch backplate assembly. 3
2. Compress piston return spring assemblies (5) 4

until the retaining ring groove is visible. 5
NOTE:
The spiral retaining ring must be installed so that
the spring leaves lay on top of each other. The leaves 6
must not cross over themselves. 6
3. Install spiral retaining ring (4).

D32a
CAUTION:
DO NOT damage the P1 planetary carrier
bushing when removing J 24204-2 from the main
housing. The threaded rod of J 24204-2 must
pass through but not touch the bushing.
5. Remove J 24204-2 and J 44530 from the main

housing.

6–3. C5 CLUTCH REACTION PLATE

1 SELECTION
Tools Required
2
NOTE:
The C5 clutch backplate installs in either direction.
3 The plate may have no grooves, one side grooved, or
both sides grooved.
1. Install C5 clutch backplate (3).
NOTE:
The C5 clutch pack uses a single selective reaction
V07805.00.00.eps plate. The C5 clutch pack is stacked out of order to
allow determining the required reaction plate part
number. When properly stacked, the top plate is a
reaction plate and the next two plates are friction
plates. The selective reaction plate is not stacked.
Reaction plates have an ID number stamped on a
tang. The ID number that does not match the other
ID numbers is the selective reaction plate.

alternately install the remaining five C5 clutch
friction plates (2) and four C5 clutch reaction
plates (1).
3. Install a C5 clutch friction plate (2).
4. Install a C5 clutch reaction plate (1).
CAUTION:
1
• DO NOT install special tools (J tools) onto the
2 gear thrust plate rivets of the C3 clutch back-
plate assembly. The special tools could damage
the gear thrust plate rivets.
• DO NOT damage the P1 planetary carrier
bushing when installing J 24204-2 into the main
housing. The threaded rod of the J 24204-2
must pass through but not touch the bushing.
3
4 main housing. Make sure J 24204-2 does not
NOTE:
V07806.00.00.eps
The C5 clutch plates need to be compressed enough
to remove the coning from the plates. Hand tighten-
ing the wing nut of J 24204-2 should be sufficient to
remove the coning.
6. Using the J 24204-2 wing nut, compress the

C5 clutch plates until hand tight.
7. Place a 1 inch (25 mm) gauge bar (2) on the

rear surface of the main housing at a location
near J 44530. B 1
2
8. Measure the distance from the top of the gauge
bar to the top of C5 clutch stack (3)
(Dimension A).
C A
9. Subtract dimension B, the width of the gauge
bar, from dimension A. Dimension C is the
result of the subtraction.
3
10. Select a C5 clutch reaction plate using
Dimension C and the table below.
Part ID
Dimension C Number Number
35.37–35.86 mm (1.393–1.412 in.) 29536481 1
35.87–36.36 mm (1.412–1.431 in.) 29536482 2
36.37–37.27 mm (1.432–1.467 in.) 29536483 3 V07807.00.00.eps
CAUTION:
1
DO NOT damage the P1 planetary carrier
bushing when removing J 24204-2 from the main
2
housing. The threaded rod of J 24204-2 must
pass through but not touch the bushing.
11. Remove J 24204-2 (3) and J 44530 (1).
3
4
V07806.00.00.eps

five C5 clutch reaction plates (1).
1
A30b

1 6–4. P2 PLANETARY MODULE AND

MAIN SHAFT INSTALLATION
Tools Required
• J 44587 Main Shaft Holder
2
1. Install P2 planetary module (2). Rotate the
module until the module drops into place.
CAUTION:
destroy the transmission.

V07808.00.00.eps facing towards P2 planetary module (2).
3. Install thrust bearing assembly (1) onto P2
planetary module (2).
4. Align J 44587 (1) with the PTO access as

follows.
• The tongue of J 44587 is facing toward the
PTO access.
• The bolts holes of J 45587 are aligned with
the two front bolt holes of the PTO access.
CAUTION:
Transmission damage may occur if special tool
J 44587 is not left in place until after the torque
converter housing is installed.
1 5. Install J 44587 (1) onto the PTO access.

2 6. Install two bolts (2) into J 45587 (1) and
V07722.00.00.eps tighten the bolts.

7. Install P2 sun gear (3) and sun gear spacer (2)

onto main shaft (4).
8. As a unit, install main shaft (4), P2 sun 2
gear (3), and sun gear spacer (2) into P2 4
1
planetary carrier (5). 3
9. Align P3 sun gear (1) so that the flat side of the
sun gear is facing the sun gear spacer.
10. Install P3 sun gear (1) onto main shaft (4).
Make sure P2 sun gear (3) and spacer (2) 5
splines are engaged.
V07720.00.00.eps
A29b
CAUTION:
destroy the transmission. 1
11. Align thrust bearing assembly (1) so that the 2

facing away from P3 sun gear (2)
12. Install thrust bearing assembly (1) into P3 sun

gear (2).
V07721.00.00.eps
6–5. C5 CLUTCH INSTALLATION

1
alternately install six C5 clutch friction
plates (2) and five C5 clutch reaction plates (3). 2
2. Install selected C5 clutch reaction plate (1). 3
V07809.00.00.eps

6–6. PARK PAWL INSTALLATION

1
1. If the transmission has a park pawl, install
2 apply assembly guide (3).
3 2. Align the tang in C5 piston return spring
assembly (1) with the notch in the main
housing.
3. Install C5 piston return spring assembly (1).
4. Install pawl support pin (2) into the main
housing.
D27
5. For transmissions with park pawls, do the

following.
1
2
• Install pawl return spring (2) onto park
pawl (1).
• Align the park pawl, pawl return spring
4 toward the rear, with support pin (3).
• Install park pawl (1) onto pawl support
pin (3).
• Connect pawl return spring (2) to the main
3
housing.
D26

6–7. OUTPUT SHAFT AND

1
P3 PLANETARY CARRIER
2
ASSEMBLY INSTALLATION
1. Install output shaft (2) into P3 planetary carrier
assembly (1).
2. While holding output shaft (2), place P3
planetary carrier assembly (1) into the top of
P3 ring gear (3).
3. Move/rotate the output shaft until the carrier
assembly drops into P3 ring gear (3). 3
4. Gently drop the output shaft onto main 4

shaft (4).
5. Rotate the carrier assembly until the carrier
assembly seats.
D25a

INSTALLATION 1
1. Install a new rear cover gasket (2) onto main

housing (3).
2. Align the rear cover module with main housing 2
dowel pin (4) and park pawl pin (5). Install the
rear cover module.
5
3. If present, turn the output tone wheel through
the output speed sensor hole. Make sure the 3
output shaft turns with the tone wheel.
D24

4. If a park brake cable bracket is present, do the

2 3
1 following.
3
2 CAUTION:
4 The bolts used to install the torque converter
similar in size and color. The rear cover bolts are
4 shorter than the torque converter housing bolts.
4 Installing torque converter housing bolts into the
rear cover may damage the main housing. To
4 help avoid installing torque converter housing
3 4 bolts into the rear cover and vice versa, store the
bolts separately. These bolts must be installed
into their correct locations to avoid main housing
damage.
3 4 4 4 4
D24d
CAUTION:
Some transmissions have park brake cable
brackets installed on their rear covers.
• Use bolts 40 mm (1.6 inch) long to install a
bracket 5 mm (0.2 inch) or less thick.
• Use bolts 45 mm (1.8 inch) long to install a
bracket thicker than 5 mm (0.2 inch).
Never install a 45 mm (1.8 inch) bolt into the rear
cover without at least a 5 mm thick park brake
cable bracket. Damage to the transmission may
result.
• Hand install four rear cover bolts (3).

• Evenly draw down rear cover bolts (3) until
the rear cover seats on the main housing.
• Install bracket (1) onto the rear cover.
• Install three bolts (2).
• Install nine bolts (4).
• Tighten the rear cover bolts (2), (3), and (4)
to 51–61 N·m (38–45 lb ft).

5. If a park brake cable bracket is not present, do

2 1
the following.
1
CAUTION: 2
The bolts used to install the torque converter 2 2

shorter than the torque converter housing bolts. 2
Installing torque converter housing bolts into the 2
rear cover may damage the main housing. To
help avoid installing torque converter housing 2
bolts into the rear cover and vice versa, store the 1 2
bolts separately. These bolts must be installed
into their correct locations to avoid main housing
damage.
1 2 2 2 2
• Hand install four rear cover bolts (1). D24e
• Evenly draw down rear cover bolts (1) until

the rear cover seats on the main housing.
• Install twelve bolts (2).
• Tighten the rear cover bolts (1) and (2) to
51–61 N·m (38–45 lb ft).

6–9. CONTROL VALVE ASSEMBLY

INSTALLATION
1
2 1. Position the main housing so that the valve
body face of the main housing is facing up.
NOTE:
Install a lint-free cloth into the park pawl apply as-
sembly guide hole to prevent the selector valve pin
from falling into the transmission.
2. Install a lint-free cloth (1) in the park pawl

apply assembly guide hole in main
housing (2).
V08025.01.00
3. Align selector valve pin (3) with manual

selector valve (2).
4. Rotate the selector valve pin until the pin can
be installed into the manual selector valve.
5. Install selector valve pin (3) into manual
selector valve (2).
6. Install the manual selector valve into shift
valve body (1).
1
2
3
V08124.00.00
CAUTION:
Do not drop the main selector valve when
1 removing or installing the control valve
assembly. The main selector valve can be easily
2 damaged.
3 7. Align the control valve assembly with the main

housing while installing selector valve pin (3)
into detent lever (1).
D23a

8. Align two control valve assembly dowel

pins (1) with the dowel pin holes in the main
housing. 1 2
9. Install control valve assembly (2) onto the
main housing.
V08123.00.00
10. Remove lint free cloth (1) from the park pawl
apply assembly guide hole.
1
2
V08026.01.00
11. Install 11 control valve assembly bolts (1).

Tighten the bolts to 10–13 N·m (7–10 lb ft).
2
1
2
1 1
1 1
1 1
1
1
1 1
1
V08121.00.00

12. Install detent spring assembly (2) onto main

1 1 valve body (4). Make sure detent spring
assembly (2) roller rests on detent lever (3).
4 2
13. Install 2 detent spring assembly bolts (1).
V08120.00.00
6–10. WIRING HARNESS ASSEMBLY

INSTALLATION
2 Tools Required
0 (R116).eps
• J 44247 Wiring Harness Connector Installer
1. Install the internal wiring harness connector by
hand into the main housing.
2. Using J 44247 (2), install the connector of
internal wiring harness (1) into the main
housing. The four tabs on the wiring harness
connector snap into place.
3. Make sure the wiring harness connector is
securely in place.
1
V08139.01.00
4. Remove ON/OFF shift solenoid retainers (1).

1
5. Install internal wiring harness (2) onto main
2
valve body (10).
11 6. Install ON/OFF shift solenoid retainers (1)
over the wiring harness tabs.
10 7. Connect internal wiring harness (2) to the
following components as shown.
• Pressure switch assembly (9)
• C ON/OFF shift solenoid (7)
• F trim solenoid (3)
• D ON/OFF shift solenoid (4)
9 3 • E ON/OFF shift solenoid (5)
4
• B trim solenoid (6)
5
6 • A trim solenoid (8)
8
7 V07821.01.00 • G ON/OFF modulated main solenoid (11)

8. Install connector shipping cover (1) into the

wiring harness connector.
V07819.02.00
6–11. OIL PAN AND SUCTION FILTER 1

INSTALLATION 7 2
CAUTION: 3
If a shallow pan and filter were removed, 4

reinstall a shallow pan and filter. If a deep pan
and filter were removed, reinstall a deep pan and
filter. Transmission damage can occur if the
correct oil pan and filter are not installed.
5
1. Install suction filter seal (6) onto suction
filter (5).
6
2. Align the neck of suction filter (5) with the
filter hole in the main housing.
3. Install filter (5). Make sure the filter is seated. V07773.01.00
4. Install a new oil pan gasket (4) onto the main

housing.
5. Install oil pan (3) onto the main housing.
6. Install twelve oil pan bolts (7). Tighten the
bolts to 24–29 N·m (18–21 lb ft).
7. Install drain plug seal (2) onto drain plug (1).
8. Install drain plug (1). Tighten the plug to
30–40 N·m (22–30 lb ft).

6–12. ROTATING CLUTCH ASSEMBLY

INSTALLATION
Tools Required
• J 44587 Main Shaft Holder

1. Position the main housing so that the front of
1 2. Remove two bolts (2) from J 44587 (1).
3. Remove J 44587 from the PTO access.
V08028.00.00
4. Apply petrolatum to thrust bearing (1).
CAUTION:
1 destroy the transmission.
5. Align thrust bearing (1) so that the blue stripe

on the thrust bearing is facing towards the P1
planetary carrier assembly.
6. Install thrust bearing (1) into the P1 planetary
carrier assembly.
V07725.00.00.eps
7. Install rotating clutch assembly (1). Rotate the

clutch assembly until the module seats.
1 8. Make sure one of the following is visible
through the turbine speed sensor hole in the
main housing:
• The teeth of the PTO gear
• The teeth of the turbine tone wheel
D17a


SUPPORT MODULE
INSTALLATION
WARNING!
The 1000/2000/2400 Series converter housing/
front support module dry weights are 1
approximately 27 kg (60 lb). To help avoid
• Use caution when installing, removing, or mov-
ing the converter housing/front support module.
• Get help when lifting the converter housing/
front support module. Assistance from a hoist
or another person may be required. 2
• Make sure lifting equipment can properly 3

support the converter housing/front support
module.
5 4
NOTE:
Separator Plate Gasket (2) has been redesigned. The A12
former and current designs are interchangeable. The

former design may be reused unless replacement is
necessary or the design is no longer available.
1. Install a new main housing/separator plate

gasket (3) onto the main housing.
2. Install two M10 x 1.5 guide bolts (5) into main
housing (4).
3. Attach a sling to converter housing (1).
4. Attach a hoist to the sling. Align converter
housing (1) with guide bolts (5).
5. Apply petrolatum to the three sealrings on the
rear of the front support.
6. Lower converter housing/front support module
(1) over turbine shaft (2) and onto main
housing (4).
CAUTION:
Transmission damage may occur if the torque
converter housing is forced into position. If
tapping does not cause the torque converter
housing to drop into position, the P3 sun gear
and/or P3 sun gear spacer or a sealring may be
misaligned.
7. Tap the converter housing until the converter

housing seats on the main housing. Remove
the sling.

CAUTION:
shorter than the torque converter housing bolts.
Installing torque converter housing bolts into the
rear cover may damage the main housing. To help
avoid installing torque converter housing bolts
into the rear cover and vice versa, store the bolts
separately. These bolts must be installed into their
correct locations to avoid main housing damage.
8. Remove two guide bolts (5) from the main
housing.
9. For SAE No. 2 or No. 3 converter housings, do
the following.
1 1 • Install fifteen bolts (1).
1 • Install five bolts (2).
1
1
• Tighten the bolts (1 and 2) to 51–61 N·m
1
(38–45 lb ft).
1 1
1
1
1 1
2
1
2 2 2 2 1
1
D10
10. For direct mount torque converter housings, do

the following.
• Install eighteen bolts (1).
1 1
1 1 • Install one bolt (2).
• Install one bolts (3).
1 1
1 • Tighten the bolts (1, 2, and 3) to 51–61 N·m
1 (38–45 lb ft).
1
1
1 1
1 1 1 1 2
1
1
3
D10a


2
SPACER INSTALLATION 1
2. Measure the distance (Dimension A) from the A
rear face of rear cover (1) to the rear face of
output tone wheel (2).
A24bi
3. Measure the distance from the rear face of rear

1
cover module (3) to the rear face of retaining 2 3
ring (4) (Dimension B).
4. Calculate Dimension C by subtracting 4
Dimension B from Dimension A
(Dimension C = Dimension A – Dimension B).
B
5. Select the appropriate selective spacer (1) from
the following table based on the Dimension C.
Part # of
Dimension C Number Thickness Holes
1.0081–1.184 mm 29536850 0.245-0.295 mm 0
(0.0397-0.0466 in.) (0.0096-0.0116 in.)
1.185-1.414 mm 29536851 0.475-0.525 mm 1
(0.0467-0.0557 in.) (0.0187-0.0207 in.) A24c
1.415-1.644 mm 29536852 0.705-0.755 mm 2

(0.0557-0.0647 in.) (0.0278-0.0297 in.)
1.645-1.874 mm 29536853 0.935-0.985 in) 3
(0.0648-0.0738 in.) (0.0368-0.0388 in.)
1.875-2.104 mm 29536854 1.165-1.215 mm 4
(0.0738-0.0828 in.) (0.0459-0.0478 in.)
2.105-2.334 mm 29536855 1.395-1.445 mm 5
(0.0829-0.0919 in.) (0.0549-0.0569 in.)
2.335-2.5015 mm 29536856 1.625-1.675 mm 6
(0.0919-0.0988 in.) (0.0640-0.0659 in.)
6. Install selective spacer (1) onto output shaft (2).


2 1
SPACER INSTALLATION
A
2. Measure the distance (Dimension A) from the
rear face of rear cover (1) to the rear face of
bearing spacer (2).
D40
3. Measure the distance from the rear face of rear

1
2 3 cover module (3) to the rear face of retaining
ring (4) (Dimension B).
4. Calculate Dimension C by subtracting
4 Dimension B from Dimension A
(Dimension C = Dimension A – Dimension B).
B
5. Select the appropriate selective spacer (1) from
the following table based on Dimension C.
Part # of
Dimension C Number Thickness Holes
1.0081–1.184 mm 29536850 0.245-0.295 mm 0
(0.0397-0.0466 in.) (0.0096-0.0116 in.)
1.185-1.414 mm 29536851 0.475-0.525 mm 1
D41 (0.0467-0.0557 in.) (0.0187-0.0207 in.)
1.415-1.644 mm 29536852 0.705-0.755 mm 2
(0.0557-0.0647 in.) (0.0278-0.0297 in.)
1.645-1.874 mm 29536853 0.935-0.985 in) 3
(0.0648-0.0738 in.) (0.0368-0.0388 in.)
1.875-2.104 mm 29536854 1.165-1.215 mm 4
(0.0738-0.0828 in.) (0.0459-0.0478 in.)
2.105-2.334 mm 29536855 1.395-1.445 mm 5
(0.0829-0.0919 in.) (0.0549-0.0569 in.)
2.335-2.5015 mm 29536856 1.625-1.675 mm 6
(0.0919-0.0988 in.) (0.0640-0.0659 in.)
6. Install selective spacer (1) onto output

shaft (2).

6–16. TRANSMISSION END

PLAY CHECK 1
Tools Required 2
• J 24446 Rear Bearing Installer
• J 5959 Dial Indicator Set
1. Using J 24446 (1), install ball bearing (2) until
the bearing seats.
A24e
2. Align retaining ring (1) so that the beveled

edge is facing up. 1
A24f
4. Position the main housing so that the front is

facing up. Assemble the following tools and 1 2
install them onto the torque converter housing
as shown. 4
• J 5959-1 (2)
3
• J 5959-2 (3)
• J 5959-3 (1)
• J 5959-7 (4)
5. Zero dial indicator (2).
6. Lift the rear of the rotating clutch housing
with a screwdriver through the PTO hole in
the main housing. Note the dial indicator
reading (end play). The end play must be
0.279–1.549 mm (0.0110–0.0610 inch).
A24g

7. If the end play is not within the specification, a

different selective spacer must be installed.
Perform the following.
• Remove the following tools from the
transmission.
— J 5959-1 (2)
— J 5959-2 (3)
— J 5959-3 (1)
— J 5959-7 (4)
• Remove the retaining ring and ball bearing
assembly per Paragraph 4–13, Rear Ball
Bearing Removal.
• Return to Paragraph 6–14, Rear Cover
Selective Spacer Installation.
• Repeat the end play check procedures in
Paragraph 6–16.

INSTALLATION
1 WARNING!
The 1000/2000/2400 Series torque converter dry
weights are approximately 29 kg (63 lb). To help
2 moving the torque converter.
• Get help when lifting the torque converter. As-
sistance from a hoist or another person may be
required.
• Make sure lifting equipment can properly sup-
port the torque converter.
D9b
1. Position the transmission so that the converter
2. Attach a sling to torque converter (1). Attach a
hoist to the sling.
3. Lower torque converter (1) over the turbine
shaft and the ground sleeve and into the main
pump assembly. Make sure the torque
converter is seated in the main pump assembly.
4. Remove the sling.

WARNING!
The torque converter must be held to the torque
converter housing by a retaining device such as
shipping brackets. Without the retaining device,
the torque converter may slide forward,
disengaging the oil pump, or may fall completely
out of the transmission causing personal injury
and/or property damage. NEVER tilt the
converter end down unless a torque converter
retaining device is installed.
NOTE:
The torque converter may not be seated if the ship-
ping brackets cannot be installed.
A correctly installed torque converter will lift when

the shipping bracket bolts are tightened.
5. If used, install two shipping brackets (2) and

four bolts (1). 1
1
2
2
1
1
D9

1
6. If used, install shipping bracket (3), two
2
bolts (1), two nuts (4), and bolt (2).
1 3
D9a
6–18. NSBU SWITCH INSTALLATION

(IF PRESENT)
Tools Required
• J 41364-A NSBU Switch Adjusting Tool (if

reusing the NSBU switch)
1. Place selector shaft (1) in the N (Neutral)

20.9° position as follows.
1
• Using a wrench on selector shaft flats (1),
rotate the shaft to its fullest clockwise
position.
• Rotate the selector shaft counter-clockwise
1 two detents.
2
D
P OD
R N
23.2°
34.3°
45.5°
56.2° 67.0°
77.8°
R63d

2. If a new NSBU switch is being installed, do the

following.
• Align the flats on the hub of NSBU
switch (1) with the flats of selector
shaft (3).
• While maintaining the correct NSBU
switch-to-selector-shaft alignment, install
the NSBU switch onto the selector shaft and
onto the main case.
• Install front splash shield (4) over the
selector shaft so that the larger diameter
seals against the NSBU switch body.
1
• Install two bolts (2). Tighten the bolts to
24–29 N·m (18–21 lb ft). 3
2
4
2 V07746.02.00
3. If the NSBU switch is being reused, do the

following.
• Align the flats on the hub of NSBU switch
(1) with the flats of the selector shaft. 1
• Install the NSBU switch onto the selector
shaft.
• Position special tool J 41364-A (2) over the
selector shaft so that the two tabs on the
tool engage two slots on the NSBU switch
near the selector shaft.
• Rotate the NSBU switch (1) and J 41364-A
until the tab at the other end of tool (2)
engages the slot at the top of the NSBU 2
switch.
• While holding J 41364-A (2) to NSBU
switch (1), tighten the bolts to 24–29 N·m V08088.01.00
(18–21 lb ft)
• Remove J 41364-A from the NSBU switch.
• Install the front splash shield over the
selector shaft so that the large diameter
seals against the NSBU switch body.

NOTE:
The shift selector lever and shift lever nut may not
be present.
4. Align selector lever (1) with selector shaft (2).

6 If the lever is punched, the punched side
should face the main case.
5. Install the lever onto the selector shaft until the
lever is fully seated on the shaft shoulder.
®
6. Hand install selector lever nut (3) onto the
selector shaft.
6 5
4 3 2 CAUTION:
1
To avoid internal damage to the transmission:
V08086.01.00 • Do not use a power impact wrench to torque
the shift lever nut.
• Hold the selector lever while torquing the shift
lever nut.
7. While holding the selector lever, tighten the

selector lever nut to 20–27 N·m (15–20 lb ft).

6–19. REAR SEAL INSTALLATION

Tools Required
1
• J 43782 Output Shaft Seal Installer
2
• J 43783 Output Shaft Seal Installer
NOTE:
• For transmissions without a parking brake pro-
vision, install the oil seal using J 43782.
• For transmissions with a parking brake provi-
sion, install the oil seal using J 43783.
1. Using J 43782 or J 43783 (1), install the oil

seal (2).
2. Check the installation of the oil seal as follows.
• For transmissions without a parking brake
provision, make sure the rear output seal is A24i
installed to 4.55–5.35 mm (0.179–0.211 inch)
below the rear face of the rear cover.
• For transmissions with a parking brake
provision, make sure the rear output seal is
installed to 31.10–31.90 mm (1.224–1.256 inch)
below the rear face of the rear cover.
6–20. OUTPUT NUT INSTALLATION

(1000 SERIES™ 4WD
TRANSMISSIONS ONLY)
Tools Required
• J 43769 Spanner Nut Wrench—4WD

20.9°
1
NOTE:
The fullest clockwise position of the selector shaft is
P (Park), which engages the park pawl.
1
1. Using a wrench on selector shaft flats (1),
2
rotate the shaft to its fullest clockwise position. D
P OD
R N
23.2°
34.3°
45.5°
56.2° 67.0°
77.8°
R63d

2. Make sure the park pawl is engaged.

3. Install J 43769 (1) onto output nut (2).
4. Using J 43769 (1), install a new output nut (2)
1 onto output shaft (3).
2 5. Tighten output nut (2) to 54–68 N·m (40–50 lb ft).
A24j
NOTE:
20.9°
1 The N (Neutral) position of the selector shaft is two
detents counter-clockwise from the fullest clockwise
position.
6. Rotate the selector shaft counter-clockwise two

1 detents.
2 7. Make sure the park pawl is disengaged.
D
P OD
R N
23.2°
34.3°
45.5°
56.2° 67.0°
77.8°
R63d

6–21. VENT INSTALLATION

1. Install vent (1) by hand.
2. Gently tap on vent (1) until seated. 1
V07744.00.00
6–22. INPUT SPEED SENSOR

1 2
INSTALLATION
1. Install sensor O-ring (3) onto speed sensor (2). 3
2. Apply petrolatum to O-ring (3).
3. Install speed sensor (2) into the converter
housing.
4
4. Install speed sensor bolt (1) into the converter
housing. Tighten the bolt to 10–13 N·m
(7–10 lb ft).
5. If present, install sensor shipping cover (4)
onto the speed sensor.
D4b

6–23. TURBINE SPEED SENSOR

1
2 INSTALLATION
3 1. Install sensor O-ring (3) onto speed sensor (2).
3. Install speed sensor (2) into the main housing.
4 4. Install speed sensor bolt (1) into the main housing.
Tighten the bolt to 10–13 N·m (7–10 lb ft).
D4a
6–24. OUTPUT SPEED SENSOR

1 INSTALLATION
2 (2WD TRANSMISSIONS ONLY)
3
1. Install sensor O-ring (3) onto speed sensor (2).
3. Install speed sensor (2) into the rear cover.
4. Install speed sensor bolt (1) into the rear cover.
Tighten the bolt to 10–13 N·m (7–10 lb ft).
4 D4

6–25. REMOVAL OF TRANSMISSION

FROM REPAIR STAND
1
Tools Required 2
• J 44723 Transmission/Stand Adapter Plate

• J 29109 Repair Stand
WARNING!
The 1000/2000/2400 Series transmission dry
weights are approximately 150 kg (330 lb). To
help avoid personal injury and/or property
damage:
moving the transmission.
• Get help when lifting the transmission. Assis- V08141.01.00
tance from a hoist or another person may be
required.
• Make sure lifting equipment can properly sup-
port the transmission.
1. Attach a sling to the transmission.

2. Attach a hoist to the sling. Put moderate lift
tension on the hoist.
3. Disconnect and remove transmission (2) from
adapter plate J 44723 (1).
4. Place the transmission on the work table with
the oil pan facing down.
NOTE:
PTO Cover Gasket (2) has been redesigned. The 2 3
1
former and current designs are interchangeable.
The former design may be reused unless replace-
ment is necessary or the design is no longer avail-
able. DO NOT use a PTO cover gasket to mount a
PTO.
5. If present, install two PTO cover gaskets (1). 1

2
6. If present, install two PTO covers (2).
3
7. If present, install twelve PTO cover bolts (3).
8. If present, install the PTO(s) per the PTO
manufacturer’s instructions. V07702.02.00

NOTES

SECTION 7 — WEAR LIMITS AND SPRING DATA
7–1. WEAR LIMITS DATA meet the load height specifications according to Table
7–2, Spring Data.
a. Maximum Variations. Wear limits information
in this Section are the maximum wear at which
b. Inspection. Inspection criteria (load vs. height)
components are expected to function satisfactorily.
and identification characteristics of the springs are pre-
Table 7–1 lists the Wear Limits Data.
sented in Table 7–2. The Spring Data are keyed to the
b. Cleaning and Inspection. Parts must be clean to exploded views (Foldouts 5 through 20) in the back of
permit effective inspection for wear or damage. Refer this manual.
to Section 3.
NOTE:
7–2. SPRING DATA When more than one spring part number is listed
for the same location, refer to the latest edition of
a. Spring Replacement. Replace springs if there Parts Catalog PC3062EN to determine which
are signs of overheating, wear due to rubbing adjacent spring is used in your specific assembly number.
parts, or permanent set. Discard springs which do not
Table 7–1. Wear Limits Data

Wear Limit
Description mm (inches)
TORQUE CONVERTER MODULE
Maximum Torque Converter End Play — Used 1.015 0.0400
Maximum Torque Converter End Play — New 0.762 0.0300
Converter Pump Hub:
Minimum OD 58.250 2.2933
Minimum Distance Between Flats 51.816 2.0400
Cover Pilot, Minimum OD 43.080 1.6960
FRONT SUPPORT AND OIL PUMP MODULE
Charging Pump:
Bushing, Maximum ID
The pump bushing must have a complete burnt-orange color
58.458 2.3015
Teflon® coating. If any portion of the Teflon® coating is worn
and bronze material is visible, replace the pump.
Gear Cavity, Maximum Depth 24.940 0.9819
Gear Cavity, Maximum ID 109.191 4.2989
Driven Gear, Max. Diametric Clearance w/ Pump Body 0.204 0.0080
Driven Gear, Maximum Tooth Clearance w/ Crescent 0.455 0.0179
Driven Gear, Minimum OD 108.987 4.2908
Wear Plate, Minimum Thickness 2.950 0.1161
Gear-to-Wear Plate, Maximum Side Clearance 0.064 0.0025
Drive Gear, Maximum Distance Between Flats 52.165 2.0537
Drive Gear, Side Clearance 0.066 0.0026

Table 7–1. Wear Limits Data (cont’d)
Wear Limit
Front Support and Ground Sleeve:
Ground Sleeve, Maximum ID at Turbine Shaft Sealring Bore 45.450 1.7894
Ground Sleeve, Maximum Spline Wear No visible wear allowable
Ground Sleeve Bushing, Maximum ID 33.820 1.3315
Thrust Washer 1.49 0.059
ROTATING CLUTCH MODULE
Rotating Clutch Housing:
Bushing, Maximum ID 78.170 3.0776
Rotating Seal Bore, Maximum ID 74.050 2.9154
C1 Friction Plates:
Maximum Cone 0.255 0.0100
Minimum Thickness 2.375 0.0935
Minimum Oil Groove Depth 0.200 0.0079
C1 Steel Reaction Plate:
C1 Backplate:
Minimum Thickness (Selective)
Part # 29536221 11.840 0.4661
Part # 29536222 12.280 0.4835
Part # 29536223 12.730 0.5012
Part # 29536224 13.180 0.5189
Part # 29536225 13.630 0.5366
C2 Friction Plates:
Turbine Shaft Bushing, Maximum ID 20.117 0.7920
Thrust Washer 2.59 0.102

WEAR LIMITS AND SPRING DATA
Wear Limit
MAIN HOUSING MODULE
C3/C4 Friction Plate:
C3/C4 Steel Reaction Plate:
C3/C4 Spring Plate:
C3 Backplate:
Thrust Plate Inner Rim, Minimum Thickness 3.000 0.1181
C4 Backplate:
C5 Friction Plate:
Minimum Thickness (Selective)
Part # 29536481 1.935 0.0762
Part # 29536482 2.435 0.0959
Part # 29536483 2.935 0.1156
C5 Backplate:
P1 Ring Gear, Maximum Spline Wear (Notching) 0.100 0.0040
Main Housing Clutch Plate, Spline Wear (Notching) 1.150 0.0450

Wear Limit
PLANETARY GEAR MODULE
P1 Carrier Assembly:
Pinion Gear, Maximum End Play 1.010 0.0400
Thrust Washer, Minimum Thickness 1.490 0.0590
Main Shaft:
Pilot, Minimum OD (Turbine Shaft and Output Shaft) 19.987 0.7869
Journal, Minimum OD (P2 Carrier Bushing) 36.405 1.4333
REAR COVER MODULE
Output Shaft Bushing (2WD and 4WD), Maximum ID 20.070 0.7940
Output Shaft (2WD and 4WD), Minimum Bearing Surface OD 44.978 1.7708
Parking Pawl Gear Wear 0.000 0.0000
OUTPUT YOKE
Output Seal Surface, Minimum OD 65.080 2.5622

Table 7–2. Spring Data
Spring Approx. Free
Length Under Load
Color No. Wire Dia. OD Length
Foldout Ref. Spring Part No. Code Coils mm (in.) mm (in.) mm (in.) mm (in.) N (lb) min.
6, 13 12, 4 C3/C4 Return Spring 29531046 No code 8.78* 1.588* 12.00* 31.89** 24.81** 162.00–187.60**
Assembly (0.0625) (0.472) (1.256) (0.977) (36.42–42.17)
9 22 Main Pressure 29531017 No Code 11.87 2.77 22.61 73.74 41.50 231.56–255.94
Regulator (0.109) (0.890) (2.903) (1.634) (52.06–57.54)
9 11 Converter Relief 29541296 No Code 12.18 1.42 13.46 44.85 22.84 45.10–55.44
(0.056) (0.529) (1.766) (0.899) (10.14–12.46)
9 7, 14 Lube Reg/Converter 29540523 Light Blue 6.79 1.60 16.10 31.43 17.05 54.23–73.89
Flow (0.063) (0.634) (1.237) (0.671) (12.19–16.61)
9 19 Clutch Backfill 29531026 No Code 8.75 0.64 9.65 29.93 11.20 5.59–6.59
(0.025) (0.380) (1.178) (0.44) (1.26–1.48)
10 16 C2 Return Spring 29536104 No Code 5.77* 1.143* 10.05* 19.60** 15.90** 652.5–770.9**
Assembly (0.0450) (0.396) (0.772) (0.626) (146.7–173.3)
10 25 C1 Return Spring 29536198 No Code 7.99* 1.295* 9.17* 19.49** 15.62** 941.2–1126.4**
Assembly (0.0510) (0.361) (0.767) (0.615) (211.6–253.2)
19B, 19C 14, 6 Control Main/Control 29541153 No Code 11.85 1.50 14.00 40.62 22.11 45.86–50.68
Relief (0.059) (0.551) (1.599) (0.870) (10.31–11.39)
19C 3 Exhaust Backfill 29531161 Orange Stripe 11.35 0.90 12.60 22.54 16.16 2.537–3.003
(0.035) (0.496) (0.887) (0.636) (0.570–0.675)
19C 11, 17, 28 A, B, and F Trim 29536313 No Code 7.44 0.76 9.80 20.15 9.44 8.14– 9.70
(0.030) (0.386) (0.793) (0.372) (1.83–2.18)

19C 13 A Trim 29537230 No Code 7.21 1.30 15.20 23.25 13.37 18.69–21.35
(0.051) (0.598) (0.915) (0.526) (4.20–4.80)
19B 4, 8, 11 C, D, and E Shift 29531176 No Code 11.55 1.00 11.00 29.29 14.26 14.61–16.59
(0.039) (0.433) (1.153) (0.561) (3.28–3.73)
WEAR LIMITS AND SPRING DATA
16A 5 C5 Return Spring 29531134 No Code 7.8* 1.702* 13.5* 31.40** 21.60** 1454.6–1620.2**
Assembly (0.0670) (0.531) (1.236) (0.850) (327.0–364.2)
16A 4 Park Pawl Return 29531147 No Code 6 0.75 8.70 29.55 41.75 11.3–14.9
(0.030) (0.343) (1.161) (1.644) (2.5–3.3)
* Individual Springs
** For the complete Spring Assembly
7–5
NOTES

SECTION 8 — CUSTOMER SERVICE
8–1. OWNER ASSISTANCE Step Two — If your problem cannot be resolved
readily at the distributor level without additional
The satisfaction and goodwill of the owners of Allison
assistance, contact the Allison Transmission
transmissions are of primary concern to Allison Trans-
Regional Office responsible for your local
mission Division (ATD), its distributors, and their
distributor. You will be assisted by a member of the
dealers.
Regional Service Manager’s staff, depending on the
As an owner of an Allison transmission, you have ser- nature of your problem.
vice locations throughout the world eager to meet your
parts and service needs with: For prompt assistance, please have the following infor-
mation available:
• Expert service by trained personnel
• Emergency service 24 hours a day in many • Name and location of authorized distributor or
areas dealer
• Complete parts support
• Type and make of equipment
• Sales teams to help determine your
• Transmission model number, serial number,
transmission requirements
and assembly number — if equipped with
• Product information and literature
electronic controls, also provide the ECU
Refer to the Worldwide Sales and Service Directory assembly number
(SA2229EN) or the Allison transmission web site
• Transmission delivery date and accumulated
www.allisontransmission.com for a current listing of
miles and/or hours of operation
Allison Transmission authorized distributor and service
dealers. This directory is available from SGI, Inc. • Nature of problem
• Chronological summary of unit’s history
Normally, any situation that arises in connection with
the sale, operation, or service of your transmission will Step Three — If you contacted a regional office and
be handled by the distributor or dealer in your area. you are still not satisfied, present the entire matter to
(Check the Allison transmission web site the Home Office by writing to the following address
www.allisontransmission.com or a telephone directory or calling the phone number below:
for the Allison Transmission service outlet nearest
you.) Manager, Warranty Administration — PF9
We recognize, however, that despite the best intentions P. O. Box 894
of all concerned, misunderstandings may occur. To Indianapolis, IN 46206-0894
further assure your complete satisfaction, we have Phone: 1-800-524-2303
developed the following three-step procedure to be
followed in the event you have a problem that has not The inclusion of all pertinent information will assist
been handled satisfactorily. the Home Office in expediting the matter. If an addi-
tional review by the Home Office of all the facts in-
Step One — Discuss the problem with a member of volved indicates that some further action can be taken,
management from the distributorship or the Regional Office will be advised.
dealership. Complaints are frequently the result of a
breakdown in communication and can be quickly When contacting the Regional or Home Office, please
resolved by a member of management. If you have keep in mind that ultimately your problem will likely
already discussed the problem with the Sales or be resolved at the distributorship or dealership utiliz-
Service Manager, contact the General Manager. All ing their facilities, equipment, and personnel. There-
ATD dealers are associated with an ATD distributor. If fore, it is suggested that the above steps be followed in
the problem originates with a dealer, explain the sequence when experiencing a problem.
matter to a management member of the distributorship
with whom the dealer has his service agreement. The Your purchase of an Allison Transmission product is
dealer will provide his ATD distributor’s name, greatly appreciated, and it is our sincere desire to as-
address, and telephone number on request. sure complete satisfaction.

8–2. SERVICE LITERATURE Table 8–1. 1000/2000/2400 Series Literature
(Table 8–1) Automatic Transmission Fluid GN2055EN
Additional service literature is available. This service Technician’s Guide
literature provides fully illustrated instructions for the *Mechanic’s Tips MT3190EN
operation, maintenance, service, overhaul, and parts *In-Chassis Maintenance JA3664EN
support for your transmission. To ensure that you get
maximum performance and service life from your *Operator’s Manual—1000/2000/2400 Series OM3063EN
unit, you may order publications from: *Operator’s Manual—2000MH Series OM3364EN
Parts Catalog PC3062EN
SGI, Inc.
Parts Catalog CD-ROM CD3062EN
Attn: Allison Literature Fulfillment Desk
8350 Allison Avenue Principles of Operation PO3065EN
Indianapolis, IN 46268 Retail Literature Catalog GN2798EN
TOLL FREE: 888-666-5799 Service Manual SM3191EN
INTERNATIONAL: 317-471-4995
Electronic Troubleshooting Manual TS3192EN
Worldwide Sales and Service Directory SA2229EN
*Also available on The Internet at www.allisontransmission.com

Legend For Foldout 1 Is On The Opposite Side Of This Page.
Copyright © 2003 General Motors Corp. Foldout 1

Legend For Foldout 1
1 — Torque converter assembly

2 — Converter housing
3 — Turbine shaft
4 — Input speed sensor
5 — Main pump assembly
6 — Front support assembly
7 — Rotating clutch assembly
8 — Turbine speed sensor
9 — PTO gear
10 — C1 clutch
11 — C2 clutch
12 — C3 clutch
13 — P1 planetary
14 — Main shaft
15 — P2 planetary
16 — C4 clutch
17 — P3 planetary
18 — C5 clutch
19 — Main housing
20 — Rear cover
21 — Output shaft
22 — Output speed sensor
23 — Output yoke
24 — Oil pan
25 — Shift valve body assembly
26 — Suction filter
27 — Main control valve assembly
28 — Tone wheel
29 — Control main filter
Foldout 1 Copyright © 2003 General Motors Corp.

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V06630.02.00
29 28 27 26 25 24
Foldout 1. 1000 Series™ — Cross Section



3 — Turbine shaft
9 — PTO gear
10 — C1 clutch
11 — C2 clutch
12 — C3 clutch
13 — P1 planetary
14 — Main shaft
15 — P2 planetary
16 — C4 clutch
17 — P3 planetary
18 — C5 clutch
19 — Main housing
20 — Rear cover
21 — Output shaft
23 — Oil pan
27 — Tone wheel
29 — Cooler manifold

F OLDOUT 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
V06631.02.00
29 28 27 26 25 24 23



3 — Turbine shaft
9 — PTO gear
10 — C1 clutch
11 — C2 clutch
12 — C3 clutch
13 — P1 planetary
14 — Main shaft
15 — P2 planetary
16 — C4 clutch
17 — P3 planetary
18 — C5 clutch
19 — Main housing
20 — Rear cover
21 — Output shaft
23 — Oil pan
27 — Tone wheel
29 — Cooler manifold

F OLDOUT 3
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V06632.02.00
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3 — Turbine shaft
9 — PTO gear
10 — C1 clutch
11 — C2 clutch
12 — C3 clutch
13 — P1 planetary
14 — Main shaft
15 — P2 planetary
16 — C4 clutch
17 — P3 planetary
18 — C5 clutch
19 — Main housing
20 — Rear cover
21 — Output shaft
22 — Oil pan
26 — Tone wheel

F OLDOUT 4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
V06633.02.00
27 26 25 24 23 22
Foldout 4. 1000 Series™ Direct Mount — Cross Section

Legend For Foldout 5A,B Is On The Opposite Side Of This Page.
Copyright © 2003 General Motors Corp. Foldout 5A,B

Legend For Foldout 5A,B
A B
1 — Torque Converter Assembly 1 — Torque Converter Assembly
2 — Converter Housing 2 — Converter Housing
— SAE No. 3, with integral cooler ports — SAE No. 2, with manifold
3 — Shipping Plug (2), A 3 — Bolt, M10 x 1.5 x 50 Flange Head (15), D
4 — O-ring (2) 4 — Bolt, M10 x 1.5 x 70 Flange Head (5), D
5 — Pressure Tap Plug, B 5 — Sensor Shipping Cover
6 — O-ring 6 — Bolt, M6 x 1.0 x 13 Flange Head, B
7 — Control Main Filter 7 — Input Speed Sensor
8 — Control Main Magnet 8 — Speed Sensor O-ring
9 — Filter Attachment Tube, C 9 — Bolt, M10 x 1.5 x 35 Flange Head (2), E
10 — Bolt, M10 x 1.5 x 50 Flange Head (15), D 10 — Bolt, M10 x 1.5 x 25 Flange Head, E
11 — Bolt, M10 x 1.5 x 70 Flange Head (15), D 11 — Shipping Bracket
12 — Sensor Shipping Cover 12 — Nut, M10 x 1.5 (2), E
13 — Bolt, M6 x 1.0 x 13 Flange Head, B 13 — Converter Housing/Manifold Plate Gasket
14 — Input Speed Sensor 14 — Cooler Manifold Channel Plate
15 — Speed Sensor O-ring 15 — Converter Housing/Manifold Plate Gasket
16 — Bolt, M10 x 1.5 x 25 Flange Head (4), E 16 — Cooler Manifold
17 — Shipping Bracket (2) 17 — Bolt, M8 x 1.25 x 30 Flange Head (8), G
18 — Hydraulic Connector Assembly (2), F 18 — Plug (2), A
19 — O-ring (2)
Torque N·m lb ft 20 — Pressure Tap Plug, B
A 2.5–3.5 2–3
21 — O-ring
B 10–13 7–10
22 — Bolt, M8 x 1.25 x 40 Flange Head (4), G
C 25–35 18–26
D 51–61 38–45 23 — Control Main Filter
E 20–34 15–25 24 — Control Main Magnet
F 20–30 15–20 25 — Filter Attachment Tube, C
26 — Elbow Adapter, 90 Degree, 11⁄ 16 x 13⁄ 16 (2)
— Lock Nut, F
— Fitting, F
Torque N·m lb ft
A 2.5–3.5 2–3
B 10–13 7–10
C 25–35 18–26
D 51–61 38–45
E 20–34 15–25
F 20–30 15–20
G 24–29 18–21
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Foldout 5A. SAE No. 3 Torque Converter Housing With Integral Cooling Ports Foldout 5B. SAE No. 2 Torque Converter Housing With Manifold
Legend For Foldout 5C,D Is On The Opposite Side Of This Page.
Copyright © 2003 General Motors Corp. Foldout 5C,D

Legend For Foldout 5C,D
C D
1 — Torque Converter Assembly 1 — Torque Converter Assembly
2 — Converter Housing 2 — Converter Housing
— SAE No. 3, with manifold — Direct Mount
3 — Bolt, M10 x 1.5 x 50 Flange Head (15), D 3 — Pressure Tap Plug, A
4 — Bolt, M10 x 1.5 x 70 Flange Head (15), D 4 — O-ring
5 — Sensor Shipping Cover 5 — Control Main Filter
6 — Bolt, M6 x 1.0 x 13 Flange Head, B 6 — Control Main Magnet
7 — Input Speed Sensor 7 — Filter Attachment Tube, B
8 — Speed Sensor O-ring 8 — Bolt, M10 x 1.5 x 50 Flange Head (18), C
9 — Bolt, M10 x 1.5 x 25 Flange Head (4), E 9 — Bolt, M10 x 1.5 x 70 Flange Head (1), C
10 — Shipping Bracket (2) 10 — Sensor Shipping Cover
11 — Converter Housing/Manifold Plate Gasket 11 — Bolt, M6 x 1.0 x 13 Flange Head, B
12 — Cooler Manifold Channel Plate 12 — Input Speed Sensor
13 — Converter Housing/Manifold Plate Gasket 13 — Speed Sensor O-ring
14 — Cooler Manifold 14 — Bolt, M10 x 1.5 x 35 Flange Head (2), D
15 — Bolt, M8 x 1.25 x 30 Flange Head (8) 15 — Bolt, M10 x 1.5 x 25 Flange Head (2), D
16 — Plug (2), A 16 — Nut, M10 x 1.5 (2), D
17 — O-ring (2) 17 — Shipping Bracket
18 — Pressure Tap Plug, B 18 — Bolt, M10 x 1.5 x 110 Flange Head, C
19 — O-ring 19 — Hydraulic Connector Assembly (2), E
20 — Bolt, M8 x 1.25 x 40 Flange Head (4), G 20 — Bolt Access Cover
21 — Control Main Filter
22 — Control Main Magnet Torque N·m lb ft
23 — Filter Attachment Tube, C A 10–13 7–10
B 25–35 18–26
24 — Elbow Adapter, 90 Degree, 11⁄ 16 x 13⁄ 16 (2)
C 51–61 38–45
— Lock Nut, F D 20–34 15–25
— Fitting, F E 20–30 15–20
Torque N·m lb ft
A 2.5–3.5 2–3
B 10–13 7–10
C 25–35 18–26
D 51–61 38–45
E 20–34 15–25
F 20–30 15–20
G 24–29 18–21
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Foldout 5C. SAE No. 3 Torque Converter Housing With Manifold Foldout 5D. Direct Mount — Torque Converter Housing
Legend For Foldout 6, 6A Is On The Opposite Side Of This Page.
Copyright © 2003 General Motors Corp. Foldout 6, 6A

Legend For Foldout 6, 6A
6 6,A
1 — Converter Housing/Front Support Module 1 — Converter Housing/Front Support Module
2 — Main Housing/Separator Plate Gasket 2 — Bolt, M10 x 1.5 x 50 Flange Head (10), A
3 — Rotating Clutch Assembly 3 — Seal
4 — Thrust Bearing Assembly, T3 4 — Converter Housing
5 — Internal Retaining Ring 5 — Converter Housing/Separator Plate Gasket
6 — C3 Clutch Backplate Assembly 6 — Front Support Module
7 — C3 Clutch Backplate
8 — Gear Thrust Plate (3) Torque N·m lb ft
9 — Rivet (6) A 51–61 38–45
10 — C3 Clutch Friction Plate (4)

11 — C3 Clutch Reaction Plate (3)
12 — C3 Piston Return Spring Assembly (3)
13 — C3 Spring Plate
14 — C3 Clutch Piston Assembly (Bonded Seals)
Foldout 6, 6A Copyright © 2003 General Motors Corp.

F OLDOUT 6,6A
3
2
3
5 4
6 1
7
4
8
9 5
10
11
12 6
13
14
V06572.02.00
V06315.01.00
Foldout 6. Converter Housing/Front Support Module, Rotating Clutch Housing, and C3 Clutch Components Foldout 6A. Converter Housing/Front Support Module Components
SM3191_Foldout 07.fm Page 1 Friday, January 30, 2004 9:24 AM
F OLDOUT 7
1 — Front Support Module

2 — Main Pump Assembly
3 — Converter/Main Case Separator Plate
4 — Butt Joint Sealring (End)
2
5 — Butt Joint Sealring (Middle)
1 3
6 — Front Support Assembly
7 — Bolt, M8 x 1.25 x 55 Flange Head (5), A
8 — Thrust Washer, W1 PEEK
9 — Butt Joint Sealring (3) 4
5 6
Torque N·m lb ft
A 24–29 18–21
7
8
9
V06317.01.01
Foldout 7. Front Support Module Components

F OLDOUT 8
1 2
1 — Main Pump Assembly
2 — O-ring 3
4
3 — Oil Seal Assembly
4 — Main Pump Bushing 5
5 — Main Pump Body

6 — Pump Driven Gear 6
7 — Pump Drive Gear 7
8 9
8 — Dowel Pin (2)
9 — Main Pump Wear Plate
8
V06316.01.00.eps
Foldout 8. Main Pump Assembly Components

F OLDOUT 9
1 — Front Support Assembly

2 — Needle Bearing
3 — Front Support
4 — Bushing, 33.8 mm (1.33 inch) ID
5 — Ground Sleeve
6 — Converter Flow Valve
7 — Converter Flow Valve Spring
8 — Converter Flow Valve Stop
9 — Converter Flow Stop Retainer Pin
3
10 — Converter Relief Valve
6
11 — Converter Relief Valve Spring
7 4
12 — Retaining Clip 1 8
13 — Lube Regulator Valve 5
14 — Lube Regulator Valve Spring 10 2
9 11
15 — O-Ring 21 12
16 — Lube Regulator Stop 13
22
17 — Lube Regulator Retainer Pin 18 14
18 — C1 Clutch Backfill Valve 23 19 15
20 16
19 — C1 Clutch Backfill Valve Spring 24 17
20 — Retaining Clip
21 — Main Regulator Valve
22 — Main Regulator Valve Spring
23 — Main Regulator Valve Stop
24 — Main Regulator Valve Retainer Pin
V06318.02.00
Foldout 9. Front Support Assembly Components

F OLDOUT 10
1 — Rotating Clutch Assembly 26 — External Retaining Ring

2
2 — Butt Joint Sealring (2) 27 — C1 Balance Piston
3 — Turbine Shaft 28 — Internal Retaining Ring 3
4 — Bushing, 20 mm (0.8 inch) ID 29 — C1 Clutch Reaction Plate (6) 1
5
5 — Rotating Clutch Housing Assembly 30 — C1 Clutch Friction Plate (6) 4 6
6 — PTO Gear 31 — C1 Clutch Backplate — Selective

7
7 — Turbine Tone Wheel ID Thickness
8 — Rotating Clutch Bushing 6221 6.44–6.64 mm (0.254–0.261 inch) 12
13 8
9 — Rotating Clutch Housing 6222 6.88–7.08 mm (0.271–0.279 inch) 9
14
10 — O-ring 6223 7.33–7.53 mm (0.289–0.296 inch)
15
11 — External Retaining Ring 6224 7.78–7.98 mm (0.306–0.314 inch)
10
12 — Piston ID Sealring 6225 8.23–8.43 mm (0.324–0.332 inch) 11
16
13 — C2 Piston OD Sealring 32 — External Retaining Ring
17
14 — C2 Balance Piston OD Sealring 33 — Internal Spiral Retaining Ring 18
15 — C2 Clutch Piston 34 — Thrust Bearing Assembly, T1 27 19
28 20
16 — C2 Piston Return Spring Assembly 35 — C1 Drive Hub 2930 21
17 — Ball 36 — Thrust Bearing Assembly, T2 22
23
18 — C1 Piston Housing 37 — C2 Clutch Reaction Plate (7) 31
32 24
19 — External Retaining Ring 38 — C2 Clutch Friction Plate (6) 33
25
20 — C2 Balance Piston 39 — C2 Drive Hub 34
35
21 — Internal Retaining Ring 40 — Thrust Washer, W2 39 26
36
22 — C1 Piston ID Sealring 41 — P1 Sun Gear 3738
40
23 — C1 Piston OD Sealring 42 — P1 Drive Flange 41
24 — C1 Clutch Piston 43 — Internal Retaining Ring 42
25 — C1 Piston Return Spring Assembly 43
V06319.01.01
Foldout 10. Rotating Clutch Assembly Components

F OLDOUT 11
1
2
1 — Fill Tube Plug (2)
2 — Fill Tube Seal (2)
3 — Deep Pan Suction Filter
4 — Suction Filter Seal
5 — Shallow Pan Suction Filter (use with shallow pan only)
6 — Suction Filter Seal
7 — Oil Pan Gasket 6
4
8 — Oil Pan Assembly 5
9 — Magnet
10 — Deep Sump Oil Pan
3
11 — Oil Pan Assembly
12 — Magnet
13 — Shallow Sump Oil Pan
14 — Drain Plug Assembly 7
15 — Drain Plug, A
16 — Drain Plug Seal
11
17 — Bolt, M8 x 1.25 x 20 Flange Head (12), B
9 8 12
Torque N·m lb ft
A 30–40 22–30 10 13
B 24–29 18–21
15 14
15 14 16
16
17
V06323.04.00
Foldout 11. Oil Pan and Suction Filter Components

F OLDOUT 12
1 — Main Housing
2 — Dowel Pin
3 — Vent Assembly
4 — Vent Cap
13 14
5 — Vent 12
6 — Rivet
7 — Nameplate
8 — Bolt, M6 x 1.0 x 13, A
9 — Sensor Shipping Cover
10 — Turbine Speed Sensor 4 3
11 — Speed Sensor O-ring 1 5
12 — PTO Cover Gasket (2) 6
13 — PTO Cover (2) 8
10
14 — Bolt, M10 x 1.5 x 20 Flange Head, Coated (12), B 11
15 — Neutral Start/Backup (NSBU) Switch 7
2
16 — Shift Lever Nut, C
9
17 — Bolt, M8 x 1.25 x 20 NSBU Switch (2), D 12
13
18 — Front Splash Shield
14 26
19 — Selector Shaft
20 — Selector Shaft Seal
21 — Selector Valve Pin 20
21
22 — Detent Lever 19 23
23 — Park Pawl Apply Assembly 25
15
22
24 — Spring Pin 17 24
25 — Selector Shaft Nut, M10 x 1.50 Flange, E 18
27
26 — Connector Shipping Cover
17
27 — Control Valve Assembly 16
31
29 — Detent Spring Assembly
31 — Internal Wiring Harness
28 30
29
V06324.03.00
Torque N·m lb ft
A 10–13 7–10
B 40–45 30–33
C 20–27 15–20
D 24–29 18–21
E 24–34 18–25
Foldout 12. Main Housing Components

F OLDOUT 13
1 — C4 Clutch Piston Assembly (Bonded Seals)

2 — P1 Ring Gear
3 — C4 Spring Plate
4 — C4 Piston Return Spring Assembly (3) 1

2
7 — C4 Clutch Backplate
3
8 — Internal Retaining Ring
4
5
10 — C5 Clutch Backplate 6
13 — C5 Clutch Reaction Plate — Selective
P/N ID No. Thickness
29536481 1 1.935–2.065 mm 10
(0.0762–0.0813 inch) 7
29536482 2 2.435–2.565 mm 11
(0.0959–0.1010 inch) 12
8
29536483 3 2.935–3.065 mm
9
(0.1156–0.1207 inch)
13
V06320.01.01
Foldout 13. C4 and C5 Clutch Components


A B
1 — P1 Planetary Module 1 — P1 Planetary Module
2 — Thrust Bearing Assembly, T4 2 — Thrust Washer, W4 PEEK
3 — P2 Planetary Module 3 — Internal Retaining Ring
4 — Thrust Bearing Assembly, T5 4 — P1 Planetary Carrier Assembly
5 — Main Shaft 5 — P2 Planetary Ring Gear
6 — P2 Sun Gear
7 — Sun Gear Spacer C
8 — P3 Sun Gear 1 — P2 Planetary Module
9 — Thrust Bearing Assembly, T6 2 — Internal Retaining Ring
3 — P2 Planetary Carrier Assembly
4 — P3 Planetary Ring Gear

F OLDOUT 14
1
1
2 1
2 3 2
3
3
4
4
5
7 V06576.02.00
V06575.02.02
8
9
V06574.01.01
Foldout 14A. P1 Planetary Module, P2 Planetary Module, and Main Shaft Components Foldout 14B. P2 Planetary Module Components Foldout 14C. P3 Planetary Module

A B
1 — P1 Planetary Carrier Assembly 1 — P2 Planetary Carrier Assembly
2 — Bushing, 53.0 mm (2.09 inch) ID 2 — P2 Planetary Carrier
3 — P1 Planetary Carrier 3 — Bushing, 36.0 mm (1.42 inch) ID
4 — P1 Spindle (4) 4 — P2 Thrust Washer (4)
5 — P1 Thrust Washer (4) 5 — P2 Roller Bearing Assembly (4)
6 — P1 Roller Bearing Assembly (8) 6 — P2 Pinion Gear (4)
7 — P1 Pinion Gear (4) 7 — P2 Thrust Washer (4)
8 — P1 Thrust Washer (4) 8 — P2 Spindle (4)

F OLDOUT 15
1
1
2
3
4
5 3
6 4
5
7
6
8
7
V06577.01.01 V06578.01.01
Foldout 15A. P1 Planetary Carrier Assembly Components Foldout 15B. P2 Planetary Carrier Assembly Components

A B
1 — Apply Assembly Guide 1 — Rear Cover Gasket
2 — Pawl Support Pin 2 — Rear Cover Assembly, 10 x 3
3 — Park Pawl 3 — Rear Cover Assembly, Non-Park Brake
4 — Pawl Return Spring 4 — Adapter Housing Assembly, T-Case
5 — C5 Piston Return Spring Assembly 5 — Rear Cover Assembly, 9 x 3
6 — Bushing, 20 mm (0.8 inch) ID 6 — Bolt, M10 x 1.5 x 40 Flange Head (16), A
7 — Output Shaft, 2WD 7 — Oil Seal Assembly
8 — Output Shaft, 4WD 8 — Rear Shipping Cover
9 — P3 Planetary Carrier Assembly 9 — Rear Shipping Cover, 2WD
10 — Output Nut, 4WD
11 — Rear Shipping Cover
Torque N·m lb ft
A 51–61 38–45

F OLDOUT 16
2
6
3
6
1
2
3
7
4
9
1
5
4
6 7
10
11
9
8 5
6
7
8
V06335.01.01
V06337.01.01
Foldout 16A. P3 Planetary Assembly, Output Shaft, C5 Piston Return Assembly, and Park Pawl Components Foldout 16B. Rear Cover Assemblies
F OLDOUT 17
1 — P3 Planetary Carrier Assembly 1

2 — P3 Planetary Carrier
3 — P3 Thrust Washer (4)
4 — P3 Roller Bearing Assembly (8) 2
5 — P3 Pinion Gear (4)
6 — P3 Thrust Washer (4)
7 — P3 Planetary Spindle (4)
8
8 — Bearing Race
4 7
V06336.02.02
Foldout 17. P3 Planetary Carrier Assembly


Legend For Foldout 18A,B
A B
1 — Rear Cover Assembly, 10 x 3 1 — Rear Cover Assembly, Non-Park Brake
2 — C5 Clutch Piston 2 — C5 Clutch Piston
3 — C5 Piston OD Sealring 3 — C5 Piston OD Sealring
4 — C5 Piston ID Sealring 4 — C5 Piston ID Sealring
5 — Internal Retaining Ring 5 — Internal Retaining Ring
6 — Needle Bearing Assembly 6 — Needle Bearing Assembly
7 — Output Tone Wheel, 6T 7 — Output Tone Wheel, 6T
8 — Rear Cover, 10 x 3 8 — Rear Cover, Non-Park Brake
9 — Tachograph Plug, M18 x 1.5, A 9 — Bolt, M6 x 1.0 x 13, A
10 — Washer 10 — Sensor Shipping Cover
11 — Bolt, M6 x 1.0 x 13, B 11 — Output Speed Sensor
12 — Sensor Shipping Cover 12 — Speed Sensor O-ring
13 — Output Speed Sensor 13 — Spacer — Selective
14 — Speed Sensor O-ring Thickness # of Holes P/N
15 — Spacer — Selective 0.245–0.295 mm 0 29536850
Thickness # of Holes P/N (0.0096–0.0116 inch)
0.475–0.525 mm 1 29536851
0.245–0.295 mm 0 29536850 (0.0187–0.0207 inch)
(0.0096–0.0116 inch)
0.705–0.755 mm 2 29536852
0.475–0.525 mm 1 29536851 (0.0278–0.0297 inch)
(0.0187–0.0207 inch)
0.935–0.985 mm 3 29536853
0.705–0.755 mm 2 29536852 (0.0368–0.0388 inch)
(0.0278–0.0297 inch)
1.165–1.215 mm 4 29536854
0.935–0.985 mm 3 29536853 (0.0459–0.0478 inch)
(0.0368–0.0388 inch)
1.395–1.445 mm 5 29536855
1.165–1.215 mm 4 29536854 (0.0549–0.0569 inch)
(0.0459–0.0478 inch)
1.625–1.675 mm 6 29536856
1.395–1.445 mm 5 29536855 (0.0640–0.0659 inch)
(0.0549–0.0569 inch)
1.625–1.675 mm 6 29536856 14 — External Retaining Ring
(0.0640–0.0659 inch) 15 — Ball Bearing Assembly
16 — External Retaining Ring 16 — Internal Retaining Ring
17 — Ball Bearing Assembly
18 — Internal Retaining Ring Torque N·m lb ft
A 10–13 7–10
Torque N·m lb ft
A 60–67 44–49
B 10–13 7–10

F OLDOUT 18A,B
2 2
3 3
1 1
4 4
5 5 9
11
6 6 11
13
14 12
7 7
8 8
12 10
15
13
16
17 14
18 15
16
10
9
V06579
V06580.01.01
Foldout 18A. Rear Cover Assembly Components, 10 x 3 Foldout 18B. Rear Cover Assembly Components, Non-Park Brake
Legend For Foldout 18C,D Is On The Opposite Side Of This Page.
Copyright © 2003 General Motors Corp. Foldout 18C,D

Legend For Foldout 18C,D
C D
1 — Adapter Housing Assembly, T-Case 1 — Rear Cover Assembly, 9 x 3
2 — C5 Clutch Piston 2 — C5 Clutch Piston
3 — C5 Piston OD Sealring 3 — C5 Piston OD Sealring
4 — C5 Piston ID Sealring 4 — C5 Piston ID Sealring
5 — Internal Retaining Ring 5 — Internal Retaining Ring
6 — Needle Bearing Assembly 6 — Needle Bearing Assembly
7 — Bearing Spacer, 4WD 7 — Output Tone Wheel, 6T
8 — Adapter Housing, T-Case 8 — Rear Cover, 9 x 3
9 — Spacer—Selective 9 — Bolt, M6 x 1.0 x 13, A
10 — Sensor Shipping Cover
Thickness # of Holes P/N
11 — Output Speed Sensor
0.245–0.295 mm 0 29536850
(0.0096–0.0116 inch) 12 — Speed Sensor O-ring
0.475–0.525 mm 1 29536851 13 — Spacer—Selective
(0.0187–0.0207 inch)
0.705–0.755 mm 2 29536852 Thickness # of Holes P/N
(0.0278–0.0297 inch) 0.245–0.295 mm 0 29536850
0.935–0.985 mm 3 29536853 (0.0096–0.0116 inch)
(0.0368–0.0388 inch) 0.475–0.525 mm 1 29536851
1.165–1.215 mm 4 29536854 (0.0187–0.0207 inch)
(0.0459–0.0478 inch) 0.705–0.755 mm 2 29536852
1.395–1.445 mm 5 29536855 (0.0278–0.0297 inch)
(0.0549–0.0569 inch) 0.935–0.985 mm 3 29536853
1.625–1.675 mm 6 29536856 (0.0368–0.0388 inch)
(0.0640–0.0659 inch) 1.165–1.215 mm 4 29536854
(0.0459–0.0478 inch)
10 — External Retaining Ring
1.395–1.445 mm 5 29536855
11 — Ball Bearing Assembly (0.0549–0.0569 inch)
12 — Internal Retaining Ring 1.625–1.675 mm 6 29536856
13 — Output Nut, A (0.0640–0.0659 inch)
14 — External Retaining Ring
Torque N·m lb ft
15 — Ball Bearing Assembly
A 58–64 40–50
Torque N·m lb ft
A 10–13 7–10
Foldout 18C,D Copyright © 2003 General Motors Corp.

SM3191_Foldout 18CD-b.fm Page 1 Friday, January 30, 2004 9:16 AM
F OLDOUT 18C,D
2
2
3
3 1
1
4
4 9
5
5 6 11
6 12
7
7 8
8 10
13
9
14
10 15
11 16
12 17
13
V06582.01.00
V06581.01.00
Foldout 18C. Rear Cover Assembly Components, Transfer Case Foldout 18D. Rear Cover Assembly Components, 9 x 3

Legend For Foldout 19A, B
A B
1 — Control Valve Assembly 1 — Shift Valve Body Assembly
2 — Shift Valve Body Assembly 2 — Retaining Clip
3 — Separator Plate 3 — D Shift Plug
4 — Main Valve Body Assembly 4 — Shift Spring
5 — Bolt, M6 x 1.0 x 50 Flange Head (23), A 5 — D Shift Valve
6 — Reverse Signal Tube 6 — Retaining Clip
7 — Bolt, M6 x 1.0 x 65 Flange Head, A 7 — E Shift Plug
8 — Pressure Switch Assembly 8 — Shift Spring
9 — Modulated Main Valve Body 9 — E Shift Valve
10 — G ON/OFF Solenoid 10 — Retaining Clip
11 — Bolt, M6 x 1.0 x 50 (4), A 11 — Shift Spring
12 — Bolt, M6 x 1.0 x 65 (2), A 12 — C Shift Valve
13 — Retaining Clip
14 — Control Main Spring
Torque N·m lb ft 15 — Control Main Valve
A 10–13 7–10 16 — Shift Valve Body
17 — ON/OFF Shift Solenoid Retainer
18 — Solenoid Screen
19 — C ON/OFF Shift Solenoid
20 — Solenoid O-ring
21 — Solenoid O-ring
22 — Manual Selector Valve
23 —

F OLDOUT 19A,B
10
6 11 13
14
3 7 12 15
2 8
3
4 9
16 17
5
20
21
8 19
5
22 18
9
6
7
10
12
11
V06583.02.00
V06325.02.00
Foldout 19A. Control Valve Assembly Components Foldout 19B. Shift Valve Body Assembly Components
F OLDOUT 20
4 7
3
1 — Breather Adapter 2
2 — 90 Degree Elbow, 1⁄ 8 Pipe x 1⁄ 4 Hose 6
3 — Hose Clamp 1
4 — Vent Hose, 1⁄ 4 ID x 27.56 inch

5 — Hose Clamp 11
6 — Park Brake Lever 5
7 — Park Brake Cable Bracket
8 — Parking Brake Assembly 8
12
9 — Flat Washer (4) 9
10 — Bolt, M16 x 2.00 Grade 10.9 (4), C 10
— Bolt, 1⁄ 2-13 Grade 8, Patchlock (4), B
11 — End Yoke Assembly 16
12 — Companion Flange Assembly
13 — End Yoke Assembly 17
14 — Flanged End Yoke Assembly

15 — Yoke Assembly, 2⁄ 3 Round 1410 Flange
16 — Brake Drum, 9 x 3
19
17 — Nut, 3⁄ 8-24 13 18
— Nut, 3⁄ 8-24 Directional Prevailing Torque Tension
18 — Bolt, 1⁄ 2-20 Flange Head, A
19 — Sealing Washer
Torque N·m lb ft 14
A 108–136 80–100 15
B 110–132 81–97
C 228–266 168–196
V06573
Foldout 20. Vent Hose and Yokes/Flanges

F OLDOUT 21
HYDRAULIC SCHEMATIC – NEUTRAL / PARK G Solenoid Added–3rd Quarter 2003
1000 SERIES™, 2000 SERIES™, 2400 SERIES™ G Solenoid Lowers Main Pressure
PRE-BLOCK 1
And Increases Cooler Flow
GAIN VALVE When Energized (Typically at
AND A TRIM Low Throttle, Low Speed)
N/C A Trim Accumulator B Trim Accumulator
SOLENOID Solenoid Solenoid
W/O SPRING (Shown Energized)
B
N/C Solenoid N/O
F Trim Filter C Shift D Shift E Shift G Mod Main
Solenoid Solenoid Solenoid Solenoid Solenoid
N/C N/C N/C N/C N/C
CONTROL MAIN CONTROL MAIN

EBF B TRIM
PRESSURE
CONV – IN
MAIN
A TRIM Selector D N R
PRESSURE Valve
MAIN
PRESSURE CONV – OUT
TAP C1
MAIN
C1
TCC SIGNAL Clutch
Valve
IDLE COOLING MAIN
MAIN TO OVERAGE VALVE C2
LEAKAGE
EXHAUST Control
Main
Filter
Control
Main Control PSC
Main Valve Main Relief
Regulator Valve
Valve C3
MODULATED MAIN PRESSURE

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
CONV – OUT TO COOLER Valve E Shift
Converter Valve
Relief
Valve OVERAGE D Shift
Charging Valve
Pump Exhaust
CONV – IN Backfill
TCC SIGNAL Valve
SUMP Cooler
LUBE Converter
Flow PSR
Valve
Lube Blocked At
Regulator Separator Plate For MAIN PRESSURE EXHAUST BACKFILL
Valve Modulated Main Pressure CONTROL MAIN PRESSURE SUCTION
CONVERTER–IN/OVERAGE A TRIM SIGNAL
Main Filter CONVERTER–OUT REVERSE SIGNAL
TORQUE CONVERTER CLUTCH (TCC) C5
LUBRICATION/COOLER A TRIM PRESSURE
EXHAUST
V06914.03.00
Foldout 21. 1000/2000/2400 Series Hydraulic Schematic — Neutral/Park

F OLDOUT 22
HYDRAULIC SCHEMATIC – 1st RANGE G Solenoid Added–3rd Quarter 2003
PRE-BLOCK 1
B
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN
C1
TCC SIGNAL Clutch
Valve
IDLE COOLING MAIN
LEAKAGE
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump Exhaust
TCC SIGNAL Valve
SUMP Cooler
LUBE Converter
Flow PSR
Valve
Lube
Regulator Blocked At MAIN PRESSURE EXHAUST BACKFILL
Valve Separator Plate For CONTROL MAIN PRESSURE SUCTION
Modulated Main Pressure
LUBRICATION/COOLER C5
EXHAUST A TRIM PRESSURE
V06915.03.00
Foldout 22. 1000/2000/2400 Series Hydraulic Schematic — First Range

F OLDOUT 23
HYDRAULIC SCHEMATIC – 2nd RANGE G Solenoid Added–3rd Quarter 2003
PRE-BLOCK 1 And Increases Cooler Flow
AND A TRIM A Trim Accumulator B Trim Accumulator Low Throttle, Low Speed)
SOLENOID N/C
Solenoid Solenoid
W/O SPRING (Shown De-energized)
B
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump Exhaust
TCC SIGNAL Valve
SUMP Cooler
LUBE Converter
Flow PSR
Valve
Lube
CONVERTER–IN/OVERAGE B TRIM SIGNAL
EXHAUST B TRIM PRESSURE
V06916.03.00
Foldout 23. 1000/2000/2400 Series Hydraulic Schematic — Second Range

F OLDOUT 24
HYDRAULIC SCHEMATIC – 3rd RANGE G Solenoid Added–3rd Quarter 2003
PRE-BLOCK 1
B
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump Exhaust
TCC SIGNAL Valve
SUMP Cooler
LUBE Converter
Flow PSR
Valve
Lube
V06917.03.00
Foldout 24. 1000/2000/2400 Series Hydraulic Schematic — Third Range

F OLDOUT 25
HYDRAULIC SCHEMATIC – 4th RANGE G Solenoid Added–3rd Quarter 2003
PRE-BLOCK 1
B
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump Exhaust
TCC SIGNAL Valve
SUMP Cooler
LUBE Converter
Flow PSR
Valve
Lube Blocked At
V06918.03.00
Foldout 25. 1000/2000/2400 Series Hydraulic Schematic — Fourth Range

F OLDOUT 26
PRE-BLOCK 1
B
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump Exhaust
TCC SIGNAL Valve
SUMP Cooler
LUBE Converter
Flow PSR
Valve
Lube Blocked At
Main Filter CONVERTER–OUT B TRIM SIGNAL
TORQUE CONVERTER CLUTCH (TCC) REVERSE SIGNAL
EXHAUST C3
A TRIM PRESSURE V06919.03.00
Foldout 26. 1000/2000/2400 Series Hydraulic Schematic — Fifth Range

F OLDOUT 27
HYDRAULIC SCHEMATIC – REVERSE – CLOSED THROTTLE (WITH NO4* SOFTWARE AND LATER)
1000 SERIES™, 2000 SERIES™, 2400 SERIES™ G Solenoid Added–3rd Quarter 2003
PRE-BLOCK 1 G Solenoid Lowers Main Pressure
GAIN VALVE And Increases Cooler Flow
AND A TRIM When Energized (Typically at
SOLENOID Solenoid Solenoid Low Throttle, Low Speed)
W/O SPRING
B (Shown Energized)
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN
C1
TCC SIGNAL Clutch
Valve
IDLE COOLING MAIN
LEAKAGE
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump Exhaust
TCC SIGNAL Valve
SUMP Cooler
LUBE Converter
Flow PSR
Valve
Lube
Regulator Blocked At MAIN PRESSURE SUCTION
Valve Separator Plate For CONTROL MAIN PRESSURE A TRIM SIGNAL
Main Filter CONVERTER–OUT C3
*EFFECTIVE JANUARY 1, 2001 EXHAUST BACKFILL V06874.03.00
Foldout 27. 1000/2000/2400 Series Hydraulic Schematic — Reverse (With N04* Software and Later)
F OLDOUT 28
HYDRAULIC SCHEMATIC – REVERSE (PRIOR TO, AND INCLUDING, NO4* SOFTWARE WITH THROTTLE APPLIED)
1000 SERIES™, 2000 SERIES™, 2400 SERIES™ G Solenoid Added–3rd Quarter 2003
G Solenoid Lowers Main Pressure
PRE-BLOCK 1
B
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump Exhaust
TCC SIGNAL Valve
SUMP Cooler
LUBE Converter
Flow PSR
Valve
Lube Blocked At
Regulator Separator Plate For MAIN PRESSURE SUCTION
Valve Modulated Main Pressure CONTROL MAIN PRESSURE A TRIM SIGNAL
*EFFECTIVE JANUARY 1, 2001 EXHAUST BACKFILL B TRIM PRESSURE V04755.03.00
Foldout 28. 1000/2000/2400 Series Hydraulic Schematic — Reverse Range (Prior To and Including N04* Software With Throttle Applied)
F OLDOUT 29
HYDRAULIC SCHEMATIC – HYDRAULIC DEFAULT REVERSE ("LIMP HOME") G Solenoid Added–3rd Quarter 2003
PRE-BLOCK 1
B
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump Exhaust
TCC SIGNAL Valve
SUMP Cooler
LUBE Converter
Flow PSR
Valve
Lube Blocked At
Regulator Separator Plate For MAIN PRESSURE SUCTION
Valve Modulated Main Pressure CONTROL MAIN PRESSURE A TRIM SIGNAL
Main Filter CONVERTER–OUT C3
*EFFECTIVE JANUARY 1, 2001 EXHAUST BACKFILL V07739.03.00
Foldout 29. 1000/2000/2400 Series Hydraulic Schematic — Default Reverse (“Limp Home”)
F OLDOUT 30
HYDRAULIC SCHEMATIC – HYDRAULIC DEFAULT FORWARD (3rd RANGE "LIMP HOME")
1000 Series™, 2000 Series™, 2400 Series™ G Solenoid Added–3rd Quarter 2003
A Trim Accumulator B Trim Accumulator When Energized (Typically at
Solenoid Solenoid Low Throttle, Low Speed)
B (Shown De-energized)
N/C Solenoid N/O C On/Off D On/Off E On/Off
F Trim Filter Shift Shift Shift G Mod Main
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump Exhaust
TCC SIGNAL Valve
SUMP Cooler
LUBE Converter
Flow PSR
Valve
Lube Blocked At
V07738.03.00
Foldout 30. 1000/2000/2400 Series Hydraulic Schematic — Default Forward (3rd Range “Limp Home”)
ts.pdf 8/19/04 9:42:01 AM
CM
MY
CY
CMY
Transmission
Troubleshooting Manual
1000 and 2000 Product Families
Electronic Controls
TS3192EN
Troubleshooting 2003 APRIL
REV. 1 2004 MAY
Manual TS3192EN
ELECTRONIC CONTROLS
1000 and 2000 Product Families

Printed in USA Copyright © 2004 General Motors Corporation

ALLISON 1000 AND 2000 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
FOREWORD — How to Use This Manual
This manual provides troubleshooting information for Allison Transmission 1000 and 2000 Product
Families transmissions. Service Manual SM3191EN, Mechanics Tips MT3190EN, and Parts Catalog
PC3062EN may be used in conjunction with this manual.
This manual includes:

• Description of the electronic control system.
• Description of the electronic control system components.
• Description of diagnostic codes, system responses to faults, and troubleshooting.
• Wire, terminal, and connector repair information.
Specific instructions for using many of the available or required service tools and equipment are not
included in this manual. The service tool manufacturer will furnish instructions for using the tools or
equipment.
Additional information may be published from time to time in Service Information Letters (SIL) and will be
included in future revisions of this and other manuals. Please use these SILs to obtain up-to-date
information concerning Allison Transmission products.
This publication is revised periodically to include improvements, new models, special tools, and
procedures. A revision is indicated by a new date on the title page and rear cover. Check with your
Allison Transmission service outlet for the currently applicable publication. Additional copies of this
publication may be purchased from authorized Allison Transmission service outlets. Look in your
telephone directory under the heading of Transmissions — Truck, Tractor, etc.
Take time to review the Table of Contents and the manual. Reviewing the Table of Contents will aid you in
quickly locating information.
NOTE: Allison Transmission is providing service of wiring harnesses and wiring harness
components as follows:
• Repair parts for the internal wiring harness will be available through the Allison
Transmission Parts Distribution Center (PDC). Use the P/N from your appropriate
parts catalog or from Appendix E in this manual. Allison Transmission is responsible
for warranty on these parts.
• Repair parts for the external harnesses and external harness components must be
obtained from the vehicle OEM or the OEM is responsible for warranty on these parts.
ii Copyright© 2004 General Motors Corp.

IMPORTANT SAFETY NOTICE
IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions used in
this manual. These warnings and cautions advise against using specific service procedures
that can result in personal injury, equipment damage, or cause the equipment to become
unsafe. These warnings and cautions are not exhaustive. Allison Transmission could not
possibly know, evaluate, or advise the service trade of all conceivable procedures by which
service might be performed or of the possible hazardous consequences of each procedure.
Consequently, Allison Transmission has not undertaken any such broad evaluation.
Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT
RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied that
neither personal safety nor equipment safety will be jeopardized by the service procedures
used.
Also, be sure to review and observe WARNINGS, CAUTIONS, and NOTES provided by the
vehicle manufacturer and/or body builder before servicing the Allison transmission in that
vehicle.
Proper service and repair is important to the safe and reliable operation of the equipment. The
service procedures recommended by Allison Transmission and described in this manual are
effective methods for performing troubleshooting operations. Some procedures require using
specially designed tools. Use special tools when and in the manner recommended.
The WARNINGS, CAUTIONS, and NOTES in this manual apply only to the Allison transmission
and not to other vehicle systems which may interact with the transmission. Be sure to review and
observe any vehicle system information provided by the vehicle manufacturer and/or body builder
at all times the Allison transmission is being serviced.

Three types of headings are used in this manual to attract your attention:
Is used when an operating procedure, practice, etc., which, if not correctly

WARNING! followed, could result in injury or loss of life.
Is used when an operating procedure, practice, etc., which, if not strictly observed,
CAUTION: could result in damage to or destruction of equipment.
NOTE: Is used when an operating procedure, practice, etc., is essential to highlight.
Copyright© 2004 General Motors Corp. iii

TRADEMARKS USED IN THIS MANUAL

• Adobe® Acrobat® Reader® are registered trademarks of Adobe Systems Incorporated.
• Allison DOC™ For PC is a trademark of General Motors Corporation.
• MagiKey™ is a trademark of Micro Processor Systems, Inc.
• LPS® Cleaner is a registered trademark of LPS Laboratories.
• Loctite® is a registered trademark of the Loctite Corporation.
• Teflon® is a registered trademark of the DuPont Corporation.
• Windows® 95, Windows® 98, Windows® XP, and Windows NT® are trademarks of Microsoft
Corporation.
SERVICE LITERATURE
This service literature provides fully illustrated instructions for operation, maintenance, service, overhaul,
and parts support for your transmission. To ensure maximum performance and service life from you unit,
you may order publications from:
SGI, Inc.
Attn: Allison Literature Fulfillment Desk
8350 Allison Avenue
Indianapolis, IN 46268
TOLL FREE: 888-666-5799
INTERNATIONAL: 317-471-4995
1000 and 2000 Product Families Service Literature

Publication Name Publication No.
Automatic Transmission Fluid Technician’s Guide GN2055EN
*Mechanic’s Tips MT3190EN
*In-Chassis Maintenance JA3664EN
*EVS Operator’s Manual OM3761EN
*HS Operator’s Manual OM3757EN
*RDS Operator’s Manual OM3759EN
*MHS Operator’s Manual OM3364EN
*PTS Operator’s Manual OM3758EN
*BUS Operator’s Manual OM3765EN
*1000, 2000, 2400 Operator’s Manual OM3063EN
*Owner’s Manual (2000MH) OM3364EN
*Parts Catalog PC3062EN
Parts Catalog On CD-ROM CD3062EN
Principles Of Operation PO3065EN
* Also Available On The Internet At www.allisontransmission.com
iv Copyright© 2004 General Motors Corp.

TABLE OF CONTENTS
Page
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SAFETY INFORMATION
Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Warnings, Cautions, and Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Trademarks Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Service Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
SECTION 1. GENERAL DESCRIPTION

1–1. TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1–2. TRANSMISSION CONTROL MODULE (TCM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
1–3. SHIFT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
A. Shift Selector Range Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
B. Manual Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
C. NSBU Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1–4. THROTTLE POSITION SENSOR (TPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
1–5. SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
A. Input (Engine) Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
B. Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
C. Output Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
1–6. CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
1–7. WIRING HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
A. External Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
B. Internal Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
SECTION 2. DEFINITIONS AND ABBREVIATIONS

2–1. CHECK TRANS LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2–2. SCAN TOOL INHIBITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2–3. SCAN TOOL (Allison DOC™ For PC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
2–4. ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2–5. RANGE INHIBIT RESPONSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
SECTION 3. BASIC KNOWLEDGE

3–1. BASIC KNOWLEDGE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–2. USING THE TROUBLESHOOTING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–3. SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS . . . . . . . . . . . . 3–2
3–5. BASIC TROUBLESHOOTING INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
3–6. TCM REPLACEMENT PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
3–7. RESETTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE . . . . . . . . . . . . 3–7
3–8. RESETTING TCM AUTOSELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
Copyright© 2004 General Motors Corp. v

TABLE OF CONTENTS (cont’d)
Page
SECTION 4. WIRE CHECK PROCEDURES

4–1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND. . . . . 4–1
4–2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS
FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND . . . . . . . . . . 4–2
SECTION 5. DIAGNOSTIC TROUBLE CODES (DTC)

5–1. DTC MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5–2. FAILURE RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5–3. CODE READING AND DTC CLEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
A. Clearing DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
B. Clearing Active Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
5–4. BEGINNING THE TROUBLESHOOTING PROCESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
A. Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
B. Solenoid Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
C. Wire/Terminal Numbering Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
D. Available Diagnostic Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5–5. DIAGNOSTIC TROUBLE CODES (DTCs — Includes Index) . . . . . . . . . . . . . . . . . . . . . . 5–6
SECTION 6. INPUT AND OUTPUT FUNCTIONS

6–1. SPECIAL INPUT AND OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
A. Input Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
B. Output Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
SECTION 7. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS. . . . . . . . . . 7–1
APPENDICES
A. DIAGNOSING INTERMITTENT DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
B. MAIN PRESSURE CHECK PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1
C. SOLENOID AND CLUTCH TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–1
D. WIRE/CONNECTOR TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–1
E. CONNECTOR REPAIR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–1
F. THROTTLE POSITION SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–1
G. WELDING ON VEHICLE/VEHICLE INTERFACE MODULE. . . . . . . . . . . . . . . . . . . . . . . G–1
H. HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H–1
J. WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J–1
K. RESISTANCE vs. TEMPERATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K–1
L. ELECTRONIC INTERFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L–1
M. DIAGNOSTIC TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M–1
N. INPUT/OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N–1
P. FLUID CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–1
vi Copyright© 2004 General Motors Corp.

SECTION 1—GENERAL DESCRIPTION
1–1. TRANSMISSION
The 1000 and 2000 Product Families Electronic Controls system features closed-loop clutch control to provide
superior shift quality over a wide range of operating conditions. The 1000 and 2000 Product Families configurations
can be programmed to provide five forward speeds, neutral, and reverse. The fifth range has an overdrive gear
ratio. The 1000 and 2000 Product Families incorporate a variety of standard and optional design features.
Figure 1–1 is a block diagram of the basic system inputs and outputs.
PRESSURE SWITCH MANIFOLD

NSBU
SPEED SENSORS SOLENOIDS

(VBS, PWM, ON/OFF)
THROTTLE POSITION SENSOR
TCM
VEHICLE/ENGINE TEMPERATURE SENSOR
COMMUNICATION LINKS (SUMP/ENGINE)
INPUTS
OUTPUTS
V05726
Figure 1–1. Transmission Control Module Block Diagram
Figure 1–2 shows the electronic control components.

Electronic Controls consist of the following elements:
• Remote 12V or 24V Sealed Transmission Control Module (TCM)
• Throttle Position Sensor (TPS), electronic engine throttle data, or PWM signal
• Speed Sensors — Input (Engine), Turbine, and Output
• Control Valve Assembly (Electro-Hydraulic Valve Body)
• NSBU Switch
• Pressure Switch Manifold (PSM)
• Wiring Harnesses
NOTE: All external harnesses are OEM-supplied.
Copyright© 2004 General Motors Corp. 1–1

GENERAL DESCRIPTION
TRANSMISSION
CONTROL
MODULE
(TCM)
VEHICLE (J1)
HARNESS “J1”
CONNECTOR
(GRAY)
J1939
TRANSMISSION (J2) CONNECTOR
HARNESS
“J2”
Bulkhead Connector (Optional) CONNECTOR
(RED)
VIW “X”
CONNECTOR
NSBU SWITCH
CONNECTORS
7-PIN
(OEM-SUPPLIED)
12-PIN VIW “Y”

CONNECTOR CONNECTOR
(USED WITH NSBU
P/N 29541852) 4-PIN
THROTTLE POSITION
SENSOR (TPS)
CONNECTOR
(OPTIONAL)
OUTPUT
SPEED SENSOR
THROTTLE CONNECTOR
POSITION
SENSOR (TPS)
TURBINE ENGINE
SPEED SENSOR SPEED SENSOR
CONNECTOR CONNECTOR
MAIN
TRANSMISSION
CONNECTOR
NOTE: Illustration is not to scale. Actual harness

configuration may differ from this illustration.
V06475.01.01
.
Figure 1–2. Electronic Control Components
1–2 Copyright© 2004 General Motors Corp.

GENERAL DESCRIPTION
1–2. TRANSMISSION CONTROL MODULE (TCM)

The electronic control of the transmission is performed by a microcomputer. The microcomputer is an independent
controller and is referred to as a Transmission Control Module (TCM). TCMs are available in both 12V and 24V
configurations to match the configuration of the vehicle electrical system.
The TCM (Figure 1–3) receives and processes signals from various switches and sensors. The TCM determines
shift sequences, shift timing, and clutch apply and release pressures. The TCM uses the information to control
transmission solenoids and valves, supply system status, and provide diagnostic information.
V05728.01.01
Figure 1–3. Transmission Control Module (TCM)
1–3. SHIFT SELECTOR

The vehicle is equipped with a lever-type shift selector (Figure 1–4). In addition to the lever assembly provided for
the operator, other components associated with the shift selector are the manual selector valve in the main control
valve body and an NSBU switch mounted on the selector shaft. Shift selector components (with the exception of
the transmission selector shaft) are customer-supplied.
A. Shift Selector Range Positions

The operator chooses the transmission range by moving the selector lever to the appropriate
gate position (Figure 1–4). When properly adjusted, the shifter gates prevent inadvertent shifting
between ranges and correspond to the internal transmission detent positions. A positive detent
is provided in the transmission to maintain the selector shaft in the selected position.
SHIFT SELECTOR
P
R
N
OD
D
2
1
TOP VIEW
V06476
Figure 1–4. Typical Lever-Type Shift Selector

GENERAL DESCRIPTION
The TCM shift calibration determines the available forward ranges for each selector position.
Although specific installations vary, typical selector positions for the 1000 and 2000 Product
Families are:
P — Park. Parking pawl or parking brake is engaged, if available. This position is not available
on all shift selectors.
R — Reverse.
N — Neutral. May be used when starting the engine and for stationary operations. The NSBU
Switch disables the starter switch if a range other than N (Neutral) or P (Park) is selected before
starting the vehicle.
OD — Overdrive. The highest forward range used for normal driving. The transmission shifts to
first range for starting, then automatically upshifts through the ranges (as operating conditions
permit) until the highest range is attained.
D, 2, 1 — Forward Range. The transmission shifts to first range for starting. The range selected
on the shift selector is the highest range which will be attained during automatic shifting.
B. Manual Selector Valve

The manual shift selector shaft is attached to the manual selector valve within the transmission
main control valve body. The selector valve has three positions: Reverse, Neutral, and Forward.
NOTE: For transmissions equipped with a Park position, the selector valve remains in
the Neutral position when the selector is moved to Park.
The Neutral and Reverse selector valve positions (refer to Appendix H—Hydraulic Schematics)
exhaust the C1 and C2 rotating clutches. By exhausting C1 and C2 clutches, forward range is
inhibited. This provides the capability for the operator to override the electronically commanded
ranges if N (Neutral) is required.
C. NSBU Switch
The installation of a transmission-mounted neutral start/reverse signal switch is required. This
switch, commonly called an “NSBU Switch” (Figure 1–5), mounts directly onto the transmission
housing from the outside and detects the angular position of the shift selector shaft. This
position is communicated to the TCM so that certain vehicle control functions can be
coordinated with the position of the shift controls. The NSBU switch has redundant circuitry to
alert the TCM in the event of a single wire or switch failure.
The neutral signal output of the NSBU switch is typically used as confirmation that the
transmission is in N (Neutral) before the engine starter is engaged. The NSBU switch is
interfaced to the starter circuit with weatherproof electrical connectors. The reverse signal
provision may be used to activate vehicle back-up lights and/or reverse warning devices.
V05729.01.00
Figure 1–5. NSBU Switch

GENERAL DESCRIPTION
1–4. THROTTLE POSITION SENSOR

The Throttle Position Sensor (TPS) can be mounted to the engine, chassis, or transmission. The TPS (Figure 1–6)
contains a pull actuation cable and a potentiometer. One end of the cable is attached to the engine fuel lever and
the other, inside a protective housing, to the TPS potentiometer. Output voltage from the TPS is directed to the
TCM through the external harness. The voltage signal indicates the throttle position and, in combination with other
input data, determines shift timing.
B
A
C
THROTTLE POSITION
SENSOR (TPS)
V00628.01
Figure 1–6. Throttle Position Sensor
1–5. SPEED SENSORS

There are three speed sensors available for use with 1000 and 2000 Product Families transmissions: the input
(engine) speed sensor, the turbine speed sensor, and the output speed sensor (Figure 1–7). The speed sensors
provide rpm information to the TCM. The speed ratios between the various sensors allow the TCM to determine the
transmission operating range. Speed sensor information is also used to control the timing of clutch apply
pressures, resulting in the best possible shift quality.
V04736
Figure 1–7. Typical Speed Sensor
The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each
sensor consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These
elements are contained in a housing which is mounted adjacent to a rotating ferrous member (such as a gear
tooth). Two signal wires extend from one end of the housing and an exposed end of the pole piece is at the
opposite end of the housing. The permanent magnet produces lines of flux around the pole piece. As a ferrous
object (such as a gear tooth) approaches and passes through the gap at the end of the pole piece, an AC voltage
pulse is induced in the wire coil. The TCM calculates the frequency of these AC pulses and converts it to a speed
value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the
sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from
voltage-related fields. Noise from other sources is eliminated by using two-wire differential inputs at the TCM.

GENERAL DESCRIPTION
NOTE: Do not rotate the speed sensor in the retaining bracket. Orientation is fixed, and if changed, may
cause improper operation.
A. Input (Engine) Speed Sensor

The input speed sensor is externally mounted in the torque converter housing directed at the
ribs protruding from the torque converter. The input speed sensor connector should be
positioned at approximately four o’clock, as viewed from the left side of the transmission
(Figure 1–8).
B. Turbine Speed Sensor

The turbine speed sensor is externally mounted in the main housing directed at the tone wheel
or PTO drive gear attached to the rotating clutch module. The turbine speed sensor connector
should be positioned at approximately three o’clock, as viewed from the left side of the
transmission (Figure 1–8).
C. Output Speed Sensor

The output speed sensor is externally mounted in the rear cover and directed at the teeth of a
tone wheel splined to and rotating with the output shaft. The output speed sensor connector
should be positioned at approximately five o’clock, as viewed from the left side of the
transmission (Figure 1–8).
ENGINE SPEED TURBINE SPEED

SENSOR CONNECTOR SENSOR CONNECTOR
ORIENTATION = 4 o'clock ORIENTATION = 3 o'clock
OUTPUT SPEED
SENSOR CONNECTOR
ORIENTATION = 5 o'clock
V06457
Figure 1–8. Speed Sensor Connector Orientation

GENERAL DESCRIPTION
1–6. CONTROL VALVE ASSEMBLY

The hydraulic control valve assembly (Figure 1–9) governs fluid flow to the clutches (including the torque converter
clutch). Solenoids, actuated by the TCM, control valve movement.
The control valve assembly consists of two components. The main valve body contains the trim valves, the TCC
valve, the exhaust backfill valve, and the control main relief valve. The shift valve body contains the shift valves, the
control main pressure valve, and the manual selector valve. The control valve assembly attaches to the bottom of
the gearbox module and is enclosed by the oil pan. An internal wiring harness connects the solenoids and PSM to
the main transmission connector and external wiring harness.
A. Modulated Main Pressure

Modulated main pressure was added to the 1000 and 2000 Product Families in the second
quarter of 2003. Starting with DEE software level, the TCM will autodetect if the hardware is
present. Main pressure is reduced by utilizing an additional on/off solenoid (“G”) that is located
in the control valve body assembly. The G solenoid body is bolted to the revised main valve
body. Main pressure will be reduced under various conditions such as low throttle, low torque,
low engine speeds, and low output speeds. The primary benefit of modulating main pressure is
to increase cooler flow at low engine speeds.
A TRIM
B TRIM
E
G D
F
V07476.01.01
Figure 1–9. Control Valve Assembly
1–7. WIRING HARNESSES

A. External Wiring Harness (Figure 1–10)
The external wiring harness requirements are typically met through the use of two separate
harnesses — one connecting the TCM to the transmission, throttle position sensor, NSBU
switch, and speed sensors; another connecting the TCM to the Scan Tool (ST) and other vehicle
interfaces. Each harness may be a single piece or may be divided into two segments joined by
bulkhead connectors. All wiring harnesses and mating connectors are customer-supplied.

GENERAL DESCRIPTION
NOTE: Allison Transmission is providing for service of wiring harnesses and wiring harness
• Repair parts for the internal wiring harness will be available through the Allison Transmission
Parts Distribution Center (PDC). Use the P/N from your appropriate parts catalog or from
Appendix E in this manual. Allison Transmission is responsible for warranty on these parts.
• Repair parts for the external harnesses and external harness components must be obtained
through the vehicle OEM. The OEM is responsible for warranty on these parts.
VEHICLE (J1)
HARNESS “J1”
CONNECTOR
(GRAY)
TRANSMISSION (J2)
HARNESS J1939
CONNECTOR
“J2”
Bulkhead Connector (Optional) CONNECTOR
(RED)
VIW “X”
CONNECTOR
NSBU SWITCH
CONNECTORS
7-PIN
(OEM-SUPPLIED)
12-PIN
CONNECTOR
(USED WITH NSBU VIW “Y”
P/N 29541852) 4-PIN CONNECTOR
THROTTLE POSITION
SENSOR (TPS)
CONNECTOR
(OPTIONAL)
OUTPUT
SPEED SENSOR
THROTTLE CONNECTOR
POSITION
SENSOR (TPS)
TURBINE ENGINE
SPEED SENSOR SPEED SENSOR
CONNECTOR CONNECTOR
MAIN
TRANSMISSION
NOTE: Illustration is not to scale. Actual harness CONNECTOR
configuration may differ from this illustration.
V06477.01.01
Figure 1–10. Typical External Wiring Harnesses

GENERAL DESCRIPTION
B. Internal Wiring Harness (Figure 1–11)
An internal wiring harness connects the shift solenoids, clutch trim solenoids, torque converter
clutch solenoid, pressure switch manifold, and temperature sensor to the external harness
leading to the TCM.
SOL C
13 mm EXTENSION
PSM
SOL G
MAIN
TRANSMISSION
CONNECTOR
SOL A
SOL B
SOL E
SOL D
SOL F V05732.01.02
Figure 1–11. Typical Internal Wiring Harness

GENERAL DESCRIPTION
NOTES

SECTION 2—DEFINITIONS AND ABBREVIATIONS
2–1. CHECK TRANS LIGHT

The electronic control system is programmed to inform the operator of a problem with the transmission system and
automatically take action to protect the operator, vehicle, and transmission. To do this, the TCM turns on the
CHECK TRANS light on the instrument panel, which notifies the operator that a Diagnostic Trouble Code (DTC)
has been stored.
Each time the engine is started, the TCM will illuminate the CHECK TRANS light, then turn it off after a few
seconds. This is a circuit check to verify that the lamp and wiring are in proper working order. Illumination of the
CHECK TRANS light at any time after start-up indicates that the TCM has set a DTC. The Scan Tool is used to
verify that the TCM has set a DTC (see Paragraph 2–5). While the CHECK TRANS light is on, upshifts and
downshifts may be restricted and direction changes (D–R, R–D) may not occur. The torque converter clutch is
inhibited when transmission shifting is restricted or during any critical transmission malfunction.
The 1000 and 2000 Product Families transmissions DTCs are latching DTCs. When a failure condition is detected,
the DTC set by the TCM remains active for the entire time the ignition is on. When the ignition is turned off and then
on again, the transmission DTCs will reset and the TCM will recheck for the failure condition. If the failure condition
is not present, the previously set DTC will remain in history; the CHECK TRANS light will turn off after the circuit
check, and the transmission will function normally unless another failure occurs. This feature allows the vehicle to
be driven to a service outlet.
2–2. SCAN TOOL INHIBITS

The following inhibit information may be displayed on the Allison DOC™ For PC (Scan Tool), depending on the
TCM software level. If TCM software does not support one of the inhibits listed below, a N/A will be shown in the
information box.
If an inhibit has occurred since the last DTC was cleared, the inhibit state will indicate ON and will stay ON until the
next manual DTC clear with the Scan Tool. These inhibits do not turn OFF after a specified number ignition cycles.
The range inhibit light will illuminate and/or an inhibited state will be shown on the Scan Tool when the transmission
is inhibited to Neutral for the following reasons:
• Low Main Pressure
If the transmission pressure switches do not indicate transmission pressurized at start-up, shifts-to-
range may be inhibited and the range inhibit light will illuminate. The Scan Tool will indicate an active
inhibit.
Common causes are transmission low on fluid, transmission filter has just been changed, or pan has
been removed and fluid recently drained.
May produce P0701.
• Transfer Case Neutral
If the transfer case is shifted into neutral while the transmission is in drive or reverse at a speed above
idle, the transmission will continue to command range until the output speed is reduced to a point where
neutral range is commanded. The range inhibit light will illuminate and the Scan Tool will indicate an
active inhibit.
• Diagnostic Active
This indicates that an active diagnostic code is set and that the CHECK TRANS light should be
illuminated. In some failure modes, Reverse cannot and will not be commanded. If Reverse is selected
during these failure modes a range inhibit light will illuminate in Reverse.
During diagnostic responses, Neutral-to-Range Inhibits and Direction Change Inhibits continue to
operate, but they may latch under certain conditions. In these cases, shutting down ignition and waiting
for at least 5 seconds before re-starting will clear the inhibit condition. The Scan tool will indicate an
active inhibit.

DEFINITIONS AND ABBREVIATIONS

• Auto Neutral for PTO
Neutral-to-Drive and Neutral-to-Reverse shifts will be inhibited to neutral and the Scan Tool will show an
inhibited state when TCM detects that auto neutral function input is active.
• Reverse Enable
Neutral-to-Reverse shifts will be inhibited to neutral and the Scan Tool will show an inhibited state when
no input is detected from dash or floor mounted reverse enable switch when selecting reverse range.
The Scan Tool will indicate an active inhibit.
This function is only used in European transit and tour buses applications.
• Refuse Packer Step Switch

Transmission operation is limited to only 1st range. Neutral-to-reverse shifts will be inhibited to neutral
and the Scan Tool will show an inhibited state when input is detected from a step switch indicating that
personnel is present on rear step platform.
• Auxiliary Function Range Inhibit

Neutral-to-Drive and Neutral-to-Reverse shifts will be inhibited to neutral and the Scan Tool will show an
inhibited state when input is detected from an auxiliary switch or device. This inhibit will remain active
until the auxiliary switch input is shut off and range is reselected.
• PTO Neutral Lockup

The Scan Tool will show an inhibited state when Neutral Lockup is active and range shifts are being
inhibited to neutral. When the selector is moved, lockup is released and the inhibit clears.
• Engine Speed
Neutral-to-Drive and Neutral-to-Reverse shifts will be inhibited to neutral and the range inhibit light
will illuminate if the Engine Speed is greater than a calibrated value (1400 rpm for medium duty
non-emergency vehicles). The Scan Tool will indicate an active inhibit.
• Output Speed
Reverse-to-Drive, Drive-to-Reverse, and Neutral-to-Reverse shifts initiated above 300 rpm of output
speed will be inhibited to neutral and the range inhibit light will illuminate. The Scan Tool will indicate an
active inhibit.
• Throttle
Reverse-to-Drive, Drive-to-Reverse, Neutral-to-Drive, and Neutral-to-Reverse shifts where throttle
position is greater then 25 percent will be inhibited to neutral and the range inhibit light will illuminate.
The Scan Tool will indicate an active inhibit.
• NSBU Function or Alignment

Reverse-to-Drive, Drive-to-Reverse, Neutral-to-Drive, and Neutral-to-Reverse shifts will be inhibited to
neutral and the range inhibit light will illuminate when a NSBU failure or misalignment is detected.
Common cause would be an error in the four-bit NSBU switch input signal that is sent to the TCM. The
Scan Tool will indicate an active inhibit.
• NSBU RPS Disagree

Reverse-to-Drive, Drive-to-Reverse, Neutral-to-Drive, and Neutral-to-Reverse shifts will be inhibited to
neutral and the range inhibit light will illuminate when the reverse pressure switch status is in the
incorrect state when compared to the NSBU switch state. The Scan Tool will indicate an active inhibit.
• MSV Mis-Alignment/Unable to detect ratio after shift to range

If the range verification test fails to detect turbine speed pull-down or valid gear ratio when shifting to
either forward or reverse range from neutral, the transmission will shift back to a neutral condition and
the range inhibit light will illuminate.


Conditions that may cause this include: Attempts to shift the transmission from Neutral-to-Drive or
Neutral-to-Reverse with the transfer case in neutral; transmission low on fluid; misadjustment in the
NSBU or Selector Linkage; turbine or output speed sensor failure that may prevent the pull down test/
ratio test from passing; solenoid A or B hydraulically failures; and possibly failed range clutch (C1 or C5
for 1st, C3 or C5 for Reverse).
The Scan Tool will indicate an active inhibit response.
• Wheel Spin or Lock
When the TCM detects that wheel lock or spin is occurring, the TCC is disengaged and a lock-to-range
response is commanded for 6 seconds. The Scan Tool will indicate an active inhibit response.
2–3. SCAN TOOL (Allison DOC™ For PC) (Figure 2–1)

The current Scan Tool (ST) is the PC Tool Software Allison DOC™ For PC, which is available through Kent-Moore
Heavy-Duty Division. When installed on a Windows® PC, the Allison DOC™ For PC transmits and receives data to
and from the TCM via the vehicle data communications link, processes the data, and displays appropriate
information. Use Allison DOC™ For PC during installation checkout and troubleshooting.
For more details on Allison DOC™ For PC features, see information in Appendix M.
V05490
Figure 2–1. Scan Tool

2–4. ABBREVIATIONS
A/N Assembly Number
ABS Anti-lock Brake System—OEM-provided means to detect and prevent wheel stoppage to
enhance vehicle handling. Retarder and engine brakes will not apply when ABS is active.
Amp Ampere—Unit of electrical current
CAN Controller Area Network—A network for all SAE J1939 communications in a vehicle
(engine, transmission, diagnostics, ABS, etc.)
CC Calibration Compatibility—First two digits of the CIN
CIN Calibration Identification Number—Used to identify transmission controls software level
CT Closed Throttle
DNA Does Not Adapt—Adaptive shift control is disabled.
DNS DO NOT SHIFT—Refers to the DO NOT SHIFT diagnostic response during which the
CHECK TRANS light is illuminated and the transmission will not shift and will not respond
to the Shift Selector.
DTC Diagnostic Trouble Code
DVOM Digital volt/ohmmeter
ECM Engine Controller Module—Available on electronically-controlled engines—provides some
relevant data to TCM.
EMI ElectroMagnetic Interference
GPI General Purpose Input—Input signal to the TCM to request a special operating mode or
condition.
GPO General Purpose Output—Output signal from the TCM to control vehicle components
(such as PTOs, backup lights, etc.) or allow a special operating mode or condition.
IPC Instrument Panel Controller
J1939 High-speed vehicle serial data communications link.
LED Light-Emitting Diode—Electronic device used for illumination.
LRTP Low-Range Torque Protection—A feature limiting engine torque in lower ranges to protect
the transmission from damage when a stall condition occurs.
NNC Neutral No Clutches—Neutral commanded with no clutches applied.
NSBU Switch Neutral Start Backup Switch
NVL Neutral Very Low—The TCM has sensed turbine speed below 150 rpm. This is usually
caused by a dragging C1 or C3 clutch or a failed turbine speed sensor. When attained, the
C4 and C5 clutches are applied to lock the transmission output.
OBD II On Board Diagnostics Second generation. EPA mandated specification for vehicle
diagnostics.
OEM Original Equipment Manufacturer—Maker of vehicle or equipment.
Ohm Unit of electrical resistance.
PC Personal Computer
PCCS Production Calibration Configuration System
PCM Powertrain Controller Module—Electronic device used on some vehicles.
PDM Parallel Data Module

2–4. ABBREVIATIONS (cont’d)

PPC Pressure Proportional to Current solenoid. Solenoid control of clutch pressure is
proportional to the current being supplied to the solenoid.
PROM Programmable Read Only Memory
PSM Pressure Switch Manifold—Part of transmission control system located inside the oil pan.
PTO Power Takeoff
PWM Solenoid Pulse Width Modulated Solenoid—Solenoids are controlled by pulse width modulation.
Solenoid control of clutch pressures is based on the solenoid’s duty cycle. Duty cycle is
determined by the ratio of solenoid’s on-time to off-time.
RFI Radio Frequency Interference
RPR Return to Previous Range—Diagnostic response in which the transmission is commanded
to return to previously commanded range.
SEM Shift Energy Management—Currently used on 2000MH Series. Allows the TCM to request
torque reduction from the ECM during upshifts for increased clutch life.
SOL OFF All SOLenoids OFF
ST Scan Tool—Most current version is the Allison DOC™ For PC. Diagnostic tool used to
interrogate the TCM for diagnostic information.
TBC Truck Body Controller
TCC Torque Converter Clutch
TCM Transmission Control Module (also commonly referred to as the “computer”)
TFT Transmission Fluid Temperature—Data provided by thermistor that is part of the PSM.
TPS Throttle Position Sensor—Potentiometer for signaling the position of the engine fuel control
lever.
V Version—Abbreviation used in describing TCM software levels.
VBS Variable Bleed Solenoid—Another name for Pressure Proportional to Current (PPC)
solenoid. Solenoid control of clutch pressure is proportional to the current being supplied
to the solenoid.
VDC Volts Direct Current (DC)
VIW Vehicle Interface Wiring—Interfaces TCM programmed input and output functions with the
vehicle wiring.
Volt Unit of electrical force
VOM Volt/ohmmeter
WOT Wide Open Throttle
∞ Infinity—Condition of a circuit with higher resistance than can be measured; effectively an
open circuit.

2–5. RANGE INHIBIT RESPONSES

The range inhibit feature is a function of the TCM logic. The TCM senses when certain input variables are
exceeded and takes action to prevent transmission damage. The TCM inhibits neutral-to-range shifts and
illuminates a light on the dash when the inhibit is active.
Listed below are three variables that, when exceeded, cause inhibited shifts (with thresholds listed).
• Engine speed above 1000 rpm
• Throttle setting above 40 percent
• Output speed above 225 rpm
There are two levels of the special logic inhibits.

• Self-clearing inhibit—This inhibit clears itself if one of the above conditions is not present after a
calibrated time. This is three seconds in the case of medium-duty vehicles. If the shift inhibit is active,
but not latched, the bulb will stay lit until self-cleared.
• Latching inhibit — This inhibit latches when one of the conditions listed above is still present after a
calibrated time. This is above three seconds for medium duty vehicles. To clear a latching inhibit, move
the selector into any other position than the one originally selected.

SECTION 3—BASIC KNOWLEDGE
3–1. BASIC KNOWLEDGE REQUIRED
To service 1000 and 2000 Product Families Electronic Controls, the technician must understand basic electrical
concepts. Technicians need to know how to use a volt/ohmmeter (VOM) to make resistance and continuity checks.
Most troubleshooting checks consist of checking resistance and continuity, and checking for shorts between wires
and to ground. The technician should be able to use jumper wires and breakout harnesses and connectors.
Technicians unsure of making the required checks should ask questions of experienced personnel or find
instruction.
The technician should also have the mechanical aptitude required to connect pressure gauges or transducers to
identified pressure ports used in the troubleshooting process. Pressure tap locations and pressure values are
shown in Appendix B — Main Pressure Check Procedure.
Input power, ground, neutral start circuitry, etc., can cause problems with electronic controls or vehicle functioning
and may not generate a DTC. A working knowledge of 1000 and 2000 Product Families Electronic Controls vehicle
installation is necessary in troubleshooting installation-related problems.
Refer to Section 7 for information concerning performance complaints (non-DTC) troubleshooting. A complete
wiring schematic is shown in Appendix J. Refer to the 1000/2000 Product Family Tech Data for information
concerning electronic controls installation and the Installation Checklist. Reliable transmission operation and
performance depend upon a correctly installed transmission. For proper installation, review the Installation Checklist
in the 1000/2000 Product Family Tech Data, available on the extranet under Engineering at
www.allisontransmission.com.
through the vehicle OEM. The OEM is responsible for warranty on these parts.
3–2. USING THE TROUBLESHOOTING MANUAL

Use this manual as an aid to troubleshooting the 1000 and 2000 Product Families Electronic Controls. Every
possible problem and its solution cannot be encompassed by any manual. However, this manual does provide a
starting point from which most problems can be resolved.
Once a problem solution is discovered in the manual do not look further for other solutions. It is necessary to
determine why a problem occurred. The root cause of a problem as well as the symptom must be corrected to
ensure trouble free operation. For example, taping a wire that has been rubbing on a frame rail will not correct the
problem unless the rubbing contact is eliminated.
3–3. SYSTEM OVERVIEW

1000 and 2000 Product Families Electronic Control functions are controlled by the TCM. The TCM reads shift
selector range selection, output speed, and throttle position to determine when to command a shift. When a shift
occurs, the TCM monitors turbine speed, output speed, and throttle position to control the oncoming and off-going
clutches during the shift.
When the TCM detects an electrical fault, it logs a DTC indicating the faulty circuit and may alter the transmission
operation to prevent or reduce damage.
When the TCM detects a non-electrical problem while trying to make a shift, the TCM may try that shift a second or
third time before setting a DTC. Once that shift has been retried, and a fault is still detected, the TCM sets a DTC
and holds the transmission in a fail-to-range mode of operation.

BASIC KNOWLEDGE
The 1000 and 2000 Product Families transmission utilizes “clutch to clutch” shift control to achieve range
changes. In every case (except shifts to or from neutral), one clutch is exhausted and another applied to make a
range shift. The “handoff” between exhausting and applying clutches is very precisely controlled by use of two
“PPC” (Pressure Proportional to Current) solenoids. These solenoids are labeled A and B in the transmission, and
are referred to as “trim” solenoids. For example, to make a 1–2 shift, A solenoid is used to trim pressure off C5
clutch, and B solenoid is used to trim pressure on C4 clutch.
The TCM (transmission control module) modulates the current to both A and B solenoid, which translates to a
proportional level of pressure to the clutch. In order to make a shift, the TCM uses software and calibration settings
of several program parameters to determine the level of current sent to the respective trim solenoids. These
parameters are referred to as “adaptive values.” With a new transmission and TCM calibration, the adaptive values
are set to “base calibration” level. The transmission uses the base calibration to perform the first of each type of
shift. However, once it has performed a shift, the TCM evaluates the actual shift and compares it to an “ideal” shift
in the TCM’s memory. Based on that comparison, the TCM changes the settings of the adaptive values to a level
that it believes will result in a shift closer to the “ideal” shift the next time it makes that type of shift. This is referred
to as “adaptive shifting.”
When the transmission/TCM calibration is new, the TCM is in “fast adaptive” mode. In other words, the TCM is
allowed to make relatively large changes in the adaptive values after each shift. Once the TCM determines that a
given shift is close to its ideal level it switches to “slow adaptive” mode. In slow adaptive the TCM still is evaluating
shifts and changing adaptive values, but is only allowed to do so in smaller increments. When a shift switches from
fast to slow adaptive mode, it is described as “converged”.
The TCM is programmed to try to switch from fast to slow adaptive mode within approximately five shifts. It is
important to understand that there are many different distinct shifts recognized by the TCM, and each of these
shifts has its own adaptive values. For example, there are upshift and downshifts to and from each range, as well
as unique adaptive values for several different throttle regions for each upshift and downshift. The point is, it may
take a significant amount of time before most of the shifts converge from fast to slow adaptive, and thus it is not
unusual to experience somewhat harsh or unpleasant shift quality until these shifts are converged.
TCC engagement is accomplished by a separate PWM (pulse-width modulated) solenoid labeled “F” in the
transmission. There are adaptive values for this as well, and thus it will also require some driving for TCC
engagement to converge.
3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS

Before beginning the troubleshooting process, read and understand the following:
• Allison recommended wire numbers (i.e. 212) are a combination of the first digit indicating the TCM
connector number (i.e. J2) and the last two digits indicating the pin-out information (i.e. 12).
• Shut off the engine and ignition before any harness connectors are disconnected or connected.
• Remember to do the following when checking for shorts and opens:
— Minimize movement of wiring harnesses when looking for shorts. Shorts involve wire-to-wire or
wire-to-ground contacts and moving the harnesses may eliminate the problem.
— Wiggle connectors, harnesses, and splices when looking for opens. This simulates vehicle
movements which occur during actual operation.
• When disconnecting a harness connector, be sure that pulling force is applied to the connector itself and
not the wires extending from the connector.
• Resistance checks involving the wiring between the TCM connectors and other components adds about
one Ohm of resistance to the component resistance shown.
• Inspect all connector terminals for damage. Terminals may have bent or lost the necessary tension to
maintain firm contact.

BASIC KNOWLEDGE
• Clean dirty terminals or connectors with isopropyl alcohol and a cotton swab, or a good quality, non-
residue, non-lubricating, cleaning solvent such as LPS Electro Contact Cleaner® or LPS NoFlash
Electro Contact Cleaner®.
The cleaning solvent must not be chlorine based, contain petroleum distillates, or conduct
electricity. The cleaning solvent should evaporate quickly to prevent the possibility of
condensation within the connectors. Always blow or shake any excess cleaner from the
CAUTION: connector before assembling it to its mating connector or hardware. Cleaner trapped in
the connector can affect the connector seal. (Refer to SIL 17-TR-94 for detailed
information on the recommended cleaners.)
Care should be taken when welding on a vehicle equipped with electronic controls. Refer
CAUTION: to Appendix G, Paragraph 1–1.
• DTCs displayed after system power is turned on while a harness connector is disconnected can be
ignored and cleared from memory. Refer to Section 5, DTCs, for the DTC clearing procedure.
3–5. BASIC TROUBLESHOOTING INFORMATION

1. Begin troubleshooting by checking the transmission fluid level and ignition voltage. Remember that
some problems may be temperature related. Do troubleshooting, including the fluid level and ignition
voltage checks, at the temperature level where the problem occurs.
NOTE: Fluid level and igniton voltage MUST be checked before any troubleshooting is performed.
NOTE: If you are experiencing harsh shifts, it is important to use the Scan Tool to check whether that
particular shift is converged. If it is not, the TCM is still “learning” how to adapt that shift and
simply needs to be driven further while performing more of that particular type of shift.
If a particular shift is converged but still objectionable, it’s good troubleshooting practice to reset
the adaptive values for that shift back to “base cal” level. This will automatically reset the TCM to
fast adaptive mode. The vehicle should then be driven to allow the TCM to “re-learn” the shift.
Many times this will correct the problem. It is possible to reset individual shifts without affecting
the other shifts.
Whenever a transmission is overhauled, exchanged, or has undergone repairs, the

Transmission Control Module (TCM) must be “RESET TO UNADAPTED SHIFTS.” This
CAUTION: will cause the TCM to erase previous adaptive information and begin to adapt in Fast
Adaptive Mode from the base calibration. Failure to follow this procedure may cause
premature failure of the overhauled, repaired, or replaced transmission.
2. If a transmission has been overhauled, exchanged, or repaired, use the Allison DOC™ For PC to
“RESET TO UNADAPTED SHIFTS”. Accomplish the reset by doing the following:
• Select the Shift Selector icon.
• Select the Reset Adaptives icon.
• Push the Reset All Adaptive Values button.
At the “Are you sure you want to reset all adaptive parameters?” prompt, select “OK.”

BASIC KNOWLEDGE
3. Before using your Allison DOC™ For PC Scan Tool, check the following:
• The desktop or laptop computer must meet the minimum system requirements (see Allison DOC™
For PC User Guide, GN3433EN):
— Microsoft Windows® 95B, Windows® ME, Windows NT® 4.0 (SP6 or later), Windows® 2000
(SP1 or later), or Windows® XP
— 60 MB free hard drive space (an additional 440 MB of disc space needed if training videos are
stored on hard drive)
— 64 MB of RAM
— Intel® Pentium® II processor
— Available serial port and parallel port
— 1024 x 768 screen resolution
— 256-color palette
— Small fonts
— A media player program (Windows Media Player® is provided on the Allison DOC™ For PC CD)
— Adobe® Acrobat® Reader® (provided on the Allison DOC™ For PC CD)
NOTE: Refer to the CD Readme.txt file for more information.

• The proper driver (electronic file) is installed for the Computer Interface Module.
• Power at the Deutsch 9-pin diagnostic connector (pin A is negative, pin B is positive).
• The proper connections exist for communicating with Allison DOC™ For PC Scan Tool (Figure 3–1
and Figure 3–2).
Presently there are two communication standards for Allison DOC™ For PC diagnostic software: J
1939 and J 1850. Both standards are supported by Allison DOC™ For PC (versions 2.0, 2.05, 3.0,
and 3.1).
The Deutsch 9-pin vehicle connector should always be used to establish communication for
troubleshooting. If it is necessary to use the J 43890 T-Adapter Harness, the following conditions
will occur:
• DTC U2105 CAN bus error sets.

• The CHECK TRANS light illuminates (beginning with M04 software, effective March 2000).
• The TCM freezes shift adapts.
• The TCM inhibits TCC engagement.
• Throttle information is defaulted; the TCM estimates throttle data from torque converter slip.
J 42660
RP1210A – COMPLIANT
COMPUTER J 42660-90
INTERFACE BOX
(MPSI MAGIKEY™ SHOWN) V06528.00.02
Figure 3–1. Proper Allison DOC™ For PC Scan Tool Connections — J1939

BASIC KNOWLEDGE
J 44652
DDL ADAPTER
J 1850/OBD II
HEAVY DUTY
(GMC)
SPX J 1850 – VPW

DIAGNOSTIC INTERFACE BOX
V06527.00.01
Figure 3–2. Proper Allison DOC™ For PC Scan Tool Connections — J1850
The J1850 Diagnostic Interface Box (J 44652) utilizes a serial port connection, rather than a parallel
port, and is used only for off-board diagnostic communications. J1939 is still used for on-board
communications such as throttle position; therefore it will necessary to use the J1939 T-Adapter Harness
(J 43890) and MPSI MagiKey™ Interface Box (J 42660) to perform a recalibration (Figure 3–3).
VEHICLE TCM J 43890
J 42660
J1 VEHICLE
HARNESS
MPSI MAGIKEY™
INTERFACE BOX
J 42660-90
V06526.00.01
Figure 3–3. Proper Allison DOC™ For PC Scan Tool Connections Using J1939 T-Adapter Harness (J 43890)

BASIC KNOWLEDGE
4. Check DTCs by using the Scan Tool.
5. When a problem exists but a DTC is not indicated, refer to the General Troubleshooting Section
(Section 7) for a listing of various electrical and hydraulic problems, their causes, and remedies.
6. If a DTC is found in the TCM memory, save all available DTC and failure record information before
clearing the active indicator (refer to Section 5).
7. When certain DTCs are active, a range selection into reverse or forward may not be possible. To
determine if a failure is electrical or hydraulic, perform the following “limp home” test.
Never remove electronic control connectors while the engine is running. Always
WARNING! turn off the ignition, set parking brakes and chock the wheels. Failure to follow this
procedure may result in unexpected vehicle movement.
Limp Home Test
With the ignition in the OFF position (engine not running), the selector in N (Neutral) and the parking
brake set, remove the wiring harness from the main transmission connector. When the engine is
restarted, the transmission will default to a “limp home” capability. In this state, trim solenoid A (de-
energized) allows C3 clutch to be applied. If the selector valve is moved to the reverse range position,
main pressure will be routed to C5 clutch, allowing reverse operation. If the selector valve is moved to
the drive range position, main pressure will be routed to C1 clutch, allowing third range operation.
This allows a technician to use “limp home” capability to determine if a hydraulic or an electrical
problem exists. If reverse and third ranges are available in “limp home,” an electrical failure may be
indicated. If only one of the two ranges or neither was obtainable, this may indicate an internal
hydraulic failure (failed clutch, stuck valve, or solenoid failure). The clutches that could possibly have
an indicated failure in “limp home” are C1, C3, and C5.
NOTE: Removing the main transmission connector will induce several DTCs. Make sure all codes are
cleared before proceeding with further troubleshooting.
8. Test drive the vehicle to confirm a DTC or performance complaint.

• If the DTC reappears, refer to the DTC section (Section 5) and the appropriate DTC table. The
DTC section lists diagnostic codes and their description. Locate the appropriate troubleshooting
table and follow the instructions.
• If the DTC does not reappear and the test has passed, it may be an intermittent problem. Use the
Scan Tool (Allison DOC™ For PC) and the DTC (Section 5). The DTC display procedure will
identify possible causes of the problem.
• Appendix A deals with the identification of potential circuit problems. Refer to Appendix A if a circuit
problem is suspected.
NOTE: Information concerning specific items is contained in the appendices located in the back of this
manual. The appendices are referred to throughout the manual.
3–6. TCM REPLACEMENT PROCEDURE

• Using the Scan Tool, verify the current calibration information number (CIN) and record or print a report
of the current customer modifiable constants (CMC) information for later reference.
• Remove the J1 and J2 connectors from the suspect TCM; inspect the J1 and J2 connectors for
damaged or bent pins.

BASIC KNOWLEDGE
• Replace TCM with a new or known good TCM from a similar vehicle.
• If the replacement TCM corrects the original complaint, reinstall the original TCM to verify the complaint
returns. If original complaint is confirmed, reinstall a new TCM.
• If the complaint does not return, leave the original TCM installed. Disconnecting and reconnecting the
TCM can often correct faulty wiring harness connections that may have been present.
• Clear any DTCs that may be present and test drive the vehicle to confirm the repair.
NOTE: All 1000 and 2000 Product Families TCMs are designed to be isolated from the vehicle chassis
ground. Be sure that the TCM case is not contacting the vehicle frame or any other point that
might provide a ground connection.
3–7. RESETTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE
Shift Energy Management (SEM) Autoselect feature was added to TCM software in the second quarter of
2002.
Autoselect is deactivated following the first 20 engine starts where engine and transmission
communication are present. If during the first 20 engine starts the TCM recognizes an engine to be on its
list of certified engines, it will lock to the SEM active state. If the engine is not supported, the TCM will lock
to a non-SEM state.
TCM Autoselect Certified Engines
Autoselect Functionality
Software Implemented in
CC Level Level TCM Software Engine Type Supported
16 U02 May 2002 Cummins ISB
18 U2A July 2002 Cummins ISB02
19 DEE September 2002 Cummins ISBe (6-cylinder)
N/A N/A Proposed first quarter 2004 Caterpillar C7
ISB engine software since December 2001 should support SEM, as well as most ISBe since
October 2002. ISB02 ECM software started supporting SEM in July 2002.
NOTE: Most engine upgrades are same type/rating; under normal circumstances there should be no
reason to reset the TCM Autoselect.
However, there may be a small chance that transmission performance, shift quality, or codes may result
from the use of different engine models within the same engine family or when a recalibration of engine
software has taken place. If a vehicle receives upgraded engine hardware or software it may become
necessary to reactivate the Autoselect feature to redetect the engines current SEM status.
NOTE: Once TCM Autoselect locks, the only way to reactivate is to perform the power-off data erase
procedure described below.
3–8. RESETTING TCM AUTOSELECT
Verify a new engine rating by checking the engine data tag. The engine must be compatible with the
transmission rating. If the engine rating is not compatible, the vehicle must be returned to the OEM for
engine recalibration. If the rating is correct for the transmission, perform the following steps.

BASIC KNOWLEDGE
PCCS Load Station is used to reset Autoselect function, to do this it is necessary to clear all power-off data
currently stored in the TCM.
• Go to the Maintenance button and select “Erase Power-off Data”
• After selecting “Erase Power-off data”, a message will indicate “PCCS is going to erase Power-off
data”. Select “Yes”. Selecting “No” will abort the clearing of Power-off Data.
• After clearing Power-off Data, there will be a prompt to cycle the ignition.
The TCM is now reset to Autoselect and will start looking for supporting engine software.
Drive the vehicle; confirm DTCs have not returned.
NOTE: Transmission shifts will now be in the unadaptive (base) state, so it will be necessary to drive the
vehicle to allow shifts to converge.
Autoselect reset function will be incorporated into the Allison DOC™ For PC service tool at a later date,
along with an indication of the current SEM Autoselect status.

SECTION 4—WIRE CHECK PROCEDURES
4–1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND

(Use Digital Volt/Ohmmeter J 34520-A and Jumper Wire Set J 39197)
NOTE: Please refer to Paragraph 3–5 to begin the troubleshooting process.
1. Make sure all connectors are tightly connected and re-check the circuit.
2. Disconnect and inspect all connectors.
3. Thoroughly clean corroded or dirty terminals. If dirty or corroded terminals are the probable cause of
the problems, reconnect the clean connectors and operate the vehicle normally. If the problem recurs,
proceed with Step (4).
The cleaning solvent must not be chlorine based, contain petroleum distillates, or
conduct electricity. The cleaning solvent should evaporate quickly to prevent the
possibility of condensation within the connectors. Always blow or shake any excess
CAUTION: cleaner from the connector before assembling it to its mating connector or hardware.
Cleaner trapped in the connector can affect the connector seal. (Refer to SIL 17-TR-94
for detailed information on the recommended cleaners.)
4. Review the wire numbering system described in Paragraph 3–4.
5. If all connectors are clean and properly seated, determine which wires in the chassis harness are in-
dicated by the DTC. For example, DTC P0748, indicates an open or a short-to-ground in the
solenoid A circuit — wires 222 and 223.
a. Check continuity of wires 222 and 223 by performing the following (Figure 4–1):
(1) Disconnect the red (J2) connector from the TCM and disconnect the harness from the
transmission main connector. At one end of the harness, using jumper wire kit J 39197 and
connector probes in J 39775-CP, connect wire 222 and 223 to each other, being careful not to
distort the terminals. Jumping the wires together creates a circuit between wires 222 and 223.
TRANSMISSION CONNECTOR
WIRING HARNESS
JUMPER
TCM
“J2” CONNECTOR
0
VOLT/OHM-
– METER –
+ (VOM) +
0 OHMS OHMS
Circuit has continuity. Jumper Circuit does not have continuity due
from 222 or 223 to another wire to a broken wire (open circuit).
produces a complete circuit. VOM VOM reading is very high
reading is near zero Ohms. (infinite Ohms or OL – overlimit). V06478
Figure 4–1. Checking Continuity (External Harness)

WIRE CHECK PROCEDURES

(2) On the opposite end of the harness, check the continuity of the jumpered pair. No continuity in
a jumpered pair circuit (infinite resistance reading) indicates an open in the wire being tested.
Refer to OEM wiring harness repair procedure.
b. If the continuity check is good (0–2 Ohms resistance), remove the jumpers. Check the harness for
shorts between wires and shorts-to-ground by performing the following (refer to Figure 4–2):
(1) At the TCM end of the harness, touch one VOM probe to one wire of the circuit being tested
and touch the other probe to each terminal in the same connector, then touch the probe to
chassis ground and to the transmission main housing. Do this for both wires in the circuit
being tested.
(2) If at any time the VOM shows zero to low resistance, or the meter’s continuity beeper sounds,
there is a short between the two points being probed — wire-to-wire or wire-to-ground. Isolate
and repair the short.
TRANSMISSION CONNECTOR
WIRING HARNESS
TCM
“J2” CONNECTOR
Wires shorted
together
Shorted to
ground on
metal frame
rail
Ground
to metal
frame rail
0 0
VOLT/OHM-
METER
– (VOM) –
+ +
0 OHMS 0 OHMS
Two wires have frayed and are shorted Harness has been chafed and one or more
together. Continuity beeper of VOM will wires are shorted-to-ground. VOM continuity
sound, or reading will go to zero Ohms beeper will sound, or reading will go to zero
when these two wires are probed with Ohms when meter is probing between this wire
the VOM. and chassis ground. V05734
Figure 4–2. Short Between Wires and to Ground (External Harness)
4–2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS

FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND
1. Disconnect the external wiring harness from the transmission.
2. Inspect the connectors. Any terminals which are corroded or dirty must be thoroughly cleaned.
The cleaning solvent must not be chlorine based, contain petroleum distillates, or
conduct electricity. The cleaning solvent should evaporate quickly to prevent the
possibility of condensation within the connectors. Always blow or shake any excess
CAUTION: cleaner from the connector before assembling it to its mating connector or hardware.
Cleaner trapped in the connector can affect the connector seal. (Refer to SIL 17-TR-94
for detailed information on the recommended cleaners.)


3. If the connectors are clean and properly seated, determine which wires in the harness to test. Use
the diagnostic code system schematic to locate the wire terminals. For this example, DTC P0748
indicates an open or a short-to-ground in the solenoid “A” circuit — wires 222 and 223 (refer to
Figure 4–3 and Figure 4–4).
a. At the transmission connector, check the resistance of the A solenoid circuit. Resistance of a
solenoid circuit should be 5.5–8 Ohms — covering a temperature range of –18°C to 149°C
(0°F to 300°F). Refer to Solenoid Resistance vs. Temperature chart in Appendix K. No continuity
in the circuit (infinite resistance) indicates an open in the internal harness, the feedthrough
connector, or the solenoid coil. Replace the internal harness, replace the feedthrough connector,
or replace the solenoid.
SOLENOID
MAIN
TRANSMISSION
CONNECTOR
3.5
– –
+ +
VOLT/OHM-
METER
(VOM)
INFINITE ( ) OHMS
5.5–8 OHMS Circuit does not have continuity due to a
AT NORMAL OPERATING broken wire (open circuit). VOM reading is
TEMPERATURE* very high (infinite ohms or OL–overlimit).
Circuit has continuity. This could also be due to an open solenoid
coil or bad connection.
* Refer to Appendix K V05735
Figure 4–3. Checking Continuity (Internal Harness)
b. If the resistance check is good, check the harness for shorts between wires and to ground by per-
forming the following (refer to Figure 4–4):
(1) At the transmission connector, touch one probe of the VOM to one wire of the circuit being
tested and touch the other probe to each terminal in the connector and to chassis ground and
the transmission main housing. Do this for both wires in the circuit being tested.
(2) If the VOM shows zero to low resistance, or the continuity beeper sounds, there is a short
between the two points being probed, wire-to-wire or wire-to-ground. An indication of a short
may be caused by a splice to the wire being checked. Check the wiring diagram in Appendix J
for splice locations. If the short is not a splice, then isolate and repair the short.

Shorted
to metal
MAIN
TRANSMISSION SOLENOIDS
CONNECTOR
Bare wires
touching
each other
0
0
VOLT/OHM- –
–
METER +
+ (VOM)
0 OHMS 0 OHMS
Two wires have frayed and are shorted Harness has been chafed and one or more
together. Continuity beeper of VOM will wires are shorted to ground. VOM continuity
sound, or reading will go to zero Ohms beeper will sound or meter reading will go
when these two wires are probed with to zero Ohms when meter is probing between
the VOM. this wire and chassis ground. V05736
Figure 4–4. Short Between Wires and to Ground (Internal Harness)
NOTE: When conducting circuit checks that include the external harness, add one (1) Ohm to the values
shown. Speed sensor resistance is 2304–2815 Ohms at 20°C (68°F).

SECTION 5—DIAGNOSTIC TROUBLE CODES (DTC)

5–1. DTC MEMORY
Diagnostic Trouble Codes (DTCs) are logged in a list in TCM memory. The DTCs contained in the list have
information recorded as shown in Table 5–1 (DTCs are examples). The TCM is capable of displaying all historical
and active DTCs.
Table 5–1. DTC List
Active CHECK
Code DTC Description Indicator TRANS Light
P0562 System Voltage Low Y Y
P0875 Transmission Pressure Switch Reverse Circuit N N
P0743 Torque Converter Clutch PWM Solenoid Circuit N Y
P1892 Throttle Position Sensor PWM Signal High Input N N
The following paragraphs define the different parts of the DTC list.
A. Code. The number assigned to a given fault condition in accordance with SAE J2012.
B. DTC Description. Name assigned to a given fault condition in accordance with SAE J2012.
C. Active Indicator. Indicates when a DTC is active. If a DTC is active, the Scan Tool displays Y (Yes). If
DTC is not active, N (No) is displayed.
D. CHECK TRANS Light. Indicates if CHECK TRANS Light/Malfunction Indicator Lamp (MIL) is
illuminated.
5–2. FAILURE RECORDS

Failure records contain a snapshot of transmission data that is stored in the TCM when DTCs are logged. A limit of
five failure records can be stored. When an additional DTC is logged, the new failure record pushes the oldest
record from the TCM memory. Table 5–2 illustrates the failure record data stored in the TCM when a DTC is set.
Table 5–2. Failure Record Data

Data Description
Gear Selected
Gear Commanded
Current Gear
Previous Gear
Ignition Voltage
Trans Fluid Temperature (TFT)
Trans Input Shaft Speed
Trans Output Shaft Speed
Turbine Speed
Present Gear Ratio
Normalized TPS
Force Motor Solenoid A Actual Current
Force Motor Solenoid B Actual Current
Force Motor Solenoid A Pressure
Force Motor Solenoid B Pressure
TCC PWM Duty Cycle
PSM C
PSM D

DIAGNOSTIC TROUBLE CODES (DTC)

Table 5–2. Failure Record Data (cont’d)
Data Description
PSM E
PSM R
Shift Solenoid C
Shift Solenoid D
Shift Solenoid E
Engine Run Time
5–3. DTC READING AND DTC CLEARING

DTCs can be read and cleared by using the Allison DOC™ For PC scan tool. The use of Allison DOC™ For PC is
described in the instruction manual furnished with each tool and briefly in Appendix M of this manual.
A. Clearing DTCs
• DTCs will automatically clear after 40 code-free warm-up cycles.
• DTCs can be manually cleared by the Allison DOC™ For PC.
B. Clearing Active Indicators
• A DTC’s active indicator can be cleared, which removes the DTC’s shift inhibitions while the DTC
remains in the queue as inactive.
• The active indicator clearing method is to power down (all active indicators are cleared at TCM
power down).
If an active indicator is cleared while the transmission is locked in a forward range or

CAUTION: reverse (fail-to-range), the transmission will remain in the forward range or reverse after the
clearing procedure is completed. N (Neutral) must be manually selected.
5–4. BEGINNING THE TROUBLESHOOTING PROCESS

A. Starting Procedure
NOTE: Review Paragraph 3–5, “Basic Troubleshooting Information” and check fluid level and ignition
voltage before any troubleshooting is performed.
1. Begin troubleshooting by reading Paragraph 3–5, checking the transmission fluid level and the
TCM input voltage. Check for DTCs by using the Allison DOC™ For PC diagnostic tool.
2. When a problem exists, but a DTC is not indicated, refer to Section 7 — General Troubleshooting
Performance Complaint for a listing of various electrical and hydraulic problems, their causes, and
remedies.
3. If a DTC is found in the TCM memory, record all available DTC information and failure record data
before clearing the DTC (refer to Paragraph 5–3).
4. Test drive the vehicle to confirm a DTC or performance complaint.
• If the DTC reappears, refer to the DTC paragraph (Paragraph 5–5) and the appropriate DTC
table. The DTC section lists DTCs and their description. Locate the appropriate troubleshooting
table and follow the instructions.
• If the DTC does not reappear, it may be an intermittent problem. Use the Allison DOC™ For PC
and the DTC display procedure described in Section 5. Refer to the troubleshooting table for
possible causes of the problem.
• Appendix A deals with the identification of potential circuit problems. Refer to Appendix A if a
circuit problem is suspected.


NOTE: Information concerning specific items is contained in the appendices located in the back of this
manual. The appendices are referred to throughout the manual.
B. Solenoid Locations
Solenoid locations in the control module are as illustrated in Figure 5–1. Refer to Figure 5–1 as
necessary when using the DTC schematics.
A TRIM
B TRIM
E
G D
F
V07476.01.01
Figure 5–1. Solenoid Locations
C. Wire/Terminal Numbering Scheme

Allison Transmission recommended wire numbers (i.e. 212) consist of three digits, where the first digit
indicates the TCM connector number (i.e. J2=2), and the last two digits indicate the pin-out
information (i.e. 12).
D. Available Diagnostic Adapters
Figures 5–2 and 5–3 show the J 43799 and J 44722 Adapters that are available for use with the
J 39700 Breakout Box.

J 43799 ADAPTER CABLE

1 2 3 4 5 6 7 8
J 39700 BREAKOUT BOX
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32
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 32
Detail of
Magnetic Overlay
for use with
J 43799
Adapter Box
To
Ground
Existing
E
L
R 9
B
E 9
x)
A
0
T 7
70 Bo
C
P 43
-39 ut
A J-
h J ako
wit re
se l B
(U ersa
J1 and J2
D
A
iv
Un
Harnesses
“J2”
CONNECTOR
(RED)
TRANSMISSION
CONTROL
MODULE
(TCM)
“J1”
CONNECTOR
(GRAY)
“J1”
CONNECTOR
(GRAY)
“J2”
CONNECTOR V06827.00.00
(RED)
Figure 5–2. J 39700 Breakout Box And J 43799 Adapter

J 39700 BREAKOUT BOX 1000/2000/2400 SERIES TM
ENGINE SPEED TURBINE SPEED OUTPUT SPEED

SENSOR SENSOR SENSOR
A B A B A B
DOUBLE 4A 4B 4C 4D
CONNECTOR SINGLE
NSBU CONNECTOR
5 6 8 4 NSBU
MAIN TRANSMISSION CONNECTOR
A B C D E F G H
J K L M N P R S
T U V W
SPEED SENSORS PIN A + B 2500 Ω @ 68˚ F
Shift selector pre-select ranges

are calibration dependent. 5 4 3 1
5 4 2 1
PIN SWA P R N 5 3 2 1
A A OFF OFF ON ON OFF OFF ON
NSBU SWITCH D B ON OFF OFF OFF OFF ON ON
OPEN ON C C ON ON ON OFF OFF OFF OFF
CLOSE/GROUNDED OFF G P OFF ON OFF ON OFF ON OFF
- NSBU TERMINAL REFERENCE -

DOUBLE CONNECTOR NSBU USES ALPHA-NUMERIC.
SINGLE CONNECTOR NSBU USES NUMERIC.
SOL A PIN M + L 5-6 Ω @ 68˚ F

SOL B PIN N + P 5-6 Ω @ 68˚ F
SOL C PIN A + C 21 - 23 Ω @ 68˚ F
SOL D PIN B + C 21 - 23 Ω @ 68˚ F
SOL E PIN W + C 21 - 23 Ω @ 68˚ F
SOL F PIN J + S 10 - 11 Ω @ 68˚ F
SOL G PIN J + R 21 - 23 Ω @ 68˚ F
PIN SWA R N 1 2 3 4 5
PRESSURE SWITCH A B OFF ON ON OFF OFF — ON
MANIFOLD B C ON ON OFF OFF OFF — OFF
C P OFF OFF OFF ON OFF — ON
OPEN OFF D B ON OFF ON ON OFF — OFF
CLOSE/GROUNDED – Switch C Off in Rev. starting with
ON TCM software level NO4 or later.
SUMP TEMP PIN G + H 3088-3942 Ω @ 68˚ F
J-44722-A
FORM 1B
Detail of
Magnetic Overlay
for use with
J 44722-A
Transmission
Breakout Harness
To Existing
Harness
To Engine
To Speed Sensor
Existing
NSBU
To 4-Pin
Connector Harness
To Existing
Harness
To Existing 12-Pin
Single Harness To Turbine
Speed Sensor
J 46971 Harness for use with
Single Connector NSBU Switch
To Existing
Harness
To Output
Speed Sensor
To Existing To Main Case

4-Pin Harness Connector
To NSBU To Existing
4-Pin Connector 32-Pin Harness V06828.01.01
Figure 5–3. J 39700 Breakout Box And J 44722 Adapter


5–5. DIAGNOSTIC TROUBLE CODES (DTCs)
DTC LIST AND DESCRIPTION INDEX
CHECK
TRANS
DTC Description Light Page
P0122 Pedal Position Sensor Circuit Low Voltage Yes 5–16
P0123 Pedal Position Sensor Circuit High Voltage Yes 5–20
P0218 Transmission Fluid Over Temperature Condition No 5–24
P0561 Unrealistic Variations In Vehicle System Voltage Yes 5–27
P0562 System Voltage Low Yes 5–31
P0563 System Voltage High Yes 5–34
P0602 TCM Not Programmed Yes 5–37
P0606 Controller Internal Performance—Not enabled for Pickups or med duty “04” Yes 5–38
P0614 Torque Control Data Mismatch—ECM/TCM Yes 5–39
P0701 Transmission Control System Performance No 5–41
P0703 Brake Switch Circuit Malfunction—GMT800 only No 5–43
Transmission Range Sensor Circuit (PNRDL input)
P0705✝ N/A
Not production enabled/could be in development cals
Transmission Range Sensor Circuit (Performance)
P0706✝ N/A
P0708 Transmission Range Sensor Circuit High Input Yes 5–46
Transmission Fluid Temperature Sensor Circuit
P0710✝ N/A
P0711 Transmission Fluid Temperature Sensor Circuit Performance No 5–50
P0712 Transmission Fluid Temperature Sensor Circuit Low Input (High Temperature) No 5–54
P0713 Transmission Fluid Temperature Sensor Circuit High Input (Low Temperature) No 5–58
P0716 Turbine Speed Sensor Circuit Performance Yes 5–62
P0717 Turbine Speed Sensor Circuit No Signal Yes 5–65
P0719 Brake Switch ABS Input Low N/A 5–69
P0721 Output Speed Sensor Circuit Performance Yes 5–71
P0722 Output Speed Sensor Circuit No Signal Yes 5–75
P0726 Engine Speed Input Circuit Performance No 5–79
P0727 Engine Speed Input Circuit No Signal No 5–82
P0731 Incorrect 1st Gear Ratio Yes 5–85
P0732 Incorrect 2nd Gear Ratio Yes 5–88
P0733 Incorrect 3rd Gear Ratio Yes 5–91
P0734 Incorrect 4th Gear Ratio Yes 5–94
P0735 Incorrect 5th Gear Ratio Yes 5–97
P0736 Incorrect Reverse Ratio Yes 5–100
P0741 Torque Converter Clutch System Stuck Off Yes 5–104
P0742 Torque Converter Clutch System Stuck On Yes 5–107
P0743 Torque Converter Clutch PWM Solenoid Circuit—Electrical (Previously P1860) Yes 5–110
P0746 Solenoid A Controlled Clutch Stuck Off (Previously P1720) Yes 5–115
P0747 Solenoid A Controlled Clutch Stuck On (Previously P1723) Yes 5–118
P0748 Pressure Control Solenoid A Electrical Yes 5–121
P0763 Shift Solenoid C Electrical Yes 5–126


DTC LIST AND DESCRIPTION INDEX (cont’d)
CHECK
TRANS
P0768 Shift Solenoid D Electrical Yes 5–131
P0773 Shift Solenoid E Electrical Yes 5–135
P0776 Solenoid B Controlled Clutch Stuck Off (Previously P1721) Yes 5–139
P0777 Solenoid B Controlled Clutch Stuck On (Previously P1724) Yes 5–142
P0778 Pressure Control Solenoid B Electrical Yes 5–145
P0840 Transmission Pressure Switch Solenoid C Circuit Yes 5–150
P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open Yes 5–155
P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed Yes 5–160
P0843 Transmission Pressure Switch Solenoid C Circuit High Yes 5–165
P0845 Transmission Pressure Switch Solenoid D Circuit Yes 5–170
P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open Yes 5–175
P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed Yes 5–180
P0848 Transmission Pressure Switch Solenoid D Circuit High Yes 5–185
P0870 Transmission Pressure Switch Solenoid E Circuit (Previously P1709) Yes 5–190
P0871 Transmission Pressure Switch Solenoid E Circuit Stuck Open (Previously P1710) Yes 5–195
P0872 Transmission Pressure Switch Solenoid E Circuit Stuck Closed (Previously P1711) Yes 5–200
P0873 Transmission Pressure Switch Solenoid E Circuit High (Previously P1712) Yes 5–205
P0875 Transmission Reverse Pressure Switch Circuit Malfunction (Previously P1713) Yes 5–210
Transmission Reverse Pressure Switch Circuit Stuck Open (Previously P1714)
P0876 Yes 5–215
Transmission Reverse Pressure Switch Circuit Stuck Closed (Previously P1715)
P0877✝ N/A
Transmission Reverse Pressure Switch Circuit High (Previously P1716)
P0878✝ N/A
P0880 TCM Supply Voltage (Previously P1760) No 5–220
Pressure Control Solenoid Control Circuit
P0960✝ N/A
P1688 Unmanaged Engine Torque Delivered To TCM Signal See Note 5–223
P1709 See DTC P0870 5–190
P1710 See DTC P0871 5–195
P1711 See DTC P0872 5–200
P1712 See DTC P0873 5–205
P1713 See DTC P0875 5–210
P1714 See DTC P0876 5–215
P1715 See DTC P0877
P1716 See DTC P0878
P1720 See DTC P0746 5–115
P1721 See DTC P0776 5–139
P1723 See DTC P0747 5–118
P1724 See DTC P0777 5–142
P1760 See DTC P0880 5–220
P1779 Engine Torque Delivered To TCM Signal See Note 5–225


DTC LIST AND DESCRIPTION INDEX (cont’d)
CHECK
TRANS
P1860 See DTC P0743 5–110
P1891 Throttle Position Sensor Pulse Width Modulation (PWM) Signal Low Input No 5–227
P1892 Throttle Position Sensor Pulse Width Modulation (PWM) Signal High Input No 5–230
P2771 Four-Wheel Drive Switch Circuit (Previously P0836, P1875) Yes 5–233
P2773 Torque Control Request Ignored—ECM/TCM Yes 5–237
P2810 Solenoid G Electrical Yes 5–239
U0031 J1850 (Class 2) Serial Data Communication Link Low (Previously U1300) No 5–244
U0032 J1850 (Class 2) Serial Data Communication Link High (Previously U1301) No 5–247
U0073 CAN Bus Reset Counter Overrun (Previously U2104) Yes 5–250
U0100 CAN Bus ECM Error (Previously U2105) Yes 5–253
U1000 Class 2 Loss of Serial Data Communication 5–256
U1016 J1850 (Class 2) Powertrain Controller State of Health Failure No * 5–256
U1041 J1850 (Class 2) ABS Controller State of Health Failure No * 5–256
U1064 J1850 (Class 2) TBC Controller State of Health Failure No * 5–256
U1096 J1850 (Class 2) IPC Controller State of Health Failure No * 5–256
U1300 See DTC U0031 5–244
U1301 See DTC U0032 5–247
U2104 See DTC U0073 5–250
U2105 See DTC U0100 5–253
* Enabled for MY2001 Non-OBD Vehicles.
✝ Call Technical Assistance Center (TAC) at 1-800-252-5283 for further information.
NOTE: Used with GM gasoline engine applications only—CHECK TRANS light will illuminate.
DTC REFERENCE TABLES

Gear Ratio Table
Range 1000 Product Family Gear Ratio 2000 Product Family Gear Ratio
1 3.10:1 3.51:1
2 1.81:1 1.90:1
3 1.41:1 1.44:1
4 1.00:1 1.00:1
5 0.71:1 0.74:1
R –4.49:1 –5.09:1
Main Pressure Schedule Table (Used Prior To S/N 6310004116)

Forward Converter 800–1380 kPa (115–200 psi) 1515–1795 kPa (220–260 psi)
Forward Lockup — 1000–1170 kPa (145–170 psi)

Main Pressure Schedule Table (Used Starting With S/N 6310004116)

Forward Converter 700–1380 kPa (102–200 psi) 1515–1795 kPa (220–260 psi)
Forward Lockup — 1000–1170 kPa (145–170 psi)
Modulated Main Pressure Schedule (Transmissions with Modulated Main G Solenoid)

Forward/Reverse Converter with G Solenoid 590–720 kPa (85–105 psi) 634–758 kPa (92–110 psi)
Active (viewable in Allison DOC™)
Forward Converter with G Solenoid Inactive 700–1380 kPa (101–200 psi) 1515–1795 kPa (220–260 psi)
Forward Lockup with G Solenoid Active* — 510–627 kPa (74–91 psi)
Forward Lockup with G Solenoid Inactive* — 1000–1170 kPa (145–170 psi)
Neutral/Park with G Solenoid Active 590–720 kPa (85–105 psi) —
NSBU Switch Table
Selector Position A B C P
P OFF ON ON OFF
R OFF OFF ON ON
N ON OFF ON OFF
5 5 5 ON OFF OFF ON
3 4 4 OFF OFF OFF OFF
2 2 3 OFF ON OFF ON
1 1 1 ON ON OFF OFF
ON = Open Circuit
OFF = Grounded Circuit
The NSBU Switch has only four positions available in the forward ranges. Therefore, one range
position will be omitted at the selector. This position may be 2nd, 3rd, 4th, or 5th range
depending upon chosen calibration.


Solenoid and Clutch Table — Software Levels Prior To N04
Clutch To Trim Solenoids Shift Solenoids TCC Sol

Range Status Logic Main A B C D E F
Steady State R — De-energized; Energized; ON ON ON OFF
C3 Applied C5 Applied
Garage Shift R–N — De-energizing; Energizing; ON ON ON OFF
C3 Trimming Off C5 Applied
Garage Shift N–R — Energizing; Energizing; ON ON ON OFF
C3 Trimming On C5 Applied
Steady State N — De-energized; De-energized; ON ON ON OFF
C5 Applied Exhausted
Garage Shift N–1 — De-energizing; Energizing; ON ON ON OFF
C5 Applied C1 Trimming On
Garage Shift 1–N — De-energizing; Energizing; ON ON ON OFF
C5 Applied C1 Trimming Off
Steady State 1 C1 De-energized; De-energized; OFF ON OFF OFF
C5 Applied C4 Exhausted
Upshift 1–2 C1 Energizing; Energizing; OFF ON OFF OFF
C5 Trimming Off C4 Trimming On
Downshift 2–1 C1 Energizing; Energizing; OFF ON OFF OFF
C5 Trimming On C4 Trimming Off
Steady State 2 C1 Energized; Energized; OFF OFF OFF ON or
C3 Exhausted C4 Applied OFF *
Upshift 2–3 C1 De-energizing; De-energizing; OFF OFF OFF ON
Downshift 3–2 C1 De-energizing; De-energizing; OFF OFF OFF ON
Steady State 3 C1 De-energized; De-energized; ON OFF OFF ON
Upshift 3–4 C1 Energizing; Energizing; ON OFF OFF ON
Downshift 4–3 C1 Energizing; Energizing; ON OFF OFF ON
Steady State 4 C2 Energized; Energized; ON OFF ON ON
C3 Exhausted C1 Applied
Upshift 4–5 C2 De-energizing; De-energizing; ON OFF ON ON
Downshift 5–4 C2 De-energizing; De-energizing; ON OFF ON ON
Steady State 5 C2 De-energized; De-energized OFF OFF ON ON
C3 Applied
* Depending upon output speed


Solenoid and Clutch Table — Software Level N04 And Later
ClutchTo Trim Solenoids Shift Solenoids TCC Sol
Range Status Logic Main A B C D E F
with Throttle C3 Applied C5 Applied
Steady State R — De-energized; Energized; OFF ON ON OFF
at Closed C5 Applied C3 Applied
Throttle
Garage Shift R–N — De-energizing; Energizing; OFF ON ON OFF
Garage Shift N–R — Energizing; Energizing; OFF ON ON OFF
C5 Applied Exhausted
C3 Exhausted C4 Applied OFF **
C3 Applied
Beginning with N04 software level, the following throttle-dependent conditions occur in Reverse range:
At closed throttle (idle), C solenoid is OFF, A trim solenoid controls C-5 clutch, and B solenoid controls C-3 clutch.
Above 20 percent throttle*, C solenoid is ON, A trim solenoid controls C-3 clutch, and B solenoid controls C-5.
Under 10 percent throttle*, the TCM reverts to the closed throttle (idle) schedule.
* Values are calibration dependent ** Depending upon output speed


Pressure Switch Status Table — Software Levels Prior To N04
Pressure Switch C Pressure Switch D Pressure Switch E Pressure Switch R

(N/O) (N/O) (N/O) (N/C)
Switch Scan Tool Switch Scan Tool Switch Scan Tool Switch Scan Tool
Range Status Status Status Status Status Status Status Status
R Closed ON Closed ON Closed ON Closed ON
N Closed ON Closed ON Closed ON Open OFF
1 Open OFF Closed ON Open OFF Open OFF
2 Open OFF Open OFF Open OFF Open OFF
3 Closed ON Open OFF Open OFF Open OFF
4 Closed ON Open OFF Closed ON Open OFF
5 Open OFF Open OFF Closed ON Open OFF
N/O = Normally OpenN/C = Normally Closed
Pressure Switch Status Table — Software Level N04 And Later
Pressure Switch C Pressure Switch D Pressure Switch E Pressure Switch R

(N/O) (N/O) (N/O) (N/C)
Switch Scan Tool Switch Scan Tool Switch Scan Tool Switch Scan Tool
Range Status Status Status Status Status Status Status Status
R Open OFF* Closed ON Closed ON Closed ON
N Closed ON Closed ON Closed ON Open OFF
1 Open OFF Closed ON Open OFF Open OFF
2 Open OFF Open OFF Open OFF Open OFF
3 Closed ON Open OFF Open OFF Open OFF
4 Closed ON Open OFF Closed ON Open OFF
5 Open OFF Open OFF Closed ON Open OFF
N/O = Normally OpenN/C = Normally Closed
* C pressure switch reverts to the CLOSED/ON state with throttle applied in Reverse.
Solenoid Resistance vs. Temperature Table
Solenoid A, B Solenoid C, D, E, G Solenoid F

Sump Temperature Resistance Resistance Resistance
(°C) (°F) (Ω) (Ω) (Ω)
0 32 4.5 20.0 9.5
20 68 5.5 22.0 10.5
40 104 6.5 24.5 11.5
80 176 7.5 27.0 12.5
120 248 8.5 29.5 13.5

Speed Sensor Resistance vs. Temperature Table
Temperature
Temperature ( Minimum Resistance Nominal Resistance Maximum Resistance
(°C) F) (Ω) (Ω) (Ω)
–25 –13 1929 2143 2358
0 32 2157 2397 2637
25 77 2340 2600 2860
50 122 2614 2904 3195
75 167 2842 3158 3474
100 212 3071 3412 3753
125 257 3299 3666 4032
150 302 3483 3870 4257
Transmission Fluid Temperature (TFT) Sensor Resistance vs. Temperature Table
Temperature Temperature Minimum Resistance Nominal Resistance Maximum Resistance

(°C) (°F) (Ω) (Ω) (Ω)
–45 –49 128 565 141 951 155 338
–40 –40 95 826 100 735 105 644
–35 –31 68 952 72 315 75 679
–30 –22 50 153 52 480 54 807
–25 –13 36 854 38 478 40 103
–20 –4 27 345 28 488 29 631
–15 5 20 476 21 286 22 097
–10 14 15 467 16 045 16 624
–5 23 11 781 12 197 12 612
0 32 9045 9345 9646
5 41 6998 7219 7441
10 50 5458 5623 5787
15 59 4291 4413 4536
20 68 3398 3490 3582
25 77 2710 2779 2849
30 86 2173 2228 2282
35 95 1754 1797 1840
40 104 1424 1459 1493
45 113 1163 1191 1218
50 122 955.0 977.1 999.2
55 131 788.6 806.5 824.5


Transmission Fluid Temperature (TFT) Sensor Resistance vs. Temperature Table (cont’d)

(°C) (°F) (Ω) (Ω) (Ω)
60 140 654.7 669.3 683.9
65 149 546.3 558.3 570.2
70 158 458.1 467.9 477.8
75 167 385.9 394.1 402.2
80 176 326.6 333.3 340.1
85 185 277.5 283.2 288.9
90 194 236.5 241.6 246.7
95 203 202.4 206.9 211.5
100 212 173.8 177.9 182.0
105 221 149.8 153.6 157.3
110 230 129.7 133.0 136.4
115 239 112.6 115.6 118.7
120 248 98.17 100.88 103.6
125 257 85.87 88.29 90.71
130 266 75.35 77.52 79.69
135 275 66.34 68.27 70.21
140 284 58.58 60.31 62.04
145 293 51.88 53.42 54.97
150 302 46.08 47.46 48.84
155 311 41.04 42.27 43.50
160 320 36.65 37.74 38.84
TPS Table (Distance (mm) of Travel vs. Volts)

mm Volts mm Volts mm Volts mm Volts
0 0 12 1.317 24 2.634 36 3.951
1 0.110 13 1.427 25 2.744 37 4.061
2 0.220 14 1.537 26 2.854 38 4.171
3 0.329 15 1.646 27 2.964 39 4.281
4 0.439 16 1.756 28 3.073 40 4.390
5 0.549 17 1.866 29 3.183 41 4.500
6 0.659 18 1.976 30 3.293 42 4.610
7 0.768 19 2.085 31 3.403 43 4.720
8 0.878 20 2.195 32 3.512 44 4.829
9 0.988 21 2.305 33 3.622 45 4.939
10 1.098 22 2.415 34 3.732 46 5.049
11 1.207 23 2.524 35 3.842

Clutch Test Failure Table

Range — Clutches
Applied C1 Failure C2 Failure C3 Failure C4 Failure C5 Failure
*Reverse / C3 and C5 NT > 0 in 3rd NT > 0 in 1st
and 5th only
First / C1 and C5 NT > 0 in 1st NT > 0 in 1st

and 4th only
Second / C1 and C4 NT > 0 in 1st NT > 0 in 4th

and 4th only
Third / C1 and C3 NT > 0 in 1st NT > 0 in 3rd

and 4th only
Fourth / C1 and C2 NT > 0 in 1st NT > 0 in 4th

and 4th and 5th
Fifth / C 2 and C3 NT > 0 in 4th NT > 0 in 3rd

and 5th and 5th
* CAUTION: Reverse is not attainable in clutch test mode. Do not stall transmission in Reverse or driveline
damage may occur.
NOTE: NT is transmission turbine speed observed during clutch test


DTC P0122 Pedal Position Sensor Circuit Low Voltage
J2 HARNESS CONNECTOR
(RED)
J2-9
TCM
TPS
CONNECTOR
J2-20 J2-19
J2
J1
A
B
C
219
C J2-19 5V
TCM
THROTTLE 209 ANALOG
POSITION B J2-9
INTERFACE
SENSOR
(TPS) 220
A J2-20
V06225.01.00
Circuit Description
The Transmission Control Module (TCM) receives input on throttle position from either a Throttle Position Sensor
(TPS) or a signal transmitted by the engine electronic controls.
Vehicles not equipped with electronically-controlled engines have a TPS attached to the engine fuel control linkage.
The TPS continuously sends the exact throttle position to the transmission TCM.
The TPS is a sliding resistor sensor (potentiometer) actuated by a mechanical linkage. The TCM delivers a
constant voltage to one terminal of the TPS resistive strip. The other TPS terminal connects to ground. The resistor
contacts of the TPS are connected to provide a regulated voltage signal input to the TCM.
When actuated by the mechanical throttle cable, the contacts of the resistor move along the resistive strip. As the
contacts slide along the resistive strip, a voltage is sent to the TCM. At each increment of 0.178 mm (0.007 inch)
along the resistive strip, the contacts deliver a different voltage to the TCM. The different voltages are interpreted as
throttle sensor movement. The TCM converts travel distance (mm) into throttle opening percentage.
Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
• DTC P0123 Pedal Position Sensor Circuit High Voltage is not active.


Conditions for Setting the DTC
DTC P0122 sets when the TCM detects a throttle position sensor voltage less than 0.55V for 5 seconds.
Action Taken When the DTC Sets

• DTC P0122 is stored in the TCM history.
• The TCM uses the default throttle value.
• The TCM freezes shift adapts (DNA).
• The CHECK TRANS light is illuminated.
Conditions for Clearing the DTC/CHECK TRANS Light

A Scan Tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.
Diagnostic Aids
• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
— A bent terminal.
— A backed-out terminal.
— A damaged terminal.
— Poor terminal tension.
— A chafed wire.
— A broken wire inside the insulation.
• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
• You may have to drive the vehicle in order to experience a fault.
Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. This step tests for the proper adjustment of TPS.
3. This step tests for the proper ignition voltage.
4. This step tests for the proper reference voltage from TCM.
5. This step tests for dead spots in the TPS rheostat.
6. This step tests for a high or low resistance in the TPS internal circuit.
7. This step tests for a harness-wiring problem.

Step Action Value(s) Yes No
1 Was the Beginning The Troubleshooting — Go to Step 2 Go to
Process (Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Refer to Appendix F to check for proper TPS — Go to Step 3 Adjust TPS to
adjustment. proper setting.
Is the TPS adjusted properly? Go to Step 11


3 1. Install the Scan Tool. 9–18V Go to Step 4 Resolve
2. Start the engine. (12V TCM); voltage problem
3. Record the DTC Failure Record data. 18–32V (Refer to
4. Using the Scan Tool, measure ignition (24V TCM) DTC P0562
voltage. and P0563)
Is voltage within the specified value?
4 1. Turn the ignition OFF. 4.75–5.0V Go to Step 5 Go to Step 10
2. Disconnect the J2 connector from the TCM
and install the J43799 adapter box.
3. Reconnect the J2 connector to the adapter
box. With the engine OFF, turn the ignition to
the ON position.
4. Using a DVOM, measure the voltage
between pins 19 and 20.
Is the voltage within the specified value?
5 1. With the engine OFF and the ignition in the — Go to Step 6 Go to Step 7
ON position, monitor throttle percentage with
the Scan Tool.
2. Slowly increase the throttle from Idle to the
full throttle position.
3. Watch for a steady increase in throttle
percentage.
Was the throttle percentage steady and without
interruptions?
6 1. Turn the ignition OFF. 9,000–15,000 Go to Step 7 Go to Step 9
2. Disconnect the TPS connector. Ohms
3. Using a DVOM, measure the resistance at
pins A and C.
Is resistance within the specified value?
7 1. Reconnect the TPS connector. 9,000–15,000 Go to Diagnostic Go to Step 8
2. Disconnect J2 connector from the TCM. Ohms Aids
3. Using a DVOM, measure resistance at
connector J2 pins 19 and 20.
8 NOTE: The vehicle OEM has responsibility — Go to Step 10 —
for all external wiring harness repair.
Harness repairs performed by Allison
Transmission distributors and dealers are
not covered by Allison Transmission
warranty.
Repair the vehicle wiring harness.
Is the repair complete?
9 Replace the throttle position sensor. — Go to Step 11 —
Is the replacement complete?


10 NOTE: In most cases, the TCM is not at fault. — Go to Step 11 —
Investigate thoroughly before replacing the
TCM. Refer to TCM Replacement Procedure
(Section 3–6).
Replace the TCM.
11 In order to verify your repair: — Begin the System OK
1. Clear the DTC. diagnosis again.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?

DTC P0123 Pedal Position Sensor Circuit High Voltage
(RED)
J2-9
TCM
TPS
CONNECTOR
J2-20 J2-19
J2
J1
A
B
C
219
C J2-19 5V
TCM
THROTTLE 209 ANALOG
POSITION B J2-9
INTERFACE
SENSOR
(TPS) 220
A J2-20
V06225.01.00
Circuit Description
The Transmission Control Module (TCM) receives input on throttle position from either a Throttle Position Sensor
(TPS) or a signal transmitted by the engine electronic controls.
Vehicles not equipped with electronically-controlled engines have a TPS attached to the engine fuel control linkage.
The TPS continuously sends the exact throttle position to the transmission TCM.
The TPS is a sliding resistor sensor (potentiometer) actuated by a mechanical linkage. The TCM delivers a
constant voltage to one terminal of the TPS resistive strip. The other TPS terminal connects to ground. The resistor
contacts of the TPS are connected to provide a regulated voltage signal input to the TCM.
When actuated by the mechanical throttle cable, the contacts of the resistor move along the resistive strip. As the
contacts slide along the resistive strip, a voltage is sent to the TCM. At each increment of 0.178 mm (0.007 inch)
along the resistive strip, the contacts deliver a different voltage to the TCM. The different voltages are interpreted as
throttle sensor movement. The TCM converts travel distance (mm) into throttle opening percentage.

• DTC P0122 Throttle/Pedal Position Sensor/Switch A Circuit Low Input is not active.


DTC P0123 sets when the TCM detects a throttle position sensor voltage greater than 4.75 for 5 seconds.


Diagnostic Aids
— A chafed wire.
Test Description
2. This step tests for the proper adjustment of TPS.
4. This step tests for the proper reference voltage from TCM.
5. This step tests for dead spots in the TPS rheostat.
6. This step tests for a high or low resistance in the TPS internal circuit.
7. This step tests for a harness-wiring problem.

Troubleshooting
Process
(Paragraph 5–4A)
2 Refer to Appendix F to check for proper TPS — Go to Step 3 Adjust TPS to
adjustment. proper setting.
Is the TPS adjusted properly? Go to Step 11


voltage. and P0563)
2. Disconnect the J2 connector from the TCM
and install the J43799 adapter box.
3. Reconnect the J2 connector to the adapter
box. With the engine OFF, turn the ignition to
the ON position.
4. Using a DVOM, measure the voltage
between pins 19 and 20.
5 1. With the engine OFF and the ignition in the — Go to Step 6 Go to Step 7
ON position, monitor throttle percentage with
the Scan Tool.
2. Slowly increase the throttle from Idle to the
full throttle position.
3. Watch for a steady increase in throttle
percentage.
Was the throttle percentage steady and without
interruptions?
6 1. Turn the ignition OFF. 9,000–15,000 Go to Step 7 Go to Step 9
2. Disconnect the TPS connector. Ohms
3. Using a DVOM, measure the resistance at
pins A and C.
7 1. Reconnect the TPS connector. 9,000–15,000 Go to Diagnostic Go to Step 8
2. Disconnect J2 connector from the TCM. Ohms Aids
3. Using a DVOM, measure resistance at
connector J2 pins 19 and 20.
warranty.
9 Replace the throttle position sensor. — Go to Step 11 —


(Section 3–6).
Replace the TCM.
2. Operate the vehicle under normal driving Go to Step 1
conditions.
Did the DTC return?


DTC P0218 Transmission Fluid Over Temperature Condition
N/C
V07737.01.00
Circuit Description
The flow of transmission fluid starts in the transmission pan. Fluid is then drawn through the filter and internal
passages into the oil pump assembly. The oil pump pressurizes the fluid into main-pressure that is regulated at the
main-pressure regulator valve. From this point, fluid is directed to the F trim solenoid and to the control-main
regulator and control-main relief valve into the control-main filter assembly and on to all solenoids for use as control
pressure. Hot fluid leaving the torque converter is routed through the converter flow valve to cooler lines and into
the cooler assembly. The transmission oil cooler is located in the radiator. The vehicle may be equipped with an
auxiliary oil cooler. The cooled fluid is returned to the transmission through the return cooler line and to the
transmission lube circuit. The automatic transmission fluid temperature (TFT) sensor, which is part of the PSM, is
located in the oil pan.
If the Transmission Control Module (TCM) detects a high TFT for an extended period of time, then DTC P0218 sets.


• DTCs P0711, P0712, P0713 are not active.
• Engine speed is greater than 200 rpm for more than 5 seconds.

DTC P0218 sets when the TCM detects a transmission sump temperature greater than 126°C (252°F) for
10 seconds.

• The TCM does not illuminate the CHECK TRANS light.
• The TCM records the operating conditions when the conditions for setting the DTC are met. The TCM stores
this information as Failure Records.
• The TCM defaults to “hot mode” shift schedule where 4th-range is held and TCC is inhibited to increase engine
speed and improve cooler flow.

• A Scan Tool may be used to clear the code from the TCM history.
• The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles
without the DTC recurring.
• The TCM cancels the DTC default actions when the fault no longer exists and the DTC passes test.
Diagnostic Aids
• Verify the customer’s driving habits, such as trailer towing, etc.
• The Scan Tool transmission fluid temperature (TFT) should rise steadily during warm-up cycles and then
stabilize.
• DTC P0218 may set after DTC P0711 (not active) has set. Follow the diagnostic table for DTC P0711 before
proceeding to the diagnostic for DTC P0218. Repairing the condition that set DTC P0711 will likely eliminate
DTC P0218.
Test Description
3. This step inspects for air restriction and loss of transmission fluid flow, causing an extremely high TFT.
4. This step tests main-pressure.
5. This step inspects for a stuck torque converter stator.
DTC P0218 Transmission Fluid Over Temperature Condition

Step Action Yes No
1 Was the Beginning The Troubleshooting Process Go to Step 2 Go to Beginning The
(Paragraph 5–4A) performed? Troubleshooting
Process
(Paragraph 5–4A)

DTC P0218 Transmission Fluid Over Temperature Condition (cont’d)

Step Action Yes No
2 1. Install the Scan Tool. Go to Step 3 Go to A/T Fluid
2. Turn ON the ignition, with the engine OFF. Checking Procedure.
3. Record the Failure Record data. (Appendix P)
4. Clear the DTC.
5. Perform the A/T Fluid Checking Procedure (Appendix P).
Was the A/T fluid level check performed?
3 1. Inspect the engine cooling system for the following Go to Step 6 Go to Step 4
conditions:
• Air flow restrictions
• Air flow blockage
• System fluid level and condition
• Debris
2. Inspect the transmission cooling system for the following
conditions:
• Air flow restrictions
• Air flow blockage
• System fluid level and condition
• Debris
• Damaged cooler lines or hoses
Did you find and correct the condition?
4 Perform the Main Pressure Check Procedure. Refer to Go to Step 6 Go to Step 5
Appendix B.
Did you find and correct a pressure problem?
5 Check for a possible torque converter stator malfunction. Go to Step 6 Go to General
A stuck stator would be indicated by no cool-down in neutral Troubleshooting
after stalling the transmission. Refer to Section 7. (Section 7)
6 Perform the following procedure in order to verify your Begin the diagnosis System OK
repair: again.
1. Clear the DTC. Go to Step 1
2. Using the Scan Tool, monitor the transmission fluid
temperature.
3. Operate the vehicle under the following conditions.
4. Turn ON the ignition, with the engine OFF.
5. The TFT must be less than 126°C (258°F) for at least
10 seconds.
6. Using the Scan tool, verify that the test to detect this code
has run.
Has the test run and passed?


DTC P0561 Unrealistic Variations in Vehicle System Voltage
J1 HARNESS CONNECTOR TCM

(GRAY)
J1-4
J1-5 J1-3
J1-2
J1-1
J2
J1
102
J1-2
104 IGNITION
J1-4
POWER
10a 103 BATTERY
J1-3 POWER TCM
10a 101
J1-1 GND
IGN 105
SWITCH J1-5 GND
+ —
12V/24V
BATTERY
V06215.01.00
Circuit Description
The Transmission Control Module (TCM) requires a switched ignition voltage input and a direct battery voltage
input. This switched ignition voltage signal originates from the ignition switch or an ignition relay to supply voltage to
pins 102 and 104 in the J1 connector at the TCM. Battery direct voltage is supplied to pin 103 at the J1 connector.

• The test becomes enabled when the engine has been running above 400 rpm for at least 0.5 seconds.

P0561 sets when the TCM detects a large variation in ignition voltage or battery direct voltage. When an ignition or
battery direct voltage variation of 4.0V or greater is detected for 0.5 seconds, a fault pending is reported. After
1.0 second of 4.0V or greater variation, a DTC is set with a failure response.

When DTC P0561 is active, the following conditions will occur:
• Hydraulic default is commanded. Shift selector position and hydraulic state of logic valves determine the range
attained.
• The CHECK TRANS light illuminates.



Diagnostic Aids
• This DTC indicates a variation in ignition voltage or battery direct voltage. Common ignition circuit problems for
this DTC are a fault in the feed wires to the TCM, a defective ignition switch, or a large vehicle accessory load
on the ignition circuit. Battery direct voltage problems may be due to loose or corroded battery cables, a bad
connection at the battery direct feed terminal (103), or an internal TCM failure due to a burnt trace.
• A vehicle charging system failure may cause this DTC under certain circumstances.
• This code may indicate that an internal voltage problem has occurred inside the TCM. The use of a substitute
TCM would be a good way to diagnose this problem.
• A defective vehicle battery may induce this DTC.
— A chafed wire.
Test Description
2. This step tests for an active DTC after clearing.

3. This step tests for the proper battery direct input voltage.
4. This step tests for the proper ignition input voltage.
5. This step tests for shorts or open conditions at battery direct input circuit.
6. This step tests for shorts or open conditions at ignition input circuit.
1 Was the Beginning The Troubleshooting Go to Step 2 Go to
Troubleshooting
Process
(Paragraph 5–4A)


2 1. Install the Scan Tool. — Go to Step 3 Go to Step 4
3. Record the failure records.
4. Clear the DTC.
5. Start vehicle and test drive.
6. Duplicate same operating conditions
observed in failure records.
NOTE: This DTC indicates that a voltage
variation exists in the ignition voltage or at
the battery direct input. This variation is
measured from min. and max. voltage
values. If the voltage variation is present for
a pre-determined amount of time, this DTC
sets.
Did DTC P0561 return?
2. Disconnect TCM connector J1 (gray) at the
TCM.
3. Install J 39700 Breakout Box and J 43799
Adapter box at the J1 connector.
4, Using a digital multimeter (DVOM), measure
voltage at J1 connector pin 1 and pin 3.
4 1. Using a digital multimeter (DVOM), 11.5–12.5V Go to Diagnostic Go to Step 6
sequentially measure voltage at J1 Aids
connector pins 2 and 4 using J1 connector
pins 1 or 5 as ground return.
5 NOTE: The vehicle OEM has responsibility — Go to Step 8 Go to Step 7
warranty.
Inspect battery direct circuit 103 for one of the
following conditions:
• Intermittent open or short.
• Loose or corroded connections at battery
or connection points.
• Defective battery.
Was one of these conditions discovered and
repaired?


6 NOTE: The vehicle OEM has responsibility — Go to Step 8 Go to Step 7
warranty.
Inspect the TCM ignition input circuit for one of
the following conditions:
• Intermittent open or short at ignition input
circuits 101, 102, 103, or 104.
• Loose or corroded connections at ignition
switch or ignition relay assembly.
• Defective ignition switch or relay.
• Loading of ignition circuit by defective
vehicle accessories.
Was one of these conditions discovered and
repaired?
(Section 3–6).
Replace the TCM.
2. Drive the vehicle under conditions shown in Go to Step 1
failure records.
Did the DTC return?


DTC P0562 System Voltage Low

(GRAY)
J1-4
J1-5 J1-3
J1-2
J1-1
J2
J1
102
J1-2
104 IGNITION
J1-4
POWER
10a 103 BATTERY
J1-3 POWER TCM
10a 101
J1-1 GND
IGN 105
SWITCH J1-5 GND
+ —
12V/24V
BATTERY
V06215.01.00
Circuit Description
The Transmission Control Module (TCM) requires a switched ignition voltage input to operate. This switched
ignition voltage signal originates from the ignition switch or an ignition relay to supply voltage to pins 102 and 104 in
the J1 connector at the TCM.
• The engine speed is greater than 450 rpm for 10 seconds.
DTC P0562 sets when the TCM detects the following condition:
• 12 volt TCM — Ignition voltage is detected below 8V at 0°C (32°F) for a total of 5 out of 7 seconds. The voltage
threshold is temperature dependent varying from 5V at –60°C (–75°F) to 9V at 20°C (68°F).
• 24 volt TCM — Ignition voltage is detected below 17V at 0°C (32°F) for a total of 5 out of 7 seconds. The
voltage threshold is temperature dependent varying from 14V at –60°C (–75°F) to 18V at 20°C (68°F).


• If the DTC is active while vehicle is in a forward range, transmission shifts to neutral, 1st, 3rd, or 5th range.
• If the DTC is active while in reverse or neutral, transmission shifts to neutral.
• If the shift selector is moved to forward range, transmission shifts to neutral, 1st, 3rd, or 5th range.
• If the shift selector is moved to reverse or neutral, transmission shifts to neutral. Diagnostic response honors
the inhibit latched at the time the DTC is set. If a latched inhibit is present and PRNDL is incorrect,
transmission shifts to neutral range. If PRNDL is correct, GPI request is responded to.

Diagnostic Aids
• A defective vehicle battery may allow this DTC to set. Test the vehicle battery to verify proper voltage and load
capacity.
• A defective vehicle charging system may cause this DTC.
• Vehicle components such as an ignition switch or TCM ignition relay may cause this DTC to set and not be
active, this indicates that an intermittent condition may exist in these components.
— A chafed wire.
Test Description
4. This step tests vehicle battery per OEM guidelines.
5. This step tests vehicle charging system per OEM guidelines.
DTC P0562 System Voltage Low

Troubleshooting
Process
(Paragraph 5–4A)


DTC P0562 System Voltage Low (cont’d)
2 1. Install the Scan Tool. Voltage should Go to Step 4 Go to Step 3
2. Turn ON the ignition, with the engine OFF. be above 9V
3. Record the failure records. (12V TCM) or
4. Clear the DTC. 18V (24V TCM)
5. Inspect the ignition voltage value on the at 20°C (68°F).
Scan Tool. See conditions
for setting the
NOTE: This DTC sets when ignition voltage DTC.
drops below a predetermined level that is
temperature dependent for 5 out of 7
seconds.
Is the ignition voltage below specified value?
3 1. Start the vehicle, if possible. — Go to Step 4 Go to Diagnostic
2. If the DTC is not active, drive the vehicle. Aids
Attempt to duplicate the same operating
conditions observed in the failure records.
Did the DTC return?
4 Test the vehicle battery per OEM instructions. See OEM for Go to Step 5 Replace the
This should include a voltage test and a load correct battery vehicle battery
test. specifications and go to Step 6
Does test indicate the battery is good?
5 Test the vehicle charging system per the OEM See OEM for Go to Diagnostic Repair the
recommended testing procedure. correct charging Aids charging system
Is the charging system operating properly? system and go to Step 6
specifications
2. Drive the vehicle under conditions shown in Go to Step 1
the failure records when the DTC set.
Did the DTC return?


DTC P0563 System Voltage High

(GRAY)
J1-4
J1-5 J1-3
J1-2
J1-1
J2
J1
102
J1-2
104 IGNITION
J1-4
POWER
10a 103 BATTERY
J1-3 POWER TCM
10a 101
J1-1 GND
IGN 105
SWITCH J1-5 GND
+ —
12V/24V
BATTERY
V06215.01.00
Circuit Description
The Transmission Control Module (TCM) requires a switched ignition voltage input to operate. This switched
ignition voltage signal originates from the ignition switch or an ignition relay to supply voltage to pins 102 and 104 in
the J1 connector at the TCM.

• The engine speed is greater than 450 rpm for one second.

DTC P0563 sets when the TCM detects the following condition:
• 12 volt TCM — Ignition voltage is above 18V for 6 out of 10 seconds.
• 24 volt TCM — Ignition voltage is above 32V for 6 out of 10 seconds.


• If the DTC is active while the vehicle is in a forward range, the transmission shifts to neutral, 1st, 3rd, or 5th
range.
• If the DTC is active while in reverse or neutral, the transmission shifts to neutral.
• If the shift selector is moved to a forward range, the transmission shifts to neutral, 1st, 3rd, or 5th range. If the
shift selector is moved to reverse or neutral, the transmission shifts to neutral. Diagnostic response honors the
inhibit latched at the time the DTC is set. If a latched inhibit is present and PRNDL is incorrect, the
transmission shifts to neutral range. If PRNDL is correct, the GPI request is responded to.

Diagnostic Aids
• A defective vehicle charging system that is overcharging may cause this DTC.
— A chafed wire.
Test Description

5. This step tests vehicle charging system per OEM guidelines.
DTC P0563 System Voltage High

Troubleshooting
Process
(Paragraph 5–4A)


DTC P0563 System Voltage High (cont’d)
2 1. Install the Scan Tool. See Conditions for Go to Step 4 Go to Step 3
2. Turn ON the ignition, with the engine OFF. Setting the DTC
4. Clear the DTC.
5. Start vehicle engine and inspect the ignition
voltage value on the Scan Tool.
NOTE: This DTC sets when ignition voltage
is detected above 18V for 12V systems or
32V for 24V systems for 6 out of 10 seconds.
Is the ignition voltage above specified value?
3 1. Start the vehicle, if possible. — Go to Step 4 Go to Diagnostic
2. If the DTC is not active, drive the vehicle. Aids
conditions observed in failure records.
Did the DTC return?
4 Test the vehicle charging system per the OEM — Go to Diagnostic Repair the
recommended testing procedure. Aids charging system
Is the charging system operating properly? and go to Step 5
1. Clear DTC. diagnosis again.
2. Drive vehicle under conditions shown in Go to Step 1
failure records when DTC set.
Did the DTC return?


DTC P0602 TCM Not Programmed
NO SCHEMATIC FOR THIS DTC

Circuit Description
At the power up and after clearing codes, the Transmission Control Module (TCM) performs a self-test to determine
if the calibration in memory is valid.

• This test will run before any TCM functions.

DTC P0602 sets if the TCM determines the present calibration is invalid.

• The TCM returns to the boot program, and then waits to be recalibrated.

TCM must be recalibrated.
DTC P0602 TCM Not Programmed

Step Action Yes No
1 Was the Beginning The Troubleshooting Process Go to Step 2 Go to
(Paragraph 5–4A) performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. Go to Step 4 —
2. If DTC P0602 is present, the TCM must be recalibrated.
Is recalibration complete?
3 NOTE: In most cases, the TCM is not at fault. Investigate Go to Step 4 —
thoroughly before replacing the TCM. Refer to TCM
Replacement Procedure (Section 3–6).
Replace the TCM.
Is replacement complete?
4 1. Install the Scan Tool. Go to Step 3 System OK
2. Start the vehicle.
Did the DTC return?


DTC P0606 Controller Internal Performance

Circuit Description
The Transmission Control Module (TCM) completes numerous scheduled tasks during normal operation. If one of
the scheduled tasks fails to complete within a specific time limit the TCM will re-attempt this task.
NOTE: The presence of DTC P0606 indicates a TCM software error has occurred and the Allison
Transmission Service Department should be contacted at 1-800-252-5283.

The components are powered and ignition voltage is greater than 9V and less than 18V for a 12V TCM, or greater
than 18V and less than 32V for a 24V TCM.
This test is run during the entire ignition cycle.

DTC P0606 sets if a task fails to complete after two consecutive attempts.

• When DTC P0606 is active, the transmission will lock in N (Neutral).

A Scan Tool can clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history
if the vehicle completes 40 warm-up cycles without failure.


DTC P0614 Torque Control Data Mismatch — ECM/TCM

Circuit Description
Shift Energy Management (SEM) allows the Transmission Control Module (TCM) to request torque reduction from
the engine controller. By reducing torque, shifts can be made quicker, at a more consistent output torque which
reduces clutch temperatures and increases clutch life. When an engine torque rating exceeds 580 lb ft, Lower
Range Torque Protection (LRTP) is used. This feature limits engine torque in lower ranges to protect the
transmission from damage if a stall condition occurs.

• No DTC U2105 CAN bus error.
• Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
• This test runs for 30 seconds for the first 20 engine starts after the engine is detected on the J1939 CAN.
• Engine must be identified by the TCM as an approved make and model.
• Engine’s torque configuration message (peak torque) must be greater than allowed without SEM (above
580 lb ft gross input torque).
NOTE: Unapproved engines or low torque engines will operate without setting a P0614.
P0614 sets when the TCM detects one of the following conditions:
• TCM detects a valid engine having the proper torque rating but ECM software is not supporting all the
messaging necessary for SEM.
• TCM detects a valid engine having a torque rating exceeding 580 lb ft that does not support Lower Range
Torque Protection (LRTP) messaging.
NOTE: Valid engines with a torque rating exceeding 580 lb ft must have software that is compatible with
LRTP or a P0614 is set.

• If the TCM and engine ECM software are not compatible, the transmission will be restricted to reverse, neutral,
first range, or third range.



Test Description
3. This step tests for an incompatible engine calibration.
5. This step tests for the proper engine torque limit.
DTC P0614 Torque Control Data Mismatch — ECM/TCM

Troubleshooting
Process
(Paragraph 5–4A)
2 If a DTC U2105 is present, troubleshoot and — Go to DTC Go to Step 3
resolve before going to the next step. U2105 and
Is a DTC U2105 present? resolve before
proceeding to
Step 7
3 Using the Scan tool, refer to the Transmission/ Scan Tool Go to Step 4 Go to Step 5
Engine shift energy management (SEM) indicates with Yes
compatibility and the Lower Range Torque or No Answer
Protection compatibility display.
Is the ECM shown as being incompatible with
TCM request for SEM or LRTP?
4 This indicates that engine software does not — Go to Step 7 —
support shift energy management for either
SEM or LRTP.
Have the OEM install the proper engine
software and calibration to support SEM.
Is the proper software and calibration installed?
5 Using Scan Tool, refer to the engine torque Scan Tool Go to Step 7 Go to Step 6
rating display. indicates with Yes
Is the torque rating displayed as acceptable? or No Answer
6 This indicates that engine torque values are — Go to Step 7 —
above the transmission ratings set in the TCM
calibration. Inspect the TCM for proper software
and calibration to support SEM. If the proper
TCM software and calibration are installed, the
engine rating is too high for the transmission.
Recalibrate the engine to a lower torque rating.
Was one of the above conditions found and
resolved?
1. Connect the Scan Tool. diagnosis again.
3. Drive the vehicle under normal operating
conditions.
Did the DTC return?


DTC P0701 Transmission Control System Performance

Circuit Description
The Transmission Control Module (TCM) monitors the status of the pressure switches at start-up to detect the
presence of hydraulic pressure.

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM).
• This test is run after engine start-up and runs as part of the transmission hydraulic initialization.

DTC P0701 sets when transmission fluid temperature is above –25°C (–13°F) with an engine speed above
500 rpm for 6 seconds or 400 rpm for 15 seconds and forward or reverse range is selected and all the pressure
switches do not indicate pressure.

Conditions for Clearing the MIL/DTC

TCM history if the vehicle completes 40 warm-up cycles without failure.
Diagnostic Aids
• DTC P0701 may be logged if a forward or reverse range is selected immediately after the engine is started and
before the TCM detects pressure at the switches (2 to 6 seconds after engine start).
• A plugged control main filter may cause this code to set. The control main filter is to be changed after the first
8000 km (5,000 miles). Failure to change the filter at this interval may cause this code and other pressure
switch codes to set.
• A cracked internal suction filter tube or damaged tube seal may cause this DTC to set.
• A stuck lube regulator valve (located in the front support) may cause this DTC to set. A high static oil level with
the vehicle running is often a good indication of this complaint. Often pressure switch DTCs are set in this
scenario.
Test Description
2. This step tests for proper fluid level.

5. This step tests for main pressure.


DTC P0701 Transmission Control System Performance
Step Action Yes No
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. Go to Step 3 Go to Step 4
2. Turn the ignition to ON, with the engine OFF.
3. Record the DTC Failure Record data.
4. Clear the DTC.
5. Start the engine; Check the Transmission Fluid Level.
Is the fluid at the appropriate level?
3 This DTC can be set after performing fluid service and Go to Step 7 Go to Step 5
filter change, after replacement of the PSM, or after a long
period of storage.
Have any of these conditions occurred?
4 Add fluid to the proper level. Go to Step 5 —
Is the fluid at the appropriate level?
5 Check main pressure (refer to Main Pressure Check Go to Step 7 Go to Step 6
Procedure — Appendix B).
Is the pressure within the specified value?
6 No main pressure at idle may be an indication of the Go to Step 7 Go to General
following: Troubleshooting
• Stuck or sticking lube regulator valve (Section 7)
• Stuck or sticking main pressure regulator valve
• Loose or damaged suction filter
• Defective suction filter seal
Was the reason for no main pressure condition found and
repaired?
7 In order to verify your repair: Go to Step 1 System OK
1. Clear the DTC.
2. Start the vehicle.
3. Use the Scan Tool, in the test passed section, to confirm
the diagnostic test was run.
Did the DTC return?


DTC P0703 Brake Switch Circuit Malfunction
TCM
(GRAY)
J1-14* J1-7**
J2
J1-28* J1
TCM
114 DIGITAL
J1-14 INTERFACE
128
J1-28
*NOTE: Brake signal provides ground
TCM
SWITCHED
POWER 107 DIGITAL
J1-7 INTERFACE
**NOTE: Brake signal provides power

V06216.01.00
Circuit Description
A mechanical switch attached to the brake pedal sends a signal to the Transmission Control Module (TCM)
indicating the service brake has been applied. This signal is either ignition voltage or a ground signal depending on
the calibration installed in the TCM.
P0703 is a type C DTC.

• No DTC P0721 or P0722.
The TCM sets a DTC when either of the following conditions occur:
• The vehicle has accelerated 10 or more times with TCM input indicating brakes applied.
• Decelerated 10 or more times with TCM input indicating brakes released.


Action Taken when the DTC Sets
• No Grade Braking allowed.
• Use the default assumption that the brake is off.
• TCM inhibits TCC engagement.
A Scan Tool can clear the code from the TCM history. The TCM automatically clears the DTC from the TCM history
if the vehicle completes 40 warm-up cycles without the DTC active.
Diagnostic Aids
Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
• A bent terminal.
• A backed-out.
• A damaged terminal.
• Poor terminal tension.
• A chafed wire.
• A broken wire inside the insulation.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment
for a change.
Step Action Value Yes No
1 Was the Beginning The Troubleshooting Go to Step 2 Go to Beginning
Process (Section 5-4A) Performed? The
Troubleshooting
Process
(Paragraph 5–4a)
2 1. Install the Scan Tool. Go to Go to Step 3
2. Turn the ignition ON, with the engine OFF. Diagnostic Aids
3. Record the DTC Failure Record Data.
4. Apply and release the service brake.
Does the Scan Tool indicate that brake switch is
toggling off and on?
3 1. Using a DVOM, probe pin 5 and pin 7 on the Battery + Go to Step 8 Go to Step 4
C1 connector.
3. There should be no voltage reading at pin 7
when the brake is applied, with the brake
released there should be 12V.
Was voltage reading proper according to brake
status?
4 1. Go to the Stop Lamp Switch, with a DVOM Battery + Go to Step 6 Go to Step 5
probe pin C at the switch, supply a ground
connection at other lead.
Is the switch turning voltage ON and OFF?


5 Using a DVOM, check the voltage at pin D on Go to Step 7 Resolve voltage
the input side of the Stop Lamp Switch. problem
Is voltage available at the input side of the Stop
Lamp Switch?
6 Replace the TCC Brake Switch/Cruise Control Go to Step 9
harness.
Is repair complete?
7 Repair or replace the Stop Lamp Switch Go to Step 9
assembly.
Is repair complete?
8 NOTE: In most cases, the TCM is not at fault. Go to Step 9
(Section 3–6).
Replace the TCM.
9 In order to verify your repair: Begin the System OK
2. Drive the vehicle making at lease 10 Go to Step 1
accelerations and decelerations cycles.
Did the test run and pass?


DTC P0708 Transmission Range Sensor Circuit High Input
(RED) TCM
J2-7 J2-6
J2-8 J2-5
J2
J2-20 J1
4-PIN AND 7-PIN
NSBU SWITCH TCM

208
P 4C 8 J2-8
207
C 4B 6 J2-7
DIGITAL
206 INTERFACE
B 4D 4 J2-6
205
A 4A 5 J2-5
220
7D 7 J2-20 GND
12-PIN
SINGLE CONNECTOR
NSBU
FORMER CURRENT
NSBU SWITCH NSBU SWITCH
4- AND 7-PIN 12-PIN
V06217.01.00
Circuit Description
The installation of a transmission-mounted Neutral Start/Back-Up (NSBU) switch is required. This switch mounts
directly onto the transmission housing from the outside and detects the angular position of the shift selector shaft.
This position is communicated to the Transmission Control Module (TCM) so that certain vehicle control functions
can be coordinated with the position of the shift controls. The NSBU switch has redundant circuitry to alert the TCM
in the event of a single wire or switch failure.
The neutral signal output of the NSBU switch is typically used as confirmation that the transmission is in
N (Neutral) before the engine starter is engaged. The NSBU switch is interfaced to the starter circuit with
weatherproof electrical connectors. The reverse signal provision may be used to activate vehicle back-up lights
and/or reverse warning devices.

• The components are powered and ignition voltage is greater than 9V and less than 18V.


Conditions for Setting the DTC — Software Levels Prior To N11
DTC P0708 sets when the TCM detects an invalid condition or parity errors occurring over consecutive ignition
cycles.
Actions Taken When the DTC Sets — Software Levels Prior To N11
• The diagnostic response is to shut all solenoids off and allow the transmission to operate in hydraulic default
mode or “limp home”. Shift selector and hydraulic state of logic valves determines range attained.
• Due to this failure and associated responses, P0722 and P0845 may also set.
Action Taken When the DTC Sets — Software Level N11 And Later
• The CHECK TRANS light illuminates but no diagnostic response is implemented until after 50 warm-up cycles
occur when a NSBU switch parity error is active. A warm-up cycle is defined as a 20 degree change in
transmission temperature.
• The diagnostic response is to shut all solenoids off and allow the transmission to operate in hydraulic default
mode or “limp home.” Shift selector and hydraulic state of logic valves determines range attained.
• Due to this failure and associated responses, P0722 and P0845 may also set.
• A shift to R (Reverse) will allow reverse range if a P0876 (previously P1714) is not active.
Conditions for Clearing the MIL/DTC

Diagnostic Aids
— A chafed wire.
• When a P0708 is shown in failure records, this indicates that conditions to set a P0708 were present at one
time. If the condition was due to moisture intrusion, the moisture may no longer be present, and thus you may
not be able to reproduce the DTC. In such case, variables such as vehicle mileage, external physical condition
of the switch should be factored in when making a decision to replace the NSBU switch.
NOTE: Due to the TCM logic used to detect and set a P0708, this code can remain active even after a
NSBU switch replacement is complete and the ignition has been cycled. It is important to clear all
active DTCs from the TCM after servicing the NSBU switch.


Test Description
3. This step tests NSBU switch status.
4. This step tests for proper TCM input response.
5. This step tests the wiring harness for opens or shorts.
DTC P0708 Transmission Range Sensor Circuit High Input

Troubleshooting
Process
(Paragraph 5–4A)
2 Is the NSBU switch and shift linkage properly — Go to Step 3 Go to
adjusted? Mechanic’s Tips
3 1. Install the Scan Tool. Refer to NSBU Go to Go to Step 4
2. Turn the ignition ON with the engine OFF. Switch Table Diagnostic Aids
3. Record the DTC Failure Record data. (Page 5–9)
4. Using the Scan Tool, monitor PRNDL A, B, C,
P status while moving the shift selector
through each range.
Does each switch toggle ON and OFF in the
correct sequence, and does the range selected
displayed on the Scan Tool match the actual
physically selected range?
4 1. Turn the ignition OFF. A=pin 5 Go to Step 5 Go to Step 10
2. Disconnect J2 connector from the TCM and B=pin 6
install J 39700 Breakout Box and J 43799 C=pin 7
Breakout Box Adapter. P=pin 8
3. Disconnect the NSBU 4-pin connector and
the NSBU 7-pin connector. Scan Tool Status
4. Turn the ignition ON. ON=Open circuit
5. In sequence, connect J2 connector pin 20 to OFF=Grounded
circuit
J2 pins 5, 6, 7, and 8.
6. Monitor the switch status on the Scan Tool.
Does each switch toggle ON and OFF in the
correct sequence as each pin is grounded?
5 Inspect the NSBU switch connector assembly. Go to Step 6 Go to Step 7
Does the NSBU have two connectors—a seven
pin and four pin connector?
6 1. Turn the ignition OFF. Scan Tool Status Go to Step 8 Go to Step 9
2. Reconnect J2 connector to the TCM. ON=Open circuit
3. In sequence, connect pins 4A, 4B, 4C, and OFF=Grounded
4D at the 4-pin NSBU connector to pin 7D** circuit
on the NSBU 7-pin connector. *
4. Monitor the switch status on the Scan Tool. 7D=wire 220
Does the Scan Tool indicate the proper switch
status for each switch when grounded?


DTC P0708 Transmission Range Sensor Circuit High Input (cont’d)
7 1. Turn the ignition OFF. Scan Tool Status Go to Step 8 Go to Step 9
2. Reconnect J2 connector to the TCM. ON=Open circuit
3. At the NSBU connector in sequence, OFF=Grounded
connect pins 4, 5, 6, and 8 to pin 7** at the circuit
12 pin connector.
4. Monitor the switch status on the Scan Tool. 7D=wire 220
Does the Scan Tool indicate the proper switch
status for each switch when grounded?
8 Replace the NSBU switch (refer to Mechanic’s — Go to Step 11 —
Tips).
9 Repair the vehicle wiring harness. — Go to Step 11 —
NOTE: The vehicle OEM has responsibility
for all external wiring, wherefore the OEM
should perform vehicle harness repairs.
warranty.
(Section 3–6).
Replace the TCM.
11 In order to verify your repair: Refer to NSBU Begin the System OK
1. Clear the DTC. Switch Table diagnosis again.
2. Drive the vehicle under normal operating (Page 5–9) Go to Step 1
conditions.
3. Using the Scan Tool, monitor PRNDL switch
status while moving selector through all
positions.
Does each switch toggle according to switch
table?
* If J 39700 Breakout Box and J 44722 Transmission Harness are available, they may be used to perform this
operation.
** Use pin H at the magnetic overlay to provide a ground source when J 44722 Harness is used.


DTC P0711 Transmission Fluid Temperature Sensor Circuit Performance
TRANSMISSION
HARNESS
CONNECTOR J2 HARNESS CONNECTOR
(RED)
H J2-10
J2-20 TCM
TRANSMISSION
BULKHEAD
CONNECTOR
H
J2
G
J1
NOTE: Letters I, O, and Q are not used.
C A
D B
E C 210
G J2-10 HI
R D TCM
TRANSMISSION
E
F 220 LO
H J2-20
NOTE: Switches C, D, and E are N/O. Switch R is N/C.

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06214.01.00
Circuit Description
The Transmission Fluid Temperature (TFT) sensor is part of the Pressure Switch Manifold (PSM) which is located
in the transmission oil pan. The TFT sensor is a thermistor that changes its resistance value based on the
temperature of the transmission fluid. The Transmission Control Module (TCM) supplies a 5V reference signal to
the TFT sensor and measures the voltage drop in the circuit. When the transmission is cold, the sensor resistance
is high and the TCM detects high signal voltage. As the transmission fluid temperature warms to a normal
operating temperature, the resistance becomes less and the signal voltage decreases. The TCM uses this
information to control shift quality and to determine torque converter clutch applies.
If the TCM detects the TFT sensor resistance has no change, an unrealistic change in a short amount of time, or
multiple changes within seconds, DTC P0711 sets.


• No DTC P0721, P0722, P0717, P0716, P0713, or P0712.
• The engine speed is greater than 200 rpm for more than 5 seconds.
• The engine speed is greater than 450 rpm for more than 2 seconds with output speed of 100 rpm or above.
This would indicate that a range is selected.
• A valid start-up temperature is detected.

DTC P0711 sets when the TCM detects one of the following conditions:
• The TCM detects a temperature change that is under a set limit when compared to samples of the minimum
and maximum temperature values.
• The TFT has an unrealistic temperature change of more than 10°C (50°F) for 10 occurrences.
• The temperature from start up decreases 40°C (104°F) or more within duration of 6 or more seconds.

• The TCM stores DTC P0711 in TCM history.
• The TCM uses calibration default for temperature values.

• The TCM cancels the DTC default actions when the fault no longer exists and the ignition has been cycled.
Diagnostic Aids
• The Scan Tool transmission fluid temperature (TFT) should rise steadily during warm-up cycles and then
stabilize.
• DTC P0218 may set after DTC P0711 has set. Follow the diagnostic table for DTC P0711 before proceeding to
the diagnostic for DTC P0218.
Test Description
2. This step tests for proper AT fluid level and condition.

3. This step tests for the proper reference voltage.
4. This step verifies which condition has set DTC P0711.
5. This step tests the resistance value of the internal wiring harness and TFT sensor.
6. This step tests for opens and shorts in the main wiring harness.
8. This step tests the resistance value of the internal TFT sensor.

DTC P0711 Transmission Fluid Temperature Sensor Circuit Performance

Troubleshooting
Process
(Paragraph 5–4A)
2 Perform the A/T Fluid Checking Procedure — Go to Step 4 Go to A/T Fluid
(Appendix P). Checking
Is the transmission fluid level correct? Procedure
(Appendix P)
2. Disconnect J2 connector at the TCM and
install J 39700 Breakout Box and J 43799
Breakout Box Adapter.
3. With the engine OFF, turn the ignition to the
ON position, Measure voltage between J2
connector pins 10 and 20.
4 1. Install the Scan Tool. 1.5°C (2.7°F) Go to Step 5 Go to
2. With the engine OFF, turn the ignition to the Diagnostic Aids
ON position.
4. Clear the DTCs.
5. Monitor the TFT on the Scan Tool.
6. Drive the vehicle and observe the Scan Tool
for one of the following conditions:
• No transmission temperature change.
• An unrealistic transmission temperature
change of greater than 1.5°C in (2.7°F) in
one second.
Did either of these conditions occur?
5 1. Disconnect the wiring harness from the main 3398–3582 Ohms Go to Step 6 Go to Step 8
transmission connector. at 20°C (68°F)
2. Using a DVOM, measure resistance at main Refer to
transmission connector pins G and H.* TFT Sensor
Is resistance within the specified values? Resistance Table
Page 5–13)
6 1. Reconnect the wiring harness to the main 3398–3582 Ohms Go to Go to Step 7
transmission connector. at 20°C (68°F) Diagnostic Aids
2. Disconnect connector J2 from the TCM. Refer to
3. Using a DVOM, measure resistance at TFT Sensor
connector J2 pins 10 and 20.* Resistance Table
Is resistance within the specified values? Page 5–13)


DTC P0711 Transmission Fluid Temperature Sensor Circuit Performance (cont’d)
warranty.
Have the vehicle wiring harness repaired.
8 1. Remove the oil pan. 3398–3582 Ohms Go to Step 9 Go to Step 10
2. Disconnect the PSM from the internal wiring at 20°C (68°F)
harness. Refer to
3. Using a DVOM, measure PSM resistance at TFT Sensor
pins E and F. Resistance Table
9 Replace the internal wiring harness (refer to — Go to Step 12 —
Mechanic’s Tips).
10 Replace the PSM (refer to Mechanic’s Tips). — Go to Step 12 —
(Section 3–6).
Replace the TCM.
2. Using the Scan Tool, monitor the Go to Step 1
transmission fluid temperature.
conditions. Look for significant changes in
TFT.
Did the DTC return?
* If J 39700 and J 44722 are available, they may be used to perform this operation.


DTC P0712 Transmission Fluid Temperature Sensor Circuit Low Input
(High Temperature)
TRANSMISSION
HARNESS
(RED)
H J2-10
J2-20 TCM
TRANSMISSION
BULKHEAD
CONNECTOR
H
J2
G
J1
C A
D B
E C 210
G J2-10 HI
R D TCM
TRANSMISSION
E
F 220 LO
H J2-20

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06214.01.00
Circuit Description
temperature of the transmission fluid. The Transmission Control Module (TCM) supplies a 5V reference to the
thermistor. The TCM’s internal impedance provides resistance at the TCM so that voltage drop can be measured
between the TCM and the thermistor. When the transmission is cold, the sensor resistance is high and the TCM
detects high signal voltage. As the transmission fluid temperature warms to a normal operating temperature, the
resistance becomes less and the signal voltage decreases. The TCM uses this information to control shift quality
and to determine torque converter clutch applies.
If the TCM detects a continuous short to ground in the TFT sensor or signal circuit, DTC P0712 is set.


• No TFT sensor DTC P0711 or P0713.
• The engine is greater than 200 rpm for more than 5 seconds.
• The engine has been running for 20 seconds with a coolant temperature above 20°C (68°F).

DTC P0712 sets when the TFT sensor indicates a voltage of less than 313mV for 2.5 seconds.

• TCM uses calibration default for temperature values.

Diagnostic Aids
— A chafed wire.
• A short to ground on wire 210 may allow a code P0712 to set. A default value of 160°C (320°F) TFT on the
Scan Tool would be a good indication this has occurred.
Test Description


(High Temperature)
Troubleshooting
Process
(Paragraph 5–4A)
(Appendix P)
Breakout Box Adapter at J2 connector.
ON position. Measure voltage at J2
4 1. Install the Scan Tool. 150°C (302°F) Go to Step 5 Go to
ON position.
3. Record the Failure Record data.
4. Clear the DTC.
5. Select TFT on the Scan Tool. Drive the
vehicle and inspect for unrealistic TFT
readings.
Is the TFT reading at or above the specified
value?
This DTC may indicate a short to ground at wire
210.
Page 5–13)
2. Disconnect J2 connector from the TCM. Refer to
3. Using a DVOM, measure resistance at J2 TFT Sensor
connector pins 10 and 20. Resistance Table
Is the resistance within the specified values? Page 5–13)


(High Temperature) (cont’d)
warranty.
Have the vehicle wiring harness repaired.
harness. Refer to
Mechanic’s Tips).
(Section 3–6).
Replace the TCM.
conditions making sure coolant temperature
is over 20°C (68°F).
4. Watch for significant change in TFT.
Did the DTC return?


DTC P0713 Transmission Fluid Temperature Sensor Circuit High Input
(Low Temperature)
TRANSMISSION
HARNESS
(RED)
H J2-10
J2-20 TCM
TRANSMISSION
BULKHEAD
CONNECTOR
H
J2
G
J1
C A
D B
E C 210
G J2-10 HI
R D TCM
TRANSMISSION
E
F 220 LO
H J2-20

PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06214.01.00
Circuit Description
temperature of the transmission fluid. The Transmission Control Module (TCM) supplies a 5V reference to the
thermistor. The TCM’s internal impedance provides resistance at the TCM so that voltage drop can be measured
between the TCM and the thermistor. When the transmission is cold, the sensor resistance is high and the TCM
detects high signal voltage. As the transmission fluid temperature warms to a normal operating temperature, the
resistance becomes less and the signal voltage decreases. The TCM uses this information to control shift quality
and to determine torque converter clutch applies.
If the TCM detects a continuous open or short-to-power in the TFT sensor or signal circuit, DTC P0713 sets.


• No DTC P0711 or P0712.
• Engine speed is greater than 200 rpm for more than 5 seconds.
• The engine has been running for 20 seconds with a coolant temperature above 20°C (68°F).

DTC P0713 sets when the TCM detects a voltage greater than 4.84V for 2.5 seconds.

• TCM uses calibration default for temperature values.

Diagnostic Aids
— A chafed wire.
• An open or a short to power at wire 210 may allow DTC P0713 to set. A default value of –60°C (–76°F) would
be a good indication this has occurred.
Test Description


(Low Temperature)
Troubleshooting
Process
(Paragraph 5–4A)
(Appendix P)
ON position. Measure voltage between J2
4 1. Install the Scan Tool. –36°C (–32.8°F) Go to Step 5 Go to
ON position.
3. Record the Failure Record data.
4. Clear the DTC.
5. Select TFT on the Scan Tool. Drive the
vehicle and inspect for unrealistic TFT
readings.
Is the TFT reading at or below the specified
value?
This DTC may indicate an open or short to
power at wire 210.
Page 5–13)
2. Disconnect the J2 connector from the TCM. Refer to
3. Using a DVOM, measure resistance at TFT Sensor
connector J2 pins 10 and 20. Resistance Table


(Low Temperature) (cont’d)
warranty.
harness. Refer to
Mechanic’s Tips).
Is the repair or replacement complete?
(Section 3–6).
Replace the TCM.
conditions making sure coolant temperature
is over 20°C (68°F).
Did the DTC return?


DTC P0716 Turbine Speed Sensor Circuit Performance
J2-13 (RED)
J2-14
TCM
J2
J1
A TCM
B
TURBINE 213
A J2-13 TURBINE SPEED HI
SPEED 214
SENSOR B J2-14 TURBINE SPEED LO
SPEED SENSOR CIRCUITS

Use twisted pairs of wires
NOTE: Typical speed sensor resistance 2304 Ω – 2815 Ω at 20°C (68°F)

V06219.01.00
Circuit Description
The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each sensor
consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are
contained in a housing which is mounted adjacent to a rotating ferrous member. Two signal wires extend from one end
of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent magnet
produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth) approaches and passes
through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil. The Transmission Control
Module (TCM) calculates the frequency of these AC pulses and converts it to a speed value. The AC voltage
generated varies from 150mV at low speed to 15V at high speed. The signal wires from the sensor are formed as
twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from voltage-related fields.
Noise from other sources is eliminated by using two-wire differential inputs at the TCM.

• DTC P0717, P0721, or P0722 is not active.
• Turbine speed is above 200 rpm.
• Shift is complete and range attained is not neutral.

DTC P0716 is set when one of the following conditions occur:
• Unrealistic large change in turbine speed. Failure is set if an unrealistic change in transmission turbine speed is
detected at or above 800 rpm for 0.15 seconds.


• Noisy turbine speed signal. Noise is determined with two counters. A low counter is incremented when turbine
speed change is below 800 rpm for 2.0 seconds. A high counter is incremented when turbine speed change is
above 800 rpm. When both counters accumulate 5 events, a failure is set.

• When DTC P0716 is active, the following conditions will occur:
— If failure occurs while in a forward range and a shift has been completed, the transmission will remain in the
current range.
— If failure occurs while in a forward range and a shift is in progress, the transmission will return to the
previous range, except in post-shift state; then the transmission will continue to the commanded range.
• The TCM freezes shift adapts.

Diagnostic Aids
— A chafed wire.
• If the condition is intermittent, connect the Scan Tool and select the speed sensor indicated by the code. If the
signal is erratic, investigate and eliminate the following:
— Intermittent wiring connection.
— Excessive vibration (driveline or engine torsionals).
— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel).
• Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in
the sensor removed.
• Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These
twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor
connector.
• Inspect the turbine speed tone wheel/PTO gear for possible damage.
Test Description
2. This step tests ignition voltage.
3. This step tests for proper turbine speed sensor resistance at the TCM side of the harness.
4. This step tests turbine speed sensor resistance.

DTC P0716 Turbine Speed Sensor Circuit Performance

Troubleshooting
Process
(Paragraph 5–4A)
voltage. and P0563)
3 1. Turn the ignition OFF. Refer to Go to Diagnostic Go to Step 4
2. Disconnect the J2 connector at the TCM. Speed Sensor Aids
3. Using a DVOM, measure the resistance Resistance Table
between connector J2 pin 13 and Page 5–13)
connector J2 pin 14.
Is the speed sensor resistance within the
specified values?
4 1. Disconnect the wiring harness from the Refer to Go to Step 5 Go to Step 6
turbine speed sensor. Speed Sensor
2. Using a DVOM, check the resistance Resistance Table
between the speed sensor terminals.* Page 5–13)
Is resistance within the specified values?
warranty.
6 NOTE: Do not rotate the speed sensor in the — Go to Step 7 —
retaining bracket. Orientation is fixed, and if
changed, may cause improper operation.
Replace the turbine speed sensor (refer to
Mechanic’s Tips).
2. Drive the vehicle under normal operating Go to Step 1
conditions.
3. Using the Scan Tool, monitor turbine speed
sensor operation.
Did the DTC return?


DTC P0717 Turbine Speed Sensor Circuit No Signal
J2-13 (RED)
J2-14
TCM
J2
J1
A TCM
B
TURBINE 213
A J2-13 TURBINE SPEED HI
SPEED 214
SENSOR B J2-14 TURBINE SPEED LO

NOTE: Typical speed sensor resistance 2304 Ω – 2815 Ω at 20°C (68°F)

V06219.01.00
Circuit Description
The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each sensor
consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are
contained in a housing which is mounted adjacent to a rotating ferrous member. Two signal wires extend from one
end of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent
magnet produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth) approaches and
passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil. The
Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a speed value.
The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the sensor
are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from voltage-
related fields. Noise from other sources is eliminated by using two-wire differential inputs at the TCM.

• Components are powered and the ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V or less than 32V (24V TCM).
• DTC P0721, P0722, P0731, P0732, P0733, P0734, P0735, P0736, or P1718 is not active.
• When unrealistic large change in turbine speed is detected.
— Engine is running.
— Shift is not in process.
— Range attained is not neutral.
— Transmission fluid temperature is above –25°C (–13°F).


• When unrealistic low turbine speed is detected.
— Transmission output speed is at or above 150 rpm or engine speed is at or above 400 rpm.

• Unrealistic large change in turbine speed. A Failure pending is set if an unrealistic change in transmission
turbine speed is detected at or above 800 rpm. The failure pending response is to lock in the current range.
• Unrealistic low value in turbine speed. A failure pending is set if turbine speed is detected below 61 rpm. A
failure is set when turbine speed is below 61 rpm and output speed is detected above 500 rpm for more than
1 second.

current range.
— If failure occurs under other conditions, the transmission shifts to 1st, 3rd, or 5th.
— If the shift selector is moved to N (Neutral), R (Reverse), or any other forward range, the transmission will
lock in N (Neutral).

Diagnostic Aids
— A chafed wire.


— Intermittent wiring connection
— Excessive vibration (driveline or engine torsionals)
— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
the sensor removed.
connector.
• Install a known good TCM, if available. If the DTC does not return, reinstall the old TCM to verify the repair.
Test Description
3. This step tests for proper turbine speed sensor resistance at the TCM side of the harness.
4. This step tests turbine speed sensor resistance at the sensor.
DTC P0717 Turbine Speed Sensor Circuit No Signal

Troubleshooting
Process
(Paragraph 5–4A)
voltage. and P0563)
3 1. Turn the ignition OFF. Refer to Go to Go to Step 4
2. Disconnect connector J2 from the TCM. Speed Sensor Diagnostic Aids
3. Using a DVOM, measure resistance at Resistance Table
connector J2 pins 13 and 14. Page 5–13)
turbine speed sensor. Speed Sensor
2. Using a DVOM, measure resistance at the Resistance Table
speed sensor terminals.* Page 5–13)


DTC P0717 Turbine Speed Sensor Circuit No Signal (cont’d)
warranty.
Replace the turbine speed sensor (refer to
Mechanic’s Tips).
conditions.
sensor operation.
Did the DTC return?


DTC P0719 Brake Switch ABS Input Low
TCM
(GRAY)
J1-13
J2
J1-28 J1
ANTI-LOCK
BRAKE TCM
CONTROLS 113
J1-13 DIGITAL
INTERFACE
Customer–furnished
relay is shown
de-energized
128
J1-28
SWITCHED
POWER
NOTE: ABS System provides ground (–) signal when active.
ANTI-LOCK
BRAKE TCM
CONTROLS 113
J1-13 DIGITAL
INTERFACE
Customer–furnished
relay is shown
de-energized
128
J1-28
NOTE: ABS System provides power (+) signal when active.

V08118.00.00
Circuit Description
If the vehicle is equipped with anti-lock brake system (ABS), an interface between the ABS and TCM is required.
This interface allows disengagement of the Torque Converter Clutch (TCC) when the ABS is activated.
This ABS action is initiated with a discrete input from the ABS system, when the ABS is activated a ground signal is
sent to TCM input wire 113. This may be a ground signal direct from the ABS controller or a positive signal from the
ABS controller that powers a relay field coil to supply a ground through the relay contacts. (Some ABS systems
require that the ground signal be switched through a relay.)

• Components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than
18V and less than 32V (24V TCM).
• DTCs P0721, P0722 are not active.
DTC P0719 will set after the TCM detects one or more vehicle acceleration cycles where the TCM ABS brake
switch input is in the “ON” activated state.


Action Taken when DTC sets
• The TCM uses the default assumption that the ABS is OFF.
A Scan Tool can be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
Diagnostic Aids
— A chafed wire.
• ABS system interface to the TCM input can be wired one of three different ways, check with the OEM for proper
wiring information concerning ABS applied input before troubleshooting.
DTC P0719 Brake Switch ABS Input Low

1 Was the Beginning the Troubleshooting — Go to Step 2 Go to
Process (Section 5-4A) Performed? Beginning The
Troubleshooting
Process
(Paragraph 5–4A)
2 Remove ABS input wire (113) from J1 — Go to Step 4 Go to Step 3
connector. Clear code and test-drive vehicle.
Did the code return?
3 Return vehicle to OEM for troubleshooting of — Go to Step 5 —
wiring leading to ABS controller.
Was the problem found and corrected?
4 NOTE: In most cases, the TCM is not at — Go to Step 5 —
fault. Investigate thoroughly before
replacing the TCM. Refer to TCM
Replacement Procedure (Section 3–6).
Replace the TCM.
Clear the DTC. diagnosis again.
1. Operate the vehicle under normal driving Go to Step 1.
conditions. Check for proper operation of
ABS.
Did the DTC return?


DTC P0721 Output Speed Sensor Circuit Performance
J2-15 (RED)
J2-16
TCM
J2
J1
A TCM
B
OUTPUT 215
A J2-15 OUTPUT SPEED HI
SPEED 216
SENSOR B J2-16 OUTPUT SPEED LO

NOTE: Typical speed sensor resistance 2304 Ω – 2815 Ω at 20°C (68°F) V06220.01.00
Circuit Description
elements are contained in a housing which is mounted adjacent to a rotating ferrous member. Two signal wires
extend from one end of the housing and an exposed end of the pole piece is at the opposite end of the housing.
The permanent magnet produces lines of flux around the pole piece. As a ferrous object (such as a gear tooth)
approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire
coil. The Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a
speed value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires
from the sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to
protect from voltage-related fields. Noise from other sources is eliminated by using two-wire differential inputs at
the TCM.

• Turbine speed is above 200 rpm.



• Unrealistic large change in output speed. A Failure pending is set if an unrealistic change in transmission
output speed is detected at or above 500 rpm. The failure pending response is to lock in the current range.
• Noisy output speed signal. Noise is determined with two counters. A low counter is incremented when output
speed change is below 500 rpm for 2.5 seconds. A high counter is incremented when output speed change is
current range.
— If the shift selector is moved to N (Neutral), R (Reverse), or any other forward range, the transmission will
lock in N (Neutral).
— If a latched inhibit is present, the transmission locks to neutral.
Diagnostic Aids
— A chafed wire.
— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel
the sensor removed.
connector.


Test Description
3. This step tests for proper output speed sensor resistance.
4. This step tests for proper resistance at the output speed sensor.
.
DTC P0721 Output Speed Sensor Circuit Performance

Troubleshooting
Process
(Paragraph 5–4A)
voltage. and P0563)
3 1. Turn the ignition OFF. Refer to Go to Go to Go to Step 4
4 1. Disconnect the wiring harness from the 2304–2815 Ohms Go to Step 5 Go to Step 6
output speed sensor. at 20°C (68°F)
2. Using a DVOM, measure resistance at the Refer to
speed sensor terminals.* Speed Sensor
Page 5–13)
warranty.
Replace the output speed sensor (refer to
Mechanic’s Tips).


DTC P0721 Output Speed Sensor Circuit Performance (cont’d)
conditions.
3. Using the Scan Tool, monitor output speed
sensor operation.
Did the DTC return?


DTC P0722 Output Speed Sensor Circuit No Signal
J2-15 (RED)
J2-16
TCM
J2
J1
A TCM
B
OUTPUT 215
A J2-15 OUTPUT SPEED HI
SPEED 216
SENSOR B J2-16 OUTPUT SPEED LO

Circuit Description
the TCM.
• DTC P0716, P0717, P0721, P0731, P0732, P0733, P0734, P0735, P0736, or P1718 is not active.
• When unrealistic large change in output speed is detected, output speed is at or above 600 rpm for more than
1 second.


• When unrealistically low output speed is detected.
— Transmission turbine speed is at or above 1050 rpm.
— Manual selector valve is not being moved to a forward range.

• Unrealistic large change in output speed. A failure pending is set if an unrealistic change in transmission output
speed is detected at or above 600 rpm. A failure is set if neutral range is attained.
• Unrealistic low value in output speed. A failure pending is set if output speed is detected below 61 rpm. A
failure is set when output speed is below 61 rpm and transmission range is 3rd, 4th, or 5th for more than
1 second.

current range.
— If the shift selector is moved to N (Neutral), R (Reverse), or any other forward range while the diagnostic
response is active, the transmission will lock in N (Neutral).
— If a latched inhibit is present, the transmission locks in neutral.

Diagnostic Aids
— A chafed wire.


— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel
the sensor removed.
connector.
Test Description
3. This step tests for proper output speed sensor resistance at the TCM side of the wiring harness.
4. This step tests for proper output speed sensor resistance.
DTC P0722 Output Speed Sensor Circuit No Signal

Troubleshooting
Process
(Paragraph 5–4A)
voltage. and P0563)
2. Disconnect connector J2 from the TCM. Speed Sensor Aids
output speed sensor. Speed Sensor


DTC P0722 Output Speed Sensor Circuit No Signal (cont’d)
warranty.
Replace the output speed sensor (refer to
Mechanic’s Tips).
conditions.
3. Using the Scan Tool, monitor output speed
sensor operation.
Did the DTC return?


DTC P0726 Engine Speed Input Circuit Performance
(RED)
TCM
J2-17
J2-18
J2
J1
A TCM
B
ENGINE 217
A J2-17 ENGINE SPEED HI
SPEED 218
SENSOR B J2-18 ENGINE SPEED LO

Circuit Description
the TCM.
• DTC P0716, P0717, P0721, or P0727 is not active.
• Engine speed is above 600 rpm for 1 second.



• Unrealistic large change in engine speed. Failure is set if an unrealistic change in transmission engine speed is
detected at or above 600 rpm.
• Noisy input speed signal. Noise is determined with two counters. A low counter is incremented when engine
speed change is below 650 rpm for 2.5 seconds. A high counter is incremented when engine speed change is

• The TCM defaults engine speed to turbine speed. Turbine speed is used to determine the missing engine
speed.

Diagnostic Aids
— A chafed wire.
— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel.
the sensor removed.
connector.
Test Description
3. This step tests for proper engine speed sensor resistance at the TCM side of the wiring harness.
4. This step tests for proper resistance value at the engine speed sensor.

DTC P0726 Engine Speed Input Circuit Performance

Troubleshooting
Process
(Paragraph 5–4A)
voltage. and P0563)
2. Disconnect connector J2 from the TCM. Speed Sensor Aids
engine speed sensor. Speed Sensor
warranty.
Replace the engine speed sensor (refer to
Mechanic’s Tips).
conditions.
3. Using the Scan Tool, monitor engine speed
sensor operation.
Did the DTC return?


DTC P0727 Engine Speed Input Circuit No Signal
(RED)
TCM
J2-17
J2-18
J2
J1
A TCM
B
ENGINE 217
A J2-17 ENGINE SPEED HI
SPEED 218
SENSOR B J2-18 ENGINE SPEED LO

Circuit Description
the TCM.

• Unrealistically low engine speed detected.
• Engine is running.
• Transmission turbine speed is at or above 400 rpm.
• Ignition is in the ON position.



• Unrealistic large change in engine speed. Failure pending is set if an unrealistic change in engine speed is
detected at or above 1140 rpm.
• Unrealistic low value in engine speed. Failure is set if engine speed is detected below 61 rpm for 4 seconds.

• The TCM defaults engine speed to turbine speed. Turbine speed is used to determine missing engine speed.
• TCM inhibits TCC momentarily.
• DTC P0727 is stored in TCM history

Diagnostic Aids
— A chafed wire.
— Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel.
the sensor removed.
connector.
Test Description
3. This step tests for proper engine speed sensor resistance at the TCM side of the wiring harness.
4. This step tests for proper resistance value at the engine speed sensor.

DTC P0727 Engine Speed Input Circuit No Signal

Troubleshooting
Process
(Paragraph 5–4A)
voltage. and P0563)
3 1. Turn the ignition OFF. Refer to Go to Go to Step 4
engine speed sensor. Speed Sensor
warranty.
Replace the engine speed sensor (refer to
Mechanic’s Tips).
conditions.
3. Using the Scan Tool, monitor engine speed
sensor operation.
Did the DTC return?


DTC P0731 Incorrect 1st Gear Ratio
REFER TO
1st RANGE HYDRAULIC SCHEMATIC
(APPENDIX H)
Circuit Description
The Transmission Control Module (TCM) uses input from the turbine speed sensor and output speed sensor to
determine gear ratios. The TCM then compares the known gear ratio to the calculated gear ratio for the current
range.

• Output speed exceeds 200 rpm.
• First range is selected and attained.
DTC P0731 sets when the calculated first range ratio (steady state) differs from the known first range ratio.

— The transmission will fail to 2nd or 5th range.
— If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral).
— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) unless the
transmission is compromised by overspeeding or a direction change; then it will lock in N (Neutral).

Diagnostic Aids
• Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C1 or C5 for 1st range.
• An incorrect ratio code could indicate a hydraulically failed solenoid. Check the DTC information for the specific
solenoid.
• You may have to drive the vehicle to experience the fault. Clutch test mode can be used to check stall speed.
• Incorrect TCM calibrations will cause this DTC to set. Verify that the proper TCM calibration is being used with
the correct transmission family (there are different gear ratios for the 1000 and 2000 Product Families
transmissions).


Test Description
4. This step tests for current first range ratio.
5. This step tests speed sensor readings.
6. This step tests for clutch slippage in first range.
7. This step checks for evidence of clutch failure.
DTC P0731 Incorrect 1st Gear Ratio

Troubleshooting
Process
(Paragraph 5–4A)
(Appendix P) and correct the fluid level if Checking
necessary. Procedure
Did you perform the procedure? (Appendix P)
3 1. Start the engine. 9–18V Go to Step 4 Resolve
2. Record the DTC Failure Record data. (12V TCM); voltage problem
3. Using the Scan Tool, measure ignition 18–32V (Refer to
voltage. (24V TCM) DTC P0562
Is voltage within the specified value? and P0563)
4 1. Install the Scan Tool. 3.1 for 1000 Go to Step 5 Go to
2. Monitor the gear ratio. 3.51 for 2000/ Diagnostic Aids
Is the correct first range ratio shown? 2400
5 1. Turn the ignition ON and drive the vehicle — Go to the Go to Step 6
under normal operating conditions. appropriate
2. Using the Scan Tool, monitor engine, turbine, speed sensor
and output speed readings. DTC
Is speed sensor data erratic or are signal
dropouts detected?


DTC P0731 Incorrect 1st Gear Ratio (cont’d)
6 — Go to Go to Step 7
WARNING: To help avoid injury or property Diagnostic Aids
damage caused by sudden and
unexpected vehicle movement, do not
start a stationary stall test until you:
• Put the transmission in N (Neutral)...and
• Apply the parking brake and service
brake...and
• Chock the vehicle wheels and take any
other steps necessary to prevent the
vehicle from moving...and
Warn personnel to keep clear of the vehicle
and its path.
CAUTION: Do not perform a clutch test In

fourth or fifth range under stall conditions
(above 1400 rpm with brakes held), or
possible clutch damage could occur.
1. Using the Scan Tool, select clutch test mode.

2. With brakes applied, move the selector lever
to D (Drive).
3. With engine at idle, select and attain the
range indicated by the DTC. Turbine speed
should go to zero.
4. Monitor turbine speed while increasing
engine speed to 1400 rpm.
Did turbine speed remain at zero?
7 Remove the dipstick and inspect the — Go to Step 8 Go to Step 9
transmission fluid for clutch debris or burnt
odor. If necessary, drain a small amount of fluid
for this inspection.
Are there signs of a clutch failure?
8 Remove the transmission for overhaul or — Go to Step 11 —
replacement (refer to Mechanic’s Tips).
9 Inspect the control valve body for stuck or — Go to Step 11 Go to Step 10
sticking trimmer valves (refer to Mechanic’s
Tips).
Was a valve problem found and repaired?
10 Replace A solenoid (refer to Mechanic’s Tips). — Go to Step 11 —
2. Operate the vehicle in all ranges under Go to Step 1
normal driving conditions.
Did the DTC return?


DTC P0732 Incorrect 2nd Gear Ratio
REFER TO
2nd RANGE HYDRAULIC SCHEMATIC
(APPENDIX H)
Circuit Description
range.

• Second range is selected and attained.
DTC P0732 sets when the calculated second range ratio (steady state) differs from the known second range ratio.

— The transmission will fail to 3rd range.
transmission is compromised by overspeeding or a direction change; then it will lock in N (Neutral).

Diagnostic Aids
• Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C1 and C4 for 2nd
range.
solenoid.
transmissions).


Test Description
5. This step tests for turbine speed not remaining at zero in second range.
DTC P0732 Incorrect 2nd Gear Ratio

Troubleshooting
Process
(Paragraph 5–4A)
4 1. Turn the ignition ON and drive the vehicle — Go to appropriate Go to Step 5
under normal operating conditions. speed sensor
2. Using the Scan Tool, monitor engine, turbine, DTC
and output speed readings.
dropouts detected?


DTC P0732 Incorrect 2nd Gear Ratio (cont’d)
brake...and
and its path.


to D (Drive).
should go to zero.
sticking trimmer valves (refer to
Mechanic’s Tips).
9 Replace B solenoid (refer to Mechanic’s Tips). — Go to Step 10 —
Did the DTC return?


DTC P0733 Incorrect 3rd Gear Ratio
REFER TO
3rd RANGE HYDRAULIC SCHEMATIC
(APPENDIX H)
Circuit Description
range.

• Third range is selected and attained.
DTC P0733 sets when the calculated third range ratio (steady state) differs from the known third range ratio.
— The transmission will fail to 4th range.
— If the shift selector is moved to R (Reverse), the transmission will shift to N (Neutral).
— If the shift selector is returned to a forward range and the transmission is compromised by overspeeding or
a direction change, the transmission will lock in N (Neutral).


Diagnostic Aids
• Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C1 and C3 for 3rd
range.
solenoid.
transmissions).
Test Description
5. This step tests for turbine speed not remaining at zero in third range.
DTC P0733 Incorrect 3rd Gear Ratio

Troubleshooting
Process
(Paragraph 5–4A)
dropouts detected?


DTC P0733 Incorrect 3rd Gear Ratio (cont’d)
brake...and
and its path.


to D (Drive).
should go to zero.
Tips).
Did the DTC return?


DTC P0734 Incorrect 4th Gear Ratio
REFER TO
4th RANGE HYDRAULIC SCHEMATIC
(APPENDIX H)
Circuit Description
range.

• Fourth range is selected and attained.
DTC P0734 sets when the calculated fourth range ratio (steady state) differs from the known fourth range ratio.

transmission is compromised by a direction change; then the transmission will shift to N (Neutral).
Diagnostic Aids
• Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C1 and C2 for 4th range.
solenoid.


Test Description
5. This step tests for turbine speed not remaining at zero in fourth range.

Troubleshooting
Process
(Paragraph 5–4A)
dropouts detected?


DTC P0734 Incorrect 4th Gear Ratio (cont’d)
brake...and
and its path.


to D (Drive).
should go to zero.
Mechanic’s Tips).
9 Replace B solenoid (refer to Mechanic’s Tips). — Go to Step 10 —
Did the DTC return?


REFER TO
5th RANGE HYDRAULIC SCHEMATIC
(APPENDIX H)
Circuit Description
range.

• Fifth range is selected and attained.
DTC P0735 sets when the calculated fifth range ratio (steady state) differs from the known fifth range ratio.

transmission is compromised by a direction change; then the transmission will shift to N (Neutral).


Diagnostic Aids
• Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C2 and C3 for 5th range.
solenoid.
The correct transmission family (there are different gear ratios for the 1000 and 2000 Product Families
transmissions).
Test Description
5. This step tests for turbine speed not remaining at zero in fifth range.

Troubleshooting
Process
(Paragraph 5–4A)
dropouts detected?


DTC P0735 Incorrect 5th Gear Ratio (cont’d)
brake...and
and its path.


to D (Drive).
should go to zero.
Mechanic’s Tips).
Did the DTC return?


DTC P0736 Incorrect Reverse Ratio
REFER TO
REVERSE RANGE
HYDRAULIC SCHEMATIC
(APPENDIX H)
Circuit Description
gear.

• Reverse is selected and attained.
DTC P0736 sets when the calculated reverse range ratio (steady state) differs from the known reverse range ratio.

• When DTC P0736 is active, the transmission will lock in N (Neutral).

Diagnostic Aids
• Incorrect ratio codes typically indicate mechanical problems with specific clutches, i.e. C3 and C5 for Reverse
range.
solenoid.


Test Description
4. This step tests for current reverse range ratio.
5. This step tests for noise induced from the engine speed sensor.
6. This step tests for turbine speed not remaining at zero in reverse range.
DTC P0736 Incorrect Reverse Ratio

Troubleshooting
Process
(Paragraph 5–4A)
4 Using the Scan Tool, monitor the reverse gear 4.49 for 1000 Go to Step 5 Go to
ratio. Product Family; Diagnostic Aids
Is the gear ratio correct for the transmission 5.09 for 2000
family that is installed in the vehicle? Product Family
5 1. Turn the ignition ON. — Go to Go to Step 6
2. Start the engine and run at idle. appropriate
3. Using the Scan Tool, monitor engine, turbine, speed sensor
and output speed readings in Reverse range DTC
with the vehicle brakes applied.
Is noise indicated on the output speed sensor
or turbine speed sensor
data?


DTC P0736 Incorrect Reverse Ratio (cont’d)
damage caused by sudden and unexpected
vehicle movement, do not start a stationary
stall test until you:
brake...and
and its path.
CAUTION: NEVER perform a full throttle stall

test (brakes held) in reverse range, or damage
to the vehicle driveline or axle may occur.
1. Apply vehicle brakes and select Reverse.

2. With engine at idle and Reverse range
attained, turbine speed should go to zero.
while increasing engine speed to 1000 rpm.
8 Using the Scan Tool, monitor turbine speed — Go to Step 10 —
while selecting first range.
If turbine speed is ever greater than zero after
first range is attained, there may be a problem
with A solenoid or A trimmer valve.
If shift to first range is harsh and delayed, there
may be a problem with B solenoid or B trimmer
valve.
Remove the control valve body and inspect for
stuck or sticking trimmer valves. If valves are
moving freely, replace either solenoid A or B
(refer to Mechanic’s Tips) based on the shift
characteristics described.


DTC P0736 Incorrect Reverse Ratio (cont’d)
The ratio must fall within the specified range.
Did the DTC return?


DTC P0741 Torque Converter Clutch System Stuck Off
N/C
V07737.01.00
Circuit Description
The Transmission Control Module (TCM) uses data from the engine speed sensor and the turbine speed sensor to
calculate torque converter slip value. The TCM then compares this calculated slip value to a preset value in the
TCM calibration.

• DTC P0122, P0123, P0716, P0717, P0721, P0722, or P0743 (previously P1860) is not active.
• Engine speed is greater than 200 rpm for 5 seconds.
• Transmission is in a valid forward range.
• Throttle position is over 10 percent but less than 90 percent.
• 6 seconds or more have expired since TCC was applied in a range.


DTC P0741 sets when the TCM detects a torque converter clutch slip value greater than 80 rpm for more than
15 seconds, indicating no TCC apply.

• The CHECK TRANS light illuminates on the second occurrence.
Diagnostic Aids
• Residue or contamination may cause shift valves to stick intermittently.
Test Description
2. This step tests for a slip speed indicating the TCC is not applied when it should be.
4. This step verifies the repair performed.
DTC P0741 Torque Converter Clutch System Stuck Off

Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. More than 80 rpm Go to Step 3 Go to
2. Turn ON the ignition, with the engine OFF. Diagnostic Aids
4. Clear the DTC.
5. Drive the vehicle.
6. With the Scan Tool, monitor converter slip
speed indicated when a range is attained
where the TCC should be applied.
NOTE: This DTC sets when converter slip
speed is detected above 80 rpm for
15 seconds or more. This indicates the TCC
has not applied.
Is the slip speed value at or above the specified
value when the TCC should be applied?


DTC P0741 Torque Converter Clutch System Stuck Off (cont’d)
3 This condition indicates that the TCC is — Go to Step 4 —
mechanically stuck OFF. Check for the following
conditions:
• Worn TCC clutch
• Faulty solenoid F
• Debris in the TCC valve bore (stuck valve)
• Clogged or restricted converter relief pas-
sage
Did you find and repair a problem?
2. Drive the vehicle under conditions noted in Go to Step 1
failure records.
3. Using the Scan Tool, monitor TCC slip
speed. The TCC must engage/disengage
when commanded.
4. Use the Scan Tool, in the test passed
section, to confirm the diagnostic test was
run.
Did the DTC return?


DTC P0742 Torque Converter Clutch System Stuck On
N/C
V07737.01.00
Circuit Description
The Transmission Control Module (TCM) uses data from the engine speed sensor and the turbine speed sensor to
calculate the torque converter slip value. The TCM then compares this calculated slip value to a preset value in the
TCM calibration.

• DTC P0122, P0123, P0716, P0717, P0721, P0722, P0726, P0727, or P0743 (previously P1860) is not active.
• Engine speed is greater than 200 rpm for 5 seconds.
• Transmission is in a valid forward range.
• The torque converter clutch is OFF.


DTC P0742 sets when the conditions listed below are present and the TCM detects converter slip speed between
–5 and –40 rpm for over 2 seconds.
• Transmission output speed is 100 rpm or higher.
• Engine throttle percentage is 15 percent or higher.
• Engine torque is 130 N·m or higher.
• Engine and turbine speed are under 5500 rpm.

• Illuminate CHECK TRANS light on second occurrence.
• Response is calibration dependent.
• If response is disabled, no action is performed.
• If enabled, when DTC is set before or during a shift, response is a shift to neutral. If DTC is set after shifting is
complete, transmission shifts to neutral or 1st range. While response is active, if the selector is moved to a
forward range, transmission shifts to neutral or 1st range. If the selector is moved to reverse, the transmission
shifts to neutral or reverse.

Diagnostic Aids
This DTC sets when converter slip speed indicates the TCC is staying applied when it should be released for a
period of time that is calibration dependent. This may indicate an internal failure of the TCC or a stuck or sticking
TCC valve.
Test Description
2. This step tests for a slip speed indicating the TCC is locked up when it should be off.
4. This step verifies the repair performed.


DTC P0742 Torque Converter Clutch System Stuck On
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. –5 to –40 rpm for Go to Step 3 Go to
2. Turn ON the ignition, with the engine OFF. more than Diagnostic Aids
3. Record the failure records. 2 seconds.
4. Clear the DTC. See Conditions for
5. Drive the vehicle. Setting the DTC
6. With the Scan Tool, observe converter slip
speed indicated when a range is attained
where TCC should not be applied.
NOTE: This DTC sets when converter slip
speed is detected between –5 and –40 rpm
for over 2 seconds. This indicates that TCC
did not release properly and remained in a
locked state for over a calibration
dependent time.
Is the slip speed value between the specified
values?
3 This condition indicates that the TCC is — Go to Step 6 —
mechanically stuck ON, check for the following
conditions:
• Worn TCC clutch
• Faulty solenoid F
• Stuck or sticking TCC valve
• Clogged converter relief passage
2. Drive the vehicle under conditions in failure Go to Step 1
records.
3. Using the Scan Tool, monitor TCC slip speed.
The TCC must engage/disengage when
commanded.
run.
Did the DTC return?


DTC P0743 (Previously P1860) Torque Converter Clutch Pulse Width Modulation (PWM)
Solenoid Circuit — Electrical
TRANSMISSION J2 HARNESS CONNECTOR

HARNESS (RED)
CONNECTOR
S J
R
TCM
J2-32
J2-30
TRANSMISSION J2-29
BULKHEAD
CONNECTOR
S
J
R J2
J1
TCM
229
J J2-29
SOL F SOL G
(PWM) TRANSMISSION R
230
J2-30
LOCKUP
232 12V
S J2-32
NOTE: Wire 232 is a 12V DC ignition power source for TCC solenoids F and G.
V06222.01.00
Circuit Description
The torque converter clutch (TCC) solenoid, solenoid F, is a pulse width modulated solenoid. Pulse width
modulation (PWM) occurs when the signal from the transmission control module (TCM) to a solenoid is modulated
at an established frequency, causing the steel check ball in the solenoid to rapidly open and close the solenoid
passage. This serves to vary the output fluid pressure.

• DTC P0122, P0123, P0716, P0717, P0721, P0722, or P0743 (previously P1860) is not active.
• TCC is commanded on.
• TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

DTC P0743 sets when the TCM detects an open circuit, a short to power, or a short to ground in the solenoid F
circuit for 6 seconds or longer.


• Reverse operation is disabled.

Diagnostic Aids
• If this DTC is cleared and does not return, but the TCC appears to be cycling, an intermittent circuit connection
may exist that is not detected by the TCM since the circuit error must be present for more than 6 seconds. If a
short to ground occurs at wire 229, the TCC will apply regardless of the range selected. A shudder in
reverse may be caused by the intermittent apply or release of C5 clutch through the F solenoid valve.
• Inspect the wiring for poor electrical connections at the TCM connector and the transmission main connector.
Look for the following conditions:
• Inspect the OEM wiring harness routing looking for possible contact points where chafing could occur. Moving
parts on the vehicle could be contacting the harness. Items to check would include the parking brake drum,
suspension components, transmission shift linkage, etc.
• Inspect the internal transmission wiring harness for possible contact areas where chafing may occur.
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 wire check procedures.
• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc.
This data can be useful in reproducing the failure mode where the DTC was set.
• If the DTC appears to be temperature related, suspect a defective F solenoid. It is possible for a shift solenoid
to be temperature sensitive causing resistance values to fluctuate. This may cause an intermittent DTC to be
set.
Test Description
2. This step tests for proper ignition voltage.

3. This step tests for an active DTC.
4. This step tests the TCM for proper command status.
5. This step tests the OEM wiring harness for an open condition.
6. This step tests for proper resistance at the main transmission connector.
8. This step tests for the proper resistance value at the shift solenoid.

DTC P0743 Torque Converter Clutch Pulse Width Modulation (PWM)

Solenoid Circuit—Electrical
Troubleshooting
Process
(Paragraph 5–4A)
4. Use the Scan Tool to measure ignition (24V TCM) DTC P0562
voltage. and P0563)
3 1. Turn ON the ignition, with the engine OFF. — Go to Step 4 Go to Diagnostic
2. Record the failure records. Aids
3. Clear the DTC.
4. Drive the vehicle under the same condition
noted in the failure records.
5. Using the Scan Tool, observe the TCC
solenoid F status.
NOTE: This DTC sets when an open, a short
to ground or a short to power is present in
the TCC circuit for over 6 seconds.
Did the DTC return?
4 With the Scan Tool in Solenoid Test Mode 85 percent duty Go to Step 5 Go to Step 11
command F solenoid ON. cycle or above
Does the Scan Tool indicate a duty cycle at or
above the indicated value?
5 NOTE: Review Section 4 — Wire Check Refer to Solenoid Go to Step 6 Go to Diagnostic
Procedures before performing the following Resistance Table Aids
steps. (Page 5–12)
1. Turn the ignition OFF.
2. Disconnect J2 connector from TCM. Using NOTE: To allow
J 39700 Breakout Box and J 43799 Breakout for resistance of
Box Adapter, connect only to the J2 harness harness wire, add
connector. See Beginning the 0.1 Ohms per foot
Troubleshooting Process, Page 5–4, Figure of length for
5–2 for diagram of J 43799 adapter harness 18-gauge wire.
hook-ups.
3. Using a DVOM, attach leads to J2 pins 29
and 32.
4. Measure the resistance of the circuit.
Is the resistance reading within the specified
value


Solenoid Circuit—Electrical (cont’d)
6 1. Turn the ignition OFF. Refer to Solenoid Go to Step 7 Go to Step 8
2. Disconnect the transmission main connector Resistance Table
from the back of the transmission. Using (Page 5–12)
J 39700 Breakout Box and J 44722 Adapter
Harness, connect only to the transmission
main connector at the rear of the
transmission. Do not attach the other end of
J 44722 to the vehicle transmission harness.
See Beginning the Troubleshooting Process,
Page 5–5, Figure 5–3 for diagram of J 44722
transmission harness hook-ups.
3. Using a DVOM, measure the resistance
between pins S and J at the magnetic
overlay.
Is the resistance within the specified value?
for all external wiring harness repair. Harness
repairs performed by Allison Transmission
distributors and dealers are not covered by
Allison Transmission warranty.
8 1. Remove the oil pan. Refer to Service Manual Refer to Solenoid Go to Step 9 Go to Step 10
or Mechanic’s Tips. Resistance Table
2. Remove the internal wiring harness from (Page 5–12)
Solenoid F (TCC) connector.
3. Using a DVOM, measure the resistance of
solenoid F.
9 Replace the internal wiring harness. Refer to — Go to Step 12 —
Service Manual or Mechanic’s Tips.
10 Replace F (TCC) Solenoid. Refer to Service — Go to Step 12 —
Manual or Mechanic’s Tips.
(Section 3–6).
Replace the TCM.


Solenoid Circuit—Electrical (cont’d)
failure records.
run.
Did the DTC return?


DTC P0746 (Previously P1720) Solenoid A Controlled Clutch Stuck Off
REFER TO HYDRAULIC SCHEMATIC

(APPENDIX H)
Circuit Description
Trim solenoid A is used to control on-coming, off-going, and holding pressure in any one of five clutches. This
solenoid is referred to as a Pressure Proportional to Current (PPC) solenoid since the output hydraulic pressure
supplied by this solenoid is proportional to the controlled current command.
The Transmission Control Module (TCM) uses information from the turbine and output speed sensors to detect if a
clutch is slipping. The clutch being controlled by the solenoid A will vary depending on the shift that is being
completed.

• Turbine speed is greater than 60 rpm.
• Output speed is greater than 125 rpm.
• Transmission is at normal operating temperature.
• DTC P0708, P0716, P0717, P0721, P0722, P0875, or P0876 is not active.

DTC P0746 sets when the TCM detects an incorrect oncoming ratio (range-to-range) for an accumulated number
of occurrences.

— If failure occurs while in a forward range, the transmission will shift to the previous range.
— If failure occurs while in N (Neutral) or R (Reverse), the transmission will lock in N (Neutral).
— If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral) (some cases may lock
in N (Neutral)).
— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) or N (Neutral).
a direction change, the transmission will shift to N (Neutral).



Diagnostic Aids
• This DTC indicates the on-coming clutch being controlled by solenoid A is not applied or applied too slowly.
This could indicate a leak or obstruction in a specific clutch apply circuit. Check the Scan Tool Failure Record
data for previous or current range information when the DTC was set to determine the specific shift when the
DTC was set. Refer to the Solenoid and Clutch Table (Appendix C) to determine which clutch circuit is suspect.
• Inspect and confirm that the OEM engine rating does not exceed the transmission model rating. Also inspect for the
presence of an add-on engine power package or module. Whenever the engine horsepower or torque is increased
over the transmission factory rating, a shift flare condition may occur leading to the diagnostic code indicated.
NOTE: Clutch failure due to an OEM engine rating exceeding the Allison transmission rating, or the
installation of a engine power package or module will not be covered under the Allison transmission
warranty.
Test Description
3. This step tests the ignition voltage.
4. This step tests for erratic speed sensor readings or signal dropout.
5. This step tests for internal hydraulic leakage.
6. This step tests for clutch capacity.
DTC P0746 (Previously P1720) Solenoid A Controlled Clutch Stuck Off

Troubleshooting
Process
(Paragraph 5–4A)
4. Use the Failure Record data to determine (24V TCM) DTC P0562
during which shift the code was set. and P0563)
5. Using the Scan Tool, measure ignition voltage.
under normal operating conditions. Make the appropriate
shift determined in Step 3. speed sensor
2. Using the Scan Tool, monitor turbine, engine, DTC
and output speed sensor readings.
Is speed sensor data erratic or are dropouts in
signal indicated?


DTC P0746 (Previously P1720) Solenoid A Controlled Clutch Stuck Off (cont’d)
5 1. Connect a 2000 kPa (300 psi) pressure — Go to General Go to Step 6
gauge to the main-pressure tap (refer to Troubleshooting
Mechanic’s Tips). — Low Pressure
2. Use the Scan Tool, in clutch test mode, to (Section 7)
cycle through all transmission ranges with
the engine at idle and vehicle brakes applied.
3. Record main pressure in each range.
Was the main pressure low in a specific range
or in ranges where the same clutch was
applied?
6 Refer to Main Go to Diagnostic Go to Step 7
CAUTION: Do not perform a clutch test on Pressure Table Aids
fourth and fifth range under stall conditions
(above 1400 rpm with brakes held), or (Pages 5–8
possible clutch damage could occur. and 5–9)
1. Using the Scan Tool, select the clutch test

mode.
2. With engine at idle speed (600 rpm), vehicle
brakes applied, select D (Drive).
3. Using clutch test mode, select and attain first
range. Turbine speed should go to zero.
4. Increase engine speed to 1400 rpm. Did
turbine speed remain at zero?
5. Repeat the two previous steps for ranges two
through five.
Did turbine speed remain at zero in all ranges?
replacement.
Is the overhaul or replacement complete?
Mechanic’s Tips).
10 Replace A solenoid. — Go to Step 11 —
Is solenoid replacement complete?
2. Use the Scan Tool to reset adaptive for all Go to Step 1
shifts.
3. Operate the vehicle in all ranges under
Did the DTC return?


DTC P0747 (Previously P1723) Solenoid A Controlled Clutch Stuck On

(APPENDIX H)
Circuit Description
Trim solenoid A is used to control on-coming, off-going, and holding pressure to any one of the five clutches. This
clutch is in a tie-up condition or 3 clutches are applied. The clutch being controlled by solenoid A will vary
depending on the shift.
• One of the following conditions occurs:
— Output speed is greater than 200 rpm.
— Turbine speed is greater than 200 rpm.

DTC P0747 sets when the TCM detects an incorrect offgoing ratio (range-to-range) for an accumulated number of
occurrences.

— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) or N (Neutral)
(some cases may lock in N (Neutral)).



Diagnostic Aids
• This DTC indicates the off-going clutch being controlled by solenoid A is not releasing or is slow to release.
warranty.
Test Description
4. This step tests for erratic speed sensor readings or signal dropout.
DTC P0747 (Previously P1723) Solenoid A Controlled Clutch Stuck On

Troubleshooting
Process
(Paragraph 5–4A)
signal indicated?


DTC P0747 (Previously P1723) Solenoid A Controlled Clutch Stuck On (cont’d)
gauge to the main-pressure tap. Refer to Troubleshooting
Mechanic’s Tips. — Low Pressure
applied?

mode.
through five.
replacement.
sticking trimmer valves. Refer to
Mechanic’s Tips.
10 Replace A solenoid. — Go to Step 11 —
shifts.
Did the DTC return?


DTC P0748 Pressure Control Solenoid A Electrical
TRANSMISSION
HARNESS J2 HARNESS CONNECTOR
CONNECTOR (RED)
L J2-22 TCM
J2-23
TRANSMISSION
BULKHEAD
CONNECTOR
M
J2
J1
L
TCM
223
M J2-23
SOL A
(PCS) TRANSMISSION
222
L J2-22
BATTERY
NOTE: Wire 222 is a battery direct power source for trim solenoid A. V06223.01.00
Circuit Description
Trim solenoid A is used to control on-coming, off-going, and holding pressure to any one of the five clutches. This
solenoid is referred to as a Pressure Proportional to Current (PPC) solenoid since the pressure output is
proportional to the amount of controlled current commanded by the TCM.
The solenoid operates at a very high 1000 Hz frequency. Unlike the pulse width modulated Torque Converter Clutch
(TCC) solenoid, where the ball follows the pulse width square wave, the PPC ball remains stationary due to the high
frequency at which the solenoid operates. This allows the ball to move in a linear up and down motion proportional to
the current commanded from the TCM. This supplies the desired signal pressure to control the trim valve.

• Engine crank time is under 4 seconds.
DTC P0748 is set when one of the following conditions is detected for 125 milliseconds.
• Open circuit — TCM commanded duty cycle between 31 percent and 87 percent with no current present at trim
solenoid A.


• Short to ground — TCM commanded duty cycle is over 87 percent with a current of less than 1.0 ampere at
trim solenoid A.
• Short to power — TCM commanded duty cycle is under 15 percent with electrical current present.
• Whenever a P0748, P0778 combination is set in failure records, this is generally caused by having the
transmission harness disconnected at the main transmission connector while the vehicle ignition is ON. Check
the connection at the transmission and clear codes.
— If failure occurs while in a forward range, the transmission shifts to 1st, 3rd, or 5th range.
transmission is compromised by a direction change; then the transmission will shift to or lock in N (Neutral).
Diagnostic Aids
The diagnostic test performed to detect this DTC is very sensitive. Therefore, there is a high probability that an
intermittent circuit condition may be causing this DTC to set. Check for the following conditions at the OEM harness
first, then at the transmission internal harness.
— A chafed wire.
— Inspect OEM wiring harness routing, looking for possible contact points where chafing could occur. Moving
parts on the vehicle could be contacting the harness. Check for contact at the parking brake drum, suspen-
sion components, transmission shift linkage, etc.
— Inspect the internal transmission wiring harness for possible contact areas where chafing may occur.
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures.
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc.
• If this DTC appears to be temperature-related, suspect a defective solenoid. A failing solenoid may be
temperature sensitive causing resistance values to fluctuate. This may cause an intermittent DTC to be set.


Test Description
3. This step tests the TCM for proper operation.
4. This step tests for the proper resistance at the OEM vehicle harness.
5. This step tests the resistance value at the transmission main connector.
7. This step tests the resistance value at the trim solenoid.
DTC P0748 Pressure Control Solenoid A Electrical

Troubleshooting
Process
(Paragraph 5–4A)
voltage. and P0563)
3 1. Install the Scan Tool. Duty cycle value of Go to Step 4 Go to Step 10
2. Turn the ignition ON, with the engine OFF. 75 percent is an
3. In solenoid test mode, command A trim indication that
solenoid ON. the TCM is com-
Did the Scan Tool indicate A solenoid as being manding the
commanded ON? solenoid ON.
4 NOTE: Review Section 4 — Wire Check Refer to Solenoid Go to Diagnostic Go to Step 5
hook-ups.
and 23.
value?


DTC P0748 Pressure Control Solenoid A Electrical (cont’d)
2. Disconnect the wiring harness from the main Resistance Table
transmission connector at the back of the (Page 5–12)
transmission. Using J 39700 Breakout Box
and J 44722 Adapter Harness, connect only
to the transmission main connector at the
rear of the transmission. Do not attach the
other end of J 44722 to the vehicle
transmission harness. See Beginning the
Troubleshooting Process, Page 5–5, Figure
5–3 for diagram of J 44722 transmission
harness hook-ups.
3. Using a DVOM, measure the resistance
between pins L and M at the magnetic overlay.
warranty.
2. Remove the internal wiring harness at (Page 5–12)
solenoid A connector.
solenoid A.
Is the solenoid resistance within the specified
value?
9 Replace solenoid A. Refer to Service Manual or — Go to Step 11 —
Mechanic’s Tips.
Investigate thoroughly before replacing
the TCM. Refer to TCM Replacement
Procedure (Section 3–6).
Replace the TCM.


DTC P0748 Pressure Control Solenoid A Electrical (cont’d)
failure records.
3. Use the Scan Tool, in the test passed section,
to confirm the diagnostic test was run.
Did the DTC return?


DTC P0763 Shift Solenoid C Electrical
TRANSMISSION
HARNESS
CONNECTOR J2 CONNECTOR
(RED)
W
C
A
J2-31 J2-26 TCM
J2-28 J2-27
TRANSMISSION
BULKHEAD
CONNECTOR
W
C
B J2
A J1
231
C J2-31 12V (A)
SOL C (ON/OFF) TCM
226
A J2-26
SOL D (ON/OFF)
TRANSMISSION 227
B J2-27
SOL E (ON/OFF)
228
W J2-28
BATTERY
NOTE: Wire 231 is a 12V DC ignition power source for shift solenoids C, D, and E. V06230.01.00
Circuit Description
Shift solenoid C is a normally closed (N/C) solenoid that provides control main pressure to stroke the C shift valve.
The TCM determines the proper solenoid command logic to move the C shift valve to attain a particular range
requested. A pressure switch, located at the end of the shift valve, sends shift valve position feedback to the TCM.

DTC P0763 is set when the TCM detects one of the following conditions for more than 100 milliseconds:
• Open circuit or short to ground detected when C solenoid is commanded OFF.

• Short to power is detected when C solenoid is commanded ON.


— If the failure occurs while in a forward range, the transmission shifts to 1st, 3rd, or 5th range.
— If the shift selector is moved to N (Neutral), the transmission will shift to neutral.
— if the shift selector is moved to R (Reverse), the transmission shifts to neutral or reverse.
— If the shift selector is moved to a forward range or reverse and transmission is compromised by
overspeeding or direction change, transmission shifts to neutral.
— If this failure is present at the solenoid electrical feed wire 231, the response is hydraulic default.
• DTC P0763 is stored in TCM history.
• The CHECK TRANS light illuminates on first occurrence.

A scan tool may be used to clear the code from the TCM history. The TCM automatically clears the DTC from the
Diagnostic Aids
• The diagnostic test performed to detect this DTC is very sensitive. Therefore, there is a high probability that an
intermittent circuit condition may be causing this DTC to set. Make sure you check for the following conditions
at the OEM harness first and then at the transmission internal harness.
— A chafed wire.
sion components, transmission shift linkage etc.
This data can be useful in reproducing the failure mode where DTC was set.
• If the DTC appears to be temperature related, suspect a defective shift solenoid. It is possible for a shift
solenoid to be temperature sensitive causing resistance values to fluctuate. This may cause an intermittent
DTC to be set.
• If the circuit problem (open or short) is present at the 231 solenoid feed wire, other shift solenoid electrical
DTCs may be present (C, D, E electrical codes).


Test Description
4. This step tests the OEM harness for an open condition.
5. This step tests for the proper resistance at the main transmission connector.
DTC P0763 Shift Solenoid C Electrical

Troubleshooting
Process
(Paragraph 5–4A)
voltage. and P0563)
3 1. Turn the ignition OFF. Battery Voltage Go to Step 4 Go to Step 10
2. Disconnect the J2 connector (RED) at the
TCM.
3. Install J 39700 breakout box and J 43799
breakout box adapter
5. Using the Scan Tool in solenoid test mode,
command C solenoid to ON.
6. Using a DVOM measure the voltage between
J2 terminal 26 and terminal 31.
Is the voltage within the range specified when C
solenoid is commanded ON?
4 NOTE: Review Section 4 — Wire Check 22 Ohms at 68°F Go to Diagnostic Go to Step 5
Procedures before performing the following Aids
steps. Refer to Solenoid
1. Turn the ignition OFF. Resistance Table
2. Disconnect J2 connector from TCM. (Page 5–12)
3. Using J 39700 Breakout Box and J 43799
Breakout Box Adapter Harness, connect only NOTE: To allow
to the J2 harness connector. See Beginning for resistance of
the Troubleshooting Process, Page 5–4, harness wire, add
Figure 5–2 for diagram of J 43799 adapter 0.1 Ohms per foot
harness hook-ups. of length for
4. Using a DMM, attach leads to J2 pins 31 and 18-gauge wire.
26


DTC P0763 Shift Solenoid C Electrical (cont’d)
5 1. Turn the ignition OFF. 22 Ohms at 68°F Go to Step 6 Go to Step 7
2. Disconnect the wiring harness from the main
transmission connector at the back of the
transmission. Refer to Solenoid
3. Using J 39700 Breakout Box and J 44722 Resistance Table
Adapter Harness, connect only to the (Page 5–12)
transmission main connector at the rear of
the transmission. Do not attach the other end
of J 44722 to the vehicle transmission
harness. See Beginning the Troubleshooting
Process, Page 5–5, Figure 5–3 for diagram
of J 44722 transmission harness hook-ups.
4. Using a DMM, measure resistance between
bulkhead connector pins A and C at the
magnetic overlay.
Is the resistance within the specified values?
warranty.
Repair or replace the vehicle wiring harness.
7 1. Remove the oil pan. Refer to Service Manual 22 Ohms at 68°F Go to Step 8 Go to Step 9
or Mechanic’s Tips.
2. Remove the connector from C solenoid. Refer to Solenoid
3. Using a DMM, measure the resistance at the Resistance Table
solenoid. (Page 5–12)
value?
9 Replace solenoid C. Refer to Service Manual or — Go to Step 11 —
Mechanic’s Tips.
(Section 3–6).
Replace the TCM.


DTC P0763 Shift Solenoid C Electrical (cont’d)
failure records.
Did the DTC return?


DTC P0768 Shift Solenoid D Electrical
TRANSMISSION
HARNESS
(RED)
W
C
A
J2-31 J2-26 TCM
J2-28 J2-27
TRANSMISSION
BULKHEAD
CONNECTOR
W
C
B J2
A J1
231
C J2-31 12V (A)
SOL C (ON/OFF) TCM
226
A J2-26
SOL D (ON/OFF)
TRANSMISSION 227
B J2-27
SOL E (ON/OFF)
228
W J2-28
BATTERY
Circuit Description
Shift solenoid D is a normally closed (N/C) solenoid that provides control main pressure to stroke the D shift valve.
The TCM determines the proper solenoid command logic to move the D shift valve to attain a particular range

• Open circuit or short to ground detected when D solenoid is commanded OFF.

• Short to power is detected when D solenoid is commanded ON.



Diagnostic Aids
— A chafed wire.
DTC to be set.


Test Description

DTC P0768 Shift Solenoid D Electrical

Troubleshooting
Process
(Paragraph 5–4A)
voltage. and P0563)
TCM.
command D solenoid to ON.
Is the voltage within the range specified when D
31


DTC P0768 Shift Solenoid D Electrical (cont’d)
pins B and C at the magnetic overlay.
warranty.
2. Remove the connector from D solenoid. Refer to Solenoid
9 Replace solenoid D. Refer to Service Manual or — Go to Step 11 —
Mechanic’s Tips.
(Section 3–6).
Replace the TCM.
failure records.
Did the DTC return?


DTC P0773 Shift Solenoid E Electrical
TRANSMISSION
HARNESS
(RED)
W
C
A
J2-31 J2-26 TCM
J2-28 J2-27
TRANSMISSION
BULKHEAD
CONNECTOR
W
C
B J2
A J1
231
C J2-31 12V (A)
SOL C (ON/OFF) TCM
226
A J2-26
SOL D (ON/OFF)
TRANSMISSION 227
B J2-27
SOL E (ON/OFF)
228
W J2-28
BATTERY
Circuit Description
Shift solenoid E is a normally closed (N/C) solenoid that provides control main pressure to stroke the E shift valve.
The TCM determines the proper solenoid command logic to move the E shift valve to attain a particular range

• Open circuit or short to ground detected when E solenoid is commanded OFF.

• Short to power is detected when E solenoid is commanded ON.



Diagnostic Aids
— A chafed wire.
DTC to be set.


Test Description

Troubleshooting
Process
(Paragraph 5–4A)
voltage. and P0563)
TCM.
command E solenoid to ON.
Is the voltage within the range specified when E
28


DTC P0773 Shift Solenoid E Electrical (cont’d)
pins W and C at the magnetic overlay.
warranty.
2. Remove the connector from E solenoid. Refer to Solenoid
9 Replace solenoid E. Refer to Service Manual or — Go to Step 11 —
Mechanic’s Tips.
(Section 3–6).
Replace the TCM.
failure records.
Did the DTC return?

DTC P0776 (Previously P1721) Solenoid B Controlled Clutch Stuck Off

(APPENDIX H)
Circuit Description
Trim solenoid B is used to control on-coming, off-going, and holding pressure to any one of the five clutches. This
clutch is slipping. The clutch being controlled by the solenoid B will vary depending on the shift that was being
completed.

• Turbine speed is greater than 60 rpm.
• Output speed is greater than 125 rpm.
• Transmission is at normal operating temperature.

DTC P0776 sets when the TCM detects an incorrect oncoming ratio (range-to-range) for an accumulated number
of occurrences.

— If the shift selector is moved to N (Neutral), the transmission will shift to N (Neutral) (some cases may lock
in N (Neutral)).
— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) or N (Neutral).



Diagnostic Aids
• This DTC indicates the on-coming clutch being controlled by solenoid B is not applied or applied too slowly.
warranty.
Test Description
DTC P0776 (Previously P1721) Solenoid B Controlled Clutch Stuck Off

Troubleshooting
Process
(Paragraph 5–4A)
3. Record DTC Failure Record data. 18–32V (Refer to
signal indicated?


DTC P0776 (Previously P1721) Solenoid B Controlled Clutch Stuck Off (cont’d)
gauge to the main-pressure tap (refer to Troubleshooting
Mechanic’s Tips). — Low Pressure
applied?
6 CAUTION: Do not perform a clutch test on Refer to Main Go to Diagnostic Go to Step 7
fourth and fifth range under stall conditions Pressure Table Aids
mode.
through five.
replacement.
Tips).
10 Replace B solenoid. — Go to Step 11 —
shifts.
Did the DTC return?


DTC P0777 (Previously P1724) Solenoid B Controlled Clutch Stuck On

(APPENDIX H)
Circuit Description
Trim solenoid B is used to control on-coming, off-going, and holding pressure to any one of five clutches. This
clutch is in a tie-up condition or if three clutches are applied. The clutch being controlled by solenoid B will vary
depending on the shift.

• One of the following conditions occurs:
— Output speed is greater than 200 rpm.
— Turbine speed is greater than 200 rpm.
DTC P0777 sets when the TCM detects an incorrect off-going ratio, range-to-range, for an accumulated number of
occurrences.

— If the shift selector is moved to R (Reverse), the transmission will shift to R (Reverse) or N (Neutral)
(some cases may lock in N (Neutral)).



Diagnostic Aids
• This DTC indicates the off-going clutch being controlled by solenoid B is not released or is released too slowly.
warranty.
Test Description
4. This step tests for correct speed sensor operation.
DTC P0777 (Previously P1724) Solenoid B Controlled Clutch Stuck On

Troubleshooting
Process
(Paragraph 5–4A)
4. Use the Failure Record Data to determine (24V TCM) DTC P0562
signal indicated?


DTC P0777 (Previously P1724) Solenoid B Controlled Clutch Stuck On (cont’d)
gauge to the main-pressure tap. Refer to Troubleshooting
Mechanic’s Tips. — Low Pressure
applied?

mode.
through five.
replacement.
sticking trimmer valves. Refer to Mechanic’s
Tips.
10 Replace B solenoid. — Go to Step 11 —
shifts.
Did the DTC return?


DTC P0778 Pressure Control Solenoid B Electrical
TRANSMISSION
CONNECTOR (RED)
P
N
J2-25 J2-24 TCM
TRANSMISSION
BULKHEAD
CONNECTOR
P
J2
N J1
TCM
224
N J2-24
SOL B BATTERY
(PCS) TRANSMISSION
225
P J2-25
NOTE: Wire 225 is a battery direct power source for trim solenoid B. V06224.01.00
Circuit Description
Trim solenoid B is used to control on-coming, off-going, and holding pressure to any of the five clutches. This
The solenoid operates at a very high 1000 Hz frequency. Unlike the pulse width modulated Torque Converter
Clutch (TCC) solenoid, where the ball follows the pulse width square wave, the PPC ball remains stationary due to
the high frequency at which the solenoid operates. This allows the ball to move in a linear up and down motion
proportional to the current commanded from the TCM. This supplies the desired signal pressure to control the trim
valve.
• Engine crank time is under 4 seconds.


DTC P0748 is set when one of the following conditions is detected for 125 milliseconds.
• Open circuit — TCM commanded duty cycle between 31 percent and 87 percent with no current present at trim
solenoid A.
• Short to ground — TCM commanded duty cycle is over 87 percent with a current of less than 1.0 ampere at
trim solenoid A.
• Short to power — TCM commanded duty cycle is under 15 percent with electrical current present.
• Whenever a P0748, P0778 combination is set in failure records, this is generally caused by having the
transmission harness disconnected at the main transmission connector while the vehicle ignition is ON. Check
the connection at the transmission and clear codes.

— If the failure occurs while in a forward range, the transmission will shift to 1st, 3rd, or 5th range.
— If the shift selector is moved to R (Reverse), the transmission will shift to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by over-
speeding or a direction change, the transmission shifts to neutral.

Diagnostic Aids
The diagnostic test performed to detect this DTC is very sensitive. Therefore, there is a high probability that an
intermittent circuit condition may be causing this DTC to set. Check for the following conditions at the OEM harness
first, then at the transmission internal harness.
• Inspect the wiring for poor electrical connections at the TCM connector and the main transmission connector.
— A chafed wire.
sion components, transmission shift linkage, etc.


determine transmission range and/or certain vehicle operating variables such as temperature, run time etc.
• If this DTC appears to be temperature-related, suspect a defective trim solenoid. It is possible for a trim
DTC to be set.
Test Description
2. This step tests for proper ignition voltage.
3. This step tests the command signal from the TCM and tests the external wiring harness for shorts or
opens.
4. This step tests for the proper resistance at the OEM vehicle harness.
5. This step tests for the proper resistance value at the main transmission connector.
8. This step tests for the proper resistance value at the trim solenoid.
DTC P0778 Pressure Control Solenoid B Electrical

Troubleshooting
Process
(Paragraph 5–4A)
voltage. and P0563)
3 1. Install the Scan Tool. Duty cycle value of Go to Step 4 Go to Step 10
2. Turn the ignition ON, with the engine OFF. 75 percent is an
3. In solenoid test mode, command B trim indication that the
solenoid ON. solenoid is in the
Did the Scan Tool indicate B solenoid as being ON state.
commanded ON?


DTC P0778 Pressure Control Solenoid B Electrical (cont’d)
hook-ups.
and 25.
value?
transmission. Using J 39700 Breakout Box
and J 44722 Adapter Harness, connect only
to the transmission main connector at the
rear of the transmission. Do not attach the
other end of J 44722 to the vehicle
transmission harness. See Beginning the
harness hook-ups.
3. Using a DVOM, measure resistance between
transmission bulkhead connector pins N
and P at the magnetic overlay.
warranty.
2. Remove the internal wiring harness at (Page 5–12)
solenoid B connector.
solenoid B.
value?


DTC P0778 Pressure Control Solenoid B Electrical (cont’d)
9 Replace solenoid B. Refer to Service Manual or — Go to Step 11 —
Mechanic’s Tips.
(Section 3–6).
Replace the TCM.
failure records.
run.
Did the DTC return?


DTC P0840 Transmission Pressure Switch Solenoid C Circuit
TRANSMISSION
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1
TCM
F
E
TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2
J1
F
E
TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4
E
F
PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06213.01.00
Circuit Description
The Pressure Switch Manifold (PSM) is a multiple-switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. The C pressure switch monitors C shift valve positioning and relays it to
the TCM. When C pressure switch is in the open state, C shift valve should be in the destroked position.

• Components are powered and the ignition voltage is greater than 5V.
• C shift valve is destroked.
• Transmission temperature is above –25°C (–13°F).
• Vehicle shutdown is not in process.


DTC P0840 sets during steady state operation when C shift valve is in the destroked state (commanded OFF) and
C pressure switch status is detected as stroked (commanded ON). Steady state is defined as attaining a valid
range. The intent of this code is to detect shorts to ground in the pressure switch wiring circuit or the pressure
switch.
Later software levels incorporate retry logic that allows the TCM to command C solenoid ON and OFF. If the
pressure switch state does not change, and remains in the ON state, DTCs P0840 and P0842 will set.

— if the shift selector is moved to R (Reverse), the transmission shifts to reverse.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by over-
speeding or direction change, the transmission shifts to neutral.

Diagnostic Aids
— A chafed wire.
• When only a P0840 is set, look for an intermittent short to ground at the pressure switch circuit or intermittent
hydraulic failure (sticking valve). This code is set when the condition occurs more than 3 times during the
current drive cycle. See Appendix A, Section B — Finding an Intermittent Fault.
• When a P0840 and P0842 are set in combination, this may indicate a short to ground at the pressure switch
circuit or the shift valve is stuck in the stroked state. See Section 4 — Beginning the Troubleshooting Process.
equipment for a change. Check for shorting to ground at individual wires within a harness to isolate an
intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B.
• Multiple inactive pressure switch DTCs may be due to a plugged Control Main Filter. Ensure that the initial
8000 km (5,000 mile) filter change was performed.


Test Description
3. This step tests for proper main pressure.
5. This step tests the TCM for proper switch status.
6. This step tests for shorts in the OEM wiring harness.
7. This step tests for shorts in the internal wiring harness.
8. This step tests the PSM switch function.
DTC P0840 Transmission Pressure Switch Solenoid C Circuit

Troubleshooting
Process
(Paragraph 5–4A)
Did you perform the procedure and correct fluid Procedure
level if necessary? (Appendix P)
3 Perform the Main Pressure Check Procedure Refer to Main Go to Step 4 Go to General
(Appendix B). Pressure Table Troubleshooting
Is main pressure within the specified values? (Pages 5–8 (Section 7)
and 5–9)
4 1. Install the Scan Tool. — Go to Step 5 Go to Diagnostic
2. Turn ON the ignition, with the engine OFF. Aids
4. Clear the DTC.
5. Start the vehicle and perform a test drive.
conditions observed in failure records (range
attained, transmission temperature, etc.).
NOTE: This DTC indicates that a short
circuit condition may exist in the OEM
harness, the internal transmission wiring
harness, or the PSM.


DTC P0840 Transmission Pressure Switch Solenoid C Circuit (cont’d)
5 1. Turn the ignition OFF. — Go to Step 6 Go to Step 12
2. Disconnect J2 connector from the TCM and
3. Connect J2 connector pin 1 to a known good
ground.
4. Turn the ignition ON.
Does the Scan Tool indicate pressure switch C
status as ON when grounded and OFF when
circuit is open?
6 1. Turn the ignition OFF and reconnect the J2 — Go to Step 7 Go to Step 11
connector to the TCM.
2. Disconnect the transmission wiring harness
from the main transmission connector at the
back of the transmission.
4. Connect wire 201 (pin D) at the main
transmission connector to a known good
ground.*
circuit is open?
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step 10
2. Disconnect the internal wiring harness from
the PSM and ground pin A.
circuit is open?
8 1. Remove the PSM from the control valve body — Go To Diagnostic Go to Step 9
and leave the internal harness connected. Aids
Refer to Service Manual or Mechanic’s Tips.
2. Provide a ground connection for the PSM to
the control valve body or the transmission
main case.
3. Use your finger or the eraser end of a pencil
to push gently on the pressure switch C
membrane.
circuit is open?
9 Replace the PSM. Refer to Service Manual or — Go to Step 13 —
Mechanic’s Tips.


DTC P0840 Transmission Pressure Switch Solenoid C Circuit (cont’d)
warranty.
(Section 3–6).
Replace the TCM.
2. Operate the vehicle under conditions noted Go to Step 1
in failure records.
run.
Did the DTC return?


DTC P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open
TRANSMISSION
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1
TCM
F
E
TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2
J1
F
E
TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4
E
F
PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06213.01.00
Circuit Description

• C shift valve is commanded to the ON (stroked) position.


DTC P0841 is set when C solenoid is commanded ON and C pressure switch status remains OFF for a period of
time. The time period is 5 seconds at 0°C (32°F) to -40°C (-40°F). The intent of this DTC is to detect a stuck shift
valve, in the destroked state, a mechanical solenoid failure, or an open circuit.

— If the failure occurs while in a forward range, the transmission shifts to 1st, 3rd or 5th range.
— If the shift selector is moved to a forward range or reverse and the transmission is compromised by
overspeeding or direction change, the transmission shifts to neutral.
Diagnostic Aids
— A chafed wire.
• When a P0841 and P0843 are set in combination, this may indicate an open circuit condition is present at the
pressure switch circuit or the shift valve is stuck in the destroked state. See Section 4 — Beginning the
Troubleshooting Process.
equipment for a change. It may be necessary to check for shorting to ground or opens at individual wires within
a harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A,
Section B.


Test Description
6. This step tests for opens in the OEM wiring harness.
7. This step tests for opens in the internal wiring harness.
DTC P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open

Troubleshooting
Process
(Paragraph 5–4A)
and 5–9)
4. Clear the DTC.
NOTE: This DTC may indicate a stuck shift
valve, mechanically failed solenoid, open in
switch circuit, or defective PSM.
ground.
circuit is open?


DTC P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open (cont’d)
4. Connect wire 201 (pin D) on the harness
connector to a known good ground.*
circuit is open?
circuit is open?
8 1. Remove the PSM from the control valve body Go to Step 9 Go to Step 12
and leave the internal harness connected.
either the control valve body or the
transmission main case.
membrane.
circuit is open?
9 Remove the control valve body and check for a Go to Step 11 Go to Step 10
stuck or sticking C shift valve. Refer to Service
Was the C shift valve stuck or sticking?
10 Replace the C shift solenoid and reinstall the Go to Step 16
control valve body. Refer to Service Manual or
Mechanic’s Tips.
Is replacement of solenoid and reinstalling of
control valve body complete?
11 Clean and/or polish the sticking valve to restore Go to Step 16
free movement or replace the control valve
body assembly. Refer to Service Manual or
Mechanic’s Tips.
Was free movement restored or valve body
replaced?
Mechanic’s Tips.


DTC P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open (cont’d)
warranty.
(Section 3–6).
Replace the TCM.
in failure records.
run.
Did the DTC return?


DTC P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed
TRANSMISSION
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1
TCM
F
E
TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2
J1
F
E
TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4
E
F
PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06213.01.00
Circuit Description
• C shift valve is commanded to the OFF (destroked) position.


DTC P0842 is set when C solenoid is commanded OFF and C pressure switch status remains ON for a period of time
that is temperature dependent. The time period is 2 seconds at 0°C (32°F) or up to 6 seconds at –40°C (–40°F). The
intent of this DTC is to detect a stuck shift valve, in the stroked state, a mechanical solenoid failure, or a circuit short
to ground.

— If the failure occurs while in a forward range, the transmission shifts to another forward range.
Diagnostic Aids
— A chafed wire.
• When a P0842 and P0840 are set in combination, this may indicate a short to ground at the pressure switch
circuit or the shift valve is stuck in the stroked state. See Section 4 — Beginning the Troubleshooting Process.
equipment for a change. It may be necessary to check for shorting to ground at individual wires within a harness
to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A, Section B.
Test Description

DTC P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed

Troubleshooting
Process
(Paragraph 5–4A)
Did you perform the procedure and correct Procedure
fluid level if necessary? (Appendix P)
and 5–9)
4. Clear the DTC.
valve, mechanically failed solenoid, short to
ground in the switch circuit, or a defective
PSM.
ground.
circuit is open?
2 Disconnect the transmission wiring harness
ground.*
circuit is open?


DTC P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed (cont’d)
Does the Scan Tool indicate reverse pressure
switch C status as ON when grounded and OFF
when circuit is open?
membrane.
circuit is open?
9 Remove the control valve body and inspect for Go to Step 11 Go to Step 10
a stuck or sticking C shift valve. Refer to
Was the C shift valve stuck or sticking?
10 Replace the C shift solenoid and reinstall the Go to Step 16
Mechanic’s Tips.
Is replacement of solenoid and reinstalling of
valve body complete?
Mechanic’s Tips.
replaced?
Mechanic’s Tips.
warranty.


DTC P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed (cont’d)
(Section 3–6).
Replace the TCM.
in failure records.
run.
Did the DTC return?


DTC P0843 Transmission Pressure Switch Solenoid C Circuit High
TRANSMISSION
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1
TCM
F
E
TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2
J1
F
E
TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4
E
F
PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06213.01.00
Circuit Description
• C shift valve is commanded to the ON (stroked) position.


DTC P0843 sets during steady state operation when C shift valve is in the stroked state (commanded ON) and C
pressure switch status is detected as destroked (commanded OFF). Steady state is defined as attaining a valid
range. The intent of this code is to detect an open condition in the pressure switch wiring circuit or the pressure
switch.
Later software levels incorporate retry logic that allows the TCM to command C solenoid OFF and ON. If the
pressure switch state does not change, and remains in the OFF state, DTCs P0841 and P0843 will set.


Diagnostic Aids
— A chafed wire.
• When only a DTC P0843 is set, look for an intermittent open condition at the pressure switch circuit or an
intermittent hydraulic failure (sticking valve). This code is set when the condition is present more than 3 times
during a current drive cycle. See Appendix A, Section B — Finding an Intermittent Fault.
equipment for a change. It may be necessary to check for an open condition at individual wires within a
harness to isolate an intermittent condition. Refer to Section 4 — Wire Check Procedures and Appendix A,
Section B.


Test Description
8. This step tests for PSM switch function.
DTC P0843 Transmission Pressure Switch Solenoid C Circuit High

Troubleshooting
Process
(Paragraph 5–4A)
and 5–9)
4. Clear the DTC.
NOTE: This DTC indicates an open circuit
condition may exist in the OEM wiring


DTC P0843 Transmission Pressure Switch Solenoid C Circuit High (cont’d)
ground.
circuit is open?
ground.*
circuit is open?
7 1. Remove the oil pan. Refer to Service Manual — Go to Step 8 Go to Step10
circuit is open?
8 1. Remove the PSM from the control valve body Go to Diagnostic Go to Step 9
membrane.
circuit is open?
Mechanic’s Tips.


DTC P0843 Transmission Pressure Switch Solenoid C Circuit High (cont’d)
warranty.
(Section 3–6).
Replace the TCM.
failure records.
run.
Did the DTC return?


DTC P0845 Transmission Pressure Switch Solenoid D Circuit
TRANSMISSION
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1
TCM
F
E
TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2
J1
F
E
TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4
E
F
PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06213.01.00
Circuit Description
normally closed (N/C) pressure switches. The D pressure switch monitors D shift valve positioning and relays it to
the TCM. When D pressure switch is in the open state, D shift valve should be in the destroked position.
• D shift valve is commanded to the OFF (destroked) position.


DTC P0845 sets during steady state operation when D shift valve is in the destroked state (commanded OFF) and
D pressure switch status is detected as stroked (commanded ON). Steady state is defined as attaining a valid
switch.
Later software levels incorporate retry logic that allows the TCM to command D solenoid ON and OFF. If the


Diagnostic Aids
— A chafed wire.
• When only a DTC P0845 is set, look for an intermittent short to ground at the pressure switch circuit or an
• When a P0845 and P0847 are set in combination, this may indicate a short to ground is present at the
pressure switch circuit or the shift valve is stuck in the stroked state. See Section 4 — Beginning the
Section B.
This data can be useful in reproducing the failure mode when the DTC was set.


Test Description
DTC P0845 Transmission Pressure Switch Solenoid D Circuit

Troubleshooting
Process
(Paragraph 5–4A)
and 5–9)
4. Clear the DTC.
NOTE: This DTC indicates a short circuit


DTC P0845 Transmission Pressure Switch Solenoid D Circuit (cont’d)
ground.
Does the Scan Tool indicate pressure switch D
circuit is open?
6 1. Turn the ignition OFF and reconnect J2 — Go to Step 7 Go to Step 11
4. Connect wire 202 (pin F) at the main
ground.*
circuit is open?
the PSM and ground pin B.
circuit is open?
8 1. Remove the PSM from the control valve body — Go to Diagnostic Go to Step 9
to push gently on the pressure switch D
membrane.
circuit is open?
Mechanic’s Tips.


DTC P0845 Transmission Pressure Switch Solenoid D Circuit (cont’d)
warranty.
(Section 3–6).
Replace the TCM.
failure report.
run.
Did the DTC return?


DTC P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open
TRANSMISSION
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1
TCM
F
E
TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2
J1
F
E
TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4
E
F
PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06213.01.00
Circuit Description
• D shift valve is commanded to the ON (stroked) position.


DTC P0846 sets when D solenoid is commanded ON and D pressure switch status remains OFF for a period of
time. The time period is 5 seconds at 0°C (32°F) to –40°C (–40°F). The intent of this DTC is to detect a stuck shift

Diagnostic Aids
— A chafed wire.
Section B.


Test Description
DTC P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open

Troubleshooting
Process
(Paragraph 5–4A)
and 5–9)
4. Clear the DTC.
valve, solenoid mechanically failed, an open
condition in the switch circuit, or a defective
PSM.
ground.
circuit is open?


DTC P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open (cont’d)
4. Connect wire 202 (pin F) on the harness
circuit is open?
circuit is open?
8 1. Remove the PSM from the control valve body — Go to Step 9 Go to Step 12
membrane.
circuit is open?
9 Remove the control valve body and check for a — Go to Step 11 Go to Step 10
stuck or sticking D shift valve. Refer to Service
Was the D shift valve stuck or sticking?
10 Replace the D shift solenoid and reinstall the — Go to Step 16 —
Mechanic’s Tips.
Is replacement of the solenoid and reinstalling
of the control valve body complete?
11 Clean and/or polish the sticking valve to restore — Go to Step 16 —
Mechanic’s Tips.
replaced?
Mechanic’s Tips.


DTC P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open (cont’d)
warranty.
(Section 3–6).
Replace the TCM.
failure records.
run.
Did the DTC return?


DTC P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed
TRANSMISSION
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1
TCM
F
E
TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2
J1
F
E
TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4
E
F
PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06213.01.00
Circuit Description
• D shift valve is commanded to the OFF (destroked) position.

DTC P0847 sets when D solenoid is commanded OFF and D pressure switch status remains ON for a period of time
that is temperature dependent. The time period is 2 seconds at 0°C (32°F) or up to 16 seconds at –40°C (–40°F).
The intent of this DTC is to detect a stuck shift valve, in the stroked state, a mechanical solenoid failure, or a circuit
short to ground.


Diagnostic Aids
— A chafed wire.
Section B.
Test Description
5. This step tests for the TCM proper switch status.

DTC P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed

Troubleshooting
Process
(Paragraph 5–4A)
and 5–9)
4. Clear the DTC.
valve, solenoid mechanically failed, a short
to ground in the switch circuit, or a defective
PSM.
ground.
circuit is open?
4. Connect wire 202 (pin F) on the harness
circuit is open?


DTC P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed (cont’d)
circuit is open?
membrane.
circuit is open?
9 Remove the control valve body and check for a Go to Step 11 Go to Step 10
stuck or sticking D shift valve. Refer to Service
Was the D shift valve stuck or sticking?
10 Replace the D shift solenoid and reinstall the Go to Step 16
Mechanic’s Tips.
Is the replacement of the solenoid and
reinstalling of the control valve body complete?
Mechanic’s Tips.
replaced?
12 Replace the PSM (refer to Service Manual or — Go to Step 16 —
Mechanic’s Tips).
warranty.


DTC P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed (cont’d)
(Section 3–6).
Replace the TCM.
failure records.
run.
Did the DTC return?


DTC P0848 Transmission Pressure Switch Solenoid D Circuit High
TRANSMISSION
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1
TCM
F
E
TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2
J1
F
E
TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4
E
F
PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06213.01.00
Circuit Description
• D shift valve is commanded to the ON (stroked) position.


DTC P0848 sets during steady state operation when D shift valve is in the stroked state (commanded ON) and D
range. The intent of this code is to detect an open condition in the pressure switch wiring circuit or the pressure switch.
Later software levels incorporate retry logic that allows the TCM to command D solenoid OFF and ON. If the


Diagnostic Aids
— A chafed wire.
Section B.


Test Description
DTC P0848 Transmission Pressure Switch Solenoid D Circuit High

Troubleshooting
Process
(Paragraph 5–4A)
and 5–9)
4. Clear the DTC.


DTC P0848 Transmission Pressure Switch Solenoid D Circuit High (cont’d)
ground.
circuit is open?
4. Connect wire 202 (pin F) at the main
ground.*
circuit is open?
circuit is open?
membrane.
circuit is open?
Mechanic’s Tips.


DTC P0848 Transmission Pressure Switch Solenoid D Circuit High (cont’d)
warranty.
(Section 3–6).
Replace the TCM.
failure records.
run.
Did the DTC return?

DTC P0870 (Previously P1709) Transmission Pressure Switch Solenoid E Circuit
TRANSMISSION
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1
TCM
F
E
TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2
J1
F
E
TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4
E
F
PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06213.01.00
Circuit Description
normally closed (N/C) pressure switches. The E pressure switch monitors E shift valve positioning and relays it to
the TCM. When E pressure switch is in the open state, E shift valve should be in the destroked position.
• E shift valve is commanded to the OFF (destroked) position.


DTC P0870 sets during steady state operation when E shift valve is in the destroked state (commanded OFF) and
E pressure switch status is detected as stroked (commanded ON). Steady state is defined as attaining a valid
switch.
Later software levels incorporate retry logic that allows the TCM to command E solenoid ON and OFF. If the


Diagnostic Aids
— A chafed wire.
• When only a DTC P0870 is set, look for an intermittent short to ground at the pressure switch circuit or an
Section B.


Test Description

Troubleshooting
Process
(Paragraph 5–4A)
and 5–9)
4. Clear the DTC.
NOTE: This DTC indicates a short circuit


DTC P0870 (Previously P1709) Transmission Pressure Switch Solenoid E Circuit (cont’d)
3. Connect J2 connector pin 3 to known good
ground.
Does the Scan Tool indicate pressure switch E
circuit is open?
4. Connect wire 203 (pin E) at the main
ground.*
circuit is open?
the PSM and ground pin C.
circuit is open?
3. Use your finger at the eraser end of a pencil
to push gently on the pressure switch E
membrane.
circuit is open?
Mechanic’s Tips.


DTC P0870 (Previously P1709) Transmission Pressure Switch Solenoid E Circuit (cont’d)
warranty.
(Section 3–6).
Replace the TCM.
failure records.
run.
Did the DTC return?


DTC P0871 (Previously P1710) Transmission Pressure Switch
Solenoid E Circuit Stuck Open
TRANSMISSION
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1
TCM
F
E
TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2
J1
F
E
TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4
E
F
PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06213.01.00
Circuit Description

• E shift valve is commanded to the ON (stroked) position.


DTC P0871 sets when E solenoid is commanded ON and E pressure switch status remains OFF for a period of
time. The time period is 5 seconds at 0°C (32°F) to –40°C (–40°F). The intent of this DTC is to detect a stuck shift


Diagnostic Aids
— A chafed wire.
Section B.
Test Description


DTC P0871 (Previously P1710) Trans Pressure Switch

Solenoid E Circuit Stuck Open
Troubleshooting
Process
(Paragraph 5–4A)
and 5–9)
4. Clear the DTC.
valve, solenoid mechanically failed, an open
condition in the switch circuit, or a defective
PSM.
ground.
circuit is open?


Solenoid E Circuit Stuck Open (cont’d)
from the main transmission connector.
ground.*
circuit is open?
circuit is open?
membrane.
circuit is open?
9 Remove the control valve body and inspect for — Go to Step 11 Go to Step 10
a stuck or sticking E shift valve. Refer to Service
Was the E shift valve stuck or sticking?
10 Replace the E shift solenoid and reinstall the — Go to Step 16 —
Mechanic’s Tips.
Mechanic’s Tips.
replaced?


Solenoid E Circuit Stuck Open (cont’d)
Mechanic’s Tips.
warranty.
(Section 3–6).
Replace the TCM.
failure records.
run.
Did the DTC return?


Stuck Closed
TRANSMISSION
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1
TCM
F
E
TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2
J1
F
E
TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4
E
F
PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06213.01.00
Circuit Description

• E shift valve is commanded to the OFF (destroked) position.


DTC P0872 sets when E solenoid is commanded OFF and E pressure switch status remains ON for a period of time
that is temperature dependent. The time period is 2 seconds at 0°C (32°F) or up to 20 seconds at –40°C (–40°F).
The intent of this DTC is to detect a stuck shift valve, in the stroked state, a mechanical solenoid failure, or a circuit
short to ground.


Diagnostic Aids
— A chafed wire.
Section B.
Test Description


DTC P0872 (Previously P1711) Trans Pressure Switch Solenoid E

Circuit Stuck Closed
Troubleshooting
Process
(Paragraph 5–4A)
and 5–9)
4. Clear the DTC.
valve, solenoid mechanically failed, a short
to ground in the switch circuit, or a defective
PSM.
ground.
circuit is open?


Circuit Stuck Closed (cont’d)
ground.*
circuit is open?
circuit is open?
membrane.
circuit is open?
9 Remove the control valve body and check for a — Go to Step 11 Go to Step 10
stuck or sticking E shift valve. Refer to Service
Was the E shift valve stuck or sticking?
10 Replace the E shift solenoid and reinstall the — Go to Step 16 —
Mechanic’s Tips.
Mechanic’s Tips.
replaced?


Circuit Stuck Closed (cont’d)
Mechanic’s Tips.
warranty.
(Section 3–6).
Replace the TCM.
2. Operate the vehicle under conditions as Go to Step 1
noted in failure records.
run.
Did the DTC return?


DTC P0873 (Previously P1712) Transmission Pressure Switch Solenoid E Circuit High
TRANSMISSION
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1
TCM
F
E
TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2
J1
F
E
TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4
E
F
PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06213.01.00
Circuit Description
• E shift valve is commanded to the ON (stroked) position.


DTC P0873 sets during steady state operation when E shift valve is in the stroked state (commanded ON) and E
range. The intent of this code is to detect an open condition in the pressure switch wiring circuit or the pressure
switch.
Later software levels incorporate retry logic that allows the TCM to command E solenoid OFF and ON. If the

Diagnostic Aids
— A chafed wire.
Section B.


Test Description

Solenoid E Circuit High
Troubleshooting
Process
(Paragraph 5–4A)
and 5–9)
4. Clear the DTC.


Solenoid E Circuit High (cont’d)
ground.
circuit is open?
4. Connect wire 203, pin E, on the main
ground.*
circuit is open?
circuit is open?
membrane.
circuit is open?
Mechanic’s Tips.


Solenoid E Circuit High (cont’d)
warranty.
(Section 3–6).
Replace the TCM.
failure records.
run.
Did the DTC return?


DTC P0875 (Previously P1713) Transmission Reverse Pressure Switch
Circuit Malfunction
TRANSMISSION
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1
TCM
F
E
TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2
J1
F
E
TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4
E
F
PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06213.01.00
Circuit Description
The Pressure Switch Manifold (PSM) is a multiple switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. Fluid pressure is supplied to the reverse pressure switch, holding it open,
when the manual selector valve is in any position except reverse. When the manual selector valve is moved to
Reverse, pressure to the reverse pressure switch is cut off, allowing the switch to close.
• TFT is greater than 0°C (32°F).
• The hydraulic system is pressurized.
• DTC P0708 is not active.


DTC P0875 sets when P (Park), N (Neutral), or a forward range is selected and the reverse pressure switch state
remains in the mechanically closed/electrically ON position for a period of time that is calibration dependent.

— Calibration Dependent — The transmission will either lock-to-neutral or shift to 3rd or 5th range.
overspeeding or direction change, the transmission shifts to neutral. If an output speed fault or NSBU fault
is present when this test fails, then hydraulic default is implemented.

Diagnostic Aids
— A chafed wire.
Section B.
• This DTC could indicate a hydraulic leak path exhausting pressure from the reverse pressure switch (refer to
hydraulic schematic).
8000 km (5,000 mile) filter change was performed. To help reduce multiple pressure switch DTCs from setting
due to a plugged control main filter or slow pump prime, later software levels have a time delay up to
30 seconds before a pressure switch test is enabled.
• If a P0875 (previously P1713) is shown in failure records as being logged first on the failure list followed by
P0872 (previously P1711) combined with P0708, this generally indicates a NSBU internal switch failure. Often
when the codes are cleared they do not return. This may be due to moisture that was present at the time the
code was logged, causing an internal short. Inspect the NSBU switch linkage for proper adjustment and for
signs of damage. If the shift linkage is properly adjusted and no damage is noted, replacement of the switch
may be indicated.


Test Description

DTC P0875 (Previously P1713) Reverse Pressure Switch Circuit Malfunction
Troubleshooting
Process
(Paragraph 5–4A)
and 5–9)
4. Clear the DTC.
NOTE: This DTC is set when P (Park),
N (Neutral), or a forward range has been
selected and the reverse pressure switch
indicates mechanically closed/electrically
ON for a period of time that is calibration
dependent. This DTC may indicate that a
short circuit condition exists in the OEM
harness, internal transmission harness or
the PSM. A defective NSBU switch may also
set this code. The intent of this DTC is to
detect discrepancies between range
selected at the NSBU and the actual
position of the manual selector valve.


DTC P0875 (Previously P1713) Reverse Pressure Switch Circuit Malfunction (cont’d)
2. Remove the J2 connector from the TCM and
Breakout Box Adapter. Leave the vehicle
harness disconnected from the J 43799
3. Connect J2 connector pin 4 on the Breakout
Box panel to a known good ground.
switch status as ON when grounded and OFF
3. Connect wire 204 (pin K) at the main
ground.*
the PSM and ground pin D.
to push gently on the reverse pressure switch
membrane.
Mechanic’s Tips.


DTC P0875 (Previously P1713) Reverse Pressure Switch Circuit Malfunction (cont’d)
10 1. Inspect for a missing or a damaged seal at — Go to Step 14 Go to Diagnostic
the reverse pressure switch assembly. Aids
2. Inspect for loose reverse transfer tube.
3. Inspect for proper shift linkage adjustment.
Shift linkage out of adjustment can allow
pressure to apply the reverse pressure
switch.
warranty.
(Section 3–6).
Replace the TCM.
failure records.
run.
Did the DTC return?


DTC P0876 (Previously P1714) Transmission Reverse Pressure Switch Circuit Stuck Open
TRANSMISSION
CONNECTOR (RED)
K J2-3 J2-2
D J2-4 J2-1
TCM
F
E
TRANSMISSION
BULKHEAD
CONNECTOR
K
D
J2
J1
F
E
TCM
201
C A D J2-1
202
D B F J2-2 DIGITAL
TRANSMISSION
203 INTERFACE
E C E J2-3
204
R D K J2-4
E
F
PRESSURE SWITCH
MANIFOLD
R E D
C
F E D C B A
V06213.01.00
Circuit Description
The Pressure Switch Manifold (PSM) is a multiple switch assembly made up of three normally open (N/O) and one
normally closed (N/C) pressure switches. Fluid pressure is supplied to the reverse pressure switch, holding it open,
when the manual selector valve is in any position except reverse. When the manual selector valve is moved to
Reverse, pressure to the reverse pressure switch is cut off allowing the switch to close.
• TFT is greater than 0°C (32°F).
• There are two cases where this DTC runs.
— Case 1 Ignition voltage is above 9V (12V TCM) or 18V (24V TCM). The PRNDL state and the reverse
pressure switch state do not agree.
— Case 2 Ignition voltage is under 9V (12V TCM) or 18V (24V TCM). All speed sensors are under 50 rpm.


DTC P0876 sets in two cases:
• When PRNDL and reverse pressure switch do not agree. When reverse range is selected and the reverse
pressure switch is detected in the mechanically open/electrically OFF state for more than 1 second.
• When engine shutdown and reverse pressure switch do not agree. When engine shutdown is in process and
the reverse pressure switch is detected in an improper state, mechanically open/electrically OFF, for more than
a period of time that is temperature dependent. The time period is 5 seconds at 35°C (95°F) to 30 seconds at
–20°C (–4°F).

— Calibration Dependent — The transmission will either lock-to-neutral or shift to 3rd or 5th range.
overspeeding or direction change, the transmission shifts to neutral. If an output speed fault or NSBU fault
is present when this test fails, then hydraulic default is implemented.
• The TCM inhibits TCC engagement

Diagnostic Aids
— A chafed wire.
Section B.
8000 km (5,000 mile) filter change was performed. To help reduce multiple pressure switch DTCs from setting
due to a plugged control main filter or slow pump prime, later software levels have a time delay up to
30 seconds before a pressure switch test is enabled.


Test Description

6. This step tests for an open condition in the OEM wiring harness.
7. This step tests for an open condition in the internal wiring harness.
DTC P0876 (Previously P1714) Reverse Pressure Switch Circuit Stuck Open
Troubleshooting
Process
(Paragraph 5–
4A)
and 5–9)
4. Clear the DTC.
NOTE: This DTC is set when reverse range
is selected and reverse switch status
remains in the mechanically open/
electrically OFF state for more than a time
that is calibration dependent. This DTC can
also set at engine shutdown when the
reverse pressure switch is detected in the
mechanically open/electrically OFF state for
a period of time that is temperature
dependent. The time period is 5 seconds at
35°C (95°F) to 30 seconds at –20°C (–4°F).


DTC P0876 (Previously P1714) Reverse Pressure Switch Circuit Stuck Open (cont’d)
2. Remove the J2 connector from the TCM and
Breakout Box Adapter. Leave the vehicle
wiring harness disconnected from the
J 43799 Breakout Box Adapter.
3. Connect J2 connector pin 4 on the Breakout
Box panel to a known good ground.
3. Connect wire 204 (pin K) at the main
ground.*
the PSM and ground pin D.
to push gently on the reverse pressure switch
membrane.
Mechanic’s Tips.


DTC P0876 (Previously P1714) Reverse Pressure Switch Circuit Stuck Open (cont’d)
10 1. Inspect for a missing or a damaged seal at — Go to Step 14 Go to Diagnostic
the reverse pressure switch assembly. Aids
2. Inspect for loose reverse transfer tube.
3. Inspect for proper shift linkage adjustment.
Shift linkage out of adjustment can allow
pressure to apply the reverse pressure
switch.
warranty.
(Section 3–6).
Replace the TCM.
failure records.
run.
Did the DTC return?


DTC P0880 (Previously P1760) TCM Supply Voltage

(GRAY)
J1-4
J1-5 J1-3
J1-2
J1-1
J2
J1
102
J1-2
104 IGNITION
J1-4
POWER
10a 103 BATTERY
J1-3 POWER TCM
10a 101
J1-1 GND
IGN 105
SWITCH J1-5 GND
+ —
12V/24V
BATTERY
V06215.01.00
Circuit Description
DTC P0880 sets if an abnormal power-down sequence has occurred. This condition means the Transmission
Control Module (TCM) has lost supply voltage (wire 103) before it has finished saving information from that drive
cycle. This process is usually completed in less than 10 seconds.

• Loss of TCM supply voltage before drive cycle data is saved.

DTC P0880 sets during the next ignition cycle if the TCM loses TCM supply voltage less than 10 seconds after the
ignition voltage has been turned off.

• The TCM loses adaptive information for the drive cycle.
• The TCM reverts to previous adaptive settings.


Diagnostic Aids
— A chafed wire.
Test Description
2. This step tests the system voltage.
4. This step tests the vehicle charging system.
5. This step tests the external wiring harness for shorts or opens.
DTC P0880 (Previously P1760) TCM Supply Voltage

Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. 10.5V Go to Step 4 Resolve battery
2. Turn the ignition to the RUN position with the (12V TCM); problem
engine OFF. 22V
3. Record the DTC Failure Record data. (24V TCM)
NOTE: If other DTCs are present refer to the
applicable diagnostic tables before
continuing.
4. Using a DVOM, measure and record voltage
at the battery terminals.
Is voltage greater than the specified value?
3 Start the engine and warm to normal operating — Repair charging Go to Step 4
temperature. system
Is the Alternator/Check Engine lamp ON?
4 1. Increase the engine speed to 13–15V Go to Step 5 Repair charging
1000–1500 rpm. (12V TCM); system
2. Using the Scan Tool, monitor system voltage. 25–30V
Is voltage within the specified value? (24V TCM)


DTC P0880 (Previously P1760) TCM Supply Voltage (cont’d)
5 1. Turn the ignition OFF. 0.5V Go to Step 6 Go to Step 7
3. Using a DVOM, measure voltage at
connector J1 pins 1 and 2 with the ignition
ON and J1 connector pins 1 and 3 with the
ignition OFF.
4. Compare the battery voltage to the wire
voltage.
Is the voltage difference greater than the
specified value?
warranty.
(Section 3–6).
Replace the TCM.
2. Start the engine and warm to normal Go to Step 1
operating temperature.
3. Using the Scan Tool, monitor system voltage.
System voltage should be 9–18V for a
12V TCM or 18–32V for a 24V TCM.
Did the DTC return?


DTC P1688 Unmanaged Engine Torque Delivered To TCM Signal
TCM
(GRAY)
J1-16 J1-09
J2
J1-22 J1
TCM
109
J1-09
ENGINE
CONTROL 116
J1-16 DIGITAL
MODULE INTERFACE
(ECM) 122
J1-22
V06538.01.00
Circuit Description
The GM 8.1 liter gasoline engine is used in some medium duty applications. The 8.1 liter engine uses a 3-wire
system to communicate engine torque data/requests between the powertrain control module (PCM) and the
transmission control module (TCM).
Unmanaged engine torque is sent from the PCM to the TCM over wire 109 (GM wire 2467).

• Pulse Width Modulation (PWM) driver demand torque option is selected in transmission calibration.

DTC P1688 sets if unmanaged (gross) engine torque signal (circuit 2467) is under 1.5 percent or over 98.5 percent
for more than a 2 second period.
Actions Taken When the DTC Sets

• The TCM defaults to a calculated unmanaged torque (gross) input value using throttle and engine speed.



Diagnostic Aids
An Intermittent condition may be the cause of the problem. Return the vehicle to the OEM for further
troubleshooting.
DTC P1688 Engine Torque Unmanaged Delivered To TCM Signal

Step Action Yes No
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. Go to Step 3 Go to
2. Start the engine. Diagnostic Aids
3. Record DTC failure records.
4. Clear the DTC and drive the vehicle. Attempt to
duplicate the same operating conditions observed in
failure records.
NOTE: This DTC indicates that the unmanaged engine
torque signal sent from the engine PCM to the
transmission TCM is either under or over a set
percentage value for a set period of time.
3 Inspect the routing of wire 109 (GM wire circuit 2467) Go to Step 4 Go to Step 5
between the TCM and PCM.
Was chafing or wire damage found?
4 NOTE: The vehicle OEM has responsibility for all Go to Step 6 —
external wiring harness repair. Harness repairs
performed by Allison Transmission distributors and
dealers are not covered by Allison Transmission
warranty.
5 Return the vehicle to the OEM to troubleshoot for cause of Go to Step 6 —
low or high torque signal. Below are some possible causes
for this DTC.
• Defective engine PCM.
• Circuit fault at wire 109.
• Improper calibration for engine PCM.
Was problem found and repaired?
2. Drive the vehicle under conditions noted in failure Go to Step 1
records.
Did the DTC return?


DTC P1779 Engine Torque Delivered To TCM Signal
TCM
(GRAY)
J1-16 J1-09
J2
J1-22 J1
TCM
109
J1-09
ENGINE
CONTROL 116
J1-16 DIGITAL
MODULE INTERFACE
(ECM) 122
J1-22
V06538.01.00
Circuit Description
The GM 8.1 liter gasoline engine is used in some medium duty applications. The 8.1 liter engine uses a 3-wire
system to communicate engine torque data/requests between the powertrain control module (PCM) and the
transmission control module (TCM).
Managed engine torque is sent from the PCM to the TCM over wire 116 (GM wire 464).

• Pulse Width Modulation (PWM) driver demand torque option is selected in transmission calibration.
• No DTC is active at the time of this test.

DTC P1779 sets if managed engine torque (net) signal (circuit 464) is under 1.5 percent or over 98.5 percent for
more than a 2 second period.

• The TCM defaults to a calculated managed torque (net) input value using throttle and engine speed.
• The TCM defaults to a calculated unmanaged torque (gross) input value using throttle and engine speed.



Diagnostic Aids
An Intermittent condition may be the cause of the problem. Return the vehicle to the OEM for further
troubleshooting.
.
DTC P1779 Engine Torque Delivered To TCM Signal

Step Action Yes No
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. Go to Step 3 Go to
2. Start the engine. Diagnostic Aids
3. Record DTC failure records.
4. Clear the DTC and drive the vehicle. Attempt to
duplicate the same operating conditions observed in
failure records.
NOTE: This DTC indicates that the managed engine
torque signal sent from the engine PCM to the
transmission TCM is either under or over a set
percentage value for a set period of time.
3 Inspect the routing of wire 109 (GM wire circuit 2467) Go to Step 4 Go to Step 5
between the TCM and PCM.
Was chafing or wire damage found?
warranty.
5 Return the vehicle to the OEM to troubleshoot for cause of Go to Step 6 —
low or high torque signal. Below are some possible causes
for this DTC.
• Defective engine PCM.
• Circuit fault at wire 116.
• Improper calibration for engine PCM.
Was problem found and repaired?
2. Drive the vehicle under conditions noted in failure Go to Step 1
records.
Did the DTC return?


DTC P1891 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM)
Signal Low Input
TCM
(GRAY)
J2-16
J2
J1
TCM
PWM 116 DIGITAL

THROTTLE J1-16
INTERFACE
SOURCE
V06228.01.00
Circuit Description
The Transmission Control Module (TCM) can be calibrated to receive throttle information from a Pulse Width
Modulation (PWM) signal.

• The components are powered and engine speed is within a 5 rpm range for 5 seconds.

DTC P1891 sets if the TCM is calibrated to receive the PWM signal and the throttle percentage falls below
5 percent for 5 seconds.

• MY ‘00 through ‘02 — no CHECK TRANS light. MY ‘03 CHECK TRANS light is illuminated.



Diagnostic Aids
— A chafed wire.

Test Description
3. This step tests the PWM signal.
4. This step tests for shorts or opens at wire 116.
Signal Low Input
Troubleshooting
Process
(Paragraph 5–4A)
voltage. and P0563)
3 1. Install the Scan Tool. — Go to Step 4 —
2. Turn the ignition to the RUN position with the
engine OFF.
4. Verify that the throttle source is functioning
correctly.
Is PWM signal OK?
4 Check wire 116 for shorts or opens. — Go to Step 5 Go to Step 6
Did you find a problem?


Signal Low Input (cont’d)
warranty.
6 Inspect the TCM and Engine Control Module — Go to Step 7 Go to Step 8
(ECM) connectors and terminals for damage
and/or corrosion.
7 Repair and clean terminals if possible. — Go to Step 9 Go to Step 8
(Section 3–6).
Replace the TCM, if necessary.
conditions.
3. Using the Scan Tool, monitor throttle position
and engine coolant temperature.
Did the DTC return?


Signal High Input
TCM
(GRAY)
J2-16
J2
J1
TCM
PWM 116 DIGITAL

THROTTLE J1-16
INTERFACE
SOURCE
V06228.01.00
Circuit Description
The Transmission Control Module (TCM) can be calibrated to receive throttle information from a Pulse Width
Modulation (PWM) signal.


DTC P1892 sets if the TCM is calibrated to receive the PWM signal and the throttle percentage exceeds 95 percent
for 5 seconds.

• MY ‘00 through ‘02 — no CHECK TRANS light. MY ‘03 CHECK TRANS light is illuminated.



Diagnostic Aids
— A chafed wire.

Test Description
3. This step tests the PWM signal.
Signal High Input
Troubleshooting
Process
(Paragraph 5–4A)
voltage. and P0563)
3 1. Install the Scan Tool. — Go to Step 4 —
2. Turn the ignition to the RUN position with the
engine OFF.
4. Verify that the throttle source is functioning
correctly.
Is the PWM signal OK?
4 Check wire 116 for shorts or opens. — Go to Step 5 Go to Step 6


Signal High Input
warranty.
6 Inspect the TCM and Engine Control Module — Go to Step 7 Go to Step 8
(ECM) connectors and terminals for damage
and/or corrosion.
7 Repair and clean terminals if possible. — Go to Step 9 Go to Step 8
(Section 3–6).
Replace the TCM, if necessary.
conditions.
3. Using the Scan Tool, monitor throttle position
and engine coolant temperature.
Did the DTC return?


DTC P2771 (Previously P0836, P1875) Four-Wheel Drive Switch Circuit
(
TCM
(GRAY)
J1-10
J2
J1-28 J1
4WD Transfer Case Switch
Signal Ground Wire 128

J1-28
TCM
Input Wire 110

J1-10
V06560.01.00
Circuit Description
Detects abnormal conditions for the four-wheel drive indication switch input. Four wheel-drive statuses are
detected using speed and ratios.

• DTCs P0721 and P0722 (output speed sensor circuits) are not active.
• Output speed is above 60 rpm.
• Transmission fluid temperature it between 20°C (68°F) and 130°C (266°F).
• Shift is complete and the range attained is not neutral.

P2771 sets when one of the following conditions occurs:
• The transfer case switch indicates high range, and the calculated range is low range for 5 seconds or more.
• The transfer case switch indicates low range, and the calculated range is high range for 5 seconds or more.

• DTC P2771 will be stored in the TCM memory.

• A Scan Tool can be used to clear the code from the TCM history. The TCM automatically clears the DTC from
the TCM history if the vehicle completes 40 warm-up cycles without a failure.


Diagnostics Aids
— A chafed wire.
• Inspect for any transmission DTCs that may have reset.
• When testing for a short or ground, the transmission should be in a range where the switch or solenoid is in the
OFF state. When testing for an open, the transmission should be in a range where the switch or solenoid is in
the ON state.
Test Description
2. This step tests the status of the 4WD Low switch.
3. This step tests for a 4WD switch failure to ground.
4. This step tests for a short in the wiring harness.
9. This step tests for 4WD switch failure to an open state.
10. This step tests for an open in the wiring harness.
DTC P2771 Four-Wheel Drive Switch Circuit

Process (Section 5–4A) performed? Beginning The
Troubleshooting
Process
(Section 5–4A)
2 1. Install the Scan Tool. — Go to Go to Step 3
2. Turn the ignition to the RUN position with the Diagnostic Aids
engine OFF.
4. Using the Scan Tool, monitor 4WD low status
and select 4HI followed by 4LO with the
transfer case selector.
Does the Scan Tool indicate 4WD low status as
NO when 4HI is selected, and YES when 4LO is
selected?
3 Select 4HI followed by 4LO using the transfer — Go to Step 4 Go to Step 9
case selector.
YES for both selector positions?


DTC P2771 Four-Wheel Drive Switch Circuit (cont’d)
4 Remove the connector at the transfer case — Go to Step 5 Go to Step 7
selector.
YES?
5 Inspect wire 110 for a short to ground. — Go to Step 6 Go to Step 15
6 Repair the short to ground in wire 110. — Go to Step 16 —
Is the repair complete (refer to OEM repair
procedures)?
7 Inspect the transfer case switch for proper — Go to Step 8 Go to Step 15
operation or a short to ground.
Did you find a problem (refer to OEM repair
procedures)?
8 Repair the short to ground in the switch? — Go to Step 16 —
9 Select 4HI followed by 4LO using the transfer — Go to Step 10 Go to Step 15
case selector.
NO for both selector positions?
10 1. Remove the connector at the transfer case — Go to Step 11 Go to Step 13
switch.
2. Ground wire 110 to a known ground.
Does the Scan Tool indicate 4WD low status
as NO?
11 Inspect wire 110 for an open condition. — Go to Step 12 Go to Step 15
12 Repair the open condition in wire 110. — Go to Step 16 —
Is the repair complete (refer to OEM repair
procedures)?
13 Inspect the transfer case switch for an open — Go to Step 14 Go to Step 15
condition.
14 Repair the open condition in the switch? — Go to Step 16 —
(Section 3–6).
Replace the TCM.


DTC P2771 Four-Wheel Drive Switch Circuit (cont’d)
2. Drive the vehicle under normal operating Go to Step 1.
conditions.
3. Using the Scan Tool, monitor the 4WD low
status. The 4WD low status must indicate NO
when 4WDHI is selected, and YES when
4WDLO is selected.
Did the DTC return?


DTC P2773 Torque Control Request Ignored — ECM/TCM

Circuit Description
Shift Energy Management (SEM) allows the Transmission Control Module (TCM) to request torque reduction from
the engine controller. By reducing torque during upshifts, shifts can be made quicker and at a more consistent
output torque. This increases clutch life by reducing clutch engagement temperatures.

• DTC U2105 CAN bus error is not active.
• Engine speed is greater than 200 rpm but less than 7500 rpm for 5 seconds.
• SEM has been activated for this vehicle.

DTC P2773 sets when the TCM detects one of the following conditions for a minimum of four upshifts (consecutive
or nonconsecutive) during one drive cycle:
• Engine ECM is not responding to torque reduction signal request from the TCM.
• A nonapproved J1939 device is interfering with the torque reduction signal request.

• All 4–5 upshifts and full throttle 3–4 upshifts are inhibited.

A Scan Tool may be used to clear the code from the TCM history. The DTC is cleared if, for one ignition cycle,
actual engine torque follows TCM commanded torque for 20 consecutive upshifts. To be counted as one upshift,
engine torque demand must be above 80 N·m (59 lb ft).
Diagnostic Aids
• It will be necessary to drive the vehicle with heavy to moderate throttle settings for at least four upshift cycles in
order to set a DTC P2773.
• If DTC P2773 becomes active shortly AFTER an engine update and the troubleshooting procedure for P2773
has been performed, see Resetting of TCM Parameters to Support Engine Update, Section 3–7.
Test Description
2. This step tests for the proper ECM torque request response.
3. This step tests for the device causing the torque request to be ignored.
4. This step tests for the offending device by removing it from the J1939 network.
5. This step tests for the presence of the proper engine controller software.

DTC P2773 Torque Control Request Ignored — ECM/TCM

Step Action Yes No
1 Was the Beginning The Troubleshooting Go to Step 2 Go to
Troubleshooting
Process
(Paragraph 5–4A)
2 This code indicates that the engine controller — Go to Step 5 Go to Step 3
has disregarded the torque request sent by the
TCM. Use the Scan Tool and refer to
Transmission/Engine Torque Reduction Status.
Does the Scan Tool indicate the ECM response
to torque reduction request as incorrect?
3 Use the Scan Tool to identify an unapproved The Scan Tool Go to Step 5 Go to Step 4
torque reduction device. shows the actual
Is the unapproved device one of the following? device at fault
1. Engine
2. Null address or all /any (information not valid)
4 If the Scan Tool is indicating another device — Go to Step 6 —
such as the brakes, cruise control,
transmission, etc., inspect the controller for the
device indicated.
If possible, eliminate the device by
disconnecting it from the J1939 CAN backbone.
It may be possible that the device causing the
interruption is only triggered under certain
conditions. For example, a traction controller
may only send commands under certain road
conditions.
Since these conditions may not be easily
repeatable, replacement of the indicated
controller with a known good controller may be
the only way to verify the failure.
Was the device causing the problem replaced
or repaired?
5 Verify that compatible engine controller — Go to Step 6 —
software is utilized. If the software is correct,
replace the engine controller. If neither solves
the problem, use a lower engine torque/power
rating.
Was the software updated or engine controller
replaced?
3. Drive the vehicle under heavy to moderate
throttle settings for at least four upshift
cycles.
Did the DTC return?


DTC P2810 Solenoid G Electrical
TRANSMISSION J2 HARNESS CONNECTOR

HARNESS (RED)
CONNECTOR
S J
R
J2-32
J2-30 TCM
TRANSMISSION J2-29
BULKHEAD
CONNECTOR
S
J R
J2
J1
TCM
229
J J2-29
SOL F
(PWM) TRANSMISSION R
230
J2-30
LOCKUP SOL G
232 12V
S J2-32
NOTE: Wire 232 is a 12V DC ignition power source for TCC solenoids F and G.
V08119.00.00
Circuit Description
Solenoid G is a normally closed (N/C) solenoid used to modulate the transmission main pressure schedule. The
TCM commands the G solenoid ON when specific transmission and engine conditions are met. When G solenoid is
applied, pressure is routed to the main regulator valve. This in turn reduces the main pressure schedule and
improves the volume of oil sent through the overage circuit. By modulating main pressure, cooler flow can be
increased, allowing improved cooling and reduced pump noise.

• The TCM must autodetect G solenoid for this test to run.
DTC P2810 is set when the TCM detects an open circuit, short to ground or short to power at G solenoid circuit for
more than 2 seconds.


When DTC P2810 is active, the following conditions will occur:


Diagnostic Aids
• When this code is set there will be a noticeable reduction of engine performance.
• An intermittent circuit condition may allow this DTC to set. Make sure you check for the following conditions at
the OEM harness first and then at the transmission internal harness.
— A chafed wire.
harness to isolate an intermittent condition. Refer to Section 4—Wire Check Procedures.
• If the DTC appears to be temperature related, suspect a defective G solenoid. It is possible for a solenoid to be
temperature sensitive causing resistance values to fluctuate. This may cause an intermittent DTC to be set.
Test Description

7. This step tests for the proper resistance value at the G solenoid.


Troubleshooting
Process
(Paragraph 5–4A)
voltage. and P0563)
TCM.
command G solenoid to ON.
Is the voltage within the range specified when G
2. Disconnect J2 connector from TCM. NOTE: To allow
3. Using J 39700 Breakout Box and J 43799 for resistance of
Breakout Box Adapter Harness, connect only harness wire, add
to the J2 harness connector. See Beginning 0.1 Ohms per foot
the Troubleshooting Process, Page 5–4, of length for
Figure 5–2 for diagram of J 43799 adapter 18-gauge wire.
harness hook-ups.
and 32.


transmission.
Breakout Box Adapter, connect only to the
harness connector. See Beginning the
harness hook-ups.
4. Using a DVOM, measure resistance between
pins R and S at the magnetic overlay.
warranty.
2. Remove the connector from G solenoid. (Page 5–12)
3. Using a DMM, measure the resistance at the
solenoid.
9 Replace solenoid G. Refer to Service Manual or — Go to Step 11 —
Mechanic’s Tips.
(Section 3–6).
Replace the TCM.


failure records.
Did the DTC return?


DTC U0031 (Previously U1300) J1850 (Class 2) Serial Data Communication Link Low
TCM
(GRAY)
J2
J1-30 J1
J1850 PCM OR ECM

POWERTRAIN CONTROLLER MODULE
OR ENGINE CONTROLLER MODULE
TCM
J1850
PCM 130 CLASS II
or J1-30 J1850
DATA LINK
ECM
V07481.01.00
Circuit Description
Applications that employ J1850 class 2 serial communication use wire 130 to send operational information and
commands among the various control modules. Included modules would be Powertrain Control Module (PCM),
Antilock Brake System (ABS) Controller, Truck Body Controller (TBC), and Instrument Panel Cluster (IPC). Each
controller sends out a state of health (SOH) message approximately once every second. The TCM uses these SOH
messages to monitor the condition of the devices on the class 2 serial link.

The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than

DTC U0031 is set when low voltage is detected on the class 2 data circuit for more than 3 seconds. This would
normally indicate a short-to-ground at wire 130.

• The CHECK TRANS light does not illuminate.
• DTC U0031 is stored in the TCM history.
• TCM uses default values for missing/erroneous information.

TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. The TCM self-clears this DTC
when software detects a failure recovery has occurred.


Diagnostic Aids
• If communication can be established with the Scan Tool at the OBDII connector, then the U0031 should be
shown in failure records only. This may indicate that an intermittent short-to-ground was present at one time.
Refer to Appendix A—Identification of Potential Circuit Problems.
• It is not possible to communicate with J1850 with this DTC active.
• Use the J 43890 T-harness to communicate with the TCM to determine if the U0031 is still active.
• U0031 in failure records may be present along with a U1000–U1096 that is active. This would indicate that the
malfunction occurred when the ignition was ON.
• This code indicates that voltage is low at wire 130. Normally, this is an indication that a short-to-ground exists
at wire 130. Inspect wire 130 for this condition.
• Inspect wire 130 for poor electrical connections at the TCM. Look for the following conditions:
— A chafed wire.
• When this DTC is active an engine no–start condition may exist. Class 2 messages will not be sent to enable
the fuel pump and starter.
Test Description
2. This step checks engine data.

Step Action Yes No
Troubleshooting
Process
(Paragraph 5–4A)
2 1. Install the Scan Tool. Go to Diagnostic Go to Step 3
2. Turn the ignition ON with the engine OFF. Aids
3. Verify engine data is being communicated via J1850.
NOTE: U0031 is set when low voltage is detected on
the J1850 serial communication link by the TCM for a
time exceeding 3 seconds.This may indicate a short-
to-ground exists at wire 130.
Is engine data communicated to the Scan Tool?
3 Inspect wire 130 for a possible short-to-ground. Go to Step 4 Go to Step 5


Step Action Yes No
warranty.
5 Switch the current TCM with a known good unit. Check for Go to Step 6 —
proper communication. If this repairs the condition, reinstall
the “defective” TCM to verify the TCM failure and then
install a new TCM.
Did the DTC return?


DTC U0032 (Previously U1301) J1850 (Class 2) Serial Data Communication Link High
TCM
(GRAY)
J2
J1-30 J1
J1850 PCM OR ECM

TCM
J1850
PCM 130 CLASS II
or J1-30 J1850
DATA LINK
ECM
V07481.01.00
Circuit Description
commands among the various control modules. Included modules would be Powertrain Control Module (PCM),
Antilock Brake System (ABS) Controller, Truck Body Controller (TBC), and Instrument Panel Cluster (IPC). Each
controller sends out a state of health (SOH) message approximately once every second. The TCM uses these SOH
messages to monitor the condition of the devices on the class 2 serial link.
DTC U0032 is set when high voltage is detected on the class 2 data circuit for more than 3 seconds. This would
normally indicate a short-to-power at wire 130.



TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. The TCM self-clears this DTC
when software detects a failure recovery has occurred.
Diagnostic Aids
• If communication can be established with the Scan Tool at the OBDII connector, then the U0032 should be
shown in failure records only. This may indicate that an intermittent short-to-power was present at one time.
Refer to Appendix A—Identification of Potential Circuit Problems.
• It is not possible to communicate with J1850 with this DTC active.
• Use the J 43890 T-harness to communicate with the TCM to determine if the U0032 is still active.
• U0032 in failure records may be present along with a U1000–U1096 that is active. This would indicate that the
malfunction occurred when the ignition was ON.
• This code indicates that voltage is high at wire 130. Normally, this is an indication that a short-to-power exists
at wire 130. Inspect wire 130 for this condition.
— A chafed wire.
• When this DTC is active an engine no-start condition may exist. Class 2 messages will not be sent to enable
the fuel pump and starter.
Test Description
2. This step checks engine data.
DTC U0032 J1850 (Class 2) Serial Data Communication Link High

Step Action Yes No
Troubleshooting
Process
(Paragraph 5–4A)
2. Turn the ignition ON, with the engine OFF. Aids
3. Verify engine data is being communicated via J1850.
NOTE: U0032 is set when high voltage is detected on
the J1850 serial communication link by the TCM for a
time exceeding 3 seconds. This may indicate a short-
to-power exists at wire 130.
Is the engine data communicated to the Scan Tool?


DTC U0032 J1850 (Class 2) Serial Data Communication Link High (cont’d)
Step Action Yes No
3 Inspect wire 130 for possible short-to-power. Go to Step 4 Go to Step 5
warranty.
install a new TCM.
1. Inspect the Scan Tool. diagnosis again.
Did the DTC return?


DTC U0073 (Previously U2104) CAN Bus Reset Counter Overrun
ENGINE (ECM) TRANS (TCM) 9-PIN DDL

CONNECTOR D
J1939 J1939 E C
Data Data
Link Link F A B
G J
H
Pin ID
determined
SHIELD PIN D (–)

PIN C (+)
Attached to
PIN 31
PIN 29
PIN 32
PIN E
by Engine ECM via
OEM Deutsch/P Should not TERMINATION
triangle 3-pin exceed 1 meter RESISTOR
connector
SHIELD
SHIELD
SHIELD
131 GREEN
129 RED
120Ω 120Ω
RESISTOR SHIELD 132 SHIELD BLACK SHIELD RESISTOR
CONTROLLER AREA NETWORK (CAN)

Should not exceed 40 meters
SAE J1939-11 V06460.01.00
Circuit Description
J1939 is the protocol currently used in medium duty applications to allow communication between an
electronically-controlled engine and the Allison 1000 and 2000 Product Families transmission. A signal is sent over
a two-wire network harness that incorporates two 120 Ohm resistors in parallel. There are two versions of J1939
currently in use in the medium duty market. Version J1939-11, the most widely used, incorporates a third shield
wire. There is also J1939-15, which uses a two-wire connection without shielding.


DTC U0073 is set when the TCM detects no communication on the Controller Area Network (CAN) backbone
harness for 3 seconds or more. This may be due to a shorted wire to ground or power in the CAN backbone
harness.

• The TCM defaults to the last-used adaptive shift values and engine throttle percentage is calculated from
torque clip speed.


Diagnostic Aids
• If communication can be established at the vehicle nine-pin connector and U0073 is listed in failure records,
this indicates an intermittent short condition was present.
• When diagnosing for intermittent shorts-to-ground, massage the wiring harness while watching the test
equipment for a change. Refer to Section 4, Wire Check Procedures.
• If an active U0073 is present, Scan Tool communication will not be possible. The cause of the active DTC must
be discovered and repaired before communication can be established with the TCM.
• A short between wires 129 and 132 within the CAN harness can cause this DTC.
• A short between wires 129 and 131 within the CAN harness can cause this DTC.
• A short to a vehicle ground and wire 129 can cause this DTC.
• A short to vehicle power and wire 132 can cause this DTC.
— A chafed wire.
• For proper data communications it is necessary to have two 120 Ohm resistors installed in parallel at the J1939
CAN backbone harness.
• If this DTC is present in a new vehicle, harsh shifting may occur due to adaptive function inhibit (DNA).
Test Description
The number below refers to the step number on the diagnostic table.
3. This step inspects the CAN backbone harness for shorts-to-ground or power.
5. This step checks TCM function.
DTC U0073 CAN Bus Reset Counter Overrun

Step Action Yes No
Troubleshooting
Process
(Paragraph 5–4A)
2. Turn the ignition ON with the engine OFF. Aids
Is Scan Tool communication possible at the diagnostic
connector?


DTC U0073 CAN Bus Reset Counter Overrun (cont’d)
Step Action Yes No
3 1. Inspect wires 129 (positive), 132 (negative), 131 (shield) Go to Step 4 Go to Step 5
at engine and transmission connectors for a possible
shorting condition or terminal damage.
NOTE: No Scan Tool communication is possible when
this DTC is active.
2. This DTC indicates that a CAN bus hardware error has
occurred. This may indicate a short-to-power or ground
has occurred at the CAN bus wiring harness.
Was a wiring problem found?
4 NOTE: The vehicle OEM has responsibility for all Go to Step 7 Go to Step 4
warranty.
Repair the vehicle J1939 CAN wiring harness.
install a new TCM.
1. If communication is established with the Scan Tool, clear diagnosis again.
the DTC. Go to Step 1
Did the DTC return?


DTC U0100 (Previously U2105) CAN Bus ECM Error

CONNECTOR D
J1939 J1939 E C
Data Data
Link Link F A B
G J
H
Pin ID
determined
SHIELD PIN D (–)

PIN C (+)
Attached to
PIN 31
PIN 29
PIN 32
PIN E
by Engine ECM via
connector
SHIELD
SHIELD
SHIELD
131 GREEN
129 RED
120Ω 120Ω

SAE J1939-11 V06460.01.00
Circuit Description
J1939 is the protocol currently used in medium duty applications to allow communication between an
electronically-controlled engine and the Allison 1000 and 2000 Product Families transmission. A signal is sent over
a two-wire network harness that incorporates two 120 Ohm resistors in parallel. There are two versions of J1939
currently in use in the medium duty market. Version J1939-11, the most widely used, incorporates a third shield
wire. There is also J1939-15, which uses a two-wire connection without shielding.

DTC U0100 is set when the TCM detects that no engine torque or throttle messages are being received on the
Controller Area Network (CAN) backbone harness for 3 seconds or more.

• The TCM defaults to last-used adaptive shift values and engine throttle percentage is calculated from torque
converter slip speed.



Diagnostic Aids
• Often an active U0100 will prevent Scan Tool communication with the TCM. Install J1939 T-adapter harness
J 43890 to confirm that the TCM is operational. This harness is only useful to confirm that the TCM is able to
communicate with the Scan Tool. An active U0100 will be set whenever J 43890 is used.
• When Scan Tool communication with the TCM can be established at the nine-pin vehicle connector and the
U0100 is active, generally it points to an open connection at wires 129 or 132 at the ECM or a terminal in the
wrong location at the engine ECM connector.
• Engine ECM parameters improperly set can cause this DTC to set.
• A missing terminating resistor can cause this DTC to set. This will prevent Scan Tool communication with the
TCM or produce very erratic communication.
• If DTC U0100 becomes active shortly AFTER an engine update and the troubleshooting procedure for U0100
has been performed, see Resetting of TCM Parameters to Support Engine Update, Section 3–7.
— A chafed wire.
• When diagnosing for an intermittent open, massage the wiring harness while watching the test equipment for a
change. It may be necessary to check for opens at individual wires within a harness to isolate an intermittent
condition. Refer to Section 4, Wire Check Procedures.
• Intermittent cycling of the TCC could indicate a J1939 wiring problem exists. It is possible to have an open
condition at the CAN backbone harness allowing TCC to cycle without a U0100 setting. For a U0100 to set, an
open condition needs to be present for 3 seconds.
• For proper data communications, it is necessary to have two 120 Ohm resistors installed in parallel at the
J1939 CAN backbone harness.
• If this DTC is present in new vehicle, harsh shifting may occur due to adaptive function inhibit (DNA).
Test Description
3. This step inspects the CAN backbone harness for open conditions to ground or terminal damage.
5. This step tests the CAN backbone harness for the proper resistance value.
DTC U0100 CAN Bus ECM Error

Troubleshooting
Process
(Paragraph 5–4A)


DTC U0100 CAN Bus ECM Error (cont’d)
2. Turn the ignition ON, with the engine OFF. Aids
Is Scan Tool communication possible at the
diagnostic connector?
3 Inspect wires 129 (positive), 132 (negative), — Go to Step 4 Go to Step 5
and 131 (shield) at engine and transmission
connectors for a possible open condition or
terminal damage.
NOTE: This DTC indicates that the TCM is
not receiving engine information. This may
indicate an open condition has occurred at
the CAN bus wiring harness.
Was a wiring problem found?
4 NOTE: The vehicle OEM has Go to Step 7 —
responsibility for all external wiring
harness repair. Harness repairs
performed by Allison Transmission
distributors and dealers are not covered
by Allison Transmission warranty.
5 Using a DVOM, measure resistance between 60 Ohms Go to Step 6 Go to Step 7
pins C and D at the vehicle 9-pin diagnostic
connector.
Does the resistance match the specified value?
6 NOTE: A resistance reading other than — Go to Step 8 —
60 Ohms indicates that a terminating
resistor is missing or a resistor with an
improper value is installed. There should
be two 120 Ohm resistors wired in parallel
in the J1939 CAN.
Return the vehicle to the OEM for repair.
7 Return the vehicle to OEM for inspection of the — Go to Step 8 —
following:
1. Confirm that the engine ECM is properly set
to broadcast J1939 messages.
2. Improper pin location at the engine ECM.
3. Defective engine ECM.
1. If communication is established with the diagnosis again.
Scan Tool, clear the DTC. Go to Step 1
run.
Did the DTC return?


DTC U1000–U1096 Class 2 Controller State of Health Failure
TCM
(GRAY)
J2
J1-30 J1

ABS
J1850
PCM 130
or J1-30 TCM
ECM
IPC TBC
V07477.01.00
Circuit Description
commands among the various control modules. The control modules included are the Powertrain Control Module
(PCM), Antilock Brake System Controller (ABS), Truck Body Controller (TBC) and Instrument Panel Cluster (IPC).
Each controller sends out a state of health (SOH) message approximately once every second. The TCM uses
these SOH messages to monitor the condition of the devices on the class 2 serial link.
The following DTCs identify the specific controller noted:
DTC Number Control Module
U1000 Class II–Loss of Serial Data Communication
U1016 Powertrain Control Module (PCM)
U1041 Antilock Brake System Module (ABS)
U1064 Truck Body Controller Module (TBC)
U1096 Instrument Panel Cluster Module (IPC)
The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than


DTC U1000–U1096 is set when the TCM has not received a state of health (SOH) message from the Control
Module indicated for a period of time exceeding 2 seconds.

• DTC U1000–U1096 is stored in the TCM history.
• For U1016 only—the TCM freezes shift adapts (DNA).
TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring. The TCM self-clears the DTC
when the software detects a failure recovery has occurred.
Diagnostic Aids
• An intermittent open between a module and the connector node may cause this DTC to set.
• A poor connection at a module or the connector node may cause this DTC to set.
• An intermittent open in a connector node may cause this DTC to set.
• An open voltage or ground circuit to a module may cause this DTC to set.
• An internal module malfunction may cause this DTC to set.
Test Description
2. This step tests for proper power inputs at the indicated module.
3. This step tests for an open condition between the controller module and the connection at wire 130.
5. This step tests the module function per OEM procedures.
DTC U1000–U1096 Class 2 Controller State of Health Failure

Step Action Yes No
Process
(Paragraph 5–4A)
2 Test the following circuits of the module for an open or a Go to Step 6 Go to Step 3
short to ground:
1. The battery positive (fuses) and ground connections at
the module.
2. The ignition positive (fuses) and ground connections.
NOTE: The DTC set indicates the module for which the
state of health (SOH) message was not detected by the
TCM for a period of time exceeding 2 seconds. This
may indicate an open wire leading to the module, or a
defective module.


DTC U1000–U1096 Class 2 Controller State of Health Failure (cont’d)
Step Action Yes No
3 Inspect for opens at the connector and the wire connecting Go to Step 4 Go to Step 5
the module to the TCM (wire 130).
4 Repair the module class 2 wiring harness connection. Go to Step 6 —
NOTE: The vehicle OEM has responsibility for all
external wiring harness repairs. Harness repairs
dealers are not covered under Allison Transmission
warranty.
5 Refer to troubleshooting procedures specific to the Go to Step 6 —
controller module indicated.
Replace the module, if defective.
Is replacement or repair complete?
2. Use the Scan Tool, in the test passed section, to confirm Go to Step 1
Did the DTC return?

SECTION 6—INPUT AND OUTPUT FUNCTIONS
6–1. SPECIAL INPUT AND OUTPUT FUNCTIONS

Each transmission control system provides additional functional control of transmission and/or vehicle operations
tailored to the expected duty of the vehicle. Specific vocational requirements can be satisfied using input and
output functions. Although these features may be used independently to control the function of the TCM, they can
be combined to provide more comprehensive vehicle control functions. An example of the combined use of input
and output functions is the combination of control signals which automatically commands the transmission to
Neutral when a PTO is operated.
NOTE: Wiring diagrams for input and output functions are shown in Appendix N.
A. Input Functions
Input functions are control signals that send vehicle data to the TCM to designate the operating state of
other vehicle systems. “Ground input” control wires activate the programmed function when the input
wire is switched to an isolated circuit ground. “Power input” control wires activate the programmed
function when the input wire is switched to 12V or 24V power. Typical input functions are:
• Secondary Shift Schedule

• PTO Enable
• Auxiliary Function Range Inhibit
• Exhaust Brake and Preselect Request (Standard, Optional, and Special)
• Automatic Neutral for PTO
• Reverse Enable
• Kickdown
• Refuse Packer Step Switch
• Overdrive Disable
B. Output Functions
Output function signals send data from the TCM for use in controlling the operation of non-
transmission components. As determined by programmed logic or attainment of preselected
conditions, the TCM activates the appropriate output control wire (the circuit goes from OPEN to
GROUND). This energizes a customer-supplied relay or switch to complete the external vehicle
circuit.
The output functions may be turned on and off based on the state of the input function signals and the
operating state of the transmission. Typical output functions are:
• Sump Temperature Indicator

• Range Indicator
• Output Speed Indicator

INPUT AND OUTPUT FUNCTIONS
NOTES

SECTION 7—GENERAL TROUBLESHOOTING OF PERFORMANCE

COMPLAINTS
IMPORTANT:
Make the following general checks before beginning specific troubleshooting, removing the transmission, or
removing attached components.
• Are there active DTCs?
• Is the shift selector lever in N (Neutral), P (Park), or PB (Park Brake Apply) to allow starting the engine?
• Is the battery properly connected and charged?
• Is isolated battery properly connected (if used)?
• Is the fluid level correct?
• Is voltage to the TCM correct?
• Is the engine properly tuned?
• Is fuel flow to the engine correct?
• Are wheel chocks in place?
• Is air flow to the cooler and radiator unrestricted?
• Is the driveline properly connected?
• Are there signs of fluid leakage under the vehicle? What is the origination point?
• Are hydraulic connections correctly made and not leaking?
• Is vehicle acceleration from a stop changed?
• Are electrical connections correctly made?
• Are there any other obvious vehicle or transmission problems?
After making these general checks use the various sections of this manual to isolate the listed problems. The
following charts address specific vehicle complaints. Some complaints involve DTCs, so all troubleshooting checks
should involve checking the system for DTCs.

GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS
Table 7–1. Troubleshooting Performance Complaints
Problem Possible Cause Suggested Remedy
VEHICLE WILL NOT START — Lever shift selector not in Select N (Neutral) and restart
ENGINE WILL NOT CRANK N (Neutral) or P (Park) or
PB (Park Brake Apply)*
Dead battery Recharge battery
Disconnected battery* Reconnect battery
Faulty starter circuit Repair vehicle starter circuit
Faulty NSBU switch* Replace NSBU switch

(refer to Mechanic’s Tips)
Misadjusted NSBU switch* Adjust NSBU switch
Faulty wiring in vehicle neutral start Repair wiring

circuit*
Connectors not properly seated on Properly install connector

NSBU switch*
CHECK TRANS LIGHT WILL NOT TCM has logged a DTC Install Scan Tool to determine if
GO OUT AT START-UP DTC is present
A. Vehicle Drives Normally Faulty CHECK TRANS light, relay, Replace relay or repair circuit
or circuit.
B. Vehicle Does Not Drive Normally Bad or no calibration in TCM Calibrate TCM via PCCS
Vehicle cannot establish Repair J1939 backbone

communication with TCM
Faulty wiring harness Repair wiring harness (refer to
Section 4 and Appendix E)
Faulty TCM Replace the TCM
CHECK TRANS LIGHT FLASHES Intermittent power to TCM* Check input power to the TCM and
INTERMITTENTLY correct if necessary
Faulty vehicle wiring Repair vehicle wiring
Loose wiring to CHECK TRANS Repair wiring

light
Faulty or incorrect ground wire Repair ground circuit

attachment
Intermittent opening in Circuit 125 Repair Circuit 125
* See Inhibit Section 2–5


Table 7–1. Troubleshooting Performance Complaints (cont’d)
NO CHECK TRANS LIGHT AT Faulty light bulb or socket Replace light bulb or socket
IGNITION
Incorrect wiring to and from CHECK Repair wiring
TRANS light bulb (refer to Appendix E)
Faulty vehicle wiring Repair vehicle wiring
Circuit 125 open Repair Circuit 125
Faulty TCM Replace TCM
TRANSMISSION WILL NOT Engine rpm too high* Reduce engine rpm (it may be
SHIFT TO FORWARD OR necessary to reselect Neutral also,
REVERSE — STAYS IN and then D or R)
NEUTRAL
Low fluid level* Add fluid to correct level
(refer to Mechanic’s Tips for
proper dipstick calibration)
Faulty throttle sensor or circuit* See throttle sensor section for

installation and operation
information (Appendix F)
Faulty throttle signal from engine Correct engine throttle signal
Faulty or misadjusted shift selector* Repair or adjust shift selector
Faulty speed sensor or circuit* Repair circuit or replace speed

sensor(s) (refer to speed sensor
DTCs and Appendix E)
Mechanical failure to C5 clutch Repair transmission
Mechanical failure in transmission Repair transmission

torque converter, shafts, or
planetaries
Low main pressure* See Low Pressure Section
Faulty wiring in TCM Input/Output Correct circuit wiring

function circuits*
Auxiliary function range inhibit Correct circuit wiring

active*
Misadjusted NSBU switch* Adjust NSBU switch



TRANSMISSION WILL NOT STAY Faulty auto-neutral for PTO circuit Repair quick-to-neutral circuit
IN FORWARD OR REVERSE (input function)*
Low fluid level* Add fluid to correct level

Faulty solenoid — leaking* Replace solenoid

TRANSMISSION WILL NOT MAKE Low engine power Correct engine problem
A SPECIFIC SHIFT (refer to engine Service Manual)
Extreme fluid temperature Inspect cooling system and fluid
level

Faulty temperature sensor or circuit Check for temperature reading

which inhibits shifts
Incorrect calibration Install proper calibration
Faulty or misadjusted shift selector* Repair or adjust shift selector
TRANSMISSION DOES Engine idle speed too high (neutral Adjust engine idle speed
NOT SHIFT PROPERLY — to range shift)* (refer to vehicle Service Manual)
ROUGH SHIFTS, SHIFTS
OCCURRING AT TOO LOW Faulty throttle sensor or circuit* See throttle sensor section for
OR TOO HIGH SPEED installation and operation
information (Appendix F)
Faulty or sticking bleed ball in Replace C1 piston housing
C1 piston housing
Excessive clutch running Rebuild transmission and adjust

clearance* clearances
Incorrect TCM calibration Install correct calibration
Instrument panel tachometer Repair or replace tachometer

incorrect
Incorrectly calibrated electronic Calibrate electronic speedometer

speedometer

Degraded fluid Change transmission fluid and filter



TRANSMISSION DOES Loose speed sensor Tighten speed sensor retainer bolt
NOT SHIFT PROPERLY —
ROUGH SHIFTS, SHIFTS Incorrect fluid level* Correct fluid level
OCCURRING AT TOO LOW (refer to Mechanic’s Tips for
OR TOO HIGH SPEED (cont’d) proper dipstick calibration)
Intermittent problems* Check wiring harnesses and

connectors (refer to Appendix E)
Loose or damaged speed gear Replace speed gear

Sticking valves in control valve Overhaul control valve assembly
assembly*
Leaking trim solenoids* Repair or replace trim solenoids

(refer to Service Manual)
ABNORMAL TRANSMISSION
ACTIVITIES OR RESPONSES
A. Excessive Creep in First and Engine idle speed too high* Adjust engine idle speed
Reverse Gears (refer to vehicle Service Manual)
B. Vehicle Moves Forward in C1 clutch failed or not released* Rebuild C1 clutch assembly (refer
Neutral to transmission Service Manual)
C. Vehicle Moves Backward in C3 clutch failed or not released* Rebuild C3 clutch assembly (refer
Neutral to transmission Service Manual)
EXCESSIVE FLARE — TPS Adjustment:

ENGINE OVERSPEED ON FULL-
THROTTLE UPSHIFTS — Overstroke — Adjust TPS linkage for proper
stroke (refer to Appendix F)
— Loose — Tighten loose bolts or

connections
Incorrect fluid level* Correct fluid level

Sticking valves in control valve Rebuild control valve assembly

assembly*


EXCESSIVE FLARE — Leaking trim solenoids* Repair or replace trim solenoids

ENGINE OVERSPEED ON FULL- (refer to Service Manual)
THROTTLE UPSHIFTS (cont’d)
G solenoid mechanical failure Repair or replace trim solenoids

(refer to Service Manual)
Erratic speed sensor signal See speed sensor DTCs
Leaking piston seals or slipping Overhaul transmission (refer to

clutch plates in range involved* transmission Service Manual)
SHUDDER WHEN SHIFTING Intermittent short to ground at F Repair or replace wire 229
INTO FORWARD OR REVERSE (TCC) solenoid circuit (wire 229).
RANGE Could be accompanied by a
P0743—F solenoid electrical DTC.
It is possible to have this complaint
without a DTC setting on earlier
software.*
This complaint is worse with pre-
N04 software levels due to the
different hydraulic schedule.
Reverse range is not fully attainable
due to TCC valve application
blocking C5 feed circuit. This
causes the range inhibit light to
illuminate.
Faulty trim solenoid* Replace solenoid (refer to Service

Manual or Mechanic’s Tips)
Sticky trim valve* Rebuild control valve assembly

(refer to Service Manual or
Mechanic’s Tips)
C–1 or C-3 clutch failure* Repair transmission (refer to
Service Manual)
ABNORMAL STALL SPEEDS

(Stall In First Range — Fifth Range)
A. High Stall Speeds Not in gear Select D (Drive)
Low fluid level, aerated fluid* Add fluid to correct level

Faulty torque converter Replace torque converter
Incorrect torque converter Replace torque converter (refer to

transmission Service Manual)
Clutch pressure low* See Low Pressure Section and

Appendix B


ABNORMAL STALL SPEEDS C1 or C5 clutch slipping* Rebuild C1 or C5 clutch assembly

(Stall In First Range — Fifth Range) Note: Use the Scan Tool to check (refer to transmission Service
(cont’d) turbine speed Manual)
Engine too powerful Confirm proper engine match
B. Low Stall Speeds Engine not performing efficiently Repair engine (refer to engine
(may be due to plugged or Service Manual or vehicle Service
restricted injectors, high altitude Manual)
conditions, dirty air filters, out of
time, throttle linkage, electronic
engine controls problem)
Stall speeds 66 percent of normal Replace converter assembly (refer
implies freewheeling stator to transmission Service Manual)
Engine smoke controls Compare lugback vs. static stall

speed
Incorrect torque converter Install correct torque converter (refer

to transmission Service Manual)
OVERHEATING IN ALL RANGES Aerated fluid — incorrect fluid level* Correct fluid level, check for
defective pump (refer to Mechanic’s
Tips and transmission Service
Manual)
Air flow to cooler obstructed Remove air flow obstruction
Engine overheat Correct overheat situation (refer to

vehicle Service Manual)
Inaccurate temperature gauge or Replace gauge and/or sending unit

sending unit
Inaccurate sump temperature Replace Pressure Switch Manifold
sensor (PSM) or internal harness (refer to
Inadequate cooler sizing See vehicle OEM for specifications
Excessive cooler circuit pressure Check for plugged cooler, lines too
drop small, collapsed hose, too many
elbows in circuit
Transmission cooler lines reversed Connect cooler lines properly (oil

and water should flow in opposite
directions)
Fluid cooler lines restricted Remove restrictions, clean or
replace lines (refer to Vehicle
Service Manual)


OVERHEATING IN ALL RANGES Torque converter (wrong converter, Replace or repair converter
(cont’d) no lockup, stuck stator, or slipping assembly (refer to transmission
stator) Service Manual)
Note: Stuck stator will not allow
cool down in neutral
Cooler flow loss due to internal Overhaul transmission (refer to

transmission leakage transmission Service Manual)
INTERMITTENT NOISE — Low fluid level* Add fluid to correct level

BUZZING (refer to Mechanic’s Tips for
Air leak in oil suction screen Replace suction filter
canister* (refer to Mechanic’s Tips)
Clogged filter* Replace filter

Aerated fluid causes noisy pump* Correct fluid level

Low main pressure causes main See transmission Service Manual

regulator valve to oscillate*
LEAKING FLUID — Dipstick loose Tighten cap, replace if necessary

FILL TUBE AND/OR BREATHER
Breather stopped up — clogged Clean or replace breather (refer to

Fluid contaminated with foreign Drain and replace fluid. Locate and
liquid fix source of additional fluid (refer to
Dipstick or fill tube seal worn Replace seals or dipstick
Incorrect dipstick marking Calibrate dipstick

LEAKING FLUID — Faulty or missing seal at output Install new lip-type seal in rear of
TRANSMISSON OUTPUT flange transmission housing
Machine lead on output flange seal Replace flange

surface
Rear cover porosity Repair or replace cover


LEAKING FLUID — Flange worn at seal surface Replace flange

TRANSMISSON OUTPUT
(cont’d)
Insufficient seal around seal OD Replace seal

Damaged, missing, or loose output Replace and/or torque output flange

flange bolt bolts
LEAKING FLUID — Leaking front seal Replace front seal

TRANSMISSION INPUT (refer to Mechanic’s Tips)
Leaking manifold seal Replace manifold seal
Leaking front support bolt seals Replace bolt seals
Leaking converter Check converter seals, cracked

converter pump tangs, converter
cover, or converter housing
porosity; replace parts as required
(refer to transmission Service
Manual)
Leaking spin-on filter Replace filter

Leaking main pressure plug Replace or torque main pressure

plug
Worn pump bushing Rebuild and repair pump
DIRTY FLUID Failure to change fluid and filters Change fluid and install new filters
Excessive heat Check cooling system for
restrictions and proper capacity
Substandard fluid Use recommended fluid

Clutch/transmission failure* Overhaul transmission (refer to



RANGE CLUTCH TROUBLESHOOTING SECTION

EXCESSIVE SLIPPAGE AND Incorrect TCM calibration Install correct calibration
CLUTCH CHATTER
Throttle Position Sensor out of Adjust or replace throttle position

adjustment or failed* sensor (refer to Appendix F)
Incorrect speed sensor readings* See speed sensor DTCs


TCC clutch not applied Inspect lockup clutch system wiring,
pressure, and controls; repair as
necessary (refer to transmission
Service Manual and Appendix B)
A. Ranges 1, 2, 3, 4 Only C1 clutch slipping, leaks at rotating Inspect C1 clutch plates,

clutch seals, leaks at piston seals, piston seals, and rotating seals;
C1 clutch plates worn* replace/rebuild as necessary
Manual and Appendix B)
B. Ranges 4, 5 Only C2 clutch slipping, leaks at rotating Inspect C2 clutch plates,

clutch seals, leaks at piston seals, piston seals, and rotating seals;
C2 clutch plates worn* replace/rebuild as necessary
C. Ranges 3, 5, R Only C3 clutch slipping, leaks at piston Inspect C3 clutch plates and piston
seals, C3 clutch plates worn* seals; replace/rebuild as necessary
D. Range 2 Only C4 clutch slipping, leaks at piston Inspect C4 clutch plates and piston
E. Ranges 1, R Only C5 clutch slipping, leaks at piston Inspect C5 clutch plates and piston


LOW PRESSURE SECTION

A. Low or No Main Pressure Incorrect fluid level* Correct fluid level
in All Ranges (refer to Mechanic’s Tips for
Clogged or faulty oil filter element* Replace oil filter

Plugged or faulty suction filter* Clean or replace oil suction filter

element and refill the transmission
Sticking main pressure regulator Overhaul front support assembly

valve* (refer to transmission Service
Manual)
Leaking solenoids in control valve Repair or replace solenoids
assembly* (refer to Mechanic’s Tips)
G solenoid failure Replace G solenoid. See

transmission Service Manual.
Weak, broken, or missing main Check spring and replace if

pressure regulator valve spring* necessary (refer to transmission
Service Manual)
Control valve body leakage* Replace or rebuild control valve

(loose control valve body bolts) assembly. Care should be taken
when removing and labeling shift
springs (refer to transmission
Service Manual)
Faulty or incorrect fluid pressure Repair or replace gauge

gauge*
Worn or damaged oil pump* Replace or rebuild oil pump (refer to
Leak in suction circuit* Check suction circuit for leaking

seal, gasket, or mating surface
B. Low Main Pressure in Specific See transmission Service Manual

Ranges, Normal Pressure in
Other Ranges

NOTES

APPENDICES—INDEX
APPENDICES
Appendix A Diagnosing Intermittent DTCs
Appendix B Main Pressure Check Procedure
Appendix C Solenoid and Clutch Table
Appendix D Wire/Connector Table
Appendix E Connector Repair Information
Appendix F TPS Adjustment
Appendix G Welding on Vehicle
Appendix H Hydraulic Schematics
Appendix J Wiring Schematics
Appendix K Resistance vs. Temperature
Appendix L Electronic Interference
Appendix M Diagnostic Tool Information
Appendix N Input/Output Function Schematics
Appendix P Fluid Check Procedure
Copyright© 2004 General Motors Corp.

APPENDICES
NOTES

APPENDIX A—DIAGNOSING INTERMITTENT DTCS
Intermittent Diagnostic Trouble Codes (DTC) are a result of faults that are detected, logged, and then disappear,
only to recur later. If, when troubleshooting, a DTC is cleared in anticipation of it recurring and it does not, check the
items in the following list for the fault’s source.
A. Circuit Inspection
1. Intermittent power/ground problems — can cause voltage problems during TCM diagnostic checks
which can set various DTCs depending upon where the TCM was in the diagnostic process.
2. Damaged terminals.
3. Dirty or corroded terminals.
4. Terminals not fully seated in the connector. Check indicated wires by uncoupling connector and
gently pulling on the wire at the rear of the connector and checking for excessive terminal
movement.
5. Connectors not fully mated. Check for missing or damaged locktabs.
6. Screws or other sharp pointed objects pushed into or through one of the harnesses.
7. Harnesses which have rubbed through and may be allowing intermittent electrical contact between
two wires or between wires and vehicle frame members.
8. Broken wires within the braiding and insulation.
B. Finding an Intermittent Fault Condition

To find a fault, like one of those listed, examine all connectors and the external wiring harnesses. Harness
routing may make it difficult to see or feel the complete harness. However, it is important to thoroughly
check each harness for chafed or damaged areas. Road vibrations and bumps can damage a poorly
installed harness by moving it against sharp edges and cause some of the faults. If a visual inspection
does not identify a cause, move and wiggle the harness by hand until the fault is duplicated.
The next most probable cause of an intermittent DTC is an electronic part exposed to excessive vibration,
heat, or moisture. Examples of this are:
1. Exposed harness wires subjected to moisture.

2. A defective connector seal allows moisture to enter the connector or part.
3. An electronic part (TCM, solenoid, or throttle sensor) affected by vibration, heat, or moisture may
cause abnormal electrical conditions within the part.
When troubleshooting Item 3, eliminate all other possible causes before replacing any parts.
Another cause of intermittent DTCs is good parts in an abnormal environment. The abnormal environment
will usually include excessive heat, moisture, or voltage. For example, a TCM that receives excessive
voltage will generate a diagnostic code as it senses high voltage in a circuit. The DTC may not be repeated
consistently because different circuits may have this condition on each check. The last step in finding an
intermittent DTC is to observe if the DTC is set during sudden changes in the operating environment.
Troubleshooting an intermittent DTC requires looking for common conditions that are present whenever the
DTC is diagnosed. Use the failure record information from the scan tool to identify the conditions when the
DTC was set.
Copyright© 2004 General Motors Corp. A–1

APPENDIXAA—DIAGNOSING
APPENDIX — DIAGNOSINGINTERMITTENT
INTERMITTENTDTC
DTCSS
C. Recurring Conditions
A recurring condition might be:
• Rain
• Outside temperature above or below a certain temperature
• Only on right-hand or left-hand turns
• When the vehicle hits a bump, etc.
If such a condition can be related to the DTC, it is easier to find the cause. If the time between DTC
occurrences is very short, troubleshooting is easier than if it is several weeks or more between DTC
occurrences.
• Repair parts for the internal wiring harness will be available through the Allison Transmission Parts
Distribution Center (PDC). Use the P/N from your appropriate parts catalog or from Appendix E in
this manual. Allison Transmission is responsible for warranty on these parts.
through the vehicle OEM and the OEM is responsible for warranty on these parts.
A–2 Copyright© 2004 General Motors Corp.

APPENDIX B—MAIN PRESSURE CHECK PROCEDURE
Checking main pressures helps to determine if a transmission malfunction is due to a mechanical or an electrical
problem. Properly making these pressure checks requires transmission and vehicle (or test stand) preparation,
recording of data, and comparing recorded data against specifications provided.
MAIN PRESSURE TAP
BOTTOM VIEW
V05742
Figure B–1. Main Pressure Check Point
Observe safety precautions during hydraulic pressure check procedures. All

personnel must stand clear of the vehicle. Take precautions against movement of the
WARNING! vehicle. Be sure that gauges (vacuum, pressure, tachometer) have extended lines so
that they can be read from inside the vehicle.
1. All transmission fluid level and pressure checks must be made at normal operating temperatures
71–93°C (160–200°F) sump; 82–104°C (180–220°F) converter-out. Check transmission fluid level.
2. Connect a 0–2070 kPa (0–300 psi) oil pressure gauge at the main pressure tap (Figure B–1). Use
the scan tool to check engine rpm. See Table B–1 for main pressure levels.
3. Disconnect the driveshaft.
4. With brakes applied, check main pressure with the engine running at 2100 rpm and 600 rpm.
5. Continue the procedure for all ranges.
Copyright© 2004 General Motors Corp. B–1

APPENDIX B—MAIN PRESSURE CHECK PROCEDURE
Table B–1. Main Pressure Test Conditions
(Used Prior To S/N 6310004116)
Forward (Converter — Torque

800–1380 kPa (115–200 psi) 1515–1795 kPa (220–260 psi)
Converter Clutch not applied)

— 1000–1170 kPa (145–170 psi)
Clutch Applied)
(Used Starting With S/N 6310004116)

— 1000–1170 kPa (145–170 psi)
Clutch Applied)
Table B–2. Modulated Main Pressure Schedule (Transmissions with Modulated Main G Solenoid)

Forward/Reverse Converter with
590–720 kPa (85–105 psi) 634–758 kPa (92–110 psi)
G Solenoid Active
Forward Converter with G Solenoid Inactive 700–1380 kPa (101–200 psi) 1515–1795 kPa (220–260 psi)
Forward Lockup with G Solenoid Active* — 510–627 kPa (74–91 psi)
Forward Lockup with G Solenoid Inactive* — 1000–1170 kPa (145–170 psi)
Neutral/Park with G Solenoid Active 590–720 kPa (85–105 psi) —
B–2 Copyright© 2004 General Motors Corp.

APPENDIX C—SOLENOID AND CLUTCH TABLE
Normal operation of the transmission requires application of two clutches to attain a forward or reverse range. A
unique combination of solenoid and shift valve actuation produces clutch application in a given range. Table C–1
lists the transmission range shifts, the clutches that are applied in each range, and the electrical state (On/Off) of
each solenoid for each range.
C–1. Solenoid and Clutch Table — Software Levels Prior To N04
Clutch Trim Solenoids Shift Solenoids TCC Sol

Range Status Logic To Main A B C D E F
C3 Applied C5 Applied
Garage Shift R–N — De-energizing; Energizing; ON ON ON OFF
Garage Shift N–R — Energizing; Energizing; ON ON ON OFF
C5 Applied — Exhausted
C3 Exhausted C4 Applied OFF *
Steady State 5 C2 De-energized; De-energized; OFF OFF ON ON
C3 Applied
* Depending upon output speed
Copyright© 2004 General Motors Corp. C–1

APPENDIX C—SOLENOID AND CLUTCH TABLE
Table C–1. Solenoid and Clutch Table — Software Level N04 And Later
Clutch Trim Solenoids Shift Solenoids TCC Sol

Range Status Logic To Main A B C D E F
with Throttle C3 Applied C5 Applied
Steady State R — De-energized; Energized; OFF ON ON OFF
at Closed C5 Applied C3 Applied
Throttle
Garage Shift R–N — De-energizing; Energized; OFF ON ON OFF
Garage Shift N–R — Energizing; Energizing; OFF ON ON OFF
C5 Applied — Exhausted
C3 Exhausted C4 Applied OFF **
C3 Applied
Beginning with N04 software level, the following throttle-dependent conditions occur in Reverse range:
At closed throttle (idle), C solenoid is OFF, A trim solenoid controls C-5 clutch, and B solenoid controls C-3 clutch.
Above 20 percent throttle*, C solenoid is ON, A trim solenoid controls C-3 clutch, and B solenoid controls C-5.
Under 10 percent throttle*, the TCM reverts to the closed throttle (idle) schedule.
* Values are calibration dependent ** Depending upon output speed
C–2 Copyright© 2004 General Motors Corp.

APPENDIX D—WIRE/CONNECTOR TABLES
The connector information in this appendix is provided for the convenience of the servicing technician. The
connector illustration and pin identifications for connection to Allison Transmission components will be accurate.
Allison Transmission components are the TCM, speed sensors, and transmission connectors. Other kinds of
connectors for optional or customer-furnished components are provided based on typical past practice for an
Allison-designed system.
Contact your vehicle manufacturer for information on connectors not found in this appendix.
Copyright© 2004 General Motors Corp. D–1

COLOR CODE RED
16 1
32 17
V06211
Figure D–1. TCM Connector J2

TCM CONNECTOR J2 (RED)
Terminal No. Color Wire No. Description Termination Point(s)
1 Blue 201 PSM Input TRANS-D
2 Pink 202 PSM Input TRANS-F
3 White 203 PSM Input TRANS-E
4 Green 204 PSM Input TRANS-K
5 Blue 205 NSBU Input NSBU-4A
6 Yellow 206 NSBU Input NSBU-4D
7 Gray 207 NSBU Input NSBU-4B
8 White 208 NSBU Input NSBU-4C
9 Blue 209 Throttle Position Sensor TPS-B
10 Tan 210 Sump Temperature Input TRANS-G
11 Orange 211 Retarder Temperature Input RTEMP-A
(optional)
12 Blue 212 Engine Coolant Temperature Input ENGWAT TEMP-A
(optional)
13 Orange 213 Turbine Speed Sensor High NT-A
14 Blue 214 Turbine Speed Sensor Low NT-B
15 Yellow 215 Output Speed Sensor High NO-A
16 Green 216 Output Speed Sensor Low NO-B
17 Tan 217 Engine Speed Sensor High NE-A
18 Orange 218 Engine Speed Sensor Low NE-B
19 Pink 219 Sensor Power TPS-C
20 Green 220 Analog Ground TRANS-H, R-TEMP-B, ENG-WAT
TEMP-B, NSBU-7D, TPS-A
21 Yellow 221 TRANS-T
22 Yellow 222 A Solenoid High (VBS) Variable TRANS-L
Bleed Solenoid
23 White 223 A Solenoid Low (VBS) Variable TRANS-M
Bleed Solenoid
24 Pink 224 B Solenoid High (VBS) Variable TRANS-N
Bleed Solenoid
25 Orange 225 B Solenoid Low (VBS) Variable TRANS-P
Bleed Solenoid
26 Green 226 C Solenoid Low (ON/OFF) TRANS-A
27 Blue 227 D Solenoid Low (ON/OFF) TRANS-B
28 Gray 228 E Solenoid Low (ON/OFF) TRANS-W
29 White 229 F Solenoid Low (PWM) TRANS-J
30 Blue 230 G Solenoid Low (ON/OFF) TRANS-R
31 Tan 231 ON/OFF Solenoid High TRANS-C
32 Green 232 PWM Solenoid High/G Solenoid TRANS-S
D–2 Copyright© 2004 General Motors Corp.
COLOR CODE GRAY
16 1
32 17
V06212
Figure D–2. TCM Connector J1
TCM CONNECTOR J1 (GRAY)

1 Gray 101 Battery Ground Vehicle System
2 Yellow 102 Ignition Power Vehicle System
3 Pink 103 Battery Power Vehicle System
4 Yellow 104 Ignition Power Vehicle System
5 Gray 105 Battery Ground Vehicle System
6 Blue 106 GPI 1 Vehicle System
7 Orange 107 GPI 2 Vehicle System
8 Green 108 GPI 3 Vehicle System
9 White 109 GPI 4 Vehicle System
10 Yellow 110 GPI 5 Vehicle System
11 Green 111 GPI 6 Vehicle System
12 Blue 112 GPI 7 Vehicle System
13 Pink 113 GPI 8 Vehicle System
14 Orange 114 GPI 9 Vehicle System
15
16 White 116 PWM Throttle Vehicle System
17 Pink 117 Sensor Power (optional) RMR-C
18 Green 118 Analog Ground RMR-A
19 Tan 119 GPO 1 Vehicle System
20 Orange 120 GPO 2 Vehicle System
21 White 121 GPO 3 Vehicle System
22 Blue 122 GPO 4 Vehicle System
23 Pink 123 Range Inhibit Indicator Vehicle System
24 White 124 GPO 6 Vehicle System
25 Green 125 CHECK TRANS Vehicle System
26 Tan 126 Vehicle Speed Vehicle System
27 Pink 127 Vehicle Speed Vehicle System
28 Yellow 128 Digital Ground Vehicle System
29 Red 129 CAN High J1939 A or H
30 Blue 130 ISO 9141 Class II J-1850 Vehicle System
31 Green 131 CAN Shield J1939 C or S
32 Black 132 CAN Low J1939 B or L

TRANSMISSION HARNESS TRANSMISSION BULKHEAD

CONNECTOR CONNECTOR
S K K S
D R
R D
W W
COLOR CODE GREEN
HARNESS DEVICE
T A A
L E E L T
NOTE: Letters I, O, and Q not used V03369.01.00
Figure D–3. Delphi-Packard Main Transmission Connector
DELPHI-PACKARD MAIN TRANSMISSION CONNECTOR

Terminal No.* Color Wire No. Description Termination Point(s)*
A Green 226 C Solenoid Low (ON/OFF) TCM J2-26
B Yellow/Black 227 D Solenoid Low (ON/OFF) TCM J2-27
C Pink 231 ON/OFF Solenoid High TCM J2-31
D Light Green 201 PSM Input TCM J2-1
E Red 203 PSM Input TCM J2-3
F Dark Blue 202 PSM Input TCM J2-2
G Yellow 210 Sump Temperature Input TCM J2-10
H Black 220 Analog Ground TCM J2-20
J Brown 229 F Solenoid Low (PWM) TCM J2-29
K Tan 204 PSM Input TCM J2-4
L Red/Black 222 A Solenoid High Variable Bleed TCM J2-22
Solenoid (VBS)
M Light Blue 223 A Solenoid Low Variable Bleed TCM J2-23
Solenoid (VBS)
N Gray 224 B Solenoid High Variable Bleed TCM J2-24
Solenoid (VBS)
P Purple 225 B Solenoid Low Variable Bleed TCM J2-25
Solenoid (VBS)
R Blue 230 G Solenoid Low (ON/OFF) TCM J2-30
S Black 232 PWM Solenoid High/F, G Solenoid TCM J2-32
T White 221 TCM J2-21
U Dark Green — — —
V Dark Green — — —
W Black/White 228 E Solenoid Low (ON/OFF) TCM J2-28
* Terminal number and termination points shown only apply when an Allison Transmission recommended harness
configuration and bulkhead connector are used.
PIN A PIN B
B A
RECEPTACLE
PLUG
V05738
Figure D–4. Speed Sensor Connector
ENGINE SPEED SENSOR CONNECTOR

A Tan 217 Engine Speed Sensor Hi TCM J2-17
B Orange 218 Engine Speed Sensor Lo TCM J2-18
TURBINE SPEED SENSOR CONNECTOR

A Orange 213 Turbine Speed Sensor Hi TCM J2-13
B Blue 214 Turbine Speed Sensor Lo TCM J2-14
OUTPUT SPEED SENSOR CONNECTOR

A Yellow 215 Output Speed Sensor Hi TCM J2-15
B Green 216 Output Speed Sensor Lo TCM J2-16

A C
PIN C PIN B PIN A

B
PLUG
RECEPTACLE
V05739
Figure D–5. TPS Connector
THROTTLE POSITION SENSOR CONNECTOR

A Green 220 Analog Ground TCM J2-20
B Blue 209 TPS Signal TCM J2-9
C Pink 219 TPS Hi TCM J2-19

A or H B or L
B or L C or S A or H C or S
MALE CONNECTOR FEMALE CONNECTOR
V06532
Figure D–6. J1939 Interface Connector
J1939 INTERFACE CONNECTOR

J1939 Connector TCM Connector
Terminal No. Color Wire No. Description Terminal No. Color
A or H Yellow 129 J1939 Controller, High TCM J1-29 Red
B or L Green 132 J1939 Controller, Low TCM J1-32 Black
C or S Uninsulated 131 J1939 Shield/Ground TCM J1-31 Green

PIN 7A PIN 7G
4C
7G 7A 4A
4D PIN 7E
PIN 7D
4B
7E 7D
7-WAY RECEPTACLE 4-WAY RECEPTACLE PIN 4C

PIN 4A
PIN 4D
PIN 4B
PLUG
V05740
Figure D–7. NSBU Switch Connectors
NSBU SWITCH CONNECTOR

4A Blue 205 NSBU Output TCM J2-5
4B Gray 207 NSBU Output TCM J2-7
4C White 208 NSBU Output TCM J2-8
4D Yellow 206 NSBU Output TCM J2-6
7A — — — —
7B Tan — NSBU Input Park Accessory
7C Blue — NSBU Output Reverse and Park
Accessory Feed
7D Green 220 Analog Ground TCM J2-20
7E Yellow — NSBU Output Park and Neutral Start
Feed
7F Pink — NSBU Input Reverse Lamps
7G Orange — NSBU Input Starter Solenoid/Starter
Relay

PIN 12
12
PIN 11
6
11
PIN 6
PIN 7
3
PIN 3 7
PIN 1
PIN LOCATION ON
NSBU SWITCH
CONNECTOR
END VIEW
SINGLE CONNECTOR
NILES NSBU SWITCH
(P/N 29541852) V08100.00.00
Figure D–8. Single Connector NSBU
NSBU SWITCH CONNECTOR

1 Orange — NSBU Input Starter Solenoid/Starter
Relay
2 and 3 — — — —
4 Yellow 206 NSBU Output TCM J2-6
5 Blue 205 NSBU Output TCM J2-5
6 Gray 207 NSBU Output TCM J2-7
7 Green 220 Analog Ground TCM J2-20
8 White 208 NSBU Output TCM J2-8
9 — — — —
10 Pink — NSBU Input Reverse Lamps
11 Blue — NSBU Output Reverse and Park
Accessory Feed
12 Yellow — NSBU Output Park and Neutral Start
Feed

D
E
C
F A B
J
G
H
9-PIN
V06481
Figure D–9. Deutsch DDR Connector
SAE STD 9-PIN DIAGNOSTIC (J1939 DIAGNOSTIC LINK) CONNECTOR

A Determined By OEM — Battery Ground (–) Vehicle System
B Determined By OEM — Ignition Power (+) Vehicle System
B (Optional) Determined By OEM — Battery Power (+) Vehicle System
C Yellow 129 J1939 High J1939 Backbone A
D Green 132 J1939 Low J1939 Backbone B
E Uninsulated 131 J1939 Shield/Ground J1939 Backbone C
F Determined By OEM — Serial Communication (+) Vehicle System
G Determined By OEM — Serial Communication (–) Vehicle System

SOL C
13 mm EXTENSION
PSM
SOL G
MAIN
TRANSMISSION
CONNECTOR
SOL A
SOL B
SOL E
SOL D
SOL F V05732.01.02
Figure D–10. Transmission Internal Harness
TRANSMISSION INTERNAL HARNESS CONNECTORS

Main Connector
Connector Name Connector Pin No. Pin No. Wire Color TCM Pin No.
Solenoid A 1 M Light Blue J2–23
2 L Red/Blk Strp J2–22
Solenoid B 1 N Gray J2–24
2 P Purple J2–25
Solenoid C A C Pink J2–31
B A Dark Green J2–26
Solenoid D A C Pink J2–31
B B Yellow/Blk Strp J2–27
Solenoid E A C Pink J2–31
B W Black/Wht Strp J2–28
Solenoid F A S Black J2–32
B J Brown J2–29
Solenoid G A S Black J2–32
B R Orange J2–30
Pressure Switch Manifold A D Light Green J2–1
B F Dark Blue J2–2
C E Red J2–3
D K Tan J2–4
E G Yellow J2–10
F H,T (Trans ID) Blk (H), White (T) J2–20, J2–21

NOTES

APPENDIX E—CONNECTOR REPAIR INFORMATION
Contents Page
List of Special Tools Required To Service 1000 and 2000 Product Families Wiring Harnesses . E–2
1–1. Delphi-Packard Micro Pack 100W Connectors (TCM J1 and J2, Main Transmission E–5
Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–2. Delphi-Packard Metri-Pack 150 Series Connectors — Pull-to-Seat (Speed Sensors) . . . . . . . . . E–9
1–3. Delphi-Packard Metri-Pack 150 Series Connectors — Push-to-Seat (NSBU Switch). . . . . . . . . . E–13
1–4. Internal Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–16
1–5. Delphi-Packard WeatherPack Connectors (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–19
1–6. Deutsch IPD/ECD (J1939 Diagnostic 9-Way Connector Link Connector). . . . . . . . . . . . . . . . . . . E–23
1–7. Deutsch DT Series Connectors (3-Way J1939 Connector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–27
1–8. Repair of a Broken Wire with In-Line Butt Splice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–29
1–9. List of 1000 and 2000 Product Families Connector Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–31
through the vehicle OEM and the OEM is responsible for warranty on these parts.
Copyright© 2004 General Motors Corp. E–1

List Of Special Tools Required To Service 1000 and 2000 Product Families Wiring Harnesses
Tool Number Tool Type Paragraph Reference

23046604 Splice, Sealed (14–16 AWG) 1–8
23046605 Splice, Sealed (18–22 AWG) 1–8
J 25070 Heat Gun 1–8
J 34182 Crimper 1 1–6, 1–7
J 34513 Remover 1 1–6
J 35123 Crimper (Alternate) 1–2, 1–3
J 35606 Crimper (Alternate) 1–5
J 35615 Wire Stripper 1 1–2, 1–3, 1–8
J 35689-A Remover 1–2, 1–3
J 38125-10 Remover 1–5
J 38125-6 Crimper 1–5
J 38125-7 Crimper 1–2
J 38125-8 Crimper 1–8
J 38582-3 Remover 1–6
J 38852 Crimper (Alternate) 1–5
J 39227 Remover 1–1
J 41194 Extractor/Inserter 1–6
J 42215 Crimper 1–1
E–2 Copyright© 2004 General Motors Corp.

RETAINER
SOCKET TERMINAL (FEMALE)
CONNECTOR
TYPICAL WIRE
SEAL
LOCKTAB (SECURES
RETAINER)
TERMINAL LOCKING
FINGER
LOCKING POST
STRAIN RELIEF
LOCKTABS
CAVITY PLUG
Lock terminal
here
SOCKET TERMINAL
WIRE
J 42215 CRIMPING TOOL

V03419
Figure E–1A. Delphi-Packard Micro Pack Connector (TCM J1 and J2)

J 39227
REMOVAL
TOOL
MATING CONNECTOR
WITH FEMALE (SOCKET)
TEMINALS
SECONDARY LOCK
VIEW A
LOCKING
FINGERS WIRE
WIRE SEAL
VIEW A
CAVITY PLUG
CONDUIT CLIP
SOCKET
TERMINAL
Lock terminal here

PIN TERMINAL
WIRE
J 42215 CRIMPING TOOL

V05743
Figure E–1B. Delphi-Packard Micro Pack Connector (Main Transmission Connector)

1–1. DELPHI-PACKARD MICRO PACK 100W CONNECTORS

(TCM J1 AND J2, MAIN TRANSMISSION CONNECTOR)
A. Connector/Terminal Repairs
Required Tools
Crimping Tool J 42215
Remover Tool J 39227
Use Description Manufacturers P/N
Main Transmission Connector Connector, 20F MIC/P 100W Gray 12160280
Lock, Secondary 20F Green 12160494
Terminal, Socket 100W 12084912
Cavity Plug, 100W 12129557
Conduit Clip, 13mm Black 12176394
B. Terminal Removal
1. TCM Harness Connectors (Figure E–1A)
a. Use a small-bladed screwdriver to gently release the locktabs at the splitline of the strain relief.
b. Spread the strain relief open.
c. Remove the retainer from the connector by using a small-bladed screwdriver to depress the
locktabs on the side of the connector.
d. Remove a selected terminal by pushing forward on the wire or by lifting the locking finger and
pulling the wire and terminal rearward out of the connector.
2. Main Transmission Connectors (Figure E–1B)
a. Use a small bladed screw driver to gently release the locktabs at the split line of the conduit
clamp.
b. Remove conduit clamp.
c. Use a small-bladed screw driver to gently release the locktab remove the lock assembly.
d. Remove a selected terminal by pushing forward on the wire or by lifting the locking finger and
pulling the wire and terminal rearward out of the connector.
C. Terminal Crimping
1. Carefully strip 5.0 mm ±0.5 mm (0.20 ±0.02 inch) of insulation from the end of the wire.
2. Insert the new terminal to be crimped in the J 42215 crimping tool. There is a spring-loaded
terminal positioner at the front of the tool to hold the terminal in place. Squeeze the crimper
handles for a few clicks to start the crimping process but leave room to insert the wire end.
3. Insert the bare wire end into the terminal. Squeeze the crimper handles to complete the crimping
process and until the crimper handles open when released to remove the terminal/wire from the
tool.

C. Terminal Crimping (cont’d)

4. Complete terminal installation for Main Transmission Connector as follows: (Figure E–1B)
a. Insert the wire seal in the back of the connector.
b. Push the terminal/wire assembly through the proper hole in the back of the wire seal. Push the
wire in until the terminal clicks into position. Gently pull rearward on the wire to be sure that the
terminal is fully seated. Install cavity plugs as needed.
c. Install the lock assist or secondary lock into the connector body.
d. Close the conduit clip around the conduit and lock the clip into the rear of the connector body.
5. Complete terminal installation of the TCM Connectors as follows: (Figure E–1A)
a. Align the locking posts on the connector with the seal and push the locking posts through the
seal into the mating holes in the strain relief (if the connector was removed from the strain
relief).
b. Push the terminal/wire assembly through the proper hole in the back of the seal. Push the wire
in until the terminal clicks into position.
NOTE: All terminals must be properly positioned to install the retainer in Step (5c).
c. Install the retainer on the connector body to lock the terminals in position. Pull gently on the wire
to be sure that the terminal is fully seated. Install cavity plugs as needed.
d. Position the conduit inside the strain relief and snap the strain relief halves together.

NOTES

RETAINER Seal plug

butts up here
CONNECTOR
Remove in J 35689-A
this direction
Seat in
WIRE AND this direction
TERMINAL
Insertion of removal tool (J 35689-A) forces

lock tang toward body of terminal
VIEW A
Butt wire against terminal holder
Use wire gauge 18-16 slot
WIRE SIDE
18-16
22-20
E
C
A
J 38125-7
D
TERMINAL
B
VIEW B
Push lock to insert
terminal end
J 35123
WIRE SIDE
TERMINAL HOLDER
18-16
22-20
VIEW C V05744
Figure E–2. Delphi-Packard Metri-Pack 150 Series Connectors — Pull-to-Seat

(Speed Sensors)

1–2. DELPHI-PACKARD METRI-PACK 150 SERIES CONNECTORS — PULL-TO-SEAT

(SPEED SENSORS)
Required Tools
Crimping Tool J 38125-7
Wire Crimp Anvil “E”
Insulation Crimp Anvil “C”
Alternate Crimping Tool J 35123
Remover Tool J 35689-A
Automatic Wire Stripper J 35615
Engine Speed (Ne) Sensor Connector 12162193
Terminal 12103881
Turbine Speed (Nt) Sensor Connector 12162193
Terminal 12103881
Output Speed (No) Sensor Connector 12162193
Terminal 12103881
B. Terminal Removal
NOTE: Do not solder crimps.
1. Insert the needle end of terminal remover J 35689-A into the small notch between the connector
and the terminal to be removed (Figure E–2, View A). Push the lock tang toward the terminal.
2. Push the wire and terminal out of the connector (this is a “pull-to-seat” terminal).
3. Pull the terminal as far as necessary from the connector. This will be limited by the number of other
wires inserted into the connector and by the distance between the back side of the connector and
the beginning of the harness covering.
4. If a terminal is to be replaced, cut the terminal between the core and the insulation crimp to
minimize wire loss.
C. Terminal Crimping — Speed Sensor Terminals (Standard Crimping Tool)

1. If a spare wire is used, the wire should be pushed through the proper hole in the strain relief
(if used), through the wire seal, and out the other side of the connector before stripping.
2. Carefully strip 4.5 mm ±0.5 mm (0.18 ±0.02 inch) of insulation from the end of the wire. Unless the
insulation crimp is overtight, Automatic Wire Stripper J 35615 will remove the insulation and crimp
from an old terminal without damaging the wire.
3. Place the core crimp portion of the terminal on the bed of anvil “E” and squeeze the crimper
enough to keep the terminal from dropping (Figure E–2, View B).
4. Position the wire core in the terminal and squeeze the crimper tool to complete the core crimp.
Be sure to orient the terminal so that it is properly aligned with the terminal cavity in the
connector. The terminal should be positioned so that the lock tang is on the side of the cavity
which has the notch in the middle (for the remover tool).

C. Terminal Crimping — Speed Sensor Terminals (Standard Crimping Tool) (cont’d)

5. Position the insulation crimp of the terminal on anvil “C” so that the entire insulation crimp area and
a portion of the terminal between the core and insulation crimp areas are supported by the anvil.
Complete the insulation crimp.
6. Be sure the lock tang is lifted to allow proper reseating of the terminal.
7. Pull on the wire to pull the terminal completely into the cavity. (A click will be heard and the
terminal should stay in place if the wire is pushed.)
D. Terminal Crimping Using Alternate Tool J 35123

1. If a spare wire is used, the wire should be pushed through the proper hole in the strain relief (if
used) and the wire seal, and out the other side of the connector prior to stripping.
2. Insert the remover tool in the front side of the connector to release the locktab, and push the
terminal out the front of connector. Pull the terminal and wire out the front of the connector to
complete Steps (3) through (7).
3. Push open the terminal holder on the crimper tool J 35123 and insert a terminal into the opening
marked 18–16 (Figure E–2, View C) so that the crimp ends point up. Release the terminal holder.
4. Slightly close the crimping tool (close until one click is heard) but do not start to crimp the terminal.
Place the terminal on the wire so it is in the same position as it will be when pulled back into the
connector. The terminal should be positioned so that the lock tang is on the side of the cavity which
has the notch in the middle (for the remover tool).
5. Insert the wire into the terminal until the wire contacts the holder. (By doing this, the core and
insulation should be properly positioned for the core and insulation crimp wings.)
6. Squeeze the crimper fully until it opens when released.
7. Open the terminal holder and remove the wire and terminal from the crimping tool.
8. Pull on the terminal to assure a tight crimp.
10. Pull on the wire to pull the terminal completely into the cavity. (A click will be heard and the ter-
minal should stay in place if the wire is pushed.)

NOTES

Install in
this direction
SECONDARY LOCK
Remove in
this direction
WIRE AND TERMINAL
Insertion of removal tool (J 35689)

forces lock tang toward body
D of terminal
B
A
C
J 35689-A
VIEW A
Butt wire against

terminal holder
Use wire gauge

18-16 slot
WIRE SIDE
E
C
A
J 38125-7
18-16
22-20
D
B
VIEW B TERMINAL
Push lock to
insert terminal
end
J 35123
WIRE SIDE
TERMINAL
HOLDER
18-16
22-20
VIEW C V05745
Figure E–3. Delphi-Packard Metri-Pack 150 Series Connectors — Push-to-Seat (NSBU Switch)

1–3. DELPHI-PACKARD METRI-PACK 150 SERIES CONNECTORS — PUSH-TO-SEAT

(NSBU SWITCH)
Required Tools
Crimping Tool J 38125–7
Wire Crimp Anvil “E”
Insulation Crimp Anvil “C”
Alternate Crimping Tool J 35123
Remover Tool J 35689–A
Automatic Wire Stripper J 35615
NSBU Switch 4 Way Tower Connector 12191757
Wire Type Seal, Dk Red 12048086
150f Terminal 12048074
B. Terminal Removal
NOTE: Do not solder crimps.
1. Remove the secondary lock.

2. Insert the needle end of terminal remover J 35689-A into the small notch between the connector
and the terminal to be removed (Figure E–3, View A). Push the lock tang toward the terminal.
3. Pull the wire and terminal out the rear of the connector (this is a “push-to-seat” terminal).
4. Pull the terminal as far as necessary from the connector. This will be limited by the number of other
wires inserted into the connector and by the distance between the back side of the connector and
the beginning of the harness covering.
minimize wire loss.
C. Terminal Crimping
1. Carefully strip 4.5 mm ±0.5 mm (0.18 ±0.02 inch) of insulation from the end of the wire. Unless the
insulation crimp is overtight, Automatic Wire Stripper J 35615 will remove the insulation and crimp
from an old terminal without damaging the wire.
2. Place the core crimp portion of the terminal on the bed of anvil “E” and squeeze the crimper
enough to keep the terminal from dropping (Figure E–3, View B).
3. Position the wire core in the terminal and squeeze the crimper tool to complete the core crimp.
Be sure to orient the terminal so that it is properly aligned with the terminal cavity in the
connector. The terminal should be positioned so that the lock tang is on the side of the cavity
which has the notch in the middle (for the remover tool).
4. Position the insulation crimp of the terminal on anvil “C” so that the entire insulation crimp area and
a portion of the terminal between the core and insulation crimp areas are supported by the anvil.
Complete the insulation crimp.

C. Terminal Crimping (cont’d)

6. Push on the wire until the terminal is completely into the cavity. (A click will be heard and the
terminal should stay in place when the wire is lightly pulled.)
D. Terminal Crimping Using Alternate Tool J 35123

1. Insert the remover tool in the front side of the connector to release the locktab, and pull the
terminal out the rear of the connector. Pull the terminal and wire out the rear of the connector to
complete Steps (3) through (7).
2. Push open the terminal holder on the crimper tool J 35123 and insert a terminal into the opening
marked 18–16 (Figure E–3, View C) so that the crimp ends point up. Release the terminal holder.
3. Slightly close the crimping tool (close until one click is heard) but do not start to crimp the terminal.
Place the terminal on the wire so it is in the same position as it will be when pulled back into the
connector. The terminal should be positioned so that the lock tang is on the side of the cavity which
has the notch in the middle (for the remover tool).
4. Insert the wire into the terminal until the wire contacts the holder. (By doing this, the core and
insulation should be properly positioned for the core and insulation crimp wings.)
5. Squeeze the crimper fully until it opens when released.
6. Open the terminal holder and remove the wire and terminal from the crimping tool.
7. Pull on the terminal to assure a tight crimp.
9. Push on the wire until the terminal is completely into the cavity. (A click will be heard and the
terminal should stay in place if the wire is lightly pulled.)

NOTES

V06482.01.00
Figure E–4. Internal Wiring Harness

1–4. INTERNAL WIRING HARNESS

Service with internal wiring harness assembly P/N 15321154 (Figure E–4).

WIRE SEAL
CONNECTOR
TERMINAL SECONDARY LOCK
THROTTLE POSITION SENSOR

CONNECTOR
J 38125-10
REMOVER TOOL
VIEW A VIEW B
WIRE SEAL
CORE CRIMP
INSULATED WIRE
STRIPPED WIRE
VIEW C
WIRE SEAL
CORE CRIMP
TERMINAL
INSULATION & SEAL CRIMP
VIEW D
5
3
1
J 38125-6
3
1
4
2
4
2
VIEW E
V01689
Figure E–5A. Delphi-Packard WeatherPack Connectors (TPS)

1–5. DELPHI-PACKARD WEATHERPACK CONNECTORS (TPS)

Required Tools
Crimping Tool J 38125-6
Wire Crimp Anvil “2”
Insulation Crimp Anvil “5”
Alternate Crimping Tool J 35606 or J 38852
Remover Tool J 38125-10
Throttle Position Sensor (TPS) Connector 12015793
Terminal 12089040
Wire Seal 12089444
B. Terminal Removal
1. Unlatch and open the secondary lock on the connector (Figure E–5A, View A).
2. From the front of the connector, insert remover tool J 38125-10 over the terminal. Push the tool
over the terminal and pull the terminal out the back of the connector (Figure E–5A, View B).
minimize wire loss.
NOTE: Two special tools are available for this operation — tool J 38125-6 (Paragraph C) and tool J 35606
or J 38852 (Paragraph D).
C. Terminal Crimping Using Crimping Tool J 38125-6

1. Place the wire seal onto the wire before stripping the wire (Figure E–5A, View C).
2. Strip 6.0 ±0.25 mm (0.24 ±0.01 inch) of insulation from the end of the wire.
3. Place the terminal onto crimping tool J 38125-6 (Figure E–5A, View E), anvil “2.”
4. Slightly close the crimping tool to hold the terminal steady.
5. Insert the wire so that the stripped portion of the wire is in the core crimp area and the insulated
portion of the wire is in the insulation crimping area (Figure E–5A, View C).
6. Crimp the stripped section of the wire.
7. Remove the terminal from the crimping tool.
8. Push the wire seal onto the terminal (Figure E–5A, View D). The second crimp will wrap around
the wire seal. This will seal the insulated area of the wire.
9. Use a pair of needle nose pliers, if necessary, to squeeze the terminal wings together to fit in
anvil “5.”
10. Crimp the wire seal in anvil “5.”
11. Tug on the terminal to be sure the crimp is tight.

C. Terminal Crimping Using Crimping Tool J 38125-6 (cont’d)

12. Insert the terminal into the connector. The terminal will click into place and should not pull out.
13. Secure the secondary lock. Both sides of the connector must be latched.
D. Terminal Crimping Using Alternate Crimper Pliers J 35606 or J 38852

1. Place the wire seal onto the wire before stripping the wire (Figure E–5A, View C).
2. Strip 6.0 ±0.25 mm (0.24 ±0.01 inch) of insulation from the end of the wire.
3. Insert terminal into crimping tool J 35606 (Figure E–5B, View A), opening marked 18–20.
4. Position the terminal so the crimp wings are pointing up from the bottom jaw of the crimper and are
properly positioned.
5. Slightly close the crimping tool to hold the terminal steady.
6. Slide the wire seal to the edge of the insulation and insert the wire and seal into the terminal
(Figure E–5B, View B).
7. Position the wire and seal and squeeze the crimping tool until it opens when released.
9. Insert the terminal into the connector. The terminal will click into place and should not pull out.
10. Secure the secondary lock. Both sides of the connector must be latched.
Figure E–5B. Terminal Crimping With Tool J 35606

NOTES

9-PIN RECEPTACLE
PIN REMOVER
J 34513
WIRES
VIEW C
CONNECTOR
RECEPTACLE
REMOVER
J 34513
REMOVER
J 38582-3 VIEW A
J 34182 CRIMPER
TERMINAL EXTRACTOR / INSERTER
J 41194 TO ROT
ISE A
RA
TE
INSPECTION HOLE SEL

NO.
PIN TERMINAL TERMINAL WIRE SIZE

INSPECTION HOLE INDICATOR
SOCKET TERMINAL
LOCKING RING
;;
;
CAVITY PLUG DEPTH ADJUSTMENT SCREW
VIEW B
V05748
Figure E–6. Deutsch IPD/ECD Connectors (9-Way DDR)

1–6. DEUTSCH IPD/ECD CONNECTORS (J1939 DIAGNOSTIC LINK 9-WAY DDR)

Required Tools
Extractor/Inserter Tool J 41194 (18 GA ECD Bulkhead)
Remover Tool Set J 34513
Remover Tool (DDR Connector) J 38582-3 (12–14 GA)
J1939 Diag Link (9-Way DDR) 9-Way Receptacle HD10-9-1939P
NOTE: If difficulty is encountered in removing or installing the plug backshell, insert the plug into the
receptacle, do not lock it into place, and loosen the backshell.
B. Terminal Removal (Figure E–6, View A)
NOTE: When using remover/inserter tool J 41194, take care not to break the tip of the tool. Lay the wire
in the widest part of the wire slot and work toward the tool tip.
1. Loosen and slide the backshell along the convolute conduit.

2. Remove the convolute conduit from the base of the backshell follower. Peel enough conduit from
the harness to allow working access.
3. Slide the backshell follower clear of the connector housing.
4. Remove as much tape wrap as necessary to allow working access.
5. Fully insert the proper remover/extractor tool into the back of the connector until it releases the
terminal.
6. Pull the terminal, wire, and tool out the back of the connector.
7. If replacing a terminal, cut the wire through the middle of the terminal crimp to minimize wire loss.
C. Terminal Crimping (Figure E–6, View B)

1. Strip approximately 6–8 mm (0.236–0.315 inch) of insulation from the end of the wire.
2. Set the crimping tool wire size to number 12. To set the wire size, remove the retainer pin. Lift and
rotate the indicator until the number 12 is aligned with the SEL NO. arrow. Reinstall the retainer
pin.
3. Insert the contact end of the terminal into crimping tool J 34182. To adjust the crimping tool depth,
loosen the locking ring until the depth adjusting screw is free. Turn the adjusting screw until the top
of the terminal is just above flush with the top of the crimping hole (the crimp jaws will contact the
middle of the terminal barrel). Tighten the locking ring to retain the adjustment.
4. Fully insert the wire into the terminal so that the stripped portion of the wire is in the crimp area.
A small section (0.5–1.0 mm (0.02–0.04 inch)) of wire will be visible above the terminal barrel.

C. Terminal Crimping (Figure E–6, View B) (cont’d)

5. Squeeze the crimping tool handle until it releases. The terminal is now crimped onto the wire.
6. Remove the terminal and wire from the crimping tool.
8. Install a 25 mm (one inch) long piece of heat shrink tubing over the wire insulation just behind the
terminal. Apply heat to shrink and lock the tubing to the insulation.
D. Terminal Insertion (all connectors except ECD bulkhead)

1. Insert the terminal and attached wire through the proper hole in the grommet.
2. Push on the terminal and wire until the terminal clicks into position. Pull gently on the wire to be
sure that the terminal is fully seated.

NOTES

WEDGELOCK
CONNECTOR SEAL
CONNECTOR
Shrink tubing goes here
STANDARD SOCKET
TERMINAL
Extended terminal for

uninsulated shield wire
J 34182 CRIMPER
TO ROT
ISE A
RA
TE
SEL
NO.
WIRE SIZE INDICATOR

TERMINAL
;;
LOCKING RING
DEPTH ADJUSTMENT SCREW ;;
V03424
Figure E–7. Deutsch DT Series Connector (3-Way J1939 Interface)

1–7. DEUTSCH DT SERIES CONNECTORS (3-WAY J1939 INTERFACE)

A. Connector/Terminal Repair
Required Tools
J1939 Interface Connector, Plug, 3-Way DT06-3S-E008
Wedgelock, Plug W3S-1939
Contact, Socket (Standard) 3662-204-1690
Contact, Socket (Extended) 0462-221-1631
Cable, J1939 Databus 23-000-13
B. Terminal Removal (Figure E–7)

1. Use a small-bladed screwdriver to remove the wedgelock that holds the terminals in place.
2. Use a sharp knife to carefully remove the shrink tubing from the rear of the connector plug.
3. Use a small screwdriver to release the locking lever for all of the terminals. Pull the wire and
terminal out the rear of the connector.
4. Slide a new piece of shrink tubing over the removed terminals and onto the cable.
5. If replacing a terminal, cut the wire through the middle of the terminal crimp to minimize wire loss.
C. Terminal Crimping (Figure E–7)

1. Strip approximately 6–8 mm (0.24–0.31 inch) of insulation from the end of the wire. (There is no
insulation on the shield wire.)
2. Set the crimping tool wire size to number 18. To set the wire size, remove the retainer pin. Lift and
rotate the indicator until the number 18 is aligned with the SEL NO. arrow. Reinstall the retainer
pin.
3. Insert the contact end of the terminal down into crimping tool J 34182. To adjust the crimping tool
depth, loosen the locking ring until the depth adjusting screw is free. Turn the adjusting screw until
the wire end of the terminal is just above flush with the top of the crimping hole. The depth
adjustment screw will need to be backed out a large amount to accept the extended shield
terminal. The crimp jaws will now contact the middle of the terminal barrel. Tighten the locking ring
to retain the adjustment.
4. Fully insert the wire into the terminal so that the stripped portion of the wire is in the crimp area.
A small section (0.5–1.0 mm (0.02–0.04 inch)) of wire will be visible above the terminal barrel.
5. Squeeze the crimping tool handle until it releases. The terminal is now crimped onto the wire.
6. Remove the terminal and wire from the crimping tool.

D. Terminal Insertion
1. Insert the terminal and attached wire into the back of the connector.
2. Push on the terminal and wire until the terminal clicks into position. Check the front of the
connector to see that the terminal is at the same height as other terminals. Pull gently on the wire
to be sure that the terminal is fully seated.
3. Insert the wedge lock to hold the terminals in place. Slide the sealing plug back into place at the
rear of the connector.
4. Slide the shrink tubing over the raised area at the rear of the connector. Use a heat gun to shrink
the tubing into position over the connector and cable.

1–8. REPAIR OF A BROKEN WIRE WITH IN-LINE BUTT SPLICE

A. Connector Check Before Repair
NOTE: Before repairing or replacing wiring harness, sensor, solenoid, switch, or TCM as indicated for a
diagnosed problem, follow the procedure below:
1. Disconnect the connector or connectors associated with the problem and inspect for:
• Bent terminals
• Broken terminals
• Dirty terminals
• Pushed back terminals
• Missing terminals
• Condition of mating tabs
• Condition of mating terminals
Ensure that terminals are secure in the connector. Clean, straighten, or replace parts as required.
2. Reconnect all previous unmated connectors. Ensure connectors are fully inserted or twisted until
they lock in place. Connectors with locking tabs make an audible click when the lock is engaged.
3. If the trouble recurs after starting the vehicle, follow the repair procedures for the trouble code or
complaint.
4. If the trouble does not recur, or if the appropriate repairs and/or replacements have been made,
the problem should be corrected.
B. Special Tools
• Heat Gun, J 25070 or equivalent
• Crimping Tool for Pre-insulated Crimp J 38125-8 (Figure E–8)
NOTE: Use crimping anvils “F” and “G.”
• Wire Strippers, J 35615

• Splices P/N 23046604 14–16 AWG
• Splices P/N 23046605 18–22 AWG
NOTE: Each splice must be properly crimped and then heated to shrink the covering to protect and
insulate the splice. Insulation-piercing splice clips should not be used.

J 38125-8
F
G
V01694
Figure E–8. Crimper J 38125-8
C. Straight Lead Repair Procedure

1. Locate the damaged wire.
2. Remove 8.0 mm (0.3 inch) of insulation from the end of each segment of the damaged wire.
3. Insert the stripped end of one wire into the crimp barrel of the splice, and crimp.
4. Insert the stripped end of the other wire into the other end of the crimp barrel, and crimp.
5. Pull on the connection to be sure of crimping integrity.
6. Heat the splice with a heat gun until the covering shrinks and adhesive flows from under the
covering.
7. The splice is now sealed and insulated. Electrical tape is not necessary and should not be used.

MATING
CONNECTOR MFG. P/N PART NAME MANUFACTURER CONFIG MFG. P/N MATING PART NAME
P/N
TCM J2 15336800 STRAIN RELIEF, 32-WAY RED DELPHI-PACKARD 1-PC/TCM J2 12186041 12186041 TCM HEADER
TCM J2 15305333 SEAL, 32-WAY DELPHI-PACKARD 1-PC/TCM J2
TCM J2 15305371 INNER CONNECT, 32-WAY DELPHI-PACKARD 1-PC/TCM J2
TCM J2 12129024 TPA, 32-WAY RED DELPHI-PACKARD 1-PC/TCM J2
TCM J2 12084912 TERMINAL, SOCKET 100W DELPHI-PACKARD 1-PC/TCM J2
TCM J2 12129557 CAVITY PLUG, 100W DELPHI-PACKARD 1-PC/TCM J2
TCM J2 12177289 CPA, 32-WAY RED DELPHI-PACKARD 1-PC/TCM J2
TCM J1 12191002 STRAIN RELIEF, 32-WAY GRAY DELPHI-PACKARD 1-PC/TCM J1 12186043 12186043 TCM HEADER
TCM J1 15305333 SEAL, 32-WAY DELPHI-PACKARD 1-PC/TCM J1
TCM J1 15305371 INNER CONNECT, 32-WAY DELPHI-PACKARD 1-PC/TCM J1
TCM J1 12129022 TPA, 32-WAY GRAY DELPHI-PACKARD 1-PC/TCM J1
TCM J1 12129557 CAVITY PLUG, 100W DELPHI-PACKARD 1-PC/TCM J1
TCM J1 12177289 CPA, 32-WAY RED DELPHI-PACKARD 1-PC/TCM J1
GP19 15300027 CONNECTOR, 2-WAY DELPHI-PACKARD 1-PC/COMP J1 15300002 15300002 CONNECTOR, 2-WAY
GP19 12077411 TERMINAL, SOCKET DELPHI-PACKARD 1-PC/COMP J1 12048159 12048159 TERMINAL, PIN
GP19 12089444 SEAL, WIRE TYPE, SILICONE DELPHI-PACKARD 1-PC/COMP J1 12089444 12089444 SEAL, WIRE TYPE, SILICONE
GP19 15300014 LOCK, SECONDARY DELPHI-PACKARD 1-PC/COMP J1 15300014 15300014 LOCK, SECONDARY
J1939 DT06-3S-E008 CONNECTOR, PLUG 3-WAY DEUTSCH 1-PC/COMP J1 DT04-3P-E008 CONNECTOR, REC., 3-WAY
J1939 W3S WEDGELOCK, PLUG DEUTSCH 1-PC/COMP J1 W3P WEDGELOCK, RECEPTACLE
J1939 29511366 CONTACT, SOCKET #16 DEUTSCH 1-PC/COMP J1 29511369 3660-201-1690 CONTACT, PIN #16
J1939 29538614 CONTACT, EXTENDED SOCKET DEUTSCH 1-PC/COMP J1 0460-247-1631 CONTACT, EXTENDED PIN
J1939 CABLE, J1939 DATABUS 1-PC/COMP J1
VIW X 12160542 CONN 20M MIC/P 100W GRAY DELPHI-PACKARD 1-PC/COMP J1 12160280 12160280 CONN 20F MIC/P 100W GRAY
VIW X 12110693 CABLE SEAL, 14M GREEN DELPHI-PACKARD 1-PC/COMP J1 15304882 15304882 CABLE SEAL, 14F GRAY

VIW X 12191178 LOCK ASSIST/SEAL, 20M WHITE DELPHI-PACKARD 1-PC/COMP J1 12191173 12191173 LOCK, SECONDARY 20F WHITE
VIW X 12160551 TERMINAL, PIN 100W DELPHI-PACKARD 1-PC/COMP J1 12084912 12084912 TERMINAL, SOCKET 100W
VIW X 12129557 CAVITY PLUG, 100W DELPHI-PACKARD 1-PC/COMP J1 12129557 12129557 CAVITY PLUG, 100W
VIW X 12176394 CONDUIT CLIP, 13 mm BLACK DELPHI-PACKARD 1-PC/COMP J1 12176394 12176394 CONDUIT CLIP, 13 mm BLACK
VIW Y 12160280 CONN 20F MIC/P 100W GRAY DELPHI-PACKARD 1-PC/COMP J1 12160280 12160280 CONN 20F MIC/P 100W GRAY
VIW Y 15304882 CABLE SEAL, 16F RED DELPHI-PACKARD 1-PC/COMP J1 15304882 15304882 CABLE SEAL, 14F GRAY
VIW Y 12191172 LOCK SECONDARY, 20F BLUE DELPHI-PACKARD 1-PC/COMP J1 12191172 12191172 LOCK, SECONDARY 20F BLUE
VIW Y 12084912 TERMINAL, SOCKET 100W DELPHI-PACKARD 1-PC/COMP J1 12084912 12084912 TERMINAL, SOCKET 100W
VIW Y 12129557 CAVITY PLUG, 100W DELPHI-PACKARD 1-PC/COMP J1 12129557 12129557 CAVITY PLUG, 100W
VIW Y 12176394 CONDUIT CLIP, 13 mm BLACK DELPHI-PACKARD 1-PC/COMP J1 12176394 12176394 CONDUIT CLIP, 13 mm BLACK
RMR 12015795 CONNECTOR, 3-WAY DELPHI-PACKARD 1-PC/COMP J1 12015092 12015092 CONNECTOR, SHROUD 3-WAY
RMR 12089040 TERMINAL, PIN DELPHI-PACKARD 1-PC/COMP J1 12089188 12089188 TERMINAL, SOCKET
RMR 12089444 SEAL, WIRE TYPE, SILICONE DELPHI-PACKARD 1-PC/COMP J1 12089444 12089444 SEAL, WIRE TYPE, SILICONE
E–31
MATING
P/N
E–32
NE 12162193 CONNECTOR, 2-WAY DELPHI-PACKARD 1-PC/COMP J2 12066016 ENGINE SPEED SENSOR
NE 12103881 TERMINAL, 150F DELPHI-PACKARD 1-PC/COMP J2 Actual sensor uses molded receptacle similar to 12066016
NO 12162193 CONNECTOR, 2-WAY DELPHI-PACKARD 1-PC/COMP J2 OUTPUT SPEED SENSOR
NO 12103881 TERMINAL, 150F DELPHI-PACKARD 1-PC/COMP J2 Actual sensor uses molded receptacle similar to 12066016
NT 12162193 CONNECTOR, 2-WAY DELPHI-PACKARD 1-PC/COMP J2 TURBINE SPEED SENSOR
NT 12103881 TERMINAL, 150F DELPHI-PACKARD 1-PC/COMP J2 Actual sensor uses molded receptacle similar to 12066016
TPS 12015793 CONNECTOR, 3-WAY DELPHI-PACKARD 1-PC/COMP J2 TPS HEADER
TPS 12089040 TERMINAL, PIN DELPHI-PACKARD 1-PC/COMP J2 TPS header similar to 12010717 connector with 12089188 sockets
TPS 12089444 SEAL, WIRE TYPE, SILICONE DELPHI-PACKARD 1-PC/COMP J2 molded into the TPS.
H2OT 12015792 CONNECTOR, TOWER, 2-WAY DELPHI-PACKARD ADAPTER (MDR) 12010973 12010973 CONNECTOR, SHROUD, 2-WAY
H2OT 12089040 TERMINAL, PIN DELPHI-PACKARD ADAPTER (MDR) 12089188 12089188 TERMINAL, SOCKET
H2OT 12089444 SEAL, SILICONE DELPHI-PACKARD ADAPTER (MDR) 12089444 12089444 SEAL, WIRE TYPE, SILICONE
NSBU 12191757 CONNECTOR, TOWER, 4-WAY DELPHI-PACKARD 1-PC/COMP J2 12459915 NSBU
NSBU 12048086 SEAL, WIRE TYPE, DK RED DELPHI-PACKARD 1-PC/COMP J2
NSBU 12129802 TERMINAL, 150F DELPHI-PACKARD 1-PC/COMP J2
NSBU 15416722 CONNECTOR, 12-WAY DELPHI-PACKARD 1-PC/COMP J2
NSBU 15441828 BACKSHELL DELPHI-PACKARD 1-PC/COMP J2
NSBU 12191819 18 GAUGE, 18AWG TXL DELPHI-PACKARD 1-PC/COMP J2
TLCT 12160280 CONN 20F MIC/P 100W GRAY DELPHI-PACKARD 1-PC/COMP J2 12160782 CONN 20M MIC/P 100W
TLCT 12177159 CABLE SEAL, 20F ORANGE DELPHI-PACKARD 1-PC/COMP J2 15317365 LOCK ASST/SEAL 20M MIC/P100W
TLCT 12160494 LOCK, SECONDARY 20F GREEN DELPHI-PACKARD 1-PC/COMP J2
TLCT 12084912 TERMINAL, SOCKET 100W DELPHI-PACKARD 1-PC/COMP J2 12160551 TERMINAL, PIN 100W

TLCT 12129557 CAVITY PLUG, 100W DELPHI-PACKARD 1-PC/COMP J2
TLCT 12176394 CONDUIT CLIP, 13MM BLACK DELPHI-PACKARD 1-PC/COMP J2
BLKHD RCP 29511368 CONNECTOR, REC., 31-WAY DEUTSCH TCM J2/COMP 29511365 CONNECTOR, PLUG, 31-WAY
BLKHD RCP 29511369 CONTACT, PIN #16 DEUTSCH TCM J2/COMP 29511366 CONTACT, SOCKET #16
BLKHD RCP 29511371 SEALING PLUG DEUTSCH TCM J2/COMP 29511371 SEALING PLUG
BLKHD RCP 29514041 HOUSING, BACKSHELL, 24/19 DEUTSCH TCM J2/COMP 29514041 HOUSING, BACKSHELL, 24/19
BLKHD RCP 29514042 FOLLOWER, BACKSHELL, 24/19 DEUTSCH TCM J2/COMP 29514042 FOLLOWER, BACKSHELL, 24/19
BLKHD RCP 29514043 GROMMET, BACKSHELL #24 DEUTSCH TCM J2/COMP 29514043 GROMMET, BACKSHELL, 24/19
BLKHD RCP 29527000 NUT, PANEL DEUTSCH TCM J2/COMP —
BLKHD RCP 29512839 O-RING DEUTSCH TCM J2/COMP —
BLKHD PGP 29511855 CONNECTOR, PLUG, 31-WAY DEUTSCH COMP J2 29511854 CONNECTOR, REC., 31-WAY
BLKHD PGP 29511369 CONTACT, PIN #16 DEUTSCH COMP J2 29511366 CONTACT, SOCKET #16
BLKHD PGP 29511371 SEALING PLUG DEUTSCH COMP J2 29511371 SEALING PLUG
BLKHD PGP 29514041 HOUSING, BACKSHELL, 24/19 DEUTSCH COMP J2 29514041 HOUSING, BACKSHELL, 24/19
MATING
P/N
BLKHD PGP 29514042 FOLLOWER, BACKSHELL, 24/19 DEUTSCH COMP J2 29514042 FOLLOWER, BACKSHELL
BLKHD PGP 29514043 GROMMET, BACKSHELL #24 DEUTSCH COMP J2 —
BLKHD RCS 29511854 CONNECTOR, REC., 31-WAY DEUTSCH TCM J2/COMP 29511855 CONNECTOR, PLUG, 31-WAY
BLKHD RCS 29511366 CONTACT, SOCKET #16 DEUTSCH TCM J2/COMP 29511369 CONTACT, PIN #16
BLKHD RCS 29511371 SEALING PLUG DEUTSCH TCM J2/COMP 29511371 SEALING PLUG
BLKHD RCS 29514041 HOUSING, BACKSHELL, 24/19 DEUTSCH TCM J2/COMP 29514041 HOUSING, BACKSHELL, 24/19
BLKHD RCS 29514042 FOLLOWER, BACKSHELL, 24/19 DEUTSCH TCM J2/COMP 29514042 FOLLOWER, BACKSHELL, 24/19
BLKHD RCS 29527000 NUT, PANEL DEUTSCH TCM J2/COMP —
BLKHD RCS 29512839 O-RING DEUTSCH TCM J2/COMP —
BLKHD PGS 29511365 CONNECTOR, PLUG, 31-WAY DEUTSCH COMP J1 29511368 CONNECTOR, REC., 31-WAY
BLKHD PGS 29511366 CONTACT, SOCKET #16 DEUTSCH COMP J1 29511369 CONTACT, PIN #16
BLKHD PGS 29511371 SEALING PLUG DEUTSCH COMP J1 29511371 SEALING PLUG
BLKHD PGS 29514041 HOUSING, BACKSHELL, 24/19 DEUTSCH COMP J1 29514041 HOUSING, BACKSHELL, 24/19
BLKHD PGS 29514042 FOLLOWER, BACKSHELL, 24/19 DEUTSCH COMP J1 29514042 FOLLOWER, BACKSHELL, 24/19
BLKHD PGS 29514043 GROMMET, BACKSHELL #24 DEUTSCH COMP J1 29514043 GROMMET, BACKSHELL, #24

E–33
NOTES

APPENDIX F—TPS ADJUSTMENT
A. Description of Operation
1. To properly communicate throttle position to the TCM, the throttle position sensor must convert
mechanical movement to an electrical form the TCM can understand. To accomplish this, contacts
move across a resistive strip inside the sensor which translates position into voltage (Figure F–1).
THROTTLE POSITION LINKAGE
CONTACTS
RESISTIVE STRIP
V00656.01
Figure F–1. Throttle Position-to-Voltage Conversion
2. Each position gives a different voltage. The TCM then converts this voltage into throttle percent.
Each millimeter of travel converts to approximately 0.110 volts. Figure F–2 diagrams the voltage
and throttle movement relationship.
Adjust so total stroke is within

0 Volt
8.9 mm – 35.7 mm band 5 Volts
0.98 volts – 3.921 volts
0.550 Volts 4.750 Volts
ERROR ERROR
ZONE 0.979 Volts 3.927 Volts ZONE
APPROX.
19 mm (0.75 in.) STROKE
CLOSED WIDE OPEN

THROTTLE THROTTLE
FULLY FULLY
RETRACTED 8.9 mm 35.7 mm EXTENDED
(AT REST) (0.35 in.) Total Stroke (1.4 in.)
CT–WOT
2.5 mm 40.6 mm
(0.1 in.) 15.2 mm–22.9 mm (1.6 in.)
0 mm
(0.63 in.–0.9 in.) 45.7 mm
1.667–2.549 Volts (1.8 in.)
V05746.00.01
Figure F–2. Throttle Position Determination Diagram
3. Throttle percent is proportional to the amount of travel of the throttle position sensor. Therefore
a small amount of travel corresponds to a low throttle percentage, and a large amount of travel cor-
responds to a high throttle percentage (Table F–1, Page F–3).
Copyright© 2004 General Motors Corp. F–1

4. The throttle position sensor is self-calibrating within its normal range of operation. Each time the
vehicle is started and the TCM is initialized, the idle position that is stored for closed throttle is in-
creased from its previous lowest reading. Also, the wide open throttle position is reduced from its
previous highest reading. Once the new position is read from the TPS, the idle and wide open
throttle set points are continuously readjusted to the lowest and highest points, respectively. This
compensates for fuel control system wear or previous mechanical adjustment. One area of partic-
ular concern is when the throttle sensor extends into the error zone. This indicates a TPS misad-
justment to the TCM, and 100 percent throttle is assumed until readjustment is performed. Simply
clearing the DTC will not resolve the situation; use the Scan Tool to reset the TPS calibrations after
a TPS adjustment.
B. Throttle Position Sensor (TPS) Adjustment

When properly installed by the equipment manufacturer (Figure F–3), the TPS should not require
adjustment. Confirm that the throttle sensor is installed to manufacturer specifications before
adjusting the throttle position sensor. The idle position should be approximately 8.9 mm or 0.98 volts
or higher, and the full throttle position should be approximately 35.7 mm or 3.921 volts or lower. The
TPS is self-calibrating, meaning there is no optimum closed throttle or wide open position. As long as
the travel is within the 8.5–35.7 mm range the TPS is set properly. A total stroke of 15.2–22.9 mm
must be maintained. Watch the movement of the throttle sensor as the controls move it through the
full stroke. Make certain the idle and full throttle positions are not in the error zones (refer to
Figure F–2). The error zones occur when the idle position is less than 2.5 mm, or when the full throttle
position is more than 40.6 mm. When idle or wide open throttle positions are in the error zones, the
TCM will log a code. When a TPS code is logged the TCM assumes a default throttle setting which will
negatively affect shift quality.
NOTE: Use Test Harness J 41339 for measuring voltages.
F–2 Copyright© 2004 General Motors Corp.

Table F–1. Distance (mm) of Travel Versus Volts
mm Volts mm Volts
0 0 24 2.634
1 0.110 25 2.744
2 0.220 26 2.854
3 0.329 27 2.964
4 0.439 28 3.073
5 0.549 29 3.183
6 0.659 30 3.293
7 0.768 31 3.403
8 0.878 32 3.512
9 0.988 33 3.622
10 1.098 34 3.732
11 1.207 35 3.842
12 1.317 36 3.951
13 1.427 37 4.061
14 1.537 38 4.171
15 1.646 39 4.281
16 1.756 40 4.390
17 1.866 41 4.500
18 1.976 42 4.610
19 2.085 43 4.720
20 2.195 44 4.829
21 2.305 45 4.939
22 2.415 46 5.049
23 2.524
Copyright© 2004 General Motors Corp. F–3

MOUNTING PROVISION: BENDING LOAD

Use M6 x 1.00 or 1⁄4-20 in. series bolts APPLIED
3 places
Torque M6 x 1.00 bolt to 10–13 N•m (84–120 lb in.)
1
Torque ⁄4-20 in. series bolts to 13–14 N•m (108–132 lb in.) UNACCEPTABLE INSTALLATION
Mount to a solid frame member. Flatness of
chassis mounting surface must not exceed 10.0° MAX INSTALLED
0.8 mm (0.03 in.). OPERATING ANGLE
IN ALL DIRECTIONS
LOADING IN
TENSION ONLY
ACCEPTABLE INSTALLATION
Attachment must provide freedom
of motion to allow cable loading in
tension only (no bending loads).
WIRING HARNESS
55.0 mm (2.17 in.)
MIN REQUIRED Fuel control must not move
the throttle sensor beyond R 152.0 mm (6.00 in.) MIN
FOR CONNECTION
the closed throttle position ALLOWANCE RADIUS
REMOVAL
at any time.
FULLY EXTENDED
FORCE REQUIRED FULLY
26.7 N (6.0 LB) MAX RETRACTED
MOUNTING (NOTE: Mounting length

47.5 mm (1.87 in.) CLOSED THROTTLE LENGTH + 50.8 mm (2 inches) equals
95.2 mm (3.75 in.) cable length)
FULL THROTTLE
118.1 mm (4.65 in.)
OPERATING BAND 15.2 – 22.9 mm
118.1 mm (0.6 – 0.9 in.)
(4.65 in.) The location of the
95.2 mm clamping bracket relative
(3.75 in.) to the fuel lever at closed
throttle must be maintained
within this range.
Attach to engine or governor

30.2 mm (1.19 in.) 93.45 mm (3.679 in.)housing using clamp and shims as
87.15 mm (3.431 in.)required. Clamp must positively
lock in cable groove.
Fuel lever attachment linkage or bracket must HITCH PIN CLIP
allow fuel lever to return to closed throttle position
ENGINE FUEL LEVER
when sensor rod is maintained at full throttle position.
Attach the throttle sensor directly to the engine fuel
lever with no breakover or yield linkages between the
engine fuel lever shaft and the attachment point of the
throttle sensor. CLOSED THROTTLE 183.1 mm (7.21 in.) MAX
FULL THROTTLE
SAME AS WITHOUT 160.2 mm (6.31 in.) MIN
SLIP LINK
FULLY EXTENDED
38.1 mm (1.50 in.)
HITCH PIN CLIP

FULLY RETRACTED
OPTIONAL THROTTLE SENSOR ASSEMBLY WITH SLIP LINK V00430.05
Figure F–3. Throttle Position Sensor Adjustment
F–4 Copyright© 2004 General Motors Corp.

APPENDIX G—WELDING ON VEHICLE/VEHICLE INTERFACE MODULE
1–1. WELDING ON VEHICLE

When frame or other welding is required on the vehicle, take the following precautions to protect the electronic
control components:
1. Disconnect the wiring harness connectors at the transmission control module (TCM).
2. Disconnect the positive and negative battery connections, and any electronic control ground wires con-
nected to the frame or chassis.
3. Cover electronic control components and wiring to protect them from hot sparks, etc.
4. Do not connect welding cables to electronic control components.
Do not jump start a vehicle with arc welding equipment. Arc welding
WARNING! equipment’s dangerously high currents and voltages cannot be reduced to safe
levels.
Copyright© 2004 General Motors Corp. G–1

APPENDIX G—WELDING ON VEHICLE/VEHICLE INTERFACE MODULE
NOTES
G–2 Copyright© 2004 General Motors Corp.

APPENDIX H—HYDRAULIC SCHEMATICS
HYDRAULIC SCHEMATIC – NEUTRAL / PARK G Solenoid Added–3rd Quarter 2003
PRE-BLOCK 1
1000 AND 2000 PRODUCT FAMILIES G Solenoid Lowers Main Pressure
B
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
C1
MAIN
PRESSURE CONV – OUT C1
TAP Clutch
Valve
MAIN
TCC SIGNAL
IDLE COOLING MAIN

LEAKAGE
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump TCC Exhaust
CONV – OUT TO COOLER Valve
SUMP
LUBE TCC SIGNAL
OVERAGE
Converter PSR
Flow
Cooler Valve CONV – IN
Lube Blocked At
Regulator SUMP Separator Plate For MAIN PRESSURE EXHAUST BACKFILL (EBF)
TCC SIGNAL Modulated Main Pressure
Valve CONTROL MAIN PRESSURE SUCTION
Converter
Flow CONVERTER–IN/OVERAGE A TRIM SIGNAL
Main Filter Valve Beginning Model Year 2004i (interim) CONVERTER–OUT REVERSE SIGNAL
Cooler Converter Flow Valve TORQUE CONVERTER CLUTCH (TCC) C5
See SIL 03-1K/2K-04 LUBRICATION/COOLER A TRIM PRESSURE
New Hydraulic Path EXHAUST
V06914.04.00
For TCC Signal
Figure H–1. Hydraulic Schematic — Neutral/Park
Copyright © 2004 General Motors Corp. H–1/H–2

HYDRAULIC SCHEMATIC – REVERSE (PRIOR TO, AND INCLUDING, NO4* SOFTWARE WITH THROTTLE APPLIED)
1000 AND 2000 PRODUCT FAMILIES G Solenoid Added–3rd Quarter 2003

PRE-BLOCK 1
B
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
C1
MAIN
PRESSURE CONV – OUT C1
TAP Clutch
Valve
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump Exhaust
TCC
LUBE Valve
CONV – OUT TO COOLER
SUMP
TCC SIGNAL
OVERAGE
Converter PSR
Cooler Flow
Valve CONV – IN
Lube Blocked At
Regulator SUMP Separator Plate For MAIN PRESSURE SUCTION
Valve TCC SIGNAL Modulated Main Pressure CONTROL MAIN PRESSURE A TRIM SIGNAL
Converter Beginning Model Year 2004i (interim) CONVERTER–IN/OVERAGE B TRIM SIGNAL
Flow
Main Filter Valve Converter Flow Valve CONVERTER–OUT REVERSE SIGNAL
Cooler
See SIL 03-1K/2K-04 TORQUE CONVERTER CLUTCH (TCC) C3
New Hydraulic Path LUBRICATION/COOLER C5
For TCC Signal EXHAUST A TRIM PRESSURE
*EFFECTIVE JANUARY 1, 2001 EXHAUST BACKFILL (EBF) B TRIM PRESSURE V04755.04.00
Figure H–2. Hydraulic Schematic — Reverse (Prior To Software Level N04)

HYDRAULIC SCHEMATIC – REVERSE – CLOSED THROTTLE (WITH NO4* SOFTWARE AND LATER)
AND A TRIM When Energized (Typically at
SOLENOID Solenoid Solenoid Low Throttle, Low Speed)
W/O SPRING
B (Shown Energized)
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN
C1
TCC SIGNAL Clutch
Valve
IDLE COOLING MAIN
LEAKAGE
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump Exhaust
CONV – IN TCC Backfill
LUBE Valve
SUMP CONV – OUT TO COOLER
TCC SIGNAL
Converter OVERAGE
Flow PSR
Cooler Valve
Blocked At
CONV – IN Separator Plate For
Lube
Regulator Modulated Main Pressure MAIN PRESSURE SUCTION
SUMP
Valve TCC SIGNAL CONTROL MAIN PRESSURE A TRIM SIGNAL
Converter Beginning Model Year 2004i (interim) CONVERTER–IN/OVERAGE B TRIM SIGNAL
Main Filter Flow CONVERTER–OUT C3
Valve Converter Flow Valve
Cooler TORQUE CONVERTER CLUTCH (TCC) C5
See SIL 03-1K/2K-04
New Hydraulic Path
For TCC Signal EXHAUST B TRIM PRESSURE
*EFFECTIVE JANUARY 1, 2001 EXHAUST BACKFILL (EBF) V06874.04.00
Figure H–3. Hydraulic Schematic — Reverse (Software Level N04 And Later)

HYDRAULIC SCHEMATIC – 1st RANGE G Solenoid Added–3rd Quarter 2003
PRE-BLOCK 1
B
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN C1
Clutch
TCC SIGNAL Valve
IDLE COOLING MAIN
LEAKAGE
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump Exhaust
TCC Valve
SUMP
TCC SIGNAL CONV – OUT TO COOLER
LUBE Converter
Flow OVERAGE PSR
Valve
Lube Cooler CONV – IN
Regulator Blocked At MAIN PRESSURE EXHAUST BACKFILL (EBF)
SUMP Modulated Main Pressure
TCC SIGNAL CONVERTER–IN/OVERAGE A TRIM SIGNAL
Main Filter Converter CONVERTER–OUT REVERSE SIGNAL
Flow
Valve Beginning Model Year 2004i (interim) TORQUE CONVERTER CLUTCH (TCC) C1
Cooler Converter Flow Valve LUBRICATION/COOLER C5
See SIL 03-1K/2K-04 EXHAUST A TRIM PRESSURE
New Hydraulic Path V06915.04.00
For TCC Signal
Figure H–4. Hydraulic Schematic — 1st Range

HYDRAULIC SCHEMATIC – 2nd RANGE G Solenoid Added–3rd Quarter 2003

AND A TRIM A Trim Accumulator B Trim Accumulator Low Throttle, Low Speed)
SOLENOID N/C
Solenoid Solenoid
B
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump TCC Exhaust
LUBE TCC SIGNAL CONV – OUT TO COOLER Valve
SUMP
OVERAGE
Converter
Flow PSR
Cooler Valve
CONV – IN
Blocked At
Lube Separator Plate For
Regulator SUMP MAIN PRESSURE EXHAUST BACKFILL (EBF)
Converter CONVERTER–IN/OVERAGE B TRIM SIGNAL
Main Filter Flow Beginning Model Year 2004i (interim) CONVERTER–OUT REVERSE SIGNAL
Cooler
Valve Converter Flow Valve
See SIL 03-1K/2K-04 LUBRICATION/COOLER C4
New Hydraulic Path EXHAUST B TRIM PRESSURE
For TCC Signal V06916.04.00
Figure H–5. Hydraulic Schematic — 2nd Range

HYDRAULIC SCHEMATIC – 3rd RANGE G Solenoid Added–3rd Quarter 2003

PRE-BLOCK 1
B
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump TCC Exhaust
LUBE CONV – OUT TO COOLER Valve
SUMP
TCC SIGNAL
OVERAGE
PSR
Converter
Cooler Flow CONV – IN
Valve Blocked At
Converter
Cooler
Converter Flow Valve TORQUE CONVERTER CLUTCH (TCC) C1
New Hydraulic Path EXHAUST A TRIM PRESSURE
Figure H–6. Hydraulic Schematic — 3rd Range


PRE-BLOCK 1
B
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump TCC Exhaust
SUMP
TCC SIGNAL
OVERAGE
Converter
Flow PSR
Cooler Valve
CONV – IN
Blocked At
Converter
Flow CONVERTER–IN/OVERAGE B TRIM SIGNAL
Cooler
Converter Flow Valve TORQUE CONVERTER CLUTCH (TCC) C1
New Hydraulic Path EXHAUST B TRIM PRESSURE
Figure H–7. Hydraulic Schematic — 4th Range


PRE-BLOCK 1
B
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN
Control C2
EXHAUST
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump TCC Exhaust
SUMP
TCC SIGNAL
OVERAGE
Converter
Flow PSR
Cooler Valve
CONV – IN
Blocked At
Converter
Main Filter Valve Beginning Model Year 2004i (interim) CONVERTER–OUT B TRIM SIGNAL
Cooler
Converter Flow Valve TORQUE CONVERTER CLUTCH (TCC) REVERSE SIGNAL
New Hydraulic Path EXHAUST C3
For TCC Signal A TRIM PRESSURE V06919.04.00
Figure H–8. Hydraulic Schematic — 5th Range

HYDRAULIC SCHEMATIC – HYDRAULIC DEFAULT FORWARD (3rd RANGE "LIMP HOME")

AND A TRIM
A Trim Accumulator B Trim Accumulator When Energized (Typically at
SOLENOID N/C Low Throttle, Low Speed)
Solenoid Solenoid
W/O SPRING
B (Shown De-energized)
N/C Solenoid N/O C On/Off D On/Off E On/Off
F Trim Filter Shift Shift Shift G Mod Main
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
PRESSURE Valve
MAIN
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2
EXHAUST Control
Main
Filter
Control
Main Control PSC
Regulator Valve
Valve C3

(G SOLENOID) C4
PSE C5
OVERAGE TCC C
Shift PSD
Converter Valve
Relief
Charging Valve
Pump TCC Exhaust
SUMP
TCC SIGNAL
OVERAGE
Converter
Flow PSR
Cooler Valve
CONV – IN
Blocked At
Lube SUMP Separator Plate For
Regulator TCC SIGNAL Modulated Main Pressure MAIN PRESSURE EXHAUST BACKFILL (EBF)
Valve Converter CONTROL MAIN PRESSURE SUCTION
Valve Beginning Model Year 2004i (interim)
Main Filter Cooler Converter Flow Valve CONVERTER–OUT REVERSE SIGNAL
New Hydraulic Path EXHAUST A TRIM PRESSURE
For TCC Signal
V07738.04.00
Figure H–9. Hydraulic Schematic — Hydraulic Default Forward

HYDRAULIC SCHEMATIC – HYDRAULIC DEFAULT REVERSE ("LIMP HOME")

1000 AND 2000 PRODUCT FAMILIES
G Solenoid Added–3rd Quarter 2003

AND A TRIM N/C A Trim Accumulator B Trim Accumulator Low Throttle, Low Speed)
B
N/C Solenoid N/O
N/C N/C N/C N/C N/C

EBF B TRIM
PRESSURE
CONV – IN
MAIN
A TRIM
PRESSURE Selector D N R
Valve
MAIN
TAP C1
MAIN
C1
Clutch
Valve
TCC SIGNAL
MAIN C2
EXHAUST Control
Main
Filter
Control
Main PSC
Valve Control
Main Main Relief
Regulator Valve
C3
Valve
(G SOLENOID) C4
C
Shift PSE C5
OVERAGE TCC
Valve PSD
CONV – OUT TO COOLER E Shift
Converter Valve
Relief
Valve
Charging SUMP
Pump TCC
Exhaust
LUBE Valve
CONV – OUT TO COOLER
TCC SIGNAL
OVERAGE
Converter PSR
Flow
Cooler Valve CONV – IN Blocked At
Separator Plate For
Lube Modulated Main Pressure MAIN PRESSURE SUCTION
Regulator SUMP
TCC SIGNAL CONTROL MAIN PRESSURE A TRIM SIGNAL
Valve
Converter CONVERTER–IN/OVERAGE B TRIM SIGNAL
Flow Beginning Model Year 2004i (interim)
Main Filter Valve Converter Flow Valve CONVERTER–OUT C3
Cooler
See SIL 03-1K/2K-04
New Hydraulic Path
For TCC Signal EXHAUST B TRIM PRESSURE
EXHAUST BACKFILL (EBF) V07739.04.00
Figure H–10. Hydraulic Schematic — Hydraulic Default Reverse

APPENDIX J — WIRING SCHEMATICS
1000 AND 2000 PRODUCT FAMILIES WIRING SCHEMATIC

TCM CONNECTOR TCM CONNECTOR ALLISON ALLISON
ALLISON ALLISON "J2" (RED)
"J1" (GRAY) RECOMMENDED RECOMMENDED
RECOMMENDED RECOMMENDED
SWITCHED COLOR WIRE NO. WIRE NO. COLOR
POWER
CHECK TRANS GREEN 125 TRANSMISSION CONTROL MODULE 215 YELLOW No HIGH
25 No 15 A
(TCM) No LOW
OUTPUT SPEED
OUTPUT FUNCTION 1 TAN 119 216 GREEN B SENSOR
19 16
OUTPUT FUNCTION 2 ORANGE 120 A 213 ORANGE NT HIGH
20 NT 13 A
TURBINE SPEED
OUTPUT FUNCTION 3 WHITE 121 214 BLUE NT LOW B SENSOR
21 14
OUTPUT FUNCTION 4 BLUE 122 L A 217 TAN N E HIGH
22 NE 17 A ENGINE SPEED
RANGE INHIBIT INDICATOR PINK 123 218 ORANGE N E LOW B SENSOR
23 18
SOL A (PCS)
OUTPUT FUNCTION 6 WHITE 124 A 223 WHITE
24 23 M
SIGNAL RETURN YELLOW 128 L 222 YELLOW
28 22 L
SOL B (PCS)
INPUT FUNCTION 9 ORANGE 114 D 224 PINK
14 BAT 24 N
INPUT FUNCTION 8 PINK 113 225 ORANGE P
13 25
INPUT FUNCTION 7 BLUE 112 L 231 TAN
12 12V or 24V 31 C
INPUT FUNCTION 6 (A) 226 SOL C ON/OFF
GREEN 111 GREEN
11 26 A
INPUT FUNCTION 5 SOL D ON/OFF
YELLOW 110 227 BLUE
10 27 B
INPUT FUNCTION 4 DIGITAL L 228 GRAY SOL E ON/OFF
WHITE 109 28 W
9 INTERFACE
INPUT FUNCTION 3 SOL F (PWM) LOCKUP
GREEN 108 229 WHITE
8 29 J
INPUT FUNCTION 2 ORANGE 107 230 BLUE SOL G ON/OFF
7 30 R
INPUT FUNCTION 1 BLUE 106 232 GREEN
6 12V or 24V (B) 32 S
MODULATED MAIN SOLENOID
IGNITION POWER YELLOW 102 221 YELLOW
2 21 T
IGNITION POWER 104 201 BLUE C
YELLOW 12V or 24V (A) AND (B) 1 D A
4
BATTERY POWER 202 PINK D
PINK 103 2 F B
3
TCM GROUND
POWER E
GRAY 101 SUPPLY 203 WHITE
1 3 E C
10A R
GRAY 105 A D L 204 GREEN
5 4 K D
DIAGNOSTIC CLASS II: PRESSURE SWITCH
BLUE 130 11
TOOL/ENGINE 30 J1850 DATA LINK MANIFOLD
INTERFACE GREEN 131 or ISO 9141 DATA LINK 210 TAN
31 10 G E
10A SUMP TEMP
RED 129 ANALOG 219 PINK H F
29 CAN 2.08 5V 19
J1939 INTERFACE 209 BLUE
BLACK 132 9 MAIN TRANSMISSION CONNECTOR
32 DATA LINK
IGNITION WHITE 116 12 C
SWITCH PWM 16
THROTTLE SPEEDO 2 (ZERO CROSSING) PINK 127 HARDWARE 220 GREEN THROTTLE
27 20 B POSITION
PULSES/REV SAME AS WIRE 126 DIVIDE A
TAN 126 TRANS 205 BLUE SENSOR
SPEEDO 1 (NON ZERO CROSSING) 26 OUTPUT 5 A
IGN TPU CALC/ SPEED 206 YELLOW
8, 16, 20 OR 40 PULSES/REV 17 5V SYNTHESIS DIGITAL 6
INTERFACE 207 GRAY
15 7
ANALOG 208 WHITE
GREEN 118 8
18 INTERFACE STARTER
12V OPTIONAL SPEEDO A 10 AWG ORANGE
or SIGNAL RETURN SOLENOID/STARTER
24V RELAY
NSBU SWITCH 10 AWG YELLOW PARK AND NEUTRAL

NSBU SWITCH P/N 29540193 START FEED
P/N 29541852 (P/N 29540479 KIT)
SAE J1939 BACKBONE
REFERENCE: FIG. J-2 WHITE 208 WHITE
P PINK
8 4C REVERSE LAMPS
GRAY 207 C GRAY
LEGEND 6 4B
YELLOW 206 B YELLOW
4 4D
L = LOGIC GROUND BLUE REVERSE AND PARK
BLUE 205 A BLUE ACCESSORY FEED
ENGINE SAE STD 9-PIN 5 4A
INTERFACE DIAGNOSTIC CONNECTOR GREEN 220 GREEN
A = ANALOG GROUND 7 7D
9 7A TAN
PARK ACCESSORY
D = DIGITAL GROUND ORANGE 10 AWG ORANGE
1 7G
12
YELLOW 10 AWG 7E
YELLOW
PINK PINK
10 7F
11
BLUE 7C
BLUE
TAN
2 7B
NSBU WITH NSBU WITH V07485.01.02

12-PIN CONNECTOR 4 AND 7-PIN CONNECTORS
Figure J–1. 1000 and 2000 Product Families Wiring Schematic
Copyright © 2004 General Motors Corp. J–1/J–2

APPENDIX J—WIRING SCHEMATICS

CONNECTOR D
J1939 J1939 E C
Data Data
Link Link F A B
G J
H
Pin ID
determined
SHIELD PIN D (–)

PIN C (+)
Attached to
PIN 31
PIN 29
PIN 32
PIN E
by Engine ECM via
connector
SHIELD
SHIELD
SHIELD
131 GREEN
129 RED
120Ω 120Ω

SAE J1939-11 V06460.01.00
Figure J–2. J1939 Backbone (CAN Bus)
Copyright© 2004 General Motors Corp. J–3

APPENDIX J—WIRING SCHEMATICS
NOTES
J–4 Copyright© 2004 General Motors Corp.

APPENDIX K—RESISTANCE VS. TEMPERATURE
1000 AND 2000 PRODUCT FAMILIES SOLENOID RESISTANCE

MAXIMUM / NOMINAL / MINIMUM
42
MAX
NOM
37
MIN
SOLENOID RESISTANCE: Ohms
32
C, D, E, and G Solenoids
27
22
17
F Solenoid
12
A and B Solenoids
7
2
0 40 80 120
TEMPERATURE (°C)
32 104 176 248

TEMPERATURE (°F) V06484.01.01
Figure K–1. Solenoid Resistance vs. Temperature Graph
Table K–1. Solenoid Resistance vs. Temperature
Solenoid A, B Solenoid C, D, E, G Solenoid F

Sump Temperature Resistance Resistance Resistance
(°C) (°F) (Ω) (Ω) (Ω)
0 32 4.5 20.0 9.5
20 68 5.5 22.0 10.5

40 104 6.5 24.5 11.5
80 176 7.5 27.0 12.5
120 248 8.5 29.5 13.5
Copyright© 2004 General Motors Corp. K–1

RESISTANCE – TEMPERATURE
CHARACTERISTIC CHART
1000000
100000
Sensor Resistance (Ohms)
Trans Fluid Temp
10000
1000
Nominal Resistance
100
10
1
-45 -30 -15 0 15 30 45 60 75 90 105 120 135 150
Temperature (C)
-49 -22 5 32 59 86 113 140 167 194 221 248 275 302
Temperature (F)
V05749
Figure K–2. Transmission Fluid Temperature Sensor Resistance vs. Sump Temperature Graph
NOTE: Look carefully at the graph. The scale for the resistance (on the left side) is not constant (linear).
It is logarithmic which means it can display a great range of values within a small space. Each
section of the graph is ten units, but the units vary from 1 to 100 000 Ohms.
Table K–2. Transmission Fluid Temperature Sensor Resistance vs. Temperature

(°C) (°F) (Ω) (Ω) (Ω)
–45 –49 128 565 141 951 155 338
–40 –40 95 826 100 735 105 644
–35 –31 68 952 72 315 75 679
–30 –22 50 153 52 480 54 807
–25 –13 36 854 38 478 40 103
–20 –4 27 345 28 488 29 631
–15 5 20 476 21 286 22 097
–10 14 15 467 16 045 16 624
–5 23 11 781 12 197 12 612
0 32 9045 9345 9646
5 41 6998 7219 7441
K–2 Copyright© 2004 General Motors Corp.

Table K–2. Transmission Fluid Temperature Sensor Resistance vs. Temperature (cont’d)
(°C) (°F) (Ω) (Ω) (Ω)
10 50 5458 5623 5787
15 59 4291 4413 4536
20 68 3398 3490 3582
25 77 2710 2779 2849
30 86 2173 2228 2282
35 95 1754 1797 1840
40 104 1424 1459 1493
45 113 1163 1191 1218
50 122 955.0 977.1 999.2
55 131 788.6 806.5 824.5
60 140 654.7 669.3 683.9
65 149 546.3 558.3 570.2
70 158 458.1 467.9 477.8
75 167 385.9 394.1 402.2
80 176 326.6 333.3 340.1
85 185 277.5 283.2 288.9
90 194 236.5 241.6 246.7
95 203 202.4 206.9 211.5
100 212 173.8 177.9 182.0
105 221 149.8 153.6 157.3
110 230 129.7 133.0 136.4
115 239 112.6 115.6 118.7
120 248 98.17 100.88 103.6
125 257 85.87 88.29 90.71
130 266 75.35 77.52 79.69
135 275 66.34 68.27 70.21
140 284 58.58 60.31 62.04
145 293 51.88 53.42 54.97
150 302 46.08 47.46 48.84
155 311 41.04 42.27 43.50
160 320 36.65 37.74 38.84
Copyright© 2004 General Motors Corp. K–3

1000 AND 2000 PRODUCT FAMILIES TRANSMISSION

SPEED SENSOR RESISTANCE VALUES
4500
4000
3500
OHMS
3000
2500
Max Ohms
2000 Nominal Ohms
Min Ohms
1500
–25 0 25 50 75 100 125 150
TEMPERATURE (°C)
–13 32 77 122 167 212 257 302

TEMPERATURE (°F)
V06096.00.01
Figure K–3. Speed Sensor Resistance vs. Temperature Graph
Table K–3. Speed Sensor Resistance vs. Temperature

(°C) (°F) (Ω) (Ω) (Ω)
–25 –13 1929 2143 2358
0 32 2157 2397 2637
25 77 2340 2600 2860
50 122 2614 2904 3195
75 167 2842 3158 3474
100 212 3071 3412 3753
125 257 3299 3666 4032
150 302 3483 3870 4257
K–4 Copyright© 2004 General Motors Corp.

APPENDIX L—ELECTRONIC INTERFERENCE
1–1. ELECTROMAGNETIC INTERFERENCE (EMI)/RADIO FREQUENCY

INTERFERENCE (RFI)
All electrical and electronic systems generate electromagnetic fields that can interfere with other electronic
systems. Allison Transmission electronic transmission controls comply with Federal Communications Commission
(FCC) regulations and other guidelines concerning emitted radio frequency interference for transportation
electronics. The position of Allison Transmission Division of General Motors is that manufacturers and installers of
Electromagnetic Interference (EMI)/Radio Frequency Interference (RFI) emitting equipment are responsible for
adhering to FCC regulations and other guidelines concerning emitted radio frequency interference for
transportation electronics.
Some radio-telephone or two-way communication radios (land-mobile radio), or the manner in which they are
installed, can adversely affect vehicle operation or be affected by other vehicle components. Expenses incurred to
protect vehicle-related systems from EMI/RFI emissions by radio-telephone or two-way communications radios
(land-mobile radio) or to integrate such devices into vehicles are not the responsibility of Allison Transmission.
1–2. GENERAL GUIDELINES FOR RADIO EQUIPMENT INSTALLATION

The following general guidelines for installing radio-telephone or two-way communications radios (land-mobile
radio) in a vehicle supplement, but DO NOT replace, detailed instructions provided by the radio equipment
manufacturer. Detailed installation instructions are the sole responsibility of the radio equipment manufacturer.
Experience has shown that most EMI/RFI problems can be prevented or eliminated by following the guidelines. If
EMI/RFI problems persist after following the guidelines and after ensuring the installation conforms to the
guidelines, contact the vehicle and radio equipment manufacturers for additional installation or equipment
operation instructions.
A. Transmitter Installation
1. Locate remote radio transmitters as far away from other electronic devices and as near to the side
of the vehicle body as possible.
2. Mount transceivers (transmitter and receiver in one box) under the dash so as not to interfere with
vehicle controls or passenger movement.
B. Antenna Installation
Each vehicle and body style reacts differently to radio frequency energy. When dealing with an
unfamiliar vehicle, test various antenna locations by using a magnetic mount antenna and checking
for adverse effects. Antenna location is a major factor in EMI/RFI problems.
C. Antenna Cable Routing

1. Use high quality, 95 percent shield coverage, coaxial (coax) cable. Route the coax well away from
any electronic components.
2. Route antenna cables as far away from vehicle wiring as possible to reduce the likelihood of the
vehicle wiring acting as an antenna for interference.
D. Radio Wiring and Connector Location

1. Connect transmitter power leads directly to the battery.
2. For transceivers (transmitter and receiver in one box) with ignition control, place a 12V power con-
tactor at the vehicle battery. Drive the contactor coil, through an appropriate in-line fuse, from an
ignition circuit not powered during engine cranking.
3. Any negative lead from a handset or control unit must return to battery negative.
4. Connect the positive lead from a handset or control unit directly to battery.
5. Fuse handset or control unit positive and negative leads separately from the transceiver negative
and positive leads. Use correctly rated fuses.
Copyright© 2004 General Motors Corp. L–1

APPENDIX L—ELECTRONIC INTERFERENCE

E. Power and Ground Wire Routing
Route radio power and ground wires as far away as possible from electronic control modules.
F. Troubleshooting
The following are common causes of EMI/RFI problems:
• Power leads connected to points other than the battery
• Improper antenna location
• Poor shielding or connections to antenna cable
• Transmitter or transceiver wiring too close to vehicle electronics
1–3. EXTERNALLY-GENERATED SPEED SENSOR SIGNALS

A. Checking for Externally-Generated Speed Sensor Signals
Use the following procedures to determine if speed sensor signals generated by a source external to
the transmission or wiring harness are present:
2. Keep the engine OFF.
3. If the TCM is ON, connect the Allison DOC™ For PC diagnostic tool.
NOTE: If false speed signals were present at the previous shutdown, the TCM might still be “ON” even
though the ignition is “OFF”. The Allison DOC™ For PC diagnostic tool is powered by ignition
power so the ignition must be “ON” to use the Allison DOC™ For PC to read the speed signals.
4. Read the speed sensor signals.

5. If a speed sensor signal is other than one (1), then there is a short to another circuit that is carrying
an AC or PWM signal.
6. Check resistance of the sensor.
7. Check for shorts to other circuits within the harness or transmission connector.
8. Check to ensure there is no conductive material inside the connector.
9. Check to be sure the speed sensor circuit wires are a twisted pair.
10. Check to ensure a properly grounded drain wire.
11. Check for the presence of a strong external AC signal.
12. Repair or replace parts as required.
L–2 Copyright© 2004 General Motors Corp.

APPENDIX M — ALLISON DOC™ DIAGNOSTIC TOOL
NOTE: Instructions for using the Allison DOC™ Diagnostic Tool when performing 1000 and 2000 Product
Families On-Highway transmission electronic controls diagnostics, are included in Appendix M.
Refer to the Allison DOC™ For PC User Guide GN3433EN for complete Allison DOC™ For PC
instructions.
1. INTRODUCTION
The Allison Diagnostic Optimized Connection For PC™ tool (Allison DOC™ For PC) is a diagnostic system
designed for use with Allison’s 1000 and 2000 Product Families transmissions. This PC-based diagnostic program
is capable of reading from a 1000 and 2000 Product Families Transmission Control Module (TCM) using J1939/
J1850 communication protocols.
Allison DOC™ For PC performs the following:
• Monitors 1000 and 2000 Product Families Transmission Control Module (TCM) data
• Displays multiple transmission parameters.
• Displays a graphical instrument panel with analog and digital gauges.
• Displays a graphical strip chart.
• Records and plays back diagnostic sessions.
• Prints diagnostic reports.
• Reprograms selected TCM settings (requires completion of Allison Transmission training).
Allison DOC™ For PC provides the following features:
• A Microsoft Windows®/PC look and feel.
• Security measures to control reprogramming TCM parameters.
• Integrated Help.
• Diagnostic Trouble Code information with a direct link to the 1000 and 2000 Product Families Troubleshoot-
ing Manual.
• A demo mode using prerecorded data.
• SmartConnect for detecting the PC-to-vehicle translation device.
• Allison DOC™ For PC is compliant with applicable TMC Recommended Practices, GM Online Standards,
SAE Standards, and CE Standards.
• Allison DOC™ For PC is RP1210A compliant.
2. WARNINGS AND NOTES
To avoid personal injury, the vehicle operator must not use or read the
WARNING! diagnostic tool while the vehicle is moving. Doing so may result in loss of
vehicle control, which may cause personal injury and vehicle damage.
WARNING! Personnel other than the vehicle operator must use the diagnostic tool.
The vehicle operator must maintain control of the vehicle while an assistant
WARNING! performs the diagnostic evaluations.
NOTE: Allison DOC™ For PC users are assumed to have a basic working knowledge of the Microsoft
Windows 95®/98®/NT/XP® Operating System(s) and Adobe® Acrobat ® Reader®.
Copyright© 2004 General Motors Corp. M–1

Trademark Information
• Windows 95®, Windows 98®, Windows ME®, Windows 2000®, Windows NT®, Windows Explorer®,
XP® Professional and Windows Media Player® are registered trademarks of Microsoft Corporation
• Adobe® Acrobat® is a registered trademark of Adobe Corporation
• Pentium® and Pentium II® are registered trademarks of Intel Corporation
• MPSI MagiKey® and MPSI PDM® are registered trademarks of NEXIQ Technologies Incorporated
• Dearborn Group Dearborn Protocol Adapter (DPA) II® and Dearborn In-line Adapter II® are registered
trademarks of Dearborn Group Technology
• Allison Diagnostic Optimized Connection™ and Allison DOC™ For PC are trademarks of General Motors
Corporation
• SPX J1850® is a registered trademark of SPX Corporation
• InstallShield® is a registered trademark of InstallShield Software Corporation
3. TEXT CONVENTIONS USED IN THIS GUIDE
The following text conventions are used in this Guide to more clearly describe using Allison DOC™ For PC:
• Screen button and keyboard key names are in bold capitals—OK, RETURN.
• Menu names are presented as displayed—File, Edit, etc.
• Menu items are presented as displayed—Exit.
• File names that may change with use are in lowercase italics—snapshot.log.
• Filenames, usually system files, that do not change are in initial capitals—Acrobat.pdf.
• Titles of windows are as they appear in the window.
6. ALLISON DOC™ FOR PC OVERVIEW
Allison DOC™ For PC has been designed to aid you, the technician, in troubleshooting and maintaining 1000 and
2000 Product Families Allison transmissions. Allison DOC™ For PC can be used with a desktop PC or a laptop PC
in the cab of a vehicle.
To avoid personal injury, the vehicle operator must not use or read the
WARNING! diagnostic tool while the vehicle is moving. Doing so may result in loss of
vehicle control, which may cause personal injury and property damage.
Allison DOC™ For PC aids you by providing:

• Displays of real-time and saved transmission operating data that include:
— Trouble codes — Range selected/attained
— Sump temperature — Configuration data
— Retarder temperature, if applicable — TPS percentage
— Percent of retarder application, — Input speed
if applicable — Turbine speed
— Shift inhibit indicator — Output speed
M–2 Copyright© 2004 General Motors Corp.

• The ability to clear active and inactive trouble codes

• Access to TCM configuration data
• With Allison Transmission approved training, the ability to change TCM configuration
• A graphic data display
• Strip chart data graphing
• A variety of reports such as:
— 1000 and 2000 Product — Diagnostic Data
Families Failure Records — Customer Modifiable Constants
— Shift Inhibits — Trouble Codes
— Allison Transmission I/O — DTC Test
Wires
NOTE: Contact your nearest Allison Distributor for additional Allison DOC™ For PC training. Allison
distributors are listed on the Allison website at www.allisontransmission.com.
6–1. ALLISON DOC™ FOR PC NAVIGATION, CONTROLS, AND STATUS INFORMATION

Allison DOC™ For PC displays the following navigation, control, and status information items regardless of what is
displayed in the main Allison DOC™ For PC window.
a. Status Bar
The status bar provides information about the connection between Allison DOC™ For PC and the TCM. It is
located in the upper portion of the main Allison DOC™ For PC window. The fields in the primary status bar are not
labeled, but their content adequately indicates their purpose.
(Transmission and CIN)

Transmission Control System and Calibration Identification Number.
Example: WTEC III 00T12352300
(Connection)
Describes the connection between Allison DOC™ For PC and an TCM. Descriptions are:
• Connected—Allison DOC™ For PC is actively connected to an TCM and receiving live data.
• Off-Line—The connection between Allison DOC™ For PC and TCM is not live and no data is being received.
• Playback—The displayed data is part of a snapshot and is not current.
• Demo—Displayed data is part of the demo program.
(Active Code)
Indicates the presence of an active Trouble Code. Indicators are:
• Active Codes
• No Active Codes

b. Menus
The menu bar at the top of the Allison DOC™ For PC window, above the Primary Status bar, displays the following
drop-down menus:
File
• Run
• Print—displays the Print Report window
• Exit—exits the Allison DOC™ For PC program
TCM Interface
• Connect/Disconnect—displays the Connect/Disconnect window
Diagnostic
• Trouble Code—displays the Trouble Code window
• Performance Complaint—displays the Performance Complaint window
• Data Monitor—displays the Data Monitor window
• TCM/Calibration Information—displays the TCM/Calibration Information window
• Custom Data Monitor—displays the Custom Data Monitor data selection window
• Graphics Monitor—displays the Graphics Monitor window
• Strip Chart—displays the Select the Data to Graph on the Strip Chart window
• Data Bus Viewer—displays the data stream being sent to Allison DOC™ For PC from the TCM.
Action Request
• Clutch Test Enabled—enables the Clutch Test
• C Solenoid Test
• Reset Adapted Shifts
• Reset Throttle Calibrations—resets TPS calibration
• Engineering Calculations—provides means to calculate converter speed ratio, vehicle speed, and acceleration
in g’s
Snapshots
• Record
• Record Options—displays the recording options window
• Stop Recording—halts recording
• Add Bookmark—displays the bookmark window
Playback
• Open Playback File—displays the Open window and the content of the Log folder.
• Play—plays a recorded data file.
• Rewind—starts the playback at the beginning.
• Stop—stops a playback.
• Fast Forward—plays a recorded data file at four times the normal speed.
• Continuous—plays a recorded data file continuously, a looped playback.
• Email—displays the Compose Email window.

Options
• Application Configuration—displays the Application Configuration tabs.
Help
• Help Topics—displays the Help Topics window.
• Demo—displays the Choose Demo window.
• 1000 and 2000 Product Families Troubleshooting Manual—activates the Adobe® Acrobat reader to display the
1000 and 2000 Product Families Troubleshooting Manual.
• Access to Allison Transmission Website —connects to the Allison Transmission website, www.allisontransmis-
sion.com. Requires Internet connection and login ID and Password to access the extranet.
• Video-based Training Materials
— 1K2K NSBU Switch
— 1K2K Internal Wiring Harness
— 1K2K Electronic Controls
— 1K2K Breakout Box
— Circuit Checks
— Circuit Basics
— Allison DOC™ Training Videos
• Hydro Schematics—displays hydraulic schematics
• ATD Calc—displays the Application Engineering Installation Design Calculations window
— Multiple-Joint Driveline Analysis
— Oil-to-Water (OTW) Cooling Analysis
— Oil-to-Air (OTA) Cooing Analysis
— OTW and OTA Combination Cooling Analysis
— Hose and Fitting Pressure Drop Analysis
• About Allison Transmission Diagnostic (Scan) Tool
c. Button and Keyboard Shortcuts

The following buttons are always available in the primary Allison DOC™ For PC window. Clicking the button or
pressing the associated function key displays the listed menu.
F1–Help
Accesses the Help system
F2–File
• Print
• Exit
F3–Diagnostic
• Trouble Code
• Performance Complaints
• Data Monitor
• TCM/Calibration Information
• Custom Data Monitor
• Graphics Monitor

• Strip Chart
• Data Bus Viewer
F4–Snapshot
Start or stop recording snapshots.
F5–Connect
Establish or break the connection between Allison DOC™ For PC and the TCM.
F6–Fire Trigger
Inserts a “bookmark” in the data stream during a recording session. Bookmarks are sequentially numbered by the
system when F6–Fire Trigger is used.
F7–Stop Recording
Stops a snapshot recording
Accelerator keys—On screen buttons have shortcuts known as accelerator keys. An underlined character in the
button text identifies the button’s accelerator keyboard key. Pressing the accelerator key activates the function
associated with the button. For example, on the button below, the P keyboard key is the accelerator key. Drop-
down menu items accelerator keys require pressing ALT before pressing the accelerator key. After pressing the
ALT/ACCELERATOR KEY combination that menu displays.
When this button is visible, and you press the P key, you activate a print function.\

8. STARTING ALLISON DOC™ FOR PC
8–1. STARTING THE PROGRAM

There are two ways to start Allison DOC™ For PC:
• Double-click the Allison DOC™ For PC tool icon on your PC desktop,
or,
• From your PC’s Start menu, select Programs_ Allison Transmission_ Allison DOC. If you stored Allison DOC™
For PC in another location, follow the path to that location and select Allison DOC.
8–2. 30-DAY TRIAL

A 30-Day trial is included as part of Allison DOC™ For PC. The 30-day trial window appears each time Allison
DOC™ For PC is started, unless the activation password has been entered. The 30-day trial window displays the
number of days remaining in the trial period. At any time before the trial period ends you may enter the activation
password. The Allison DOC™ For PC application will not function after 30 days if a valid activation password has
not been entered. Contact your Allison Support Representative to obtain the product activation password.
• Once you have the password, enter it into the Password field of the 30-Day Trial window and press OK.
• During the 30-day trial period, press CANCEL to run the Allison DOC™ For PC program.

8–3. AT START-UP
When you start Allison DOC™ For PC, a brief animation sequence plays (stop the 13 seconds sequence by
pressing the SPACEBAR). When the animation sequence ends, the Warning window displays (if the activation
password has been entered, otherwise the 30-Day Trial window displays). The Warning window lists basic
transmission troubleshooting tasks and outlines basic safety considerations (see Warnings and Notes). The
CONNECT TO VEHICLE button initiates the software connection to a vehicle and the DEMO button starts Allison
DOC™ For PC Demos.
10. USING THE ALLISON DOC™ FOR PC
10–1. CONNECTING/DISCONNECTING
a. Connecting
NOTE: Allison DOC™ For PC supports only RP1210A compliant devices.
The Connect/Disconnect window establishes the software connection between Allison DOC™ For PC and the
TCM through a PC-to- TCM data translator. In order for Allison DOC™ For PC to read information from the TCM,
both the vehicle ignition and the PC-to-vehicle translator must be powered on. Upon successful connection, the
Trouble Code window automatically displays. Any logged Diagnostic Trouble Code information is displayed in the
Trouble Code window.
To establish a connection between Allison DOC™ For PC and TCM:
1. From the Warnings window of Allison DOC™ For PC, click the button or select
Connect/Disconnect from the TCM Interface drop-down menu, or click the F5–Connect button, or
press the F5 key—The Connect/Disconnect window appears.

2. To have Allison DOC™ For PC automatically select the translation device:

• Click the SmartConnect check box.
• Select a transmission series from the Transmission drop down menu.
• Click the button. Upon successful connection, a Trouble Code window
displays.

3. To select the translation device manually:

• If SmartConnect is selected, click the SmartConnect checkbox to deselect
SmartConnect.
• Select the TCM Vendor from the drop-down Vendor list. If the Vendor line is blank, verify
that the PC-to-vehicle translator’s driver software has been installed on your PC.
• Select the translator device connecting the PC to the TCM from the drop-down Device list.
If a connection is not established, the Connect Failure window displays.
b. Disconnecting
NOTE: Disconnection breaks the Allison DOC™ For PC to TCM connection; it does not deactivate the
Allison DOC™ For PC software.
To break the connection between Allison DOC™ For PC and TCM:
1. Select Connect/Disconnect from the TCM Interface drop-down menu, click the but-
ton, or press the F5 key—the Transmission Connect/ Disconnect window appears.
2. Click the button—Allison DOC™ For PC/vehicle communications stop.
10–2. VIEWING DIAGNOSTIC DATA

Diagnostic data can be displayed in any of seven different formats. Each transmission type displays data
differently. The same seven formats are available to all transmission types. The seven formats appear in the
Diagnostic Options window. Access a format by clicking on the format name or typing the first letter of the format
name. The transmission type selected during the Connect process determines what data is displayed.

c. 1000 and 2000 Product Families Diagnostic Trouble Codes

A 1000 and 2000 Product Families Diagnostic Trouble Code consists of the letter “P” or “U” followed by four or five
numbers. A “P” indicates a transmission internal problem, while a “U” indicates a problem in a vehicle system or
the transmission-to-vehicle interface.
1000 and 2000 Product Families Diagnostic Trouble Code View
DTC
The 1000 and 2000 Product Families uses a five character, a letter and four numbers, diagnostic trouble code. Any
DTC that is unknown to the system generates a message stating that the DTC is unsupported and to call Allison
Transmission.
Active
Y/N (Yes/No) indicates if the Trouble Code is active. When a code is logged by the TCM and the condition causing
the code still exists, that code is said to be active; otherwise the trouble code is inactive.
Historic
Y/N (Yes/No) indicates if the Trouble Code is active. When a code is logged by the TCM and the condition causing
the code still exists, that code is said to be active, otherwise the trouble code is historic.
Check Trans
A “Y” indicates the CHECK TRANS light is illuminated.

Failure Record
A “Y” indicates that a failure record has been generated for the DTC.
Description
Describes the DTC.
Clear DTC information

Clears DTC information for a selected DTC row.
Cal ID
Calibration Identification.
Software Level
Software version loaded into the TCM.
Serial Number
The TCM’s serial number. If a nonprintable character is encountered, the character is represented by *. The TCM
serial number consists of the following components:
• Product Code
• Broadcast code
• Supplier Code
• Supplier Manufacturing Code
• Last Digit of the calendar year
• Julian day of the year
• Serial Number
HCN
Hardware Compatibility Number.
Sump Temp
Temperature in the transmission sump.
PRNDL A
Status of NSBU switch A.
PRNDL B
Status of NSBU switch B.
PRNDL C
Status of NSBU switch C.
PRNDL P
Status of NSBU switch P.

Gear Select/Attain
The range selected at the shift selector and the actual range attained by the transmission.
TCM Input Volts

The TCM input voltage.
c–1. Viewing Troubleshooting Manual Information for a Trouble Code

In the Trouble Code window of Allison DOC™ For PC, double-click the DTC or DTC Description for which more
information is needed. Adobe Acrobat® displays the 1000 and 2000 Product Families Troubleshooting Manual
page appropriate for the DTC.
c–2. Clearing Active Codes

1. In the Trouble Code window, click the button.
A window appears displaying the message, “Clear Active Codes Request Completed Successfully!”
2. Click the OK button.
Active Trouble Codes and associated information are cleared from the Allison DOC™ For PC window. If the cause
of the Trouble Code is not corrected, the Trouble Code may immediately reappear.
NOTE: To clear active Trouble Codes, the vehicle must be stopped and in Neutral. If these conditions are
not met. A message “Request Denied. Output Speed not less than maximum allowable value.” or
“Neutral not attained.” displays.

d. Displaying Failure Records

You can view the last five DTC failure records by double clicking on a DTC row in the Failure Record Available
column of the DTC grid or by selecting the Failure Record item from the Diagnostic main menu. A message
displays if Failure Records cannot be displayed.
Failure Record Display
e. Performance Complaint
The Performance Complaint function assists you in diagnosing a problem by selecting a symptom.
1. Select the Diagnostic drop-down menu or click the F3–Diagnostic button, or press the F3 key.
2. Select Performance Complaint—The Performance Complaint window displays.
3. Select the appropriate Vehicle Complaint from the drop-down list.

4. Click OK—the appropriate Troubleshooting Manual pages display information relevant to the se-
lected Vehicle Complaint.

f. Diagnostic Data Monitor
f–1. Displaying the Diagnostic Data Monitor

The Data Monitor allows you to view TCM information in a table format. The data displayed is dynamic. Speed and
other data changes are displayed as they occur.
To display the Data Monitor:
1. Click the button, or select Data Monitor from the Diagnostics drop-down menu, or
press the F3 key.
The diagnostic options window appears.
2. Click Data Monitor—the appropriate Diagnostic Data Monitor appears.
h. 1000 and 2000 Product Families Data Monitor

The 1000 and 2000 Product Families Data Monitor can display diagnostic data for TCMs with Configuration
Identification Numbers (CIN) starting with 11, 12, and 13 in four different vocations.
These vocations are:
• Standard—displays data for standard North American vocations
• Euro Bus—displays data for European bus vocations
• Euro Truck—displays data for European truck vocations
• Medium Duty Gas—displays data for medium-duty gasoline engine vocations
A vocation menu displays to allow selecting a vocation.
NOTE: Be sure to select the appropriate vocation to display the correct data.

1000 and 2000 Product Families Standard Data Monitor
The 1000 and 2000 Product Families Data Monitor displays data in two sections:
• Diagnostic Data
• ATD Wire Data
h–1. Diagnostic Data

• Diagnostic Data—A brief description of the diagnostic data being measured.
• Value—The value of the associated diagnostic data.
• Units—units of measure for the value.
h–2. ATD Wire Data

• ATD Wire #—The wire circuit number of the programmed function.
• Input/Output Function.
• State—On/Off.
i. TCM Calibration Information

To display current TCM and Calibration information:
2. Select TCM/Calibration Information.

1000 and 2000 Product Families TCM Calibration Information
j. The Custom Data Monitor

You may select the information to be displayed in the Custom Data Monitor window by adding or removing data
types to the display. Data types are added or removed in the Custom Data Monitor data selection window. The
Custom Data Monitor window is the same as the Data Monitor window, except that only the selected data is
displayed. Selected data types must be re-selected each time the Custom Data Monitor is displayed unless a
Custom Data List is saved.
To select Custom Data Monitor data types:
2. Select Custom Data Monitor—the Custom Data Monitor data selection window displays.

3. Select the desired Diagnostic Data type(s); up to eight data types may be selected from the left-
hand column.
4. Click the button or double click the selection—the selected data types appear in the right-
hand column.
5. Click the OK button—the selected data types appear in the Custom Data Monitor window.
1000 and 2000 Product Families Custom Data Monitor
To remove Customer Data Monitor data types:

1. Select the Diagnostic drop-down menu, or click the F3–Diagnostic button, or press the F3 key.
2. Select Custom Data Monitor—the Select Diagnostic Data to Track window displays.
3. Select the desired Diagnostic Data types from the right-hand column.
4. Click the button—the selected data types are restored to the left-hand column.
5. Click the OK button—the deleted data types no longer appear in the Custom Data Monitor window
and the window closes.
j–1. Custom Data List

You can save a list of data to display in the Custom Data Monitor by using the Custom Data List feature.
1. Move data to track into the right-hand window.
2. Click the SAVE button—the Custom Data Monitor List Save window displays

3. Type a name for the list

4. Click the OK button—the list is saved under the name you entered.
To use the saved data list:
1. Click on the Select One drop-down arrow in the data select window.
2. Highlight a list name—the Load and Delete buttons become active.
3. Click either Load, to load the list, or Delete, to delete the list.
k. The Graphics Monitor

The Graphics Monitor displays diagnostic data using gauges, thermometers, indicator lights, text boxes, and a
scrollable ATD Wire # data display.
k–1. Displaying the Graphics Monitor

To display the Graphics Monitor:
1. Select the Diagnostic drop-down menu, or click the F3–Diagnostic button, or press the F3 key.
2. Select Graphics Monitor—the Graphics Monitor window displays.
1000 and 2000 Product Families Graphics Monitor
The following information is included in the Graphics Monitor:
NOTE: A gauge can be expanded to a full-screen display by double-clicking on the gauge. Return the
display to normal by pressing the ESC key or double clicking in the expanded display.
Engine Speed
RPM indicated by needle gauge and digital readout.

Output Speed
Turbine Speed
TPS %
The TPS Percentage is indicated by needle gauge.
Gear Selected
The selected range displays.
Gear Attained
The attained range displays.
PRNDL Switch States

On/off position of the PRNDL switches.
Sump Oil Temperature

Temperature indicated by Fahrenheit thermometer and Fahrenheit/Celsius readout.
Shift Inhibits
A brief description of the shift inhibit and the associated value.
ATD Wire information

• ATD Wire # - The wire circuit number of the programmed function.
• State – On/Off
l. The Strip Chart
l–1. Displaying the Strip Chart

The Strip Chart is a graph that tracks, over time, changes in selected data as the changes occur. The data-against-
time data stream is continuous regardless of the Strip Chart mode selected.

To display the Strip Chart:

2. Select Strip Chart—the Select the Data to Graph on the Strip Chart window displays.
3. Select up to eight Diagnostic Data types from the left-hand column.

4. Choose a color for the trace of the data selected or allow the default color.
NOTE: Contrasting colors are easier to see on the strip chart.

5. Click OK.
The selected data types appear in the Strip Chart window.
1000 and 2000 Product Families Strip Chart
l–2. Data Trace Identification

The selected data is assigned a color on the graph. The name of the data and its corresponding color is displayed
in the upper-right corner of the Strip Chart display.

l–3. X-axis Scaling

The passage of time in seconds is indicated on the X-axis, horizontal bottom of the graph. As time passes, data
lines on the graph move to the right. The Strip Chart displays 10 seconds of data at a time. If playing back recorded
data, the VCR Control window displays the Total File Time and the Current File Time, in minutes. Total File Time is
the total length of the recording. Current File Time is the time elapsed since you started the playback.
l–4. Y-axis Scaling

The Y-axis, vertical left side of the Strip Chart, displays a range of values based upon the data selected for display.
If you select data having different types of measurements such as input rpm and engine cooling temperature, a
divisor, preceded by a slash (/), displays next to the data that requires calculation to determine the correct value.
For example: input speed and engine cooling temperature. RPM is displayed on the Y-axis, from 0 to 4000. To
determine the engine cooling temperature, divide the value of the engine cooling temperature trace by 15.7. An
easier method is to use the Strip Chart Cursor mode, which calculates the adjustment and displays the correct
value.
l–5. Strip Chart Modes

Several data display modes are selectable from the tool bar in the upper left portion of the Strip Chart window.
These modes, or commands, allow you to control the data display on the Strip Chart. To change to a particular
mode, simply click the desired mode icon. When a mode other than Plot is selected, the data display at that time is
frozen; but the data-against-time stream continues in the background. When Plot is re-selected, the data-against-
time stream is re-entered at the time Plot was re-selected.
The control modes are:
Plot
Plot is the default Strip Chart mode, where data lines move from left to right across the Strip Chart graph.
Pause
Pauses the plot. Data continues to be collected, but not displayed in the graph. Click the PLOT button to resume
normal plotting.
Zoom Out All Axes

Each click on the Zoom Out All Axes button increases the values displayed to the left of the graph, which increases
the area displayed and provides a less detailed display than the standard plot mode. Click the PLOT button to
resume normal plotting.
Zoom In All Axes

Each click on the Zoom In All Axes button decreases the values displayed to the left of the graph, which decreases
the area displayed and provides a more detailed display than the standard plot mode. Click the PLOT button to
resume normal plotting.
Cursor
Cursor mode allows you to place a vertical line at any point in the graph. A widow containing the Y, vertical, value
of the selected trace displays next to the cursor. Use drag and drop to position the cursor line. The Y value is for
the data selected from the list relating a line color to data. The cursor line color is the same as the selected data
line.

Print
Sends the Strip Chart data display to your printer.
Data Bus Traffic View

The data flowing between the TCM and Allison DOC™ For PC is viewable in the Data Bus Traffic View. The 1000
and 2000 Product Families data is on the J1850 bus. You can view Data Bus Messages in either decimal, base 10,
or hexadecimal, base 16, number systems. The data bus traffic can also be saved to a file for later retrieval.
To view Data Bus Traffic:
1. Select the Diagnostics drop-down menu.
2. Click on the Data Bus Viewer menu item—the Data Bus Traffic Viewer window displays.
Data Bus Messages

The numeric representations of the data flow on the data bus.
MID/SA
Message Identifier/Source Address code— the message type/source/destination.
Component ID
Manufacturer of a controller.
Model
A controller’s model number.
Software ID
Identifies the software used by the controller.

Hexadecimal
Toggles the Data Bus Message display between decimal and hexadecimal number systems.
Pause/Continue Button
Pauses and continues the Data Bus Message display.
Clear Button
Clears all Data Bus Message data.
Save Button
Saves the data as displayed in Data Bus Viewer in a file named by data and time that is located in the Allison
DOC™ For PC Saved DataBusViewerFiles folder. Use Windows Explorer to navigate to the hard drive on which
Allison DOC™ For PC is located, then to the following path—…\Program Files\Allison Transmission\Allison DOC
For PC\Saved DataBusViewer Files. The saved data can be viewed with NotePad® or WordPad™.
Exit Button
Closes the Data Bus Traffic viewer.
10–3. CLUTCH TESTS
b. 1000 and 2000 Product Families Clutch Test

The 1000 and 2000 Product Families Clutch Test uses a software tool bar to command a particular range. Fourth
and Fifth range are inhibited if the engine speed is above 1400 rpm. When clutch test is enabled, a appears
next to the Clutch Test item in the Action Request menu.
Enable the 1000 and 2000 Product Families Clutch Test by:
1. Selecting the Action Request drop-down menu.
2. Selecting Clutch Test—the Clutch Test Tool Bar displays with the current range highlighted.
To select a range from the Clutch Test Tool Bar, click on the desired range. When the shift or range change is
accomplished, the selected number is highlighted. A successful clutch test is indicated by a message display.
Disable the 1000 and 2000 Product Families Clutch Test by:
1. Selecting the Action Request drop-down menu.
2. Selecting Clutch Test—the Clutch Test Tool Bar display and the Clutch Test in the Action Request menu
are removed.

10–4. 1000 AND 2000 PRODUCT FAMILIES SOLENOID TEST
1000 and 2000 Product Families Solenoid Test provides a means of troubleshooting a particular solenoid’s
performance.
To enable the Solenoid Test function:
1. Select the Diagnostics drop-down menu.
2. Click on the Solenoid Test menu item—the Solenoid Data window displays.
To test a particular solenoid:
1. Select the solenoid from the Select a Solenoid To Test drop-down list
2. Click the TEST SOLENOID button—test data appears in the Solenoid Data window.
Sensor Name
The name of the device for which data is being reported
Value
The data being reported for each sensor—duty cycle for solenoids A, B, and F, On/Off state for solenoids C, D, and
E.
To disable the Solenoid Test function, click the CLOSE button.
10–6. 1000 AND 2000 PRODUCT FAMILIES RESET ADAPTIVE SHIFT PARAMETERS
Reset Adaptive Shift Parameters replaces all adaptive clutch control parameters with the factory calibration values
and invokes fast adaptive algorithms to adapt clutch control parameters.

To reset Adaptive Shift Parameters:
1. Select the Action Request drop-down menu
2. Click on the Reset Fast Adaptive menu item—the Reset Fast Adapt window displays.
The Reset Fast Adapt window contains 10 tabs; one for each shift that can be reset to fast adaptive.
The following information displays in the Reset Fast Adapt window:
Item Name
The name of a parameter
Value
The numerical value of the parameter
UOM
Unit Of Measure for the parameter value—cc (cubic centimeter), kPa (kilopascal), sec (second)
The fast adaptive parameters are reset when you click on the RESET FAST ADAPTIVE button—the Rest Fast
Adaptive Successful window displays. Click the OK button.
Reset Fast Adaptive Garage

Resets N (Neutral) to D (Drive) or N (Neutral) to R (Reverse) shifts to fast adaptive.
10–9. 1000 AND 2000 PRODUCT FAMILIES THROTTLE CALIBRATION
Throttle Calibration re-initializes the values of throttle sensor input that indicates closed throttle and wide open
throttle. Reset throttle calibration if the throttle sensor experienced over-travel or under-travel outside of normal
operational limits and within failure limits.

To reset open throttle calibration:
1. Select the Action Request drop-down menu.
2. Select Reset Open Throttle Calibration. The Throttle Action window displays.
3. Fully depress the throttle.
4. Click OK.
5. The Reset Open Throttle Calibration Successful window displays.
To reset closed throttle calibration:
1. Select the Action Request drop-down menu.
2. Select Reset Closed Throttle Calibration. The Throttle Action window displays.
3. DO NOT depress the n throttle.
4. Click OK.
5. The Reset Closed Throttle Calibration Successful window displays.

10–11. ENGINEERING CALCULATIONS

The Engineering Calculations function allows you to calculate Converter Speed Ratio, Vehicle Speed, and
Acceleration in g’s.
Enter the required data and press the OK button. The calculated data is added to the transmission information
displayed in the Data Monitor and Custom Data Monitors windows.
10–12.RECORDING SNAPSHOTS
Snapshots record all data being tracked by the TCM, allowing you to save the data for playback. At start up the
Allison DOC™ For PC automatically begins receiving data. Data is not saved unless a save method is selected in
the Record Options window.
If no data bus traffic is detected for 6 seconds, Allison DOC™ For PC assumes the vehicle ignition has been turned
off, recording is halted, and the Ignition Off window displays.
• Click NO to not save the recording.

• Click YES to save the recording—the Save As window displays.
If you close Allison DOC™ For PC during a recording session the following window displays—
• Click SAVE to save the recording

• Click CANCEL to return to Allison DOC™ For PC
NOTE: Data is recorded in 30-minute blocks. If a session lasts more than 30 minutes, data recorded at
the beginning of the session is lost. This function is similar to adding a ball to a tube filled with
balls. The new ball pushes the oldest ball out of the end of the tube.
To record a snapshot:
1. Select the Snapshot drop-down menu, or click the F4–Snapshot button, or press the F4 key.

2. Select Record.
3. Select Recording Options—the Record Options window displays.
NOTE: The Sub Code field is disabled for 1000 and 2000 Product Families transmissions.
4. Select one of the following trigger conditions to start recording data:

• When this Trouble Code appears, remember this session. You must enter a Trouble Code or select one from the
drop-down list. If the Trouble Code entered occurs, the session is recorded.
• When any Trouble Code appears, remember this session. The session is recorded if any Trouble Code occurs.
• Remember this session. Recording begins immediately after you click OK.
5. Click OK.
a. F6–FIRE TRIGGER
F6 –FIRE TRIGGER is a feature that allows you to bookmark a position for future reference in the TCM data
recording. Bookmarks are assigned a sequential number in the order in which they were inserted into the playback
file. In addition to their bookmark number, bookmarks are associated with a time relative to the length of the
recording. To insert a bookmark while recording data either press the F6 keyboard key or click on the F6–FIRE
TRIGGER BUTTON.
NOTE: If a recording has not been started and a bookmark is inserted, recording starts immediately and
ignores all record options. Bookmark #1 and a time stamp are set to the beginning of the file.
NOTE: The FIRE TRIGGER button text changes to display the next Bookmark #.
Example:
Bookmark number 4 has been inserted in the recording.
10–13. STOPPING/SAVING PLAYBACK FILES
1. Press the F7—Stop Recording button or press the F7 key.
2. Select record.
3. Click YES.
The Save As window displays.

4. Type a log file filename. Do not type a filename extension.

(Example – Alpha5, NOT alpha5.log).
NOTE: To save a recording in a folder other than the Logs folder, navigate to the desired folder before
clicking the SAVE button.
5. Click the button.
10–14. PLAYING BACK SNAPSHOTS

Snapshot playback provides data to any of the diagnostic views.
1. Select the Snapshot drop-down menu, or click the F4–Snapshot button, or press the F4 key.
2. Select Playback.
3. Select Open Playback File.
NOTE: Allison DOC™ For PC breaks any live connection to an TCM and the Open File window displays.
4. Navigate to the appropriate directory.
5. Select the playback file to be played (example – playback1).
6. Click OK—the Trouble Code window and the Playback VCR control window display.
Playback indicators and VCR controls are:

• Meter bar—the percentage of the playback file played.
• Total File Time—the length of the playback file in minutes and seconds
• Current File Time—the elapsed time in minutes and seconds since the beginning of the file, based on the cur-
rent location of the meter bar.
Using your mouse pointer, you may click and drag the meter bar to any point within the file and play the file from
that point. Other controls include:
• Open file—displays the Open File window

• Rewind to beginning of file
• Play
• Stop
• Play at four times normal speed
• Loop—continuous play
• Jump to trigger—displays data starting at the trigger condition selected when the data was recorded.
• Jump to Bookmark—displays the bookmark window
• Email Playback as Attachment—displays the Compose E-mail window
NOTE: A playback file that is not loaded can also be e-mailed. Click on the e-mail menu item in the
snapshot menu.
If you have not configured your PC for sending Email, click the CONFIGURATION button. The Email Configuration
window displays.

Contact your E-mail Administrator for the correct values to enter for your configuration.
11. REPROGRAMMING TCM

11–1. REPROGRAMMING THE TCM
NOTE: You must have obtained and entered the proper authorization code for reprogramming the TCM.
Select the Reprogram drop-down menu or the TCM Reprogramming tab from the Application Configuration
window.
‘

Reprogram TCM Window

1. Select the Reprogram drop-down menu or the TCM Reprogramming tab from the Application Con-
figuration window.
2. The Reprogram TCM window displays.
Reprogramming Status
During the reprogramming function, a red, flashing status line displays at the bottom of the reprogramming window.
a–6. TCM Calibrations in the Reprogram TCM Window
b. Wire Number
The wire circuit number of the programmed function described below the wire number.
Status
The enabled or disabled status of the function. Click on the Check Box to toggle between enable/disable.
Customer Modifiable Constraints

Based on the assigned Current Vocation Package (see Reprogramming Package Assignments), the associated
CMCs appear in display in the Reprogram TCM window. CMC information includes:
• Customer Modifiable Constants—a description of the CMC
• Value—the current assigned value of the CMC
Reprogram TCM
After all data has been entered or changed, click the REPROGRAM TCM button.

Select One
Allison DOC™ For PC can save TCM configurations under a unique file name.
• To load a saved configuration, select the configuration from the drop down list and click LOAD.
• To save a configuration, be sure the correct data is entered. Type a unique configuration name and click SAVE.
12. REPORTS
The Allison DOC™ For PC Report function allows you to generate TCM information reports. At least one report
must be selected for printing to occur. If the translator device uses the printer port on your PC, you must save the
report and print it when the translation device is no longer connected to the printer port. One or all report sections
may be printed at the same time. One or all report sections may be saved then printed under a single file name.
12–1. PRINTING ALLISON DOC™ FOR PC REPORTS

1. Select the File drop-down menu, or click the F2–File button, or press the F2 key.
2. Select Print—the Print Report window displays.
3. Select any or all of the available Report Sections to print.
4. Click the PRINT button.
1000 and 2000 Product Families Report Selection
• I/O Wires
• Diagnostic Data
• Customer Modifiable Constants
• Trouble Codes
• Failure Records (1000 and 2000 Product Families)
• Adapt Shifts (1000 and 2000 Product Families)
• DTC Test (1000 and 2000 Product Families)
5. Select any or all of the available Report Sections to print.

12–2. SAVING ALLISON DOC™ FOR PC REPORTS
1. Select the File drop-down menu
3. Select any or all of the available Report Sections to save
4. Click the SAVE button—the Report Name Dialog Box displays.
5. Type a unique name for the report.
6. Click the OK button—the report(s) is saved under the name typed in the Report Name Dialog Box.
NOTE: You do not have to exit the Print Report window to display a report on the screen.
12–3. DISPLAYING A SAVED REPORT ON THE SCREEN
1. Select the File drop-down menu
3. Select a report from the drop-down list of saved reports
4. Click the LOAD button—the selected report displays
12–4. PRINTING A SAVED REPORT
1. Select the File drop-down menu.
3. Select a report from the drop-down list of saved reports.
4. To confirm that you have the correct report, click the LOAD button—the selected report displays.
12–5. REPORT EXAMPLES
The reports may be printed or saved as a file. Saved reports can be displayed on the screen. Examples of each
report, as displayed on the screen, are on the following pages. All reports are configured with calibration
information at the beginning of the report.

Failure Records Report (1000 and 2000 Product Families)
Adapt Shift Report (1000 and 2000 Product Families)
DTC Test Report (1000 and 2000 Product Families)

12–6. PRINTING SCREENS

The Print Screen function of Allison DOC™ For PC allows you to print the screen being displayed.
To print a screen:
Select Print Screen from the drop-down list above the primary status bar. The Allison DOC™ For PC screen being
displayed prints at the default printer.
12–7. EXITING ALLISON DOC™ FOR PC

There are three ways to Exit Allison DOC™ For PC:
1. Click the EXIT button in the top right corner of the Allison DOC™ For PC window, or, Click the
button and select Exit or select the File drop-down menu and select Exit—the Allison
DOC™ For PC program closes.

NOTES

APPENDIX N—INPUT/OUTPUT FUNCTIONS

The schematics which followThis
wereschematic
taken fromshows
the Techthe intended
Data Book foruse
theof the and
1000 specified controls
2000 Product featureThese
Families. which
schematics provide detail information
has beenneeded to correctly
validated in the perform input and
configuration output Any
shown. function connections.
miswiring or useForof
anthis
overview of Input/Output Functions,
feature refer
whichto Section 6 of this
differs from thatmanual.
shown could result in damage to equipment or
WARNING! property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING OR
This schematic shows the intended use of the specified controls feature which
UNINTENDED USE OF THESE FEATURES.
has been validated in the configuration shown. Any miswiring or use of this
feature which differs from that shown could result in damage to equipment or
A. SECONDARY SHIFT SCHEDULE

USES: Provides for operator selection of primary or secondary shift schedules. Can be used for performance/
economy, loaded/empty, or other shift schedule combinations.
VARIABLES TO SPECIFY: None
VOCATIONS: No vocational restrictions
WIRE 110 (INPUT)
DASH SWITCH
J1-10
J1 (GRAY)
Open: PRIMARY
(usually “PERFORMANCE”)
WIRE 128 Closed: SECONDARY
J1-28
SIGNAL RETURN (usually “ECONOMY”)
OPTIONAL
VIW CONNECTOR(S)
TCM
NOTE: When the TCM is turned ON,

the active shift schedule is determined
J2 (RED)
by the current switch position.
NOTE: All items shown, except TCM, are customer furnished.
V05693.01
Figure N–1. Secondary Shift Schedule
Copyright© 2004 General Motors Corp. N–1


C. PTO ENABLE
USES: Permits the PTO to be engaged only when calibration-defined conditions are met. Also automatically
disengages the PTO if specified speeds are exceeded.
VARIABLES TO SPECIFY: Maximum engine speed for engagement, maximum engine speed for allowable
operation, maximum output speed for engagement, maximum output speed for
allowable operation, and neutral lockup ON shift speed.
VOCATIONS: Various (with usage of PTO)
When the PTO is disengaged due to overspeed, it will be automatically

re-engaged at the “Max. Engine Speed for PTO Engagement” speed (a User
CAUTION: Specified Variable), which is typically set at a relatively low speed. The resultant
re-engagement shock could cause damage to a high-inertia PTO system.
OPTIONAL
VIW CONNECTOR(S) SWITCHED
J1 (GRAY)
POWER
J1-6
DASH
J1-19 PTO LIGHT
SWITCH
PTO
TCM WIRE 106 (INPUT) PRESSURE
SWITCH
NC
J2 (RED)
COM PTO
NO
Relay shown
WIRE 119 (OUTPUT) de-energized
NOTE: All items shown, except TCM, are customer furnished. V05694.01
Figure N–2. PTO Enable
N–2 Copyright© 2004 General Motors Corp.


E. AUXILIARY FUNCTION RANGE INHIBIT

USES: Prevents inadvertent range selection when auxiliary equipment (e.g. wheelchair lift) is operating. May
also be used to prevent neutral-to-range shifts unless the brake pedal is depressed.
VOCATIONS: Various. Not for use in emergency equipment.
Typical Uses: School bus — brake pedal input

Special service bus— wheelchair lift interlock
Motorhome — “Door Ajar” interlock
If this function is enabled in the shift calibration, the function MUST be

integrated into the vehicle wiring. If the function is available in the shift
WARNING! calibration but will not be used in the vehicle, it MUST be disabled in the
calibration.
OPTIONAL WIRE 111 (INPUT) WIRE 111 INPUT

VIW CONNECTOR(S) — OR —
J1 (GRAY)
Switch is open BRAKE Switch closes

J1-11 when auxiliary PRESSURE when brakes
equipment is SWITCH are applied
WIRE 128 operating
J1-28 WIRE 128
(SIGNAL RETURN)
SIGNAL RETURN
TCM
J2 (RED)
NOTE: TCMs with this function activated must have wire 111
permanently connected to wire 128 if the function is not being used.
V05695.01
Figure N–3. Auxiliary Function Range Inhibit


H. EXHAUST BRAKE/PRESELECT REQUEST, PLUS EXHAUST BRAKE ENABLE

(STANDARD)
USES: Signals the TCM that the engine exhaust-type brake is active. By automatically preselecting a lower
transmission range when the brake is enabled, this function creates increased braking and/or maintains
engine water and transmission fluid flows at elevated levels. Also prevents engagement of the exhaust
brake if throttle > 0 or if the TCC is disengaged.
VARIABLES TO SPECIFY: Preselect range (standard value is third range)

“Lowered” or “Standard” preselect downshift schedule.
NOTE: This switch is part of the engine brake system and

EXHAUST–TYPE ENGINE BRAKE provides an indication when the engine is at closed throttle.
OPTIONAL DASH SWITCH This switch, or an equivalent control feature, is REQUIRED
VIW CONNECTOR(S) SWITCHED for all installations.
J1 (GRAY)
POWER
WIRE 107 (INPUT)
J1-7 NOTE: The engine exhaust brake must provide a low engine
speed shutoff feature, set to disable the brake at a speed
slightly higher than idle speed.
WIRE 120 (OUTPUT)
J1-20
TCM ENGINE THROTTLE

SWITCH
NC
J2 (RED)
COM NO ENGINE
DASH BRAKE EXHAUST–TYPE
LIGHT ON BRAKE
Relay shown
de-energized
V06485.01
Figure N–4. Exhaust Brake/Preselect Request, Plus Exhaust Brake Enable (Standard)

H. EXHAUST BRAKE/PRESELECT REQUEST, PLUS EXHAUST BRAKE ENABLE

(OPTIONAL)
VARIABLES TO SPECIFY: Preselect range (standard value is third range)

SWITCHED
POWER NOTE: Maximum current must not exceed
NC engine manufacturers specification
WIRE 107 (INPUT)
J1 (GRAY)
J1-7
COM NO
ENGINE
J1-20 ECM
ENGINE
OPTIONAL Relay shown EXHAUST BRAKE
VIW CONNECTOR(S) de-energized DASH SWITCH
TCM NC
COM NO ENGINE
J2 (RED)
WIRE 120 (OUTPUT)

EXHAUST
DASH BRAKE BRAKE
NOTE: The exhaust brake must provide a low engine speed Relay shown LIGHT ON
shutoff feature, set to disable the brake at a speed slightly de-energized (OPTIONAL)
higher than idle rpm.
SWITCHED
NOTE: All items shown, except TCM, are customer furnished. POWER
V07486
Figure N–5. Exhaust Brake/Preselect Request, Plus Exhaust Brake Enable (Optional)


I. EXHAUST BRAKE/PRESELECT REQUEST, PLUS ENGINE BRAKE ENABLE

(SPECIAL)
VARIABLES TO SPECIFY: Preselect range (standard value is third range).

ENGINE BRAKE
OPTIONAL DASH SWITCH
VIW CONNECTOR(S) SWITCHED NOTE: This switch is part of the engine brake system and
provides an indication when the engine is at closed throttle.
J1 (GRAY)
POWER
WIRE 107 This switch, or an equivalent control feature, is recommended
J1-7 for all installations.
(INPUT)
WIRE 120
J1-20
(OUTPUT)
TCM ENGINE THROTTLE
SWITCH
NC
J2 (RED)
COM NO
ENGINE
DASH BRAKE
BRAKE
LIGHT ON
Relay shown
de-energized
V06487.01
Figure N–6. Exhaust Brake/Preselect Request, Plus Engine Brake Enable (Special)


L. AUTOMATIC NEUTRAL FOR PTO

USES: Provides a means to automatically command N (Neutral) when PTO is operated. Requires the operator
to re-select a range to shift out of N (Neutral). Frequently used in utility trucks or wrecker/recovery trucks.
VARIABLES TO SPECIFY: Maximum output speed for activating this function.

Range indicator = N (Neutral).
VOCATIONS: Various. Not for use in emergency equipment.

calibration.
SWITCHED
DASH POWER
SWITCH
AUTO NEUTRAL (INPUT) DASH
J1-8
J1 (GRAY)
WIRE 108 OR WIRE 111 LIGHT
PTO
RANGE INDICATOR PRESSURE
J1-21
WIRE 121 (OUTPUT) SWITCH
NC
OPTIONAL
TCM VIW CONNECTOR(S)
COM NO
J2 (RED)
Relay shown PTO

de-energized
V07487.00.01.eps
Figure N–7. Automatic Neutral for PTO


V. REVERSE ENABLE
USES: This function provides for a separate instrument panel-mounted switch which must be pressed
simultaneously with the R (Reverse) shift selector pushbutton to achieve reverse operation.
VOCATIONS: European transit buses and tour buses.

calibration.
MOMENTARY
SWITCH
SWITCHED POWER
J1 (GRAY)
WIRE 106
J1–06
REVERSE ENABLE
TCM OPTIONAL
J2 (RED)
VEHICLE INTERFACE
WIRING CONNECTOR
V07488
Figure N–8. Reverse Enable


AH. KICKDOWN
USES: Permits both “Economy” and “Performance” shift schedules to be used in the same operating mode.
Typically used in stop-and-go duty cycles with an emphasis on fuel economy.
CLOSED THROTTLE
OPTIONAL
VIW CONNECTOR(S) ENGINE
FULL THROTTLE OPERATING
J1-9 ECONOMY SHIFT POINTS RANGE
J1 (GRAY)
J1-28 THROTTLE FULL THROTTLE

PEDAL KICKDOWN SHIFT POINTS
Pedal movement beyond
this point must not change
MOMENTARY engine fuel setting or
TCM SWITCH transmission throttle position
WIRE 109
J2 (RED)
(INPUT) NOTE: “Full throttle economy shift points” position on the pedal should
coincide with full stroke of the Allison throttle position sensor (if used) and/or
“full fuel” setting of the engine control. Thus, pedal movement beyond
WIRE 128 “full throttle economy shift points” must not change fuel setting of the engine
(SIGNAL RETURN) or the throttle position signal to the transmission control system.
V05702.01
Figure N–9. Kickdown


AM. REFUSE PACKER STEP SWITCH

USES: This signal can be used to denote the presence of personnel who are riding on a rear platform of the
vehicle (refuse packer).
VOCATIONS: Refuse packer.

calibration.
MOMENTARY
SWITCH
Function is activated when
SWITCHED switch is depressed.
J1 (GRAY)
POWER Function is de-activated when

switch is released.
WIRE 108
REFUSE PACKER Switch opens to indicate
STEP SWITCH presence of personnel on step.
J1–08
TCM
OPTIONAL SWITCH OPENS
VIW CONNECTOR(S) TO INDICATE NOTE: Transmission will shift according to preselect
PRESENCE OF downshift schedule when function is activated while
J2 (RED)
PERSONNEL above 1st range.

ON STEP
If function is activated while in Reverse, transmission
will shift to Neutral.
V07489
Figure N–10. Refuse Packer Step Switch


AR. OVERDRIVE DISABLE

USES: Can be used in conjunction with a 5–3–2–1 selector configuration to permit hold selection of all forward
ranges. This feature has no effect on 4-speed configurations.
SWITCHED LIGHTED CLOSED: Overdrive (5th)

POWER DASH is disabled
SWITCH
OPEN: Normal operation
J1 (GRAY)
OVERDRIVE DISABLE
J1–12
WIRE 112 (INPUT)
SIGNAL RETURN
J1–28
WIRE 128
TCM OPTIONAL
VIW CONNECTOR(S)
J2 (RED)
V07490
Figure N–11. Overdrive Disable


B. SUMP TEMPERATURE INDICATOR

USES: Provides a means to turn on a dash indicator or other alarm when transmission sump temperature has
exceeded specified limits.
SWITCHED
POWER
J1 (GRAY)
WIRE 124 (OUTPUT) TRANSMISSION

J1-24 TEMP
OPTIONAL
VIW CONNECTOR(S)
TCM
If current in lamp circuit exceeds NC
0.5 amp, ground lamp through TRANS
a relay TEMP
COM
J2 (RED)
NO
SWITCHED
POWER
WIRE 124

V05703.01
Figure N–12. Sump Temperature Indicator


C. RANGE INDICATOR
USES: May be used in the control system of an auxiliary vehicle system to permit its operation only when the
transmission is engaged in specified gear range(s), including Neutral.
NOTE: P (Park) can be an indicated range for a 1000 Product Family or 2000 Product Family transmission
(with a park pawl). For a 2000 Product Family transmission (without a park pawl), the “P” position
can be used to indicate a second NEUTRAL position.
NOTE: This feature is not suitable for activating a customer-furnished park brake in the second
NEUTRAL position (2000 Product Family transmissions), since the indicator is active only when
the engine is running.
VARIABLES TO SPECIFY: Range or ranges to be indicated.
SWITCHED
POWER
J1 (GRAY)
WIRE 121 (OUTPUT)

J1-21
NC
OPTIONAL
VIW CONNECTOR(S) COM NO
TCM
Relay shown
de-energized
AUXILIARY
J2 (RED)
VEHICLE
SYSTEM
NOTE: This signal should not be used to automatically
apply the park brake or service brakes when the
transmission is shifted to N (Neutral).
V05704.01
Figure N–13. Range Indicator


D. OUTPUT SPEED INDICATOR

USES: To indicate reaching a minimum or maximum operating speed to assist in the indication of and/or control
of the vehicle or auxiliary equipment. Frequently used to alert the operator that output speed has
exceeded a specified value.
VARIABLES TO SPECIFY: Output speed to turn indicator ON and to turn indicator OFF (ON value must be
higher than the OFF value).
SWITCHED
POWER
NC
J1 (GRAY)
COM NO
WIRE 122 (OUTPUT)
J1-22
TRANSMISSION
OPTIONAL Relay shown OR VEHICLE
OVERSPEED
VIW CONNECTOR(S) de-energized INDICATOR
TCM
J2 (RED)

V05705.01
Figure N–14. Output Speed Indicator

APPENDIX P — FLUID CHECK PROCEDURE
For vehicles containing 1000 Product Family and 2000 Product Family (2400
models), each time you park the vehicle or leave the operator’s station with the engine
WARNING! • Engage the P (Park) range by slowly releasing the service brake.
• Apply the emergency brake and/or parking brake, if present, and make sure it
is properly engaged.
• If the operator’s station will be unoccupied with the engine running, chock the
wheels and take any other steps necessary to keep the vehicle from moving.
If this procedure is not followed, the vehicle can move suddenly and you or others
could be injured.
For vehicles containing 2000 Product Family transmissions without auto-apply

parking brakes, each time you park the vehicle or leave the operator’s station with the
engine running, do the following.
WARNING!
• Apply the emergency brake and/or parking brake and make sure they are
properly engaged.
could be injured.
For vehicles containing 2000 Product Family transmissions with auto-apply parking
brakes, each time you park the vehicle or leave the operator’s station with the engine
• Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the
WARNING! parking brake is properly engaged.
• Apply the emergency brake, if present, and make sure it is properly engaged.
could be injured.
Copyright© 2004 General Motors Corp. P–1

NOTE: To ensure accurate fluid level checks, be sure that the fill tube and dipstick meet Allison
Transmission specifications. Requirements for the standard oil pan are shown in Figure P–1
and requirements for the shallow oil pan are shown in Figure P–2.
When checking a long dipstick calibration:
• Be sure the dipstick contacts the oil pan surface as shown in Figures P–1 and P–2.
• Take measurements from the end of the dipstick.
When checking a short dipstick calibration:
• Remove the oil pan.



72.6 mm 72.6 mm
10.0 mm (2.86 in) 10.0 mm (2.86 in)
(0.39 in) (0.39 in)
30.0 mm 30.0 mm
OIL PAN OIL PAN
BAND BAND
101.9 mm
(4.01 in)
Dipstick must
contact oil pan
V05803
Figure P–1. Fill Tube And Dipstick Requirements (Standard Oil Pan)
P–2 Copyright© 2004 General Motors Corp.



72.6 mm 72.6 mm
10.0 mm (2.86 in) 10.0 mm (2.86 in)
(0.39 in) (0.39 in)
30.0 mm 30.0 mm
OIL PAN OIL PAN
BAND BAND
88.5 mm
(3.48 in)
Dipstick must
contact oil pan
V05804
Figure P–2. Fill Tube And Dipstick Requirements (Shallow Oil Pan)
A. Manual Fluid Check Procedure

Clean all dirt from around the end of the fluid fill tube before removing the dipstick. Do not allow dirt or
foreign matter to enter the transmission. Dirt or foreign matter in the hydraulic system may cause
undue wear of transmission parts, make valves stick, and clog passages. Check the fluid level using
the following procedure and report any abnormal fluid levels to your maintenance persons.
B. Cold Check Procedure

The purpose of the cold check is to determine if the transmission has enough fluid to be operated
safely until a hot check can be made.
The fluid level rises as fluid temperature increases. DO NOT fill above the “COLD
CAUTION: CHECK” band if the transmission fluid is below normal operating temperatures.
• Park vehicles containing 1000 Product Family and 2000 Product Family (2400 models) as follows:
— Bring the vehicle to a complete stop on a level surface using the service brake.
— Ensure that the engine is at low idle rpm.
— Put the transmission in P (Park).
— Engage the P (Park) range by slowly releasing the service brake.
— Apply the emergency brake and/or parking brake, if present, and make sure it is properly
engaged.

• Park vehicles containing 2000 Product Family transmissions with auto-apply parking brakes as
follows:
— Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the parking brake is
properly engaged.
— Apply the emergency brake, if present, and make sure it is properly engaged.
• Park vehicles containing 2000 Product Family transmissions without auto-apply parking brakes as
follows:
— Put the transmission in N (Neutral).
— Apply the emergency brake and/or parking brake and make sure they are properly engaged.
• Chock the wheels and take any other steps necessary to keep the vehicle from moving.
• Run the engine for at least one minute. Apply the service brakes and shift to D (Drive), then to
N (Neutral), and then shift to R (Reverse) to fill the hydraulic system. Finally, shift to P (Park)
or PB (Auto-Apply Parking Brake), if available, or N (Neutral) and allow the engine to idle
(500–800 rpm). Slowly release the service brakes.
• With the engine running, remove the dipstick from the tube and wipe the dipstick clean.
• Insert the dipstick into the tube and remove. Check the fluid level reading. Repeat the check
procedure to verify the reading.
• If the fluid level is within the “COLD CHECK” band, the transmission may be operated until the fluid
is hot enough to perform a “HOT RUN” check. If the fluid level is not within the “COLD CHECK”
band, add or drain as necessary to bring it to the middle of the “COLD CHECK” band.
• Perform a hot check at the first opportunity after the normal operating sump temperature of
71ºC–93ºC (160ºF–200ºF) is reached.
C. Hot Check Procedure
The fluid must be hot to ensure an accurate check. The fluid level rises as
CAUTION: temperature increases.
• Operate the transmission in D (Drive) range until normal operating temperature is reached:
— sump temperature 71ºC–93ºC (160ºF–200ºF)
— converter-out temperature 82ºC–104ºC (180ºF–220ºF)
— If a transmission temperature gauge is not present, check fluid level when the engine water
temperature gauge has stabilized and the transmission has been operated under load for at
least one hour.
• Park vehicles containing 1000 Product Family and 2000 Product Family (2400 models) as follows:
— Apply the emergency brake and/or parking brake, if present, and make sure it is properly
engaged.

• Park vehicles containing 2000 Product Family transmissions with auto-apply parking brakes as
follows:
— Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the parking brake is
properly engaged.
— Apply the emergency brake, if present, and make sure it is properly engaged.
• Park vehicles containing 2000 Product Family transmissions without auto-apply parking brakes as
follows:
— Apply the emergency brake and/or parking brake and make sure they are properly engaged.
• Chock the wheels and take any other steps necessary to keep the vehicle from moving.
• With the engine running, remove the dipstick from the tube and wipe the dipstick clean.
• Insert the dipstick into the tube and remove. Check fluid level reading. Repeat the check procedure
to verify the reading.
NOTE: Safe operating level is within the “HOT RUN” band on the dipstick. See Figures P–1 and P–2. The
width of the “HOT RUN” band represents approximately 1.0 liter (1.06 quart) of fluid at normal
operating sump temperature.
• If the fluid level is not within the “HOT RUN” band, add or drain as necessary to bring the fluid level
to within the “HOT RUN” band.
D. Consistency of Readings
Always check the fluid level at least twice using the procedure described above. Consistency
(repeatable readings) is important to maintaining proper fluid level. If inconsistent readings persist,
check the transmission breather to be sure it is clean and unclogged. If readings are still inconsistent,
contact your nearest Allison distributor or dealer.

NOTES

TS3192EN 200304 www.allisontransmission.com Printed in U.S.A. 200406
Mechanic’s Tips
1000 and 2000 Product Family
Transmissions
MT3190EN
Mechanic’s 2004 MARCH 01
Tips MT3190EN
VOCATIONAL MODELS
1000 EVS 2100 EVS 2200 EVS 2500 EVS
1000 HS 2100 HS 2200 HS 2500 HS
1000 MH 2100 MH 2200 MH 2500 MH
1000 PTS 2100 PTS 2200 PTS 2500 PTS
1000 RDS 2100 RDS 2200 RDS 2500 RDS
1000 SP 2100 SP 2200 SP 2500 SP
B 210 B 220
1000 Series™ 2000 Series™ 2000 MH Series 2400 Series™

Printed in USA Copyright © 2004 General Motors Corporation

i
IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and
cautions described in this handbook. It is, however, important to understand that
these warnings and cautions are not exhaustive. Allison Transmission could not
possibly know, evaluate, and advise the service trade of all conceivable ways in
which service might be done or of the possible hazardous consequences of each
way. The vehicle manufacturer is responsible for providing information related to
the operation of vehicle systems (including appropriate warnings, cautions, and
notes). Consequently, Allison Transmission has not undertaken any such broad
evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR
TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION OR
THE VEHICLE MANUFACTURER MUST first be thoroughly satisfied that neither
personal safety nor equipment safety will be jeopardized by the service methods
selected.
Proper service and repair is important to the safe, reliable operation of the
equipment. The service procedures recommended by Allison Transmission (or the
vehicle manufacturer) and described in this handbook are effective methods for
performing service operations. Some of these service operations require the use of
tools specially designed for the purpose. The special tools should be used when and
as recommended.
Three types of headings are used in this manual to attract your attention. These
warnings and cautions advise of specific methods or actions that can result in personal
injury, damage to the equipment, or cause the equipment to become unsafe.
WARNING: A warning is used when an operating procedure, practice,

etc., if not correctly followed, could result in personal injury or loss of life.
CAUTION: A caution is used when an operating procedure,

practice, etc., if not strictly observed, could result in damage to or
destruction of equipment.
NOTE: A note is used when an operating procedure, practice, etc., is

essential to highlight.
TRADEMARK INFORMATION
DEXRON® is a registered trademark of General Motors Corporation.
Allison DOC™ is a trademark of General Motors Corporation.
TranSynd™ is a trademark of Castrol Ltd.
ii
TABLE OF CONTENTS
Paragraph Description Page
SECTION I PREVENTIVE MAINTENANCE

1–1 Periodic Inspections And Care. . . . . . . . . . . . . . . . . . . . . . . 1
1–2 Importance Of Proper Transmission Fluid Level. . . . . . . . . 3
1–3 Transmission Fluid Check . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1–4 Keeping Fluid Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1–5 Fluid Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1–6 Transmission Fluid And Filter Change Intervals . . . . . . . . . 11
1–7 Transmission Fluid Contamination . . . . . . . . . . . . . . . . . . . 13
1–8 Transmission Fluid And Filter Change Procedure. . . . . . . . 14
1–9 Oil Vent (Breather) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION II REMOVING TRANSMISSION

2–1 Draining Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2–2 Disconnecting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2–3 Uncoupling From Driveline, Engine, And Vehicle . . . . . . . 18
2–4 Removing The Transmission . . . . . . . . . . . . . . . . . . . . . . . . 18
2–5 Removing The Flexplate Adapter . . . . . . . . . . . . . . . . . . . . 19
2–6 Removing Output Flange Or Yoke . . . . . . . . . . . . . . . . . . . 19
SECTION III PREPARING THE TRANSMISSION FOR INSTALLATION

3–1 Checking Input Components . . . . . . . . . . . . . . . . . . . . . . . . 20
3–2 Installing Output Flange Or Yoke . . . . . . . . . . . . . . . . . . . . 20
3–3 Installing PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3–4 Installing Fill Tube And Seal . . . . . . . . . . . . . . . . . . . . . . . . 24
3–5 Checking Plugs And Openings . . . . . . . . . . . . . . . . . . . . . . 25
SECTION IV PREPARING VEHICLE FOR TRANSMISSION

INSTALLATION
4–1 Engine, Transmission Adaptation Requirements . . . . . . . . . 26
4–2 Checking Flexplate Drive Assembly . . . . . . . . . . . . . . . . . . 30
4–3 Chassis And Driveline Inspection . . . . . . . . . . . . . . . . . . . . 30
4–4 Cooler, Filter, And Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4–5 Checking Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
iii
Paragraph Description Page
SECTION V INSTALLING TRANSMISSION INTO VEHICLE

5–1 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5–2 Mounting To Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5–3 Installing Transmission Mounting Components . . . . . . . . . 37
5–4 Coupling To Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5–5 Connecting Power Takeoff Controls . . . . . . . . . . . . . . . . . . 37
5–6 Connecting Parking Brake Control . . . . . . . . . . . . . . . . . . . 38
5–7 Connecting Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5–8 Connecting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5–9 Filling Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5–10 Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5–11 Road Test And Vehicle Operation Checklist . . . . . . . . . . . . 42
SECTION VI CUSTOMER SERVICE

6–1 Owner Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6–2 Service Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
iv
PREFACE
This handbook is a mechanic’s reference for maintaining, removing, or installing
1000 and 2000 Product Families transmissions. All features of the transmission and
the vehicle involved in installation procedures are discussed. The information
presented will help the mechanic maintain, remove, or install the transmission in a
manner that assures satisfactory operation and long service life. For additional
detailed information, refer to the appropriate transmission service manual and
electronic controls troubleshooting manual.
Unless specifically indicated otherwise, this handbook refers to all 1000 and 2000
Product Families transmissions. The differences between the various transmissions
are explained as required.
v
1000 AND 2000 PRODUCT FAMILIES — CROSS SECTION
CONVERTER HOUSING/FRONT SUPPORT MODULE
• CONVERTER HOUSING MAIN HOUSING MODULE
• INPUT SPEED SENSOR • MAIN HOUSING
• OIL PUMP • C3 CLUTCH
TORQUE • FRONT SUPPORT TURBINE • C4 CLUTCH
CONVERTER SPEED • C5 CLUTCH
ASSEMBLY SENSOR
MAIN SHAFT
OUTPUT YOKE
vi
REAR COVER MODULE
• REAR COVER
• OUTPUT SPEED SENSOR
• OUTPUT SHAFT
• P3 PLANETARY
• PARK PAWL (1000/2200 ONLY)
P2 PLANETARY
P1 PLANETARY
DEEP OIL PAN
CONTROL MAIN FILTER CONTROL VALVE MODULE
ROTATING CLUTCH MODULE SUCTION FILTER
• TONE WHEEL (IF NO PTO) OR PTO DRIVE GEAR
• C2 CLUTCH
• C1 CLUTCH
• TURBINE SHAFT V04525.02.02
1000 AND 2000 PRODUCT FAMILIES — CROSS SECTION
with Optional Converter Housing, Rear Cover, and Shallow pan
CONVERTER HOUSING
REAR
COVER
vii
SHALLOW PAN V05719.02.02
OIL VENT
MOUNTING PROVISION
TURBINE SPEED
SENSOR
INPUT SPEED
SENSOR
OUTPUT SPEED SENSOR
viii
NSBU SWITCH
SELECTOR SHAFT
SAE 6-BOLT
PTO PAD
AVAILABLE
OIL FILL TUBE
LOCATION
1000 AND 2000 PRODUCT FAMILIES TRANSMISSION – LEFT-FRONT VIEW V04779.03.02

INPUT SPEED
SENSOR
TURBINE SPEED
SENSOR
OIL VENT
(BREATHER)
OUTPUT SPEED
SENSOR
ix
MOUNTING PAD
COOLER PORTS
AVAILABLE
OIL FILL TUBE
LOCATION
PROVISION FOR SAE 6-BOLT
CUSTOMER-SUPPLIED PTO PAD
SPEED SENSOR OR (DRIVE GEAR OPTIONAL)
TACHOGRAPH
(OPRIONAL) MAIN ELECTRICAL
CONNECTOR
1000 AND 2000 PRODUCT FAMILIES TRANSMISSION – RIGHT-REAR VIEW V04780.01.05

NOTES
x
PREVENTIVE S ECTION
MAINTENANCE I
1–1. PERIODIC INSPECTIONS AND CARE
Transmission Product Families
Beginning January 2004, Allison Transmission began shipping new 1000 and 2000
Product Families vocation specific transmission models for North America. 1000
and 2000 Product Families vocational models are:
• Emergency Vehicle Series—1000 EVS, 2100 EVS, 2200 EVS, 2500 EVS
• Highway Series—1000 HS, 2100 HS, 2200 HS, 2500 HS
• Motorhome Series—1000 MH, 2100 MH, 2200 MH, 2500 MH
• Pupil Transportation/Shuttle Series—1000 PTS, 2100 PTS, 2200 PTS,
2500 PTS
• Rugged Duty Series—1000 RDS, 2100 RDS,·2200 RDS,·2500 RDS
• Specialty Series—1000 SP, 2100 SP, 2200 SP, 2500 SP
• Bus Series—B 210, B 220
The 1000 and 2000 Product Families include the 1000/2000/2400 Series
transmissions. Refer to WATCH 309 for detailed descriptions of the vocational
models and their correlation to the existing 1000/2000/2400 Series.
Transmission Inspection
CAUTION: When cleaning the transmission, do not spray steam,

water, or cleaning solution directly at the breather (oil vent). Spraying
steam, water, or cleaning solution at the breather can force the water or
cleaning solution into the transmission and contaminate the
transmission fluid.
1
Clean and inspect the exterior of the transmission at regular intervals. Severity of
service and operating conditions determine the frequency of these inspections.
Inspect the transmission for:
• loose bolts—transmission and mounting components

• fluid leaks—repair immediately
• loose, dirty, or improperly adjusted throttle sensor or shift selector linkage
• damaged or loose hoses
• worn, frayed, or improperly routed electrical harnesses
• worn or frayed electrical connections
• worn or out-of-phase driveline U-joints and slip fittings
• clogged or dirty oil vent (breather)
Vehicle Inspection
Check the vehicle cooling system occasionally for evidence of transmission fluid
which would indicate a faulty oil cooler.
Welding
CAUTION: When welding on the vehicle:

• DO NOT WELD on the vehicle without disconnecting
from the TCM all control system wiring harness connectors.
• DO NOT WELD on the vehicle without disconnecting
TCM battery power and ground leads.
• DO NOT CONNECT welding cables to any control components.
A label describing on-vehicle welding precautions is available from your authorized

Allison service dealer and should be installed in a conspicuous place. A vehicle used
in a vocation that requires frequent modifications or repairs involving welding must
have an on-vehicle welding label (SA2607).
2
1–2. IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL
Transmission fluid cools, lubricates, and transmits hydraulic power.
Always maintain proper fluid level. If fluid level is too low, the torque
converter and clutches do not receive an adequate supply of fluid and the
transmission overheats. If the level is too high, the fluid aerates—causing
the transmission to shift erratically and overheat. Fluid may be expelled
through the breather or dipstick tube when the fluid level is too high.

WARNING: For vehicles containing 1000 or 2200 models, each time
you park the vehicle or leave the operator’s station with the engine
• Make sure that the engine is at low idle rpm.
• Engage the P (Park) range by slowly releasing the service brake.
• Apply the emergency brake and/or parking brake, if present, and
make sure it is properly engaged.
If this procedure is not followed, the vehicle can move suddenly and
you or others could be injured.
WARNING: For vehicles containing 2100 or 2500 models with auto-

apply parking brakes, each time you park the vehicle or leave the
sure that the parking brake is properly engaged.
• Apply the emergency brake, if present, and make sure it is properly
engaged.
3
WARNING: For vehicles containing 2100 or 2500 models without
auto-apply parking brakes, each time you park the vehicle or leave the
• Apply the emergency brake and/or parking brake and make sure
NOTE: For accurate fluid level checks, be sure that the fill tube and
dipstick meet Allison Transmission specifications. Requirements for
the standard oil pan are shown in Figure 1–1 and requirements for the
shallow oil pan are shown in Figure 1–2.
When checking a long dipstick calibration:
• Be sure the dipstick contacts the oil pan surface as shown in
Figures 1–1 and 1–2.
• Take measurements from the end of the dipstick.
When checking a short dipstick calibration:
• Remove the oil pan.
4

72.6 mm 72.6 mm
10.0 mm (2.86 in) 10.0 mm (2.86 in)
(0.39 in) (0.39 in)
30.0 mm 30.0 mm
HOT RUN HOT RUN
5
(1.18 in) (1.18 in)
OIL PAN OIL PAN
BAND BAND
101.9 mm
(4.01 in)
Dipstick must
contact oil pan
Figure 1–1. Fill Tube And Dipstick Requirements (Standard Oil Pan)
V05803

72.6 mm 72.6 mm
10.0 mm (2.86 in) 10.0 mm (2.86 in)
(0.39 in) (0.39 in)
30.0 mm 30.0 mm
6
OIL PAN OIL PAN
BAND BAND
88.5 mm
(3.48 in)
Dipstick must
contact oil pan
Figure 1–2. Fill Tube And Dipstick Requirements (Shallow Oil Pan)
V05804
a. Manual Fluid Check Procedure. Clean all dirt from around the end
of the fluid fill tube before removing the dipstick. Do not allow dirt or
foreign matter to enter the transmission. Dirt or foreign matter in the
hydraulic system may cause undue wear of transmission parts, make
valves stick, and clog passages. Check the fluid level using the
following procedure and report any abnormal fluid levels to your
maintenance persons.
b. Cold Check Procedure. The purpose of the cold check is to determine if the
transmission has enough fluid to be operated safely until a hot check can be made.
CAUTION: The fluid level rises as fluid temperature increases.

DO NOT fill above the “COLD CHECK” band if the transmission
fluid is below normal operating temperatures.
• Park vehicles containing 1000 or 2200 models as follows:

— Bring the vehicle to a complete stop on a level surface using the service
brake.
— Make sure that the engine is at low idle rpm.
— Apply the emergency brake and/or parking brake, if present, and make
sure it is properly engaged.
• Park vehicles containing 2100 or 2500 models with auto-apply parking brakes
as follows:
brake.
— Put the transmission in PB (Auto-Apply Parking Brake). Make sure that
— Apply the emergency brake, if present, and make sure it is properly
engaged.
7
• Park vehicles containing 2100 or 2500 models without auto-apply parking
brakes as follows:
brake.
— Apply the emergency brake and/or parking brake and make sure they are
properly engaged.
• Chock the wheels and take any other steps necessary to keep the vehicle from
moving.
• Run the engine for at least one minute. Apply the service brakes and shift to
D (Drive), then to N (Neutral), and then shift to R (Reverse) to fill the hydraulic
system. Finally, shift to P (Park) or PB (Auto-Apply Parking Brake), if
available, or N (Neutral) and allow the engine to idle (500–800 rpm). Slowly
release the service brakes.
• With the engine running, remove the dipstick from the tube and wipe the
dipstick clean.
• Insert the dipstick into the tube and remove. Check the fluid level reading.
• If the fluid level is within the “COLD CHECK” band, the transmission may
be operated until the fluid is hot enough to perform a “HOT RUN” check. If
the fluid level is not within the “COLD CHECK” band, add or drain as
necessary to bring it to the middle of the “COLD CHECK” band.
• Perform a hot check at the first opportunity after the normal operating sump
temperature of 71˚C–93˚C (160˚F–200˚F) is reached.
c. Hot Check Procedure.
CAUTION: The fluid must be hot to provide an accurate check. The

fluid level rises as temperature increases.
• Operate the transmission in D (Drive) range until normal operating

temperature is reached:
— sump temperature 71˚C–93˚C (160˚F–200˚F)
— converter-out temperature 82˚C–104˚C (180˚F–220˚F)
— If a transmission temperature gauge is not present, check fluid level when
the engine water temperature gauge has stabilized and the transmission
has been operated under load for at least one hour.
8
• Park vehicles containing 1000 or 2200 models as follows:
brake.
— Apply the emergency brake and/or parking brake, if present, and make
sure it is properly engaged.
• Park vehicles containing 2100 or 2500 models with auto-apply parking brakes
as follows:
brake.
— Put the transmission in PB (Auto-Apply Parking Brake). Make sure that
— Apply the emergency brake, if present, and make sure it is properly
engaged.
• Park vehicles containing 2100 or 2500 models without auto-apply parking

brakes as follows:
brake.
— Apply the emergency brake and/or parking brake and make sure they are
properly engaged.
• Chock the wheels and take any other steps necessary to keep the vehicle from
moving.
• With the engine running, remove the dipstick from the tube and wipe the
dipstick clean.
• Insert the dipstick into the tube and remove. Check fluid level reading. Repeat
the check procedure to verify the reading.
9
NOTE: Safe operating level is within the “HOT RUN” band on the
dipstick. See Figures 1–1 and 1–2. The width of the “HOT RUN” band
represents approximately 1.0 liter (1.06 quart) of fluid at normal
operating sump temperature.
• If the fluid level is not within the “HOT RUN” band, add or drain as necessary
to bring the fluid level to within the “HOT RUN” band.
d. Consistency of Readings. Always check the fluid level at least twice using the
procedure described above. Consistency (repeatable readings) is important to
maintaining proper fluid level. If inconsistent readings persist, check the
transmission breather to be sure it is clean and unclogged. If readings are still
inconsistent, contact your nearest Allison distribution or dealer.
1–4. KEEPING FLUID CLEAN

Prevent foreign material from entering the transmission by using clean containers,
fillers, etc. Lay the dipstick in a clean place while filling the transmission.
CAUTION: Containers or fillers that have been used for antifreeze

solution or engine coolant must NEVER be used for transmission
fluid. Antifreeze and coolant solutions contain ethylene glycol which,
if put into the transmission, can cause the clutch plates to fail.
1–5. FLUID RECOMMENDATIONS

Hydraulic fluids (oils) used in the transmission are important influences on
transmission performance, reliability, and durability. Only fluids meeting TES-295
(TranSynd™) or DEXRON®-III specifications are acceptable for use in the 1000
and 2000 Product Families transmissions.
To make sure the fluid is qualified for use in Allison transmissions, check for a
TES-295 or a DEXRON®-III fluid license or approval numbers on the container, or
consult the lubricant manufacturer. Consult your Allison Transmission dealer or
distributor before using other fluid types.
CAUTION: Disregarding minimum fluid temperature limits can

result in transmission malfunction or reduced transmission life.
When choosing the optimum viscosity grade of fluid to use, duty cycle, preheat
capabilities, and/or geographical location must be taken into consideration.
Table 1–1 lists the minimum fluid temperatures at which the transmission may be
safely operated without preheating the fluid. Preheat with auxiliary heating
equipment or by running the equipment or vehicle with the transmission in P (Park)
10
or PB (Auto-Apply Parking Brake), if available, or N (Neutral) for a minimum of
20 minutes before attempting range operation.
Table 1–1. Transmission Fluid Operating Temperature Requirements

Ambient Temperature Below
Which Preheat is Required
Viscosity Grade Celsius Fahrenheit
DEXRON®-III –27 –17
TranSynd™ –33 –22
(Ref. SIL 13-TR-90)
1–6. TRANSMISSION FLUID AND FILTER CHANGE INTERVALS
CAUTION: Transmission fluid and filter change frequency is

determined by the severity of transmission service. More frequent
changes may be necessary than recommended in the general
guidelines when operating conditions create high levels of
contamination or overheating.
a. Frequency. Change the control main filter at or before the initial 8000 km
(5000 miles) then follow the schedule in Table 1–2. Table 1–2 is given only as a
general guide for fluid and filter change interval.
11
Table 1–2. 1000 and 2000 Product Families Transmission Fluid and Filter Change
Filters Filters
Schedule 1. Recommended Fluid and Filter Change Intervals (Non-TranSynd™/Non-TES 295 Fluid)
25,000 Miles 25,000 Miles 25,000 Miles 50,000 Miles 50,000 Miles 50,000 Miles
(40 000 km) (40 000 km) (40 000 km) (80 000 km) (80 000 km) (80 000 km)
12 Months 12 Months Overhaul 12 Months 24 Months 24 Months Overhaul 24 Months
NOTE: The following recommendations in Schedule 2 are based upon the transmission containing 100 percent of TranSynd™ fluid. For transmissions that
contain a mixture of TranSynd™ and non-TranSynd™ fluids, refer to Schedule 3.
Flushing Machines are not recommended or recognized due to variation and inconsistencies with ensuring removal of 100 percent of the used fluid.
Recommendations in Schedule 2 are based upon standard Allison fluid change procedures.
Schedule 2. Recommended Fluid and Filter Change Intervals (TranSynd™/TES 295 Fluid)
(80 000 km) (80 000 km) (80 000 km) (160 000 km) (80 000 km) (80 000 km)
12
Schedule 3. Modified Fluid and Filter Change Intervals With a Mixture* of TranSynd™ and Non-TranSynd™ Fluids
(40 000 km) (40 000 km) (40 000 km) (80 000 km) (80 000 km) (80 000 km)
* Mixture is defined as the quantity of oil remaining in the transmission after a standard fluid change combined with the quantity of TranSynd™ that is
required to fill the transmission to the proper level. A mixture of TranSynd™ or TES 295 equivalent vs. non-TranSynd™ other than as defined in this
paragraph does not meet the requirements that permit the eligibility for the recommendations given in Schedule 3.
Severe Vocation: On/Off Highway, Refuse, City Transit, Shuttle Transit, and MH models.
Local conditions, severity of operation or duty cycle may require more or less frequent fluid change intervals that differ from the published recommended
fluid change intervals of Allison Transmission. Transmission protection and fluid change intervals can be optimized by the use of fluid analysis. Filters must be
changed at or before recommended intervals.
b. Abnormal Conditions. Transmissions used in high cycle rate applications
should use fluid analysis to be certain that a proper fluid change interval is
established. Transmission fluid must be changed whenever there is evidence of dirt
or a high temperature condition. A high temperature condition is indicated by the
transmission fluid being discolored or having a strong odor, or by fluid analysis.
Local conditions, severity of operation, or duty cycle may require more or less
frequent fluid or filter change intervals.
c. Fluid Analysis. Transmission protection and fluid change intervals can be

optimized by monitoring fluid oxidation according to the tests and limits shown in
Table 1–3. Consult your Distributor/Dealer for an Oil Analysis Kit (refer to
SIL 17-TR-96, Rev A). To be sure of consistent and accurate fluid analysis, use only
one fluid analysis firm. Refer to the Technician’s Guide for Automatic Transmission
Fluid, GN2055EN, for additional information.
Table 1–3. Fluid Oxidation Measurement Limits
Test Limit
Viscosity ±25% change from new fluid
Total Acid Number +3.0 change from new fluid
1–7. TRANSMISSION FLUID CONTAMINATION

a. Fluid Examination. At each fluid change, examine the drained fluid for
evidence of dirt or water. A normal amount of condensation will appear in the fluid
during operation.
b. Water. Obvious water contamination of the transmission fluid or transmission

fluid in the heat exchanger coolant indicates a leak between the water and fluid areas
of the cooler. Inspect and pressure test the cooler to confirm the leak. Replace
leaking coolers.
NOTE: Coolant can also be contaminated by engine oil; be sure to
locate the correct source of coolant contamination.
c. Engine Coolant.
CAUTION: Engine coolant in the transmission hydraulic system

requires immediate action to prevent malfunction and possible serious
damage. Completely disassemble, inspect, and clean the transmission.
Remove all traces of the coolant, and varnish deposits resulting from
engine coolant contamination. Refer to SIL 18-TR-98 for more
information.
13
d. Metal. Metal particles in the fluid (except for the minute particles normally
trapped in the oil filter) indicate internal transmission damage. If these particles are
found in the sump, the transmission must be disassembled and closely inspected to
find their source. Metal contamination requires complete transmission disassembly.
Clean all internal and external hydraulic circuits, cooler, and all other areas where
the particles could lodge.
CAUTION: After flushing the cooler with Kwik-Flush Cart J 46550,

be sure to check the external cooler circuit restriction. If circuit
pressure drop is above specification, the cooler has excessive trapped
particles and must be replaced.
NOTE: When equipment to flush the oil cooler is not available, install
a filter in the cooler line between the oil cooler and the transmission
“from cooler” port. The cooler circuit pressure drop specifications
must still be met (see AS64–071 or AS 64–072 in the Allison Sales
Tech Data book). Frequent initial changes of this filter element may be
required as debris is flushed out of the oil cooler circuit. Closely
monitoring change in cooler circuit pressure drop will indicate when a
filter change is needed.
1–8. TRANSMISSION FLUID AND FILTER CHANGE PROCEDURE

a. Drain Fluid.
NOTE: Do not drain the transmission fluid if changing the control

main filter only.
• Drain the fluid when the transmission is at normal operating sump

temperature—71˚C–93˚C (160˚F–200˚F). Hot fluid flows quicker and drains
more completely.
• Remove the drain plug from the oil pan and allow the fluid to drain into a
suitable container.
• Examine the fluid as described in Paragraph 1–7.
b. Replace Control-Main Filter. (Figure 1–3)

1. Using J 45023 filter wrench or a strap filter wrench, remove the control-main
filter by rotating it in the counterclockwise direction. Use a standard strap-
type filter wrench.
14
MAGNET
FILTER
V05805
Figure 1–3.
2. Remove the magnet from the filter attachment tube or from the top of the
filter element.
3. Clean any metal debris from the magnet. Report any metal pieces larger than
dust to your maintenance personnel.
4. Reinstall the magnet onto the filter attachment tube.
5. Lubricate the gasket on the control-main filter with transmission fluid.
6. Install, by hand, the control-main filter until the gasket on the control-main
filter touches the converter housing or cooler manifold.
CAUTION: Turning the control-main filter more than ONE FULL

TURN after gasket contact will damage the filter.
7. Turn the filter ONE FULL TURN ONLY after gasket contact.
8. Reinstall the drain plug and sealing washer. Tighten the drain plug to 30–40 N·m
(22–30 lb ft).
15
c. Refill Transmission. The amount of refill fluid is less than the amount used for
the initial fill. Fluid remains in the external circuits and transmission cavities after
draining the transmission.
After refill, check the fluid level using the procedure described in Paragraph 1–3.
Table 1–4. Transmission Fluid Capacity
Initial Fill* Refill*

Sump Liters Quarts Liters Quarts
Standard 14 14.8 10 10.6
Shallow 12 12.7 7 7.4
* Approximate quantities, do not include external lines and cooler hose.
1–9. OIL VENT (BREATHER)

a. Location and Purpose. The breather is located at the top left-rear of the
transmission main housing. The breather prevents air pressure buildup within the
transmission and its passage must be kept clean and open.
b. Maintenance. The amount of dust and dirt encountered will determine the
frequency of breather cleaning. Use care when cleaning the transmission.
CAUTION: When cleaning the transmission, do not spray steam,

water, or cleaning solution directly at the breather (oil vent). Spraying
steam, water, or cleaning solution at the breather can force the water
or cleaning solution into the transmission and contaminate the
transmission fluid.
16
S ECTION REMOVING
II TRANSMISSION
2–1. DRAINING TRANSMISSION

Drain the transmission fluid before removing the transmission from the vehicle.
• Remove the drain plug from the oil pan. Examine the drained fluid for
evidence of contamination—refer to Paragraph 1–7. Reinstall the drain plug.
• Remove the transmission fill tube if it interferes with transmission removal.
Plug the fill tube hole in the main housing to keep dirt from entering the
transmission.
NOTE: A significant amount of fluid may drain from the hydraulic
lines when they are disconnected from the transmission.
• Disconnect all hydraulic lines from the transmission. Remove the lines from
the vehicle if they interfere with transmission removal. Plug all openings to
keep dirt from entering the hydraulic system.
2–2. DISCONNECTING CONTROLS

• Disconnect the external wiring harness from the main electrical connector,
three speed sensors and the NSBU switch (refer to Pages viii and ix). Prevent
dirt or moisture from entering a disconnected connector. Position the wiring
harness so it does not interfere with transmission removal.
• Disconnect linkage from the customer-furnished transmission shift lever.
Position the disconnected linkage so it does not interfere with transmission
removal. Leave the shift lever and NSBU switch on the transmission.
• If PTO(s) is (are) used, disconnect the PTO(s) wiring harness(es).
• If parking brake is present, disconnect linkage.
17
2–3. UNCOUPLING FROM DRIVELINE, ENGINE, AND VEHICLE
WARNING: Chock wheels to prevent vehicle from moving when

driveline is disconnected. This is not necessary if vehicle is on a lift or
jackstands.
• Disconnect the vehicle drive shaft from the transmission output flange or
yoke. Position the disconnected shaft to avoid interference when removing the
transmission.
• If PTO equipped, disconnect PTO connections such as:
— PTO hydraulic hoses
— PTO-powered equipment drive shaft
• If transmission mountings support the rear of the engine, place a jack or other
support under the engine.
• Securely support the transmission with a hoist, jack, or other suitable removal
equipment.
• Remove all bolts, nuts, washers, spacers, and supports that attach the
transmission to the vehicle and the engine.
NOTE: It may be necessary to remove an engine flywheel housing
access cover to remove flexplate or flexplate adapter bolts. This is the
engine to transmission connection.
2–4. REMOVING THE TRANSMISSION
CAUTION: Do not pull the transmission away from the torque

converter assembly. The torque converter drive cover must be entirely
free of any restraint by the flexplate drive or crankshaft pilot when the
transmission separates from the engine.
WARNING: Be sure the torque converter is moving rearward with the

transmission as it is removed. Do not allow the torque converter to
become disengaged from the oil pump or to fall and injure yourself or
others.
• Move the transmission away from the engine, approximately 34.6 mm

(1.36 inch) for a number 2 flywheel housing or 44.2 mm (1.74 inch) for a
number 3 flywheel housing, until it is completely clear of the engine. If used,
remove the adapter ring and/or gasket.
• Raise or lower the transmission as necessary to remove it from the vehicle.
18
2–5. REMOVING THE FLEXPLATE ADAPTER
• Remove the flexplate adapter, if present, from the front of the torque
converter. This part will be needed for transfer if a replacement transmission
is being installed.
WARNING: Handle the transmission carefully whenever the torque

converter retaining bracket is not present. NEVER tilt the converter
end down or the torque converter may slide forward, disengaging the
oil pump, or may fall completely out of the transmission causing
damage and/or personal injury.
• Attach a torque converter retaining bracket at the earliest opportunity. The

bracket keeps the torque converter from sliding out of engagement with the oil
pump or from falling off completely and being damaged or causing personal
injury.
2–6. REMOVING OUTPUT FLANGE OR YOKE
If replacing the transmission, you may need to transfer the output flange or
yoke to the replacement transmission. The output flange or yoke is retained
by one 1⁄2-20 x 23⁄4 inch flanged-head bolt.
19
PREPARING THE
S ECTION
TRANSMISSION FOR
INSTALLATION III
3–1. CHECKING INPUT COMPONENTS

a. Bolt Holes. Check all bolt holes on the front of the transmission and rear of the
engine that are used in connecting the transmission to the engine. The threads must
be undamaged and the holes free of chips or foreign material.
b. Pilot Boss. Check the pilot boss (at the center of the torque converter) for
damage or raised metal that prevents free entry into the crankshaft hub (or adapter).
c. Starter Ring Gear. Check the starter ring gear for excessive wear or damage.
d. Transmission Mounting Flange. Check the transmission mounting flange for

raised metal, dirt, or if used, pieces of gasket material.
e. Transmission-to-Engine Mounting Flange. Inspect the transmission-to-engine

mounting flange for raised metal, burrs, or pieces of gasket material (if used).
Remove any of these defects. Inspect the threaded holes for damaged threads.
3–2. INSTALLING OUTPUT FLANGE OR YOKE

a. Output Oil Seal. Check the output oil seal for leaks or damage. Refer to
JA3664EN, In-Chassis Maintenance, for replacement instructions. If not replacing
the oil seal, lubricate it with high-temperature grease or transmission fluid.
b. Check Flange or Yoke.
CAUTION: DO NOT attempt to polish the oil seal contact surface on

the flange or yoke. Scratches or machine-type lead can cause the seal
to leak. Replace the output flange/yoke if light scoring cannot be
removed using crocus cloth.
Check each flange or yoke for damage or wear. The oil seal contact surface must be
smooth and regular to prevent oil leaking past the seal. Rotate the flange after
installation to check for binding.
20
c. Install Output Flange or Yoke.
CAUTION: Be sure that the flange, output shaft and retaining

hardware are clean.
Care must be exercised to avoid transmission output seal or journal
damage. Check to be sure that the seal is free of tears and cuts. Nicks
and scratches must not exist on the lead-in chamfer or seal journal
section of the output flange or yoke.
Lubricate the splines of the output shaft and the oil seal assembly with transmission
fluid or oil-soluble grease.
CAUTION: Do not use a hammer or other similar tool to force the

flange/yoke onto the shaft. Forcing the flange/yoke onto the shaft may
result in transmission damage.
Start the yoke/flange assembly onto the output shaft, being sure that the splines are
properly engaged and slide freely. Push the yoke/flange assembly into the rear cover
module.
Install a new output shaft sealing washer and the output shaft bolt.
CAUTION: Use of an impact wrench requires the retention of the

yoke/flange to prevent internal transmission damage.
Tighten the output shaft bolt to 110–135 N·m (80–100 lb ft).
Rotate the yoke/flange assembly by hand to check for binding, interference, and
runout.
3–3. INSTALLING PTO

Access to the PTO mounting pads and the space available to maneuver the
transmission determine whether the PTO should be installed before or after the
transmission is installed.
CAUTION: DO NOT use cork or other soft gaskets to install the PTO.
Use only the shims/gaskets listed in the 1000 and 2000 Product
Families Tech Data Book.
NOTE: DO NOT use sealing compounds—they are usually

incompatible with automatic transmission fluid.
21
a. Install Guide Pins—included in the PTO manufacturers installation kit.
Determine the required position of the guide pins in relation to the mounted position
of the PTO. Install two headless guide pins into the converter-housing PTO pad.
Tighten the pins.
b. Install Gasket. Install the special gasket over the guide pins—ribbed surface
away from the transmission.
c. Mount the PTO.
CAUTION: M10 bolts MUST be used to attach the PTO to the

transmission. Inch series threads (.375-16 UNC) will damage the
transmission main housing.
Mount the PTO on the guide pins or studs provided in PTO kit. Mesh the PTO
driven gear with the transmission PTO drive gear. Retain the PTO by installing a
bolt in the top bolt hole. Install the remaining bolts and nuts, if used. When nuts are not
used, two bolts replace the guide pins. Tighten all bolts to 57–68 N·m (42–50 lb ft).
Tighten nuts to manufacturers specifications. Be sure that the PTO backlash meets
manufacturers requirements.
d. Connect PTO Lube, if required. Some PTOs require pressure lubrication.
When needed, tap into the cooler return fitting or line at the transmission converter
housing (see Figure 3–1). An orifice of 0.81 mm (0.031 inch) must be present in the
line to control the amount of fluid diverted from the transmission. Some PTO assem-
blies contain internal restrictions equivalent to the required orifice (check the PTO
manufacturer for lubrication needs and the orifice installation). This connection can
be made later if the lube line will interfere with transmission installation. See
Figure 3–2 which shows this connection schematically.
MAIN PRESSURE TAP
“TO COOLER” PORT

“FROM COOLER” PORT
BOTTOM VIEW V05742.01
Figure 3–1. Cooler Port and Main Pressure Tap Location
22
PTO LUBE LINE

(with 0.81 mm (0.032 in.) orifice)
COOLER RETURN
OIL LINE
ENLARGED DETAIL
V05816
Figure 3–2. PTO Lube Plumbing Schematic
e. Connect PTO Clutch Feed, if required. Some PTOs are clutch-applied. Use
transmission main pressure from the main pressure tap for applying the PTO clutch.
See Figure 3–1 for the location of the main pressure tap and Figure 3–3 for a typical
plumbing schematic when this feature is needed. This connection can be made later
if the clutch apply line will interfere with transmission installation.
23
EXHAUST TO
TRANSMISSION TRANSMISSION
MAIN PRESSURE THROUGH PTO
MANUAL HYDRAULIC
VALVE OR SOLENOID
VALVE

PTO LUBE LINE
(with 0.81 mm (0.032 in.) orifice)
V05817
Figure 3–3. PTO Clutch Pressure Plumbing Schematic
3–4. INSTALLING FILL TUBE AND SEAL

a. Location. The fill tube may be mounted on either the right or left side. The unused
fill tube provision must have a plug in the fill tube opening.
CAUTION: Install a fill tube bracket using the correct length M8

self-tapping screw which is 24.0 mm (0.95 inch). A screw that is too
long may cause cracks and leaks in the main housing. Refer to
AS64-065 in the Allison Sales Tech Data book for the correct screw
specifications.
b. Installation. If the fill tube will interfere with the installation of the
transmission, delay this step until after the transmission is in the vehicle. Install the
fill tube seal into the main housing. Insert the fill tube through the seal until the
shoulder at the bottom of the fill tube contacts the seal. Align the tube bracket with its
bolt location. Install the fill tube bolt and tighten until it is firmly seated against the
bracket.
24
3–5. CHECKING PLUGS AND OPENINGS
Carefully check all sides and the bottom of the transmission for loose or missing
plugs.
a. Main Pressure Tap Plug. Check that 0.4375–20 UNF-2A pressure plug is
tightened to 10–13 N·m (7–10 lb ft).
b. Fluid Drain Plug. Check that the drain plug is tightened to 25–32 N·m (18–24 lb ft).
c. Tachograph Plug. If present, tighten to 60–67 N·m (44–49 lb ft).
d. Cleanliness. Check the openings into which the cooler lines connect for defor-
mities or obstructions. Check the transmission electrical connectors for cleanliness.
Clean electrical connections with an LPS cleaner only (refer to Service Information
Letter 17-TR-94).
25
PREPARING VEHICLE S ECTION
FOR TRANSMISSION
INSTALLATION
IV
4–1. ENGINE, TRANSMISSION ADAPTATION REQUIREMENTS

You must make sure a new transmission installation can be adapted to the vehicle’s
engine. Using the measurements described in this section assures correct
transmission-to-engine adaptation. Refer to Figure 4–1, 4–2, or installation
drawings AS64-022 and/or AS64-023 in the Allison Sales Tech Data book. Typical
arrangement of adaptation components is shown in Figure 4–3.
a. Measuring Equipment. The following measuring equipment is required:

• 600 mm (24 inch) precision caliper
• 50–100 mm (2–4 inch) telescoping gauge
• 25–76 mm (1–3 inch) outside micrometer
• Dial indicator and mounting attachments—base, posts, and clamps
• 0–150 mm (0–6 inch) depth micrometer
b. Flywheel Housing Pilot Bore Diameter. The flywheel housing pilot bore
diameter must measure:
• No. 3 Housing—409.58–409.70 mm (16.125–16.130 inch)
c. Flywheel Housing Bore Runout. Flywheel housing bore runout cannot exceed
0.51 mm (0.020 inch) TIR.
d. Flywheel Housing Face Squareness. The flywheel housing face cannot be
out-of-square more than 0.51 mm (0.020 inch) TIR.
e. Crankshaft Hub Pilot or Adapter Diameter. The crankshaft hub pilot or hub
adapter pilot diameter must measure between 43.26–43.31 mm (1.703–1.705 inch).
f. Crankshaft Hub Pilot or Adapter Squareness. The crankshaft hub or hub
adapter cannot be out-of-square more than 0.013 mm (0.0005 inch) TIR per inch of
diameter.
g. Crankshaft Hub Pilot or Adapter Concentricity. The crankshaft hub pilot or
the hub adapter pilot concentricity cannot exceed 0.25 mm (0.010 inch) TIR.
26
Must be maintained 44.21 mm Society of Automotive Engineers (SAE) J617 standard
when installed 40.15 mm number 3 engine flywheel housing mounting face
1.741 in. (cast iron or aluminum)
( )
1.581 in. Hardened flat washer recommended
(Lockwasher permissible)
* MOUNTING BOLT
BOLT (12), M10 x 1.5 x 15 Thread grade and torque to be compatible with engine
General Motors P/N 23049056 flywheel housing. A minimum of 10 bolts is required,
Torque to 57–68 N•m (42–50 lb-ft) including the top two.
* FLEXPLATE ADAPTER 409.5 mm DIA
23045170 (16.12 in.)
NOTES: Opening must be provided in flywheel housing

for access to attach flexplates bolts
Parts with asterisk ( *) are not supplied with

292.1 mm (11.50 in.) DIA transmission assembly
BOLT CIRCLE
Torques shown are for plain (non-plated) customer
* FLEXPLATE BLANK – 23045169
27
furnished components. Torque requirements should
(No crankshaft bolt holes) be reviewed if plated fasteners will be used. Consult
with your fastener supplier.
* SCUFFPLATE
Converter space claim exceeds that of AT500 outside
120.4 mm (4.70 in.) diameter. When using existing AT500
* CRANKSHAFT HUB ADAPTER flexplate adaptations, this area must be checked to
ensure proper clearance.
See Drawing AS64-023 in Allison Sales Tech Data book

4.05 mm (0.159 in.) MIN CLEARANCE
CRANKSHAFT
43.26–43.31 mm CENTERLINE 49.95–50.00 mm
(1.703–1.705 in.) (1.967–1.969 in.)
I.D. PILOT ON HUB PILOT O.D.
CRANKSHAFT 2.54 mm (0.100 in.) MIN PILOT
HUB ADAPTER 4.05 mm (0.159 in.) MIN CLEARANCE
V05821
Figure 4–1. 1000 and 2000 Product Families Engine Adaptation (No. 3 Housing)
Must be maintained Society of Automotive Engineers (SAE) J617 standard
when installed 34.56 mm number 2 engine flywheel housing mounting face
30.50 mm (cast iron or aluminum)
1.361 in. * MOUNTING BOLT
( )
1.201 in. Thread grade and torque to be compatible with engine
flywheel housing. A minimum of 10 bolts is required,
including the top two.
BOLT (12), M10 x 1.5 x 15 447.6 mm DIA Hardened flat washer recommended
General Motors P/N 23049056 (17.62 in.) (Lockwasher permissible)
Torque to 57–68 N•m (42–50 lb-ft)
* FLEXPLATE ADAPTER
23045170
NOTES: Opening must be provided in flywheel housing

for access to attach flexplates bolts
Parts with asterisk ( *) are not supplied with

transmission assembly
292.1 mm (11.50 in.) DIA
BOLT CIRCLE
28
Torques shown are for plain (non-plated) customer
* FLEXPLATE BLANK – 23045169 furnished components. Torque requirements should
(No crankshaft bolt holes) be reviewed if plated fasteners will be used. Consult
with your fastener supplier.
* SCUFFPLATE
Converter space claim exceeds that of AT500 outside
120.4 mm (4.70 in.) diameter. When using existing AT500
* CRANKSHAFT HUB ADAPTER flexplate adaptations, this area must be checked to
ensure proper clearance.
See Drawing AS64-022 in Allison Sales Tech Data book

4.05 mm (0.159 in.) MIN CLEARANCE
CRANKSHAFT
43.26–43.31 mm CENTERLINE 49.95–50.00 mm
(1.703–1.705 in.) (1.967–1.969 in.)
I.D. PILOT ON HUB PILOT O.D.
CRANKSHAFT 2.54 mm (0.100 in.) MIN PILOT
HUB ADAPTER 4.05 mm (0.159 in.) MIN CLEARANCE V05822
Figure 4–2. 1000 and 2000 Product Families Engine Adaptation (No. 2 Housing)
SAE # 2 OR # 3
FLYWHEEL HOUSING
SAE # 2 OR # 3
FLYWHEEL HOUSING TRANSMISSION
MAIN HOUSING
TRANSMISSION
MAIN HOUSING
STARTER FLYWHEEL/STARTER
RING GEAR RING GEAR ASS'Y
FLEXPLATE
ADAPTER FLEXPLATE
ADAPTER
FLEXPLATE
29
FLEXPLATE CONVERTER
CONVERTER DRIVE COVER
DRIVE COVER
CRANKSHAFT CRANKSHAFT
WEARPLATE
CRANKSHAFT HUB ADAPTER
CRANKSHAFT
HUB ADAPTER WEARPLATE
CONVERTER PILOT CONVERTER PILOT
FLEXPLATE-MOUNTED STARTER FLYWHEEL-MOUNTED STARTER

RING GEAR RING GEAR
V05823
Figure 4–3. Typical Arrangement Of Adaptation Components

h. Flexplate Flatness. Flexplate flatness must be 0.76 mm (0.030 inch) TIR, or
less, when measured at 292 mm (11.5 inch) diameter.
i. Torque Converter Axial Location. This is controlled by the engine physical

adaptation. Using a depth gauge, measure from the face of the engine flywheel
housing to the face at the 292.1 mm (11.50 inch) diameter. The torque converter
axial location should measure:
4–2. CHECKING FLEXPLATE DRIVE ASSEMBLY

a. Flexplate Inspection. Check the flexplate for cracks, distortion, or elongated
bolt holes. Replace a worn or damaged flexplate.
b. Engine Crankshaft End Play. Make sure engine crankshaft end play is within
the engine manufacturer’s specifications.
NOTE: When assembling the flexplate to the crankshaft hub or hub

adapter, make sure the outer flexplate bolt holes are aligned.
c. Flexplate Assembly Installation. Install the flexplate onto the engine crankshaft
hub using the bolts and torque values specified for that engine. Refer to Figure 4–1
or 4–2 for the proper position of an installed flexplate.
4–3. CHASSIS AND DRIVELINE INSPECTION

Inspect the chassis and driveline components for the following conditions, and
correct them as appropriate.
• Transmission mounts—broken or worn-out
• Bolts and other hardware—damaged, missing, or incorrect
• Isolators (rubber mounts)—damaged or missing
• Driveline angles—runout, or balance which does not conform to the
manufacturer’s recommendations
• Driveline yoke slip joints:
— freedom of movement
— damaged or worn-out
— correctly lubricated
— correctly indexed
30
• Driveline midship or hanger bearings—damaged or misaligned
• Universal joints:
— damaged or worn-out
— correctly lubricated
— correctly indexed
• Vehicle differential backlash—manufacturer’s specification
• Universal joint coupling—alignment and differential damage
• Cross-frame members and rear support members—condition and location
• PTO-driven equipment shafts and couplings—damaged or misaligned
• Auxiliary transmission:
— shaft alignment
— alignment of yoke or flange
— backlash
— fluid leaks
4–4. COOLER, FILTER, AND LINES

a. Inspection. Perform the following and correct any faulty conditions:
• Transmission fluid cooler and related coolant lines:

— Check for contamination—clean and flush as necessary
— Inspect for deterioration
— Inspect for faulty connectors or kinks
— Clean and flush transmission fluid cooler, both coolant and oil sides.
Pressure check both sides using a 276 kPa (40 psi) air supply.
• Hydraulic lines:
— Check for contamination—clean and flush as necessary
— Inspect for deterioration
— Inspect for faulty connectors or kinks
31
b. After Overhaul. A complete cleanup of the transmission system after an over-
haul cannot be assumed. See JA3664EN, In-Chassis Maintenance, for cooler flush-
ing procedure.
NOTE: When equipment to flush the oil cooler is not available, install
a filter in the cooler line between the oil cooler and the transmission
“from cooler” port. The cooler circuit pressure drop specifications
must still be met (see AS64–071 or AS 64–072 in the Allison Sales
Tech Data book). Frequent initial changes of this filter element may be
required as debris is flushed out of the oil cooler circuit. Closely
monitoring change in cooler circuit pressure drop will indicate when a
filter change is needed.
4–5. CHECKING CONTROLS

a. Inspection. Inspect the following and correct any faulty conditions:
• Shift selector:
— improper operation
— improper cable routing
• Cab and chassis wiring harness:
— poor connections
— frayed insulation
— wiring damage
• Throttle sensor components, if present:
— improper routing
— bellows damage
— improper or loose cable mounting
• PTO controls, if present:
— damage
— wear
— improper operation
— lubrication
— electrical harness connections and wiring damage
• Temperature gauge:
— capillary tube damage (if used)
— sensor damage
32
• Fluid pressure gauge tubing:
— damage
— kinks
— improper routing
b. Throttle Position Sensor (TPS) Adjustment. When properly installed by the

equipment manufacturer, the TPS, if used, should not need adjustment. If TPS
adjustment is necessary, confirm that it has been installed to ATD specification (refer
to Figure 4–4). The TPS is self-calibrating and therefore has no optimum closed
throttle or full throttle value. Be sure there is no misalignment or obstruction to
smooth movement through the full stroke of the TPS.
The Allison DOC™ for PC diagnostic tool can be used to check the TPS adjustment.
See the users manual that comes with the diagnostic tool for details. Also, be sure to
check for diagnostic codes (DTCs) associated with TPS function.
c. Hitch-Pin Throttle Position Sensor Installation.
• Install the throttle sensor body as follows:

— Clamp cable end using clamp and shims (refer to Figure 4–4).
— Secure the sensor body using the mounting holes provided.
— Install a heat shield if any part of the throttle sensor is near the exhaust
manifold, turbochargers, or any other heat source.
• Adjust the throttle sensor as follows:

— The engine fuel lever must be at the closed throttle position.
— Install the hitch pin cable end of the sensor to the engine fuel
lever with brackets so that at the idle position the cable end is
11–17 mm (0.44–0.67 inch) from its fully retracted position, and
at wide open throttle the cable end is pulled an additional
15–22.9 mm (0.60–0.90 inch) from the idle position.
— Recheck the stroke distance of the throttle sensor, from closed to wide
open after installation is completed. Stroke distance must be from
15.2–22.9 mm (0.60–0.90 inch).
— Recheck for zero clearance at the fuel lever. Make sure that the
15.2–22.9 mm (0.60–0.90 inch) dimension has not changed.
— Design throttle sensor linkage brackets and levers to nominal
dimensions so that the system stays within tolerance bands throughout
its operating life.
33
BENDING LOAD
APPLIED
UNACCEPTABLE INSTALLATION
MOUNTING PROVISION:
Use M6 x 1.00 or 1⁄4-20 in. series bolts 3 places 10.0° MAX INSTALLED
Torque M6 x 1.00 bolt to 10–13 N•m (84–120 lb in.) OPERATING ANGLE
1
Torque ⁄4-20 in. series bolts to 13–14 N•m (108–132 lb in.) IN ALL DIRECTIONS
Mount to a solid frame member. Flatness of
chassis mounting surface must not exceed
0.8 mm (0.03 in.).
LOADING IN
TENSION ONLY
ACCEPTABLE INSTALLATION
Attachment must provide freedom
of motion to allow cable loading in
tension only (no bending loads).
WIRING HARNESS
55.0 mm (2.17 in.)
MIN REQUIRED Fuel control must not move
FOR CONNECTION the throttle sensor beyond R 152.0 mm (6.00 in.) MIN
REMOVAL the closed throttle position ALLOWANCE RADIUS
at any time.
FULLY EXTENDED
FORCE REQUIRED FULLY
26.7 N (6.0 LB) MAX RETRACTED
MOUNTING
CLOSED THROTTLE LENGTH
47.5 mm (1.87 in.) (NOTE: Mounting length
95.2 mm (3.75 in.)
+ 50.8 mm (2 inches) equals
FULL THROTTLE cable length)
118.1 mm (4.65 in.)
OPERATING BAND 15.2 – 22.9 mm
(0.6 – 0.9 in.)
118.1 mm
(4.65 in.) The location of the
95.2 mm clamping bracket relative
(3.75 in.) to the fuel lever at closed
throttle must be maintained
within this range.
Attach to engine or governor

30.2 mm (1.19 in.) 93.45 mm (3.679 in.) housing using clamp and shims as
87.15 mm (3.431 in.) required. Clamp must positively
lock in cable groove.
Fuel lever attachment linkage or bracket must HITCH PIN CLIP

allow fuel lever to return to closed throttle position ENGINE FUEL LEVER
when sensor rod is maintained at full throttle position.
Attach the throttle sensor directly to the engine fuel
lever with no breakover or yield linkages between the
engine fuel lever shaft and the attachment point of the
throttle sensor.
CLOSED THROTTLE 183.1 mm (7.21 in.) MAX

FULL THROTTLE
SAME AS WITHOUT 160.2 mm (6.31 in.) MIN
SLIP LINK
FULLY EXTENDED
38.1 mm (1.50 in.)
HITCH PIN CLIP

FULLY RETRACTED
OPTIONAL THROTTLE SENSOR ASSEMBLY WITH SLIP LINK
V00430.06
Figure 4–4. Hitch-Pin Throttle Position Sensor Installation Diagram
34
S ECTION INSTALLING
TRANSMISSION
V INTO VEHICLE
5–1. HANDLING
a. Preventing Damage. Carefully handle the transmission to prevent damage to
components in the installation path.
b. Control of Transmission Movements. Use a hoist or transmission jack that

allows precise control of transmission movements during installation.
5–2. MOUNTING TO ENGINE

Use the following procedure to mount the transmission to the engine:
WARNING: Handle the transmission carefully whenever the

torque converter retaining bracket is not present. NEVER tilt the
converter end down or the torque converter may slide forward,
disengaging the oil pump, or may fall completely out of the
transmission causing damage and/or personal injury.
• Inspect the flexplate adapter, if used, for cracks or other damage and
replace it when these conditions are found.
• Remove the torque converter retaining bracket just before the
transmission is ready to be installed in the vehicle.
• Attach the flexplate adapter to the front of the torque converter or to the
flexplate using six new adhesive-coated M10 x 1.5 x 15 bolts. Tighten each
bolt to 57–68 N·m (42–50 lb ft).
• Align one of the flexplate’s bolt holes with the access opening in the engine
flywheel housing.
• Lubricate the center pilot boss with molybdenum disulfide grease

(Molycote G, or equivalent).
• Install an M10 x 1.5 headless guide bolt into one of the flexplate bolt holes in
the flexplate adapter or torque converter mounting lug (see Figure 5–1). Align
the guide bolt with the flexplate hole at the access opening.
35
FLYWHEEL HOUSING
GUIDE BOLT
Make from
M10 x 1.5" bolt
TAPER
Screwdriver slot
to aid removal
V05824
Figure 5–1. Pilot Tool For Transmission-To-Engine Alignment
• Push the transmission toward the engine while guiding the pilot boss on the
torque converter into the flexplate hub adapter or flywheel, and the guide bolt
into the hole on the flexplate (a headless guide bolt in the engine flywheel
housing may also aid in the transmission installation).
• Seat the transmission squarely against the engine flywheel housing—no force
is required. If interference is encountered, move the transmission away from
the engine and investigate the cause.
• Align the bolts holes in the converter housing with those in the engine
flywheel housing.
• Install all transmission-to-engine bolts and washers finger tight (a minimum
of 10 bolts is required and must include the top two).
CAUTION: The entire converter housing circumference must be

flush against the engine flywheel housing before tightening any bolts.
DO NOT use the bolts to seat the housing.
• Tighten four bolts at equally-spaced intervals around the converter housing

bolt circle. Use the torque specified by the engine or vehicle manufacturer.
• Remove the flexplate guide bolt through the engine flywheel housing access
opening. Replace it with a self-locking bolt. Tighten the bolt finger tight.
36
NOTE: DO NOT tighten any flexplate-to-flexplate adapter bolts until
all of the bolts have been installed and tightened finger tight.
• Rotate the engine crankshaft to install the remaining new adhesive-coated

bolts into the flexplate adapter. After all bolts have been installed finger tight,
tighten the bolts to 57–68 N·m (42–50 lb ft).
• Install the flywheel housing access cover, if used.
5–3. INSTALLING TRANSMISSION MOUNTING

COMPONENTS
CAUTION: Use the type and grade of mounting bolts recommended

by the vehicle manufacturer.
• Install all bolts, washers, spacer, isolators, or supports required to support the
transmission in the vehicle frame.
• Tighten the bolts to the torque values recommended by the vehicle
manufacturer.
5–4. COUPLING TO DRIVELINE

• Couple the driveline companion flange or universal joint yoke to the flange or
yoke on the transmission. Use the bolts and torque values recommended by
the vehicle manufacturer.
• Check the universal joint angularity of all U-joints in the driveline. Determine
if they are within specification.
5–5. CONNECTING POWER TAKEOFF CONTROLS

If not already mounted, mount the PTO(s) onto the transmission—refer to Paragraph
4–3.
• Check the PTO harness routing for kinks and sharp bends. Avoid routing the
cable close to exhaust pipes or manifold. The PTO harness must not rub or
interfere with adjacent parts.
• Connect controls to the PTO.
• Check for proper PTO control operation.
37
CAUTION: PTO units using transmission main pressure to engage
the PTO gear must have a positive main pressure shut-off at the
solenoid valve when the PTO is not engaged. Failure to provide this
feature may cause inadvertent clutch apply and PTO damage.
• Couple the PTO output to its driven equipment. Check couplings or

universal joints for correct assembly and alignment. If the driven component
is not a direct mount arrangement, check the PTO drivelines for angularity,
phasing, and offsets.
5–6. CONNECTING PARKING BRAKE CONTROL

• Connect and properly adjust the parking brake.
• If present, adjust the brake shoe-to-drum clearance as specified by the
manufacturer.
5–7. CONNECTING COOLER
Figure 5–2 shows typical cooler port locations on the transmission. Consult
AS64-071 (in Allison Sales Tech Data book) for cooler fitting torque values.
\
MAIN PRESSURE TAP
“TO COOLER” PORT

BOTTOM VIEW V05742.01
Figure 5–2. Cooler Port Location
• Remove the cover from the main transmission electrical connector and
carefully connect the transmission external wiring harness. Keep dirt and
debris out of the connector.
38
• Connect the external wiring harness to the engine, turbine, and output speed
sensors.
• If used, connect the PTO(s) connector(s). The PTO connector is NOT part of
the Allison Transmission external wiring harness.
• If used, connect wire(s) to electric tachograph.
• Make sure the speed sensors, the PTO connector, and all other connectors are
securely seated and latched. A connector can be heard or felt to latch, but
confirm the latching by pulling on the connector—NOT THE WIRES.
• The transmission has a sump fluid thermistor on the pressure switch manifold.
Actual temperature readings may be made using the PC-based diagnostic tool.
Consult the users manual furnished with the Allison DOC™ diagnostic tool.
• A temperature gauge may be installed in the “To Cooler” line. If equipped for
them, install a temperature probe—capillary tube and bulb or a thermocouple.
If equipped with a capillary tube and bulb:
— Tighten the adapter tight enough to prevent leakage.
— Install the bulb into the adapter and tighten the nut.
— Check the capillary tube for interference with other parts that might chafe
or damage the tube. Long tubes may require support clips or brackets.
If equipped with a thermocouple:
— Install the thermocouple and connect the leads.
5–8. CONNECTING CONTROLS

• Remove any protective covering from the wiring harness connectors. Connect
the external wiring harness to the main electrical connector, the three speed
sensors and the NSBU switch (refer to Pages viii and ix).
• Connect linkage to the transmission shift lever. For information on adjusting
the NSBU switch or the shift linkage, see JA3664EN, In-Chassis
Maintenance.
• If PTO(s) is (are) used, connect the PTO(s) wiring harness(es).
• If parking brake is present, connect linkage.
5–9. FILLING HYDRAULIC SYSTEM

• Check that all unused hydraulic openings are plugged.
• Fill the transmission with the required amount of Allison-approved
DEXRON®-III fluid—refer to Paragraph 1–5 and 1–8.
• Run the engine for about one minute and check the fluid level—refer to
Paragraph 1–3.
39
5–10. INSTALLATION CHECKLIST
Use this list after transmission installation. As items are checked, mark
them off this list.
• Torque Values:
❑ All oil pan bolts—24–29 N·m (18–21 lb ft)
❑ Main pressure tap—10–13 N·m (7–10 lb ft)
❑ Cooler fittings —
0.750-16 (inch series), 20–30 N·m (15–22 lb ft)
1.0625-12 (inch series), 34–47 N·m (25–35 lb ft)
❑ Cooler manifold bolts—20–34 N·m (15–25 lb ft)
❑ Flexplate adapter-to-converter cover bolts—57–68 N·m (42–50 lb ft)
❑ Flexplate-to-crankshaft hub bolts—Consult Engine Manufacturer
Specifications
❑ Flexplate-to-flexplate adapter bolts—57–68 N·m (42–50 lb ft)
❑ Fluid drain plug—30–40 N·m (22–30 lb ft)
❑ Fluid fill tube bracket bolt—Firmly seated against bracket
❑ Speed sensor bolts—10–13 N·m (7–10 lb ft)
❑ Output flange bolt—108–136 N·m (80–100 lb ft)
❑ PTO cover bolts—51–61 N·m (38–45 lb ft)
❑ PTO mounting bolts—51–61 N·m (38–45 lb ft)
❑ NSBU switch to main housing—24–29 N·m (18–21 lb ft)
❑ Selector lever nut (customer-supplied)—20–27 N·m (15–20 lb ft)
❑ PTO pressure hose to transmission—10–13 N·m (7–10 lb ft)
❑ Rear cover bolts—51–61 N·m (38–45 lb ft)
❑ TPS to engine bracket
(M6 bolts)—10–13 N·m (7–10 lb ft)
(0.250-20 bolts)—12–15 N·m (9–11 lb ft)
• Cooler Fluid Lines and Air Hose for:
❑ No leaks
❑ Connection tightness
❑ Correct routing
• Throttle Sensor for:
❑ Proper adjustment
❑ Correct routing of cable and harness
40
• Driveline for:
❑ Proper indexing of universal joints
❑ Proper drive shaft angles
❑ Driveline backlash
❑ Lubricated universals and slip-joints
• Hydraulic System for:
❑ Recommended fluid—TranSynd™
❑ Correct fluid level in transmission
❑ Dipstick correctly calibrated—refer to Figure 1–1
❑ Fill tube tight
❑ Fill tube cap tight
❑ Breather clean and free of restrictions
❑ No fluid leaks during operation
• Instruments and Electrical Equipment for:
❑ Proper wiring and electrical connections
❑ Instruments, gauges, and lights work correctly
❑ Shift selector display is on and CHECK TRANS light is off
❑ Fluid temperature gauge
• Power Takeoff—if installed—for:
❑ Controls connected and operative
❑ Correctly coupled to driven equipment
❑ Lubrication line correctly installed and routed—if used
❑ Clutch apply line correctly installed and routed—if used
41
5–11. ROAD TEST AND VEHICLE OPERATION CHECKLIST
NOTE: Refer to the latest edition of the 1000 and 2000 Product
Families transmission Operator’s Handbook for operating
instructions. Refer to Section VI for the latest publication number.
a. Driveability Drive-away checks are performed to verify proper

transmission and support equipment installation and operation. The
following steps outline drive-away check procedures:
• Check Fluid—fill the transmission with appropriate fluid.
• Start the Vehicle—check for proper system response during start-up

— Turn on the vehicle’s master/ignition switch.
— The CHECK TRANS light should come on.
— Start the engine.
— The CHECK TRANS light should go off.
• Clear Trouble Codes—during installation, it is common for “false” codes to

be stored in the electronic control’s TCM. These codes must be cleared prior
to road testing the vehicle. Refer to Allison DOC™ users manual for details.
• Road Test the Vehicle—allow the electronic control time to “converge” shifts.
• Check for Proper Operation—check all components for proper mounting and
operation, and check for transmission fluid leaks at gasket surfaces, lines, and
hoses.
• Re-check for Trouble Codes—use the Allison DOC™ diagnostic tool to

determine if codes were set during the road test. See Allison DOC™ users
manual for details.
• Troubleshoot—if codes exist after the road test, problems must be found
and corrected. Refer to TS3192EN, 1000 and 2000 Product Families
Electronic Troubleshooting Manual.
b. Service and Maintenance. Following an initial unit-exchange program, refer to

the 1000 and 2000 Product Families Service Manual (SM3191EN) for detailed
transmission service and maintenance instructions (available late 1999).
42
c. Road Test Checklist. Complete the following check list.
• Neutral Start Circuit:
❑ Starts only in N (Neutral) or P (Park)
• Instruments:
❑ CHECK TRANS light
❑ Transmission fluid pressure gauge—if used
❑ Speedometer
❑ Temperature gauge—if used
❑ Reverse warning system—if used
• Transmission Fluid:
❑ Fluid level meets specifications—cold, neutral, level
❑ No leaks
❑ Warm-up and check fluid level—hot, neutral, level
• No-Load Governed Engine Speed:
❑ No-load governed speed of engine
❑ Adjust governor as necessary—refer to the manufacturer’s specifications
for the engine-transmission being tested.
• PTO—if installed:
❑ PTO operation—Refer to the 1000 or 2000 vocational model specific
operator’s manual (see Section VI for the latest publication number).
• Shift Sequence:
❑ Transmission upshifts and downshifts smoothly through all ranges
• Other Checks:
❑ Stall test (must only be performed by qualified service technician)
❑ Shift quality
• Comments:
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
43
CUSTOMER S ECTION
SERVICE VI
6–1. OWNER ASSISTANCE

There are distributors and dealers around the world ready to stand behind every
Allison Transmission product. Any situation that arises in connection with the sale,
operation, or service of your transmission will be handled by the distributor or
dealer in your area. Technical support is available from the Technical Assistance
Center (TAC) by telephone at 1-800-252-5283.
Refer to the Allison Transmission website www.allisontransmission.com or to the
Worldwide Sales and Service Directory SA2229EN for a current listing of Allison
Transmission authorized distributors and service dealers.
6–2. SERVICE LITERATURE

This service literature provides fully illustrated instructions for operation,
maintenance, service, overhaul, and parts support for your transmission.
For maximum performance and service life from your unit, see your
dealer or distributor for the following publications. Check the telephone
directory for the Allison Transmission service outlet nearest you.
Table 6–1. 1000 and 2000 Product Families Service Literature
*Parts Catalog PC3062EN
CD3062EN
Principles of Operation PO3065EN
*EVS Operator’s Manual OM3761EN
*HS Operator’s Manual OM3757EN
*RDS Operator’s Manual OM3759EN
*MHS Operator’s Manual OM3364EN
*PTS Operator’s Manual OM3758EN
*BUS Operator’s Manual OM3765EN
*In-Chassis Maintenance JA3664EN
*1000, 2000, 2400 Operator’s Manual OM3063EN
* Also Available On The Internet At www.allisontransmission.com
44
NOTES
45
NOTES
46
MT3190EN 200403 www.allisontransmission.com Printed in USA 200405
Halvorsen
Section 4. Axles and Steering
KESSLER & CO., OFF-HIGHWAY AXLE DIVISION
SERVICE MANUAL - JBT ML 42K4P (41.3485.3)

Drive and Steer Axle
DANFOSS HYDRAULICS
SERVICE MANUAL (HN.21.AD.02)

Hydrostatic Steering Unit OSPB/OSPC
SPARE PARTS (HN.21.UA.52)

Danfoss Steering Units OSPB/OSPC/OSPL/OSPD/OSPQ/OSPF
5-4
AXLES AND STEERING
Page 1
December 2015
Service-Manual
JBT
ML 42K4P (41.3485.3)
Version 04/2012
Original
Service Manual

© Kessler & Co. GmbH & Co.KG
All rights reserved

Copyright ©
Reproduction and dissemination of this documentation in
any form (photocopying, printing or electronic
Firma Kessler & Co. GmbH &Co.KG dissemination) is prohibited without the written
permission of Kessler & Co. GmbH & Co.KG.

This documentation is not subject to revision. We
reserve the right to make modifications without prior
notice.

All rights reserved 08.06.2011

Service Manual

All rights reserved

Table of contents
1 Important remarks
2 Lubrication intervals and maintenance instructions
3 General instructions for correct assembly and disassembly

Service tools
4 Assembly drive assembly
5 Assembly hub assembly
6 Assembly panetary gear drive
7 Assembly service brake
8 Assembly parking brake

All rights reserved
Service
Revised 01.09.2007
Section
Important remarks

All rights reserved
Service
Revised 01.09.2007
Section
Important remarks
1.1
For safety reasons, the operator should verify and service at regular intervals all of the bolted
assemblies and all of the important safety locks such as:
• Wheel nuts
• Nuts of axle mounting bolts
• Bolts on the steering components and the brake system parts; if the screws are tightable,
the Loctite contact breaks loose and remounting is necessary.
• Corrosion and cracks on the carrier elements (such as the axle spindle) are not
acceptable for operational safety reasons.
• Verify seals, oil levels and lubrication at regular intervals.
Brakes
• Inspect brake lining and brake drum / brake disc regulary as well as wear of brake system
parts.
• Inspect the free movement of brake system rods.
• In case of signs of excessive heating, consult a brake specialist or the manufacturer.

All rights reserved
Service
Revised 31.05.2010
Section
Instructions for ordering spare parts
1.3
We only accept liability for the original spare parts supplied by ourselves. We express clearly that the
utilisation of other parts than the form us prescribed original spare parts, can change infavourably the
characteristics of the axle prescribed by the construction and that thereby the safety can be affected.
For damage caused by the utilisation of not original spare parts and accessories, any liability of the
Kessler & Co. GmbH & Co.KG is excluded. Please bear in mind that special manufacturing and
delivery specifications apply to own as well as to foreign parts and that we always offer spare parts to
the up - dated technical conditions and the up - dated legal prescriptions.
When ordering Kessler spare parts, please furnish the following information:
1. Order number (installation drawing no.) → see identification plate

2. Fabrication number → see identification plate
3. Vehicle producer
4. Description of the spare part
5. Spare part number (drawing - resp. DIN no.)
6. Number of pieces
7. Kind of delivery
In case of doubt, consult Kessler & Co. GmbH & Co.KG.
For major repairs or overhaul, it is recommendet that the complete axle assembly be returned to
Kessler & Co. GmbH & Co.KG.

All rights reserved
Service
Revised 31.05.2010
Section
Lubrication intervals and maintenance instructions

All rights reserved
Service
Revised 28.03.2011
Section
General lubrication instructions
2.1
Lubrication points see sheet 2.2 resp. installation drawing.

Lubricants see sheet 2.3
Fill levels Are checked at the level control plugs.
Oil change Place the vehicle in a horizontal position. Draining of the oil is to be
accomplished only in warm condition. Clean all lubrication points before
opening them. Open the drain holes on the carrier assembly, on the
wheel assemblies, and if present, on the interaxle differential and drop
gear housing. On the hub assemblies, the drain plug should be turned
downward.
Oil draining
Replacement of the oil draining plugs.
Remove the oil filler plug as well as the oil level control plug on the carrier
assembly, on the wheel assembly, and, if present, on the interaxle
differential and drop gear housing. (See sheet 2.2 → lubrication points).
Oil filling
Check the oil level at the oil level plug hole (Overflow control). Wait a few
minutes. If the oil level falls, add oil until the level remains constant.
Clean the grease nipples before lubrication.
Lubrication intervals see sheet 2.3
Important!
On the axles with self locking differentials, a noise is produced if normal oils are used.
In case of abnormal noises and in case of a jerky roll off of the tyres, use gear oil EP with additives of
the “Limited Slip” type conforming to specification M 2C - 104 A.
In case of prolonged non - operation of the vehicle, it is recommended to start - up and operate all of
the parts of the gear train every 6 months. For this purpose, maintain the proper oil level which also
protects the axle against water intrusion.
The surfaces of the brake areas are to be preserved in humid locations. On start - up, a break - in of
the braking system by intermittent operation is indispensable.

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Service
Revised 09.06.2010
Section
Lubrication points
2.2.1
The binding lubrication points have to be taken from the according installation drawing of the axle.
Single drive assembly
*The position is dependent from the

respective axle version.
Drive assembly with throughdrive
*Version with interaxle differential.

Fill 1,5 litre oil at *I for first - time filling and
for refilling!
Drop gear D51 / D108
*II – only at version with separately oil

space.
Cardan shaft intermediate bearing
I = Oil fill plug III = Oil drain plug

II = Oil level control plug IV = Grease nipple

All rights reserved
Service
Revised 31.05.2010
Section
Lubrication points
2.2.2
Hub assembly with planetary gear drive
Lubrication points at universal joint and brake shaft.

(If not maintenance - free)
Hub assembly with wet disc brake
Tumbler bearing
I = Oil fill plug III = Oil drain plug

II = Oil level control plug IV = Grease nipple

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Service
Revised 01.09.2007
Section
Lubricants and lubrication intervals
2.3
Lubrication
Lubricant Remarks Lubrication intervals 1.)
point
after every every min. min.
100Bh 500Bh 1000Bh 1x 1x in
1000Km 5000Km 10000Km Year 2 Years
⊕ ⊕ ⊕
Hypoid – gear oil per Oilchange
Drive assembly MIL-L – 2105 B / API GL 5
Hypoid – gear oil in multi –
range characteristic per
Wheel hub plane- MIL-L – 2105 C / D / API GL 5 Check oil level at ⊕ ⊕ ⊕
tary gear drive SAE 90 or multi grade oils for
normal external temperature
control points
Interaxle SAE 75 W – 90;
monthly ⊕ ⊕ ⊕
differential SAE 75 W – 85 for external
temperature lower – 10°C
Drop gear/ SAE 140 or multi grade oils ⊕ ⊕ ⊕
Gear boxes for external temperature
over + 30°C
Wheel bearing
oil lubricated
⊕ ⊕ ⊕
Multi disk parking Hydraulicoil Oilchange
brake ISO VG 32 wet running
⊕ ⊕ ⊕
Cardan shaft inter- Fuchs Renolit
mediate bearing LX-NHU 2 if provided for ⊕ ⊕
Steering knuckle
bearing ⊕ ⊕
Steering knuckle Multi – use grease maintenance
bearing lithium saponified reduced ⊕ ⊕
groove penetration
Universal joint per NLGI 2 if provided for ⊕ ⊕
Track rod f. e. Fuchs if provided for ⊕ ⊕
Steering cylinder Renolit MP 150
-ball head/
-spherical plain
if provided for ⊕ ⊕
bearing
if grease
pinion bearing
lubricated
⊕ ⊕ ⊕
Brake shaft
bearing
Attention! 2.) ⊕ ⊕
Brake shoe Lightly greased at brake
Attention! 2.)
bearing shoe new assembly
if grease Change grease at wheel
Wheel bearing
lubricated hub disassembly ⊕
external cooled dependent on tank volume / cooling
Wet disc brake see chapter -7- system / operation conditions
oilchange
not external cooled
oilchange ⊕ ⊕ ⊕
(Bh = Hours of operation)
1.) Whichever occurs first.
2.) The bearing point is to be lightly lubricated only, to avoid the penetration of grease in the interior of the brake
(use only hand operated grease gun and remove surplus grease!). Check regularly the brake shafts and if
need correct the lubrication intervals (danger of overheating!)

All rights reserved
Service
Revised 31.05.2010
Section
Recommendable hypoid gear oils corresponding
MIL-L 2105 B/API GL 5 resp. MIL-L 2105 C/D/API GL 5 2.3.1
ARAL - Gearoil Hyp 90
AVIA - Gearoil Hypoid 90 EP
BP - Multiuse - Gearoil EP SAE 90
ELF - Tranself Typ B 90 / Tranself Typ B 80 W - 90
ESSO - Gearoil GX - D 90
FINA - Pontonic MP SAE 85 W - 90
FUCHS - Renogear Hypoid 90
MOBIL - HD 90 - A
SHELL - Spirax MB 90 / HD 90
TEXACO - Multigear EP SAE 85 W / 90
AGIP - Rotra MP / Rotra MP DB
On no account use “normal” gear oils!

All rights reserved
Service
Revised 28.03.2011
Section
General maintenance instructions
2.4
Check - and main-

Remarks Maintenance intervals 1.)
tenance points
after after every every min.
50Bh 100Bh 500Bh 1000Bh 1x
500Km 1000Km 5000Km 10000Km Year
Inspect, if necessary readjust

Wheel bearing
wheel bearing  
Check and tighten with a torque
Wheel nuts wrench (after tire change after   
50km and 200km)
Castle nuts/track rod
Check and retighten
Screws/drive flange
(Verify the adjustment)    
Nuts/axle mounting bolts
Check lining wear, if necessary
Brakes readjust, control the proper  monthly
(see also chapter 7) operation of the brake shafts
Wet disc brake Check lining wear 

Wet disc brake -
spring load design
Check lining wear 
Steering - and trackrod Check and retighten mounting
lever bolts )  
Bolted connections
(for example drive assembly)
Check from time to time 
Ring gear support bolt
on drive assembly
Readjust (if necessary) 
Seals Check from time to time monthly
Check function and the auto-

Differential lock monthly
matic return in original position
(Bh = Hours of operation)
*) If the bolts are moving (Loctite brakes loose), the lever has to be mounted once more.
1.) Whichever occurs first.

All rights reserved
Service
Revised 28.03.2011
 General assembly /disassembly instructions
Section
 service tools

All rights reserved
Service
Revised 08.03.2012
General instructions for correct
Section
assembly and disassembly 3.1
• The assembly is to be accomplished only by trained personnel.
• The disassembly can be made reverse to the respective assembly instruction.
• Drain oil before removing, check for presence of metal particles.
• Mark the parts to each other before dismantle.
• Never use a hard objekt to separate tightly fitted assemblies. To remove bearings, drive flanges and
similair parts, use the proper pullers.
• It is recommended that the special tools according 3.6 used for disassembly.
• Do not place parts on a dirty surface.
• Systematically replace used seals, O - rings and if need bearings on disassembly.
• Clean parts before reassembly.
• Replace or clean corroded parts.
• Replace carrier elements with cracks!
• The cages of bearings rotating in oil are to be coated with oil at reassembly.
• Seal ring treads on flanges, shafts etc. must be preserved with Castrol Rustilo DWX 32 before
mounting.
• Oil seal rings and particularly the anti - dust lip seals must be filled with grease.
• The universal joint shafts and the axle shafts must not be force mounted (they must slide).
• At mounting of radial seal rings pay attention that there is suffice overlap to the housing bores. Pay
attention for a plain alignment of the radial seal ring. The seal lips always must not be contacted
with Loctite!
• The bolted or keyed assemblies safeties are to be checked according to instructions; in case of
doubt, consult Kessler & Co.
• Refill the oil after assembly!
• Repair weldment is only allowed after consultation with Kessler & Co!

All rights reserved
Service
Revised 01.06.2010
Section
Using of Loctite and operating supplies
3.2.1
Type Colour Application

1. LOCTITE 243 blue Lightly locked screws
262 red Middle locked screws
270 green Highly locked screws
270 green Increased coefficient of friction in contact surfaces
510 orange Surface gasket
572 white Special gasket
638 light-green Glueing with big width of slit

5926 and
blue Surface gasket
209 125
2. EPPLE 33 grey Surface gasket
3. DIRKO grey Elastic gasket
Remarks for working up Loctite and operating supplies
• Threads and surfaces have to be cleaned and free from colour, oil and grease before applying
Loctite.
• Loctite will harden under following conditions:

- Exclusion of air
- Metal contact
- Increased temperature
• Pre - assembly and control tightening has to be made in a short time (5 to 10 min.).
• The time between glueing and mounting of the parts should be shorter than 1h.
Exception: parts made from nonferrous metal have to be glued within one minute.
• Assembled parts must remain unloaded for at least 24 hours.
• Loctite quantity
at screws:
1 bead
At contact surfaces:
Pay attention for a sufficient Loctite application

All rights reserved
Service
Revised 01.06.2010
Section
Use of Loctite and operating supplies
3.2.2
Hub assembly
Safety blocked
Joint Loctite Operating supplies
parts
Spacer ring Contact surface 572 -
Axle spindle Screws 262 -
Axle spindle Contact surface 270 -
in planetary
Grommet 270 -
housing
Disc in axle spindle 270 -
Adjusting screw in planetary

270 -
with nut housing
Support Screw 262 -
Ring gear
Screws 270 -
retainer
Pol wheel Contact surface 638 -
Steering lever
Screws 262 -
Track rod lever
Steering lever
Contact surface 270 -
Track rod lever
Wheel hub cover Thread 572 -
Radial seal rings

Rubber casing
Radial seal rings
Steel casing
Wheel safety nut → see chapter 5 → Adjustment of wheel
bearings

all rights reserved
Service
Revised 01:09:2007
Section
Use of Loctite and operating supplies
3.2.3
Drive assembly
Safety blocked
Joint Loctite Operating supplies
parts
Epple 33 alternative
Drive flange Nut surface -
Dirko grey
Diff-housing Screws 262 -
Shifter cylinder
(Diff-lock)
Diff.carrier
(Through drive)
Drop gear housing Contact surface 510 -
Epple 33 alternative
Diff.carrier Contact surface -
Loctite 5926 and 209125
Through drive
cover
Differential strap Screws 262 -
Adjustment nut
Screw 270 -
screw
Ring gear Screws 262 -
Ring gear Contact surface 270 -
Ring gear
Cap 270 -
support
Ring gear Epple 33 alternative
Thread -
support Dirko grey

All rights reserved
Service
Revised 01.06.2010
Kapitel
Tightening torques (Nm)
3.3
General instructions for tightening torques
 = 0,14
All tightening torques are rated in Nm.
Tolerance of the tightening torques is ±5%

(assuming a manually operated torque spanner is used)
Tightening torque of metric coarse-pitch thread
Screw Nut Screw Nut Screw Nut

Thread
8.8 8 10.9 10 12.9 12
M4 3,0 4,4 5,1
M5 5,9 8,7 10
M6 10 15 18
M8 25 36 43
M 10 49 72 84
M 12 85 125 145
M 14 135 200 235
M 16 210 310 365
M 18 300 430 500
M 20 425 610 710
M 22 580 830 970
M 24 730 1050 1220
M 27 1100 1550 1800
M 30 1450 2100 2450

All rights reserved
Service
Revised 05/03/2012
Kapitel
Tightening torques (Nm)
3.3
Tightening torque of metric fine pitch thread
Screw Nut Screw Nut Screw Nut

Thread
8.8 8 10.9 10 12.9 12
M8x1 27 39 46
M 10 x 1 55 81 95
M 10 x 1,25 52 76 90
M 12 x 1,25 93 135 160
M 12 x 1,5 89 130 155
M 14 x 1,5 145 215 255
M 16 x 1,5 225 330 390
M 18 x 1,5 340 485 570
M 20 x 1,5 475 680 790
M 22 x 1,5 650 920 1050
Thigtening torque for galvanized bolts and nuts!
Regard reduced thightening torque for galvanized bolts and nuts!
Tightening torque for brake caliper dowel screws (greased !)
M 20 x 1,5 400 + 100

M 27 x 2 900 + 100
Tightening torque of the nut for steering stop
300
Approximate value for the thigthening torque for screw plug
Tightening torque Tightening torque

Thread
(Approximate value) (Screw plugs with O-Ring)
M14x1,5 ca. 45 45
M16x1,5 ca. 60 -
M22x1,5 ca. 100 100
M24x1,5 ca. 120 -
M30x1,5 ca. 160 -
M42x1,5 ca. 260 -
M45x1,5 ca. 280 -

All rights reserved
Service
Revised 05/03/2012
Section
Tightening torques of wheel nuts
3.4
Wheel nut with spring lock Wheel nut with clamp Wheel nut with thrust collar
washer (for clamp fixation) (for rims with centerring)
Wheel nut with spring lock washer
Dimensions Phosphourus darkened Galvanized
M 18 x 1,5 270 Nm 250 Nm

M 22 x 1,5 450 Nm 350 Nm
Wheel nut with thrust collar
Dimensions Phosphourus darkened
M 22 x 1,5 650 Nm
Wheel nut with clamp
Dimensions Galvanized
M 18 x 2 350 Nm

All rights reserved
Service
Revised 01.09.2007
Tightening torques for castle nuts
Section
and adjusting nuts 3.5
Tightening torques for castle nuts on ball joints for track rods and ram cylinders
Cone size Thread Torque

d1 (mm) d2 (mm) (Nm)
26 M 20 x 1,5 200 - 220
30 M 24 x 1,5 280 - 300
32 M 27 x 1,5 290 - 320
38 M 30 x 1,5 340 - 360
45 M 39 x 1,5 410 - 430
The tightening torques of the different thread dimensions of the joints are applicable for nuts of quality
S6.
Tightening torque of the adjusting nut resp. slotted nut at flanges resp. gearwheels ect.
Thread Torque
d1 (mm) (Nm)
M 24 x 1,5 360
M 30 x 1,5 450
M 36 x 1,5 540
M 42 x 1,5 850
M 45 x 1,5 850
M 48 x 1,5 850
M 52 x 1,5 950
M 64 x 1,5 1050 - 1100

All rights reserved
Service
Revised 01.09.2007
Section
Service tools
3.6.1
When ordering service tools please provide order number (installation drawing no.), resp. fabrication
number → see identification plate. (The illustrations are not binding for the design).
Spanner for wheel safety nut
Spanner for splined nut (hub assembly)

All rights reserved
Service
Revised 01.09.2007
Section
Service tools
3.6.2
Seal ring sleeve driver
Spanner for thread rings

(Differential bearing)
Spanner for counter nut

(Planetary gear drive)
Assembly cone for o - ring

(Differential lock)

All rights reserved
Service
Revised 01.09.2007
Section
Service tools
3.6.3
Assembly sleeve for piston

(Differential lock)
Assembly sleeve for piston

(Differential lock)
Sleeve driver for universal joint bearing

(Needle bearing / bearing bushing)
Sleeve driver for bearing bushings

(Steering knuckle bearing)

All rights reserved
Service
Revised 01.09.2007
Section
Service tools
3.6.4
Puller for universal joint bearing

(Needle bearing / bearing bushing)
Device to press in king pins
Hydraulic device to press in king pins

All rights reserved
Service
Revised 01.09.2007
Section
Service tools
3.6.5
Mechanical puller for king pins
Hydraulic puller for king pins
Screw spindle for king pin pullers

All rights reserved
Service
Revised 01.09.2007
Section
Assembly of drive assembly

All rights reserved
Service
Revised 01.09.2007
Section
Adjustment of gear meshing of Gleason gears
4.0.1
It is only possible to achieve a perfect gear meshing, if the fabrication number of the drive pinion
(marked on the end face) and the ring gear (marked on the circumference) are corresponding.
Perfect marking.
The following figures show improper gear meshing marks of the ring gear. The text alongside gives
the corrections to obtain correct gear meshing. The dark colored arrows in the sketch of the drive
pinion and ring gear indicate the direction towards which the drive pinion has to be moved. The
clear arrows indicate the direction towards which the ring gear has to be moved, to get further more
a correct backlash.
Gear meshing too deep.
Increase the drive pinion distance by correction of

the adjustment disc thickness.
Regulate the backlash by inwards moving of the

ring gear.
Gear meshing too high.
Decrease the drive pinion distance by correction of

the adjustment disc thickness.
Regulate the backlash by outwards moving of the

ring gear.

All rights reserved
Service
Revised 01.09.2007
Section
Securing of the striking nut
4.0.2
The brim of the striking nut has to be sheared only along the slot flank and the corner has to be
bended on the slot ground.
Use of Loctite and other operating supplies
1. Striking nut at drive flange
• In thread: assembly paste with MoS2 (exception: through drive pinion

see point 2).
• Front side contact surface: sealing compound (Epple 33 or equivalent).
2. Striking nut at through drive pinion
• In thread: Loctite 262.
3. Striking nut at gear wheels, bearings etc.
• In thread: assembly paste with MoS2.
Removing of the striking nut
Bend away the nose and screw the nut off.

All rights reserved
Service
Revised 01.09.2007
Section
Drive assembly D 41 Hy
4.2

All rights reserved
Service
Revised 01.09.2007
Section
Adjustment of drive pinion distance
4.2.1
To obtain the proper tooth flank contact, adjust the

axial position of the drive pinion with the thickness of
the adjustment disc. The necessary thickness of the
adjustment disc for first time assembly can be
obtained by measurement (see calculation example).
The final thickness of the adjustment disc can be fixed

during the checking of gear meshing at the assembled
drive assembly (see page “Adjustment of gear
meshing of Gleason gears”) (S theor. = 3 mm).
*) A = Set value for correct pinion support. This dimension is writed on the end face of the pinion in
millimetre. It indicates the deviation from the theoretic distance (set point dimension).
**) B = Measured width of the taper roller bearing (B theor. = 27,25 mm).
Calculation example to ascertain the thickness S from the adjustment disc:
A = + 0,10; B = 27,20
S= 3,00 mm (theor.)
+ 0,05 mm → B = 0,05 mm smaller than B theor.
= 3,05 mm
- 0,10 mm → drive pinion value A
= 2,95 mm → necessary thickness of the adjustment disc
Fit corresponding disc and outer rings of the taper roller bearings.
*) Hint: if value A is positive (e.g. + 0,1) the adjustment disk has to be 0,1 mm thinner than theor. S.
If value A is negative (e.g. – 0,1) the adjustment disc has to be 0,1 mm thicker than theor. S.
**) Hint: if value B is positive (e.g. 27,30) the adjustment disc has to be 0,05 mm thinner than
theor. S.
If value B is negative (e.g. 27,20) the adjustment disc has to be 0,05 mm thicker than theor. S.

All rights reserved
Service
Revised 01.09.2007
Section
Assembly of the drive pinion bearing
4.2.2
1. Insert the two outer rings of the taper roller

bearings into the differential carrier.
2. Calculate the thickness C of the spacer disc.
a. Place the two inner rings of the taper roller

bearings in their outer rings. Measure A.
b. Measure the dimension B of the roller

bearing.
c. Measure the dimension D of the spacer

bushing.
d. Thickness of the spacer disk C = A - B - D.
3. Heat the drive pinion side taper roller bearing to

about 100°C and install it on the drive pinion
shaft. (Drive on completely after it cools).
4. Install the spacer bushing and the spacer disc

on the pinion shaft.
5. Install the drive pinion into the differential

carrier. Heat the taper roller bearing inner ring at
undersize to about 100°C and install it with a
tube onto the drive pinion shaft.
6. Install the drive flange onto the drive pinion

shaft. Tighten the safety nut according sheet
3.5. For tightening fix the differential carrier and
block the drive flange.
7. Measure the roll resistance of the bearings by using a torque wrench. If the measured value is
not the prescribed 0,8 to 1,5 Nm, adjust the resistance by modification of the thickness of the
spacer disc. After arriving at the adjustment of the bearing, back - off the safety nut and draw off
the drive flange.
8. Install the radial seal ring with Loctite 572 applied. Fill the radial seal ring with bearing grease.
Slip on the drive flange, screw on the safety nut with sealing compound between the contact
surfaces. Tighten the safety nut according sheet 3.5. Lock the nut by striking the nut brim into
the slot of the pinion.

All rights reserved
Service
Revised 01.09.2007
Section
Assembly of the Differential
4.1.3
Before assembly all of the bevel gears and the

thrust rings should be well oiled.
1. Place one differential side gear with the side

gear thrust washer in the differential case.
2. Install the spider with differential gears and

differential pinion thrust washers in the
differential case.
3. Install the other differential side gear and side

gear thrust washer. (At variants with Nospin
differential install the Nospin diff. instead of the
differential gears)
4. Install the other half of the differential case over

the assembly and observe the alignment marks,
tighten the differential case bolts. Secure with
Loctite 262.
5. Check that all differential pinions can rotate

easily.
6. Coat the contact surface of the ring gear with

Loctite 270 and install the ring gear on the
differential case by tapping lightly on the
circumference. Tighten the ring gear bolts.
Secure with Loctite 262.
7. Heat the two taper roller bearings to about 100°C

and install them by using a sleeve.

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Service
Revised 01.09.2007
Section
Assembly of drive assembly
4.1.4
Place the differential with the outer rings of the taper
roller bearings on the differential carrier which is in a
vertical position, with mounted drive pinion.
Mount the differential straps and align them with the

thread rings.
During this operation be careful of the alignment

marks on the differential straps with respect to the
differential carrier. (Do not interchange the differential
straps.)
Tighten the differential strap bolts by hand. By a

counter rotation of the two thread rings, move the
differential until the backlash is correct. (The smallest
admissible value at the closest place is marked on the
ring gear).
Therefore hold the drive pinion at the drive flange.

Check the backlash by careful forwards and rearwards
rotating the ring gear. Use a dial indicator.
Measure the backlash during a few times turns of the

ring gear and if need correct the backlash, because of
the smallest admissible value at the closest place
must not be fall short of.
Adjust gear meshing according to sheet “Adjustment

of gear meshing of Gleason gears”.
Tighten screws of the differential straps and lock them

with Loctite 262.
Adjust the bearing roll resistance trough tightening of

the thread rings. Set value: 2,0 to 3,0 Nm. Check the
value with a torque wrench. If measuring at the drive
pinion / drive flange, take the ratio of the bevel wheel
set into account.
Screw the lock plates for the thread rings and secure
with Loctite 270, if need bend the lock plates.

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Service
Revised 01.09.2007
Section
Assembly of the ring gear support bolt
4.2.3
1. Glue the cap with Loctite 270 onto the support bolt.
2. Coat the support bolt with Epple 33.
3. Screw the support bolt with cap by hand to contact to the ring gear, without exerting pressure.
4. Screw the counter nut onto the support bolt.
5. Turn back the support bolt max. 15°.
6. Tighten the counter nut, during this operation the support bolt must not move.
In tightened condition the clearance between the ring gear surface and the contact surface of the
support bolt amounts about 0,1 mm.
Attention:
The support bolt has to be sealed again when adjusting timely.

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Service
Revised 01.09.2007
Section
Limited-slip differential
4.2.4
 Pay attention about the arrangement of the disks.

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Service
Revised 24/04/2011
Section
Assembly of the hub assembly

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Service
Revised 01.09.2007
Section
Hub assembly steer drive axle
5.1

All rights reserved
Service
Revised 24.04.2012
Assembly bearing of steering knuckle
Section
and bearing of universal joint 5.1.1
Prepare the steering knuckle:
• Assembly of the spacer ring (if present) see sheet 5.1.6.
• Introduce the bearing bushing (4) into the lower bore of the steering knuckle and press in, by
using a sleeve. Press in the upper bearing bushing (5), by using a sleeve, into the upper bore of
the steering knuckle. (At version with spring support the upper bearing bushing (5) has to be
mounted after installation of the king pin).
• Press the bearing (6) into the steering knuckle and secure it with the circlip (7). Install the seal
rings (8) with Loctite 572 resp. 270, place the support disc (10) (if present) between the seal
rings. Fill the seal rings with bearing grease.
Prepare the axle housing:
• Insert the inner cliclip (7) into the axle housing. Press the bearing (6) into the axle housing and
secure it with the second circlip (7). Install the seal rings (8) with Loctite 572 resp. 270, place
the support disc (10) (if present) between the seal rings. Fill the seal rings with bearing grease.

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Service
Revised 01.09.2007
Assembly of the drive assembly
Section
onto the axle housing 5.1.2
Coat the contact surface of the axle housing with Epple 33 (at version through drive with Loctite
510), and mount the complete drive assembly. The axle housing being placed in a horizontal
position, secure the screws with Loctite 262. Mount the pol wheel (if present) onto the universal joint
(see 5.1.7).
Very carefully engage the long shaft of the universal joint into the axle housing.
The universal joint shaft should be able to be moved easily (by hand) in the toothing of the
differential side gear.
At version with differential lock on the outside (D 71/ D 109) the differential lock must always be
actuated when assemble or disassemble the universal joint.
Direction:
Actuating of the differential lock is necessary to prevent the sliding sleeve to drop out of the shifter
fork into the axle housing when pulling out or sliding in the universal joint. This would entail
disassembly of the axle.

All rights reserved
Service
Revised 01.09.2007
Assembly of the steering knuckle
Section
onto the axle housing 5.1.3
At version with maintenance reduced steering knuckle bearing install the o-rings according to the
respective version.
Fit the steering knuckle (1) onto the axle fork. Caution: Be very careful and do not damage the seal
rings in the steering knuckle with the universal joint shaft!
Introduce the thrust discs (9) according the respective version.
Before mounting the king pins apply Molykote – powder or – paste on the pins and in the bores
(danger of gripping).
Press in the king pins (11 + 12).
Disassembly king pin:
Draw off the lower king pin to the bottom, and the upper king pin to the top.

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Service
Revised 01.09.2007
Section
Assembly of steering- resp. track rod lever
5.1.4
Important: threads and surfaces have to be cleaned and free from colour, oil and grease before
applying Loctite. Note further remarks for working up Loctite (see sheet 3.2).
Coat the contact surface between lever (6 resp. 13) and steering knuckle at the contact area with
Loctite 270 and install the lever by screws onto the steering knuckle, secure the screws with Loctite
262. Time needed for Loctite 270 to harden = 24 hours.
Coat the contact surface between cover (7 resp. 14) and steering knuckle with Loctite 510 and
install the cover by screws onto the steering knuckle.
Screw the grease nipples into the lever resp. cover and grease the steering knuckle bearing with
bearing grease according to the lubrication plan 2.3.
At version with dowel pins for increased torque, the dowel pins have to be knocked in before
tightening the screws, note the position of the slits in the dowel pins (180° turned to one another).
Steer drive axle Steer axle

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Service
Revised 01.09.2007
Section
Assembly of the hub assembly
5.1.5.1
• Assembly of the spacer ring (if present) see sheet 5.1.6.
• Install the brake onto the steering knuckle, be careful of the brake control position and bolt it. At
version with disc brake install the brake carrier (if present), then mount the wheel hub with the
brake disc, and after this operation install the brake.
• Prepare and mount the wheel hub see chapter 5.5.

Attention: Hold the wheel hub with a hoist till the outer bearing with ring gear carrier is mounted.
• Assembly of the planetary gear drive see chapter 6.
• At version with drum brake mount the brake drum.
• Assembly of the ABS - sensor installation (if present) see 5.1.7.

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Service
Revised 15.07.2008
Section
Prepare and mount wheel hub
5.5.93
Prepare wheel hub
Press the radial seal ring (5) with Loctite 572 (rubber cage) resp. Loctite 270 (steel cage) applied
into the wheel hub (1).
Fill the radial seal ring with bearing grease.
Press in outer rings of taper roller bearings (2 + 3), do not hammer them. Install inner ring of taper
roller bearing (3). Fill the taper roller bearing with bearing grease.
Press the radial seal ring (4) with Loctite 572 (rubber cage) resp. Loctite 270 (steel cage) applied
into the wheel hub. Fill the radial seal ring with bearing grease.
At version with cassette seal ring observe the mounting instruction 5.6.
Mount wheel hub
Push the pre - assembled wheel hub (1) parallel onto the axle spindle resp. steering knuckle.
Attention: Be careful not to damage the seal rings (4 + 5).
At version with cassette seal ring observe the mounting instruction 5.6.

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Service
Revised 24.04.2012
Section
Adjustment of wheel bearings
5.7.1
Tightening torque of the wheel safety nut
series Nm
41 300
51 350
61 400
71/ 72 400
81/ 82 450
91 500
109 500
116 500
L101 500
L102 550
D/ LT 101/ 102 600-650
106 650-700
111 750
112 1000
Adjusting of wheel bearings
The temperature of the axle parts should be between 0 and + 20°C at the bearing adjustment.
Screw on the wheel safety nut (Loctite- resp. Molykote- using see page 5.7.2) and adjust and
secure as following described:
Screw on the wheel safety nut and tighten it with a 1,5 - 2 times higher tightening torque than the
finish tightening torque. During the tightening, turn the wheel hub a few times and knock it with a
plastic hammer. Untighten the wheel safety nut (about 180° back rotation), then tighten the wheel
safety nut to the tightening torque according to the table. At this tightening turn the wheel hub also a
few times, if there is no possibility for securing, the wheel safety nut has to be turned back to next
securing possibility.

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Service
Revised 01.09.2007
Section
Wheel safety nut
5.7.2
Designation Version Security/ Remarks
Shaft nut with cheese Cheese head screw &

head screw Loctite 270
Shaft nut with cheese

Cheese head screw &
head screw and
Loctite 270
bushing
Shaft nut with set Set screw & Loctite 243/

screw 262 Back off set screw ½
rotation after tightening
Shaft nut with counter Security spline & counter

nut nut & Loctite 243

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Service
Revised 01.09.2007
Section
Assembly steering cylinder assembly
5.9.4
• Push in the steering cylinder into the steering cylinder brackets.
• Install the bolt.
• Attach the shim and screwon the nut.
• Tighten the nut by hand and further tightening to next safety possibility and install the split pin.
• Screw in the grease nipple and lubricate the bearing with bearing grease.

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Service
Revised 01.09.2007
Section
Mount wheel studs
5.12
Mount wheel studs
1) Place the disk (1) on the planetary gear (2) until the contact surface.
2) Apply the thread from the cap screw (3) with Loctite.
Loctite 262
3) Bolt the disk (1) with the cap screw (3).
4) Thigthen the cap screw (3).
Tightening torque 610 Nm
5) Apply the wheel studs (4) with Loctite.
Loctite 262
6) Screw in the wheel studs (4).
7) Standout (A) according to the axle installation drawing.

All rights reserved
Service
Revised 25.04.2012
Section
Assembly of planetary gear drive

All rights reserved
Service
Revised 01.09.2007
Section
Planetary gear drive
6.2

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Service
Revised 01.09.2007
Assembly of the ring gear and ring gear carrier
Section
Assembly of the sun gear 6.1.1
Prepare the ring gear and the ring gear

carrier
Heat the taper roller bearing inner ring with cage (1) to
about 100°C and install it onto the ring gear carrier (2).
Place the ring gear (3) onto the ring gear carrier. Bolt
the retainer (5) with the screws (4), secure the screws
with Loctite 270.
Assembly of the ring gear carrier
Install the ring gear carrier (2) with ring gear (3) into the wheel hub resp. onto the steering knuckle
resp. axle spindle. The oil compensating hole in the ring gear carrier must be on the bottom.
Subsequent adjust wheel bearings (see chapter 5.7).
Assembly of the thrust ring
Press the thrust ring (6) into the steering knuckle

resp. axle spindle. Secure with Loctite 270.
Assembly of the sun gear
Slip the sun gear (7) onto the universal joint resp.
axle shaft, install the circlip (9) and push the
universal joint resp. axle shaft towards the inside
until the circlip contacts to the sun gear and the sun
gear contacts to the thrust ring.

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Service
Revised 01.09.2007
Section
Assembly of planetary gear
6.1.2
Prepare planetary gear:

Install the needle bearing (10 resp. 11) into the planetary
gear (12 resp. 13).
Insert the preassembled planetary gears (12 resp. 13)

with needle bearings (10 resp. 11), rings (16) (if present)
and thrust discs (14 resp. 15) into the planetary housing
(22 resp. 23) (planetary housing in horizontal position).
Place o - ring (19) into the slot of the planetary housing

(22). Because of the difference of diameter of 0,1 mm
press the planetary pin (17 resp. 18) in direction of arrow.
Be sure, that the bore hole of the locking pin in the
planetary pin and planetary housing are aligned. After
inserting, secure the planetary pin with the locking pin (20
resp. 21).

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Service
Revised 01.09.2007
Assembly of the planetary housing
Section
Adjustment of the axial clearance 6.2.1
Assembly of the planetary housing
Place o - ring (30) into the slot of the planetary housing. Install the planetary housing and bolt it.
Adjustment of the axial clearance
The axial clearance between axle shaft resp. universal joint and adjusting screw must be
0,3 - 0,7 mm.
The adjustment has to be made by screwing in the adjusting screw until it touches the axle shaft
resp. universal joint. Back - off the adjusting screw 72° - 170° from the tightened position (this
corresponds to about 0,3 - 0,7 mm axial clearance).
Secure the adjusting screw and the counter nut with Loctite 270.
Attention:
When tightening the counter nut (29), hold the adjusting screw unconditional in order to prevent
turning of the adjusting screw.

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Service
Revised 01.09.2007
Section
Disassembly of planetary gear
6.1.4
Knock the locking pin (20 resp. 21) completely to the inner
side of the planetary pin.
Press the planetary pin in direction of arrow out of the

planetary housing.
Attention:
Because of the difference of diameter of 0,1 mm do not

press the planetary pin against the direction of arrow out
of the planetary housing, to prevent damaging the bore.
Remove the planetary gears with the thrust discs and

needle bearings.

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Service
Revised 01.09.2007
Assembly/ disassembly of cageless
Section
needle bearing (planetary gear bearing) 6.1.5
Assembly:
Version 1: Install the needle bearing with mounting bushings into the planetary gear, thereby
the outer mounting bushing will be stripping.
Insert the planetary gear with thrust discs into the planetary housing.
Press in the planetary pin, thereby the inner mounting bushing will remove.
Version 2: Place one thrust disc on the work bench, place on the planetary gear and insert the
mounting bushing.
Insert the cylindrical rollers/ needles alternately with the rings (according to the
design).
Insert the planetary gear with thrust discs into the planetary housing.
Press in the planetary pin, thereby the mounting bushing will remove.
Hint: Note the passage “Assembly of the planetary gear”!
Disassembly:
At the disassembly of the planetary pin the cageless needle bearing will fall asunder, if not a
mounting bushing will be pushing inwards at planetary pin removing.
Hint: Note the passage “Disassembly of the planetary gear”!

All rights reserved
Service
Revised 01.09.2007
Service Manual

All rights reserved

Kessler & Co. GmbH & Co. KG Phone +49 (0) 73 66/81-32
Huettlinger Straße 18-20 Fax +49 (0) 73 66/81-69
D-73453 Abtsgmuend service@kessler-axles.com
Germany www.kessler-axles.com
Service Manual
Hydrostatic Steering Unit

OSPB/OSPC
HN.21 .AD.02 replaces HN.21 .AC.02
Page
Table of contents Cost-free repairs ........................................................................ 2
Tools .......................................................................................... 2
Dismantling ................................................................................ 8
Reassembling ............................................................................ 14
Max. tightening torque and hydraulic connections ...................... 28
Service shops ................. . ............................................................ 29
Exploded view: OSPB / OSPC / OSPC LS .................................. 29-30
,b
104989 HN.21 .AD.02 1

Cost-free We would point out that cost-free repairs as mentionedw
repairs in Danfoss General Conditions of Sale, are carried out
only at Danfoss Nordborg or at service shops
authorized by Danfoss (page 29).
!rooLs
A Holding tool. Code no.: SJ 150-9000-2.
.; '. ;. ,_ B Assembly tool for o-ring and kin-ring.

Code no. SJ 150-9000-11.
C Assembly tool for lip seal.

Code no. SJ 150-9000-17.
2
D Assembly tool for cardan shaft.
Code no. SJ 150-9000-3.
E Assembly tool for dust seal.

Code no. SJ 150-9000-22.
F Torque wrench O-7 daNm.

13 mm socket spanner.
6, 8 and 12 mm hexagon sockets.
12 mm screwdriver.
2 mm screwdriver.
13 mm ring spanner.
6, 8 and 12 mm hexagon socket spanners.
Plastic hammer.
Tweezers.
The tools named under point F are not
available from Danfoss.
3
DISMAN!L'LING
1 Dismantle steering column from steering unit

and place the steering unit in the holding
tool. Screw out the screws in the end cover
(6-off plus one special screw).
2 Remove the end cover, sideways.
3 Lift the gearwheel set (with spacer if

fitted) off the unit. Take out the two
o-rings.
4 Remove cardan shaft.
5 Remove distributor plate.
6 Screw out the threaded bush over the check

valve.
7 Remove o-ring.
8 OSPB; OSPB LS; OSPBX LS:
Shake out the check valve ball (0 8 mm).
OSPC; OSPC LS; OSPC LSR:
Shake out the check valve ball and suction
valve pins and balls.
Note: On some pins in the OSPC there are two
springs (see page 30, pos. 28). See also
spare parts list for OSPC HN.21.CA.52.
9 Take care to keep the cross pin in the sleeve

and spool horizontal. The pin can be seen
through the open end of the spool. Press the
spool inwards and the sleeve, ring, bearing
races and needle bearing will be pushed out
of the housing together.
10 Take ring, bearing races and needle bearing

from sleeve and spool. The outer (thin)
bearing race can sometimes "stick" in the
housing, therefore check that it has come
out.
6
lla OSPB CN and OSPC CN
A small mark has been made with a pumice

stone on both spool and sleeve close to one
of the slots for the neutral position
springs (see drawing).
If the mark is not visible, remember to
leave a mark of your own on sleeve and spool
before the neutral position springs are
dismantled.
12 Carefully press the spool out of the sleeve.
13 Press the neutral position springs out of

their slots in the spool.
14 Remove dust seal and -o-ring/kin-ring.
7
Dismantling the dual shock valves for OSPC/OSPC LS
15 Remove plugs from shock valves using a 6 mm

hexagon socket spanner.
16 Remove seal washers (2-off).
17 Unscrew the setting screws using a 6 mm

8
18 Shake out the two springs and two valve balls
into your hand. The valve seats are bonded
into the housing and cannot be removed.
19 The dual shock valves are now dismantled.

..
x
w ‘:.
”
. .
Dismantling the pressure relief valve (cartridge) for OSPC
20 Screw out the plug using an 8 mm hexagon

socket spanner. Remove seal washers.
9
21 Unscrew the setting screw using an 8 mm
22 Shake out spring and piston. The valve seat

is bonded into the housing and cannot be
removed.
23 The pressure relief valve is now dismantled.
10
b Dismantling the pressure relief valve (cartridge) for OSPC LS/OSPC LSR
24 Screw out the pressure relief valve using an

8 mm hexagon socket spanner. Remove the seal
ring* If the valve is defective it must be
replaced (see OSPC spare parts list,
HN.21.CA.52).
.,.
25 The pressure relief valve is now dismantled.
..,. ;
.,
‘.
..,
.,
.’ . A ,
i’ ..
.:.. .,, :.’
26 The steering unit OSPB is now completely

dismantled.
11
27 The steering unit OSPB LS is now completely
dismantled.
28 The steering unit OSPC is now completely

dismantled.
29 The steering unit OSPC LS is now completely

dismantled.
Cleaning
Clean all parts carefully in Shellsol K or the like.
Inspection and replacement
Replace all seals and washers. Check all parts carefully and make any
replacements necessary.
Lubrication
Before assembly, lubricate all parts with hydraulic oil.
12
Assembly pattern and colour code for neutral position springs for
u OSP-steering units
STANDARDSPRINGS (GREY)
2-off flat, grey: code no. 150-0720
4-off curved, grey: code no. 150-0721
GREY SET
Spare set: code no. 150-4209
WEAK SPRINGS (BLUE)

2-off flat, blue: code no. 150-0748
2-off curved, blue: code no. 150-0749
BLUE SET
STRONGSPRINGS (GREY AND BLUE)

a-off flat, grey: code no. 150-0720
4-off curved, blue: code no. 150-0749
x
GREY/BLUE SET
STIFF SPRINGS (YELLOW)

2-off flat, yellow: code no. 150N0602
2-off curved, yellow: code no. 150N0603
YELLOW SET
30 Assemble spool and sleeve.
I Note
OSPB LS, OSPBX LS, OSPC LS and OSPC LSR

When assembling spool and sleeve only one of
two possible ways of positioning the-spring
slots is correct. There are three slots in
the spool and three holes in the sleeve in
the end of the spool/sleeve opposite to the
end with spring slots. Place the slots and
holes opposite each other so that parts of
the holes in the sleeve are visible through
the slots in the spool.
OSPB CN and OSPC CN
Assemble the spool/sleeve and make sure the
marks on spool and sleeve are opposite each
other (see drawing page 7).
31 Place the two flat neutral position springs

in the slot.
Place the curved springs between the flat
ones and press them into place (see assembly
pattern, page 13).
32 Line up the spring set.
14
33 Guide the spool into the sleeve. Make sure
that spool and sleeve for OSPB LS, OSPBX LS,
OSPC LS and OSPC LSR are placed correctly in
relation to each other (see page 14).
34 Press the springs togehter and push the

neutral position springs into place in the
sleeve.
35 Line up the springs and centre them.
kd
. .. . . ‘.
:‘:A:.‘,::..: ._ ,..* .i.n ,..n;v. .._ .<.>,,. ::j,yy:
36 Guide the ring down over the sleeve.

Note: The ring should be able to rotate -
free of the springs.
/ .,::.., ,,, .. ,.,” .; ,: .,
.: ,,
b ...“’
15
37 Fit the cross pin into the spool/sleeve.
38 Fit bearing races and needle bearing as shown

on below drawing.
Assembly pattern for standard bearings
1 Outer bearing race

2 Needlebearing
3 Inner bearing race
4 Spool
5 Sleeve
16
‘w Assembly pattern for double bearings
1 Washer for axial bearing

2 Outer needlebearing
3 Outer bearing race
4 Spool
5 Sleeve
6 Inner needlebearing
7 Inner bearing race
The inside chamfer on the inner bearing race must face the inner
spool.
Installation instructions for o-ring/kin-ring (standard)
39 Turn the steering unit until the bore is

horizontal. Guide the outer part of the
assembly tool into the bore for the
spool/sleeve.
17
40 Grease o-ring and kin-ring with hydraulic oil
and place them on the tool.
41 Hold the outer part of the assembly tool in

the bottom of the steering unit housing and
guide the inner part of the tool right to the
bottom.
42 Press and turn the o-ring/kin-ring into

position in the housing.
43 Draw the inner and outer parts of the

assembly tool out of the steering unit bore,
leaving the guide from the inner part in the
bore.
18
w Imstallation in8tructioa8 for lip ma1
44 Lubricate the lip seal with hydraulic oil and

place it on the assembly tool.
45 Guide the assembly tool right to the bottom.
: ,::::: ..’ .: ,,
..
46 Press and turn the lip seal into place in the

housing.
19
47 With a light turning movement, guide the
spool and sleeve into the bore.
Note: Fit the spool set holding the cross
pin horizontal.
48 The spool set will push out the assembly tool

guide. The o-ring and kin-ring are now in
position.
49 Turn the stearing unit until the bore is

vertical again. Put the check valve ball into
the hole indicated by the arrow.
50 Screw the threaded bush lightly into the

check valve bore. The top of the bush must
lie just below the surface of the housing.
Assembly of the two suction valves for OSPC/OSPC LS/OSPC LSR
51 Place a ball in the two holes indicated by

the arrows.
52 Place a pin in the same two holes.
53 In some cases a spring has to be fitted (see

page 30, pos. 28) on the pin before it is
placed in the housing. (See OSPC spare parts
list, HN.21.CA.52).
54 Grease the o-ring with mineral oil approx.
viscosity 500 cSt at 200C.
55 Place the distributor plate so that the

channel holes match the holes in the housing.
-.. .:.
j. ..
56 Guide the cardan shaft down into the bore so

that the slot is parallel with the connection
flange.
57 Place the cardan shaft as shown - so that it

is held in position by the mounting fork.
58 Grease the two o-rings with mineral oil
approx. viscosity 500 cSt at 200C and place
them in the two grooves in the gear rim. Fit
the gearwheel and rim on the cardan shaft.
59 Important: Fit the gearwheel (rotor) and

cardan shaft so that a tooth base
in the rotor is positioned in
relation to the shaft slot as
shown. Turn the gear rim so that
the seven through holes match the
holes in the housing
60 Fit the spacer, if any.
61 Place the end cover in position.
23
62 Fit the special screw with washer and place
it in the hole shown.
63 Fit the six screws with washers and insert

them. Cross-tighten all the screws and the
rolled pin with a torque of 3.0 +/-0.6 daNm.
The OSPB, OSPB LS and OSPBX LS can now be
function tested.
64 Place the dust seal ring in the housing. With

the OSPC, PSPC LS and OSPC LSR the dust seal
ring must be placed only after the pressure
relief valve and shock vamhave been
fitted.
24
66 Press the plastic plugs into the connection
ports. Do not use a hammer!
Assembly of the pressure relief valve for OSPC
67 Fit the piston.
68 Fit the spring.
25
69 Screw in the setting screw with an 8 mm
hexagon socket spanner. Make the pressure
setting on a panel or the vehicle.
0 1.7 spring for 50 - 70 bar.
0 1.9 spring for 70 - 105 bar.
0 2.1 spring for 110 - 155 bar.
(See OSPC spare parts list HN.21.CA.52).
70 Screw plug with dust seal into the housing

using an 8 mm hexagon socket spanner.
Tightening torque: 5 +/-1 daNm.
Assembly of the pressure relief valve (cartridge) for OSPC LS/OSPC LSR
71 Place the seal ring on the cartridge and

screw the cartridge into the housing using a
12 mm hexagon socket spanner. Tightening
torque: 5 +/-1 daNm. Make the pressure
setting on a panel or the vehicle. The
cartridge is factory-set at 175 bar. Use a
4 mm hexagon socket spanner. (See OSPC spare
parts list HN.21.CA.52 for setting range).
26
72 Screw plug with seal ring into the housing
using an 8 mm Allen key.
Tightening torque: 5 +/-1 daNm.
Assembly of the dual shock valves for OSPC/OSPC LS/OSPC LSR
73 Put a ball in the two holes indicated by the

arrows.
74 Place springs and valve cones over the two

balls.
Note: The blue spring applies to
setting range 90480 bar. The
untreated spring applies to
setting range 190-260 bar. (See
OSPC spare parts list
HN.21.CA.52).
27
75 Screw in the two setting screws using a 6 mm
hexagon socket spanner. Make the pressure
setting on a panel or the vehicle. (See OSPC
spare parts list HN.21.Ll.52).
76 Screw plug with seal ring into the two shock

valves and tighten them with a torque of
3 +/-0 daNm using a 6 mm hexagon socket
spanner.
Steering unit type OSPB, OSPB LS, OSPBX LS,
OSPC, OSPC LS or OSPC LSR is now assembled.
Max. tightening torque and hydraulic connections
Max. tightening torque

daNm (lbf in)
Screwed
connection With With with With
cutting copper aluniniun O-ring L: Left port
edse washer washer R: Right port
I--
T: Tank
1/4 BSP.F P: Pump
3/8 BSP.F
IM 18 x 1,s 7 (620) 2 (180) 5 (440) 5 (440)
10 (900) 13 t270,/ 8 (700) / 7 (620) 1
28
Authorized service shops:
bd
Asean : Danfoss Industries Pte. Ltd., Singapore
Australia : Danfoss (Australia) Pty. Ltd., Melbourne
Austria : Hainzl Industriesysteme, Gesellschaft m.b.H, Linz
Belgium .. N.V. Danfoss S.A., Bruxelles
Canada : Danfoss Mfg. Co. Ltd., Mississauga
Denmark : H. Sondergaard A/S, Malov
Finland : OY Danfoss AB, Espoo
France : Danfoss S.a.r.l., Trappes (Paris)
FRG (W. Germany): Danfoss GmbH, Offenbach/Main
Great Britain : Danfoss Limited, Greenford
Iceland : Velsmidjan Hedinn, Reykjavik
Italy : Sordella & C. Oleodinamica s.r.l., Torino
Japan : Danfoss (Japan) Manufacturing Co., Ltd., Gotemba
Netherlands : ITHO B.V., Schiedam
New Zealand : Danfoss (New Zealand) Limited, Auckland
Norway : Danfoss Norge A/S, Skui
Spain .. Danfoss S.A., Madrid
Sweden : Transventor Hydraulik AB, Molndal, Goteborg
Switzerland : Werner Kuster AG, Frenkendorf
U.S.A. : Danfoss Inc., Rockford, Illinois
Service shops:
Greece : A. Skoura & Co. E.E., Athens
Norway : Servi Produksjon A.S., Trondheim
Item Spare Parts
1 Dust seal ring

2 Housing spool
+ + sleeve
3 Ball B 8,5 mn
4 Thread bushing
5 O-ring 25, 12x1,78 m-t, is
used with kin-ring (item 6)
6 Kin-ring
6a Lip seal
7 Bearing assembly
8 Bearing assembly
10 Ring I/D 39,6x0,7x4,5 m
11 Cross pin 06x41 mn
12 Neutral position spring
13 Cardan shaft
14 Spacer
15 O-ring 080,5x1,5 mn
16 Distributor plate
17 Gearwheel
18 O-ring 0,92x1,78 mn
19 End cover
20 Washer 88,2x11,9x1,0 m
22 Special screw
23 Screw
24 Rating plate
25 Drive screw
26 Spacer OSPB
tern
Spare Parts
i Bust seal ring
2 busing, spool and sleeve
:heck valve and the seats
for relief and dual shock
malves are locktited
3 all 08,s mn
4 hrcad tmhing
5 b-ring used with kin-ring
item 6)
6 :in-ring
7 learing assembly
8 ling
9 iross pin
10 ipacer
11 :ardan shaft
12 iet of springs
13 I-ring
14 jistributor plate
15 Gearwheel set
16 D-ring
17 End cover
18 Uasher
20 Special screw
21 Screw
22 Name plate
23 Drive screw
OSPC
24 Complete relief valve
25 Spring wire @1,7x36,6 ion
26 Complete dual shock valve
27 Ball r3/16 in
28 Spring
- 29 Rolled pin
OSPC LS
JM/KEJ/LKR
30
Spare parts Hydraulics
Danfoss Steering Units
,_, OSPB/OSPC/OSPL/
OSPD/OSPQ/OSPF
HN.21.UA.52 replaces HN.21.CB.52, HN.21.DA.52, HN.21.EB.52 and HN.21.HB.52
Index Page
Cost-free repairs ......................................................... 2
Service shops ........................................................... 2
Exploded view OSPB ..................................................... 3
Exploded view OSPC/OSPF ................................................ 4
Explodes view OSPQ ..................................................... 5
Exploded view OSPD ..................................................... 6
Exploded view OSPL ..................................................... 7
Spare parts ............................................................. 8
Danfoss Hydraulics Organization ............................................ 15
02-1998 HN.21
.UA.52 Book6 Partition
3 1
Vederlagsfri reparation Vi ger opmaerksomp& at den vederlagsfrie reparation som er omtalt i Danfoss Almindelige
Leveringsbetingelser kun udferes hos Danfoss Nordborg eller hos Danfoss autoriserede service ,_
shops.
Cost-free repairs We would point out that cost-free repairs as mentioned in Danfoss General Conditions of Sale,
are carried out only at Danfoss Nordborg or at service shops authorized by Danfoss.
Kostenlose Reparatur Wir machen darauf aufmerksam, dal3die in den "AIIgemeinen Lieferbedingungen" von Danfoss
erw&hnte kostenlose Reparatur nur bei Danfoss Nordborg oder bei den von Danfoss autorisier-
ten Kundendienswerkst&tten ausgef(Jhrt wird.
Reparation gratuite Nous faisons observer que la r_paration gratuite mentionnee dans les Conditions generales de
Vente de Danfoss ne devra _tre effectu6e que dans les ateliers Danfoss & Nordborg ou dans
les ateliers de d_pannage agrees par Danfoss.
Authorized Service Shops Australia : Danfoss (Australia) Pty. Ltd., Melbourne

Austria : HAINZL Industriesysteme, Gesellschaft m.b.H, Linz
Belgium : N.V. Danfoss S.A., Bruxelles
Brazil : Danfoss do Brasil Ind.e Com. Ltda., S&o Paulo
Canada : Danfoss Mfg. Co. Ltd., Mississauga
Denmark : Danfoss Hydraulik A/S, Stenlose
Finland : OY DanfossAB, Espoo
France : Danfoss S.a.r.l., Trappes (Paris) _,"
Germany : Danfoss GmbH, Offenbach/Main
Great Britain : Danfoss Limited, Greenford (London)
Iceland : HEDINN VERSLUN H/F, Reykjavik
India : DANTAL HYDRAULICSPVT Ltd., New Delhi
Italy : Danfoss s.r.l. Division Sordella, Torino
Japan : DanfossK.K., Gotemba
Korea : UNITEKCorporation,Seoul
Netherlands : ITHO B.V., Schiedam
New Zealand : Danfoss (New Zealand) Limited, Auckland
Norway : Danfoss A/S, Skui
Republic of South Africa : Danfoss (Pty) Ltd., Johannesburg
Singapore : Danfoss Industries Pte. Ltd., Singapore
Spain : Danfoss S.A., San Sebastian de los Reyes, (Madrid)
Sweden : DanfossAB, Mj61by
Switzerland : Danfoss Werner Kuster AG, Frenkendorf
Turkey : MERTTEKNIK A.S., Istanbul
U.S.A. : Danfoss Fluid Power Div. Racine, Wisconsin
Service shops Australia : Danfoss (Australia) Pty. Ltd., Adelaide

Australia : Danfoss (Australia) Pty. Ltd., Brisbane
Australia : Danfoss (Australia) Pty. Ltd., Perth
Australia : Danfoss(Australia)Pty.Ltd.,Sydney
Czech Rep. : TECHNOTRADE, Olomouc
Greece : A. SKOURA& Co. E.E.,Athens
New Zealand : Danfoss (New Zealand) Limited, Christchurch
Portugal : Danfoss (Portugal), da., Carnaxide
Taiwan : SYMBRIDGE Machinery Co. Ltd., Taipei
2 HN.21
.UA.52
Exploded view OSPB
20
22
HN.21
.UA.52 3
Exploded view OSPC/OSPF
32
32
1
33
38
34
31
30 5
2
7 _
_-o
a<
\
2
13
14
15 _ \
12 _
\ z
16 __
23
17
24
40 18
19
20
22
4 HN.21 .UA.52
Exploded view OSPQ
HN.21
.UA.52 5
Exploded view OSPD
32
J
32
33
5O
30 31 I_
57....
4 10 _o
_
z_
_.. 36
_ 35
13 "
15 "_
16 _ 12
-.. /
x /
51 "_
18
17
/ \
, 20
24
6 HN.21.UA.52
Exploded view OSPL
HN.21
.UA.52 7
Spare parts , ,
Number per
Item Spare
Parts Code
No. Comments unit
I I I I I
1 Dust
seal
ring 633B9002 1
I I I I I
2 Housing,
spoolandsleeve Notsoldseparately 1
i I i i i
150N4027 Set of spare parts

3 Ball
08.5
mm 689X1031 1
4 Thread
bushing 150-0304 1
i
I I I I I
4 Thread
bushing
withpin 150G4336 OSPD 1
I I I I I
5 Shaft
seal 150N4014Roto Glyd 1
150N4007 O-ring/Kin-ring 1
633B2060 Lipseal 1
I I I I I
7 Bearing 150-4262 1
I I I I I
150N4026 Set of spare parts

10 Ring 150-0310 1
11 Cross
pin 150-0305 1
I I I I I
12 Set
ofsprings 150-4091 1
150-4207
i 1
150-4209 1
150-4265 1
150-4269 1
i 150N4018 1
150
N4019 1
150N4020 1
150N4028 1
150N4035 1
150N4037 1 i
I I I I I
13 Cardanshaft 150-0844 On steeringunits manufacturedbeforeweek 20 1991, 1

the gearwheel set must be changed if the cardan
shaft is replaced.
150N0653 For gearwheel set without stepped splines 1
150-0967 OSPD 1
i i i i i
14 Spacer OSP40,OSP50,OSP70nospacer
150-0435 OSP 80 1
150-0436 OSP 100 1
150N0654 OSP 100 for gearwheelset 150-4064 1
150-0437 OSP 125 1
150N0655 ©SP 125 for gearwheelset 150-4065 1
150-0438 OSP 160 1
150-0439 OSP 200 1
150-0441 OSP 315 1
150-0412
*) OSP400 1
150-0413
*) OSP 500 1
150-0414
*) OSPB630 1
150-1595
*) OSPL630 1
150-0415
*) OSPB800 1
i
*) Not available, change cardan shaft and gearwheel set
8 HN.21 .UA.52
Spare parts
Item Spare
Parts Code
No. Comments Number
unit per'
I I i I I
14 (continued) 150-1596
*) OSPL800 1
150-0416
*) OSPB
1000 1
150-1597
*) OSPL
1000 1 ,
I I I I I I
15 O-ring 633B1202 1
I I I I I I
16 Distributor
plate 150N0610 1
i 150G4301OSPD 1
I i J i i
17 Gearwheel
set 150-4169 OSP 40 w= 6,5 1
150-4171 OSP 50 w= 6,5 1
150G4200 OSPD 60 Low excentricity w = 9,1 1
150-4170 OSP 70 w= 9,1 , 1
150-4139 OSP 70 Noslip w = 9,1 1
150G4201 OSPD 70 w = 9,1 1
150-4172 OSP 80 w = 10,4 1
150-4140 OSP 80 Noslip w= 10,4 1
150G4202 OSPD 80 w= 10,4 1
150-4173 OSP 100 w= 13,0 1
150-4064 OSP 100 Without stepped splines w = 13,0 1
150-4141 OSP 100 Noslip w = 13,0 1
150G4203 OSPD100 w= 13,0 1
150-4174 OSP 125 w= 16,2 1
150-4142 OSP 125 Noslip w = 16,2 1
150G4204 OSPD125 w = 16,2 1
150G4211 OSPD 125 Lowexcentricity w = 16,2 1
150-4175 OSP 160 w= 20,8 1
150-4145 OSP 160 Noslip w = 20,8 1
150G4206 OSPD160 w= 20,8 1
150G4212 OSPD 160 Low excentricity w = 20,8 1
150-4166 OSP 185 w= 24,0 1
150-4186 OSP 200 w= 26,0 1
150-4146 OSP 200Noslip w= 26,0 1
150G4207 OSPD200 w = 26,0 1
150G4214 OSPD 200 Lowexcentricity w= 26,0 1
150G4215 OSPD 230 Low excentricity w= 35,1 1
150-4187 OSP 250 w =32,5 1
150-4188 OSP 315 w= 40,9 1
150G4209 OSPD315 w= 40,9 1
150-4189 OSP 400 w= 52,0 1
150-4190 OSP 500 w=65,0 1
150-4194 OSPL 520 w= 67,8 1
150-4191 OSPB630 w= 82,0 1
150-4195 OSPL 630 w= 82,0 1
150-4192 OSPB800 w= 104,0 1
150-4196 OSPL 800 w= 104,0 1
150-4193 OSPB1000 w = 134 1
150-4197 OSPL1000 w = 134 1
I I I I I I
18 O-ring 633B1173 2
633B0208OSPD 6
HN.21
.UA.52 9
Spare parts
Number per
Item Spare
Parts Code
No. Comments unit
19 End
cover 150-0328 1
150-1355 Balanced
endcover 1
20 Washer 684X2481 7
22 Special screw 150-0326 OSP 40/OSP 50 = 67,4 1

150-0321 OSP 70/OSP 80 = 63,0 1
150-0322 OSP 100 = 106,0 1
150-1450 OSP 125 = 68,5 1
150-0323 OSP 160 = 73,0 1
150-0324 OSP 200/OSP 185 = 78,5 1
150-0325 OSP 315 -- 93,5 1
150-0451 OSP 400 = 104,5 1
150-0452 OSP 500 = 117,5 1
150-1579 OSPL520 = 131,5 1
150-0453 OSPB630 = 134,5 1
150-1580 OSPL630 = 146,5 1
150-0454 OSPB800 = 156,5 1
150-1581 OSPL800 = 166,5 1
150-0455 OSPB1000 = 186,5 1
150-1582 OSPL1000 = 196,5 1
23 Screws 681X1577 OSP 40/OSP 50 = 30 6

681X1939 OSPD 60/120 = 90 7
681X1270 OSPD 60/185 = 100 7
681X1178 OSPD 60/220 = 105 7
150G4385 OSPD 60/260, OSPD 60/290 = 115 7
681Xl 578 OSP 70/OSP 80 = 35 6
681X1939 OSPD 70/140, OSPD 70/150 = 90 7
681X1480 OSPD 70/170 = 95 7
150G4384 OSPD 70/195 = 97 7
681X1270 OSPD 70/230 = 100 7
681X1178 OSPD 70/270 = 105 7
681X1487 OSPD 70/385 = 120 7
681X1480 OSPD 80/160, OSPD 80/180 = 95 7
150G4384 OSPD 80/205 = 97 7
681X1178 OSPD 80/240 = 105 7
681X1940 OSPD 80/280 = 110 7
150G4386 OSPD 80/395 = 125 7
150G4384 OSPD 100/200 = 97 7
681X1270 OSPD 100/225 = 100 7
681Xl178 OSPD 100/260 = 105 7
681X1940 OSPD 100/300 = 110 7
150G4386 OSPD 100/415 = 125 7
681X1178 OSPD 125/250 = 105 7
681X1940 OSPD 125/285 = 110 7
150G4385 OSPD 125/325 = 115 7
681X1941 OSPD 125/440 = 130 7
681X1580 OSP 160 = 45 6
681X1581 OSP 185/OSP 200 = 50 6
681X1582 OSP 315 = 65 6
681X1583 OSP 400 = 80 6
681X1939 OSP 500 = 90 6
681X1178 OSPL520 = 105 6
681X1940 OSPB630 = 110 6
10 HN.21
.UA.52
Spare parts
Number
per
Item Spare
Parts Code
No. Comments unit
i i i i
23 (continued 681X1487 OSPL630 I= 120 6

681X1941 OSPB800 I= 130 6
681X1488 OSPL800 I= 140 6
681X1339 OSPB
1000 I= 160 6
681X1489 OSPL1000 I= 170 6
i i i i
24 Name
plate 150A6009 1
26 Spacer 150-0443*) AllOSPB400-1000andallOSPL800-1000 1
27 Intermediate
plate 150-1591 OSPL 1
30 Relief
valve 150-4270 Open
center 1
150-4281LS 1
150N4021 Opencenter
07,2 1
150-4054 OSPQ 1
Special
reliefvalve 150-4084 UsedinCNforJohnDeere 1
i i i i
31 Spring for relief valve

Setting < 70 bar 1015 Ibf/in2 wire O1,6 663X6021 LS 1
70-210 bar 1015-3047Ibf/in2 wire O2,1 663X6022 LS 1
140-175 bar 2030-2470 Ibf/in2 wire ®1,9 663X6183 OSPQ 1
Spring for relief valve

40-70 bar 580-1015 Ibf/in2 wire O1,8 663X1800 Open center 1
70-105 bar 1015-1525 Ibf/in2 wire O1,9 Ii 663X1774 Open center 1
110-155 bar 1595-2250 Ibf/in2 wire O2,1 663X1802 Open center 1
140-180 bar 2030-2610 Ibf/in2 wire 02,2 663Xl 128 Open center 1
140-180 bar 2030-2610 Ibf/in2 wire 02,7 663X6026 For relief valve 150N4021 1
i i i i
32 Completeshockvalve 150-4268
90-180 bar (1300-2610 Ibf/in2) wire O1,7 2
170-260 bar (2470-3770 Ibf/in2) wire O1,9 2
i i i i
33 Ball 3/16 in 689X1005 2

i i i i
34 Pinforsuction
valve 150-4080 2
150G4337OSPD 2
I I I
35 LScheck
valve,
screw 150-1606 1
150G
1355 OSPQ 1
I I I I
36 LScheck
valve,ball3,0mm 689X1043 1
ball 3/16in 689X1005 OSPQ 1
I I I I
37 Check
valve 150N4091M18 x 1,5 1
150N4092 3/4 - 16 UNF 1
150N4093 G1/2,PF/2 1
150N4094M22 x 1,5 1
I I I I
38 Springs
forsuction
valve 663X1134 2
i i
HN.21
.UA.52 11
Spare parts
Numberper
Item Spare Parts Code No. Used in units unit
I i I
39 Seal ring 150N0630 For no slipgearwheelset 1

i i i
40 O-ring 633B0116 For no slipgearwheelset 1

i i i
50 Mountingpin 150G4354 OSPD 60/120 I = 44,8 2

150G4363 OSPD 60/185 I = 56,5 2
150G4345 OSPD 60/220 I = 61,7 2
!
! 150G4381 OSPD 60/260 I = 68,2 2
!
150G4370 OSPD 60/290 I = 68,9 2
150G4354 OSPD 70/140 I = 44,8 2
150G4355 OSPD 70/150 I= 46,1 2
150G4357 OSPD 70/170 I = 48,7 2
150G4359 OSPD 70/195 I = 52,0 2
150G4363 OSPD 70/230 I = 56,5 2
150G4345 OSPD 70/270 I = 61,7 2
150G4371 OSPD 70/385 I = 76,7 2
150G4356 ii OSPD 80/160 I = 47,4 2
150G4358 OSPD 80/180 I = 50,0 2
150G4361 OSPD 80/205 I= 53,3 2
150G4364 OSPD 80/240 I= 57,8 2
150G4367 OSPD 80/280 I= 63,0 2
150G4372 OSPD 80/395 I= 78,0 2
i 150G4359 OSPD 100/200 I= 52,6 2
150G4362 OSPD 100/225 I= 55,9 2
150G4366 OSPD 100/260 I= 60,4 2
150G4369 OSPD 100/300 I= 65,6 2
150G4373 OSPD 100/415 I= 80,6 2
150G4365 OSPD 125/250 I= 59,1 2
150G4368 OSPD 125/285 I= 63,7 2
150G4370 OSPD 125/325 I= 68,9 2
150G4374 OSPD 125/440 I= 83,8 2
51 Cardan
shaft 150G4350
OSPD 1
150G4389 OSPD,315 cm3 gearwheelset 1
= = i
52 Distributor
plate 150G4303 1
53 Distributor
plate 150G4305 1
, , ,
54 Valve
andvalve
housing 150G4213 1
, , ,
55 Spring 663X6151 1
i , J
56 Guide
pin 682L2004 1
60 Amplification
spool Notsoldseparately 1
61 Spring 633X6145 1
62 Plug 150G1201 1
63 Amplification
orifice Notsoldseparately 1
12 HN.21 .UA.52
Set of seals
' Number
per!
Item Spare
Parts Code
No. Comments unit
I I I I I I
Standard 150N4038 Setofseals

1 Dust
seal
ring 633B9002 1
5 Shaft
seal 150N4014 Roto
Glyd 1
15 O-ring 633B1202 1
18 O-ring 633B1173 2
20 Washer 684X2481 7
I I I I I I
Universal 150N4039 Setof seals

1 Dustseal
ring 633B9002 1
5 Shaft
seal 150N4014 Roto Glyd 1
633B2060 Lipseal 1
15 O-ring 633B1202 1
18 O-ring 633B1173 2
20 Washer 684X2481 7
I I I I I I
_,_ No slip gearwheel set 150N4044 Set of seals

1 Dust seal ring 633B9002 1
5 Shaft seal 150N4014 Roto Glyd 1
15 O-ring 633B1202 1
18 O-ring 633B1173 2
20 Washer 684X2481 7
39 Sealring 150N0630 Fornoslipgearwheel
set i 1
40 O-ring 633B0116 Fornoslipgearwheel
set 1
! i i i i
OSPL 150N4042 Setofseals
1 Dust
seal
ring 633B9002 1
5 Shaft
seal 150N4014 Roto Glyd 1
15 O-ring 633B1202 1
18 O-ring 633B1173 3
20 Washer 684X2481 7
I I I I I I
OSPD 150N4041 Setofseals

1 Dust
seal
ring 633B9002
I 1
_' 5 Shaft
seal 150N4014 Roto
Glyd 1
15 O-ring 633B1202 1
18 O-ring 633B0208 6
20 Washer 684X2481 7
I I I I I I
O-ring/Kin-ring 150-4206 Set of seals

633B9002 1
1 Dust sealring
5 Shaft seal i 150N4007 O-ring/Kin-ring 1
15 O-ring 633B1202 1
18 O-ring 633B1173 2
20 Washer 683X2481 i 7
I I I I I I
LipSeal 150-4267 Setofseals

1 Dustsealring 633B9002 1
5 Shaft
seal 633B2060 Lipseal 1
15 O-ring 633B1202 1
18 O-ring 633B1173 2
20 Washer 684X2481 7
I I I
HN.21 .UA.52 13
Set of seals
Number per
Item Spare
Parts Code
No. Comments unit
OSPA 150-4205 Setofseals

Shaft
seal 633B9004Kinring 1
O-ring 633B1202 1
O-ring 633B1173 2
O-ring 633B1192 1
Washer 683X2481 7
Roto Glyd, O-ring/Kin-ring 150N4040

1 Dust sealring 633B9002 1
5 Shaftseal 150N4014Roto Glyd 1
15 O-ring 633B1202 1
18 O-ring 633B1173 2
20 Washer 684X2481 7
14 HN.21.UA.52
Danfoss Hydraulics Organization
Danfoss is an international concern with factories in 10 countries and subsidiaries in 32 countries.

In addition to the hydraulic components, the Danfoss range of products includes refrigeration controls,
industrial automatics, precision step systems, industrial instrumentations, electrical drives and controls,
controls for heating plant, system controls, components for burners and boilers, compressors
and thermostats for refrigerators and freezers.
Argentina Danfoss S.A. Colombia Fiza Ltda. Greece A. SKOURA & Co. E.E.
SanLorenzo 4310 Carrera 40 N° 163-A-55 SpirouPatsi105
1605 Munro (Toberin) GR-118 55Athens
Buenos Aires Santaf_ deBogot& Tel. : 30013453906
Tel. 54 1 756 4200 D.C. Colombia S.A. 30 01 346 3967
Telex 9900 Booth-AR Tel.: 57 1 677 6346/677 6440 Telex : 216713 Deda Gr.
Fax 5417564100 5716775142 Fax : 30-1-34 74106(Skouras)
Fax: 57 677 7025
Ing. Lahusen S.R.L.
Av.Belgrano, 615- 8° I HongKong NICKO INTERNATIONAL
1092 - Buenos Aires Croatia Danfoss d.o.o RM. 1203, Chevalier Commercial Centre
Tel. : 54 1 342 1083/1835 Heinzelova 6a 8 Wang Hoi Road
Fax : 541 3317314 HR-10000 Zagreb Kowloon Bay,HongKong
Tel.:+3851 4553 444 Tel. : 85227552783
Fax:+3851 4487 75 Fax : 85227988656
Australia Danfoss (Australia) Pty. Ltd.
Melbourne (Head Office)
1 Ricketts Road Cyprus Tektron Ltd. Hungary KITE Nadudvar
Private Bag 20, Mt. Waverley 25, Heroes Street 4181 Nadudvar, Bem. J.U.2.
Victoria, 3149 P.O. Box 2123 Tel.
Telex ::72431
36 54 48 0401
Strovolos-Nicosia
Tel.:613 95431033
Fax:613 9543 4027 Tel. : 3572497907 Fax : 3654480331
Danfoss authorized service shop Telex : 3968 tektron cy
Fax :357 2 31 4844
Iceland HEDINN VERSLUN H/F
Austria HAINZL INDUSTRIESYSTEME Seljaveg 2
Gesellschaft m.b.H. & Co KG Czech Republic TECHNO TRADE GmbH P.O. Box 512
Industriezeile 56 Slovak Republic Petr Kejdus IS-121 Reykjavik
P.O. Box 100 Tovarni ul. 41 Tel. 354 562 4260
A-4040 Linz CS77200Olomouc Telex2003Hedinn IS
Tel. : 43 732 7892 Tel.: 420 68 52 22 004 Fax 354 562 4315
Telex : 22 1522 Fax: 420 68 52 32 055 Danfoss authorized service shop
Fax :43 732 7892 150
Danfoss authorized service shop
Denmark Danfoss A/S India DANTAL HYDRAULICS PVT Ltd.
DK-6430Nordborg 805-806ChiranjeevTower
Belgium N.V. Danfoss S.A. International tel.: 45 74 88 2222 Nehru Place
ErasmusBusinessPark National tel.:74882222 NewDelhi110019
Av.JosephWybran45 Telex: 50599 Tel.:91 64601 55+ 6425036+ 6453806
B-1070 Bruxelles Fax : 4574490949 Fax:91116476089
Tel. :32 02 525 0711 45 74 49 1613 (Hydr.) Danfoss authorized service shop
Telex : 24828
Fax :32 02 525 0757 Danfoss Hydraulik A/S
Danfoss authorized service shop Toppevadvej 44-46, GanlQse Iran Dancool Iran Co. Ltd.
DK-3660Stenlese PicheShemiran
Tel. : 4542 184055 Kh.TonekabonNo.15
Brazil Danfoss do Brasil Telex : 40041 Sondgd dk Teheran 11488
Ind.eCom.Ltda. Fax :4542184603 Tel. : 98217532026
Rua Nelson Francisco 26, Casa Verde Danfoss authorized service shop 98 21 7523 835
CEP 02712-100 S&o Paulo Fax : 98 21 7530 565
Tel.:55118555400 Telex: 222235 dicIR
Fax: 55 11 855 5455 Finland OY Danfoss AB
Danfoss authorized service shop Kivenlahdentie 7
SF-02360 Espoo Israel Radion EngineeringCompany Ltd.
Tel. : 358 9 802 81 11 Ha'sivimSt.
Canada DanfossFluid Power Fax : Hydraulicsdept. 358 9 802 85 61 P.O.B. 7111
7880 Transmere Drive Danfoss authorized service shop Petah-Tikvah49250
Mississauga Tel. 972 3 922 6688
Ontario L5S IL9 Telex 3812 93reco IL
Tel. : 1 905 673 0559 France Danfoss S.a.r.I. Fax 972 3 922 6655
Telex : 06961216 Z.A.deTrappes-Elancourt
Fax : 1 905 673 5039 7, Av. Roger Hennequin
Danfoss authorized service shop P.O. Box 58 Italy Danfoss s.r.I. Division Sordella
F-78193Trappes-Cedex StradaCarignano48
Tel. : 33 1 30 62 5000 1-10024Moncalieri / Torino
Chile TALLERES LUCAS LTDA. Telex : 697 809 F Tel. : 39 11 682 7111
Av.BlancoEncalada 1737 Fax : 33 1 30625009 Fax : 39116827199
Santiago Danfoss authorized service shop Danfoss authorized service shop
Tel.: 56 2 672 6223/695 4233
Fax: 56 2 698 2515
Germany Danfoss Antriebs- und Regeltechnik GmbH Japan Danfoss K.K.
Gesch&ftsbereichHydraulik Head Office
China Danfoss (Tianjin) Ltd. CarI-Legien-Str. 8 Shinyokohama Mineta Bldg.
Wuging Development Area Road 3 D-63073 Offenbach/Main 3-19, Shinyokohama 2-chome
Tianjin 301 700 P.O. Box 10 04 53, D-63004 Kohoku-ku
Peoples Republic of China Offenbach/Main Yokohama, 222 Japan
Tel.: (8622) 2 933 6400-06 Tel. 49 069 8902 0 Tel. : 81 45 476 5001
Fax:(8622)29336407 Telex 4-152876 Fax :81454765010
Fax 49 69 8902 319 Danfoss authorized service shop
49 69 8902 316
SYMBRIDGE INTERNATIONAL Danfoss authorized service shop
Room E 12F Korea UNITEK Corporation
GaoJia BuildingNo.1 Korea World Trade Center
Chungfeng Road Great Britain Danfoss Limited P.O. Box 181
Shenzhen 518005 PerivaleIndustrialPark Room201Seokyung Bldg.
P.R. China Horsenden Lane South 1000-3 Daichi-Dong, Kang Nam-Ku
Tel.: +86 755 218 6843 Greenford, Middx. UB6 7QE Seoul, Korea
Fax: +867552170147 Tel. 440819917000 Tel. : 822 5670090
Telex 24223 Fax : 822 5692894
Fax 44 181 991 7053 Danfoss authorized service shop
Danfoss authorized service shop
HN.21
.UA.52 15
Danfoss Hydraulics Organization
Malaysia Danfoss Industries Sdn. Bhd. Rumania Michail Petrache Switzerland Danfoss Werner Kuster AG
No. 14, Jalan 5 S.C. LYRA PRODIMPEX Ltd. Parkstrasse 6
TamanPerindustrian BatuTiga B-dulTimisoara41 CH-4402Frenkendorf
40000 ShahAtam, BI.P14,Sc.B.Ap.24 Tel. : 410619011515
Selangor 773621 BUCURESTI Fax :410619014180
Tel. : 60 3 550 1685 Tel. : 401 323 8373, 401 323 8379 Danfoss authorized service shop
Fax : 603 5502805 Fax : 4013238399
Taiwan Symbridge Machinery Co. Ltd.

Mexico Ignacio Gomez, General Manager Russia ZAO Danfoss 28 Lane 205, Sec. 3
MillerPotenciaFluida Marksistskaya ul.34 ChungChingNorthRoad
Israel 301 ESQ Damasco 109147 Moscow P.O. Box 47-132
Col. Ricardo B. Anaya 2A Seccion Tel.: 7 095 792 5757 Taipei/Taiwan R.O.C.
Apdo.PostalF-1241 7 5017925757(Satellite) Tel. 8860259108168 (threelines)
San Luis Potosi, S.L.P. Mexico Fax: 7 095 792 5760 Telex 19437 SYMBRI
Tel. : 5248 21 1937 7 5017925760(Satellite) Fax 886025914190
Fax : 52 48 21 2160
Republic of Danfoss (Pty) Ltd. Thailand Danfoss (Thailand)Co., Ltd.

Netherlands ITHO bv South Africa Cambridge Commercial Park 47/11 Ngam Wong Warn Road
Adm. deRuyterstraat2 23TrinityClose Bangkhen,
3115HBSchiedam PaulshofExt.45 Bangkok 10900
P.O. Box21 Johannesburg Tel. :662561 1130
3100AASchiedam Tel. : 27118038390 Fax :662561 1446
Tel. 31 0104278500 Fax : 27 11 8038244
Telex 23 337 Danfoss authorized service shop
Fax 31 10 427 1534 Turkey MERT TEKNIK FABR. MALZEMELERI
Danfoss authorized service shop TICARET ve SANAYI A.S.
Singapore Danfoss IndustriesPte. Ltd. Tersane Cad. No. 43
6 Jalan Pesawat 80000 Karak_y - Istanbul
New Zealand Danfoss (New Zealand) Limited Singapore 619364 Tel. 90 0 212 252 8435
8 George Bourke Drive Tel. :652614088 Telex (18)931251
P.O.Box12-422, Penrose Fax :652610488 Fax 900 2122456369
MT Wellington Danfoss authorized service shop Danfoss authorized service shop
Auckland
Tel. :6492702110
Fax : 64 9 270 2112 Slovenia TechnicalOffice Klun U.S.A. Danfoss Fluid Power
Danfoss authorized service shop Ut. BratovMartinec 16 Division of Danfoss Inc.
S1-1000Ljubljana Norht American Headquarters
Slovenija 8635 WashingtonAvenue
Norway Danfoss A/S Tel. : 386 61 127 3718 Racine, Wisconsin53406
Arenga 2 Fax : 386 61 127 t624 Tel. : 1 414 884 7400
N-1314 Skui Fax : 1 414 884 7440
Tel. : 47 87 13 5680 Danfoss authorized service shop
Fax : 47 67 13 6850 Spain Danfoss S.A.

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Halvorsen Halvorsen

25 000 lb. Loader for Aircraft

Location Warranty and Service Part Sales

4. IMPORTANT SAFETY NOTICE

Please send this information to:

Technical Publications Dept.

This vehicle meets or exceeds the following CE requirements:

• Machinery Directive - Annex IV . . . . . . . . . . . . . . . . . . . . . . 2006/42/EC

EC Type Examination Certificate Number “(Pending)”

This Machine also fulfills the applicable requirements of the following

Standards taken into consideration:

Place of Manufacture Technical Documentation Contact

LOCATION OF THE VEHICLE

GENERAL TABLE OF CONTENTS

OPERATION AND MAINTENANCE MANUAL

Volume I – OPERATION AND MAINTENANCE

CHAPTER 1. GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Volume II – ILLUSTRATED PARTS LIST

CHAPTER 4. ILLUSTRATED PARTS LIST

CHAPTER 5. MANUFACTURERS’ APPENDICES

OPERATION AND MAINTENANCE MANUAL

This volume includes the following options:

Refer to Volume II for

JBT, Ground Support Equipment

All pages in this issue are original.

The following pages have had changes incorporated:

Aug. 2011 Edition 1 Volume I New edition.

Updated: warnings and cautions,

Updated: warnings and cautions, general

Updated: warnings and cautions,

Updated: general format, DoC, warnings

Added: emergency stop symbol, warning

MANDATORY ACTION PROHIBITION

EMERGENCY STOP (E-STOP) BUTTON

• FIRE ON THE VEHICLE

SAFETY RELATED DECALS

LOADER REAR SECTION

WARNING: OVERHEAD CRUSH HAZARD. ALWAYS INSTALL SAFETY SUPPORT

LIST OF WARNINGS AND CAUTIONS USED IN THIS MANUAL

A CAUTION INDICATES A PROCEDURE THAT MUST BE FOLLOWED OR A CONDITION THAT

WHEN OPERATING THE VEHICLE IN FREEZING CONDITIONS, OCCASIONALLY TURN THE

CIRCUIT BREAKER MUST BE IN THE “OFF” POSITION WHENEVER AC POWER CABLE IS

AC POWER CABLE MUST BE REMOVED FROM RECEPTACLE BEFORE STARTING ENGINE.

ENGINE CAN BE STARTED WHEN AC POWER CABLE IS NOT ENERGIZED OR CIRCUIT

DO NOT OPERATE EQUIPMENT WITH DEFECTIVE WARNING INDICATOR LIGHTS.

DO NOT EXCEED 15 KM (9 MILES) OF TRAVEL IN A ONE HOUR PERIOD OF TIME. IF THAT

DO NOT ENERGIZE HYDRAULIC EMERGENCY PUMP DURING NORMAL VEHICLE

CONTINUOUS OPERATION OF HYDRAULIC EMERGENCY PUMP FOR MORE THAN 30

COMPLY WITH ALL LOCAL AND GOVERNMENT REGULATIONS FOR DISPOSING OF

USE CLEAN LINT-FREE RAGS FOR CLEANING OF TANKS AND COMPONENTS.

WHEN INSTALLING OR REMOVING GAUGES AND FITTINGS OR REPLACING COMPONENTS,

WHEN ELECTRICALLY CHARGING BATTERIES ON THE VEHICLE, ENSURE CHARGER

ENSURE FUEL IS CLEAN AND FREE OF WATER AND DIRT.

ALLOW THE ENGINE TO COOL BEFORE ADDING WATER OR ANTI-FREEZE SOLUTION.

USE ONLY ETHYLENE-GLYCOL BASED ANTIFREEZE IN CORRECT CONCENTRATIONS TO

DO NOT DISCONNECT THE BATTERY OR TURN OFF OPTIONAL BATTERY DISCONNECT

BEFORE WELDING ON THE VEHICLE, DISCONNECT THE VEHICLE’S POSITIVE AND

PERFORM A COMPLETE MAINTENANCE CHECK AFTER REPAIRS ARE COMPLETED.

DO NOT MIX SYNTETHIC OILS WITH NON-SYNTHETIC OILS!

TO PREVENT ENGINE DAMAGE AND POSSIBLE COMPLETE DESTRUCTION OF THE

DO NOT ALLOW THE FRONT OF THE TRANSMISSION TO BE LOWER THAN LEVEL TO

IF A CONDITION OCCURS THAT INTRODUCES DEBRIS INTO THE TRANSMISSION

CONTAINERS OR FILLERS THAT HAVE BEEN USED TO HANDLE ANTIFREEZE OR ENGINE