153430-CO2FC6T3LSMERMID-Case 621e Tier 3 Wheel Loader Factory Service Repair Manual - Improved - Download-1

Please cut where indicated and place the label on the spine of the binder
r--------------, r-------,
WHEEL LOADER WHEEL

SERVICE LOADER
SERVICE
621 E Tier 3
621 E Tier 3
84243974
(Replaces
84243974 87634756)
(Replaces 87634756)
84243976
621 E Wheel Loader
Service Manual 84243974
(Replaces 87634756)
Table of Contents
Section
Description Form No.
No.
General Tab 1
Section Index - General 5-7320
Standard Torque Specifications 1001 8-71603
Fluids and Lubricants 1002 5-7330
Metric Conversion Chart 1003 7-52950
Engines Tab2
Section Index - Engines 5-7340
Engine and Radiator Removal and Installation 2000 5-2700
Stall Tests 2002 5-7350
After Cooler 2003 6-49850
For Engine Repair, See the Engine Service Manual 87519803
Fuel System Tab3

Section Index- Fuel System 5-7360
For Fuel System Repair, See the Engine Service Manual 87519803
Electrical Tab 4
Section Index- Electrical 5-7370
Removal and Installation of Starter and Alternator 4001 5-2740
Electrical Specifications and Troubleshooting 4002 5-7380
Batteries 4003 6-42331
Instrument Cluster 4005 5-2760
Steering TabS
84298385
Section Index - Steering
(Replaces 5-7390)
Removal and Installation of Steering Components 5001 5-7400
Steering Specifications, Pressure Checks, and Troubleshooting 5002 5-7410
Steering Cylinders 5005 5-2800
Center Pivot 5006 6-42420
Auxiliary Steering Motor and Pump 5008 6-42430
Joystick Steering 5009 5-17010
84243975 Copyright© 2009 CNH America LLC.

CNH America LLC. All rights reserved.
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. (Replaces 5-7310) Issued September, 2007 Revised December 2009
621 E Wheel Loader
(Replaces 87634756)
Table of Contents
Section
Description Form No.
No.
Power Train Tab6
84251800
Section Index - Power Train (Replaces 5-7420)
Removal and Installation of Power Train Components 6001 5-7430
Transmission Specifications, Pressure Checks, and Troubleshooting 6002 5-2841
Transmission 6003 5-2850
Front Axle 6004 6-45240
Rear Axle 6004 6-47320
Rear Axle, Serial Number N8F203848 and After 6004 84243977
Drive Shafts, Center Bearing, and Universal Joints 6005 5-2880
Wheels and Tires 6006 6-47730
Transmission Control Valve 6007 6-81450
Brakes Tab7
Section Index - Brakes 5-7440
Removal and Installation of Brake Components 7001 5-2900
Hydraulic Brake Troubleshooting 7002 5-7450
Brake Pump 7003 5-2920
Brake Accumulators 7004 5-7460
Parking Brake 7008 5-2930
Hydraulics Tab8
Section Index- Hydraulics 5-7470
How to Read Hydraulic Schematics 8000 5-5670
Removal and Installation of Hydraulic Components 8001 5-7480
Hydraulic Specifications, Troubleshooting, and Pressure Checks 8002 5-7490
Cleaning the Hydraulic System 8003 7-49641
Hydraulic Pump 8004 5-2970
Loader Control Valve 8005 5-7500
Cylinders 8006 5-7510
Coupler Solenoid Locking Valve 8007 6-42600
Ride Control Accumulator 8013 5-7520
Ride Control Valve 8014 5-3010

621 E Wheel Loader
(Replaces 87634756)
Table of Contents
Description Section Form No.

No.
Mounted Equipment Tab9
Section Index - Mounted Equipment 5-7530
Air Conditioning Troubleshooting and System Checks For Systems with HFC- 5-4030
134a Refrigerant 9002
Air Conditioner System Service 9003 5-3030

Removal And Installation Of Air Conditioning And Heater Components 9004 5-3040
Loader 9006 5-7540
Roll Over Protective Structure (ROPS), Cab Structural Frame (CSF) 9007 5-7550
Cab Glass Installation 9010 6-42710
Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear 5-7560

Pocket

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

Fluids and Lubricants ..................................................................... 1002
Metric Conversion Chart ................................................................... 1003
Copyright© 2007 CNH America LLC.

Racine, WI 53404 U.S.A. Bur 5-7320 Issued September, 2007
Section
1001
GENERAL TORQUE SPECIFICATIONS

CASE, LLC. All rights reserved.
Racine, WI 53404 U.S.A. Bur 8-71603 Issued April, 2003 Revised April, 2004
1001-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS- DECIMAL HARDWARE . . . . . . . ...... ....... ...... ....... ...... ..... 3
TORQUE SPECIFICATIONS- METRIC HARDWARE . . . . . . . . ...... ....... ...... ....... ...... ..... 4
TORQUE SPECIFICATIONS- STEEL HYDRAULIC FITTINGS ...... ....... ...... ....... ...... ..... 5
TORQUE SPECIFICATIONS- STEEL HYDRAULIC FITTINGS ...... ....... ...... ....... ...... ..... 6
Bur 8-71603 Revised 4-04 Printed in U.S.A.

1001-3
TORQUE SPECIFICATIONS- DECIMAL HARDWARE

Use the torques in this chart when special torques
are not given. These torques apply to fasteners with Grade 8 Bolts, Nuts, and Studs
both UNC and UNF threads as received from
suppliers dry, or when lubricated with engine oil. Not
applicable if special graphities, Molydisulfide
greases, or other extreme pressure lubricants are
0 ® f\7\
'\!5I
used.
Grade 5 Bolts, Nuts, and Studs
00@

1001-4
TORQUE SPECIFICATIONS- METRIC HARDWARE

Use the following torques when specifications are not
given. Grade 10.9 Bolts, Nuts, and Studs
These values apply to fasteners with coarse threads
as received from supplier, plated or unplated, or
when lubricated with engine oil. These values do not
apply if graphite or Molydisulfide grease or oil is
used.
Grade 8.8 Bolts, Nuts, and Studs
M8 324 to 384 37 to 43
Pound- Newton
Size Feet metres
Grade 12.9 Bolts, Nuts, and Studs
Usually the torque values specified for grade 10.9

fasteners can be used satisfactorily on grade 12.9
fasteners.

1001-5
TORQUE SPECIFICATIONS- STEEL HYDRAULIC FITTINGS

Tube OD Thread Pound- Newton Tube OD Thread Pound- Newton
Hose ID Size Inches metres Hose ID Size Inches metres
37 Degree Flare Fitting Straight Threads with 0-ring
1/2 inch 3/4-16 540 to 804 57 to 91

12.7 mm
Tube OD Thread Pound- Newton

Hose ID Size Feet metres
Split Flange Mounting Bolts

1001-6
TORQUE SPECIFICATIONS- STEEL HYDRAULIC FITTINGS
Nom.
SAE
Dash Thread Pound- Newton Thread Pound- Newton
Size Tube OD Size Inches metres Size Inches metres
0-ring Boss End
0-ring Face Seal End Fitting or Lock Nut
Nom.
SAE
Dash Thread Pound- Newton

Section
1002
FLUIDS AND LUBRICANTS

1002-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS ............................................................. 3
ENGINE OIL RECOMMENDATIONS .......................................................... 4
TRANMISSION TEMPERATUER CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIESEL FUEL SYSTEM .................................................................... 5
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Model 621 E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Model 621 E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bur 5-7330 Issued 9-07 Printed in U.S.A.

1002-3
CAPACITIES AND LUBRICANTS

Engine Oil
Capacity with Filter Change ........................................................................................ 13.2 liters (14 U.S. Quarts)
Type of oil .......................................................................................... See engine oil recommendations on page 4
Engine Cooling System
Capacity ....................................................................................................................... 36.0 liters (38 U.S. Quarts)
Type of Coolant ............................................................................................ 50% water and 50% Ethylene Glycol
Fuel Tank
Capacity ...................................................................................................................... 246 liters (65 U.S. Gallons)
Type of Fuel. ............................................................................................ See Diesel fuel specifications on page 5
Hydraulic System
Hydraulic Reservoir Refill Capacity .......................................................................... 90.8 liters (24.0 U.S. Gallons)
Total System Capacity ............................................................................................ 147.6 liters (39.0 U.S. Gallons)
Type of Oii .............................................................................................................. Case AKCELA Hy-Tran Ultra®
Transmission
Refill Capacity with Filter Change ................................................................................ 19.9 liters (21 U.S. Quarts)
Total System Capacity ............................................................................................... 26.7 liters (28.2 U.S. Quarts)
Type of Oil ....................................................................................................... Case AKCELA No. 1 15W-40
Axles
Capacity
Front ...................................................................................................................... 22.0 liters (23.2 U.S. Quarts)
Rear ...................................................................................................................... 22.0 liters (23.2 U.S. Quarts)
Type of Lubricant.. .................................................................................................. Case AKCELA Transaxle Fluid
NOTE: DO NOT use an alternate oil in the axles. The brake components in the axles could be damaged as a result
of using an alternate oil. Machines are shipped from the factory with break-in oil.
Brake System
Type of Fluid (Same as Hydraulic System) ................................................................ Case AKCELA Hy-Tran Ultra®

1002-4
ENGINE OIL RECOMMENDATIONS

Case AKCELA No. 1 Engine oil is recommended
for use in your Case engine. Case AKCELA No. 1
Engine Oil will lubricate your engine correctly
under all operating conditions.
If Case AKCELA No. 1 Multi-Viscosity Oil is not
available, use only oil meeting API engine oil service
category CH-4 (preferred) or CG-4.
See the chart below for
recommended viscosity at
ambient air temperature
ranges.
BD03A102
NOTE: Do not put performance
additives or other oil additive
products in the engine
crankcase. The oil change
RH99K130
intervals given in this manual
are according to tests with Case
'------------'
AKCELA lubricants.
TEMPERATURE FAHRENHEIT
TEMPERATURE CELSIUS
~ Indicates the use of an Engine Oil Heater or a Jacket Water Heater is required.
BC02N250

1002-5
TRANMISSION TEMPERATUER CHART
TEMPERATURE FAHRENHEIT
-1 0° 0° 10° 20°
TEMPERATURE CELSIUS
DIESEL FUEL SYSTEM

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

specifications as shown below in, "Specifications for
Acceptable No. 2 Diesel Fuel", or "Specification
D975-81" of the American Society for Testing and
Materials.
Specifications for Acceptable No. 2 Diesel Fuel

API gravity, minimum ............................................................................................................................................. 34
Flash point, minimum ............................................................................................................................ 60°C (140°F)
Cloud point (wax appearance point), maximum ........................................................... -20°C (-5°F) See Note above
Pour point, maximum .................................................................................................. -26°C (-15°F) See Note above
Distillation temperature, 90% point ................................................................................ 282 to 338°C (540 to 640°F)
Viscosity, at 38°C (1 00°F)
Centistokes ......................................................................................................................................... 2.0 to 4.3
Cetane number, minimum .......................................................................... 43 (45 to 55 for winter or high altitudes)
Water and sediment, by volume, maximum ..................................................................................................... 0.05%

1002-6
MAINTENANCE SCHEDULE
Modei621E
G)
FREQUENCY IN HOURS
SERVICE a: .
u
·:;:
G) LlJ
LlJ
!;j: LlJ
SERVICE POINTS
~
LlJ (.) I-
INTERVAL
1/) ~ z Cl z en
[!]
:::2;:::2;
~
(.)
LlJ
<(
LlJ
z
<( <( a:
[!]
...J
0.. ....,
::J
LlJ::J I ...J I a: ::J LlJ 0
t::z :E (.) (.) (.) 0 ...J a: <(
29 Air cleaner * *
18 Bleed Fuel Filter of Condensation *
Variable 19 Hydraulic Filter *
Periodic 22 Alternator, AC, Drive Belt *
(*) 13 Radiator Coolant Level *
XX Fire extinguisher *
14 Tires *
Every 1 0 Hours 1 Check Engine Oil Level 10
2 Check Engine Coolant Level 50
3 Check Transmission Oil Level 50
Every 50 Hours
4 Check Hydraulic Oil Level 50
5&6 Grease Bucket Mounting Fittings 50
7 Grease Front Drive Shaft Support Bearing 100
Lubricate The Steering Cylinder Pivots - Rod And
8&9 100
Every 100 Hours Closed End (4 Fittings)
10 Lubricate Loader Lift & Cylinder Pivots (1 0) Z -bar 100
11 Lubricate Loader Lift & Cylinder Pivots (18) XT 100
12 Check Cab Air Filter 250
Every 250
13 Check Tire Pressure & Wheel Torque 100 250
Hours
14 Check Drive Belt 250
15 Check Battery Electrolyte Level 500
16 Check Axle Oil Level 500
17 Drain Fuel Tank Condensation & Water Separator 500
Every 500
18 Change Engine Oil and Filter 100 500
Hours
18 Change Crankcase Filter 500
19 & 27 Replace Fuel Filter 100 500
XX ROPS/CSF and seat belt torques 500
20 Change Front & Rear Axle Oil 100 1000
21 Replace Hydraulic Oil filter 100 1000
22 Replace Cab Air Filter 1000
23 Replace Drive Belt 1000
24 Change Transmission Oil and Filter 100 1000
Every 1000
25 Grease Articulation Fittings 1000
Hours
26 Check Injector Calibration 1000
27 Fuel Pre-Filter 1000
XX Drive Shaft Slip Joint 1000
XX Check Valve Adjustment (Engine Manual) 1000
XX Trans Clutch Calibration (See Section 6002) 250 1000
28 Change Hydraulic Oil 2000
Every 2000
29 Change Coolant 2000
Hours
30 Replace Engine Air Cleaner 2000
Every 4000
XX Valve Clearance (Engine Manual) 4000
Hours

1002-7
MAINTENANCE POINTS
Modei621E
BS070423
See your Operators manual for maintenance of If you operate the machine in severe conditions,
safety related items and for detailed information of lubricate and service the machine more frequently.
the service items on this chart. Operators and
service manuals are available for this machine from
your dealer.

1002-8
NOTES

Section
1003
METRIC CONVERSION CHART
CNH AMERICA LLC

© 2005 CNH America LLC
Racine, WI 53404 U.S.A. Bur 7-52950 June, 1997
1003-2
TABLE OF CONTENTS
CONVERSION FACTORS ............................................................................................................................................. 3
Metric to U.S ........................................................................................................................................................... 3
U.S. to Metric ......................................................................................................................................................... 4
Bur 7-52950 Issued 6-97 Printed in U.S.A

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

hectare 2.471 05 acre
Force: newton 3.596 942 ounce force

newton 0.224 809 pound force
Length: millimeter 0.039 370 inch

meter 3.280 840 foot
kilometer 0.621 371 mile
Mass: kilogram 2.204 622 pound
Mass/Area: kilogram/hectare 0.000 466 ton/acre
Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.
Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.
Power: kilowatt 1.341 02 horsepower
Pressure: kilo pascal 0.145 038 lb/sq. inch

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

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

cubic meter 35.31466 cubic foot
cubic meter 1.307 950 cubic yd.
milliliter 0.033 814 ounce (US fluid)
litre 1.056 814 quart (US liquid)
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

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

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

acre 0.404 686 hectare
Force: ounce force 0.278 014 newton

pound force 4.448 222 newton
Length: inch 25.4 * millimeter

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

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

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

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

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

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

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

87519803

Section
2000
ENGINE AND RADIATOR REMOVAL AND INSTALLATION
Copyright© 2006 CNH Ameica LLC.

Racine, WI 53404 U.S.A. Bur 5-2700 Issued August, 2006
2000-2
TABLE OF CONTENTS
Engine .................................................................................. 3
Removal .............................................................................. 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal ............................................................................. 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2000-3
ENGINE
Removal STEPS
STEP 1
Put a 37 liter (1 0 gallon) container below radiator

BD03A040
drain. Remove radiator cap. Remove cap and drain
Park machine on a level surface and lower bucket to coolant into container. Install cap after coolant has
ground. Put articulation lock in LOCKED position. drained. Install radiator cap.
STEP2 STEPS
Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.
STEP3
Slowly loosen the filler cap for hydraulic reservoir to
release air pressure in hydraulic reservoir.
STEP4
BD02N160
Put a 14.2 liter (15 U.S. quarts) container below

engine oil drain. Remove cap and drain oil into
container. Install cap after oil has drained.
NOTE: After draining oil disconnect drain hose from
frame for removal with engine.
BD06F108
The master and hood raise switch are located in the

right batter box. Raise the hood with the hood lift
motor. Put master disconnect switch in OFF position.
Remove both battery covers and disconnect
batteries from the machine.

2000-4
STEP7 STEP10
Double up a nylon lifting strap (1) and slide through Tag and disconnect hood wiring harness connector
the exhaust stack (2) on the hood. from rear chassis wiring harness connector.
STEPS STEP 11
BD03A230
Place a solid steel bar through the strap, raise the

hood and release tension on the lifting motor.
STEP9
Remove mount bolt (1) and backup alarm wiring

harness clamp from cooler housing. Have another
person balance the hood and remove the hood hinge
BD03A228 mounting bolts (2) from the cooler frame.
Remove the pin from the top of the lifting motor.

2000-5
STEP12 STEP15
BD03A232
Carefully raise and remove hood from loader. Lower Loosen clamps on turbocharger and air cleaner,
hood onto suitable platform and disconnect lifting remove the intake hose.
equipment.
STEP16
STEP13
Loosen the clamp on the turbocharger for the after

Tag and disconnect engine wiring harness connector cooler inlet hose.
from air filter restriction switch.
STEP17
STEP14
BD03A115
Loosen the clamp on the after cooler and remove the

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

2000-6
STEP18 STEP 21
BD06F111 BD06F112
Loosen the clamp on the intake manifold for the after Remove the air cleaner and muffler from the bracket.
cooler output hose.
STEP 22
STEP19
BD03A118
Loosen the clamp on the after cooler and remove the

after cooler outlet hose from the machine.
STEP 20
BD06F114
Remove the four mounting bolts from the belt cover,

remove the cover.
NOTE: After removing the belt cover remove the
cover mounting brackets from the machine frame.
Loosen the exhaust clamp from the turbocharger.

2000-7
STEP 23 STEP 26
BD06F118
Remove the drive belt from the engine. Tag and disconnect the wiring from the alternator.
STEP 24 STEP 27
Loosen clamps and remove lower cooler hose from Remove bolt securing wiring harness clamp to
the engine. engine.
STEP 25 STEP 28
BD06F117
If loader is equipped with air conditioning, identify, Remove bolt securing wiring harness clamp (1) to the
tag, and disconnect the engine wiring harness engine. Remove ground wires (2} from the engine.
connectors from air compressor clutch connector (1 ).
Remove the three mounting bolts (2} for the
compressor and set the compressor on the left
battery cover.

2000-8
STEP 29 STEP 32
BD06F121
Tag and remove the wires from the starter solenoid Tag and remove the grid heater cable.
(3), remove the ground cable (2), and ground strap
(1) from the starter. STEP 33
NOTE: Move the starter cables away from the
engine, move the wiring harness away from the
engine.
STEP 30
BD03A142
Disconnect the wiring harness from the EDC 7

controller.
NOTE: Lifting up on the lever will release the
connector from the controller.
BD06F146
Disconnect the engine coolant vent hose and root to STEP 34

the rear of the engine.
STEP 31
Remove the fuel line from the top of the EDC 7

controller, plug the line and cap the fitting.
BD06F122
Remove the radiator hose (1) from the rear of the

engine, remove the heater hose from the rear of the
engine (2}, remove the clamp bolts and clamps (3}
from the bell housing.
2000-9
STEP 35 STEP 38
BD06F124 BD06F127
Tag and disconnect the fuel filter heater wires (1 ), Remove the lower cover for the drive shaft.
disconnect the fuel line (2) from the fuel filter head,
plug the line and cap the fitting. STEP 39
STEP 36
Remove the drive shaft bolts from the flywheel. Move

BD06F125 the drive shaft clear of the flywheel.
Remove bolt and clamp.
STEP 40
STEP 37 Connect suitable lifting equipment to engine lifting
brackets. Take up all slack in lifting equipment.
Remove the engine mounting bolts and lift the engine
enough to gain access to the drain hose, pull the
drain hose with the engine.
STEP 41
Slowly raise engine from rear chassis. Be sure all
harness connections and hoses have been
disconnected and are clear of the engine. Remove
engine from machine.
BD06F126
Connect and turn on vacuum pump to hydraulic

reservoir. Tag and remove the hydraulic lines from
the brake system pump, plug the lines and cap the
fittings.

2000-10
Installation
8S038035
1. ENGINE MOUNT BOLT 3. INSOLATOR UPPER 5. WASHER 7. NUT
2. WASHER 4. INSOLATOR LOWER 6. WASHER 8. REMOTE OIL DRAIN HOSE
STEP 42 STEP 47
If engine rubber isolators require replacement,
remove and discard isolators (3 and 4). Install new
rubber isolator (4), then rubber isolator (3).
STEP 43
Slowly raise engine and move into position over rear
chassis. Be sure all harness connections and hoses
are out of the way then lower engine. Put washer (5)
between front rubber isolator (4) and chassis. Install
washer (2), bolt (1 ), washer (6), and nut (7) in engine
isolators. Lower engine into position.
STEP 44 At front of engine, position drive shaft on engine

Tighten engine mounting bolts to a torque of 244 to coupling. Install six bolts to secure drive shaft to
298 Nm (180 to 220 lb-ft). engine coupling. Tighten the six bolts to a torque of
53 to 62 Nm (39 to 46 lb-ft).
STEP 45
Disconnect lifting equipment from engine lifting
brackets.
STEP 46
Connect engine oil drain hose to frame bracket.

2000-11
STEP 48 STEP 51
BD06F127 BD06F124
Install the lower cover for the drive shaft. Remove cap from fitting and plug from the hose,
connect fuel line (2). Connect fuel filter heater wires
STEP 49 (1 ). Remove and discard tag.
STEP 52
Connect and turn on vacuum pump to the hydraulic

reservoir. Remove caps from fittings and plugs from
hoses. Connect hoses to brake pump following tags Remove cap from fitting and plug from the hose,
installed during removal. Remove and discard tags. connect fuel line to EDC 7.
Turn off and disconnect vacuum pump from hydraulic
reservoir. STEP 53
STEP 50
BD03A142
Connect wiring harness to EDC 7 controller.

BD06F125
Install bolt and clamp for fuel return hose. NOTE: Start the connector on the EDC 7 with lever
straight out from EDC 7. Use lever to pull connector
into position.

2000-12
STEP 54 STEP 57
BD06F121
Connect grid heater cable to grid heater. Remove Install the wires to the starter solenoid (3), install the
and discard tag. ground cable (2), and ground strap (1) to the starter.
Remove and discard tags.
STEP 55
STEP 58
BD06F122
Install the heater hose (2) to the rear of the engine,

mount the clamps (3), install the radiator hose (1 ). Install bolt securing wiring harness (1) clamp to the
engine. Install ground wires (2) to the engine.
STEP 56
STEP 59
BD06F146
Connect the engine coolant vent hose.

Install bolt securing wiring harness clamp to engine.

2000-13
STEP 60 STEP 63
BD06F118
Connect the wiring to the alternator. Remove and Install the drive belt.
discard tags.
STEP 64
STEP 61
BD06F117
If loader is equipped with air conditioning, mount the

compressor using the three mounting bolts (2),
connect the engine wiring harness connectors to air
compressor clutch connector (1 ). Remove and
discard tags.
STEP 62
Install the cover mounting brackets to the machine

frame. Install the belt cover, install the four mounting
bolts for the belt cover.
BD06F116
Install lower cooler hose to the engine and tighten the

clamps to a torque of 10.1 to 11.3 Nm (90 to 100
lb-inch).

2000-14
STEP 65 STEP 68
BD06F112 BD06F111
Place the muffler and air cleaner on the bracket. Tighten the clamp on the intake manifold for the after
Install mounting bolts in air cleaner and tighten, cooler output hose.
install the mounting bolts in the muffler and leave
loose at this time. STEP 69
STEP 66
BD03A115
Place the after cooler inlet hose on the machine.

Tighten the clamp on the after cooler.
Install and tighten the exhaust clamp on the
turbocharger, tighten the muffler mounting bolts. STEP 70
STEP 67
Tighten the clamp on the turbocharger for the after

BD03A118 cooler inlet hose.
Place the after cooler outlet hose on the machine.
Tighten the clamp on the after cooler.

2000-15
STEP 71 STEP 74
BD03A232
Install the intake hose and tighten the clamps on Carefully raise and place hood over loader.
turbocharger and air cleaner.
NOTE: Refer to step 7 and 8 of removal for lifting
procedure.
STEP 72
STEP 75
Install the crankcase ventilation hose and tighten the

clamp on air cleaner intake hose.
STEP 73
BD03A226
Have another person balance the hood, install the

hood hinge mounting bolts (2) to the cooler frame.
Install mount bolt (1) and backup alarm wiring
Connect engine wiring harness connector to air filter harness clamp to cooler housing.
restriction switch. Remove and discard tag.

2000-16
STEP 76 STEP 78
BD03A221
BD03A228
Install the pin from the top of the lifting motor, lower NOTE: If hood strut is not adjusted properly the
and remove lifting equipment. hood will be damaged.
When a hood is removed and replaced an initial
STEP 77 adjustment on the strut is necessary. Adjust between
the top of the lift motor adjusting jam nut (1) to the top
of the threads (2) to 20 mm (X). With the motor down
to its lowest point take a measurement between the
left hand side hood bumper and the counter weight,
record this measurement (Y). Use the following table
to adjust the strut (X).
Hood Adjustment Table
y X y X y X y X
(MM) (MM) (MM) (MM) (MM) (MM) (MM) (MM)
1 19 21 14 41 9 61 5
2 19 22 14 42 9 62 5
3 18 23 14 43 9 63 4
Connect hood wiring harness connector to rear
chassis wiring harness connector. Remove and 4 18 24 13 44 9 64 4
discard tag. 5 25 45 65
18 13 9 4
6 18 26 13 46 8 66 4
7 17 27 13 47 8 67 3
8 17 28 12 48 8 68 3
9 17 29 12 49 8 69 3
10 17 30 12 50 7 70 3
11 16 31 12 51 7 71 2
12 16 32 12 52 7 72 2
13 16 33 11 53 7 73 2
14 16 34 11 54 6 74 2
15 16 35 11 55 6 75 2
16 15 36 11 56 6 76 1
17 15 37 10 57 6 77 1
18 15 38 10 58 6 78 1
19 15 39 10 59 5 79 1
20 14 40 10 60 5 80 0

2000-17
STEP 79 STEP 85
BD02N160 BD06F108
Check and make sure that drain caps are tight. Lower the hood with the hood lift motor.
STEP 80 STEP 86
Install a new oil filter on engine. Fill engine with 14.2 Put articulation lock in OPERATING position.
liters (15 quarts) of Case AKCELA No. 1 Engine Oil
(SAE 15W-40).
STEP 81
If hydraulic reservoir was drained, fill reservoir with
105.7 liters (27.9 gallons) of Case AKCELA Hy-Tran
Ultra® fluid.
STEP 82
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 36.9 liters (9.75 gallons). Install the
radiator cap. Fill the coolant reservoir up to the FULL
mark on the reservoir.
STEP 83
Connect the batteries, install battery covers, put
master disconnect switch in ON position.
STEP 84
Start engine and run the engine at low idle. Run the
engine at operating temperature for approximately
five minutes to completely mix the Ethylene Glycol
and water. When the coolant is at operating
temperature, stop the engine. When engine has
cooled, check the coolant level at the reservoir.
WARNING: Hot coolant can spray out if radiator cap
is removed. To remove radiator cap: Let system cool,
turn to first notch, then wait until all pressure is
released. Scalding can result from fast removal of
radiator cap.

2000-18
RADIATOR
Removal STEPS
STEP 1
Park loader on level surface and lower bucket to
ground. Apply parking brake and shut down engine.
STEP2
Remove bolt and washer securing LH fender.

Remove LH fender.
STEPS
BD03A040
Put articulation lock in LOCKED position.
STEP3
Put master disconnect switch in OFF position.
STEP4
BD02N160
Put a 37 liter (1 0 gallon) container below radiator

drain. Remove radiator cap then remove cap and
drain coolant into container. Install cap after coolant
has drained. Install radiator cap.
STEP7
Have another person raise and hold the side panel

up into the raised position. Remove the two mounting
screws for the side panel, remove the panel.
NOTE: Photo is of the oil cooler side of the machine,
the procedure is the same.
BD03A109
Release catch and tilt air conditioning condenser

core up to gain access to upper radiator hose.

2000-19
STEPS STEP 11
BD03A108 BD03A106
Loosen the upper radiator hose clamps, remove the Remove screws and install lifting eyes (1 ). Attach
hose. suitable lifting equipment to lifting eyes. Remove four
mounting bolts (2), remove radiator from machine.
STEP9
BD06F129
Loose and remove the lower radiator hose from the

radiator.
STEP10
BD03A113
Disconnect overflow hose from radiator. Disconnect

connector from coolant level sender.

2000-20
Installation STEP15
STEP12
Move radiator into position above cooling frame.
Carefully lower radiator while guiding it into position
in cooling frame.
STEP13
BD06F129
At bottom of radiator, install bottom radiator hose.

Position and tighten two hose clamps to a torque of
10.1 to 11.3 Nm (90 to 100 lb-inch).
STEP16
BD03A106
Install four lock washers and bolts (2} to secure

radiator to cooling frame. Disconnect lifting
equipment from lifting eyes. Remove lifting eyes and
install screws (1 ).
STEP14
BD03A108
At top of cooling system frame, install hose. Position

hose clamps and tighten to a torque of 10.1 to 11.3
Nm (90 to 100 lb-inch).
STEP17
BD03A113
Connect connector to coolant level sender, connect

overflow hose to radiator.
BD06F130
When installing fender make sure it is behind the

fender mounting bolt.

2000-21
STEP18 STEP 21
BD06F131
Align the whole in the fender on the bolt. Have another person raise and hold the side panel
up into position. Apply Loctite 242 to the threads,
STEP19 install the two mounting screws for the side panel
and torque to 6.5 ± 3.0 Nm (57.5 ± 26.5
pound-inches).
NOTE: Photo is of the oil cooler side of the machine,
the procedure is the same.
STEP 22
BD06F132
Align the slots in the fender with the tabs on the body
of the machine.
STEP 20
BD02N160
Check that coolant drain cap is tight.
STEP 23
capacity is 36.9 liter (9.75 gallon). Install the radiator
cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.
Push the fender towards the front of the machine and

secure it using washer and bolt.

2000-22
STEP 24 WARNING: Hot coolant can spray out if radiator cap
Put master disconnect switch in ON position. is removed. To remove radiator cap: Let system cool,
released. Scalding can result from fast removal ot
STEP 25
radiator cap.
Start engine and run the engine at low idle. Run the
engine at operating temperature for approximately STEP 26
five minutes to completely mix the Ethylene Glycol
Put articulation lock in OPERATING position.
and water. When the coolant is at operating
temperature, stop the engine. When engine has
cooled, check the coolant level at the reservoir.

Section
2002
STALL TEST

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

2002-3
SPECIFICATIONS
Low idle ..............................................................................................................................................870 to 930 rpm
Alternate low idle .................................................................................................................................570 to 630 rpm
Cold low idle ....................................................................................................................................1170 to 1230 rpm
In gear low idle when in boost or auto power modes (see note) ..................................................... 1050 to 1150 rpm
Full throttle (no load) ........................................................................................................................2095 to 2225 rpm
Temperature of the torque converter oil. ...................................................................... 82° to 104 o C (180° to 220° F)
Temperature of the hydraulic oil. ...................................................................................... 54° to 5rC (129° to 134°F)
NOTE: This low idle will be held after the engine has accelerated over 1400 rpm while in gear. It will remain at this
accelerated level until the transmission is placed back into neutral for two seconds.
Stall Speeds
Torque converter ..............................................................................................................................1975 to 2125 rpm
Hydraulic system .............................................................................................................................1895 to 2205 rpm
Torque converter and hydraulic system together ............................................................................. 1455 to 1765 rpm
STALL TESTS
During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or
both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor
performance is one or more of the following: (1) engine, (2} torque converter or transmission, and (3} hydraulic
system.
INSTRUMENT CLUSTER DISPLAYS

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

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

shown.

2002-4
6. Press the down button again and the Trip 1

BD06F027 screen will display. The LCD provides two trip
4. Info 2 will be displayed next. The Info 2 screen computers. These will display since last reset the
will display coolant temperature, turbocharger air total time in hours, the total fuel, and the average
temperature, engine oil temperature in either fuel consumption per hour.
Fahrenheit or Celsius, as well as oil pressure
PSI.
BD06F170
7. By continuing to scroll down, the fifth screen will

display the Trip 2 screen. Trip 1 and Trip 2
BD06F184
screens can be reset independently. The
5. Push the down button again and the Info 3 previous screen can be accessed by using the
screen. This screen displays the temperature in up arrow key.
Fahrenheit or Celsius of the transmission oil
hydraulic oil, sump oil, and radiator coolant
temperature.

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

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

2002-6
POWER MODE SELECTION

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

two seconds to arrive at the above service
screen.

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

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

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

Section
2003
AFTER COOLER

245 E NORTH AVENUE Printed in U.S.A.
CAROL STREAM, IL 60188 U.S.A. Bur 6-49850 Issued January, 2004
2003-2
TABLE OF CONTENTS
TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AFTERCOOLER REMOVAL ................................................................. 4
Removal .............................................................................. 4
Leak Test ............................................................................. 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2003-3
TROUBLESHOOTING AFTER COOLER

STEP 1
Park machine on level ground, lower the bucket. Put
transmission in neutral, apply the parking brake. Turn
off engine.
STEP2
Raise hood. Install 'T' fitting in waste gate valve hose.
Attach pressure gauge. Install another pressure
gauge into the intake manifold port.
STEP3
Have assistant start engine and run at 2000 r/min BD03A118
(rpm). Record pressure readings for both gauges. If Inspect the after cooler outlet flex hose for leaks or
the pressure difference is greater than 60 mBar holes and insure that the clamps are tight.
(0.87 psi), inspect cooler components for damaged
or missing parts.
STEPS
STEP4
Inspect the intake manifold flex hose for leaks or

holes and insure that the clamps are tight.
Inspect the turbocharger flex hose for leaks or holes
and insure that the clamps are tight.
STEP7
STEPS
BD03A109
Visually inspect top of after cooler for damage or

BD03A115
leaks
Inspect the after cooler inlet flex hose for leaks or
holes and insure that the clamps are tight. NOTE: If the leak source has not been located,
remove and test the after cooler.

2003-4
AFTERCOOLER REMOVAL
Removal STEP4
STEP 1
Loosen clamps and remove air cooler outlet hose.
Loosen clamps and remove turbocharger outlet STEPS

components.
STEP2
Raise air conditioning/air cooler cover. Support cover

with appropriate lifting device. Remove cover support
BD03A115 latch.
Loosen clamps and remove air cooler inlet hose.
STEPS
STEP3
BD03A111
BD03A119 Remove three cover mounting bolts and lift cover off.
Loosen clamps and remove Intake hose.

2003-5
STEP7 STEP10
BD03A109 BD03A113
Unlatch air conditioning condenser clamp. Remove two bolts, one from each side of the after
cooler mounting frame.
STEPS
STEP 11
Lift air cooler and frame from machine with
appropriate lifting devise.
STEP12
Rotate air conditioning condenser up and remove the

two retaining bolts, one on each side. Move the air
conditioning condenser back away from the air cooler
STEP9 BD03A111
Remove four bolts that mount air cooler in the air

cooler frame. Remove air cooler from frame.
BD03A117
Remove the two bolts at the rear of the after cooler

mounting frame.

2003-6
Leak Test Installation
STEP 1
8S038028 Install after cooler in its frame. Install four mounting

Check the core for leaks by closing off the outlet tube bolts. Support after cooler with appropriate lifting
and attaching regulated air pressure 550kPa (80psi) device. Install the after cooler and frame in the
to the inlet tube. Submerge the cooler in water and machine.
watch for air leakage.
STEP2
NOTE: If leakage is detected replace the after
cooler.
8D03A113
Install two side mounting bolts
STEP3
8D03A117
Install two bolts at the rear of the after cooler

mounting frame.

2003-7
STEP4 STEP7
Position air conditioner condenser and install Install air cooler inlet hose. Tighten clamps at
mounting bolts. Rotate the condenser down and turbocharger outlet.
latch.
STEPS
STEPS
BD03A115
BD03112 Tighten clamps at air cooler inlet.

Support cover with appropriate lifting device. Raise
air conditioning/air cooler cover over machine. Install STEP9
cover support latch.
STEPS
BD03A119
Install air cooler outlet hose and tighten clamps at

engine intake.
Install three cover mounting bolts.

2003-8
STEP10 STEP 11
Install 'T' fitting in waste gate valve hose. Attach
pressure gauge. Install another pressure gauge into
the intake manifold port.
STEP12
Have assistant start engine and run at 2000 r/min
(rpm). Record pressure readings for both gauges.
confirm that the pressure difference is less than 60
mBar (0.87 psi).
BD03A118
Tighten clamps at air cooler outlet.

SECTION INDEX
FUEL SYSTEM
FOR FUEL SYSTEM REPAIR;. SEE THE ENGINE REPAIR MANUAL

o7519803

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

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

Section
4001
REMOVAL AND INSTALLATION OF STARTER AND

ALTERNATOR

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

4001-3
STARTER
Removal STEP4
STEP 1
Park machine on a level surface and lower bucket to
ground.
STEP2
BD06F135
Remove the ground strap from the starter, remove

the starter mounting bolts, remove the stater.
BD06F133
Raise the engine compartment with lifting motor.

Place the master disconnect switch in the OFF
position.
STEP3
BD06F134
Place identification tags on the positive cables and

remove the positive cables from the starter.

4001-4
Installation STEP7
'-...
'"'" BD06F134
'"'" Install and tighten the wires on the starter solenoid.
'" -~- Remove and discard tags.
"- '-.1' STEPS

Place the master disconnect switch in the ON
BC05G047
1. STUDS position. Lower the engine compartment with lifting
2. NUTS motor.
Apply Loctite 747 primer to studs and holes, apply 2
drops of Loctite 271 to each hole and stud.
Immediately install and torque studs to 19 to 29 Nm
(14 to 21 pound-feet). Allow adhesive to cure for 20
minutes before installing starter.
STEP6
Position the starter on the machine, attach the

ground cable to the bottom mounting stud (2) and
install the nut, attach the ground strap and wire to the
outer stud (1) and install the nut, install the lower nut.
Torque the three nuts to 40 to 50 Nm
(29 to 37 pound-feet).

4001-5
ALTERNATOR
Removal STEP4
STEP 1
ground.
STEP2
BD06F133
Raise the engine compartment with lifting motor.

position.
STEP3
Remove four belt cover mounting bolts, remove
cover.
STEPS
Disconnect wires from the alternator.
Use a wrench to move the belt tensioner to loosen

the tension on the belt. Remove the belt.

4001-6
STEP6 Installation
STEP7
BD06F140
Remove mounting bolts for alternator, remove

alternator.
Place alternator onto engine, install mounting bolts
for alternator and tighten.
STEPS
Use a wrench to move the belt tensioner, install the

belt.
NOTE: Belt routing instructions are on belt cover.

4001-7
STEP9 STEP10
Connect wires to the alternator, place rubber boot

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

bolts and tighten.
BD06F133

position. Lower the engine compartment with lifting
motor.

4001-8
BELT INSTALLATION
··:;;;__
~~~_...,::~).
:f
\<
WITH OUT AIR CONDITIONING
WITH AIR CONDITIONING

Section
4002
ELECTRICAL SPECIFICATIONS AND

TROUBLESHOOTING

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

4002-4
Turn Signal, High-Low Beam, and Horn Switch ................................................ 85
Driving Lamp Switch .................................................................... 86
LIGHTS - 03 AND HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Left Hand Front Combination Lamp ......................................................... 88
Right Hand Front Combination Lamp ........................................................ 89
Horn Relay ............................................................................ 90
Horn ................................................................................. 90
LIGHTS - 04 AND BACK UP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Right Hand Rear Combination Lamp (North America Only) ...................................... 92
Right Hand Rear Combination Lamp (Europe Only) ............................................ 93
Left Hand Rear Combination Lamp (North America Only) ........................................ 94
Left Hand Rear Combination Lamp (Europe Only) ............................................. 95
License Plate Lamp (North America Only) .................................................... 95
License Plate Lamp (Europe Only) ......................................................... 96
Back-up Alarm (North America Only) ........................................................ 96
Back-up Alarm (Europe Only) ............................................................. 96
CAB WINDOW WASHER AND WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Front Wiper High Speed Relay ............................................................ 98
Front Wiper Cut Out Relay ................................................................ 98
Front Wiper Low Speed Relay ............................................................. 99
Rear Wiper and Washer Switch ............................................................ 99
Front Wiper and Washer Switch .......................................................... 100
Front Wiper Motor ..................................................................... 101
Rear Wiper Motor ...................................................................... 102
Rear Washer Pump Motor ............................................................... 102
Front Washer Pump Motor ............................................................... 102
Wiper Diodes ......................................................................... 103
SECONDARY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Secondary Steering Diodes .............................................................. 105
Secondary Steering Solenoid (Option) ...................................................... 105
Secondary Steering Module (Option) ....................................................... 106
Secondary Steering Motor (Option) ........................................................ 107
Secondary Steering Pressure Switch (Option) ................................................ 107
CAN COMMUNICATION .................................................................. 108
CAN Communication Diagnostics Connector ................................................ 109
RADIO AND POWER CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Power Relay Module E .................................................................. 111
Power Converter 24 volts to 12 volts (Option) ................................................ 111
Power Outlet (Option) ................................................................... 111
12 Volt Radio Ready (Option) ............................................................. 112
Right Speaker (Option) .................................................................. 112
Left Speaker (Option) ................................................................... 112
AIR SEAT- CIGAR LIGHTER- AIR CONDITIONING COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Seat Compressor and Switch (Option) ...................................................... 114
Cigar Lighter (Option) ................................................................... 114
Compressor Clutch Relay ............................................................... 114
A/C High/Low Pressure Switch ........................................................... 115
Compressor Clutch .................................................................... 115
HEATING, VENTILATION, AND AIR-CONDITIONING ........................................... 116
Air Recirculation Motor .................................................................. 117
Driver ............................................................................... 117
Electronic Water Valve .................................................................. 118
Blower Motor Speed Resistors with Thermal Fuse ............................................ 118
Blower Motor ......................................................................... 118
Thermostat ........................................................................... 119
Blower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4002-5
Air Conditioning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Control Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Water Valve Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Air Recirculating Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
HOOD RAISE AND LOWER SYSTEM ....................................................... 121
Hood Up Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Hood Down Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Hood Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Hood Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
CONNECTORS ......................................................................... 124

4002-6
NOTES

4002-7
SPECIFICATIONS
Electrical System ............................................................ Two 12 volt batteries connected in series, negative ground
System Voltage ................................................................................................................................................24 volts
Batteries
Group Size ..........................................................................................................................................................31
Reserve Capacity ................................................................................................................................ 170 minutes
Cold Cranking Capacity At -17° C (0° F) for 60 Seconds At 6.0 Volts ................................................ 700 amperes
Load of Capacity (Load} Test ............................................................................................................. 400 amperes
Alternator ..................................................................................................................................... 24 volt, 65 amperes
Voltage Regulator ............................................................................................................. Solid State, Not Adjustable
Starter. ............................................................................................................................... 24 volt, Solenoid Actuated
Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20° C (68° F) (Nominal) ................ 68.2 ohms
Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20° C (68° F) (Nominal) ........... 305 ohms
Fuel Level Sender. .............................................................................................................................. 33 to 240 ohms
Coolant, Torque Converter, and Hydraulic Temperature Sender 20° C (68° F) ......................................... 3521 ohms
Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open)
Closing Set point ............................................................................................................................ 2.8 Bar (40 psi)
Hydraulic Filter Restriction Switch (Normally Open) Closing Set point .............................................. 2.8 Bar (40 psi)
Air Filter Restriction Switch (Normally Open) Closing Set point.. ............................... -6.4 kPa (Gauge) (-0.928 psig)
A/C Trinary Pressure Switch (Closed With Normal System Pressure)
Opens With Pressure ............................................................................ Above 28.5 ± 2.5 bar (413.3 ± 36,25 psi)
Below 2.5 ± 0.25 bar (36.25 ± 3.6 psi)
Brake Declutch Pressure Switch (Normally Closed} Opening Set point... ......................................... 24 Bar (350 psi)
Brake Warning Pressure Switch (Normally Closed) Opening Set point ................. 106 to 115 bar (1530 to 1670 psi)
Brake Redundant Pressure Switches (Normally Open) Closing Set point 55 to 69 bar decreasing (800 to 1000 psi)
Brake Lamp Pressure Switch (Normally Open) Closing Set point... ..................... 5 to 6 bar increasing (75 to 85 psi)
Secondary Steering Pressure Switch (Form C) Closing Set point ..................................................... 2.4 Bar (35 psi)
Fuel Filters Heater Resistance At 20° C (68° F) (Nominal) .......................................................................... 1.9 ohms
Parking Brake Solenoid DC Resistance At 20° C (68° F) (Nominal) .......................................................... 40.3 ohms
Pilot Pressure Solenoid (Joystick) DC Resistance At 20° C (68° F) (Nominal) .......................................... 29.9 ohms
Pilot Pressure Solenoid (Single Axis) DC Resistance At 20° C (68° F) (Nominal) ..................................... 27.4 ohms
Ride Control Solenoid DC Resistance At 20° C (68° F) (Nominal) ............................................................. 22.7 ohms
Pin Engage Solenoid DC Resistance At 20° C (68° F) (Nominal) .............................................................. 28.8 ohms
Secondary Steering Solenoid DC Resistance At 20° C (68° F) (Nominal) ................................................. 39.3 ohms
Fan Reversing Solenoid DC Resistance At 20° C (68° F) (Nominal) .......................................................... 39.3 ohms
Fan PWM Solenoid DC Resistance At 20° C (68° F) (Nominal) ................................................................. 29.3 ohms
Rollback Pressure Switch (Normally Closed} Opening Set point ....................................................... 6.2 Bar (90 psi)
Fuel Temperature Sensor At 20° C (68° F) (Nominal) ............................................................................... 2500 ohms
Grid Heater .................................................................................................................................................. 500 ohms
Engine Control Unit ............................................................................................... Electronic Diesel Control (EDC 7)
Analog Throttle .................................................................................. Idle Validation Switch Closes At 0. 775V ± 0.1 V
Throttle Position Potentiometer. ................................................................................................. 5V Reference ± 0.2V
Low Idle Position .............................................................................................................................. 0.4V ± 0.025V
High Idle Position ................................................................................................................................. 4.0V ± 0.1 V

4002-8
ELECTRICAL WIRE IDENTIFICATION
Wire Identification Codes

21C Bk- 1.0
----
~ T I
Wire Size (mm 2 ) 0.8 mm 11.0 mm 12.0 mm 15.0 mm I
Wire Color Bk =Black DU = Dark Blue S =Gray LG = Light Green K =Pink
Wire Name T= Tan W= White N =Brown G =Green U =Blue
LU = Light Blue Or= Orange R =Red P =Purple Y =Yellow
Wire Identification From Connector To Connector

Color, Size,
Wire Circuit Connector Cavity Connector Cavity
and Material
14 Alternator D+ Lg 1.0 SXL AD, Alternator D+ 1 ENG, Engine Cab 26
42 Work Lights Switched Fused Pwr R2.0 GXL SPL-WL, Ultrasonic A EGG, Work Lights 23
44 Brake Lt Control Power T 1.0 SXL FRONT, Cab Front Chassis 23 PBL, Brake Light Press Switch 2
49 Back Lt Power DU1.0 GXL D-OR, Diode OR c SPL-BCK-LGT, Spl Back Lgt Pwr A
52 Fan Reverse LSD W 0.8 TXL AIC-1, Adv lnstr Clust 1 23 ECB, Electrical Center B BB
56 Fan Control PWM W 0.8 TXL CAB-E, Cab Engine 23 AIC-1, Adv lnstr Clust 1 26
57 Pin Engage Sol Pwr W 1.0 SXL FRONT, Cab Front Chassis 20 YPE, Pin Engage Option A
58 Ride Control Sol Pwr W 1.0 SXL PRBF, Rollback Press Sw A YRC, Ride Control Option 1
64 Horn Power Or 1.0 SXL FRONT, Cab Front Chassis 13 HN1, Horn Power 1
SPL-BCK-LT-GD2, Spl Back Lgt
0 29 RTT/Fioat Ground Bk 0.8 GXL SFL, Return To Travel Sw 4 K
Gnd
OAA Proximity Switch Grnd Bk 1.0 SXL PXH, Height Control RTT B SPL-A2, Ultrasonic A
DAB Proximity Switch Grnd Bk 1.0 SXL SPL-A2, Ultrasonic A GND-FC, Ground A 1
OAC Proximity Switch Grnd Bk 1.0 SXL PXF,RTD B SPL-A2, Ultrasonic A
DAD Ride Control Ground Bk 1.0 SXL YRC, Ride Control Option 2 SPL-A1, Ultrasonic A
OAE Pin Engage Ground Bk 1.0 SXL SPL-A1, Ultrasonic A YPE, Pin Engage Option B
OAF Horn Ground Bk 1.0 SXL HN2, Horn Ground 1 SPL-A1, Ultrasonic A
OAG Front Chassis Ground Bk 2.0 SXL SPL-A1, Ultrasonic A GND-FC, Ground A 1
OAH RH Front Lights Ground Bk 1.0 SXL SPL-A1, Ultrasonic A LRF, Lights RH 1
0 AJ LH Front Lights Ground Bk 1.0 SXL SPL-A1, Ultrasonic A LLF, Lights LH 1
OAK Park Brake/Warning Ground Bk 1.0 SXL SPL-A4, Ultrasonic A GND-FC, Ground A 1
0 AL Brake Warning Press Sw Gnd Bk 1.0 SXL PBW, Brake Warn Press Sw 2 SPL-A4, Ultrasonic A
DAM RTD Grnd Bk 1.0 SXL PXM, RTD B PXT,RTD B
DAN Park Brake Solenoid Ground Bk 1.0 SXL YPB, Park Brake Solenoid 2 SPL-A4, Ultrasonic A
OAP Front To Rear Chassis Ground Bk 5.0 SXL GND-S1, Ground A 1 GND-S2, Ground A 1
OAQ Comfort Steering Solenoid Gnd Bk 1.0 SXL YCS, Comfort Steer Solenoid B SPL-A4, Ultrasonic A
OAR Front Axle Temp Sensor Ground Bk 1.0 SXL FRONT, Cab Front Chassis 9 HOT-FA, Front Axle Oil Temp 2
OB Front Washer Ground Bk 1.0 SXL FWW, Front Washer 2 SPL-ENG-GRD, Gnd Spl 6 Pck E
SPL-PED-BL-GD, Spl Bk Lgt

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

4002-9

21C Bk- 1.0
----
T I
Wire Size (mm 2) 0.8 mm 11.0 mm 12.0 mm 15.0 mm I
Wire Name T= Tan W=White N =Brown G =Green U =Blue

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

4002-10

21C Bk- 1.0
----
~ T I

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

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

0 BAN Ether Start Ground Bk 1.0 SXL ETHR, Ether Solenoid B 1
Motor
0 BAP QSM11 Ground Bk 0.8 GXL SPL-EDC1, Ultrasonic A QSM11, Engine Controller 50
GND-WIF, Gnd WIF Ring
0 BAR WIF Body Ground Bk 1.0 SXL 1 GND-ENG6, Dedicated 1
Term
0 BAS Rear Axle Temp Sensor Ground Bk 1.0 SXL HOT-RA, Rear Axle Oil Temp 2 GND-ENG7, Tranny, Cool Temp 1
0 BB Fan Reverse Solenoid Ground Bk 1.0 SXL YFR, Fan Reverse Sol Opt 2 SPL-FAN, Ultrasonic A
0 BC EDC7 Grnd Bk 1.0 GXL SPL-EDC1, Ultrasonic A EDC7, Engine Controller 11
4002-11

21C Bk- 1.0
----
T I

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

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

OBW Water Separator Htr Ground Bk 2.0 SXL 1 WSH, Water Separator Heater A
WSH
0 BX Fuel Filter Heater Ground Bk 2.0 SXL FFH, Fuel Filter Heater B GND-ENG1, Start, FFH, WSH 1
SPL-ENG-GRD, Grd Spl 6
0 BY Air Filter Restriction Sw Grd Bk 1.0 SXL B PAF, Air Filter Restriction Sw 2
Pck
GND-ENG3, SPLC-PK, Washer
0 BZ Sec. Steering Splice Grd Bk 1.0 SXL ENG-T, Engine To Trans 1 1
Motor
0 CA Sec. Steering Signal Ground Bk 1.0 SXL SSM, Sec. Steering Mod 11 SPL-SEC-STR, Sec. Steer 6 Pck B
0 CB Sec. Steering Signal Ground Bk 1.0 SXL SSM, Sec. Steering Mod 12 SPL-SEC-STR, Sec. Steer 6 Pck A
PSS, Sec. Steer Press

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

4002-12

21C Bk- 1.0
----
~ T I

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

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

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

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

4002-13

21C Bk- 1.0
----
T I

Color, Size,
and Material
0 EA Time Delay relay Control Grnd Bk 0.8 GXL B PRM-B2, PRM Signal B
Light Ground
0 EB Ignition Relay Control Ground Bk 0.8 GXL
Light Ground
c PRM-A 1, PRM Signal B

0 EC ACC Relay Control Ground Bk 0.8 GXL D PRM-D1, PRM Signal B
Light Ground
0 ED HVAC Grounds Bk 3.0 SXL HVAC2,HVAC2 2 GND-CAB4, Ground C 1
GND-CAB-SPL, Cab Grnd

0 EE DIODE Suppression Grounds Bk 0.8 GXL
Spl
A 140M, DIODE Module c
0 EF Brake Lights Relay Ctrl Grnd Bk 0.8 GXL M ECC, Work Lights B6
Light Ground
GND-CAB-SPL2, Spl Back Light
0 EG Flasher Module Ground Bk 0.8 GXL FLSHR, Flasher Module 4 L
Ground
GND-CAB-SPL2, Spl Back Light
0 EH Flasher Module Ground Bk 0.8 GXL FLSHR, Flasher Module 3 K
Ground
CNV, 24V to 12V Pwr
0 EJ Power Converter Ground Bk 1.0 GXL 3 GND-CAB4, Ground C 1
Convert
0 EK AUX Power Outlet 1 Grnd Bk 1.0 GXL P01, Power Outlet c GND-CAB5, Ground C 1
0 EL AUX Power Outlet 2 Grnd Bk 1.0 GXL P02, Power Outlet c GND-CAB5, Ground C 1
0 EM Radio Ground Bk 0.8 GXL CAB-RF, Cab to Roof Conn. M GND-CAB-SPL, Cab Grnd Spl B
0 EN Radio Ground Bk 0.8 GXL ROOF, Roof to Cab Conn. M RAD, Radio Power 8
0 EP Horn Switch Ground Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl c SRHSTLK, RH Stalk Switch 31
Splice Pack GND-CAB-SPL2 GND-CAB-SPL2, Spl Back GND-CAB6, Start, FFH, Water
0 EQ Bk 0.8 GXL H 1
Grnd Light Ground Sep Htr
0 ER Power Converter Grnd Bk 1.0 GXL CNV, 24V to 12V Pwr Conv 6 GND-CAB4, Ground C 1
GND-GH1, STRT, FFH, Water

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

4002-14

21C Bk- 1.0
----
~ T I

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

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

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

4002-15

21C Bk- 1.0
----
T I

Color, Size,
and Material
0 PA Left Speaker Grnd Bk 0.8 GXL LSPK, Left Speaker 2 SPK, Speaker 8
0 PB Right Speaker Grnd Bk 0.8 GXL RSPK, Right Speaker 2 SPK, Speaker 2
12ACC Ignition Switch ACC Power W 0.8 GXL S-KEY, Ignition Switch 4 SPL-ACC, Ultrasonic A
12ACC
ACC PRM control Power W 0.8 GXL SPL-ACC, Ultrasonic A PRM-D1, PRM Signal A
B
12ACC Power Converter PRM Control
W 0.8 GXL SPL-ACC, Ultrasonic A PRM-E2, PRM Signal A
c Power
12V 12V Pwr To Outlet 1 Or 1.0 GXL P01, Power Outlet A ECD, Elect Center D AA4
12V A 12V Pwr To Outlet 2 Or 1.0 GXL P02, Power Outlet A ECD, Elect Center D AA5
12V B 12V Fused Pwr to Radio Or 1.0 GXL CAB-RF, Cab to Roof Conn. N ECD, Elect Center D AA6
12V C 12V Switched Power Or 2.0 GXL CNV, 24V to 12V Pwr Conver 5 SPL-12V, Ultrasonic A
12V D Plug 112V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECD, Elect Center D A4
12V E Plug 2 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECD, Elect Center D A5
12V F Radio 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECD, Elect Center D A6
12V G 2 Way Radio 12V Switched Pwr Or 1.0 GXL SPL-12V, Ultrasonic A ECD, Elect Center D A7
12V H 12V Fused Power to Radio Or 0.8 GXL ROOF, Roof to Cab Conn. N SPL-RAD, Ultrasonic A
12V
12V Fused Power to Radio Or 0.8 GXL SPL-RAD, Ultrasonic A RAD, Radio Power 7
HA
12V
12V Fused Power to Radio Or 0.8 GXL SPL-RAD, Ultrasonic A RAD, Radio Power 4
HB
13C Fuel Shutoff Fused Power Or 1.0 SXL DC3, Fuel Solenoid Disc 1 DISC, Disconnect Engine A
13CA Fuel Shutoff Fused Power Or 1.0 SXL ENG-D, Disc Harness A ENG, Engine Cab 21
13C B Fuel Shutoff Fused Power Or 1.0 SXL CAB-E, Cab Engine 21 EGA, Elect Center A A9
13D Time Delay Relay Control Pwr Or 1.0 SXL TOM, Time Delay Module 1 PRM-B2, PRM Signal A
13H Time Delay Power Or 3.0 GXL SPL-DLY-RL, Ultrasonic A PRM-B1 PRM Output c
13H B AIC Time Delay Power Or 0.8 GXL SPL-DLY-RL, Ultrasonic A ECD, Elect Center D A3
13H C Trans ECM Time Delay Power Or 0.8 GXL SPL-DLY-RL, Ultrasonic A ECD, Elect Center D A1
13H D Engine ECM Time Delay Power Or 3.0 GXL SPL-DLY-RL, Ultrasonic A ECD, Elect Center D A2
13K Ignition Switch Pwr Or 1.0 GXL S-KEY, Ignition Switch 3 SPL-PK1, Slice 3-4 Way E
13KA Ignition Switch Pwr Or1.0GXL TOM, Time Delay Module 5 SPL-PK1, Slice 3-4 Way G
13K B Ignition Switch Pwr Or 1.0 GXL SPL-PK1, Slice 3-4 Way F PRM-A 1, PRM Signal A
13K C Ignition Switch Pwr Or 1.0 GXL SPL-PK1, Slice 3-4 Way H ECB, Elect Center B D1

4002-16

21C Bk- 1.0
-- -
~ T I

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

4002-17

21C Bk- 1.0
----
T I

Color, Size,
and Material
18G F RH Position/Tail Fused Power Or 0.8 GXL CAB-E, Cab Engine 9 SPL-POS-R, Ultrasonic
18G G RH Position/Tail Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis A SPL-POS-R, Ultrasonic
18G H RH Position/Tail Fused Power Or 1.0 SXL ENG, Engine Cab 9 SPL-POS, Ultrasonic A
18G
RH Position/Tail Fused Power Or 1.0 SXL ENG, Engine Cab 9 ENG-H, Engine to Hood 5
HN
LRR-E, RH Rear
18G J RH Position/Tail Fused Power Or 1.0 SXL 3 SPL-POS, Ultrasonic A
Combination Light
18G
RH Position/Tail Fused Power Or 1.0 SXL HD-N, Hood to Engine 5 SPL-POS-NA, Ultrasonic A
JN
18G K RH Position/Tail Fused Power Or 1.0 SXL HD-N, Hood to Engine 5 SPL-P9, Ultrasonic A
18G L RH Position/Tail Fused Power Or 1.0 SXL SPL-P9, Ultrasonic A E-HD9, Trans Hood A
LRR-9, RH Rear Combination
18G M RH Position/Tail Fused Power Or 1.0 SXL SPL-P9, Ultrasonic A 3
Light
18J EDC7 Time Delay Fused Power Or 2.0 GXL CAB-E, Cab Engine 18 SPL-D2, Ultrasonic A
18J A EDC7 Time Delay Fused Power Or 2.0 GXL ENG, Engine Cab 18 SPL-EDC2, Ultrasonic A
18J B EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 3
18J c EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 2
18J D EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC4, Ultrasonic A EDC7, Engine Controller 8
18J E EDC7 Time Delay Fused Power Or 1.0 GXL SPL-EDC4, Ultrasonic A EDC7, Engine Controller 9
18J F EDC7 Time Delay Fused Power Or 2.0 SXL ENG, Engine Cab 14 SPL-EDC4, Ultrasonic A
18J G EDC7 Time Delay Fused Power Or 2.0 GXL CAB-E, Cab Engine 14 SPL-D2, Ultrasonic A
18J H Water In Fuel Sensor Fused Pwr Or 1.0 GXL SPL-EDC4, Ultrasonic A WIF, Water In Fuel Sensor 3
18J K EDC7 Time Delay Fused Power Or3.0 GXL SPL-D2, Ultrasonic A ECD, Elect Center D AA2
18J L QSM11 Time Delay Power Or 0.8 GXL SPL-EDC4, Ultrasonic A QSM11, Engine controller 17
18J M QSM11 Time Delay Power Or 0.8 GXL SPL-EDC2, Ultrasonic A QSM11, Engine controller 7
18J N QSM11 Time Delay Power Or 0.8 GXL SPL-EDC2, Ultrasonic A QSM11, Engine controller 8
18J p QSM11 Time Delay Power Or 0.8 GXL SPL-EDC4, Ultrasonic A QSM11, Engine controller 18
18J Q QSM11 Time Delay Power Or 0.8 GXL SPL-EDC4, Ultrasonic A QSM11, Engine controller 28
18K A Diagnostic Fused Power Or 0.8 GXL DIA, Diagnostic B ECC, Work Lights A9
18L A Comfort Steer Fused Power Or 0.8 GXL SPL-CSTR, Ultrasonic A EGA, Elect Center A A2
18L B Comfort Steer Fused Power Or 0.8 GXL SPL-CSTR, Ultrasonic A ECC, Work Lights D9
18L C Comfort Steer Fused Power Or 0.8 GXL SPL-CSTR, Ultrasonic A ECC, Work Lights B9

4002-18

21C Bk- 1.0
-- -
~ T I

Color, Size,
and Material
18L D Comfort Steer Fused Power Or 0.8 GXL SCS, Comfort Steer Switch 2 SPL-CSTR, Ultrasonic A
18M AC Relay Fused Power Or 0.8 GXL EGA, Elect Center A C5 ECD, Elect Center D B9
18N Blower Motor Fused Power Or3.0 GXL SPL-BLWR, Ultrasonic A EGA, Elect Center A C1
18N A Blower Motor Fused Power Or 0.8 GXL SPL-BLWR, Ultrasonic A HVAC1, HVAC1 2
18N B Blower Motor Fused Power Or3.0 GXL SPL-BLWR, Ultrasonic A HVAC2,HVAC2 1
18R Voltmeter Relay Fused Power Or 2.0 SXL ENG, Engine Cab 13 PRM-C1, PRM Output A
18RA Voltmeter Relay Fused Power Or 2.0 GXL CAB-E, Cab Engine 13 ECB, Elect Center B B1
19A Output Speed Sensor Fused Pwr Or 1.0 SXL TRANS, Cab Transmission 29 OSS, Out Speed Sensor 3
19AA Brake Declutch Sw Fused Pwr Or 1.0 SXL FRONT, Cab Front Chassis 27 PBD, Dec. Pressure Switch A
19A B FNR Switched Fused Power Or 0.8 GXL 197M, FNR Main Cab 1 SPL-FNR, Ultrasonic A
19AC FNR Switched Fused Power Or 0.8 GXL 197F, Main Cab FNR 1 SPL-TRNS-PWR, Trans Pwr F
19A D Trans Enable Switch Fused Pwr Or 0.8 GXL STE, Trans Enable Switch 2 SPL-015, Ultrasonic A
19A E Trans Enable Switch Fused Pwr Or 0.8 GXL STE, Trans Enable Switch 10 SPL-015, Ultrasonic A
19A F Trans Enable Switch Fused Pwr Or 0.8 GXL SPL-TRNS-PWR, Trans Pwr B SPL-015, Ultrasonic A
19A G FNR Sw Fused Power Or 0.8 GXL SPL-FNR, Ultrasonic A SFNR, FNR Switch 8
19A H Trans Shifter Fused Power Or 0.8 GXL TS1, Transmission Shifter A SPL-TRNS-PWR, Trans Pwr M
Pilot Control Switched Fused

19A J Or 0.8 GXL SPC, Pilot Control Switch 2 SPL-PB1, Ultrasonic A
Pwr
SPL-TRANS-PWR, Trans
19A K TECM Fused Power Or 0.8 TXL J TECM, Trans 45
Pwr
19A L Park Brake Switched Fused Pwr Or 0.8 GXL SPB, Parking Brake Switch 2 SPL-PB1, Ultrasonic A
19AM Output Speed Sensor Fused Pwr Or 0.8 TXL CAB-T, Cab Transmission 29 SPL-TRNS-PWR, Trans Power K
19A N Trans Fused Power Or 1.0 GXL A EGA, Elect Center A A1
Pwr
Backup Alarm Relay Control SPL-TRANS-PWR, Trans
19A P Bk 1.0 GXL G ECD, Elect Center D AA10
Fused Power Pwr
19A Q Trans/Auto Switch Fused Power Or 0.8 GXL STA, Trans Auto Switch 2 SPL-TRANS-PWR, Trans Pwr c
19A R Declutch Switch Fused Power Or 0.8 GXL SOC, Declutch Switch 2 SPL-TRANS-PWR, Trans Pwr H
19AS Trans Fused Power Or 0.8 GXL L SPL-PB1, Ultrasonic A
Pwr
Brake Declutch Switch Fused
19AT Or 0.8 GXL CAB-F, Cab Front Chassis 27 SPL-TRANS-PWR, Trans Pwr D
Power

4002-19

21C Bk- 1.0
----
T I

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

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

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

4002-20

21C Bk- 1.0
----
~ T I

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

19M Or 0.8 GXL CAB-T, Cab Transmission 3 EGA, Elect Center A C7
Pwr
Sec. Steering Accessory Fused
19M A Or 1.0 SXL TRANS, Cab Transmission 3 TR-SS, Sec. Steering Module Opt A
Pwr
19M C Sec. Steering Accessory Fused Or 1.0 SXL SSM, Sec. Steering Module 7 SS-TR, Sec. Steering Mod Trans A
Pwr
19N Seat Compressor Fused Pwr Or 1.0 GXL SC, Seat Compressor Motor A EGA, Elect Center A C6
19P Pin Engage/Fan Fused Pwr Or 0.8 GXL SPL-PIN, Spl Back Lgt Pwr B EGA, Elect Center A A7
19PA Pin Engage Sw Fused Pwr Or 0.8 GXL SPE, Pin Engage Sw 2 SPL-PIN, Spl Back Lgt Pwr A
19P C Fan Rev Sw Fused Pwr Or 0.8 GXL SFC, Fan Control Switch 5 SPL-PIN, Spl Back Lgt Pwr c
19P D Fan Rev Relay Fused Pwr Or 0.8 GXL SPL-PIN, Spl Back Lgt Pwr E ECB, Elect Center B D7
19P E Fan Rev Relay Fused Pwr Or 0.8 GXL SPL-PIN, Spl Back Lgt Pwr F ECB, Elect Center B B7
19R Sec. Steering lgn Fused Pwr Or 0.8 GXL DM, Diode OR c SPL-2 Ultrasonic A
19RR Sec. Steering lgn Fused Pwr Or 0.8 GXL DM, Diode OR A EGA, Elect Center A A4
19RA Sec. Steering lgn Fused Pwr Or1.0SXL TRANS, Cab Transmission 4 TR-SS, Sec. Steering Module Opt B
19R C Sec. Steering lgn Fused Pwr Or1.0SXL SSM, Sec. Steering Module 1 SS-TR, Sec. Steering Mod Trans B
19R D Alternator Resistor Fused Pwr Or 0.8 GXL SPL-2, Ultrasonic A 216F, Alternator Resistor 1
19R E Sec. Steering lgn Fused Pwr Or 0.8 GXL SPL-2, Ultrasonic A CAB-T, Cab Transmission 4
19S1 Sec. Steering Fused Pwr Or 1.0 GXL SS, Sec. Steering Fused Pwr 1 CAB-T, Cab Transmission 26
19S1 E Sec. Steering Fused Pwr Or 1.0 SXL TRANS, Cab Transmission 26 TR-SS, Sec. Steering Module Opt E
SS-TR, Sec. Steering Module

19S1 X Sec. Steering Fused Pwr R 1.0 SXL SSM, Sec. Steering Module 3 E
Trans
19S B AIC Delay Fused Power Or 0.8 GXL SPL-DKY3, Ultrasonic A ECD, Elect Center D AA3
19S c AIC Delay Fused Power Or 0.8 TXL SPL-DKY3, Ultrasonic A AIC-2, Advanced lnstr Cluster 2 20
19S D AIC Delay Fused Power Or 0.8 TXL SPL-DKY3, Ultrasonic A AIC-2, Advanced lnstr Cluster 2 14
19TA TECM Delay Fused Power Or 0.8 TXL TECM, Trans 23 ECD, Elect Center D AA1
19U Horn Relay Fused Power Or 0.8 GXL SPL-HRN, Ultrasonic A ECC, Work Lights A6
19U A Horn Relay Fused Power Or 0.8 GXL SPL-HRN, Ultrasonic A ECC, Work Lights B7
19U B Beacon Dome Lt Fused Pwr Or 1.0 GXL SPL-LT, Ultrasonic A ECC, Work Lights A1
19U C Dome Lt Fused Pwr ROOF, Roof to Cab D 1

Or 0.8 GXL LDM1, Dome Light B+
Connection

4002-21

21C Bk- 1.0
----
T I

Color, Size,
and Material
CAB-RF, Cab to Roof
19U D Dome Lt Fused Pwr Or 0.8 GXL D SPL-LT, Ultrasonic A
Connection
19U E Horn Relay Fused Power Or 0.8 GXL SPL-HRN, Ultrasonic A ECC, Work Lights 07
ROOF, Roof to Cab

19U F Door Sw Fused Power Bk 0.8 GXL
Connection
s DS, Door Switch A
CAB-RF, Cab to Roof

19U G Door Sw Fused Power Or 0.8 GXL
Connection
s SPL-LT, Ultrasonic A
19U H Beacon Switch Fused Power Or 1.0 GXL SBE, Beacon Switch 2 SPL-LT, Ultrasonic A
19W Cigar Lighter Pwr Or3.0 GXL CL, Cigar Lighter 1 ECC, Work Lights A8
19Y Hood control Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Work Lights A7
19YA Hood Up Relay Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Work Lights 02
19Y B Hood Down Relay Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Work Lights 04
19YC Hood Switch Fused Power Or 1.0 GXL CAB-E, Cab Engine 35 SPL-HOOD, Ultrasonic A
19Y D Hood Switch Fused Power Or 1.0 GXL ENG, Engine Cab 35 HD, Hood Switch B
19Z Driving Lights Sw Fused Power Or 1.0 GXL SPL-PK2, Splice 3-4 Way G ECC, Work Lights A3
19ZA Driving Lights Sw Fused Power Or 1.0 GXL SDR, Driving Lights Sw 2 SPL-PK2, Splice 3-4 Way E
19Z B Driving Lights Sw Fused Power Or 1.0 GXL SDR, Driving Lights Sw 5 SPL-PK2, Splice 3-4 Way F
19Z C High Beam Flash Fused Power Or 1.0 GXL SRHSTLK, RH Stalk Switch 56d SPL-PK2, Splice 3-4 Way H
1A lgn Switch Fused Power R 1.0 GXL S-KEY, Ignition Switch 1 SPL-DL Y, Ultrasonic A
1GB Cab CB Protected Power R 19.0 SXL CB1A, Circuit Breaker 1 CBPW, Cab Power 1
1GB A Cab CB Protected Power R 19.0 SXL P-A3, B+ Power 1 CAB-PW, Cab Power 1
10M Time Delay/lgn Sw Fused Pwr R 1.0 GXL SPL-DLY, Ultrasonic A ECC, Work Lights A5
1DN Time Delay Fused Power R 1.0 GXL TOM, Time Delay Module 2 SPL-DL Y, Ultrasonic A
1NC Cab CB PRM Power R 19.0 SXL B1, Starter Power Stud 1 CB2B, Cab B+ CB 1
1 AA Brake Lt Sw Pwr R 1.0 SXL FRONT, Cab Front Chassis 22 PBL, Brake Light Press Switch 1
1 B9 PRM C Power R 8.0 SXL CB3B, Cab B+ CB 1 P-C5, B+ Power from PRMC 1
1 BA Alternator B+ R 13.0 SXL AB+, Alternator B+ 1 B2 Starter Power 1
1 BB Starter Solenoid Pwr R 8.0 SXL 193 Starter Relay 1 194 Starter Signal 1
1 BC Cab CB Power R 19.0 SXL P-C3, B+ Power From PRMC 1 CB1 B, Cab B+ CB 1
1 BE Grid Htr Pwr R 19.0 SXL 115 Grid Htr Pwr 1 GH, Grid Htr 1
1c ECC Bat Power R 8.0 GXL P-A 1, B+ Power 1 L1-ECC, ECC Battery Power cs01
1 DR Brake Light Switch Power R 1.0 GXL CAB-F, Cab Front Chassis 22 SPL-FLSHR-PWR, Ultrasonic A

4002-22

21C Bk- 1.0
----
~ T I

Color, Size,
and Material
1 DU Flasher Module Pwr R 1.0 GXL FLSHR, Flasher Module 1 SPL-FLSHR-PWR, Ultrasonic A
SPL-FLSHR-PWR,
1 DV Brake Lights/Flasher Bat Pwr R 2.0 GXL A ECC, Work Lights A4
Ultrasonic
SPL-FLSHR-PWR,
1DW Brake Lt Relay Bat Pwr R 1.0 GXL A ECC, Work Lights B5
Ultrasonic
1E Grid heater Fuse Bat Power R 19.0 SXL P-C2, B+ Power from PRMC 1 GHF1, Grid Heater Fuse 1
1 GA Filter Htr Pwr R 3.0 SXL PRM-C1, PRM Output c SPL-HTR, Ultrasonic A
1GB Fuel Filter Htr Pwr R 2.0 SXL SPL-HTR, Ultrasonic A FFH, Fuel Filter Heater A
1 GC Water Sep Htr Pwr R 2.0 SXL SPL-HTR, Ultrasonic A WSH, Water Separator Heater B
1 KA Hazard Switch Pwr R 1.0 GXL SHZ, Hazard Switch 2 SPL-FLSHR-PWR, Ultrasonic A
1 NA Battery Crossover R 62.0 SGR BT3, Starter Battery 1 BT2, Disconnect Battery 1
1 NB Battery Starter R 62.0 SGR BT1, Battery Starter 1 B3, Starter Battery 1
1 NC B+ Power PRMC R 19.0 SXL B1, Starter Power Stud 1 P-C1, B+ Power From PRMC 1
1 ND SSM Power R 62.0 SGR 244F Starter Sec. Strg Mtr 1 B4, Starter Power 1
1y Grid Heater Fused Power R 19.0 SXL GHF3, Grid heater Fuse 1 GHF4, Grid Heater 1
1 z Starter Relay Battery Power R 8.0 SXL P-C4, B+, Power From PRMC 1 195, Starter Relay Power 1
20G A EDC7 ESO-K Interface W 0.8 TXL ENG, Engine Cab 31 EDC7, Engine Controller 89
20GB EDC7 ESO-K Interface W 0.8 GXL CAB-E, Cab Engine 31 DIA, Diagnostic E
21C Neutral Start Relay Output W 0.8 GXL SPL-CR, Ultrasonic A ECB, Elect Center B D4
21CA Neutral Start Relay Output W 0.8 GXL SPL-CR, Ultrasonic A ECB, Elect Center B D5
21C B Neutral Start Relay Output W 0.8 GXL SPL-CR, Ultrasonic A ECB, Elect Center B A10
21CC Starter Relay Signal W 0.8 GXL CAB-E, Cab Engine 1 SPL-CR, Ultrasonic A
21C D Starter Relay Signal W 1.0 SXL SR-9, Starter Relay Signal 1 ENG, Engine Cab 1
210 Starter Relay Signal W 1.0 SXL SRC-1, Relay 1 ENG, Engine Cab 15
210A Starter Relay Signal W 0.8 GXL SPL-4, Ultrasonic A ECB, Elect Center B AA9
210 B Starter Relay Signal W 0.8 GXL 140M, Diode Module E SPL-4, Ultrasonic A
210 c Starter Relay Signal W 0.8 GXL CAB-E, Cab Engine 15 SPL-4, Ultrasonic A
21E Key Switch Crank W 0.8 GXL CAB-E, Cab Engine 27 ECB, Elect Center B D6
21E A Key Switch Crank W 0.8 TXL ENG, Engine Cab 27 EDC7, Engine Controller 32
21F EDC7 Digital Ground W 0.8 GXL CAB-E, Cab Engine 11 ECB, Elect Center B B5
21F A EDC7 Digital Ground W 0.8 GXL ENG, Engine Cab 11 SPL-EDC3, Ultrasonic A

4002-23

21C Bk- 1.0
----
T I

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

4002-24

21C Bk- 1.0
----
~ T I

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

4002-25

21C Bk- 1.0
----
T I

Color, Size,
and Material
26F B FNR Forward Signal LU 0.8 TXL 197F, Main Cab FNR 2 TECM, Trans 20
26J FNR Switch Jumper LU 0.8 GXL SFNR, FNR Switch 2 SFNR, FNR Switch 4
26N A FNR Neutral Signal LU 0.8 GXL SFNR, FNR Switch 3 197M, FNR Main Cab 3
26N B FNR Neutral Signal LU 0.8 TXL 197F, Main Cab FNR 3 TECM, Trans 44
26R A FNR Reverse Signal LU 0.8 GXL SFNR, FNR Switch 1 197M, FNR Main Cab 4
26R B FNR Reverse Signal LU 0.8 TXL 197F, Main Cab FNR 4 TECM, Trans 30
28E Ether Relay Signal W1.0SXL PRM-C2, PRM Signal A ENG, Engine Cab 16
28F Filter Htrs Relay Control W 0.8 TXL PRM-C2,PRM Signal A EDC7, Engine Controller 36
28G Grid Heater Source Dr. W 1.0 GXL GHC, Grid Htr Relay 1 EDC7, Engine Controller 12
28H Ether Switch Signal W 0.8 GXL CAB-E, Cab Engine 16 SETHR, Ether Switch 3
28J Ether AIC Ok Signal W 0.8 GXL SETHR, Ether Switch 2 AIC-1, Adv Instrument Cluster 1 19
28P Ether Solenoid Power W 1.0 SXL PRM-C1, PRM Output c ETHR, Ether Solenoid A
310 Coolant Level Signal Y 1.0 SXL TRANS, Cab Transmission 2 CLS, Cool Jump-Cool Send A
310 A Coolant Level Signal Y 0.8 TXL CAB-T, Cab Transmission 2 AIC-2, Adv Instrument Cluster 2 26
310 B Coolant Level Sender Eng Trans Y 1.0 SXL TRANS, Cab Transmission 2 TRAN-E, Trans to Engine 3
31DC Coolant Level Sender Eng Trans Y 1.0 SXL CLS, Cool Jump Cool Send A ENG-T, Engine to Trans 3
31F Air Filter Rest Sw Signal Y 1.0 SXL ENG, Engine Cab 28 PAF, Air Filter Rest Sw 1
31 FA Air Filter Rest Sw Signal Y 0.8 TXL CAB-E, Cab Engine 28 SW-PD, Switch Pad 5
31H Hyd Filter Rest Sw Signal Y 1.0 SXL TRANS, Cab Transmission 23 PHF, Hyd Oil Filter Rest Sw 1
31H A Hyd Filter Rest Sw Signal Y 0.8 GXL SW-PD, Switch Pad 4 CAB-T, Cab Transmission 23
31L Pilot Control Switch High Y 0.8 TXL SPC, Pilot Control Switch 3 AIC-2, Advance lnstr Cluster 2 18
32F Trans Filter Main! Sw Y 1.0 SXL TRANS, Cab Transmission 31 FM, Filter Main! Sw 1
32F A Trans Filter Main! Sw Y 0.8 TXL CAB-T, Cab Transmission 31 TECM, Trans 17
32J A Trans Enable Indiction Y 0.8 GXL SFNR, FNR Switch 7 197M FNR Main Cab 5
32J c Trans Enable Indiction Y 0.8 GXL STE, Trans Enable Switch 9 SPL-D16, Ultrasonic A
32J D Trans Enable Indiction Y 0.8 TXL SPL-D16, Ultrasonic A TECM, Trans 5
32J E Trans Enable Indiction Y 0.8 GXL 197F, Main Cab FNR 5 SPL-D16, Ultrasonic A
33P Brake Warning Press Low Y 1.0 SXL FRONT, Cab Front Chassis 26 PBW, Brake Warning Press Sw 1
33P A Brake Warning Press Low Y 0.8 TXL CAB-F, Cab Front Chassis 26 AIC-2, Advance lnstr Cluster 2 5
Redundant Brake Accumulator

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

4002-26

21C Bk- 1.0
----
~ T I

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

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

4002-27

21C Bk- 1.0
----
T I

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

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

4002-28

21C Bk- 1.0
----
~ T I

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

4002-29

21C Bk- 1.0
----
T I

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

4002-30

21C Bk- 1.0
----
~ T I

Color, Size,
and Material
45N B Flasher OPP Side Control N 0.8 GXL FLSHR, Flasher Module 12 64M, Flasher Connector 1
45R Right Turn Signal N 1.0 SXL FRONT, Cab Front Chassis 3 LRF, Lights RH 5
45R 9 Right Turn Signal N 1.0 SXL HD-9, Hood to Engine 4 LRR-9, RH Rear Comb Light 2
45RA Right Turn Signal N 1.0 SXL ENG, Engine Cab 12 LRR-E, RH Rear Comb Light 2
45R
Right Turn Signal N 1.0 SXL ENG, Engine Cab 12 ENG-H, Engine to Hood 4
AN
45R B Right Turn Signal N 0.8 GXL CAB-E, Cab Engine 12 SPL-PK3, Splice 3-4 Way H
45R
BN
Right Turn Signal N 1.0 SXL HD-N, Hood to Engine 4 LRR-N, RH Rear Comb Light c
45R C Right Turn Signal N 0.8 TXL SPL-PK3, Splice 3-4 Way E AIC-2, Adv Instrument Cluster 2 10
45R D Right Turn Signal N 0.8 GXL CAB-F, Cab Front Chassis 3 SPL-PK3, Splice 3-4 Way G
45R E Right Turn Signal N 0.8 GXL FLSHR, Flasher Module 7 SPL-PK3, Splice 3-4 Way F
46 c Beacon Switched Power K 1.0 GXL CAB-RF, Cab to Roof Conn. E SBE, Beacon Switch 3
46 D Beacon Switched Power K 1.0 GXL ROOF, Roof to Cab Conn. E LBEPWR, Light Beacon power 1
46 E Beacon Switched Power K 1.0 GXL LBEE, Light Beacon Exten A LBEP, Light Beacon power 1
49A Back Light Power S 0.8 GXL HVAC1, HVAC1 3 SPL-BCK-LGT, Spl Back Lgt Pwr F
49S Back Light Power S 0.8 GXL STA, Trans Auto Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr J
SPL-PED-BL, Spl Back Lgt Pwr 6
49U Back Light Power S 0.8 GXL SETHR, Ether Switch 8 D
Pck
49 A Back Light Power S 0.8 GXL SWL, Work Lights Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr M
49 B Back Light Power S 0.8 GXL SBE, Beacon Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr L
49 c Back Light Power S 0.8 GXL SRWP, Rear Wiper Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr c
49 D Back Light Power S 0.8 GXL SHZ, Hazard SWitch 8
Pck
c
SPL-BCK-LGT2, Spl Back
49 E Back Light Power S 0.8 GXL A SPL-BCK-LGT, Spl Back Lgt Pwr K
Lgt Pwr
SPL-BCK-LGT2, Spl Back Lgt
49 F Back Light Power S 0.8 GXL SPE, Pin Engage Switch 10 F
Pwr
49 G Back Light Power S 0.8 GXL SRC, Ride control Switch 8 K
Pwr
49 H Back Light Power S 0.8 GXL STE, Trans Enable Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr D

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

4002-31

21C Bk- 1.0
----
T I

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

49 M Back Light Power S 0.8 GXL SHC, Height Control Switch 8 D
Pwr
49 N Back Light Power S 0.8 GXL SPC, Pilot Control Switch 8 B
Pck
49 p Back Light Power S 0.8 GXL SDR, Driving Lights Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr G
49 Q SPL-BCK-LGT2, Spl Back Lgt

Back Light Power S 0.8 GXL SFC, Fan Control Switch 8 G
Pwr
49 R Back Light Power S 0.8 GXL SOC, Declutch Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr H
SPL-PED-BL, Spl Back Lgt SPL-BCK-LGT2, Spl Back Lgt
49 s Back Light Power S 0.8 GXL F M
Pwr 6 Pck Pwr
49 T Back Light Power S 0.8 GXL SFWW, Front Wiper/Washer 8 H
Pwr
49 u Back Light Power S 0.8 GXL SCS, Comfort Steer Switch 8
Pck
A

49 v Back Light Power S 0.8 GXL SPB, Parking Brake Switch 8 E
Pck
51B A Comfort Steer Solenoid Power W 0.8 GXL SCS, Comfort Steer Switch 6 SPL-CSS, Ultrasonic A
51B B Comfort Steer Solenoid Power W 0.8 GXL SPL-CSS, Ultrasonic A EGG, Work Lights 010
51B c Comfort Steer Solenoid Power W 0.8 GXL SPL-CSS, Ultrasonic A CAB-F, Cab Front Chassis 2
51B D Comfort Steer Solenoid Power W 1.0 SXL FRONT, Cab Front Chassis 2 YCS, Comfort Steer Solenoid A
AIC-1, Adv Instrument
51C Comfort Steer control W 0.8 TXL 21 EGG, Work Lights B10
Cluster 1
51CS Comfort Steer Switch W 0.8 TXL SCS, Comfort Steer Switch 3 AIC-1, Adv Instrument Cluster 1 17
51P A Sec. Str High Press W1.0SXL SSM, Sec. Steer Module 9 PSS, Sec. Steer Pressure Switch A
51S Standard Steering Signal W 0.8 TXL SCS, Comfort Steer Switch 1 AIC-1, Adv Instrument Cluster 1 16
51 A Sec. Str Motor Control W1.0SXL SSM, Sec. Steer Module 2 SPL-SS, Ultrasonic A
51 B Sec. Str Motor Control W 1.0 SXL SPL-SS, Ultrasonic A SSS, SS Mag Switch 1
51 c Sec. Strg Sol Control W1.0SXL SPL-SS, Ultrasonic A YSS, Sec. Steering Solenoid 1
52 AU Fan Reverse Auto W 0.8 TXL SFC, Fan Control Switch 3 AIC-2, Adv Instrument Cluster 2 8
52AA Fan Reverse Relay Out W 1.0 GXL CAB-E, Cab Engine 22 ECB, Elect Center B DB
52A B Fan Reverse Relay Out W 1.0 SXL ENG, Engine Cab 22 YFR, Fan Rev Solenoid Option 1

4002-32

21C Bk- 1.0
----
~ T I

Color, Size,
and Material
52C Parking Brake Solenoid LSD W 0.8 TXL 14 ECB, Elect Center B B10
Cluster 1
52J Fan Control Switch Jumper W0.8 GXL SFC, Fan Control Switch 4 SFC, Fan Control Switch 2
52M Fan Reverse Manual W 0.8 TXL SFC, Fan Control Switch 6 AIC-2, Adv Instrument Cluster 2 7
52P Parking Brk Relay Out W 1.0 SXL FRONT, Cab Front Chassis 24 YPB, Park Brake Solenoid 1
52P A Parking Brk Relay Out W 0.8 GXL CAB-F, Cab Front Chassis 24 SPL-PB, Ultrasonic A
52P B Parking Brk Relay Out W 0.8 GXL SPL-PB, Ultrasonic A ECB, Elect Center B D10
52P C Parking Brk Relay Out W 0.8 TXL SPL-PB, Ultrasonic A TECM, Trans 21
53 A RTD Switch Power W 0.8 GXL SRTD, Detent Switch 3 EM, RTD Height Control RTT 3
53B RTD Signal W 1.0 SXL FRONT, Cab Front Chassis 12 PXF,RTD c
53B A RTD Signal W 1.0 SXL PXM,RTD A PXT,RTD A
53B B RTD Signal W 0.8 GXL EM, RTD Height Control RTT 4 CAB-F, Cab Front Chassis 12
53CA Pilot Control Solenoid LSD W 0.8 TXL 20 ECD, Elect Center D B6
Cluster 1
53P A Pilot Control Relay Out W 0.8 GXL SPL-D25, Ultrasonic A YPP, Pilot Pressure Solenoid A
53P B Pilot Control Relay Out W 0.8 GXL SFL, Return to Travel Switch 2 SPL-D25, Ultrasonic A
53P C Pilot Control Relay Out W 1.0 GXL SPL-D25, Ultrasonic A ECD, Elect Center D D6
53P D Pilot Control Relay Out W 0.8 GXL SHC, Height Control Switch 2 SPL-D25, Ultrasonic A
53P E Pilot Control Relay Out W0.8 GXL SRTD, Detent Switch 2 SPL-D25, Ultrasonic A
53P F Pilot Control Relay Out W 0.8 GXL CAB-F, Cab Front Chassis 19 SPL-D25, Ultrasonic A
53P G Pilot Control Relay Out W1.0SXL FRONT, Cab Front Chassis 19 SPL-A3, Ultrasonic A
53P H Pilot Control Relay Out W1.0SXL SPL-A3, Ultrasonic A PXF,RTD c
53P I Pilot Control Relay Out W 1.0 SXL PXM, RTD c PXT,RTD c
53P J Pilot Control Relay Out W 1.0 SXL SPL-A3, Ultrasonic A PXH, Height Control RTT c
54A Height Control Switch Power W 0.8 GXL SHC, Height Control Switch 6 EM, RTD Height Control RTT 2
54B Height RTT Control Signal W 1.0 SXL FRONT, Cab Front Chassis 11 PXH, Height Control RTT A
54B A Height RTT Control Signal W 0.8 GXL CAB-F, Cab Front Chassis 11 SPL-D1, Ultrasonic A
54B B Height RTT Control Signal W 0.8 GXL EM, RTD Height Control RTT 5 SPL-D1, Ultrasonic A
54B c Height RTT Control Signal W 0.8 GXL SFL, Return to Travel Switch 6 SPL-D1, Ultrasonic A
55AA RTT Float Sw Power W 0.8 GXL EM, RTD Height Control RTT 1 SPL-RTT, Ultrasonic A
55A B RTT Float Sw Power W 0.8 GXL SFL, Return to Travel Switch 1 SPL-RTT, Ultrasonic A

4002-33

21C Bk- 1.0
----
T I

Color, Size,
and Material
55A C RTT Float Sw Power W 0.8 GXL SFL, Return to Travel Switch 3 SPL-RTT, Ultrasonic A
55B RTT Float Switch Control W 0.8 GXL SFL, Return to Travel Switch 5 EM, RTD Height Control RTT 6
56 A Fan Control PWM W 1.0 SXL ENG, Engine Cab 23 YFN, Fan PWM Solenoid A
57 A Pin Engage Sol Pwr W 0.8 GXL CAB-F, Cab Front Chassis 20 SPL-PINE, Ultrasonic A
57 B Pin Engage Sol Pwr W 0.8 GXL SPE, Pin Engage Switch 1 SPL-PINE, Ultrasonic A
57 c Pin Engage Sol Pwr W 0.8 TXL SPL-PINE, Ultrasonic A AIC-2, Adv Instrument Cluster 2 16
58C Ride Control Switch Jumper WO.B GXL SRC, Ride Control Switch 5 SRC, Ride Control Switch 3
58H A Ride Control Sw Pwr VPS2 W 0.8 TXL TECM, Trans 8 ECD, Elect Center D 07
58L Ride Control Relay LSD Bk 0.8 TXL TECM, Trans 57 ECD, Elect Center D BB
58S E Ride Control Sol to Front Cab W 1.0 SXL FRONT, Cab Front Chassis 21 YRC, Ride Control Option 1
58T Ride Control Relay Sw Pwr W 0.8 GXL SRC, Ride Control Switch 4 ECD, Elect Center D B7
58 A Ride Control Sol Pwr W1.0SXL 202M, Rollback Jumper A 202M, Rollback Jumper B
58 B Ride Control Sol Pwr W1.0SXL FRONT, Cab Front Chassis 21 PRBF, Rollback Pressure Switch B
58 c Ride Control Sol Pwr W 0.8 GXL CAB-F, Cab Front Chassis 21 SPL-026, Ultrasonic A
58 D Ride Control Sol Pwr W 0.8 GXL 140M, Diode Module D SPL-026, Ultrasonic A
58 E Ride Control Sol Pwr W 0.8 GXL SPL-026, Ultrasonic A ECD, Elect Center D DB
58 F Ride Control Sol Pwr W 0.8 GXL SRC, Ride Control Switch 6 SPL-026, Ultrasonic A
590 Hood Relay Control Down W1.0GXL CAB-E, Cab Engine 37 ECC, Work Lights 03
59DA Hood Relay Control Down W 1.0 SXL ENG, Engine Cab 37 HD, Hood Switch A
59U Hood Relay Control Up W 1.0 GXL CAB-E, Cab Engine 39 ECC, Work Lights 01
59U A Hood Relay Control Up W 1.0 SXL ENG, Engine Cab 39 HD, Hood Switch c
600 Hood Down Relay Out W 1.0 GXL CAB-E, Cab Engine 36 ECC, Work Lights B3
600 A Hood Down Relay Out W 1.0 SXL ENG, Engine Cab 36 HOM, Hood Lift Motor 2
60U Hood Up Relay Out W1.0GXL CAB-E, Cab Engine 38 ECC, Work Lights B1
60U A Hood Up Relay Out W 1.0 SXL ENG, Engine Cab 38 HOM, Hood Lift Motor 1
61A Trinary Press Sw Input W 1.0 SXL ENG, Engine Cab 30 PR, Trinary Press Sw A
61A B Trinary Press Sw Input W 0.8 GXL CAB-E, Cab Engine 30 HVAC1, HVAC1 1
61C AC Relay Out Or 0.8 GXL CAB-E, Cab Engine 2 ECD, Elect Center D 010
61CA AC Relay Out Or 1.0 SXL ENG, Engine Cab 2 ACT, AC Comp Clutch 1
61C B AC Relay Out Or 1.0 SXL ENG, Engine Cab 2 ACT-9, AC Comp Clutch 1
61R AC Relay Control W 1.0 SXL ENG, Engine Cab 29 PR, Trinary Press Sw B

4002-34

21C Bk- 1.0
----
~ T I

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

CAN2, CAN Bulk Head EDC7, Engine Controller 35
TWIST

4002-35

21C Bk- 1.0
----
T I

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

4002-36

21C Bk- 1.0
----
~ T I

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

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

4002-37

21C Bk- 1.0
----
T I

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

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

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

4002-39
STARTING AND CHARGING SYSTEMS
10
BS06H241 I BS06H242
1. STARTING RELAY 7. TIME DELAY MODULE

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

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

Continuity Bad ground connection.
ground
Between the B+ terminal of Check circuit to positive post of left battery. Bad master
24 volts
alternator and ground disconnect switch.
Between terminal for wire 1-BA and

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

4002-41
4 - Crank Control Relay

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

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

4002-42
7 - Time Delay Module

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

Terminal for wire 1ON to ground 24 volts
and wire 1OM to fuse ECC F5.
Terminal for wire 13K-A to ground 24 volts Bad ignition switch (1 0), also check circuit 13K.
NOTE: Put the ignition switch in the ON position. Turn ignition switch to the OFF position. After 30 seconds time
delay an audible click will be heard.
Within 30 seconds of putting the 24 volts

ignition switch in the OFF position, Key OFF
Bad time delay module.
check terminal for wire 130 to 0 volt after 30
ground seconds
After 30 seconds of turning ignition

switch to the OFF position, check 0 volt Bad time delay module.
terminal for wire 130 to ground
8- Master Disconnect Switch

Located on right side battery box cover, remove battery box cover to gain access.
Correct
Reading
NOTE: Disconnect cables from both terminals of master disconnect switch (main contact). Put master disconnect
switch in ON position.
Between terminals of master

Continuity If there is no continuity, the master disconnect switch (2) is bad.
disconnect switch
NOTE: Put the master disconnect switch in the OFF position.
Between terminals of master Open Circuit If there is continuity, the master disconnect switch is bad.
disconnect switch
NOTE: Use the same method to check the master disconnect switch (auxiliary contact).

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

ground
Starter B+ stud to ground 24 volts Check circuit to batteries.
NOTE: Put the transmission in NEUTRAL. Have another person hold the ignition switch in the START position.
Bad starting relay (1 ). Also check wire 1-BB between starter

Terminal S to ground 24 volts
and starting relay (1 ).
NOTE: If the readings are good, repair or replace the starter.
10 - Ignition Switch
Located on steering column.
Correct
Reading
Terminal for wire 1A to ground 24 volts Check circuit 1A to ECC-F5 fuse.
NOTE: Disconnect the connector from the ignition switch. Turn the switch to ON.
Between Bat and lgn Continuity Bad ignition switch.
Between Bat and Accessory Continuity Bad ignition switch.
NOTE: Hold the ignition switch in the START position.
Between Bat and Starter Continuity Bad ignition switch.
Between Bat and lgn Continuity Bad ignition switch.
NOTE: Put the switch in the Accessory position.
Between Bat and Accessory Continuity Bad ignition switch.

4002-44
11 - Neutral Start Relay

Correct
Reading
Terminal for wire O-DE to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Make sure transmission is in NEUTRAL.
Terminal for wire 25T to ground 24 volts Check circuit 25T, check FNR switch (55).
NOTE: Have another person hold the ignition switch in the START position.
Terminal for wire 21 K-B to ground 24 volts Check circuit 21 K-B and ignition switch (1 0).
Terminal for wire 21 C to ground 24 volts Bad neutral start relay.
12 - Voltmeter Relay
Correct
Reading
Terminal for wire 0-DB to ground Continuity Bad ground circuit.
Check circuit 18R to power relay module C in engine

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

4002-45
POWER RELAY MODULES AND COLD STARTING SYSTEMS
BS06H241 I BS06H242
13. POWER RLEAY MODULE A 18. POWER RELAY MODULE D

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

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

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

Terminal for wire 1CB-A to ground 24 volts
compartment, check circuit breaker.
Terminal for wire 13K-B to ground 24 volts Check circuit 13K and check ignition switch (1 0).
Terminal for wire J1 BUSS to ground 24 volts Bad power relay module A.
14 - Power Relay Module B, Ignition Power

Correct
Reading
Terminal for wire 0-EA to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch in the ON position. Turn the ignition switch to the ON position.
Terminal for wire PRM-B BUSS to Check circuit 1CB to 105 Amp circuit breaker in engine
24 volts
ground compartment, check circuit breaker.
24 volts Check circuit 13 to Time Delay Module, check TDM (7), check
Terminal for wire 130 to ground
ignition switch (1 0).
Terminal for wire 13H to ground 24 volts Bad power relay module B.
15 - Power Relay Module C, For Fuel Filter Heater and Water Separator Heater
Correct
Reading
NOTE: Make sure engine temperature is below -0° C (32° F).
Terminal for wire 0-GA to ground Continuity Bad ground circuit or bad EDC7 (24).
Terminal for wire 1-NC to ground 24 volts Check circuit 1 and circuit to batteries.
Terminal for wire 28F to ground 24 volts Check EDC7 (24).
Terminal for wires 1-GA ground 24 volts Check 40 ampere fuse, bad power relay module.

4002-47
16 - Grid Heater Relay

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

Resistance If an open or short circuit is obtained, replace the grid heater.
to ground
18 - Circuit breaker Cab B+

Correct
Reading
Between terminal A and Bon circuit

Continuity Bad circuit breaker
breaker
19 - Water Separator Heater

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

4002-48
20 - Fuel Fi Iter Heater

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

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

24 volts Bad power relay module D.
ground

4002-49
ENGINE CONTROLLER
BS06H241 I BS06H242
22. WATER IN FUEL SENSOR

23. THROTTLE POTENTIOMETER
24. ENGINE CONTROLLER

4002-50
22 - Water In Fuel Sensor

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

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

4002-51
24 - Electronic Diesel Control

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

Continuity Bad ground circuit.
ground
Terminal for wire 0-BF pin 6 to
ground
Terminal for wire 0-BD pin 10 to
ground
Terminal for wire 0-BC pin 11 to
ground
NOTE: Put the master disconnect switch in the ON position. Put the ignition switch in the ON position.
Terminal for wire 18J-C pin 2 to 24 volts Bad fuse ECD-F2, bad wire 18J.
ground
Terminal for wire 18J-B pin 3 to
24 volts Bad fuse ECD-F2, bad wire 18J.
ground
Terminal for wire 18J-D pin 8 to

ground
Terminal for wire 18J-E pin 9 to

ground
NOTE: Use diagnostic service tool for additional tests on EDC7.

4002-52
RETURN TO TRAVEL- RETURN TO DIG - PIN ENGAGE
BS06H241 I BS06H242
25. RETURN TO TRAVEL FLOAT SWITCH 30. HEIGHT CONTROURETURN TO TRAVEL PROXIMITY SWITCH
26. HEIGHT CONTROL SWITCH 31. RETRUN TO DIG SWITCH
27. ELETROMAGNETIC DETENTS 32. PIN ENGAGE SWITCH (OPTION)
28. RETURN TO DIG PROXIMITY SWITCH 33. PILOT PRESSURE SOLENOID
29. PILOT CONTROL RELAY ECD-K3 34. PIN ENGAGE SOLENOID (OPTION)

4002-53
25 - Return-To-Travel/Float Switch
Located on right side console.
Correct
Reading
Terminal for wire O-B2 to ground Continuity Bad ground circuit.
Terminal for wire 0-29 to ground Continuity Bad ground circuit.
NOTE: Disconnect the wiring harness connector from the return-to-travel/float switch. Put the return-to-
travel/float switch in FLOAT position.
Between switch terminals 1 and 2 Continuity Bad return-to-travel/float switch.
NOTE: Put the return-to-travel/float switch in the TRAVEL position.
Between switch terminals 2 and 3 Continuity Bad return-to-travel/float switch.
NOTE: Put ignition switch in OFF position. Connect wiring harness connector to return-to-travel/float switch. Put
ignition switch in ON position. Put driving lamp switch (95) in position 3.
Bad circuit 49-K. Also check driving lamp switch (95). If

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

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

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

24 volts Bad height control switch. Also check wires 54A.
to ground
NOTE: Place the return to dig switch in the ON position.
Wiring harness connector EM, pin 3 24 volts Bad return to dig switch. Also check wires 53A.
to ground
28 - Return-To-Dig Proximity Switch

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

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

4002-55
29 - Pilot Control Relay

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

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

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

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

4002-56
32 - Pin Engage Switch (Option)

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

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

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

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

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

4002-58
35 - Ride Control Switch

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

Continuity Bad ride control switch.
(positive) to terminal 7 (negative)
NOTE: Connect connector SRC to ride control switch. Put master disconnect switch and ignition switch in ON
position. Put ride control switch in OFF position.
24 volts Check fuse ECA-F5 and power relay module A. Also check
Terminal for wire 19C-D to ground
circuit 19C.
Terminal for wire 58C to ground 0 volt Bad ride control switch.
NOTE: Put the ride control switch in the ON position.
Terminal for wire 58C to ground 24 volts Bad ride control switch.
NOTE: Put the driving light switch (95) in position 3.
Check driving lamp switch (95). Also check circuit 49. If LED in
Terminal for wire 49-G to ground 24 volts ride control switch is not ON with 24 volts at check point,
replace ride control switch.
36 - Ride Control Relay

Correct
Reading
Terminal 85 for wire 58L to

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

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

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

4002-59
37 - Fan Reversing Switch (Option)

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

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

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

Correct
Reading
NOTE: Put master disconnect switch and ignition switch in ON position.
Terminal for wire 19P-D and 19P-E

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

4002-60
39 - Pilot Control Switch

Located on steering column pedestal.
Correct
Reading
Terminal for wire OB1 to ground Continuity Bad ground circuit.
Terminal for wire 19C to ground 24 volts Bad fuse ECA-F1, also check circuit 19C.
NOTE: Press pilot control switch to turn ON switch LED.
Terminal for wire 31 L to ground 24 volts Bad pilot control switch.
NOTE: Put the driving lamp switch (95) in position 3.
24 volts Check driving lamp switch (95) and fuse ECC-F3. Also check
Terminal for wire 49-N to ground
circuit 49.
NOTE: If the readings are correct replace the pilot control switch.
40 - Ride Control Solenoid

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

control solenoid
41 - Rollback Pressure Switch (Option)

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

switch
Terminal for wire 588 to ground 37 to 43 ohms Bad ride control solenoid (40).
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put the ride control switch
(35) in the ON position. Accelerate the machine to at least 5 kmlhr (3 m.p.h.).
24 volts at
Bad ride control relay (36) or ride control switch (35). Also
Terminal for wire 58-B to ground 5 kmlhr
check circuit 58.
(3 m.p.h.)

4002-61
42 - Rollback Jumper (Option)

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

switch
43 - Fan PWM Solenoid (Option)

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

YFN to ground
NOTE: In the options menu of the instrument cluster select auto for the fan. Stall the transmission to raise
transmission temperature to high operating range.

24 volts Bad instrument cluster. Also check wire 56.
YFN to ground
44 - Fan Reversing Solenoid (Option)

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

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

YFR to ground
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Put fan reversing switch in ON
position (hold rocker in momentary position).

24 volts Bad fan reversing switch. Also check wire 52-A.
YFR to ground

4002-62
TRANSMISSION
BS06H241 I BS06H242
45. OUTPUT SPEED SENSOR 54. TRANSMISSION ENABLE SWITCH

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

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

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

4002-64
WARNING BUZZER, INSTRUMENT CLUSTER 1, PARK BRAKE
BS06H241 I BS06H242
62. INSTRUMENT CLUSTER CONNECTOR 1 66. AIR FILTER RESTRICTION SWITCH

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

4002-65
62 - Instrument Cluster Connector 1

Located on instrument cluster.
Correct
Reading
NOTE: Disconnect the connector AIC-1 from the instrument cluster and SW-PD from the switch pad.
Connector terminal SW-PD 5 to

Open Circuit Bad air filter restriction switch (66). Also check circuit 31 F-A.
ground
Connector terminal SW-PD 4 to Bad hydraulic filter restriction switch (72). Also check circuit
Open Circuit
ground 31 H-A.
Connector terminal AIC-1 6 and 12

Continuity Bad ground circuit. Check wires 0-DW and 0-DX.
to ground
Connector terminal AIC-1 11to 130 to 9500 Bad engine coolant temperature sender (68). Also check circuit
ground ohms circuit 36C-A and ground circuit at sender.
Connector terminal AIC-1 2 to Bad fuel level sender (65). Also check circuit 36F-A and ground
33 to 240 ohms
ground circuit at sender.
Connector terminal AIC-1 9to 130 to 9500 Bad hydraulic oil temperature sender (73). Also check circuit
ground ohms 36H-A and ground circuit at sender.
Connector terminal AIC-1 25 to

Continuity Bad wire 17P-A.
connector terminal SW-PD 9

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

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

SW-PD 7 to terminal 25 on the
Continuity Bad circuit CAN-H.
transmission electronic control
module (53)
Connector terminal AIC-1 15 to Check LH and RH stop lamps and circuit 44A-B. Also check
Continuity
ground ground circuit at lamps.
NOTE: Put the parking brake switch in the ON position.
Connector terminal AIC-1 14to Bad parking brake switch. Also check fuse ECA-F6 and circuit
24 volts
ground 190 and 52C.
NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
Check fuse G, blower switch, thermostat switch, and A/C low

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

4002-66
NOTE: Put the driving lamp switch in position four or five. Put the high/low beam switch in HIGH BEAM position.
Connector terminal SW-PO 1to Check high/low beam switch, driving lamp switch, and fuse
24 volts
ground ECC-F3. Also check circuit 41 H-0.
Connector terminal AIC-1 14 to Bad parking brake relay or fuse ECA-F6. Also check circuits
24 volts
ground 52C and 190.
Connector terminal AIC-1 20 to Bad pilot control relay or fuse ECA-F5. Also check circuits 53C
24 volts
ground and 19C.
63 - Warning Buzzer
Located on steering column under instrument cluster.
Correct
Reading
I I
NOTE: Buzzer sounds for five seconds during self test when ignition switch is turned on.
Terminal for wire O_B27 to ground Continuity I Bad ground circuit.

I
NOTE: Turn the ignition switch to the ON position
Terminal for wire 35B to ground 24 volts I Bad instrument cluster

I
NOTE: If all readings are good, replace buzzer.
64 - Parking Brake Relay

Correct
Reading
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the parking brake
switch (74) is OFF.
Terminal for wire 190-B and 190-C

24 volts Bad fuse ECA-F6, also check circuit 190.
to ground
Terminal for wire 52C to ground 0 volt Bad instrument cluster (62). Also check circuit 52C.
Terminal for wire 52P-B to ground 24 volts Bad parking brake relay.
NOTE: Put the parking brake switch in the ON position.
Terminal for wire 52C to ground 24 volts Bad instrument cluster (62). Also check wire 52C.

4002-67
65- FuelleveiSender
Located on the fuel tank top right side.
Correct
Reading
Terminal for wire 0-BU to ground Continuity Bad ground circuit.
Approximately
Terminal for wire 36F to ground Check the instrument cluster (62).
5 volts
NOTE: Put the ignition switch and the master disconnect switch in the OFF position. Tag and disconnect the wires
from the fuel level sender.
Between terminals of fuel level 33 to 240

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

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

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

4002-68
68 - Radiator Coolant Temperature Sender

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

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

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

Continuity Bad brake warning pressure switch.
switch
NOTE: Start and run the engine at idle two minutes.
Bad brake warning pressure switch or brake pressure is below

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

4002-69
SWITCH PAD, INSTRUMENT CLUSTER 2, PARK BRAKE
BS06H241 I BS06H242
70. SWITCH PAD 74. PARK BRAKE SWITCH

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

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

I

4002-71
71 - Instrument Cluster Connector 2

Located on instrument cluster.
Correct
Reading
NOTE: Disconnect the connector AIC-2 from the instrument cluster and SW-PD from the switch pad.
Connector terminal AIC-2 5 to Bad brake warning pressure switch (69). Also check circuit
Continuity
ground 33P-A and ground circuit at brake warning pressure switch.
Connector terminal AIC-2 26 to Bad coolant level sender (77). Also check circuit 31 D-A and
Continuity
ground ground circuit at coolant level sender.
Connector terminal AIC-2 11 to Bad secondary steering pressure switch (118). Also check
Continuity
ground circuit 35X and ground circuit at pressure switch.
Connector terminal 8W-PD 5 to

Open Circuit Bad air filter restriction switch (66). Also check circuit 31 F-A.
ground
Connector terminal 8W-PD 4 to Bad hydraulic filter restriction switch (72). Also check circuit
Open Circuit
ground 31 H-A.
Connector terminal AIC-2 15 and 22

Continuity Bad ground circuit. Check wires 0-DB and 0-D-A.
to ground.

Open Circuit Bad redundant brake switche(s) (75). Also check circuit 33R.
ground
Connector terminal AIC-2 14 and 20 Bad fuse ECD-F3. Also check circuit 198-C and 198-D. Also
24 volts
to ground check power relay module B (14).
Connector terminal AIC-2 21 to Bad fuse ECA-F3. Also check circuit 19E-A. Also check power
24 volts
ground relay module A (13).
NOTE: Put the blower switch in any position other than OFF and thermostat switch fully clockwise.
Check fuse G, blower switch, thermostat switch, and A/C low

Connector terminal 10 to ground 24 volts
pressure switch. Also check circuits 61 R, 61A, and 61T.
NOTE: Put the driving lamp switch in position four or five. Put the high/low beam switch in HIGH BEAM position.
Connector terminal 8W-PD 1to Check high/low beam switch, driving lamp switch, and fuse
24 volts
ground ECC-F3. Also check circuit 41 H-D.
NOTE: Put the turn signal switch in the LEFT TURN position.
24 volts on and Check fuse ECA-F8, turn signal switch, and flasher module.
Connector terminal AIC-2 9to off every 1-2 Also check wire 19B, circuit 45A-A to flasher module, and
ground
seconds circuit 45L from flasher module to instrument cluster.
NOTE: Put the turn signal switch in the RIGHT TURN position.
24 volts on and Check fuse ECA-F8, turn signal switch, and flasher module.
Connector terminal AIC-2 1Oto
off every 1-2 Also check wire 19B, circuit 45B-A to flasher module, and
ground
seconds circuit 45R from flasher module to instrument cluster.
Connector terminal AIC-2 18to Bad pilot control switch or fuse ECA-F1. Also check wire 31 L
24 volts
ground and circuit 19A.

4002-72
72 - Hydraulic Filter Restriction Switch

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

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

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

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

4002-73
74 - Parking Brake Switch

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

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

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

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

4002-74
77 - Coolant Level Sender

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

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


4002-76
78 - Back-up Alarm Relay

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

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

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

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

4002-78
80 - Work Lamps Switch

Correct
Reading
Terminal for wire O-B14 to ground Continuity Bad ground circuit
NOTE: Put master disconnect witch in the ON position.
Terminal for wire 42-A and 42-B to

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

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

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

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

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

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

4002-80
86 - Right Hand Front Work Lamp

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

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

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

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

4002-82
LIGHTS- 02
BS06H241 I BS06H242
90. BRAKE LIGHTS SWITCH 93. HAZARD SWITCH

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

4002-83
90 - Brake Lamp Pressure Switch

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

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

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

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

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

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

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

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

4002-86
95 - Driving Lamp Switch

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

I
Terminal for wire 41 J to ground 24 volts I Bad driving lamp switch.

I

4002-87
LIGHTS - 03 AND HORN
BS06H241 I BS06H242
96. LEFT HAND FRONT COMBINATION LAMPS 98. HORN RELAY

97. RIGHT HAND FRONT COMBINATION LAMPS 99. HORN

4002-88
96 - Left Hand Front Combination Lamp

Located on the left front of the machine.
Correct
Reading
NOTE: Disconnect wiring harness connector LF from LH front combination lamp connector.
Combination lamp connector pin 3 to

Continuity Bad high beam lamp bulb.
pin 1

Continuity Bad position lamp bulb.
pin 1

Continuity Bad low beam lamp bulb.
pin 1

Continuity Bad turn signal lamp bulb.
pin 1
NOTE: Connect wiring harness connector LF to LH front combination lamp connector.
Terminal for wire 0-AJ to ground Continuity Bad ground circuit.
24 volts Check fuse ECB-F7 and driving lamp switch (95). Also check
Terminal for wire 18F to ground
circuit 18F.
NOTE: Put high/low beam lever (94) in HIGH beam position.
Check fuse ECB-F3, high/low beam relay (80), driving lamp

Terminal for wire 18B to ground 24 volts switch (95), and high/low beam switch (94). Also check circuit
18B and wire 41H.
NOTE: Put high/low beam lever (94) in LOW beam position.
24 volts Check fuse ECB-F6, driving lamp switch (95), and high/low
Terminal for wire 180 to ground
beam switch (94). Also check circuit 180 and wire 41 L-A.
NOTE: Put ignition switch in ON position. Put turn signal lever in LEFT turn position.
Intermittent 24 Check the turn signal switch (94) and flasher module (92). Also
Terminal for wire 45L to ground
volts check circuit 45L to flasher module.
NOTE: If all readings are good, and lamps still do not turn ON replace the LH front combination lamp.

4002-89
97 - Right Hand Front Combination Lamp

Located on the right front of the machine.
Correct
Reading
NOTE: Disconnect wiring harness connector RF from RH front combination lamp connector.

Continuity Bad high beam lamp bulb.
pin 1

Continuity Bad position lamp bulb.
pin 1

Continuity Bad low beam lamp bulb.
pin 1

Continuity Bad turn signal lamp bulb.
pin 1
NOTE: Connect wiring harness connector RF to RH front combination lamp connector.
Terminal for wire 0-AH to ground Continuity Bad ground circuit.
24 volts Check fuse ECB-F8 and driving lamp switch (95). Also check
Terminal for wire 18G-A to ground
circuit 18G and wire 41T-A.
NOTE: Put high/low beam lever (94) in HIGH beam position.
Check fuse ECB-F4, driving lamp switch (95), and high/low

Terminal for wire 18C to ground 24 volts
beam switch (94). Also check circuit 18C and wire 41 H.
NOTE: Put high/low beam lever (94) in LOW beam position.
24 volts Check fuse ECB-F5, driving lamp switch (95), and high/low
Terminal for wire 18E to ground
beam switch (94). Also check circuit 18E and wire 41 L-C.
NOTE: Put ignition switch in ON position. Put turn signal/ever in RIGHT turn position.
Terminal for wire 45R to ground
volts check circuit 45R to flasher module.
NOTE: If all readings are good, and lamps still do not turn ON replace the RH front combination lamp.

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

4002-91
LIGHTS - 04 AND BACK UP ALARM
BS06H241 I BS06H242
100.RIGHT HAND REAR COMBINATION LAMPS 102.LICENSE PLATE LAMP

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

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

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

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

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

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

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

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

Located on the right rear of the machine.
Correct
Reading
NOTE: Disconnect wiring harness connector LRR-E from RH rear combination lamp connector.

pin 5

pin 5

pin 5

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

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

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

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

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

to pin D
Combination lamp connector pin C

to pin D
Combination lamp connector pin B

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

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

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

Correct
Reading
NOTE: Disconnect wiring harness connector LLR-E from LH rear combination lamp connector.

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

pin 5

pin 5

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

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

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

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

4002-96
102 - License Plate Lamp (Europe Only)

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

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

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

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

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

4002-97
CAB WINDOW WASHER AND WIPER SYSTEM
BS06H241 I BS06H242
104.FRONTWIPER HIGH SPEED RELAY 109.FRONTWIPER MOTOR

1OS .WIPER CUT OUT RELAY 11 O.REAR WIPER MOTOR
106.FRONTWIPER LOW SPEED RELAY 111.REAR WASHER MOTOR
107.REAR WIPER/WASHER SWITCH 112.FRONT WASHER MOTOR
108.FRONTWIPER/WASHER SWITCH 113.DIODES

4002-98
104 - Front Wiper High Speed Relay

Correct
Reading
Terminal for wire 19J-D and 19J-E to Bad fuse ECA-F12, check circuit 19J, also check power relay
24 volts
ground module D (21 ).
NOTE: Put the front wiper switch in the HIGH position.
Terminals for wire 63HC-B to ground Continuity Bad front wiper and washer switch (1 08).
Terminals for wire 63HC-B to ground 24 volts Bad wiper high speed relay.
NOTE: Put the front wiper switch in the LOW position.
Terminals for wire 63C2 to ground 24 volts Bad wiper high speed relay.
105 - Front Wiper Cut Out Relay

Correct
Reading
24 volts Check fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-G to ground
module D (21 ).
Terminal for wire 63L-B to ground 24 volts Bad wiper cut out relay.
Terminals for wire 63HC-A to ground Continuity Bad front wiper and washer switch (1 08).
Terminals for wire 63L-B to ground 0 volts Bad wiper cut out relay.

4002-99
106 - Front Wiper Low Speed Relay

Correct
Reading
Bad fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-F to ground 24 volts
module D (21 ).
NOTE: Put the front wiper switch in the LOW position.
Terminals for wire 63C to ground 24 volts Bad wiper low speed relay.
Terminals for wire 63LC to ground Continuity Bad front wiper and washer switch (1 08).
Bad wiper low speed relay, also check high speed wiper relay
Terminals for wire 63C3 to ground 24 volts
(1 04).
107 - Rear Wiper and Washer Switch

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

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

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

4002-100
108 - Front Wiper and Washer Switch

Correct
Reading
Terminal for wire 0-DT to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Make sure the front wiper and
washer switch is in the OFF position.
Check fuse ECA-F12, check circuit 19J, also check power relay
Terminal for wire 19J-B to ground 24 volts
module D (21 ).
NOTE: Put the front wiper and washer switch in the LOW position.
Continuity Bad front wiper and washer switch also check grounding
Terminal for wire 63LC to ground
circuit.
NOTE: Put the front wiper and washer switch in the HIGH position.
Bad front wiper and washer switch also check grounding

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

4002-101
109 - Front Wiper Motor

Located in front of steering column.
Correct
Reading
NOTE: Make sure the front wiper and washer switch (108) is in the OFF position.
Between terminals Band D for wires

Continuity Bad front wiper motor.
63C and 63L
Terminal for wire 19J to ground 24 volts Check fuse ECA-F12, also check circuit 19J.
NOTE: Put the front wiper and washer switch (108) in the LOW position.
Check fuse ECA-F12, also check circuit 19J. Bad front wiper
Terminal for wire 63L-A to ground 24 volts
and washer switch (1 08), low speed relay or cut out relay.
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (75)
NOTE: Put the front wiper and washer switch (108) in the HIGH position.
Check fuse ECA-F12, also check circuit 19J. Bad front wiper
Terminal for wire 63H-A to ground 24 volts
and washer switch (1 08), high speed relay or cut out relay.
Terminal for wire 63C to ground 0 volt Bad front wiper and washer switch (1 08).
NOTE: Put the front wiper and washer switch in the intermittent position.
Terminal for wire 63L to ground 24 volts pulse Bad front wiper and washer switch (1 08).
Terminal for wire 63C to ground 24 volts pulse Bad front wiper and washer switch (1 08).
NOTE: If the readings are good, replace the front wiper motor.

4002-102
110 - Rear Wiper Motor

Located in top of rear cab head liner.
Correct
Reading
Terminal for wire 0-MA to ground Continuity Bad ground circuit.
NOTE: Make sure the rear wiper and washer switch (107) is in the OFF position.
Between terminals for wires 68C-A

Continuity Bad rear wiper and washer switch (1 07).
and 68L-A
Terminal for wire 19K-C to ground 24 volts Check fuse ECA-F13, also check circuit 19K.
NOTE: Put the rear wiper and washer switch (107) in the ON position.
Terminal for wire 68C-A to ground 24 volts Bad rear wiper and washer switch (1 07).
Terminal for wire 68L-A to ground 0 volt Bad rear wiper and washer switch (1 07).
NOTE: If the readings are good, replace the rear wiper motor.
111 - Rear Washer Pump Motor

Located in left side engine compartment.
Correct
Reading
Terminal for wire 0-BL to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Depress and hold rear wiper and washer
switch (107) in WASH position.
24 volts Bad rear wiper and washer switch (1 07) Also check wires
Terminal for wire 68W-A to ground
68W-A and 68W.
NOTE: If the readings are good, replace the rear washer pump motor.
112 - Front Washer Pump Motor

Located in left side engine compartment.
Correct
Reading
Terminal for wire 0-B to ground Continuity Bad ground circuit.
NOTE: Put the master disconnect switch and the ignition switch in the ON position. Connect volt meter to check
point then push down on front wiper and washer switch (108).
Bad front wiper and washer switch (1 08), also check circuit
Terminal for wire 63W-A to ground 24 volts
63W.
NOTE: If the readings are good, replace the front washer pump motor.

4002-103
113 - Wiper Diodes

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

4002-104
SECONDARY STEERING
BS06H241 I BS06H242
114.SECONDARY STEERING DIODES 117.SECONDARY STEERING MOTOR

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

4002-105
114 - Secondary Steering Diodes

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

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

36 to 42 ohms Bad secondary steering solenoid.
steering solenoid
Between pin 2 of connector YSS and

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

4002-106
116 - Secondary Steering Module (Option)

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

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

Pin 8 of connector SSM to ground Continuity
wires 35X-D, 35X-C, and 35X-A.
Open Circuit Bad secondary steering pressure switch (118). Also check wire
Pin 9 of connector SSM to ground
51 P-A.
NOTE: Put the master disconnect switch and the ignition switch in ON position.
Pin 3 of connector SSM to ground 24 volts Bad wire 19S1-X to power relay module A fuse 2 (13).
Pin 7 of connector SSM to ground 24 volts Bad fuse ECA-F17 or ignition switch. Also check circuit 19M.
Check fuse ECA-F4, power relay module A (13), ignition

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

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

4002-107
117 - Secondary Steering Motor (Option)

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

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

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

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

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

4002-108
CAN COMMUNICATION
BS06H241 I BS06H242
119.DIAGNOSTIC CONNECTOR

4002-109
119 - CAN Communication Diagnostics Connector

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

4002-110
RADIO AND POWER CONVERTER
BS06H241 I BS06H242
120.POWER RELAY MODULE E 123.RADIO

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

4002-111
120 - Power Relay Module E

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

Correct
Reading
Terminal for wire 0-EJ to ground Continuity Bad ground circuit.
Terminal for wire 19L-B and 19L-A to

24 volts Bad fuse F1 in power relay module E, also check circuit 19L.
ground
Terminal for wire 12V-C to ground 12 volts Bad power converter.
122 - Power Outlet (Option)

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

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

4002-112
123 - 12 Volt Radio Ready (Option)

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

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

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

Continuity Bad circuit between the right speaker and the radio (123).
RSPK to ground
NOTE: If the readings are good, replace the right speaker.
125 - Left Speaker (Option)

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

Continuity Bad circuit between the left speaker and the radio (123).
LSPK to ground
NOTE: If the readings are good, replace the left speaker.

4002-113
AIR SEAT- CIGAR LIGHTER -AIR CONDITIONING COMPRESSOR
BS06H241 I BS06H242
126.AIR SEAT 129.HIGH/LOW SWITCH

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

4002-114
126 - Seat Compressor and Switch (Option)

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

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

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

Correct
Reading
Terminal for wire 0-DJ to ground Continuity Bad ground circuit.
NOTE: Put master disconnect switch and ignition switch in ON position. Put blower switch (137) to HIGH and
thermostat switch to COLD.
Terminal for wire 61 R-B to ground 24 volts Check thermostat switch, also check wire 61 R-B.
Terminal for wire 61 C to ground 24 volts Bad compressor clutch relay.
NOTE: Put ignition switch in OFF position. Disconnect wiring harness connector PR from A/C trinary pressure
switch. Connect a jumper wire between pins A and 8 of connector PR. Put ignition switch in ON position.
Terminal for wire 61 R-C to ground 24 volts Check wires 61 R-B and 61 R.

4002-115
129 - A/C High/Low Pressure Switch

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

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

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

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

4002-116
HEATING, VENTILATION, AND AIR-CONDITIONING
BS06H241 I BS06H242
131.AIR RECIRCULATION MOTOR 137.FAN SPEED SWITCH

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

4002-117
131 - Air Recirculation Motor

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

4002-118
133 - Electronic Water Valve

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

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

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

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

Bad blower motor resistor.
resistor 7.0 ohm

5.5 ohm Bad blower motor resistor.
resistor

Bad blower motor resistor.
resistor 3.5 ohm
135 - Blower Motor

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

4002-119
136 - Thermostat
Correct
Reading
I I
NOTE: Disconnect wires from switch. Thermostat contacts closed at or above 5°C (40° F).
Terminal to terminal Continuity I Bad thermostat switch

I
137 - Blower Switch

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

I

I

I

I
138 - Air Conditioning Switch

Correct
Reading
I I
terminal for wire DNS-2 to ground 24 volts I Check fuse ECA-F11, check circuit18N.
I
NOTE: Push AC switch to turn ON.
Terminal for wire DNS-68 to ground I 24 volts I Bad AC switch
139 - Control Panel Lights

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

4002-120
140 - Water Valve Potentiometer

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

heat position
Place potentiometer in mid range 2.5 volts Bad potentiometer

position
Place potentiometer in maximum 0 volts Bad potentiometer

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

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

I
NOTE: Place switch in recirculate air position.
Between terminals on switch Open I Bad recirculating switch.

I

4002-121
HOOD RAISE AND LOWER SYSTEM
BS06H241 I BS06H242
142.HOOD UP RELAY 144.HOOD SWITCH

143.HOOD DOWN RELAY 145.HOOD MOTOR

4002-122
142 - Hood Up Relay

Correct
Reading
NOTE: Turn the master disconnect switch ON.
Terminal for wire 19Y-A 24 volts Check fuse ECC-F7, check circuit 19Y.
NOTE: Hold the hood switch (144) in the raise position.
Terminal for wire 59U 24 volts Bad hood switch (144), check wire 59U.
Terminal for wire 60U 24 volts Bad hood up relay.
143 - Hood Down Relay

Correct
Reading
NOTE: Turn the master disconnect switch ON.
Terminal for wire 19Y-B 24 volts Check fuse ECC-F7, check circuit 19Y.
NOTE: Hold the hood switch (144) in the lower position.
Terminal for wire 590 24 volts Bad hood switch (144), check wire 590.
Terminal for wire 600 24 volts Bad hood down relay.
144 - Hood Switch

Located in the right battery compartment with the master disconnect switch.
Correct
Reading
NOTE: Disconnect connector HD, turn the master disconnect ON.
Terminal for wire 19Y-O to ground 24 volts Check fuse ECC-F7, check circuit 19Y.
Hold the hood switch in the raise

Continuity Bad hood switch.
position, between pin C and B
Hold the hood switch in the lower Continuity Bad hood switch.
position, between pin A and B

4002-123
145 - Hood Motor

Located in the left side of the engine compartment.
Correct
Reading
NOTE: Turn the master disconnect switch ON and disconnect connector HDM. Hold the hood switch (144) in the
raise position.
Bad hood up relay (142), bad hood switch (144), and check
Terminal for wire 60U-A 24 volts
fuse ECC-F7.
NOTE: Hold the hood switch (144) in the lower position.
Bad hood down relay (143), bad hood switch (144), and check
Terminal for wire 600-A 24 volts
fuse ECC-F7.
NOTE: If all readings are good replace the hood motor.

4002-124
CONNECTORS
CONNECTOR 108F- DIAGNOSTIC CONNECTOR CONNECTOR 197F- MAIN CAB FNR
10 06 I
(.)
20 w 0s I-
::::>
30 04 0
291663A1 225350C1
CAV WIRE IDENT CIRCUIT CAV WIRE IDENT CIRCUIT

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

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

4002-125
CONNECTOR 202M - ROLLBACK JUMPER CONNECTOR 20M -TRANSMISSION KICK-DOWN
SWITCH
mill
~
245482C1
CAV WIRE IDENT CIRCUIT 225316C1
A 58-A Ride Control Solenoid Power CAV WIRE IDENT CIRCUIT

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

JUMPER CONNECTOR 215F- ALTERNATOR RESISTOR
~
I I
245481C1 199436A1

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

JUMPER
~
I I
199436A1
CAV WIRE IDENT CIRCUIT

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

4002-126
CONNECTOR 64F- FLASHER CONNECTOR CONNECTOR AIC1 - ADV INSTRUMENT
CLUSTER 1
2 34 5 6 7
8
14
~7 13
' 19
gg
245481C1
20 21 22 23 24 25 26
1 45N-A Flasher Optional Side Control
87419488

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

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

4002-127
CONNECTOR AIC2 - ADV INSTRUMENT CONNECTOR BUZ- AIC BUZZER
CLUSTER 2
1234567
8
14
~l 13
19
2 1
101101
20 21 22 23 24 25 26
00
222136A1
87410948
CAV WIRE IDENT CIRCUIT 1 35B AIC Buzzer HSD
1 Not Used 2 O-B27 Buzzer Ground
2 43S-C Door Open Signal
3 Not Used
4 33R Redundant Brk Accm Press Low
5 33P-A Brake Low Pressure Warning
6 33U Park Brake Switch
7 52M Fan Reverse Manual
8 52AU Fan Reverse Auto
9 45L-E Left Turn Signal
10 45R-C Right Turn Signal
11 35X Sec. Steering Low Press Signal
12 Not Used
13 Not Used
14 19S-D AIC Delay Fused Power
15 0-DB AIC Power Ground Red
16 57-C Pin Engage Solenoid Power
17 21K-A Ignition Switch Start Signal
18 31L Pilot Control Switch High
19 Not Used
20 19S-C AIC Delay Fused Power
21 19E-A AIC Wake Up Ignition
22 0-DA AIC Chassis Ground
23 Not Used
24 Not Used
25 Not Used
26 31D-A Coolant Level Signal

4002-128
CONNECTOR CAB-E- CAB TO ENGINE CAV WIRE IDENT CIRCUIT
10 9 8 1 6 54 3 1 I 37 59D Hood Down Relay Control

0 Hood Up Relay Out
····!I
38 60U
I~....
•·.... . ...
II• • • • "
io.... . ...•
o • • •
-~
•21
II
0 11
39
40
59U
35A-F
Hood Up Relay Control
Backup Alarm Relay Out
0
40 39 38 37 36 35 34 33 31 31

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

4002-129
CONNECTOR CAB-F - CAB FRONT CHASSIS CONNECTOR CAB-RF- CAB TO ROOF
CONNECTION
HG F E C DB A
'
,;.='~~~~~~~~
J K L MN P R S
388710A1
291661A1 A 43-A Dome Light Auto Mode
CAV WIRE IDENT CIRCUIT B 42R-C Rear Work Light Fused Power
1 45L-C Left Turn Signal c 42C-A Front Work Lights Fused Power
2 51B-C Comfort Steering Solenoid Pwr D 19U-D Dome Light Fused Power
3 45R-D Right Turn Signal E 46-C Beacon Switch Power
4 Not Used F 0-DR Roof Splice Grounds
5 18G-G Position RH Fused Power G O-DS Roof Splice Grounds
6 18F-E Position LH Fused Power J 19K-C Rear Wiper Motor Fused Power
7 18B-A High Beam LH Fused Power K 68C Rear Wiper Park Control
8 36B Front Axle Temperature L 68L-B Rear Wiper Switch Power
9 0-DY Front Axle Temperature Ground M O-EM Radio Ground
10 Not Used N 12V-B 12V Fused Power to Radio
11 54B-A Height-RTT Signal R 43S-A Door Open Signal
12 53B-B RTD Signal s 19U-G Door Switch Fused Power
13 64A Horn Power

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

4002-130
CONNECTOR CAB-T- CAB TO TRANMISSION CONNECTOR CAN - CAN BULK HEAD
3031 82021
18 19 2 9 I 0
29 17 7 I 3 I 122
28 16 6 5 4 1223
2715141324
26 25

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

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

4002-131
CONNECTOR CL - CIGAR LIGHTER CONNECTOR D-OR - DIODE OR
245485C1

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

CONNECTOR CLS - COOL JUMP- COOL SEND
194788A1

A 310 Coolant Level Signal CAV WIRE IDENT CIRCUIT
B 0-HV Coolant Level Sender Ground A 0-DH Ground
B 18K-A Diagnostics Fused Power
CONNECTOR CNV- 24V TO 12V POWER c CAN-HB Controller Area Network High
CONVERTER D CAN-LB Controller Area Network Low
E 20G-B EDC7 ISO-K Interface
CONNECTOR DISC - DISCONNECT ENGINE
225351C1

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

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

4002-132
CONNECTOR OM - DIODE OR CONNECTOR DNS-CTRL-PANEL-LIGHT
ART NOT AVAILABLE

1 DNS69
2 DNS70
2454ssc1 CONNECTOR DNS-WATER-VALVE-POT

A 19RR Sec. Steering Ignition Fused Pwr ART NOT AVAILABLE
B Not Used
c 19R Sec. Steering Ignition Fused Pwr
1 DNS55
2 DNS54
CONNECTOR DNS-AC-SWITCH
ART NOT AVAILABLE CONNECTOR DNS-RECIRCULATING-SWITCH
CAV WIRE IDENT CIRCUIT ART NOT AVAILABLE

1 DNS72
2 DNS68
1 DNS51
4 DNS71
2 DNS53
CONNECTOR DNS-ACTUATOR
CONNECTOR DNS-THERMOSTAT-1
ART NOT AVAILABLE ART NOT AVAILABLE

CIRCUIT
5 DNS48
6 DNS49
CONNECTOR DNS-THERMOSTAT-2
CONNECTOR DNS-SPEED-SELECTOR
ART NOT AVAILABLE ART NOT AVAILABLE

CAV WIRE IDENT CIRCUIT I ~AV I D:~:· IDENT I CIRCUIT
1 DNS74
2 DNS61
3 DNS62 CONNECTOR DNS-ELECTRIC-FAN
4
5
DNS63
DNS73
ART NOT AVAILABLE
1 DNS65
2 DNS66

4002-133
CONNECTOR DNS-RESISTOR CONNECTOR DNS-HVAC1-S
ART NOT AVAILABLE

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

CONNECTOR DNS-ELECT-WATER-VALVE-S A DNS67
ART NOT AVAILABLE B

c
DNS76
DNS69
1 DNS60
CONNECTOR DNS-HVAC2-S
2 Not used
3 DNS56 2
4 DNS57
5 DNS58
6 DNS59
CONNECTOR DNS-DRIVER

1 DNS74
2 DNS75
411311A1

2 DNS50
3 DNS52
4 DNS49
5 DNS48
6 DNS55
7 DNS57
8 DNS58
9 DNS59
11 DNS51
12 DNS53
13 DNS54
14 DNS56

4002-134
CONNECTOR DS - DOOR SWITCH CONNECTOR E-HD - TRANSMISSION HOOD
245485C1
245482C1
A 18G-D Lie Plate Light Fused Power
A 19U-F Door Switch Fused Power
B 35A-G Backup Alarm Relay Out
B 43S-B Door Open Signal
c 0-BAG Hood Ground (EURO)

4002-135
CONNECTOR ECA- ELECTRICAL CENTER A
A c
I
0 0
2
0 0
3
0 0
.. 0 0
•0 0
•0 0
7
0 0
8
0 0
•0 0
.. o 0
0 D 0
87315248
CAV WIRE IDENT CIRCUIT L1 J6 Pltem Dints Park Brake Sol
A1 19A-N Transmission Fused Power L1 J7 Park Brake Solenoid Horn
A2 18L-A Comfort Steering Fused Power L1 J8 Fan Reverse/Turn Signal
A3 19E-A AIC Wake Up Ignition L1 J9 Turn Signal Engine Shutdown
Sec. Steering Ignition Fused L2 J11 Blower Motor Power

A4 19RR
Pwr L2 J12 Blower Mtr Front Wiper Washer
AS 19C-A Pilot Control Relay Fused Pwr
L2 J13 Front Wiper Rear Wiper Washer
A6 190-A Park Brake Relay Fused Power L2 J14 Rear Wiper Washer Backup
A? 19P Pin Engage/Fan Fused Power
L2 J15 Backup AC
A8 19B Turn Signal Fused Power L2 J16 AC Seat Compressor
A9 13G-B Fuel Shutoff Fused Power
Seat Compressor Emergency
L2 J18
C1 18N Blower Motor Fused Power Steering
C2 19J Front Wiper Fused Power

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

4002-136
CONNECTOR ECB - ELECTRICAL CENTER B
AAAr-B CD Q
Or-
t oo ooor-
2 00 000
4 00 000
3 00 000
I 00 000
I 00 000
7 00 000
8 00 000
8 00 000
to 00 000
o-- I J
~a
87312843
CAV WIRE IDENT CIRCUIT B3 21K-B Ignition Switch Start Signal
A1 42FS Front Work Lights Power B4 O-DE Neutral Start Relay Control Gnd
A2 42RS Rear Work Lights Power B5 21F EDC7 Digital Ground
A3 41H-B High Beam LH Power B6 0-DF Crank Request Relay Ctrl Gnd
A4 41H-C High Beam RH Power B7 19P-E Fan Reverse Relay Fused Pwr
AS 41L-C Low Beam LH Power B8 52 Fan Reverser LSD
A6 41L-B Low Beam RH Power B9 19D-C Park Brake relay Fused Pwr
A? 41T-B Position Lights LH Sw Power B10 52C Park Brake Solenoid LSD
AS 41T-A Position Lights RH Sw Power D1 13K-C Ignition Switch Power
A9 21H Crank Control Relay LSD D2 13V Voltmeter Input ANALOG
A10 21C-B Neutral Start Relay Output D3 25T Neutral Signal
AA1 42C-C Front Work Lights Fused Power D4 21C Neutral Start Relay Output
AA2 42R-C Rear Work Lights Fused Power D5 21C-A Neutral Start Relay Output
AA3 18B-A High Beam LH Fused Power D6 21E Key Switch Crank
AA4 18C-A High Beam RH Fused Power D7 19P-D Fan Reverse Relay Fused Pwr
AA5 18E-A Low Beam RH Fused Power DB 52A-A Fan Reverse Relay Out
AA6 18D-A Low Beam LH Fused Power D9 19D-B Park Brake Relay Fused Pwr
AA7 18F-C Pos Tail Lights LH Fused Power D10 52P-B Park Brake Relay Out
AA8 18G Pos Tail Lights RH Fused Power

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

4002-137
CONNECTOR ECC- ELECTRICAL CENTER C
A B C D
0 0
0
1 000
20 000
30 000
•0 000
50 000
eO 000
70 000
80 000
90 000
L1100 000
0 0~ 0
87315249
D4 19Y-B Hood Down Relay Fused Power
A1 19U-B Beacon/Dome Lt Fused Pwr
D5 44-A Brake Light Control Power
A2 42 Work Lights Sw Fused Pwr
D6 44A-A Brake Light Relay Out
A3 19Z Driving Lights Sw Fused Pwr
D7 19U-E Horn relay Fused Power
A4 1-DV Brake Us/Flasher Bat Pwr
D8 64-A Horn Power
AS 1DM Time Delay/lgn Sw Fused Pwr
D9 18L-B Comfort Steering Fused Power
A6 19U Horn Relay Fused Power
D10 51B-B Comfort Steering Solenoid Pwr
A7 19Y Hood Control Fused Power
L1-1 ECC-L 1 Beacon/Dome Lights Ll ECC
A8 19W Cigar Lighter Fused Power
L 1-1 J2-ECC Beacon/Dome Lt Work Lights
A9 18K-A Diagnostic Fused Power
L 1-2 J2-ECC Beacon/Dome Lt Work Lights
B1 60U Hood Up Relay Out
L 1-2 J3-ECC Work Lights Driving Lights
B2 O-B25 Hood Up Control Ground
L 1-3 J3-ECC Work Lights Driving Lights
B3 60D Hood Down Relay Out
L 1-3 J4-ECC Driving Lights Brake Lights
B4 O-B16 Hood Down Control Ground
1-DW L 1-4 J4-ECC Driving Lights Brake Lights
B5 Brake Light Relay Bat Power
L 1-4 J5-ECC Brake Lights Delay Power
B6 0-EF Brake Light Relay Control Gnd
19U-A L1-5 J5-ECC Brake Lights Delay Power
B7 Horn Relay Fused Power
L1-5 J6-ECC Delay Power Horn
B8 64C Horn Relay Control
18L-C L 1-6 J6-ECC Delay Power horn
B9 Comfort Steering Fused Pwr
L 1-6 J7-ECC Horn HOD Control
B10 51C Comfort Steering Control
O-B22 L 1-7 J7-ECC Horn HOD Control
C2 Hood Up Relay Ground
L 1-7 J8-ECC HOD Control Cigar Lighter
C4 O-B12 Hood Down Relay Ground
L 1-8 J8-ECC HOD Control Cigar Lighter
D1 59U Hood Up Relay Control
L1-8 J9-ECC Diagnostic Power
D2 19Y-A Hood Up Relay Fused Power
L 1-9 J9-ECC Diagnostic Power
D3 59D Hood Down Relay Control

4002-138
CONNECTOR ECD- ELECTRICAL CENTER D
Q_
t 00
2 00
AAA -.000
c D
r-0
000
4 00 000
3 00 000
& 00 000
8 00 000
7 00 000
8 00 000
9 00 000
to 00 000
o- I I --o
87312843

CAV WIRE IDENT CIRCUIT B5 19C-B Pilot Control Relay Fused Pwr
A1 13H-C Trans ECM Time Delay Pwr B6 53C-A Pilot Control Solenoid LSD
A2 13H-D Engine ECM Time Delay Pwr B7 58T Ride Control Relay Switch Pwr
A3 13H-B AIC Time Delay Power BB 58L Ride Control Relay LSD
A4 12V-D Plug 1 12V Switched Power B9 18M AC Relay Fused Power
A5 12V-E Plug 2 12V Switched Power B10 0-DJ AC Relay Control Ground
A6 12V-F Radio 12V Switched Power C2 63C2 Front Wiper Park Control
A? 12V-G 2 Way Radio 12V Sw Power C4 63C Front Wiper Park Control
A9 35C Backup Alarm Relay Control Front Wiper Relay HS Ctrl
D1 19J-D
Fused Pwr
A10 19H Backup Alarm Relay Fused Pwr
D2 63H-B Front Wiper HS Relay Out
AA1 19T-A TECM Delay Fused Power
Front Wiper Relay LS Ctrl Fused
AA2 18J-K EDC7 Time Delay Fused Power D3 19J-F
Pwr
AA3 19S-B AIC Delay Fused Power
D4 63C2 Front Wiper Park Control
AA4 12V 12V Power to Outlet 1 D5 19C-C Pilot control Relay Fused Pwr
AA5 12V-A 12V Power to Outlet 2 53 P-C
D6 Pilot Control Relay Out
AA6 12V-B 12V Fused Power to Radio D7 58H-A Ride Ctrl Switched Pwr VPS2
AA9 35A-A Backup Alarm Relay Out 58-E
DB Ride Control Solenoid Power
Backup Alarm Relay Ctrl Fused D9 61R-B AC Relay Control
AA10 19A-P
Pwr
D10 61C AC Relay Out
B1 19J-E Front Wiper Relay Fused Power
B2 63HC-B Front Wiper HS Relay Control
B3 63C3 Front Wiper Park Control
B4 63LC Front Wiper LS Relay Control

4002-139
CONNECTOR EDC7- ENGINE CONTROLLER CAV WIRE IDENT CIRCUIT
42 35W Water In Fuel Indicator
89 71 53 35 48 24L Low Idle Switch
88 70 52 34
75 0-BV Grid Heater Control Ground
\_) 87
86
85
84
69
68
67
66
51
50
49
48
33
32
31
30
77
78
79
24S
24R
248
Throttle Supply
Throttle Ground
Throttle Signal
83 65 47 29
82 64 46 28 89 20G-A EDC7 ISO-K Interface
81 63 45 27
80 62 44 26
79 61 43 25 CONNECTOR EM - HEIGHT CONTROL RTD - RTT
y ~
78
77
76
60
59
58
42
41
40
24
23
22
I r-' -..,r'l 75 57 39 21
74 56 38 20
73 55 37 19
72 54 36 18
6 17
5 11 16
II ) 10
225351C1
0
0
0 4 15 CAV WIRE IDENT CIRCUIT
0
0
0
0
0 3 9 14 1 55A-A RTT/Fioat Switched Power
0 2 54 A Height Control Switched Power
0
0
0
8 13
0
0 0
0
0 2 3 53 A RTD Switched Power
~ 7 12
4 538-B RTD Control Signal
l w 1 5 548-B HC-RTT Control Signal

BOSCH-89-POLE 6 558 RTT Float Switch Control
2 18J-C EDC7 Time Delay Fused Power
3 18J-B EDC7 Time Delay Fused Power
5 0-BE EDC7 Ground
6 0-BF EDC7 Ground
8 18J-D EDC7 Time Delay Fused Power
9 18J-E EDC7 Time Delay Fused Power
10 0-BD EDC7 Ground
11 0-BC EDC7 Ground
12 28G Grid Heater Source DR
13 0-BN Filter Heater Control
17 21H-A Crank Control Relay LSD
29 21F-B EDC7 Digital Ground
32 21 E-A Key Switch Crank
34 CAN-L CAN Low
35 CAN-H CAN High
36 28F Fuel Filter Heater Relay Control
37 21GA EDC7 Crank Control Relay
40 13M-A Fuel Shutoff Fused Power

4002-140
CONNECTOR ENG - ENGINE TO CAB CAV WIRE IDENT CIRCUIT
30 61A Trinary Pressure Switch Input
31 20G-A EDC7 ISO-K Interface
I 2345 6 7 8 9 10
! • • • I ' ...• 32 36A-A Rear Axle Temperature

II
21 ......
••
i
0 0 0 0 h
I'--'
0
0
0
0
•
•
0
0
••
••
20
30
33 36F Fuel Level ANALOG
•
0 0 0 0 0
~
a a o
• 34 36C Radiator Coolant Temp Signal
31 32 33 34 35 36 37 38 39 40 19Y-D Hood Switch Fused Power
35
36 60D-A Hood Down Relay Out
CAV WIRE IDENT CIRCUIT 37 59D-A Hood Down Relay Control
1 21C-D Starter Relay signal 38 60U-A Hood Up Relay Out
2 61C-A AC Relay Out 39 59U-A Hood Up Relay Control
2 61G-B AC Relay Out 40 35A-G Backup Alarm Relay Out
3 21GA EDC7 Crank Control Relay 40 35A-GN Backup Alarm Relay Out
4 21H-A Crank Control Relay LSD

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

4002-141
CONNECTOR ENG-H - ENGINE TO HOOD CONNECTOR ESS - ENGINE SPEED SENSOR
I I
8 7 6 5 H 1-
0000 !---'
2001 }-
DEUTSCH I I
0000
l £ v
~
291718A1

225320C1
1 25A Engine Speed Signal
CAV WIRE IDENT CIRCUIT 2 0-HF Engine Speed Sensor Ground
1 0-BAG-N Hood Ground (NA)
2 44A-DN Brake Light Relay Out
45L-AN Left Turn Signal
CONNECTOR FFH- FUEL FILTER HEATER
3
4 45R-AN Right Turn Signal
5 18G-HN RH Position!Tail Fused Pwr
6 18F-AN LH Position!Tail Fused Pwr
7 35A-GN Backup Alarm Relay Out
8 Not used
CONNECTOR ENG-T- ENGINE TO

TRANSMISSION
182069A1

A 1-GB Fuel Filter Heater Power
I 4 B 0-BX Fuel Filter Heater Ground
2 3

1 0-BZ Sec. Steering Splice Ground
2 0-BK Transmission Splice Grounds
Coolant Level Sender Eng
3 31D-C
Transmission
4 Not Used

4002-142
CONNECTOR FLSHR- FLASHER MODULE CONNECTOR FRONT - CAB FRONT CHASSIS

373358A1
1 1-DU Flasher Module Power
2 45N-A Flasher Optional Side Control
1 45L Left Turn Signal
3 0-EH Flasher Module Ground
2 51 B-D Comfort Steering Sol Power
4 0-EG Flasher Module Ground
3 45R Right Turn Signal
5 Not Used
4 Not Used
6 Not Used
5 18G-A RH Position/Tail Fused Power
7 45R-E Right Turn Signal
6 18F LH Position/Tail Fused Power
8 45L-D Left Turn Signal
7 18B LH High Beam Fused Power
9 45A-A Left Turn Switch Power
8 36B-A Front Axle Temperature
10 45B-A Right Turn Switch Power
9 O-AR Front Axle Temp Sensor GND
11 45H Hazard Switch Power
10 Not Used
12 45N-B Flasher Optional Side Control
11 54B Height-RTT Control Signal
12 53B RTD Control Signal
CONNECTOR FM - FILTER MAINTENANCE 13 64 Horn Power
SWITCH 14 180 LH Low Beam Fused Power
15 18E RH Low Beam Fused Power
16 18C RH High Beam Fused Power
17 Not Used
18 Not Used
19 53P-G Pilot Control Relay Out
20 57 Pin Engage Sol Pwr
21 58-B Ride Control Sol Pwr
Ride Control Solenoid to Front
21 58S-E
Cab
22 1-AA Brake Lamp Switch Power
371614A1
23 44 Brake Lamp Control Power
24 52P Park Brake Relay Out
1 32F Trans Filter Main! Sw
25 Not Used
2 36R-B Trans FM Switch Return
26 33P Low Brake Pressure Warning
27 19A-A Brake Declutch Sw Fused Pwr
28 25G Brake Declutch Switch Control
29 Not Used
30 Not Used
31 Not Used

4002-143
CONNECTOR FWM - FRONT WIPER MOTOR CONNECTOR FWW- FRONT WASHER
I--
A
0
-
-
r------i
B
0
~
D
._lQ_
c
..0-
'\...
245715C1 3227856R1

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

GROUND
3227856R1
245480C1
1 28G Grid Heater Source DR
2 0-BV Grid Heater Control Ground
1 0-88 Front Wiper Ground

4002-144
CONNECTOR GND-CAB-SPL- CAB GROUND CAV WIRE IDENT CIRCUIT
SPLICE
E O-DD Voltmeter Relay Control Gnd
Crank Request Relay Control
F 0-DF
Gnd
G O-DE Neutral Start Relay Control Gnd
Splice Pack Gnd Cab SPL2
H 0-EQ
GND
J Not Used
K 0-EH Flasher Module Ground
L 0-EG Flasher Module Ground
M 0-EF Brake Lights Relay Control Gnd
CONNECTOR HD - HOOD SWITCH

87324393

A 0-EE Diode Suppression Grounds
B O-EM Radio Ground
c 0-EP Horn Switch Ground
D Not Used
E Not Used
F 0-DG Cab Splice Grounds
G 0-DT Front Wiper/Washer Sw Gnd 245485C1
H 0-DL Power Converter Relay Ctrl Gnd CAV WIRE IDENT CIRCUIT
I 0-DK Seat Compressor Motor Ground A 59D-A Hood Relay Control Down
K 0-DJ AC Relay Control Ground B 19Y-D Hood Switch Fused Power
L 0-DU Pilot Pressure Solenoid Gnd c 59U-A Hood Relay Control Up
M 0-DH Diagnostic Connector Ground
CONNECTOR HO-E- HOOD HARNESS TO

CONNECTOR GND-CAB-SPL2 - SPLICE BACK TRANSMISSION HARNESS
LIGHT GROUND
245484C1

A 18G-E License Plate Light Fused Pwr
B 35A-H Backup Alarm Relay Out
87324393
c 0-JA Hood Ground (EURO)
A 0-DC Time Delay Module Ground
B 0-EA Time Delay Relay Control Gnd
c 0-EB Ignition Relay Control Ground
D 0-EC ACC Relay Control Ground

4002-145
CONNECTOR HD-N - HOOD TO ENGINE CONNECTOR HOT- HYDRAULIC OIL
TEMPERATURE SENDER
1 2 3 4
GGGG 194788A1

GGGG
8 7 6 5 A 36H Hydraulic Oil Temp Signal
B 0-HW Hydraulic Oil Temp Ground
225319C1

1 0-JA-N Hood Grounds (NA) CONNECTOR HVAC1 - HVAC1
2 44A-EN Brake Light relay Out
3 45L-BN Left Turn Signal
4 45R-BN Right Turn Signal B
5 18G-JN RH Position/Tail Fused Power
6 18F-BN LH Position/Tail Fused Power
7 35A-HN Backup Alarm Relay Out
8 Not used c
225295C1

CONNECTOR HOM - HOOD LIFT MOTOR
1 61A-B Trinary Pressure Switch Input
2 18N-A Blower Motor Fused Power
3 49A Back Light Power
CONNECTOR HVAC2- HVAC2

Will
~
225316C1

1 60U-A Hood Up Relay Out
2 60D-A Hood Down Relay Out
87552622

1 O-ED HVAC Grounds
2 18N-B Blower Motor Fused Power

4002-146
CONNECTOR HVAC-CAN1 - CAN-HVAC-ATC CONNECTOR K-WCO -WIPER CUTOUT
87
v
B A
CJ~LJ
86 85
245731C1

87315267
30 63L-B Front Wiper LS Relay Out
85 63HC-A Wiper Cut Out Relay Control
A CAN-HK CAN High
86 19J-G Wiper Cut Out Relay Fused Pwr
B CAN-LL CAN Low
87 Not Used
87A 63C3 Front Wiper Park Control
CONNECTOR ISS- INT-SPEED-SENSOR
CONNECTOR LBEE- LIGHT BEACON EXTESION
/I I
---! 1-
---1
2001 }---
'-.I 1/
291718A1

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

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

4002-147
CONNECTOR LLF- LH FRONT LIGHTS CONNECTOR LLR-12- LH REAR COMBINATION
LAMP
aG) G1
sG) G2
4G G)s 4G G1
225351C1 3G G2
239451A1
1 0-AJ Lights Ground LH
2 18D Low Beam LH
1 0-BR-N LH Rear Light Ground (NA)
3 18B High Beam LH
2 44A-FN Brake Lamp Relay Out
4 18F Position LH Fused Power
3 18F-BN LH Tail Lamp Fused Pwr
5 45L Left Turn Signal
4 45L-BN Left Turn Signal
6 Not Used
CONNECTOR LLR-E - LH REAR COMBINATION

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

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

4002-148
CONNECTOR LLR-N - LH REAR COMBINATION CONNECTOR LRF - RH FRONT COMBINATION
LAMP LAMP
t--
A
0
r-
r-
-----1
B
0
~
D c
-.0. l.Q.._
225351C1
/
" 245715C1
CAV WIRE IDENT CIRCUIT 1 0-AH RH Front Lights Ground
A 44A-FN Brake Lamp Relay Out 2 18E RH Low Beam Fused Pwr
B 18F-BN LH Tail Lamp Fused Pwr 3 18C RH High Beam Fused Pwr
c 45L-BN Left Turn Signal 4 18G-A RH Position/Tail Fused Pwr
D 0-BR-N LH Rear Light Ground (NA) 5 45R Right Turn Signal
6 Not Used
CONNECTOR LLRW- LH REAR WORK LAMP

CONNECTOR LRFW- RH FRONT WORK LAMP
245483C1

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

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

4002-149
CONNECTOR LRR-12- RH REAR COMBINATION CONNECTOR LRR-N - RH REAR COMBINATION
LAMP LAMP
t--
A
0
-
-
-----1
0
B
~
D
._lQ_
c
_Q._

239451A1
" 245715C1

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

LAMP
245483C1

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

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

4002-150
CONNECTOR OSS - OUTPUT SPEED SENSOR CONNECTOR PBD- BRAKE DECLUTCH
PRESSURE SWITCH
245482C1
291719A1 CAV WIRE IDENT CIRCUIT

CAV WIRE IDENT CIRCUIT A 19A-A Brake Declutch Sw Fused Pwr
1 0-HE Output Speed Ground B 25G Brake Declutch Switch Control
2 250 Output Speed Signal
3 19A Output Speed Fused Pwr
CONNECTOR PBL- BRAKE LAMP PRESSURE
SWITCH
CONNECTOR PAF- AIR FILTER RESTRICTION
SWITCH
2 1
I I
00
--; 1-
--;
2001 J-
222136A1
I I CAV WIRE IDENT CIRCUIT

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

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

4002-151
CONNECTOR P01 - POWER OUTLET CONNECTOR PR- TRINARY PRESSURE SWITCH
AB

12176446
A 61-A Trinary Pressure Switch Input
B 61R AC Relay Control
A 12V 12V Pwr to Outlet 1
B Not Used
c 0-EK Aux Power Outlet 1 Gnd CONNECTOR PRB1 - REDUNDANT BRAKE
SWITCH
CONNECTOR P02 - POWER OUTLET
245483C1

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

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

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

4002-152
CONNECTOR PRBF- ROLLBACK PRESSURE CONNECTOR PRM-82- PRM SIGNAL
SWITCH
A B
245483C1
CAV WIRE IDENT CIRCUIT 256340A1
A 58 Ride Control Solenoid Power CAV WIRE IDENT CIRCUIT

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

CONNECTOR PRM-C1 - PRM OUTPUT
c A

CAV WIRE IDENT CIRCUIT A 18R Voltmeter Relay Fused Pwr
A 13K-B Ignition Switch Power c 28P Ether Solenoid Power
B 0-EB Ignition Relay Control Ground c 1-GA Filter Heater Power
CONNECTOR PRM-81 - PRM SIGNAL
C A

A Not Used
c 13H Time Delay Power

4002-153
CONNECTOR PRM-C2- PRM SIGNAL ONNECTOR PRM-E1 - PRM SIGNAL
C A
A B

256340A1 A Not Used
CAV WIRE IDENT CIRCUIT c 19L Power Converter FSD Power
A 28E Ether Relay Signal
A 28F Fuel Filter Heater Relay Control
CONNECTOR PRM-E2 - PRM SIGNAL
B 0-BAM Ether Relay Signal Ground
B 0-BN Filter Heater Control ground
CONNECTOR PRM-01 - PRM SIGNAL
A B
256340A1

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

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

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

4002-154
CONNECTOR PXF - RTD CONNECTOR PXT - RTD
245485C1 245485C1

A 538 RTD Signal A 538-A RTD Control Signal
B 0-AC Proximity Switch Ground B 0-AM RTD Ground
c 53 P-H Pilot Control Relay Out c 53 P-I Pilot Control Relay Out
CONNECTOR PXH - HEIGHT CONTROL RTT CONNECTOR RAD - RADIO POWER
245485C1

A 548 RTT Signal 292495A1
B 0-AA Proximity Switch Ground CAV WIRE IDENT CIRCUIT
c 53P-J Pilot Control Relay Out 1 Not Used
2 Not Used
CONNECTOR PXM - RTD 3 Not Used

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

A 538-A RTD Control Signal
B 0-AM RTD Ground
c 53 P-I Pilot Control Relay Out

4002-155
CONNECTOR RAD-J1 - RADIO POWER CONNECTOR RAD-J3 - RADIO JUMPER
I 2
3 4
5 6 411311A1
7 8 CAV
1
WIRE IDENT
RAD10
CIRCUIT
Right Speaker Ground
2 RAD8 Not Used
3 RAD4 Left Speaker Ground
CAV WIRE IDENT CIRCUIT 4 RAD6 Not Used
1 Not Used 5 RAD1 Radio Ground
2 Not Used 6 Not Used
3 Not Used 7 RAD3 12V Fused Power to Radio
4 RAD3 12V Fused Power to Radio 8 RAD11 Right Speaker
5 Not Used 9 RAD9 Not Used
6 Not Used 10 RAD5 Left Speaker
7 RAD2 12V Fused Power to Radio 11 RAD7 Not Used
8 RAD1 Radio Ground 12 RAD2 12V Fused Power to Radio
13 Not Used
14 Not Used
CONNECTOR RAD-J2 - SPEAKER
CONNECTOR RECT- ENGINE COOLANT

TEMPERATURE
I 2
3 4 B A
5 6 00
7 8
194788A1

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

4002-156
CONNECTOR ROOF- ROOF TO CAB CONNECTOR RTHP -THROTTLE PEDAL
CONNECTION
ABCDE FGH
n n n
S RP NML K J
388708A1
A 43-B Dome Light Auto Mode CAV WIRE IDENT CIRCUIT
B 42R-F Rear Work Light Fused Power 1 21F-C EDC7 DIGITAL Ground
c 42C-F Front Work Lights Fused Power 2 Not Used
D 19U-C Done Light Fused Power 3 24B Throttle Signal
E 46-D Beacon Switch Power 3 24B-A Throttle Signal
F 0-MN Roof Grounds 4 24R Throttle Position Sensor Ground
G 0-MK Roof Grounds 4 24R-A Throttle Position Sensor Ground
J 19K-D Rear Wiper Motor Fused Power 5 24S Throttle Supply

K 68C-A Rear Wiper Park Control 5 24S-A Throttle Supply
L 68L-A Rear Wiper Switched Power 6 24L Low Idle Switch
M 0-EN Radio Ground
N 12V-H 12V Fused Power to Radio
CONNECTOR RWM - REAR WIPER MOTOR
R 43S-B Door Open Signal
~
s 19U-F Door Switch Fused Power
CONNECTOR RSPK- RIGHT SPEAKER t--

r-
r-----;
r-
A B
0 0
D c
_..Q_ Lo.-
'-. ./
245715C1

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

4002-157
CONNECTOR RWMG - REAR WIPER MOTOR CONNECTOR S-KEV - IGNITION SWITCH TO
GROUND PEDESTAL HARNESS
245480C1
225253C1
1 0-MA Rear Wiper Motor Ground
1 1A lgn Sw Fused Power
2 21K lgn Switch Start Signal
CONNECTOR RWW- REAR WASHER 3 13K Ignition Switch Power
4 12ACC lgn Switch Accessory Power
5 Not Used
6 Not Used
CONNECTOR SBE - BEACON SWITCH
3227856R1

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

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

4002-158
CONNECTOR SBU - BACKUP ALARM DISABLE CONNECTOR SCS - COMFOR STEER SWITCH
SWITCH
382391A1
382391A1
1 51S Standard Steering Signal
1 35R-C Backup Alarm Switch 2 18L-D Comfort Steering Fused Power
2 35A-B Backup Alarm Disable Switch
3 51CS Comfort Steering Switch
4 Not Used
5 Not Used
5 Not Used 51 B-A Comfort Steering Solenoid Pwr
6
6 Not Used O-B9
7 Back Light Ground
8 49-U Back Light Power
8 49-L Back Light Power
9 Not Used
10 Not Used
CONNECTOR SOC - DECLUTCH SWITCH

CONNECTOR SC- SEAT COMPRESSOR MOTOR
245482C1
382391A1
A 19N Seat Compressor Fused Pwr
1 25G-B Brake Declutch Switch Control
B 0-DK Seat Compressor Motor Ground
2 19A-R Declutch Switch Fused Power
3 Not Used
4 Not Used
5 Not Used
6 Not Used
8 49-R Back Light Power
9 Not Used
10 Not Used

4002-159
CONNECTOR SDR - DRIVING LIGHTS SWITCH CONNECTOR SFC - FAN CONTROL SWITCH
382391A1
382391A1
2 19Z-A Driving lights Switch Fused Pwr 2 52J Fan Control Switch Jumper
3 41T Position Lights Switch Power 3 52-AU Fan Reverse Auto
4 Not Used 4 52J Fan Control Switch Jumper
Driving Lights Switch Fused 5 19P-C Fan Reverse Switch Fused Pwr
5 19Z-B
Power 6 52M Fan Reverse Manual
6 41J Driving Lights Power 7 O-B7 Back Light Ground
7 O-B19 Back Light Ground 8 49-Q Back Light Power
8 49-P Back Light Power 9 Not Used
10 Not Used
CONNECTOR SFL- RETURN-TO-TRAVEL

CONNECTOR SETHR - ETHER SWITCH SWITCH
382391A1
382391A1

1 55A-B RTT/Fioat Switch Power
1 Not Used
2 53P-B Pilot Control Relay Out
2 28J Ether AIC OK Signal
3 55A-C RTT/Fioat Switch Power
3 28H Ether Switch Signal
4 0-29 RTT/Fioat Ground
4 Not Used
5 55B RTT Float Switch Control
5 Not Used
6 54B-C HC-RTT Control Signal
6 Not Used
O-B30 7 O-B2 Back Light Ground
7 Back Light Ground
8 49-K Back Light Power
8 49U Back Light Power
9 Not Used
9 Not Used

4002-160
CONNECTOR SFNR - FNR SWITCH CONNECTOR SHC- HEIGHT CONTROL SWITCH
382391A1 382391A1

1 26R-A FNR Reverse Signal 1 Not Used
2 26J FNR Switch Jumper 2 53P-D Pilot Control Relay Out
3 26N-A FNR Neutral Signal 3 Not Used
4 26J FNR Switch Jumper 4 Not Used
5 19A-V FNR Switch Fused Power 5 Not Used
6 26F-A FNR Forward Signal 6 54 A HC Control Switch Power
7 32J-A Trans Enable Indication 7 O-B3 Back Light Ground
8 19A-G FNR Switch Fused Power 8 49-M Back Light Power
CONNECTOR SFWW- REAR WIPER AND CONNECTOR SHZ- HAZARD SWITCH

WASHER SWITCH
0 9 5 6 7 8 rr=
r-r--- 000 00 r---
'---'----- r---
000 00
10 1 2 3 4
87345132 382391A1

2 0-DT Front Wiper/Washer Sw Gnd 2 1-KA Hazard Switch Power
3 63LC Front Wiper LS Relay Control 3 45H Hazard Switch Power

INT Wiper/Washer Sw Fused 5 Not Used
5 19J-B
Pwr
6 Not Used
6 Not Used 7 O-b24 Back Light Ground
7 63W Front Washer Pump 49-D
8 Back Light Power
8 49-T Back Light Power
9 Not Used
9 63HC Front Wiper HS Relay Control
10 Not Used
10 Not Used

4002-161
CONNECTOR SPB - PARKING BRAKE SWITCH CONNECTOR SPE - PIN ENGAGE SWITCH
382391A1
382391A1
1 Not Used 1 57-B Pin Engage Solenoid Power
2 19A-L Park Brk Switch Fused Power 19P-A
2 Pin Engage Sw Fused Power
3 33U Park Brake Switch Not Used
3
4 Not Used
4 Not Used
5 Not Used Not Used
5
6 Not Used
6 Not Used
7 O-B29 RTT/Fioat Ground 7 Not Used
8 49-V Back Light Power
8 Not Used
9 Not Used O-B5 Back Light Ground
9
10 Not Used 49-F
10 Back Light Power
CONNECTOR SPC- PILOT CONTROL SWITCH CONNECTOR SPK- SPEAKER
2 I
4 3
6 5
8 7
382391A1

1 Not Used CAV WIRE IDENT CIRCUIT
2 19A-j Pilot Control Switch Fused Pwr 1 65R Right Speaker
3 31L Pilot Control Switch High 2 0-PB Right Speaker Ground
7 O-B1 Back Light Ground 6 Not Used
8 49-N Back Light Power 7 65L Left Speaker
9 Not Used 8 0-PA Left Speaker Ground
10 Not Used

4002-162
CONNECTOR SPL-BCK-LGT - SPLICE BACK CAV WIRE IDENT CIRCUIT
LIGHT POWER
D 49-M Back Light Power
E 49-K Back Light Power
F 49-F Back Light Power
G 49-Q Back Light Power
H 49-T Back Light Power
J Not Used
K 49-G Back Light Power
L Not Used
M 49-S Back Light Power
CONNECTOR SPL-BCK-LT-GD - SPLICE BACK

87324393 LIGHT GROUND
A 49 Back Light Power
B Not Used
c 49-C Back Light Power
D 49-H Back Light Power
E 49-L Back Light Power
F 49A Back Light Power
G 49-P Back Light Power
H 49-R Back Light Power
J 49S Back Light Power
K 49-E Back Light Power
87324393
L 49-B Back Light Power
M 49-A Back Light Power
A O-B13 Back Light Ground
B O-B14 Back Light Ground
CONNECTOR SPL-BCK-LGT2 - SPLICE BACK c O-B15 Back Light Ground
LIGHT POWER
D Not Used
E O-B17 Back Light Ground
F O-B18 Back Light Ground
G O-B19 Back Light Ground
H O-B8 Front Wiper Motor Ground
J O-B21 Back Light Ground
K 0-DAP Back Light Ground
L O-B23 Back Light Ground
M Not Used
87324393

A 49-E Back Light Power
B Not Used
c 49-J Back Light Power

4002-163
CONNECTOR SPL-BCK-LT-GD2- SPLICE BACK CAV WIRE IDENT CIRCUIT
LIGHT GROUND
D 0-BS Fan Control Ground
E 0-B Front Washer Ground
F 0-BL Rear Washer Ground
CONNECTOR SPL-HOOD-GND- HOOD GROUND

SPACK
87324393

A Not Used
c O-B3 Back Light Ground
D O-B4 Back Light Ground
87324391
E O-B5 Back Light Ground
F O-B6 CAB2 Ground
A O-B12 Hood Down Relay Ground
G O-B26 Buzzer Switch Pad Ground
B O-B16 Hood Down Control Ground
H Not Used
J O-B20 Back Light Ground
c O-B22 Hood Up Relay Ground
D O-B25 Hood Up Control Ground
K 0-29 RTT/Fioat Ground
E O-B10 Hood Ground
L O-B11 Back Light Ground
F Not Used
M O-B7 Back Light Ground
CONNECTOR SPL-ENG-GND - GROUND SPLICE

SPACK
87324391

A 0-BM Engine Splice Grounds
B 0-BY Air Filter Restriction Switch Gnd
c Not Used

4002-164
CONNECTOR SPL-PED-BL- SPL BACK LIGHT CONNECTOR SPL-PIN - SPL PIN ENGAGE/FAN
POWERS PACK REVERSE POWER
87324391 87324391

A 49-U Back Light Power A 19P-A Pin Engage Switch Fused Pwr
B 49-N Back Light Power B 19P Pin Engage/Fan Fused Power
c 49-D Back Light Power c 19P-C Fan Reverse Switch Fused Pwr
D 49U Back Light Power D Not Used
E 49-V Back Light Power E 19P-D Fan Reverse Relay Fused Pwr
F 49-S Back Light Power F 19P-E Fan Reverse Relay Fused Pwr
CONNECTOR SPL-PED-BL-GD- SPL BACK

LIGHT GROUND 6 PACK
87324391

A O-B9 Back Light Ground
c O-B24 Back Light Ground
D O-B30 Back Light Ground
E O-B29 RTT/Fioat Ground
F O-B11 Back Light Ground

4002-165
CONNECTOR SPL-PK1 - SPLICE 3- 4 WAY CONNECTOR SPL-PK2 - SPLICE 3- 4 WAY
87324462 87324462

A 42C-A Front Work Lights Fused Pwr A 41T-B Position Lights LH Switch Pwr
B 42C-E Front Work Lights Fused Pwr B 41T-E Position Lights Switch Pwr
c 42C-D Front Work Lights Fused Pwr c 41T Position Lights Switch Pwr
D 42C-C Front Work Lights Fused Pwr D 41T-A Position Lights RH Switch Pwr
E 13K Ignition Switch Power E 19Z-A Driving Light Switch Fused Pwr
F 13K-B Ignition Switch Power F 19Z-B Driving Light Switch Fused Pwr
G 13K-A Ignition Switch Power G 19Z Driving Light Switch Fused Pwr
H 13K-C Ignition Switch Power H 19Z-C High Beam Flash Fused Pwr
J 35A-D Backup Alarm Relay Out J 41H-C High Beam RH Power
K 35A-B Backup Alarm Disable Switch K 41 H-B High Beam LH Power
L 35A-A Backup Alarm Relay Out L 41H-A High Beam Power
M 35A-C Backup Alarm Relay Out M 41 H-D High Beam Power

4002-166
CONNECTOR SPL-PK3- SPLICE 3- 4 WAY CAV WIRE IDENT CIRCUIT
E 0-MF RH Rear Work Light Ground
F 0-MA Rear Wiper Motor Ground
G Not Used
H Not Used
J 0-MJ RH Front Work Light Ground
K Not Used
L 0-MN Roof Grounds
M 0-MK Roof Grounds
CONNECTOR SPL-SEC-STR - SEC STR 6PK

87324462

A 45L-E Left Turn Signal
B 45L-D Left Turn Signal
c 45L-C Left Turn Signal
D 45L-B Left Turn Signal
E 45R-C Right Turn Signal
F 45R-E Right Turn Signal
G 45R-D Right Turn Signal
H 45R-B Right Turn Signal
Front Wiper/Washer Sw Fused
J 19J-B 87324391
Pwr
K 19J Front Wiper Fused Power CAV WIRE IDENT CIRCUIT
L 19J-C Front Wiper Relay Fused Power A 0-CB Sec. Steering Signal Ground
M 19J-A Front Wiper Motor Fused Power B 0-CA Sec. Steering Signal Ground
c 0-CC Sec. Steering Press Switch Gnd
D 0-CF Sec. Steering Solenoid Ground
CONNECTOR SPL-ROOF - SPLICE ROOF
E Not Used
GROUND
F 0-CD Sec. Steering Splice Ground
87324393

A 0-MC Beacon Light Ground
B 0-MB Dome Light Ground
c 0-MU LH Front Work Light Ground
D 0-ME LH Rear Work Light Ground

4002-167
CONNECTOR SPL-TRN-GRD- SPLICE CAV WIRE IDENT CIRCUIT
TRANSMISSION GROUND
Output Speed Sensor Fused
K 19A-M
Pwr
L 19A-S Trans Fused Pwr
M 19A-H Trans Shifter Fused Pwr
CONNECTOR SRC- RIDE CONTROL SWITCH
87324391

A 0-HC Transmission Splice Grounds
B Not Used
382391A1
c 0-HW HOT Ground
D 0-HV Coolant Level Sender Ground
1 Not Used
E 0-HL Redundant Brake Switch Grd
2 19C-D Ride Ctrl Switch Fused Pwr
F O-HM Redundant Brake Switch Grd
3 58C Ride Ctrl Switch Jumper
4 58T Ride Ctrl Relay Switch Pwr
CONNECTOR SPL-TRNS-PWR- TRANSMISSION 5 58C Ride Ctrl Switch Jumper
POWER
6 58-F Ride Ctrl Solenoid Pwr
8 49-G Back Light Power
9 Not Used
10 Not Used
CONNECTOR SRC-1- STARTER RELAY
87324393
CAV WIRE IDENT CIRCUIT h3J1J]

A 19A-N Trans Fused Power ~
B 19A-F Trans Enable Switch Fused Pwr
c 19A-Q Trans/Auto Switch Fused Pwr 225316C1
D 19A-T Brake Declutch Sw Fused Pwr CAV WIRE IDENT CIRCUIT

E 19A-W Diagnostic Conn. Fused Pwr 1 21D Starter Relay Signal
F 19A-C FNR Switch Fused Pwr 2 0-GB Starter Relay Control Ground
Backup Alarm Rly Ctrl Fused
G 19A-P
Pwr
H 19A-R Declutch Switch Fused Pwr
J 19A-K TECM Fused Pwr

4002-168
CONNECTOR SRHSTLK - RH STALK SWITCH CONNECTOR SRWP - REAR WIPER SWITCH
31b
382391A1

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

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

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

4002-169
CONNECTOR SSM - SECONDARY STEERING CAV WIRE IDENT CIRCUIT
MODULE
8 49S Back Light Power
9 Not Used
10 Not Used
CONNECTOR STE -TRANSMISSION ENABLE

SWITCH

1 19R-C
Pwr
2 51-A Secondary Steer Control
3 19S1-X Secondary Steer Fused Power
4 0-CE Secondary Steer Chassis Grnd
5 Not Used 382391A1
6 Not Used CAV WIRE IDENT CIRCUIT

Secondary Steer ACC Fused 1 Not Used
7 19M-C
Pwr
2 19A-D Trans Enable Sw Fused Power
8 35X-D Secondary Steer Low Press Sig
3 26E Trans Enable Signal
9 51 P-A Secondary Steer High Press
4 Not Used
10 Not Used
5 Not Used
11 0-CA Secondary Steer Signal Grnd
6 Not Used
12 0-CB Secondary Steer Signal Grnd
7 0-DAP Back Light Ground
8 49-H Back Light Power
CONNECTOR STA- TRANSMISSION AUTO 9 32J-C Trans Enable Indiction
SWITCH 10 19A-E Trans Enable Sw Fused Pwr
382391A1

1 Not Used
2 19A-Q Trans Auto Sw Fused Power
3 25H Trans Auto Signal
4 Not Used
5 Not Used
6 Not Used

4002-170
CONNECTOR SWL -WORK LIGHTS SWITCH CAV WIRE IDENT CIRCUIT
8 CAN-LF CAN Low
9 17P-A Switch Pad Pwr From AIC Pwr
10 O-B28 Switch Pad Ground
CONNECTOR TCOT- TORQUE CONVERTER

OUTPUT SENDER
382391A1

1 Not Used
2 42-A Work Lights Fused Power
3 42FS Front Work Lights Switch Power
4 Not Used
5 42-B Work Lights Fused Power
6 42RS Rear Work Lights Switch Power
291718A1
8 49-A Back Light Power
A 36G TCO Temperature Signal
9 Not Used
B 36R-D TCO Temperature Return
10 Not Used
CONNECTOR TOM -TIME DELAY MODULE

CONNECTOR SW-PD - SWITCH PAD
225351C1

1 13D Time Delay Relay Ctrl Power
87552623 2 1DN Time Delay Fused Power
CAV WIRE IDENT CIRCUIT 3 0-DC Time Delay Module Ground
1 41 H-D High Beam Power 4 43S-D Time Delay Mod Door Sw Reset
2 41T-D Position Lights Switch Pwr 5 13K-A Ignition Switch Power
3 42C-E Front Work Light Fused Pwr 6 Not Used
4 31H-A Hydraulic Filter Rest Sw Signal
5 31 F-A Air Filter Rest Switch Signal
6 Not Used
7 CAN-HF CAN High

4002-171
CONNECTOR TECM - TRANSMISSION CAV WIRE IDENT CIRCUIT
ELECTRONIC CONTROL MODULE
21 52 P-C Park Brake Relay Out
22 25Y-A Trans Kick Down Signal
23 19T-A Time Delay Fused Power
23 25 CAN-HD CAN High
45 68 26 CAN-LK CAN Low
22 44 67 27 CAN-LJ CAN Low
21 66
-
29 25H Trans Auto Signal
.J 20 43 65 30 26R-B FNR Reverse Signal
0
oO
19 42 64 31 26E Trans Enable Signal
ooo
ooo
18 41 63 32 25M-A Trans Sol Valve Y3
ooo
ooo 17 40 62
ooo
ooo 16 39 61
39 36T-A Valve Body Temp Signal
ooo
15 38 60
41 25C-A Turb Speed Signal
ooo
ooo 14 37 59
42 25B-A lnt Speed Signal
ooo
ooo 13 36 58
43 25F Forward Signal
eoo
12 35 57 44 26N-B FNR Neutral Signal
ooo
ooo
11 34 56 45 19A-K TECM Fused Power
ooo
10 33
ooo
ooo 32 55 46 36R-E Trans Temp/Filter Return
ooo
ooo
9 31 54 49 36G-A Torque Conv Out Temp Signal
ooo 8 30 53 51 25J-A Trans Sol Valve Y6

ooo
7 29 52 55 25N-A Trans Sol Valve Y4
-
0 0
6 28 51 56 25K-A Trans Sol Valve Y1
5 50 57 58L Ride Control Relay LSD
4 27 49
~
'I 3 26 48
62 25D-A Output Speed Signal
2 25 47
63 25Z 1st and 4th Gear Signal
1 24 46
64 25R- Reverse Signal
65 25W 3rd and 4th Gear Signal
66 25G-C Brake Declutch Switch Control
411398A1
67 25T-C Neutral Signal
1 0-DP Diag TECM Ground
2 0-DQ Diag TECM Ground
3 0-DM Speed Sensors Ground
4 0-DN Out Speed Sensor Ground
5 32J-D Trans Enable Indicator Lamp
7 35C Backup Alarm Relay Control
8 58H-A Ride Control Sw Power VPS2
9 25P-A Trans Sol Valve Y5
10 25L-A Trans Sol Valve Y2
12 25S-B Output Sw Power VPS1
13 25S-C Output Sw Power VPS1
15 37D-A Diagnostic Signal
17 32F-A Trans Filter Maint Switch
18 37E Diagnostic Signal Switched
19 25A-A Engine Speed Signal
20 26F-B FNR Forward Signal

4002-172
CONNECTOR TR-SS - SEC-STR-MOD-OPT CONNECTOR TRANS - CAB TO TRANSMISSION
21 20o 8 031
Ogo ~ o1~3o
100 3 0 7 Q18
220 0 1 0 029
110 4 0 6 017
230 0 5 0 028
120 0 016
24~,So ~ o15027
250 026

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

4002-173
CONNECTOR TRC - TRANSMISSION CONTROL CONNECTOR TS1 -TRANSMISSION SHIFTER
CAV WIRE IDENT CIRCUIT A 19A-H Trans Shifter Fused Power

1 25K Trans Solenoid Valve Y1 B 25F Forward Signal
1 25L-9 Trans Solenoid Valve Y1 c 25R Reverse Signal

2 25K-9 Trans Solenoid Valve Y2 D 25T-B Neutral Signal
2 25L Trans Solenoid Valve Y2

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

4002-174
CONNECTOR TSS- TURBINE SPEED SENSOR CONNECTOR YCS- COMFOR STEERING
SOLENOID
I I
--j 1-
--j
2001 }--
I I
245482C1
291718A1
CAV WIRE IDENT CIRCUIT A 51 B-D Comfort Steering Solenoid Pwr
1 25C Turbine Speed Signal B 0-AQ Comfort Steering Solenoid Gnd
2 0-HH Turbine Speed Ground
CONNECTOR YFN - FAN PWM SOLENOID

CONNECTOR WIF- WATER IN FUEL SENSOR
8602416
CAV WIRE IDENT CIRCUIT 256340A1
1 35W Water Indicator CAV WIRE IDENT CIRCUIT

2 0-BP Sensor Ground A 56-A Fan Control PWM
3 18J-H Sensor Fused Power B 0-BQ Fan Speed PWM Solenoid Gnd
CONNECTOR WSH -WATER SEPARATOR CONNECTOR YFR - FAN REVERSING SOLENOID

HEATER
h3J1J]
~
225316C1

182069A1 1 52A-B Fan Reversing Relay Out
CAV WIRE IDENT CIRCUIT 2 0-BB Fan Reversing Solenoid Ground
A 0-BW Water Separator Heater Ground
B 1-GC Water Separator Heater Power

4002-175
CONNECTOR YPB - PARKING BRAKE SOLENOID CONNECTOR YRC - RIDE CONTROL OPT
I I I I
H 1-
H
2001 }--
H
H
2001
1-
}--
I I I I
291718A1 291718A1

1 52P Parking Brake Relay Out 1 58 Ride Control Solenoid Power
2 0-AN Park Brake Solenoid Ground 1 58S-E Ride Control Sol To Front Cab
2 0-AD Ride Control Ground
CONNECTOR YPE - PIN ENGAGE OPT

CONNECTOR YSS - SECONDARY STEERING
SOLENOID
h3J1J]
245482C1 ~
A 57 Pin Engage Solenoid Power 225316C1
B 0-AE Pin Engage Ground CAV WIRE IDENT CIRCUIT

1 51-C Sec. Steering Solenoid Control
CONNECTOR YPP- PILOT PRESSURE 2 0-CF Sec. Steering Solenoid Ground

SOLENOID
245482C1

A SP-A Pilot Control Relay Out
B 0-DU Pilot Pressure Solenoid Gnd

4002-176
NOTES

4002-177
Symbols Connector 215F ................................................... 125
12 Volt Radio ....................................................... 112 Connector 216F ................................................... 125
Connector 64F ..................................................... 126
A Connector 64M .................................................... 126
A/C High/Low Pressure Switch ............................ 115 Connector 69 ....................................................... 157
Air Filter Restriction Switch .................................... 67 Connector ACT .................................................... 126
Air Seat Compressor and Switch ......................... 114 Connector AIC1 ................................................... 126
Alarm Connector AIC2 ................................................... 127
Back-up (Europe Only} ...................................... 96 Connector BUZ .................................................... 127
Back-up (North America Only} .......................... 96 Connector CAB_E ............................................... 128
Back-up, Disable Switch ................................... 76 Connector CAB_F ............................................... 129
Back-up, Relay .................................................. 76 Connector CAB_RF ............................................. 129
Alternator ............................................................... 40 Connector CAB_T ............................................... 130
Connector CAN ................................................... 130
B Connector CAN2 ................................................. 130
Back-up Alarm (Europe Only) ................................ 96 Connector CL ...................................................... 131
Back-up Alarm (North America Only) .................... 96 Connector CLS .................................................... 131
Back-up Alarm Disable Switch .............................. 76 Connector CNV ................................................... 131
Back-up Alarm Relay ............................................. 76 Connector D_OR ................................................. 131
Batteries ................................................................ 41 Connector DIA ..................................................... 131
Beacon Switch ....................................................... 79 Connector DISC .................................................. 131
Beacon, Rotating (Option) ..................................... 78 Connector DM ..................................................... 132
Brake Lamp Pressure Switch ................................ 83 Connector DNS-AC-SWITCH .............................. 132
Brake Lamps Relay ............................................... 83 Connector DNS-ACTUATOR .............................. 132
Brake Warning Pressure Switch ............................ 68 Connector DNS-CTRL-PANEL-LIGHT ................ 132
Buzzer ................................................................... 66 Connector DNS-DRIVER .................................... 133
Connector DNS-ELECTRIC-FAN ........................ 132
c Connector DNS-ELECT-WATER-VALVE-S ........ 133
Connector DNS-HVAC1-S .................................. 133
CAN Communication Diagnostics Connector ...... 109
Cigar Lighter ........................................................ 114 Connector DNS-HVAC2-S .................................. 133
Circuit Breaker Cab B+ ......................................... .47 Connector DNS-RECIRCULATING-SWITCH ..... 132
Climate Control, Standard Connector DNS-RESISTOR ................................ 133
Air Conditioning Switch ................................... 119 Connector DNS-SPEED-SELECTOR ................. 132
Air Recirculation Motor .................................... 117 Connector DNS-THERMOSTAT-1 ...................... 132
Air Recirculation Switch .................................. 120 Connector DNS-THERMOSTAT-2 ...................... 132
Blower Motor ................................................... 118 Connector DNS-WATER-VALVE-POT ................ 132
Blower Motor Speed Resistors with Thermal Fuse Connector DS ...................................................... 134
118 Connector E_HD ................................................. 134
Blower Switch .................................................. 119 Connector ECA ................................................... 135
Control Panel Lights ........................................ 119 Connector ECB ................................................... 136
Driver ............................................................... 117 Connector ECC ................................................... 137
Electronic Water Valve .................................... 118 Connector ECD ................................................... 138
Thermostat ...................................................... 119 Connector EDC7 ................................................. 139
Water Valve Potentiometer ............................. 120 Connector EM ..................................................... 139
Cluster, Instrument Connector 1 ............................ 65 Connector ENG ................................................... 140
Cluster, Instrument Connector 2 ............................ 71 Connector ENG_D .............................................. 140
Compressor Clutch .............................................. 115 Connector ENG_H .............................................. 141
Compressor Clutch Relay .................................... 114 Connector ENG_T ............................................... 141
Compressor, Seat ................................................ 114 Connector ESS .................................................... 141
Connector 108F ................................................... 124 Connector FFH .................................................... 141
Connector 140M .................................................. 124 Connector FLSHR ............................................... 142
Connector 197F ................................................... 124 Connector FM ...................................................... 142
Connector 197M .................................................. 124 Connector FRONT .............................................. 142
Connector 202M .................................................. 125 Connector FWM .................................................. 143
Connector 209F ................................................... 125 Connector FWMG ............................................... 143
Connector 209M .................................................. 125 Connector FWW .................................................. 143
Connector 20M .................................................... 125 Connector GHC ................................................... 143

4002-178
Connector GNO CAB_SPL ................................. 144 Connector RSPK ................................................. 156
Connector GNO_CAB_SPL2 ............................... 144 Connector RTHP ................................................. 156
Connector HO ...................................................... 144 Connector RWM .................................................. 156
Connector HO_E ................................................. 144 Connector RWMG ............................................... 157
Connector HO_N ................................................. 145 Connector RWW ................................................. 157
Connector HOM ................................................... 145 Connector S_KEY ............................................... 157
Connector HOT ................................................... 145 Connector SBE .................................................... 157
Connector HVAC_CAN1 ..................................... 146 Connector SBU ................................................... 158
Connector HVAC1 ............................................... 145 Connector SC ...................................................... 158
Connector HVAC2 ............................................... 145 Connector SCS ................................................... 158
Connector ISS ..................................................... 146 Connector SOC ................................................... 158
Connector K_WCO .............................................. 146 Connector SOR ................................................... 159
Connector LBEE .................................................. 146 Connector SETHR ............................................... 159
Connector LLF ..................................................... 147 Connector SFC .................................................... 159
Connector LLFW ................................................. 147 Connector SFL .................................................... 159
Connector LLR_12 .............................................. 147 Connector SFNR ................................................. 160
Connector LLR_E ................................................ 147 Connector SFWW ............................................... 160
Connector LLR_N ................................................ 148 Connector SHC ................................................... 160
Connector LLRW ................................................. 148 Connector SHZ .................................................... 160
Connector LPL ..................................................... 148 Connector SPB .................................................... 161
Connector LRF .................................................... 148 Connector SPC ................................................... 161
Connector LRFW ................................................. 148 Connector SPE .................................................... 161
Connector LRR_12 .............................................. 149 Connector SPK .................................................... 161
Connector LRR_E ............................................... 149 Connector SPL_BCK_LGT .................................. 162
Connector LRR_N ............................................... 149 Connector SPL_BCK_LGT2 ................................ 162
Connector LRRW ................................................ 149 Connector SPL_BCK_LT_GO ............................. 162
Connector LSPK .................................................. 149 Connector SPL_BCK_LT_G02 ........................... 163
Connector OSS ................................................... 150 Connector SPL_ENG_GNO ................................ 163
Connector PAF .................................................... 150 Connector SPL_HOOO_GNO ............................. 163
Connector PBO .................................................... 150 Connector SPL_PEO_BL .................................... 164
Connector PBL .................................................... 150 Connector SPL_PEO_BL_GO ............................. 164
Connector PBW ................................................... 150 Connector SPL_PIN ............................................ 164
Connector P01 .................................................... 151 Connector SPL_PK1 ........................................... 165
Connector P02 .................................................... 151 Connector SPL_PK2 ........................................... 165
Connector PR ...................................................... 151 Connector SPL_PK3 ........................................... 166
Connector PRB1 .................................................. 151 Connector SPL_ROOF ........................................ 166
Connector PRB2 .................................................. 151 Connector SPL_SEC_STR ................................. 166
Connector PRBF ................................................. 152 Connector SPL_TRN_GRO ................................. 167
Connector PRM_A 1 ............................................. 152 Connector SPL_TRNS_PWR .............................. 167
Connector PRM_B1 ............................................. 152 Connector SRC ................................................... 167
Connector PRM_B2 ............................................. 152 Connector SRC_1 ............................................... 167
Connector PRM_C1 ............................................ 152 Connector SRHSTLK .......................................... 168
Connector PRM_C2 ............................................ 153 Connector SRTO ................................................. 168
Connector PRM_01 ............................................ 153 Connector SRWP ................................................ 168
Connector PRM_E1 ............................................. 153 Connector SS_TR ............................................... 168
Connector PRM_E2 ............................................. 153 Connector SSM ................................................... 169
Connector PSS .................................................... 153 Connector STA .................................................... 169
Connector PXF .................................................... 154 Connector STE .................................................... 169
Connector PXH .................................................... 154 Connector SW_PO .............................................. 170
Connector PXM ................................................... 154 Connector SWL ................................................... 170
Connector PXT .................................................... 154 Connector TCOT ................................................. 170
Connector RAO ................................................... 154 Connector TOM ................................................... 170
Connector RAO_J1 .............................................. 155 Connector TECM ................................................. 171
Connector RAO_J2 .............................................. 155 Connector TR_SS ............................................... 172
Connector RAO_J3 .............................................. 155 Connector TRAN_E ............................................. 172
Connector RECT ................................................. 155 Connector TRANS ............................................... 172
Connector ROOF ................................................. 156 Connector TRC ................................................... 173

4002-179
Connector TS1 .................................................... 173 Fuel Filter Heater Relay ....................................... .46
Connector TS2 .................................................... 173 Fuel Level Sender ................................................. 67
Connector TSS .................................................... 174
Connector WIF .................................................... 174 G
Connector WSH ................................................... 174 Grid Heater ............................................................ 47
Connector YCS .................................................... 174 Grid Heater Relay ................................................. .47
Connector YFN .................................................... 174
Connector YFR .................................................... 174 H
Connector YPB .................................................... 175 Hazard Switch ....................................................... 85
Connector YPE .................................................... 175 Heater
Connector YPP .................................................... 175 Fuel Filter .......................................................... 48
Connector YRC ................................................... 175 Grid ................................................................... 47
Connector YSS .................................................... 175 Water Separator ................................................ 47
Connector, Diagnostic ........................................... 63 Height Control Switch ............................................ 53
Coolant Level Sender ............................................ 74 Height Control/Return-To-Travel Proximity Switch 55
Crank Control Relay ............................................. .41 High-Low Beam Switch ......................................... 85
Crank Request Relay ........................................... .41 Hood
Down Relay ..................................................... 122
D Motor ............................................................... 123
Declutch Brake Switch ........................................... 63 Switch ............................................................. 122
Declutch Switch ..................................................... 63 Up Relay ......................................................... 122
Diagnostic Connector ............................................ 63 Horn ....................................................................... 90
Diodes Horn Relay ............................................................ 90
Lights ................................................................. 81 Horn Switch ........................................................... 85
Secondary Steering ......................................... 105 Hydraulic Filter Restriction Switch ......................... 72
Wipers ............................................................. 103 Hydraulic Oil Temperature Sender ........................ 72
Dome Lamp ........................................................... 79
Door Switch ........................................................... 78
Driving Lamp Switch .............................................. 86 Ignition Switch ....................................................... 43
Instrument Cluster Connector 1 ............................ 65
E Instrument Cluster Connector 2 ............................ 71
Electrical Wire Identification .................................... 8 Intermediate Speed Sensor ................................... 63
Electromagnetic Detents ....................................... 54
Electronic Diesel Control ....................................... 51 L
Engine Speed Sensor ............................................ 63 Lamp
Dome ................................................................ 79
F High Beam .................................................. 88, 89
Fan PWM Solenoid ................................................ 61 Left Hand Front Combination ............................ 88
Fan Reverse Relay ................................................ 59 Left Hand Front Work ........................................ 79
Fan Reversing Solenoid ........................................ 61 Left Hand Rear Combination (Europe Only) ..... 95
Fan Reversing Switch ............................................ 59 Left Hand Rear Combination (North America Only)
Filter Maintenance Switch ..................................... 63 ............................................................ 94
Flasher Module ...................................................... 84 Left Hand Rear Work ........................................ 80
FNR Switch for Joystick Controls .......................... 63 License Plate (Europe Only) ............................. 96
FNR Switch for Single Axis Controls ..................... 63 License Plate (North America Only) .................. 95
Front Low Beam ................................................... 88, 89
Left Hand Work Lamp ....................................... 79 Position ....................................................... 88, 89
Right Hand Work Lamp ..................................... 80 Right Hand Front Combination .......................... 89
Front Left Hand Combination Lamp ...................... 88 Right Hand Front Work ..................................... 80
Front Right Hand Combination Lamp .................... 89 Right Hand Rear Combination (Europe Only) ... 93
Front Washer Pump Motor .................................. 102 Right Hand Rear Combination (North America
Front Wiper and Washer Switch .......................... 100 Only) .................................................. 92
Front Wiper Cut Out Relay .................................... 98 Right Hand Rear Work ...................................... 80
Front Wiper High Speed Relay .............................. 98 Switch, Driving .................................................. 86
Front Wiper Low Speed Relay ............................... 99 Turn ............................................................. 88, 89
Front Wiper Motor ................................................ 101 Left Hand Front Combination Lamp ...................... 88
Fuel Filter Heater .................................................. .48 Left Hand Front Work Lamp .................................. 79
4002-180
Left Hand Rear Combination Lamp (Europe Only) 95 Rear
Left Hand Rear Combination Lamp (North America Left Hand Combination Lamp (Europe Only) .... 95
Only) ......................................................... 94 Left Hand Combination Lamp (North America
Left Hand Rear Work Lamp ................................... 80 Only) .................................................. 94
Left Speaker ........................................................ 112 Left Hand Work Lamp ....................................... 80
License Plate Lamp ......................................... 95, 96 Right Hand Combination Lamp (Europe Only) . 93
License Plate Lamp (Europe Only) ........................ 96 Right Hand Combination Lamp (North America
License Plate Lamp (North America Only) ............ 95 Only) .................................................. 92
Lights Diodes ......................................................... 81 Right Hand Work Lamp ..................................... 80
Locating Components on the Schematic Posters .. 38 Rear Washer Pump Motor ................................... 102
Rear Wiper and Washer Switch ............................ 99
M Rear Wiper Motor ................................................ 102
Magnetic Detents ................................................... 54 Redundant Brake Pressure Switch 1 .................... 73
Master Disconnect Switch .................................... .42 Redundant Brake Pressure Switch 2 .................... 73
Module Relay
Flasher .............................................................. 84 Backup Alarm .................................................... 76
Secondary Steering ......................................... 106 Brake Lamps ..................................................... 83
Time Delay ........................................................ 42 Compressor Clutch ......................................... 114
Transmission Electronic Control ....................... 63 Crank Control .................................................... 41
Motor Crank Request .................................................. 41
Hood ................................................................ 123 Fan Reverse ..................................................... 59
Starter ............................................................... 43 Front Wiper Cut Out .......................................... 98
Front Wiper High Speed ................................... 98
N Front Wiper Low Speed .................................... 99
Neutral Start Relay ............................................... .44 Fuel Filter Heater ............................................. .46
Grid Heater ....................................................... 47
0 Hood Down ..................................................... 122
Outlet, Power ....................................................... 111 Hood Up .......................................................... 122
Output Speed Sensor ............................................ 63 Horn .................................................................. 90
Neutral Start ...................................................... 44
p Parking Brake ................................................... 66
Parking Brake Relay .............................................. 66 Pilot Control ...................................................... 55
Parking Brake Solenoid ......................................... 67 Power Relay Module A Ignition Power ............. .46
Parking Brake Switch ............................................ 73 Power Relay Module B Ignition Power ............. .46
Pilot Control Relay ................................................. 55 Power Relay Module C Water Separator Htr .... 46
Pilot Control Switch ............................................... 60 Power Relay Module D Accessory Power ....... .48
Pilot Pressure Solenoid ......................................... 56 Power Relay Module E Power Converter ....... 111
Pin Engage Solenoid ............................................. 56 Ride Control ...................................................... 58
Pin Engage Switch ................................................ 56 Starting .............................................................. 40
Potentiometer Voltmeter ........................................................... 44
Throttle .............................................................. 50 Resistor
Power Converter (24 volts to 12 volts) ................ 111 Alternator .......................................................... 40
Power Outlet ........................................................ 111 Return to Dig Switch Switch .................................. 55
Power Relay Module Return-To-Dig Proximity Switch ............................ 54
A Ignition Power ............................................... .46 Return-To-Travel/Float Switch .............................. 53
B Ignition Power ............................................... .46 Ride Control Relay ................................................ 58
C Fuel Filter Heater ........................................... 46 Ride Control Solenoid ........................................... 60
D Accessory Power .......................................... .48 Ride Control Switch ............................................... 58
E Power Converter 24V to 12V ....................... 111 Right Hand Front Combination Lamp .................... 89
Proximity Switch Right Hand Front Work Lamp ................................ 80
Height Control/Return-To-Travel ....................... 55 Right Hand Rear Combination Lamp (Europe Only) .
Return-To-Dig ................................................... 54 93
Right Hand Rear Combination Lamp (North America
R Only) ......................................................... 92
Right Hand Rear Work Lamp ................................ 80
Radiator Coolant Temperature Sender ................. 68
Right Speaker ...................................................... 112
Radio
Rollback Jumper .................................................... 61
12 Volt ............................................................. 112
4002-181
Rollback Pressure Switch ...................................... 60 Door .................................................................. 78
Rotating Beacon (Option) ...................................... 78 Driving Lamp ..................................................... 86
Fan Reversing ................................................... 59
s Filter Maintenance ............................................. 63
Seat Compressor and Switch .............................. 114 FNR for Joystick Controls ................................. 63
Secondary Steering FNR for Single Axis Controls ............................ 63
Module ............................................................ 106 Front Wiper and Washer ................................. 100
Motor ............................................................... 107 Hazard .............................................................. 85
Pressure Switch .............................................. 107 Height Control ................................................... 53
Solenoid .......................................................... 105 High-Low Beam ................................................. 85
Secondary Steering Diodes ................................. 105 Hood ............................................................... 122
Sender Horn .................................................................. 85
Coolant Level .................................................... 7 4 Hydraulic Filter Restriction ................................ 72
Fuel Level .......................................................... 67 Ignition .............................................................. 43
Hydraulic Oil Temperature ................................ 72 Master Disconnect ............................................ 42
Radiator Coolant Temperature .......................... 68 Pad .................................................................... 70
Torque Converter Output Temperature ............. 63 Parking Brake .................................................... 73
Sensor Pilot Control Switch ........................................... 60
Engine Speed .................................................... 63 Pin Engage ....................................................... 56
Intermediate Speed ........................................... 63 Proximity, Height Control/Return-To-Travel ...... 55
Output Speed .................................................... 63 Proximity, Return-To-Dig ................................... 54
Transmission Solenoid Valve and Temperature ... Rear Wiper and Washer .................................... 99
63 Redundant Brake Pressure 1 ............................ 73
Turbine Speed ................................................... 63 Redundant Brake Pressure 2 ............................ 73
Water In Fuel ..................................................... 50 Return to Dig ..................................................... 55
Shifter, Transmission ............................................. 63 Return-To-Travel/Float ...................................... 53
Solenoid Ride Control ...................................................... 58
Fan PWM .......................................................... 61 Rollback Pressure ............................................. 60
Fan Reversing ................................................... 61 Seat Compressor ............................................ 114
Parking Brake .................................................... 67 Secondary Steering Pressure ......................... 107
Pilot Pressure .................................................... 56 Transmission Auto ............................................ 63
Pin Engage ........................................................ 56 Transmission Enable ......................................... 63
Ride Control ...................................................... 60 Transmission Kick-down ................................... 63
Secondary Steering ......................................... 105 Turn Signal ........................................................ 85
Speaker Work Lamps ...................................................... 78
Left .................................................................. 112 Switch Pad ............................................................ 70
Right ................................................................ 112
Specifications .......................................................... 7 T
Speed Resistors Thermal Fuse
Blower Motor ................................................... 118 Blower Motor ................................................... 118
Starter Motor .......................................................... 43 Throttle Potentiometer ........................................... 50
Starting Relay ........................................................ 40 Time Delay Module .............................................. .42
Steering Torque Converter Output Temperature Sender .... 63
Secondary, Module ......................................... 106 Transmission Auto Switch ..................................... 63
Secondary, Motor ............................................ 107 Transmission Electronic Control Module ............... 63
Secondary, Pressure Switch ........................... 107 Transmission Enable Switch ................................. 63
Secondary, Solenoid ....................................... 105 Transmission Kick-down Switch ............................ 63
Switch Transmission Shifter .............................................. 63
A/C High/Low Pressure ................................... 115 Transmission Solenoid Valve and Temperature Sen-
Air Filter Restriction ........................................... 67 sors ........................................................... 63
Back-up Alarm Disable ...................................... 76 Turbine Speed Sensor .......................................... 63
Beacon .............................................................. 79 Turn Signal Switch ................................................ 85
Blower ............................................................. 119
Brake Lamp Pressure ....................................... 83 u
Brake Warning Pressure ................................... 68 Understanding the Troubleshooting Tables .......... 38
Declutch ............................................................ 63
Declutch Brake .................................................. 63

4002-182
v
Voltmeter Relay .................................................... .44
w
Warning Buzzer ..................................................... 66
Water In Fuel Sensor ............................................. 50
Water Separator
Heater ............................................................... 47
Heater Relay ..................................................... 46
Wiper
Front Cut Out Relay .......................................... 98
Front Motor ...................................................... 101
Front Switch .................................................... 100
Front Washer Pump Motor .............................. 102
Front Washer Switch ....................................... 100
Front Wiper High Speed Relay ......................... 98
Front Wiper Low Speed Relay .......................... 99
Rear Motor ...................................................... 102
Rear Switch ....................................................... 99
Rear Washer Pump Motor .............................. 102
Rear Washer Switch ......................................... 99
Wiper Diodes ....................................................... 103
Wire Identification .................................................... 8
Work Lamp Switch ................................................. 78

Section
4003
BATTERIES

Racine, WI 53404 U.S.A. Bur 6-42331 Issued April, 2003 Revised February, 2007
4003-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHARGING A BATTERY ................................................................... 7
Charging Guide For Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging Guide For Batteries Other Than Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

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

released when the battery is turned upside
down. If you turn the battery upside down,
make sure that the end of the ventilation tube
is away from you and away from any other
people in the area. Battery acid can cause
severe burns.
48-57B
SPECIAL TOOLS
The CAS1 0147 tester is used to do the Capacity

(Load) Test. This tool is first used on Page 6.

4003-4
MAINTENANCE
Electrolyte Level Inspecting and Cleaning a Battery

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

4003-5
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the
battery.
CD
160- -•.032
0
70-
--•.030
150- -•.028 =-•.028
--•.026
140- -•.024
Visual Checks 130-
--•.022
-•.020
60-
=-•.021
--•.018
120- -+.016 so-
--+.014
1. Make sure the cable connections are clean and 110- -•.012
=-•.014
100- _--;:ooa--•.010 40-
tight. Clean foreign material from the top of the --•.006 -=--•.007
90- -•.004
battery. --•.002 30-
80-
70-
---.002
~-.006
26.7----=
20-
-
2. Inspect the battery case, battery posts, and 60- --.008 =--.007
---.010
cables for damage. 50- --.012
---.014 10-
40- --.016 =--.014
-~-.018
3. Check the electrolyte level. See Page 4. 30-
---.022
o-
20- --.024 =--.021
---.026
10- -10-
4. If you added water to the battery, the battery ~-.030 =--.028
0- --.032
must be charged for 15 minutes at 15 to 25 -20-
amperes to mix the water with the electrolyte.
B790863
Specific Gravity Check
1. TEMPERATURE IN F 2. TEMPERATURE INC
A hydrometer is used to check the specific gravity SPECIFIC GRAVITY CHART
(weight) of the electrolyte. The specific gravity is an 4. Make a record of the corrected specific gravity
indication of the level of charge for each cell. reading for each cell.
Hydrometers are made to show the correct specific 5. If the difference between the high reading and
gravity when the temperature of the electrolyte is the low reading is 0.050 or more, charge the
26.7°C (80°F). battery and check the specific gravity again. If
When you check the specific gravity, you must know after charging, the difference is still 0.050 or
the temperature of the electrolyte. If your hydrometer more, install a new battery.
does not have a thermometer, get a thermometer to 6. The corrected specific gravity reading shows the
check the temperature of the electrolyte. The level of charge for the cell. The level of charge
thermometer must indicate a high temperature of at must be at least 75% in each of the cells. In
least 52°C (120°F). maintenance free batteries the level of charge is
1. Remove enough electrolyte from a cell so that at least 75% if the corrected specific gravity
the float is free in the tube. reading is 1.240 or higher. In all other batteries
the level of charge is at least 75% if the corrected
NOTE: If the specific gravity cannot be checked specific gravity reading is 1.230 or higher.
without first adding water to the cell, the battery must
be charged for 15 minutes at 15 to 25 amperes to mix 7. If the difference between the high reading and
the water with the electrolyte. Then check the specific the low reading is less than 0.050, and the level
gravity. of charge is at least 75% in all of the cells, do the
Capacity (Load) Test.
2. Read the float.
8. If the difference between the high reading and
3. Read the thermometer. If the reading is above the low reading is less than 0.050, but the level of
26.7°C (80°F) add specific gravity points to the charge is less than 75% in any of the cells,
reading for specific gravity. If the reading is below charge the battery and check the specific gravity
26.5°C (80°F) subtract specific gravity points again. If after charging:
from the reading for specific gravity. See the
following illustration and add or subtract specific A. The level of charge is less than 75% in any of
gravity points as needed. the cells, discard the battery.
B. The level of charge is at least 75% in all of the
cells, do the Capacity (Load) Test.

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

ARROW AWAY FROM
BATTERY)

4003-7
CHARGING A BATTERY
The charging rate must be decreased if:
h WARNING: Never try to charge the battery if
. . . the electrolyte in the battery is frozen. 1. Too much gas causes the electrolyte to flow from
47·83
the cells.
Before you charge the battery, check the level of the 2. The temperature of the electrolyte rises above
electrolyte. 52°C (125°F).
It is difficult to give an exact charging rate because of NOTE: For the best charge, use the slow charging
the following variable conditions: (1) temperature of rates.
the electrolyte, (2} level of charge, and (3} condition
The battery is fully charged when, over a three hour
of the battery. Use the charging guide for the correct
period at a low charging rate, no cell is giving too
charging rate and time.
much gas, and the specific gravity does not change.
See Specifications in Section 4001 for the reserve
capacity of the battery in this machine.
Charging Guide For Maintenance Free Batteries

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

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

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

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

Above 125 to 170 Minutes 10 Hours at 10 Amperes 2 Hours at 50 Amperes

*Initial rate for standard taper charger.
NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If
the center part of the decal has been removed to get access to the battery caps, it is possible the words
Maintenance Free will have been removed from the decal.
Continued on next page

4003-8
Charging Guide For Batteries Other Than Maintenance Free

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

Reserve Capacity under Slow Charge Fast Charge
Specifications

80 Minutes or Less

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

Above 125 to 170 Minutes

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

1. Remove the caps from the battery. 5. Charge the battery at 30 amperes until the
specific gravity is 1 .250 or more and the
2. Fill each cell to the top of the separators with
temperature of the electrolyte is at least 15.5°C
electrolyte. This will permit the volume of
(60°F).
electrolyte to increase when heated by charging
the battery. 6. If necessary, fill each cell with electrolyte until the
electrolyte is just below split ring at the bottom of
3. Install the caps on the battery.
the cell opening.
4. Connect a battery charger to the battery.

Section
4005
INSTRUMENT CLUSTER

4005-2
TABLE OF CONTENTS
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Navigating Through The LCD Multi-function Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Entering The Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Select Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hardware Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Software Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Language Screen, Measurement Units, and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fan Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Display Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RPM .............................................................................. 13
MPH/KPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General Fault Code Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fault Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LCD Fault Code Display Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ENGINE FAULT CODES ................................................................... 18
TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4005-3
INSTRUMENT CLUSTER
1. LOW BRAKE PRESSURE INDICATOR 9. LACK OF AUX STEER PRESSURE (OPTIONAL)

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

4005-4
Self-Test Power Circuit Test

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

4005-5
LCD Multi-function Display 2. This example, shows that the Transmission

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

4005-6
Navigating Through The LCD Using The Arrow Keys

Multi-function Display Screens At any time, during operation or with the key switch
on, the operator may scroll through three information
screens and two trip screens by using the arrow
keys. These five screens are in a circular loop and
may be reached by pressing the up or down key. The
following sequence is using the down key only.
NOTE: Pressing the escape key will return the LCD
back to the normal driving screen.
BD06F186
Located on the steering column, just to the left of the
Park Switch, is the key pad. Use this key pad to
move from one screen to another, choose various
selections, monitor the machine functions, and
retrieve information. All functions can be accessed in
the same basic manner.
A. Escape key: Use this key to exit and return to
BD06F188
the driving screen. Use this key anytime you
would like to start over and begin again, plus From the driving screen push the down arrow, as
use to check active, acknowledge errors. shown.
B. Enter key: Use this key to confirm, yes, this is

the desired function.
C. Up arrow key: Use this key to scroll up to
selections.
D. Down arrow key: Use this key to scroll down
to selections.
NOTE: Arrows on the screen will indicate if
selections are up or down from the current selection.
NOTE: Display units can be changed by the
operator.
Info 1 is the first information screen using the down

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

4005-7
69
Press the down button again and the Trip 1 screen
BD06F027
will display. The LCD provides two trip computers.
Info 2 will be displayed next. The Info 2 screen will These will display since last reset the total time in
display coolant temperature, turbocharger air hours, the total fuel, and the average fuel
temperature, engine oil temperature in either consumption per hour.
Fahrenheit or Celsius, as well as oil pressure PSI.
BD06F170
By continuing to scroll down, the fifth screen will
BD06F184
Push the down button again and the Info 3 screen. display the Trip 2 screen. Trip 1 and Trip 2 screens
This screen displays the temperature in Fahrenheit can be reset independently. The previous screen can
or Celsius of the transmission oil, hydraulic oil, sump be accessed by using the up arrow key.
oil, and radiator coolant temperature.

4005-8
Reset The Trip Information
BD06F170 The trip screen will indicate a reset message. At this

Highlight the trip screen you wish to set. screen, press confirm to clear the numbers and reset
the trip information. The current date and time will
display automatically. The hours, fuel consumption,
and fuel used per hour will reset and revert to zero.
BD06F187
Press the confirm button to reset the trip selection to
zero.

4005-9
Entering The Service Screens

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

4005-10
*The tests in the configuration menu should be Software Screen
performed only by a qualified operator or technician,
as some tests require the engine to be running at
high RPM's.
Select Screen
The select screen will allow you to make time
settings as well as give access to machine
information. Navigate this screen by highlighting your
selection and pressing confirm. This will allow you to
change clock settings or view the hardware and
software screens. No operator changes can be made
to the hardware or software screens.
BD06H028
The cluster software selection will display the CNH
part number, serial number, ID number and software
version of the Instrument cluster. This display is a
convenient source of information when ordering parts
or accessories. Press escape to exit from this field
and return to the selection menu or use the up or
down arrow key to toggle to the software information
screen.
Selecting Power Modes
The power mode allows the operator to choose the
BS06F177 most effective machine power for the current job
Hardware Screen conditions. Most commonly auto is chosen, as the
power will automatically increase or decrease
Scroll to the hardware selection and press confirm to between maximum power and standard power while
display machine information. the machine is working. This allows for maximum
power if necessary, but will switch to standard mode
for economy. Maximum power can be chosen for
more severe work conditions. Economy can be
chosen for limited power and fuel efficiency.
Press and hold the confirmation button for two
seconds to arrive at the service screen.
The cluster hardware selection will display the CNH

part number, serial number, ID number and version
of the Instrument cluster. This display is a convenient
source of information when ordering parts or
accessories. Press escape to exit from this field and
return to the selection menu or use the up or down
arrow key to toggle to the software information BD06H038
screen. At the screen shown above, highlight the power
mode and press the confirmation button to move to
the Power Mode Selection Menu.

4005-11
Preferences
78
At the Power Mode Menu press the confirmation BD06F179
button again to activate the selections. The Language Screen, Measurement Units,
highlighted section will flash to indicate a new
and Clock
selection can be made.
The LCD screen can be set with language, units, and
Press the up or down button to select the Power
clock preferences. Use the arrow keys to scroll to the
Mode, and then press the confirmation button again.
preferences menu. Press confirm.
This changes the mode and locks it into memory.
Choose the preferences desired, language in
The selected mode will display in zone 3 (bottom) of
(English, Italian, Spanish, Portuguese, German,
the Multi-Function Display when power mode is
French, measurement units in English, Metric, or
correctly selected.
Imperial and clock units in either 12 or 24 hour).
NOTE: Selecting options and navigating through the Highlight the preference you wish to change and
screen menus are similar for all functions. The press the confirm key. The preference will flash and
display will tell the operator if errors have occurred. allow you to scroll through the choices. When the
correct preference is chosen, use the confirm key to
lock in the preference for the display. The escape
key will allow you to leave this application.
BD06F176
Should an error message display, press the
confirmation button to acknowledge and begin again.

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

4005-13
Auto Idle
Idling can be changed from automatic to a fixed rate.
The fixed idle rate is defined as Standard Idle at 900
RPM. Highlight the auto idle selection by using the
arrow keys, then press confirm. When you have
chosen the selection, lock the selection into memory
by pressing the confirm key.
Display Menu
The display menu can be used to change the
background and brightness of the screen. Use the
arrow keys to make your selection from the display
menu and press the confirm key to lock the selection
into memory. The screen display can be changed to
Options Menu suit working conditions for day and night separately.
Use the arrow keys to choose the options menu. RPM
Press the confirm key, and the options sub-menu will
Engine speed in RPM will show on the display if the
appear. The options menu will allow the operator to
engine speed is running up to 550 RPM's, and will
choose options for the fan, idle.
disappear if the engine speed is lower than 300
Fan Auto RPM.
The fan can be set to run at automatic or the fan will MPH/KPH
run at maximum speed. Automatic is the more
common or preferred setting. It will change speeds Vehicle speed will show on the display if it is up to 1.0
and reverse as conditions require depending on MPH I 1.5 KPH and will disappear if the vehicle
actual temperature of the coolant, turbocharger air, speed is less than 0.6 MPH I 1.0 KPH.
transmission oil, and hydraulic oil.
The operator can choose fan speed or reversing
capabilities. Highlight the fan auto selection by using
the arrow keys and then press confirm. When you
have chosen the selection, lock the selection into
memory by pressing the confirm key.

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

1. Press and hold the escape key and up arrow key
for more than 2 seconds to access the fault
codes.
BD07C010
1. If a fault code occurs, it will be displayed in the
upper zone of the LCD. Depending on how
critical the code is, the RED master STOP or the
BD06F186
YELLOW caution indicator will also come on.
A. Escape key
B. enter key
C. up key
D. down key
2. Yellow Faults, buzzer will beep once every 2
seconds:
A. Operator can acknowledge it by pressing the
enter key.
B. The message will disappear.
C. Buzzer will not beep anymore.
D. Yellow lamp will stay ON.
E. Fault will remain in Yellow list until it is closed. 2. To retrieve the code/s, press the two upper
buttons of the keypad for 2 seconds. When the
3. Red Faults, buzzer will be continuous, screen comes up press ENTER on the category
alternating sounds: with codes present.
A. Operator can acknowledge it by pressing the
enter key.
B. Buzzer will change to a less stressing sound,
but will remain.
C. Message will remain on display with indication
of URGENT STOP.
2
3. If more than one code is present in the category,
scroll through to each by pressing the DOWN
button on the keypad.
4005-15
LCD Fault Code Display Breakdown
Pri~nw <AJ~r Rum:ber in the

RED list attd Will of
YELLOW Err~r in the fist
WHitE
MEBORY
BD07C009
Fault Code Grouping

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

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

1311 Engine air filter blocked Change filter
1312 Hydraulic oil temperature above normal 1. Stop machine operations
2. Run engine at 1500 rpm
1313 Hydraulic oil temperature to high 3. Check fan operation
1314 4. Check cooling core for clogs
Transmission oil temperature above normal
1315 Transmission oil temperature to high
1. Stop machine operations
1316 Brake pressure too low 3. Check brake system pressure
4. Check brake system for leaks
1317 Steering pressure too low 3. Check steering system for operation
4. Check steering system for leaks
1318 Engine coolant temperature above normal 1. Stop machine operations
1319 Engine coolant temperature high - critical 3. Check fan operation
4. Check radiator core for clogs
1320 Engine oil pressure too low 1. Stop machine operations
2. Check engine oil level
1321 Engine oil pressure below normal 3. Check pressure sender unit
1. Check engine oil for proper type
1322 Engine oil pressure above normal 2. Check pressure sender unit
1323 Battery voltage low
Check charging system
1324 Battery voltage high
1325 Oil temperature too high 2. Run engine at 1500 rpm
3. Check sending unit
1326 Coolant level low Fill radiator level
1327 Moved during accelerated idle No information available at time of print.
1328 Moving when shifting to low idle No information available at time of print.
Electrical charging system voltage low - 1. Stop machine operations
1331 2. Check charging system
critical level
1332 Water detected in fuel Drain fuel filter
1333 Engine overspeed Check engine speeds
1334 Intake manifold temperature high - critical Check for defective or clogged after cooler
1335 Brake pressure too low 3. Check brake system pressure
4. Check brake system for leaks

4005-17
1336 Transmission oil filter blocked Replace filter
NOTE: The following fault codes are for optional climate controlled heating and air conditioning system.
DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR
1909 Open circuit evaporator temperature sensor AC relay compressor is disabled.

1. Check sensor for short circuit to ground or
open circuit.
1910 Short circuit evaporator temperature sensor
2. Check harness between control module and
relay.
1. Verify if the system controls are functioning
Water valve motor output failure, does not properly when requesting heat or AC.
1919
work correctly 2. The motor is working in a degraded mode,
replace valve.
1. Turn system on with fan speed on low, verify
position of flap.
Recirculation actuator DC motor output failure, 2. Place the fan speed on high, check position of
1920
does not work correctly flap.
3. Check harness between controller and flap
motor.
1. Check for proper connection of relay.
2. Replace relay with known good relay and retest
system.
1921 AC relay output failure, does not work. 3. Verify system activation when AC button is
pressed.
4. Check charge level of AC system.

4005-18
ENGINE FAULT CODES

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

or accelerator pedal defect.
3001 Foot throttle sensor signal not plausible
Check wiring, replace idle switch or replace
accelerator pedal.
3002 Short circuit in wiring or in accelerator pedal.

Foot throttle sensor signal above range max.
Check wiring or replace accelerator pedal.
Short circuit in wiring or in accelerator pedal.
3003 Foot throttle sensor signal below range min.
Check wiring or replace accelerator pedal.
3004 Foot throttle sensor- no signal Check wiring or replace accelerator pedal
Coolant temperature sensor signal not See OTS (Oil Temperature Sensor) plausibility
3006
plausible check (Fault 3033)
Sensor defective or short circuit to external
Coolant temperature sensor signal above
3007 source.
range max.
Check wiring or replace sensor.
Coolant temperature sensor signal below Sensor defective or short circuit to ground.
3008
range min. Check wiring or replace sensor.
No CAN plausibility check performed, restart
3009 Coolant temperature sensor null (via CAN) system, if problem reoccurs.
3015 Fuel temperature signal above range max. source.
Sensor defective or short circuit to ground.
3016 Fuel temperature signal below range min.
Boost pressure sensor signal above range
3019 source.
max.
3021 Boost pressure sensor null (via CAN) system, if problem reoccurs.
Difference of ambient and boost pressure is out
3022 Boost pressure sensor signal not plausible of range.
Atmospheric pressure sensor signal not
3023
plausible
Ambient pressure sensor inside ECU is defect.
Atmospheric pressure sensor signal above
3024 Replace ECU (not necessary if never running in
range max.
high altitude and if turbocharger is without VGT)
Atmospheric pressure sensor signal below
3025
range min.

4005-19

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

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

4005-20

CODE DEFINITION
STEPS FOR REPAIR
Cylinder 1 injector cable short-circuit low side Short circuit in wiring with external source.
3061
to battery Check the wiring or replace injector
3062 Cylinder 1 signal low
replace ECU
Defective coil of injector.
3063 Cylinder 1 short-circuit high side to ground
Check the wiring and replace injector
replace ECU
3065
replace ECU.
replace ECU
3069
3070 Check the wiring and the injection signals,

Cylinder 3 signal low
replace ECU.
replace ECU
3073
replace ECU.
replace ECU

4005-21

CODE DEFINITION
STEPS FOR REPAIR
3077
replace ECU.
replace ECU
3081
replace ECU.
Signal interrupted do to wiring problem, defective
or incorrectly installed crankshaft speed sensor.
3088 Crankshaft sensor lost synchronization Check wiring, sensor installation and proper
functioning of crankshaft sensor (evaluate raw
signals)
Check wiring, sensor installation and proper
3089 Crankshaft sensor defective functioning of crankshaft sensor (evaluate raw
signals).
or incorrectly installed camshaft phase sensor.
3090 Camshaft sensor lost phase Check wiring, sensor installation and proper
functioning of camshaft phase sensor (evaluate
raw signals)
Camshaft sensor phase synchronization
3091 functioning of camshaft phase sensor (evaluate
failure
raw signals).
or incorrectly installed camshaft or crankshaft
Offset between camshaft and crankshaft sensor.
3093
outside boundaries Check wiring, sensor installations and proper
functioning of camshaft and crankshaft sensors
(evaluate raw signals)
3095 Operating with camshaft sensor only functioning of crankshaft sensor (evaluated raw
signals).
Short circuit of wiring to ground or defective
Rail pressure sensor CP3 signal below range pressure sensor.
3102
min. Check wiring and proper functioning of rail
pressure sensor

4005-22

CODE DEFINITION
STEPS FOR REPAIR
Defective rail pressure sensor, defect in other

injection relevant component.
3104 Rail pressure relief valve open Check rail pressure sensor for plausible values,
ensure proper functioning of the injection
components
PRV does not open once the pressure limit is
reached: Mechanical defect or wrong application
Rail pressure relief valve pressure shock
3105 parameter.
requested
Check application value of maximum rail
pressure, check functioning of the PRV
PRV does not open even after pressure shock:
Rail pressure relief valve did not open after Stuck PRV or wrong application parameter.
3106
pressure shock Check application value of maximum rail
pressure, check functioning of the PRV
Short circuit of wiring to external source or inside
Metering unit output short-circuit to battery on
3107 relay.
low side
Check wiring or replace relay
Rail pressure sensor offset monitoring signal
3110 Rail pressure sensor inaccurate.
above range max.
Ensure correct wiring and proper functioning of
Rail pressure sensor offset monitoring signal rail pressure sensor, replace sensor
3111
below range min.
Short circuit of wiring to external source or
defective pressure sensor, rail pressure
Rail pressure sensor CP3 signal above range
3112 overshoot.
max.
Check wiring and proper functioning of rail
pressure sensor
Short circuit of main relay to external source or
Grid heater battery switch relay short-circuit to defective main relay.
3113
battery Check the wiring connecting the battery to the
EDC or replace main relay
Short circuit to ground of main relay or defective
3114 Grid heater battery switch relay short-circuit to main relay.
ground Check the wiring connecting the battery to the
EDC or replace main relay
3118 ECM 12V sensor supply voltage high Ambient pressure sensor inside ECU is defective.
Replace ECU (not necessary if never running in
3119 ECM 12V sensor supply voltage low high altitude and if turbocharger without VGT)
Short circuit to ground of grid heater.
3131 Grid heater always switched on
Check grid heater switch and replace it
Broken or disconnected wiring or defective relay.
3137 Metering unit open load
Check of wiring or replace relay
Defective wiring, ECU, power stage or metering
unit.
3138 Metering unit signal not plausible
Check wiring, ECU, power stage and metering
unit

4005-23

CODE DEFINITION
STEPS FOR REPAIR
High pressure system: Rail pressure sensor

inaccurate, high pressure pump defective.
Set point of fuel volume flow through metering
3141 Low pressure system: Metering unit reflux too
unit is lower than calculated limit
low.
Check for defects according to failure list.
Oil temperature sensor signal above normal Check oil temperature sensor for accuracy and
3147
range check oil system.
3154 Grid heater relay short-circuit to battery relay.
3155 Short circuit of wiring to ground or inside relay.

Grid heater relay short-circuit to ground
3156 Grid heater relay no load
3161 Fan actuator signal low No information available at time of print.
High pressure side: Leakage in high pressure
section, injection nozzle stuck in open position,
worn high pressure pump, worn injector, leaking
3171 Fuel rail/system pressure -too low pressure relieve valve
Low pressure side: Pressure before gear pump
too low, gear pump output too low (fuel filter
clogged, leakage in low pressure side}.
Metering unit stuck in open position,
zero-delivery throttle clogged, metering unit
without power due to electrical error.
3172 Fuel rail/system pressure -too high
Low pressure side: Pressure before gear pump
too high (e.g. by pressure relieve valve), pressure
after zero-delivery throttle too high.
3173 Fuel rail/system pressure -too low See fault 3171
3174 Fuel rail/system pressure -too high See fault 3172
Leakage in the high pressure section, injection
nozzle stuck in open position, worn high pressure
3175 Fuel system leak detected - large leak
pump, worn injector, leaking pressure relieve
valve, injector reflux too high.
High pressure system: Leakage in the high
pressure section, injection nozzle stuck in open
position, worn or defective high pressure pump,
Fuel delivery exceeded threshold for pressure worn injector, leaking pressure relieve valve.
3176
in overrun mode Low pressure system: 'Zero delivery' is not active
in metering unit (excessive leakage in metering
unit).
Check for defects according to failure list.

4005-24

CODE DEFINITION
STEPS FOR REPAIR
Defective CAN controller of Body Computer,

3178 Time-out of CAN message BC2EDC1 undervoltage of BC, missing BC, CAN cable
connecting the BC is disconnected or broken.
Short circuit in wiring. Check presence and
correct connection of the BC to the network,
3179 Time-out of CAN message BC2EDC2 Check correct functioning of the BC CAN
controller and its voltage supply. Check wiring.
Defective CAN controller of Vehicle Control
Module, undervoltage of VCM, missing VCM,
CAN cable connecting the VCM is disconnected
or broken. Short circuit in wiring. Check presence
3180 Time-out of CAN message VCM2EDC
and correct connection of the VCM to the
network, Check correct functioning of the VCM
CAN controller and its voltage supply. Check
wiring.
3188 Cylinder 1 open load
3196 Cylinder 3 open load Broken wire or disconnection of wiring or inside
injector.
3200 Cylinder 4 open load Check the wiring or replace injector.
Short circuit of high-side to battery or ground.
3210 Bank 1 general short-circuit on injection cable
Check the wiring or replace injector.
Short circuit of low-side to ground in injector
Bank 1 injection cable short-circuit low side to
3211 cable.
ground
3212 Bank 1 no signal No information available at time of print.
cause the defect, internal ECU problem.
3213 Bank 1 unclassified error
replace ECU
Short circuit of high-side to battery or ground.
3218 Bank 2 general short-circuit on injection cable
Short circuit of low-side to ground in injector
Bank 2 injection cable short-circuit low side to
3219 cable.
ground
3220 Bank 2 no signal No information available at time of print.
cause the defect, internal ECU problem.
3221 Bank 2 unclassified error
replace ECU

4005-25

CODE DEFINITION
STEPS FOR REPAIR
Clock error or interruption of the power supply

voltage.
3227 Injection processor error- stop engine
Check the power supply or replace ECU if
problem reoccurs.
Defective ECU, reset ECU.
If no recovery, replace ECU.
Internal failure of ECU or 'TESTMODE' takes too
long.
Check 'TESTMODE' parameters or replace ECU
if problem reoccurs
Defective SPI-bus participant, timing problem
3230 due to software bug.
Injection processor error- stop engine
Replace ECU if problem reoccurs (Send in ECU
for investigation)
3232 Injection processor error- stop engine Defective ECU.
3233 Injection processor error- stop engine Replace ECU if problem reoccurs

Electric disturbances, internal defect of the ECU
3238 Communication error of CJ940 processor leading to a SPI bus communication error.
Replace ECU if failure remains present
3242 Recovery which is locked Electronic disturbances, various hardware
defects (ECU internal) or configuration problems.
3243 Recovery which is suppressed Analyze what error triggered the recovery (Read
out label HWEMon_numRecovery and compare
the value with the according table). If error occurs
3244 Recovery which is visible repeatedly, reprogram EDC. If error remains,
replace EDC.
Defective monitoring module or CPU (e.g.
impaired functioning of the CPU clock) of the
EDC. Disturbed SPI-Bus.
3245 Communication supervision watchdog control If error exists only temporary (i.e. injection
flag reoccurs) error can be ignored and error deleted
in the fault memory. In case of a permanent error
the injection remains blocked and the ECU has to
be replaced
Watch dog switch off path defect.
3246 Redundant shutoff paths during initial If failure remains after ECU initialization: replace
ECU
3247 Redundant shutoff paths during initial Electronic disturbances, internal ECU problem.
If failure remains after ECU initialization: replace
3248 Redundant shutoff paths during initial ECU

4005-26

CODE DEFINITION
STEPS FOR REPAIR
3253 Error status ADC monitoring

3254 Error status ADC monitoring Buffer overrun
3255 Error status ADC monitoring No additional information available at time of print
3256 Error status ADC monitoring

3258 Short-circuit to battery at high side power
relay.
stage
Short-circuit to ground at high side power Short circuit of wiring to ground or inside relay.
3259
stage Check of wiring or replace relay
3260 Open load at low side power stage
Short-circuit to battery or excessive
3261 relay.
temperature at low side power stage
Short circuit of wiring to ground or inside relay.
3262 Short-circuit to ground at low side power stage
Electronic disturbances, requested torque
increase via tester, wrong application of injection
3265 Energizing time exceeds limit of over run
relevant parameters, defective ECU.
monitoring
Check injection relevant application, if failure
persists replace ECU
Electronic disturbances, internal ECU problem.
3266 Plausibility error in engine speed check
If failure persists after reinstallation replace ECU
Excessive voltage supply of a CJ940 component:
High battery voltage, defective wiring, internal
defect of the EDC.
3278 Supply voltage CJ940 upper limit
Check the battery for correct voltage supply,
check wiring. If defect remains replace EDC
(internal defect)
Insufficient voltage supply of a CJ940
component: Low battery voltage, defective wiring,
internal defect of the EDC.
3279 Supply voltage CJ940 lower limit
Check the battery for sufficient voltage supply,
check wiring. If defect remains replace EDC
(internal defect)
Excessive battery voltage, defect in wiring
harness, electrical failure in connected sensors
or in the EDC.
3280 Sensor supply voltage 1 high
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC

4005-27

CODE DEFINITION
STEPS FOR REPAIR
Insufficient battery voltage, defect in wiring

harness, electrical failure connected sensors or
in the EDC.
3281 Sensor supply voltage 1 low
replace EDC
or in the EDC.
3283 Sensor supply voltage 2 high
replace EDC
in the EDC.
replace EDC
3285 or in the EDC.
Sensor supply voltage 3 high
replace EDC
in the EDC.
replace EDC
Turbo compound monitoring signal not
3290 No information available at time of print.
plausible

4005-28
TRANSMISSION FAULT CODES
1. Check the cables from the TCU to the FNR

switch.
4113 Logical error at FNR switch 2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch.
switch.
4114 Logical error at direction select signal 2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch signal combinations.
1. Check the cables from the TCU to the
4116 Logic error at park brake status instrument cluster connector 2 pin 6.
2. Check park brake switch.
switch.
4117 Logic error at direction select signal 2 2. Check the connectors from the TCU to the FNR
switch.
3. Check the FNR switch signal combinations.
4119 Short circuit to ground at ride control 1. Check the cables from the TCU to the ride
control relay.
4120 Short circuit to battery voltage at ride control 2. Check the connectors from the TCU to the ride
control relay.
4121 Open circuit at ride control 3. Check the ride control relay.
Short circuit to battery voltage or open circuit 1. Check the connectors.
4133
at temperature sensor 2. Check the temperature sensor.
4134 Short circuit to ground at temperature sensor
Short circuit to battery voltage or open circuit 1. Check the cables from TCU to the sensor.
4135
at converter output temperature sensor 2. Check the connectors.
3. Check the temperature sensor.
Short circuit to ground at converter output
4136
temperature sensor
1. Check the cables from TCU to the sensor.
Short circuit to battery voltage or open circuit 2. Check the connectors.
4137
at parking brake sensor input 3. Check the parking brake sensor.
Short circuit to battery voltage or open circuit 1. Check the parking brake fuse.
4145
at engine speed sensor 2. Check the parking brake relay.
4146 Short circuit to ground at engine speed sensor 3. Check the parking brake solenoid.

2. Check the connectors.
3. Check the speed sensor.
4147 Logical error at engine speed sensor input
NOTE: This fault code is reset after power up of the
TCU. It is also reset if the signal is above zero
speed threshold.

4005-29
Short circuit to battery voltage or open circuit

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

4005-30
4209 Short circuit to battery voltage at clutch K1

4210 Short circuit to ground at clutch K1
4211 Open circuit at clutch K1
4213 Short circuit to ground at clutch K2
1. Check the cable from the TCU to the
4216 Short circuit to ground at clutch K3 transmission control valve.
4217 Open circuit at clutch K3 2. Check the connectors from the TCU to the
transmission control valve.
4225 Short circuit to battery voltage at clutch K4 3. Check the regulator resistance.
4226 4. Check internal wire harness of the transmission
Short circuit to ground at clutch K4
control valve.
4228 Short circuit to battery voltage at clutch KV
4229 Short circuit to ground at clutch KV
4230 Open circuit at clutch KV
4231 Short circuit to battery voltage at clutch KR
4232 Short circuit to ground at clutch KR
4233 Open circuit at clutch KR
4241 Short circuit to ground at backup alarm relay 1. Check the cable from the TCU to the backup.
alarm relay.
Short circuit to battery voltage at backup alarm 2. Check the connectors from the backup alarm
4242
relay relay to TCU.
3. Check the resistance of backup alarm relay
4243 Open circuit at backup alarm relay circuit.
1. Check pressure at clutch K1.
2. Check main pressure in the system.
4273 Slippage at clutch K1 3. Check signal at internal speed sensor.
4. Check signal at output speed sensor.
5. Replace clutch.
5. Replace clutch.
5. Replace clutch.

4005-31

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

4005-32

Joystick status indicator short-circuit to battery 2. Check the connectors from the TCU to the
4293
voltage joystick.
2. Check the connectors from the TCU to the
4294 Joystick status indicator over current joystick.
Power supply for sensors short-circuit to 1. Check the cables from the sensors TCU.
4305 2. Check the connectors from the sensors to the
battery voltage
TCU.
4306 Power supply for sensors short-circuit to
ground
4307 Low voltage at battery 1. Check batteries.
2. Check B+ wires from batteries to TCU.
4308 High voltage at battery 3. Check voltage at TCU connector pin 45.
4309 Error at VPS 1 for solenoid power supply 1. Check fuse A2.
2. Check cable from control valve to TCU.
4310 3. Check connectors from control valve to TCU.
Error at VPS 2 for solenoid power supply
4. Replace TCU.
4325 Vehicle ID #1 time out No information available at time of print.
4326 Undefined VIN request via CAN. No information available at time of print.
4337 General EEPROM fault Replace the TCU.
4338 Reprogram the correct configuration for the

Configuration error
vehicle.
4339 Application error (ZF internal) Replace the TCU.
4341 Clutch calibration fault
Do the transmission clutch calibration procedure.
4342 Clutch adjustment data lost

4005-33
INSTRUMENT CLUSTER FAULT CODES

CODE DEFINITION
STEPS FOR REPAIR
9128 CAN timed out during operation

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

4005-34
NOTES

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

Steering Specifications, Pressure Checks, and Troubleshooting .................................... 5002
Steering Cylinders ........................................................................ 5005
Center Pivot ............................................................................. 5006
Auxiliary Steering Motor and Pump ........................................................... 5008
Joystick Steering System ................................................................... 5009

Racine, WI 53404 U.S.A. 84298385 Issued December, 2009
Section
5001
REMOVAL AND INSTALLATION OF STEERING

COMPONENTS

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

5001-3
STEERING CONTROL VALVE
Removal STEPS
NOTE: When disconnecting hydraulic fittings, plug
hoses and cap fittings to prevent entry of foreign
matter into hydraulic system.
STEP 1
Park loader on level ground and lower bucket to
ground. Put transmission in NEUTRAL, apply parking
brake, and shut down engine.
STEP2
Put master disconnect switch in OFF position.
STEP3 Pull floor mat away from the column.

Remove the front skirt from the cab or canopy.
STEP9
STEP4
Remove all dirt and grease from steering control
valve.
STEPS
Remove hydraulic reservoir fill cap, attach a vacuum
pump to the reservoir, start the pump.
STEPS
Tag hoses connected to steering control valve.
STEP7
Remove the mounting screws from the lower trim.
STEP10
BD06G262
Disconnect hoses from steering control valve, cap or
plug the fittings and hoses, turn off the vacuum
pump.
BD07B101
Tilt the steering wheel and remove the mounting

screws from lower trim, remove the trim.

5001-4
STEP 11 Installation
STEP12
BD078102
Remove the four mounting bolts for the steering

control valve, two shown and two in the front.
IMPORTANT: Have an assistant support and remove Put the rubber bushing (1) on the spacer with the
the valve while removing the mounting bolts. tapered end towards the steering valve. Rubber
bushing (2} is mounted between the cab and the
steering valve.
STEP13
Put one rubber bushing on the sleeve and place in
the mounting hole and hold in place, have an
assistant push the other rubber bushing onto the
sleeve.
STEP14
Have an assistant push the valve into place while
turning the steering shaft, this will engage the
splines.
STEP15
BD078102
Install and tighten the four mounting bolts for the

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

5001-5
STEP16 STEP19
BD078101 BD06G262
Install the lower trim onto the column, tilt the steering Start the vacuum pump, remove the caps and plugs
wheel and install and tighten the mounting screws. the fittings and hoses. Connect hoses to steering
control valve according to the tags installed during
STEP17 removal, remove and discard the tags.
STEP 20
Remove the vacuum pump from the reservoir, install
and tighten the reservoir fill cap.
STEP 21
Put battery disconnect switch in ON position. Start
and run the machine at low idle, turn the wheel to full
left and then to full right, stop the machine and check
for leaks.
BD078100
STEP 22
Install and tighten the mounting screws into the lower Install the front skirt onto the cab or canopy.
trim.
STEP 23
STEP18 Check fluid level in hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
Put floor mat back into position on the cab floor.

5001-6
AUXILIARY STEERING PRIORITY VALVE

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

5001-7
"-., ."-
.'-...._ ."-
'-...._/
/ . "'-...._
/.
""-
""-
""-
""-
""- /
9
gr·.
[(
/
/
BS07D339
1. CAP SCREWS 6. TANK RETURN TUBE

2. STEERING SOLENOID 7. STEERING PRESSURE HOSE
3. STEERING LOAD SENSING HOSE TO PRIORITY VALVE 8. PRESSURE SWITCH
4. STEERING LOAD SENSING HOSE TO STEERING VALVE 9. PRESSURE HOSE
5. PRESSURE HOSE PUMP OUTPUT 10. INLET HOSE TO PUMP
AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION

5001-8
AUXILIARY STEERING PUMP AND MOTOR
Removal 7. Connect positive cable (2) to B+ stud of auxiliary

steering pump and motor (6) following tag
1. Park loader on level ground and lower bucket to installed during removal.
ground. Put transmission in NEUTRAL, apply
parking brake, and shut down engine, 8. Connect wiring harness wires to auxiliary
steering pump and motor following tags installed
2. Put master disconnect switch in OFF position. during removal.
3. Tag and disconnect two wiring harness from 9. Put master disconnect switch in ON position.
auxiliary steering pump and motor solenoid. See
illustration on page 9. 10. Start and run engine at low idle and raise bucket
500 mm (20 inches) above ground. Check that
4. Tag and disconnect positive cable (2) from B+ auxiliary steering light on instrument cluster is
stud of auxiliary steering pump and motor (6). OFF.
5. Tag and disconnect ground cable (1) from ground IMPORTANT: In following Step, do not run auxiliary
stud of auxiliary steering pump and motor (6). steering pump and motor continuously for more than
6. Remove hydraulic reservoir fill cap. 20 seconds at a time without a two minute cool down.
7. Connect a vacuum pump to hydraulic reservoir. 11. With engine at low idle and machine steering
straight ahead, turn key switch to OFF position to
8. Start vacuum pump. stop engine and then immediately back to ON
9. Disconnect suction hose (5). Install a plug in position (not START position). Auxiliary steering
suction hose and cap on fitting. pump and motor should start operating
immediately. Check that auxiliary steering light
10. Stop vacuum pump. on instrument cluster is ON and auxiliary
11. Disconnect pressure hose (4). Install a plug in steering pump and motor is operating.
suction hose and cap on fitting. 12. Turn steering wheel all the way to left and right to
12. Support auxiliary steering pump and motor (6). make sure that auxiliary steering pump and
Remove nuts (3), cap screws, and washers motor operates correctly.
securing auxiliary steering pump and motor (6). 13. Restart engine. Check that auxiliary steering
13. Remove auxiliary steering pump and motor (6). light on instrument cluster stays ON and auxiliary
steering pump and motor is operating. After
about three seconds motor should stop operating
and auxiliary steering light should go out.
Installation 14. Let engine run and allow batteries to recharge for
1. Position auxiliary steering pump and motor (6) on a minimum of 10 minutes.
its mounting plate, have an assistant install cap
screws, washers, and nuts (3) to secure auxiliary
steering pump and motor (6), tighten the nuts.
See illustration on page 9.
2. Remove plug from pressure hose (4) and cap
from elbow. Connect pressure hose to the
auxiliary steering pump and motor (6).
4. Remove plug from suction hose (5) and cap from
elbow. Connect suction hose to elbow installed in
auxiliary steering pump and motor (6).
5. Stop and disconnect vacuum pump. Install fill
cap in hydraulic reservoir.
6. Connect ground cable (1) to ground stud of
auxiliary steering pump and motor (6) following
tag installed during removal.

5001-9
BS07D349
1. GROUND CABLE 4. PRESSURE HOSE

2. POSITIVE CABLE 5. SUCTION HOSE
3. NUT (4) 6. AUXILIARY STEERING PUMP AND MOTOR
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

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

5001-11
I ..
'------JJ
8S038141
1. GREASE HOSE 5. PIVOT PIN 9. HOSE ASSEMBLY 13. CAP SCREW

2. HOSE ASSEMBLY 6. SPACER 10. HOSE ASSEMBLY 14. WASHER
3. HOSE ASSEMBLY 7. WASHER 11. STEERING CYLINDER 15. LOCKNUT
4. WASHER B. CAP SCREW 12. PIN 16. GREASE HOSE
STEERING CYLINDER ILLUSTRATION

5001-12
STEERING BACK PRESSURE VALVE
1. Remove the fill cap for the hydraulic reservoir to 1. Install the valve, bolts, spacers and nuts onto the
release pressure in the reservoir, attach a machine, tighten the bolts.
vacuum pump to the reservoir, start the pump.
2. Install new 0-rings onto the fittings of the hoses,
2. Disconnect hoses 2 and 6 from the pressure install and tighten the hoses.
valve.
3. Stop the vacuum pump, install and tighten the
3. Remove the nuts, bolts and spacers from the reservoir filler cap.
pressure vale, remove the valve from the
4. Start and run the machine at low idle, turn the
machine.
steering wheel from full left lock to full right lock
holding the steering over relief.
5. Stop the machine and check for leaks.
6. Check fluid level in hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.

5001-13
1. STEERING CONTROL VALVE 5. RELIEF VALVE

2. RETURN HOSE 6. RETURN HOSE TO FILTERS
3. PRESSURE HOSE 7. RETURN MANIFOLD
4. CONNECTOR M27 ORB
STEERING BACK PRESSURE VALVE ILLUSTRATION

5001-14
NOTES

Section
5002
STEERING SPECIFICATIONS, PRESSURE CHECKS,

AND TROUBLESHOOTING

Racine, WI 53404 U.S.A. BurS-7410 Issued September, 2007
5002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AUXILIARY STEERING SYSTEM PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AUXILIARY STEERING SYSTEM MOTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
UNDERSTANDING THE RESULTS OF THE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STEERING RELIEF VALVE ................................................................. 7
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bur5-7410 Issued 9-07 Printed in U.S.A.

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

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

5002-4
AUXILIARY STEERING SYSTEM PUMP TEST
Equipment Required
1. CAS 10280 Flowmeter
2. CAS1808 Flowmeter fitting kit
Test Procedure
BB830300
1. AMMETER CLAMP
6. Connect the ammeter clamp (1) to the cable as
in illustration above.
7. Make sure that the parking brake is applied and
the bucket is on the floor.
BDOOM030
8. Make sure that the oil is at operating
1. ARTICULATION LOCK temperature.
1. Install articulation lock. 9. Make sure that the load valve for the flowmeter is
open (zero pressure).
NOTE: When performing this pressure check,
always be sure the articulation lock is in place, 10. Start and run the engine.
especially when working in the articulation joint 11. Stop the engine and turn the key back to the On
areas. position.
2. Loosen and remove the outlet hose of the 12. Turn the steering wheel, this will activate the
Auxiliary Steering Pump from the Steering auxiliary steering pump.
Priority Valve.
13. Turn the load valve on the flowmeter towards
3. Install a plug into the hose. CLOSED until the pressure is 104 bar (1500 psi).
4. Connect the inlet of the flowmeter to the outlet 14. Read the flowmeter and ammeter gauges and
fitting on the Steering Priority Valve. record the readings.
5. Install the outlet hose of the flowmeter in the 15. The flowmeter reading must not be less than
hydraulic reservoir and hold in place with wire. 24.6 Umin, (6.5 U.S. gpm). The ammeter reading
must be 315 amps.
16. Turn the key switch to the OFF position. If the
flow was less than the specification, or if the
amperage was more than 315 amperes, remove
the auxiliary steering motor and pump. Test the
auxiliary steering motor. If the motor is good,
make repairs to the pump.

5002-5
AUXILIARY STEERING SYSTEM MOTOR TEST
Test Equipment
1. A 24 volt battery that is fully charged.
NOTE: A 24 volt battery system (two 12 volt
batteries in a series) is used for this test. A 12 volt
battery system will cause damage to the auxiliary
steering motor.
2. A remote starter switch.
3. A tachometer to check the armature speed.
4. A Sun Electric VAT-33 Starting and Charging
System Tester.
B790852
Test Procedure 1. REMOTE STARTER SWITCH
1. Remove the connector that is between the 2. TESTER
3. AUXILIARY STEERING MOTOR
terminals on the magnetic switch and the
4. AMMETER CLAMP
auxiliary steering motor.
5. 24 VOLT BATTERY SYSTEM
2. Remove the auxiliary steering motor from the
auxiliary steering pump.
3. Remove the drive coupling from the auxiliary
steering motor (3}.
4. Connect the auxiliary steering motor (3}, remote
starter switch (1) and tester (2} to the 24 volt
battery system (5) as illustrated in Figure 3.
5. Push the button on the remote starter switch (1)
and look at the voltmeter in the tester.
6. Turn the load control (8} until the voltmeter (7)
indicates 24 volts. Refer to figure 4. Look at the
ammeter (6} in the tester. Make a record of the
ammeter indication.
7. Hold the tachometer against the armature shaft. 6. AMMETER
7. VOLTMETER
Look at the tachometer. Make a record of the
B. LOAD CONTROL
indication.
8. Release the button on the remote starter switch
(1 ).

5002-6
UNDERSTANDING THE RESULTS OF THE TEST

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

5002-7
STEERING RELIEF VALVE

NOTE: The pump differential pressure must be properly adjusted before doing this test. Refer to Section 8002
Testing and Adjusting the Pump Differential Pressure.
Pressure Setting Test
BD03A092
1. SAFETY LINK
BD03A092
1. SAFETY LINK
3. Remove the safety link (1) and lower the loader
arms to the ground.
1. Install the safety link (1) and lower the loader
arms slowly, until the safety link is supporting the 4. Stop the engine.
loader arms.
BDOOM030
BDOOM041 1. ARTICULATION LOCK

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

5002-8
6. Make sure that the temperature of the hydraulic
oil is at least 52° C (125° F).
7. To measure the temperature of the oil using the
instrument panel:
A. Press the program switch (left side of the
program/reset switch).
B. Press the up count switch to function 008.
C. Return the program switch to the OFF (center)
position.
8. Apply the parking brake.
9. Start and run the engine at full throttle. BDOON018
10. Hold the bucket control lever in the rollback 1. LOADER CONTROL VALVE
position. 2. PUMP PRESSURE TEST
PORT
11. Hold the lift lever in the "FLOAT" position.
15. Remove the dust cap from the test port (2).
12. Continue holding until the specified temperature
16. Connect a 345 bar (5000 psi) pressure gauge to
of the oil is reached.
the test port (2) on the front of the loader control
13. Stop the engine. valve (1 ).
14. Remove the cap on the hydraulic reservoir to NOTE: Make sure when you connect the pressure
release any pressure in the hydraulic system. gauge that you do so in a manner that you can read
the pressure gauge while sitting in the operators
seat.
17. Start the engine and operate the machine at full
throttle.
18. With the articulation lock still in place, turn and
hold the steering wheel for a hard right turn.
19. Continue holding the steering wheel, and read
the pressure gauge.
20. The pressure gauge must indicate 239 to 243
bar (3465 to 3523 psi). If the pressure is not
correct, adjust the steering relief valve.

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

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

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

5002-10
STEERING CYLINDER LEAK TEST

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

Section
5005
STEERING CYLINDERS

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

5005-3
SPECIFICATIONS
Torque for piston cap screw ........................................................................ 810 to 925 Nm (597.5 to 682 pound feet)
Torque for gland ............................................................................................. 339 to 475 Nm (250 to 350 pound feet)
STEERING CYLINDER
Disassembly Inspection
1. Fasten tube (1) in a vise. Be careful not to 1. Clean all parts in cleaning solvent.
damage the tube. See illustration on page 4.
2. Check to be sure that piston rod (19) is straight. If
2. Remove gland (6) from tube (1 ). piston rod is bent, install a new piston rod.
3. Pull piston rod (19) and piston (17) straight out of 3. Inspect inside of tube (1) for deep grooves and
tube (1 ). other damage. If there is any damage to tube, a
new tube must be used.
4. Fasten piston rod (19) yoke in vise and put a
support below piston rod near piston (17). Put a 4. Remove small scratches on piston rod (19) or
shop cloth between support and piston rod to inside tube (1) with emery cloth of medium grit.
prevent damage to piston rod. Use emery cloth with a rotary motion.
5. Loosen and remove bolt and washer (18} that 5. Inspect bushing (3}. If bushing requires
mounts the piston (17} to the piston rod (19}. replacement, remove grease fitting (4) and
retaining rings (2} then press bushing from tube
6. Remove piston (17) from piston rod (19).
end.
7. Remove and discard seal (13), loader ring (15),
wear ring (14), and cast iron ring (16) from piston
(17}.
8. Remove gland (6) from piston rod (19).
9. Remove and discard 0-ring (8), backup ring (9),
0-ring (7), rod wiper (5), rod seal (1 0), buffer seal
(11 ), and bearing (12} from gland (6}.

5005-4
BU~F~F~ER:-:S=---------
1. TUBE
2. RETAINING RING
6·
9
0-RING
7. GLAND
8. B
0-RING
. ACKUP RING
11.
12. BEARING EAL
13. SEAL
6 1 · RING CAS ---~-
17. PISTON T IRON
RO~ASHER
3. BUSHING
~- GREASE FITTING 10. ROD SEAL 14. WEAR RING 18. BOLT AND
. RODWIPER STEERING CYL 15. RING LOADER 19. PISTON
INDER ILLUSTRATION

5005-5
Assembly 14. Install a new loader ring (15) on piston (17).
1. Install bearing (12) in gland (6). See illustration 15. Install a new seal (13) over loader ring (15).
on page 4. 16. Clean the threads on the end of piston rod (19)
2. Install buffer seal (11) in gland (6) so that lips of and threads of bolt (18) using Loctite cleaning
seal are toward small end of gland. solvent. Allow to dry. Apply Loctite 243 to piston
rod threads 6.4 mm (1/4 inch) from open end of
3. Install rod seal (1 0) in gland (6). Rod seal must piston rod so that there is 12.7 mm (1 /2 inch) of
be installed so that lips of seal are toward small Loctite 243 on piston rod threads. DO NOT apply
end of gland. Seal can be difficult to install. Use Loctite to first 6.4 mm (1 /4/inch) of piston rod
tools that will not damage seal. threads.
4. Install rod wiper (5) in gland (6) with wiper lips 17. Install bolt and hardened washer (18} in piston
toward large end of gland. (17}.
5. Install 0-ring (7) in groove at large end of gland 18. Install piston (17} on piston rod (19} and start bolt
(6). (18} into piston rod.
6. Install 0-ring (8) on gland (6). The 0-ring (8) 19. Tighten bolt (18} to a torque of 810 to 925 Nm
must be toward small end of gland. (597.5 to 682 pound feet).
7. Install backup ring (9) on gland (6). The backup 20. Fasten tube (1) in vise. Be careful not to damage
ring must be toward large end of gland. If backup tube.
ring is not flat on both sides, the side that is not
flat must be toward 0-ring (8). 21. Apply petroleum jelly to 0-rings (7 and 8} and
backup ring (9} on gland (6} and to sealing
8. Fasten piston rod (19) yoke in vise. surface in tube (1 ).
9. Lubricate piston rod (19) and bore in gland (6) 22. Lubricate piston (17} and inside of tube (1) with
with clean hydraulic oil. clean hydraulic oil.
NOTE: If a new gland (6) is being installed, stamp 23. Push the piston (17} straight into tube (1 ). Be
part number of cylinder on gland. careful not to damage cast iron ring (16}, wear
10. Push gland (6) onto piston rod (19) large end ring (14}, and seal (13} on piston (17}.
first. If necessary, use a soft hammer to drive the 24. When piston (17} is in smooth part of tube (1 ),
gland onto piston rod. start gland (6} into tube (1 ).
11 . Put a support below and near the end of piston 25. Tighten gland (6} to 339 to 475 Nm (250 to 350
rod (19). Put a cloth between support and piston pound feet).
rod to prevent damaging piston rod.
12. Install new cast iron ring (16) on piston (17).
13. Install new wear ring (14) on piston (17).

5005-6
NOTES

Section
5006
CENTER PIVOT
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright© 2001 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Bur 6-42420 August, 2001
5006-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................... 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CENTER PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly .............................................................................. 6
CONNECTING THE FRONT FRAME TO THE REAR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5006-3
SPECIFICATIONS
SPECIAL TORQUES
M16 bolt for upper pivot pin .......................................................................220 to 250 Nm (162 to 184 pound-feet)
M12 bolts for the lower pin plate ....................................................................................... 124 Nm (91 pound-feet)
M12 bolts screws for the lower pin plate ..................................................... 128 to 136 Nm (94 to 100 pound-feet)
Ferry head screws for the drive shaft ................................................................ 61 to 81 Nm (45 to 60 pound-feet)
LUBRICANT
Pivot bearings and seals .......................................................................................... Case IH molydisulfide grease
Steering cylinder rod eyes ........................................................................................ Case IH molydisu If ide grease
FLUIDS
Hydraulic system reservoir .............................................................................................. MS-1209, Hy-Tran® Ultra
SPECIAL TOOLS
CAS-1 0219 ...................................................................................................................... Hand pump (hydraulic ram)
CAS-1 0512 ...................................................................................................................................... 10 ton ram (long)
CAS-10592 .......................................................................................................... Puller set, includes 24827 leg ends
CAS-10600 ............................................................................... Bearing cup and seal puller, includes 24850 adapter
CAS-10193 ............................................................................................................................. Vacuum pump (12 volt)
CAS-1960 .................................................................................. *Top bearing driver, bottom bearing driver and plate
*(Requires screw, two nuts, and two washers from CAS-10592)

5006-4
CENTER PIVOT
Disassembly 19. Disconnect the supply hose.
1. Remove all dirt and grease from the area of the 20. Install a cap on the hose and a plug in the fitting.
center pivot. Park the machine on a level surface. 21. Stop the vacuum pump.
2. Lower the bucket until the bucket is flat on the 22. Loosen and remove the self-locking nut and bolt
floor. that hold the pivot pin for the steering cylinder
3. Stop the engine and apply the parking brake. rod eye.
4. Remove the covers from both sides of the 23. Remove the pivot pin from the rear frame and the
machine. steering cylinder rod eye.
5. Disconnect the front wiring harness from the cab 24. Remove the washer from the rear frame. Move
floor. the steering cylinder out of the way.
6. Remove any tie straps that fasten the front wiring 25. Repeat steps 22, 23 and 24 for the other steering
harness to the chassis near the center pivot. cylinder.
7. Loosen and remove the nut and washer that 26. Loosen and remove the Ferry head screws and
fasten the chassis ground wire and cab ground retainers that fasten the drive shaft to the front
wire to the studs. yoke. Move the drive shaft out of the way.
8. Loosen and remove the bolt, lock washer, and 27. Place two stands below and in contact with the
nut that fasten the clamp on the front wiring front frame.
harness to the bracket on the rear frame. Move 28. Install blocks between the rear axle and the rear
the front wiring harness out of the way. frame on both sides of the machine to prevent
9. Loosen and remove the fill plug for the hydraulic the rear frame from tipping.
reservoir. 29. Put a jack in contact with both sides of the rear
10. Connect a vacuum pump to the hydraulic frame near the center pivot area. Use another
reservoir. Start the vacuum pump. jack at the rear of the machine to prevent the rear
frame from tipping.
11. Disconnect the brake hose from the backside of
front brake line bracket. 30. Loosen and remove the bolt (1), washer (2), and
spacer (3) that fasten the upper pivot pin (4) to
12. Install a plug in the tube and a cap on the fitting. the rear chassis (5), refer to Figure 1.
13. Disconnect the hoses for the steering cylinder. 31. Use a prybar to remove the upper pivot pin (4).
14. Install caps on the fittings and plugs in the hoses. 32. Loosen and remove the bolts (1) and hardened
15. Loosen and remove the bolts, lock washers, and washers (2) that fasten the lower pin plate (15) to
self-locking nuts that fasten the mounting bracket the lower pivot pin (1 0).
for the hoses to the bracket on the front frame. 33. Loosen and remove the cap screws (1) and
16. Loosen and remove the bolts, flat washers, and washers (2) that fasten the lower pin plate (15) to
self-locking nuts that fasten the bracket for the the bottom of the rear chassis (5).
hoses to the rear frame. 34. Use the ram and hand pump to remove the lower
17. Disconnect the return hose. pivot pin (10).
18. Install the cap on the hose and a plug in the 35. Install the puller on the bottom spacer (14), see
fitting. Special Tools in this section.

5006-5
BS01B225
1. BOLT 5. REAR CHASSIS 9. UPPER PIVOT BEARING 13. BEARING RETAINER

2. WASHER 6. SEAL 10. LOWER PIVOT PIN 14. BOTTOM SPACER
3. SPACER 7. BEARING RETAINER 11. LOWER BEARING SPACER 15. LOWER PIN PLATE
4. UPPER PIVOT PIN 8. SHIM 12. LOWER PIVOT BEARING 16. FRONT CHASSIS
FIGURE 1. CENTER PIVOT ASSEMBLY

5006-6
36. Remove the bottom spacer (14). Assembly
37. Release the parking brake. 1. Pack the bearing cones with grease. See
38. Use prybars to turn the left rear wheel backwards Specifications in this section. Be careful not to
and the right rear wheel forward to move the front mix the bearing cones.
of the rear frame to the left for access to the 2. Lubricate the bore in the top pivot with grease.
bearings. Install blocks under the wheels to See Specifications in this section for the correct
prevent the rear frame from moving. grease.
39. Apply the parking brake. 3. Install a bearing cup in the top pivot, refer to
40. Hold the bearing retainer (13) in place and Figure 2.
loosen and remove the bolts (1) and washers (2) 4. Install the bearing driver and plate.
that fasten the bearing retainer (13) and shims
(8) to the bottom of the rear pivot.
41. Remove the bearing retainer (13) and shims (8).
42. Remove the lower bearing spacer (11) from the
top of the lower pivot.
43. Loosen and remove the bolts (1) and washers (2)
that fasten the bearing retainer (7) and shims (8)
to the top of the top pivot.
44. Remove the bearing retainer (7) and shims (8).
45. Use the puller to remove the seal (6) from the top
of the bottom pivot.
46. Use the puller to remove the seal (6) from the B1423A88J
bottom of the top pivot. FIGURE 2.
47. Use an acceptable driver, the hydraulic ram, and 5. Tighten a nut on the screw until the bearing cup
the hand pump to remove the upper pivot is seated in the bore of the top pivot. Remove the
bearing (9) from the top pivot. See Special Tools bearing driver and plate from the top pivot.
in this section. 6. Install a bearing cone, spacer, the other bearing
NOTE: The spacers are matched to the bearing cone, and the remaining bearing cup in the top
sets. Do not mix the spacers. Do not use the old pivot, refer to Figure 3.
spacers if new bearing sets are being installed. 7. Install the bearing driver and plate.
48. Use an acceptable driver, the hydraulic ram, and 8. Tighten a nut on the screw until the bearing cup
the hand pump to remove the lower pivot bearing is seated against the spacer. Remove the
(12) from the bottom pivot. See Special Tools in bearing driver and plate from the top pivot.
this section.
NOTE: The spacers are matched to the bearing
sets. Do not mix the spacers. Do not use the old
spacers if new bearing sets are being installed.
49. Use an acceptable driver to press the seal (6) out
of each bearing retainer (7 and 13).
B1424A88J
FIGURE 3.

5006-7
9. Put the bearing retainer (7) in place on the upper 17. Fill the other seal (6) for the top pivot with grease.
pivot bearing (9), refer to Figure 1. See Specifications in this section for the correct
grease.
10. Install the bearing driver and plate, refer to
Figure 4. 18. Use an acceptable driver to install the seal (6) in
the bottom of the top pivot, refer to Figure 6.
11. Tighten a nut on the screw until the bearing
retainer (7) is tight against the upper pivot 19. The bottom of the seal (6) must be even with the
bearing (9). bottom of the top pivot.
UP
B1425A88J B1430A88J
FIGURE 4. FIGURE 6.
12. Measure the gap between the bearing retainer 20. Apply grease to the upper pivot pin (4).
(7) and the top pivot. Make a record of the
21. Install the upper pivot pin (4) in the top pivot.
measurement. Subtract 0.0762 to 0.1016 mm
(0.003 to 0.004 inch) from the measurement, 22. Lubricate the top pivot until grease is forced out
refer to Figure 4. Select shims (8) equal to that of the seal (6). See Specifications in this section.
value.
23. Rotate the upper pivot pin (4) to check the
13. Remove the bearing driver, plate, and bearing bearing assembly. The upper pivot pin (4) must
retainer (7) from the top pivot. rotate smoothly, but not easily. Leave the upper
pivot pin (4) in place to keep dirt out of the upper
14. Install the shims (8) and the bearing retainer (7).
pivot bearing (9).
15. Install the washers (2) and bolts (1 ). Tighten the
24. Lubricate the bore for the bottom pivot with
bolts (1) to 124 Nm (92 pound-feet).
grease. Install a bearing cup in the bottom pivot.
16. Install the seal (6) in the bearing retainer (7). The
top of the seal (6) must be even with the top of
Figure 7.
the bearing retainer (7), refer to Figure 5.
B1426A88J
B1427A88J
FIGURE 5.
FIGURE 7.

5006-8
26. Tighten a nut on the screw until the bearing cup 35. Measure the gap between the bearing retainer
is seated in the bore in the bottom pivot. (13) and the bottom pivot. Make a record of the
27. Remove the bearing driver and plate from the
(0.003 to 0.004 inch) from the measurement.
bottom pivot.
Select shims (8) equal to that value.
28. Install a bearing cone, spacer, the other bearing
36. Remove the bearing driver, plate and bearing
cone, and the remaining bearing cup in the
retainer (13) from the bottom pivot.
bottom pivot.
37. Install the shims (8), the bearing retainer (13),
washers (2) and bolts (1).
Figure 8.
38. Tighten the bolts (1) to 124 Nm (92 pound-feet).
39. Fill the seal (6) for the bearing retainer (13) with
grease. See Specifications in this section for the
correct grease.
40. Install the seal (6) in the bearing retainer (13).
The bottom of the seal (6) must be even with the
bottom of the bearing retainer (13). Be careful
not to damage seal (6), refer to Figure 10.
B1428A88J
FIGURE 8.
30. Tighten a nut on the screw until the bottom
bearing cup is seated against the spacer.
31. Remove the bearing driver and plate from the
bottom pivot.
32. Put the bearing retainer (13) in place on the
B1430A88J
lower pivot bearing (12).
FIGURE 10.
41. Install the other seal (6) in the bottom pivot, refer
Figure 9.
to Figure 11. The top of the seal (6) must be even
with the top of the bottom pivot.
B1429A88J
FIGURE 9.
B1426A88J
34. Tighten a nut on the screw until the bearing FIGURE 11.
retainer (13) is tight against the lower pivot
42. Install the lower bearing spacer (11) and the
bearing (12).
bottom spacer (14).

5006-9
43. Apply grease to the lower pivot pin (1 0). See 46. Rotate the lower pivot pin (1 0) to check the
Specifications in this section. bearing assembly. The lower pivot pin (1 0) must
rotate smoothly, but not easily.
44. Install the lower pivot pin (1 0) in the bottom pivot.
47. Remove the lower pivot pin (10) and the upper
45. Hold the bottom spacer (14) in place and
pivot pin (4).
lubricate the bottom pivot until grease is forced
out of the seal (6). 48. Remove the bottom spacer (14).
CONNECTING THE FRONT FRAME TO THE REAR FRAME

1. Release the parking brake. 20. Remove the blocks from the rear axle.
2. Move the rear frame into alignment with the front 21. Remove the stands from the front frame.
frame.
22. Put the drive shaft in position on the front yoke.
3. Move the steering cylinders as required to move
23. Install new Ferry head screws that fasten the
the rear frame into alignment with the front
drive shaft to the front yoke.
frame.
24. Tighten the Ferry head screws to 61 to 81 Nm
(45 to 60 pound-feet).
5. Apply grease to the upper pivot pin (4), refer to
25. Put the steering cylinder rod eye in position in the
Figure 1.
frame. Install the washer between the steering
6. Install the upper pivot pin (4), spacer (3), washer cylinder rod eye and the rear frame.
(2) and bolt (1). Be careful not to damage the
26. Align the hole in the pivot pin with the holes in the
seal (6).
steering cylinder rod eye, and install the pivot
7. Tighten the bolt (1) to 220 to 250 Nm (162 to 184 pin.
pound-feet).
27. Install the bolt and self-locking nut that hold the
8. Apply grease to the lower pivot pin (1 0). pivot pin.
9. Install the lower pivot pin (1 0) in the frames. Be 28. Repeat steps 25, 26 and 27 for the other steering
careful not to damage the seal (6). cylinder.
10. Use the ram and hand pump to install the bottom 29. Start the vacuum pump.
spacer (14). See Special Tools in this section.
30. Connect the return hose.
11. Install the lower pin plate (15), three inner bolts
31. Connect the supply hose.
(1 ), and washers (2) that fasten the lower pin
plate (15) to the lower pivot pin (1 0). 32. Put the bracket for the hoses in position on the
rear frame. Install the bolts, flat washers, and
12. Tighten the bolts (1) to 69 Nm (51 pound-feet).
self-locking nuts that fasten the bracket to the
13. Measure the gap between the lower pin plate rear frame.
(15) and the bottom pivot. Make a record of the
33. Put the bracket for the hoses in position on the
front frame.
(0.003 to 0.004 inch) from the measurement.
Select shims equal to that value. 34. Install the bolts, flat washers, and self-locking
nuts that fasten the bracket to the front frame.
14. Loosen the bolts (1) that fasten the lower pin
plate (15) to the lower pivot pin (1 0). 35. Connect the hoses for the steering cylinders.
15. Start the six outer bolts (1) into the lower pin 36. Connect the brake hose for the front brakes at
plate (15) and the bottom pivot. the front bracket.
16. Install the shims (8). 37. Stop the vacuum pump.
17. Tighten the six outer bolts (1) to 128 to 136 Nm 38. Connect the front wiring harness to the rear
(94 to 100 pound-feet). wiring harness.
18. Tighten the three inner bolts (1) to 124 Nm (92
pound-feet).
19. Remove the jacks from the rear frame.
5006-10
39. Put the clamp on the wiring harness in position 43. Check the fluid level in the hydraulic reservoir.
on the bracket. Install the bolt, lock washer, and Add oil as required. See Specifications in this
nut that fasten the clamp on the wiring harness to section.
the bracket.
44. Install the fill plug on the hydraulic reservoir.
40. Put the ground wire in position on the stud. Install
45. Bleed air from the front axle bleed screws. Refer
the washer and nut that fasten the ground wire to
to Section 7002 for complete brake bleeding
the stud.
instructions.
41 . Install a tie strap to fasten the wiring harness to
46. Lubricate the pivot pins for the steering cylinder
the tube.
rod eyes.
42. Disconnect the vacuum pump from the hydraulic
47. Install the covers on both sides of the machine.
reservoir.

Section
5008
AUXILIARY STEERING MOTOR AND PUMP

Racine, WI 53404 U.S.A. Bur 6-42430 Issued April, 2003
5008-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................... 3
AUXILIARY STEERING MOTOR AND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly .............................................................................. 4

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

5008-4
AUXILIARY STEERING MOTOR AND PUMP
Disassembly Assembly
NOTE: Refer to Section 5001 for removal and 1. Lubricate all parts with clean hydraulic oil before
installation of the auxiliary steering motor and pump. assembly.
NOTE: The pump is the only component that is 2. Lubricate and install a new seal (4) and retaining
disassembled. The switch (B) and motor (1) are ring (3) on the plate (17). Refer to the illustration
replaced as units and are not serviced. Refer to the on page 5.
3. Lubricate and install a new backup ring (5) and a
1. Make an alignment mark on the pump assembly new seal (6) on the plate (17).
and motor (1 ).
4. Lubricate and install new 0-rings (7) on the body
2. Loosen and remove the two screws (15) and lock (18).
washers (14) that hold the pump assembly to the
5. Lubricate and install the pins (22), drive gear
motor (1 ).
(20), driven gear (19) and wear plates (23) on the
3. Remove and discard the mounting gasket (13), body (18).
retaining ring (3) and seal (4) from the pump
6. Lubricate and install a new backup ring (5) and a
assembly.
new seal (6) on the end plate (21 ).
4. Loosen and remove the four bolts (2) that hold
7. Align the marks, made during disassembly, on
the pump assembly together.
the end plate (21 ), body (18) and plate (17) and
5. Remove the end plate (21) from the body (18). install the four bolts (2). Tighten the four bolts (2).
6. Remove and discard the seal (6) and backup ring 8. Install a new gasket (13) on the pump assembly.
(5) from the end plate (21 ).
9. Align the marks, made during disassembly, on
7. Remove the wear plate (23), drive gear (20) and the pump assembly and the motor (1 ).
driven gear (19) from the body (18).
10. Install the lock washer (14) and screw (15).
8. Remove the body (18) from the plate (17). Torque the screw (15) to 35 to 39 Nm (312 to 348
pound-inches).
9. Remove and discard the 0-rings (7) from the
body (18).
10. Remove the pins (22) and wear plate (23) from
the body (18).
11. Remove and discard the seal (6) and backup ring
(5) from the plate (17).
NOTE: The only serviceable items on the pump
assembly are the seals (6), backup rings (5), 0-rings
(7), seal (4), retaining ring (3) and gasket (13). If any
of the other items are damaged, replace the pump
assembly.
Inspection
1. Inspect the wear plates (23) for grooves, scoring
and pitting. If damage is found replace the pump
assembly. Refer to the illustration on page 5.
2. Inspect the drive gear (20) and driven gear (19).
If the shafts are worn or damaged, replace the
pump assembly.
3. Clean all parts in cleaning solvent and air dry.
4. Inspect the plate (17), end plate (21) and body
(18). Replace the pump assembly as necessary.

5008-5
BS01C121
1. MOTOR 7. 0-RING 13. GASKET 19. DRIVEN GEAR

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

5008-6
NOTES

Section
5009
JOYSTICK STEERING SYSTEM

(JSS)
(optional)
Copyright© 2009 Case, LLC. All rights reserved.

CASE, LLC. Case is a registered trademark of Case, LLC.
Racine, WI 53404 U.S.A. 5-17010 Issued December 2009
5009-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
JOYSTICK STEERING SYSTEM (JSS) ........................................................ 4
Description of the JSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F-N-R Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Procedures for Turning the JSS On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Kick-down Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Illustration of the valve PVFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Illustration of the valve PVG32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exploded view of the valve PVG32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
STEERING VALVES PVG32 AND PVFC ...................................................... 20
Removal ............................................................................. 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
JOYSTICK STEERING SYSTEM ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal ............................................................................. 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
JSS HYDRAULIC PRESSURE ADJUSTMENTS ................................................ 48
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Steering Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
STEERING SPEED CALIBRATION PROCEDURE .............................................. 50
5-17010 Printed in U.S.A.

5009-3
SAFETY RULES
A WARNING A
This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully
read the message that follows and be alert to the possibility of machine damage, serious injury, or death.
M171C
A WARNING A
Be cautious when turning with joystick steering. Abrupt movements of the joystick to the left or right could cause
the machine to turn more sharply than acceptable. Take necessary precautions. Do not use the joystick for primary
steering. It is intended for short repetitive operations. Failure to comply could result in machine damage, death or
serious injury.
M1336
A WARNING A
If hydraulic pilots are disengaged, the joystick steering still remains active. Always disengage joystick steering
when not in use. Failure to comply could result in machine damage, death or serious injury.
M1348
A WARNING A
Do not use joystick steering when loading or unloading the machine from a truck or trailer. Always use the primary
steering wheel when loading or unloading the machine from transport. Failure to comply could result in machine
damage, death or serious injury.
M1345
A WARNING A
Use caution when moving about in the operator's compartment when joystick steering is active. An inadvertent
movement against the joystick steering control could cause the machine to turn or move abruptly. Failure to
comply could result in machine damage, death or serious injury.
M1347
A WARNING A
Do not use joystick steering when traveling on a public road or highway. The left arm rest must be raised and in a
locked position. Use the primary steering wheel if travel on a public road or highway is required. Failure to comply
could result in machine damage, death or serious injury.
M1346
A WARNING A
Do not use joystick steering if operating at speeds over 20 km/h (12.4 mph). Always use the primary steering
wheel at higher speeds for optimum control of the machine. Failure to comply could result in machine damage,
death or serious injury.
M1349
5-17010
5009-4
JOYSTICK STEERING SYSTEM (JSS)
Description of the JSS Preliminary check
The JSS is mounted in parallel with the standard Preset condtion must be met by:
steering system. The standard steering system • left armrest completely lowered
always has priority. If during joystick operation, the • gear lever in neutral
primary steering wheel is moved, steering will revert
to primary steering. Joystick steering is designed for • equipment locking switch disenabled
short, repetitive machine operations. • pilot pressure switch on
• joystick steering switch in neutral
---A WARNING A--- • machine is stationary.
Do not use joystick steering if operating at speeds
over 20 km/h (12.4 mph). Always use the primary System efficiency check
steering wheel at higher speeds for optimum control
• with the JSS off, the pilot pressure must be less
of the machine. Failure to comply could result in
than or equal to 8 bar (115 psi).
machine damage, death or serious injury.
M1349
• the software monitors the armrest position switch.
When the JSS is turned on and during operation,
the switch position is checked. If the position of the
armrest is raised or the switch is shorted, the
system will deactivate.
After all conditions have been met, the JSS will be

powered by closing PIN 1:21 of the output AIC that
switches over the relay K2 enabling the electric
supply of the JSS with consequent activation of the
system under safety conditions.
The system will stay active if the following conditions
are maintained:
• the left armrest stays lowered
• the main gear lever stays in neutral
• the steering wheel stays inactive
• the control switch stays ON
• no system errors occur
Joystick steering is turned off as soon as:
• the left armrest is raised.
• the gearbox I main lever control is moved from
1. JOYSTICK STEERING CONTROL neutral to forward or reverse drive.
2. ARMREST
3. MONITOR • the steering wheel is operated.
4. FORWARD - NEUTRAL- REVERSE SWITCH
• the proportional valve suffers trouble.
5. KICK-DOWN BUTTON
• system errors occur.
Activation logic of the software and
joystick steering • the JSS switch is disconnected.
To activate the joystick steering system, it is • ignition turned off.

necessary that the machine meet specific conditions
prior to activation. The software will run a preliminary
test to verify the machine is in the preset conditions
and check the condition of the JSS system.
5-17010
5009-5
ALARM • In order to activate the JSS F-N-R switch, it is

An audible alarm and a message on the instrument necessary to check the position of the switch
cluster display will indicate the JSS is not functioning. A. the JSS F-N-R switch must be in neutral
To reactivate the JSS, turn the switch OFF and back B. if the JSS F-N-R switch is not in neutral, move
to the ON position. the JSS F-N-R switch to the neutral position
Errors for the JSS system are only displayed when and the system will be activated without
the JSS switch is in the ON position. They can be pressing the JSS activation switch again
reset by cycling the JSS switch to OFF and then back • The JSS F-N-R switch is deactivated when the
to the ON position. JSS is turned OFF
F-N-R Switch Turning the JSS ON
The joystick steering system requires the integration • Press the JSS switch to the ON position
of third F-N-R switch. The software of the A. the armrest on left-hand side must be lowered
transmission control unit (TCU) is able to turn the B. loader locking switch disabled
F-N-R switch on the armrest ON/OFF when the JSS
is activated. C. JSS pilot pressure must be low
D. JSS joystick in neutral
Locations of F-N-R switches E. no error in the JSS system
1. Main F-N-R located on steering column F. steering column F-N-R lever in neutral
2. AUX F-N-R on the equipment control joystick (or G. vehicle stationary
on right-hand console)
3. AUX JSS F-N-R on the armrest on the left-hand The JSS is turned OFF by one of the following:
side A. Using the steering wheel
B. F-N-R lever on the steering column is moved
Procedures for Turning the JSS On out of the neutral position
and Off C. armrest on left-hand side is raised
Of the three F-N-R controls, the one on the steering D. JSS switch is turned OFF
column has priority over the two auxiliary F-N-R
switches. The auxiliary F-N-R switches have a E. an error occurs in the JSS system
specific signal when activated. If activated, the JSS F. ignition switch is turned OFF
F-N-R switch on the left-hand armrest has priority
over the F-N-R switch on the equipment control Kick-down Button
joystick (or on right-hand console).
The joystick steering system in the left arm rest
Steering Column F-N-R Lever features a kick down button that can be activated
when the JSS system is activated.
• The steering column F-N-R lever is always active
• The steering column F-N-R lever has priority over
all the auxiliary F-N-R switches
• One of the auxiliary F-N-R switches can be
activated only if the steering column F-N-R lever is
in neutral
Activation Procedure For Auxiliary JSS F-N-R

The JSS F-N-R switch is in the left-hand side
armrest:
• The JSS F-N-R switch will be enabled with the
activation of the JSS
• When the JSS is activated, a message is sent via
CAN to the transmission control unit (TCU)
• This will activate the JSS F-N-R switch
5-17010
5009-6
Summary table of the ON/OFF statuses

State of activation of the JSS, JSS F-N-R and auxiliary F-N-R:
Starting JSS OFF JSS OFF JSS OFF JSSON

status
JSS I AUX F-N-R (JSS) AUX F-N-R JSS I AUX F-N-R JSS (AUX) F-N-R
disabled enabled disabled enabled
Activation JSS activation signal JSS activation signal Auxiliary F-N-R F-N-R enable signal
signal enabling signal or JSS enable signal
JSS safety Equipment locking Equipment locking

conditions to
be met
. switch disabled;
Armrest on left-hand . switch disenabled;
Armrest on left-hand
. side lowered;
Vehicle stationary; . side lowered;
Vehicle stationary;
Main F-N-R gear lever Main F-N-R gear lever
=neutral; =neutral;
• JSS pilot pressure • JSS pilot pressure
. less than 8 bar;

JSS Joystick= . less than 8 bar;
JSS Joystick =
neutral; neutral;
No errors on JSS No errors on JSS
system. system.
Resulting • JSSON • JSSON • JSS OFF • JSSON

JSS status
F-N-R • JSSON • JSSON • Vehicle stationary; • Vehicle stationary

conditions • JSS F-N-R = neutral. • JSS F-N-R = neutral. Main F-N-R gear Main F-N-R gear
lever = neutral; lever= neutral;
• AUX F-N-R = • AUX F-N-R =
neutral. neutral.
Resulting
F-N-R
.• JSS F-N-R Enabled
Stays enabled. .• JSS F-N-R Enabled
Stays enabled.
•
.
AUX F-N-R
Enabled
• JSS F-N-R
Enabled
within 8 seconds
status
release parking
brake and engage
F or R to maintain
enabling.
F-N-R If JSS F-N-R not in If JSS F-N-R not in If AUX F-N-R not in
conditions neutral. neutral. neutral.
not met
F-N-R • JSS I AUX F-N-R • JSS I AUX F-N-R • JSS I AUX F-N-R
alternative disabled. disabled. disabled.
status
5-17010
5009-7
ERROR CODES
Errors for the JSS will only be displayed if the switch is in the ON position.
The errors can be reset by turning the JSS system OFF and On. The following two errors will not reset:
• 1821 r Power Supply Failure • 1830y Activation Switch failure.
The errors will always be shown on the display once they are present. To reset these errors the engine must be
turned off.
ERROR CODES TABLE
1 1812 JSS Failure Armrest Switch

2 1816 JSS Activation Button Failure
3 1820 JSS Power Supply Failure
4 1821 JSS Power Supply Failure
JSS Active
5 1823 JSS Relais Grd Failure
6 1824 JSS Activation Switch Short to
7 1830 JSS Activation Switch failure
8 1831 JSS Error JSC
9 1832 JSS Signal Input Error JSC
10 1833 JSS Signal Output Error JSC
11 1835 JSS Valve Failure Power
12 1841 JSS Valve Alarm
13 1842 JSS Valve Alarm Open Circuit
14 1843 JSS Pilot Pressure is High
15 1844 JSS Pilot Pressure Switch Short to Ground
16 1845 JSS Pilot Pressure is Low
17 1846 JSS Failure on LS Pressure Switch
18 1850 JSS Joystick Failure
Neutral Switch I Power Supply
19 1852 JSS Error in Ground Connection
20 9134 JSS CAN communication failed
- - - - -
5-17010
5009-8
11\ll
100"""
...n~ !g
m
0 ...n©11
-"@ll
=" Wi'3
,.... W-.,n
C\1 ~m
0010 =
..... ,.. =!I
)( :z9 )!>
)»IF
0 ©§)
~
L--------------- ------~
.....
CIS
C\1.0
0
,....
C\1
W190-4R091
ILLUSTRATION OF THE VALVE PVFC
Connections
port 1. to the steering priority valve
port 2. to the auxiliary steering valve
port 3. to the LS port of the valve PVG32
5-17010
5009-9
W190-4R092
ILLUSTRATION OF THE VALVE PVG32
Connections
Ports A I B to the steering cylinder on the stem Port PP pilot pressure switch 8 bar
side and bottom side 350 bar, 65 1/min Port T outlet 25/40 bar
LS port to port 3 of the valve PVFC Port T2 not used
Port P to the steering priority valve 350 bar, 65 Port TO LX not used
I/min
5-17010
5009-10
W190-4R099
EXPLODED VIEW OF THE VALVE PVG32
1. Valve PVPV 7. Screws

2. Valve PVM 8. Seal
3. Valve PVB 9. Seal
4. Shuttle PVBS 10. Seal
5. Valve PVES 11. Seal
6. Shuttle PVSI
5-17010
5009-11
ELECTRICAL SYSTEM
Removal STEP4
STEP 1
Park loader on firm, level surface and lower bucket to
ground. Put transmission in NEUTRAL, apply parking
brake, and shut down engine. Put the master
disconnect switch in the OFF position.
STEP2
Remove all dirt and grease from the steering system
valves and adjacent area.
NOTICE: MARK and LABEL all the various parts
(electric connections, hydraulic connections, etc.)
prior to disassembly.
STEP3
W190-4R072
Remove nut (1 0) from stud (8) to release the chassis

grounding cable (1) from the rear chassis frame (9).
W130R0003
Disconnect the cable (1) from valve PVG32 (2).

Disconnect connector (3) from the pilot pressure
switch, connector (4) of the proportional valve,
connector (5) from the solenoid valve. Remove
capscrews (7) and washers from PVFC (1') .
5-17010
5009-12
STEPS STEPS
W190-4R073 W190-4R074
Open the access panel on the right-hand side of the Disconnect the cab/joystick cable (2) from the cab
cab to access the fuse and relay compartment wiring (3) by disconnecting the connector (4).
Disconnect the connector from the chassis harness
(1) from the joystick cable (2}. Remove the chassis
harness (1 )-
5-17010
5009-13
STEP7 STEP9
W190-4R075
Disconnect the connector (1) from the joystick W190-4R077

harness (2}. Disconnect the armrest harness (3} from Remove the steering control device (5) from the
the six position connector (4). supporting plate (9) by removing the three nuts (1 0),
screw (11 ), and washers (12).
STEPS
W190-4R076
Disconnect the joystick cable (2) from the steering

control module (5) by detaching the sixteen position
connector (6}. Disconnect the connector (7) from the
transmission switch and the cab harness connector
(8}.
5-17010
5009-14
STEP10 STEP 11
W190-4R080
W190-4R078
To remove the armrest harness (9), refer to the
Detach the joystick harness(1) from the mounting
section titled JOYSTICK STEERING ARMREST
brackets on the fuse and relay panel (2). Remove the
two connectors (3) by removing the two nuts (4),
washers (5) and capscrews (6). Remove the joystick
harness (1 ).
5-17010
5009-15
Detail B
view from C <D II
I I
oe I I
I .
I I
'~>i Detail D
~w~--;;;-~~~ j)l~ji;;~~</
,!
view from E
' ~///
u /;>/ 1. Plate 19. Control joystick
2. Steering control device 20. CAN Module
3. Cab/joystick cable 21. Relays
4. Chassis cable 22. Diode
5. Washer 23. 8 bar pressure switch
6. Screw 24. 60 bar pressure switch
7. Nut 25. Steering valve PVFC
8. Joystick Steering System switch 26. Steering valve PVG32
9. Nylon strap 27. Armrest position switch
10. Screw 28. F-N-R switch
11. Washer 29. Kick-Down switch
12. Nut 30. Solenoid valve
13. 1OA fuse in position ECA-F2
14. Cab
View from C 15. Stud pin on rear chassis frame
16. Cable terminal with eyelet
17. Metal cable clamp
18. Armrest cable
521E-4R002
ELECTRICAL COMPONENTS OF THE JOYSTICK STEERING SYSTEM

5-17010
5009-16
l~. ......v•~cl tll,lll!¥.1 CXi.Wi!Uj

!IMAM.
II.!.~ $II
I
I GIIIUJID I
!"
!-
.;
.a
l·~.&
----l!~111MII,.C 1·0 . ...,_
W190-4R097
WIRING DIAGRAM OF THE JOYSTICK STEERING SYSTEM

5-17010
5009-17
Installation STEP14
STEP12
W190·4R083
Open the access panel on the right-hand side of the

cab to access the fuse and relay compartment. Install
W130R0003
the steering control module (12) on the supporting
plate (13} by installing the three nuts (14}, capscrews
Connect the chassis harness (1) to the valve PVG32
(15} and washers (16}. Tighten the capscrews.
(2), connect the connector (3) to the pilot pressure
switch. Connect connector (5) to the solenoid valve.
Connect connector (4) of the proportional valve.
Replace capscrews on PVFC (6) and secure the
harness with tie (7).
STEP13
W190·4R088
Fasten the chassis harness (1) to the grounding stud

(9) on the rear chassis frame (1 0). Install and tighten
the nut (11 ).
5-17010
5009-18
STEP15 STEP17
W190-4R085
Mount the joystick cable (1) with the connectors (8} to

W190-4R100 the fuse and relay panel (9} by installing the two nuts
Install the two 24-volt relays (2} and the four diodes (1 0}, washers (11) and capscrews (12}. Tighten the
(3} into the respective connectors of the joystick capscrews.
harness (1 )-
STEP16 STEP18
W190-4R086
Connect the joystick harness (1) to the cab harness

(13} with the connector (14}.
W190-4R084
Connect the joystick harness (1) to the steering
control module (4) with connector (5). Connect the
connector (6} and the cab harness connector (7).
5-17010
5009-19
STEP19 STEP 21
W190-4R073 W190-4R087
Connect the interface connector (1) to the joystick Connect the interface connector (4) of the joystick
harness (2}. harness (2} with the armrest harness (3} to the
six-position connector (5).
STEP 20
W190-4R082
To install the armrest cable (3), refer to the section

JOYSTICK STEERING ARMREST.
5-17010
5009-20
STEERING VALVES PVG32 AND PVFC
Removal STEP3
STEP 1
Remove all dirt and grease from the steering valves 4
and adjacent areas. Plug hoses and lines, cap all
fittings to prevent oil loss and contamination from
entering the system.
STEP2
W130R0006
Tag and disconnect hose (4) and (5) from Valve

PVFC (2). Plug hoses in order to avoid
contamination.
STEP4
W130R0005
Tag and disconnect the LS (3) line from valve PVG32

(1) and from the valve PVFC (2).
W130R0007
Tag and disconnect the flexible suction hose of the

emergency steering assembly from the valve PVG32.
5-17010
5009-21
STEPS STEPS
W130R0008
Tag and disconnect the flexible outlet hose.
STEPS
.. --------10
~--
I
&.. ®
W130R0011
Remove the steering valve PVG32 (2} from the

support (1) by removing four mounting screws (3}
and washers (4).
W130R0009
Tag amd disconnect the steering cylinder suppy

hose.
STEP7
W130R0010
Tag and disconnect the supply hose of stem side

steering cylinder line.
5-17010
5009-22
STEP9 STEP12
W130R0012
Remove the support (1) from the side wall of the rear
chassis frame by removing the three nuts (2),
W130R0015
washers (3), which lock the screws (4) and washers
(5).
Unscrew the joints (9) from the steering valve PVFC
(2).
STEP10
W130R0013
Remove the support (1 ).
STEP 11
W190-4R011
Remove the steering valve PVFC (4) from the

support (1) by removing the two nuts (5) and the
washers (6) which secure the screws (7) and
washers (8).
5-17010
5009-23
STEP13 STEP16
W190-4R01
Remove the pilot pressure switch (1) with seal (2} Remove the two unions (5) from the ports "A" and "B"
from valve PVG32. supplying the steering cylinder line.
STEP14 STEP17
Remove the reduction fitting (3).
STEP15 W130R0017
Unscrew the joint (6} from the port "P."
STEP18
W190-4R016
Unscrew the union (4) from the "LS" port of the valve
PVG32.
Remove joint (7) from port ''T".
5-17010
5009-24
Legend Of Jss Hydraulic Components
1. Steering valve support
2. Steering valve PVG32
3. Washer
4. Screw
5. Steering valve PVFC
6. Joint
7. Steering LS pipe
8. Joint
9. Joint
10. Steering cylinder line pipes
12. Joint
13. Outlet pipe of valve PVG32
14. Joint
15. Joint
16. Auxiliary steering valve suction hose
17. Joint
18. LS priority steering valve pipe
19. Washer
20. Nut
21. Screw
22. Washer
23. Nut
24. Screw
25. 60 bar pressure switch
27. Seal
30. Tool distributor line pipe
31. Joint
33. Reduction
34. Auxiliary steering valve
5-17010
5009-25
View from C
31
30
10
*
/
/
Detail A
View from B
view from D
* For installation see table 2 view E

W130R0019
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERING SYSTEM -Table 1
5-17010
5009-26
11
View from E ViewG
9. Joint
11. Tool distributor
14. Joint
16. Auxiliary steering valve suction hose
18. LS auxiliary steering valve flexible hose
28. Steering cylinder line pipe (bottom side)
29. Steering cylinder line pipe (stem side)
30. Tool distributor line pipe
34. Auxiliary steering valve
* For installation see view G

W130R0020
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERINGSYSTEM -Table 2
5-17010
5009-27
Detail A
View from B
'
'~', Cl
t<O--"----------'"'~-
1. Steering valve support 18. LS line flexible hose of power
I
I
060
o
2. Steering valve PVG32
3. Washer
steering valve
19. Washer
II 4. Screw 20. Nut
Cl
5. Steering valve PVFC 21. Screw
6. Joint 22. Washer
7. Steering LS pipe 23. Nut
8. Joint 24. Screw
',~,
~,, '~ '
',~, '~
[;Cl
~
~/
/
9. Joint
11. Joint
25.60 bar pressure switch
27. Seal
/
12. Joint 30. Tool distributor line pipe
"<::::~~ /lp ~~"~/ 13. Outlet pipe of valve PVG32

14. Joint
31. Joint
32. Joint
<:z,, ;f ViewD
15. Joint
16. Steering priority valve suction
hose
17. Joint
33. Reduction
34. Power steering valve
*See table 2
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITHOUT AUXILIARY STEERING SYSTEM -Table 1
5-17010
5009-28
()
Front Ax!&
0
Rear Ax!&
BR3
10micron
media
Bypass
3.4bar
Warning
'------1>------' Sw 2,7 bar
HYDRAULIC SCHEMATIC OF THE JOYSTICK STEERING SYSTEM

5-17010
5009-29
Installation STEP 21
Before reassembling the steering valves, clean all the
disassembled parts thoroughly using solvent.
1. Inspect each part for dents, scoring or other

defects.
2. Replace all damaged or deformed parts with new
ones.
STEP 20
W130R0022
Install the union (2) for connection with the suction

hose of the steering priority valve on the port "P.
Torque to 170 Nm (125 pound feet)
STEP 22
Install the union (1) into port "T" of the steering valve
PVG32. Torque to 310 Nm (228 pound feet).
Install the two joints (3) for connection with the

steering cylinder line supply flexible hoses on the
ports "A" and "B. Torque to 100 Nm (74 pound feet).
5-17010
5009-30
STEP 23 STEP 26
5
Install the union (1) on the port "LS. Torque to 45 Nm
(33 pound feet).
W130R0024
Assemble the union (6) on the port "1" of the valve

STEP 24 PVFC (5), the "T" fitting (7) on the port "2" and the
elbow (8) on the port "3. Torque to 45 Nm (33 pound
feet).
STEP 27
Install reducer (2) into port "Pp. Torque to 45 Nm. (33

pound feet).
STEP 25
W130R0025
Install the the pressure switch (1 0) with seal (11) on

the ''T" fitting (9).
Install the pilot pressure switch (3) with seal (4) on

the reducer (2).
5-17010
5009-31
STEP 28 STEP 30
W130R0026
Install the valve PVFC (2) on the support (1) with the
Install the valve support (1) on the side wall of the
two screws (3) and washers (4), the nuts (5) and
rear chassis frame with three screws (7) and washers
washers (6).
(8). Tighten the screws to a torque of 110 Nm (81
pound feet).
STEP 29
STEP 31
W130R0013
Position the support (1) of the steering valves on the

right-hand side of the rear chassis frame
11 ~--
I
.. - - - @
,.. @
W130R0027
Install the valve PVG32 (1) on the support (11) using

the four screws (12} and washers (13}. Torque the
screws to 30 Nm (22 pound feet).
5-17010
5009-32
STEP 32 STEP 34
W130R0010 W130R0008
Connect the stem side steering cylinder supply hose Connect and tighten the outlet hose to a torque of
to valve PVG32. Torque to 60 Nm (44 pound feet). 125 Nm (92 pound feet).
STEP 33 STEP 35
--~
Q
W130R0009 W30R0007
Connect the bottom side steering cylinder supply Connect the suction hose of the solenoid valve of the
hose. Torque to 60 Nm (44 pound feet). emergency steering assembly. Torque to 60 Nm (44
pound feet).
5-17010
5009-33
STEP 36 STEP 37
W130R0028
Connect the connection hose (2) on the valve PVFC

(1) with the hose (3) coming from the LS line of the
power steering valve. Torque to 14 Nm (1 0 pound W130R0029
feet). Connect the "LS" line (5) to the valve PVG32 (4) and
to the valve PVFC (1 ). Torque to 14 Nm (1 0 pound
feet).
5-17010
5009-34
JOYSTICK STEERING SYSTEM ARMREST
Removal STEP3
STEP 1
(~
(-~ \
\
W190-4R037
Remove the four locking screws (6) from the the

W190-4R036 armrest (3) and the support (4). Remove the armrest
Unscrew and remove the knob (1) and the washer (2} (3).
for armrest adjustment
STEP4
STEP2
W190-4R101
W190-4R035
Disconnect the connector (7) from the "Kick-Down"
Remove the cover (3}, support (4) from the armrest
adjustment device (5). button (8) with the armrest cable connector (9).
5-17010
5009-35
STEPS STEP7
W190-4R102
From the inside and bottom of the armrest cover (1)

unscrew the threaded washer (2) and remove the W190-4R038
Kick-Down button (3 through the top of the armrest Remove the two nuts (8), washers (9), screws (1 0)
cover. and washers (11) from the PVRES joystick (7).
Disconnect the connector (12) from the valve (7).
STEPS
W190-4R103
Disconnect the connector (4) of the "F-N-R" switch

(5) from the armrest cable (6). Remove the switch (5)
from the armrest (1 ).
5-17010
5009-36
STEPS STEP 11
2
l>/~
W190-4R040
Disconnect the connector (2) from the CAN module

(1 )- Release the armrest cable (3) from the mounting
bracket
STEP9
W190-4R041
Unscrew and remove the knob (1 0) for height

adjustment of the armrest and spacer (11 )- Raise
and extract the armrest (12) from the support (13).
Detach the CAN module (1) from the support (8).
STEP10
Disconnect the connector (9) from the armrest

positioning switch. Remove the armrest cable.
5-17010
5009-37
STEP12 STEP13
W190-4R043
Remove the armrest height I angle adjustment

device (2) from the support assembly (1) by removing
the nut (3) washers (4), capscrews (5) and two nylon
bushings (6}. I
/'®
I
W190-4R104
Remove the locking bracket (7) with pin (8} from the
armrest height/angle adjustment device (2}. Unscrew
thetwo nuts (9}, capscrews (1 0} and washers (11 )-
Remove the pin (8) from inside the seat of the
bracket (7).
5-17010
5009-38
STEP14 STEP16
Remove the support fastening the seat belt by

removing the nut (1 0) washer (11 ), capscrew (12)
and washer (13).
STEP17
W190-4R044
Unscrew the knob (2} from the support (1) and

extract the armrest height/angle adjustment pin (3}.
Remove the closing plate (4) from the support (1} by
removing the four capscrews (5) with washers.
Remove the armrest position switch (6} from the
inside of the support (1) by removing the two screws
(7) and the washers.
Remove the four screws (14) and washers from the
STEP15 seat cushion.
W190-4R045
Disconnect the wiring harness from the operator's

seat (if equipped with air seat). Remove the four
capscrews (8} and washers (9} from the base of the
seat. Remove the seat.
5-17010
5009-39
STEP18 STEP 20
Pressing down on the seat cushion support plate (1 ), Unhook the rod (4) from the support (3) and remove
slightly tilt the aluminium tongue (2) to release the the seat cushion support plate (1 ).
support (1) and allow raising/rotating the front. Use
care when releasing aluminium tongue (2) to avoid STEP 21
breaking it.
STEP19
Turn the knob of the locking support (3) clockwise

and move the plate (5) forward until the the four
sliding blocks (6) are in slots (7). Remove the plate
Raise, while slowly rotating, the seat cushion support (5).
plate (1 ).
5-17010
5009-40
STEP 22 STEP 23
Remove the plate (1) of the seat by removing the four

retaining bolts (2) and washers (3). Slide the plate (1)
forward to gain access to the two front nuts (4) and W190·4R053
washers (5) inside the two guides (6) under the plate
Remove the armrest support plate (8).
(1) of the seat. Repeat the procedure for the two rear
screws (7) by sliding the plate (1) back. Remove the armrest support plate (8).
5-17010
5009-41
STEP 24
W190-4R054
Position the armrest support plate (8) on the seat

runners (6).
STEP 25
Oo
Push the seat plate (1) forward. From the top, insert
the two front capscrews (3) and washers (4). From
the seat runners (7), install the nuts (5) and the
washers (6). Tighten the nuts to a torque of 32 Nm
(24 pound feet). Repeat the procedure for the two
Position the seat plate (1) on the seat support plate rear capscrews (8).
(2).
5-17010
5009-42
STEP 27 STEP 29
Install the seat plate (9). Turn the locking support (1 0) Lock the seat cushion support plate (1) by bending
clockwise and at the same time push the plate (9) the aluminium tongue (2). Use caution when bending
toward the rear of the seat to lock it. the aluminium tongue (2) to avoid breaking it.
STEP 28 STEP 30
Insert the two lugs for the seat cushion support plate Install the seat cushion (3) on the plate (1) and
(11) inside the two openings on the seat plate (9). secure it with thefour screws (4) and washers.
Hook the rod (13) to the catch (12). Slowly lower the
seat cushion support plate (11 ).
5-17010
5009-43
STEP 31 STEP 33
Install the seat belt, install capscrew (5) washer (6),

nut (7) and the washer (8). Tighten the nut to a
torque of between 47 and 68 Nm (35-50 pound feet).
Check that the seat belt mounting hardware is tight
and the seat belt is not cut or frayed.
STEP 32
W190-4R062
Install the armrest switch (2) on the support (1) using

the two screws (3) and washers. Insert the adjuster
pin (4) inside the support (1) and screw the knob (5)
on it. Install the plate (6) on the support (1) and
secure it using four capscrews (7) and washers.
Put the seat in the cab. Connect the wiring harness

to the operator's seat (if equipped with air seat
option). Install the seat on the base and secure it with
the four capscrews (9) and washers (1 0). Tighten the
screws to a torque of between 73 and 87 Nm (54-64
pound feet). Check parts for any wear or damage,
replace as necessary.
5-17010
5009-45
STEP 38 STEP 39
Connect the positioning switch connector (11 ). Install the CAN module (1) in the seat (2} on the
armrest.
STEP 40
W190-4R067
Connect the connector (3) to the CAN module (1 ).

Secure the cable (4) to the mounting bracket using
capscrew (5), washer (6), nut (7) and washer (8).
5-17010
5009-46
STEP 41 STEP 43
~-~
\
W190-4R068
Connect the connector (1 0} to the PVRES Joystick

(9}. Mount the joystick to support (11 ), install the two
capscrews (12}, four washers (13} and the two nuts
(14). Position the valve (9) so t the letter "A" stamped
on it is on the left-hand side of the armrest.
W190-4R108
STEP 42
Connect connector (1) of the Kick-Down button (2}
with the cable (3}.
W190-4R107
Insert the "Kick-Down" button (16) on the armrest

cover (15) and secure with the nut (17).
5-17010
5009-47
STEP 44 STEP 46
W190-4R070
Position the armrest (1) with support (2) onto the

armrest adjustment (3) and install knob (4) with
W190-4R109
washer (5).
Insert the "F-N-R" switch (5) in the armrest (4),
connect connector (6) to cable (7). STEP 47
Put the battery disconnecting switch in the ON
STEP 45 position and start the engine.
Turn the steering wheel all the way to the left and
then to the right several times.
Switch off the engine. Check the hydraulic oil level.
See the specific section for the specifications.
W190-4R069
Put the armrest (4) on the support (8) and secure it

with the four capscrews (9).
5-17010
5009-48
JSS HYDRAULIC PRESSURE ADJUSTMENTS

NOTICE: The differential pressures must be properly 3. Connect a 345 bar (5000 psi) pressure gauge to
adjusted before doing this test. Refer to Section 8002 the test port (2).
Testing and Adjusting Pump Differential Pressures.
NOTE: Make sure when you connect the pressure
gauge that you do so in a manner that you can read
Pressure Setting Test the pressure gauge while sitting in the operator's
seat.
4. Make sure that the temperature of the hydraulic
oil is at least 54° C (129° F).
5. To measure the temperature of the oil using the
instrument panel:
A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures
that need to be monitored.
7. Start and run the engine at full throttle.
8. Lower the lift arms and hold the control lever in
1. Install articulation lock (1 ). the FLOAT position.
9. Hold the bucket control lever in the rollback
---A WARNING A--- position.
Keep clear of the articulation area when the engine 10. Continue holding until the specified temperature
is running. Machine could pivot unless the transport of the oil is reached.
and service link is in the locked position. After
servicing is complete, unlock the transport and 11. Operate the machine at full throttle.
service link and secure in place on the rear frame. 12. With the articulation lock still in place, turn and
Failure to comply could result in machine damage, hold the steering wheel for a hard right turn.
death or serious injury.
SA069
13. Continue holding the steering wheel, and read
the pressure gauge.
14. The pressure gauge must indicate 239 to 243
bar (3465 to 3525 psi). If the pressure is not
correct, adjust the steering relief valve.
NOTE: See Section 8002 for pump 1 high pressure
pump differential pressure testing.
W100R379
1. G1 lEST PORT
2. G2 lEST PORT
2. Remove the dust cap from the test port (1 ).
5-17010
5009-49
Pressure Setting Adjustment Steering Times

1. Turn the adjusting screw clockwise to increase IMPORTANT: When performing the following
the pressure setting. Turn the adjusting screw procedure check that the articulation of the unit is
counterclockwise to decrease the pressure NOT locked.
setting. The speed of steering is not constant but depends on
2. Repeat pressure test procedure. the speed reached by the vehicle. On reaching 20
km/h the steering sensitivity is reduced by 80%
3. If necessary, adjust the limit valve again until compared to the normal speed of steering.
within the specified range. The JSS can be set on three different levels of
4. Stop the engine before removing the pressure steering speed.
gauge. The three speed levels are:
1. from 4.5 to 5.5 sec.*
2. from 3.2 to 4.5 sec.*
3. from 2.8 to 3.2 sec.*
*(time to take the unit from full right to full left turn).
The purpose of these settings is to make steering the
unit similar to the standard steering system.
1. With the engine at low idle, with all the controls in
neutral and JSS ON, steer the unit completely to
the left.
2. Set a speed level (e.g. 1, 2 or 3).
3. Move the joystick to the right, time the steering
rate from full left to full right. Compare the time
with the time specified in the table of speed
1. STEERING PRIORITY VALVE
2. LIMIT VALVE
levels.
4. Move the joystick to the left, time the steering
rate from full right to full left. Compare the time
with the time specified in the table of speed
levels.
5. If the times are not in the range shown in the
table, calibrate the system, see Calibrating
Steering Speed in this is section.
6. Repeat tests 1 through 4 with the engine at high
idle.
5-17010
5009-50
STEERING SPEED CALIBRATION PROCEDURE

STEP 1 STEP4
Before running the unit calibration procedure, the
following procedures must be completed.
- Start the engine; Calibration
- Set the unit in a straight position;
llmeout
Cancelled
- Activate the Joystick Steering System;
- Slightly lift the bucket off the ground;
- Release the parking brake.
STEP2
CASE
521E-4R005
Press the enter button (2) within two seconds to

confirm access to the calibration procedure. If you do
not press any buttons after two seconds, the screen
will show "Calibration", "Timeout", "Cancelled".
Repeat Step 2 to reenter the calibration procedure.
STEPS
At the same time press the Joystick Steering {§] Power Mode
activation switch (1) and the confirm/send button (2}. { ) I P!ifi!Jli!1Q1<® I
OPT Options
STEP3
JSS Calibration? CASE
YES :Press ENTER
NO: Press ESC
521E-4R006
If it is kept pressed longer than expected, the main

CASE
menu screen will appear.
521E-4R004
Keep pressed until the screen shows "Calibration?".
5-17010
5009-51
STEPS STEPS
521 E-4R007 521 E-4R009
The display will show a screen with the wording After this operation, the display will read "0. K." The
"Steer. Straight?" Press the enter button to confirm display will automatically read "Joyst Full Left"
the operation. "Release when WL starts moving". Move the
joystick lever completely to the left. As soon as
STEP7 machine movement is noticed, release the lever.
Joyst Full Left

STEP9
Release when
WL starts moving
CASE
CASE
The display will read "Joyst Full Left" "Release

when WL starts moving". Move the Joystick lever 521E-4R010
completely to the left. As soon as movement is The display will then automatically show the screen
noticed, release the lever. with the wording "Joyst Full Right" "Release when
WL starts moving". Move the Joystick lever
completely to the right. As soon as machine
movement is noticed, release the lever.
5-17010
5009-52
STEP10
Calibration
Succesful
O.k.
CASE
CASE
521E-4R011
521E-4R009 The display will read "Calibration Successful"

After this operation, the display will read "0. K.". The indicating the calibration is complete.
display will automatically show the screen with the
wording "Joyst Full Right" "Release when WL
starts moving",Move the Joystick lever completely
to the right. As soon as machine movement is
noticed, release the lever.
NOTICE: Steps are repeated twice before calibration
is complete.
5-17010
SECTION INDEX
POWER TRAIN
Removal and Installation of Power Train Components ............................................ 6001

Transmission Specifications, Pressure Checks, and Troubleshooting ................................. 6002
Transmission ............................................................................ 6003
Front Axle .............................................................................. 6004
Rear Axle ...............................................................................6004
Rear Axle, Serial Number N8F203848 and After ................................................ 6004
Drive Shafts, Center Bearing, and Universal Joints ............................................... 6005
Wheels and Tires ......................................................................... 6006
Transmission Control Valve ................................................................. 6007

Racine, WI 53404 U.S.A. Replaces 5-7 420 Issued December 2009
Section
6001
REMOVAL AND INSTALLATION OF POWER TRAIN

COMPONENTS

6001-2
TABLE OF CONTENTS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal .............................................................................. 3
Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal ............................................................................. 13
Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal ............................................................................. 18
Rear Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6001-3
TRANSMISSION
Removal STEP7
STEP 1
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
STEP2
position.
STEP3
Refer to Section 9007 and remove ROPS cab or
ROPS canopy. Disconnect transmission wiring harness connector
from control valve connector. Remove socket head
STEP4 bolt securing wiring harness clamp. Move wiring
Refer to Section 8001 and remove the hydraulic harness away from transmission.
pump.
STEPS
STEPS
Put a 25.5 liter (27 quarts) container under
transmission drain plug. Remove drain plug and drain
transmission oil. Install drain plug after oil has
drained.
STEPS
BD01D317
Just above where clamp was installed, tag and

disconnect transmission wiring harness connector
from temperature sensor. Move wiring harness away
from transmission.
STEP9
BD01D306
Identify, tag, and disconnect brake pump pressure

hose and brake to hydraulic reservoir hose. Position
hoses away from transmission. Remove and discard
0-ring face seals from fittings. Plug hoses and cap
fittings to prevent entry of foreign matter into
hydraulic system.
BD01D310
Remove two socket head bolts securing transmission

wiring harness clamps.
6001-4
STEP10 STEP13
BD010312
Identify, tag, and disconnect transmission wiring Remove two bolts and washers securing hose
harness connectors from engine speed sensor, retainer to front of rear chassis. Move hose retainer
intermediate speed sensor, and turbine speed towards front of machine.
sensor. Move transmission wiring harness away from
transmission. STEP14
STEP 11
BD03A165
Identify, tag, and disconnect parking brake hose from

BD010316 parking brake. Plug hose and cap fitting to prevent
Remove socket head bolt securing wiring harness entry of foreign matter into hydraulic system. Move
clamp. Move wiring harness away from transmission. hose away from transmission. Remove four bolts and
two straps securing center drive shaft to transmission
STEP12 output flange. Disconnect center drive shaft from
transmission.
BD010314
Identify, tag, and disconnect transmission wiring

harness connectors from filter maintenance switch
and output speed sensor. Move transmission wiring
harness away from transmission.

6001-5
STEP15 STEP18
BD03A161 BD01D339
Remove four bolts and two straps securing rear drive Remove fitting. Remove and discard 0-ring from
shaft to transmission output flange. Disconnect rear fitting. Install a plug in transmission port.
drive shaft from transmission.
STEP19
STEP16
BD03A160 Repeat Steps 17 and 18 and disconnect the other

Remove two bolts. Remove fill tube, with cap and oil cooler hose and remove fitting.
gauge assembled, two seals, and metal strainer.
Discard seals. STEP 20
STEP17
BD01D343
Connect lifting equipment to transmission lifting eyes.

BD01D318 Take up all slack in lifting equipment.
Identify, tag, and disconnect cooler hose from fitting
installed in LH side of transmission. Install a plug in
hose. Remove and discard 0-ring face seal from
fitting.

6001-6
STEP 21 STEP 23
BD010342 BD03A164
In area between the transmission and the engine, Raise transmission just enough to enable removal of
remove four bolts and two straps. Use pry bar to RH and LH mounting brackets. Remove two bolts
disconnect engine drive shaft from transmission. and washers securing RH and LH mounting brackets
Using 3/4 inch drive socket, extensions, and impact to transmission. Remove RH and LH mounting
wrench, remove four bolts and washers securing brackets.
transmission to top mounting bracket.
STEP 24
STEP 22
BD010345
BD03A163 Slowly and carefully raise transmission from loader

Remove bolts and washers securing RH and LH while checking that all hoses, electrical connectors,
mounting brackets to rear chassis. and wires have been disconnected and nothing
interferes with transmission removal. Remove
transmission from loader.
STEP 25
If top mounting bracket requires removal, remove bolt

and washer then remove bracket.

6001-7
Transmission Mounting
1. ISOLATOR BOLT 6. MOUNTING BRACKET

2. WASHER 7. TOP MOUNTING BRACKET
3. BOLT A. REAR CHASSIS TRUNNION
4. BOLT B. BRACKET (6 OR 7)
5. BOLT C. SMALLER PIECE ON TOP

6001-8
STEP 26
Check isolators for deterioration, tears, deformation,
or other damage. Replace as necessary: refer to
Page 7.
STEP 27
BD03A164
Install RH and LH mounting brackets on transmission

using two washers and bolts. Do not tighten bolts.
STEP 30
BD01D361
If top mounting bracket was removed, put bracket on

rear chassis trunnion and secure using washer and
bolt. Do not tighten bolt.
STEP 28
BD03A163
Loosely install washers and bolts to secure RH and

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

lower transmission into loader.

6001-9
STEP 31 STEP 33
NOTE: In this step, new straps and bolts securing
the drive shaft must be installed whenever these
parts are removed. Bolts have a nylon patch to
maintain torque which requires new bolts.
BD010343
Disconnect lifting equipment from transmission lifting

eyes.
BD010342
STEP 34
Using 3/4 inch drive socket, extensions, and impact
wrench, install four washers and bolts to secure top
mounting bracket to transmission. Then tighten bolts
to a torque of 251 to 319 Nm (185 to 235 pound feet).
If bracket had been removed, tighten bolt to a torque
of 890 to 1000 Nm (655 to 735 pound feet). Connect
engine drive shaft to transmission. Install two new
straps and four new bolts. Tighten bolts to a torque of
61 to 81 Nm (45 to 60 pound feet).
STEP 32
Install new 0-ring on fitting and install fitting in

transmission. Install new 0-ring face seal in fitting
then connect cooler hose to fitting following tag
installed during removal. Remove and discard tag.
STEP 35
BD03A163
Tighten bolts securing RH and LH mounting brackets

to a torque of 890 to 1000 Nm (655 to 735 pound
feet).
BD010318
Install new 0-ring on fitting and install fitting in

transmission. Install new 0-ring face seal in fitting
then connect cooler hose to fitting following tag
installed during removal. Remove and discard tag.

6001-10
STEP 36 STEP 39
BD03A160
Position fill tube, two new seals, and metal strainer Position hose retainer on front of rear chassis and
on transmission; metal strainer is installed between secure using two washers and bolts.
seals. Secure using two bolts. Tighten bolts to a
torque of 17 to 33 Nm (12 to 24 pound feet). STEP 40
STEP 37
BD01D314
Connect transmission wiring harness connectors to

BD03A161 output speed sensor and filter maintenance switch
Connect rear drive shaft to transmission then install following tags installed during removal. Remove and
two straps and four bolts. Tighten bolts to a torque of discard tags.
STEP 41
STEP 38
BD01D316
BD03A165 Install socket head bolt to secure wiring harness

Connect center drive shaft to transmission and install clamp.
two straps and four bolts. Tighten bolts to a torque of
61 to 81 Nm (45 to 60 pound feet). Connect parking
brake hose to parking brake following tag installed
during removal. Remove and discard tag.
6001-11
STEP 42 STEP 45
BD010312 BD010315
Connect transmission wiring harness connectors to Install socket head bolt to secure wiring harness
turbine speed sensor, intermediate speed sensor, clamp. Connect transmission wiring harness
and engine speed sensor following tags installed connector to control valve connector.
during removal. Remove and discard tags.
STEP 46
STEP 43
BD010306
BD010310 At brake valve, install new 0-ring face seals in

Install two socket head bolts to secure transmission fittings. Connect brake to hydraulic reservoir hose
wiring harness clamps. and brake pump pressure hose following tags
installed during removal. Remove and discard tags.
STEP 44
STEP 47
BD010317
Connect transmission wiring harness connector to

temperature sensor following tag installed during Check that transmission drain plug is tight.
removal. Remove and discard tag.

6001-12
STEP 48 STEP 50
Fill transmission with 15-40W engine oil until oil level Refer to Section 9007 and install ROPS cab or ROPS
is up to the arrow in sight glass. canopy.
STEP 49 STEP 51
Refer to Section 8001 and install the hydraulic pump. Start and run engine at idle speed with transmission
in neutral. If transmission oil level is at or below
bottom of crosshatch region, put articulation lock in
LOCKED position and add oil specified in Section
1002 until oil level is up to crosshatch region. Shut
down engine and put articulation lock in OPERATING
position.

6001-13
FRONT AXLE
Removal STEP4
STEP 1
Remove four bolts and two straps securing front drive

BD03A040
shaft to front axle.
Park machine on level surface. Have assistant put
articulation lock in LOCKED position. STEPS
IMPORTANT: If machine is equipped with
quick-attached components, disconnect them from
machine prior to proceeding.
STEP2
Remove clamp securing lubrication hose to machine

and nut securing opposite end of hose. Remove four
bolts and two straps securing center drive shaft to
front drive shaft. Use a pry bar to separate drive
shafts. While supporting center bearing and front
BD03A092
drive shaft, remove four nuts and bolts and eight
Raise bucket and have assistant install safety link. washers. Lower center bearing and front drive shaft
Lower loader arms slowly until safety link is from mounting plate and remove from machine.
supporting loader arms.
STEP3
Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from

6001-14
STEP6 STEP9
BD03A168 BD01F297
Disconnect brake hose from elbow. Remove and Use an acceptable jack to hold front axle.
discard 0-ring face seal from elbow.
STEP10
STEP7
BD01F295
Remove bolts and washers from front wheels.

Remove both wheels from front axle.
STEP 11
BD01D392
Using an acceptable hydraulic jack, raise one tire

from ground and install an acceptable jack stand
under machine. BD01F296
Remove eight nuts bolts, and washers securing front

STEPS axle to machine.
Repeat Step 7 to raise other front axle tire from
ground. STEP12
Carefully lower front axle and remove from under
machine.

6001-15
Front Axle Mounting
BS07D018
FRONT AXLE TORQUE SEQUENCE
Installation STEP15
STEP13
Carefully move front axle under machine and raise
against mounting pads on machine.
STEP14
BD01F296
Apply one drop of engine oil to threads prior to

assembly. Install eight washers, bolts, washers, and
nuts to secure front axle to machine. Tighten bolts to
a torque of 765 to 855 Nm (565 to 630 pound feet)
using torque sequence shown. B0987A88
Install both wheels on front axle and secure. Tighten

bolts to a preliminary torque of 298 Nm (230 pound
feet) in sequence indicated; then tighten to a torque
of 640 to 720 Nm (475 to 530 pound feet) in same
sequence.

6001-16
STEP16 STEP19
BD01F297 BD03A168
Remove jack from front axle. Install a new 0-ring face seal in elbow. Connect
brake hose to elbow.
STEP17
STEP 20
Position and support center bearing and front drive

shaft and install eight washers and four bolts and
nuts. Tighten bolts to a torque of 99 to 128 Nm (73 to
94 pound feet). Install two straps and four bolts.
Tighten bolts to a torque of 75 to 81 Nm (50 to 60
pound feet). Secure lubrication hose to machine
using clamp; secure opposite end of hose using nut.
BD01D392
Using an acceptable hydraulic jack, raise axle and

remove jack stand from under machine.
STEP18
Repeat Step 17 to remove other jack stand from
under machine.

6001-17
STEP 21 STEP 23
Refer to Section 7002 and bleed brakes.
STEP 24
Secure drive shaft to front axle using two straps and

four bolts. Tighten bolts to a torque of 75 to 81 Nm
(50 to 60 pound feet). BD03A092
Start engine and raise bucket. Have assistant

STEP 22 remove safety link. Lower bucket to ground and stop
If necessary, fill axle with gear lubricant specified in engine.
Section 1002.
STEP 25

6001-18
REAR AXLE
Removal STEPS
STEP 1
Park machine on a level surface; be sure to allow
adequate space at side of machine for removal of
rear axle. Stop engine. Actuate brake pedal several
times to discharge brake accumulators. Put key
switch in ON position and move loader control lever
back and forth at least 30 times to release any
pressure from hydraulic circuit.
STEP2
Disconnect brake hose from elbow. Remove and

discard 0-ring face seal from elbow.
STEPS
BD03A040
Put articulation lock in LOCKED position.
STEP3
Install wood blocks between rear axle and chassis to
prevent rear axle from pivoting.
Using an acceptable hydraulic jack, raise one tire
STEP4 from ground and install an acceptable jack stand
under machine. Repeat this step for other tire.
STEP7
BD03A162
Remove four bolts and two straps. Use a pry bar to

disconnect rear drive shaft from rear axle.
BD01F302
Use an acceptable jack to hold rear axle.

6001-19
STEPS STEP10
Carefully lower rear axle and remove through side of
machine.
STEP 11
Remove and discard two seals from rear axle pivot
point.
BD01F295
Remove bolts and washers from rear wheels.

Remove both wheels from rear axle.
STEP9
BD03A170
At front of trunnion, remove two Allen head bolts and

washers. Remove front cap: if necessary use two
M12 by 32 mm (1.25 inches) bolts in puller holes (A);
tighten bolts evenly to pull cap from axle and
trunnion. Remove and discard 0-ring from cap.
Repeat this step at rear of trunnion except remove
and retain shim(s) after removal of rear cap. Remove
pivot shaft using acceptable sleeve or rod if
necessary.

6001-20
__Rear Axle Mounting
.. ~.. ~ 5
/'. ~~
"""" _y/. l
/_';./_./.·
/
BS01D132
1. TRUNNION 5. WASHER 9. REARAXLE

2. 0-RING 6. BOLT 10. PIVOT PIN
3. SEAL 7. WASHER 11. SHIM(S)
4. FRONTCAP 8. BOLT 12. REAR CAP

6001-21
Installation STEP13
NOTE: If shim(s) (11) have been lost or pivot pin
(10) has been replaced, do Step 12 to determine
required shim(s) otherwise go to Step 13.
STEP12
BS01E091A
Install pivot pin (1 0) and caps (4 and 12) in trunnion

(1) without rear axle or shim(s). Install washers (5)
and bolts (6). Tighten bolts securely. Push
assembled pivot pin and caps to rear of machine as
far as possible. Measure and record gap (A) between
rear cap (12) and trunnion. Select shims from the
following:
NOTE: Shims are available in following sizes: 0.50
mm (0.020 inch), 1.0 mm (0.039 inch), and 1.50 mm Clean front (A) and rear (B) pivot area of rear axle
(0.059 inch). where seals (3) will be installed.
MEASURED SHIM(S) REQUIRED STEP14

GAP (mm) (mm)
0.07 to 0.55 None
0.56 to 1.09 0.50
1.10 to 1.59 1.0
1.60 to 2.09 1.50
2.10 to 2.59 0.50 plus 1.50
2.60 to 3.02 1 .0 plus 1 .50
BS01E092
Lubricate two new seals (3) and new 0-rings (2)

using Molydisulfide Grease. Install seals, smooth
side out, into front and rear of axle housing (A) until
flush with housing or recessed 2.0 mm (0.079 inch).
Install an 0-ring in each cap (4 and 12).
STEP15
Carefully move rear axle under machine. Raise axle
into position in trunnion and align pivot holes in
trunnion with pivot holes in axle.

6001-22
STEP16 STEP18
Remove hydraulic jack supporting rear axle and jack
stands supporting loader.
STEP19
BS01E091
Lubricate pivot pin (1 0) using Molydisulfide Grease.

At rear of trunnion (1 ), install pivot pin into trunnion
and axle (A). Install shim pack (11), rear cap (12)
with 0-ring installed, and two washers and bolts (6).
At front of trunnion install front cap (4) with 0-ring Install a new 0-ring face seal in elbow. Connect
installed. Use Loctite primer 747 on bolt threads and brake hose to elbow.
let dry for 70 seconds. Then, apply Loctite 243 on
bolt threads and install washers and bolts (6).
STEP 20
Tighten bolts (6) to a torque of 325 to 353 Nm (240 to
260 pound feet).
STEP17
BD03A162
Connect rear drive shaft to rear axle. Install two

straps and four bolts. Tighten bolts to a torque of 75
to 81 Nm (50 to 60 pound feet).
BD01F295
STEP 21
If necessary, fill axle with gear lubricant specified in
Section 1002.
STEP 22
Refer to Section 7002 and bleed brakes.
STEP 23
B0987A88
Install both wheels on front axle and secure. Tighten

bolts to a preliminary torque of 298 Nm (220 pound
feet) in sequence indicated; then tighten to a torque
of 640 to 720 Nm (475 to 530 pound feet) in same
sequence.

Section
6002
TRANSMISSION SPECIFICATIONS, PRESSURE

CHECKS, AND TROUBLESHOOTING

Racine, WI 53404 U.S.A. Bur 5-2841 Issued August, 2006, Revised September, 2007
6002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS ......................................................................... 3
TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General ............................................................................... 9
Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission ECM Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission Sensor Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Automatic Problem Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Clutch Modulation Substitute Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Limp-Home Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission!Transmission ECM Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gear Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Automatic/Manual Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Upshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Downshifting in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Upshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Downshifting in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Downshift Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cold Start Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake Pedal Transmission Declutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TRANSMISSION PRESSURE TEST POINTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CHART FOR RECORDING PRESSURE READINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PRESSURE TEST RESULTS ............................................................... 16
All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONSUMPTION TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES ...................... 19

6002-3
SPECIAL TOOLS
CAS-1953A Transmission supplemental fitting kit. CAS-1808 Flowmeter kit
Includes: CAS-2324 special 90 degree adapter and
CAS-2702 Flowmeter adapter
CAS-2325 plug and cap set.
CAS-2278 Flow test kit
CAS-1804 Master pressure test kit
SPECIFICATIONS
Main pressure and clutch pressure ................................................................................ 16 to 18 bar (232 to 261 psi)
Converter in pressure .......................................................................................................8 to 10 bar (116 to 145 psi)
Pressure reduction for solenoids ........................................................................................7 to 9 bar (1 02 to 131 psi)
Converter out pressure .....................................................................................................3.5 to 6.5 bar (51 to 96 psi)
Lubrication pressure ...........................................................................................................0.2 to 1.2 bar (3 to 18 psi)
Minimum pump output (at 2000 rpm) ..................................................................................... 80 Umin (21 U.S. gpm)
Transmission oil operating temperature .......................................................................... 80 to 120 oc (176 to 248 °F)
Clutch KV ........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch KR .......................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K1 ........................................................................................................................16 to 18 bar (232 to 261 psi)

6002-4
BS01A190
1. TRANSMISSION ELECTRONIC CONTROL MODULE 8. INDUCTIVE TRANSMITTER - INTERMEDIATE SPEED SENSOR
2. DOWNSHIFT BUTTON 9. INDUCTIVE TRANSMITTER -TURBINE SPEED SENSOR
3. DECLUTCH ROCKER SWITCH 10. INDUCTIVE TRANSMITTER- ENGINE SPEED SENSOR
4. MANUAUAUTOMATIC ROCKER SWITCH 11. HALL SENSOR -OUTPUT SPEED SENSOR
5. SHIFTER 12. TRANSMISSION CONTROL VALVE CABLE
6. SUPPLY SYSTEM CONNECTIONS B+ AND RETURN 13. DECLUTCH LIMIT SWITCH
7. TRANSMISSION 14. PLUG
COMPONENT LOCATIONS SYSTEMS

6002-5
BS03A262
1. CLUTCH SHAFT KR 9. TRANSMISSION PUMP
2. POWER TAKE OFF 10. INPUT FLANGE
3. CLUTCH SHAFT KV 11. CONVERTER
4. CLUTCH SHAFT K2 12. INDUCTIVE TRANSMITTER FOR ENGINE SPEED
5. CLUTCH SHAFT K3 13. CLUTCH SHAFT K4
6. OUTPUT FLANGE REAR 14. CONVERTER RELIEF VALVE
7. OUTPUT FLANGE CONVERTER SIDE 15. CLUTCH SHAFT K1
8. OUTPUT SHAFT
COMPONENT LOCATIONS TRANSMISSION LAYOUT

6002-6
BS01A191
3. OUTPUT FLANGE CONVERTER
1. ATTACHMENT FOR OIL FILLER PIPE WITH OIL DIPSTICK
SIDE
2. TRANSMISSION SUSPENSION BORES 4. OIL DRAIN PLUG
COMPONENT LOCATIONS FRONT VIEW

6002-7
BS01A192
1. CONVERTER BELL HOUSING 6. OUTPUT FLANGE REAR

2. BREATHER 7. OIL DRAIN PLUG
3. TRANSMISSION CASE COVER 8. OUTPUT FLANGE CONVERTER SIDE
4. FILTER HEAD 9. TRANSMISSION CASE
5. FILTER 10. PARKING BRAKE
COMPONENT LOCATIONS SIDE VIEW

6002-8
6 1-----+-J~
88018048
1. LIFTING LUGS 5. OUTPUT FLANGE REAR
2. POWER TAKE OFF 6. FILTER
3. TRANSMISSION CONTROL VALVE 7. FILTER HEAD
4. TRANSMISSION SUSPENSION BORES
COMPONENT LOCATIONS REAR VIEW

6002-9
TRANSMISSION OPERATION
General Transmission ECM Tasks

The transmission is equipped with a Transmission The Transmission ECM performs a variety of tasks in
ECM (Electronic Control Module). This module the overall system. The Transmission ECM:
controls modulation and shifting that were normally
A. Determines which clutches to engage in the
associated with hydraulically modulated
transmission.
transmissions, providing smoother shifts and
enhanced clutch life. B. Protects the engine and transmission turbine
from overspeed conditions during
The Transmission ECM relies on signals from several
downloading.
sensors that are incorporated into the design. These
sensors measure the speed of several components, C. Receives speed information from the engine
as well as other sensors that measure temperature. speed sensor, the turbine speed sensor, the
These solenoids and sensors are further defined in intermediate shaft speed sensor and the
the following paragraphs. transmission output shaft speed sensor.
These speed sensors are checked to
In addition, the transmission incorporates a
determine if normal sensor operation is
two-piece transmission case for ease of transmission
present. The data is also used to control
maintenance, helical cut gears that help reduce
modulation during shifting and to determine
noise, and all external hoses have been eliminated
the appropriate shift patterns.
(all oil passages are internal).
D. Detects system failures and determines the
Transmission ECM appropriate alternative actions.
Modulation and shifting are controlled by the E. Provides various diagnostic messages to the
Transmission Electronic Control Module Information Center.
(Transmission ECM). This module replaces the oil F. Provides other information to the information
and springs that are found in hydraulically modulated center, which in turn displays engine speed,
transmissions. wheel speed, gear shift selection, and actual
The Transmission ECM controls the clutch gear selection.
engagement, providing smoother shifts and G. Provides a method to calibrate the
enhanced clutch life, whether the transmission is set transmission clutch control.
to the automatic or manual shift mode.
H. Establishes clutch modulation pressure during
The Transmission ECM also informs the Information transmission shifts.
Center, by the use of diagnostic codes, of any
transmission error and the hours of operation that the
error occurred.
Electrical Shift Solenoids

Electrical Shift Solenoids control the modulation of
the clutches, eliminating the need for a modulation
valve, and providing a smooth shift while maintaining
constant control over clutch engagement as follows:
A. A temperature sensor relays the oil
temperature to the Transmission ECM.
B. The Transmission ECM times the rate the
solenoid energizes and de-energizes.
C. As the transmission changes gears, there is
reduced hesitation from one gear to the next.

6002-10
Transmission Sensor Data Clutch Modulation Substitute Mode

Collection In this mode, the transmission clutch modulation is
The Transmission ECM collects and uses information time dependant rather than load dependant. The
from four sensors to accurately shift the transmission transmission will go into the Clutch Modulation
and determine if any clutches are slipping. These Substitute Mode if any of the four speed sensors fail.
sensors are: If the output speed sensor is working and the
Engine (Speed) Sensor - monitors engine speed to transmission is in gear, the shift points in Automatic
determine the load on the engine for shift points and mode will be speed dependant but the modulation
sends the engine rpm to the Transmission ECM, will be a predetermined amount of time.
which sends the information to the tachometer in the If the output speed sensor is not working and the
Information Center. transmission is in gear, the shift points will be load
Turbine (Speed) Sensor- assists the engine speed dependant but the modulation will still be a
sensor in determining the load going into the predetermined amount of time.
transmission and helps determine shift points. If the transmission is shifted from neutral into a
Intermediate (Shaft Speed) Sensor- determines direction in the Clutch Modulation Substitute Mode in
differential gear speed in the transmission to check automatic, the transmission will shift into 4th gear
for clutch slippage. and shift down until it gets the correct output speed
from the turbine.
Output (Speed) Sensor- monitors transmission
output shaft speed to help determine the load on the Limp-Home Mode
transmission and to assist in determining shift points.
Sends output shaft speed to Transmission ECM In this mode, the transmission will go into second
which sends the information to the speedometer in gear, forward or reverse, no matter what gear is
the Information Center. selected. If second gear is not obtainable, the
Transmission ECM selects a series of prioritized
The transmission ECM also reviews voltage
gears until an operable gear is found. The
information from the shifter and transmission
transmission will go into the Limp Home Mode if
solenoids to determine if there are any short circuits
there is a fault on one clutch, a fault on one clutch
or open circuits in the system.
valve, or a fault on more than one speed sensor.
Automatic Problem Modes Transmission/Transmission ECM

If the Transmission ECM detects an error condition in Shutdown Mode
the transmission system, it will generate a service
code in the Information Center and will enter one of In this mode, the Transmission ECM has detected a
three modes: severe failure that disables control of the
transmission. The transmission will go into Shutdown
A. Clutch Modulation Substitute Mode
Mode if there is a fault on more than one clutch, a
B. Limp-Home Mode fault on the solenoid power supply, or invalid voltage.
C. Transmission/Transmission ECM Shutdown In this mode, the Transmission ECM will shut off all
Mode solenoid valves and the power supply and the
transmission shifts into and stays in neutral.
If the Transmission ECM generates a code, a
warning triangle will be illuminated on the Information
Center.

6002-11
Transmission Clutch Calibration Gear Selections

The Transmission ECM has the capability to find the The transmission provides 4 forward and 3 reverse
optimal adjustment of the clutch filling parameters for gear selections. The transmission ratios were
each individual transmission, providing the ability to designed to give optimized speed and torque for
individually adjust the optimum fill time for the each gear selection. The torque converter is a single
individual transmission in the machine. Clutch Filling stage torque converter (one locking unit in the torque
Parameter Calibration is performed on each machine converter).
at the plant and should be repeated at the first 250
hours of use and every 1000 hours thereafter. Automatic/Manual Modes
Before doing the following transmission clutch The automatic/manual switch is located on the right
calibration procedures make sure of the following: control panel. The transmission is in automatic mode
1. The machine is running and the transmission oil when the top of the automatic/manual switch is
is warm. depressed. The Transmission Display Center
indicates when the machine is in the automatic
2. Engine low idle speed is correct. mode.
3. The transmission is in neutral.
4. The park brake is applied.
Upshifting in Automatic Mode
5. If steps 1 through 4 have been accomplished, Upshifting is determined by machine speed and the
calibrate the transmission clutches as follows: torque on the transmission.
A. Press and hold the enter key for 2 to 3 The transmission will shift from first or second gear
seconds and the monitor will change to up to the highest gear selected as the accelerator is
SELECT. depressed, machine speed increases, and required
torque is reduced.
B. Use the down arrow and high light "CONFIG",
press the enter key. If the machine speed is increasing, but the operator
is not depressing the accelerator (such as when
C. Press the down arrow and high light "CALIS going down a hill}, the transmission will not upshift.
G/B", press the enter key.
As the operator depresses the accelerator and the
D. Monitor will state "CALIS G/B" "CONFIRM torque on the transmission is lowered, the
PLEASE", press the enter key. transmission will upshift.
E. If the conditions are not correct for clutch
calibration the monitor will display the problem Downshifting in Automatic Mode
that needs to be corrected.
Downshifting is determined directly by machine
F. Clutch calibration status will be displayed on speed and transmission torque. The transmission will
the monitor, "ADJUST K1, K2, K3, K4, KV, downshift to first or second gear as machine speed
KR". decreases and transmission torque increases. For
example, if the unit begins to climb a hill in forth gear
G.After completing the Clutch Calibration and the machine speed decreases, as the torque
procedure, turn the machine OFF for 15 requirement increases, the transmission will
seconds. This sets the calibration in the downshift into third, then second, and down to first
controller. gear, if necessary.
Upshifting in Manual Mode

In the manual mode, the transmission starts out in
the selected gear and stays in that gear until the
operator selects another gear or direction. The
transmission can be upshifted without reducing
engine speed or machine speed.
If the gear selected is two or more gears higher than
the present gear, the transmission will shift up
through the gears at 2.5 second intervals until the
selected gear has been reached.

6002-12
Downshifting in Manual Mode Manual Mode

The transmission can be downshifted in the manual In the manual mode, the downshift button toggles
mode without reducing engine speed or machine between 1st and 2nd gear. The manual mode is
speed. useful in short haul operations. In this mode, the
downshift button functions in two ways in 1st and 2nd
If 1st gear is selected from 3rd or 4th gear, the
gear.
transmission will downshift into 2nd gear for 1.2
seconds and then will shift into 1st gear. When the operator is in 2nd gear and pushes the
downshift button, the transmission instantly shifts into
Downshift Button 1st gear. When the operator pushes the downshift
button again, the transmission upshifts into 2nd gear.
The downshift button is located on front of the
joystick control lever in machines with a single lever If the machine is in 2nd gear and the downshift
configuration, and on top of the control tower in button is pushed, the transmission instantly shifts into
machines with a three lever configuration. 1st gear. When the operator shuttles the shifter, the
transmission upshifts back into 2nd gear.
With the number of different ways the downshift
button functions, the operator can tailor the use of the Cold Start Protection System
machine to the application at hand.
The transmission has a cold start protection system.
Automatic Mode When the transmission sump temperature is minus
10° C (14° F), the Transmission ECM will keep the
In the Automatic Mode, the downshift button only transmission in neutral.
shifts down. The downshift button allows the operator
to downshift through the entire range of gears. This is When the transmission sump temperature warms up
useful in long haul applications or reading. to minus 1oo C (14°F) (within approximately one
minute), the machine will operate in all gears.
Each time the button is pushed the transmission will
instantly downshift one gear from 4th to 3rd, then Brake Pedal Transmission
from 3rd to 2nd, and then from 2nd to 1st.
Declutch
The transmission will automatically downshift and
then upshift, as needed, to the last gear that was A transmission declutch feature concentrates more
selected with the downshift button. engine power on the loader when digging in heavy or
tough conditions, providing smoother stops and
Example: If the downshift button was used to shift starts. Total disconnection of the transmission from
from 4th to 3rd gear, the transmission will the engine is prevented. This feature will function in
automatically shift from 3rd down and then back up to 1st, 2nd, or 3rd gear only. It will not function in 4th
3rd again. It will not shift into 4th until the gear.
transmission has been returned to the full range
automatic mode. When the transmission declutch switch is in the on
position and the brake pedal is pushed, the
The transmission will return to the full range Transmission ECM reduces the pressure to the
automatic mode when: transmission forward or reverse clutch.
A. Another gear is selected. The Transmission ECM will not completely
B. The shifter is moved into neutral and then into disconnect the clutch from the engine, but gradually
forward or reverse. reduces the forward or reverse clutch pressure down
to a lower level.
C. The autoshift switch is recycled.
When the brake pedal is released, the Transmission
ECM gradually increases the forward or reverse
clutch back up to system clutch pressure.
If the direction is changed while the transmission is
declutched, the selected forward or reverse clutch
will be filled and maintain a low pressure until the
brake pedal is released. Then the selected forward or
reverse clutch pressure will gradually increase up to
system clutch pressure.

6002-13
TRANSMISSION PRESSURE TEST POINTS DIAGRAM

DESIGNATION ON
No. IDENTIFICATION/LOCATION CONNECTION
VALVE BLOCK
Measuring Points for Pressure Oil and Temperature
51 Before the Converter- Opening Pressure 8 bar (116 psi) M10x1 H
52 Behind the Converter- Opening Pressure 2.5 bar (36 psi) M14x1.5
53 Clutch Forward 16+2 bar (232 + 29 psi) KV M10x1 8
55 Clutch Reverse 16+2 bar (232 + 29 psi) KR M1 Ox1 E
56 Clutch 16+2 bar (232 + 29 psi) K1 M10x1 D
57 Clutch 16+2 bar (232 + 29 psi) K2 M1 Ox1 A
58 Clutch 16+2 bar (232 + 29 psi) K3 M1 Ox1 c
60 Clutch 16+2 bar (232 + 29 psi) K4 M1 Ox1 F
63 Behind the Converter Temperature 1ooo C, Short Time 120° C M14x1/5
65 System Pressure 16+2 bar (232 + 29 psi) M10x1 K
Measuring Points for Delivery Rates
15 Connection to the Heat Exchanger 1 5/16"- 12 UNF-28
16 Connection from the Heat Exchanger 1 5/16"- 12 UNF-28
Inductive Transmitter and Speed Sensor
21 Inductive Transmitter for Turbine Speed M18x1.5
34 Output Speed Sensor
47 Inductive Transmitter for Central Gear Train Speed M18x1.5
48 Inductive Transmitter for Engine Speed M18x1.5
Connections
49 Plug Connection on the Hydraulic Control Unit
68 System Pressure M16x1.5 G
69 Pilot Pressure M16x1.5 J
NOTE: See next page for Measuring Point, Transmitter, Sensor and Connection locations.

6002-14
VIEW X
VIEW X
VIEWY
e PRESSURE REGULATOR UNDER VOLTAGE

FORWARD REVERSE NEUTRAL
CLUTCH PRESSURE REGULATOR I 2 3 4 I 2 3
KV Y5 • • •
KR Y2 • • •
Kl Y3 • •
K2 Y6 • •
K3 Y4 • • •
K4 Yl •
BC01B047
MEASURING POINTS AND CONNECTIONS

6002-15
CHART FOR RECORDING PRESSURE READINGS

Use this chart to record the pressure readings.
P.I.N. Number: Date:
TEST POINTS
Shift p v R 1 2 3 4 5 6
LP
Speed 65 53 55 56 57 58 60 51 52
1st F
2nd F
3rd F
4th F
1st R
2nd R
3rd R
Neut
P= MAIN PRESSURE 1= FIRST GEAR CLUTCH 4= FOURTH GEAR CLUTCH LP= LUBE PRESSURE
V= FORWARD CLUTCH 2= SECOND GEAR CLUTCH 5= CONVERTER IN
R= REVERSE CLUTCH 3= THIRD GEAR CLUTCH 6= CONVERTER OUT

6002-16
PRESSURE TEST RESULTS
All or Most Pressures Low and/or Not Enough Power

Flow Test Low Possible causes include:
Possible causes include: 1. Check Electrical Troubleshooting in this Section
1. Oil level not correct. to verify actual gear selected.
2. Oil type and grade not correct. 2. Engine RPM below Stall Test specified RPM.
(Refer to Section 2002 for specifications.)
3. Oil operating temperature high.
A. Check engine and fuel system for problem.
4. Screen for suction tube plugged.
B. Check that torque converter installation is
5. Suction tube or gaskets leak. correct.
6. Main pressure valve, springs, or valve bore. 3. Engine RPM above Stall Test specified RPM.
7. Reduction valve, springs, or valve bore. (Refer to Section 2002 for specifications.)
8. Charge pump seals or gaskets leak. A. Check converter pressures and flow.
9. Charge pump worn. B. Check that torque converter installation is

correct.
10. Oil supply flange not sealing correctly.
Machine Stops or Hesitates While
Some Pressures Low Shifting - Intermittent
Possible causes include:
Possible causes include:
1. Circuit isolation does not correct low pressure.
1. Check orifice and 0-ring. (See Section 6007 for
A. Control valve or gasket. replacing.)
B. Channel plate or gasket. 2. Check for foreign material plugging orifices or
sticking valves.
2. Circuit isolation corrects low pressure.
3. Check for reduced pressure at test pressure
A. Clutch shaft or seals.
points.
B. Clutch drum or piston.
4. See Electrical Troubleshooting in this Section for
electrical system problem.

6002-17
CONVERTER OUT PRESSURE CHECK
Test Equipment Required 3. Install the pressure gauge.
0 to 28 bar (400 psi) gauge with hose long enough to 4. Heat the oil to an operating temperature of 80 to
take readings in the cab and CAS-2324 Special 100° C (176 to 212° F).
Adapter. 5. While in the cab, put the transmission in
NEUTRAL. Run the engine at full throttle. Record
Test Procedure the reading in the chart on page 16. Pressure
must be a minimum of 3.5 to 6.5 bar
1. Block the machine tires. (51 to 96 psi).
2. Apply the parking brakes.
LUBRICATION PRESSURE CHECK
Test Equipment Required 3. Install the pressure gauge in the cooler return
line at the transmission.
0 to 7 bar (1 00 psi) gauge.
4. Heat the oil to an operating temperature of 80 to
100° C (176 to 212 oF).
Test Procedure
5. While in the cab, run the engine at full throttle.
1. Block the machine tires. Put the transmission in each gear and record the
2. Apply the parking brakes. reading in the chart on page 16. Pressure must
be 0.2 to 1.2 bar (3 to 18 psi).
FLOWMETER TEST
Test Equipment Required 3. Heat the oil to an operating temperature of 80 to

100° C (176 to 212° F).
CAS-1808 Flowmeter Kit; CAS-2702 Flowmeter
Adapter. 4. Remove the filter and install the CAS-2702
adapter.
Flowmeter Test Procedure 5. Install the flowmeter between the adapter and
the filter.
1. Block the machine tires.
2. Apply the parking brakes. Put the transmission in NEUTRAL and record the
flow measurement. The correct flow is 80 Umin
(21 U.S. gpm) at 2000 rpm.
CONSUMPTION TEST PROCEDURE

1. Block the machine tires. 6. Repeat the procedure with the transmission in
FORWARD in third gear. The flow must be 9.1
2. Apply the parking brakes.
Umin (2 U.S. gpm).
3. Heat the oil to an operating temperature of 80 to
7. Repeat the procedure with the transmission in
100° C (176 to 212 oF).
REVERSE in third gear. The flow must be 9.1
4. Install the flowmeter to converter outlet line (line Umin (2 U.S. gpm).
to cooler) in series.
Put the transmission in NEUTRAL and record the
flow measurement. The flow must be 9.1 Umin
(2 U.S. gpm).

6002-18
TRANSMISSION OVERHEATING
1. Operate machine in normal operating conditions and observe:
A. Verify actual oil temperature at test point. Normal operating temperature can be 56°C (1 00°F) above the
ambient temperatures.
B. Use a stop watch to establish the exact length of time required to reach the overheating condition.
C. Observe engine temperature, does the engine overheat? Which overheats first - engine or transmission?
2. When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast idle
(1250 to 1450 RPM).
A. Oil temperature returns to Normal - establish length of time.
1. Check oil level, type and grade is correct (See Section 1002).
2. Check operator's gear selection is correct for conditions.
3. Make sure brakes are fully released.
4. Check the engine full throttle and stall speeds are correct as specified (See Section 2002).
B. Oil temperature remains overheated.
1. Check for dirty radiator- airflow restricted.
2. Check for engine overheating problem.
3. Check for faulty oil temperature gauge and sender or switch (See Section 4002).
3. Perform all the pressure and flow tests.
4. Compare the pressure and flow test results to the specifications in this section to determine if any circuits are
not within specifications.
5. Refer to Pressure Test Results to determine possible cause of any test results not within specifications.

6002-19
ERROR CODES
In case of possible errors in the system, an amber or red warning appears on the instrument panel, combined with
a recorded error number. See section 4005 for error code retrieval procedures and definitions.
TRANSMISSION SHIFTER LOGIC INFORMATION
Shifter Wire Shifter Tower Shifter Shroud Harness Harness

Function Shifter Trans. ECM #
Color Connector Connector Wire# pedicab#
power 8+ black/red A A 19A_H 43 45
forward v yellow - 8 25F 44 43
reverse R pink - c 25R 45 64
neutral N gray - D 25T_8 46 67
gear2(3-4) 82 green 8 - 25W 48 65
gear1 (1-2) 81 blue c - 25Z 49 63
downshift DS purple D - 25Y 50 22
NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within the
shifter are limit switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. In
neutral N is high. In first gear, 81 is high and 82 is low. In second gear, 81 and 82 are low. In third gear, 81 is low
and 82 is high. In fourth gear, 81 and 82 are high. Downshift, OS, is activated when the end of the shifter is
engaged.
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES
Transmission ECM Transm iss ion Transmission Transmission Trans/Cab

Clutch# Wire#
Function ECM Pin# Valve Valve Pin# Pin #
A1 P1 56 Y1 K4 1 25K 16
A1P2 10 Y2 KR 2 25L 17
A1P3 32 Y3 K1 3 25M 18
A1P4 55 Y4 K3 4 25N 19
A1P5 9 Y5 KV 5 25P 20
A1P6 51 Y6 K2 6 25J 21
VPSI 12,13 allY all K 7 258 22
TEMP 39 TEMP none 8 36T 5
TEMP 46 TEMP none 9 36R 12

6002-20
NOTES

Section
6003
TRANSMISSION

6003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES ....................................................................... 3
SPECIAL TORQUES (continued} . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS ......................................................................... 4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6003-3
SPECIAL TOOLS
CAS2885 TRANSMISSION VALVE

ADJUSTMENT TOOL SET
~
CAS2807 TRANSMISSION
INPUT/OUTPUT SHAFT SEAL CAS2869 TRANSMISSION
INSTALLATION TOOL OUTPUT SHAFT SEAL
CAS2803 TRANSMISSION INSTALLATION TOOL
RQUE CONVERTER SEAL (521 AND 621
INSTALLATION TOOL MODELS ONLY)
BS02C093 THRU 096

CAS40075 TRANSMISSION TOOL KIT
~@(0 C>~~ ~
CAS2799 CLUTCH PACK ~~-rf; ~
CAS2802 ALIGNMENT
DOWEL SET
HOLDER AND SPRING
COMPRESSOR TOOLS ~~~~
®!;)
~~~~
:!!!"" ~ <iir_;;;;.---
~
CAS2801 TRANSMISSION
CAS2796 NESTING MOUNTING BRACKETS
w
PLATE
CAS2800 CLUTCH
~~~~
CAS2797 LIFTING
CAS2868 CLUTCH SPRING
COMPRESSOR
(521 AND 621
MODELS ONLY)
ASSEMBLY HOLDING EYEBOLT SET
CAS2798 GEAR KNOB SET
PULLER COLLET SET
BS02C097 THRU 104
CAS40079 TRANSMISSION OVERHAUL KIT
SPECIAL TORQUES
Oil pipes
Studs ............................................................................................................................... 9 Nm (80 pound inches)
Socket head screw ...................................................................................................... 23 Nm (204 pound inches)
Screw plug .......................................................................................................................... 51 Nm (38 pound feet)
Clutch K1, K2, K3, K4 Stud ............................................................................................. 17 Nm (150 pound inches)
Plugs ................................................................................................................................. 25 Nm (221 pound inches)
Output shaft
Output shaft screws (apply Loctite 243 to threads) ..................................................... 23 Nm (204 pound inches)
Housing cover screws (apply Loctite 574 to threads) .................................................. 46 Nm (407 pound inches)
Output flange screws ................................................................................................... 34 Nm (301 pound inches)
Oil feed housing and transmission pump
Transmission pump screws ......................................................................................... 46 Nm (407 pound inches)
Oil feed housing screws .............................................................................................. 25 Nm (221 pound inches)
Engine connection and converter
Input shaft screws ............................................................................................................ 115 Nm (85 pound feet)
Converter housing screws .................................................................................................. 68 Nm (50 pound feet)
Cover ............................................................................................................................ 23 Nm (204 pound inches)
Converter cover ........................................................................................................... 46 Nm (407 pound inches)
Input flange .................................................................................................................. 34 Nm (301 pound inches)

6003-4
SPECIAL TORQUES (CONTINUED)

Duct plate
Screws ......................................................................................................................... 25 Nm (221 pound inches)
Screw plug ................................................................................................................... 30 Nm (265 pound inches)
Hydraulic control unit ........................................................................................................ 9.5 Nm (84 pound inches)
Filter
Filter head screws ....................................................................................................... 25 Nm (221 pound inches)
Oil distribution cover screws ........................................................................................ 25 Nm (221 pound inches)
Speed sensor and inductive transmitter
Speed sensor screw .................................................................................................... 23 Nm (204 pound inches)
Inductive transmitter .................................................................................................... 30 Nm (265 pound inches)
Cover plate .................................................................................................................. 23 Nm (204 pound inches)
Screw plug ...................................................................................................................... 140 Nm (1 03 pound feet)
SPECIFICATIONS
Clutch KV and KR plate clearance ......................................................................... 2. 7 to 2.9 mm (0.1 06 to 0.114 in)
Clutch K1 plate clearance ........................................................................................ 2.4 to 2.6 mm (0.094 to 0.102 in)
Clutch K2 and K3 plate clearance .......................................................................... 1.8 to 2.0 mm (0.071 to 0.079 in)
Clutch K4 plate clearance ....................................................................................... 1.2 to 1.4 mm (0.047 to 0.055 in)

6003-5
DISASSEMBLY
STEP 1 STEP 4
Fasten transmission on an assembly stand using Remove two socket head screws and install
CAS2801 transmission mounting brackets. CAS2885 transmission valve adjustment tool set.
Remove remaining 21 socket head screws securing
STEP 2 control valve. Loosen and remove hex rods (part of
CAS2885) from studs then remove control valve.
STEP 5
Remove and discard oil filter.
STEP 3
Remove both gaskets and the intermediate plate.
STEP 6
Remove hex head screws securing filter head.

Remove filter head from transmission.
Remove socket head screws and hex nuts. Remove
duct plate. Remove flat gasket.
6003-6
STEP 7 STEP 10
Bend lock plate away from hex head screws.

Using proper size rod, press input shaft and
Remove two hex head screws, lock plate, and
converter from cover.
washer. Remove input flange from shaft.
STEP 11
STEP 8
Put alignment marks on converter cover and Remove retaining ring then remove bearing.
housing to aid in assembly. Remove 12 nuts and
hex head screws. STEP 12
STEP 9
Remove four hex head screws and remove

diaphragm and input shaft.
Connect suitable lifting equipment to shaft.
Remove cover, shaft, and converter from
transmission and place in hydraulic press.

6003-7
STEP 13 STEP 16
Put input shaft and diaphragm in vise as shown. Remove the socket head screws for removal of the
Remove 12 hex head screws to separate transmission pump.
diaphragm and input shaft.
STEP 17
STEP 14
Apply a bearing separator on the splines shoulder of

Remove the inductive transmitter. the stator shaft and pull the pump out of the housing
bores, using two-leg puller.
STEP 15 NOTE: If traces of wear should be encountered in
the pump housing or the cam disk, the complete
pump has to be replaced.
STEP 18
Remove the hex head screws and remove the

converter housing.
Separate the transmission pump from stator.

Separate the cam plate from pump.
6003-8
STEP 19 STEP 23
Turn the transmission 180 degrees and remove the
rear output flange.
STEP 24
Remove the hex head screws and remove the oil

feed housing. Remove the flat gasket.
STEP 20
Remove the speed sensor and both inductive
transmitters.
STEP 25
Remove the hex head screws, cover, and flat gasket.
STEP 21
Remove the hex nuts and the two covers.
STEP 26
Remove the lock plate, hex head screws, and pry the
converter side output flange from the shaft.
STEP 22
Pry the shaft seal out of the housing bore. Install CAS2802 alignment dowel set.
NOTE: The following steps describe the common
removal of all clutches.
6003-9
STEP 27 STEP 30
Remove CAS2800 clutch assembly holding knob
set and lift cover free.
STEP 31
Install CAS2800 clutch assembly holding knob set.

With knobs installed on all clutches in housing cover,
install CAS27971ifting eyebolt set and lifting device to
transmission cover.
Remove the socket head screws and remove the
STEP 28 output shaft and both oil baffle plates.
STEP 32
Separate the cover along with clutches from the

transmission housing, using lifting device.
STEP 29 Remove clutch K2.
STEP 33
Place clutch disc carriers onto CAS2796 nesting

plate.
Remove clutch K1 while lifting clutch K4.

6003-10
STEP 34 STEP 37
Remove clutch K3. Remove the bearing outer race and pull output shaft
out of the housing bore.
STEP 35
STEP 38
Remove clutch K4 while lifting input shaft slightly.

Remove the rectangular ring and separate ball
STEP 36 bearing from the shaft.
NOTE: The following steps are for the disassembly
of the clutch KV. The disassembly of the clutch KR is
similar.
STEP 39
Remove clutches KV and KR together with input

shaft.
Remove the sealing ring. Pull the tapered roller

bearing from the shaft. Remove the opposite tapered
roller bearing.
6003-11
STEP 40 STEP 43
Separate the clutch disc carrier from the shaft. Remove snap ring.
STEP 41 STEP 44
Remove the snap ring and remove the clutch disc Remove the compression spring.
pack.
STEP 45
STEP 42
Remove piston from clutch pack holder. Remove and

Preload compression spring using CAS2799 clutch discard the 0-rings from piston.
pack holder and spring compressor tool.

6003-12
STEP 46 STEP 48
Remove the snap ring. Remove the snap ring and remove the ball bearing.
STEP 47 NOTE: The following steps are for disassembly of

clutch K3. Disassembly of clutches K1 and K2 is
similar
STEP 49
Remove the rectangular ring. Pull the tapered roller

bearing from the shaft.
STEP 50
Press the idler gear from the shaft using a bearing

separator. Remove released needle bearing.
Remove the thrust washer, thrust bearing, and thrust

washer.

6003-13
STEP 51 STEP 54
Remove the idler gear. Preload compression spring using CAS2799 clutch
STEP 52
STEP 55
Remove the needle bearings and thrust bearing.

Remove the snap ring.
STEP 53
STEP 56
Remove the snap ring and remove the clutch disc

pack. Remove the compression spring.

6003-14
STEP 57 STEP 59
Remove the sealing ring. Remove bearing using Remove and discard two sealing rings. Pull two
bearing puller. Tap assembly until piston drops out of bearings from shaft using bearing puller. Remove the
the clutch pack carrier. Then, remove and discard snap ring and separate the clutch disc carrier from
0-rings from piston. the shaft.
STEP 58 STEP 60
Remove the clutch disc carrier from the shaft. Remove the snap ring and remove the clutch disc
pack.
NOTE: The following steps are for the disassembly
of the clutch K4.
STEP 61
Preload compression spring using CAS2799 clutch


6003-15
STEP 62 NOTE: The following two steps are for disassembly

of the input shaft.
NOTE: A snap ring is used to lock turbine shaft in
input shaft. Snap ring will be destroyed when turbine
shaft is pressed from input shaft.
STEP 64
STEP 63
If turbine shaft is to be removed from input shaft, use

proper size diameter sleeve or rod and press turbine
shaft out of input shaft.
STEP 65
Remove bearings from input shaft using a bearing
puller.
Remove the compression spring.

6003-16
ASSEMBLY
NOTE: The following steps are for the reassembly of STEP 69
the oil pipes.
STEP 66
Install a new 0-ring on plug. Tighten the plug to a

torque of 51 Nm (38 pound feet).
STEP 70
Install suction tube (1), pressure pipes (2), and

lubrication pressure pipe (3) in housing.
STEP 67
Secure suction tube (1) and pressure pipes (2) with
socket head screw and hex nuts. Tighten to a torque
of 23 Nm (204 pound inches)
STEP 68
Install all bearing outer races in housing bores.
STEP 71
Tilt the cover 180 degrees. Install the suction tubes

and pressure pipes into the housing bores using a
rolling tool.
NOTE: Pipe end of the pressure pipes must be
slightly below the housing plane face.
Install both oil pipes into the housing cover. Tilt the
cover 180 degrees and install pipes into the housing
bores using a rolling tool.
NOTE: The pipe end must be slightly below the
housing plane face.
6003-17
STEP 72 STEP 75
Install the studs. Tighten the studs to a torque of 9

Nm (80 pound inches).
NOTE: The following steps are for the assembly of
clutches KV and KR, starting with assembly of the
clutch disc carrier.
STEP 73
Install compression spring and two spring cups in

clutch disc carrier. Preload compression spring
using CAS2799 clutch pack holder and spring
compressor tool.
STEP 76
Check that drain hole is clear and free of foreign

matter. Install both 0-rings in recesses of the piston
and apply oil.
STEP 74
Install the snap ring.

NOTE: The following steps are for the KV and KR
clutch disc packs. The disc stacking of clutches KV
and KR is identical.
Install piston in clutch disc carrier.

6003-18
STEP 77 STEP 79
4
225B Install end shim and snap ring.
1. PLATE CARRIER
2. PISTON STEP 80
3. OUTER PLATE- ONE-SIDED COATED
4. INNER PLATES
5. OUTER PLATES- COATED ON BOTH SIDES
6. SNAP RING
7. END SHIM
A RUNNING CLEARANCE 2.7 TO 2.9 MM (0.106 TO 0.114
IN)
Install clutch disc plates in KV and KR clutch disc

carriers in position and sequence shown above.
Install outer plates (3) with steel faced side facing
piston and end shim (7).
NOTE: Snap rings of different thickness are
available for adjustment of the running clearance. To
ensure correct adjustment, do not apply oil to clutch
discs until after adjustment is completed. Adjust running clearance to 2. 7 to 2.9 mm (0.1 06 to
0.114 in). Press down on the end shim with
STEP 78 approximately 10 kg (20 lb}. Measure and record
dimension (A) from carrier face to end shim using
depth gauge as shown.
Example
Dimension A ................. 7.25 mm (0.29 in)
Install the clutch disc pack.

6003-19
STEP 81 STEP 84
Use tools to lift the end shim against snap ring Apply Loctite 243 to stud. Tighten stud to a torque of
(upward) until contact is obtained. Measure and 17 Nm (150 pound inches).
record dimension (B) from carrier face to end shim
using depth gauge as shown. Subtract this STEP 85
measurement from the measurement of Step 80. The
difference is the running clearance.
Example
Dimension A ................. 7.25 mm (0.29 in)
Dimension B ................. 4.45 mm (0.18 in)
Difference = Running ........... 2.80 mm (0.11 in)
Clearance
Required running clearance is 2.7 to 2.9 mm (0.1 06
to 0.114 in). Use snap ring(s) of different thickness as
necessary to obtain correct running clearance.
STEP 82
Remove clutch disc pack, apply oil to discs, and
install clutch disc pack, end shim, and snap ring as Install ball bearing until contact is obtained. Secure
determined in Step 81. using snap ring.
STEP 83 STEP 86
Install idler gear to align and engage all inner discs, Install needle bearing.
then remove idler gear.

6003-20
STEP 87 STEP 90
Support the idler gear on the bearing inner race. Install gear and shaft into heated bore.
Press the idler gear against the shoulder.
STEP 91
STEP 88
Heat bearing.
Secure idler gear using snap ring.
STEP 92
STEP 89
A WARNING: Always wear heat protective
. . gloves to prevent burning your hand when
handling heated parts.
SM121A
Use heat gun to heat assembled clutch disc carrier

inner bore.
Install heated bearing on shaft against shaft

shoulder.

6003-21
STEP 93 STEP 96
Check operation of the clutch using compressed air.
NOTE: The following steps are for assembly of
clutch K1, K2, and K3.
STEP 94

matter. Install both 0-rings in recesses of piston and
apply oil.
STEP 97
Press bearing against shoulder of shaft. Apply
Loctite 243 to the stud and install the stud. Tighten
the stud to a torque of 17 Nm (150 pound inches).
STEP 95
Install piston in clutch disc carrier.
STEP 98
Install the clutch disc carrier until contact is obtained.
Install the compression spring and spring cup.

6003-22
STEP 99 STEP 101
4
232A
1. PLATE CARRIER
2. PISTON
4. INNER PLATES
6. SNAP RING
7. END SHIM
A. CLUTCH K1 RUNNING CLEARANCE 2.4 TO 2.6 MM
(0.094 TO 0.1021N); CLUTCHES K2 AND K3 RUNNING
CLEARANCE 1.8 TO 2.0 MM (0.071 TO 0.079 IN)
Install clutch disc plates in K1, K2, and K3 clutch disc

carriers in position and sequence shown above.
Install compression spring and two spring cups in Install outer plate (3) with steel faced side facing
clutch disc carrier. Preload compression spring piston.
using CAS2799 clutch pack holder and spring NOTE: Snap rings of different thickness are
compressor tool. available for adjustment of the running clearance. To
ensure correct adjustment, do not apply oil to clutch
STEP 100 discs until after adjustment is completed.
STEP 102
Install the snap ring.

NOTE: The following steps are for K1, K2 and K3
clutches. The assembly of clutches K1, K2, and K3 is Install the clutch disc pack.
identical except for running clearance dimensions.

6003-23
STEP 103 STEP 105
Install the end shim and snap ring. Use tools to lift the end shim against snap ring
(upward) until contact is obtained. Measure and
STEP 104 record dimension (B) from carrier face to end shim
using depth gauge as shown. Subtract this
measurement from the measurement of Step 104.
The difference is the running clearance.
Example
Dimension A ................... 8.2 mm (0.32 in)
Dimension B ................... 6.1 mm (0.24 in)
Difference = Running Clearance ... 2.1 mm (0.08 in)
Required running clearance for K1 is 2.4 to 2.6 mm
(0.094 to 0.102 in); for K2 and K3 required running
clearance is 1.8 to 2.0 mm (0.071 to 0.079 in). Use
snap ring(s) of different thickness as necessary to
obtain correct running clearance.
Adjust running clearance for K1 to 2.4 to 2.6 mm STEP 106

(0.094 to 0.1 02 in); adjust running clearance for K2 Remove clutch disc pack, apply oil to discs, and
and K3 to 1.8 to 2.0 mm (0.071 to 0.079 in). Press install clutch disc pack, end shim, and snap ring as
down on the end shim with approximately 10 kg (20 determined in Step 105.
lb). Measure and record dimension (A) from carrier
face to end shim using depth gauge as shown. STEP 107
Example
Dimension A .................. 8.2 mm (0.32 in)
Install the thrust washer (1 ), thrust bearing (2), and

thrust washer (3).
NOTE: Install the thrust washer (1) with the chamfer
facing the thrust bearing.

6003-24
STEP 108 STEP 111
Install both needle bearings. Heat bearing.
STEP 109 STEP 112

h WARNING: Always wear heat protective
. . . gloves to prevent burning your hand when
SM121A
Install idler gear until all inner discs are engaged.
STEP 110
Place heated bearing on the shaft.
STEP 113
Install the thrust washer (3}, thrust bearing (2}, and

thrust washer (1 ). Install the thrust washer (1) with
the chamfer facing the thrust bearing.
NOTE: Ensure the thrust washer (1) is overlapping
with the chaff collar to accommodate all the inner
discs.

6003-25
NOTE: The following steps are for assembly of STEP 116
clutch K4.
STEP 114
h ~ARNING: Always wear heat protective
... ~loves to prevent burning your hand when
SM121A
Apply Loctite 243 to the stud and install the stud.

Tighten the stud to a torque of 17 Nm (150 pound
inches).
STEP 117
Heat the gear to about 120° C (248° F) and install

until seated in position.
STEP 115

matter. Install both 0-rings in recesses of the piston
and apply oil.
STEP 118
Install retaining ring to secure gear.
Install piston in clutch disc carrier. Be sure piston

bottoms out.

6003-26
STEP 119 STEP 121
4
BS02C131
1. PLATE CARRIER
2. PISTON
4. INNER PLATES
6. SNAP RING
7. END SHIM
A. RUNNING CLEARANCE 1.2 TO 1.4 MM (0.047 TO 0.055
IN)
Install clutch disc plates in K4 clutch disc carrier in

position and sequence shown above. Install outer
plate (3) with steel faced side facing piston.
NOTE: Snap rings of different thickness are
available for adjustment of the running clearance. To
Install compression spring and two spring cups in ensure correct adjustment, do not apply oil to clutch
clutch disc carrier. Preload compression spring discs until after adjustment is completed.
using CAS2799 clutch pack holder and spring
compressor tool. STEP 122
STEP 120
Install clutch disc pack.
Install snap ring.

NOTE: The following steps are for installing the
clutch disc pack in clutch K4.

6003-27
STEP 123 STEP 125
Install end shim and snap ring. Use tools to lift the end shim against snap ring
(upward) until contact is obtained. Measure and
STEP 124 record dimension (B) from carrier face to end shim
using depth gauge as shown. Subtract this
measurement from the measurement of Step 124.
The difference is the running clearance.
Example
Dimension A ................... 7.2 mm (0.28 in)
Dimension B ................... 6.0 mm (0.24 in)
Difference = Running ............ 1.2 mm (0.04 in)
Clearance
Required running clearance is 1.2 to 1.4 mm (0.047
to 0.055 in). Use snap ring(s) of different thickness as
necessary to obtain correct running clearance.
STEP 126
Adjust running clearance to 1.2 to 1.4 mm (0.047 to Remove clutch disc pack, apply oil to discs, and
0.055 in). Press down on the end shim with install clutch disc pack, end shim, and snap ring as
approximately 10 kg (20 lb}. Measure and record determined in Step 125.
dimension (A) from carrier face to end shim using
depth gauge as shown. STEP 127
Example
Dimension A .................. 7.2 mm (0.28 in)
Install the idler gear until all inner discs are engaged,
then remove idler gear.

6003-28
STEP 128 STEP 131
Assemble two thrust washers and thrust bearing. Assemble thrust washer (3), thrust bearing (2), and
thrust washer (1 ). Install the thrust washer (1) with
NOTE: Upper and lower thrust washers are the
the chamfer facing the thrust bearing.
same thickness.
STEP 132
STEP 129
Install the assembled clutch disc carrier until all the

Install both needle bearings.
inner discs are engaged.
STEP 130
STEP 133
Install the idler gear.

Install snap ring to secure clutch disc carrier.

6003-29
STEP 134 STEP 138
h !wARNING: Always wear heat protective
. . . !gloves to prevent burning your hand when
SM121A
Heat bearing.
STEP 135
h WARNING: Always wear heat protective
... ~loves to prevent burning your hand when Heat gear to about 120° C (248° F) and install on
handling heated parts. input shaft until contact is obtained.
SM121A
STEP 139
Install heated bearing on the shaft shoulder.

Secure gear with snap ring.
STEP 136
Repeat Steps 134 and 135 to install bearing on STEP 140
opposite end of shaft.
STEP 137
NOTE: The following steps are for the reassembly of
the input shaft.
Install snap ring into recess of turbine shaft.

6003-30
STEP 141 STEP 144
Install the turbine shaft until the snap ring snaps into Install output shaft into housing bore until contact is
the recess of the input shaft. made.
STEP 142 NOTE: The following steps are for the installation of
the output shaft and clutches. All clutches have a
h. WARNING: Always wear heat protective common installation .
. . gloves to prevent burning your hand when
handling heated parts. STEP 145
SM121A
Install bearing outer races into housing cover until

Heat bearings and install on turbine shaft until contact is obtained.
bearings are against shoulder.
STEP 146
STEP 143
Install the clutches onto CAS2796 nesting plate.

Install bearing then install rectangular ring.

6003-31
STEP 147 STEP 150
Using CAS2797 lifting eye bolt set and acceptable Install the sealing rings and insert rings in their
lifting equipment, install housing cover onto respective grooves. Apply grease to the sealing rings
clutches. Install CAS2800 clutch assembly holding and align the rings centrally.
knob set to secure clutch shafts to cover.
STEP 151
STEP 148
Install both the 0-rings into the annular groove of the

The above photo shows the position of the single oil pipes and apply grease.
clutches in the housing cover.
STEP 152
STEP 149
Tilt the housing cover 180 degrees.
The above shows the position of the single clutches

and the input and output clutches.

6003-32
STEP 153 STEP 156
Install output gear and shaft in transmission housing. Install screen sheet on output shaft. Press front and
Install alignment screws. Carefully lower the cover rear bearings on output shaft until contact with
and clutches into the gear box housing. shoulder of output shaft is made.
STEP 154 STEP 157

Remove CAS2800 clutch assembly holding knob set.
STEP 155
Install the screening plate.
STEP 158
Separate the housing cover from the gearbox, using
a lifting device.
NOTE: The following steps are for the reassembly of
the output shaft.
Install the output shaft.

6003-33
STEP 159 STEP 162
Apply Loctite 243 to the socket head screws and Heat the output flange to about 90° C (194 o F). Apply
install the screws. Tighten the screws to a torque of Loctite 574 to the contact area and assemble the
23 Nm (204 pound inches). flange with the washers and hex head screws.
Tighten the screws to a torque of 34 Nm (301 pound
STEP 160 inches). Bend corner of lock plate over hex head
screws.
STEP 163
Repeat Steps 161 and 162 to install shaft seal and
output flange on converter side.
the oil feed housing and transmission pump.
STEP 164
Install rectangular rings in grooves of clutch shafts.

Apply grease to rings and align rings.
STEP 161
Install two alignment studs and install the gasket.
Position shaft seal with sealing lip facing oil chamber.

Apply grease to sealing lip. Use CAS2807
transmission output shaft seal installation tool to
install seal.

6003-34
STEP 165 STEP 168
Install the oil feed housing with washers and hex Install transmission pump.
head screws. Screw the hex head screws in only until
contact is obtained, do not tighten. STEP 169
STEP 166
Apply grease to new 0-rings. Install the 0-rings on

the socket head screws.
Install the two alignment screws and install the stator
shaft. STEP 170
STEP 167
Secure the transmission pump with the socket head

screws. Tighten screws to a torque of 46 Nm (407
Apply oil and install the 0-ring. pound inches).

6003-35
STEP 171 STEP 173
Install the oil feed housing with the hex head screws Position converter housing. Secure with hex head
and flat washers. Tighten the screws to a torque of screws. Tighten the screws to a torque of 68 Nm (50
25 Nm (221 pound inches). pound feet).
STEP 172 STEP 174
Position the gasket and cover. Secure the cover with Put input shaft in a vise as shown. Position
the hex head screws. Tighten the screws to a torque diaphragm on input shaft and secure using 12 hex
of 23 Nm (204 pound inches). head screws. Tighten screws to a torque of 115 Nm
(85 pound feet).
the engine connection and converter. STEP 175
Position diaphragm and input shaft on converter.

Apply Loctite 262 to threads of hex head screws.
Install screws and tighten to a torque of 115 Nm (85
pound feet).
6003-36
STEP 176 STEP 178
Position converter cover on converter housing. Make

sure alignment marks made during removal of cover
are aligned. Install input flange, two hex head
screws, lock plate, and washer. Pull cover against
housing by tightening two hex head bolts evenly.
STEP 179
Position converter. Check and ensure that impulse

disk of converter is centered on the bore for the
inductive transmitter.
STEP 177
Secure converter cover using 12 hex head screws

and nuts. Tighten screws to a torque of 46 Nm (407
pound inches).
Position converter cover as shown. Install bearing

against shoulder in cover. Secure using retaining
ring.

6003-37
STEP 180 NOTE: The following steps are for installation of

transmission control valve.
STEP 183
Tighten input flange hex head screws to a torque of

34 Nm (301 pound inches). Lock screws by bending
corners of lock plate over screws.
Install CAS2885 transmission valve adjustment tool
STEP 181 set. Be sure hex rods (part of tool set) are not
installed on studs. Mount the gasket (1 ), intermediate
plate (2), and gasket (3).
STEP 184
Install the screw plug with new 0-ring. Tighten the
plug to a torque of 30 Nm (265 pound inches).
STEP 185
Install new sealing rings and both plugs in duct plate.
STEP 182
Install control valve on duct plate and CAS2885

studs. Install hex rods on studs and tighten against
control valve. Install 21 socket head screws. Tighten
screws to a torque of 9.5 Nm (84 pound inches).
Remove CAS2885 transmission valve adjustment
tool set. Install remaining two socket head screws.
Tighten screws to a torque of 9.5 Nm (84 pound
inches).
NOTE: The following steps are for the installation of
Install the gasket and place the duct plate against the filter.
shoulder. Install socket head screws and hex nuts.
Tighten to a torque of 25 Nm (221 pound inches).

6003-38
STEP 186 STEP 189
Install new 0-rings in recesses of oil filter head. Apply grease to the new 0-ring and install the speed
Position filter head on transmission and secure using sensor with the socket head screw. Tighten the screw
two socket head screws. Tighten screws to a torque to a torque of 23 Nm (204 pound inches).
of 25 Nm (221 pound inches).
STEP 190
STEP 187
With new 0-rings, install the inductive transmitters.

Install a new transmission filter. Tighten to a torque of 30 Nm (265 pound inches).
STEP 188 STEP 191

Install the breather.
STEP 192
Install new 0-rings in oil distribution covers. Install

the two oil distribution covers on the housing with hex
Install the gasket and the cover plate. Tighten to a
nuts and flat washers. Tighten to a torque of 25 Nm
torque of 23 Nm (204 pound inches). With a new
(221 pound inches).
0-ring, install the screw plug. Tighten to a torque of
140 Nm (1 03 pound feet).
Section
6004
FRONT AXLE
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-45240 June, 2002
6004-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................... 3
SPECIAL TORQUES ........................................................................ 3
SPECIAL TOOLS .......................................................................... 3
GEARTOOTHCONTACTPATTERNS ......................................................... 4
LUBRICATION ............................................................................ 6
WEAR MEASUREMENT ON MULTI-DISC BRAKE ................................................ 6
WHEEL END AND BRAKE ................................................................... 7
Disassembly ............................................................................ 7
Cleaning and Inspection .................................................................. 13
Assembly .............................................................................. 13
BRAKE HYDRAULICS LEAKAGE TEST ....................................................... 23
High Pressure Test ...................................................................... 23
Low Pressure Test ...................................................................... 23
DIFFERENTIAL CARRIER DISASSEMBLY ..................................................... 24
DIFFERENTIAL DISASSEMBLY .............................................................. 27
DRIVE PINION DISASSEMBLY .............................................................. 28
BRAKETUBESREMOVAL .................................................................. 29
BRAKE TUBES INSTALLATION .............................................................. 30
DIFFERENTIAL CARRIER ASSEMBLY ........................................................ 32
Determine Shim Thickness for Correct Tooth Contact Pattern ..................................... 32
Install Drive Pinion ...................................................................... 33
Drive Pinion Bearing Rolling Torque Adjustment ............................................... 34
DIFFERENTIAL ASSEMBLY ................................................................. 36
Adjust Backlash and Bearing Preload ........................................................ 41

6004-3
SPECIFICATIONS
Lubricant Capacity ........................................................................................................ 22.1 Liters (23.5 U.S. Quarts)
Distance Between Gripping Rings and Shoulder of Pin ...................................... 10.5 to 10.8 mm (0.41 to 0.43 inch)
Top of Pins to Top of Support Shim ......................................................................... 4.5 to 5.0 mm (0.18 to 0.20 inch)
Sun Gear Shaft End Play ............................................................................................................ 1.00 mm (0.04 inch)
Drive Pinion Rolling Torque ................................................................................... 1.1 to 2.3 Nm (9.7 to 20.3 lb-inch)
Seal Caps Depth in Differential Housing ................................................................. 1.5 to 2.5 mm (0.06 to 0.10 inch)
Differential Carrier Disc Clearance .............................................................................................. 0.40 mm (0.02 inch)
SPECIAL TORQUES
Bolts Securing Wheel End to Axle Housing .................................................................................... 390 Nm (288 lb-ft)
Locknut Securing Planetary Carrier. ....................................................................... 700 to 1000 Nm (516 to 737 lb-ft)
Vent Valve and Fitting ....................................................................................................................... 130 Nm (96 lb-ft)
Axle Housing Connector for Brake Tube ........................................................................................ 190 Nm (140 lb-ft)
Nut Securing Brake Tube to Connector .............................................................................................. 70 Nm (52 lb-ft)
Brake Tube Fitting to Wheel End Fitting ............................................................................................. 80 Nm (60 lb-ft)
Breather Plug ......................................................................................................................................70 Nm (52 lb-ft)
Nut Securing Input Flange (Apply Loctite 262 to Threads) ............................................................. 700 Nm (516 lb-ft)
Bolts Securing Differential Ring Gear ............................................................................................. 250 Nm (185 lb-ft)
Bolts Securing Differential Bearing Caps (Apply Loctite 262 to Threads) ...................................... 280 Nm (207 lb-ft)
Differential Carrier Mounting Bolts .................................................................................................. 250 Nm (185 lb-ft)
SPECIAL TOOLS
Brake housing seal installer. . . . . . . . . . . . CAS2880 Step plate set (includes 8061 , 8067,
Differential bearing cone puller collet set .. CAS2871 and 8073) ........................ OEM4288
Differential bearing preload wrench ...... CAS2851 Step plate .............................. 8061
Brake housing inner bearing cup installer . CAS2877 Step plate .............................. 8067
Brake housing outer bearing cup installer. CAS2878 Step plate .............................. 8073
Wear ring installer adapter ............ CAS2875 Socket ............................ CAS2876
Pinion depth gauge set ............... CAS2872 Planetary Gear Puller ................. CAS2848
Puller body and screw ................ CAS2882 Brake Housing Puller Bridge ........... CAS2850
Support bracket ..................... CAS2883 Pressure Ring Installer ................ CAS2860
Slide hammer puller adapter ......... CAS1 0846-3 Holding Bracket . . . . . . . . . . . . . . . . . . . . CAS2847
Slide hammer ...................... OEM4252 Puller ............................. CAS2848
Replacer .......................... CAS2297 Pulling Attachment ................... OEM4175
Dial indicator with magnetic base ..... CAS10066A Puller Legs ............................. 1103
Heat gun ......................... CAS10810 Step Plate .............................. 8065
Engine stand ....................... OEM4135 Holding Wrench .................... CAS1579A
Snap ring pliers ..................... OEM6484 Pinion Inner Bearing Cup Installer ..... CAS2293-1
Snap ring pliers ..................... OEM6177 Pinion Outer Bearing Cup Installer ..... CAS2293-2
Snap ring pliers ..................... OEM6492 Pinion Seal Installer .................. CAS2288
Alignment Studs . . . . . . . . . . . . . . . . . . . . CAS2861 Pinion Seal Installer .................. CAS2299
Pulling Attachment ................... OEM4054

6004-4
GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased
(+)
BS01D01 1 BSOW009
COAST SIDE (CONCAVE)
BSOW013
BSOW012
DRIVE SIDE (CONVEX)
BSOW014
DRIVE SIDE (CONVEX)

6004-5
Pinion Distance Must Be Decreased
BSOW016
BSOW010 DRIVE SIDE (CONVEX)
BSOW015

6004-6
LUBRICATION
BSOOM069 BSOOM070
1. OIL DRAIN HOLE (AXLE HOUSING) 3. PLUG 5. BREATHER

2. OIL DRAIN HOLE (OUTPUTS) 4. BRAKE BLEEDER 6. DIPSTICK AND OIL FILL
NOTE: Refer to section 1002 of this service manual for proper lubricant.
WEAR MEASUREMENT ON MULTI-DISC BRAKE
BDOOM234 BSOOM071
NOTE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement
should also be made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking
function is impaired.
Wear measurement must be made on both wheel end sides.
Remove plug, actuate brake and determine dimension (A) using a thickness gauge. If dimension (A) is less than or
equal to 4.0 mm (0.16 inch) the lined discs on both output sides must be replaced. Replace 0-ring when installing
the plug. Tighten plug to a torque of 70 Nm (52 lb-ft).

6004-7
WHEEL END AND BRAKE
Disassembly STEP3
NOTE: Tools and axle shown in the following
photographs may appear slightly different than the
tools and axle you may have. The use of the tools
and disassembly/assembly of axle is the same
regardless of appearance.
STEP 1
BDOOM238
Using two pry bars, remove cover from output shaft.

Remove and discard 0-ring from cover.
STEP4
BDOOM235
Fasten axle on a stand.
STEP2
BDOOM239
Remove pin from lock nut using OEM4252 slide

hammer and CAS10846-3 adapter.
STEPS
BDOOM236
BDOOM240
Remove lock nut using CAS2883 support bracket

BDOOM237 and CAS2876 socket and nuts.
Remove drain plugs and drain oil from axle housing.
6004-8
STEPS STEP9
ddt
BDOOM241 BDOOM244
Use acceptable lifting equipment to hold wheel end in Remove the shim(s) from the sun gear shaft.
place. Loosen and remove the bolts and washers.
STEP10
STEP7
BDOOM245
BDOOM242 Pull the sun gear shaft out of the planetary gears and
Carefully pull the wheel end from the axle housing. remove.
Remove and discard 0-ring from axle housing wheel
end. STEP 11
STEPS
BDOOM246
Using OEM4054 pulling attachment, remove the

BDOOM243
planetary carrier.
Pull the stub shaft out of the sun gear shaft. Be
careful not to lose shim(s) that may be installed in
sun gear shaft.

6004-9
STEP12 STEP15
BDOOM247 '
BDOOM250
Remove retaining ring. Put alignment marks on planetary ring gear and
brake housing to aid in assembly. Using suitable
STEP13 puller, remove planetary ring gear from brake
housing.
STEP16
BDOOM248
Using CAS2848 planetary gear puller and step plate

8061, remove planetary gear and outer bearing from BDOOM251
planetary carrier shaft. Using a suitable puller, Remove and discard two 0-rings from planetary ring
remove the inner bearing from carrier shaft. gear.
STEP14 STEP17
Repeat Steps 12 and 13 to remove the remaining
three retaining rings, planetary gears, and six
bearings.
BDOOM252
Remove and discard 0-ring from brake housing port.

6004-10
STEP18 STEP 21
BDOOM253 BDOOM256
Remove the brake disc pack from brake housing. WEAR FACE PROTECTION WHEN USING
COMPRESSED AIR. Apply compressed air to brake
STEP19 housing port to push brake piston from brake
housing.
STEP 22
BDOOM254
Using suitable tool, push the three pins down until

pins are even with top surface of shim.
BDOOM257
STEP 20 Remove the support shim from the brake piston.
STEP 23
BDOOM255

BDOOM258
Remove three pins from support shim.

6004-11
STEP 24 STEP 27
BDOOM262
BDOOM259
Lift and remove the piston from the brake housing.
Put support shim in a press and compress Belleville
washers. Remove retaining ring and pull pin with
Belleville washers and rings installed from support STEP 28
shim. Repeat this step to remove the remaining five
retaining rings and pins from support shim.
STEP 25
BDOOM263
BDOOM260
Remove seven Belleville washers from each pin.
STEP 26
BSOOM072
1. BRAKE HOUSING 5. U-RING

2. GUIDE RING 6. SUPPORT RING
3. SUPPORT RING 7. WHEEL END SHAFT
BDOOM261 4. U-RING
Using a press, remove four gripping rings from each
Remove the guide ring (2), support rings (3 and 6),
pin. and U-rings (4 and 5) from the grooves of the brake
housing.

6004-12
STEP 29 STEP 32
BD01F102A BDOOM267
Using the CAS2850 brake housing puller bridge and Remove the face seal from the brake housing.
8073 step plate, pull the brake housing from the
wheel end shaft and remove the inner bearing. STEP 33
Using a puller, remove the outer bearing from the
STEP 30 wheel end shaft.
STEP 34
BDOOM265
Use acceptable lifting equipment and lift the brake

housing from the wheel end shaft.
Remove and discard the face seal metal ring from
STEP 31 the wheel end shaft.
BDOOM266
If replacement of bearing cups is necessary, drive

both bearing cups out of the brake housing.

6004-13
Cleaning and Inspection Assembly

IMPORTANT: Do not use compressed air to dry
bearings. Allow bearings to air dry. STEP 40
STEP 35
Clean all parts except friction plates in brake disc
pack using cleaning solvent. WEAR FACE
PROTECTION WHEN USING COMPRESSED AIR.
Use compressed air to clear passages in planetary
ring gear and brake housing.
STEP 36
Inspect bearing rollers for pitting, scoring,
deformation, or other damage. Check inner face and
bearing cage for deformation, dents, and other
damage. Check associated bearing cups for BDOOM271
scratches, grooves, or cracks. Check bearings for Install a new face seal metal ring on the wheel end
rough spots or binding by holding bearing and shaft.
rotating. If bearing binds or action is not smooth,
replace the bearing. STEP 41
STEP 37
Inspect bearing cups for pitting, scoring, cracks, or
other damage. Replace if any of these conditions are
seen.
NOTE: If a bearing or bearing cup requires
replacement, the associated part must also be
replaced.
STEP 38
Check planetary ring gear, planetary gears, and
planetary carrier gear teeth for cracks, breaks,
chipping, or other damage. Replace the part if any of
these conditions are seen. Check planetary carrier
shaft splines for broken, cracked, or twisted
condition. Replace if necessary.
STEP 39
Check wheel end shaft for cracked, broken, or
twisted splines. Replace if any of these conditions
are seen.
BD01F105
Install CAS2875 pressure ring installer adapter on

wheel end shaft. Press the face seal metal ring over
the collar of the wheel end shaft using CAS2860
pressure ring installer.

6004-14
STEP 42 STEP 45
~ WARNING: Always wear heat protective
ill gloves to prevent burning your hand when
SM121A
BDOOM275
BDOOM273
Heat the wheel end shaft outer bearing to 1ooo C

(212° F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearing on the wheel
end shaft until the bearing is against the shoulder on
the wheel end shaft.
STEP 43
BSOOM073
1. FACE SEAL
2. BRAKE HOUSING
A FILL WITH GREASE
Wet the outer diameter of the face seal with a
solution of 50% water and 50% mineral spirits. Use
CAS2880 seal installer to install the face seal with
the seal lip positioned as shown. Apply grease to
seal as indicated by (A) above.
BDOOM274 STEP 46
Using CAS2877 inner bearing cup installer, press the
inner bearing cup into the brake housing until seated
against the shoulder in the brake housing.
STEP 44
Using CAS2878 outer bearing cup installer press the
outer bearing cup into the brake housing until seated
BDOOM276
Use acceptable lifting equipment and install the

brake housing on the wheel end shaft.

6004-15
STEP 47 STEP 48
SM121A
BDOOM278
BDOOM277
Heat the wheel end shaft inner bearing to 1 ooo C

end shaft until the bearing is against the bearing cup
in the brake housing.
BSOOM072
GUIDE RING, SUPPORT RINGS AND U-RINGS LOCATION

4. U-RING
Install the support rings and U-rings in the grooves of

the brake housing.

6004-16
STEP 49 STEP 51
BDOOM279 BDOOM282
1. GRIPPING RINGS
Clean the groove of the brake housing with cleaning
solvent. Install the guide ring in the groove. Make Press the gripping rings on the pins. Ends of gripping
sure the ends (A) of the guide ring are facing up rings must be 180° opposite from each other.
towards the top (B) of the brake housing and the
guide ring is installed completely in its groove in the STEP 52
brake housing. Apply Loctite 415 to ID of guide ring
to secure guide ring in its groove.
STEP 50
BDOOM283
BDOOM280
Apply oil on the sliding surface of the piston, support

rings, U-rings and guide ring. Carefully install piston
BSOOM074
1. PIN 4. SUPPORT SHIM

2. GRIPPING RINGS 5. RETAINING RING
3. BELLEVILLE SPRINGS A. 10.5 TO 10.8 MM (0.41 TO 0.43
INCH)
Install the Belleville springs on the pins. Make sure
dimension (A) is 10.5 to 10.8 mm (0.41 to 0.43 inch).

6004-17
STEP 53 STEP 56
BDOOM284 BDOOM287
Put the assembled pins into the support shim and

install the snap ring.
STEP 54
BSOOM075
1. BRAKE HOUSING 4. SUPPORT SHIM

2. SNAP RING 5. PISTON
3. PIN A. 4.5 TO 5.0 MM (0.18 TO 0.20
BDOOM285 INCH)
Put the assembled support shim in the piston. Install the three pins (3) in the support shim (4) to
lock the snap ring (2). Dimension (A) between top of
STEP 55 pins (3) and top of support shim (4) must be 4.5 to
5.0 mm (0.18 to 0.20 inch).
STEP 57
BDOOM286
Install the snap ring to secure the support shim.
BDOOM288
1. SPLINE
If removed, drive the stop bolt into the planetary

carrier until contact. Then coat the spline with Loctite
No. 767 antiseize lubricant.
6004-18
STEP 58 STEP 61
Install the planet carrier into the spline of the wheel Apply grease to new 0-rings and install on planetary
end shaft. ring gear.
STEP 59 STEP 62
BDOOM291
Apply oil to the clutch discs. Install the outer and
Install two alignment studs in the brake housing.
inner clutch discs alternately starting with an outer
Position the planetary ring gear on the brake
clutch disc.
housing. Make sure alignment marks made during
disassembly are aligned. Press planetary ring gear
STEP 60 into brake housing.
Install a new 0-ring in the brake housing port.

6004-19
STEP 63 STEP 65
~ WARNING: Always wear heat protective ~ WARNING: Always wear heat protective
ill gloves to prevent burning your hand when ill gloves to prevent burning your hand when
handling heated parts. handling heated parts.
SM121A SM121A
BDOOM292 BDOOM294
Heat the planetary gears inner bearings to 1ooo C Heat the planetary gears outer bearings to 1ooo C
(212° F) in a bearing oven. Wearing heat resistant (212° F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearings on the shafts gloves or mittens, install the bearings on the shafts
until the bearing is against the bottom of the shaft. until the bearing is against the gear.
STEP 64 STEP 66
BDOOM293 BDOOM295
Install the planetary gears on the bearings. Install the retaining rings on the planetary gear
shafts.

6004-20
Sun Gear Shaft End Play Adjustment STEP 69
STEP 67
BDOOM298
Install the sun gear shaft in the stub shaft. Make sure
BDOOM296 the stub shaft is installed all the way into the sun gear
Using two M18 bolts of suitable length, secure shaft.
planetary ring gear to brake housing. Then,
determine dimension A, from the face of the STEP 70
planetary carrier stop bolt to the mounting face of the
planetary ring gear.
Example:
Dimension A ............. 36.00 mm (1.42 inch)
STEP 68
BDOOM299
Determine dimension B from the face of the sun gear

shaft to the mounting face of the axle housing.
Example:
Dimension B .............. 32.80 mm (1.29 inch)
BDOOM297 STEP 71
Install the stub shaft in the spline of the axle bevel Subtract dimension B from dimension A. Then
gear. Make sure the stub shaft is installed all the way subtract 1 mm (0.04 inch) from the difference. The
into the axle bevel gear. difference is the required shim size.
Example:
Dimension A + 36.00 mm (1.42 inch)
Dimension B - 32.80 mm (1.29 inch)
Difference 3.20 mm (0.13 inch)
Required end play - 1.00 mm (0.04 inch)
Difference= shim
2.20 mm (0.09 inch)
size

6004-21
STEP 72 STEP 75
BDOOM245 BDOOM300
Install the sun gear shaft in the planet carrier. Install the washers and bolts to secure the wheel end
to the axle housing. Tighten the bolts to a torque of
STEP 73 390 Nm (288 lb-ft).
STEP 76
BDOOM244
Install the shim set (size as determined in Step 71

above) into the sun gear shaft with grease. BDOOM301
Install the lock nut by hand and tighten using

STEP 74 CAS2883 support bracket and CAS2876 locknut
socket and nuts. Tighten the lock nut to a torque of
700 to 1000 Nm (516 to 737 lb-ft).
STEP 77
BDOOM242
Apply grease to a new 0-ring and install 0-ring in

brake port. Use acceptable lifting equipment and
install the assembled wheel end onto the axle
housing. BDOOM302
Install the slotted pin into the wheel end lock nut.

6004-22
STEP 78 STEP 79
BDOOM303 BDOOM304
1. 0-RING
Install the cover into the wheel end.
Install a new 0-ring on the wheel end cover.

6004-23
BRAKE HYDRAULICS LEAKAGE TEST

IMPORTANT: DO NOT EXCEED 100 BAR (1450 High Pressure Test
PSI) PRESSURE IN THE FOLLOWING STEPS. If
the maximum pressure of 100 bar (1450 psi) is
STEP 81
exceeded, the piston will move too much changing
the gripping rings adjustment. If the gripping rings Operate the hand pump to increase pressure to 100
adjustment changes, the wheel end must be bar (1450 psi) maximum. Close connection to hand
removed and disassembled and the gripping rings pump using the shutoff valve. During a 5 minute
adjusted to the correct dimension (Step 52). period, pressure shall not drop more than 2 bar (29
psi).
STEP 80
Low Pressure Test
STEP 82
Reduce pressure to 5 bar (72.5 psi) and close the
shutoff valve. During a 5 minute period pressure shall
not drop.
BDOOM305
Connect a hand pump with pressure gauge to the

brake port as shown above. Fill the hand pump with
Case MS-1209 Hy-Tran® Ultra. Build up pressure in
the axle internal brake lines then bleed air from the
lines. After air is bled, actuate the brakes a minimum
of 10 times by operating the hand pump.

6004-24
DIFFERENTIAL CARRIER DISASSEMBLY

STEP 83 STEP 85
"~
BDOOM306 BDOOM241
Fasten the axle to a stand. Use acceptable lifting equipment to hold wheel end in
place. Remove the bolts and washers.
STEP 84
STEP 86
BDOOM307
BDOOM242
Carefully pull the wheel end from the axle housing.

end.
BDOOM308
Remove drain plugs and drain oil from axle.

6004-25
STEP 87 STEP 91
BDOOM243
BDOOM314
Pull the stub shaft out of the sun gear shaft. Be Mount differential carrier in OEM4135 engine stand
careful not to lose shim(s) that may be installed in using one CAS2847 holding bracket.
sun gear shaft.
STEP 92
STEP 88
Do Steps 85 to 87 to remove the other wheel end.
STEP 89
BDOOM315
Drive out the roll pins from the bearing caps.
STEP 93
BDOOM312
Put alignment marks on the differential carrier and

axle housing. Remove 15 bolts securing differential
carrier.
STEP 90
Connect lifting equipment to flange and remove the
differential carrier from axle housing.
BD01F072
Remove both adjusting nuts using CAS2851 wrench.

6004-26
STEP 94 STEP 96
BDOOM317 BDOOM319
Heat the differential carrier using a hot air blower. Remove both bearing cups.
NOTE: Bolts are installed with Loctite.
STEP 97
STEP 95
IMPORTANT: Do not use an air ratchet or wrench to
remove bolts.
BDOOM320
Use acceptable lifting equipment and remove the

differential from the differential carrier.
BDOOM318
1. ALIGNMENT MARK
Make alignment marks on bearing caps and

differential housing to aid in assembly. Remove four
bolts then remove both bearing caps.

6004-27
DIFFERENTIAL DISASSEMBLY
STEP 98 STEP 101
BD01F059
BDOOM324
Remove the bearing from the differential housing
Remove the housing cover from the differential
using CAS2848 puller, OEM4175 pulling attachment,
housing.
1103 puller legs, and 8065 step plate.
STEP 99 STEP 102
BD01F075 BDOOM325
Remove the bearing from the housing cover using Remove all parts from the differential housing.
CAS2871 collet set, CAS2882 puller body, and 8067
step plate. STEP 103
STEP 100
BDOOM326
BDOOM323 Press the ring gear from the differential housing.

Place the differential in a press to prevent it from
turning. Remove the bolts.

6004-28
DRIVE PINION DISASSEMBLY

STEP 104 STEP 107
Heat lock nut securing flange with a hot air blower to
loosen Loctite.
STEP 105
BDOOM330
Remove the shaft seal from the axle drive housing.
STEP 108
BD01F091 Using a rubber hammer remove the drive pinion from
Install CAS1579A holding wrench on input flange. the axle drive housing. Remove the pinion outer
Hold flange using holding wrench and remove lock bearing.
nut and washer. Remove holding tool from flange.
STEP 109
STEP 106 Remove the spacer ring and inner bearing from the
drive pinion.
STEP 110
Remove the input flange from the drive pinion.
BDOOM333
If necessary drive out both bearing cups from the

differential carrier.

6004-29
BRAKE TUBES REMOVAL

STEP 111 STEP 114
BDOOM334
t1
BDOOM337
Remove the plug with the breather installed from the Loosen the fitting on the opposite end of the brake
axle housing. tube then remove the brake tube from the axle
housing.
STEP 112
STEP 115
BDOOM335
Remove the nut securing the brake tube to the axle BDOOM338
housing. Remove the vent valve from the fitting.
STEP 113 STEP 116
BDOOM336 BDOOM339
Loosen and remove the connector from the axle. Remove the fitting. Remove and discard 0-ring and
rectangular ring from fitting.
NOTE: Do Steps 112 to 116 on other wheel end.

6004-30
BRAKE TUBES INSTALLATION

STEP 117 STEP 119
BDOOM340 BDOOM342
1. VENTVALVE
Install a new 0-ring on the connector. Install the
2. FITTING
3. 0-RING
connector in the axle and tighten to a torque of 190
4. RECTANGULAR RING Nm (140 lb-ft).
Install new 0-ring and rectangular ring on fitting. STEP 120

Install and tighten vent valve in fitting.
STEP 118
BDOOM343
1. 0-RING
Install a new 0-ring in the groove of the brake tube

BDOOM341
fitting.
Install the assembled vent valve and fitting in the
axle. Tighten the fitting to a torque of 130 Nm (96
lb-ft).

6004-31
STEP 121 STEP 123
BDOOM344 BDOOM346
1. BRAKE TUBE 3. CONNECTOR Connect fitting on opposite end of brake tube to

2. FITTING fitting installed in wheel end. Tightening brake tube
fitting to a torque of 80 Nm (60 lb-ft).
Install the brake tube (1) in the axle housing,
inserting the fitting (2) through the connector (3). NOTE: Do Steps 117 to 123 on other wheel end.
STEP 122 STEP 124
BDOOM347
1. 0-RING
2. PLUG
3. BREATHER
BDOOM345
Install the nut to secure the brake tube fitting. Tighten Remove and discard 0-ring (1) from plug (2) and
the nut to a torque of 70 Nm (52 lb-ft). install a new 0-ring. Install breather (3) in plug.
STEP 125
MDOOM348
Install the plug in axle housing. Tighten plug to a

torque of 70 Nm (52 lb-ft)

6004-32
DIFFERENTIAL CARRIER ASSEMBLY

NOTE: The ring gear and the drive pinion are a STEP 128
matched gear set and cannot be serviced separately.
Determine Shim Thickness for

Correct Tooth Contact Pattern
NOTE: Make the following measurements at
maximum accuracy. Inaccurate measurements will
result in a faulty tooth contact pattern causing
disassembly of the drive pinion and differential.
STEP 126
Install the CAS2872 pinion depth gauge set on the
BDOOM350
Determine dimension C (bearing width).

STEP 127
Dimension C (Example) .... 33.50 mm (1.319 inch)
STEP 129
BDOOM349
Determine dimension B (gap between the measuring

shaft and the measuring pin) using a thickness
gauge. 1. 148.00 MM (+0.05 MM)
BDOOM351
Dimension B (Example) . . . . . 1.00 mm (0.039 inch)

Read dimension D (dimension for pinion).
Example A.:
Dimension D (Example) .... 148.05 mm (5.83 inch)
181.75mm
Dimension A (tool constant) Example B:
(7.155 inch)
+1.00mm 33.50mm
Dimension B (gap) Dimension C
(0.039 inch) (1.319 inch)
182.75mm +148.05mm
Results in Dimension X Dimension D
(7.195 inch) (5.829 inch)
181.55mm
Results in Dimension Y
(7.148 inch)
STEP 130
Subtract dimension Y from dimension X. The
difference is the required shim thickness.
Example C:
Dimension X 182.75 mm (7.195 inch)
Dimension Y -181.55 mm (7.148 inch)
Difference= Shim 1.20 mm (0.047)

6004-33
Install Drive Pinion STEP 133

~ WARNING: Always wear insulated gloves or
STEP 131
~ mittens when handling frozen parts.
BDOOM352
Install the shim set determined in Step 130 in the

BD01F062
bearing bore on the differential carrier.
Freeze new outer bearing cup in dry ice for several
hours. Install bearing cup in differential carrier using
STEP 132 CAS2293-2.
~ mittens when handling frozen parts. STEP 134
BD01F065
BD01F062 Press the inner bearing on the drive pinion shaft

Freeze new inner bearing cup in dry ice for several using CAS2297.
CAS2293-1.

6004-34
Drive Pinion Bearing Rolling STEP 137

Torque Adjustment
STEP 135
BD01F101
Using CAS2882 puller tube, press the dust shield on

the input flange.
BDOOM356
STEP 138
Install an 8.90 mm (0.35 inch) thick spacer on the
pinion shaft.
STEP 136
~ gloves to prevent burning your hand when
SM121A
BDOOM359
Install the input flange on the pinion shaft.
STEP 139
BDOOM357
Heat the pinion shaft outer bearing to 100° C (212°

F) in a bearing oven. Wearing heat resistance gloves
or mittens, install the bearing on the pinion shaft until
contact.
BDOOM360
Put the washer in place on the pinion shaft.

6004-35
STEP 140 STEP 143
BD01F091 BD01F066
Install CAS1579A holding wrench on input flange. Using the CAS2288 and CAS2299 pinion seal
Hold flange using holding tool and tighten nut to a installers, install the shaft seal with the seal lip down.
torque of 700 Nm (516 lb-ft). Remove CAS1579A.
NOTE: Just before installation, wet the outer
NOTE: When tightening rotate the pinion shaft in diameter of the shaft seal with a solution of 50%
both directions several times. water and 50% mineral spirits. Fill the space between
the sealing and dust lip with grease.
STEP 141
STEP 144
BDOOM362
Check the rolling torque of the drive pinion bearing. BD01F091
The rolling torque should be 1.1 to 2.3 Nm (9.7 to Install the input flange. Install CAS1579A holding
20.3 lb-inch). If rolling torque is too low, install a wrench on input flange. Apply Loctite No. 262, on the
thinner spacer (Step 135); if rolling torque is too high, threads of the locknut. Install the washer and locknut
install a thicker spacer (Step 135). by hand. Hold flange using holding tool and tighten
nut to a torque of 700 Nm (516 lb-ft). Remove
STEP 142 CAS1579A.
Remove the nut and input yoke from the drive pinion
shaft.

6004-36
DIFFERENTIAL ASSEMBLY
STEP 145 STEP 146
BDOOM365 BDOOM366
1. GROOVE
1 Install the retaining ring in the groove in the bottom of

the differential housing.
STEP 147
2 A
BSOOM077
1. DIFFERENTIAL HOUSING
2. SEAL CAPS
A. 1.5 TO 2.5 MM (0.06 TO 0.10 INCH)
Install the seal caps. Seal caps must be installed to

depth A. BDOOM367
1. GROOVES
NOTE: Be sure to apply oil to all parts before
Install the driving pins in the grooves of the
assembly.
differential housing.

6004-37
STEP 148 STEP 152
BDOOM368 BDOOM371
Install both thrust washers in the differential housing. Install the axle bevel gear. Make sure axle bevel gear
splines mate with splines of all inner clutch discs.
STEP 149- LIMITED SLIP DIFFERENTIAL
STEP 153
BDOOM369
Starting with an outer clutch disc install alternately BDOOM372

the outer and inner clutch discs. Thickness of disc Assemble the differential spider and install into the
pack must be the same on both sides. differential housing.
STEP 150- OPEN DIFFERENTIAL STEP 154

Install four outer clutch discs in differential housing.
Thickness of disc pack must be the same on both
sides.
STEP 151
BDOOM373
Install the second axle bevel gear.
BDOOM370
Install the pressure ring in the differential housing.

6004-38
STEP 155 Determine Disc Clearance

STEP 159
BDOOM374
Install the second pressure ring in the differential

BDOOM377
housing.
Determine dimension A, from mounting face of the
STEP 156- LIMITED SLIP DIFFERENTIAL differential housing to face of the outer clutch disc.
Dimension A (Example) ...... 15.60 mm (0.61 inch)
STEP 160
BDOOM375
Starting with an inner clutch disc, install alternately

the inner and outer clutch disc. Thickness of disc
BDOOM378
pack must be the same on both sides.
Determine dimension B, from contact surface of the
outer clutch disc to mounting face of the housing
STEP 157- OPEN DIFFERENTIAL
cover.
Install four outer clutch discs. Thickness of disc pack
Dimension B (Example) ...... 15.20 mm (0.60 inch)
must be the same on both sides.
Example B:
15.60mm
STEP 158 Dimension A
(0.62 inch)
+15.20mm
Dimension B
(0.60 inch)
= 0.40mm
Difference = Disc clearance
(0.02 inch)
NOTE: If required disc clearance of 0.040 mm (0.02
inch) is not obtained, install new outer clutch discs of
thickness necessary to obtain 0.040 mm (0.002 inch)
disc clearance. Difference in thickness between left
and right disc pack must not exceed 0.1 mm (0.004
inch). Outer clutch discs are available in following
thicknesses: 2.1 mm (0.083 inch), 2.2 mm (0.087
inch), 2.3 mm (0.090 inch), 2.4 mm (0.094 inch), and
BDOOM376 2.5 mm (0.098 inch).
Install the driving pin in the differential housing.
6004-39
STEP 161 STEP 163

SM121A
BDOOM379
Install the thrust washer with grease in the recess of

the housing cover.
STEP 162 BDOOM381
Heat the ring gear to 1ooo C (212° F) in a bearing

oven. Wearing heat resistance gloves or mittens,
install the ring gear on the differential.
STEP 164
BDOOM380
Put the housing cover on the differential housing.
BDOOM382

turning. Install new bolts and tighten bolts to a torque
of 250 Nm (185 lb-ft).

6004-40
STEP 165 STEP 168
BDOOM383 BDOOM385
Press both bearings on the differential. Install both bearing caps. Apply Loctite No. 262 to
threads of bolts. Install the bolts and washers.
STEP 166 Tighten the bolts to a torque of 280 Nm (207 lb-ft).
STEP 169
BDOOM320

differential into the differential carrier. BD01F072
Use CAS2851 wrench to tighten the two adjusting

STEP 167 nuts evenly until there is light pressure against the
bearings on each side of the differential.
BDOOM384
Install both bearing cups and install adjusting nuts.

6004-41
Adjust Backlash and Bearing STEP 175

Preload
STEP 170
BDOOM388
Apply marking ink on several teeth of the ring gear

and rotate it in both directions. Compare the obtained
tooth contact pattern with the examples on pages 4
BD01F061
and 5.
Place CAS1 0066A dial indicator right-angled at the
outer diameter of the tooth flank (ring gear). Adjust NOTE: If the tooth contact pattern differs, the wrong
the pinion to ring gear backlash to the low side of shim size was selected in Step 130. Remove
specifications (see numbers etched on the outer differential and repeat Steps 126 though 130.
diameter of the ring gear) by alternately turning each
of the adjusting nuts to move the ring gear closer to STEP 176
or further away from the pinion.
STEP 171
Go to the adjusting nut opposite the ring gear and
loosen the nut approximately one turn to release
pressure on the bearing. It should be very noticeable
that pressure is released on the bearing, as the
adjusting nut will turn much easier.
STEP 172
Tighten the bearing adjusting nut slowly until firm
contact is made with the bearing.
NOTE: As the adjusting nut makes firm contact with BDOOM389
the bearing, the adjusting nut will immediately begin Install pins to secure both adjusting nuts.
to turn with more effort.
STEP 177
STEP 173 Apply sealing compound (Three Bond Type 1215) to
To adjust the differential bearing preload, note the differential mounting surface on axle housing. Install
position of the adjusting nut. Now tighten the nut two two CAS2861 alignment studs in axle housing to aid
additional notches. installation of differential carrier. Using suitable lifting
equipment, install the differential carrier in the axle
STEP 174 housing then remove alignment studs.
When the bearing preload is adjusted the backlash
may increase slightly. Check pinion backlash to
confirm that it is within specifications. If within
specifications, install the adjusting nut locking roll
pins. If backlash is outside of specified range, repeat
Step 170 through 174 again.

6004-42
STEP 178 STEP 181
BDOOM391 BDOOM242
Using new bolts, secure the differential carrier to the Apply grease to a new 0-ring and install 0-ring in
axle housing. Tighten bolts to a torque of 250 Nm brake port. Position the wheel end on the axle
(185 lb-ft). housing.
STEP 179 STEP 182
BDOOM392 BDOOM394
Install the stub shaft into the spline of the differential Install the washers and bolts on the wheel end.
bevel gear. Tighten the bolts to a torque of 390 Nm (288 lb-ft)
NOTE: Repeat Steps 179 through 182 for the other
STEP 180 wheel end.
NOTE: Refer to Section 1002 of this service manual
for proper lubricant.
BDOOM393
Install the thrust washer removed at disassembly.

Use grease to keep it in the sun gear.

Section
6004
REAR AXLE
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-47320 June, 2002
6004-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................... 3
SPECIAL TORQUES ........................................................................ 3
SPECIAL TOOLS .......................................................................... 3
GEARTOOTHCONTACTPATTERNS ......................................................... 4
LUBRICATION ............................................................................ 6
Disassembly ............................................................................ 7
Assembly .............................................................................. 13
DIFFERENTIAL CARRIER DISASSEMBLY ..................................................... 24
DIFFERENTIAL DISASSEMBLY .............................................................. 27
DRIVE PINION DISASSEMBLY .............................................................. 28
PIVOT PIN BUSHINGS ..................................................................... 29
BRAKE TUBES REMOVAL .................................................................. 30
BRAKE TUBES INSTALLATION .............................................................. 31
DIFFERENTIAL CARRIER ASSEMBLY ........................................................ 33
Determine Shim Thickness for Correct Tooth Contact Pattern ..................................... 33
Install Drive Pinion ...................................................................... 34
DIFFERENTIAL ASSEMBLY ................................................................. 37
Open Differential Assembly ................................................................ 37
Limited Slip Differential Assembly ........................................................... 38
Adjust Backlash and Bearing Preload ........................................................ 41

6004-3
SPECIFICATIONS
Lubricant Capacity ........................................................................................................ 22.1 Liters (23.5 U.S. Quarts)
Distance Between Gripping Rings and Shoulder of Pin ...................................... 10.5 to 10.8 mm (0.41 to 0.43 inch)
Top of Pins to Top of Support Shim ......................................................................... 4.5 to 5.0 mm (0.18 to 0.20 inch)
Sun Gear Shaft End Play .................................................................................... 0.5 to 2.0 mm (0.020 to 0.079 inch)
Drive Pinion Rolling Torque ...................................................................................... 1.1 to 4.5 Nm (9.7 to 40 lb-inch)
Differential Carrier Bevel Gear End Play .......................................................... Zero to 0.15 mm (zero to 0.006 inch)
SPECIAL TORQUES
Bolts Securing Wheel End to Axle Housing .................................................................................... 390 Nm (288 lb-ft)
Locknut Securing Planetary Carrier. ....................................................................... 700 to 1000 Nm (516 to 737 lb-ft)
Vent Valve Fitting ............................................................................................................................ 140 Nm (1 03 lb-ft)
Vent Valve ...........................................................................................................................................80 Nm (59 lb-ft)
Axle Housing Connector for Brake Tube ........................................................................................ 140 Nm (1 03 lb-ft)
Nut Securing Brake Tube to Connector .......................................................................................... 140 Nm (1 03 lb-ft)
Brake Tube Fitting to Wheel End Fitting ............................................................................................. 80 Nm (60 lb-ft)
Breather Plug .................................................................................................................................. 140 Nm (1 03 lb-ft)
Nut Securing Input Flange (Apply Loctite 262 to Threads) ............................................................. 600 Nm (442 lb-ft)
Bolts Securing Differential Ring Gear
M12 Bolts ..................................................................................................................................... 120 Nm (88 lb-ft)
M16 Bolts ................................................................................................................................... 300 Nm (221 lb-ft)
Bolts Securing Differential Bearing Caps (Apply Loctite 262 to Threads) ...................................... 185 Nm (136 lb-ft)
Differential Carrier Mounting Bolts (Apply Loctite 262 to Threads) ................................................ 390 Nm (288 lb-ft)
SPECIAL TOOLS
Brake housing seal installer. . . . . . . . . . . . CAS2880 Step plate .............................. 8061
Differential bearing cone puller collet set .. CAS2871 Step plate .............................. 8067
Brake housing inner bearing cup installer . CAS2877 Step plate .............................. 8073
Brake housing outer bearing cup installer. CAS2878 Socket ............................ CAS2876
Wear ring installer adapter ............ CAS2875 Planetary Gear Puller ................. CAS2848
Pinion depth gauge set .............. CAS(*TBS) Brake Housing Puller Bridge ........... CAS2850
Support bracket ..................... CAS2883 Pressure Ring Installer ................ CAS2860
Slide hammer puller adapter ......... CAS1 0846-3 Holding Bracket . . . . . . . . . . . . . . . . . . . . CAS2847
Slide hammer ...................... OEM4252 Puller ............................. CAS2848
Replacer .......................... CAS2297 Pulling Attachment ................... OEM4175
Dial indicator with magnetic base ..... CAS10066A Puller Legs ............................. 1103
Heat gun ......................... CAS10810 Step Plate .............................. 8065
Engine stand ....................... OEM4135 Holding Wrench .................... CAS1579A
Snap ring pliers ..................... OEM6484 Pinion Inner Bearing Cup Installer ..... CAS2293-1
Snap ring pliers ..................... OEM6177 Pinion Outer Bearing Cup Installer ...... CAS(*TBS)
Snap ring pliers ..................... OEM6492 Pinion Seal Installer ................. CAS(*TBS)
Alignment Studs . . . . . . . . . . . . . . . . . . . . CAS2861 Pinion Seal Installer ................. CAS(*TBS)
Step plate set (includes 8061 , 8067, Pulling Attachment ................... OEM4054
and 8073) ....................... OEM4288
*TBS: To Be Supplied

6004-4

(+)
BS01D01 1 BSOW009
BSOW013
BSOW012
DRIVE SIDE (CONVEX)
BSOW014
DRIVE SIDE (CONVEX)

6004-5
BSOW016
BSOW010 DRIVE SIDE (CONVEX)
BSOW015

6004-6
LUBRICATION
85020084
1. OIL DRAIN PLUG (AXLE HOUSING) 4. OIL DIPSTICK

2. OIL DRAIN PLUG (OUTPUTS) 5. BRAKE BLEEDER
3. OIL FILL PLUG 6. BLEEDER
NOTE: Refer to section 1002 of this service manual for proper lubricant.
80020001 85020085
Remove plug, actuate brake and determine dimension (A) using a thickness gauge. If dimension (A) is less than or
the plug. Tighten plug to a torque of 70 Nm (52 lb-ft).

6004-7
WHEEL END AND BRAKE
Disassembly STEP3
STEP 1
80020005
Using two pry bars, remove cover from output shaft.
Remove and discard 0-ring from cover.
STEP4
80020002
STEP2
80020006
Remove pin from lock nut using OEM4252 slide
hammer and CAS10846-3 adapter.
STEPS
80020003
80020007
Remove lock nut using CAS2883 support bracket
80020004 and CAS2876 socket and nuts.
Remove drain plugs and drain oil from axle housing.
6004-8
STEPS STEP9
80020008 80020011
Use acceptable lifting equipment to hold wheel end in Remove the shim(s) from the sun gear shaft.
place. Loosen and remove the bolts and washers.
STEP10
STEP7
80020012
80020009 Pull the sun gear shaft out of the planetary gears and
Carefully pull the wheel end from the axle housing. remove.
end. STEP 11
STEPS
80020013
Using two pry bars, remove ring gear from brake
80020010
housing.
Pull the stub shaft out of the sun gear shaft. Be
careful not to lose shim(s) that may be installed in
sun gear shaft.

6004-9
STEP12 STEP15
80020014 80020017
Remove and discard 0-rings from ring gear. Using CAS2848 planetary gear puller and step plate
8061, remove planetary gear and outer bearing from
STEP13 planetary carrier shaft. Using a suitable puller,
remove the inner bearing from carrier shaft.
STEP16
Repeat Steps 14 and 15 to remove the remaining
two retaining rings, planetary gears, and four
bearings.
STEP17
80020015
Using OEM4054 pulling attachment, remove the

planetary carrier.
STEP14
80020018
Remove and discard 0-ring from brake housing port.
80020016
Remove retaining ring.

6004-10
STEP18 STEP 21
80020019 80020022
Remove the brake disc pack from brake housing. WEAR FACE PROTECTION WHEN USING
COMPRESSED AIR. Apply compressed air to brake
STEP19 housing port to push brake piston from brake
housing.
STEP 22
80020020
Using suitable tool, push the three pins down until

pins are even with top surface of shim.
80020023
STEP 20 Remove the support shim from the brake piston.
STEP 23
80020021

8000M258
Remove three pins from support shim.

6004-11
STEP 24 STEP 27
80020024
8000M259
Lift and remove the piston from the brake housing.
Put support shim in a press and compress Belleville
washers. Remove retaining ring and pull pin with
Belleville washers and rings installed from support STEP 28
shim. Repeat this step to remove the remaining five
retaining rings and pins from support shim.
STEP 25
80020025
8000M260
Remove seven Belleville washers from each pin.
STEP 26
85020086

8000M261 4. U-RING
Using a press, remove four gripping rings from each
Remove the guide ring (2), support rings (3 and 6),
pin. and U-rings (4 and 5) from the grooves of the brake
housing.

6004-12
STEP 29 STEP 32
80020026 80020029
Using the CAS2850 brake housing puller bridge and Remove the face seal from the brake housing.
8073 step plate, pull the brake housing from the
wheel end shaft and remove the inner bearing. STEP 33
Using a puller, remove the outer bearing from the
STEP 30 wheel end shaft.
STEP 34
80020027

housing from the wheel end shaft. 80020030
Remove and discard the face seal metal ring from

80020028
If replacement of bearing cups is necessary, drive

both bearing cups out of the brake housing.

6004-13

IMPORTANT: Do not use compressed air to dry
bearings. Allow bearings to air dry. STEP 40
STEP 35
Clean all parts except friction plates in brake disc
PROTECTION WHEN USING COMPRESSED AIR.
STEP 36
damage. Check associated bearing cups for 80020031
scratches, grooves, or cracks. Check bearings for Apply Loctite 57 4 to inside diameter of a new face
rough spots or binding by holding bearing and seal metal ring. Install face seal metal ring on wheel
rotating. If bearing binds or action is not smooth, end shaft.
replace the bearing.
STEP 41
STEP 37
seen.
replaced.
STEP 38
planetary carrier gear teeth for cracks, breaks,
STEP 39
are seen.
Install CAS2875 pressure ring installer adapter on

wheel end shaft. Press the face seal metal ring over
the collar of the wheel end shaft using CAS2860
pressure ring installer.

6004-14
STEP 42 STEP 45
SM121A
80020034
80020032
Heat the wheel end shaft outer bearing to 1ooo C

the wheel end shaft.
STEP 43
8SOOM073
1. FACE SEAL
2. BRAKE HOUSING
A FILL WITH GREASE
Wet the outer diameter of the face seal with a
solution of 50% water and 50% mineral spirits. Use
CAS2880 seal installer to install the face seal with
the seal lip positioned as shown. Apply grease to
seal as indicated by (A) above.
80020033 STEP 46
Using CAS2877 inner bearing cup installer, press the
inner bearing cup into the brake housing until seated
STEP 44
Using CAS2878 outer bearing cup installer press the
outer bearing cup into the brake housing until seated
80020027

brake housing on the wheel end shaft.

6004-15
STEP 47 STEP 48
SM121A
80020025
80020035
Heat the wheel end shaft inner bearing to 1 ooo C
end shaft until the bearing is against the bearing cup
85020086
GUIDE RING, SUPPORT RINGS AND U-RINGS LOCATION

4. U-RING
Install the support rings and U-rings in the grooves of

the brake housing.

6004-16
STEP 49 STEP 51
80020036 8000M282
1. GRIPPING RINGS
Clean the groove of the brake housing with cleaning
solvent. Install the guide ring in the groove. Make Press the four gripping rings on the pins. Ends of
sure the ends (A) of the guide ring are facing up gripping rings must be 180° opposite from each
towards the top (B) of the brake housing and the other.
guide ring is installed completely in its groove in the
brake housing. Apply Loctite 415 to ID of guide ring STEP 52
to secure guide ring in its groove.
STEP 50
8000M283
80020037
Apply oil on the sliding surface of the piston, support

rings, U-rings and guide ring. Carefully install piston
8SOOM074
1. PIN 4. SUPPORT SHIM

2. GRIPPING RINGS 5. RETAINING RING
3. BELLEVILLE SPRINGS A. 10.5 TO 10.8 MM (0.41 TO 0.43
INCH)
Install the Belleville springs on the pins. Make sure
dimension (A) is 10.5 to 10.8 mm (0.41 to 0.43 inch).

6004-17
STEP 53 STEP 56
8000M259 80020020
Put the assembled pins into the support shim and

STEP 54
85020087
1. BRAKE HOUSING 4. SUPPORT SHIM

2. SNAP RING 5. PISTON
3. PIN A. 4.5 TO 5.0 MM (0.18 TO 0.20
80020038 INCH)
Put the assembled support shim in the piston. Install the three pins (3) in the support shim (4) to
lock the snap ring (2). Dimension (A) between top of
STEP 55 pins (3) and top of support shim (4) must be 4.5 to
5.0 mm (0.18 to 0.20 inch).
STEP 57
80020039
Install the snap ring to secure the support shim.
80020040
1. SPLINE
If removed, drive the stop bolt into the planetary

carrier until contact. Then coat the spline with Loctite
No. 767 antiseize lubricant.
6004-18
STEP 58 STEP 61
80020014
Install the planet carrier into the spline of the wheel Apply grease to new 0-rings and install on planetary
end shaft. ring gear.
STEP 59 STEP 62
80020044
Apply oil to the clutch discs. Install the outer and
Install two alignment studs in the brake housing.
inner clutch discs alternately starting with an outer
Position the planetary ring gear on the brake
clutch disc.
housing. Make sure alignment marks made during
disassembly are aligned. Press planetary ring gear
STEP 60 into brake housing.
80020043
Install a new 0-ring in the brake housing port.

6004-19
STEP 63 STEP 65
~ WARNING: Always wear heat protective ~ WARNING: Always wear heat protective
ill gloves to prevent burning your hand when ill gloves to prevent burning your hand when
handling heated parts. handling heated parts.
SM121A SM121A
80020045 80020047
Heat the planetary gears inner bearings to 1ooo C Heat the planetary gears outer bearings to 1ooo C
(212° F) in a bearing oven. Wearing heat resistant (212° F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearings on the shafts gloves or mittens, install the bearings on the shafts
until the bearing is against the bottom of the shaft. until the bearing is against the gear.
STEP 64 STEP 66
80020046 80020048
Install the planetary gears on the bearings. Install the retaining rings on the planetary gear
shafts.

6004-20
Sun Gear Shaft End Play Adjustment STEP 69
STEP 67
80020051
Install the sun gear shaft in the stub shaft. Make sure
80020049 the stub shaft is installed all the way into the sun gear
Using two M18 bolts of suitable length, secure shaft.
planetary ring gear to brake housing. Then,
determine dimension A, from the face of the STEP 70
planetary carrier stop bolt to the mounting face of the
planetary ring gear.
Example:
STEP 68
80020052
Determine dimension B from the face of the sun gear

shaft to the mounting face of the axle housing.
Example:
Dimension B .............. 31.40 mm (1.24 inch)
80020050 STEP 71
Install the stub shaft in the spline of the axle bevel Subtract dimension B from dimension A. Then
gear. Make sure the stub shaft is installed all the way subtract 1 mm (0.04 inch) from the difference. The
into the axle bevel gear. difference is the required shim size.
Example:
Dimension A + 35.60 mm (1.40 inch)
Dimension B - 31.40 mm (1.24 inch)
Required end play - 1.00 mm (0.04 inch)
Difference= shim
3.20 mm (0.12 inch)
size

6004-21
STEP 72 STEP 75
80020012
Install the sun gear shaft in the planet carrier. Install the washers and bolts to secure the wheel end
to the axle housing. Tighten the bolts to a torque of
STEP 73 390 Nm (288 lb-ft).
STEP 76
80020011
Install the shim set (size as determined in Step 71
above) into the sun gear shaft with grease. 80020155
Install the lock nut by hand and tighten using
STEP 74 CAS2883 support bracket and CAS2876 locknut
socket and nuts. Tighten the lock nut to a torque of
700 to 1000 Nm (516 to 737 lb-ft).
STEP 77
80020009
Apply grease to a new 0-ring and install 0-ring in
brake port. Use acceptable lifting equipment and
install the assembled wheel end onto the axle
housing. 80020156
Install a new slotted pin into the wheel end lock nut.

6004-22
STEP 78 STEP 79
BOOOM303 80020153
1. 0-RING
Install the cover into the wheel end.

6004-23

STEP 81
exceeded, the piston will move too much changing
the gripping rings adjustment. If the gripping rings Operate the hand pump to increase pressure to 100
adjustment changes, the wheel end must be bar (1450 psi) maximum. Close connection to hand
removed and disassembled and the gripping rings pump using the shutoff valve. During a 5 minute
adjusted to the correct dimension (Step 52). period, pressure shall not drop more than 2 bar (29
psi).
STEP 80
Low Pressure Test
STEP 82
not drop.
80020157

brake port as shown above. Fill the hand pump with
Case MS-1209 Hy-Tran® Ultra. Build up pressure in
the axle internal brake lines then bleed air from the
lines. After air is bled, actuate the brakes a minimum
of 10 times by operating the hand pump.

6004-24
DIFFERENTIAL CARRIER DISASSEMBLY

STEP 83 STEP 85
80020002 80020008
Fasten the axle to a stand. Use acceptable lifting equipment to hold wheel end in
place. Remove the bolts and washers.
STEP 84
STEP 86
80020003
80020054

end.
80020004

6004-25
STEP 87 STEP 91
80020010
Pull the stub shaft out of the sun gear shaft. Be Mount differential carrier in OEM4135 engine stand
careful not to lose shim(s) that may be installed in using one CAS2847 holding bracket.
sun gear shaft.
STEP 92
STEP 88
Do Steps 85 to 87 to remove the other wheel end.
STEP 89
Drive out the roll pins from the bearing caps.
STEP 93
Remove 15 bolts securing differential carrier.
STEP 90
Remove both adjusting nuts.
Connect lifting equipment to flange and remove the

differential carrier from axle housing.

6004-26
STEP 94 STEP 96
80020059 80020061
Heat the differential carrier using a hot air blower. Remove both bearing cups.
NOTE: Bolts are installed with Loctite.
STEP 97
STEP 95
IMPORTANT: Do not use an air ratchet or wrench to
remove bolts.
80020062
Remove the differential from the differential carrier.
80020060
1. ALIGNMENT MARK
Make alignment marks on bearing caps and

differential housing to aid in assembly. Remove four
bolts then remove both bearing caps.

6004-27
DIFFERENTIAL DISASSEMBLY
STEP 98 STEP 101
8001F059
80020064
Remove the bearing from the differential housing
Remove the differential cage half and remove all
using CAS2848 puller, OEM4175 pulling attachment,
parts from the differential housing.
1103 puller legs, and 8065 step plate.
STEP 102
STEP 99
Repeat Step 98 to remove the bearing from the
housing cover.
STEP 100
80020065
Press the ring gear from the differential cage.
80020063


6004-28
DRIVE PINION DISASSEMBLY

STEP 103 STEP 106
Heat nut securing flange with a hot air blower to
loosen Loctite.
STEP 104
80020067
Remove the shaft seal from the differential carrier.
STEP 107
8001F091 Put the differential carrier in a press. Press the drive
Install CAS1579A holding wrench on input flange. pinion from the differential carrier. Remove the pinion
Hold flange using holding wrench and remove nut outer bearing.
and washer. Remove holding tool from flange.
STEP 108
STEP 105 Remove the spacer ring and inner bearing from the
drive pinion.
STEP 109
80020066
80020068
If necessary drive out both bearing cups from the

6004-29
PIVOT PIN BUSHINGS

STEP 110 STEP 112
80010499
80010499
1. DIFFERENTIAL CARRIER PIVOT PIN BUSHING
2. AXLE HOUSING PIVOT PIN BUSHING 1. DIFFERENTIAL CARRIER PIVOT PIN BUSHING
A. THRUST SURFACE 2. AXLE HOUSING PIVOT PIN BUSHING
A. GROOVE
Inspect pivot pin bushings in differential carrier and
axle housing for cracks, breaks, deformation, or
other damage. Check oil splash grooves for scoring ,& WARNING: Always wear insulated gloves
or chipping. Check for scoring on thrust surface (A). • or mittens when handling frozen parts.
If bushing (1 or 2) requires replacement, do Steps
111 and 112.
Freeze new bushing in dry ice for several hours.
STEP 111 Install bushing in axle housing or differential carrier
with groove (A) on circumference of bushing facing
center of housing or carrier. Install bushing against
shoulder in housing or carrier.
80010491
Put axle housing or differential carrier in hydraulic

press. Make sure housing or carrier is properly
supported. Using a 66.6 mm (2.625 inches) diameter
by suitable length rod, press bushing out of housing
or carrier.
6004-30
BRAKE TUBES REMOVAL

STEP 113 STEP 116
80020069 80020072
Remove the plug with the breather installed from the Loosen the fitting on the opposite end of the brake
axle housing. tube then remove the brake tube from the axle
housing.
STEP 114
STEP 117
80020070
Remove the nut securing the brake tube to the axle 80020073
housing. Remove the vent valve from the fitting.
STEP 115 STEP 118
80020071 80020074
Loosen and remove the connector from the axle. Remove the fitting. Remove and discard 0-ring and
rectangular ring from fitting.
NOTE: Do Steps 114 to 118 on other wheel end.

6004-31
BRAKE TUBES INSTALLATION

STEP 119 STEP 121
8000M340 80020116
1. VENTVALVE
Tighten the vent valve to a torque of 80 Nm (59 lb-ft).
2. FITTING
3. 0-RING
4. RECTANGULAR RING STEP 122
Install new 0-ring and rectangular ring on fitting.
Install and tighten vent valve in fitting.
STEP 120
80020117
Install a new 0-ring on the connector. Install the

connector in the axle and tighten to a torque of 140
Nm (103 lb-ft).
80020115
STEP 123
Install the assembled vent valve and fitting in the
axle. Tighten the fitting to a torque of 140 Nm (1 03
lb-ft).
8000M343
1. 0-RING
Install a new 0-ring in the groove of the brake tube

fitting.

6004-32
STEP 124 STEP 126
80020118 80020120
1. BRAKE TUBE 3. CONNECTOR Connect fitting on opposite end of brake tube to

2. FITTING fitting installed in wheel end. Tighten brake tube
fitting to a torque of 80 Nm (60 lb-ft).
Install the brake tube (1) in the axle housing,
inserting the fitting (2) through the connector (3). NOTE: Do Steps 119 to 126 on other wheel end.
STEP 125 STEP 127
8000M347
1. 0-RING
2. PLUG
3. BREATHER
80020119
Install the nut to secure the brake tube fitting. Tighten Remove and discard 0-ring (1) from plug (2) and
the nut to a torque of 140 Nm (1 03 lb-ft). install a new 0-ring. Install breather (3) in plug.
STEP 128
80020121
Install the plug in axle housing. Tighten plug to a

torque of 140 Nm (103 lb-ft)

6004-33
DIFFERENTIAL CARRIER ASSEMBLY

NOTE: The ring gear and the drive pinion are a STEP 131
Determine Shim Thickness for

Correct Tooth Contact Pattern
NOTE: Make the following measurements at
maximum accuracy. Inaccurate measurements will
result in a faulty tooth contact pattern causing
disassembly of the drive pinion and differential.
STEP 129
Install the CAS(*TBS) pinion depth gauge set on the
80020122
Determine dimension C (bearing width).

STEP 130
Dimension C (Example) .... 33.65 mm (1.325 inch)
STEP 132
8001F076
Determine dimension B (gap between the measuring

shaft and the measuring pin) using a thickness
gauge. 1. 138.00 MM (+/-0 MM)
80020123
Dimension B (Example) ...... 1.00 mm (0.039 inch)

Read dimension D (dimension for pinion).
Example A:
Dimension D (Example) ... 138.00 mm (5.433 inch)
171.75mm
Dimension A (tool constant) Example B:
(6.762 inch)
+1.00mm 33.65mm
Dimension B (gap) Dimension C
(0.039 inch) (1.325 inch)
172.75mm +138.00mm
Results in Dimension X Dimension D
(6.801 inch) (5.433 inch)
171.65mm
Results in Dimension Y
(6.758 inch)
STEP 133
Subtract dimension Y from dimension X. The
difference is the required shim thickness.
Example C:
Dimension X 172.75 mm (6.801 inch)
Dimension Y -171.65 mm (6.758 inch)
*TBS: To Be Supplied Difference= Shim 1.10 mm (0.043 in)

6004-34
Install Drive Pinion STEP 136

STEP 134
~ mittens when handling frozen parts.
80020124
Install the shim set determined in Step 133 in the

8001F062
bearing bore on the differential carrier.
STEP 135 CAS(*TBS).
~ mittens when handling frozen parts. STEP 137
80020125
8001F064 Press the inner bearing on drive pinion shaft using

Freeze new inner bearing cup in dry ice for several suitable size sleeve pressing on inner race of
hours. Install bearing cup in differential carrier using bearing.
CAS2293-1.

6004-35

Torque Adjustment
STEP 138
80020128
Using CAS(*TBS) puller tube, press the dust shield

on the input flange.
80020126
STEP 141
Install an 16.90 mm (0.665 inch) thick spacer on the
pinion shaft.
STEP 139
SM121A
80020129
STEP 142
80020127
Install the assembled pinion shaft in the differential

carrier. Heat the pinion shaft outer bearing to 1ooo C
(212° F) in a bearing oven. Wearing heat resistance
gloves or mittens, install the bearing on the pinion
shaft until contact.
80020130
Put the washer in place on the pinion shaft.
6004-36
STEP 143 STEP 146
8001F091 80020132
Install CAS1579A holding wrench on input flange. Using the CAS(*TBS) and CAS(*TBS) pinion seal
Hold flange using holding tool and tighten nut to a installers, install the shaft seal with the seal lip down.
torque of 600 Nm (442 lb-ft). Remove CAS1579A.
NOTE: Just before installation, wet the outer
NOTE: When tightening rotate the pinion shaft in diameter of the shaft seal with a solution of 50%
both directions several times. water and 50% mineral spirits. Fill the space between
the sealing and dust lip with grease.
STEP 144
STEP 147
80020131
Check the rolling torque of the drive pinion bearing. 8001F091
The rolling torque should be 1.1 to 4.5 Nm (9.7 to 40 Install the input flange. Install CAS1579A holding
lb-inch). If rolling torque is too low, install a thinner wrench on input flange. Apply Loctite No. 262, on the
spacer (Step 138); if rolling torque is too high, install threads of the locknut. Install the washer and locknut
a thicker spacer (Step 138). by hand. Hold flange using holding tool and tighten
nut to a torque of 600 Nm (442 lb-ft). Remove
STEP 145 CAS1579A.
shaft.
6004-37
DIFFERENTIAL ASSEMBLY
STEP 148 Open Differential Assembly
STEP 149
80020133
Install two slotted pins (2 and 3)in each of the four

blind holes in the differential cage half (1 ). Install 80020134
slotted pins so that slots are 180° from center of Using suitable size sleeve press the ring gear (4)
differential cage and slots of pins are 180° offset to onto the slotted pins until ring gear is against
each other.
85010140
1. DIFFERENTIAL CAGE HALF 5. THRUST WASHER 9. SHAFT 13. BOLT

2. SLOTTED PIN 6. BEVEL GEAR 10. BEVEL GEAR 14. BOLT
3. SLOTTED PIN 7. BEVEL GEAR 11. THRUST WASHER
4. RING GEAR 8. THRUST WASHER 12. DIFFERENTIAL CAGE HALF
STEP 150 STEP 152

Install thrust washer (5) then bevel gear (6) in Install shaft (9) with bevel gears (7) and thrust
differential cage half (1). washers (8) on differential cage half (1). Check that
teeth of bevel gears (7 and 6) mesh.
STEP 151
Install bevel gears (7) and thrust washers (8) on shaft STEP 153
(9). Install and mesh bevel gear (1 0) with gears (7) and
install thrust washer (11) on gear (10). Install
differential cage half (12). Go to Step 163.
6004-38
Limited Slip Differential Assembly STEP 157
STEP 154
80020137
Install assembled shafts (11) with gears (9) and
80020135
thrust washers (1 0) in differential cage (1) making
Install the thrust washer (5), coated surface to clutch sure gear teeth mesh. Check that tabs on thrust
discs, and outer and inner clutch discs (6 and 7) on washers (1 0) are positioned as shown above.
bevel gears (8) in the sequence shown above.
STEP 158
STEP 155
80020138
80020142
Carefully assemble the differential cage halves.
Put the bevel gear (8) with installed parts (5 through Make sure the manufacturers markings (A) on both
7) in the differential cage half (1). halves are aligned.
STEP 156 STEP 159
80020139
80020136
Put the other bevel gear (8) with installed parts (5 Secure the differential cage halves together using
through 7) in differential cage half (12). two bolts.

6004-39
85010141
1. DIFFERENTIAL CAGE HALF 5. THRUST WASHER 9. BEVEL GEAR 13. BOLT

2. SLOTTED PIN 6. SEPARATOR PLATE 10. THRUST WASHER 14. BOLT
3. SLOTTED PIN 7. FRICTION PLATE 11. SHAFT
4. RING GEAR 8. BEVEL GEAR 12. DIFFERENTIAL CAGE HALF
STEP 160 STEP 161

After obtaining the required end play, disassemble
the differential. Install the adjusted clutch pack that
was in the differential cage half (12) in the other
differential cage half (1 ). Repeat Step 160 to check
the end play. After both clutch packs have been
adjusted, go to Step 162.
STEP 162
80020140
Check the end play (zero to 0.15 mm (0.006 inch)) of

the bevel gear (8). Do this by mounting a dial
indicator as shown set to indicate from the top
separator plate through one of the top holes in
differential cage half (12). Zero the dial indicator.
Using screwdrivers or other suitable tools inserted in
holes in side of cage half, move the bevel gear up.
Record the dial indicator reading. Dial indicator 80020141
should indicate zero to 0.15 mm (0.006 inch) After adjustment is completed, separate the cage
(required end play). halves, and remove the parts. Keep clutch packs
If required end play of zero to 0.15 mm (0.006 inch) together and identify which side they are installed.
is not obtained, install new outer clutch discs of Apply oil to all parts. Do Steps 154 to 158 to
thickness necessary to obtain required end play. assemble the differential, then go to Step 163.

6004-40
STEP 163 STEP 166
80020143 80020146
Put the differential in a press to prevent it from Install both bearing cups and adjusting nuts.
turning. Apply Loctite 262 to threads of bolts (13 and
14). Tighten M16 bolts (13), to a torque of 300 Nm STEP 167
(221 lb-ft); tighten M 12 bolts (14) to a torque of 120
Nm (88 lb-ft).
STEP 164
80020147
Position bearing brackets; make sure threads of

bearing brackets and adjusting nuts are not crossed.
Put Loctite 262 on threads of four bolts. Install bolts
80020144 and tighten to a torque of 185 Nm (136 lb-ft).
Using proper size sleeve pushing on inner race of
bearing, press bearing on differential housing until STEP 168
bearing is against housing. Repeat to install other Using a spanner wrench, tighten the two adjusting
bearing. nuts evenly until there is a light pressure against the
bearings on each side of the differential.
STEP 165
80020145
Install differential in differential carrier.

6004-41
Adjust Backlash and Bearing STEP 174

Preload
STEP 169
80020149
Apply marking ink on several teeth of the ring gear

and rotate it in both directions. Compare the obtained
tooth contact pattern with the examples on pages 4
80020148
and 5.
Place CAS1 0066A dial indicator right-angled at the
outer diameter of the tooth flank (ring gear). Adjust NOTE: If the tooth contact pattern differs, the wrong
the pinion to ring gear backlash to the low side of shim size was selected in Step 133. Remove
specifications (see numbers etched on the outer differential and repeat Steps 129 though 133.
diameter of the ring gear) by alternately turning each
of the adjusting nuts to move the ring gear closer to STEP 175
or further away from the pinion.
STEP 170
Go to the adjusting nut opposite the ring gear and
loosen the nut approximately one turn to release
pressure on the bearing. It should be very noticeable
that pressure is released on the bearing, as the
adjusting nut will turn much easier.
STEP 171
Tighten the bearing adjusting nut slowly until firm
contact is made with the bearing.
NOTE: As the adjusting nut makes firm contact with 80020150
the bearing, the adjusting nut will immediately begin Install pins to secure both adjusting nuts.
to turn with more effort.
STEP 176
STEP 172 Apply sealing compound (Three Bond Type 1215) to
To adjust the differential bearing preload, note the differential mounting surface on axle housing. Install
position of the adjusting nut. Now tighten the nut two two CAS2861 alignment studs in axle housing to aid
additional notches. installation of differential carrier. Using suitable lifting
equipment, install the differential carrier in the axle
STEP 173 housing then remove alignment studs.
When the bearing preload is adjusted the backlash
may increase slightly. Check pinion backlash to
confirm that it is within specifications as marked on
the ring gear. If within specifications, install the
adjusting nut locking roll pins. If backlash is outside
of specified range, repeat Step 169 through 173
again.

6004-42
STEP 177 STEP 180
80020151 80020054
Using new bolts, secure the differential carrier to the Apply grease to a new 0-ring and install 0-ring in
axle housing. Tighten bolts to a torque of 390 Nm brake port. Position the wheel end on the axle
(288 lb-ft). housing.
STEP 178 STEP 181
80020050
Install the stub shaft into the spline of the differential Install the washers and bolts on the wheel end.
bevel gear. Tighten the bolts to a torque of 390 Nm (288 lb-ft)
STEP 179 wheel end.
NOTE: Refer to Section 1002 of this service manual
for proper lubricant.
80020011
Install the thrust washer removed at disassembly.

Use grease to keep it in the sun gear.

Section
6004
REAR AXLE
Serial Number N8F203848 and After

Racine, WI 53404 U.S.A. Rae 84243977 Issued December 2009
6004-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................... 3
SPECIAL TORQUES ........................................................................ 3
GEAR TOOTH CONTACT PATTERNS ......................................................... 4
LUBRICATION ............................................................................ 6
Disassembly ............................................................................ 7
Assembly .............................................................................. 14
REPLACE HUB SEAL ...................................................................... 27
Removal .............................................................................. 27
Installation ............................................................................. 28
DIFFERENTIAL ........................................................................... 31
Removal .............................................................................. 31
Disassembly ........................................................................... 32
Assembly .............................................................................. 36
Drive Pinion Removal .................................................................... 42
Brake Tube Removal .................................................................... 44
Brake Tube Installation ................................................................... 46
Pivot Pin Bushing Removal ................................................................ 48
Pivot Pin Bushing Installation .............................................................. 50
Drive Pinion Installation ................................................................... 51
Setting Backlash and Bearing Preload ....................................................... 55
Contact Pattern Check ................................................................... 56
Installation ............................................................................. 57
6004-3
SPECIFICATIONS
Lubricant Capacity ............................................................................................................. 22 liters (23.2 U.S. quarts)
Brake Wear Measurement ............................................................................................................. 4.0 mm (0.16 inch)
Sun Gear Shaft End Play ..................................................................................... 0.5 to 2.00 mm (0.02 to 0.079 inch)
Drive Pinion Rolling Torque ......................................................................... 1.1 to 2.3 Nm (9.75 to 20 pound inches)
SPECIAL TORQUES
Bolts Securing Brake Housing to Axle Housing ................................................................... 390 Nm (288 pound feet)
Wheel End Retainer Bolts ................................................................................................... 500 Nm (369 pound feet)
Nut Securing Input Flange (Apply Loctite 262 to Threads) .................................................. 700 Nm (516 pound feet)
Bolts Securing Differential Housing to Axle Housing ........................................................... 390 Nm (288 pound feet)
Bolts Securing Differential Cover and Ring Gear ............................................................... .41 0 Nm (302 pound feet)
Nut for Securing Brake Tube to Axle Housing ....................................................................... 100 Nm (74 pound feet)
Brake Tube to Axle Housing Fitting ........................................................................................ 100 Nm (74 pound feet)
Brake Tube Axle Housing Fitting .............................................................................................. 36 Nm (27 pound feet)
Oil Drain Plugs (Outputs) ......................................................................................................... 50 Nm (37 pound feet)
Oil Fill Plug/Dipstick ................................................................................................................. 50 Nm (37 pound feet)
Brake Lining Check Plug ......................................................................................................... 50 Nm (37 pound feet)
Brake Bleeder ........................................................................................................................... 6 Nm (4.4 pound feet)
Brake Return Spring Retainer Bolts ........................................................................................ 34 Nm (25 pound feet)
6004-4

BS01D009
DRIVE SIDE (CONVEX)
DRIVE SIDE (CONVEX)

6004-5
BS01D010 DRIVE SIDE (CONVEX)

6004-6
LUBRICATION
BC06G003
1. INPUT 4. AXLE HOUSING

2. OUTPUT 5. AXLE DRIVE HOUSING
3. BRAKE
NOTE: Refer to Section 1002 of this service manual for proper lubricant.
Remove plug, actuate brake and determine dimension (X) using a thickness gauge. If dimension (X) is less than or
the plug. Tighten plug to a torque of 50 Nm (37 pound feet).
6004-7
WHEEL END AND BRAKE
Disassembly STEP3
STEP 1
Using acceptable lifting equipment to hold wheel end.

Loosen and remove the bolts and washers.
STEP4
STEP2

NOTE: Pay attention for shim(s) that are placed
between the sun gear and stub shaft. Mark location
of shim(s) to aid in assembly.
STEPS
BD06G003-01 Remove and discard the 0-ring from the brake port
Remove drain plugs and drain oil from axle housing. (1) and axle housing (2).
6004-8
STEPS STEP9
BD07N045-01
Mount the wheel end on a stand or suitable work Using a suitable puller remove the three planetary
bench. gears.
STEP7 STEP10
BD07N11 0-01
Remove the shim(s) from the sun gear shaft. Remove the steel end shim from brake housing.
Pull the sun gear shaft out of the planetary gears and
remove.
NOTE: Mark location of shim(s) to aid in assembly.
STEPS
Using snap ring pliers remove the retaining rings

from the three planetary gears.
6004-9
STEP 11 STEP13
BD07N094-01
Remove and discard 0-ring.
STEP14
Remove the reaction and friction brake plates

alternately until all brake plates have been removed. Remove the wheel end retainer bolts.
STEP12 STEP15
Remove the wheel end retainer.

Remove cover from wheel end.
6004-10
STEP16 STEP18
Use acceptable lifting equipment and lift the wheel

end from the brake housing.
STEP17
BD06G015-01
Inspect the stop pin for wear, if necessary drill a hole

into the pin, use 380001545 adapter and OEM4236
BDOOM251
and OEM 4237 kits and remove the pin.
housing from the planetary carrier. STEP19
Inspect wheel bearing, if bearing needs replaced cut

bearing cage with a die-grinder and remove cage.
Score the bearing surface with a die-grinder and
break bearing from planetary carrier using a hammer
and chisel.
6004-11
STEP 20 STEP 23
Loosen and remove the six bolts that secure the Carefully pry brake piston up, alternate sides in order
return spring retainer to the brake housing. to raise piston evenly.
STEP 21 STEP 24
Remove the retainer and return spring from the brake Once brake piston is free remove from housing.
housing.
STEP 25
STEP 22
Remove and discard the wear ring from top groove in

Remove the shim from the brake housing. brake housing.
6004-12
STEP 26 STEP 29
Remove and discard the upper back up ring from the Remove and discard the lower back up ring from the
brake housing. brake housing.
STEP 27 STEP 30
Remove and discard the upper piston seal from the Inspect outer bearing cup, if worn or damaged drive
brake housing. outer bearing cup from brake housing and discard.
STEP 28 STEP 31
Remove and discard the lower piston seal from the

Inspect inner bearing cup, if worn or damaged drive
brake housing.
inner bearing cup from brake housing and discard.
6004-13
STEP 32 STEP 34
Remove and discard the face seal from brake Remove the metal face seal ring and discard.
housing.
STEP 35
STEP 33
Inspect wheel end bearing, if bearing needs replaced

Inspect the metal face seal ring, if worn or damaged cut bearing cage with a die-grinder and remove cage.
loosen from wheel end shaft using a pry bar. Score the bearing surface with a die-grinder and
break bearing from wheel end shaft using a hammer
and chisel.
6004-14

IMPORTANT: Do not use compressed air to dry NOTE: Tools and axle shown in the following
bearings. Allow bearings to air dry. photographs may appear slightly different than the
STEP 36 and disassembly/assembly of axle is the same
Clean all parts except friction plates in brake disc regardless of appearance.
PROTECTION WHEN USING COMPRESSED AIR. STEP 41
.A. WARNING: Always wear heat protective
gloves to prevent burning your hand when
STEP 37
SM121A
damage. Check associated bearing cups for
scratches, grooves, or cracks. Check bearings for
rough spots or binding by holding bearing and
rotating. If bearing binds or action is not smooth,
replace the bearing.
STEP 38
seen.
Heat the wheel end shaft outer bearing to 120° C
replaced.
planetary carrier gear teeth for cracks, breaks, STEP 42
STEP 40
are seen.
Clean the seal ring mounting surface with solvent.

6004-15
STEP 43 STEP 45
BD06G084-01
Apply Loctite 574 to the seal ring mounting surface. Use Special Tool 380001566 and drive the sealing
ring into position onto the hub.
NOTE: Only use the special tool to install the sealing
STEP 44
ring to ensure proper seating.

STEP 46
SM121A
.A. WARNING: Always wear gloves to prevent
frostbite to your hands when handling frozen
parts.
SM118A
Heat the metal face seal ring to approximately 120° C

(248° F), place the face seal ring on the wheel end
BD07N083-01
shaft.
Freeze new inner bearing cup in dry ice for several
hours. Install bearing cup in brake housing.
6004-16
STEP 47 STEP 49
.A. WARNING: Always wear gloves to prevent

parts.
SM118A
Clean the seal grooves of the brake housing with

solvent.
BD07N082-01
STEP 50
hours. Install bearing cup in brake housing.
STEP 48
BC08A246
BSOOM073 WEAR RING, BACK-UP RINGS AND PISTON SEAL LOCATION
1. FACE SEAL 2. BRAKE HOUSING A GREASE 1. LOWER BACK-UP RING 5. UPPER BACK-UP RING
Wet the outer diameter of the face seal with a 2. LOWER PISTON SEAL 6. WEAR RING
solution of 50% water and 50% mineral spirits. Use a 3. BRAKE HOUSING 7. BRAKE PISTON
4. UPPER PISTON SEAL
suitable seal installer to install the face seal with the
seal lip positioned as shown. Apply grease to seal as Install the lower back-up ring (1) in the brake
indicated by (A) above. housing.
6004-17
STEP 51 STEP 54
BD07N077-01
BD07N072-01
Install the lower piston seal (2) in the brake housing, Install the wear ring (6) in the top groove of the brake
make sure the groove in the seal is facing upwards. housing. End points of the wear ring must be
installed in the 12 o'clock (top) position of the brake
STEP 52 housing. Make sure the wear ring is installed
completely in its groove in the brake housing.
NOTE: Apply Loctite 415 to the end points of the
wear ring.
STEP 55
BD07N074-01
Install the upper piston seal (4) in the brake housing,

make sure the groove in the seal is facing
downwards.
STEP 53
BD07N086-01
Set the slack adjuster pins on the brake piston by

driving them in until they are flush with the pin mount.
Install the upper back up ring (5) in the brake

housing.
6004-18
STEP 56 STEP 59
Apply oil on the sliding surface of the piston, back-up Install the brake return spring, make sure that the
rings, seals and wear ring. Carefully install piston in tapered end of the spring is facing up.
the brake housing.
STEP 60
STEP 57
Install the brake spring retainer.

Using a plastic mallet fully seat the brake piston.
Strike piston on alternate sides to seat piston evenly. STEP 61
STEP 58
Apply oil to both sides of return spring shim and Install the six retainer bolts and tighten to a torque of
install in brake housing. 34 Nm (25 pound feet).
6004-19
STEP 62 STEP 64
BDOOM251
Use acceptable lifting equipment and lower the brake

If stop pin was removed, drive a new stop pin into the housing onto the planetary carrier.
planetary carrier until contact.
STEP 65
STEP 63 Coat the splines of the planetary carrier shaft with
Loctite No. 767 antiseize lubricant.
handling heated parts. STEP 66
SM121A
BD07N046-01 Using acceptable lifting equipment lower the wheel

If inner wheel bearing was removed, heat the wheel end onto the brake housing. A slight rotation of the
bearing to 120° C (248° F) in a bearing oven. wheel end may be necessary in order align the
Wearing heat resistant gloves or mittens, install the splines of the carrier shaft with the splines in the
bearing on the planetary carrier until the bearing is wheel end.
against the shoulder on the carrier shaft.
6004-20
STEP 67 STEP 69
BD07N095-01

Install the wheel end retainer.
STEP 70
STEP 68
BD07N092-01 Install the cover on the wheel end.

Install new bolts, evenly tighten the four bolts in a
cross pattern to a torque of 500 Nm (369 pound feet).
While tightening bolts rotate the brake housing
several time in both directions.
NOTE: Use only new bolts.
6004-21
BS08A216
BRAKE PLATE AND RETURN SPRING PARTS LOCATION
1. END SHIM 5. RETURN SPRING RETAINER

2. THIN REACTION PLATE (2.0 MM) 6. RETURN SPRING
3. THICK REACTION PLATE 7. SHIM
4. FRICTION BRAKE DISC 8. RETAINER BOLT (6)
STEP 71 STEP 72
Install a friction brake disc into the brake housing.

Install a thin (2.0 MM) reaction brake plate into the
brake housing.
NOTE: Refer to Illustration above for correct brake
plate installation.
6004-22
STEP 73 STEP 75
BD07N11 0-01
Install the end shim into the brake housing.
STEP 76

SM121A
Install a thick reaction brake plate and then another

friction brake disc. Repeat this step until all thick
reaction plates and friction brake discs have been
installed.
STEP 74
Heat the three planetary gears to 120° C (248° F) in

a bearing oven. Wearing heat resistant gloves or
mittens, install the planetary gears on the planetary
carrier.
Install a thin (2 mm) reaction plate.

6004-23
STEP 77 STEP 79
Install the three planetary gear retaining rings with Take a measurement from the straight edge to the
snap ring pliers. face of the brake housing, the difference between
this measurement and the next measurement will be
dimension A.
Sun Gear Shaft End Play Adjustment Measure from the stop pin to the face of the brake
housing.
STEP 78 Example:
STEP 80
Install the stub shaft in the spline of the axle bevel
gear. Make sure the stub shaft is installed all the way
into the axle bevel gear.
STEP 81
1. PLANETARYCARRIER 5. SUNGEARSHAFT
2. STOP PIN 6. SHIM(S)
3. BRAKE HOUSING 7. STUB SHAFT
4. AXLE HOUSING
Install the sun gear on the stub shaft (without shim)

until contact.
6004-24
STEP 82 STEP 84
Determine dimension B from the mounting face of

the axle housing to the face of the sun gear.
Example:
Dimension B ................ 19 mm (0. 75 inch)
STEP 83
Subtract dimension A from dimension B. Then
subtract 1.25 mm (0.05 inch) from the difference. The
difference is the required shim size.
Example:
Dimension A 21.25 mm (0.84 inch)
Dimension B -19.00 mm (0. 75 inch)
BD08B035-01
Install the sun gear shaft into the planetary gears.
Required end play -1.25 mm (0.05 inch) Install the shim set (size as determined in Step 83)
Difference= shim into the sun gear shaft with grease.
1.00 mm (0.04 inch)
size
STEP 85
Install a new 0-ring in brake port (1 ), and a new

0-ring on the axle housing (2).
6004-25
STEP 86 STEP 89
Using acceptable lifting equipment, install the BD06G003-01
assembled wheel end onto the axle housing. Install axle drain plug in differential housing and
torque to 50 Nm (37 pound feet).
NOTE: Turn the input flange to align splines of the
stub shaft into the sun gear.
STEP 90
STEP 87
Remove dip stick from axle housing and wipe clean.

BD02D154-01
Install the washers and bolts to secure the wheel end
to the axle housing. Tighten the bolts to a torque of STEP 91
390Nm (288 pound feet).
STEP 88
--- BD06G002-01
Install drain plug in wheel end and torque to 50 Nm
(37 pound feet).
To check oil level, do not screw in dip stick, but bring
it into contact with the face of the axle housing.
Remove dip stick, oil level should be between upper
and lower marks on dip stick. Add Transaxle Fluid
(SAE 80W-140) as needed.
Install dip stick and torque to 50 Nm (37 pound feet).
6004-26

STEP 94
exceeded damage to brake piston seals may occur.
Operate the hand pump to increase pressure to 100
bar (1450 psi) maximum. Close connection to hand
STEP 92
pump using the shutoff valve. During a 5 minute
period, pressure shall not drop more than 3 bar (44
psi).
Low Pressure Test
STEP 95
not drop.

brake port as shown above.
STEP 93
Fill the hand pump with hydraulic oil. Build up

pressure in the axle internal brake lines then bleed
air from the lines. After air is bled, actuate the brakes
a minimum of 5 times to a pressure of 100 bar (1450
psi) by operating the hand pump.
Torque brake bleeder to 6 Nm (4.4 pound feet)
6004-27
REPLACE HUB SEAL
Removal STEP 98
STEP 96
BD07N094-01
Remove and discard 0-ring.
STEP 99
--- BD06G002-01
Remove drain plug and drain oil from the brake

housing.
STEP 97
Loosen and remove the wheel end retainer bolts.
STEP 100
Use a pry bar and remove the end cover.
Remove the wheel end retainer.

6004-28
Installation
STEP 103
Use acceptable lifting equipment to hold the wheel

end. Separate the output shaft using a puller.
BD06G081-01
STEP 101
BSOOM073
Use a pry bar and remove the face seal from the 1. FACE SEAL
brake housing and discard. 2. BRAKE HOUSING
A FILL WITH GREASE
STEP 102 Wet the outer diameter of the face seal with a
solution of 50% water and 50% mineral spirits. Use a
suitable seal installer to install the face seal with the
seal lip positioned as shown. Apply grease to seal as
indicated by (A) above.
BD07N035-01
Inspect the metal face seal ring for damage or wear,

if required remove the seal ring and discard.
6004-29
STEP 104 STEP 107
BD06G084-01
Clean the seal ring mounting surface with solvent. Use Special Tool 380001566 and drive the sealing
ring into position onto the hub.
STEP 105 NOTE: Only use the special tool to install the sealing
ring to ensure proper seating.
STEP 108
BD07N038-01
Apply Loctite 574 to the seal ring mounting surface.
STEP 106 BD06G086-01

WARNING: Always wear heat protective
wheel end onto the brake housing.
STEP 109
SM121A
BD07N039-01
Install the wheel end retainer.
Heat the metal face seal ring to approximately 120° C
(248° F), place the face seal ring onto the wheel end
shaft.
6004-30
STEP 110 STEP 113
BD07N092-01
Install new bolts, evenly tighten the four bolts in a
cross pattern to a torque of 500 Nm (369 pound feet).
--- BD06G002-01
Install drain plug on brake housing and torque to 50

Nm (37 pound feet).
While tightening bolts rotate the brake housing
several time in both directions.
STEP 114
NOTE: Use only new bolts.
STEP 111
Remove dip stick from axle housing and wipe clean.

BD07N095-01
STEP 115
STEP 112
To check oil level, do not screw in dip stick, but bring

BD02D053-01
it into contact with the face of the axle housing.
Install the wheel end cover into the wheel end.
Remove dip stick, oil level should be between upper
and lower marks on dip stick. Add Transaxle Fluid
(SAE 80W-140) as needed.
6004-31
DIFFERENTIAL
Removal STEP 117

NOTE: Tools and axle shown in the following ;
photographs may appear slightly different than the \.

STEP 116
Fasten the axle to a stand, support the center of the

axle as shown, facing the input shaft attach suitable
lifting equipment to the left axle housing, remove the
mounting bolts and axle half.
--- BD06G002-01
ATTENTION: Differential can fall out of housing
when axle half is removed.
STEP 118
BD06G003-01

Connect suitable lifting equipment to the differential
and remove the differential from axle housing.
NOTE: Make sure that the right axle stub shaft
releases from the differential.
6004-32
Disassembly STEP 122
STEP 119
BD07N162-01
Remove the ring gear from the differential housing.

BD01 F075-01
If required, remove the bearing from the housing STEP 123

cover using a suitable puller.
STEP 120

STEP 121
BD07N148-01
Remove the outer set of clutch plates, thrust washer,

and bevel gear from the differential housing.
BD07N163-01
Remove the housing cover from the differential

housing.
6004-33
STEP 124 STEP 125
Remove the two differential half shafts, spider gears

and thrust washers from the differential housing.
STEP 126
1. ROLL PIN SET

2. DIFFERENTIAL HALF SHAFT
3. DIFFERENTIAL SHAFT
Drive both roll pin sets (1) out of the differential
housing (4) to remove the differential half shafts (2).
BD07N136·01
Remove the differential shaft from the differential

housing.
6004-34
STEP 127 STEP 129
Remove the remaining two spider gears and thrust If required, remove bearing from differential housing
washers from the differential housing. using a suitable puller and a press.
STEP 128 STEP 130
__ .---~
< ~..
\
'-~.--.-.,.,y.._._
Pull the bearing cups and shims from both axle

housings.
NOTE: Make sure to identify the shims into which
axle housing they were removed.
BD07N114-01
Remove the inner set of clutch plates, thrust washer,

and bevel gear from the differential housing.
6004-35
BS08A334
DIFFERENTIAL ASSEMBLY EXPLODED VIEW
1. INNER BEVEL GEAR 5. DIFFERENTIAL 9. THRUST WASHER 13. OUTER BEVEL GEAR
2. THRUST WASHER (COPPER COLOR) 6. ROLL PIN 10. SPIDER GEAR 14. RING GEAR
3. REACTION PLATE 7. ROLL PIN 11. DIFFERENTIAL HALF SHAFT 15. COVER DIFFERENTIAL
4. FRICTION PLATE 8. BEARING 12. DIFFERENTIAL SHAFT 16. BOLT
6004-36
Assembly STEP 134
STEP 131
!
I
I
\
\
BD07N119-01
Install one reaction plate on the inner bevel gear.
STEP 135
Install bearing on differential housing using a press.
STEP 132
Check reaction plates, friction plates and thrust
washers for damage or wear, replace if necessary.
NOTE: Be sure to apply oil to all parts before
assembly.
STEP 133
BD07N120-01
Install one friction plate on the inner bevel gear.
STEP 136
BD07N118-01
Install the (copper color) thrust washer on the inner

bevel gear.
NOTE: Clutch plates must be installed on the inner
bevel gear in the correct order, refer to illustration on
page 35.
BD07N122-01
Install two reaction plates on the inner bevel gear.

6004-37
STEP 137 STEP 140
BD07N124-01 BD07N127-01
Install two friction plates on the inner bevel gear. Install one reaction plate on the inner bevel gear.
STEP 138 STEP 141
BD07N125-01 BD07N128-01
Install one reaction plate on the inner bevel gear. Align all tabs of reaction plates on the inner bevel
gear.
STEP 139
BD07N126-01
Install one friction plate on the inner bevel gear.

6004-38
STEP 142 STEP 144
__ .---~
< ~..
\
'-~.--.-.,.,y.._._
BD07N130-01
Install the clutch pack and inner bevel gear assembly Install the full differential shaft into the housing
into the differential housing. through both thrust washers and spider gears
installed in the previous step. Make sure position of
STEP 143 hole in center of differential shaft is horizontal to the
differential housing.
STEP 145
1. THRUST WASHER 2. SPIDER GEAR

Install a thrust washer (1) and spider gear (2) into the
differential housing. Install another thrust washer (1)
and spider gear (2) directly across from the first. 1. THRUST WASHER 2. SPIDER GEAR
Make sure to install in the correct location for the full Install a thrust washer (1) and spider gear (2) into the
differential shaft. differential housing. Install another thrust washer (1)
and spider gear (2) directly across.
NOTE: The stop tab on the thrust washers must face
upwards.
6004-39
STEP 146 STEP 148
Install both differential half shafts into housing

through thrust washers and spider gears installed in
previous step. The tapered end of half shafts (1)
insert into the hole in center of differential shaft.
Make sure the holes on the other end of the half
shafts (2) align with the holes in the differential
housing (3). BS08B044
1. ROLL PIN SET

2. Dl FFERENTIAL HALF SHAFT
STEP 147
3. Dl FFERENTIAL SHAFT
Drive new roll pins (1) into the differential housing to
secure half shafts.
NOTE: Use new roll pins only.
Spider gear assembly installed in differential housing.

6004-40
STEP 149 STEP 152
BD07N149-01 BD07N153-01
Install the (copper color) thrust washer on the outer Install two reaction plates on the outer bevel gear.
bevel gear.
NOTE: Clutch plates must be installed on the outer STEP 153
bevel gear in the correct order, refer to illustration on
page 35.
STEP 150
BD07N155-01
Install two friction plates on the outer bevel gear.
STEP 154
BD07N150-01
Install one reaction plate on the outer bevel gear.
STEP 151
BD07N156-01
Install one reaction plate on the outer bevel gear.
BD07N151-01
Install one friction plate on the outer bevel gear.

6004-41
STEP 155 STEP 158
BD07N156-01 BD07N160-01
Install one friction plate on the outer bevel gear. Clean ring gear mounting surface on differential
housing.
STEP 156
STEP 159
BD07N158-01
Align all tabs of reaction plates on the outer bevel BD07N161-01
gear. Clean mating surfaces of ring gear and differential

cover.
STEP 157 NOTE: The ring gear and the drive pinion are a
STEP 160
BD07N159-01
Install the clutch pack and outer bevel gear assembly

into the differential housing.
BD07N162-01
Install ring gear on differential housing.

NOTE: Make sure to align bolt holes when installing
ring gear and differential cover.
6004-42
STEP 161 Drive Pinion Removal
NOTE: The ring gear and the drive pinion are a
STEP 164
Heat lock nut securing flange with a hot air blower to
loosen Loctite, approximately 120° C (248° F).
STEP 165
BD07N163-01
Install cover on differential housing.
STEP 162
Install holding wrench on input flange. Hold flange

and remove lock nut and washer. Remove holding
tool from flange.
STEP 166
BD07N166-01

turning. Install new bolts and tighten to a torque of
410 Nm (302 pound feet).
NOTE: Use new bolts only.
STEP 163
BD08B037-011
If bearing was removed from differential cover install

bearing using a press.
6004-43
STEP 167 STEP 170
BD07N181-01
Remove the shaft seal from the axle drive housing. Drive inner bearing cup from the differential housing.
STEP 168 STEP 171
BD06G141-01
Press the input pinion out of the housing. Remove inner bearing cup and shim from differential
housing.
STEP 169 NOTE: Mark shim and bearing cup location to aid in
assembly.
STEP 172
BD07N183-01
Drive outer bearing cup from the differential housing.
BD07N175-01
Remove the spacer ring from the drive pinion.

6004-44
STEP 173 Brake Tube Removal
STEP 174
Remove inner bearing from the drive pinion using a

suitable puller and a press.
Remove the plug with the breather installed from the
axle housing.
STEP 175
Remove fitting from the brake tube on the axle

housing.
6004-45
STEP 176 STEP 178
Remove the brake tube from the axle housing.
STEP 179
Loosen and remove the nut holding the brake tube

connector to the axle housing.
STEP 177 Loosen and remove brake tube fitting inside axle
housing.
STEP 180
Loosen the opposite end of brake tube from fitting

inside axle housing.
BD07N017-01
Remove and discard 0-ring from fitting.

side of the axle
6004-46
Brake Tube Installation
\
'
--------------------------r
BS08B043
BRAKE TUBE PARTS LOCATION
1. BRAKE TUBE FITTING 36NM (27 POUND FEET) 4. AXLE HOUSING

2. 0-RING 5. BRAKE TUBE
3. BRAKE TUBE THREADED NUT 100NM (74 POUND FEET) 6. HEXAGON NUT 100NM (74 POUND FEET)
STEP 181 STEP 182
BD07N017-01
Install a new 0-ring on the brake tube fitting. Install the fitting in the axle and tighten to a torque of
36 Nm (27 pound feet)
6004-47
STEP 183 STEP 185
BDOOM343-01
Install a new 0-ring in the groove of the brake tube.
STEP 184
BD07N005-01
Install the nut to secure the brake tube. Tighten the

nut to a torque of 100 Nm (74 pound feet).
Install the brake tube in axle housing. STEP 186
BD07N009-01
Connect the opposite end of brake tube to the fitting
installed in axle housing. Hold fitting with a wrench
and tighten brake tube to a torque of 100 Nm (74
pound feet).
NOTE: Do Steps 181 through 186 for the other
wheel end.
6004-48
STEP 187 Pivot Pin Bushing Removal

STEP 189
BDOOM347-01
BD01 0499-01
BREATHER VENT EXPLODED VIEW
1. DIFFERENTIAL HOUSING PIVOT PIN BUSHING
1. 0-RING 2. PLUG 3. BREATHER A. THRUST SURFACE
Remove and discard 0-ring (1) from plug (2) and Inspect pivot pin bushings (1) in differential housing
install a new 0-ring. Install breather (3) in plug and for cracks, breaks, deformation, or other damage.
tighten to general bolt torque specifications. Check oil splash grooves for scoring or chipping.
Check for scoring on thrust surface (A). If bushings
STEP 188 require replacement, do Steps 190 through 198.
STEP 190
Install the breather plug in axle housing and tighten Support left axle housing and wheel end with a
to general bolt torque specifications. suitable stand. Using acceptable lifting equipment to
support differential housing, remove bolts and
remove from left axle housing.
STEP 191
Remove and discard 0-ring from axle housing.

6004-49
STEP 192 STEP 194
BS08B045
Cut a slot in the pivot bushing.
STEP 193
Using a suitable length and diameter rod and spacer,

press bushing out of differential housing.
Repeat Steps 192 and 194 to remove the other pivot
Put differential housing in hydraulic press. Make sure bushing.
housing is properly supported.
6004-50
Pivot Pin Bushing Installation STEP 196
WARNING: Always wear gloves to prevent

parts.
SM118A
STEP 195
Install a new 0-ring on the left axle housing.
STEP 197
Position differential housing with left axle housing

and install bolts.
STEP 198
BD01 0499-01
1. DIFFERENTIAL HOUSING PIVOT PIN BUSHING

2. CENTER OF DIFFERENTIAL HOUSING
A. GROOVE
Freeze new bushing in dry ice for several hours.
Install bushing in differential housing with groove (A)
on circumference of bushing facing center of housing
Install bushing against shoulder in housing.
Repeat Step 195 to install the other pivot bushing.
Torque bolts evenly to 390 Nm (288 pound feet).

6004-51
Drive Pinion Installation STEP 201
STEP 199
·-C'
)~ ~
BD06G139-01
1. MATING NUMBER (MARKED MANUALLY)
2. PINION BASIC DIMENSION (STAMPED)
3. PINION DISTANCE DEVIATION+ OR- (MARKED
Find and record the housing dimension "X". MANUALLY)
Dimension X (Example) ..... 205.30 mm (8.08 inch)
Distance deviation is indicated in 1/100 mm. If no
distance deviation is indicated the pinion basic
STEP 200 dimension is identical with the pinion dimension.
Record this as dimension "II".
Dimension II
(Example). . . . . . . . . . . 168 -0.05 mm = 167.95 mm
......... (6.614 inch -0.002 inch = 6.612 inch)
STEP 202
Calculation example A:
36.13mm
Dimension I
(1.422 inch)
+167.95mm
Dimension II
(6.612 inch)
BD06G138-01 204.08mm
Results in dimension V
Measure the thickness of the inner bearing and (8.034 inch)
record its measurement, dimension "1". Calculation example B:
Dimension I (Example) ..... 36.13 mm (1.422 inch)
205.30mm
Dimension X
NOTE: Deduct the thickness of the gauge blocks (8.080 inch)
being used to support the bearing from the overall -204.08mm
Dimension Y
measurement, (8.034 inch)
IE: overall measurement 106.13 mm (4.178 inch) = 1.22mm
Difference = shim
minus gauge block thickness 70 mm (2. 756 inch) will (0.046 inch)
thickness
equal dimension I.
NOTE: Shims are available in 0.10 mm (0.004 inch),

round up or down to the next available shim
thickness, s = 1.20 (0.044 inch)
6004-52
STEP 203 STEP 205

SM121A
Heat the bearing hole to approximately 120° C (248°

F) and install the outer bearing cup until contact is
made using a suitable driver.
STEP 204 BD07N178-01
Heat the pinion inner bearing to 120° C (248° F) in a

bearing oven. Wearing heat resistance gloves or
mittens, install the bearing on the pinion shaft until
contact.
NOTE: After installing bearing on pinion shaft, allow
the bearing to cool to ambient temperature.
Heat the inner bearing hole on the differential

housing to approximately 120° C (248° F). Install the
shim set determined in Step 202 in the bearing bore
and pull the bearing cup into to the bearing hole
using a suitable tool.
6004-53

Torque Adjustment
STEP 206
Press the dust shield on the input flange.
STEP 209
BD07N175-01
Install a 9.03 mm (0.35 inch) thick spacer on the

pinion shaft.
STEP 207

SM121A
STEP 210
Put the washer and nut in place on the pinion shaft.
Heat the pinion shaft outer bearing to 120° C (248°

F) in a bearing oven. Wearing heat resistance gloves
or mittens, install the bearing on the pinion shaft until
contact.
NOTE: Prior to mounting the input flange and
tightening the nut, allow the bearing to cool to
ambient temperature.
6004-54
STEP 211 STEP 212
Install a holding wrench on input flange. Hold flange Check the rolling torque of the drive pinion bearing.
and tighten nut to a torque of 700 Nm (516 pound The rolling torque should be 1.1 to 2.3 Nm (9.75 to
feet). Remove holding wrench. 20 lb-inch). If rolling torque is too low, install a thinner
spacer (Step 206); if rolling torque is too high, install
NOTE: When tightening rotate the pinion shaft in
a thicker spacer (Step 206).
both directions several times.
STEP 213
shaft.
6004-55
Setting Backlash and Bearing Preload

Deviation Value -20 -10 0 +10 +20
Shim A 1.20 1.10 1.00 0.90 0.80
Shim B 0.80 0.90 1.00 1.10 1.20
STEP 214 STEP 216
BD06G163-01 Insert shim A (0.90 mm) and install the bearing cup
Record the deviation value from side of ring gear, the using a suitable driver until seated in axle housing.
value will be a + or-, use the table to determine shim
thicknesses needed. STEP 217
Example: Deviation value of +10 requires the
following shims:
Shim A= 0.90
Shim B = 1.10
STEP 215
Insert shim B (1.1 0 mm) and install the bearing cup

using a suitable driver until seated in axle housing.
1. DIFFERENTIAL 5. AXLE HOUSING

2. DRIVE HOUSING A. RING GEAR SIDE
3. AXLE HOUSING B. CARRIER SIDE
4. INPUT PINION
6004-56
Contact Pattern Check STEP 221
STEP 218
Roll the input pinion several times in both directions

over the ring gear. Remove the differential and
Apply marking ink on several teeth of the ring gear. compare the contact pattern with examples on page
4 and page 5.
STEP 219 NOTE: If the tooth contact pattern differs, the wrong
shim size was used in Step 204. Remove differential
and repeat Steps 199 though 204.
Position the differential assembly in the axle drive

housing.
STEP 220
Position the axle housing on the drive housing, install

4 bolts, top center, bottom center, front center, rear
center, torque bolts evenly to 390 Nm (288 pound
feet).
6004-57
STEP 222
Loosen and remove the nut and input flange.
Position the differential assembly in the axle drive STEP 226

housing.
STEP 223
BD06G172
Install the shaft seal with the sealing lip towards oil
sump using suitable seal installer.
NOTE: Wet the outer diameter of the seal with a
Install a new 0-ring on the axle housing. solution of 50% water and 50% mineral spirits. Fill
the space between the sealing and dust lip with
STEP 224 grease.
BD07N207-01
Position the axle housing on the differential housing,

install bolts and torque bolts evenly to 390 Nm (288
pound feet).
6004-58
STEP 227 STEP 229
Install the input flange. Install holding wrench on

input flange. Apply Loctite No. 262, on the threads of
---
the locknut. Install the washer and locknut by hand.
Hold flange using holding tool and tighten nut to a
torque of 700 Nm (516 pound feet).
NOTE: Rotate the input pinion several times in both
directions when tightening.
STEP 228
BD06G003-01
Install axle drain plugs and torque to 50 Nm (37

pound feet).
Check optional axle pivot stop plates for wear or

damage, replace if required. Torque bolts to general
bolt torque specifications.
6004-59
STEP 230 STEP 231
Remove dip stick from axle housing and fill with 22 To check oil level, do not screw in dip stick, but bring
Liters (23.2 U.S. Quarts) of Transaxle Fluid (SAE it into contact with the face of the axle housing.
80W-140). Remove dip stick, oil level should be between upper
and lower marks on dip stick.
6004-60
NOTES
Section
6005
DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL

JOINTS

6005-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal .............................................................................. 3
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CENTER BEARING ........................................................................ 5
Removal .............................................................................. 5
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal .............................................................................. 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal .............................................................................. 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal .............................................................................. 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal ............................................................................. 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6005-3
SPECIAL TORQUES
Coupler to Flywheel Bolts ...................................................................................... 53 to 62 Nm (39 to 46 pound feet)
Engine Drive Shaft to Coupler Bolts ...................................................................... 53 to 62 Nm (39 to 46 pound feet)
Engine Drive Shaft to Transmission Bolts .............................................................. 75 to 81 Nm (55 to 60 pound feet)
Center, Rear and Front Drive Shaft Bolts .............................................................. 75 to 81 Nm (55 to 60 pound feet)
Carrier Bearing Bolts ........................................................................................... 99 to 128 Nm (73 to 94 pound feet)
Lock Nut for Yoke on Front Drive Shaft .......................................................... 339 to 375 Nm (250 to 275 pound feet)
FRONT DRIVE SHAFT
Removal STEP4
Use an acceptable puller and remove the yoke from
STEP 1 the end of the front drive shaft.
STEPS
Loosen the set screws that secure the center bearing
to the front drive shaft.
STEPS
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
STEP7
BD03A166
Loosen and remove the bolts and straps that fasten
the center drive shaft to the yoke of the front drive
shaft.
STEP2
Loosen and remove the bolts and straps that fasten

the front drive shaft to the front axle.
STEPS
Use a prybar to disengage the front drive shaft from
BD03A183 the front axle and remove the front drive shaft from
Remove the lock nut that fastens the yoke to the front the machine.
drive shaft.
NOTE: If necessary, use a brass hammer to drive
the front drive shaft out of the center bearing.
STEP3
Make an alignment mark on the yoke and the end of
the front drive shaft to make sure that the yoke is
installed correctly.

6005-4
FRONT DRIVE SHAFT
Installation STEP14
STEP9
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP10
Place the front drive shaft into position in the center
bearing of the machine.
STEP 11
Install the lock nut and washer which fastens the

yoke to the front drive shaft. Tighten the lock nut to a
torque of 339 to 375 Nm (250 to 275 pound feet).
STEP15
Tighten the set screws that secure the center bearing
to the front drive shaft alternately until they stop
turning and the hex head socket wrench starts to
spring.
Install the bolts and straps that fasten the front drive
STEP16
shaft to the front axle. Tighten the bolts to a torque of
STEP12
Apply antiseize compound to the splines on the front
drive shaft.
STEP13
Install the yoke to the front drive shaft, making sure
the alignment marks made during removal are
aligned.
NOTE: If a new front drive shaft has been installed,
make sure the yoke being installed is 90° to the yoke Install the bolts and straps that fasten the front drive
on the other end of the front drive shaft. shaft to the center drive shaft. Tighten the bolts to a
torque of 75 to 81 Nm (55 to 60 pound feet).

6005-5
CENTER BEARING
Removal STEP 20
Make an alignment mark on the yoke and the front
STEP17 drive shaft to be sure that the yoke is installed
correctly.
STEP 21
Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
STEP 22
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
BD03A166
STEP 23
Loosen and remove the bolts and straps that fasten Loosen the set screws that secure the center bearing
the center drive shaft to the front drive shaft. to the front drive shaft.
STEP18 STEP 24
BD03A183
Loosen and remove the lubrication hose from the Loosen and remove the bolts, washers and nuts that
center bearing fasten the bearing housing to the front frame.
STEP19 STEP 25
Install two longer bolts, at least 3 inches, to hold the
bearing housing during removal. Use an acceptable
puller to remove the bearing housing from the front
drive shaft.
BD03A183
Loosen and remove the lock nut that fastens the yoke
to the front drive shaft.
6005-6
CENTER BEARING
Apply antiseize compound to the splines on the front
NOTE: The center bearing and the bearing housing
drive shaft. Install the yoke to the front drive shaft,
are not serviced separately. If the center bearing is
making sure the alignment marks made during
worn or damaged or if the bearing housing is
removal are aligned.
cracked, a new center bearing and bearing housing
must be used.
STEP 31
STEP 26
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 27
Install the bearing housing so that the lubrication
fitting is at the top.
STEP 28
BD03A183
Install the washer and lock nut that fasten the yoke to
the front drive shaft. Tighten the lock nut to a torque
of 339 to 375 Nm (250 to 275 pound feet).
STEP 32
BD03A183
Apply Loctite 242 to bolt threads. Install the bolts,

washers and nuts that fasten the bearing housing to
the front frame. Tighten the bolts to a torque of 99 to
128 Nm (73 to 94 pound feet).
STEP 29
BD03A166
Install the straps and bolts that fasten the center

drive shaft to the yoke on the front drive shaft.
Tighten the bolts to a torque of 75 to 81 Nm (55 to 60
pound feet).
STEP 33
Install the lubrication hose into the fitting on the
bearing housing.
BC05M214
STEP 34
Turn the set screw down to the shaft and then back it
Lubricate the center bearing with the grease
off 1/4th turn and lock it with the jam nut. Repeat the
specified in Section 1002.
procedure with the other set screw.

6005-7
CENTER DRIVE SHAFT
STEP 35 STEP 39
Loosen and remove the bolts and straps that fasten Hold the center drive shaft in position and install the
the center drive shaft to the yoke of the front drive bolts and straps that fasten the center drive shaft to
shaft. the transmission. Tighten the bolts to a torque of 75
to 81 Nm (55 to 60 pound feet).
STEP 36
Use a prybar to disengage the center drive shaft from STEP 40
the yoke of the front drive shaft.
STEP 37
Install the bolts and straps that fasten the center

drive shaft to the yoke of the front drive shaft. Tighten
the bolts to a torque of 75 to 81 Nm (55 to 60 pound
Loosen and remove the bolts and straps that fasten feet).
the center drive shaft to the transmission.
STEP 38
Hold the center drive shaft and remove from the
machine.

6005-8
REAR DRIVE SHAFT
STEP 41 STEP 45
BD010323
Loosen and remove the bolts and straps that fasten Hold the rear drive shaft into position and install the
the rear drive shaft to the transmission. bolts and straps that fasten the rear drive shaft to the
rear axle. Tighten the bolts to a torque of 75 to 81 Nm
STEP 42 (55 to 60 pound feet).
Use a prybar to disengage the rear drive shaft from
the transmission. STEP 46
STEP 43
BD010323
Install the bolts and straps that fasten the rear drive
shaft to the transmission. Tighten the bolts to a
Loosen and remove the bolts and straps that fasten torque of 75 to 81 Nm (55 to 60 pound feet).
the rear drive shaft to the rear axle.
STEP 44
Hold the rear drive shaft and remove from the
machine.

6005-9
ENGINE DRIVE SHAFT
STEP 47 STEP 50
BD010342 BD010342
Remove and discard the bolts and straps that fasten Place the engine drive shaft into position on the
the engine drive shaft to the transmission. transmission and install new straps and bolts.
Tighten the bolts to a torque of 61 to 81 Nm
IMPORTANT: The bolts and straps that fasten the
(45 to 60 pound feet).
engine drive shaft to the transmission must be
replaced when removed.
STEP 51
STEP 48
Apply Loctite 242 to bolt threads. Install the six bolts

that fasten the engine drive shaft to the engine.
Loosen and remove the six bolts that fasten the
Tighten the bolts to a torque of 53 to 62 Nm (39 to 46
engine drive shaft to the engine.
pound feet)
STEP 49
Remove the engine drive shaft from the machine.

6005-10
UNIVERSAL JOINTS
NOTE: The bearing race and journal that make up
STEP 52 the universal joint are not serviced separately. If the
Remove the drive shaft from the machine. bearing race or journal is worn or damaged, a new
universal joint must be used.
STEP 53
STEP 55
Clean the slots in the yoke of the drive shaft.
STEP 56
Install the universal joint and install the bearings (2)
and the rings (1 ). Refer to the photo in Step 53.
STEP 57
Install the drive shaft.
1. RING 2. BEARING
Remove the ring (1) and the bearing (2) from the
drive shaft.
NOTE: The above photo shows the drive shaft on
the machine and is for reference of the ring and
bearing only.
STEP 54
Remove the universal joint from the drive shaft.

Section
6006
WHEELS AND TIRES
Copyright© 2003 Case, LLC. All rights reserved.

CASE, LLC. Case is a registered trademark of Case, LLC.
6006-2
TABLE OF CONTENTS
WHEELS AND BOLTS . . . ...... ....... ...... .................................... ........... 3
General Information . . . ...... ....... ...... .................................... ........... 3
Torque Specification . . . ...... ....... ...... .................................... ........... 3
TIRE PRESSURES . . . . . . ...... ....... ...... .................................... ........... 3
CHANGING TIRES . . . . . . ...... ....... ...... .................................... ........... 4
INSTALLING A WHEEL . . ...... ....... ...... .................................... ........... 4

6006-3
WHEELS AND BOLTS
General Information Torque Specification

The wheel bolts must be tightened after every 20 Tighten the wheel bolts to 298 Nm (220 pound-feet)
hours of operation until the wheel bolts stay tight: in the sequence shown in Figure 1. Then a final
torque of 640 to 720 Nm (475 to 530 pound-feet) in
A. If the machine is new.
the same sequence.
B. If a wheel has been removed and installed.
TIRE PRESSURES
20.5 x 25 L2 ....................................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
20.5R x 25 XTLA TL .......................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
20.5R x 25 XHA TL. ........................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
20.5 x 25 GP2B ................................................................................. Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
20.5 x 25 RT3B .................................................................................. Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
20.5R x 25 VUT ................................................................................. Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
20.5R x 25 VMT ................................................................................. Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)

6006-4
CHANGING TIRES
1. Have a qualified tire mechanic service the split
The split rim wheels used on this machine rim wheels used on this machine.
can be dangerous. When inflating a tire on
the machine, use a self-locking nozzle and 2. The correct tire equipment, especially a tire
stand at the front or rear of the tire. inflation cage, is required. Using the wrong
procedure for a split rim wheel can result in
.&, When inflating a tire off the machine, put death.
the wheel in a tire inflation cage. The IMPORTANT: When installing a Michelin tire,
retaining ring and rim can come off with lubricate the tire with a tire mounting lubricant and
enough force to result in death to a person inflate the tire to 551 kPa, 5.5 bar (80 psi) to make
in front of the rim. sure that the tire is seated on the rim. Then decrease
48·44 the pressure to the specified pressure.
INSTALLING A WHEEL
1. Make sure the mounting surfaces of the rim and 4. Tighten the wheel bolts to 298 Nm (220
axle flange are clean and free of dirt and grease. pound-feet) in the sequence shown in Figure 1.
Then tighten the wheel bolts in the same
2. Install the wheel, hardened washers and wheel
sequence to 640 to 720 Nm (475 to 530
bolts.
pound-feet).
3. Use a hand wrench (not an impact) to tighten the
wheel bolts to pull the wheel against the
planetary housing. DO NOT use an impact
wrench to tighten the wheel bolts.
1
10 8
0
6
0 0 12
0 0
4 3
0 0
11 5
0 0
2
0
B0987A88
FIGURE 1. WHEEL BOLT TORQUE SEQUENCE

Section
6007
TRANSMISSION CONTROL VALVE

245 E NORTH AVENUE Printed in U.S.A.
CAROL STREAM, IL 60188 U.S.A. Bur 6-81450 Issued March, 2006
6007-2
TABLE OF CONTENTS
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly .............................................................................. 5

6007-3
CONTROL VALVE
Disassembly STEP4
STEP 1
Loosen and remove the cap screws, remove the

BD06A007
cover. Remove the opposite cover.
Mark the installation position of the wiring harness to
the valve block. STEPS
STEP2
Remove the wiring harness.

BD06A008
Loosen and remove the cap screws that secure the STEPS
distribution plate and intermediate plate to the valve
body, remove the intermediate plate and distribution
plate.
STEP3
BD06A012
Loosen and remove the retaining plate cap screws,

remove the retaining plates and solenoids.
BD06A009
Remove the wiring harness retaining clamp.

6007-4
STEP7 STEP9
Loosen and remove two cap screws, install two Remove the components.
adjusting screws. Loosen and remove the remaining
cap screws. STEP10
STEPS
Remove the opposite solenoids, housing, and

components.
Separate the housing from the valve body by equally
loosening the adjusting screws.

6007-5
Inspection Assembly
1. Clean all metal parts in cleaning solvent. NOTE: Apply clean engine oil (15W-40) to pistons
and springs, orifices, new 0-rings, and filter screens
2. Immerse end housings, valve housing, valve
before assembly.
plate, and distribution plate in cleaning solvent
and agitate cleaning solvent. WEAR EYE
PROTECTION WHEN USING COMPRESSED STEP 11
AIR. Use compressed air to remove foreign
matter from interior of housings and plates and to
ensure that all bores are clear of foreign matter.
3. WEAR EYE PROTECTION WHEN USING
COMPRESSED AIR. Use compressed air to
ensure that orifices are clear of foreign matter.
4. Check filter screens for blockage, rips, or tears.
Replace if any of these conditions are seen.
5. Inspect the plates, housings and covers for
corrosion, cracks, breaks, chipping or other
damage. Check bores in housings for deep
scratches, gouges, and other damage. Replace Place the valve body on the bench with the orifices
a housing or cover if any of the above conditions up.
are seen.
6. Check pressure regulators for cracks, breaks, or STEP12
other damage. Check connector contacts for
looseness or signs of corrosion. Replace a
pressure regulator if any of these conditions are
seen. Check resistance of pressure regulators
using a multimeter. Replace a pressure regulator
if resistance is not 17 to 21 ohms.
7. Check wiring harness connectors for signs of
breaks, cracks, or other damage. Check contacts
for foreign matter or corrosion. Check harness
wiring for signs of broken or cracked insulation
and broken or frayed wiring at connection to
connectors. Replace wiring harness if any of
these conditions are seen.
1. VIBRATION DAMPER 3. PRESSURE REDUCING
8. Check springs for cracks, breaks, distortion, or 2. PISTONS VALVE
signs of permanent set. Replace a spring if any Install components in positions shown.
of these conditions are seen.
9. Inspect pistons for cracks, breaks, chipping, STEP13
grooves, or other damage. Replace if any of
BD06A019
Preload the compression springs of the pistons,

install a roll pin of a diameter of 5.0 mm (0.20 inch).
6007-6
STEP14 STEP17
BD06A023
Install the adjusting screws, gasket, and housing Install the cap screws and torque in a criss cross
cover. pattern to 7.5 Nm (66.3 pound-inch).
STEP15 STEP18
BD06A024
Tighten the adjusting screws equally until the cover is Install the solenoids and secure them with the
flush on the valve body. retaining plates and cap screws. Torque the cap
screws to 5.5 Nm (48.5 pound-inch).
STEP16 NOTE: Install the retaining plate with the neck
towards valve body, install controllers with
connectors as shown.
STEP19
Push the pistons down through the pressure

controller wholes and remove the roll pins. .. /
1. VIBRATION DAMPER 3. MAIN PRESSURE VALVE

2. PISTONS
Install components in positions shown.

6007-7
STEP 20 STEP 23
BD06A028
Preload the compression springs of the pistons, Install the wiring harness with connector on side of
install a roll pin of a diameter of 5.0 mm (0.20 inch). valve body marking made during disassembly.
Install the adjusting screws, gasket, and housing Connect wiring harness to the solenoids.
cover.
STEP 24
STEP 21
BD06A029
Install the gasket, install the wiring harness plug in

Install the cap screws and torque in a criss cross the cover. Install the cap screws and torque in a criss
pattern to 7.5 Nm (66.3 pound-inch). cross pattern to 7.5 Nm (66.3 pound-inch).
STEP 22 STEP 25
Install the solenoids and secure them with the Install the wiring harness retaining clamp.
retaining plates and cap screws. Torque the cap
screws to 5.5 Nm (48.5 pound-inch).
NOTE: Install the retaining plate with the neck
towards valve body, install controllers with
connectors as shown.

6007-8
STEP 26 STEP 28
BD06A031 BD06A033
Install the screens into the bores of the intermediate Install the distribution plate, install the cap screws
plate towards the distribution plate. and torque in a criss cross pattern to 9.5 Nm (84
pound-inch).
STEP 27
STEP 29
BD06A032
Install two adjusting screws. Place the intermediate

plate with the screens facing up. Install new a-rings on the plugs, install and torque
plugs to 6 Nm (53 pound-inch).

SECTION INDEX
BRAKES
Removal and Installation of Brake Components ................................................. 7001

Hydraulic Brake Troubleshooting ............................................................. 7002
Brake Pump .............................................................................7003
Brake Accumulators ....................................................................... 7004
Parking Brake ........................................................................... 7008

Section
7001
REMOVAL AND INSTALLATION OF BRAKE

COMPONENTS

7001-2
TABLE OF CONTENTS
BRAKE VALVE ........................................................................... 4
Removal .............................................................................. 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal .............................................................................. 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal .............................................................................. 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7001-3
\
\
\
\~
\
BC05M136
1. FRONT AXLE 5. FRONT ACCUMULATOR FOR REAR AXLE

2. REARAXLE 6. REAR ACCUMULATOR FOR FRONT AXLE
3. BRAKE VALVE 7. BRAKE PUMP
4. PARKING BRAKE ACCUMULATOR 8. CONNECTOR TO FAN VALVE
COMPONENT LOCATION ILLUSTRATION

7001-4
BRAKE VALVE
1. Park the machine on a level surface and lower 1. Install the brake valve (1) in the cab or canopy.
the loader bucket to the floor. Stop the engine. Refer to the illustration on page 5.
2. Put blocks on both sides of each tire to prevent 2. Remove the plugs from the hydraulic lines and
machine movement. connect the hydraulic lines to the brake valve (1 ).
3. Make sure the brake accumulators are 3. Stop the vacuum pump and remove.
completely discharged. Push down and release 4. Connect all of the electrical connections.
the brake pedals at least 30 times.
5. Turn the master disconnect switch to the ON
4. Turn the master disconnect switch to the OFF position.
position.
6. Bleed the brake system. See Section 7002.
5. Remove the cab skirts located under the cab or
canopy. 7. Install the cab skirts.
6. To release the pressure on the parking brake 8. Check the hydraulic reservoir oil level and add oil
accumulator, the line at the accumulator must be as required. See Section 1002 for the correct oil.
SLOWLY cracked open. A pan will be needed to
catch the hydraulic oil.
7. Connect a drain hose to the quick disconnect
couplings in each brake circuit to release any
pressure in the brake circuit.
8. Clean the brake valve (1) and lines, refer to the
9. Put identification tags on all electrical and
hydraulic lines that are connected to the brake
valve (1 ).
10. Connect a vacuum pump to the hydraulic
reservoir. Start the vacuum pump
11. Disconnect the lines from the brake valve (1) and
put plugs in each line.
12. Remove the brake valve (1 ).

7001-5
1. BRAKE VALVE 6. FRONT BRAKE LINE

2. FRONT ACCUMULATOR LINE (REAR AXLE) 7. REAR BRAKE LINE
3. PARKING BRAKE LINE 8. REAR ACCUMULATOR (FRONT AXLE)
4. BRAKE PUMP INPUT 9. RETURN TO TANK
5. BRAKE VALVE DISCHARGE TO FAN VALVE 10. PARKING BRAKE ACCUMULATOR
BRAKE VALVE ILLUSTRATION

7001-6
SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS
1. Park the machine on a level surface and lower 1. Mount the accumulators (8) in the accumulators
the loader bucket to the floor. Stop the engine. clamps (6), do not tighten clamps at this time.
Refer to illustration on page 7.
2. Put blocks on both sides of each tire to prevent
machine movement. 2. Connect the tubes to both brake accumulators
(8) and tighten.
3. Make sure the service brake accumulators (8)
and the parking brake accumulator (1) are 3. Tighten accumulator clamp studs (6) to 17Nm
completely discharged. Push down and release (13 pound feet).
the brake pedal at least 30.
4. Install the parking brake accumulator (1) into the
4. Turn the master disconnect switch to the OFF bracket.
position.
5. Install the nut (2) and tighten.
5. Remove the left cab skirt located under the cab
6. Connect the line to the parking brake
or canopy to gain access to accumulators.
accumulator (1 ).
6. To release the pressure on the parking brake
7. Stop the vacuum pump and remove.
accumulator, the line at the accumulator must be
SLOWLY cracked open. A pan will be needed to 8. Install the left cab skirt.
catch the hydraulic oil.
9. Refer to Section 7004 and check the nitrogen
7. Connect a drain hose to the quick disconnect charge on the accumulators.
couplings in each brake circuit to release any
10. Turn the master disconnect switch to the ON
pressure in the brake circuit.
position.
8. Clean the brake accumulators (8), parking brake
accumulator (1) and lines. Refer to illustration on
page 7. 12. Refer to Section 7008 and perform the Parking
Brake Test Procedure.
9. Put identification tags on the line that is
connected to the parking brake accumulator (1 ). 13. Check the hydraulic reservoir oil level and add oil
as required. See Section 1002 for the correct oil.
reservoir. Start the vacuum pump.
11 . Disconnect the tubes from both brake
accumulators (8).
12. Loosen the clamp stud (7) on the accumulator
clamp (6).
13. Remove the accumulators (8) from the
accumulator clamps (6).
14. Install plugs in the tubes.
15. Disconnect the hose from parking brake
accumulator (1 ).
16. Remove the nut (2), remove the parking brake
accumulator (1 ).
17. Install a plug in the hose.

7001-7
1. PARKING BRAKE ACCUMULATOR 6. CLAMP ACCUMULATOR

2. MOUNTING NUT 7. CLAMP STUD
3. HOSE PARKING BRAKE ACCUMULATOR 8. FRONT ACCUMULATOR (REAR AXLE)
4. TUBE FRONT BRAKE ACCUMULATOR 9. REAR ACCUMULATOR (FRONT AXLE)
5. TUBE REAR BRAKE ACCUMULATOR 10.
BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION

7001-8
BRAKE PUMP
1. Park the machine on a level surface and lower NOTE: DO NOT use an impact tools on the slotted
the loader bucket to the floor. Stop the engine. nut for mounting the pump drive gear.
2. Put blocks on both sides of each tire to prevent 1. Install gear (2} onto the pump shaft, install
machine movement. washer (3} and slotted nut (5), torque nut to 70 to
79 Nm (52 to 58 pound feet). Refer to the
3. Turn the master disconnect switch to the OFF
position.
2. Install the cotter pin (4).
4. Clean the brake pump (1) and lines, refer to the
illustration on page 9. 3. Install the brake pump (1 ), mounting bolts (7) and
washers (6}.
5. Put identification tags the lines that are
connected to the brake pump (1 ). 4. Torque mounting bolts (7) to 57 to 65 Nm (42 to
48 pound feet).
reservoir. Start the vacuum pump. 5. Remove the plugs or caps and connect the lines
to the brake pump (1 ).
7. Disconnect the lines from the brake pump (1)
and put plugs in each line. 6. Stop the vacuum pump and remove.
8. Remove the mounting bolts (7) and washers (6} 7. Turn the master disconnect switch to the ON
from the brake pump (1) and remove the brake position.
pump (1 ).
9. Check the hydraulic reservoir oil level and add oil
as required. See Section 1002 for the correct oil.

7001-9
1. BRAKE PUMP 4. COTTER PIN 7. MOUNTING BOLTS (2)

2. DRIVE GEAR 5. SLOTTED NUT 8. SUCTION HOSE
3. WASHER 6. WASHERS (2) 9. PRESSURE HOSE
BRAKE PUMP ILLUSTRATION

7001-10
NOTES

Section
7002
HYDRAULIC BRAKE TROUBLESHOOTING

7002-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................... 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM ........................................ 4
BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BRAKE MODULATION PRESSURE CHECK .................................................... 6
Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake Valve Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7002-3
SPECIFICATIONS
Brake pump output ..............................................................................................................42 to 45 Umin at 172 bar
(11 to 12 gpm at 2500 psi at 2000 rpm)
Accumulator nitrogen charge pressure .......................................................................... .48 to 59 bar (700 to 850 psi)
Accumulator valve cut in pressure ......................................................................... 157 to 167 bar (2280 to 2420 psi)
Accumulator valve cut out pressure ....................................................................... 190 to 196 bar (2755 to 2845 psi)
Brake warning pressure switch (normally closed) opening set point ...................... 106 to 115 bar (1530 to 1670 psi)
Brake redundant pressure switch (normally closed) opening set point ..... 55 to 69 bar decreasing (800 to 1000 psi)
Brake light pressure switch (normally open) closing set point.. ............................ 5 to 6 bar increasing (75 to 85 psi)
Modulation pressure front brake cylinders .................................................................. 90 to 97 bar (1305 to 1406 psi)
Modulation pressure rear brake cylinders ................................................................... 87 to 94 bar (1262 to 1363 psi)
SPECIAL TOOLS
380001676 NITROGEN REGULATOR VALVE USED TO CHECK

AND CHARGE THE ACCUMULATOR WITH NITROGEN. 380001168 ACCUMULATOR CHARGING ADAPTER
B877168V
CAS-1808 FLOW METER FITTING KIT
CAS-10280 FLOWMETER

7002-4
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM

NOTE: The hydraulic brake schematic is included in 8. Stop the engine. Turn the ignition switch to the
the hydraulic schematic. Refer to the rear pocket of ON position. Push and release the brake several
this manual. times while reading the pressure on the gauges.
Each push and release of the pedal will result in
1. Check the oil level in the hydraulic reservoir; add
a slight drop in pressure, but not necessarily
oil as necessary.
equal on the two gauges.
2. Push and release the brake pedal many times
9. As the lowest pressure reaches 106 to 115 bar
with the engine stopped to remove all hydraulic
(1530 to 1670 psi) the brake warning lamp and
pressure from the brake system until there is no
alarm buzzer must actuate. If the warning lamp
pressure on the pedal.
and alarm buzzer fail to work, test the low brake
3. Install two 207 bar (3000 psi) pressure gauges to pressure warning switches and electrical circuit.
front and rear hydraulic brake accumulator test If the warning lamp and alarm buzzer actuate at
ports, refer to page 6 for the locations of the test a higher or lower pressure than specified, test
ports. the low brake pressure warning switches and
replace as needed.
4. Make sure that the pressure gauge hoses are
long enough so the gauges can be read while 10. After the low brake pressure light activates, press
sitting in the operators seat. the brake pedal eight more times.
NOTE: The gauges can not be connected to the test 11. Record the readings on the pressure gauges.
ports if hydraulic pressure remains in the system. The pressure gauges should read at or above
48 to 59 bar (700 to 850 psi).
5. Start the engine. Run the engine at low idle while
12. If the pressures are at or above 48 to 59 bar (700
reading the pressure gauges. The alarms
to 850 psi), the test is complete.
(buzzer, master warning light and brake pressure
warning light) should shut off when the 13. If the pressures are not within the required
accumulator with the lowest pressure reaches specifications, then the brake system must be
106 to 115 bar (1530 to 1670 psi), approximately bled.
40 seconds at any engine speed. 14. After bleeding the brake system, perform the
6. After the alarms stop, run the machine at high brake system check again.
idle to finish charging the accumulators. The 15. Continue to slowly push and release the brake
pressure must increase on both gauges until 190 pedal several times until the gauge pressure
to 196 bar (2757 to 2843 psi) is reached. This is suddenly drops to zero. The last pressure
the accumulator valve cut-out pressure. It is reading before the drop to zero is the nitrogen
normal for the pressure to drop slightly once the charge pressure in the accumulator. Test the
cut-out pressure is reached. pressure in both accumulators. If the pressure is
7. With the engine running at high idle, push and below 48 to 59 bar (700 to 850 psi), charge or
release the brake pedal rapidly while reading the replace the accumulator(s) (see section 7004).
drop in pressure on the gauges. The pressure NOTE: Nominal temperature of 20° C (68° F), colder
drops may not be equal, but as the lowest temperature will reduce pressure, hotter temperature
pressure reaches 157 to 167 bar (2280 to 2420 will increase pressure.
psi), the system pressure must start to increase.
This is the valve cut in pressure.
NOTE: The brake cut-in and cut-out pressures of the
brake system charge valve are factory preset and are
not adjustable.
NOTE: If the pressure on one of the pressure
gauges is lower than specified, the problem can be a
bad accumulator valve.

7002-5
BLEEDING THE BRAKE SYSTEM

1. Check the level of hydraulic fluid in the reservoir. 8. Start the engine and run at low idle.
Add fluid to the reservoir if necessary.
9. Push the brake pedal all the way down and
IMPORTANT: If machine is equipped with slowly release for one cycle.
10. Close all four wheel end bleed screws.
11. Fully depress the brake pedal three times in 5
second cycles.
12. With the brake pedal partially depressed, open
the bleed screw on the left front axle. Hold the
brake pedal in position until the oil is clear (no
bubbles). Close the bleed screw.
13. Open the bleed screw on the right front axle.
Repeat step 12.
14. Open the bleed screw on the left rear axle.
Repeat step 12.
15. Open the bleed screw on the right rear axle.
BD03A092
Repeat step 12.
1. SAFETY LINK 16. Replace all bleed screws, caps and plugs.
17. Check the hydraulic fluid and add as necessary.
2. Raise loader arms and install the safety link (1)
for safe access to the front axle bleed screws.
4. Keep the engine speed at high idle until both
brake accumulators are fully charged.
NOTE: This will be approximately 30 seconds after
the low brake pressure light goes out.
5. Stop the engine.
6. Pump the brake pedal until there is no hydraulic
pressure in the brake system (approximately 20
pumps).
7. Remove the plastic and rubber caps from each
wheel end and slowly open all four bleed screws.
NOTE: Attach a hose to the bleed screws to prevent
spilling any fluids.

7002-6
BRAKE MODULATION PRESSURE CHECK
1. FRONT AXLE TEST PORT 3. FRONT BRAKE ACCUMULATOR TEST PORT

2. REAR AXLE TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT
Testing the Brake Modulation 6. Start the engine.

Pressure 7. Operate the machine at low idle and watch the
pressure gauges on the brake accumulators until
1. Make sure the hydraulic accumulator cut-in and the gauges rise above 170 bar (2645 psi).
cut-out pressures are correct. Refer to page 4 of
this section. 8. Apply and hold the brakes for 10 to 15 seconds.
2. Stop the engine. Pump the brake pedal until 9. Make a note of the pressure on the gauges for
there is no pressure in the brake system. the front and rear brakes.
3. Remove the cab skirts to gain access to the 10. The front brake pressure should read 90 to 97
brake test ports. bar (1305 to 1406 psi). This is the modulation
pressure for the front axle.
4. Connect two 207 bar (3000 psi) pressure gauges
to the front brake test port (1) and the rear brake 11. The rear brake pressure should read 87 to 94 bar
test port (2). (1262 to 1363 psi).
5. Connect two 207 bar (3000 psi) pressure gauges 12. If the pressures are not within the specified
to the front brake accumulator test port (4) and range, it will be necessary to adjust the
the rear brake accumulator test port (3). modulation pressures.

7002-7
Adjusting the Brake Modulation 1. Remove the tamper evident cover (1 ).

Pressure NOTE: This is a tamper evident cover and it will be
necessary to install a new cover after the modulation
NOTE: The adjusting bolt to adjust the modulation pressure is adjusted.
pressure is located in the cab, under the brake pedal.
2. Turn the adjusting bolt (2) to adjust the
modulation pressure.
NOTE: The rear brake modulation pressure cannot
be adjusted separately from the front brake
modulation pressure.
3. Repeat steps 5 through 10 in the Testing the
Brake Modulation Pressure procedure.
4. Repeat these steps until the brake modulation
pressure is within the specified range.
BDOON121
1. TAMPER RESISTANT COVER

2. ADJUSTING BOLT

7002-8
SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY)
1. FRONT AXLE TEST PORT 3. FRONT BRAKE ACCUMULATOR TEST PORT

2. REAR AXLE TEST PORT 4. REAR BRAKE ACCUMULATOR TEST PORT
NOTE: Prior to doing this procedure make sure that 6. Start the engine and let idle until both the front
the accumulator pressures are correct. and rear accumulators 3 and 4 are fully charged.
1. Check the level of the hydraulic fluid in the The accumulators are fully charged at 190 to 196
reservoir, add as needed. bar (2755 to 2842 psi).
7. Stop the engine.
8. Push the brake pedal down slowly, allowing for
full piston actuation.
NOTE: Depress the brake pedal at the rate of three
strokes per minute.
9. Continue pressing the brake pedal down. The
low brake pressure light should activate when
the pressure reaches 106 to 115 bar (1530 to
1670 psi). After the low brake pressure light
activates, press the brake pedal eight more
times.
10. Record the readings on the pressure gauges.
The pressure gauges should read at or above
1. ARTICULATION LOCK 48 to 59 bar (700 to 850 psi).
2. Install the articulation lock (1) before doing this 11. If the pressures are at or above 48 to 59 bar (700
test. to 850 psi), the test is complete.
3. Remove the left side cab skirt to gain access to 12. If the pressures are not within the required
the brake accumulator test ports. specifications, then the brake system must be
4. Pump the brake pedal until there is no hydraulic bled.
pressure in the brake system (approximately 20 13. After bleeding the brake system, perform the
pumps). brake system check again.
5. Connect two 207 bar (3000 psi) pressure gauges
to the test ports 3 and 4.

7002-9
BRAKE PUMP OUTPUT TEST

1. Connect the flowmeter to the brake pump as 3. Measure the flow at 0 bar (0 psi). Record the flow
shown below. reading. Slowly close the load valve on the
flowmeter and read the flow at 170 bar (2500
2. Make sure the load control of the flowmeter is
psi). Record the flow reading.
open. Start the engine. Run the engine at full
throttle. Make sure the oil is at operating 4. Divide the flow reading at 170 bar (2500 psi) by
temperature. the reading at 0 bar (0 psi). Multiply the result by
100. This is the percent efficiency of the pump. If
the efficiency of the pump is less than 85%,
repair or replace the pump.
BS02M026
1. FROM HYDRAULIC RESERVOIR 5. BRAKE PUMP 9. FILTER INLET MANIFOLD

2. ELBOW 6. FLOWMETER INLET HOSE 10. FILTER
3. PLUG 7. CAS1 0280 FLOWMETER 11. FILTER TO RESERVOIR HOSE
4. TO ACCUMULATOR VALVE 8. FLOWMETER OUTLET HOSE 12. 0-RING
NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION
BRAKE PUMP OUTPUT TEST

7002-10
BC05G011
BRAKE VA LVE EXPLODED VIEW

7002-11
1. CAP SCREW (T 22 NM (16 LB-FT)) 13. CAP (T 60 NM (44 LB-FT)) 25. CHECK VALVE
2. 0-RING 14. SPOOL 26. CARTRIDGE
3. BUSHING 15. PLUG (T 10 NM (88.5 LB-IN)) 27. PLUG (T 60 NM (44 LB-FT))
4. SLEEVE 16. PLUG (T 60 NM (44 LB-FT)) 28. JET
5. SPRING 17. PLUG (T 22NM (16 LB-FT)) 29. WVI UNIT
6. SPRING RETAINER 18. VALVE SEAT 30. PLUG (T 60 NM (44 LB-FT))
7. SPRING RETAINER 19. THROTTLE SCREW 31. PLUG (T 100 NM (74 LB-FT))
8. CIRCLIP 20. PLUG (T 22NM (16 LB-FT)) 32. RV UNIT
9. SHAFT SEAL 21. CAP 33. SPRING RETAINER
10. SLEEVE LVE 22. SLEEVE 34. SLEEVE
11. GUIDE RING 23. SPRING RETAINER 35. THRUST RING
12. 0-RING 24. SLEEVE 36. SLEEVE LVV

7002-12
NOTES

Section
7003
BRAKE PUMP

7003-2
TABLE OF CONTENTS
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly .............................................................................. 4

7003-3
1. RETAINING RING 8. BACKUP SEAL 14. WASHER

2. SEAL RETAINER 9. CHANNEL SEAL 15. BOLT
3. 0-RING 10. DOWEL PIN 16. DRIVEN GEAR
4. OUTER LIP SEAL 11. THRUST PLATE 17. DRIVE GEAR
5. INNER LIP SEAL 12. GEAR HOUSING 18. DRIVE SCREW
6. SHAFT END COVER HOUSING 13. PORT END COVER HOUSING 19. NAME PLATE
7. QUAD RING
PUMP ILLUSTRATION

7003-4
BRAKE PUMP
1. Secure the pump by the port end cover (13) in a 1. Install a new lip seal (3) into the seal retainer (2)
soft jawed vise. so the lip of the seal will be facing away from the
2. Draw a line the length of the pump to assist gears when the seal retainer (2) is installed into
during assemble. the shaft end cover housing (6).
3. Loosen and remove bolts (15). 2. Install a new lip seal (4) into the shaft end cover
housing (6) with the lip of the seal facing towards
4. Tap the shaft end cover housing (6) with soft the gears.
hammer to loosen it, remove the shaft end cover
housing (6). 3. Install a new 0-ring (3) onto the seal retainer (2),
lubricate the 0-ring with hydraulic oil.
5. Remove the backup seal (8), channel seal (9),
and thrust plate (11 ). 4. Press the seal retainer (2) into the shaft end
cover housing (6) and install the retaining ring
6. Remove the drive gear (17) from the gear (1 ).
housing (12).
5. Place the shaft end housing (6), facing down,
7. Remove the driven gear (16) from the gear into a soft jawed vise.
housing (12).
6. Install new backup seals (8) and channel seals
8. Tap the gear housing (12) with a soft hammer to (9) into the thrust plates (11 ).
loosen it, remove the gear housing (12).
7. Place a thrust plate (11) onto the shaft end cover
9. Remove the backup seal (8), channel seal (9), housing (6).
and thrust plate (11 ).
IMPORTANT: Be sure to place the thrust plate (11)
10. Remove the retaining ring (1) form the shaft end
onto the shaft end cover housing (6) in the position
cover housing (6).
shown in the illustration on page 3.
11. Remove the seal retainer (2), 0-ring (3), and
8. Lubricate the driven gear (16) with hydraulic oil,
outer lip seal (4) from the shaft end cover
slide the driven gear (16) through the thrust plate
housing (6).
(11) into the shaft end cover housing (6).
12. Remove the inner lip seal (5) from the shaft end
9. Lubricate the drive gear (17) with hydraulic oil,
cover housing (6).
slide the drive gear (17) through the thrust plate
(11) into the shaft end cover housing (6).
Inspection
10. Install a new quad ring (7) into the gear housing
(12). Check that dowel pins (1 0) are in place
1. Discard all seals and quad rings. Clean all parts either in the gear housing (12) or the shaft end
in cleaning solvent. Check all machined surfaces cover housing (6).
for damage or wear.
11. Align the marks made during disassembly,
2. Hold a straightedge across each gear housing carefully place the gear housing (12) onto the
and use a feeler gauge to measure the amount gears.
of wear caused by the gear teeth in the gear
12. Slide the thrust plate (11) onto the shafts of the
pocket. If the wear in any gear pocket is more
gears.
than 0.18 MM. (0.007 inch), use a new gear
housing. IMPORTANT: Be sure to place the thrust plate (11)
3. Inspect the thrust plates for scoring, pitting, or onto the gears in the position shown in the illustration
other damage. on page 3.
4. Inspect the gears for wear and damage. There 13. Install a new quad ring (7) into the gear housing
must be no scoring on the gear hubs or on the (12). Check that dowel pins (1 0) are in place
outside edges of the gear teeth. There must be either in the gear housing (12) or the port end
no more than 0.05 MM. (0.002 inch) wear in the cover housing (13).
seal area of the drive shaft. If any gear must be 14. Align the marks made during disassembly, place
discarded, you must use a new hydraulic pump. the port housing (12) onto the gear housing (12).
15. Install bolts (15) with clean and dry threads,
washers (14). Torque bolts to 192 ± 5.5 Nm
(141.5 ± 4 pound feet).
Section
7004
BRAKE ACCUMULATORS

7004-2
TABLE OF CONTENTS
ACCUMULATOR SPECIAL TORQUES ........................................................ 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

7004-3
ACCUMULATOR SPECIAL TORQUES

Gas Charging Valve ..................................................................................................................20Nm (15 pound-feet)
SPECIAL TOOLS
380001676 NITROGEN REGULATOR VALVE 380001168 ACCUMULATOR VALVE ADAPTER

NOTE: Check your inventory of tools, if you have
nitrogen charging kit CAS10899 use it in place of the
above listed tools.
BS06M003
380001390 ACCUMULATOR CHARGING HOSE

7004-4
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR
BS07A156
NITROGEN CHARGING KIT
1. Use the Nitrogen Charging Kit to check 7. Connect valve A to the valve stem on the adapter
accumulator pressure. (F).
2. Close valve (E). 8. Connect the accumulator to the adapter (F)
3. Adjust the regulator (D) to the minimum pressure 9. Open valve on accumulator using the adapter's
setting by turning the knob counterclockwise. square drive (G).
4. Turn the T-handle on valve (A) fully out. 10. Turn the T-handle inward on valve (A) to engage
5. Remove the valve cap from the accumulator. the pin in the valve stem on the adapter.
6. Install adapter 380001168 (F) onto the 11. Slowly open valve (E).
accumulator. 12. Check the charge pressure on gauge (B).
h. WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
. . explosion.
M;,5;jf
A WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar
(450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M406
A WARNING: Do not expose the accumulator to temperatures above 49° C (120° F). A charged accumulator
contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M407

7004-5
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

1. Use the Nitrogen Charging Kit to discharge the 7. Connect valve A to the valve stem on the adapter
accumulator, refer to the illustration on page 4. (F).
The tool must be disconnected from the nitrogen 8. Open valve on accumulator using the adapter's
tank. square drive (G).
2. Close valve (E). 9. Turn the T-handle inward on valve (A) to engage
3. Adjust the regulator (D) to the minimum pressure the pin in the valve stem on the adapter.
setting by turning the knob counterclockwise. 10. Slowly open valve (E).
4. Turn the T-handle on valve (A) fully out. 11. Slowly open valve (D) and allow the nitrogen to
5. Remove the valve cap from the accumulator. bleed off.
6. Install adapter 380001168 (F) onto the
accumulator.

7004-6
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

IMPORTANT: The four valves A, D, and E must be in the positions noted in the procedure before connecting the
Nitrogen Accumulator Charging Kit to the machine or nitrogen, refer to illustration on page 4.
1. Close the shutoff valve (D) by turning it all the 11. Fill the accumulator to pressure according to
way to the left (counterclockwise), refer to the Temperature/Charge Pressure chart.
I TEMPERATURE II CHARGE PRESSURE I
2. Close the gauge valve (E) by turning it all the way 10° c soc F S3.1 BAR 770 PSI
to the right (clockwise). 13° c sse F S3.6 BAR 777 PSI
3. Connect the charging gauges to the nitrogen 16° c 60° F S4.1 BAR 78S PSI
supply tank, open the supply tank valve. 18° c 6Sa F S4.6 BAR 7g2 PSI
4. Slowly turn valve (D) clockwise while watching

21° c 70° F SS.2 BAR 800 PSI
the pressure gauge (B). Stop turning valve (D)

24° c 7Sa F SS.7 BAR 2S4 PSI
when the needle on the gauge (B) reaches 10

27° c 80° F S6.2 BAR 81S PSI
2go c sse F S6.7 BAR 823 PSI
bar (145 psi).
32° c goa F S7.2 BAR 830 PSI
NOTE: If the needle goes over the needed pressure, 3S c
0 gsa F S7.7 BAR 837 PSI
quickly open and close valve (E) and check the 38° c 100° F S8.3 BAR 84S PSI
pressure again. TEMPERATURE/CHARGE PRESSURE CHART
The charging kit is now ready to be installed on the 12. Close valve (E) by turning to the right
accumulator. (clockwise). After a few minutes open valve (E)
5. Remove the cap from the accumulator. and check the accumulator for leakage.
6. Loosen the sealing plug with an Allen wrench. 13. Back off the needle valve (A) on the accumulator
end of the charging hose by turning it
NOTE: Just loosen do not open to far so the gas counterclockwise the maximum amount. This will
leaks out prevent nitrogen from escaping from the
7. Install adapter 380001168 (F). accumulator as the hose is removed.
8. Back off the needle valve (A) on the accumulator 14. Close the valve on the nitrogen supply tank.
end of the charging hose by turning it 15. Adjust the regulator (D) to the minimum pressure
counterclockwise to the maximum amount. This setting by turning the knob counterclockwise.
prevents nitrogen from escaping from the
16. Slowly remove the charging hose from the
accumulator when the charging hose is attached
accumulator pressure valve.
to the accumulator gas charging valve.
NOTE: A small amount of nitrogen will escape when
9. Install the charging hose fitting onto the adapter.
disconnecting the hose.
10. Tighten the needle valve by turning it clockwise.
17. Snug the gas charging valve on the accumulator,
Slowly open the gauge valve (E) and observe the
remove the adapter from the accumulator.
reading on the gauge. This reading is the
nitrogen pressure level inside the accumulator. 18. Torque the gas charging valve to 20 Nm
(15 pound feet)
19. Install the cap on the accumulator.
20. Remove the charging gauges from the nitrogen
supply tank.

Section
7008
PARKING BRAKE

7008-2
TABLE OF CONTENTS
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly .............................................................................. 4
PARKING BRAKE TEST PROCEDURE ........................................................ 5

7008-3
PARKING BRAKE
Disassembly STEP7
STEP 1
Park the machine on a hard level surface and lower
the loader bucket to the ground.
STEP2
Place wheel chocks on each wheel to prevent
machine movement.
STEP3
BD03A185
Loosen the jam nut, turn adjusting bolt

counterclockwise until the brake pads are loose.
STEPS
Install the articulation lock.
STEP4
position.
STEPS BD03A186
Remove the retainer pin and brake pin.
Pump the brake pedal at least 30 times to discharge
the accumulators.
STEP9
STEPS
87
Remove the two brake pads from the parking brake
BD03A184 assembly.
Loosen and remove the cover from the parking
brake.

7008-4
Inspection STEP14
Disengage the parking brake.
STEP10 NOTE: Hydraulic pressure will not be applied to the
Clean and inspect all parts for wear and damage. parking brake until the parking brake rocker switch is
Inspect the brake disc for wear and damage. turned off, the service brakes applied and the
transmission is put into gear.
Replace all parts that are worn or damaged.
A. Place the parking brake rocker switch in the
OFF position.
Assembly
B. Apply the service brake and put the machine
STEP 11 into gear.
C. The parking brake light on the cluster will turn
off at this time.
Place the transmission back into neutral before
proceeding.
STEP15
BD03A187
Install the two brake pads in the parking brake

assembly.
STEP12
Turn the adjusting bolt clockwise until both brake

pads contact the brake disc, then turn the adjusting
bolt counterclockwise one turn. Tighten the jam nut
to secure the adjusting bolt.
STEP16
Install the cover on the parking brake.
STEP17
Perform the Parking Brake Test Procedure as
BD03A186
described in this section.
Install the brake pins and retainer pins.
STEP18
STEP13 Remove the articulation lock.
Start the machine and run the engine at low idle with
the bucket resting on the ground.
STEP19
IMPORTANT: It will be necessary to have an Place the master disconnect switch to the ON
assistant help for this procedure. An operator must position.
be present in the cab at all times to apply the service
brakes and shut down the machine in the event of
mechanical failure.

7008-5
PARKING BRAKE TEST PROCEDURE

STEP 20 STEP 25
While testing, the machine must be on a clear level
surface with the bucket in the travel position.
~ARNING: Always know the location of all

.A. workers in your area. Warn them before you
!start working the machine. Always keep all
other persons away from your area. Serious
injury or death can result if you do not follow
these instructions.
SA015
STEP 21
Start the machine and run the engine at low idle in
third gear neutral. Use up or down arrow and highlight config, press the
enter key to select the config menu.
STEP 22
Place the Transmission-Auto switch to the manual STEP 26
position.
STEP 23
Place the Parking Brake switch to the ON position.
STEP 24
BD06F143
Press the up or down arrow and high light brake test,

press the enter key.
BD06F141
Press and hold the enter key for 2 to 3 seconds until

the instrument cluster monitor display changes to the
select screen.

7008-6
STEP 27 STEP 33
Verify that the machine does not move.
STEP 34
Reduce the engine speed to low idle and return the
transmission to neutral.
STEP 35
BD06F144
Monitor will display Test Park Brake if all conditions

are met to test the brake, press the enter key.
NOTE: If all conditions are not met to test the brake
the monitor will display the condition that needs
corrected prior to proceeding.
Press the escape switch on the key pad to exit the
STEP 28 test mode.
Monitor will display Test Park Brake Ready.
STEP 36
STEP 29 If any machine movement was detected, the parking
Shift the gear selector into third gear forward and brake must be adjusted, see procedures this section.
slowly increase the engine speed to wide open
throttle.
STEP 30
Verify that the machine does not move.
STEP 31
Reduce the engine speed to low idle and return the
transmission neutral.
STEP 32
Shift the gear selector to third gear reverse and
slowly increase the engine speed to wide open
throttle.

SECTION INDEX
HYDRAULICS
How to Read Hydraulic Schematics .......................................................... 8000

Removal and Installation of Hydraulic Components .............................................. 8001
Hydraulic Specifications, Troubleshooting, and Pressure Checks .................................... 8002
Cleaning the Hydraulic System .............................................................. 8003
Hydraulic Pump .......................................................................... 8004
Loader Control Valve ...................................................................... 8005
Cylinders ...............................................................................8006
Coupler Solenoid Locking Valve ............................................................. 8007
Ride Control Accumulator .................................................................. 8013
Ride Control Valve ........................................................................ 8014

Section
8000
HOW TO READ HYDRAULIC SCHEMATICS

Racine, WI 53404 U.S.A. Bur 5-5670 Issued February, 2007
8000-2
TABLE OF CONTENTS
HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Symbol Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Using Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lines, Tubes, and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crossing or Joining Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pump Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Motor Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Control Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Directional Control Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Composite Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Flow Control Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SIMPLE SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
COMMON SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Line and Line Fuctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mechanical Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pumps and Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valve Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

8000-3
HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC
Introduction Using Schematic Symbols

A hydraulic schematic diagram is a line drawing Reservoirs
composed of hydraulic symbols that indicate the
types of the components the hydraulic circuit
contains and how they are interconnected. Accurate
diagrams of hydraulic circuits are essential to the
service technician who must repair them. The
VENTED RESERVOIR PRESSURIZED RESERVOIR
schematic diagram is a valuable aid in diagnosing
possible causes of a problem when troubleshooting 88078620
machinery. A rectangle with the top removed represents a

vented reservoir. A rectangle with the top in place
The purpose of this section is to show how to read
represents a pressurized reservoir.
and effectively use schematic circuit diagrams.
Circuit Diagrams
1. Cutaway Circuit Diagrams show the internal
construction of the components, as well as the
( )
flow paths. By using colors, shades or various PRESSURIZED RESERVOIR PRESSURIZED RESERVOIR
patterns in the lines and passages, they are able
88078621
to show many different conditions of flow and The are other schematic diagrams that show a
pressure. Cutaway diagrams take considerably slightly different version of a pressurized reservoir,
longer to produce because of their complexity. but the symbols are similar and easily recognized. An
2. Schematic Circuit Diagrams, the "shorthand" oval with a short line on top or a rectangle with
system of the industry, are usually preferred for curved sides represents a reservoir that is
troubleshooting. A schematic diagram is made pressurized.
up of simple geometric symbols for the
components and their controls and connections.
Symbol Systems
There are several systems of symbols used when RETURN LINE ABOVE
making schematic diagrams. They are as follows: THE OIL LEVEL
88078622
I.S.O. - International Standards Organization Lines connected to the reservoir usually are drawn
A.N.S.I.- American National Standards Institute from the top, regardless of where the actual
connection is.
A.S.A. - American Standards Association
J.I.C. -Joint Industry Conference
A combination of these symbols is shown in this
section. There are differences between the symbols,
but there is enough similarity so that if you
understand the symbols in this section, you will be SUCTION LINE OR RETURN LINE
able to interpret other symbols as well. BELOW THE OIL LEVEL
88078623
If the hydraulic line terminates below the fluid level, it
is drawn all the way to the bottom of the symbol
88078624
RESERVOIR WITH SUCTION LINE ATTACHED AT THE
BOTTOM

8000-4
A hydraulic line connected to the bottom of the Lines, Tubes, and Hoses
reservoir may be drawn from the bottom of the A hydraulic line, tube, hose, or any conductor that
symbol if the bottom connection is essential to the carries the fluid between components is shown as a
system operation. line.
8S078626
A working line, such as an inlet pressure or return, is
shown as a solid line.
8S078625
If the pump inlet must be charged or flooded with a 8S078627
positive head of oil above the inlet port, the reservoir OIL FLOWS ONE WAY ONLY
symbol will be above the pump symbol with a suction
line drawn out of the bottom of the reservoir symbol.
Every vehicle or system reservoir has at least two
hydraulic lines connected to it, and some may have
8S078628
many more. Often the components that are
connected to the reservoir are spread all over the OIL CAN FLOW EITHER WAY
schematic. Rather than having a number of Working lines with arrows show direction of flow.
confusing lines all over the schematic, it is customary
to draw individual reservoir symbols close to the
components. The reservoir is usually the only
component symbol pictured more than once.
- 8S078629
Pilot or control lines are broken into long dashes.
---------
Drain lines for leakage oil are broken into short
8S078630
dashes.
8S078631
A flexible line is show as an arc between two dots
and is always represented by a solid line.
~----__)
8S078632
Quite often you will see an enclosure outline that
indicates that there are several symbols that make up
a component assembly such as a valve or a valve
stack. The enclosure outline appears like a box and
is broken with dashes on all sides.

8000-5
Crossing or Joining Lines
++ LINES THAT ARE NOT CONNECTED

The shortest distance between two components that
8S078633 Variable Displacement Variable Displacement
Pressure Compensated
8S078636
are connected is a straight line. There are lines that A variable displacement pump is designated by
cross other lines, but are not connected. There are a drawing an arrow through the pump symbol at 45
number of ways to show crossing lines. degrees. To indicate a variable displacement
pressure compensated pump, a small box with an
arrow in it will be added to the side of the pump
---L
+ LINES THAT ARE CONNECTED
8S078634
Lines that are connected are shown with a dot that

symbol
t¢ 1=¢
represents the connection or shown as a tee Lever Controlled Pedal or Treadle
connection. The dot connection is the most Controlled
commonly used when drawing schematic diagrams. 8S078637
If the pump is controlled by a lever or a pedal, it will
be shown on the side of the pump.
Pump Symbols
Pump with Drive Shaft Pump with Drive Shaft

L....J Fixed Displacement
and Directional Arrow
Fixed Displacement
Reversible 8S078638
A drive shaft is shown as two short parallel lines
8S078635 extending from the side of the pump. If a curved
There are many basic pump designs. A simple fixed arrow is shown on the drive shaft, it will indicate the
displacement pump is shown as a circle with a black direction of the rotation.
triangle that is pointing outwards. The black triangle
is like an arrow head and points in the direction that
the oil will flow. If the pump is reversible or designed
to pump in either direction, it will have two black
triangles in it and they will be opposite each other.

8000-6
Hydraulic Motor Symbols
2
Nonreversible Motor
9
Reversible Motor
88078639
Double Rod End Cylinder
88078643
A double rod end cylinder has a rod extending from
each end of the rectangle.
Hydraulic motor symbols are circles with black
triangles, but opposite a pump the triangles point
inward to show the motor is a receiver of oil. One
triangle is used for a non-reversible motor and two
triangles are used for a reversible motor.
Single Rod End Fixed Cushion Both Ends
Pump 88078644
~--
Mota/ I I
A simple schematic diagram is shown with a

L._j
hydraulic motor connected to a hydraulic pump.

88078640
I tz1-~--l
Single Rod End Adjustable Cushion Rod End Only
730L8E
Cylinder Symbols SINGLE ROD END ADJUSTABLE CUSHION ROD END ONLY
Some cylinders have cushions built into them. The
Tee cushion slows down the movement of the piston as it
_ ___,,
Rectan~~..__ ___._I:;::?~
nears the end of its stroke. Cylinder cushions are
shown as a smaller rectangle on the piston. If the
cushion has an adjustable orifice, a slanted arrow is
drawn at 45 degrees across the symbol.
88078641
A cylinder symbol is a simple rectangle representing
the barrel. The piston and rod are represented by a
tee that is inserted into the rectangle. The symbol
can be drawn in any position.
Port ~ ...........
~~ I I
I ~---1 -
Single Acting Cylinder
I
Double Acting Cylinder
I
88078642
If the cylinder is single acting, there is only one port
shown on the symbol. The port is shown on the end
of the cylinder that receives pressurized fluid and the
opposite end of the cylinder is left open.
A double acting cylinder symbol has both ends
closed and has two ports on the symbol.

8000-7
Pressure Control Symbols Relief Valve

The basic symbol is a square (which is called an
envelope) with external port connections and an Pressure Line
arrow inside to show the oil passage and direction of
flow. Usually this type of valve operates by balancing
the oil pressure against a spring, so a spring is
shown on one side of the symbol and a pilot pressure
~ump
line on the other side.
Normally Closed
Arrow Offset Arrow Aligned 88078648
With Ports
·--
From Ports
A relief valve is shown as a normally closed symbol
Inlet Pilot connected between the pressure line and the
reservoir. The flow direction arrow points away from
Sprin*] Line the pressure line port and toward the reservoir. This
Outlet
Normally Closed '*
Visualize square
moving toward spring
88078646
A normally closed valve, such as a relief or sequence
shows very graphically how a relief valve operates.
When pressure in the system overcomes the valve
spring, flow is from the pressure line through the
relief valve to the reservoir.
Pressure Reducing Valve

valve, is shown with the arrow offset from the ports High Pressure Inlet
and toward the pilot pressure line side of the square.
The spring holds the valve closed until the pilot line
oil pressure is greater than the spring pressure.
Mentally visualize a build up of pressure in the pilot PilotiH
line and the square moving over, compressing the Liner 1 Drain Line to
1- W
t- R .
eservo1r
spring. The oil now can flow through the valve.
Reduced Outlet Pressure
Normally open
88078649
Inlet
Spring~ J. Line
Pilot
·--. ~
A pressure reducing valve is shown as a normally
open symbol in a pressure line. This valve works
opposite of a relief valve, since it senses outlet
pressure versus inlet pressure. As the outlet
pressure builds, it works against a predetermined
spring force. As the spring force is overcome, flow
Outlet Visua quare
Normally Open through the valve is modulated or shut off.
moving toward spring
88078647
A normally open valve is shown with the arrow
connecting the two ports. It closes when the pressure
overcomes spring force. Mentally visualize a build up
of pressure in the pilot line and the square moving
over, compressing the spring. The oil flow through
the valve is now blocked.

8000-8
Sequence Valve Directional Control Symbols

Supply Line Simplified Symbols
One Way Valve
Pump
No Flow
Qo- (J Free Flow
To Secondary
88078676
Cylinder
A simple ball check valve is shown. When oil
88078650
pressure is exerted on the left side of the ball, the ball
The normally closed symbol is also used for a
is forced into the V and no oil can flow past it. When
sequence valve. The inlet port is connected to a
oil pressure is applied to the right side of the ball, the
primary cylinder and the outlet port o the secondary
ball moves away from the V and oil can flow past.
cylinder line. When the piston in the primary cylinder
reaches the end of its stroke, the pressure in the
supply line increases. The sequence valve is also By Pass Valve
connected to the supply line and also feels the
increase in pressure. As pressure increases, the
square and directional flow arrow moves over,
connecting the inlet and outlet ports, allowing fluid to
flow to the secondary cylinder.
88078677
A by pass valve is shown as a one way valve with a
spring on the ball end of the symbol. This shows that
a pressurized flow will be necessary to overcome the
spring force and allow flow around the ball.

8000-9
Composite Symbols Three - Position Valves
One - Way Valves
No 88078680
Flow Visualize a build up OPEN CENTER THREE POSITION VALVE
of pressure on the
One way valve shown right side of valve
in the closed position
88078678
A more complex one way valve is shown. This
directional control symbol uses a multiple envelope
(square) system that has a separate square for each
position. Remember all of the port connections are
made to the envelope that shows the neutral 88078681
condition of the valve. Within each envelope are CLOSED CENTER THREE POSITION VALVE
arrows showing the flow paths when the valve is Three position valves will have a centered (neutral)
shifted to that position. position. The centered position can be either open or
closed to flow. The open center is usually used with a
Two - Position Valves fixed displacement pump and the closed center is
usually used with a variable displacement pump.
88078679
A simple control valve has two envelopes
(representing the spool) if it is a two position valve.
The envelopes show the flow conditions when they
are in one position. The above schematic is showing
that oil is being supplied to the rod end of the
cylinder. If we visualize the directional control valve
moved to the other position, it would be shown as
below.
88078710
Pressurized oil is being supplied to the piston end of
the cylinder and oil from the rod end of the cylinder is
allowed to flow to the reservoir.

8000-10
Actuating Controls Flow Control Symbols
Lever Ji Restrictors
Pedal)::[
88078682
~
Non Adjustable
Restrictor
A~
Restrictor
88078686
The basic flow control symbol is a representation of a

restrictor. If the restrictor is adjustable, a slanted
arrow is drawn across the symbol. The restrictor
could be a special fitting with a small hole in it or a
small drilled passageway within a valve. If it is an
Two Position Controlled Two Position adjustable restriction, it could be thought of as a
by External Controlled water faucet that can be controlled by turning the
Pilot Pressure By Solenoids handle to regulate the flow. Restrictors can be
applied to meter out, meter in, and bleed off circuits.
88078683
Adjustable Restrictor Adjustable Restrictor

Three Position, Solenoid Controlled Pressure Pressure and
With Internal Pilot Assist Pressure Compensated Temperature
88078684
Compensated
Valve spools are controlled by levers, pedals, pilot oil, 88078687
electric solenoids, etc. which are called actuating There are adjustable restrictors that are pressure
controls. These actuating controls are shown by compensated. That means that the size of the
w
symbols placed on the ends of the envelopes. openings in the restrictor will change with increases
and decreases in pressure. A perpendicular arrow
Solenoid Control With Internal indicates pressure compensation. If the restrictor has
Pilot Pressure "'-.. both pressure and temperature compensation, the
symbol for a thermometer will also be shown.
XI~ ~II I~
88078685
THREE POSITION, SPRING CENTERED
To show that a valve is spring centered, a spring
symbol is placed at each end of the envelope. The
above schematic shows that an electrical solenoid
and pilot pressure assist are required to overcome
spring force to move the valve spool.

8000-11
Accessories An oval with details inside indicates an accumulator.

The details inside will tell you what type of
Filters, strainers, and heat exchangers are
accumulator it is: spring loaded, gas charged, or
represented as squares that are turned 45 degrees
other features.
and have the port connection at the corners.
Gas Charged
8S078691
8S078688
A dotted line perpendicular to the flow line indicates a The divider line indicates there is a separator
filter or strainer. between the charge and the oil. A hollow triangle
indicates gas.
Cooler
A solid line perpendicular to the flow with black

8S078689
~
Spring Loaded
8S078692
triangles pointing out indicates a cooler. A spring shows that the accumulator is spring
loaded.
Heater
8S078690
The symbol for a heater is like the symbol for a
cooler, except the black triangles point in.
Temperature Control Unit

8S078693
Two sets of triangles pointing in and out indicates a
temperature control.
As you can see, the black triangles point in the
direction that the heat is dissipated. or in the case of
the control unit, they show that the heat can be
regulated.

8000-12
SIMPLE SCHEMATIC
The illustration below has put some of the previous symbols together to form a simple hydraulic schematic. See if
you can find your way around the schematic without reading the text for each valve. The text explains the function
of each valve.
Detent
© ®
88078596

8000-13
Valve A Valve C
This valve is a three position valve. The spool is lever This valve is also similar to valve A, but is designed
operated and spring centered. It is an open center to control a single acting cylinder. When you visualize
valve. Visually place the envelopes into the center placing the upper envelope in the center position you
position and you will see that the valve will direct oil will see that oil can drain back to the reservoir from
into one end or the other of cylinder A. when the cylinder C.
spool in valve A is moved out of the centered At the same time, oil from the pump can flow through
position, the valves downstream will receive no oil. valve C to the next valve.
Valve 8 ValveD
Valve B is similar to valve A but it is a four position Valve D is a lever operated, spring centered valve
valve. The fourth position is a float position and is and is designed to control a hydraulic motor. If a
held into that position with a detent. With this valve hydraulic motor was turning a flywheel and the oil
the cylinder B can be extended, retracted, or placed supply and return were shut off abruptly, this would
in the float position. Visualize the envelope for the cause damage to the hydraulic lines, the motor, or
float position in the inlet passageway. whatever it was powering. Therefore when the valve
You will see that oil can continue to flow to the next supplying the motor is shut off, the motor should be
valve downstream and that the rod in cylinder B able to slow down gradually. The center (neutral)
could be pushed back and forth. The oil could move position of valve D will allow that to happen by letting
from one end of the cylinder. oil from the outlet of the motor return to the inlet side.
Use this information to read hydraulic schematics.
The more experience you have reading schematics,
the easier and more comfortable it will become to
use hydraulic schematics as a troubleshooting guide.

8000-14
COMMON SYMBOLS
Line and Line Fuctions Mechanical Devices
Mechanical Connections
Solid Line
-
710LSH Two Parallel Lines
Main Line (Shafts, Levers, etc.)
730L8G
Dashed Line
711l8A
Pilot Line
711LBB Dotted Line

Exhaust or Drain
Variable Component
(Run arrow through
729LSM Enclosure symbol at 45°)
Outline
730L8H
Lines
711LBE Crossing
\M730L8J
Spring
Lines
Crossing
710LSM
8S078696
l 710LSP
Lines
Joining
Liquid Direction
729l8N of Flow
-----tt>>--- Gaseous Direction

of Flow
729l8P
Flexible Line
711LSC
8S078694

8000-15
Pumps and Motors Reservoirs
Hydraulic Pump
Fixed Displacement
I 710LSB
I Reservoir Open
to Atmospere
729l8D
Hydraulic Pump
Variable Displacement Pressurized Reservoir
710LSA
729t.SE
Pressure
Compensated Variable
Displacement Pump Line to Reservoir
Below Fluid Level
729L8F 710L8F
Fixed Displacement
Hydraulic Pump
(Two Directional Flow) Line to Rexervoir
711l!!K
I 710L8E
I Above Fluid Level
88078699
Hydraulic Motor
Fixed Displacement
711L8M
Hydraulic Motor
Variable Displacement
730L8B
Hydraulic Oscillator
730LSC
88078695

8000-16
Cylinders Valves
I Single Acting
I 711l8P
0 112.l8J
Check Valve
I
I I
I 711L8P
Double Acting
Single Rod End -ffi= 731L8A
Pilot Operated
Check
I I
I -t><l- On-Off
Manual Shut-off
I 712L8A
Double Acting
Double Rod End
731L8B
I
1$ I749L8EP
Single Rod End
Fixed Cushion
Both Ends
Pressure
Reducing Valves
712.l8H
I I Single Rod End
I tA I f:lUI..Ilt:
Rod End Only
Adjustable Cushion
\..._,/
~
Non-Adjustable
Restrictor
716L8H
Differential
Cylinder
730L8F
8S078706
't 716L8B
Adjustable
Restrictor
Adjustable
Restrictor
Pressure
Compensated
716L6C
Adjustable
Restrictor
(Temperature and
Pressure
Compensated}
8S078697

8000-17
Valve Actuators
Regulating or
Selector Valves
D [JJ Solenoid
749L8A 749L8F
2-Position
rz[ yG731LSL
4m 731LSC
2-WayValve
~
Detent
2-Position 729LS
ttTIJ 731LSD
3-WayValve
\f\A
730LSJ
Spring
~
2-Position
731L8t:
4-WayValve
t:::[ 729LSA
Manual
3-Position
4-WayValve
Push Button
729L8K
2-Position 4-Way
Open Center
Cross Over Push-Pull
Lever
729LBL
729LSC
Valve Capable of
Infinite Positioning
(Indicated by
Horizontal Lines
Drawn Parallel to Pedal
the Envelope)
713LSF
~J Pressure Relief
Valve
Mechanical
712LSB
88078698
729LBG
88078700

8000-18
Accessories
rr(
Pressure
Compensated
<I> 716LSE
Filter
729L8H
<l> 716LSF
Cooler
-{ 731L8F
Pilot Pressure
Remote Supply
$ 731LBG
Heater
$ Temperature
s=
Controller
731LBH
Liquid Supply
731l8M Accumulator
Hydro-Pneumatic
88078708
716LBG
~
Reversing
Motor
730L8K
Station or
X Test Point
730L8L
6) 730L8M
Pressure
Indicator
CD 730L8N
Temperature
Indicator
88078705

8000-19
Presssure
Switch
730LSP
Quick Disconnects
(Disconnected)
731LSJ
-o>+<o- 731L8K
Quick Disconnects
(Connected)
88078707

8000-20
NOTES

Section
8001
REMOVAL AND INSTALLATION OF HYDRAULIC

COMPONENTS

8001-2
TABLE OF CONTENTS
LOADER CONTROL VALVE ................................................................. 3
Removal .............................................................................. 3
4 spool line removal and installation illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 spool line removal and installation illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal .............................................................................. 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Joystick and 2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Joystick and 1 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Joystick Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal ............................................................................. 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal ............................................................................. 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BUCKET CYLINDER- Z-BAR LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal ............................................................................. 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
BUCKET CYLINDERS- XT LOADER ......................................................... 26
Removal ............................................................................. 26
XT Loader Bucket Cylinder Removal And Installation Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal ............................................................................. 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
RIDE CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal ............................................................................. 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal ............................................................................. 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
FAN REVERSING VALVE.................................................................. 36
Removal ............................................................................. 36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
THERMAL VALVE ........................................................................ 38
Removal ............................................................................. 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8001-3
LOADER CONTROL VALVE
Removal STEPS
STEP 1
Park the machine on a level surface.
IMPORTANT: If machine is equipped with
STEP2
BD06F213
Relieve the pressure in the ride control accumulator

with the manual bleeder valve located on the top of
the ride control valve. Remove the plug and turn the
valve two turns counter-clockwise.
STEPS
Loosen the filler cap on the reservoir to release the
air pressure in the reservoir.
Raise the lift arms and install the safety link on the lift STEP7
arm cylinder.
Drain the hydraulic reservoir.
STEP3
STEPS
Stop the engine and apply the parking brake.
IMPORTANT: With the engine NOT running, pump
the brake repeatedly to be sure the brake
accumulators have no hydraulic pressure, put the
ignition switch in the ON position then move the
loader control valve back and forth several times to
release any hydraulic pressure in the pilot control
circuit, turn ignition switch OFF.
STEP4
position.
BDOOM041
Loosen and remove the bolts and washers that

fasten the access cover plate for the loader control
valve. Remove the cover plate.

8001-4
YEllOW & WHITE
ORANGE & WHIT£

YELLOW & BLACK
GREEN & WHITE
BS07H031
1. LOADER CONTROL VALVE 4. CHECK VALVE

2. PILOT ACCUMULATOR HOSE 5. SWITCH FITTING (XT WITH RIDE CONTROL ONLY)
3. PILOT PRESSURE HOSE 6. SWITCH (XT WITH RIDE CONTROL ONLY)
4 SPOOL LINE REMOVAL AND INSTALLATION ILLUSTRATION
STEP9 STEP10
Disconnect the hoses from the remote control Install a plug in each hose and a cap on each fitting.
valve(s) at the loader control valve one at a time and
fasten an identification tag to each hose. Refer to the
illustration above.

8001-5
STEP 11 STEP12
BD01D376 BD01D381
1. VALVE RETURN HOSE 1. ROD ENDTILTTUBE

2. RIDE CONTROL TANK HOSE 2. HEAD END TILT TUBE
3. ACCUMULATOR DRAIN HOSE 3. HEAD END LIFT TUBE
4. PUMP LOAD SENSING HOSE 4. ROD END LIFT TUBE
5. STEERING LOAD SENSING HOSE
A. Tag and disconnect the rod end tilt tube (1)
6. STEERING PRESSURE HOSE
from the loader control valve and install a plug
7. PUMP PRESSURE HOSE (NOT SHOWN)
in the tube and a cap on the fitting.
A. Tag and disconnect the valve return hose (1)
at the loader control valve and install a plug in B. Tag and disconnect the head end tilt tube (2)
the hose and a cap on the fitting. from the loader control valve and install a plug
B. Tag and disconnect the pump pressure hose
(7) and install a plug in the hose and a cap on C. Tag and disconnect the head end lift tube (3)
the fitting. from the loader control valve and install a plug
NOTE: The pump pressure hose (7) will be
connected to a elbow at the bottom of the loader D. Tag and disconnect the rod end lift tube (4)
control valve. from the loader control valve and install a plug
C. Tag and disconnect the ride control tank hose
E. Tag and disconnect any auxiliary spool tubes
(2} and install a plug in the hose and a cap on
if equipped.
the fitting.
D. Tag and disconnect the accumulator drain STEP13
hose (3} and install a plug in the hose and a
cap on the fitting.
E. Tag and disconnect the pump load sensing
hose (4) and install a plug in the hose and a
cap on the fitting.
F. Tag and disconnect the steering load sensing
hose (5) and install a plug in the hose and a
cap on the fitting.
G. Tag and disconnect the steering pressure
hose (6} and install a plug in the hose and a
cap on the fitting.
BS01D190
Loosen and remove the three bolts and washers that
hold the loader control valve to the valve mounting
plate.
8001-6
STEP14 B. Connect the head end lift tube (3) to the

Use proper lifting device to lift and remove the loader loader control valve.
control valve. C. Connect the head end tilt tube (2) to the
loader control valve.
Installation D. Connect the rod end tilt tube (1) to the loader
control valve.
STEP15
STEP17
80010376
1. VALVE RETURN HOSE

2. RIDE CONTROL TANK HOSE
88010190
3. ACCUMULATOR DRAIN HOSE
A. Install and align the loader control valve with 4. PUMP LOAD SENSING HOSE
the valve mounting plate. 5. STEERING LOAD SENSING HOSE
6. STEERING PRESSURE HOSE
B. Install the bolts and washers that fasten the
7. PUMP PRESSURE HOSE (NOT SHOWN)
loader control valve to the valve mounting
plate. Tighten the bolts. A. Connect the steering pressure hose (6) to the
IMPORTANT: Before installing the fittings or
connecting the tubes to the fittings, install new B. Connect the steering load sensing hose (5) to
0-rings on the fittings. the loader control valve.
C. Connect the pump load sensing hose (4) to
STEP16 the loader control valve.
D. Connect the accumulator drain hose (3) to the
E. Connect the ride control tank hose (2) to the
loader control valve/
F. Connect the pump pressure hose (7) to the
bottom of the loader control valve.
G. Connect the valve return hose (1) to the
80010381
1. ROD END TILT TUBE

2. HEADENDTILTTUBE
3. HEAD END LIFT TUBE
4. ROD END LIFT TUBE
A. Connect the rod end lift tube (4) to the loader
control valve.

8001-7
YEllOW & WHITE
ORANGE & WHITE

YEllOW & BlACK
GREEN & WHITE
\
w
BS07H031
8. LOADER CONTROL VALVE 11. CHECKVALVE

9. PILOT ACCUMULATOR HOSE 12. SWITCH FITTING (XT WITH RIDE CONTROL ONLY)
10. PILOT PRESSURE HOSE 13. SWITCH (XT WITH RIDE CONTROL ONLY)
4 SPOOL LINE REMOVAL AND INSTALLATION ILLUSTRATION

8001-8
STEP18 STEP 22
Connect the lines from the remote control valve to Start the engine and run at half throttle.
the loader control valve. Refer to the above
illustration. STEP 23
Slowly and completely extend and retract all
STEP19 cylinders at least 10 times to remove any air from the
Fill the hydraulic reservoir with oil. Refer to Section circuits.
1002 for the correct oil.
STEP 24
STEP 20 Stop the engine and check for leaks.
position. STEP 25
Install the access cover on the front of the machine.
STEP 21
STEP 26
Check the level of the hydraulic oil and add hydraulic
oil as required.
BD03A092
Raise the loader arms and remove the safety link.

8001-9
REMOTE CONTROL VALVE
Removal STEP 32
STEP 27
parking brake.
Open and remove the access panel.
STEP 28
Place the master disconnect switch in the OFF STEP 33
position.
STEP 29
Unlatch and open the right hand side access door.
STEP 30
Lift the access door up and remove the access door
from the pins.
STEP 31
Remove the front access panel.
STEP 34
Unlatch and open the window on the right hand side.
BD06F210
Disconnect the electrical connectors for the remote

control valve.
STEP 35
Loosen the filler cap on the reservoir to release any
air in the reservoir. Connect a vacuum pump to the
hydraulic reservoir, turn on the pump.

8001-10
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install STEP 40
plugs in the hoses and caps on the fittings. Install new 0-rings on the adapters for the remote
control valve.
STEP 37
Loosen and remove the screws and washers holding STEP 41
the hydraulic control tower cover. Remove the cover. Install the remote control valve and screws in the
hydraulic control tower and tighten the screws.
STEP 38
Loosen and remove the screws that fasten the STEP 42
remote control valve to the hydraulic control tower. Install the cover over the remote control valve and
install the screws and washers.
STEP 39
Remove the remote control valve from the hydraulic STEP 43
control tower. Remove the plugs from the hoses and the caps from
the fittings and connect the hydraulic hoses to the
fittings according to the identification tags. (Refer to
illustrations on pages 12, 13, and 14 as necessary.
STEP 44
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.
STEP 45
Connect the electrical connectors for the remote

control valve.
STEP 46
position.
STEP 47
Start the engine and run the engine at low idle.
STEP 48
Check to see that the remote control valve works
correctly.

8001-11
STEP 49 STEP 52
Check for hydraulic oil leakage at the remote control
valve.
STEP 50
Check the level of hydraulic oil in the reservoir and
add as required.
STEP 51
BD06F208
Install and close the access panel.
STEP 53
Position the access panel on the ROPS cab or the

ROPS canopy and install and tighten the screw.
BD06F207
Close the right hand window.

8001-12
BS07D284
1. ORANGE BLACK 5. ORANGE WHITE 8. GREEN BLACK

2. YELLOW BLACK 6. YELLOW WHITE 9. RED BLACK
3. REDWHITE 7. PILOT PRESSURE HOSE 10. PILOT TANK HOSEL
4. GREEN WHITE
JOYSTICK AND 2 LEVER HOSE COLOR CODING

8001-13
BS07D283
1. YELLOW WHITE 1. YELLOW WHITE

2. PILOT PRESSURE HOSE 2. PILOT PRESSURE HOSE
3. RED BLACK 3. RED BLACK
4. PILOT TANK HOSE 4. PILOTTANKHOSE
5. ORANGE BLACK 5. ORANGE BLACK
6. YELLOW BLACK 6. YELLOW BLACK
7. GREEN BLACK 7. GREEN BLACK
8. REDWHITE 8. REDWHITE
JOYSTICK AND 1 LEVER HOSE COLOR CODING 3 LEVER HOSE COLOR CODING

8001-14
88070285
1. PILOT PRESSURE HOSE

2. RED BLACK
3. PILOT TANK HOSE
4. ORANGE BLACK
5. YELLOW BLACK
6. GREEN BLACK
JOYSTICK HOSE COLOR CODING

8001-15
HYDRAULIC PUMP
Removal STEP 58
STEP 54
parking brake.
STEP 55
position.
STEP 56
Drain the hydraulic reservoir then refer to Section
9007 and remove the ROPS cab or ROPS canopy.
Loosen and remove the bolts holding the bracket for
STEP 57 the hydraulic hoses. Slide the bracket up to gain
enough clearance for the hydraulic pump to be
removed.
BD01D303
1. BOLTS (4) 3. SUCTION HOSE

2. CASE DRAIN HOSE 4. HYDRAULIC PUMP
A. Loosen and remove the four bolts (1)
connecting the suction hose (3) to the
hydraulic pump (4).
B. Tag and disconnect the case drain hose (2)
from the top of the hydraulic pump (4).
C. Plug all lines and cap all fittings.

8001-16
STEP 59 STEP 61
BD01D308 BD01D307
1. BOLTS (4) 3. PRESSURE HOSE Loosen and remove the two bolts that fasten the
2. LOAD SENSING HOSE 4. HYDRAULIC PUMP hydraulic pump to the transmission.
A. Loosen and remove the four bolts (1)
connecting the pressure hose (3} to the STEP 62
hydraulic pump (4). Remove the hydraulic pump from the machine.
B. Tag and disconnect the load sensing hose (2}
from the hydraulic pump (4). STEP 63
C. Plug all lines and cap all fittings.
STEP 60
Remove and discard the 0-ring from the hydraulic

pump.
Use proper lifting device to strap and support the

hydraulic pump.

8001-17
STEP 64
BD010308
1. PRESSURE HOSE
2. HYDRAULIC PUMP
3. LOAD SENSING HOSE
Use proper lifting device to lift and support the
hydraulic pump. Install a new 0-ring on the hydraulic A. Install the pressure hose (1) to the hydraulic
pump. pump (2).
B. Install the load sensing hose (3) to the
STEP 65 hydraulic pump (2).
STEP 68
Install the hydraulic pump on the transmission.

BD010303
STEP 66 1. SUCTION HOSE
2. HYDRAULIC PUMP
3. CASE DRAIN HOSE
A. Install the suction hose (1) to the hydraulic
pump (2).
B. Install the case drain hose (3) to the hydraulic
pump (2).
BD01D307
Install the two bolts that fasten the hydraulic pump to
the transmission. Tighten the two bolts to a torque of
335 to 375 Nm (245 to 275 lb ft).

8001-18
STEP 69 STEP 72
position.
STEP 73
Start the engine and run the engine at low idle for two
minutes.
NOTE: If any unusual vibration is heard coming from
the pump, stop the machine immediately and check
for obstructions in the pump suction line.
STEP 74
Stop the engine and check for hydraulic oil leakage at
the hydraulic pump.
Install the bracket holding the hydraulic hoses.
Tighten the bolts.
STEP 75
Check the level of the hydraulic oil in the reservoir
STEP 70
and add hydraulic oil as required.
See Section 9007 for installing the ROPS cab or
ROPS canopy.
STEP 71
Fill the hydraulic reservoir with hydraulic oil. See
Section 1002 for correct oil type.

8001-19
LIFT CYLINDERS
Removal STEP 80
STEP 76
parking brake.
BD010709
STEP 77 Loosen and remove the bolt, washer and spacer that
Relieve the pressure in the ride control accumulator hold the pivot pin for the yoke.
with the manual bleeder valve located at the rear of
the front chassis. STEP 81
STEP 78
Loosen the filler cap on the hydraulic reservoir to
release any pressure.
STEP 79
BD01D711
Use a proper lifting device and secure a strap around
the lift cylinder.
STEP 82
Tag and disconnect the hoses on each side of the lift

cylinder. Install plugs in the hoses and caps on the
fittings.
BD010712
Remove the pivot pin from the yoke end of the lift
cylinder.

8001-20
STEP 86
Apply antiseize compound to the bores in the front
frame and the yoke on the piston rod.
STEP 87
BD01D710
Loosen and remove the bolt, washer and spacer that
hold the pivot pin at the closed end of the lift cylinder.
STEP 84
BD01D714
Use a proper lifting device and position the lift
cylinder on the machine.
STEP 88
BD01D713
Remove the pivot pin from the closed end of the lift
cylinder.
STEP 85
Remove the lift cylinder from the machine
BD01D713
Align the closed end of the lift cylinder with the front
frame and install the pivot pin.

8001-21
STEP 89 STEP 92
BD01D710 BD01D712
Align the pivot pin with the front frame and install the Install the pivot pin for the yoke. Stop the engine.
spacer, washer and bolt. Tighten the bolt.
STEP 93
STEP 90
BD01D709
Align the pivot pin with the yoke and install the
Remove the caps and plugs and connect the hoses spacer, washer and bolt. Tighten the bolt.
to the lift cylinder.
STEP 94
STEP 91 SLOWLY extend and retract the piston rod three
If the yoke of the lift cylinder is not aligned with the times to remove any air from the lift cylinders.
loader frame, have another person start and run the
engine at low idle and use the loader control lever to STEP 95
SLOWLY move the yoke into alignment with the Lubricate the pivot pins with molydisulfide grease.
loader frame.
STEP 96
Check the level of hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the

8001-22
BUCKET CYLINDER - Z-BAR LOADER
Removal STEP 101
STEP 97
parking brake.
STEP 98
With the engine stopped, move the bucket control
lever to release pressure in the bucket circuit.
STEP 99
Loosen and remove the two bolts that fasten the

mounting bracket to the machine. Remove the
mounting bracket.
STEP 102
BD01D694
Disconnect the proximity switch connector from the

wiring harness connector.
STEP 100

mounting bracket for the proximity switch to the
bucket cylinder. Remove the mounting bracket and
switch.
BD010696

target bar to the mounting bracket. Remove the
target bar.

8001-23
STEP 103 STEP 106
BD010701
Disconnect the hoses from each side of the bucket Remove the pivot pin from the rod end of the bucket
cylinder. Install plugs in the hoses and caps on the cylinder.
fittings.
STEP 107
STEP 104
BD010700 Remove the pivot pin from the head end of the bucket
Use acceptable equipment to hold the bucket cylinder.
cylinder.
NOTE: It is not necessary to remove the grease line
from the pivot pin unless the pivot pin is to be
STEP 105 replaced.
STEP 108
Loosen and remove the bolt, washer and spacer that

fasten the pivot pin from both ends of the bucket
BD010706
cylinder.
Raise the bucket cylinder and remove the cylinder
from the machine.

8001-24
STEP 109
Apply antisieze compound to the bores in the front
frame and the bores in the loader arm for the bucket
cylinder.
STEP 110
BD010699
Connect the hoses to each side of the bucket
cylinder.
STEP 114
If the rod end of the bucket cylinder is not aligned
with the bellcrank, have another person start the
BD010706 engine and run the engine at low idle and use the
Use acceptable lifting equipment to lower the bucket bucket control lever to SLOWLY move the piston rod
cylinder into position. eye into alignment with the bellcrank.
STEP 111 STEP 115

Install the pivot pin and stop the engine.
STEP 116
BD010704
Install the pivot pin to the head end of the bucket
cylinder.
BD010698
STEP 112 Install the spacer, washer and bolt that fasten the
Install the spacer, washer and bolt that fasten the pivot pin to the bellcrank. Tighten the bolt.
pivot pin to the front frame. Tighten the bolt.
NOTE: If a new pivot pin is being installed, connect
the grease line to the pivot pin.

8001-25
STEP 117 STEP 120
BD010694
Install the two bolts that fasten the mounting bracket Connect the proximity switch connector to the wiring
for the switch to the bucket cylinder. harness connector.
STEP 118 STEP 121

See Section 9006 for the adjustment procedure for
adjusting the proximity switch.
STEP 122
Start and run the engine at low idle.
STEP 123
SLOWLY extend and retract the piston rod three
times to remove any air from the bucket cylinder.
STEP 124
Lubricate the pivot pins with molydisulfide grease.
Install the two bolts for the mounting bracket for the STEP 125
target bar.
and add as required. Tighten the filler cap on the
STEP 119 hydraulic reservoir.
BD01D696
Install the two bolts that fasten the target bar to the
mounting bracket.

8001-26
BUCKET CYLINDERS - XT LOADER
Removal STEP 129

Disconnect the hoses from the elbows at both ports
STEP 126 of the bucket cylinders. Install a plug in the tube and
Lower the bucket to the floor. With the engine a cap on the elbow.
stopped, move the bucket control lever to release any
pressure in the bucket circuit. STEP 130
Remove the roll pin (1) from the yoke (2). Remove
NOTE: The following two steps apply only to the left
the pivot pin (3). Refer to the illustration on page 28.
hand bucket cylinder.
STEP 131
STEP 127
Loosen and remove the nuts (4) and washers (5) at
the top and bottom of the cylinder bellcrank.
STEP 132
Remove the inner bellcrank (6) from the pivot pins
(7).
STEP 133
Remove the nut (8) and the grease line (9) from the
bucket cylinder (1 0).
STEP 134
Fasten acceptable lifting equipment to the bucket
cylinder (1 0) and remove the bucket cylinder (1 0)
1. BUCKET CYLINDER (LEFT HAND SIDE)
2. PROXIMITY SWITCH MOUNTING BRACKET
from the machine.
3. TARGET MOUNTING BRACKET
4. PROXIMITY SWITCH GUARD
5. PROXIMITY SWITCH
6. TARGET BAR
Disconnect the Return-to-Dig proximity switch (5)

and remove with the mounting bracket (2) as an
assembly.
STEP 128
Remove the Return-to Dig target bar (6) with the
mounting bracket (3) from the yoke of the bucket
cylinder (1 ).

8001-27
BS01C085
1. ROLL PIN 6. INNER BELLCRANK

2. YOKE 7. PIVOT PIN
3. PIVOT PIN 8. NUT
4. NUT 9. GREASE LINE
5. WASHER 10. BUCKET CYLINDER
XT LOADER BUCKET CYLINDER REMOVAL AND INSTALLATION ILLUSTRATION

8001-28

Install the Return-to Dig target bar and proximity
STEP 135 switch assembly. Connect the proximity switch
Use acceptable lifting equipment to install the bucket connector to the wiring harness connector. This step
cylinder (1 0} closed end on the pivot pins (7). applies only to the left hand bucket cylinder.
STEP 136 STEP 142

Install the grease line (9} and the nut (8} on the Remove the plugs and caps and connect the hoses
bucket cylinder (1 0}. to the elbows at the cylinder ports.
STEP 137 STEP 143

Install the inner bellcrank (6) on the pivot pins (7). Start the engine and run the engine at low idle.
STEP 138 STEP 144

Install the washers (5) and nuts (4) on the retaining SLOWLY, extend and retract the piston rod three
bolts. Tighten the nuts (4). times to remove any air from the bucket cylinder (1 0).
STEP 139 STEP 145

Align and install the pivot pin (3} in the yoke (2}. Lubricate the pivot pins with molydisulfide grease.
STEP 140 STEP 146

Install the roll pin (1) in the yoke (2) and pivot pin (3). Check the level of the hydraulic oil in the hydraulic
reservoir and add as required. See Section 1002 for
the correct hydraulic oil.

8001-29
OIL COOLER
Removal STEP 152
STEP 147
bucket to the ground. Stop the engine and apply the
parking brake.
STEP 148
position.
STEP 149
Raise the engine hood and remove the shield on the
right side of the machine between the tire and the oil BD03A154
cooler. Disconnect the top hose and install a plug in the hose
and a cap on the fitting.
STEP 150
STEP 153
Have assistant hold side panel in raised position,

remove two mounting screws, remove side panel. BD03A179
Loosen and remove the bolt and washer that fasten

STEP 151 the oil cooler to the cooling frame.
release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.
STEP 154 BD03A217
Raise oil cooler and disconnect the hose from the

bottom of the oil cooler. Install a plug in the hose and
a cap on the fitting. Remove oil cooler from the
machine.

8001-30
STEP 155
Have assistant hold side panel in raised position,

install and tighten two mounting screws.
Place the oil cooler in position in the cooling frame. STEP 159
Connect the lower hose to the oil cooler. Turn off the vacuum pump and disconnect from the
NOTE: Make sure that the oil cooler slides into
retaining bracket on frame.
STEP 160
STEP 156 Place the master disconnect switch in the ON
position.
STEP 161
minutes. Stop the engine and check for hydraulic oil
leakage at the ports on the oil cooler.
STEP 162
Install the shield between the right rear tire and the
oil cooler and tighten the two bolts holding the shield.
STEP 163
BD03A179
Install the bolt and washer that fasten the oil cooler to and add hydraulic oil as required.
the cooling frame
STEP 157
BD03A154
Connect the hose to the top of the oil cooler.

8001-31
RIDE CONTROL ACCUMULATOR
Removal STEP 167
STEP 164
parking brake.
BD03A196
STEP 165 Disconnect the hose from the elbow at the bottom of
the ride control accumulator. Install a plug in the hose
and a cap on the fitting.
STEP 168

Loosen and remove the nuts and washers from the
U-bolt. Remove the U-bolt.
STEP 166
STEP 169
pump.

accumulator bracket to the front frame. Remove the
ride control accumulator from the machine.
8001-32
STEP 170
Place the ride control accumulator in position on the
front frame.
STEP 171
BD03A196
Remove the caps and plugs and install the hose on

the elbow at the bottom of the ride control
accumulator.
STEP 174
BD03A196
Turn off and disconnect the vacuum pump from the
Install the two bolts that fasten the accumulator hydraulic reservoir.
bracket to the front frame. Tighten the bolts.
STEP 175
STEP 172 Tighten the accumulator manual bleeder valve
located on the top of the ride control valve to a torque
of 3.5 Nm (31 lb-in). Install the plug and torque to
7 Nm (62 lb-in).
STEP 176
Refer to Section 8002 Testing the Ride Control for
the proper charging of the accumulator to check for
leaks.
STEP 177
BD03A195
Install the U-bolt, washers and nuts. Tighten the nuts.

8001-33
RIDE CONTROL VALVE
Removal STEP 180

STEP 178 release the air pressure in the reservoir. Connect a
Park the machine on a level surface and lower the vacuum pump to the hydraulic reservoir, turn on the
bucket to the floor. Stop the engine and apply the pump.
parking brake.
STEP 181
position.
loader control valve back and forth several times to STEP 182
release any hydraulic pressure in the pilot control Disconnect the electrical connector on top of the ride
circuit, turn ignition switch OFF. control valve.
STEP 179 STEP 183

Tag and disconnect the hoses from the ride control
valve. Install a plug in the hoses and caps on fittings.
STEP 184
Loosen and remove the two bolts and washers that
fasten the ride control valve to the frame.
STEP 185
Remove the ride control valve from the machine.
STEP 186
Remove and discard all 0-rings.


8001-34

Connect the electrical connector to the ride control
STEP 187 valve.
Install the ride control valve in position on the front
frame. STEP 193
STEP 188 hydraulic reservoir.
Install the washers and bolts through the frame and
into the ride control valve. Tighten the bolts. STEP 194
STEP 189 position.
STEP 195
Start and run the engine at low idle for two minutes.
STEP 196
the ride control valve.
STEP 197
BD06F213
Tighten the accumulator manual bleeder valve STEP 198

located on the top of the ride control valve to a torque Refer to Section 8002 and perform the Ride Control
of 3.5 Nm (31 lb-in). Install the plug and torque to Test Procedure.
7 Nm (62 lb-in).
STEP 190
Lubricate and install new 0-rings.
STEP 191
Connect the hoses to the ride control valve.

8001-35
FAN REVERSING VALVE
Removal STEP 202
STEP 199
parking brake.
BD03A174
STEP 200 Tag and disconnect the fan forward hose (1) from the
Loosen the filler cap on the hydraulic reservoir to fan reversing valve. Install a plug in the hose and a
release the air pressure in the reservoir. Connect a cap on the fitting. Tag and disconnect the fan reverse
vacuum pump to the hydraulic reservoir, turn on the hose (2} from the fan reversing valve. Install a plug in
pump. the hose and a cap on the fitting.
STEP 201 STEP 203
BD03A173
BD03A174
Tag and disconnect the fan valve return hose (3) from
Disconnect the electrical connector for the fan the fan reversing valve. Install a plug in the hose and
reversing valve. a cap on the fitting. Tag and disconnect the fan valve
supply hose (4) from the fan reversing valve. Install a
plug in the hose and a cap on the fitting.
STEP 204
Loosen and remove the nuts, washers and bolts.
STEP 205
Remove the fan reversing valve from the machine.
STEP 206
Remove and discard all 0-rings from the fittings.

8001-36
STEP 207
Place the fan reversing valve into position on the
machine.
STEP 208
Lubricate and install new 0-rings in the fittings.
STEP 209
Install the bolts, washers and nuts. Tighten the nuts.
STEP 210
Connect the electrical connector for the fan reversing
valve.
STEP 213
STEP 214
Check the level of the hydraulic oil in the reservoir.
STEP 215
BD03A173
Connect the fan valve supply hose (4) to the fitting on Start the engine and run the engine at low idle for two
the fan reversing valve. Connect the fan valve return minutes.
hose (3) to the elbow on the fan reversing valve.
STEP 216
STEP 211 Stop the engine and check for hydraulic oil leakage at
the fan reversing valve.
STEP 217
reservoir.
Connect the fan reverse hose (2) to the fitting on the

fan reversing valve. Connect the fan forward hose (1)
to the fitting on the fan reversing valve.

8001-37
THERMAL VALVE
STEP 218 STEP 222
Park the machine on a level surface and lower the Place the thermal valve into position on the machine.
parking brake. STEP 223
IMPORTANT: With the engine NOT running, pump Lubricate and install new 0-rings in the fittings.
accumulators have no hydraulic pressure, put the STEP 224
ignition switch in the ON position then move the Install the bolts, washers and nuts. Tighten the nuts.
release any hydraulic pressure in the pilot control STEP 225
Connect the hoses to the thermal valve, remove and
discard tags.
STEP 219
Loosen the filler cap on the hydraulic reservoir to STEP 226
pump.
STEP 227
STEP 220
Check the level of the hydraulic oil in the reservoir.
STEP 228
minutes.
STEP 229
the thermal valve.
STEP 230
Tag and disconnect the hoses from the thermal valve. and add as required. Tighten the filler cap on the
Install a plug in the hose and a cap on the fitting. reservoir.
STEP 221
Remove the mounting bolts from the thermal valve,
remove the valve from the machine.

8001-38

Section
8002
HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING,

AND PRESSURE CHECKS

8002-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................... 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in all Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in all Loader Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in the Braking Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in a Single Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TESTING AND ADJUSTING THE PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTING AND ADJUSTING THE MAIN RELIEF VALVE.......................................... 10
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TESTING THE PILOT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES...................................... 13
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TESTING THE RIDE CONTROL ............................................................. 14
HYDRAULIC COMPONENT LOCATIONS ..................................................... 15
HYDRAULIC COMPONENT LOCATIONS ..................................................... 16

8002-3
SPECIFICATIONS
Pump Output ...............................................................................................170 to 178 Umin at 2000 rpm at 248 bar
(45 to 47 gpm at 2000 rpm at 3600 psi)
Main relief valve pressure settings ...................................................................... 248 and 255 bar (3596 to 3700 psi)
Differential pressure ........................................................................................................22 to 25 bar (320 to 360 psi)
Pilot pressure ..................................................................................................................29 to 40 bar (420 to 580 psi)
Circuit relief valve pressure setting
Auxiliary A and B port (XT and Z Bar) ........................................................................................290 bar (4206 psi)
Bucket A and B port (Z Bar) .......................................................................................................290 bar (4206 psi)
Bucket A port (XT) ...................................................................................................................... 183 bar (2654 psi)
Bucket B port (XT) ......................................................................................................................290 bar (4206 psi)
Steering relief valve pressure setting .............................................................................................. See Section 5002
Accumulator pressure ..................................................................................................................... See Section 7002

8002-4
SPECIAL TOOLS
633L95 8877168V
CAS1904 PRESSURE FITTING KIT CAS1808 FLOWMETER FITIING KIT
632L95 8877895M
CAS1906 PRESSURE FITTING KIT CAS10090 HAND PUMP
8785789M
CAS1 0280 FLOWMETER CAS1804 PRESSURE FITTING KIT

8002-5
TROUBLESHOOTING PROCEDURE
Visually check the machine for oil leakage and

damaged or missing parts. Repair or replace
any damaged or missing parts.
Check the oil level in the hydraulic reservoir. Is Fill the hydraulic reservoir with the hydraulic oil
____.. No
the oil level correct?. specified in Section 1002.
Yes t
Heat the oil in the hydraulic system to
operating temperature. Operate the
machine to find which circuits have
problems.
Problem in all Circuits

Replace the return line hydraulic filter.
See Section 2002. Do the stall test to see if
the engine is good.
See page 7. Test and adjust pump

differential pressure then proceed to Page 7
See Section 8003 and check for contaminated ____.. No and do the flowmeter tests of the hydraulic
oil. Is the oil contaminated? pump. See page 12 and test the pilot
pressure.
Yes t
See Section 8003 and clean or replace the
oil.
Problem in all Loader Circuits

See Page 10 and check the pressure setting
Adjust the main relief valve. See page 10 in
of the main relief valve in the loader control ----.. No
this section.
valve. Is the pressure setting correct?
Problem in the Braking Circuit

See Section 7002 and check the braking
circuit.

8002-6
Problem in a Single Loader Circuit

Start and run the engine at full throttle. The loader control valve is damaged. See
Operate the control for the bad circuit. Does ----.. No Section 8005 and repair the loader control
the cylinder move in both directions? valve
Yes
Check the cylinder piston packing. Is the ____.. No See Section 8006 and repair the cylinder.
packing good?
Yes t
See Page 13. Check and adjust the circuit See Section 8005. Disassemble the loader
relief valves. Then check the operation of ____.. No control valve and check for worn or
the circuit again. Does the circuit work damaged parts.
correctly?
Yes t
The problem is repaired.
Problem in the Steering Circuit

See Section 5002 and check the steering
____.. No Repair the component as necessary.
circuit. Is the steering circuit good?
Yes t
See Page 7. Do the Primary Pump Output
Test.
Problem in the Ride Control

Lift arms rapidly and continuously sink See the ride control Test Procedure page 14
____.. No
towards the ground. in this section.
Yes t
Check the manual bleed valve for the ride
control accumulator to be sure that it is
closed.

8002-7
TESTING AND ADJUSTING THE PUMP DIFFERENTIAL PRESSURE

NOTE: The Pump Differential Pressure must be set before attempting any other tests.
Pressure Check STEP3
STEP 1
Make sure that the temperature of the hydraulic oil is
at least 52°C to 60°C (125°F to 140°F). The following
is the procedure for heating the hydraulic oil.
A. Apply the parking brake.
B. Start the engine.
C. To measure the oil temperature with the
instrument cluster:
• Press the up or down arrow key.
• Stop at the info screen with the temperatures
that need to be monitored are on. BDOOM041
1. COVER PLATE
D. Run engine at full throttle.
E. Hold the bucket control lever in the Remove the cover plate to gain access to the loader
ROLLBACK position while raising and control valve.
lowering the lift arms from ground level to full
height.
F. Continue this procedure until the temperature
of the hydraulic oil is 54° to src (129° to
134°F).
STEP2
BD03A092
1. SAFETY LINK
Raise the loader arms and install the safety link (1 ).

8002-8
STEP4 STEPS
Subtract the reading of the test port (1) from the
reading of the test port (3).
STEP9
The difference between the two readings should be
22 to 25 bar (320 to 360 psi).
STEP10
If this reading is more or less than that specified, it
will be necessary to adjust the pump.
Adjusting the Main Hydraulic

Pump
STEP 11
BDOON017
BD07H002
1. TEST PORT (LOAD SENSE)
2. TEST PORT (PILOT PRESSURE)
The delta pressure adjusting screw is the farthest
3. TEST PORT (PUMP PRESSURE) from the pump. Turn the screw clockwise to increase
the differential pressure. Turning the screw
counterclockwise will decrease the differential
Connect two 69 bar (1 000 psi) test gauges to the test
pressure.
ports (1) and (3) located on the loader control valve.
NOTE: One turn of the adjustment screw will change
STEPS the pressure approximately 16 bar (230 psi).
Start the engine and run at low idle.
STEP6
Make sure all of the controls are in the neutral
position and record the readings on the test gauges
(1) and (3}.
STEP7
The pressure on test port (1) should read
approximately 29 bar (420 psi). The pressure on test
port (3) should read approximately 51 bar (740 psi).
NOTE: These readings may vary from one machine
to another. The important value is the difference
between the readings of gauges 1 and 3.

8002-9
-~ \ ::
f
n·
\ .. 11
.r
J~ .-~
~~-
10
BC06C158
1. CAP 1-7/16-12 ORFS 7. FILTER INLET MANIFOLD

2. LOADER CONTROL VALVE 8. INLINE NEEDLE VALVE
3. FLOWMETER INLET HOSE 9. UNION
4. LOADER CONTROL VALVE INLET HOSE 1-7/16-12 ORFS 10. 'T' FITTING
5. CAS10280 FLOWMETER 11. LOAD SENSE HOSE 9/16 X 18 ORFS
6. FLOWMETER OUTLET HOSE 12. CAP 9/16 X 18 ORFS
NOTE: If unit is equipped with auxiliary steering a tee fitting will have to be used in this location.

8002-10
TESTING AND ADJUSTING THE MAIN RELIEF VALVE

NOTE: The Pump Differential Pressure must be set before attempting any other tests. Refer to page 7 of this
section.
STEP 1
BDOOM041
Remove the cover plate to gain access to the loader

BDOOM030
control valve.
1. ARTICULATION LOCK
STEP4
Install the articulation lock (1 ).
STEP2
BDOON017

2. TEST PORT
BD03A092
1. SAFETY LINK
Stop the engine and install a 345 bar (5000 psi)
pressure gauge to the test port (2) on the front of the
Raise the loader arms and install the safety link (1 ).
loader control valve (1 ).

8002-11
STEPS Adjustment
Make sure that the temperature of the hydraulic oil is
at least 52°C to 60°C (125°F to 140°F). The following
is the procedure for heating the hydraulic oil. STEP 10
A. Apply the parking brake.
B. Start the engine.
instrument cluster:
• Press the up or down arrow key.
that need to be monitored are on.
D. Run engine at full throttle.
E. Hold the bucket control lever in the
ROLLBACK position while raising and
lowering the lift arms from ground level to full
height.
of the hydraulic oil is 54° to 5rC (129° to
134°F).
STEPS
Start the engine and remove the safety link (refer to
step 2) and lower the loader arms to the ground.
STEP7 BS01A046
Operate the machine at full throttle. Tilt the bucket to 1. LOADER CONTROL VALVE
a full rollback position and hold while observing the 2. RELIEF VALVE ADJUSTMENT
pressure gauge.
With the engine running and the loader on the
ground, loosen the jam nut and turn the adjustment
STEPS screw (2) clockwise for higher pressure or
The pressure should read between 248 and 255 bar counterclockwise for lower pressure.
(3596 to 3700 psi).
NOTE: 1/4 turn of the adjusting screw changes the
STEP9 pressure setting approximately 35 bar (500 psi).
If the pressure is not within the specifications, it will
be necessary to adjust the main relief valve.
STEP 11
Repeat the Pressure Check Procedure.
STEP12
If the pressure is not within the specifications, repeat
steps 10 and 11 until pressure is within the required
range.
STEP13
Stop the engine before removing the pressure
gauge.

8002-12
TESTING THE PILOT PRESSURE

STEP 1 STEP3
Make sure that the temperature of the hydraulic oil is Start and run the engine at low idle, roll the bucket
at least 52°C to 60°C (125°F to 140°F). The following back against the stops and hold.
is the procedure for heating the hydraulic oil.
A. Apply the parking brake. STEP4
B. Start the engine. A pressure reading of 29 to 40 bar (420 to 580 psi)
should be obtained.
instrument cluster: STEPS
• Press the up or down arrow key. If pressure is not as specified, replace the pressure
reducing valve, refer to section 8005.
that need to be monitored are on.
STEPS
D. Run engine at full throttle. If pressure is correct, raise lift arms to the top and
E. Hold the bucket control lever in the turn off the engine. Turn the ignition switch to the
ROLLBACK position while raising and "RUN" position and disengage the controller lockout
lowering the lift arms from ground level to full switch.
height.
STEP7
of the hydraulic oil is 54° to 5rC (129° to Wait for the buzzer to stop then repeatedly put the
134°F). loader control lever into "FLOAT" position and back
to neutral.
STEP2
STEPS
The system should allow a minimum of 10 actuations
into float and still cause the lift arms to come down.
NOTE: If 10 full actuations cannot be made, an
internal hydraulic leak exists.
BDOON020
Stop the engine and connect a 69 bar (1 000 psi) test

gauge to the pilot pressure test port located on the
NOTE: This can be accessed through the articulated
joint area, use articulation joint lock before
connecting gauge in this manner.

8002-13
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES

Connect the hand pump to the disconnected line that
STEP 1 goes to the loader control valve.
Circuit relief valves are located as shown below.
STEP4
Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21 oc (70°F).
STEPS
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
be sure of the reading.
STEPS
Compare the reading to the specifications on Page 3.
STEP7
If the pressure is not correct, adjust the circuit relief
valve.
Adjustment
STEP 1
Loosen the lock nut. Turn the adjustment screw
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
BS01A046
1. CIRCUIT RELIEF VALVE STEP2

2. MAIN RELIEF VALVE Check the pressure again. Repeat the adjustment as
3. BUCKET SPOOL
necessary.
4. LIFT SPOOL
5. AUXILIARY SPOOL
Remove the cover at the front of the machine.
STEP2
Lower the bucket to the floor. Shut off the engine.
Find an easy place to disconnect the line for the
circuit to be tested.

8002-14
TESTING THE RIDE CONTROL

STEP 1 STEPS
Move the machine to a clear level surface with Dump the bucket until it hits the dump stops. Hold the
clearance for full lift arm and bucket movement. bucket in the dump position for 5 to 10 seconds.
NOTE: This will charge the ride control accumulator.
STEP2
Install the articulation lock, start the machine, STEP7
activate the parking brake.
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
STEP3 their stops, place the pilot control lever in the neutral
With the pilot controller in neutral, set the ride control position.
rocker switch on the right side console to the "Always
On" position and observe the switch lamp, the lamp STEPS
should illuminate.
Set the ride control rocker switch to the "Always On"
position. The lift arms should rise 15 to 30 em (6 to
STEP4 12 inches) with an empty bucket.
Set the ride control rocker switch to the "Off" position
and observe the switch lamp, the lamp should go out. NOTE: Test results will be for a machine with a
empty factory bucket and no attachments.
NOTE: This indicates that the switch is operating
correctly and has power, if the switch does not STEP9
illuminate see section 4002 and troubleshoot the
If there is little or no lift arm raise, the test may have
electrical system for the ride control.
been done too slowly. The elapsed time between
step 6 and step 8 should not exceed six seconds.
STEPS
Raise the lift arms to the top of their travel and dump NOTE: If test was done too slowly, repeat in the
the bucket. allotted time.
NOTE: Keep rocker switch in the "Off" position STEP10

during steps 5, 6, 7.
If test was completed in the allotted time and the lift
arms still do not rise, test the nitrogen charge in the
accumulator.

8002-15
HYDRAULIC COMPONENT LOCATIONS
I
,,.""*""'- .................
,..,.,---......... ............ ' ' ,.."" ,' ...··~
,' .... ~~ ....
,' ..../"' ,'\ I
,' ...::' , ...... ' ' : : ,

' '
"", : ' ...
,"' I 1,'
...
I
I
1
,'
I I
!: .~
,....,... ,
',', '
,'
...
~·"'''
1"-.,
.
,''
...................
",,',-w,' _,', ' , ,

. . . . '' , ...
I
,'::
til
1 I
',',
................................ '
) I
,' '
'.,.'
'
,,"""'-,....._..,
'
. ''
,
1 I 1 I ·''' ,··:~:-:::,_
\ : : II II ,- ,-_;,I
\ ,."'1 I I ,,'' , , ' , . '...'::::'... ::..._"::!-
';,"'' II :: ,'', , ... " ' , , ' ',!~
f...... ;: ,' .........................;. . ,' ,('-... \
\ ', '..,'.._.... , 1 I I 'J' ,, ,' \ '
\ ' ',' 1 I
''..:_!_.,, . . . , I
I
1I ,'1'1 ._, , \
I
\
\
.._. I I I ' \ I
,' /,' ,' II I I
I II I I I I
1 II 1\ , I I ,'
I ,,,'l,..,_ :~ i ,, ,:' ,/ /
}'' \', I ' \ .,' ' I
...........~_,,,' ', '.J...\ ...,......
........
.......
\
\
.... __ ...... , '~'' ,' r
.... ~.... ... __ ...... ,,'
BCOON140
1. RIDE CONTROL VALVE (OPTIONAL) 11. STEERING PRESSURE DIAGNOSTIC COUPLER
2. RIDE CONTROL ACCUMULATOR 12. BRAKE ACCUMULATORS
3. RIDE CONTROL ACCUMULATOR BLEEDER VALVE 13. BRAKE AND ACCUMULATOR CHARGING VALVE
4. LIFT CYLINDERS 14. BRAKE WARNING PRESSURE SWITCH
5. BUCKET CYLINDER (TILT CYLINDER) 15. BRAKE LIGHT PRESSURE SWITCH
6. STEERING CONTROL VALVE 16. BRAKE ACCUMULATOR PRESSURE DIAGNOSTIC COUPLER
7. STEERING CYLINDERS 17. REAR BRAKE CYLINDERS
8. AUXILIARY STEERING PUMP AND MOTOR (OPTION - 18. FRONT BRAKE CYLINDERS
NORTH AMERICAN MODELS) 19. PARKING BRAKE CYLINDER
9. AUXILIARY STEERING PRIORITY VALVE (OPTION- 20. FRONT AND REAR AXLE BRAKE PRESSURE DIAGNOSTIC
NORTH AMERICAN MODELS) COUPLERS
10. AUXILIARY STEERING PRESSURE SWITCH
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.

8002-16
HYDRAULIC COMPONENT LOCATIONS
40
\
\
'
BCOON140
21. FAN DRIVE MOTOR 32. PILOT PRESSURE ACCUMULATOR

22. FAN REVERSING VALVE (OPTIONAL) 33. PILOT PRESSURE DIAGNOSTIC COUPLER
23. FAN VALVE (STANDARD) 34. FLOAT SWITCH
24. BRAKE HYDRAULIC PUMP 35. CONTROLLER
25. COUPLER LOCKING VALVE 36. LOADER CONTROL VALVE
26. COUPLER LOCKING CYLINDERS 37. PUMP PRESSURE DIAGNOSTIC COUPLER
27. IMPLEMENT HYDRAULIC PUMP 38. LOAD SENSING DIAGNOSTIC COUPLER
28. HYDRAULIC FILTER 39. BRAKE PRESSURE SWITCH (2)
29. HYDRAULIC RESERVOIR 40. AUXILIARY STEERING LOAD SENSE SOLENOID VALVE (OPTIONAL)
30. HYDRAULIC RESERVOIR BREATHER 41. PARKING BRAKE ACCUMULATOR
31. HYDRAULIC COOLER 42. PARKING BRAKE ACCUMULATOR DIAGNOSTIC COUPLER
NOTE: The hydraulic schematic is located in the rear pocket. All numbers are coordinated with the hydraulic
schematic for reference.

Section
8003
CLEANING THE HYDRAULIC SYSTEM

Racine, WI 53404 U.S.A. Bur 7-49641 Issued April, 2003 Revised August, 2006
8003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TYPES OF CONTAMINATION ............................................................... 4
CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

8003-3
SPECIAL TOOLS
CAS1 0508, fitting kit.
806127
CAS1 01162A, filter unit, portable.
CAS10192, vacuum pump.

8003-4
GENERAL INFORMATION
Contamination in the hydraulic system is a major 1. Cylinder rod seals leak.
cause of the malfunction of hydraulic components.
2. Control valve spools do not return to neutral.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in 3. Movement of control valve spools is difficult.
several ways.
4. Hydraulic oil becomes too hot.
1. When you drain the oil or disconnect any line.
5. Pump gears, housing, and other parts wear
2. When you disassemble a component. rapidly.
3. From normal wear of the hydraulic components. 6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals. 7. Quick failure of components that have been
repaired.
5. From a damaged component in the hydraulic
system. 8. Cycle times are slow; machine does not have
enough power.
All hydraulic systems operate with some
contamination. The design of the components in this If your machine has any of these problems, check the
hydraulic system permits efficient operation with a hydraulic oil for contamination. See types of
small amount of contamination. An increase in this contamination below. If you find contamination, use
amount of contamination can cause problems in the the Portable Filter to clean the hydraulic system.
hydraulic system. The following list includes some of
these problems.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic 3. Visible contamination is foreign material that can
and visible. be found by sight, touch, or odor. Visible
contamination can cause a sudden failure of
1. Microscopic contamination occurs when very fine
components. Examples of visible contamination:
particles of foreign material are in suspension in
the hydraulic oil. A. Particles of metal or dirt in the oil.
2. These particles are too small to see or feel. B. Air in the oil
Microscopic contamination can be found by
C. The oil is dark and thick.
identification of the following problems or by
testing in a laboratory. Examples of the D. The oil has an odor of burned oil.
problems:
E. Water in the oil. See page 7.
A. Cylinder rod seal leak.
B. Control valve spools do not return to
NEUTRAL.
C. The hydraulic system has a high operating
temperature.

8003-5
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter on page 3 by doing the 8. Using the fitting kit shown on page 3, install the
following steps: valve in the hole for the drain plug. Make sure
that the valve is closed.
A. Remove all the hydraulic oil from the inlet and
outlet hoses for the portable filter. 9. Stop the vacuum pump.
B. Remove the filter element from the portable 10. Connect the inlet hose for the portable filter to
filter. the valve that is installed in the hole for the drain
plug.
C. Remove all hydraulic oil from the portable
filter. 11. Disconnect the vacuum pump from the hydraulic
reservoir air breather hose. Remove the filler
D. Clean the inside of the housing for the filter
cap.
element.
12. Install the outlet hose for the portable filter in the
2. You must know whether the contamination is
hydraulic reservoir filler neck.
microscopic or visible. See types of
contamination on page 4. 13. Open the valve that is installed in the hole for the
drain plug.
3. If the contamination is microscopic:
14. Move the switch for the portable filter to the ON
A. Check the maintenance schedule for the
position. Start and run the engine at 1500 rpm
machine to learn if the hydraulic oil must be
(r/min).
changed. If needed, change the hydraulic oil.
See Section 1002 for specifications. Change 15. Run the portable filter for 10 minutes.
the hydraulic filter.
16. Continue to run the portable filter. Increase the
B. Do steps 6 through 35. engine speed to full throttle. Heat the oil to
operating temperature by doing the following
4. If the contamination is visible:
steps:
A. Change the hydraulic oil and hydraulic filter. A. Hold the blade control lever in the TILT
See Section 1002 for specifications. position for five seconds.
B. Do steps 5 through 35. B. Return the blade control lever in the
5. Check the amount of contamination in the NEUTRAL position for five seconds.
hydraulic system by doing the following steps: C. Repeat steps A and B until the oil in the
hydraulic system is at operating temperature.
A. Disassemble one cylinder in two different
circuits. Check for damage to seals, scoring of 17. Continue to run the engine at full throttle.
the cylinder wall, etc. Repair the cylinders as Continue to run the portable filter.
necessary.
18. Operate each hydraulic circuit to completely
B. If, in your judgment, the damage to the extend and retract the cylinders. Continue to
cylinders was caused by sever contamination operate each hydraulic circuit two times, one
and is not the result of normal wear, it is after the other for 45 minutes.
necessary to remove, clean and repair valves,
pump, lines, cylinders, hydraulic reservoir, etc.
in the hydraulic system. 20. Continue to run the portable filter for 10 minutes.
6. Remove the breather from the reservoir and 21. Stop the portable filter.
connect the vacuum pump to the opening. Start
the vacuum pump.
23. Remove the hose from the hydraulic reservoir.
7. Loosen and remove the drain plug from the
reservoir.

8003-6
24. Close the valve that is installed in the hole for the 30. Stop the vacuum pump. Disconnect the vacuum
drain plug. pump from the opening in the reservoir and
install the breather.
25. Disconnect the inlet hose for the portable filter
from the valve. Remove the outlet hose from the 31. Remove the hydraulic filter elements from the
reservoir filler neck and replace filler cap. machine.
26. Connect a vacuum pump to the breather hose of 32. Install new hydraulic filter elements on the
the hydraulic reservoir. machine.
27. Start the vacuum pump. 33. Start the engine. Check for oil leakage around
the new hydraulic filters.
28. Remove the valve from the hole for the drain
plug. 34. Stop the engine.
29. Install the drain plug. 35. Check the oil level in the hydraulic reservoir. Add
oil as required. See Section 1002 for
specifications.

8003-7
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/min). 13. Slowly move each control lever in both directions
until oil begins to flow from the open line. Hold
2. Completely retract the cylinders of all
the control lever in place until clean oil flows from
attachments on the machine. Angle the blade to
the open line.
the right, the right cylinder will be fully retracted
and the left will be fully extended. Stop the 14. Stop the engine.
engine.
15. Connect the system line to the CLOSED end of
each cylinder.
~ARNING: If retracting the cylinder rods
h causes the attachments to be raised, block 16. Connect a suitable drain line to the OPEN end of
. . . the attachments in place before proceeding each cylinder and place the other end in an
to the next step! acceptable container for contaminated oil.
39·4
NOTE: Any attachment or part of an attachment that 18. Slowly and completely extend all cylinders. As
is raised must be supported with acceptable the piston rod comes in/out of the cylinder, oil will
equipment to prevent the attachment from falling. be pushed out of the OPEN end of the cylinders.
3. Move each control lever in both directions to NOTE: Any attachment or part of an attachment that
release pressure in the hydraulic circuits. is raised must be supported with acceptable
4. Loosen and remove the filler cap from the equipment to prevent the attachment from falling.
reservoir. 19. Support any attachments that will be in the
5. Drain the hydraulic oil from the reservoir. RAISED position.
A. See Section 1002 for capacity specifications. 20. Stop the engine.
B. Have available acceptable equipment to drain 21. Disconnect the drain lines and connect the
the hydraulic oil. system lines to the cylinders.
C. Remove the drain plug from the bottom of the 22. Check the oil level in the hydraulic reservoir. Add
reservoir. oil as required. See Section 1002 for
specifications.
6. Remove the hydraulic filter elements from the
machine. 23. Install the filler cap on the reservoir.
7. Install new hydraulic filter elements on the 24. Remove the hydraulic filter elements from the
machine. machine.
8. Install the drain plug in the bottom of the 25. Install new hydraulic filter elements on the
reservoir. machine.
9. Fill the hydraulic reservoir with hydraulic fluid. 26. Start and run the engine at 1500 rpm (r/min),
See Section 1002 for specifications. operate each hydraulic circuit to completely
extend and retract the cylinders.
10. Disconnect the line from the OPEN end and
CLOSED end of each cylinder. 27. Stop the engine and check for leaks. Check the
oil level in the hydraulic reservoir. Add oil as
11. Be sure all control levers are in the NEUTRAL required. See Section 1002 for specifications.
position.
12. Start and run the engine at low idle.
IMPORTANT: Check the oil level in the hydraulic
reservoir frequently while doing step 13. Have
another person hold a container under the hydraulic
lines while you do step 13.

8003-8
NOTES

Section
8004
HYDRAULIC PUMP

8004-2
TABLE OF CONTENTS
PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . ...... ...... .................... .............. 3
PREPARING THE EQUIPMENT PUMP FOR USE . ...... ...... .................... .............. 3
EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... .................... .............. 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... .................... .............. 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... .................... ............. 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... ...... .................... ............. 12

8004-3
PUMP SPECIFICATIONS
Manufacturer. .................................................................................................................................................. Rexroth
High pressure pump (steering pump next to transmission) ............. 120 Umin at 20 680 kPa, 170 bar, at 2000 r/min
(31.6 U.S. gpm at 2500 psi at 2000rpm)
Low pressure pump (loader pump farthermost from transmission) ... 86 Umin at 20 680 kPa, 170 bar, at 2000 r/min
(22.5 U.S. gpm at 2500 psi at 2000rpm)
Rotation ................................................................................................. Clockwise as seen from the end of the shaft
Special torques
Pump end cover bolts ................................................................................................... 165 Nm (121.5 pound-feet)
Pump housing plug ........................................................................................................ 127 Nm (93.5 pound-feet)
Control piston plug .............................................................................................................. 90 Nm (66 pound-feet)
PREPARING THE EQUIPMENT PUMP FOR USE

Do the following procedure any time you install a new 4. Repeat Step 3 for three minutes.
or overhauled equipment pump:
5. Increase the engine speed to full throttle and
1. Start and run the engine at half throttle for three repeat Steps 3 and 4.
minutes.
6. Stop the engine and check for leaks.
2. With the engine running at half throttle, move the
7. Replace the hydraulic filter.
bucket control lever into roll back position. Hold
the bucket control lever in this position until the
bucket stops moving.
3. Hold the bucket control lever in the roll back
position for five seconds. Then put the bucket
control lever in the NEUTRAL position for five
seconds.

8004-4
EQUIPMENT PUMP
BC06F550-01
1. SNAP RING 11. TAPERED BEARING 21. PRESSURE PINS

2. SEAL 12. BEARING RACE 22. BACKUP PLATE
3. MAIN BODY 13. SHIM 23. SPRING
4. 0-RING 14. SPRING 24. SNAP RING
5. PLUG 15. HALF BEARING 25. PORT PLATE
6. CONTROL VALVE 16. SWASH PLATE 26. SHIM
7. CAP SCREW 17. PISTONS 27. TAPERED BEARING
8. PISTON ROD 18. RETAINING PLATE 28. BEARING RACE
9. CONTROL PISTON 19. BALL 29. DOWEL PIN
10. SHAFT 20. CYLINDER 30. END COVER

8004-5
Disassembly STEP3
STEP 1
Remove all dirt, oil, and grease from the exterior of
the equipment pump.
STEP2
BC06F552·01
Remove the control valve.
BC06F551·01
Put alignment marks on the end cover and housing.

8004-6
STEP4 STEPS
BC06F554·01
Remove the four bolts. Remove the end cover.

NOTE: Watch for the flow plate, it can be stuck to
either the end cover or pump body.

8004-7
STEPS STEP7
BC06F555-01
Use a suitable bearing race puller and pull the Remove the bearing and shim.
bearing race from the end cover.
NOTE: Do not damage the sealing surfaces. STEPS
BC06F557-01
Remove the rotary group from the housing in a

horizontal position.

8004-8
STEP9 STEP 11
BC06F560-01
Remove the bearing and spring_
STEP12
BC06F558-01
Remove plug, pull control piston using a suitable tool

as shown.
NOTE: Do not use a magnet to pull the piston.
BC06F561-01
Remove the shaft and bearing_

STEP10
STEP13
BC06F559-01
Remove the piston rod and swash plate. Turn the

swash plate slightly to break it free from the bearings_
Remove the retaining ring and seaL

8004-9
STEP14 STEP15
Use a suitable bearing race puller and pull the Remove the shim and plug.
bearing race from the housing.

8004-10
Inspection STEP19
STEP16
Clean all parts in cleaning solvent. Be careful not to
remove the alignment marks made during
disassembly.
STEP17
Check the bearing surface.
STEP 20
BC06F565-01
Check for wear on the splines, seal areas for

grooves, bearing areas for scaring, and key set.
STEP18
BC06F568-01
Check that the retaining plate is free of grooves and

that there is no sign of wear.
STEP 21
BC06F566-01
Check the surface that the pistons contact for

grooves and scaring.
BC06F569-01
Check the sliding surface for scratches or metal

deposits, check the tightness of the cup on the
piston.
NOTE: If a piston needs to be replaced, all of the
pistons must be replaced.

8004-11
STEP 22 STEP 24
BC06F572-01
Check the cylinder bores and splines for damage. Check cylinder surface for grooves, wear, embedded
particles. Check flow plate for scratches or wear.
STEP 23
STEP 25
BC06F571-01
Check ball for grooves and wear.

Check mounting surface for the flow plate for
damage.

8004-12
Assembly STEP 27
STEP 26
Put the shaft and bearing in the housing.
Install the plug in the housing, and tighten to 127 Nm STEP 28

(93.5 pound-feet). Install shim, and press in the
bearing race.
Press in a new race into the end cover.

8004-13
STEP 29 STEP 31
Install the end cover, 4 bolts, and hand tighten. Install the seal and retaining ring.
STEP 30
BC06F578-01
A bearing pre load of 0.05 mm (0.002 inch) must be

obtained, add remove shims from bearing as
required.

8004-14
STEP 32 STEP 33
Put new bearings in the housing. Install the reaction Install the swash plate into the housing, work the
spring. swash plate from side to side to seat it in the
bearings and spring. Install the piston rod.

8004-15
STEP 34 STEP 36
BC06F584-01
Use a suitable compressor, compress the spring and

STEP 37
Install the piston into the housing with flat surface

out. Lubricate the 0-ring and install the plug, tighten
the plug to 90 Nm (66 pound-feet).
STEP 35 BC06F585-01
Place the ball onto the pressure pins, install the

pistons into the retaining plate.
STEP 38
~-
BC06F583-01
Use grease to hold the pressure pins into position,

install the spacer, spring and snap ring.
BC06F586-01
Lubricate the piston and retaining plate with clean oil,

install the piston into the rotating housing.

8004-16
STEP 39 STEP 40
Hold the pistons in the rotating housing using an Use the shim that was required for the bearing pre
0-ring, install the rotating group into the housing, load in step 30. Install the shim and bearing onto the
remove the 0-ring. shaft.

8004-17
STEP 41 STEP 42
BC06F589-01
Install a new 0-ring on the end cover, place the flow Install and tighten the four bolts to 165 Nm
plate onto the rotating group with aligning notch up. (121.5 pound-feet).
Place the end cover onto the housing, make sure
that the aligning pin in the end cover aligns with the
slot in the flow plate.

8004-18
STEP 43
BC06F552-01
Use new 0-rings, install and tighten the control valve.

Section
8005

8005-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................... 3
2 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 and 4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
LOADER CONTROL VALVE ................................................................. 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Circuit Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

8005-3
SPECIFICATIONS
Special Torques
End plate mounting bolts .......................................................................... 20 to 25 Nm (177 to 221 pound-inches)
Pressure relief, flow limit, and pilot pressure reducing valves .................. 20 to 25 Nm (177 to 221 pound-inches)
Allen head plugs .................................................................................................................. 60 Nm (44 pound-feet)
Steering Priority Spool Cap ................................................................................................. 60 Nm (44 pound-feet)
Allen head cover screws (short) .................................................................................. 10.4 Nm (92 pound-inches)
Allen head cover screws (long) ........................................................................................ 6 Nm (53 pound-inches)
Anticavitation valves ............................................................................................................ 60 Nm (44 pound-feet)
Combination anticavitation and circuit relief ........................................................................ 90 Nm (66 pound-feet)
Cone and plug ............................................................................................................. 10 Nm (88.5 pound-inches)
Main relief valve pressure settings .........................................................................248 to 252 bar (3596 to 3654 psi)
Circuit relief valve pressure setting
Auxiliary A and B port ................................................................................................................290 bar (4206 psi)
Bucket A and B port ..................................................................................................................290 bar (4206 psi)

8005-4
BC06D160
1. HOUSING 5. LOAD CHECK VALVE 7. ANTICAVITATION AND CIRCUIT RELIEF 10. 0-RINGS
2. PLATE SA. REGENERATION CHECK VALVE 8. LS (MAIN) RELIEF VALVE 11. LS BLEED ORIFICE
3. BOLT 6. REGENERATION RELIEF VALVE 9. PILOT PRESSURE REDUCING VALVE 12. STEERING RELIEF VALVE
4. WASHER 13. LS SHUTTLE CHECK VALVE
2 SPOOL VALVE HOUSING CONFIGURATION

8005-5
16
BC06D161
14. CAP SCREW 18. SPRING RETAINER 22. ADJUSTING NUT 26. STEERING PRIORITY SPOOL
15. THROTTLE CHECK VALVE 19. SPRING RETAINER 23. ADJUSTING ROD 27. COMPENSATION SPOOL
16. COVER 20. SPOOL 24. PLUG 28. PLUG
17. SPRING 21. JAM NUT 25. ORIFICE 29. RING
2 SPOOL VALVE SPOOL CONFIGURATION

8005-6
BC06D162
2. PLATE 17. SPRING

3. BOLT 24. PLUG
4. WASHER 27. COMPENSATION SPOOL
5. LOAD CHECK VALVE 30. HOUSING
10. 0-RING 31. ANTICAVITATION AND CIRCUIT RELIEF
3 SPOOL MOUNTING CONFIGURATION

8005-7
-~~
~
BC06D163
2. PLATE 24. PLUG

3. BOLT 27. COMPENSATION SPOOL
4. WASHER 30. HOUSING
5. LOAD CHECK VALVE 31. ANTICAVITATION AND CIRCUIT RELIEF
10. 0-RING 32. NUT
17. SPRING 33. STUD
4 SPOOL MOUNTING CONFIGURATION

8005-8
BS03C037
10. 0-RING 18. SPRING RETAINER

14. CAP SCREW 20. SPOOL
15. THROTTLE CHECK VALVE 21. JAM NUT
16. COVER 22. ADJUSTING NUT
17. SPRING 23. ADJUSTING ROD
3 AND 4 SPOOL VALVE SPOOL CONFIGURATION

8005-9
Disassembly STEP 11
Remove the pilot pressure reducing valve (6}.
STEP 1
Remove valve from machine, see section 8001. STEP12
Remove bolts (3} and washers (4), remove plate (2}
STEP2 from housing (1 ).
Remove bolts (14), covers (16), and springs (17). NOTE: For 4 spool configuration remove nut (32)
from stud (33), remove valves from housing (1 ).
STEP3
Remove cap (24}, spring (17}, and plug (28}. STEP13
STEP4
Use wooden dowel or brass drift and push spools (20
and 26} from housing (1 ).
IMPORTANT: Do not force spools from housing, if
spool binds work back and forth until spool comes
out freely.
NOTE: Repeat steps 2 and 4 for 3 and 4 spool valve
configuration.
STEPS
BS03C026
Remove anticavitation valves (7 and 27).
1. 0-RINGS 2. THRUST RINGS
NOTE: Repeat step 5 for 3 and 4 spool anticavitation Remove and discard 0-rings and thrust rings from
valves (31). flow limit valve (11 ).
STEPS STEP14
Remove cone (13}.
STEP7
Remove pressure relief valve (8 and 12}.
STEPS
Remove flow limit valve (9).
STEP9
Remove check valves (5).
STEP10
Remove flow limiting valve (11 ). 1. 0-RINGS 2. THRUST RINGS
Remove and discard 0-rings and thrust rings from
pilot pressure reducing valve (9).

8005-10

Remove and discard 0-rings and thrust rings from pressure relief valve (8 and 12).

8005-11
STEP15
BS03C032
1. 0-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Remove and discard 0-rings and thrust rings from anticavitation and circuit relief valves (7 and 31 ).

8005-12
Inspection 4. Check the parts of the pressure relief valve,

anticavitation valves, and the anticavitation and
1. Discard all 0-rings, thrust rings, and spool seals. circuit relief valves. Use new parts as necessary.
2. Clean all parts in cleaning solvent. 5. Inspect the other parts of the control valve. If any
3. Check the spools and the spool bores for of the parts are damaged, install new parts.
damage and wear.
Assembly
STEP 1
BS03C032
1. 0-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Install new 0-rings and thrust rings on anticavitation and circuit relief valves (7 and 31 ). Torque relief valve (A) into
anticavitation valve to 140 Nm (1 03 pound-feet).
NOTE: Spool seal mounting position is critical, seal must be mounted with lip facing as shown above, pressure is in
direction of arrow.

8005-13
STEP2

Install new 0-rings and thrust rings on pressure relief valve (8 and 12}.
STEP3 STEP4
BS03C026
1. 0-RINGS 2. THRUST RINGS 1. 0-RINGS 2. THRUST RINGS

Install new 0-rings and thrust rings on flow limiting Install new 0-rings and thrust rings on flow limit valve
valve (9). (11 ).

8005-14
STEPS STEP12
Install and torque regeneration check valve (14) to Install and torque check valves (5) to 40 Nm
100 Nm (73.7 pound-feet). (29.5 pound-feet).
STEPS STEP13
Install new 0-rings on housing (1 ). Install plate (2), Install and torque cone and plug (13) to 10 Nm
bolts (3) and washers (4), onto housing (1 ). Torque (88.5 pound-inches).
bolts to 20 to 25 Nm (177 to 221 pound-inches).
NOTE: For 4 spool configuration install new 0-rings STEP14
between housings (30) and housing (1), install nuts Install and torque plug (28) to 60 Nm (44 pound-feet).
(32) on studs (33). Torque nuts to 70 Nm (51.5
pound-feet). STEP15
Lubricate spools with hydraulic oil and push spools
STEP7 (20 and 26) into housing (1 ).
Install and torque pilot pressure reducing valve (6) to
90 Nm (66 pound-feet). IMPORTANT: Do not force spools into housing.
STEPS STEP16
Install and torque anticavitation valves (7) to 90 Nm Install spring retainers (18), springs (17), covers (16),
(66 pound-feet). and bolts (14). Torque bolts to 6 Nm
(53 pound-inches).
NOTE: Repeat step for 3 and 4 spool anticavitation
valves (31). NOTE: Repeat steps 15 and 16 for 3 and 4 spool
valve configuration.
STEP9
Install anticavitation valves (27), spring (17), and cap
STEP17
(24) and torque cap to 60 Nm (44 pound-feet). Install spring (17) and cap (24) and torque cap to
60 Nm (44 pound-feet).
STEP10 NOTE: Prior to installation in the machine, circuit
Install and torque flow limit valve (9 and 11) to 20 to reliefs can be tested.
25 Nm (177 to 221 pound-inches).
STEP18
STEP 11 Install valve in machine, see section 8001.
Install and torque pressure relief valves (8 and 12) to
20 to 25 Nm (177 to 221 pound-inches). STEP19
Check loader limit pressure, see section 8002.

8005-15
CIRCUIT RELIEF
Pressure Test Adjustment
STEP 1 STEP 1
Connect the hand pump to the port for anticavitation Loosen the lock nut. Turn the adjustment screw
and circuit relief valves (7). clockwise to increase the pressure or
counterclockwise to decrease the pressure.
NOTE: Repeat steps for machines that are
configured with a 3 or 4 spool valve.
STEP2
STEP2 Check the pressure again. Repeat the adjustment as
necessary.
Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21oc (70°F).
STEP3
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
be sure of the reading.
STEP4
Compare the reading to the specifications on Page 3.
STEPS
If the pressure is not correct, adjust the circuit relief
valve.

8005-16
NOTES

Section
8006
CYLINDERS

8006-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................... 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly .............................................................................. 6
BUCKET CYLINDERS Z-BAR MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly .............................................................................. 9
BUCKET CYLINDERS FOR XT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REPLACING BUSHINGS FOR THE BUCKET CYLINDER Z-BAR MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REPLACING BUSHINGS FOR THE BUCKET CYLINDERS XT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

8006-3
SPECIFICATIONS
Approximate weight
Lift Cylinder- XT and 2-Bar ....................................................................................................... 75.7 kg (167 pounds)
Bucket Cylinder- Z-Bar Models ................................................................................................. 75.6 kg (167 pounds)
Bucket Cylinder- XT Models ........................................................................................................ 73 kg (160 pounds)
SPECIAL TORQUES
Screw in Gland Z-Bar Bucket Cylinder .......................................................... 135 to 542 Nm (1 00 to 400 pound-feet)
Screw in Gland XT Bucket Cylinder. .............................................................. 135 to 542 Nm (1 00 to 400 pound-feet)
Screw in Gland for Lift Cylinders XT and Z-Bar Models ................................ 135 to 542 Nm (1 00 to 400 pound-feet)
Piston Bolt for Lift Cylinders XT and Z-Bar Models ............................... 1780 to 2180 Nm (1312 to 1607 pound-feet)
Piston Bolt for Z-Bar Bucket Cylinder .................................................... 331 0 to 3850 Nm (2440 to 2838 pound-feet)
Piston Bolt for XT Bucket Cylinder. ........................................................ 1780 to 2180 Nm (1312 to 1607 pound-feet)
Lock Screw for all Cylinders .............................................................................................. 2.3 Nm (20 pound-inches)
SPECIAL TOOLS
Torque Multiplier .......................................................................................................................................... CAS1 039

8006-4
LIFT CYLINDER
1. Clean the outside of the cylinder. If the hoses 1. Discard the parts that were removed from the
were removed with the cylinder, remove the piston and the gland.
hoses from the cylinder.
2. Clean all parts in cleaning solvent. Use only lint
2. Fasten the tube (1) in an acceptable repair stand free cloths for cleaning and drying.
or other holding equipment, refer to Figure 1. Do
3. Check to be sure that the piston rod is straight. If
not damage the tube (1 ).
the piston rod is not straight, replace it with a new
3. Loosen and remove the self-tapping screw (12}. piston rod.
4. Use a spanner wrench to loosen and remove the 4. Illuminate the inside of the tube for deep grooves
gland (4) out of the tube (1 ). and other damage. If there is any damage to the
tube, replace it with a new tube.
5. Pull the piston rod (13} straight out of the tube (1)
to prevent damage to the tube (1 ). 5. Remove any small scratches on the piston rod or
inside the tube with emery cloth of medium grit.
6. Fasten the piston rod eye or yoke in a vise and
Use the emery cloth with a rotary motion.
put a support under the piston rod (13} near the
piston (15}. Put a shop cloth between the support 6. Inspect the bushings in the piston rod eye or
and the piston rod (13} to prevent damage to the yoke and the tube. Replace as required.
piston rod (13}.
7. Inspect the gland for rust. Clean and remove rust
7. Use a torque multiplier, CAS1 039, to loosen and as necessary.
remove the bolt (14} that fastens the piston (15}
8. Inspect the gland end of the tube for sharp edges
to the piston rod (13}.
that will cut the gland 0-ring and remove as
8. Remove the piston (15} from the piston rod (13}. necessary.
9. Remove the gland (4) from the piston rod (13}. 9. Inspect the piston for damage and wear. If the
piston is damaged or worn, replace it with a new
10. Remove the seal (16}, ring (17}and the wear ring
piston.
(18} from the piston (15}.
11. Remove the 0-ring (1 0}, ring (9}, 0-ring (11 ),
wiper (5), seal (6}, seal (7), and bushing (8} from
the gland (4).

8006-5
88038200
1. TUBE 6. ROD SEA 11 · 0-RING 16. SEAL

7 L
2. BUSHING . BUFFER SEAL 12.
13. SCREW
ROD (NOT SHOWN)
17. RING
3. WIPER 8. BUSHING 18. WEAR RING
4. GLAND 9. BACKUP RING 14. BOLT
5. WIPER 10· 0-RING 15. PISTON
FIGURE 1. LIFT CYLINDER
Bur 5-7510 Issued 9_07 Printed in U.S.A.

8006-6
Assembly 15. Install the bolt (14} into the piston rod (13}.
Tighten the bolt (14} to a torque of 1780 to 2180
NOTE: If a new gland is being used, put the part Nm (1312 to 1607 pound-feet). A torque
number of the cylinder on the new gland. multiplier can be used to help torque the bolt
1. Install the bushing (8) in the gland (4), refer to (14}.
Figure 1. 16. Install a new wear ring (18} in the wide groove on
2. Install the seal (6) in the gland (4). The seal (6) is the outside of the piston (15}, refer to Figure 1.
to be installed so that the lips of the seal (6) are 17. Install a new ring (17} in the other groove on the
toward the bushing (8). The seal (6) can be outside of the piston (15}.
difficult to install.
18. Install a new seal (16} on the top of the ring (17}.
3. Install the seal (7) in the gland (4). The side of
the seal (7) with the groove must be toward the 19. Fasten the tube (1) in an acceptable repair stand
bushing (8). or other holding equipment. Be careful to prevent
damage to the tube (1 ).
4. Install a new wiper (5) in the gland (4). The lips of
the wiper (5) must be toward the outside end of 20. Lubricate the inside of the tube (1) and the piston
the gland (4). (15} with clean oil.
5. Install a new 0-ring (11) in the groove on the OD 21. Push the piston (15} straight into the tube (1 ).
of the gland (4). 22. When the piston (15} is in the smooth part of the
6. Install a new ring (9) in the groove on the OD of tube (1 ), start the gland (4) into the tube (1 ).
the gland (4). If both sides of the ring (9) are not 23. Lubricate the 0-rings (1 0 and 11) on the gland
flat, the side that is not flat must be toward the (4) with clean oil.
small end of the gland (4).
24. Turn the gland (4) into the tube (1}. Tighten the
7. Install a new 0-ring (1 0) next to the ring (9) in the gland (4) to a torque of 135 to 542 Nm (1 00 to
groove on the outside of the gland (4). The 400 pound-feet).
0-ring (1 0) must be toward the small end of the
gland. 25. If the original parts are being assembled:
8. Fasten the piston rod eye or yoke in the vise. A. Tighten the gland to a torque of 135 to 542
Nm (1 00 to 400 pound-feet).
9. Remove any marks and sharp edges on the
chamfer at the end of the piston rod (13). Make B. Install and tighten the lock screw (12} to a
sure that the piston rod (13) is clean. torque of 2.3 Nm (20 inch-pounds}.
10. Lubricate the bore of the gland (4) and the piston C. If, after tightening the gland, the lock screw
rod (13) with clean oil. (12} holes are not aligned, a new hole for the
lock screw (12} must be drilled. See Step 27.
11. Push the gland (4) onto the piston rod (13). If
necessary, use a soft hammer to drive the gland 26. If a new gland (4) or a new tube (1) are being
(4) onto the piston rod (13). assembled:
12. Put a support below and near the end of the A. Tighten the gland (4) to 135 to 542 Nm (100 to
piston rod (13). Use a shop cloth between the 400 pound-feet).
support and the piston rod (13) to prevent B. Use a No. 27 drill bit and drill a hole half in the
damage to the piston rod (13). gland (4) and half in the tube (1 ). Drill to a
13. Start the piston (15) onto the piston rod (13). depth of 11 mm (7/16 inch). Do not drill within
13 mm (1 /2 inch) of a hole for the gland
14. Clean the threads on the end of the piston rod wrench.
and the threads of the piston bolt using Loctite
cleaning solvent. Allow to dry. Apply Loctite 242 C. Install and tighten the lock screw (12} to a
to the piston rod threads 1/4 inch from the open torque of 2.3 Nm (20 inch-pounds}.
end of the piston rod so that there is 1/2 inch of 27. If the hoses were removed with the cylinder,
Loctite 242 on the piston rod threads. DO NOT install new 0-rings, if equipped, on the hose
apply Loctite to the first 1/4 inch of the piston rod fittings. Lubricate 0-rings with clean oil. Install
threads. the hoses.

8006-7
BUCKET CYLINDERS Z-BAR MODELS
2. Fasten the tube (1) in an acceptable repair stand free cloths for cleaning and drying.
or other holding equipment, refer to Figure 2. Do
not damage the tube (1 ).
3. Loosen and remove the locking screw (12} from piston rod.
the gland (4) and tube (1}.
4. Illuminate the inside of the tube for deep grooves
4. Use a spanner wrench to loosen and remove the and other damage. If there is any damage to the
gland (4) out of the tube (1 ). tube, replace it with a new tube.
5. Pull the piston rod (12} straight out of the tube (1) 5. Remove any small scratches on the piston rod or
to prevent damage to the tube (1 ). inside the tube with emery cloth of medium grit.
6. Fasten the piston rod eye or yoke in a vise and
put a support under the piston rod (12} near the 6. Inspect the bushings in the piston rod eye or
piston (16}. Put a shop cloth between the support yoke and the tube. Replace as required.
and the piston rod (12} to prevent damage to the
7. Inspect the gland for rust and clean and remove
piston rod (12}.
rust as necessary.
7. Use a torque multiplier, CAS1 039 to loosen and
remove the bolt (15}, washer (14} that fastens the
piston (16} to the piston rod (12}.
necessary.
8. Remove the piston (16} from the piston rod (12}.
9. Inspect the piston for damage and wear. If the
9. Remove the gland (4) from the piston rod (12}. piston is damaged or worn, replace it with a new
piston.
10. Remove the seal (17}, backup ring (19} and wear
ring (20} from the piston (16}.
11. Remove the 0-ring (11 ), backup ring (1 0}, wiper
(5), seal (6}, seal (7) and bushing (8} from the
gland (4).

8006-8
1. TUBE 6. SEAL 16. PISTON

7. SEAL 11. 0-RING
2. BUSHING 17. SEAL
8. BUSHING 12. PISTON ROD
3. SCREW( 18. BACKUP RING
4. GLAND NOT SHOWN) 9. 0-RING
10 13. BUS HING
19. WEAR RING
. BACKUP RING 14. WIPER
5. WIPER
FIGURE 2 . BUCKET CYLINDER FO15 . BOLT AND WASHER
R Z-BAR MODELS

8006-9
Assembly 15. Install the bolt (15} into the piston rod (12}.
Tighten the bolt (15} to a torque of 3310 to 3850
NOTE: If a new gland is being used, put the part Nm (2440 to 2838 pound-feet). A torque
number of the cylinder on the new gland. multiplier can be used to help torque the bolt
1. Install the bushing (8) in the gland (4), refer to (15}.
Figure 2. 16. Install a new wear ring (19} in the wide groove on
2. Install the seal (6) in the gland (4). The seal (6) is the outside of the piston (16}, refer to Figure 2.
to be installed so that the lips of the seal (6) are 17. Install a new backup ring (18} in the other groove
toward the bushing (8). The wide seal (6) can be on the outside of the piston (16}.
difficult to install.
18. Install a new seal (17} on the top of the backup
3. Install the seal (7) in the gland (4). The side of ring (18}.
the seal (7) with the groove must be toward the
bushing (8). 19. Fasten the tube (1) in an acceptable repair stand
or other holding equipment. Be careful to prevent
4. Install a new wiper (5) in the gland (4). The lips of damage to the tube (1 ).
the wiper (5) must be toward the outside end of
the gland (4). 20. Lubricate the inside of the tube (1) and the piston
(16} with clean oil.
5. Install a new 0-ring (9) in the groove on the
gland (4). 21. Push the piston (16} straight into the tube (1 ).
6. Install a new backup ring (1 0) in the groove on 22. When the piston (16} is in the smooth part of the
the OD of the gland (4). If both sides of the tube (1 ), start the gland (4) into the tube (1 ).
backup ring (1 0) are not flat, the side that is not 23. Lubricate the 0-rings (9 and 11) on the gland (4)
flat must be toward the small end of the gland with clean oil.
(4).
24. Turn the gland (4) into the tube (1 ). Tighten the
7. Install a new 0-ring (11) next to the backup ring gland (4) to a torque of 407 +1- 68 Nm (300 +1- 50
(1 0) in the groove on the outside of the gland (4). pound-feet).
The 0-ring (11) must be toward the small end of
the gland. 25. If the original parts are being assembled:
8. Fasten the piston rod eye or yoke in the vise. A. Tighten the gland to a torque of 135 to 542
Nm (1 00 to 400 pound-feet).
9. Remove any marks and sharp edges on the
chamfer at the end of the piston rod (12). Make B. Install and tighten the lock screw (3} to a
sure that the piston rod (12) is clean. torque of 2.3 Nm (20 inch-pounds}.
10. Lubricate the bore of the gland (4) and the piston C. If, after tightening the gland, the lock screw (3}
rod (12) with clean oil. holes are not aligned, a new hole for the lock
screw (3} must be drilled. See Step 27.
11. Push the gland (4) onto the piston rod (12). If
necessary, use a soft hammer to drive the gland 26. If a new gland (4) or a new tube (1) are being
(4) onto the piston rod (12). assembled:
12. Put a support below and near the end of the A. Tighten the gland (4) to a torque of 135 to 542
piston rod (12). Use a shop cloth between the Nm (1 00 to 400 pound-feet).
support and the piston rod (12) to prevent B. Use a No. 27 drill bit and drill a hole half in the
damage to the piston rod (12). gland (4) and half in the tube (1 ). Drill to a
13. Start the piston (16) onto the piston rod (12). depth of 11 mm (7/16 inch). Do not drill within
13 mm (1 /2 inch) of a hole for the gland
14. Clean the threads on the end of the piston rod wrench.
and the threads of the piston bolt using Loctite
cleaning solvent. Allow to dry. Apply Loctite 242 C. Install and tighten the lock screw (3} to a
to the piston rod threads 1/4 inch from the open torque of 2.3 Nm (20 inch-pounds}.
end of the piston rod so that there is 1/2 inch of 27. If the hoses were removed with the cylinder,
Loctite 242 on the piston rod threads. DO NOT install new 0-rings, if equipped, on the hose
apply Loctite to the first 1/4 inch of the piston rod fittings. Lubricate 0-rings with clean oil. Install
threads. the hoses.

8006-10
BUCKET CYLINDERS FOR XT MODELS
2. Fasten the cylinder in a vise or other holding free cloths for cleaning and drying.
equipment. Be careful to prevent damage to the
tube (1 ), refer to Figure 3.
3. Loosen and remove the lock screw (3} from the piston rod.
gland (4) and tube (1 ).
4. Illuminate the inside of the tube for deep grooves
4. Use a spanner wrench to loosen and remove the and other damage. If there is any damage to the
gland (4) from the tube (1 ). tube, replace it with a new tube.
5. Pull the piston rod (12} straight out of the tube (1) 5. Remove any small scratches on the piston rod or
to prevent damage to the tube (1 ). inside the tube with emery cloth of medium grit.
6. Fasten the rod yoke in a vise and put a support
below the piston rod (12} near the piston (13}. 6. Inspect the bushings in the piston rod eye or
Use a shop cloth between the support and the yoke and the tube. Replace as required.
piston rod (12} to prevent damage to the piston
7. Inspect the gland for rust and clean and remove
rod (12}.
rust as necessary.
7. Use a torque multiplier, CAS-1 039, to loosen and
remove the piston bolt (17} that secures the
piston (13}.
necessary.
8. Remove the piston (13} from the piston rod (12}.
9. Inspect the piston for damage and wear. If the
9. Remove the gland (4) from the piston rod (12}. piston is damaged or worn, replace it with a new
piston.
10. Remove the backup ring (14}, piston seal (15}
and wear ring (16} from the piston (13}.
11. Remove the wiper (5), seal (7), seal (8} and the
bushing (6} from the gland (4).
NOTE: Use care not to scratch the 10 of gland when
removing seals.
12. Remove the 0-ring (1 0) and backup ring (11)
from the OD of gland (4).

8006-11
88038202
1. TUBE 6. BUSHING 11. BACKUP RING 16. WEAR RING

2. BUSHING 7. ROD SEAL 12. PISTON ROD 17. BOLT
3. SCREW 8. BUFFER SEAL 13. PISTON 18. GREASE FITTING
4. GLAND 9. 0-RING 14. BACKUP RING 19. WIPER
5. WIPER 10. 0-RING 15. SEAL
FIGURE 3. BUCKET CYLINDER FOR XT MODELS

8006-12
Assembly 15. Install the piston bolt (17}. Tighten the piston bolt
(17} to a torque of 1780 ti 2180 Nm (1312 to
NOTE: If a new gland (4) is being installed, put the 1607 pound-feet). A torque multiplier can be
part number of the cylinder on the new gland (4). used to help tighten the piston bolt (17}.
1. Install the bushing (6) in the gland (4), refer to 16. Install a new wear ring (16} in the groove on the
Figure 3. outer end of the piston (13}.
2. Install the seal (8). The seal (8) must be installed 17. Install the piston backup ring (14} into the
with the seal lips toward the small end of the remaining groove in the piston (13}.
gland (4). The seal (8) can be difficult to install.
18. Install a new piston seal (15} on top of the
3. Install the seal (7). The seal (7) must be installed backup ring (14}.
with the lips toward the small end of the gland (4)
also. 19. Fasten the tube (1) in a vise or other holding
equipment. Be careful to prevent damage to the
4. Install a new wiper (5) in the gland (4). The lips of tube (1 ).
the wiper (5) must be toward the large end of the
gland (4). 20. Lubricate the inside of the tube (1) and the piston
(13} with clean oil.
5. Install a new 0-ring (9) in the groove of the gland
(4). 21. Push the piston (13} straight into the tube (1 ).
6. Install a new backup ring (11) in the groove on 22. When the piston (13} is in the smooth part of the
the outside of the gland (4). If both sides of the tube (1 ), start the gland (4) into the tube (1 ).
backup ring (11) are not flat, the side that is not 23. Lubricate the 0-ring (9 and 10} on the gland (4)
flat must be toward the small end of the gland with clean oil.
(4).
24. Tighten the gland (4) into the tube (1}. Tighten
7. Install the 0-ring (10) on the gland (4). The the gland to a torque of 135 to 542 Nm (1 00 to
0-ring (1 0) must be toward the small end of the 400 pound-feet).
gland (4).
25. If the original parts are being assembled:
8. Fasten the piston rod yoke in the vise.
A. Tighten the gland to a torque of 135 to 542
9. Remove any marks and sharpen edges on the Nm (1 00 to 400 pound-feet).
chamfer at the end of the piston rod (12).
B. Install and tighten the lock screw (3} to a
10. Lubricate the bore of the gland (4) and the piston torque of 2.3 Nm (20 inch-pounds}.
rod (12) with clean oil.
C. If, after tightening the gland, the lock screw (3}
11. Push the gland (4) onto the piston rod (12). If holes are not aligned, a new hole for the lock
necessary, use a soft hammer to drive the gland screw (3} must be drilled. See Step 27.
(4) onto the piston rod (12).
26. If a new gland (4) or a new tube (1) are being
12. Put a support below and near the end of the assembled:
piston rod (12). Use a shop cloth between the
support and the piston rod (12) to prevent A. Tighten the gland (4) to 135 to 542 Nm (100 to
damage to the rod. 400 pound-feet).
13. Put the piston (13) on the end of the piston rod B. Use a No. 27 drill bit and drill a hole half in the
(12). gland (4) and half in the tube (1 ). Drill to a
depth of 11 mm (7/16 inch). Do not drill within
14. Clean the threads on the end of the piston rod 13 mm (1 /2 inch) of a hole for the gland
and the threads of the piston bolt using Loctite wrench.
cleaning solvent. Allow to dry. Apply Loctite 242
to the piston rod threads 1/4 inch from the open C. Install and tighten the lock screw (3} to a
end of the piston rod so that there is 1/2 inch of torque of 2.3 Nm (20 inch-pounds}.
Loctite 242 on the piston rod threads. DO NOT 27. If the hoses were removed with the cylinder,
apply Loctite to the first 1/4 inch of the piston rod install new 0-rings, if equipped, on the hose
threads. fittings. Lubricate the 0-rings with clean oil.
Install the hoses.

8006-13
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS
Disassembly
1. Put the piston tube (4) in a press, refer to Figure
4.
2. Use an acceptable driver to press the wipers (1)
and bushings (2) out of the piston tube (4).
3. Clean the bore for the bushings (2) in the tube
(4).
Assembly
1. Use an acceptable driver to press a new bushing
(2) into the tube (4) until the bushing (2) is
centered in the tube (4).
2. Use an acceptable driver to install the wipers (1)
in the tube (4). The lips of the wipers (1) must be
toward the outside of the bore.
1. WIPER 3. PISTON ROD YOKE

2. BUSHING 4. TUBE
FIGURE 4. BUSHING AND WIPER REMOVAL AND
REPLACEMENT LIFT CYLINDERS

8006-14
REPLACING BUSHINGS FOR THE BUCKET CYLINDER Z-BAR MODELS
Disassembly
1. Put the piston rod eye (3} in a press, refer to
Figure 6.
2. Use an acceptable driver to press the wipers (1)
and bushing (2} out of the piston rod eye (3}.
3. Put the tube (4) in a press.
4. Use an acceptable driver to press the bushings
(2} out of the tube (4).
5. Clean the bore for the bushings (2} in the piston
rod eye (3} and the tube (4).
Assembly
1. Use an acceptable driver to press new bushings
(2} into the piston rod eye (3}. Refer to Figure 6.
2. Use an acceptable driver to install the wipers (1)
in the piston rod eye (3}. The lips of the wipers
(1) must be towards the outside of the bore.
3. Use an acceptable driver to press new bushings
(2} into the tube (4).
BS01C004
1. WIPER 3. PISTON ROD EYE

2. BUSHING 4. TUBE
REPLACEMENT BUCKET CYLINDER

8006-15
REPLACING BUSHINGS FOR THE BUCKET CYLINDERS XT MODELS
1. Put the piston tube (4) in a press, refer to Figure 1. Use an acceptable driver to press new bushings
5. (2) into the tube (4). Refer to Figure 5.
2. Use an acceptable driver to press the wipers (1) 2. Use an acceptable driver to install the wipers (1)
and bushing (2) out of the piston tube (4). in the tube (4). The lips of the wipers (1) must be
toward the outside of the bore.
3. Clean the bore for the bushings (2) in the tube
(4).
BS01C002
1. WIPER 3. PISTON ROD YOKE

2. BUSHING 4. TUBE
REPLACEMENT XT BUCKET CYLINDERS

8006-16
NOTES

Section
8007
COUPLER SOLENOID LOCKING VALVE
CASE CORPORATION
700 State Street
Burlington, ON L7N 3M6 CANADA Bur 6-42600 August, 2001
8007-2
TABLE OF CONTENTS
COUPLER SOLENOID LOCKING VALVE ...................................................... 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly .............................................................................. 3

8007-3
COUPLER SOLENOID LOCKING VALVE
Disassembly STEP 11
Install solenoid (2) on valve cartridge (3).
STEP 1
Clean exterior of valve. STEP12
Install nut (1) to secure solenoid (2).
STEP2
Remove nut (1) and solenoid (2) from valve cartridge
(3).
STEP3
Remove valve cartridge (3) from valve housing (7).
STEP4
Remove and discard all 0-rings (4 and 5) and
back-up rings (6).
Cleaning and Inspection
STEPS
Immerse valve cartridge (3) and valve housing (7) in
cleaning solvent and agitate cleaning solvent. WEAR
EYE PROTECTION WHEN USING COMPRESSED
AIR. Use compressed air to remove foreign matter
from interior of valve cartridge and housing and to
ensure that all passage ways and bores are clear.
STEPS
Check valve cartridge for (3) for cracks, breaks,
chipping, or other damage. Replace if any of these
conditions are seen.
STEP7
Check bores in valve housing (7) for deep scratches,
gouges, and other damage. Replace valve if any of
STEPS
Connect an ohmmeter across terminals of solenoid
(2) connector. Replace solenoid (2) and valve
cartridge (3) if ohmmeter indicates short or open
circuit.
Assembly
GS98J818
1. NUT 5. 0-RING
STEP9
2. SOLENOID 6. BACKUP RING
Install new 0-rings (4 and 5) and back-up rings (6) as 3. VALVE CARTRIDGE 7. VALVE HOUSING
shown. 4. 0-RING
STEP10
Lubricate 0-rings (4 and 5) using clean oil then install
valve cartridge (3) in valve housing (7).
8007-4
NOTES

Section
8013
RIDE CONTROL ACCUMULATOR

8013-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................... 3
ACCUMULATOR SPECIAL TORQUES ........................................................ 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TESTING RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Checking Nitrogen Charge On Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Charging Accumulator With Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

8013-3
SPECIFICATIONS
Ride Control Accumulator Dry Nitrogen Pressure ...................................................................... See chart on page 6
Ride Control Accumulator Fluid Capacity ............................................................................. 3.79 liters (231 cu. inch)
Ride Control Accumulator Maximum Operating Pressure ........................................................... 248.4 bar (3600 psi)
ACCUMULATOR SPECIAL TORQUES

Accumulator Gas Charging Valve Cap ................................................................................. 13.6 Nm (1 0 pound-feet)
Gas Charging Valve ............................................................................................. 88 to 102 Nm (65 to 75 pound-feet)
Cap screws for the protection bracket .......................................................... 54 to 61 Nm (480 to 540 pound-inches)
Gland ............................................................................................................. 163 to 176 Nm (120 to 130 pound-feet)
SPECIAL TOOLS
BC04A001
380001676 NITROGEN REGULATOR VALVE 380001168 ACCUMULATOR VALVE ADAPTER
Check your inventory_ of tools, if you have nitrogen
charging kit CAS 10899 use it in place of the a/Jove
listed tools.
BS06M003
380001390 ACCUMULATOR CHARGING HOSE

8013-4
TESTING RIDE CONTROL

STEP 1 STEPS
Move the machine to a clear level surface with Dump the bucket until it hits the dump stops. Hold the
clearance for full lift arm and bucket movement. bucket in the dump position for 5 to 10 seconds.
NOTE: This will charge the ride control accumulator.
STEP2
Install the articulation lock, start the machine, STEP7
activate the parking brake.
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
STEP3 their stops, place the pilot control lever in the neutral
With the pilot controller in neutral, set the ride control position.
rocker switch on the right side console to the "Always
On" position and observe the switch lamp, the lamp STEPS
should illuminate.
Set the ride control rocker switch to the "Always On"
position. The lift arms should rise 15 to 30 em (6 to
STEP4 12 inches) with an empty bucket.
Set the ride control rocker switch to the "Off" position
and observe the switch lamp, the lamp should go out. NOTE: Test results will be for a machine with a
empty factory bucket and no attachments.
NOTE: This indicates that the switch is operating
correctly and has power, if the switch does not STEP9
illuminate see section 4002 and troubleshoot the
If there is little or no lift arm raise, the test may have
electrical system for the ride control.
been done too slowly. The elapsed time between
step 6 and step 8 should not exceed six seconds.
STEPS
Raise the lift arms to the top of their travel and dump NOTE: If test was done to slowly repeat in the
the bucket. allotted time.
NOTE: Keep rocker switch in the "Off" position STEP10

during this steps 5, 6, 7.
If test was completed in the allotted time and the lift
arms still do not rise, test the nitrogen charge in the
accumulator.

8013-5
Checking Nitrogen Charge On Accumulator
BS07A156
NITROGEN CHARGING KIT
1. Use the Nitrogen Charging Kit to discharge the 7. Connect valve A to the valve stem on the adapter
accumulator, refer to the illustration above. The (F).
tool must be disconnected from the nitrogen 8. Connect the accumulator to the adapter (F)
tank.
9. Open valve on accumulator using the adapter's
2. Close valve (E). square drive (G).
3. Adjust the regulator (D) to the minimum pressure 10. Turn the T-handle inward on valve (A) to engage
setting by turning the knob counterclockwise. the pin in the valve stem on the adapter.
4. Turn the T-handle on valve (A) fully out. 11. Slowly open valve (E).
5. Remove the valve cap from the accumulator. 12. Check the charge pressure on gauge (B).
6. Install adapter 380001168 (F) onto the
accumulator.
h WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
. . explosion.
M253fl
A WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar
(450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M4Ut
A WARNING: Do not expose the accumulator to temperatures above 49° C (120° F). A charged accumulator
contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M4U7

8013-6
Charging Accumulator With Nitrogen

IMPORTANT: The four valves A, D, and E must be in the positions noted in the procedure before connecting the
Nitrogen Accumulator Charging Kit to the machine or nitrogen, refer to illustration on page 5.
1. Close the shutoff valve (D) by turning it all the
way to the left (counterclockwise), refer to the I TEMPERATURE II CHARGE PRESSURE I
10° c soc F 16.36 BAR 237 PSI
13° c sse F 16.SS BAB 240 PSI
2. Close the gauge valve (E) by turning it all the way 16° c 60° F 16.74 BAR 243 PSI
to the right (clockwise). 18° c 6Sa F 16.87 BAB 24S PSI
3. Connect the charging gauges to the nitrogen 21° c 70° F 17.06 BAR 248 PSI
supply tank, open the supply tank valve. 24° c 7Sa F 17.26 BAB 2S4 PSI
27" c 80°F 17.4S BAR 2SO PSI
4. Slowly turn valve (D) clockwise while watching
2go c asaF 17.S8 BAB 2S3 PSI
the pressure gauge (B). Stop turning valve (D)
32° c goaF 17.77 BAR 2S8 PSI
when the needle on the gauge (B) reaches 10
3S c
0 gsaF 17.g6 BAB 261 PSI
bar (145 psi).
38° c 100° F 18.1S BAR 263 PSI
NOTE: If the needle goes over the needed pressure, TEMPERATURE/CHARGE PRESSURE CHART
quickly open and close valve (E) and check the
12. Close valve (E) by turning to the right
pressure again.
(clockwise). After a few minutes open valve (E)
The charging kit is now ready to be installed on the and check the accumulator for leakage.
accumulator.
13. Back off the needle valve (A) on the accumulator
5. Remove the cap from the accumulator. end of the charging hose by turning it
6. Loosen the sealing plug with an Allen wrench. counterclockwise the maximum amount. This will
prevent nitrogen from escaping from the
NOTE: just loosen do not open to far so the gas
accumulator as the hose is removed.
leaks out
14. Close the valve on the nitrogen supply tank.
7. Install adapter 380001168 (F).
15. Adjust the regulator (D) to the minimum pressure
8. Back off the needle valve (A) on the accumulator
setting by turning the knob counterclockwise.
end of the charging hose by turning it
counterclockwise to the maximum amount. This 16. Slowly remove the charging hose from the
prevents nitrogen from escaping from the accumulator pressure valve.
accumulator when the charging hose is attached NOTE: A small amount of nitrogen will escape when
to the accumulator gas charging valve. disconnecting the hose.
9. Install the charging hose fitting onto the adapter. 17. Snug the gas charging valve on the accumulator,
10. Tighten the needle valve by turning it clockwise. remove the adapter from the accumulator.
Slowly open the gauge valve (E) and observe the 18. Torque the gas charging valve to 20 to 25 Nm (15
reading on the gauge. This reading is the to 18.5 pound feet)
nitrogen pressure level inside the accumulator.
19. Install the cap on the accumulator.
11. Fill the accumulator to pressure according to
20. Remove the charging gauges from the nitrogen
Temperature/Charge Pressure chart.
supply tank.

Section
8014
RIDE CONTROL VALVE

8014-2
TABLE OF CONTENTS
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly .............................................................................. 4

8014-3
RIDE CONTROL VALVE
BC05B015.
1. PLUG 6. SPRING 10. ACCUMULATOR DRAIN SCREW 14. POPPET

2. CAPSCREW 7. SPOOL 11. PLUG 15. ORFICE
3. BUSHING 8. PLUG 12. SOLENOID 16. VALVE BLOCK
4. SPRING CARRIER 9. PLUG 13. ORFICE 17. RELIEFVALVE
5. SPRING
Dissasembly STEPS
Remove the pressure relief valve (17).
STEP 1
Remove ride control valve, refer to section 8001. Inspection
1. Discard all 0-rings.
STEP2
Remove plugs (1 ), (8}, (9}, and (11 ). 2. Clean all parts in cleaning solvent.
3. Check the spools and the spool bores for
STEP3 damage and wear.
Remove the solenoid (12). 4. Check the parts of the pressure relief valve.
STEP4 If any of the parts are damaged, install new parts.

Remove the spool (7) from the valve block (16}.
STEPS
Remove cap screw (2}, bushing (3}, spring carrier
(4), springs (5 & 6} from spool (7).
STEPS
Remove orifice (13), poppet (14), and orifice (15).
STEP7
Remove accumulator drain screw (1 0}.

8014-4
Assembly STEPS
Install springs (5 &6), spring carrier (4), bushing (3),
STEP 1 cap screw (2) onto spool (7) and torque cap screw
Install new 0-rings. (2) to 5.5 Nm (48.5 lb-in).
STEP2 STEP7
Install and torque pressure relief valve (17) to 50 Nm Install spool (7) into valve block (16).
(37 lb-ft).
STEPS
STEP3 Install and torque plug (1) to 270 Nm (199 lb-ft).
Install and torque accumulator drain screw (1 0) to
3.5 Nm (31 lb-in). Install the plug for accumulator STEP9
drain screw and torque to 7 Nm (62 lb-in). Install plug (8) and torque to 140 Nm (1 03 lb-ft), plug
(9) and torque to 30 Nm (22 lb-ft), and plug (11) and
STEP4 torque to 90 Nm (66 lb-ft).
Install and torque orifice (15) to 15 Nm (11 lb-ft),
install poppet (14), install and torque orifice (13) to STEP10
15 Nm (11 lb-ft). Install the ride control valve in the machine, see
section 8001.
STEPS
Install and torque solenoid valve to 12 Nm (1 06 lb-in). STEP 11
Test the ride control system, see section 8002.

SECTION INDEX
MOUNTED EQUIPMENT
Air Conditioning Troubleshooting and System Checks for Systems with HFC134a Refrigerant ............. 9002
Air Conditioning System Service ............................................................. 9003
Removal and Installation of Air Conditioning and Heater Components ................................ 9004
Loader .................................................................................9006
Roll Over Protective Structure (ROPS) Cab Structural Frame (CSF) ................................. 9007
Cab Glass Installation ..................................................................... 9010

Section
9002
AIR CONDITIONING TROUBLESHOOTING AND SYSTEM

CHECKS FOR SYSTEMS WITH HFC-134A
REFRIGERANT

9002-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING ..................................................................... 6
Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cab Temperature Check................................................................. 10
Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Evaporator/Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Test Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PRESSURE-TEMPERATURE CHART........................................................ 14
QUICK REFERENCE TROUBLESHOOTING CHART ............................................ 14
A/C RECOVERY AND CHARGING STATION CONNECTIONS .................................... 15
PROBLEM: NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of No Refrigerant or Low Refrigerant Charge: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Indication of Large Quantity of Air in System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Condenser Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Expansion Valve Malfunctioning - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refrigerant Contamination: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
HFC-134a Stable Saturation Pressure/ Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PROBLEM: NOT ENOUGH COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Not Enough Refrigerant - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
High Side Restriction - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Expansion Valve Not Operating- Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressor Turning But Not Pumping Properly- Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Expansion Valve Stuck Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Condenser Not Operating - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PROBLEM: INTERMITTENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Moisture in the System - Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PROBLEM: NOISE IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Too Much Refrigerant in System- Indications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TUBE CONNECTIONS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

9002-3
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH. M171B
ATTENTION: Only authorized technicians certified 3. Keep refrigerant containers in the correct upright
by an approved training and certification organization position. Always keep refrigerant containers
may service or repair motor vehicle or mobile air away from heat and sunlight. The pressure in a
conditioning systems. It is mandatory that all container will increase with heat.
refrigerant must be RECOVERED and RECYCLED
4. Always reclaim refrigerant from the system, if you
when removed from a system during servicing.
are going to weld or steam clean near the air
Refrigerant HFC-134a is the most stable, and easiest conditioner system.
to work with of the refrigerants now used in air
5. Always check the temperature and pressure of
conditioner systems. Refrigerant HFC-134a does not
the air conditioner system before reclaiming
contain any chlorofluorocarbons (CFC's) which are
refrigerant and when you test the system.
harmful to the earth's ozone layer.
6. Dangerous gas can form when refrigerant comes
Safety procedures must be followed when working
in contact with an open flame. Never permit
with Refrigerant HFC-134a to prevent possible
fumes to be inhaled.
personal injury.
7. Never leak test with compressed air or flame
1. Always wear safety goggles when doing any
testers. Tests have indicated that compressed
service work near an air conditioner system.
mixtures of HFC-134a and air can form a
Liquid refrigerant getting into the eyes can cause
combustible gas.
serious injury. Do the following if you get
refrigerant near or in your eyes: 8. Always reclaim refrigerant from the system
before removing any air conditioning component.
A. Flush your eyes with water for 15 minutes.
B. See a physician immediately.
2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
frostbite or a physician must be seen if you get
refrigerant on your skin.

9002-4
299L7C
BELT TENSION TOOL CAS-1 0808 REFRIGERANT RECOVERY, RECYCLING AND CHARGING
STATION, OEM-1415
109L7
ELECTRONIC LEAK DETECTOR OEM-1437
SAFETY GOGGLES CAS-10073-3

9002-5
OPERATION
The refrigerant circuit of the air conditioning system The refrigerant, still in a high pressure liquid form,
contains five major components: compressor, then flows from the receiver-drier to the expansion
condenser, receiver-drier, expansion valve and valve. The expansion valve then causes a restriction
evaporator. These components are connected by in flow of refrigerant to the evaporator core. The
tubes and hoses and operate as a closed system. evaporator meters refrigerant flow based on
The air conditioner system is charged with HFC-134a evaporator heat load.
refrigerant.
As the refrigerant flows through the evaporator core,
The compressor receives the refrigerant as a low the refrigerant is heated by the air around and flowing
pressure gas. The compressor then compresses the through the evaporator fins. The combination of
refrigerant and sends it in the form of a high pressure increased heat and decreased pressure causes the
gas to the condenser. The air flow through the air flow through the evaporator fins to become very
condenser then removes the heat from the cool and the liquid refrigerant to become a low
refrigerant. As the heat is removed the refrigerant pressure gas. The cooled air then passes from the
changes to a high pressure liquid. evaporator to the cab for the operator's comfort.
The high pressure refrigerant liquid then flows from The electrical circuit of the air conditioning system
the condenser to the receiver-drier. The consists of a fan speed control, temperature control,
receiver-drier is a container filled with moisture one (1) relay, a blower motor, blower resistor, A. C.
removing material, which removes any moisture that compressor clutch, A.C. low pressure switch, A.C.
may have entered the air conditioner system in order high pressure switch, and A.C. warning light.
to prevent corrosion of the internal components of
the air conditioner system.
1 . ~LOW PRESSURE GAS
~ .. J • • • L OW PRESSURE LIQUID
-:3 D r:~~ (
·--·---------- ',•
·~ IIIIIIIIIIIIIIIHIG H PRESSURE GAS
- H I G H PRESSURE LIQUID
I
II.-.
·--------~·---·
"CD
I'
®--
v. '\ ~~~
~
~
--..lo
~ ~
~ ..,
I I'
,
{ .
" )
.oill
208L95
1. EXPANSION VALVE 3. COMPRESSOR 5. RECEIVER-DRIER

2. EVAPORATOR 4. CONDENSER

9002-6
TROUBLESHOOTING
Perform a visual inspection of the machine. Check 5. - Are there heavy accumulations of oil, or oily
the following and correct as necessary: dust around the fittings, indicating refrigerant
leakage?
1. - Obtain service history if possible.
6. - Are air ducts undamaged, sealed properly and
2. - Is compressor drive belt in place and tensioned?
in position?
3. - Are grille screens, fan blades, condenser, air filter, and
7. - Condensate drain hoses and check valves
evaporator unobstructed?
present and unobstructed?
4. - Are there any sharp bends or kinks in the
hoses?
Problem: No Cooling
Mechanical - See Mechanical Compressor
Check Page 8
Compressor Runs No----..
Electrical - See Blower and Compressor
Clutch Check Page 9
Yes t
Internal System Problem
See Pressure Testing, Page 13

9002-7
Problem: Problem:
Not Enough Cooling Erratic Cooling
MECHANICAL
See Mechanical Compressor Check Page 8.

HEATER
Make sure the heater control is OFF and that there is no coolant
flow through the heater core.
ELECTRICAL
See Blower and Compressor Clutch Check - Blower Motor
Check, Blower Switch Check and Compressor Clutch Check
on Page 9.
SEAL
Make sure the sealing material is correctly in place.
INTERNAL SYSTEM PROBLEMS

See Pressure Testing, Page 13.
MECHANICAL
See Mechanical Compressor Check page 8. See Evaporator
Heater Core Check Page 12.
Problem:
System Makes Noise
ELECTRICAL
See Blower and Compressor Clutch Check on Page 9.
MECHANICAL
See Mechanical Compressor Check Page 8.

See Blower Motor Check Page 9.
REFRIGERANT
See Cab Temperature Check Page 10.

ELECTRICAL
See Compressor Clutch Check Page 9.
INTERNAL SYSTEM PROBLEM
See Pressure Testing, Page 13. INTERNAL SYSTEM PROBLEM
See Pressure Testing, Page 13.

9002-8
SYSTEM CHECKS
Mechanical Compressor Check

1 . Too much belt wear - replace a worn belt,
Compressor and Fan Belts because a worn belt will cause too much
slippage.
1. Loose bracket mounting bolts - tighten the

bolts to the correct torque.
Compressor Mounting Brackets 2. Bracket has cracks or breaks - replace the
bracket.
1. The compressor belt will slip on the

compressor pulley if there is compressor
seizure. Remove the compressor for
service or replacement.
2. Remove the dust cover and check the air
gap on the compressor clutch. The gap
Compressor Clutch between the front plate and pulley
assembly must be 0.41 to 0.79 mm.
3. Use a socket wrench to slowly rotate the
compressor clockwise. Compressor
rotation should be smooth and not require
much effort.
1. The compressor pulley and the

compressor drive pulley must be aligned
within 1.6 mm (1/16 inch) of each other.
Pulley and Belt Alignment Use a straight edge to check pulley
alignment. Adjust the compressor
mounting bracket if needed.

9002-9
Blower and Compressor Clutch Check

NOTE: Check supply voltage with
compressor lead plugged in and engaged.
Voltage drops will not be apparent without
current flow.
Compressor Clutch
1. If there is electrical system voltage to the
clutch, check for excessive voltage drop in
the ground circuit, then see Section 9004
and replace the compressor.
1. See Section 4002 and check the high and

Low and High Pressure Switches low pressure switches.
Blower Fuse (1 0 amp) 1. Check for damaged blower fuse.
1. Check switch operation. Switch must give

four different blower speeds: OFF, Low,
High, and Purge.
Blower Fan Switch 2. Check for loose connections or broken
wires. Repair or replace as necessary.
3. Check resistor board.
1. Check the wiring to the blower motor.

Make repairs or replace items as
necessary.
Blower Motor 2. Check motor ground wire. Make sure
motor ground wire is making good contact
with mounting bracket.
1. With key in ON position, turn switch to

maximum cold. Compressor clutch must
engage.
NOTE: Blower must be operating, since
electrical power to temperature control switch
is received from blower switch.
Temperature Control Switch 2. Turn the blower off. Disconnect the wires
from the temperature control. Using an
ohmmeter, check the continuity between
switch terminals. If continuity is not
present when switch is on maximum cold,
replace switch.

9002-10
Cab Temperature Check

1. Make sure louvers and recirculation vents are fully open
for most efficient air conditioning operation. Defrost
Air Louvers louvers must be closed.
2. Check blower; blower must be running.
ATTENTION: Use caution when feeling hoses. Hoses

become very hot. Check temperature by slowly reaching for
hose and touching briefly several times with finger tips,
increasing the duration with each touch.
Air Conditioning 1. Feel the air conditioning hoses. The high pressure hoses
(small line) must be warmer than the low pressure hose
(large line).
2. If no temperature difference, the system is low on
refrigerant, or compressor is not working correctly.
1. Put a thermometer in the air duct behind the seat and

run the compressor for five minutes to make
temperature stable. Refer to page 12.
2. Duct temperature must be below 25° C (72° F) if the
system is operating at maximum efficiency.
Duct Temperature NOTE: Ambient temperature must be 27 to 43' C (80 to
1100 F).
3. If temperature is above 25° C (72° F), system is low on
refrigerant, there is a restriction in the system,
compressor is not working correctly, or air ducts are not
sealed correctly.
1. Turn the engine OFF, key switch ON, blower switch ON

and temperature control switch turned fully clockwise.
2. Remove the temperature sensing probe from the
evaporator. Refer to Section 9004.
3. Put the end of the temperature sensing probe in a
container with ice and water.
Temperature Sensing Probe Check 4. When the sensing tube has cooled to the temperature of
the ice and water mixture, the temperature control switch
should interrupt the current flow to the compressor.
Check for current at the control switch terminals as on
previous page. If current is not interrupted then replace
the control switch.

9002-11
Visual and Leak Check

1. Make sure that all hose connections are
tight.
Compressor Hoses 2. Check hoses for bends or cracks. Replace
all hoses that have damage.
1. Shut off the engine.

WARNING: When refrigerant comes in
contact with an open flame, it can form
dangerous gas. Never breathe these fumes.
2. Use electronic leak detector OEM -1437
to inspect all connections. Use
instructions from manufacturer of leak
Leak Finding Check finding tool.
NOTE: When checking compressor seal for a
leak, remove the dust cover and rotate the
clutch shaft clockwise.
NOTE: To properly check the expansion valve
for leaks, remove the insulation tape.
3. Repair all leaks and recharge the system.
See Section 9003.
1. Make sure the condenser is clean and the

seals are in place. Make sure condenser
Condenser fans run when temperature control switch
is ON.

9002-12
Evaporator/Heater Core Check

Make sure heater valve is closed
Evaporator/Heater Core
1. See Section 9004 for access to the
evaporator/heater core.
2. Inspect the fins on the evaporator/heater
core. All the fins that have bends or
damage must be made straight.
3. Inspect the evaporator/heater core for
restrictions. If the core is dry, use
compressed air or a brush and vacuum
cleaner. If the core is wet or filled with
Evaporator/Heater Core mud, flush the core with water using a
hose without pressure. Make sure the
water drains freely from the
evaporator/heater core. DO NOT USE
STEAM.
WARNING: Do not steam clean any air
conditioning systems parts while the system is
charged. The heat will cause the refrigerant to
rise to a pressure that could cause the system
to explode.
1. See Section 9004 for access to the

2. Make sure seals are in place so blower
Evaporator/Heater Core Sealing will pull air only through the
evaporator/heater core and not around the
Filters 1. Make sure the filters are clean.

9002-13
PRESSURE TESTING
Manifold Gauge Set During normal operation the low pressure gauge
must always indicate from 10 to 35 psi (0.7 to 2.4
NOTE: The gauge set is not accurate enough to bar) after the system has run 10 to 15 minutes.
optimize an existing charge of HFC-134a. The best
use of the gauge set is to determine whether HIGH PRESSURE GAUGE - The high pressure
undercharge or overcharge exists, and then gauge is used to indicate pressures in the high side
evacuate, reclaim and recharge system with the of the system. The gauge must indicate from 0 to 400
recommended quantity (charge) of HFC-134a. psi (0 to 27.6 bar) minimum.
The manifold gauge set is the most important tool During normal operation, the high pressure gauge
used to service the air conditioning system. The will normally indicate from 120 to 310 psi (8.3 to 21.4
manifold gauge set is used to measure the high and bar). See pressure-temperature chart on page 14.
low pressures of the system, as a tool to troubleshoot
for correct refrigerant charge quantity, system Pressure Test Connection
diagnosis, and operating efficiency. The manifold
Connect the manifold gauge set into the air
gauge set can read both the high (discharge) and low
conditioning system as shown. Make sure that both
(suction) sides at the same time, since pressure must
valves in the manifold gauge set are closed.
be compared in order to make a diagnosis of system
operation.
LOW PRESSURE GAUGE -The low pressure gauge
is a compound gauge. It is best used to judge
evacuation effectiveness. A vacuum reading
indicates a system malfunction. For this reason, it is
necessary to use a compound gauge that will
indicate both pressure and vacuum.

9002-14
PRESSURE-TEMPERATURE CHART
AMBIENT NORMAL LOW NORMAL HIGH AIR LOUVER (BEHIND

TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION SEAT) MAXIMUM TEMP.
OF (OC) psi (bar) psi (bar) OF (OC)
110 (43) 22 to 24 290 to 310 72 (25)

(1.93 to 2.14) (20 to 21.37)
The pressure-temperature chart is based on the 2. All panels and access doors installed and closed.
following conditions:
3. Cab filters clean and installed.
NOTE: High humidity will cause higher air louver
4. Heater valve at engine closed.
temperatures and dramatic increase in suction
pressure. The table shown represents readings taken 5. Measurements taken 15 minutes after startup.
in low relative humidity. Adjust the chart according to
local conditions.
1. Engine at 1500 RPM, no load, fan speed &
temperature control at max setting, A/C switch
ON, all louvers and doors open
QUICK REFERENCE TROUBLESHOOTING CHART
PROBLEM LOW PRESSURE HIGH PRESSURE SEE

GAUGE GAUGE PAGE

9002-15
A/C RECOVERY AND CHARGING STATION CONNECTIONS

STEP 1 STEP4
Clean the external surfaces of the compressor and Connect the hose from the high pressure gauge to
hoses. Remove the caps from the service ports on the port on the discharge hose.
the suction and pressure hoses.
~ARNING: Always wear safety goggles
WARNING: Do not steam clean any air h when working with liquid refrigerant. Liquid
conditioning system parts while the system is . . . refrigerant in your eyes could cause
h charged. The heat will cause the refrigerant blindness. SM105A
. . . to rise to a pressure that could cause the
f9ystem to explode. SM104A
STEPS
Make sure the charging station manifold gauge
STEP2 valves are in the closed position.
Connect the hoses from the test gauges to the
service ports by turning the knurled knobs on the STEPS
depressors. Start the engine and run at 1500 RPM maximum
speed. Operate the air conditioner system at
STEP3 maximum cooling setting and blower speed for 15
Connect the hose from the low pressure gauge to the minutes with the cab door open. Observe the test
port on the suction hose. gauges and check the chart on page 13 against the
gauge readings.

9002-16
PROBLEM: NO COOLING
476L7
SEE PRESSURE- TEMPERATURE CHART ON PAGE 14
Indication of No Refrigerant or Low Refrigerant Charge:

1. Leak test the system, see Page 11. It may
be necessary to add refrigerant. See
Section 9003.
2. Evacuate and reclaim rema1mng

refrigerant from system. See Section
9003.
3. Repair system leaks as needed. Follow

the given repair procedure.
A. Discharge air from evaporator warm.
B. Compressor does not run, or cycles off Yes____.. 4. Check level of oil in compressor- possible
rapidly after start-up. (A/C warning light for compressor to have an oil loss.
in cab should illuminate).
5. Remove air and moisture from the
system. Replace Receiver-Drier. See
Section 9004.
6. Charge system with new refrigerant. See

Section 9003.
7. Continue performance test for other

possible problems.

9002-17
476L7
Indication of Large Quantity of Air in System:

1. Evacuate and reclaim refrigerant from
system. See Section 9003.
2. Replace receiver-drier.
Discharge air from evaporator warm Yes----. 3. Remove air and moisture from the
Section 9003.
Condenser Malfunctioning- Indications:

1. Check for loose or worn compressor or engine fan
belt and proper condenser fan operation.
2. Check to see that condenser is clean and

unobstructed and that the fins are straight.
3. Check system for too much refrigerant. Evacuate,
reclaim and recharge refrigerant until gauge
pressure is normal. See Section 9003.
4. Remove and check condenser for restrictions

A. Liquid line (between evaporator and
caused by oil or reduced heat transfer.
condenser) is very hot.
B. Discharge air from evaporator warm.
A. Remove refrigerant from the system. See
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9003.
5. Continue the performance test for other possible

problems.

9002-18
Expansion Valve Malfunctioning- Indications:

A. Discharge air from heater/evaporator
warm.
B. Much condensation on suction hose at See Section 9004 and replace the expansion
compressor. valve.
C. Much condensation on evaporator
outlet.
Refrigerant Contamination:
1. See table below and check stable saturation pressures at
given temperature to determine if contamination exists.
A. Measure pressure from gauge on reclamation unit.
B. Measure temperature from refrigerant in reclamation
tank. If refrigerant has been in reclamation unit for some
time, use ambient temperature. The numbers in the
Refrigerant Contamination
table represent the boiling point for HFC-134a.
C. Pressure readings below range given in chart indicate
contaminated refrigerant.
IMPORTANT: Do not use contaminated refrigerant or mix
with uncontaminated refrigerant. Dispose of in accordance
with all applicable laws and local procedure.
HFC-134a Stable Saturation Pressure/ Temperature Chart
Temperature v F (v C) Pressure PSIG (Bar)
50 (1 0) 45 (3.1)
55 (13) 51 (3.5)
60 (16) 57 (3.9)
65 (18) 64 (4.4)
70 (21) 71 (4.9)
75 (24) 78 (5.4)
80 (27) 88 (6.1)
85 (29) 95 (6.6)
90 (32) 104 (7.2)
95 (35) 114 (7.9)
100 (38) 124 (8.6)
102 (39) 129 (8.9)
104 (40) 133 (9.2)
106 (41) 138 (9.5)
108 (42) 142 (9.8)
110(43) 147 (10.1)
112 (44) 152 (1 0.5)
114 (46) 157 (1 0.8)
116 (47) 162 (11.2)
118(48) 167 (11.5)
120 (49) 172 (11.9)

9002-19
PROBLEM: NOT ENOUGH COOLING
476L7
Air in the System- Indications:

1. Test system for leaks. See page 11 . Possible
leak has let air enter; check compressor seal
carefully.
2. Discharge system of refrigerant. See Section
9003.
A. Suction line warm to your hand. 3. Repair system leak as necessary.
B. Discharge air from heater/evaporator 4. Replace receiver-drier.
only a little cool.
5. Check compressor oil level.
6. Remove air and moisture from the system.
See Section 9003.
Section 9003.

9002-20
476L7
Not Enough Refrigerant- Indications:

1. Leak test system - system has a loss of refrigerant.
NOTE: Normally, the system will lose 1/2 to 1 ounce (14.7
to 29.5 grams) of refrigerant between seasons.
A. If leak is found, go to Step 2.
B. If no leak is found, go to Step 6.
2. Discharge refrigerant from system. See Section 9003.
A. Discharge air from evaporator 3. Repair system leaks as needed.

cool or warm- not cold.
4. Check oil level in compressor - It is possible for
compressor to lose oil.
5. Remove air and moisture from the system. Replace

Receiver-Drier. See Section 9004.
6. Charge system with new refrigerant. See Section

9003.
High Side Restriction - Indications:

A. Discharge air from heater/evaporator
1. Discharge refrigerant from system-restriction in
only a little cool.
receiver-drier or liquid line must be removed.
B. Condensation or frost on
2. Remove and replace part with restriction.
receiver-drier.
3. Remove air and moisture from the system. See
C. Liquid line to receiver-drier cool, with
Section 9003.
frost or condensation.
4. Charge system with new refrigerant. See Section
NOTE: The frost will form downstream from
9003.
or at the point of the restriction

9002-21
Expansion Valve Not Operating - Indications:

.------------------------------------,
1. Expansion valve outlet with condensation or frost is
A. Discharge air from evaporator warm an indication of a restriction in the expansion valve.
or cool - not cold. Replace expansion valve. See Section 9004.
B. Condensation or frost on expansion 2. Inlet end of expansion valve is warm (not hot),
valve outlet. indicating expansion valve is not completely open.
C. Inlet end of expansion valve is If the valve is stuck closed, there will be little or no
warm. flow of refrigerant through the valve. Replace
expansion valve. See Section 9004.

9002-22
476L7
SEE THE PRESSURE- TEMPERATURE CHART ON PAGE 14
Compressor Turning But Not Pumping Properly- Indications:

1. Discharge refrigerant from system. See Section
9003.
2. Remove the compressor from the machine. See
Section 9004.
3. Remove and replace compressor because there is
indication of internal leak in compressor.
A. System is fully charged. 4. Replace compressor.
B. Cool discharge air from evaporator. 5. Replace receiver-drier if:
A. System has been opened before.
B. Receiver-drier has been used two or more
years. See Section 9004 for receiver-drier
replacement.
6. Charge the system with refrigerant. See Section
9003.
Expansion Valve Stuck Open

I Expansion Valve Stuck Open 1. Replace expansion valve. See Section 9004.

9002-23
476L7
Condenser Not Operating - Indications:

1. Check for loose or worn compressor belt and
proper condenser fan operation.
2. Check to see that condenser is clean and that
the fins are straight.
3. Check system for too much refrigerant.
A. Remove refrigerant from system until gauge
pressure is below normal. See Section 9003.
B. Add refrigerant until gauge pressures are
A. Liquid line very hot.
normal. See Section 9003.
B. Discharge air from evaporator warm.
C. If there is still a problem, do step 4.
4. Remove and inspect condenser for restrictions
caused by oil or reduced heat transfer.
A. Discharge refrigerant from system. See
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier. See Section 9004.
Air in the System- Indications:

1. Discharge refrigerant from system. See
Section 9003.
2. Replace receiver-drier.
Warm discharge air from evaporator. 3. Remove air and moisture from the
Section 9003.

9002-24
PROBLEM: INTERMITTENT COOLING
476L7
Moisture in the System - Indications:

1 . Discharge system of refrigerant. If too
much moisture enters the orifice of the
expansion valve, the freezing of this
moisture can stop refrigerant flow. See
Section 9003.
2. Replace receiver-drier. The moisture

removing material could be full to capacity
with moisture. See Section 9004.
Cooling is acceptable during cool part of day
but not acceptable during hot part of day.
3. Remove air and moisture from the
NOTE: The time needed to remove a large
amount of moisture will be two to three hours
minimum.

Section 9003.

9002-25
PROBLEM: NOISE IN SYSTEM
476L7
Too Much Refrigerant in System- Indications:

1 . Remove refrigerant from system until gauge
readings are below normal. See Section
A. Cool discharge air from heater/evaporator.
9003.
B. Compressor makes noise.
2. Add new refrigerant until gauge readings are
normal. See Section 9003.

9002-26
TUBE CONNECTIONS TORQUE CHART
TUBING SIZE 3/8 inch 1/2 inch 5/8 inch

THREAD SIZE M10 -1.25 5/8-18 3/4-18 7/8-18 1-14
OR OR
3/4-16 7/8-14
STEEL TO STEEL 31-36 Nm 31-36 Nm 40-46 Nm 45-52 Nm 45-52 Nm
ALUMINUM TO BRASS 10-14 Nm 10-14 Nm 24-30 Nm 30-37 Nm 45-52 Nm
NOTE: When tightening air conditioning hose or pipe fittings, a second wrench serving as support must be used.
IMPORTANT: Special care is required when tightening the fittings on the compressor, condenser and evaporator
since these connections are easily distorted.

Section
9003
AIR CONDITIONER SYSTEM SERVICE

9003-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................... 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING .................................. 7
PRESSURE- TEMPERATURE CHART....................................................... 10

9003-3
SPECIFICATIONS
Air conditioning system refrigerant capacity ...................................................................................... 1.7 kg (3.75 lbs)
SPECIAL TOOLS
A22094 109L7
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING SAFETY GOGGLES CAS-10073-3

STATION OEM-1415

9003-4
SAFETY PROCEDURES

4. Always reclaim refrigerant from the system, if you
Refrigerant HFC-134a is the most stable and easiest conditioner system.
conditioning systems. Refrigerant HFC-134a does
not contain chlorofluorocarbons (CFC's) which are
harmful to the Earth's ozone layer.
with refrigerant HFC-134a to prevent possible
personal injury.
combustible gas.

9003-5
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

Recovered refrigerant passes through an oil STEP3
separator and a filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system off before proceeding.
STEP 1
A22114
Open the high and low valves.
STEP4
Clean the external surfaces of the compressor and

hoses. Remove the caps from the service ports on
the suction and pressure hoses.
STEP2
A22107
Make certain the refrigerant tank gas and liquid

valves are open.
With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports.
Connect the hose from the low pressure gauge to the
port on the suction hose. Turn in valve depressor.
Connect the hose from the high pressure gauge to
the port on the discharge hose. Turn in valve
depressor.

9003-6
STEPS STEP7
A22112
Connect the main power plug to a 115 volt AC outlet. Slowly open the oil drain valve and drain the oil into
Move the main power switch to the ON position and the reservoir. When the oil stops draining, close the
depress the recovery start switch. oil drain valve completely.
The compressor will shut OFF automatically when
recovery is complete. Wait for 5 minutes and observe STEPS
the manifold pressure gauges for a pressure rise. If
pressure rises above 0 psi (0 bar), depress the
hold/cont switch. Then wait for the compressor to
automatically shut OFF.
STEPS
A22111
Fill the A/C compressor with fresh SP-20 PAG oil

equal to the amount in the reservoir.
STEP9
A22108
Drain the oil separator of the A/C system oil. Open

the air purge valve long enough to let some of the
compressor discharge pressure back into the
separator.
BD03A213
Remove the hoses from the service ports and install

the caps.

9003-7
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or Air and moisture are removed from the system by a
more of the following conditions occurs before you vacuum pump. A vacuum pump is the only
remove the air and moisture from the system. equipment made to lower the pressure enough to
change the moisture to vapor that can be removed
A. The system has been opened for service
from the system.
before.
NOTE: Refer to the vacuum pump manufacturer's
B. Receiver-drier has operated two or more
user manual for additional information.
years.
C. Disassembly of compressor shows small STEP 11
particles of moisture removing material (gold
or brown particles).
D. Large system leak (broken hose, break in
line).
E. Too much air or moisture in system.
F. Removal of compressor caused the system to
be open (uncapped) longer than 5 minutes.
STEP10
Connect the main power plug to a 115 volt AC outlet.

Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum of
45 minutes and press the Enter key. The display will
flash once indicating the programmed data has been
accepted.
STEP12
BD03B001
With the charging station manifold gauge valves in

the closed position, connect the hoses from the test
gauges to the service ports as follows:
1. Connect the hose from the low pressure gauge
to the port on the suction hose.
2. Connect the hose from the high pressure gauge
to the port on the discharge hose.
3. Turn in both thumbscrews to depress the service
valves.
Removal of air and moisture from the system is
necessary after the refrigerant has been removed Press the Charge key. "Program" and "Charge" will
after the system has been opened for maintenance. appear on the display.
Air enters the system when the system is opened. Air
has moisture that must be removed to prevent
damage to the system components.
NOTE: The pump on the reclamation unit will not pull
a sufficient vacuum to remove air and moisture.

9003-8
STEP13 STEP16
A22113 A22123
Program 3.5 lbs and press the enter key. The display Press the Vacuum key. "Automatic" will appear on the
will flash once indicating the programmed data has display. Vacuum will appear on the display and after
been accepted. a slight delay, the vacuum pump will start. The
display will show the amount of time programmed
STEP14 and begin a countdown to zero.
When the programmed time has elapsed, an
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 10 minutes. A previously charged,
leak-free system will leach refrigerant from
compressor oil and raise system pressure under
vacuum. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See Section 9002 in the manual for a leak
test.
A22114
Fully open the low and high pressure valves.

STEP17
STEP15
A22113
Press the charge key to begin refrigerant charging.

"Automatic" and "Charge" will appear on the display.
Open the red (vapor) and blue (liquid) valves on the The display shows the programmed amount and
tank. counts down to zero as charging proceeds. When
charging is completed, the display shows "CP~'.

9003-9
STEP18 STEP 21
A22114 BD038001
Completely close the high and low pressure manifold Stop the engine, close any open valves and carefully
valves. remove the manifold gauge hoses.
ATTENTION: Check the OEM equipment manual
before performing Step 19 to avoid damaging the STEP 22
recovery unit. The pressure reading should be
obtainable with valves closed. Damage may occur if
the machine is started with the valves accidently
open or if either or both valves are opened while the
A/C system is operating.
STEP19
Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting
and blower speed with the doors and windows open.
NOTE: The compressor will not operate if the
system pressure is too low or too high. The pressure BD038213
indicator lamp will illuminate when the relay is Install the caps on the service ports on the suction
actuated by a low or high pressure and the and discharge hoses.
compressor clutch will disengage. To restart the
compressor, the air conditioner control or blower
switch must be turned to the OFF position and then
to the ON position.
STEP 20
Observe the pressure gauge readings to determine

that the correct amount of refrigerant has entered the
system. See chart on Page 9002-9 for temperature
and pressure variations.

9003-10
PRESSURE - TEMPERATURE CHART
AMBIENT NORMAL LOW NORMAL HIGH AIR LOUVER

TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION MAXIMUM TEMP.
oF (0 C) psi (bar) psi (bar) OF (OC)
110 (43) 22 to 24 290 to 310 72 (25)

(1.93 to 2.14) (20 to 21.4)
The pressure-temperature chart is based on the 5. Both cab doors open

following conditions:
6. All panels and access doors installed and closed.
1. Engine operating at 1500 RPM
7. Cab filters clean and installed.
2. No engine load
8. Heater valve at engine closed.
3. Fan speed control in maximum position and all
9. Measurements taken 15 minutes after start-up.
louvers open.
4. Cab temperature control set to maximum
cooling.

Section
9004
REMOVAL AND INSTALLATION OF AIR CONDITIONING

AND HEATER COMPONENTS

9004-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal .............................................................................. 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EXPANSION VALVE, EVAPORATOR/HEATER CORE,
HEATER VALVE, BLOWERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal .............................................................................. 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CONDENSER AND RECIEVER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal ............................................................................. 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

9004-3
SAFETY PROCEDURES
A
4. Always reclaim refrigerant from the system if you
Refrigerant HFC-134a is the most stable, and easiest conditioner system.
conditioner systems. Refrigerant HFC-134a does not
contain any chlorofluorocarbons (CFC's) which are
harmful to the earth's ozone layer.
with Refrigerant HFC-134a to prevent possible
personal injury.
combustible gas.

9004-4
SPECIAL TOOLS
BS03H012
REFRIGERANT RECOVERY, RECYCLING AND CHARGING SAFETY GOGGLES CAS-10073-3
STATION OEM-1415

9004-5
COMPRESSOR
Removal STEP4
STEP 1
position.
STEP2
Discharge the air conditioning system according to
the instructions in Section 9003.
STEP3
BD06F116
Remove the fan belt.
STEPS
Disconnect the low pressure line from the suction

port and the high pressure line from the discharge
port on the compressor. Immediately install
protective caps on the open ports and lines.
Loosen and remove the four bolts holding the

protective shield. Remove the shield.

9004-6
STEP6 Installation
STEP9
Place the compressor into position on the machine.
STEP10
Disconnect the compressor clutch wire from the

engine harness assembly.
STEP7
Install the three bolts to mount the compressor.
STEP 11
Loosen and remove the three compressor mounting

bolts.
STEPS
Remove the compressor from the machine. Connect the compressor clutch wire to the engine
harness assembly.

9004-7
STEP12 STEP13
Carefully remove the protective cap, install a new
0-ring, and connect the low pressure line to the
suction port on the compressor.
STEP14
Install the belt.
STEP15
Install the protective shield.
STEP16
Charge the air conditioning system according to the
BD06F117 instructions in Section 9003.
Slowly remove the protective cap, install a new
0-ring, and connect the high pressure line to the
discharge port on the compressor.
IMPORTANT: Use caution when removing cap as
new compressors have internal pressure when
shipped.

9004-8
EXPANSION VALVE, EVAPORATOR/HEATER CORE,

HEATER VALVE, BLOWERS
BS06G118
1. EVAPORATOR 7. WASHER 13. LOWER BOX PPE

2. UPPER BOX PPE 8. GROMMET 14. EXPANSION VALVE
3. COVER PPE 9. HEATER CORE 15. BLOWER
4. SOLENOID DRIVER 10. HEATER VALVE 24V 16. RECIRCULATING VAIN
5. UPPER BOX 11. THERMOSTAT 17. RECIRCULATING MOTOR
6. BOLT 12. LOWER BOX 18. RESISTOR BLOWER MOTOR

9004-9
Removal STEP 23
STEP17
bucket to the floor.
STEP18
If changing any air conditioning components,
discharge the air conditioning system according to
STEP19
BD06G212
Open the cover on the cooler.
STEP 24
BD02N160
If changing the heater core, put a 37 liter (1 0 gallon)

container below radiator drain. Remove radiator cap.
Remove cap and drain coolant into container. Install
cap after coolant has drained. Install radiator cap. BD06G213
Remove the four screws securing the air vent,

STEP 20 remove the vent cover.
Place the master disconnect in the OFF position.
STEP 25
STEP 21
Disconnect the wiring harness from the operator's
seat (if equipped with air seat option).
STEP 22
BD06G214
Remove the three screws securing the cooler to the

cab, remove the cooler.
STEP 26
Fold the rubber mat over to gain access to the upper
box mounting bolts.
Remove the four bolts that fasten the operator's seat
to the upper box, remove the seat from the machine.

9004-10
STEP 27 STEP 30
BD06G215 BD06G217
Remove the six bolts securing the upper box. Going through the inside filter area feel the
recirculating vain to make sure is is in the outside air,
STEP 28 "closed", position.
STEP 31
BD06G216
Remove two screws, one on each side of the upper

box, securing the upper box to the lower box. BD06G218
The above photo shows that the recirculating vain is

STEP 29 not in the outside air "closed" position.
Place the air selector on the control panel to outside
air. STEP 32
NOTE: In step 30 and 33 the upper box is shown
removed for clarity only, these steps must be done
prior to removing the upper box.
BD06G240
Use a screw driver and disconnect the linkage.

9004-11
STEP 33 STEP 36
BD06G219
Close the vain so the upper cover can be removed. BD06G203
Disconnect the solenoid driver.

STEP 34
Remove the upper box up and rest it against the STEP 37
console.
NOTE: The wiring harness for the HVAC system
goes through the upper cover, by resting the cover
against the console the wiring harness will not need
to be removed.
STEP 35
BD06G236
Remove the upper PPE from the heater and air

conditioning cores.
NOTE: If testing on the electrical components are
required the solenoid driver can be reconnected
once the upper PPE is removed.
Pull the wiring harness loose from the upper PPE.

9004-12
NOTE: If replacing the heater control valve, heater STEP 40
core, air conditioning expansion valve, air
conditioning evaporator core do steps 38 through 47,
if replacing electrical components go to step 48.
STEP 38
BD06G206
Remove the thermostat probe and clamp from the

evaporator core.
STEP 41
BD06G204
Remove the right side cab skirt.
STEP 39
BD06G237
Disconnect the electrical connectors from the

thermostat control.
STEP 42
BD06G205
1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES
3. HEATER HOSES
Fasten identification tags on the hoses. Disconnect

the hoses for the heater core and evaporator core,
install plugs in the hoses and caps on the fittings.
BD06G236
Disconnect the electrical connectors from the heater

control valve.

9004-13
STEP 43 STEP 49
Pull the heater core and evaporator core from the
lower box PPE.
STEP 44
Remove the expansion valve from the evaporator
core.
STEP 45
Remove and discard the 0-rings from the openings
in the expansion valve.
STEP 46
Remove the screws from the heater core and remove BD06G208
the control valve. Disconnect the electrical connector for the

recirculating vain motor, disconnect the linkage from
STEP 47 the vain. Remove the mounting screws and remove
the motor.
Remove and discard the 0-rings from the heater
control valve.
STEP 50
STEP 48
BD06G209
1. FAN SPEED AND AIC SWITCH
2. INSIDE/OUTSIDE AIR SELECTOR SWITCH
1. RESISTORS 3. THERMOSTAT
2. RESISTOR CONNECTOR
3. BLOWER MOTOR CONNECTOR Remove the switch panel from the console.
Disconnect the electrical connectors and remove
Remove the fans from the lower PPE, disconnect the
switches as required.
electrical connectors. Remove the two mounting
screws for the resistor, remove the resistor.

9004-14
STEP 51
BD06G207
1. RESISTORS
2. RESISTOR CONNECTOR
BD06G209 3. BLOWER MOTOR CONNECTOR
1. FAN SPEED SWITCH
2. INSIDE/OUTSIDE AIR SELECTOR SWITCH Install the resistor, install the two mounting screws
3. THERMOSTAT and tighten. Install the fans in the lower PPE, connect
Replace switches and connect the electrical the electrical connectors.
connectors as required. Install the switch panel in the
console. STEP 54
Install new 0-rings on the heater control valve.
STEP 52
STEP 55
Install the control valve, install and tighten the screws
to the heater core.
STEP 56
Install new 0-rings on the openings of the expansion
valve.
STEP 57
Install the heater core and evaporator core into the
lower box PPE.
BD06G208 STEP 58
Install the motor and install the mounting screws and
tighten. Connect the electrical connector for the
recirculating vain motor, connect the linkage to the
vain.
Connect the electrical connectors to the heater

control valve.

9004-15
STEP 59 STEP 61
BD06G237
Connect the electrical connectors to the thermostat BD06G205

control.
3. HEATER HOSES
STEP 60
Remove the plugs from the hoses and the caps from
the fittings. Install new 0-rings in the evaporator
fittings, connect the heater and evaporator hoses.
Remove and discard identification tags that were
used during disassemble.
STEP 62
BD06G206
Install the thermostat probe coil and clamp to the

evaporator core "cold" tube.
BD06G204
Install the right side cab skirt.
STEP 63
BD06G238
Install the upper PPE on the heater and air

conditioning cores.
9004-16
STEP 64 STEP 67
BD06G203 Make sure that the recirculating vain is in the closed

Connect the solenoid driver. position.
IMPORTANT: This photo shows it in the open
STEP 65 position and the upper box will not go back into
position without damaging the recirculating vain.
STEP 68
BD06G239
Push the wiring harness into the preformed notches

in the upper PPE.
Set the upper box into position on the heater and
STEP 66 evaporator cores.
Place the air selector on the control panel to outside
air. STEP 69
BD06G216
Install two screws, one on each side of the upper box

securing the upper box to the lower box.

9004-17
STEP 70 STEP 74
BD06G242 BD06G214
Install the insolation panel in the center of the upper Install and tighten the three screws securing the
box. cooler to the cab.
STEP 71 STEP 75
BD06G215 BD06G213
Install and tighten the six bolts securing the upper Install the vent cover, install and tighten the four
box. screws securing the air vent.
STEP 72 STEP 76
Install the right rear floor mat into the cab, if machine
is equipped with air ride seat make sure to pull the Install and torque the four bolts to 73 to 87 Nm (55 to
wiring up above the mat for the seat. 65 pound-feet).
STEP 73
Install the remainder of the floor mat.

9004-18
STEP 77 STEP 79
Connect the wiring connector to the operator's seat Charge the air conditioning system according to the
(if equipped with air seat option). instructions in Section 9003.
STEP 78
Ethylene Glycol and 50% water. Install the radiator
cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.

9004-19
CONDENSER AND RECIEVER DRIER
Removal STEP 85
STEP 80
bucket to the ground.
STEP 81
position.
STEP 82
Discharge the air conditioning system according to
STEP 83 Fasten identification tags on the hoses and

disconnect the hoses from the condenser.
STEP 86
Install plugs in the hoses and caps on the fittings.
STEP 87
BD010142
1. COVER 2. CONDENSER
Open the cover (1) to gain access to the condenser
(2).
STEP 84
Loosen the bolts that fasten the condenser to the
bracket, pivot the condenser and remove the bolts
and condenser.
BD03A109
The condenser is connected to a bracket which

pivots on the cooling frame. Pivot the condenser to
gain access to the hoses.

9004-20
STEP 91
Put the condenser in position on the bracket.
STEP 92
BD06G211
Fasten identification tags on the hoses and

disconnect the hoses from the receiver drier.
STEP 89
Install plugs in the hoses and caps on the fittings.
Install the bolts that fasten the condenser to the
STEP 90 bracket, pivot the condenser down and tighten the
Disconnect the trinary switch, remove the mounting bolts.
bolt, remove the receiver drier and bracket.
STEP 93
BS03A107
Pivot the condenser to gain access to the hoses.
STEP 94
Remove the plugs from the hoses and the caps from
the fittings. Install new 0-rings and connect the
hoses to the fittings. Remove and discard
identification tags that were used during
disassemble.
STEP 95
Pivot the condenser down and close the cover.
STEP 96
Mount the receiver drier and bracket, install and
tighten the mounting bolt.

9004-21
STEP 97 STEP 98
Charge the air conditioning system according to the
instructions in Section 9003.
STEP 99
position.
BD06G211
Remove plugs from the hoses and caps from the

fittings, install new 0-rings and connect the hoses to
the fittings, connect the trinary switch. Remove and
discard identification tags that were used during
disassemble.

9004-22
NOTES

Section
9006
LOADER

9006-2
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................... 3
BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Tooth Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of the Bucket Corner Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RETURN TO DIG ADJUSTMENT (Z-BAR AND XR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RETURN TO DIG ADJUSTMENT (XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT
(Z-BAR, XT, AND XR MODELS) .............................................................. 6
LOADER FRAME (Z-BAR AND XR MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remove ............................................................................... 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LOADER FRAME (XT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remove.............................................................................. 11
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

9006-3
SPECIFICATIONS
Special Torques
Bolts for the Bucket Teeth ........................................................................ 1315 to 1480 Nm (970 to 1090 pound-feet)
BUCKET TEETH
Replacement of the Tooth Points

1. Use a hammer and punch to drive the retaining
pin (2} for the tooth point (1) out of the tooth
shank (3}, refer to the illustration on this page.
2. Remove the tooth point (1 ).
3. Install a new tooth point (1) on the tooth shank
(3}.
4. Install the retaining pin (2) into the tooth point (1)
and tooth shank (3}. Make sure the shoulder on
the retaining pin is toward the cutting edge. Use
a hammer to hit the retaining pin (2} until the
retaining pin (2} is even with the outside of the
tooth shank (3}.
Replacement of the Bucket Teeth

1. Loosen and remove the nuts (4), hardened
washers (5), and bolts (6) from the bucket teeth.
NOTE: If wear of the bolt or nut makes removal
difficult, the bolt or nut can be cut off.
2. Remove the tooth.
B0740A88J
3. Install the new tooth on the bucket cutting edge 1. TOOTH POINT 6. BOLT
(7). 2. RETAINING RING 7. CUTTING EDGE
3. TOOTH SHANK B. PLOWBOLT
4. Use new nuts (4), hardened washers (5), and
4. NUT 9. NUT
bolts (6) for the tooth being installed.
5. HARDENED WASHER 10. CORNER TOOTH
5. Tighten the nuts (4) to 1315 to 1480 Nm (970 to
1090 pound-feet). BUCKET TEETH ILLUSTRATION
Replacement of the Bucket Corner

Teeth
1. Loosen and remove the nuts (9} and bolts (8}
from the bucket corner teeth (1 0}.
NOTE: If wear of the bolt or nut makes removal
difficult, the bolt or nut can be cut off.
2. Remove the corner tooth (1 0).
3. Install the new corner tooth (1 0) on the bucket
cutting edge (7).
4. Use new nuts (9) and bolts (8) for the corner
tooth being installed.
5. Tighten the nuts (9) to 1315 to 1480 Nm (970 to
1090 pound-feet).
9006-4
RETURN TO DIG ADJUSTMENT (Z-BAR AND XR MODELS)
j I
I ~
..... --~---,
k!'
f: t
. : I ,, ••. · - · -
-
! ,. - ) i _...... -'"
...... ·· .... / ;_~ ..·
BS01C083
1. TARGET MOUNTING BRACKET 3. TARGET BAR 5. PROXIMITY SWITCH

2. BUCKET CYLINDER 4. PROXIMITY SWITCH MOUNTING BRACKET 6. PROXIMITY SWITCH GUARD
RETURN TO DIG ADJUSTMENT ILLUSTRATION Z-BAR MODELS
IMPORTANT: Before adjusting the return-to-dig, 7. Loosen the bolts holding the target bar (3) to the
make sure that the target bar on the bucket linkage is target mounting bracket (1 ). Slide the target bar
not damaged. Slowly roll back and dump the bucket (3) towards the proximity switch (5) until the face
and make sure that the target bar stays the same of the proximity switch (5) is completely covered.
distance from the switch. The switch mounting 8. Align the target bar (3) parallel to the tilt cylinder
bracket protects the switch. Make sure the target bar (2) and tighten the bolts.
cannot touch the switch when the bucket is dumped.
9. Turn the ignition switch to the ON position. Do
1. Park the machine on a level surface. Raise the lift NOT start the engine.
arms until they are approximately horizontal and
dump the bucket. Lower the bucket until the 10. Place the bucket control lever in the ROLLBACK
bucket edge is on the ground. position.
2. Apply the parking brake and stop the engine. 11. Loosen the bolts holding the target bar (3) to the
target mounting bracket (1 ).
3. Loosen the bolts holding the target mounting
bracket (1) to the tilt cylinder eye. Align the target 12. Slide the target bar (3) slowly away from the
mounting bracket (1) parallel to the tilt cylinder proximity switch (5), until the control lever returns
(2). Tighten the bolts, refer to the illustration on to the center position. Tighten the bolts holding
this page. the target bar (3).
4. Loosen the bolts holding the proximity switch 13. Check to make sure that the 3.2 to 5.0 mm (1/8
mounting bracket (4) to the tilt cylinder (2). to 3/16 inch) gap is still maintained.
Position the proximity switch (5) parallel to the 14. Start the engine.
target bar (3) and tighten the bolts. 15. Place the detent switch in the ON position and
5. Adjust the proximity switch (5) out towards the place the return to travel/float detent switch to the
target bar (3), until an air gap of 3.2 to 5.0 mm TRAVEL position.
(1/8 to 3/16 inch) is obtained. Torque the jam nut 16. Raise the lift arms approximately horizontal, and
to 6 to 7.5 Nm (4.5 to 5.5 pound-feet). put the bucket in the fully dumped position.
NOTE: The proximity switch (5) must not protrude 17. Place the loader control lever in the ROLLBACK
past the proximity switch guard (6). position, and verify that the electromagnet holds
6. Start the engine, position the bucket to the it in that position until the end of the target bar (3)
correct digging angle and stop the engine. passes in front of the proximity switch (5).
18. Lower the lift arms and verify that the bucket is at
the correct digging angle.

9006-5
RETURN TO DIG ADJUSTMENT (XT MODELS)
; \
! I
\ ...__.i
···-.
BS01C084
1. BUCKET CYLINDER (LEFT HAND SIDE) 3. TARGET MOUNTING BRACKET 5. PROXIMITY SWITCH
2. PROXIMITY SWITCH MOUNTING BRACKET 4. PROXIMITY SWITCH GUARD 6. TARGET BAR
RETURN TO DIG ADJUSTMENT ILLUSTRATION XT MODELS
IMPORTANT: Before adjusting the return-to-dig, 8. Loosen the bolts holding the target bar (6) to the
make sure that the target bar on the bucket linkage is target mounting bracket (3). Slide the target bar
not damaged. Slowly roll back and dump the bucket (6) away from the proximity switch (5) until the
and make sure that the target bar stays the same face of the proximity switch (5) is completely
distance from the switch. The switch mounting uncovered.
bracket protects the switch. Make sure the target bar 9. Align the target bar (6) parallel to the bucket
cannot touch the switch when the bucket is dumped. cylinder (1) and tighten the bolts.
1. Park the machine on a level surface. Raise the lift 10. Turn the ignition switch to the ON position. Do
arms until they are approximately horizontal and NOT start the engine.
dump the bucket. Lower the bucket until the
bucket edge is on the ground. 11. Place the bucket control lever in the ROLLBACK
position.
2. Apply the parking brake and stop the engine.
12. Loosen the bolts holding the target bar (6) to the
3. Loosen the bolts holding the target mounting target mounting bracket (3).
bracket (3) to the bucket cylinder clevis. Align the
target mounting bracket (3) parallel to the bucket 13. Slide the target bar (6) slowly towards the
cylinder (1) and tighten the bolts. Refer to the proximity switch (5), until the bucket control lever
illustration on this page. returns to the center position. Tighten the bolts
holding the target bar (6).
4. Loosen the bolts holding the target bar (6) to the
target mounting bracket (3). Align the target bar 14. Check to make sure that the 3.2 to 5.0 mm (1/8
(6) parallel to the bucket cylinder (1) and tighten to 3/16 inch) gap is still maintained.
the bolts. 15. Start the engine.
5. Loosen the bolts holding the proximity switch 16. Place the detent switch in the ON position and
mounting bracket (2) to the bucket cylinder (1 ). set the return to travel/float detent switch to the
Position the proximity switch (5) face parallel to return to travel position.
the target bar (6) and tighten the bolts. 17. Raise the lift arms to approximately the
6. Adjust the proximity switch (5) out towards the horizontal position and put the bucket in the fully
target bar (6) until an air gap of 3.2 to 5.0 mm dumped position.
(1/8 to 3/16 inch) is obtained. Torque the jam nut 18. Place the loader control lever in the ROLLBACK
to 6 to 7.5 Nm (4.5 to 5.5 pound-feet). position and verify that the electromagnet holds it
NOTE: The proximity switch (5) must not protrude in that position until the end of the target bar (6)
past the proximity switch guard (4). passes in front of the proximity switch (5).
7. Start the engine, position the bucket to the 19. Lower the lift arms to the ground and verify that
correct digging angle and stop the engine. the bucket is at the correct digging angle.

9006-6
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT

(Z-BAR, XT, AND XR MODELS)
BS01C081
1. LIFT ARM 3. FRONT CHASSIS (TOP LEFT HAND SIDE) 5. HEIGHT CONTROL TARGET
2. RETURN TO TRAVEL TARGET 4. PROXIMITY SWITCH 6. TARGET MOUNTING PLATE
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION Z-BAR, XT AND XR MODELS
1. Park the machine on a level surface. 5. Position the return to travel target (2) opposite
2. Start the engine and apply the parking brake. the proximity switch (4) and tighten it to the target
mounting plate (6).
3. Lower the lift arms and place the bucket flat on
the ground. 6. Adjust the proximity switch (4) out towards the
return to travel target (2) until an air gap of 3.2 to
4. Stop the engine. 5.0 mm (1 /8 to 3/16 inch) is obtained.
NOTE: To avoid damage to the proximity switch (4), 7. Lock the proximity switch (4) in this position with
it must be adjusted back to clear everything on the lift the jam nut. Torque the jam nut to 6 to 7.5 Nm
arm as it passes. Refer to the illustration on this (4.5 to 5.5 pound-feet).
page.
WARNING: Raised equipment on the machine

without an operator can cause injury or death.
Before you leave the operators compartment,
h. always support or lower the equipment
. . . (backhoe, blade, boom, bucket, etc.) to the
ground and stop the engine.
CSM105

9006-7
t
A
'
+
B
'
BS01C082
2. RETURN TO TRAVEL TARGET 5. HEIGHT CONTROL TARGET 6. TARGET MOUNTING PLATE
APPROXIMATE APPROXIMATE
RESULTING RETURN TO RESULTING HEIGHT
MACHINE A B
TRAVEL HINGE PIN CONTROL HINGE PIN
HEIGHT HEIGHT
621 E Z-BAR 54 mm (2.12 inches) 380 mm (14.9 inches) 48 mm (1.9 inches) 3302 mm (130 inches)
621 EXT 51 mm (2 inches) 403 mm (15.8 inches) 43 mm (1.7 inches) 3302 mm (130 inches)
621 E XR 78 mm (3.07 inches) 459 mm (18 inches) 54 mm (2.12 inches) 3302 mm (130 inches)
TARGET ADJUSTMENT ILLUSTRATION Z-BAR, XT AND XR MODELS
8. Refer to the table and the illustration on this 13. Place the detent switch in the ON position, and
page. Position the height control target (5) on the set the return to travel/float detent switch to the
target mounting plate (6) using the table above. return to travel position.
NOTE: The higher the height control target (5) is 14. Place the loader control lever in the raise position
positioned in its slot in the target mounting plate (6), and verify that the electromagnet holds it in that
the lower the lift arms will stop as they are raised. position until the height control target (5) passes
in front of the proximity switch (4). Refer to the
9. Tighten the height control target (5).
10. Position the return to travel target (2) using the
15. With the lift arms still raised, place the loader
table above.
control lever in the lower position and verify that
NOTE: The higher the return to travel target (2) is the electromagnet holds it in that position until
positioned in its slot in the target mounting plate (6), the return to travel target (2) passes in front of
the lower the lift arms will stop as they are lowered. the proximity switch (4). Refer to the illustration
on page 6.
11. Check to make sure the proximity switch (4) and
all of the mounting bolts are tight. Refer to the 16. Repeat steps 8 through 15 until the desired
illustration on page 6. heights are reached.
12. Start the engine. 17. Lower the bucket to the ground and stop the
engine.

9006-8
LOADER FRAME (Z-BAR AND XR MODELS)
Remove 17. Loosen and remove bolt (1 ), flat washer (2) and
spacer (22) that fasten the pivot pin (3) to the
1. Park the machine on a level surface and apply front frame.
the parking brake. Roll the bucket all the way
forward and lower the bucket to the floor. Stop 18. Raise the loader frame slightly. Use an
the engine. acceptable driver and drive the pivot pin (3) out
of the front frame. Do not lose the washers (4)
2. Loosen the filler plug in the reservoir to release and wipers (5) between the front frame and the
the air in the reservoir. loader frame (9).
3. Fasten a chain hoist to the cross member (23) of
the loader frame (9), refer to the illustration on
page 9.
4. Loosen and remove the bolt (19), flat washer
(18), and spacer (20) that fasten the pivot pin
(17) to the piston rod yoke of the right lift cylinder
(21 ).
5. Use an acceptable driver and drive the pivot pin
(17) out of the piston rod yoke of the right lift
cylinder (21 ). Do not remove the driver.
6. Repeat Steps 4 and 5 for the left lift cylinder (6).
7. Start the engine. Roll the bucket back and lower
the bucket so that the bucket is flat on the floor
and fasten the chain hoist to a lift cylinder (6 or 19. Remove the proximity switch cover.
21 ). side of the machine only.
8. Raise the lift cylinder (6 or 21) slightly and
remove the driver, lower cylinder and let it rest on
the frame.
9. Repeat steps 7 and 8 for the other lift cylinder (6
or 21 ).
10. Connect the chain hoist to the bucket cylinder
(8).
11. Loosen and remove the bolt (14), flat washer
(13), and spacer (12) that fasten the pivot pin
(11) for the piston rod eye of the bucket cylinder
(8) to the bell crank (1 0).
BD01G010
(11) out of the piston rod eye of the bucket
1. ELECTRICAL CONNECTION 2. PROXIMITY SWITCH
cylinder (8).
20. Disconnect the electrical connector (1 ), remove
13. Raise the bucket cylinder (8) and use a chain or
the lock nut from the proximity switch (2) and
other acceptable holding equipment to hold the
remove the proximity switch (2) from the
bucket cylinder (8) in place.
machine. Left-hand side of the machine only.
14. If the machine is equipped with auxiliary
21. Repeat Steps 17 and 18 for pivot pin (7).
hydraulics, disconnect the two hoses from the
tubes at the bracket on the right side of the 22. Raise the loader frame (9) out of the front frame.
loader frame (9). Install caps on the hoses and Carefully move the machine out of the loader
plugs in the tube fittings. frame (9).
15. If the machine is equipped with front lamps,
loosen and remove the cap screws and lock
washers that fasten the lamp brackets to the front
frame. Put the lamp brackets on the fenders.
16. Connect the chain hoist to the loader frame (9).

9006-9
BS01G022
1. BOLT 7. PIVOT PIN 13. WASHER 19. BOLT

2. WASHER 8. BUCKET CYLINDER 14. BOLT 20. SPACER
3. PIVOT PIN 9. LOADER FRAME 15. PIVOT PIN 21. LIFT CYLINDER
4. WASHER 10. BELL CRANK 16. DUMP LINK 22. SPACER
5. WIPER 11. PIVOT PIN 17. PIVOT PIN 23. CROSS MEMBER
6. LIFT CYLINDER 12. SPACER 18. WASHER
LOADER FRAME- Z-BAR MODELS ILLUSTRATION

9006-10
Install 17. Disconnect the chain hoist from the bucket

cylinder (8).
1. Apply antiseize compound to the inner bores and
outer bores for the pivot pins of the front frame, 18. Fasten the chain hoist to one of the lift cylinders
refer to the illustration on page 9. (6 or 21 ).
2. Move the machine into alignment with the loader 19. Raise the piston rod yoke of the lift cylinder (6 or
frame (9}. 21) so the piston rod yoke is aligned with the
loader frame (9}.
3. Lower the loader frame (9) into alignment with
the front frame. 20. Install a driver in the piston rod yoke and the
loader frame (9).
4. Apply antiseize compound to the pivot pins (3
and 7) that fasten the loader frame (9} to the front 21. Repeat Steps 18, 19, and 20 for the other lift
frame. cylinder (6 or 21 ).
5. Start the pivot pins (3 and 7) into the front frame. 22. Disconnect the chain hoist from the lift cylinder (6
Install the washers (4) and new wipers (5) or 21 ).
between the loader frame (9) and the front frame. 23. Start the engine. Raise the loader frame and roll
6. Install the pivot pins (3 and 7) all the way. the bucket all the way forward. Lower the bucket
to the floor. Stop the engine.
7. Install the bolt (1 ), washer (2} and spacer (22}
that fasten the pivot pins (3 and 7). Torque the 24. Fasten the chain hoist to the cross member (23)
bolt to 325 to 373 Nm (240 to 275 pound feet). of the loader frame (9).
8. Install the proximity switch and cover. Left-hand 25. Start the engine and run the engine at low idle.
side of the machine only. 26. Have another person help you at this time. Move
9. Disconnect the chain hoist from the loader frame the lift control lever as required to align the piston
(9). rod yoke of one of the lift cylinders (6 or 21) with
the loader frame (9).
10. If the machine is equipped with front lamps, hold
the front lamps in place and install the cap IMPORTANT: Do not use your fingers to
screws and lock washers that fasten the front h.check the alignment of the cylinder rod.
lamps to the front frame. Tighten the cap screws. . . Personal injury can be the result.
11. If the machine is equipped with auxiliary 48-88
hydraulics, remove the plugs from the tube 27. Remove the driver and install the pivot pin (17}.
fittings and the caps from the hoses. Connect the
28. Install the bolt (19), washer (18), and spacer(20)
hoses to the tubes.
that fasten the pivot pin (17). Torque the bolt to
12. Connect the chain hoist to the bucket cylinder 325 to 373 Nm (240 to 275 pound feet).
(8).
29. Repeat Steps 26, 27, and 28 for the other lift
13. Start the engine and run the engine at low idle. cylinder (6 or 21 ). Stop the engine.
14. Have another person help you at this time. Move 30. Lubricate the pivot pins with molydisulfide
the bucket control lever as required to align the grease.
piston rod eye of the bucket cylinder (8) with the
31. Disconnect the chain hoist from the cross
bell crank (1 0). Stop the engine.
member (23) of the loader frame (9).
IMPORTANT: Do not use your fingers to 32. Tighten the filler plug in the reservoir.
h. check the alignment of the cylinder rod. 33. If the machine is equipped with auxiliary
. . Personal injury can be the result. hydraulics, start the engine and run the engine at
48·88 low idle.
15. Install the pivot pin (11) in the bell crank (1 0) and 34. Slowly extend and retract the clam cylinders four
the piston rod eye of the bucket cylinder (8). times to remove air from the auxiliary circuit.
16. Install the bolt (14), washer (13), and spacer (12) 35. Stop the engine, check the level of the oil in the
that fasten the pivot pin (11 ). Torque the bolt to reservoir, and check for leaks. Add oil to the
325 to 373 Nm (240 to 275 pound feet). reservoir as required.

9006-11
LOADER FRAME (XT MODELS)
Remove 13. Disconnect the hoses to the bucket cylinders.

Disconnect the hoses from the tubes at the
1. Remove all dirt and grease from the hose and bucket cylinders.
tube connections for the bucket cylinders and
clam cylinder, if equipped. 14. Install a cap on each hose and a plug in each
tube.
2. With the engine running at low idle, roll the
bucket all the way forward and lower the loader 15. If equipped, disconnect the clam hydr~ulic
frame until the bucket is on the floor. connections, the auxiliary hydraulic connections,
and the coupler connections as necessary. Plug
3. Stop the engine and apply the parking brake. and cap lines as needed.
4. Loosen the filler plug in the reservoir to release 16. Disconnect the wiring harnesses.
the air in the reservoir.
17. Connect the chain hoist to the loader frame (6}.
5. Loosen and remove the bolt (9), washer (1 0),
and spacer (8) that fasten the pivot pin (7) to the 18. Loosen and remove the bolt (1 ), washer (2), and
piston rod yoke of the lift cylinder (11 or 15), refer spacer (14) that fasten the loader frame (6), pivot
to the illustration on page 12. pin (3) and anchor link (12) pivot pin (13) to the
machine frame.
(7) out of the piston rod yoke of the lift cylinder 19. Raise the loader frame (6) slightly. Use an
(11 or 15}. Do not remove the driver. acceptable driver and drive both the pivot pins (3
and 13) from the loader frame (6) and anchor link
7. Repeat Steps 5 and 6 for the other lift cylinder (12).
(11 or 15).
20. Do not lose the washers (4) between the front
8. Start the engine. Roll the bucket back and lower frame and the loader frame (6}.
the bucket so that the bucket is flat on the floor.
Fasten the chain hoist to a lift cylinder (11 or 15). 21. If equipped, remove the proximity switch co~er
and the proximity switch from the left-hand s1de
9. Raise the lift cylinder (11 or 15} slightly and of the machine.
remove the driver, lower the cylinder and let it
rest on the frame. 22. Repeat Steps 18 and 19 on the opposite side of
the machine.
1o. Repeat Steps 8 and 9 for the other lift cylinder
(11 or 15). 23. Raise the loader frame from the machine. Be
sure all the necessary hydraulic lines, wiring etc.
11 . Stop the engine. are properly disconnected.
12. Move the bucket control lever to the ROLLBACK 24. Carefully move the machine out of the loader
position and the lift control lev~r to th~ LC?WER frame.
position to relieve any pressure 1n the c1rcu1ts.

9006-12
BS01G021
1. BOLT (325- 373 NM (240- 275 LB-FT)) 7. PIVOT PIN 13. PIVOT PIN
2. WASHER 8. SPACER 14. SPACER
3. PIVOT PIN 9. BOLT 15. LIFT CYLINDER (NOT SHOWN)
4. WASHER 10. WASHER 16. LOADER LINKAGE BOLT (650 -732 NM (480- 540 LB-FT))
5. WIPER 11. LIFT CYLINDER 17. GUIDE LINK NUTS (240- 305 NM (175- 225 LB-FT))
6. LOADER FRAME 12. ANCHOR LINK
LOADER FRAME- XT MODELS ILLUSTRATION

9006-13
Install 16. Disconnect the chain hoist from the lift cylinder
(11 or 15).
1. Apply antiseize compound to the inner bores and
outer bores of the front frame. 17. Start the engine. Raise the loader frame (6) and
roll the bucket all the way forward. Lower the
2. Move the machine into alignment with the loader bucket to the floor. Stop the engine.
frame (6), refer to the illustration on page 12.
18. Fasten the chain hoist to the cross member of
3. Lower the loader frame (6) into alignment with the loader frame (6}.
the machine frame.
4. Apply antiseize compound to the pivot pins (3}
and (13} that fasten the loader frame (6} to the 20. Have another person help you at this time. Move
machine frame. the lift control lever as required to align the piston
rod yoke of one of the lift cylinders (11 or 15) with
5. Start the loader frame pivot pin (3), washer (4) the loader frame (6).
and wiper (5).
6. Install the loader frame pivot pin (3) and anchor IMPORTANT: Do not use your fingers to
link pivot pin (13) on one side of the machine. h check the alignment of the cylinder rod.
. . . Personal injury can be the result.
7. Repeat Steps 5 and 6 for the opposite side of the 48-88
machine.
21. Remove the driver and install the pivot pin (7).
8. Install the bolt (1 ), washer (2) and spacer (14)
that secure the pivot pins (3 and 13) to the 22. Install the bolt (9), washer (1 0), and spacer (8)
machine on each side of the machine. Torque the that fasten the pivot pin (7). Torque the bolt to
bolt to 325 to 373 Nm (240 to 275 pound feet). 325 to 373 Nm (240 to 275 pound feet).
9. Disconnect the chain hoist from the loader frame 23. Repeat Steps 20, 21, and 22 for the other lift
(6). cylinder (11 or 15}. Stop the engine.
10. If the machine is equipped with auxiliary 24. Lubricate the pivot pins with molydisulfide
hydraulics, clam hydraulics, or coupler grease.
hydraulics, remove the plugs from the tube 25. Disconnect the chain hoist from the cross
fittings and the caps from the hoses and make member of the loader frame (6).
the necessary connections.
11. Connect the hoses and tubing to the bucket
27. Slowly extend and retract the cylinders four times
cylinders.
to remove air from the hydraulic circuit.
12. Fasten the chain hoist to one of the lift cylinders
28. If equipped with auxiliary hydraulics, slowly
(11 or 15).
extend and retract the clam cylinders four times
13. Raise the piston rod yoke of the lift cylinder (11 to remove air from the auxiliary circuit.
or 15} so the piston rod yoke is aligned with the
29. Stop the engine, check the level of the oil in the
loader frame (6}.
reservoir, and check for oil leaks. Add oil to the
14. Install a driver in the piston rod yoke and the reservoir as required.
loader frame (6).
15. Repeat Steps 12, 13, and 14 for the other lift
cylinder (11 or 15).

9006-14
NOTES

Section
9007
ROLLOVER PROTECTIVE STRUCTURE (ROPS)

CAB STRUCTURAL FRAME (CSF)

9007-2
TABLE OF CONTENTS
CAB STRUCTURAL FRAME (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY . . . . . . . . . . . . . . . . . . . . . . . . 3
CSF CAB AND ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal .............................................................................. 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

9007-3

CABSTRUCTURALFRAME(CS~
After an accident, fire or rollover, the following MUST
be performed before returning the machine to field or
Attention
job site operation:
• The ROPS or CSF structure MUST be replaced.
The Rollover Protective Structure (ROPS) or Cab • The ROPS or CSF mounting or suspension,
Structural Frame (CSF) is a special safety operator seat and suspension, seat belts and
component of your machine. mounting components and wiring within the
DO NOT attach any device to the ROPS or CSF for operator's protective system MUST be carefully
pulling purposes. inspected for damage.
The ROPS or CSF is a certified structural support • All damaged parts MUST be replaced.
and any damage, fire, corrosion or modification will DO NOT WELD, ATTEMPT TO STRAIGHTEN OR
weaken the structure and reduce your protection. If REPAIR THE ROPS OR CAB STRUCTURAL
this occurs, the ROPS or CSF MUST be replaced so FRAME.
that it will provide the same protection as a new
ROPS or CSF.
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY

After every 500 hours of operation or every six
months, whichever comes first, do the following: !WARNING: Do not install attachments that
will make the total weight of the machine
1. Check the torque on the CSF cab or ROPS
canopy mounting bolts; torque should be 773 to
854 Nm (570 to 630 lb-ft). If necessary, tighten
A more than the weight shown in the maximum
19ross vehicle weight section of the ROPS
serial number plate. 47·26
the bolts to the correct torque.
2. Check that seat belt mounting hardware is tight !WARNING: Do not change the ROPS in any
and seat belt is not cut or frayed. Check the way. Changes made to the ROPS which are
torque on operators seat mounting bolts; torque not authorized, such as welding, drilling or
should be 73 to 87 Nm (54 to 64 lb-ft). If cutting will make the ROPS weaker and
necessary, tighten the bolts to the correct torque.
Replace parts that are worn or damaged.
A decrease your protection. Replace the
ROPS if it becomes damaged in any way.
DO NOT TRY TO MAKE REPAIRS TO THE
WARNING: Grade 8 hardware is used to ROPS. 47·25
h mount and anchor the ROPS. Parts used for
.a_ replacement must be those shown in the
lparts catalog. 47·27A

9007-4
CSFCABANDROPSCANOPY
Removal STEPS
NOTE: Procedures and photos in following steps
cover in detail removal and installation of CSF
structure. Removal and installation of ROPS is
similar to removal and installation ofCSF structure.
STEP 1
floor. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in
ON position and move loader control lever back and
forth at least 30 times to release any pressure from
Remove skirting under each side and front of cab.
STEP2
STEPS
BD01F143
Put articulation lock in LOCKED position. BD06G186
Remove the ducts from the machine.

STEP3
Put battery disconnect switch in OFF position. STEP7
STEP4
BD06G189
At RH rear, bottom of cab, disconnect ground strap

BD01F184 from rear chassis.
If machine is equipped with a heater, put a 40 liters
(1 0 Gallons) container below radiator drain. Remove
cap and drain coolant into container. Install cap after
coolant has drained.

9007-5
STEPS STEP 11
BD06G194 BD06G192
If machine is equipped with windshield washers, Identify, tag, and disconnect hoses from steering
identify, tag, and disconnect front and rear windshield control valve. Plug hoses and cap steering control
washer nozzle hoses from supply hoses. valve fittings to prevent entry of foreign matter into
hydraulic system.
STEP9
STEP12
3. HEATER HOSES
Unlatch and open the window on the right hand side.
If machine is equipped with a heater disconnect
heater hoses (3), if machine is equipped with air STEP13
conditioning discharge the air conditioning system,
see section 9003, and disconnect the air conditioning
hoses (2), cap and plug lines and fittings.
STEP10
Open and remove the access panel.
Disconnect throttle connector and the air duct.

9007-6
STEP14 STEP19
BD06G187
Remove the front access panel. Disconnect the electrical connectors, push
connectors out of the bottom of the cab with the
STEP15 rubber gromment
STEP 20
BD06F210
Disconnect the electrical connectors for the remote

control valve.
Raise floor mat up and away from brake pedal to gain
STEP16 access to mounting hardware.
Loosen the filler cap on the reservoir to release any
air in the reservoir. Connect a vacuum pump to the STEP 21
hydraulic reservoir, turn on the pump.
STEP17
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install
plugs in the hoses and caps on the fittings to prevent
entry of foreign matter into hydraulic system.
STEP18
Push the hoses out of the bottom of the cab with the
rubber gromment.
BD06G185
Remove hardware securing brake valve to cab floor.

Let brake valve rest on the frame.

9007-7
STEP 22 STEP 25
Slowly raise cab from rear chassis. Check that all tie
straps and clamps have been removed and all hoses,
tubes, and wires are disconnected and free. Check
that brake valve with hoses attached are free and
clear of cab. Remove the ROPS or CSF from the
machine. Lower ROPS or CSF onto wooden blocks
to prevent damaging cab or canopy.
BD06G184
Install lifting eyes in threaded holes at top of the cab.
STEP 23
Connect lifting equipment to cab at lifting eyes. Take
up all slack in lifting equipment.
STEP 24
Remove nuts, bolts, and washers securing cab to
rear chassis.

9007-8
~
~)-__
,,1I I ---!'1"""1 ~~f'1\
~ ~
(=I•
AI I L1 <----- 4
,~,~ ~~ --l'n~ ~
:,--
f;''f l~j ~-Jij --;--.:_

// I - 1
2
i ;·._,_
tl I t- J-~-
{:-;7 _____
!
r::::::i 0 T-
I
- - ! 1\
- !...-.
I I y+
/ I I ,,../!I II I /@
;=J
I
I
,.I
I I Eo
-
--
- -I
L 0
- -:-._
I ' --,
II \
)--.J ------·-·-·-·----~
r' / - ./r-... \
~~~
/ V_ ; 1
,.-·_./
I.
I
'
~ I r-J /_
tf--· t !!;!:/
/ I
'~
I p_;;
HI
"' ::::- •I -. . . . . -...
!('::
-, ~ .A·
\_
1 1
--,
= ;,.. ';,.__
I ~f iii~ /If~ j_- ~-r-- ~--:~

I
; :__ -(/ 1' 1
I
l//1
I
'!I
,_,.
''
I
I'
I
j___..,.
I
.,,._I
_9
@t
1
I'"""'
y
1 Ill
Q
e
Q
-
1
"' ~-_
I f
-
--~--r--.....__
-
--_@I- -. -. . . -....
i1-'?!"---~.J
I i
!=""- -
~
- -
I
I •
iZ
_
--~
---~----1!t' r:::-. 1 ------.
I-- -
9 I Ill
:r· -
-~'0;;;..........._
- _D'o.,.,
1""---''
-,
•
,
(
... ~·
,./.. <:::':> -
--
- -..:. ' ------1 --
lr--_ - - --- - - ---( I~·
!iii
/!: I
I c·---.~=:\-~--i --~"'§"-:r- ~---
li!l
c-- l~ I
]"- I
f.""O"'j
/e'i
I .
'..,
I
- - - ---- }' j
I
®---~ ·---~""·=·,) ·~~-,..)''/I I I

- - :--- I \ I --- I
--l- - - - , v
- - ----..1. !i==== - - \
\ } - - -
\.1,----t----
•qj I .
I
:1!·
-'ltf~1b:) --..~~ --=~-- -~-- _. _. .~
- -• j , e i
~---- I },.
'1I bo;-~1= ~- ;;_: =_ _
I I
)
•i ~ r =.::: I - _EW---®
___ f --_
__
1
\ II I --......:
- .::--::::::-:::-
- ~--(-~--? '1
/"'.'i
~- . . ----~l~ <;;>
I
I ~ - -::::::- _; ::---,. i.,..-;~\
~---......--::---
·l j
ll, ~t
\ .... _ I''1(';
' ~ ~ -t~\ J
'-. . ·-·-·-I- -·-·- . . ,.r==-- = == =---
.--::----HI
l'
.....; -.::: == -=- <;;>
~
\~
- --
E::.:: /
BC06G031
1. NUT 4. RUBBER MOUNT

2. WASHER 5. WASHER
3. RUBBER MOUNT 6. BOLT

9007-9
STEP 26
Check rubber mounts (3 an 4) for deterioration, tears,
deformation, or other damage; replace rubber
mounts as necessary.
STEP 27
BD06G188
Position floor mat.
STEP 33
BD01D388
Position cab over rear chassis then put wood blocks

under brake valve. Slowly lower cab onto rear
chassis making sure that brake valve is positioned so
that brake pedal enters into cab. Remove wood
blocks as cab is lowered onto brake valve.
STEP 28
Install washers, bolts, and nuts to secure cab to rear
chassis. Tighten bolts to a torque of 773 to 854 Nm
Remove plugs from hoses and caps from fittings.
(570 to 630 pound feet)
Connect hoses to steering control valve following
tags installed during removal. Remove and discard
STEP 29 tags.
Disconnect lifting equipment from cab.
STEP 34
STEP 30
Remove lifting eyes.
STEP 31
Connect throttle connector and mount air duct.
Align mounting holes in brake valve with associated

holes in cab or canopy floor. Install hardware to
secure brake valve to floor.
9007-10
STEP 35 STEP 38
BD06G186 BD06G205
Install the ducts on the machine.
3. HEATER HOSES
STEP 36
If machine is equipped with a heater, remove plugs
from hoses and caps from fittings, connect heater
hoses (3), if machine is equipped with air
conditioning, remove plugs from hoses and caps
from fittings, connect air conditioning hoses (2),
charge the air conditioning system, see section 9003.
STEP 39
Remove plugs from hoses and caps from fittings.
Connect hoses to joystick and two-lever controller
and install in hose mounting grommet halves as
shown on pages 11 , 12, and 13.
At RH rear, bottom of cab, connect ground strap to

rear chassis.
STEP 37
BD06G194
If machine is equipped with windshield washers,

connect front and rear windshield washer nozzle
hoses following tags installed during removal.
Remove and discard tags.

9007-11
BS07D284
1. ORANGE BLACK 5. ORANGE WHITE 8. GREEN BLACK

2. YELLOW BLACK 6. YELLOW WHITE 9. RED BLACK
3. REDWHITE 7. PILOT PRESSURE HOSE 10. PILOT TANK HOSEL
4. GREEN WHITE
JOYSTICK AND 2 LEVER HOSE COLOR CODING

9007-12
BS07D283
1. YELLOW WHITE 1. YELLOW WHITE

2. PILOT PRESSURE HOSE 2. PILOT PRESSURE HOSE
3. RED BLACK 3. RED BLACK
4. PILOT TANK HOSE 4. PILOTTANKHOSE
5. ORANGE BLACK 5. ORANGE BLACK
6. YELLOW BLACK 6. YELLOW BLACK
7. GREEN BLACK 7. GREEN BLACK
8. REDWHITE 8. REDWHITE
JOYSTICK AND 1 LEVER HOSE COLOR CODING 3 LEVER HOSE COLOR CODING

9007-13
STEP 40
BD06F210
Connect the electrical connectors for the remote

control valve.
STEP 41
88070285
1. PILOT PRESSURE HOSE Place the access panel into position, install and
2. RED BLACK tighten the screw.
3. PILOT TANK HOSE
4. ORANGE BLACK
STEP 42
5. YELLOW BLACK
6. GREEN BLACK
JOYSTICK HOSE COLOR CODING
Connect wiring harness connectors.

9007-14
STEP 43 STEP 46
BD06F208 BD01F184
Install and close the access panel. If machine is equipped with a heater and coolant was
drained, check that coolant drain cap is tight.
STEP 44
STEP 47
capacity is 36.9 liters (9.75 U.S. Gallons). Install
radiator cap. Fill coolant reservoir up to FULL mark
on reservoir.
STEP 48
Put battery disconnect switch in ON position.
STEP 49
Start engine and run engine at low idle. Run engine
BD06F207 at operating temperature for approximately five
Close the right hand window. minutes to completely mix Ethylene Glycol and
water. When coolant is at operating temperature,
stop engine. When engine has cooled, check coolant
level at reservoir.
STEP 45
WARNING: Hot coolant can spray out if radiator cap
is removed. To remove radiator cap: let system cool,
released. Scalding can result from fast removal of
radiator cap.
STEP 50
BD06G191
Install skirting under each side and front of cab.

Section
9010
CAB GLASS INSTALLATION

9010-2
TABLE OF CONTENTS
PREPARATION FOR GLASS REPLACEMENT .................................................. 3
GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SILICONE SEALANT APPLICATION- FRONT WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

9010-3
PREPARATION FOR GLASS REPLACEMENT

1. Remove all of the damaged glass section and 5. Clean the new glass section. Apply a 25 mm (1
the silicone sealant from the window frame inch) wide band of glass primer (349-11 0) to the
black ceramic painted edges of the window.
2. Remove all the adhesive from the window frame.
6. When replacing a front window section, a
3. The window frame recesses must be free of oil
silicone forming tool is needed, refer to Figure 2.
and dust. Clean the frame with rubbing alcohol
Use the template and instructions provided to
with a clean rag. Do not reuse the rag.
make the tool.
4. Apply a 25 mm (1 inch) wide band of metal
primer (349-1 08) to the window recesses.
GLASS INSTALLATION
NOTE: Once the adhesive is applied, the glass must 3. For front glass installations install a glass spacer
be installed within 5 minutes. If the glass is not 12 mm (1 /2 inch) from each corner on bottom
installed within the 5 minute period, the adhesive edge of each glass section, refer to Figure 3.
must be removed and applied again.
4. Install the glass. The glass edges must not
1. Apply a 10 mm (3/8 inch) diameter bead of contact the metal frame at any point.
adhesive (345-135) to the primed surface
5. For front glass installations position the glass to
approximately 12 mm (1/2 inch) from edge.
maintain a uniform 3 mm (1/8 inch) gap between
2. The adhesive may be applied either to the front and front side glass sections.
primed glass or to the primed metal frame. DO
NOT apply the adhesive to both the glass and
the frame.
NOTE: When replacing two or more sections of the
front glass apply extra adhesive in corners, refer to
Figure 3.
SILICONE SEALANT APPLICATION- FRONT WINDOWS

1. Clean the edges of the front center and front side 6. Fill the joint with the clear silicone sealant
windows. Use glass cleaning primer. (114328A1), refer to Figure 1. The silicone must
completely penetrate and fill the gap between the
2. Apply masking tape to the inside edge of each
glass sections. The sealant must extend at least
glass section next to the gap.
1.5 mm (1/16 inch) above the outside surface of
3. Apply the polyester tape on top of the masking the glass section for the length of the gap. Be
tape across the inside side gap. Do not push the sure the sealant fills against the adhesive at each
tape into the gap. end of the joint.
4. Apply masking tape to the outside edge of each 7. Remove the polyester tape from the inside joint.
glass section. Align the edge of the tape with
8. Remove the extra silicone from the outside joint
edge of glass on both sections.
by carefully sliding the forming tool down the
5. The tape must be smooth to get the best result length of the joint. The tool must remain in
when using the silicone forming tool. contact with the glass sections during this
process. Refer to Figure 2 for forming tool
template.

9010-4
9. Remove all the silicone from the forming tool
immediately after use.
10. Remove the outside tape from the glass
sections.
11. Remove the extra silicone sealant from the inside
joint by carefully sliding the forming tool down the
length of the joint.
12. Remove all the silicone from the forming tool
immediately after use.
13. Remove the inside joint masking tape.
14. If two or more glass sections are being replaced,
498L93
use the procedure on the second joint.
1. FRONT RH SIDE GLASS 3. SILICONE BEFORE 15. Apply the gray silicone sealant above the front
SMOOTHING center, front side or rear windows for additional
2. FRONT CENTER GLASS 4. SILICONE AFTER leak protection.
SMOOTHING
FIGURE 1. SILICONE APPLICATION 16. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top on
NOTE: Make the forming tool from 10 mm (3/8 inch)
each front side window replaced, refer to Figure
plexiglass, or wood. Sand all radius and edges
3.
smooth.
17. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top
edge of the rear glass, if replaced.
496L93
FIGURE 2. SILICONE FORMING TOOL TEMPLATE

9010-5
497L93
1. SIDE GLASS ADHESIVE 4. RIGHT HAND SIDE GLASS SPACER LOCATIONS

2. CENTER GLASS ADHESIVE 5. APPLY GRAY SILICONE SEALANT DOWN 50 MM (2 INCHES)
FROM TOP OF FRONT SIDE GLASS
3. APPLY EXTRA ADHESIVE HERE WHEN REPLACING BOTH 6. APPLY GRAY SILICONE SEALANT ALONG BOTTOM EDGE OF
CENTER AND SIDE PANELS CENTER GLASS
FIGURE 3 SILICONE APPLICATION
NOTE: After completting the installation, DO NOT slam the cab door. The increased air pressure may break the
seal on newly installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and
silicone to properly set.
9010-6
NOTES

STARTING AND CHARGING SYSTEM POWER RELAY MODULES - COLD STARTING SYSTEM ENGINE CONTROLLER RETURN TO TRAVEL • RETURN TO DIG • PIN ENGAGE PILOT CONTROL - RIDE CONTROL - FAN CONTROL
19P-D OR-0.8
1-NC R-19.0 1-NC R-19.0 21H W-0.8 21H W-0.8 21H W-0.8 58T W-0.8 19P-E OR-0.8
1 1-Z R-8.0 1-Z R-8.0 21G W-0.8 21G W-0.8 21G W-0.8 58H-A W-0.8 37 ECB 86
75 21F W-0.8 21F W-0.8 21F W-0.8 25 SPL-BCK-LT-GD2 35 30
30 193
87 195
1-BB R-8.0 2 21E W-0.8 21E W-0.8 21E W-0.8
Not Used A ECD
86 30
7 7 0-B7 BK-0.8 K4
1-Z R-8.0 18R-A OR-2.0 18R-A OR-2.0 18R-A OR-2.0 7 7 0-B2 BK-0.8 7 7 0-B20 BK-0.8 8 8 49-Q S-0.8
215F 216F 0-B2 BK-0.8 B K4
19R-D OR-0.8
1-NC R-19.0 18R OR-2.0 18R OR-2.0 8 8 49-K S-0.8 0-B3 BK-0.8 C 8 8 49-G S-0.8 5 5 19P-C OR-0.8 38
86
85
1
14 LG-1.0 26 26 14-A LG-0.8
1-Z R-8.0 0-BN BK-0.8
28F W-0.8
0-BN BK-0.8
28F W-0.8
5 5 55B W-0.8 0-B4 BK-0.8 D 5 5 58C W-0.8 36 4 4 52J W-0.8
2 4 4 0-29 BK-0.8 53A W-0.8 3 3 0-B5 BK-0.8 E 4 4 58T W-0.8 10 10 Not Used
SRC-1
1 1 21C-C W-0.8 SPL-4 13C OR-1.0 13C OR-1.0 13C OR-1.0 13C OR-1.0 A A 13C-A OR-1.0 10 10 Not Used 53B-B W-0.8 4 4 27 0-B6 BK-1.0 F 9 9 Not Used SPL-D26 6 6 52M W-0.8 85 87A 87
21D W-1.0 15 15 21D-C W-0.8 21D-B W-0.8 13M OR-1.0 13M OR-1.0 13M OR-1.0 13M OR-1.0 B B 13M-A OR-0.8 SPL-D1 85 87A 87
0-GB BK-1.0 21H W-0.8 21H W-0.8 6 6 54B-C W-0.8 54A W-0.8 2 2 0-B26 BK-0.8 G 6 6 58-F W-0.8 1 1 Not Used 52 W-0.8
ENG CAB-E 0-BV BK-0.8 0-BV BK-0.8 0-BV BK-0.8
21G W-0.8 21G W-0.8 DISC ENG-D 1 1 55A-B W-0.8 54B-B W-0.8 5 5 Not Used H 1 1 Not Used 58-E W-0.8 9 9 Not Used 56 W-0.8 52A-A W-1.0
14 LG-1.0 F9/F10 ECB SPL-CR 28G W-1.0 28G W-1.0 28G W-1.0 9 9 Not Used 55A-A W-0.8 1 1 0-B20 BK-0.8 J 10 10 Not Used 3 3 52AU W-0.8 23 22 CAB-E
AD 21F W-0.8 21F W-0.8 SPL-RTT
58-C W-0.8
58-D W-0.8
30 30 21C-B W-0.8 21C W-0.8 21E W-0.8 21E W-0.8 3 3 55A-C W-0.8 55B W-0.8 6 6 0-29 BK-0.8 K 3 3 58C W-0.8 2 2 52J W-0.8 23 22 ENG
D+ PRM-B PRM-B1
87 87 21D-A W-0.8 13C OR-1.0 13C OR-1.0
2 2 53P-B W-0.8 EM 0-B11 BK-0.8 L 2 2 19C-D OR-1.0 SFC 56-A W-1.0 52A-B W-1.0
AB+ A Not Used 58L BK-0.8
R B+ 1-BA R-13.0 87A 87A Not Used 13M OR-1.0 13M OR-1.0 SFL 19C-C OR-0.8 0-B7 BK-0.8 M SRC
85 85 21H W-0.8 C 13H 0R-3.0 13H-D 0R-3.0 13H-D 0R-3.0 YFN YFR
18R-A OR-2.0 18R-A OR-2.0 SPL-DLY-RL 19C-B OR-1.0
43 44
13H-D 0R-3.0
0-B7 BK-0.8 0-B7 BK-0.8
0-BB BK-1.0
28
0-BQ BK-1.0
3 86 86 21G W-0.8
85 B 0-EA BK-0.8
SPL-D24
C – + 0-B11 BK-0.8 0-B11 BK-0.8
A B
A B
2 1
2 1
26
13H-C 0R-0.8
13H-B 0R-0.8
86 A 0-B20 BK-0.8 0-B20 BK-0.8
4 40 A F1
19C-D OR-1.0
PRM-B2 A B C 0-B26 BK-0.8 0-B26 BK-0.8
SPL-DLY
1A R-1.0 7 7 0-B3 BK-0.8 ECD 86 30 A B C 0-B6 BK-1.0 0-B6 BK-1.0 41
PXT
BUSS-PRM-E 29.3 AT 20°C 39.3 AT 20°C
19C-A OR-1.0
1DM R-1.0 8 8 49-M S-0.8
14 24 40 A
A2
A
P
0-AM BK-1.0
BUSS-PRM-B
53B-A W-1.0
9 9 Not Used K3 0-BS BK-1.0 SPL-FAN
53P-I W-1.0
B
13D OR-1.0 1 10 A F2 30 PRBF
21C-A W-0.8
Not Used
7 10 10
39
ECD-F2
1DN R-1.0 2 13D OR-01.0 18J-C OR-1.0 2 58 W-1.0 A
BT2 BT1 6 6 54A W-0.8 SPL-PIN
SPL-EDC2 18J-B OR-1.0 3 B
21F W-0.8
E 0-DC BK-0.8 3
1-NA R-62
Not Used SPL-BCK-LGT2 19P-A OR-0.8
30 A
5 5
18R OR-2.0
PRM-A 1 2 YRC A
1-NC R-19.0
1-ND R-62.0
1-NB R-62.0
1-BA R-13.0
ECA-L1
29 Not Used
PXF PXM
0-BE BK-1.0 10 10
21E W-0.8
58-B W-1.0
5 A
1-BB R-8.0
F 43S-D W-0.8 4 C – +
0-BN BK-0.8
5 4 4 Not Used 49-E S-0.8 19P OR-0.8 B
0-AD BK-1.0
A
6 A 19S1-OR-1.0 0-BF BK-1.0 A B C 7 7 0-B1 BK-0.8 1 2
58-A W-1.0
A5
28F W-0.8
6
13K-A OR-1.0 13 85 87A 87 B
B
G 5
B2
Not Used 19P-C OR-0.8
B
1 1 Not Used B C
K3 ECB H Not Used 6
C BUSS-J1-ECA 15 PRM-C 18J-D OR-1.0 8
3 3 Not Used SPL-D25 A B C
A B C
49-J S-0.8 C
8 8 49-N S-0.8
42 202M Not Used D
18J-E OR-1.0 1 1 Not Used
ECA-F5
BT3 BT4 PRM-C1 SPL-EDC4 9
18J-K OR-3.0
30 30 SPL-PK1 TDM 2 2 53P-D W-0.8 53P-C W-1.0 A B C 49-M S-0.8 D 19P-D OR-0.8 E
53P-H W-1.0
PXH
0-AC BK-1.0
85 B 0-EB BK-0.8 22.7 AT 20°C
13K-C OR-1.0
Not Used
13K-B OR-1.0
A 0-BD BK-1.0 10 9 9
87 87 ECC-F5 SPL-HTR 53C-A W-0.8 19P-E OR-0.8 F
53B W-1.0
49-K S-0.8
13K OR-1.0
86 A 13K-B OR-01.0 SHC E
Not Used
5A
194 C 1-GA R-3.0 SPL-EDC1 0-BC BK-1.0 11 5 5
0-AA BK-1.0
53P-J W-1.0
87A 87A Not Used 40 A F1 49-F S-0.8 F
1DM R-1.0
54B W-1.0
B S A B 6 6 Not Used
0-NC BK-62
PRM-A1 See Note 1 28G W-1.0 12
L1-5
85 85 10 A
A
L1-5 A5 49-Q S-0.8 G 4 4 Not Used
0-BN BK-0.8 13 SPL-PED-BL-GD
1-GB R-2.0
86 86 BUSS-PRM-B 85 B
9 S-KEY 1-C R-8.0
86 A 1-GC R-2.0 21H-A W-0.8 17 31 BUSS-J5-ECA
49-T S-0.8
Not Used
H
J
3 3 31L Y-0.8 19P OR-0.8 Not Used A
BUSS-L1-ECA
8
0-DF BK-0.8
20 A F2 P-A1 40 A F1 21F-B W-0.8 29 BUSS-J6-ECA 2 2 19A-J OR-0.8 A7 L1-7

PRM-C2
49-G S-0.8 K 0-B1 BK-0.8 B
Not Used 5
CAB-PW CBPW 21E-A W-0.8 32 10 10 Not Used SPC B A
0-B24 BK-0.8 C
0-BW BK-2.0
BAT B A WSH 7.5 A
SPL-CRK 1A R-1.0 1 P-A3 7 7 0-B4 BK-0.8 Not Used L
M 1-CB-A R-19.0 1 1 1CB R-19.0 CAN-L G-0.8 34 Not Used D
13K-B OR-1.0
IGN B A ECA-F7
0-BX BK-2.0
DC1 13K OR-1.0 3 B A FFH 49-J S-0.8 49-S S-0.8 M
13D OR-1.0
21G W-0.8 3 3 21GA W-0.8 CAN-H Y-0.8 35 8 8 0-B29 BK-0.8 E
20 A F2
P-C1
BUSS-J6-ECC
BUSS-J5-ECC
ST
0-NB BK-62 21K W-0.8 2 16 BUSS-PRM-PWR B A
P-C2
DC2 21H W-0.8 4 4 21H-A W-0.8 28F W-0.8 36 9 9 Not Used 49-S S-0.8 49-S S-0.8 0-B11 BK-0.8 F
STTR-GND
P-C4
ACC SPL-EDC3
12ACC W-0.8 4 1.9 ±0.3
P-C3
1-NC R-19.0 21F W-0.8 11 11 21F-A W-0.8 21GA W-0.8 37 6 6 Not Used 49-G S-0.8 49-G S-0.8
13C OR-1.0 Not Used 30 GHF4
DC3 6 1-Y R-19.0 1-E R-19.0 1-E R-19.0 1.9 ±0.3 18R-A OR-2.0 13 13 18R OR-2.0 13M-A OR-0.8 40 5 5 Not Used 54B-A W-0.8 11 11 54B W-1.0 49-T S-0.8 49-T S-0.8
13M OR-1.0 SPL-ACC 87 115 150 A 20 SPL-D2 53B-B W-0.8 12 12 53B W-1.0 SPL-PED-BL
21K-A W-0.8
DC4 GHF3 GHF1 1-Z R-8.0 18J-G OR-2.0 14 14 18J-F OR-2.0 35W W-0.8 42 4 4 Not Used 49-Q S-0.8 49-Q S-0.8
10 GHC GH FUSE
21 Not Used 16 16 Not Used 24L W-0.8 48 1 1 Not Used 53P-F W-0.8 19 19 53P-G W-1.0 49-E E-0.8 49-E S-0.8 Not Used A
1-BE R-19.0
86 1BC R-19.0 57-A W-0.8 20 20 57 W-1.0 SPL-A3
13D OR-1.0 1 105 A 18J OR-2.0 18 18 18J-A OR-2.0 0-BV BK-0.8 75 3 3 53A W-0.8 SPL-A2 49-N S-0.8 B
K2 ECB 85 CB1A CB1B
13K-B OR-1.0 2 CAB B+ 13C-B OR-1.0 21 21 13C-A OR-1.0 24S W-0.8 77 2 2 53P-E W-0.8 21 21 58-B W-1.0 49-D S-0.8 C
30 30 21K-B W-0.8
11 87 87 21C W-0.8 12ACC-B W-0.8
28G W-1.0 19 21E W-0.8 27 27 21E-A W-0.8 24R W-0.8 78 SRTD CAB-F FRONT 58-B W-1.0 58-B W-1.0 Not Used D
49-V S-0.8 E
20G-B W-0.8 31 31 20G-A W-0.8 24B W-0.8 79 58-C W-0.8 58-C W-0.8 58-C W-0.8
87A 87A Not Used 0-BV BK-0.8 18 20G-A W-0.8 89 49-S S-0.8 F
13C-B OR-1.0
H 0-EQ BK-0.8 12ACC-C W-0.8 19-1 1 CAB-E ENG
85 85 0-DE BK-0.8 GH A
G 0-DE BK-0.8 86 86 25T LU-0.8 BUSS-J5-ECC 13-17 2 PRM-D ECA-L2 EDC7 32 19C-D OR-1.0 19C-D OR-1.0
F 0-DF BK-0.8 BUSS-J6-ECC 14-2 3 A Not Used 1 35W W-0.8
E 0-DD BK-0.8 43S-D W-0.8
19R-D OR-0.8
12-2 4
17
C BUSS-J11-ECA 22 2 0-BP BK-1.0
10 10 49-F S-0.8
D 0-EC BK-0.8 17-3 5 P 3 3 Not Used
K1 ECB 3 18J-H OR-1.0 6 6 24L W-0.8
C 0-EB BK-0.8 21D-B W-0.8 16-5 6 85 B Y 8 8 Not Used 0-AD BK-1.0 0-AD BK-1.0 49-V S-0.8 10-19 9
A9
GH-1 B 0-DU BK-0.8
B
30 30 18R-A OR-2.0 21K-A W-0.8 WIF 1 1 21F-C W-0.8 53P-A W-0.8 58L BK-0.8 7-6 1 49-D S-0.8 13-14 10
B 0-EA BK-0.8 12 87 87 13V OR-0.8 1-ND R-62.0
10-2 7
17-1 8 40 A F1
86 A R
5 5 24S W-0.8
7
6
7
6
Not Used
Not Used
0-AE BK-1.0
SPL-A1 58-D W-0.8 16-4 2 0-B29 BK-0.8 10-18 11
ECA-F9
A 0-DC BK-0.8 PRM-D1 G A B YPP BUSS-J6-ECA 9-11 2
33
0-ES BK-19.0
87A 87A Not Used 13V OR-0.8 3 3 24B W-0.8 Not Used 58H-A W-0.8 7-2 3 0-B24 BK-0.8 13-15 12
9-3 9 BK 5 5 BUSS-J5-ECA 17-7 3
0-AB BK-2.0
GND-CAB-SPL2 A B YPE
85 85 0-DD BK-0.8 4 4 24R W-0.8 A B
34
10 A
25T-C LU-0.8 7-7 10 BUSS-PRM-PWR 13H-C 0R-0.8 8-3 1 1 1 57-B W-0.8 SPL-PINE 53C-A W-0.8 9-7 4 0-B26 BK-0.8 9-2 4 0-BS BK-1.0 16-2 13
0-B6 BK-1.0
SPL-NEU A B
0-BAC BK-2.0
86 86 13K-C OR-1.0 2 2
0-BW BK-2.0
31L Y-0.8 10-3 5 52 W-0.8 9-9 14
0-GB BK-1.0
0-EQ BK-0.8
25T-B LU-0.8 6-1 11 0-B5 BK-0.8
0-BX BK-2.0
0-BP BK-1.0
13H-B 0R-0.8 10-4 2 9 9 0-DU Bk-0.8 19-7 5
10 A F2
L1-9
A
RTHP 4 4 Not Used 19A-J OR-0.8 10-20 6 56 W-0.8 9-10 15
BUSS-J1-ECA 8-2 3 29.9 AT 20°C (JOYSTICK) 0-AF BK-1.0 14-1 6
12ACC-B W-0.8 12ACC-B W-0.8 BUSS-L1-ECA 12-13 4 23 2 2 19P-A OR-0.8 27.4 AT 20°C (SINGLE AXIS) 28.8 AT 20°C
0-AJ BK-1.0 14-5 7 52M W-0.8 10-8 16
0-EC BK-0.8 0-EC BK-0.8 0-EC BK-0.8 0-EC BK-0.8 BUSS-J11-ECA 22-2 5 20G-B W-0.8 18-1 1 CAN-H Y-0.8 18-5 3 SPE 0-AH BK-1.0 14-4 8 49-T S-0.8 16-13 7 52AU W-0.8 10-7 17
0-EB BK-0.8 0-EB BK-0.8 0-EB BK-0.8 BUSS-PRM-E 19-2 6 BUSS-J9-ECA 13-2 2 CAN-L G-0.8 18-4 4 19P-A OR-0.8 19P-A OR-0.8 49-E S-0.8 12-22 8 BUSS-J8-ECA 13-1 18
0-EA BK-0.8 0-EA BK-0.8 0-EA BK-0.8 19S1-OR-1.0 17-4 7 57-C W-0.8 10-1 1 0-AG BK-2.0 BUSS-J7-ECA 9-12 19
FRAME 1 FRAME 2 FRAME 3 FRAME 4 FRAME 5

BC07E173-01A BC07E173-02A BC07E173-03A BC07E173-04A BC07E173-05A
TRANSMISSION-01 TRANSMISSION-02 TRANSMISSION-03 WARNING BUZZER - INSTRUMENT CLUSTER 1 - PARK BRAKE SWITCH PAD - INSTRUMENT CLUSTER 2 - PARK BRAKE BACK-UP ALARM
46
TECM
53 54 JOYSTICK ONLY F-N-R SWITCH 0-DB BK-0.8 0-DB BK-0.8
FORWARD REVERSE NEUTRAL 0-DP BK-0.8 1
SPL-D15 56 36H-A P-0.8 36H-A P-0.8
CLUTCH 1 2 3 4 1 2 3 4 1 2 3 4 0-DQ BK-0.8 2 10 10 19A-E OR-0.8 19A-F OR-0.8 17P-A OR-0.8 17P-A OR-0.8
71
25K LU-0.8 25K LU-0.8 1 K4 -- -- -- -- -- -- -- -- -- -- -- 0-DM BK-0.8 3 AIC-2
7 7 0-DAP S-0.8 2 33P-A Y-0.8 33P-A Y-0.8 ECA-F14 C4
25L LU-0.8 25L LU-0.8 2 KR -- -- -- -- -- -- -- -- -- 0-DN BK-0.8 4 13V OR-0.8 1 14 52C W-0.8 Not Used 1 14 19S-D OR-0.8 L2-4
8 8 49-H S-0.8 25Y-C LU-0.8 2 2 0-B28 BK-0.8 0-B28 BK-0.8 BUSS-J14-ECA
25M LU-0.8 25M LU-0.8 3 K1 -- -- -- -- -- -- -- -- -- 32J-D Y-0.8 5 1 1 Not Used 36F-A P-0.8 2 15 44A-B T-0.8 43S-C W-0.8 2 15 0-DB BK-0.8 A B
19A-U OR-0.8 1 1 31F-A Y-0.8 31F-A Y-0.8 5 10 0-B28 BK-0.8 BUSS-J15-ECA 5A
25N LU-0.8 25N LU-0.8 4 K3 -- -- -- -- -- -- -- 35C Y-0.8 7 6 6 Not Used 1 CAN-HG Y-0.8 3 16 Not Used Not Used 3 16 57-C W-0.8
20M 31H-A Y-0.8 4 9 17P-A OR-0.8
25P LU-0.8 25P LU-0.8 5 KV -- -- -- -- -- -- -- -- -- 58H-A W-0.8 8 5 5 Not Used CAN-LG Y-0.8 4 17 Not Used 33R Y-0.8 4 17 21K-A W-0.8
42C-E DU-1.0 3 8 CAN-LF G-0.8 19A-P BK-1.0 19H OR-1.0
25J LU-0.8 25J LU-0.8 6 K2 -- -- -- -- -- -- -- -- -- -- -- 25P-A LU-0.8 9 4 4 Not Used 36A P-0.8 5 18 Not Used 33P-A Y-0.8 5 18 31L Y-0.8
SPL-D16 41T-D K-1.0 2 7 CAN-HF Y-0.8
25S LU-0.8 25S LU-0.8 7 -- -- -- -- -- -- -- -- -- -- -- -- -- 25L-A LU-0.8 10 9 9 32J-C Y-0.8 57 0-DX BK-0.8 6 19 Not Used
41H-D OR-0.8 1 6 Not Used
33U Y-0.8 6 19 Not Used ECD 86 30
36T P-0.8 36T P-0.8 8 -- -- -- -- -- -- -- -- -- -- -- -- -- 25S-B LU-0.8 12 3 3 26E LU-0.8 P K Y N 55 SFNR 43-A DU-0.8 7 20 53C-A W-0.8
SW-PAD
52M W-0.8 7 20 19S -C OR-0.8 F9/F10
36R-C P-0.8 36R-C P-0.8 36B P-0.8 8 21 Not Used 52AU W-0.8 8 21 19E -A OR-0.8
9 -- -- -- -- -- -- -- -- -- -- -- -- -- 25S-C LU-0.8 13 2 2 19A-D OR-0.8 3 4 2 1 6 5 197M 32J-A Y-0.8 7 7
Not Used
70 45L-E N-0.8 0-DA BK-0.8 78
45 Not Used
Not Used
10
11
--
--
-- -- -- --
-- -- -- --
--
--
-- -- --
-- -- --
--
--
-- --
-- --
--
--
37D-A P-0.8
32F-A Y-0.8
15
STE 19A-G OR-0.8 8 8 36H-A P-0.8
Not Used
9
10
22
23 52 W-0.8 45R-C N-0.8
9
10
22
23 Not Used
17 19A-V OR-0.8 5 5
Not Used 12 -- -- -- -- -- -- -- -- -- -- -- -- -- 32J-E Y-0.8 SPL-FNR 36C-A W-0.8 11 24 Not Used 35X Y-0.8 11 24 Not Used
37E P-0.8 18 5 5 32J-A Y-0.8 26J LU-0.8 4 4
Not Used 13 -- -- -- -- -- -- -- -- -- -- -- -- -- 25A-A LU-0.8 19 25Y-B LU-0.8 6 6 25Y-C LU-0.8 Not Used 9 9 0-DW BK-0.8 12 25 17P-A OR-0.8 Not Used 12 25 Not Used 85 87A 87
Not Used 14 -- -- -- -- -- -- -- -- -- -- -- -- -- 26F-B LU-0.8 20 19A-C OR-0.8 1 1 19A-B OR-0.8 26F-A LU-0.8 6 6 35B W-0.8 13 26 56 W-0.8 Not Used 13 26 31D-A Y-0.8
C B A Not Used 15 -- -- -- -- -- -- -- -- -- -- -- -- -- 52P-C W-0.8 26F-B LU-0.8 2 26R-A LU-0.8 TRANS CAB-T 35C Y-0.8 35A-A Y-0.8
21 2 26F-A LU-0.8 1 1 AIC-1
0SS 3 2 1 Not Used 16 -- -- -- -- -- -- -- -- -- -- -- -- -- 25Y-A LU-0.8 22
58 26R-B LU-0.8 4 4 26R-A LU-0.8 Not Used 10 10 33R-A Y-1.0 33R Y-0.8
TRC 19T-A OR-0.8 23 26N-B LU-0.8 3 3 26N-A LU-0.8 26N-A LU-0.8 3 3 62 72 PHF 31D Y-1.0
1
2
1
2
See Note 2 10 10 31D-A Y-0.8
Not Used 15 15 Not Used CAN-HD Y-0.8 25 26J LU-0.8
0-B17 BK-0.8 197F 197M 2 2
63 19D-B OR-0.8 31H Y-1.0 23 23 31H-A Y-0.8
0-HE BK-1.0
7 7
19A OR-1.0
25D LU-1.0
25K LU-0.8 16 16 25K-A LU-0.8 25K-A LU-0.8 25K-A LU-0.8 CAN-LK G-0.8 26 19D-C OR-1.0 36H P-1.0 30 30 36H-A P-0.8
SPL-D5 8 8 49S S-0.8 PBD
25L LU-0.8 17 17 25L-A LU-0.8 25L-A LU-0.8 25L-A LU-0.8 CAN-LJ G-0.8 27 SPL-PBS 79
19D-A OR-1.0
9 9 Not Used ECB 86 30
25M LU-0.8 18 18 25M-A LU-0.8 25M-A LU-0.8 25M-A LU-0.8 25H LU-0.8 29 A A 19A-A OR-1.0 BUZ
25N LU-0.8 19 19 25N-A LU-0.8 25N-A LU-0.8 25N-A LU-0.8 26R-B LU-0.8 30
6 6 Not Used B B 25G LU-1.0 60 K5 73 74
35B W-0.8 1 1
64 10 10 Not Used
19S -C OR-0.8
Not Used
SPL-DLY3 19S-D OR-0.8

5 5 SDC
25P LU-0.8 20 20 25P-A LU-0.8 25P-A LU-0.8 25P-A LU-0.8 26E LU-0.8 31 FRONT 28 27 0-B27 BK-0.8 2 2 7 7 0-B21 BK-1.0
25J LU-0.8 25J-A LU-0.8 25J-A LU-0.8 25J-A LU-0.8 25M-A LU-0.8
4 4 Not Used 59 28 27 Not Used 10 10
36H P-1.0 10 10 Not Used
52C W-0.8
21 21 32 CAB-F SPL-BUZ A A 8 8 49-L S-0.8
19E -A OR-0.8
1 1 Not Used 0-B18 BK-0.8 7 7 7 7 0-B29 BK-0.8
25S LU-0.8 22 22 25S-A LU-0.8 36T-A P-0.8 36T-A P-0.8 36T-A P-0.8 39 B B 0-HW BK-1.0 9 9 Not Used
3 3 25H LU-0.8 49-R S-0.8 8 8
19A-T OR-0.8
A6
25G-A LU-0.8
36T P-0.8 5 5 36T-A P-0.8 32F-A Y-0.8 32F-A Y-0.8 25C-A LU-0.8 41 8 8 49-V S-0.8
B
2 2 19A-Q OR-0.8 Not Used 9 9 HOT 6 6 Not Used
32F Y-1.0 31 31 32F-A Y-0.8 0-DN BK-0.8 0-DN BK-0.8 25B-A LU-0.8 42 0-B28 BK-0.8 85 87A 87 1 1 Not Used 5 5 Not Used
13H-C OR-0.8
Not Used
ECA-F6
6 6 0-B26 BK-0.8 ENG-T TRAN-E
A1
STA 9 9 Not Used
A
0-HE BK-1.0 0-DN BK-0.8 25D-A LU-0.8 25D-A LU-0.8 25F LU-0.8
47 28 28 43 52P-B W-0.8 1 1 35R-C Y-0.8
L1-1
BUSS-J1-ECA
Not Used 5 5 0-BK BK-1.0 2 2 0-HC BK-1.0 5 5 Not Used
A
25D LU-1.0 25D-A LU-0.8
BUSS-J2-ECA
10 10 36R-E P-0.8 36R-E P-0.8 26N-B LU-0.8 44
TRANS ECM DLY

4 4 Not Used
ECD-F1
25G-B LU-0.8 1 1
TRANS ECM
Not Used Not Used Not Used
5A
19A OR-1.0 19A-M OR-0.8 36G-A P-0.8 36G-A P-0.8 19A-K OR-0.8 3 0-DAV BK-0.8 3 3 6 6
19S -B OR-0.8
29 29 45
7.5 A
3 3 Not Used
A3
ECA-F1
Not Used
B
32F Y-1.0 5 Not Used SPL-DC 4 4 0-DX BK-0.8 17 17 0-BJ BK-0.8 Not Used 4 4 Not Used 4 4 Not Used
33R-A Y-1.0
A 1 Not Used 24 24 Not Used 25A-A LU-0.8 25A-A LU-0.8 36R-E P-0.8 46 2 2 35A-B Y-0.8
7.5 A
L1-6
A
2 37D-A P-0.8 Not Used 3 3 0-DW BK-0.8 19 19 0-BG BK-0.8 3 3 33U Y-0.8
B 2 36R-B P-1.0 36R-A P-1.0 12 12 36R-E P-0.8 0-DM BK-0.8 0-DM BK-0.8 36G-A P-0.8 49
61
ECA-F3
SPL-H1 19A-R OR-0.8 2 2 0-DB BK-0.8 20 20 0-BH BK-0.8 SPL-PB SBU
510 6 Not Used 2 2
B1
36G P-1.0 13 13 36G-A P-0.8 25J-A LU-0.8 51
B
FM 0-HC BK-1.0
A
4 37E P-0.8 31F-A Y-0.8 28 28 31F Y-1.0 CAB-F FRONT
A1
7.5 A
Not Used 14 14 Not Used 25N-A LU-0.8 55 SPB
B
Not Used Not Used
B
19A-L OR-0.8
1 19A-W OR-0.8 36A P-0.8 32 32
19T-A OR-0.8
BUSS-J7-ECA
BUSS-J6-ECA
25A W-0.8 25A-A LU-0.8 25B-A LU-0.8 25B-A LU-0.8 25K-A LU-0.8
48 7 7 56 36B P-0.8 8 8 Not Used 0-HW BK-1.0
C
L1-3
36F-A P-0.8 33 33 36F P-1.0
B3
0-HD BK-1.0 11 11 0-DM BK-0.8 58L BK-0.8 57 0-DY BK-1.0 Not Used
B
108F 9 9
SPL-TRNS-PWR 36C-A W-0.8 34 34 36C P-1.0 0-HV BK-1.0
D
25B W-0.8 9 9 25B-A LU-0.8 25D-A LU-0.8 62 52P-A W-0.8 24 24 52P W-1.0 0-HL BK-1.0
E J 35A-D Y-0.8
A 2 36R-D P-1.0 19A-N OR-1.0
ECD-F3
25C W-0.8 8 8 25C-A LU-0.8 25C-A LU-0.8 25C-A LU-0.8 25Z LU-0.8 63 A CAB-E ENG
33P-A Y-0.8 26 26 33P Y-1.0 0-HM BK-1.0
F K 35A-B Y-0.8
BUSS-J3-ECA
BUSS-J4-ECA
B 1 36G P-1.0 19A-F OR-0.8 B
TRANS CAB-T 25R LU-0.8 64 L 35A-A Y-0.8
SPL-TRN-GRD SPL-PB1
10 A
TCOT
25W LU-0.8 65 19A-Q OR-0.8 C
SPL-A4
SPL-D12 57-C W-0.8 4-1 1 M 35A-C Y-0.8
25S-A LU-0.8 25S-A LU-0.8 25S-B LU-0.8 25G-C LU-0.8 66 19A-T OR-0.8 D
A3
A 1 25A W-0.8 21K-A W-0.8 1-7 2
A
SPL-PK1
19A-S OR-0.8
19A-J OR-0.8
25S-C LU-0.8 25T-C LU-0.8 67 19A-W OR-0.8 E
66
36F P-1.0
B 2 0-HF BK-0.8 PAF
0-AL BK-1.0
19A-C OR-0.8 F 31L Y-0.8 5-5 3
SPL-RD
33P Y-1.0
0-AK BK-1.0
0-AN BK-1.0
ESS 25W LU-0.8 25W LU-0.8 19A-P BK-1.0 G 1 1 31F Y-1.0 13H-B OR-0.8 2-2 4
52
52P W-1.0
25G-C LU-0.8 25G-C LU-0.8 BUSS-J3-ECA 8-2 5
49 25Z LU-0.8 25Z LU-0.8
0-HM BK-1.0
0-BY BK-1.0
0-HL BK-1.0
19A-R OR-0.8 H 2 2
33R-C Y-1.0
209F 209M
33R-BY-1.0
TS2 BUSS-J4-ECA 17-6 6 SPL-D8-C1
25R LU-0.8 25R LU-0.8
67
0-HV BK-1.0
FORWARD REVERSE NEUTRAL BK A A 19A-K OR-0.8 19A-K OR-0.8 19A-K OR-0.8 J
35A-E Y-0.8 A A
SPL-H2 25F LU-0.8 25F LU-0.8 1 52AU W-0.8 5-17 7
65
31D Y-1.0
1 2 3 4 1 2 3 4 1 2 3 4 G B B 26N-B LU-0.8 26N-B LU-0.8 19A-M OR-0.8 K RFL PBW 1 2
25W LU-0.8 25Y-A LU-0.8 25Y-A LU-0.8 S 52M W-0.8 5-16 8
50 A 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V U C C
25Z LU-0.8 25Y-B LU-0.8 25Y-B LU-0.8
26E LU-0.8 26E LU-0.8 19A-S OR-0.8 L 1 2 YPB 2 1 35X Y-0.8 17-2 9
B -- -- 24V 24V -- -- 24V 24V -- -- 24V 24V 26R-B LU-0.8 26R-B LU-0.8 19A-H OR-0.8 M
2 1 See Note 3
D D 25Y LU-0.8 19A-M OR-0.8 19A-M OR-0.8 25H LU-0.8 25H LU-0.8 PRB1 A B PRB2 A B 45R-C N-0.8 13-7 10
A 2 0-HG BK-0.8 C 24V -- -- 24V 24V -- -- 24V 24V -- -- 24V SPL-D11 G 1
19A-H OR-0.8 19A-H OR-0.8 13V OR-0.8 1-9 3 A B A B 45L-E N-0.8 13-6 11
36C P-1.0
19T-A OR-0.8 19T-A OR-0.8 CLS A B
B 1 25B W-0.8 D -- -- -- -- -- -- -- -- -- -- -- -- R A RFLG 43-A DU-0.8
A 19A-H OR-0.8 26F-B LU-0.8 26F-B LU-0.8 12-3 4 A B 43S-C W-0.8 12-1 12
Y B 40.3 AT 20°C CAN-LG Y-0.8 18-10 5
ISS B 25F LU-0.8 CAN-LF G-0.8 18-8 13
A 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V K C C 25R LU-0.8
37E P-0.8
37D-A P-0.8
37E P-0.8
37D-A P-0.8 BUSS-J2-ECA 10-5 1 69 CAN-HG Y-0.8 18-11 6 CAN-HF Y-0.8 18-9 14 35A-F Y-0.8 13-9 1
A 2 0-HH BK-0.8 B 24V 24V 24V 24V -- -- -- -- -- -- -- -- S
D D 25T-B LU-0.8 1 11-5 35C Y-0.8 32J-D Y-0.8 32J-D Y-0.8 BUSS-J1-ECA 2-3 2 53C-A W-0.8 4-4 7 41H-D OR-0.8 13-4 15 35A-C Y-0.8 13-10 2
0-BAE BK-1.0
C -- -- -- -- 24V 24V 24V 24V -- -- -- -- A B RECT
25C W-0.8
0-BG BK-0.8
B 1
0-BH BK-0.8
0-BU BK-1.0
0-DA BK-0.8
0-AK BK-1.0
0-BK BK-1.0
44A-B T-0.8 13-16 8
0-DY BK-1.0
2 5-3 58H-A W-0.8 13H-C OR-0.8 2-1 3 41T-D K-1.0 13-5 16 49-L S-0.8 12-17 3
0-BJ BK-0.8
0-DAV BK-0.8
TS1
0-DQ BK-0.8
0-DP BK-0.8
D -- -- -- -- -- -- -- -- 24V 24V 24V 24V A B

TSS 3 9-13 52P-C W-0.8 19A-S OR-0.8 10-21 8 52 W-0.8 5-14 9 42C-E DU-1.0 12-4 17 0-B21 BK-1.0 12-10 4
25Y-B LU-0.8 25Y-B LU-0.8
19A-P BK-1.0 11-6 9 56 W-0.8 5-15 10 75 76 77 0-B29 BK-0.8 5-11 18
51 4 18-7
5 18-6
CAN-HD Y-0.8
CAN-LD G-0.8
19A-M OR-0.8 19A-M OR-0.8 0-DAP S-0.8 12-11 4
49-H S-0.8 12-16 5 49-R S-0.8 12-20 10
68 BUSS-J6-ECA 4-2 11 49-V S-0.8 5-9 19
35C Y-0.8
19A-P BK-1.0
7-1 5
8-9 6
19A-H OR-0.8 19A-H OR-0.8
6 5-1 58L BK-0.8 0-B17 BK-0.8 12-6 6 0-B18 BK-0.8 12-7 11 0-BY BK-1.0 16-1 1 BUSS-J7-ECA 5-19 12 19A-J OR-0.8 5-6 20 BUSS-J15-ECA 22-5 7
1-11 1 7 1-10 25T-C LU-0.8 49S S-0.8 12-21 7 0-B26 BK-0.8 5-4 2 52P-C W-0.8 7-3 13 19A-S OR-0.8 8-8 21 BUSS-J14-ECA 16-8 8
FRAME 6 FRAME 7 FRAME 8 FRAME 9 FRAME 10 FRAME 11

BC07E173-06A BC07E173-07A BC07E173-08A BC07E173-09A BC07E173-10A BC07E173-11A
LIGHTS-01 LIGHTS-02 LIGHTS-03 AND HORN LIGHTS-04 AND BACKUP ALARM LIGHTS-04 AND BACKUP ALARM COMPONENT
A 42C-A DU-1.0 NORTH AMERICA EUROPE FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS
B 42C-E DU-1.0 0-MC BK-1.0 45L-C N-0.8 1 1 45L N-1.0 45L N-1.0
CAB-RF ROOF ECB-F8
C 42C-D DU-1.0 46-D K-1.0 A 45L-E N-0.8 A8 B8 SPL-POS-R 45R-D N-0.8 3 3 45R N-1.0 45R N-1.0 1 - 1. Starting Relay 5- 37.
Fan Control Switch (Option) 10 - 73. Hydraulic Oil Temperature Sender NORTH AMERICA
D 42C-C DU-1.0 43-A DU-0.8 A A 43-B DU-0.8 B 45L-D N-0.8 41T-A K-1.0 A B 18G OR-1.0 18G-G OR-0.8 5 5 18G-A OR-1.0 18G-A OR-1.0
LBEPWR
LBEGRD
SPL-PK1
B
10 A
A A B 42R-C DU-1.0 B B 42R-F DU-1.0
1 1
C 45L-C N-0.8
5A
18F-E OR-0.8 6 6 18F OR-1.0 18F OR-1.0 1 - 2. Resistor - 75 Ohm 5- 38.
Fan Reverse Relay (Option) 10 - 74. Park Brake Switch
10 A A B
B1
ECB-F1
A1 A2
ECB-F2
B2 42C-A DU-1.0 C C 42C-F DU-1.0 D 45L-B N-0.8 A7
ECB-F7
B7 SPL-POS-L
18B-A OR-0.8 7 7 18B OR-1.0 18B OR-1.0
96 1 - 3. Alternator 5- 39.
Pilot Control Switch 10 - 75. Redundant Brake Pressure Switch 1 15 - 100. Right-Hand Rear Combination Lamps
19U-D OR-0.8 D D 19U-C OR-0.8 E 45R-C N-0.8 18D-A OR-0.8 14 14 18D OR-1.0 18D OR-1.0
46-C K-1.0 E E 46-D K-1.0 M F 45R-E N-0.8
41T-B K-1.0 A
5A
B 18F-C OR-1.0
18E-A OR-0.8 15 15 18E OR-1.0 18E OR-1.0 100 1 - 4. Crank Control Relay 5- 40.
Ride Control Solenoid (Option) 10 - 76. Redundant Brake Pressure Switch 2 Pin 1 - Ground
80 42FS DU-1.0
0-DR BK-1.0 F F 0-MN BK-1.0 82 G 45R-D N-0.8 18F-A OR-0.8 18C-A OR-0.8 16 16 18C OR-1.0 18C OR-1.0 1 - 5. Batteries 5- Rollback Pressure Switch
41. 10 - 77. Coolant Level Sender Pin 2 - Brake Lamp
G G H 45R-B N-0.8 1-DR R-1.0 22 22 1-AA R-1.0 0-AJ BK-1.0 1 1 44A-E T-1.0 1 1
7 7 0-B14 BK-0.8
0-DS BK-1.0 0-MK BK-1.0 18G-F OR-0.8
44-A T-0.8 23 23 44 T-1.0 18D OR-1.0 2 2 45L-A N-1.0 2 2
1 - 6. Crank Request Relay (XT with Ride Control Only) Pin 3 - Tail Lamp
SPL-PK3
8 8 49-A S-0.8 43S-A W-0.8 R R 43S-B W-0.8 19U-C OR-0.8 A B CAB-F FRONT 18B OR-1.0 3 3 18F-B OR-1.0 3 3 1 - 7. Time Delay Module 5 - 42. Rollback Jumper 11 - 78. Backup Alarm Relay Pin 4 - Turn Lamp
SPL-PK2
SPL-D
18F OR-1.0 35A-L K-1.0 15 - 101. Left-Hand Rear Combination Lamps

5 5 42-B R-2.0 19U-G OR-0.8 S S 19U-F BK-0.8 43-B DU-0.8 A3
5A
B3 90 4 4 4 4
1 - 8. Master Disconnect Switch 5 - 43. Fan PWM Solenoid 11 - 79. Backup Alarm Disable Switch
41H-B OR-0.8
Not Used A 41T-B K-1.0 ECB-F3 45L N-1.0 5 5 0-BT BK-1.0 5 5

18E-A OR-0.8
10 10 CAB-RF ROOF 0-MB BK-0.8

41T-E K-1.0 PBL 1 - 9. Starter 5 - 44. Fan Reverse Solenoid (Option) Pin 1 - Ground
LDM1
B Not Used Not Used

LDM3
6 6 6 6
LDM2
9 9 Not Used
6 6 42RS DU-1.0 DS
3 2 1 C 41T K-1.0 A
5A
B 1 1 1-AA R-1.0 LLF LLR-E
1 - 10. Ignition Switch 12 - 80. Work Lamps Switch Pin 2 - Brake Lamp
D 41T-A K-1.0 A4 B4
41T-C K-1.0
41T-D K-0.8
44 T-1.0
41H-C OR-0.8
1 1 Not Used SPL-DS A A 2 2

81 ECB-F4 Pin 3 - Tail Lamp
18D-A OR-0.8
4 4 Not Used B B E 19Z-A OR-1.0 1 - 11. Neutral Start Relay 6 - 45. Output Speed Sensor 12 - 81. Door Switch
83 F 19Z-B OR-1.0 97 44A-D T-1.0 SPL-B8
101 Pin 4 - Turn Lamp
1 - 12. Voltmeter Relay
43S-C W-0.8
43S-D W-0.8
3 3 42FS DU-1.0 35A-J K-1.0

G 19Z OR-1.0
A
5A
B
44-A T-0.8 SPL-A1A 6 - 46. Transmission Solenoid Valve and 12 - 82. Rotating Beacon (Optional)
2 2 42-A R-2.0 A5 B5 SPL-FLSHR-PWR 15 - 102. Licence Plate Lamp
41L-C OR-0.8
SWL
SPL-WL H 19Z-C OR-1.0 ECB-F5 1-DW R-1.0 91 44A-F T-1.0 1 1 Temperature Sender 12 - 83. Dome Lamp
42 R-2.0 J 41H-C OR-0.8 ECC 86 0-AH BK-1.0 1 1 100 45R-A N-1.0 2 2 2- 13. Power Relay Module A 15 - 103. Backup Alarm
A B
30
6 - 47. Filter Maintenance Switch 12 - 84. Rotating Beacon Switch (Optional)
19U-G OR-0.8
19U-D OR-0.8
42R-F DU-1.0 K 41H-B OR-0.8 5A 18E OR-1.0 2 2 SPL-J2-N 18G-J OR-1.0 3 3

1-KA R-1.0
1-DU R-1.0
1-DV R-2.0
BUSS-J3-ECC A6 B6 K K3 2- 14. Power Relay Module B 6 - 48. Torque Convertor Output Temperature 12 - 85. Left-Hand Front work Lamp
41L-B OR-0.8
B A 42C-F DU-1.0 L 41H-A OR-1.0 ECB-F6 18C OR-1.0 3 3 0-BAG-N BK-1.0 1 1 0-JA-N BK-1.0 44A-EN T-1.0 44A-GN T-1.0 2 2 35A-K K-1.0 4 4
15 A BUSS-J2-ECC A 0-MC BK-1.0 M 41H-D OR-0.8 L
BRAKE
18G-A OR-1.0 44A-DN T-1.0 2 2 44A-EN T-1.0 18G-CN OR-1.0 0-BR BK-1.0 5 5 2- 15. Power Relay Module C EUROPE
A2 L1-2 4 4 3 3
Sender 12 - 86. Right-Hand Front work Lamp
0-EH BK-0.8
ECC-F2 LIGHTS
B 0-MB BK-0.8 M 45R N-1.0 5 5 45L-AN N-1.0 3 3 45L-BN N-1.0 45R-BN N-1.0 4 4 Not Used 6 6 100. Right-Hand Rear Combination Lamps
0-EG BK-0.8
RELAY 2- 16. Grid heater Relay

C 0-MU BK-1.0 GND-CAB-SPL2 Not Used 6 6 45R-AN N-1.0 4 4 45R-BN N-1.0
SPL-POS-NA
0-BT-N BK-1.0 1 1 LRR-E 6 - 49. Engine Speed Sensor 12 - 87. Left-Hand Rear work Lamp Pin 1 - Brake Lamp
D 0-ME BK-1.0 LRF 18G-HN OR-1.0 5 5 18G-JN OR-1.0 LRR-12 2- 17. Grid Heater 6 - 50. Intermediate Speed Sensor 12 - 88. Right-Hand Rear work Lamp
SPL-WRKR
SPL-WRKF
A B 19U-B OR-1.0 1 1-DU R-1.0 85 87A 87

Pin 2 - Turn Lamp
L1-1
7.5 A
A-1 SPL-LT
E 0-MF BK-1.0
0-MA BK-1.0
92 2 45N-A N-0.8
SPL-LB
0-EF BK-0.8
18F-AN OR-1.0 6 6 18F-BN OR-1.0
2- 18. Power Relay Module D 6 - 51. Turbine Speed Sensor 12 - 89. Diodes
ECC-F1 F
3 0-EH BK-0.8 35A-GN Y-1.0 7 7 35A-HN Y-1.0
101 Pin 3 - Tail Lamp
19U-H OR-1.0
G Not Used 44A-A T-0.8 98 Not Used 8 8 Not Used 2- 19. Circuit Breaker Cab + 6 - 52. Transmission Shifter
0-MU BK-1.0
42C-H DU-1.0
0-MJ BK-1.0
42C-G DU-1.0
0-ME BK-1.0
42R-H DU-1.0
0-MF BK-1.0
42R-G DU-1.0
4 0-EG BK-0.8 Pin 4 - Backup Lamp

BUSS-L1-ECC
Not Used K4 ECC

84 H
5 Not Used 44A-C T-0.8
SPL-BRK
93
ENG-H HD-N
2- 20. Water Separator Heater 13 - 90. Brake Lamp Switch
J 0-MJ BK-1.0
6 Not Used Not Used 10 10 30 30 19U-A OR-0.8 CAB-F FRONT 44A-FN T-1.0 2 2 Pin 5 - Ground
2- 21. Fuel Filter Heater
44A-B T-0.8
K Not Used 0-B24 BK-0.8 7 7 87 87 64-A OR-0.8 13 13 18F-BN OR-1.0 3 3

7 - 53. Transmission Electronic Control Module 13 - 91. Brake Lamp Relay Pin 6 - Not Used
A3
10 10 Not Used 7 45R-E N-0.8

B
L 0-MN BK-1.0 49-D S-0.8 87A 87A Not Used 45L-BN N-1.0 4 4
64 OR-1.0
7 7 0-B15 BK-0.8 45L-D N-0.8 8 8

8 13 - 92. Flasher Module
15 A
M 0-MK BK-1.0 Not Used 9 9 85 85 64C OR-0.8 0-JA-N BK-1.0 0-BR-N BK-1.0 1 1 101. Left-Hand Rear Combination Lamps
ECC-F3
LRFW
LLFW
LLRW
LRRW
8 8 49-B S-0.8 B A B A B A B A 9 45A-A N-0.8

9 9 Not Used SPL-ROOF B A B A B A B A 10 45B-A N-0.8 Not Used 6 6 86 86 19U-E OR-0.8 SPL-J1 LLR-12 3 - 22. Water In Fuel Sensor 8- 54. Transmission Enable Switch 13 - 93. Hazard Switch Pin 1 - Brake Lamp
Not Used 5 5
3 - 23. Throttle Potentiometer
0-JB BK-1.0
0-JC BK-1.0
6 6 Not Used 11 45H N-0.8 8- 55. FNR Switch for Joystick Controls 13 - 94. Turn Signal, High-Low Beam, and Horn Pin 2 - Turn Lamp
5 5 Not Used 12 45N-B N-0.8 Not Used 4 4 SPL-HRN 19U-E OR-0.8 SPL-POS E-HD HD-E 102
L1-3
1 1
3 - 24. Engine Controller 8- 56. Transmission Kick-Down Switch Pin 3 - Tail Lamp
A
4 4 Not Used FLSHR 64M 64F

Not Used 1 1 19U-A OR-0.8 18G-D OR-1.0 A A 18G-E OR-0.8
LPL Switch
45H N-0.8 3 3
8- 57. FNR Switch for Single Axis Controls 13 - 95. Driving Lamps Switch Pin 4 - Backup Lamp
45A-A N-0.8
1 1 Not Used 35A-H Y-1.0

19B OR-0.8
1-KA R-1.0 2 2 102 35A-G Y-1.0 B B 18G-E OR-0.8 A A
45B-A N-0.8
3 3 46-C K-1.0 0-JA BK-1.0

95 0-BAG BK-1.0 C C 0-JC BK-1.0 B B
4 - 25. Return-to-Travel Float Switch 8- 58. Transmission Auto Switch Pin 5 - Ground
BUSS-J4-ECA
94
41T-C K-1.0
2 2 19U-H OR-1.0 SHZ SPL-J1

SBE 85 86 87 88 0-B19 BK-0.8 7 7 HN1
18G-EN OR-1.0 A A 4 - 26. Height Control Switch 8- 59. Brake Declutch Pressure Switch 14 - 96. Left-Hand Front Combination Lamps Pin 6 - Not Used
49A 49A 0-JC BK-1.0 B B
49-P S-0.8 8 8 64 OR-1.0 4 - 27. Electromagnetic Detents 8- 60. Declutch Switch Pin 1 - Ground 102. Licence Plate Lamp
A8
L L LPL
B
19U OR-0.8
0-AF BK-1.0
0-B13 BK-1.0
A
41T-C K-1.0 R R
19Z-B OR-1.0 5 5
HN2
103 Pins 3 and 4 - Return-to-Dig 8- 61. Diagnostic Connector Pin 2 - Low Beam 103. Backup Alarm
5A
Not Used 10 10
43S-C W-0.8
103
ECA-F8
56 56 41J OR-1.0
0-B14 BK-0.8
B
Not Used Pins 2 and 5 - Height Control Pin 3 - High Beam
43S-D W-0.8
9 9
0-B15 BK-0.8
C A 49 DU-1.0 89 56A 56A 41H-A OR-1.0 99 BU1
41J OR-1.0 6 6
Pins 1 and 6 - Return-to-Travel 9- 62. Instrument Cluster Connector 1
43-A DU-0.8
56B 56B 41L-A OR-1.0 0-JB BK-1.0 Pin 4 - Position

42C-E DU-1.0
Not Used
D B Not Used D-OR 18F-A OR-0.8 5
Not Used
1-DV R-2.0
1 1 BU1
56D 56D 19Z-C OR-1.0 35A-H Y-1.0 4 - 28. Return-to-Dig Proximity Switch
A6
35A-C Y-0.8
L1-8
0-B17 BK-0.8 49-C S-0.8 42C-D DU-1.0 A 7

9- 63. Warning Buzzer Pin 5 - Turn Signal
B
E C
A
31B 31B 64C OR-0.8 Not Used 4 4 0-JB BK-1.0

0-B18 BK-0.8
F 10-12 1 D 49-H S-0.8 41T-C K-1.0 B 44A-C T-0.8 8 BU2
7.5 A
41T K-1.0 3 3 35A-HN Y-1.0 4 - 29. Pilot Control Relay ECD-K3 9- 64. Parking Brake Relay 14 - 97. Right-Hand Front Combination Lamps
ECC-F6
0-B19 BK-0.8
G 1-4 2 E 49-L S-0.8 49 DU-1.0 C 31 31 0-EP BK-0.8 18G-F OR-0.8 9 15-1 8
19Z-A OR-1.0 2 2 BU2
0-B8 BK-0.8
H 9-4 3 F 49A S-0.8 SRHSTLK 45L-B N-0.8 10 (ENG)
SDR 4 - 30. Height Control and Return-to-Travel 9- 65. Fuel Level Sender Pin 1 - Ground
18F-AN OR-1.0 5 18F-B OR-1.0
A4
0-B21 BK-1.0
J 10-17 4 G 49-P S-0.8 0-MA BK-1.0 16-10 14 45R-B N-0.8 12 5
B
Not Used 35A-J K-1.0 Proximity Switch 9- 66. Air Filter Restriction Switch Pin 2 - Low Beam
ECC-F4
BUSS-J3-ECC 13-3 5 49-C S-0.8 16-7 15 35A-F Y-0.8 40 7 7

L1-6
0-DAP S-0.8
K H 49-R S-0.8
10 A
4 - 31. Return-to-Dig Switch

0-BAG-N BK-1.0
64C OR-0.8
49-P S-0.8 12-19 12

0-B23 BK-0.8
L 0-B17 BK-0.8 8-6 6 J 49S S-0.8 49-H S-0.8 8-5 16 BUSS-J8-ECA 5-18 1 CAB-E 44A-DN T-1.0 8 44A-D T-1.0 8
9- 67. Parking Brake Solenoid Pin 3 - High Beam
0-BAG BK-1.0
0-B13 BK-1.0
0-B19 BK-0.8 12-8 13 0-AF BK-1.0 4-6 1

0-DR BK-1.0
18G-HN OR-1.0 13-8 1
0-BR BK-1.0
0-DS BK-1.0
9 18G-H OR-1.0 9
0-BT BK-1.0
Not Used
M 0-B18 BK-0.8 8-11 7 K 49-E S-0.8 49-L S-0.8 11-3 17 BUSS-J9-ECA 3-2 2 13-8 1 (CAB-E)
0-B19 BK-0.8 13-13 8 L 49-B S-0.8 49A S-0.8 22-1 18 BUSS J3-ECC 12-15 3 35A-F Y-0.8 11-1 9 49-D S-0.8 5-10 14 BUSS-J6-ECC 1-3 2 45L-AN N-1.0 10 45L-A N-1.0 10 (CAB-E)
4 - 32. Pin Engage Switch (Option) 9- 68. Radiator Coolant Temperature Sender Pin 4 - Position
SPL-BCK-LT-GD
0-B8 BK-0.8 16-11 9 M 49-A S-0.8 49-P S-0.8 13-12 19 41H-D OR-0.8 10-15 4 35A-C Y-0.8 11-2 10 0-B24 BK-0.8 5-12 15 BUSS-J7-ECC 21-2 3 45R-AN N-1.0 12 45R-A N-1.0 12 4 - 33. Pilot Pressure Solenoid 9- 69. Brake Pressure Warning Switch Pin 5 - Turn Signal
L1-4
A
0-B21 BK-1.0 11-4 10 49-R S-0.8 8-10 20 41T-D K-0.8 10-16 5 0-EP BK-0.8 19-4 11 44A-B T-0.8 9-8 16 0-AH BK-1.0 4-8 4 35A-GN Y-1.0 40 35A-G Y-1.0 40
0-DAP S-0.8 8-4 11
SPL-BCK-LGT
49S S-0.8 8-7 21 45L-E N-0.8 10-11 6 BUSS-J4-ECA BUSS-J5-ECC 1-2 17 0-AJ BK-1.0 4-7 5 ENG ENG
4 - 34. Pin Engage Solenoid (Option) 14 - 98. Horn Relay
BUSS-L1-ECC 2-4 13 0-B23 BK-0.8 16-6 12 49-E S-0.8 5-8 22 45R-C N-0.8 10-10 7 64C OR-0.8 64C OR-0.8 10 - 70. Switch Pad 14 - 99. Horn
5 - 35. Ride Control Switch (Option) 10 - 71. Instrument Cluster Connector 2
FRAME 12 FRAME 13 FRAME 14 FRAME 15-NA FRAME 15-EU 5 - 36. Ride Control Relay (Option) 10 - 72. Hydraulic Filter Restriction Switch
BC07E173-12A BC07E173-13A BC07E173-14A BC07E173-NA15A BC07E173-EU15A
CIRCUIT DIAGRAM LEGEND WIRE IDENTIFICATION NOTES

NOTE 1: Electrical Center C - Power Stud
SPL-00
Frame and Wire Tag
Number where circuit
WIRE TAGS
00-0 1
FEMALE MALE BK . BLACK
WIRE NUMBER
702A G-1.0
WIRE SIZE NOTE 2: Indicates Modulated and Current Controller.
ELECTRICAL SCHEMATIC
CONNECTOR CONNECTOR DU . DARK BLUE
continues. 1 00-0 MALE
TERMINAL
FEMALE
TERMINAL
INDICATES
EXTERNAL
INDICATES
INTERNALLY
1 1
INDICATES PARTIAL G. . . GREEN WIRE COLOR NOTE 3: Disconnect when Backup Alarm Disable Switch is installed. Applicable only on TUV Road Approved Machines. 621E WHEEL LOADER
FRAME - WIRE WIRE 54 GROUND GROUNDED
CONNECTOR 2 2
3 3 4 4
CONNECTOR K . . . PINK OR . ORANGE T . . TAN
NUMBER LG. . LIGHT GREEN P . . . PURPLE (Violet) U . . . BLUE
SHOWS CIRCUIT SHOWS COMPONENT 45E 45D 18 18 NOT ALL
Wire Tag assigned to wire in Frame.
CONNECTOR
RELAY REAR 27 27
CONNECTIONS LU . . LIGHT BLUE R . . . RED W . . WHITE Additional copies of this Hydraulic and Electrical Schematic can be ordered through Technical Publications Distribution System. The part number is 5-7560
CROSSING CIRCUIT SPLICE COMPONENT GROUND
NOT CONNECTED CONNECTION CIRCUIT CONTINUATION NUMBER IDENTIFICATION ARE SHOWN N . . . BROWN S . . . GREY Y . . . YELLOW
Copyright © 2007. CNH America, LLC. All Rights Reserved. BC07E173-00A
CAB WINDOW WASHER AND WIPER SYSTEM SECONDARY STEERING COMMUNICATION RADIO / POWER CONVERTER AIR SEAT CIGAR LIGHTER AIR-CONDITIONING COMPRESSOR
SPL-FW 0-BZ BK-1.0 1 1 0-HP BK-1.0 PRM-E PRM-E1

SFWW
19J-C OR-0.8 ENG-T TRAN-E A Not Used SPL-CNV 121
Not Used 1
108 120 C 19L OR-2.0 19L-A OR-2.0 1
K1 ECD J
K
19J-B OR-0.8
19J OR-0.8
0-DT BK-0.8 2 114 CAB-T TRANS
CAN-HG Y-0.8 19L-B OR-2.0 2
30 30 19J-E OR-0.8 63LC W-0.8 3 DM 19M OR-0.8 3 3 19M-A OR-1.0 19M-A OR-1.0 A A 19M-C OR-1.0 SPL-CAN CAN-HE Y-0.8
104 87 87 63H-B W-0.8
L 19J-C OR-0.8 Not Used 4 A A 19RR OR-0.8 19R-E OR-0.8
4 4 19R-A OR-1.0 19R-A OR-1.0 B B 19R-C OR-1.0 CAN-HF Y-0.8 SPL-CAN-TRANS CAN-HC Y-0.8
85
86
B
A
0-DL BK-0.8
12ACC-C W-0.8
0-EJ BK-1.0
Not Used
3
4 128
M 19J-A OR-0.8 Not Used 35X Y-0.8 6 6 35X-B Y-1.0 C C 35X-C Y-1.0 CAN-HD Y-0.8
87A 87A 63C2 W-0.8 19J-B OR-0.8 5 B B
35X-B Y-1.0 20 A F1 12V-C OR-2.0 5 K5 ECD
SPL-PK3 19R OR-0.8 PRM-E2
85 85 63HC-B W-0.8 Not Used 6 C C SPL-2 19S1 OR-1.0
26 26
19S1-E OR-1.0 0-HP BK-1.0 D D 0-CD BK-1.0
0-ER BK-1.0 6 30 30 18M OR-0.8
86 86 19J-D OR-0.8 63W W-0.8 7 19S1-E OR-1.0 E E 19S1-X R-1.0
BUSS-PRM-E
19R-D OR-0.8
CNV 87 87 61C OR-0.8
49-T S-0.8 8 Not Used F F Not Used ECD-F7
SPL-HC 87A 87A Not Used
K-WCO
63HC W-0.8 9 TR-SS SS-TR
20 A F2
12V-G OR-1.0 A B
122 85 85 0-DJ BK-0.8
Not Used 10 CAN-LG G-0.8 15 A
30 30 63L-B W-0.8 A7 B7 A B C 86 86 61R-B W-0.8
105 87 87 Not Used Not Used 11 SPL-CAN-L CAN-LE G-0.8 PO1 A B C
Not Used 12 CAN-LF G-0.8 SPL-CAN-TRANS-L CAN-LC G-0.8
87A 87A 63C3 W-0.8 116 CAN-LD G-0.8 12V-D OR-1.0 A B 12V OR-1.0
85 85 63HC-A W-0.8 FWM 115 SSM
SPL-12V
A4
10 A
B4
0-EK BK-1.0
86 86 19J-G OR-0.8 SPL-WHS ECD-F4
63H-A W-0.8 A A YSS
SPL-WLS
63L-A W-0.8 B B
M A 1 51-C W-1.0
SPL-SS 19R-C OR-1.0
51-A W-1.0
1
2
122 61C OR-0.8 2 2 61C-A OR-1.0
K2 ECD 19J-A OR-0.8 C C 12V-E OR-1.0 A B
B 2 0-CF BK-1.0 19S1-X R-1.0 3 10 A A B C 61R-B W-0.8 29 29 61R W-1.0
30 30 63C3 W-0.8 63C W-0.8 D D A5 B5
106 87 87 63C2 W-0.8 39.3 AT 20°C PSS
0-CE BK-1.0
Not Used
4
5 SPL-CAN-HVAC
ECD-F5 PO2 A B C 61A-B W-0.8 30 30 61A W-1.0
CAB-E ENG
87A 87A 63C W-0.8 N.O. 12V-A OR-1.0
109 CAN-H Y-0.8 A A CAN-HA Y-0.8
0-EL BK-1.0
0-B8 BK-0.8 A A A A 51P-A W-1.0 Not Used 6
CAN-L G-0.8
85 85 63LC W-0.8 COM
B B 0-CC BK-1.0 B B CAN-LA G-0.8
19M-C OR-1.0
CAN-HM Y-0.8
FWMG 7
86 86 19J-F OR-0.8 N.C. SPL-C3 Not Used Not Used SPL-CAN-HVAC-L 12V-F OR-1.0 A B 12V-B OR-1.0 PR
C C 35X-A Y-1.0 35X-D Y-1.0 8 C C
127
CAN-LN G-0.8
10 A
51P-A W-1.0 9 CAN2 CAN 123 A6
ECD-F6
B6 126 A A 61A W-1.0
SRWP
RWM 0-ND BK-62 117 Not Used 10 RAD-J3 RAD-J1 RAD 0-EN BK-0.8 M M
B B 61R W-1.0
0-CA BK-1.0
107
7 7 0-B23 BK-0.8
Not Used A A 242F 118 11 1 1 Y/BK-0.8 4 4 12V-HB OR-0.8 12V-H OR-0.8 N N
129
0-EM BK-0.8
8 8 49-C S-0.8 SSS 0-CB BK-1.0 12 SPL-RAD 1 2
Not Used H H Not Used 68L-A OR-1.0 B B 2 2 U/BK-0.8 5 5 Not Used ROOF CAB-RF CL 1 2
CAN-LC G-0.8
5 5 19K-B OR-0.8 M 51-B W-1.0
19K-C OR-1.0 J J 19K-D OR-1.0 19K-D OR-1.0 C C CAN-HK Y-0.8 3 3 R/BK-0.8 6 6 Not Used
4 4 Not Used 19N OR-1.0 19W OR-3.0
CAN-HC Y-0.8
CAN-LL G-0.8 4 4 W/BK-0.8 7 7 12V-HA OR-0.8 A A
68C OR-1.0 K K 68C-A OR-1.0 68C-A OR-1.0 D D
0-DV BK-3.0
10 10 Not Used 1-ND R-62 Not Used 0-DK BK-0.8 B B
68L-B OR-1.0 L L 68L-A OR-1.0 5 5 BK/W-0.8 8 8 0-EN BK-0.8 61A-B W-0.8
19W OR-3.0
6 6 68W W-0.8 224F 6 6 Not Used RSPK SC 18N-A OR-0.8
1 1 68C OR-1.0
CAB-RF ROOF 0-MA BK-1.0 A A 110 A B C HVAC-CAN1
7 7 OR/W-0.8 1 1 65R OR-0.8 1 1 49A S-0.8
9 9 Not Used RWMG SPL-CAN-DIAG-L 8 8 Y-0.8 2 2 0-PB BK-0.8 2 2
3 3 19K-A OR-1.0 23-1 12 U-0.8 HVAC1 C B A
2 2 68L OR-1.0
SPL-3
SPL-CAN-DIAG
9 9 3 3 Not Used 124
10 10 R-0.8 4 4 Not Used
AB
B
68W W-0.8 24 24 68W-A W-1.0 11 11 W-0.8 5 5 Not Used 23-2 7
15 A
63W W-0.8 25 25 63W-A W-1.0 111 12 12 G/W-0.8 6 6 Not Used LSPK 24-1 8
ECC-F8
0-DH BK-0.8 A
CAB-E ENG 13 13 Not Used 7 7 65L OR-0.8 1 1
SPL-RWW RWW 18K-A OR-0.8 B
19K OR-1.0 14 14 Not Used 8 8 0-PA BK-0.8 2 2
1 1 CAN-HB Y-0.8 C SPL-BLWR
68W-A W-1.0 M CAN-LB G-0.8 RAD-J2 SPK 125 18N-B OR-3.0
C3
L1-B
D
B
0-BL BK-1.0 2 2
A
20G-B W-0.8 E 0-ED BK-3.0
19J OR-0.8
10 A
ECA-F13
FWW A 0-CB BK-1.0 HVAC2 2 1

DIA
B 0-CA BK-1.0
119 0-EE BK-0.8
61C-A OR-1.0
0-BM BK-1.0 63W-A W-1.0 1 1 A
18N OR-3.0
A
BUSS-J9-ECC
M
BUSS-J8-ECC
0-B BK-1.0 2 2
C 0-CC BK-1.0 B 0-EM BK-0.8
A A 63H-C W-0.8 B 0-BY BK-1.0
63L-C W-0.8 D 0-CF BK-1.0 0-EP BK-0.8 23-3 9
19M OR-0.8
Not Used C
L2-3
B B C
A
19RR OR-0.8
E Not Used 24-2 10
0-DK BK-0.8
0-EE BK-0.8 D Not Used
18M OR-0.8
0-BS BK-1.0
19N OR-1.0
C C D
D D 58-D W-0.8 E 0-B BK-1.0 112 F 0-CD BK-1.0 E Not Used
BUSS-J13-ECA
C2
SPL-SEC-STR
C1
B
F 0-BL BK-1.0 F 0-DG BK-1.0
B
E E 21D-B W-0.8
L1-9
G 0-DT BK-0.8 ACT
10 A
F F
A
68L-C OR-1.0
ECA-F12
25 A
SPL-ENG-GRD
ECA-F11
L1-7
C7
20G-B W-0.8 3-1 1 H 0-DL BK-0.8
10 A
140M
A
A4
21-1 2
ECC-F9
18K-A OR-0.8
C6
C5
I 0-DK BK-0.8 0-DK BK-0.8
B
113
7.5 A
B
ECA-F17
75 A
0-BY BK-1.0 9-1 1 0-DH BK-0.8 19-8 3 K 0-DJ BK-0.8
ECC-F7
7.5 A
7.5 A
130
10 A
ECA-F16
ECA-F15
ECA-F4
0-BS BK-1.0 5-13 2 CAN-L G-0.8 3-4 4 L 0-DU BK-0.8
L2-2
L2-1
A
A
0-EE BK-0.8 19-3 3 1-ND R-62 1-8 1 CAN-H Y-0.8 3-3 5 M 0-DH BK-0.8
A9
B
0-CE BK-1.0
0-BM BK-1.0
0-ER BK-1.0
0-BZ BK-1.0
0-ED BK-3.0
0-EK BK-1.0
10-9 2
0-DV BK-3.0
0-ND BK-62
35X Y-0.8
0-EL BK-1.0
58-D W-0.8 5-2 4 CAN-LD G-0.8 7-5 6 0-EE BK-0.8 16-3 3 49A S-0.8 12-18 1
0-EJ BK-1.0
L2-7
0-DG BK-1.0
GND-CAB-SPL
A7
B
21D-B W-0.8 1-6 5 19R-D OR-0.8 1-5 3 CAN-HD Y-0.8 7-4 7 0-EP BK-0.8 13-11 4 BUSS-J11-ECA 2-5 2
L1-4
L2-6
L2-5
A
A
0-B23 BK-0.8 12-12 6 10 12-14 0-MA BK-1.0 19S1-OR-1.0 2-7 4 CAN-LF G-0.8 10-13 8 0-DT BK-0.8 16-12 5 BUSS-J12-ECA 16-9 3
49-C S-0.8 12-15 7 11 12-9 0-B8 BK-0.8 BUSS-J18-ECA 20-2 5 CAN-HF Y-0.8 10-14 9 0-DJ BK-0.8 22-4 6 18K-A OR-0.8 18-2 1 0-DJ BK-0.8 19-6 4
BUSS-J14-ECA 11-8 8 12 19-5 0-DT BK-0.8 BUSS-J4-ECA 10-6 6 CAN-LG G-0.8 9-5 10 12ACC-C W-0.8 1-1 1 0-DU BK-0.8 4-5 7 BUSS-J16-ECA 22-6 1 BUSS-J7-ECC 14-3 2 BUSS-J15-ECA 11-7 5
BUSS-J12-ECA 22-3 9 13 5-7 49-T S-0.8 BUSS-J5-ECA 4-3 7 CAN-HG Y-0.8 9-6 11 BUSS-PRM-E 2-6 2 0-DH BK-0.8 18-3 8 BUSS-J18-ECA 17-5 2 19Y OR-1.0 25-1 3 BUSS-J16-ECA 20-1 6
FRAME 16 FRAME 17 FRAME 18 FRAME 19 FRAME 20 FRAME 21 FRAME 22

BC07E173-16A BC07E173-17A BC07E173-18A BC07E173-19A BC07E173-20A BC07E173-21A BC07E173-22A
HEATING, VENTILATION, AND AIR-CONDITIONING HOOD LIFT GROUND CONNECTIONS

0-BA BK-5.0
142 RIGHT CONSOLE • GND-CAB1
ECC
132 K1 ABOVE PEDESTAL PIVOT • GND-PDST
30 30 60U W-1.0
4 5 2 10 11 3 12 13 6 1 14 7 8 9 87 87 19Y-A OR-1.0 0-BA BK-5.0
87A 87A 0-B22 BK-1.0 RIGHT CONSOLE • GND-CAB2
4 5 2 10 11 3 12 13 6 1 14 7 8 9
85 85 0-B25 BK-1.0 BELOW PEDESTAL PIVOT CAB FLOOR • GND-PDST2
59U W-1.0
DNS51 ORW-0.5
86 86
DNS59 WBK-0.5
Not Used
Not Used
DNS56 WG-0.5
DNS57 WU-0.5
DNS58 WR-0.5
DNS50 OR-0.5
DNS52 BK-0.5
0-AP BK-5.0
DNS48 R-0.5
DNS53 N-0.5
DNS49 K-0.5
DNS55 U-0.5
DNS54 S-0.5
FUEL FILTER HEAD BRACKET • GND-WIF

REAR CHASSIS GROUND WELD STUD • GND-S1
133 ECC K2
0-AP BK-5.0
60D W-1.0 30 30
131 DNS59 WBK-0.5 6 19Y-B OR-1.0 87 87
FRONT CHASSIS GROUND WELD STUD • GND-S2
SENSOR GROUND • GND-ENG6
DNS58 WR-0.5 5 0-B12 BK-1.0 87A 87A ENGINE BLOCK NEAR OIL FILTER
6 DNS49 K-0.5 DNS57 WU-0.5 4 0-B16 BK-1.0 85 85
M M
5 DNS48 R-0.5 DNS56 WG-0.5 3 59D W-1.0 86 86
Not Used 2
DNS60 OR-0.5 SENSOR GROUND • GND-ENG7
M. LOCK070-PF
1
M. LOCK070-PM
143 ENGINE BLOCK NEAR OIL FILTER
KOSTAL
134 0-B12 BK-1.0 A CONNECTION NEAR MOTOR/PUMP GROUND • GND-SSCHAS

0-B16 BK-1.0 B NEAR AIC (WITHIN 4 INCHES) • GND-PDST1
DNS61 S-1.0 1 0-B22 BK-1.0 C
DNS62 GBK-1.5 2 0-B25 BK-1.0 D
DNS63 LUBK-1.5 3 0-B10 BK-1.0 E CONNECTION NEAR SS MODULE GROUND • GND-SSMOD
DNS64 LUR-1.5 4 Not Used F REAR CHASSIS BELOW CAB • GND-FC
Not Used 5
SPL-HOOD-GRND
ENGINE BLOCK NEAR STARTER • GND-ENG3

144 RIGHT-HAND CONSOLE • GND-CAB3D
S3-S
DNS65 UR-2.5 HD
M 1
DNS66 BK-2.5 A A
RIGHT CONSOLE • GND-CAB5
DNS67 G-0.5 19Y-C OR-1.0 35 35 19Y-D OR-1.0 B B
3
DNS76 OR-0.5
DNS69 YBK-0.5
S2-S 135 60D W-1.0 36 36 60D-A W-1.0 C C
2 GND-ENG2
59D W-1.0
19Y-C OR-1.0
59D-A W-1.0
19Y-A OR-1.0
19Y-B OR-1.0
37 37
ENGINE BLOCK NEAR STARTER
60U W-1.0 38 38 60U-A W-1.0 RIGHT CONSOLE • GND-CAB4
A B C DNS-HVAC 1-S
59U W-1.0 39 39 59U-A W-1.0
CAB-E ENG
22-8 1
136 RIGHT CONSOLE • GND-CAB3
GND-GH1
ENGINE BLOCK
S1-S
DNS75 BK-2.5 SPL-HOOD 1 1 LU NEAR GRID HEATER
M
DNS74 LU-2.5 DNS67 G-0.5 2 2 N
HDM
2 1 DNS-HVAC 2-S
19Y OR-1.0
DNS6 Y-0.5 GND-ENG4

DNS63 LUBK-1.5
DNS51 ORW-0.5
ENGINE BLOCK NEAR STARTER GND-CAB6

DNS62 GBK-1.5
DNS69 YBK-0.5
DNS72 OR-0.5
DNS73 UR-2.5
DNS70 BK-0.5
DNS71 BK-0.5
22-10 2
DNS74 LU-2.5
RIGHT-HAND CONSOLE
DNS55 U-0.5
DNS53 N-0.5
DNS54 S-0.5
DNS61 S-1.0
DNS68 Y-0.5
CLOSED ABOVE 5 ±1 C°
145
Not Used
Not Used
Not Used
Not Used
OPEN BELOW 0 ±1 C°
GND-ENG4 GND-ENG1
1 2 3 4 5 1 2 3 4 2 1 1 2 3 4 5 ENGINE BLOCK ENGINE BLOCK
0 1 2 3 4 NEAR STARTER NEAR STARTER
0-BAG-N BK-1.0
0-B10 BK-1.0
0-DAV BK-0.8
NOTE:
0-BAG BK-1.0
0-BAR BK-1.0
0-BAR BK-1.0
0-BAC BK-2.0
0-BAE BK-1.0
0-ES BK-19.0
0-BW BK-2.0
0-B13 BK-1.0
0-B10 BK-1.0
0-DQ BK-0.8
141
0-GB BK-1.0
0-DP BK-0.8
0-BX BK-2.0
0-DY BK-1.0
0-DR BK-1.0
0-BG BK-0.8
0-EQ BK-0.8
0-AG BK-2.0
0-BM BK-1.0
0-DG BK-1.0
0-BR BK-1.0
0-DS BK-1.0
0-BH BK-0.8
0-ER BK-1.0
0-ED BK-3.0
0-BU BK-1.0
0-DA BK-0.8
0-BK BK-1.0
0-AB BK-1.0
0-AK BK-1.0
0-BP BK-1.0
0-CE BK-1.0
0-BT BK-1.0
0-EK BK-1.0
0-DV BK-3.0
0-B6 BK-1.0
0-BZ BK-1.0
137 138
0-EJ BK-1.0
0-BJ BK-0.8
0-EL BK-1.0
0-ND BK-62
THIS GROUND
139
140 USED ONLY ON
EUROPEAN
MACHINES
19Y OR-1.0 21-3 1
FRAME 23 FRAME 24 CASE ONLY NH ONLY FRAME 25

BC07E173-23A BC07E173-24A BC07E173-25A
COMPONENTS
FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS
16 - 104. Front Wiper High Speed Relay 23 - 131. Actuator

16 - 105. Wiper Cutout Relay 23 - 132. Driver
16 - 106. Front Wiper Low Speed Relay 23 - 133. Electronic Water Valve
16 - 107. Rear Wiper and Washer Switch 23 - 134. Blower Fan Resistor
16 - 108. Front Wiper and Washer Switch 23 - 135. Blower Motor
16 - 109. Front Wiper Motor 23 - 136. Thermostat
16 - 110. Front Wiper Motor 23 - 137. Fan Speed Switch
16 - 111. Rear Washer Motor 23 - 138. Air Conditioning Switch
16 - 112. Rear Washer Motor 23 - 139. Control Panel Lamps
16 - 113. Diodes 23 - 140. Water Valve Potentiometer
23 - 141. Air Recirculating Switch
17 - 114. Secondary Steering Diodes
17 - 115. Secondary Steering Solenoid 24 - 142. Hood Up Relay
17 - 116. Secondary Steering Module 24 - 143. Hood Down Relay
17 - 117. Secondary Steering Motor 24 - 144. Hood Switch
17 - 118. Secondary Steering Pressure Switch 24 - 145. Hood Motor
18 - 119. Diagnostic Connector
19 - 120. Power Relay Module E

19 - 121. Power Converter - 24 to 12 Volt
19 - 122. 12 Volt Power Outlets (Option)
19 - 123. Radio
19 - 124. Right Speaker
19 - 125. Left Speaker
20 - 126. Air Seat
21 - 127. Cigar Lighter
22 - 128. Air Conditioning Clutch Relay

22 - 129. Air Conditioning High-Low Pressure
Switch
22 - 130. Air Conditioning Compressor Clutch
CIRCUIT DIAGRAM LEGEND WIRE IDENTIFICATION NOTES

NOTE 1: Electrical Center C - Power Stud
SPL-00
Frame and Wire Tag
Number where circuit
WIRE TAGS
00-0 1
FEMALE MALE BK . BLACK
WIRE NUMBER
702A G-1.0
WIRE SIZE NOTE 2: Indicates Modulated and Current Controller.
ELECTRICAL SCHEMATIC
CONNECTOR CONNECTOR DU . DARK BLUE
continues. 1 00-0 MALE
TERMINAL
FEMALE
TERMINAL
INDICATES
EXTERNAL
INDICATES
INTERNALLY
1 1
INDICATES PARTIAL G. . . GREEN WIRE COLOR NOTE 3: Disconnect when Backup Alarm Disable Switch is installed. Applicable only on TUV Road Approved Machines. 621E WHEEL LOADER
FRAME - WIRE WIRE 54 GROUND GROUNDED
CONNECTOR 2 2
3 3 4 4
CONNECTOR K . . . PINK OR . ORANGE T . . TAN
NUMBER LG. . LIGHT GREEN P . . . PURPLE (Violet) U . . . BLUE
SHOWS CIRCUIT SHOWS COMPONENT 45E 45D 18 18 NOT ALL
Wire Tag assigned to wire in Frame.
CONNECTOR
RELAY REAR 27 27
CONNECTIONS LU . . LIGHT BLUE R . . . RED W . . WHITE Additional copies of this Hydraulic and Electrical Schematic can be ordered through Technical Publications Distribution System. The part number is 5-7560
CROSSING CIRCUIT SPLICE COMPONENT GROUND
NOT CONNECTED CONNECTION CIRCUIT CONTINUATION NUMBER IDENTIFICATION ARE SHOWN N . . . BROWN S . . . GREY Y . . . YELLOW
Copyright © 2007. CNH America, LLC. All Rights Reserved. BC07E173-00A
MAIN HYDRAULIC PUMP AND RESERVOIR PILOT CONTROLS EQUIPMENT VALVE EQUIPMENT VALVE CYLINDERS STEERING
7 F3-C7 C3
a1 BUCKET CYLINDERS - XT MODELS
7A C1 F11-C5 C9 F5-C2 C10 F5-C5 F5-C3 C11 C1 F2-C7 C2 F2-C9
C2 F1-C2 C8 F5-C1 F5-C6 C12
6 10 a2 a3 a4
C3 F11-C2 C7 F2-C3 8M 8M 8M
P 9 8N 8P 8S 15
F3-C6 C3 SX LS S a1 A1 B1 A2 B2 A3 B3 A4 B4
F6-C3 C4 7B 8 11
F8-C2 C5 C1 F12-C1 8G 8G 8G 8G
F10-C1 C6 C1 F3-C8
F11-C1 C7 12
C2 F3-C9
F12-C2 C8 Ø1.8 MP
b1 F3-C13 C4
F3-C4 C1 F3-C2 C2
4 T 8R
6 F3-C10 C5
B X a2 8A
3 P
C4 F1-C1
3A 5 8B BUCKET CYLINDER - Z-BAR and XR MODELS L R
7C 16
C1 F3-C8
C2 F3-C5
S
C5 F2-C2
8F
C2 F3-C9 13
2
b2 8D
F3-C14 C6
3B 8E 16A
SEE NOTE 1 8C
3C F4-C1 C7 T
a3 C6 F1-C3 16B
LIFT CYLINDERS
7D 8H
8H 8L
8K 8J 8J 8J 8J 14
b3 8J
F4-C3 C8 C3 F3-C11
S L1 L C4 F10-C3 16C
F4-C2 C9
a4
b1 P LS T
1
7E C13 F2-C4 C5 F10-C2
1 b2 8M b3 8M b4 8M
C6 F3-C12 17
C1 F11-C4 F11-C3 C2
C14 F2-C6 C3 F2-C8 C4 F2-C10
b4 F4-C4 C10
F1-C4 C3
SEE NOTE 2
BC07G260-01A BC07G260-02A BC07G260-03A BC07G260-04A BC07G260-5A BC07G260-6A
BRAKES HYDRAULIC OIL COOLER AND FAN DRIVE MOTOR FAN REVERSING VALVE RIDE CONTROL AUXILIARY STEERING COUPLER LOCKING CYLINDERS AND VALVE
(OPTIONAL) (OPTIONAL) (OPTIONAL) (OPTIONAL)
24 25
27 28
22 23 26
S3 S1 DS2 36
C4 F6-C1
C3 F6-C2
45
Ø0.60 39 C2 F3-C3 F3-C1 C5
23A
Ø1.20 23F M2 P 41 MX 42 LS SLS ST CF
F7-C1 C1
M2 39C 44
BR3 P 40
P 38 41B 42A
41C
21 39B 41A
35 39A
36A 37
LOCK
UNLOCK
23B 42B Ø 0.31
37A X2 A
F5-C5 C5
23E C1 F1-C6 F5-C4 C5
BR1
23D 2.2 Ø= T B
20 4.5 l/m
29 41D
39D 42C
23C 39B
M1 T 46
19 T P
T
M1
BR2
34 F1-C5 C2
C1 F1-C7
DS1 37B SEE NOTE 3

43
18 S2 T N
30 31 33 F8-C1 C1
C1 F2-C1 F1-C8 C2
1 1 1
32

BC07G260-07A BC07G260-08A BC07G260-9A BC07G260-10A BC07G260-11A BC07G260-12A
COMPONENTS
FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS FRAME - COMPONENT NUMBERS
FRAME 1 COMPONENTS FRAME 3 COMPONENTS FRAME 5 COMPONENTS FRAME 7 COMPONENTS 7- 32. Rear Axle Accumulator
1 - 1. Hydraulic Reservoir 3 - 8. Equipment Valve: 2-spool 5- 12. Bucket Cylinders 7- 1. Hydraulic Reservoir Pre-charge (55 Bar/800 psi) FRAME 10 COMPONENTS
1 - 2. Breather - Hydraulic Reservoir 3 - 8A. Steering Pressure Relief Bore: 114 mm (4.49 in) 7- 18 Rear Brakes Capacity (2.8 liter/170.8 cu/in) 10 - 40. Ride Control Accumulator
Check Valve (0.03 Bar/0.43 PSI) (217 Bar/3147 psi) Rod: 63.5 mm (2.5 in) Modulation Pressure: 7- 33. Rear Accumulator Test Port Pre-charge (17 Bar/247 psi)
Relief Valve (0.35 Bar/5.07 PSI) 3 - 8B. Pilot Pressure Reducing Valve Stroke: 820 mm (32.28 in) (87 to 94 Bar/1262 to 1363 psi) 7- 34. Brake and Cooling Fan Pump Capacity (3.78 liter/231 cu/in)
1 - 3. Implement Hydraulic Pump (30 Bar/435 psi) 5- 13. Bucket Cylinder 7- 19. Rear Brake Pressure Test Port 23cc/rev (0.77 cu/in) 10 - 41. Ride Control Valve
Displacement ( 90 cc rev/5.5 cu in rev) 3 - 8C. Pilot Pressure Relief Bore: 127 mm (5 in) 7- 20. Front Brake Pressure Test Port FRAME 8 COMPONENTS 10 - 41A. Pressure Relief Valve
Cutoff (280 Bar/4061 psi) (45 Bar/653 psi) Rod: 76.2 mm (3 in) 7- 21. Front Brake 8- 1. Hydraulic Reservoir (280 BAR/4061 psi)
Delta (24 Bar/348 psi) 3 - 8D. Steering Priority Spool Stroke: 619.7 mm (24.5 in) Modulation Pressure: 8- 35. Fan Drive Motor 10 - 41B. Manual Bleed Valve
1 - 3A. Compensator Differential Spool 3 - 8E. Loader Main Relief 5- 14. Lift Cylinders (90 to 97 Bar/1350 to 1406 psi) Displacement: 23 cc/rev (1.4 cu/in) 10 - 41C. Ride Control Spool Valve
1 - 3B. Compensator High Pressure Cutoff (227 Bar/3292 psi) Bore: 120.9 mm (4.9 in) 7- 22. Parking Brake Cylinder 8- 36. Fan Valve 10 - 41D. Ride Control Solenoid
Spool Rod: 63.5 mm (2.5 in) 7- 23. Brake Valve and Accumulator Fan Speed: 1200 ± 25 rpm
3 - 8F. Load Sense Bleed Down Orifice
1 - 3C. Control Piston with Spring Stroke: 787.7 mm (31 in) Charging Valve 8- 36A. Fan Relief FRAME 11 COMPONENTS
(0.7 L/min)
1 - 4. Hydraulic Filter Assembly Cut-in Pressure: (162 Bar/2350 psi) 11 - 1. Hydraulic Reservoir
3 - 8G. Flow Compensator Spool FRAME 6 COMPONENTS (157 to 167 Bar/2277 to 2422 psi) 8- 37. Cooler Bypass Valve (Optional) 11 - 42. Auxiliary Steering Priority Valve
Bypass (3.4 Bar/50 psi) 3 - 8H. Regeneration Check Valve
Warning Switch (2.7 Bar/40psi) 6- 15. Steering Cylinders Cut-out Pressure: 8- 37A. Priority Valve Relief Pressure: (241 Bar/3495 psi)
3 - 8J. Circuit Relief Valve with Anti-Cavitation Bore: 76.2 mm (3 in) (190 to 196 Bar/2755 to 2843 psi) 8- 37B Relief Valve 11 - 42A. Auxiliary Steering Activation Solenoid
(290 Bar/4206 psi) Rod: 44.5 mm (1.75 in) 7- 23A. Park Brake Solenoid 0.3 ± 0.6 Bar/ 5 ± 8 psi 11 - 42B. Relief Valve (241 BAR/3495 psi)
FRAME 2 COMPONENTS 3 - 8K. Circuit Relief Valve with Anti-Cavitation Stroke: 486.9 mm (19 in) 7- 23B. Front Brake Valve 8- 38. Hydraulic Cooler 11 - 42C. Priority Spool
2 - 1. Hydraulic Reservoir (XT Models: 183 Bar/2654 psi) 6- 16. Steering Control Valve 7- 23C. Rear Brake Valve 11 - 43. Auxiliary Steering Pump
2 - 5. Pilot Pressure Accumulator (Z-Bar Models: 290 Bar/4206 psi) Displacement: 7- 23D. Accumulator Isolation Check Valve FRAME 9 COMPONENTS Displacement:
Pre-charge (13.8 Bar /200 psi) 3 - 8L. Regeneration Relief Valve 983 cc/rev (60 cu in/rev) 7- 23E. Accumulator Charging Spool 9 - 39. Fan Reversing Valve 11 cc/rev (0.671 cu/in)
Capacity (0.75 liter/45.8 cu in) (6.7 Bar/97 psi) 6- 16A. Circuit Relief Valve 7- 23F. Priority Spool Fan Speed: 1200 ± 25 rpm 11 - 44. Auxiliary Steering Pressure Switch
2 - 6. Pilot Pressure Test Port 3 - 8M. Shuttle Check Valve (290 Bar/4206 psi) 7- 24. Parking Brake Accumulator 9- 39A. Fan Crossover Relief NO (Normally Open)
2 - 7. Controller (4-Spool Valve) 3 - 9. Load Sense Pressure Test Port 6- 16B. Gerotor Pump Pre-charge (96 Bar/1392 psi) (234 BAR/3394 psi) Closes at 2.00-2.75 Bar/30-40 psi
2 - 7A. Pilot ON/OFF Solenoid 3 - 10. Steering Pressure Test Port 6- 16C. Steering Spool Capacity: 0.16 liter/9.7 cu/in) 9- 39B. Reversing Spools FRAME 11 COMPONENTS
2 - 7B. Bucket Control 6- 17. Back Pressure Valve 7- 25. Front Axle Accumulator 9- 39C. Pulse Width Modulator (PWM) Relief 12 - 45. Coupler Locking Cylinders
2 - 7C. Lift Control FRAME 4 COMPONENTS (8-10 Bar/115-145 psi) Pre-charge (55 Bar (800 psi) Solenoid 12 - 46. Coupler Locking Valve
2 - 7D. Auxiliary Control #1 3 - 8G. Flow Compensator Spool Capacity (2.8 liter/170.8 cu/in) 9- 39D. ON/OFF Reverse Solenoid
2 - 7E. Auxiliary Control #2 3 - 8J. Circuit Relief Valve with Anti-Cavitation 7- 26. Front Accumulator Test Port
(290 Bar/4206 psi) 7- 27. Redundant Brake Pressure Switch
4 - 8M. Shuttle Check Valve (NO, Closes at 62 Bar/900 psi)
4 - 8N. Auxiliary Valve #1 7- 28. Low Brake Pressure Switch
4 - 8P. Auxiliary Valve #2 Rising (128 Bar/1856 psi)
4 - 8R. Pressure Differential Valve Falling (103 Bar/1494 psi)
(40 Bar/580 psi) 7- 29. Brake Declutch Switch
(NC, Opens at 24 Bar/350 psi)
4 - 8S. End Cover
7- 30. Brake Lamp Switch
4 - 11. Pump Pressure Test Port
(NO, Closes at 4.1 Bar/60 psi)
7- 31. Redundant Brake Pressure Switch
(NO, Closes at 62 Bar/900 psi)
HYDRAULIC SYMBOLS CIRCUIT CONTINUATION NOTES

NOTE 1. Reverse Control Check Valve.
54 PRESSURE
Frame Number and Circuit
Number where Circuit
CIRCUIT TAGS
F4-C3 C10 Used with Ride Control equipped Models ONLY. HYDRAULIC SCHEMATIC
continues.
CHECK VALVE FILTER OR SCREEN CIRCUIT LOAD SENSE
C6 F1-C3
NOTE 2. Used for XT Model Machines ONLY. 621E WHEEL LOADER
36D FRAME - CIRCUIT CIRCUIT NOTE 3. This will replace Item 36 in Frame 8 when this Option is installed on machine. Additional copies of this Hydraulic and Electrical Schematic can be ordered through Technical Publications Distribution System.
SHOWS CIRCUIT SHOWS COMPONENT PILOT PRESSURE NOTE 4. See the Repair Manual for the proper Testing and Adjustment for Hydraulic The part number is 5-7560
COMPONENT CROSSING CIRCUIT
RESTRICTOR Circuit Number assigned to Circuit in Frame.
Components.
NUMBER NOT CONNECTED CONNECTED OIL COOLER DIRECTION OF FLOW LINE TYPES
Copyright © 2007. CNH America, LLC. All Rights Reserved. BC07G260-00A
North American English
Part Number 84243974
CNH AMERICA LLC Printed in U.S.A. • Rac
700 STATE STREET © 2009 CNH America LLC. All Rights Reserved.
RACINE, WI 53404 U.S.A. Case is a registered trademark of CNH America

153430-CO2FC6T3LSMERMID-Case 621e Tier 3 Wheel Loader Factory Service Repair Manual - Improved - Download-1

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

153430-CO2FC6T3LSMERMID-Case 621e Tier 3 Wheel Loader Factory Service Repair Manual - Improved - Download-1

Uploaded by

Copyright:

Available Formats

Please cut where indicated and place the label on the spine of the binder

WHEEL LOADER WHEEL

Fuel System Tab3

84243975 Copyright© 2009 CNH America LLC.

84243975 Copyright© 2009 CNH America LLC.

Description Section Form No.

Air Conditioner System Service 9003 5-3030

Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear 5-7560

84243975 Copyright© 2009 CNH America LLC.

Section Title Section Number

Standard Torque Specifications .............................................................. 1001

Copyright© 2007 CNH America LLC.

GENERAL TORQUE SPECIFICATIONS

Copyright© 2004 CNH America LLC.

Bur 8-71603 Revised 4-04 Printed in U.S.A.

TORQUE SPECIFICATIONS- DECIMAL HARDWARE

Grade 5 Bolts, Nuts, and Studs

Bur 8-71603 Revised 4-04 Printed in U.S.A.

TORQUE SPECIFICATIONS- METRIC HARDWARE

Grade 8.8 Bolts, Nuts, and Studs

Grade 12.9 Bolts, Nuts, and Studs

Usually the torque values specified for grade 10.9

Bur 8-71603 Revised 4-04 Printed in U.S.A.

TORQUE SPECIFICATIONS- STEEL HYDRAULIC FITTINGS

1/2 inch 3/4-16 540 to 804 57 to 91

Tube OD Thread Pound- Newton

Split Flange Mounting Bolts

Bur 8-71603 Revised 4-04 Printed in U.S.A.

TORQUE SPECIFICATIONS- STEEL HYDRAULIC FITTINGS

Bur 8-71603 Revised 4-04 Printed in U.S.A.

FLUIDS AND LUBRICANTS

Copyright© 2007 CNH America LLC.

Bur 5-7330 Issued 9-07 Printed in U.S.A.

CAPACITIES AND LUBRICANTS

Bur 5-7330 Issued 9-07 Printed in U.S.A.

ENGINE OIL RECOMMENDATIONS

Bur 5-7330 Issued 9-07 Printed in U.S.A.

TRANMISSION TEMPERATUER CHART

DIESEL FUEL SYSTEM

The diesel fuel used in this machine must meet the

Specifications for Acceptable No. 2 Diesel Fuel

Bur 5-7330 Issued 9-07 Printed in U.S.A.

Bur 5-7330 Issued 9-07 Printed in U.S.A.

Bur 5-7330 Issued 9-07 Printed in U.S.A.

Bur 5-7330 Issued 9-07 Printed in U.S.A.

METRIC CONVERSION CHART

CNH AMERICA LLC

Bur 7-52950 Issued 6-97 Printed in U.S.A

Area: sq. meter 10.763 91 square foot

Force: newton 3.596 942 ounce force

Length: millimeter 0.039 370 inch

Mass: kilogram 2.204 622 pound

Mass/Area: kilogram/hectare 0.000 466 ton/acre

Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.

Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.

Power: kilowatt 1.341 02 horsepower

Pressure: kilo pascal 0.145 038 lb/sq. inch

Temperature: degree C 1.8 XC +32 degree F

Torque: newton meter 8.850 748 lb/inch

Velocity: kilometer/hr. 0.621 371 miles/hr.

Volume: cubic centimeter 0.061 024 cubic inch

Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

Bur 7-52950 Issued 6-97 Printed in U.S.A.

Area: square foot 0.092 903 square meter