Service Manual: W W270C Wheel Loader W300C

SERVICE MANUAL
Wheel Loader
W270C
W300C
Print No. 84547255A

SERVICE
MANUAL
Wheel Loader
W270C
W300C
Print No. 84547255A

Copyright © New Holland
W270C
W300C
Wheel Loader
84547255A
Use for Service Manual

W270C - W300C Wheel Loader

Service Manual
84547255A
Table of Contents
Description Section No.
General Tab 1
Section Index - General
Standard Torque Specifications 1001
Fluids and Lubricants 1002
Metric Conversion Chart 1003
Engines Tab 2
Section Index - Engines
Engine and Radiator Removal and Installation 2000
Stall Tests 2002
After Cooler 2003
For Engine Repair, See the Engine Service Manual 84394558
Fuel System Tab 3

Section Index - Fuel System
For Fuel System Repair, See the Engine Service Manual 84394558
SCR System 3002
Electrical Tab 4
Section Index - Electrical
Removal and Installation of Starter and Alternator 4001
Electrical Specifications and Troubleshooting 4002
Batteries 4003
Jump post option 4003a
Instrument Cluster 4005
Rear view Camera and Monitor 4006
Steering Tab 5
Section Index - Steering
Removal and Installation of Steering Components 5001
Steering Specifications, Pressure Checks, and Troubleshooting 5002
Steering Cylinders 5005
Center Pivot 5006
Copyright © 2011 CNH Italia S.p.A.

CNH Italia S.p.A. All rights reserved.
Via Plava, 80
10135 Torino Printed in E.C.
Italia 84547255A Issued November, 2011

Service Manual
84547255A
Table of Contents
Auxiliary Steering Motor and Pump 5008
Joystick Steering System (JSS) (Optional) 5009
Power Train Tab 6

Section Index - Power Train
Removal and Installation of Power Train Components 6001
Transmission Specifications, Pressure Checks, and Troubleshooting 6002
Transmission 6003
Front Axle 6004
Rear Axle 6004
Drive Shafts, Center Bearing, and Universal Joints 6005
Wheels and Tires 6006
Transmission Control Valve 6007
Brakes Tab 7
Section Index - Brakes
Removal and Installation of Brake Components 7001
Hydraulic Brake Troubleshooting 7002
Brake Pump 7003
Brake Accumulators 7004
Parking Brake 7008
Hydraulics Tab 8
Section Index - Hydraulics
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
Ride Control Accumulator 8013
Ride Control Valve 8014

Service Manual
84547255A
Table of Contents
Mounted Equipment Tab 9
Section Index - Mounted Equipment
Air Conditioning Troubleshooting and System Checks For Systems with HFC-134a Refrigerant 9002
Air Conditioner System Service 9003
Removal and Installation of Air Conditioning and Heater Components 9004
Loader 9006
Rollover Protective Structure (ROPS) Cab Structural Frame (CSF) 9007
Cab Glass Installation 9010
Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear Pocket

Via Plava, 80
SECTION INDEX
GENERAL
Section Title Section Number
Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001

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

Via Plava, 80
1001
Section
1001
GENERAL TORQUE SPECIFICATIONS

Via Plava, 80
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
84547255A Issued 11-11 Printed in E.C.

1001-3
TORQUE SPECIFICATIONS - DECIMAL HARDWARE

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

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

1001-4
TORQUE SPECIFICATIONS - METRIC HARDWARE

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

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

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

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

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

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

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

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

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

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

1002
Section
1002
FLUIDS AND LUBRICANTS

Via Plava, 80
1002-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRANSMISSION OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HYDRAULIC OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1002-3
CAPACITIES AND LUBRICANTS

W270C CAPACITIES AND SPECIFICATIONS
Engine
Type of oil AMBRA Mastergold HSP (SAE 15W-40)
Capacity (with filter change) 28.5 l (30.1 US qt)
Cooling system
System capacity 56.8 l (60.0 US qt)
Fuel system
System capacity 473.0 l (125.0 US gal)
Hydraulic system
Type of fluid AMBRA Hydrosystem 46 HV
Total system capacity 250.0 l (66.0 US gal)
Reservoir capacity 134.0 l (35.4 US gal)
Transmission
Type of oil AMBRA Supergold (SAE 10W-30)
Service capacity - with filter change 45.4 l (48 US qt)
Axles
Type of oil AMBRA TRX Transaxle Fluid
Front axle STD 42 l (44 US qt)
Rear axle STD 42 l (44 US qt)
Front axle HD 62 l (65.5 US qt)
Rear axle HD 65.7 l (69.4 US qt)
Tank Urea (AD Blue)
Type of fluid Fluid Diesel exhaust (Spec ES-B5001)
Capacity 91 l (96 US qt)

1002-4
W300C Capacities and Specifications
Engine
Type of oil AMBRA Mastergold HSP (SAE 15W-40)
Capacity (with filter change) 28.5 l (30.1 US qt)
Cooling system
System capacity 56.8 l (60.0 US qt)
Fuel system
System capacity 473.0 l (125.0 US gal)
Hydraulic system
Type of fluid AMBRA Hydrosystem 46 HV
Total system capacity 250.0 l (66.0 US gal)
Reservoir capacity 134.0 l (35.4 US gal)
Transmission
Type of oil AMBRA Supergold (SAE 10W-30)
Service capacity - with filter change 45.4 l (48 US qt)
Axles
Type of oil AMBRA TRX Transaxle Fluid
Front axle STD 64.0 l (67.6 US qt)
Rear axle STD 64.0 l (67.6 US qt)
Front axle HD 62 l (65.5 US qt)
Rear axle HD 65.7 l (69.4 US qt)
Tank Urea (AD Blue)
Type of fluid Fluid Diesel exhaust (Spec ES-B5001)
Capacity 91 l (96 US qt)

1002-5
HYDRAULIC OIL TEMPERATURE CHART
LEEN11T0128EA
TRANSMISSION OIL TEMPERATURE CHART
LEEN11T0127EA
ENGINE OIL TEMPERATURE CHART
LEEN11T0126FA

1002-6
Coolant solution Fuel storage
Put only ethylene-glycol coolant solution in the Prolonged storage of fuel can lead to the
cooling system. Use good quality ethylene-glycol that accumulation of impurities and condensation in the
has a high boiling point with no additives to prevent fuel. Engine trouble can often be traced to the
l e a k a g e . D o n o t u se n o n - a p p r o v e d a n t i - r u s t presence of water in the fuel.
additives. Anti-rust additives and ethylene-glycol can
The storage tank must be placed outside and the
mix and work against each other, reducing
temperature of the fuel should be kept as low as
anti-corrosion protection, forming deposits in the
possible. Drain off water and impurities regularly.
cooling system, and causing damage to the cooling
system and radiator. Contact your dealer who can Hydraulic fluid
supply you with the suitable coolant solution.
Ambra Hydrosystem 46 HV Ultra hydraulic fluid is
Anti-freeze/Anti-corrosion specifically designed for high pressure applications
and for New Holland hydraulic systems. Your New
Use anti-freeze in all seasons to protect the cooling
Holland Dealer can provide hydraulic fluid to fulfill
system from corrosion and risk of freezing. For areas
different climate/temperature conditions. Refer to the
where the ambient temperature is over -36 °C (-32.8 °F)
charts at the beginning of this section.
use a blend of 50 % ethylene-glycol based anti-freeze.
For areas where the temperature is below -36 °C Transmission component oil
(-32.8 °F)- it is advisable to use a blend of 40 %
water and 60 % anti-freeze. Extreme pressure oil should be used for enclosed
transmission components. Choose an oil that is
Fuel manufactured for your climate/temperature
conditions such as Ambra Supergold SAE 10W-30.
Use diesel fuel suitable for the ambient temperature See charts at the beginning of this section.
conditions ( ASTM D975).
Use fuel which is to ASTM (American Society for Grease
Testing and Materials) D975 standard (North
The type of grease to use depends on ambient
America). In Europa, fuel must comply with
temperature such as: Ambra GR 75 MD.
Specification Standard EN 590 or ITS EQUIVALENT.
Use grade No. 2 fuel. The use of other types of fuel Environment
can result in a loss of power of the engine and may
Before you service this machine and dispose of oil,
cause high fuel consumption.
fluids, and lubricants, obey environmental
In very low ambient temperatures, use a mixture of regulations. Do not drain oil or fluids on to the ground
fuels No. 1 and No. 2 as necessary. Consult your fuel or into containers that leak. Check with your local
supplier for appropriate fuel supply. environmental, recycling center or your dealer for
If the temperature falls below the fuel cloud point correct disposal information.
(point at which wax begins to form) the wax crystals
will cause power loss or will prevent the engine from
starting.
In cold weather, fill the fuel tank at the end of the
day's work in order to prevent the formation of
condensation.
Engine oil
Ambra Mastergold engine oil is recommended for
your engine. This oil insures correct lubrication of
your engine in all working conditions. See charts at
the beginning of this section to choose the correct oil
for climate/temperatures.
If Ambra Mastergold engine oil cannot be obtained,
use only oil of the API SERVICE CI-4 category.
NOTE: Do not put any Performance Additive or other
additive in the sump. Oil change intervals shown in this
manual are based on tests carried out utilizing New Holland
lubricants.
LEEN11T0129AA

Section
1003
1003
METRIC CONVERSION CHART

Via Plava, 80
1003-2
TABLE OF CONTENTS
CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

hectare 2.471 05 acre
Force: newton 3.596 942 ounce force

newton 0.224 809 pound force
Length: millimeter 0.039 370 inch

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

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

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

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

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

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

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

acre 0.404 686 hectare
Force: ounce force 0.278 014 newton

pound force 4.448 222 newton
Length: inch 25.4 * millimeter

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

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

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

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

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

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

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

84394558

Via Plava, 80
Section
2000
ENGINE AND RADIATOR REMOVAL AND

INSTALLATION
2000

Via Plava, 80
2000-2
TABLE OF CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2000-3
ENGINE
Removal STEP 8
NOTE: Put caps on the fittings and plugs in the hoses to
prevent foreign material from entering the system when
disconnecting fuel lines or hydraulic hoses.
STEP 1
W270R613
Put the master disconnect switch (1) in the off

position.
W270R612
Park the machine on a level surface and lower the STEP 9

bucket to the ground. Put the articulation lock (1) in Drain the engine radiator coolant.
the locked position.
STEP 10
STEP 2
Drain the engine oil.
Key in the run position, engine off, place the pilot
control switch in the normal operation position.
STEP 11
STEP 3
Move the loader hydraulic control handle to the raise
and lower position in order to release any hydraulic
pressure in the lift circuit.
STEP 4
Move the loader control handle in and out of the tilt
position several times, this will relieve any pressure
in the pilot accumulator.
STEP 5
Release the pressure in the ride control accumulator
with the bleeder valve in the ride control valve.
W270R614
STEP 6 Loosen the hose clamp (1) on the air box snorkel
Depress the brake pedal several times to discharge under the air inlet hood.
brake accumulators.
STEP 7
Slowly loosen the filler cap on the hydraulic oil tank to
release air pressure.

2000-4
STEP 12 STEP 14
W270R615 W270R617
Remove the mounting bolts on the exhaust stack Disconnect the deaeration tank overflow hose (2).
hood. Attach lifting equipment to the exhaust stack. Remove the P-clamps (1) that secure the overflow
Remove the exhaust stack hood (1). hose to the wall and brackets. Position the overflow
hose away from the engine and engine wall.
STEP 13
STEP 15
W270R616
Remove the SCR line support bracket (1). W270R618
Remove the left bracket (1) and right bracket (2).

2000-5
STEP 16 STEP 18
W270R651 W270R620
Remove the hydraulic oil lines (1). Remove the oil dipstick P-clamp (3) . Pull the oil
dipstick tube (1) through the wall.
STEP 17 Label and disconnect the hood lift strut electrical
connector (2).
STEP 19
W270R619
Remove the after air cooler tube (1) .

Remove the bulkheads (2).
W270R621
Remove the before air coller tube (1).

Remove the upper radiator tube (2).

2000-6
STEP 20 STEP 22
W270R622
Label and disconnect the humidity sensor electrical W270R624

connector (1). Remove the turbo inlet tube (2). Remove the lower, right panel (1) on the engine wall.
Label and disconnect the air filter restriction sensor
electrical connector (3). STEP 23
STEP 21
W270R625
Remove the air box assembly.

W270R623
Remove the wire harness P-clamp (1). STEP 24

Loosen the hose clamp on the air box snorkel (2).
Disconnect the air box snorkel (3).
W270R626
Remove the lower radiator tube (1) .

2000-7
STEP 25 STEP 27
W270R627 W270R629
Attach lifting equipment to the engine wall. Remove Disconnect the SCR coolant solenoid heater hose
the engine wall’s hold-down bolts. Lift and remove (1).
the engine wall.
STEP 28
STEP 26
W270R630
W270R628 Remove two bolts (2), washers (3), and nuts (4).
Remove the turbo exhaust tube (1). Remove the air box snorkel (1) .

2000-8
STEP 29 STEP 31
W270R631 W270R633
Disconnect the inlet and outlet heater core heater Disconnect the following from the crank case
hoses (1). ventilation/fuel filter bracket assembly:
● Fuel pump electrical connector;
STEP 30
● Water sensor electrical connector;
● Ground wire;
● Wire harness P-clamp;
● Crank case filter inlet hose;
● Crank case filter outlet hose;
● Crank case filter oil return hose;
● Fuel pump inlet tube;
● Fuel pump outlet tube.
STEP 32
Remove the crank case ventilation/fuel filter bracket
assembly.
STEP 33
W270R632
Disconnect the starter battery cables (1) and starter

switch wire (2).
W270R634
Label and disconnect the engine control module

electrical connector (1).

2000-9
STEP 34 STEP 36
W270R635 W270R637
Disconnect the fuel return line (1). Disconnect the Remove the engine serpentine belt (1).
battery positive wire (2) on the air grid heater.
STEP 37
STEP 35
W270R638
Label and disconnect the A/C compressor electrical

W270R636 connector (1).
Disconnect the engine ground wires (1). Label and disconnect the A/C pressure switch
Remove the wire harness P-clamp (2). electrical connector (4).
Remove the alternator power wire (3). Label and
disconnect the bulk electrical connector (5).
Remove the A/C compressor (2). Position the A/C
compressor (2) away from the engine.

2000-10
STEP 38 STEP 40
W270R641
W270R639 Attach lifting equipment to the engine. Support the
Remove the wire harness P-clamps (1). engine.
STEP 39 STEP 41
W270R640 W270R642
Remove the engine oil drain tube (1). Remove the hydraulic oil return tube P-clamp (1).
Position the hydraulic oil return tube away from the
converter housing cover plate.

2000-11
STEP 42 STEP 45
W270R646
W270R643
Remove the front engine mounts (1) and engine
Remove the converter housing cover plate (1). mount plate (2).
STEP 43 STEP 46
W270R644 W270R647
Remove the flex plate bolts (1). Remove the bell housing bolts (1).
STEP 44 STEP 47
W270R645 W270R641
Remove the harmonic balancer (1). Remove the engine.

2000-12
Install STEP 50
STEP 48
W270R649
Install the engine mount plate (5) and the engine

W270R641
mount brackets (1), but do not tighten the bolts to a
Carefully lower the engine into the chassis. torque value.
Tighten the engine bracket upper bolts (2) to a torque
of 171 - 231 N·m (126 - 170 lb ft). Tighten the engine
STEP 49
bracket lower bolts (3) to a torque of 69 - 80 N·m (51
- 59 lb ft). Tighten the engine mount plate bolts (4) to
a torque of 386 - 434 N·m (285 - 320 lb ft). Tighten
the engine bracket-to-engine mount plate bolts (6) to
a torque of 397 - 447 N·m (293 - 330 lb ft).
STEP 51
W270R647
Install the bell housing bolts (1). Tighten the bell

housing bolts (1) to a torque of 54 - 60 N·m (40 - 44
lb ft).
W270R650
Install the harmonic balancer (1). Tighten the

harmonic balancer bolts (2) to a torque of 115 N·m
(85 lb ft).

2000-13
STEP 52 STEP 54
W270R644 W270R631
Install the flex plate bolts (1). Tighten the flex plate Connect the inlet and outlet heater core heater hoses
bolts (1) to a torque of 33 - 41 N·m (24 - 30 lb ft). (1).
STEP 53 STEP 55
W270R642
W270R643
Reposition the hydraulic oil return tube. Install the
Apply DOW 732 RTV SILICONE CLEAR to the hydraulic oil return tube P-clamp (1).
converter housing cover plate (1).
Install the converter housing cover plate (1).

2000-14
STEP 56 STEP 58
W270R630 W270R628
Install the air box snorkel (1). Install two bolts (2), Install the turbo exhaust tube (1).
washers (3), and nuts (4).
STEP 59
STEP 57
W270R641
W270R629 Remove lifting equipment from the engine.
Connect the SCR coolant solenoid heater hose (1).
STEP 60
W270R627
Install the engine wall.

2000-15
STEP 61 STEP 63
W270R626 W270R623
Install the lower radiator tube (1). Install the wire harness P-clamp (1). Connect the air
box snorkel (3). Tighten the hose clamp on the air
STEP 62 box snorkel (2).
STEP 64
W270R625
Install the air box.

W270R624
Install the lower, right panel (1) on the engine wall.

2000-16
STEP 65 STEP 67
W270R622
Install the turbo intlet tube (2). W270R640

Connect the humidity sensor electrical connector (1). Install the engine oil drain tube (1).
Connect the air filter restriction sensor electrical
connector (3). STEP 68
STEP 66
W270R639
W270R621
Install the wire harness P-clamps (1).
Install the upper radiator tube (2).
Install the before air cooler tube (1). STEP 69
W270R637
Install the engine serpentine belt (1).

2000-17
STEP 70 STEP 72
W270R638
Install the A/C compressor (2). W270R635

Connect the A/C compressor electrical connector (1). Connect the fuel return line (1).
Connect the A/C pressure switch electrical connector Connect the battery positive wire (2) on the air grid
(4). Connect the alternator power wire (3). Connect heater.
the bulk electrical connector (5).
STEP 73
STEP 71
W270R636
Connect the engine ground wires (1). W270R634
Install the wire harness P-clamp (2). Connect the engine control module electrical
connector (1).
STEP 74
Install the crank case ventilation/fuel filter bracket
assembly.

2000-18
STEP 75 STEP 77
W270R633 W270R620
Connect the following on the crank case ventilation/ Connect the hood lift strut electrical connector (2).
fuel filter bracket assembly: Slip the oil dipstick tube (1) through the engine wall.
Install the dipstick tube P-clamp (3).
● Fuel pump electrical connector
● Water sensor electrical connector STEP 78
● Ground wire
● Wire harness P-clamp
● Crankcase filter inlet hose
● Crankcase filter outlet hose
● Crankcase filter oil return hose
● Fuel pump inlet tube
● Fuel pump outlet tube
STEP 76
W270R619
Install the bulkheads (2).

Install the after air cooler tube (1).
W270R632
Connect the starter battery cables (1) and starter

switch wire (2).

2000-19
STEP 79 STEP 82
W270R651 W270R616
Install the hydraulic lines (1). Install the SCR line support bracket (1).
STEP 80 STEP 83
W270R618 W270R615
Install the left bracket (1) and right bracket (2). Lower the exhaust stack hood (1) in front of the
engine wall and onto the left bracket, right bracket,
STEP 81 and hydraulic oil tank.
Install the exhaust stack hood mounting bolts.
W270R652
Install the P-clamps (2) and overflow tube (1) to the

engine wall, left bracket, and deaeration tank (3).
2000-20
STEP 84
W270R614
Attach the air box snorkel to the air inlet hood.

Tighten the air box snorkel hose clamp (1).
STEP 85
Check and adjust all fluid levels.

2000-21
RADIATOR
Removal STEP 5
STEP 1
Park the machine on a level surface and lower the
bucket to the ground. stop the engine and apply the
parking brake.
STEP 2
Raise the engine hood.
STEP 3
Place the master disconnect switch in the OFF
position.
STEP 4
W270R606
Disconnect the top hose and install a plug in the hose

and a cap on the fitting.
STEP 6
W270R571 W270R608
Put a 30 liter (8 gallon) container below radiator Disconnect the hose from the bottom of the oil
drain. Remove radiator cap then remove cap and cooler. Install a plug in the hose and a cap on the
drain coolant into container. Install cap after coolant fitting.
has drained. Install radiator cap.

2000-22
STEP 7 STEP 9
4 5
4
3
2
1
W270R608
W270R607 Connect the lower hose to the oil cooler to cooling
Loosen and remove the bolt (1) and washer (2), the frame.
nut (3), washer (4) and bolt (5) that fasten the oil
cooler to the cooling frame. STEP 10
Remove radiator from machine.
Insallation
STEP 8
4 5
4
3
W270R606
Connect the hose to the top of the oil cooler.
2
1
W270R607
Place the oil cooler in position in the cooling frame.

Install and tighten the two mounting bolts (5), washer
(4) and nuts (3), the washers (2) and bolts (1).

2000-23
STEP 11 STEP 13
Put master disconnect switch in ON position.
STEP 14
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 coola nt is a t ope ratin g
temperature, stop the engine. When engine has
cooled, check the coolant level at the reservoir.
WARNING: Hot coolant can spray out if radiator cap is
removed. To remove radiator cap: Let system cool, turn to
first notch, then wait until all pressure is released. Scalding
can result from fast removal of radiator cap.
STEP 15
Put articulation lock in OPERATING position.
W270R571
Check that coolant drain cap is tight.
STEP 12
Fill engine coolant system with a solution of 50%
Ethylene Glycol and 50% water. Cooling system
capacity is 30 liter (8 gallon). Install the radiator cap.
Fill the coolant reservoir up to the FULL mark on the
reservoir.

2000-24
NOTES

2002
Section
2002
STALL TEST

Via Plava, 80
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
ENGINE W/4 Speed Trans. (W270C-W300C)

A. Idle RPM 870-930
Alternate Low Idle 570-630
Alternate Accelerated Idle 1170-1230
B. Maximum No Load RPM 2187±25
C. Converter Stall 1st gear 1970 - 2nd/4th gear 2075
D. Hydraulic Stall 1885-2195
E. Converter & Hydraulic Stall 1665
Note: Hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the
bucket held rolled back and the engine at WOT in max power mode.
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.
W230R435
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 Urea
level.
BD06F188
2. From the driving screen push the down arrow, as

shown.

2002-4
W230R436 W230R438
4. Info 2 will be displayed next. The Info 2 screen 7. Press the down button again and the Trip 1
will display coolant temperature, turbocharger air screen will display. The LCD provides two trip
temperature, engine oil temperature in either computers. These will display since last reset the
Fahrenheit or Celsius, and the Urea level. total time in hours, the total fuel, and the average
fuel consumption per hour.
W230R437
W230R439
5. Push the down button again and the Info 3
screen. This screen displays the temperature in 8. By continuing to scroll down, the fifth screen will
Fahrenheit or Celsius of the transmission oil, display the Trip 2 screen. Trip 1 and Trip 2
hydraulic oil, sump oil, and the Urea level. screens can be reset independently. The
previous screen can be accessed by using the
up arrow key.
Info 4
Voltage V 24.2
Air Turbo °C 42
DefTemp °C 32
DefLvl % 24
W230M171
6. Push the down key again to display the info 4

screen. This screen display the voltage level,
turbocharger air temperature, Urea temperature
and Urea level.

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

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

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
W230R440
2. Press and hold the confirmation “enter” button for W230R441
two seconds to arrive at the above service A. Max - Maximum power possible
screen.
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.

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. Run the engine at low idle.
4. Run engine at low idle. Push the clutch cutout
5. Push down and hold the brake pedal for the
switch to OFF. Put the transmission in manual
remainder of this test.
mode. Push down and hold the brake pedal for
the remainder of this procedure. 6. Turn the transmission control lever to third gear.
5. Turn the transmission control lever to third gear. 7. Increase the engine speed to full throttle.
6. Increase the engine speed to full throttle. 8. Check the engine speed.
7. Hold the bucket control lever in the ROLLBACK 9. Decrease the engine speed to low idle.
position and raise the lift arms. The stall speed
10. Place the transmission in neutral and apply the
must be read while the lift arms are in motion.
parking brake.
8. Check the engine speed.
11. Stop the engine.
9. Release the bucket control lever.
10. Decrease the engine speed to low idle. Understanding the Results of Test
No. 2
11. Lower the bucket to the ground, place the
1. If the engine speed was as specified, the engine,
transmission in neutral and apply the parking
torque converter and transmission are probably
brake.
good.
2. If the engine speed was more than specified, the
problem can be in the torque converter or the
Understanding the Results of Test transmission. See Section 6002 for
No. 1 troubleshooting information.
1. If the engine speed was as specified, the engine,
3. If the engine speed was less than specified, do
torque converter, transmission and hydraulic
Test No. 3.
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.
3. Increase the engine speed to full throttle.
2. If the engine speed was more or less than
4. Hold the bucket control lever in the ROLLBACK specified the main relieef setting may be too low
position and raise the lift arms. The stall speed or too high. See Section 8002 for troubleshooting
must be read while the lift arms are in motion. information.
5. Check the engine speed. 3. If the engine speed was less than specified in all
tests, the engine is probably the cause.
6. Release the bucket control lever.
7. Decrease the engine speed to low idle.
8. Lower the bucket to the ground.
9. Stop the engine.

Section
2003
2003
AFTER COOLER

Via Plava, 80
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 STEP 6
Park machine on level ground, lower the bucket. Put
transmission in neutral, apply the parking brake. Turn
off engine.
STEP 2
Raise hood. Install ‘T’ fitting in waste gate valve
hose. Attach pressure gauge. Install another
pressure gauge into the intake manifold port.
STEP 3
Have assistant start engine and run at 2000 r/min
(rpm). Record pressure readings for both gauges. If W230R429
the pressure difference is greater than 60 mbar Inspect the after cooler outlet flex hose for leaks or
(0.87 psi), inspect cooler components for damaged holes and insure that the clamps are tight.
or missing parts.
STEP 7
STEP 4
W270R602
W270R601
Inspect the intake manifold flex hose for leaks or
Inspect the turbocharger flex hose for leaks or holes holes and insure that the clamps are tight.
and insure that the clamps are tight.
STEP 8
STEP 5
W270R603
BD03A115
Visually inspect top of after cooler for damage or
Inspect the after cooler inlet flex hose for leaks or leaks
holes and insure that the clamps are tight.
NOTE: If the leak source has not been located, remove
and test the after cooler.

2003-4
AFTERCOOLER REMOVAL
Removal STEP 5
STEP 1
bucket to the floor. Stop the engine and apply the
parking brake.
STEP 2
Raise the hood and place the master disconnect
switch in the OFF position.
NOTE: Radiator drain is located under the rear chassis
behind the rear axle.
W270R602
Drain of coolant from engine cooling system. Loosen clamps and remove Intake hose.
STEP 3 STEP 6
W270R601 W230R429
Loosen clamps and remove turbocharger outlet Loosen clamps and remove air cooler outlet hose.
components.
STEP 4
BD03A115
Loosen clamps and remove air cooler inlet hose.

2003-5
STEP 7
1
2
3
W270R604
Remove the two nuts (1), washer (2) and U-bolt (3) of
the plate of the after cooler mounting frame.
STEP 8
1
1 2
3 2 4
2
W270R605
Remove four bolts (1), washers (2) and springs (3) of

the after cooler mounting frame (4). Remove air
cooler from frame.

2003-6
Leak Test Installation

STEP 1
1
1 2
3 2 4
2
BS03B028
Check the core for leaks by closing off the outlet tube
and attaching regulated air pressure 550kPa (80psi)
to the inlet tube. Submerge the cooler in water and
watch for air leakage.
NOTE: If leakage is detected replace the after cooler.
W270R605
Install after cooler in its frame (4). Install four

mounting washers (2), springs (3) and bolts (1).
STEP 2
1
2
3
W270R604
Install U-bolt (3), washers (2) and nuts (1) of the plate
of the after cooler mounting frame.

2003-7
STEP 3 STEP 6
W270R601 W230R429
Install air cooler inlet hose. Tighten clamps at Tighten clamps at air cooler outlet.
turbocharger outlet.
STEP 7
STEP 4 Refill the cooling system.
STEP 8
Install ‘T’ fitting in waste gate valve hose. Attach
pressure gauge. Install another pressure gauge into
the intake manifold port.
STEP 9
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 Bar
(0.87 psi).
BD03A115
Tighten clamps at air cooler inlet.
STEP 5
W270R602
Install air cooler outlet hose and tighten clamps at

engine intake.

2003-8
NOTES

SECTION INDEX
FUEL SYSTEM
SCR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3002
FOR FUEL SYSTEM REPAIR, SEE THE ENGINE SERVICE MANUAL

84394558

Via Plava, 80
3002
Section
3002
SCR SYSTEM

Via Plava, 80
3002-2
TABLE OF CONTENTS
Selective catalytic reduction (SCR) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Storage, handling and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SCR System Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Upstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Upstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Downstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Downstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
NOx Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
NOx Sensor Reinstall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Intake Temperature/Humidity Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DEF/ADBLUE Heater Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DEF/ADBLUE DNOx Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DEF/Adblue Dosing Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DEF/AdBlue Supply Tank Level and Temperature Sensor Pickup and Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DEF/adblue supply filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Removal Supply Tank Filler Neck Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation Supply Tank Filler Neck Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal Supply Line Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation Supply Line Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Removal DNOx Supply Module Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation DNOx Supply Module Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Air Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Primary/Secondary Fillter Element Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Primary/Secondary Element Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3002-3
SELECTIVE CATALYTIC REDUCTION (SCR) ● No additives are required.
SYSTEM
NOTE: Contaminated DEF/AdBlue can affect the
Your machine is equipped with additional performance of your machine.
components to comply with national and local
exhaust emissions requirements. The main Shelf life
components of the SCR system include the SCR Constant ambient storage temperature Minimum
catalyst, the Diesel Exhaust Fluid (DEF) /AdBlue shelf life
(27), injection unit (7), the DEF/AdBlue tank (1), and
the DEF/AdBlue electronic control unit (26). Less than or equal to 10 °C (50 °F) 36 months
Less than or equal to 25 °C (77 °F) ¹ 18 months
During combustion, harmful Nitrogen Oxide (NOx) Less than or equal to 30 °C (86 °F) 12 months
molecules are formed in the exhaust. By injecting a Less than or equal to 35 °C (95 °F) 6 months
DEF/AdBlue solution into the exhaust prior to a Greater than 35 °C (95 °F) -²
catalyst, the NOx can be converted to harmless
elemental Nitrogen and water. This happens when ¹ To prevent decomposition of DEF/AdBlue,
the NOx olecules react inside the catalyst with the prolonged transportation or storage above 25 °C (77
heat generated by the engine and the ammonia in °F) should be avoided.
the DEF/AdBlue solution. ² Significant loss of shelf life: check every batch
before use. See your New Holland dealer for more
Storage, handling, and transport information on testing.
NOTE: Storage temperatures above 30 °C (86 °F) Disposal
greatly reduce the shelf life of DEF/AdBlue.
● Dispose of DEF/AdBlue and any filter
DEF/AdBlue has a typical shelf life of 6-12 months. In accumulations in accordance with all applicable
order for DEF/AdBlue to remain in a useable Federal, State, and local laws governing waste
condition, storage requirements need to be met. disposal.
● Store between -11 °C (12 °F) and 30 °C (86 °F).
● Use only an approved DEF/AdBlue container.
Contact your dealer to obtain proper storage
container(s).
● Keep container tightly closed.
● Keep container in a cool, well-ventilated area.
● Keep away from heat and direct sunlight.
● Your machine is equipped with an internal tank
heater to thaw frozen DEF/AdBlue. Your machine
will still function until the DEF/AdBlue begins to
flow. The SCR system will then function normally.
Do not heat DEF/AdBlue for long periods of time at
temperatures above 30 °C (86 °F). This causes the
solution to decompose, which very slowly decreases
the expected shelf life.
NOTE: Do not use an anti-gelling or freeze point
improver in your DEF/AdBlue. The 32.5 % solution is
specifically designed to provide the optimum NOx
reduction properties. Any further blending or
adjusting of the DEF/AdBlue mixture will lessen its
ability to perform correctly and may cause damage to
the SCR components.
Handling and supply of additives, if any.
● Personal Protective Equipment (PPE) is not
required under normal conditions. If splashing is
likely, wear eye protection. For prolonged or
repeated contact, impervious gloves are
recommended.
3002-4
COMPONENT LOCATION ILLUSTRATION SCR SYSTEM (table 1)
1. Tank - 90 liter (24 gallon)
2. Bracket tank
3. Cap
4. Hose
5. Clamp
6. Clamp
7. Module DNOX2 UREA dosing
8. Bracket module
9. Filler neck
10.Screw
11.Bolt
15.Hose UREA fill
16.Washer
17.Bracket sensor mount
19.Nut
20.Bracket DEF support
21.Hose
22.Screw - torque 7 ± 0.5 Nm (5 ± 0.36 lb-ft)
23.Muffler
24.Rear chassis
25.Clamp
27.Solution aqueous UREA (Ad Blue)
A1.White connection
A2.Black connection
A3.Blue connection
A4.White connection

3002-5
16
19
22 16 19
25
16 20
21 6 17
11 16
A1 A2
7
5
A3 A4
23
4
3
A 19 16 11
10 19
16
9
5
16 11
16 24
19 8
15
1 27
11
A
2
W270R093

3002-6
32
42 28 34
28 33
32
26
28 41
34 28 33
32 43
30
40
36
37
38
33
28
31
35 28
28 39
29
32
42
W270R094

3002-7
COMPONENT LOCATION ILLUSTRATION SCR SYSTEM (table 2)
26.Electronic control unit DNOX2 UREA

28.Washer
29.Bolt - torque 24 ± 4 Nm (17.7 ± 3 lb-ft)
30.Valve, heater
31.Bolt - torque 18 ± 2 Nm (13 ± 1.5 lb-ft)
32.Clamp
33.Bolt
34.Nut
35.Clamp
36.Fitting
37.Clamp
38.Hose
39.Clamp
40.Clamp
41.Sleeve protective heat
42.Clamp
43.Engine cap

3002-8
SCR SYSTEM SENSORS
Upstream Exhaust Temperature STEP 3

Sensor Removal
NOTE: Emission sensor in the exhaust system and on the
2
vehicle may be damaged by vibrations from use of impact
wrenches or hammers during service work. Avoid using
these tools servicing components close to the sensor. 1
Remove the sensors with care if use of these tools cannot
be avoided.
STEP 1
W270R097
Locate exhaust temperature sensor (1) on exhaust

system before the catalyst (2).
STEP 4
W270R095
Raise the hood using controls located behind the

access cover.
STEP 2
W270R098
Loosen hex nut on sensor.
W270R096
Turn master electric switch to the “off” position.

3002-9
STEP 5 Upstream Exhaust Temperature
Sensor Reinstall
these tools servicing components close to the sensor.
be avoided.
STEP 1
W270R099
Remove temperature sensor from exhaust system.
STEP 6
W270R099
Install temperature sensor into exhaust pipe.
STEP 2
W270R100
Remove wire ties securing wire harness to support

brackets. Unplug sensor from machine wiring
harness and remove it.
W270R098
Secure sensor into exhaust pipe. Sensor torque 40 to

50 Nm (30 to 36 lb ft.). Reconnect sensor to wire
harness and secure harness to support brackets
using new wire ties.

3002-10
STEP 3 STEP 2
W270R096 W270R096
Turn master electric switch to “on” position. Clear any Turn master electric switch to the “off” position.
fault code. Start engine and check to see if problem
has been corrected. STEP 3
Downstream Exhaust Temperature

Sensor Removal
vehicle may be damaged by vibrations from use of impact 2
these tools servicing components close to the sensor. 1
be avoided.
STEP 1
W270R101
Locate the exhaust temperature sensor (1) on

exhaust system after catalyst (2).
STEP 4
W270R095

access panel.
W270R102
Loosen hex nut and remove sensor from exhaust

system.
3002-11
STEP 5 Downstream Exhaust Temperature
Sensor Reinstall
be avoided.
STEP 1
W270R659
Loosen hex nut and remove P-clamp securing

sensor wiring harness to catalyst mounting support
bracket. Remove any wire ties securing wiring
harness to machine.
STEP 6
W270R102
Install temperature sensor into exhaust system.

Secure sensor by tightening hex nut. Sensor torque
40 to 50 Nm (30 to 36 lb ft.).
STEP 2
W270R660
Disconnect sensor from wiring harness.
STEP 7
W270R661
Install hex nut and P-clamp holding sensor wiring

harness to catalyst mounting support bracket.
W270R100
Remove sensor and wiring harness as one

component from machine.
3002-12
STEP 3 NOx Sensor Removal
be avoided.
STEP 1
W270R662
Reconnect sensor to machine wiring harness.
STEP 4
W270R095

access cover.
STEP 2
W270R096
Turn master electric switch to “on” position. Clear any

has been corrected.
W270R096

3002-13
STEP 3 STEP 5
W270R103 W270R104
Locate NOx sensor (1) on exhaust system down Loosen hex nut on NOx sensor.
stream of catalyst (2).
STEP 6
STEP 4
2
1
W270R105
W270R663
Remove NOx sensor from exhaust system.
Loosen hex nut and remove P-clamp (1) holding
sensor wiring harness to catalyst mounting support STEP 7
bracket (2).
W270R106
Locate NOx sensor module (1) on the backside of

the SCR catalyst mounting support bracket (2).

3002-14
STEP 8 NOx Sensor Reinstall
be avoided.
STEP 1
W270R664
Disconnect NOx sensor module from machine wiring

harness.
STEP 9
W270R105
Install NOx sensor into exhaust system.
STEP 2
W270R107
Remove hex bolts securing NOx sensor module to

mounting support bracket and remove module.
STEP 10
W270R104
Secure NOx sensor with hex nut. Sensor torque 40

to 60 Nm (30 to 44 lb ft.)
W270R665
Remove wire ties securing NOx sensor wiring

harness to machine and remove sensor.

3002-15
STEP 3 STEP 5
2
1
W270R107 W270R667
Install NOx sensor module and secure it to mounting Secure NOx sensor wire harness with P-clip (1) to
support bracket using hex bolts. NOx sensor module catalyst mounting support bracket (2) using hex
torque 10.5 to 14.5 Nm (8 to 10.5 lb ft.). bolts. Secure wire harness with wire ties where
appropriate.
STEP 4
STEP 6
W270R096
W270R666
Turn master electric switch to “on” position. Clear any
Reconnect machine wiring harness to NOx sensor
module.
has been corrected.

3002-16
INTAKE TEMPERATURE/HUMIDITY SENSOR
Removal STEP 3
be avoided.
STEP 1
W270R108
Locate the intake temperature/humidity sensor on air

intake pipe between the air filter housing and
turbocharger.
STEP 4
W270R095
Raise the engine compartment hood using controls

located behind the access cover.
STEP 2
W270R109
Disconnect wiring harness plug.
W270R096
Turn the master electric switch to the “off” position.

3002-17
STEP 5 Installation
be avoided.
STEP 1
W270R110
Remove hex bolts.
STEP 6
W270R111
Remove plug covering hole in intake pipe. Insert

sensor.
STEP 2
W270R111
Remove sensor.
NOTE: Cover hole in the intake pipe to prevent debris
from entering the system.
W270R110
Secure sensor with hex bolts.

Maximum tightening torque: 17 Nm (12.5 lb ft).

3002-18
STEP 3
W270R109
Reconnect wiring harness plug.
STEP 4
W270R096
Turn master electric switch “on”. Clear any fault

code. Start machine and confirm that problem has
been corrected.

3002-19
DEF/ADBLUE HEATER CONTROL VALVE
Removal STEP 3
STEP 1
W270R095

access cover.
W270R571
STEP 2 Place a suitable container below radiator drain

located behind access cover. Remove radiator cap.
Remove drain cap and drain engine coolant. Install
tank drain plug and radiator cap after coolant has
drained.
NOTE: Use compressed air and water to clean debris
from around drain plug area prior to draining the system.
STEP 4
W270R096
W270R668
Locate DEF/AdBlue Heater Control valve next to the

DNOx Supply Module on the left hand side of the
engine.

3002-20
STEP 5 STEP 7
W270R669 W270R671
Disconnect the machine wiring harness from the Remove hex bolts securing heater control valve to
DEF/AdBlue heater control valve. mounting support bracket.
STEP 6 STEP 8
W270R670 W270R672
Using a small flat blade screw driver, pull up on the Remove heater control valve from machine.
fitting retaining clip and disconnect the coolant
inlet/outlet lines from the heater control valve.

3002-21
Installation STEP 3
STEP 1
W270R0962
Turn master electric switch to the “on” position. Clear

any fault code. Start the machine and check for
engine coolant leaks. Confirm that problem has been
W270R673 corrected.
Position DEF/AdBlue heater control valve on the
mounting support bracket and secure it with hex
bolts.
STEP 2
W270R674
Reconnect coolant inlet/outlet lines and wiring

harness. Refill engine cooling system.

3002-22
DEF/ADBLUE DNOX SUPPLY MODULE
Removal STEP 3
STEP 1
W270R095 W270R112
Raise the hood using controls located behind the On the left hand side of engine mark supply and
access cover. return line connection locations for reference during
reassembly.
STEP 2
STEP 4
W270R096
Turn the master electric switch to the “off” position.
W270R113
From the bottom of the module disconnect

DEF/AdBlue supply and return lines from underneath
DNOx supply module.
NOTE: To disconnect fittings, squirt water into the fitting
connection to lubricate the O-ring. Squeeze the locking tabs
together while slightly pushing the fitting ends together and
then pulling them apart. If the fitting will not release, but is
free to rotate, the O-ring is likely stuck and additional water
should be used.
from supply and return line connections.

3002-23
STEP 5 Installation
STEP 1
1 2
W270R114
Remove hex bolts securing the DNOx supply module

to the mounting support bracket. W270R676
Position the DNOx supply module on its mounting

STEP 6 support bracket. Connect wiring harness to back of
supply module. Be sure the lever (1) is fully engaged
and the plug (2) is fully seated.
2
1 STEP 2
W270R675
Partially remove DNOx supply module from its

mounting support bracket to gain access to the wiring
harness (1). Open the lever (2) and disconnect wiring
harness from DNOx supply module. W270R114
Remove DNOx supply module from the machine. Fit the DNOx supply module into mounting support
bracket and secure with hex bolts. Bolts torque 24 ±
4 Nm (17.7 ± l Lb ft).

3002-24
STEP 3 STEP 4
W270R113
Reconnect supply and return lines underneath DNOx W270R112
control module. To connect, push the two fitting ends Check wire harness and supply lines for proper
together until an audible snap is heard. positioning.
NOTE: Test fitting connections to be sure they are secure. NOTE: Make sure wire harness and supply lines do not
Match supply and return markings to ensure correct contact anything that would cause damage.
connections are made.
STEP 5
W270R096
Turn master switch to “on” position. Clear any fault

codes. Start engine. Check for fluid leaks at
connections. Confirm problem has been corrected.
Close engine compartment hood.

3002-25
DEF/ADBLUE DOSING INJECTOR
Removal STEP 3
be avoided.
STEP 1
W270R116
Clean dirt and debris from around engine air intake

pipe connections and DEF/AdBlue dosing injector.
STEP 4
W270R095

access cover.
STEP 2
W270R115
NOTE: The dosing injector (1) is located in the exhaust

system upstream from the SCR catalyst and downstream of
the turbocharger.
W270R096
Turn master electric switch “off”.

3002-26
STEP 5 STEP 7
1 2
W270R658 W270R678
Remove fuel pipe emissions (1) for easier access to Mark location of DEF/AdBlue supply and return lines
dosing injector (2). for reference dur ing reassembly. Remove
DEF/AdBlue supply and return lines. Cap lines to
NOTE: Mark location and routing of coolant lines for
prevent debris from entering the system.
reference during reassembly.
NOTE: To separate connections, squirt water into fittings
STEP 6 to lubricate O-rings. Squeeze fitting locking tabs slightly
and push fitting together then pull it apart. If fitting will not
release, but is free to rotate, the O-ring is likely stuck and
additional water should be applied.
STEP 8
W270R677
Disconnect dosing injector wiring harness.
W270R679
Remove bolts securing dosing injector into mixing

pipe.

3002-27
STEP 9 Installation
be avoided.
STEP 1
W270R680
Remove dosing injector. Cover opening to prevent

debris from entering exhaust system.
STEP 10
W270R682
Remove cover from exhaust system and install

dosing injector.
NOTE: Use markings made during disassembly to
determined proper positioning.
STEP 2
W270R681
Inspect dosing injector and service or replace as

recommended.
W270R683
Secure dosing injector to exhaust pipe. Torque

screws to 7 +/- 0.5 Nm (62 +/- 4 lb in.).

3002-28
STEP 3 STEP 5
W270R684
Connect DEF/AdBlue supply and return lines and W270R096
wiring harness to dosing injector. Turn master electric switch to “on”. Clear any fault
code. Start machine. Check for leaks at DEF/AdBlue,
NOTE: Use marks made during disassembly to determine exhaust and intake system connections. Confirm
proper positioning. problem has been corrected.
STEP 4
W270R685
Secure fuel pipe emissions.

3002-29
DEF/ADBLUE SUPPLY TANK

LEVEL AND TEMPERATURE SENSOR PICKUP AND HEATER
Removal STEP 3
STEP 1
W270R095

access cover.
1
STEP 2
W270R118
Open the frame (1) of the engine cooling system.
W270R096

3002-30
STEP 4 STEP 6
W270R119
Place a suitable container below DEF/AdBlue supply

tank drain plug. Remove filler neck cap from supply
tank. Loosen drain plug and drain DEF/AdBlue.
Install drain plug and access cover after DEF/AdBlue
has drained.
W270R571 STEP 7
Place a suitable container below radiator drain
located beneath the access cover at rear left hand
side of machine. Remove radiator cap. Remove
drain cap. Drain coolant. Install tank drain plug and
radiator cap after coolant has drained.
from around drain plug area.
STEP 5
W270R125
Remove bolts securing filler neck screen assembly.

NOTE: Place a plug in filler neck hole to prevent loose
screws from entering the supply tank.
W270R117
Loosen hex bolts and remove access cover below

supply tank to gain access to the drain.
NOTE: Use compressed air and water, to clean debris
from around drain plug area.

3002-31
STEP 8 STEP 10
W270R686
Unplug wiring harness. Disconnect engine coolant

lines and DEF/AdBlue lines by pushing coupling
W270R126 together, squeezing tabs and then pulling connection
Remove filler neck/screen assembly and O-ring from apart.
supply tank by pulling upward while twisting
assembly left and right. Pull wire and hose harness up and off to the side out
of the way.
STEP 9 NOTE: Plug all lines to prevent debris from entering the
system.
STEP 11
W270R120
Remove rubber boot cover (1) from liquid level/temp

sensor sending unit wires, DEF/AdBlue and engine W270R687
coolant supply lines. Mark wire and hose connection Mark location of pickup unit within tank before
positions. removal. Twist DEF/AdBlue level temperature sensor
NOTE: Use compressed air and water to clean debris unit counter clockwise to loosen it from tank.
from top of DEF/AdBlue supply tank around liquid
level/temp sensor sending unit area.

3002-32
STEP 12 Installation
STEP 1
2
3 1
W270R122
W270R121 Install DEF/AdBlue supply tank into the fuel tank

Lift DEF/AdBlue level/temp sensor unit out of tank. cradle and secure it using hex bolts (1) and upper
support mounting bracket.
NOTE: Cover tank opening to prevent debris from
entering it. Fix the tank urea through the belts (2). Connect the
hose urea fill with the clamp (3).
STEP 13
STEP 2
2
3 1
W270R122
Remove hex bolts (1) from mounting support bracket

above tank, remove belts fuel tank (2) and loosen
hose clamp urea fill (3). Lift tank urea up and out of
its cradle from the fuel tank. W270R121
Lower DEF/AdBlue level temp sensor and pick-up

unit into tank.

3002-33
STEP 3 STEP 6
W270R688
Use reference marks from disassembly procedure to

position DEF/AdBlue level temp sensor and pick-up
W270R690
unit. Secure by turning it clockwise.
Reinstall the O-ring onto the DEF/AdBlue supply tank
with the radius surface facing upward.
STEP 4
NOTE: Lubricate O-ring with petroleum jelly.
STEP 7
W270R689
Remove plugs from all lines. Reconnect DEF/AdBlue

supply/return and purge lines, engine coolant
supply/return lines and liquid level gage sensor
wiring harness. To connect, push connections
together all the way, and then pull back to lock. W270R691
Reinstall filler neck assembly onto supply tank.

STEP 5
W270R120
Replace rubber boot protective cover (1).

3002-34
STEP 8
W270R692
Secure filler neck assembly using Torx bolts. Refill

DEF/AdBlue storage tank and engine cooling
system.
STEP 9
W270R096
Turn master electric power switch to “on” position.

Clear any fault codes. Start machine and check for
DEF/AdBlue and coolant leaks. Confirm that the
problem has been corrected.

3002-35
DEF/ADBLUE SUPPLY FILTERS
Removal Supply Tank Filler Neck STEP 3

Screen
STEP 1
W270R096
Turn off master electric switch to the “off” position.
STEP 4
W270R123
Locate the DEF/AdBlue supply tank on the left hand

side of the machine beneath an access cover.
STEP 2
W270R124
Open access cover and remove filler cap from filler

W270R095
neck of supply tank.
Raise the hood using controls located behind the NOTE: Use compressed air and water, to clean debris
access cover. from around filler cap/neck area.

3002-36
STEP 5 STEP 7
W270R693
Remove plug from filler neck. Rinse screen with

W270R125
water to remove accumulated debris. Reinstall plug
Remove bolts securing filler cap/neck screen
into filler hole.
assembly.
NOTE: If the screen is damaged replace it. To replace,
NOTE: Place a stopper into filler neck hole to prevent
remove bolts and separate filler neck from screen. Attach
loose screws and debris from entering supply tank.
new screen to filler neck and secure with bolts.
STEP 6
Installation Supply Tank Filler
Neck Screen
STEP 1
W270R126
Remove filler cap/neck screen assembly and O-ring.

Pull upwards while twisting assembly left and right.
NOTE: Cap opening of supply tank to prevent debris from
entering tank.
W270R127
Reinstall O-ring (1) with radius surface facing

upward.

3002-37
STEP 2 Removal Supply Line Screen
STEP 1
W270R126 W270R128
Reinstall filler cap/neck screen assembly. DEF/AdBlue supply line screen is located under the
engine hood on the left side of engine at rear of
STEP 3 machine.
STEP 2
W270R125
Secure assembly with bolts and remove stopper from W270R095

filler neck hole. Reinstall supply tank filler neck cap. Raise the hood using controls located behind the
access cover.
STEP 4
STEP 3
W270R096
Close side cover concealing supply tank. Turn W270R096

master electric switch to “on” position. Lower engine Turn master electric switch to “off” position.
compartment hood.
3002-38
STEP 4 STEP 6
W270R130
Remove filter screen from housing with needle nose

pliers. Rinse filter screen with water to remove
W270R129
accumulated debris.
Locate supply line filter screen housing within supply
line between supply tank (1) and DNOx supply NOTE: If filter screen is damaged, replace it.
module (2) mounted on left hand side of engine.
NOTE: Use compressed air and water to clean debris Installation Supply Line Screen
from around screen assembly.
STEP 1
STEP 5
W270R130
Install filter screen into supply line filter housing.

W270R694
To open fitting, push fitting together, squeeze locking

tabs slightly, and then pull apart. STEP 2
NOTE: Squirt water into fitting connection to lubricate
O-ring. If fitting will not release, but is free to rotate, O-ring
is likely stuck and additional water should be used to free
connection.
NOTE: Use a suitable container to catch any fluid
discharged during hose and filter disassembly.
W270R695
Reconnect supply line coupling.

3002-39
STEP 3 STEP 2
W270R096 W270R095
Turn master electric switch to “on” position. Clear any Raise the hood using controls located behind the
fault codes. Start engine and check connections for access cover.
leaks. Confirm problem has been corrected.
STEP 3
Removal DNOx Supply Module
Filter
STEP 1
W270R096
STEP 4
W270R128
The DEF/AdBlue Supply filter is located inside the

DNOx supply module under the hood on the left side
of the engine at the rear of the machine.
2
W270R131
Locate the DNOx supply module (1). The filter

element assembly (2) is located on the underside of
the module.
NOTE: Clean dirt and debris from filter element housing
using compressed air and water.

3002-40
STEP 5 STEP 7
W270R696 W270R698
Squirt water into fitting connections to lubricate Remove filter element (1) from housing (2) by turing
O-rings. Disconnect fittings by pushing them it counter clockwise. Discard filter element following
together. Then squeeze locking tabs and pull fitting local environmental and waste regulations.
down and off.
NOTE: If the fitting will not release, but is free to rotate, Installation DNOx Supply Module
the O-ring is likely stuck and lubrication of the O-ring Filter
should be repeated.
STEP 1
STEP 6
2
1
W270R699
W270R697
Lubricate filter element O-ring (1) on housing side.
Remove the DEF/AdBlue filter element assembly Lubricate housing O-ring (2). Install filter element on
from DNOx supply module by turning it counter housing by turing it clockwise.
clockwise. Pull straight down and away from module.
NOTE: Use a suitable container to catch any fluid
discharged during disassembly. NOTE: Hand tighten filter only.

3002-41
STEP 2 STEP 5
W270R700
W270R096
Lubricate filter element O-ring on control module
side. Turn master electric switch to “on” position. Clear any
fault codes. Start engine and check connections for
NOTE: Lubricate O-ring with petroleum jelly. leaks. Confirm problem has been corrected.
STEP 3
W270R697
Insert filter housing assembly into DNOx supply

module and turn clockwise to tighten.
NOTE: Hand tighten filter only.
STEP 4
W270R701
Reinstall DEF/AdBlue supply line. Push connection

together and then pull back to make sure it is secure.

3002-42
AIR FILTRATION
Primary/Secondary Fillter Element STEP 3

Disassembly
STEP 1
W270R133
Release all clips securing air filter element housing

cover.
2 STEP 4
W270R702
Raise engine compartment hood using controls

located behind access cover (1). Airfilter
housing/element (2) is located in main engine
compartment on right hand side of engine.
W270R134
STEP 2 Remove cover from air filter element housing.
STEP 5
W270R096

W270R135
Remove primary filter element by lifting up on handle.

3002-43
STEP 6 STEP 2
W270R136 W270R135
Remove secondary filter element from right side of Install new primary filter element by sliding it down
housing. Remove debris from inside filter element into housing.
housing before installing new filter elements.
NOTE: Make sure primary and secondary filter elements
NOTE: Do not clean the seconday filter element. It must form an effective seal.
be replaced if damaged or clogged.
STEP 3
Primary/Secondary Element
Reassembly
STEP 1
W270R134
Install housing cover.
W270R136
Install new secondary filter element by inserting it

into positioning slot.
NOTE: Make sure filter element is firmly seated into
housing.

3002-44
STEP 4
W270R133
Lock clips to secure filter housing cover.

NOTE: If cover does not fit properly, recheck filter
element installation. Cover will be difficult to install if filter
elements are not properly installed.
STEP 5
W270R096
Turn master electric power switch “on”. Clear any

fault codes. Start machine and confirm problem has
been corrected.

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

Electrical Specifications and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003
Jump Post Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003a
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005
Rear view Camera and Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4006

Via Plava, 80
4001
Section
4001
REMOVAL AND INSTALLATION OF STARTER AND

ALTERNATOR

Via Plava, 80
4001-2
TABLE OF CONTENTS
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4001-3
STARTER
Removal STEP 4
STEP 1
Park machine on a level surface and lower bucket to
ground.
STEP 2
BD06F135
Remove the ground strap from the starter, remove

the starter mounting bolts, remove the stater.
2
1
W270R587
1. HOOD SWITCH
2. MASTER DISCONNECT
Raise the engine compartment with lifting motor.

position.
STEP 3
BD06F134
Place identification tags on the positive cables and

remove the positive cables from the starter.

4001-4
Installation STEP 7
STEP 5
1
BD06F134
2 Install and tighten the wires on the starter solenoid.
Remove and discard tags.
STEP 8
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.
STEP 6
BD06F135
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 48 Nm
(29 to 35 pound-feet).

4001-5
ALTERNATOR
Removal STEP 4
STEP 1
ground.
STEP 2
W270R589
Use a wrench to move the belt tensioner to loosen

the tension on the belt. Remove the belt.
2 STEP 5
1
W270R587
1. HOOD SWITCH
Raise the engine compartment with lifting motor.

position.
STEP 3
W270R590
Remove mounting bolts for alternator, remove

alternator.
W270R588
Disconnect wires from the alternator.

4001-6
Installation STEP 8
STEP 6
W270R588
Connect wires to the alternator, place rubber boot

over positive post.
STEP 9
W270R590
Place alternator onto engine, install mounting bolts

for alternator and tighten.
STEP 7
2
1
W270R587
1. HOOD SWITCH

position. Lower the engine compartment with lifting
motor.
W270R589
Use a wrench to move the belt tensioner, install the

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

4001-7
BELT INSTALLATION
W270R591

4001-8
NOTES

4002
Section
4002
ELECTRICAL SPECIFICATIONS AND

TROUBLESHOOTING

Via Plava, 80
4002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4002-3
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 -17qC (0qF) 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 20qC (68qF) (Nominal) ................ 68.2 ohms
Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20qC (68qF) (Nominal) ............ 305 ohms
Fuel Level Sender .............................................................................................................................. 33 to 240 ohms
Coolant, Torque Converter, and Hydraulic Temperature Sender 20qC (68qF) ......................................... 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 20qC (68qF) (Nominal)............................................................................ 1.9 ohms
Parking Brake Solenoid DC Resistance At 20qC (68qF) (Nominal) ........................................................... 40.3 ohms
Pilot Pressure Solenoid (Joystick) DC Resistance At 20qC (68qF) (Nominal) ........................................... 29.9 ohms
Pilot Pressure Solenoid (Single Axis) DC Resistance At 20qC (68qF) (Nominal) ...................................... 27.4 ohms
Ride Control Solenoid DC Resistance At 20qC (68qF) (Nominal) .............................................................. 22.7 ohms
Pin Engage Solenoid DC Resistance At 20qC (68qF) (Nominal) ............................................................... 28.8 ohms
Secondary Steering Solenoid DC Resistance At 20qC (68qF) (Nominal) .................................................. 39.3 ohms
Fan Reversing Solenoid DC Resistance At 20qC (68qF) (Nominal)........................................................... 39.3 ohms
Fan PWM Solenoid DC Resistance At 20qC (68qF) (Nominal) ...................................................................xx.x ohms
Rollback Pressure Switch (Normally Closed) Opening Set point ....................................................... 6.2 Bar (90 psi)
Fuel Temperature Sensor At 20qC (68qF) (Nominal) ................................................................................ 2500 ohms
Grid Heater .................................................................................................................................................. 500 ohms
Engine Control Unit ............................................................................................... Electronic Diesel Control (EDC 7)
Analog Throttle ................................................................................. Idle Validation Switch Closes At 0.775V ± 0.1V
Throttle Position Potentiometer ................................................................................................. 5V Reference ± 0.2V
Low Idle Position .............................................................................................................................. 0.4V ± 0.025V
High Idle Position ................................................................................................................................. 4.0V ± 0.1V

4002-4
ELECTRICAL WIRE IDENTIFICATION
Wire Identification Codes

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

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

Color, Size,
Wire Circuit Connector Cavity Connector Cavity
and Material
W0 8 GXL
1 JUMP1, JSS LOAD SENSE A JUMP2, JSS LOAD SENSE C
TWIST
BK0 8 GXL
2 JUMP1, JSS LOAD SENSE B JUMP2, JSS LOAD SENSE A
TWIST
14 Alternator D+ Lg 1.0 SXL AD, Alternator D+ 1 ENG, Engine Cab 26
30 Battery sensing R 1.0 SXL ALT_5, Alternator D+ 2 AB_5, Alternator B+ 1
31 EDC Relay CNTL OR 0.8 GXL EDC7, Engine controller 13 SPL_EDC4, Ultrasonic A
38 Doser valve B+ R 0.8 GXL DNOX2, NOX Controller 12 DEFDM, Doser metering VLV 1
42 Work Lights Switched Fused Pwr R 2.0 GXL SPL-WL, Ultrasonic A ECC, ELect CNTR C A2
44 Brake Lt Control Power T 1.0 SXL BTM_C, CAB Bottom bulkhd J PBL, Brake Light Press Switch 2
49 Back Lt Power DU1.0 GXL D-OR, Diode OR C SPL-BCK-LGT, Spl Back Lgt Pwr A
52 Fan Reverse LSD W 0.8 TXL AIC-1, Adv Instr Clust 1 23 ECB, Electrical Center B B8
56 Fan Control PWM W 0.8 TXL CAB-E, Cab Engine 23 AIC-1, Adv Instr Clust 1 26
57 Pin Engage Sol Pwr W 1.0 SXL FRONT, Cab Front Chassis 17 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
460 Fan speed sensor signal Y 1.0 GXL FSS, Fan_speed_sens 1 ENG, Engine-CAB1 16
BTM_C, CAB BOTTOM

016B Pedal Sensor Grnd DU 0.8 GXL D BPP, Pedal position 6
BULKHD
GND_ENG7, Tranny, cool
017A Fan speed sensor GND BK 1.0 GXL 1 FSS, Fan_speed_sens 2
temp
GND_CAB_SPL, CAB GRND
OD_C DIAG2 GRND BK 0.8 GXL DIA_2, Diagnostic A D
SPLICE
OE_A Exht temp up GND BK 0.8 GXL UTS, Upstream temp sense 2 DNOX2, NOX Controller 17
SPL-BCK-LT-GD2, Spl Back Lgt
0 29 RTT/Float Ground Bk 0.8 GXL SFL, Return To Travel Sw 4 K
Gnd
0 AA Proximity Switch Grnd Bk 1.0 SXL PXH, Height Control RTT B SPL-A2, Ultrasonic A
0 AB Proximity Switch Grnd Bk 1.0 SXL SPL-A2, Ultrasonic A GND-FC, Ground A 1
0 AC Proximity Switch Grnd Bk 1.0 SXL PXF, RTD B SPL-A2, Ultrasonic A
0 AD Ride Control Ground Bk 1.0 SXL YRC, Ride Control Option 2 SPL-A1, Ultrasonic A
0 AE Pin Engage Ground Bk 1.0 SXL SPL-A1, Ultrasonic A YPE, Pin Engage Jumper B
0 AF Horn Ground Bk 1.0 SXL HN2, Horn Ground 1 SPL-A1, Ultrasonic A

4002-5

21C Bk - 1.0


Color, Size,
and Material
0 AG Front Chassis Ground Bk 2.0 SXL SPL-A1, Ultrasonic A GND-FC, Ground A 1
0 AH RH Front Lights Ground Bk 1.0 SXL SPL-A1, Ultrasonic A LRF, Lights RH 1
0 AJ LH Front Lights Ground Bk 1.0 SXL SPL-A1, Ultrasonic A LLF, Lights LH 1
0 AK Park Brake/Warning Ground Bk 1.0 SXL SPL-A4, Ultrasonic A BTM_E, CAB BOTTOM 2
0 AL Brake Warning Press Sw Gnd Bk 1.0 SXL PBW, Brake Warn Press Sw 2 SPL-A4, Ultrasonic A
0 AM RTD Grnd Bk 1.0 SXL PXM, RTD B PXT, RTD B
0 AN Park Brake Solenoid Ground Bk 1.0 SXL YPB, Park Brake Solenoid 2 SPL-A4, Ultrasonic A
0 AP Front To Rear Chassis Ground Bk 5.0 SXL GND-S1, Ground A 1 GND-S2, Ground A 1
0_AS GRND, Joystick BK 1.0 GXL JSS_FRM, JSS Frame to cab G SPL_JSS_17, Ultrasonic A
0_AT GRND, JSS VLV BK 1.0 GXL JSS_Valve, JSS HYD Valve 3 SPL_JSS_17, Ultrasonic A
0_AU GRND, Pilot dump BK 1.0 GXL SPL_JSS_17, Ultrasonic A JSS_PIL_Dump, JSS Pilot dump 2
0_AV GRND BK 1.0 GXL SPL_JSS_17, Ultrasonic A GND_JSS, Ground_A 1
0_AW PIN Engage GND BK 1.0 SXL YPE1, PIN Engage jumper B YPE2, PIN_Engage_OPT B
0B Front Washer Ground Bk 1.0 SXL FWW, Front Washer 2 SPL_ENG, ULTRASONIC A
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
SPL-BCK-LT-GD2, Spl Bk Lgt
0 B2 Back Light Ground Bk 0.8 GXL SFL, Return To Travel Switch 7 B
Grnd
0 B3 Back Light Ground Bk 0.8 GXL SHC, Height Control Switch 7 C
Grnd
0 B4 Back Light Ground Bk 0.8 GXL SRTD, Detent Switch 7 D
Grnd
0 B5 Back Light Ground Bk 0.8 GXL SPE, Pin Engage Switch 9 E
Grnd
SPL_BCK_LT_GD, SPL SPL-BCK-LT-GD2, Spl Bk Lgt
0 B6 Cab2 Ground Bk 1.0 GXL D F
BACK LGHT GD Grnd
0 B7 Back Light Ground Bk 0.8 GXL SFC, Fan Control Switch 7 M
Grnd
0 B8 Front Wiper Motor Ground Bk 0.8 GXL GND_CAB2, GROUND_A 1 FWMG, Wiper Ground A
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 SPL-PED-BL-GD, Spl Bk Lgt
0 B11 Back Light Ground Bk 0.8 GXL L F
Lgt Grnd Grnd 6 Pck

4002-6

21C Bk - 1.0


Color, Size,
and Material
SPL-HOOD-GRND, Hood
0 B12 Hood Down Relay Ground Bk 1.0 GXL A ECC, Elect Cntrc C4
Grnd 6 Pck
SPL-BCK-LT-GD, Spl Bk
0 B13 Back Light Ground Bk 1.0 GXL A SPL_WL1, ULTRASONIC A
Lght Grnd
0 B14 Back Light Ground Bk 0.8 GXL SWL, Work Lights Switch 7 SPL-BCK-LT-GD, Spl Bk Lght Grnd B
0 B15 Back Light Ground Bk 0.8 GXL SBE, Beacon Switch 7 SPL-BCK-LT-GD, Spl Bk Lght Grnd C
SPL-HOOD-GRND, Hood
0 B16 Hood Down Control Ground Bk 1.0 GXL B ECC, ELECT CNTR C B4
Grnd 6 Pck
0 B17 Back Light Ground Bk 0.8 GXL STA, Trans Auto Switch 7 SPL-BCK-LT-GD, Spl Bk Lght Grnd E
0 B18 Back Light Ground Bk 0.8 GXL SDC, Declutch Switch 7 SPL-BCK-LT-GD, Spl Bk Lght Grnd F
0 B19 Back Light Ground Bk 0.8 GXL SDR, Driving Lights Switch 7 SPL-BCK-LT-GD, Spl Bk Lght Grnd G
SPL-BCK-LT-GD2, Spl Bk ghLt

0 B20 Back Light Ground Bk 0.8 GXL SRC, Ride Control Switch 7 J
Grnd
0 B21 Back Light Ground Bk 0.8 GXL SBU, Backup Alarm Disc Sw 7 SPL-BCK-LT-GD, Spl Bk Lght Grnd J
SPL-HOOD-GRND, Hood
0 B22 Hood Up Relay Ground Bk 1.0 GXL C ECC, ELECT CNTR C C2
Gnd 6 Pck
0 B23 Back Light Ground Bk 0.8 GXL SRWP, Rear Wiper Switch 7 SPL-BCK-LT-GD, Spl Bk Lght Grnd L
SPL-PED-BL-GD, Spl Bk Lght

0 B24 Back Light Ground Bk 0.8 GXL SHZ, Hazard Switch 7 C
Grnd 6 Pck
SPL-HOOD-GRND, Hood
0 B25 Hood Up Control Ground Bk 1.0 GXL D ECC, ELECT CNTR C B2
Gnd 6 Pck
0 B26 Buzzer/Switch Pad Ground Bk 0.8 GXL SPL-BUZ, Ultrasonic A GND_CAB2, Ground_A 1
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
SPL-PED-BL-GD, Spl Bk Lgt

0 B29 RTT/Float Ground Bk 0.8 GXL SPB, Parking Brake Switch 7 E
Grnd 6 Pck
SPL_BCK_LT_GD2,
0_B31 SDA GND BK 0.8 GXL A SDA, Diff lock switch 7
SPL_Back LGT GRND
SPL_BCK_LT_GD, SPL Back lght
0_B32 Back light GND BK 0.8 GXL SRP, Work lights SW 7 M
GD
0 BA Pedestal Gnd Strap Bk 5.0 SXL. GND-PDST, Ground A 1 GND-PDST2, Ground A 1
0 BAC EDC7 Ground Bk 2.0 SXL SPL-EDC1, Ultrasonic A GND-ENG2 Dedicated, WIF, EDC 1
0 BAE EDC7 Sender Ground Bk 1.0 GXL RECT, Engine Coolant Temp B GND-ENG7Grnd Trans. Clnt 1
0 BAG Hood Grounds (EURO) Bk 1.0 SXL GND-ENG4, Rear Lighting 1 E-HD, Trans Hood C

4002-7

21C Bk - 1.0


Color, Size,
and Material
0 BAG
Hood Grounds (NA) Bk 1.0 SXL ENG-H, Engine to Hood 1 GND-ENG4, Rear Lighting 1
N
GND-WIF, Gnd WIF Ring

0 BAR WIF Body Ground Bk 1.0 SXL 1 GND-ENG6, Dedicated 1
Term
GND_ENG2 Dedicated, WIF,
0_BAT Crank request GND BK 1.0 SXL ENG, Engine-CAB1 6 1
EDC
GND_ENG2 Dedicated, WIF,
0_BAU EVGT_2 GND BK 1.0 TXL Turbo, ENG DASH_Turbo 5 1
EDC
0 BB Fan Reverse Solenoid Ground Bk 1.0 SXL YFR, Fan Reverse Sol Opt 2 SPL-FAN, Ultrasonic A
0_BBA Joystick ground BK 0.8 GXL SPL_JSS_1, Ultrasonic A SJS, Joystick_control_SW 4
0_BBB Joystick ground BK 0.8 GXL SJS, Joystick_control_SW 7 SPL_JSS_1, Ultrasonic A
GND_CAB_SPL2, SPL Back

0_BBC Joystick ground BK 0.8 GXL F SPL_JSS_1, Ultrasonic A
lght GD
0_BBD Joystick ground BK 0.8 GXL JSS_Cab, JSS Cab 8 SPL_JSS_1, Ultrasonic A
0_BBE Joystick ground BK 0.8 GXL SJS, Joystick_control_SW 9 SPL_JSS_1, Ultrasonic A
0_BBF DNOX2 Module GND BK 2.0 SXL SPL_DCUG, Ultrasonic A GND, ENG7 GRND, Trans Clnt 1
GND_ENG3, SPLC_PK, WSHR

0_BBR Ground BK 1.0 SXL ENG_B, Cab bottom 2 1
MTR
0_BC EDC7 GND BK 1.0 GXL SPL_EDC1, Ultrasonic A EDC7, Engine controller 11
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 1 19 GND-ENG6, Dedicated 1
0 BH AIC Power Ground Red Bk 0.8 GXL ENG, Engine Cab 1 20 GND-ENG6, Dedicated 1
0 BJ AIC Sensor Ground Bk 0.8 GXL ENG, Engine Cab 1 17 GND-ENG6, Dedicated 1
0 BK Tele Ground Bk1 0 SXL ENG, Engine Cab 1 7 GND, ENG7, Grnd Trans Clnt 1
0 BL Rear Washer Ground Bk 1.0 SXL RWW, Rear Washer 2 SPL_ENG, Ultrasonic A
GND-ENG3, SPLC-PK, Washer

0 BM Engine Splice Grounds Bk 1.0 SXL SPL_ENG, Ultrasonic A 1
Motor
GND-ENG2 Dedicated, WIF,
0 BP WIF Sensor Ground Bk 1.0 GXL 1 WIF, Water In Fuel Sensor 2
EDC
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 1 SPL-J1, Ultrasonic A
4002-8

21C Bk - 1.0


Color, Size,
and Material
0 BS Fan Control Ground Bk 1.0 SXL SPL-FAN, Ultrasonic A SPL_ENG, Ultrasonic A
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 1 SPL-J1, Ultrasonic A
0 BU Fuel Level Sender Ground Bk 1.0 SXL RFLG, Fuel Send Ground 1 GND-ENG7, Grnd Trans Clnt 1
0 BV Grid Heater Control Grnd Bk 0.8 TXL GHC, Grid Heater Relay 2 EDC7, Engine Controller 75
GND-ENG1, Start, FFH,

0 BW Water Separator Htr Ground Bk 2.0 SXL 1 WSH, Water Separator Heater A
WSH
GND_ENG1, STRT, FFH,
0 BX Fuel Filter Heater Ground Bk 2.0 SXL FFH, Fuel Filter Heater B 1
WAT_SEP_HTR
0 BY Air Filter Restriction Sw Grd Y 1.0 GXL SPL_ENG, Ultrasonic A PAF, Air Filter Restriction Sw 2
0 BZ Fuel level sender GND Bk 1.0 SXL RFL_23, Fuel_level_send B GND_ENG7, Grnd Trans Clnt 1
0 CA Sec. Steering Signal Ground Bk 1.0 SXL SSM, Sec. Steering Mod 11 SPL_SEC, Ultrasonic A
0 CB Sec. Steering Signal Ground Bk 1.0 SXL SSM, Sec. Steering Mod 12 SPL_SEC, Ultrasonic A
PSS, Sec. Steer Press

0 CC Sec. Steering Press Sw Ground Bk 1.0 SXL B SPL_SEC, Ultrasonic A
Switch
GND_SSMOD, SEC STR Chasis
0 CD Sec. Steering Splice Ground Bk 1.0 SXL SPL_SEC, Ultrasonic A 1
GND
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, Ultrasonic A
0_CG SEC STR Flyback GND BK 1.0 SXL 245F, SEC_STR_Flyback 1 SSD, SEC_STR_Diode B
0_CH SEC STR Flyback GND BK 1.0 SXL 245F, SEC_STR_Flyback 1 SSD, SEC_STR_Diode A
0 DA AIC Chassis Ground Bk 0.8 TXL GND-PDST1, Ground A 1 AIC-2, Advanced Inst Cluster 2 22
SPL-BCK-LT-GD, Splice Back

0 DAP Back Light Ground S 0.8 GXL STE, Trans Enable Switch 7 K
Light Ground
0 DAV TECM Diagnostic Ground Bk 0.8 GXL 108F, Diagnostic connector 3 GND-CAB3D, Ground A 1
0 DB AIC Power Ground Red Bk 0.8 TXL CAB-E, Cab Engine 20 AIC-2, And Instr Cluster 2 15
0 DD Work Lights GRND BK 2.0 GXL SPL_WL1, Ultrasonic A GND, Cab 1, Ground A 1
GND-CAB-SPL2, Spl Back

0 DE Neutral Start Relay Control Grd Bk 0.8 GXL G ECB, Elect Center B B4
Light Ground
Crank Request Relay Control
0 DF Bk 0.8 GXL Cab_E, Cab-Engine 6 ECB, Elect Center B B6
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

4002-9

21C Bk - 1.0


Color, Size,
and Material
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 1.0 GXL GND-CAB-SPL, Cab Grd Spl J SC, Seat Comp Motor B
0 DM Speed Sensor Grounds Bk 0.8 TXL CAB-T, Cab Transmission 11 TECM, Trans 3
0 DN Output Speed Sensor Ground Bk 0.8 TXL CAB-T, Cab Transmission 28 TECM, Trans 4
0 DP DIAG TECM Ground Bk 0.8 TXL GND-CAB3D, Ground A 1 TECM, Trans 1
0 DQ DIAG TECM Ground Bk 0.8 TXL GND-CAB3D, Ground A 1 TECM, Trans 2
0 DR Roof Splice Grounds Bk 1.0 GXL CAB-RF, Cab to Roof Conn. F GND-CAB1, Ground A 1
0 DS Roof Splice Grounds Bk 1.0 GXL CAB-RF, Cab to Roof Conn. G GND-CAB1, Ground A 1
0 DT Front Wiper/Washer Sw Grd Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl G SFWW, Front Wiper/Washer 2
0 DU Pilot Pressure Sol Grd Bk 0.8 GXL GND-CAB-SPL, Cab Grd Spl L YPP, Pilot Press Sol B
0 DV Cigar Lighter Ground Bk 3.0 SXL CL, Cigar Lighter 2 GND-CAB3, Ground C 1
0 DW AIC Power Ground Bk 0.8 TXL CAB-E, Cab Engine 19 AIC-1, Adv Instr Cluster 1 12
0 DX AIC Sensor Ground Bk 0.8 TXL CAB-E, Cab Engine 17 AIC-1, Adv Instr Cluster 1 6
0 DY Roof Splice GNDS BK 1.0 GXL SPL_WL1, Ultrasonic A Cab_RF, Cab to Roof Connection B
0_DZ Work Lights GRND BK 2.0 GXL Cab_RF, Cab to Roof Conn. A SPL_WL1, Ultrasonic A
0 EA PWR Relay GND BK0_8-GXL ECB, Elect CNTR B C2 SPL_SD3, Ultrasonic A
0 EB Ignition Relay Control Ground Bk 0.8 GXL SPL_SD3, Ultrasonic A PRM-C1, PRM Signal B
0 EC ACC Relay Control Ground Bk 0.8 GXL SPL_SD3, Ultrasonic A PRM-B1, PRM Signal B
0 ED HVAC Grounds Bk 3.0 SXL HVAC2, HVAC2 2 GND-CAB4, Ground C 1
GND-CAB-SPL, Cab Grnd

0 EE DIODE Suppression Grounds Bk 0.8 GXL A 140M, DIODE Module C
Spl
GND-CAB-SPL2, Spl Back
0 EF Brake Lights Relay Ctrl Grnd Bk 0.8 GXL M ECD, ELEC CNTR D A1
Light Ground
GND-CAB-SPL2, Spl Back Light
0 EG Flasher Module Ground Bk 0.8 GXL FLSHR, Flasher Module 4 L
Ground
GND-CAB-SPL2, Spl Back Light
0 EH Flasher Module Ground Bk 0.8 GXL FLSHR, Flasher Module 3 K
Ground
CNV, 24V to 12V Pwr
0 EJ Power Converter Ground Bk 1.0 GXL 3 GND-CAB4, Ground C 1
Convert
0 EK AUX Power Outlet 1 Grnd Bk 1.0 GXL PO1, Power Outlet C GND-CAB5, Ground C 1
0 EL AUX Power Outlet 2 Grnd Bk 1.0 GXL PO2, Power Outlet C GND-CAB5, Ground C 1
0 EM Radio Ground Bk 0.8 GXL CAB-RF, Cab to Roof Conn. M GND-CAB-SPL, Cab Grnd Spl B

4002-10

21C Bk - 1.0


Color, Size,
and Material
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
0 ES 1 GND-GH1, STRT, FFH, Water 1

Grid Heater Ground Bk 19.0 SXL GH-1, Grid Heater
Sep Htr
0 ET Power Relat GND BK 0.8 GXL ECB, ELECT CNTR B D2 SPL_SD1, Ultrasonic A
0 EU PWR Converter RLY CTRL GND BK 0.8 GXL SPL_SD3. Ultrasonic A PRM_A2, PRM Signal B
0 EV IGN Latch GND BK 0.8 GXL ECB, ELECT CNTR B B2 SPL_SD1, Ultrasonic A
GND_Cab_SPL2, SPL Back
0 EW Power Relay GND BK 0.8 GXL E ECB, ELECT CNTR B B1
Light GD
0 EY Power Relay GND BK 0.8 GXL SPL_SD1, Ultrasonic A ECD, ELEC CNTR D A4
0 EZ Power Relay Control W 0.8 GXL ECD, ELEC CNTR D A3 AIC_1, ADV Instr Cluster 1 22
GND CB Ground, on Cooling

0G BK2 0 SXL 1 GND GL, Ground, Rear Grill 1
Box
GND-ENG1, STRT, FFH, Water
0 GB Starter Relay Control Ground Bk 1.0 SXL SRC-1, Relay 2 1
Sep Htr
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
Bk 0.8 GXL
0 HG Inter Speed Sensor Grnd ISS, Inter Speed Sensor 2 SPL-H2, Ultrasonic A
Twist
Bk 0.8 GXL
0 HH Turbine Speed Sensor Grnd TSS, Turbine Speed Sensor 2 SPL-H2, Ultrasonic A
Twist
0 HL Redundant Brake Switch Grnd Bk 1.0 SXL PRB2, Redundant Brake Sw B GND_Trans, Ground_Trans 1
0 HM Redundant Brake Switch Grnd Bk 1.0 SXL PRB1, Redundant Brake Sw B GND_Trans, Ground_Trans 1
0 HR HYD FLTR SW GRND BK 1.0 SXL PHF9, HYD_FLTR_RES_SW 1 GND_Trans, Ground_Trans 1
HOT, Hydraulic Oil Temp

0 HW Hot Ground Bk 1.0 SXL B GND_Trans, Ground_Trans 1
Send
GND_CAB_SPL2, SPL Back
0J Start Lockout RLY GND BK 0.8 GXL ECC, ELECT CNTR C 85 A
LGHT GD
0 JA Hood Grounds (EURO) Bk 1.0 SXL HD-E, Hood Trans C SPL-J1, Ultrasonic A

4002-11

21C Bk - 1.0


Color, Size,
and Material
0 JA N Hood Grounds (NA) Bk 1.0 SXL HD-N, Hood to Engine 1 SPL-J1, Ultrasonic A
0 JB Backup Alarm Grnd Bk 1.0 SXL BU1, Backup Alarm Grnd 1 SPL-J1, Ultrasonic A
0 JC License Plate Light Grnd Bk 1.0 SXL LPL, Lic Plate Light B SPL-J1, Ultrasonic A
GND_Cab_SPL2, SPL Back

0K Camera GND BK 0.8 GXL C MON, Camera/Monitor 2
Light GD
0 KA AA3 GND_Cab_SPL2, SPL Back Light B

IGN PWR Control GND BK0_8-GXL ECD, ELEC CNTR D
GD
0L Telematics GRND BK 1.0 GXL CAB-E, Cab Engine 7 TEL, Telematics H
0 LB DNOX2 Module GND BK 1.0 GXL DNOX2, NOX Controller 14 SPL_DCUG, Ultrasonic A
0 LC DNOX2 Module GND BK 1.0 GXL SPL_DCUG, Ultrasonic A DNOX2, NOX Controller 15
0 LD Heat Load Vlv Sol BK1 0 SXL YLV, Heated Valve Opt. 2 SPL, FAN, Ultrasonic A
0 LE Heat Load Vlv Sol BK1 0 SXL YLV2, Heated Valve Opt. 2 YLV3, Heated Valve OPT 2
0 MA Rear Wiper Motor Grnd Bk 1.0 GXL SPL-ROOF, Spl Rood Grnd C RWMG, Rear Wiper Motor Grnd 1
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 ME LH Rear Work Light Grnd Bk 1.0 GXL LLRW, LH Rear Work Light 2 SPL_WR, Ultrasonic A
0 MF RH Rear Work Light Grnd Bk 1.0 GXL LRRW, RH Rear Work Light 2 SPL_WR, Ultrasonic A
0 MG RH Front Work Light GND Bk 1.0 GXL LRFS, Front_WK_LT_OPT 2 SPL_WRK2, Ultrasonic A
0 MH Rear Work Light GND Bk 1.0 GXL ROOF, Roof to Cab Conn. B SPL_WR, Ultrasonic A
0 MJ RH Front Work Light Grnd Bk 1.0 GXL LRFW, RH Front Work Light 2 SPL_WR, Ultrasonic A
0 MK Roof Grounds Bk 1.0 GXL ROOF, Roof to Cab Conn. G SPL-ROOF, Spl Rood Grnd E
0 ML RH Front Work Light GND Bk 1.0 GXL SPL_WRK2, Ultrasonic A LRFR, Front_WK_LT_OPT 2
0 MN Roof Grounds Bk 1.0 GXL ROOF, Roof to Cab Conn. F SPL-ROOF, Spl Rood Grnd D
0 MP RH Front Work Light GND Bk 1.0 GXL SPL_WRK2, Ultrasonic A LRFO, Front_WK_LT_OPT 2
0 MU LH Front Work Light Grnd Bk 1.0 GXL LLFW, LH Front Work Light 2 SPL_WK, Ultrasonic A
0 MV RH Front Work Light GND Bk 2.0 SXL SPL_WK, Ultrasonic A ROOF, Roof to Cab Connector A
0 NA Hood Grounds (EU) Bk 1.0 SXL HD 9, Hood to ENG 1 SPL, B1 A
0 NB Master Disconnect Grnd Bk 62.0 SGR DC2, Discon Black Grnd 1 B3, Starter Battery 1
0 NC Battery Disconnect Bk 62.0 SGR BT4, Discon Black Grnd 1 STTR GRN, Grid HTR Fuse 1
242F, Chassis Grnd Sec. GND-SSCHAS, SSM Ground

0 ND SSM Ground Bk 62.0 SGR 1 1
Strg Motor Cable
0 NE Hood Grounds (EU) Bk 1.0 SXL SPL, B1 A LLR 9, LH Rear Comb. LT 5

4002-12

21C Bk - 1.0


Color, Size,
and Material
0 NF Hood Grounds (EU) Bk 1.0 SXL SPL, B1 A LRR 9, RH Rear Comb. LT 5
0 NG Hood Grounds (EU) Bk 1.0 SXL SPL, B1 A SPL_J1, Ultrasonic A
0 PA Left Speaker Grnd Bk 0.8 GXL LSPK, Left Speaker B SPK, Speaker 8
0 PB Right Speaker Grnd Bk 0.8 GXL RSPK, Right Speaker B SPK, Speaker 2
0 RD Ride Control GND Bk 1.0 SXL YRC_J, Ride Cntrl_Jumper 2 YRC_J2, Ride_Control_opt 2
JSS_Arm, JSS Armrest to

0 SC GRND, Joystick Bk 0.8 GXL 7 PVRES, JSS Joystick V
Cab
0 SD GRND, Joystick Bk 0.8 GXL SPL_JSS_14, Ultrasonic A Cab_Arm, Cab to Armrest 7
0 SE GRND Bk 0.8 TXL SPL_JSS_10, Ultrasonic A CAN_MOD_2, JSS CAN MOD 10
0 SF GRND Bk 0.8 GXL SPL_JSS_14, Ultrasonic A Cab_FRM, Cab to JSS Frame G
0 SG COMMON Bk 0.8 GXL SPL_JSS_10, Ultrasonic A Arm_pos, Arm position 1
JSS_Arm, JSS Armrest to

0 SH GRND, CAN MOD Bk 0.8 GXL 2 SPL_JSS_10, Ultrasonic A
Cab
0 SJ GRND, CAN MOD Bk 0.8 GXL SPL_JSS_9, Ultrasonic A Cab_Arm, Cab to Armrest 2
Cab_Arm_FRM, Cab to Arm

0 SK GRND, CAN MOD Bk 0.8 GXL 8 SPL_JSS_9, Ultrasonic A
to FRM
0 SL GROUND Bk 0.8 GXL JSS_RLY, Relay K2 87A SPL_JSS_9, Ultrasonic A
0 SM GRND, Joystick Bk 0.8 GXL JSS_CNT, JSS Controller 10 SPL_JSS_20, Ultrasonic A
0 SN GRND, Joystick Bk 0.8 GXL SPL_JSS_20, Ultrasonic A JSS_CNT, JSS Controller 11
0 SP GRND, Joystick Bk 0.8 GXL SPL_JSS_14, Ultrasonic A R1, Resistor CS0
0 SR GRND, Joystick Bk 0.8 GXL SPL_JSS_14, Ultrasonic A JSS_CNT, JSS Controller 15
0 SS GRND, Joystick Bk 0.8 GXL JSS_197F, Main_Cab_FNR 1 FNR_RLY, Relay K2 87A
0 ST GRND, Joystick Bk 0.8 GXL FNR_RLY, Relay K2 85 SPL_JSS_9, Ultrasonic A
0 SU GRND, Joystick Bk 0.8 GXL SPL_JSS_20, Ultrasonic A SPL_JSS_9, Ultrasonic A
0T DEF Sensor GND Bk 0.8 GXL UBJ, DEF Level Temp 2 DNOX2, NOX Controller 19
DTLTS, DEF_Tank Level Temp

0 TA DEF Sensor GND LU 0.8 GXL UBJM, DEF Level Temp 2 2
Sensor
0U EXHT Temp DWN GND BK 0.8 SXL DNOX2, NOX Controller 25 DTS, Downstream Temp Sens 2
GND, CAB SPL, CAB GRND

0 VA Heated Mirrors GND Bk 1.0 SXL MH, Heated Mirrors B H
SPLICE
0 VB Heated Mirrors GND Bk 1.0 GXL SPL1, Ultrasonic A MH C, Heated Mirrors B
0 VC Heated Mirrors GND Bk 1.0 GXL TRLY, Timer Relay 87A SPL1, Ultrasonic A

4002-13

21C Bk - 1.0


Color, Size,
and Material
0 VD Heated Mirrors GND Bk 1.0 GXL SPL1, Ultrasonic A MHS, Trans. Enable SW 9
0 VE Heated Mirrors GND Bk 1.0 GXL SPL1, Ultrasonic A MHS, Trans. Enable SW 7
0 VH Heated Mirrors GND Bk 1.0 GXL SPL1, Ultrasonic A MH L, Mirror HTR 2
0 VJ Heated Mirrors GND Bk 1.0 GXL SPL1, Ultrasonic A MH R, Mirror HTR 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-B1, PRM Signal A
B
12ACC Power Converter PRM Control
W 0.8 GXL SPL-ACC, Ultrasonic A PRM-A2, PRM Signal A
C Power
12V 12V Pwr To Outlet 1 Or 1.0 GXL PO1, Power Outlet A ECB, Elect Center B AA1
12V A 12V Pwr To Outlet 2 Or 1.0 GXL PO2, Power Outlet A ECB, Elect Center B AA2
12V B 12V Fused Pwr to Radio Or 1.0 GXL CAB-RF, Cab to Roof Conn. N ECB Elect Center B AA9
12V C 12V Switched Power Or 2.0 GXL CNV, 24V to 12V Pwr Conver 5 SPL-12V, Ultrasonic A
12V D Plug 1 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECB, Elect Center B A1
12V E Plug 2 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECB, Elect Center B A2
12V F Radio 12V Switched Power Or 1.0 GXL SPL-12V, Ultrasonic A ECB, Elect Center B A9
12V G 2 Way Radio 12V Switched Pwr Or 1.0 GXL SPL-12V, Ultrasonic A ECB, Elect Center B A10
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
13A EVGT Relay OR 0.8 TXL EVGT_4, EVGT D EDC7, ENGINE Controller 51
13B EVGT Relay PWR OR 1.0 GXL Turbo, ENG DASH_Turbo 6 EVGT_4, EVGT A
13C Fuel Shutoff Fused Power Or 1.0 SXL DC3, Fuel Solenoid Disc 1 DISC, Disconnect Engine A
13C A Fuel Shutoff Fused Power Or 1.0 SXL ENG-D, Disc Harness A ENG, Engine Cab 1 21
13C B Fuel Shutoff Fused Power Or 1.0 SXL CAB-E, Cab Engine 21 ECA, Elect Center A A9
13K Ignition Switch Pwr Or 1.0 GXL S-KEY, Ignition Switch 3 SPL_SD2, Ultrasonic A
13K A IGN PWR Control B+ W 0.8 GXL SPL_SD2, Ultrasonic A ECD, Elect Center D AA4
13K B IGN PWR Latch B+ W 0.8 GXL ECB, ELECT CNTR B D1 SPL_SD2, Ultrasonic A
13K C Ignition Switch Pwr Or 1.0 GXL SPL_SD2, Ultrasonic A PRM_C1, PRM Signal A
13M Fuel Shutoff Fused Power Or 1.0 SXL DC4, Fuel Sol Disconnect 1 DISC, Disconnect Engine B

4002-14

21C Bk - 1.0


Color, Size,
and Material
13M A Fuel Shutoff Fused Power Or 0.8 TXL SPL, 13M, Ultrasonic A EDC7, Engine Controller 40
13M B WIF IGN PWR Or 1.0 SXL ENG D, Disc Harness B SPL, 13M, Ultrasonic A
13M C WIF Sensor Fused PWR Or 1.0 GXL SPL, 13M, Ultrasonic A WIF, Water in Fuel Sensor 3
14_5 Alternator D+ LG 1.0 SXL ALT_5, Alternator D+ 3 ENG, Engine-Cab1 26
14 A Alternator D+ LG 0.8 GXL SPL_ALT, Ultrasonic A 215F, Alternator Resistor 1
14 AB Alternator D+ LG 0.8 GXL SPL_ALT, Ultrasonic A Cab_E, Cab-Engine 26
14 AC Altenator Running LG 0.8 GXL SPL_ALT, Ultrasonic A TEL, Telematics D
16R C FNR reverse Signal LU 0.8 GXL JSS_197M, FNR-Main_Cab 4 RVS_Diode, Diode Assy C
17P A Switch Pad Power From AIC Pwr Or 0.8 TXL SW-PD, Switch Pad 9 SPL_SW_PD, Ultrasonic A
17P B SW PAD PWR FR0M AIC PWR OR 0.8 TXL SPL_SW_PD, Ultrasonic A AIC_1, ADV INSTR Cluster 1 25
17P C B+, CAN Module OR 0.8 GXL SPL_SW_PD, Ultrasonic A JSS_Cab, JSS Cab 2
17P D B+, CAN Module OR 0.8 GXL SPL_JSS_18, Ultrasonic A Cab_Arm, Cab to Armrest 4
17P E B+, CAN Module BK 0.8 TXL JSS_Arm, JSS Armrest to Cab 4 CAN_MOD_2, JSS CAN MOD 9
17P F B+, JSS Controller OR 0.8 GXL SPL_JSS_18, Ultrasonic A JSS_CNT, JSS Controller 3
17P G B+, Joystick OR 0.8 GXL SPL_JSS_18, Ultrasonic A Cab_Arm_FRM, Cab to Arm to FRM 2
18B LH High Beam Fused Power OR 2.0 SXL FRONT, Cab Front Chassis 6 LLF, Lights LH 3
18B A LH High Beam Fused Power OR 2.0 GXL CAB-F, Cab Front Chassis 6 ECB, Elect Center B AA3
18C RH High Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 16 LRF, Lights RH 3
18C A RH High Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 16 ECB, Elect Center B AA4
18D LH Low Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 14 LLF, Lights LH 2
18D A LH Low Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 14 ECB, Elect Center B AA6
18E RH Low Beam Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 15 LRF, Lights RH 2
18E A RH Low Beam Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 15 ECB, Elect Center B AA5
18F LH Position/Tail Fused Power Or 1.0 SXL FRONT, Cab Front Chassis 10 LLF, Lights LH 4
CABE2, CAB TO ENG2

18F A LH Position/Tail Fused Power Or 0.8 GXL M SPL-POS-L, Ultrasonic A
BULKHD
18F
LH Position/Tail Fused Power Or 1.0 SXL ENG2, ENG BULKHD 2 M ENG-H, Engine to Hood 6
AN
18F B LH Position/Tail Fused Power Or 1.0 SXL ENG2, ENG BULKHD 2 M 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 3
BN Light
18F C LH Position/Tail Fused Power Or 1.0 GXL SPL-POS-L, Ultrasonic A ECB, Electric Center B AA7

4002-15

21C Bk - 1.0


Color, Size,
and Material
18F E LH Position/Tail Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 10 SPL-POS-L, Ultrasonic A
18F F LH Position/Tail Fused Power Or 1.0 SXL HD 9, Hood to ENG 6 LLR 9, LH Rear Comb. LT 3
18G RH Position/Tail Fused Power Or 1.0 GXL SPL-POS-R, Ultrasonic A 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 3
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
CABE2, CAB TO ENG2

18G F RH Position/Tail Fused Power Or 0.8 GXL N SPL-POS-R, Ultrasonic A
BULKHD
18G G RH Position/Tail Fused Power Or 0.8 GXL CAB-F, Cab Front Chassis 5 SPL-POS-R, Ultrasonic A
18G H RH Position/Tail Fused Power Or 1.0 SXL ENG2, ENG BULKHD 2 N SPL-POS, Ultrasonic A
18G
RH Position/Tail Fused Power Or 1.0 SXL ENG2, ENG BULKHD 2 N 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-9, Hood to Engine 5 SPL-P9 A
18G L LIC Plate LT Fused Power Or 1.0 SXL SPL-P9 A LPL, LIC Plate Light A
18G M RH Position/Tail Fused Power Or 1.0 SXL SPL-P9 A LRR-9, RH Rear Comb. LT 3
18J B EDC7 Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 3
18J C EDC7 Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 2
18J D EDC7 Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 8
18J E EDC7 Fused Power Or 1.0 GXL SPL-EDC2, Ultrasonic A EDC7, Engine Controller 9
18J F EDC7 Fused Power OR 3.0 GXL PRM_D1, PRM OUTPUT A SPL-EDC2, Ultrasonic A
18K A Diagnostic Fused PWR OR 0.8 GXL SPL_PK1, Splice 3-4Way K ECC, Elect Cntr C A9
18K B Diagnostic Fused B+ OR 0.8 GXL SPL_PK1, Splice 3-4Way L DIA_2, Diagnostic B
18K D Diagnostic Fused B+ OR 0.8 GXL SPL_PK1, Splice 3-4Way J DIA, Diagnostic B
18N Blower Motor Fused Power Or 3.0 GXL SPL-BLWR, Ultrasonic A ECA, Elect Center A C1
18N A Blower Motor Fused Power Or 0.8 GXL SPL-BLWR, Ultrasonic A HVAC1, HVAC1 2

4002-16

21C Bk - 1.0


Color, Size,
and Material
18N B Blower Motor Fused Power Or 3.0 GXL SPL-BLWR, Ultrasonic A HVAC2, HVAC2 1
18S A B+, JSS Fused OR 0.8 GXL SPL_JSS_3, Ultrasonic A ECA, ELECT CNTR A A2
18S B B+, JSS Fused OR 0.8 GXL SPL_JSS_3, Ultrasonic A SJS, Joystick_Control_SW 2
18S C B+, JSS Fused OR 0.8 GXL JSS_Cab, JSS Cab 11 SPL_JSS_3, Ultrasonic A
Cab_Arm_FRM, Cab to Arm to

18S D B+, JSS Fused OR 0.8 GXL Cab_FRM, Cab to JSS Frame J 11
FRM
JSS_PIL_PR, JSS Pilot
18S E B+, JSS Fused OR 1.0 SXL A JSS_FRM, JSS Frame to Cab J
Pressure
18T DNOX SW B+ OR 0.8 GXL ECA, ELECT CNTR A A10 Cabe2, Cab to ENG2 BULKHD H
18T A DNOX2 SW B+ OR 1.0 SXL ENG2, ENG BULKHD 2 H DNOX2, NOX Controller 24
18U A DCU B+ N0N Disconnectd OR 5.0 GXL PRM A1, PERM Output A SPL TEL, Ultrasonic A
18U B DCU B+ N0N Disconnectd OR 3.0 GXL ENG2, ENG BULKHD 2 E DNOX2, NOX Controller 4
Cabe2, Cab to ENG2

18U C DCU B+ N0N Disconnectd OR 3.0 GXL B SPL TEL, Ultrasonic A
BULKHD
18U D DCU B+ N0N Disconnectd OR 3.0 GXL DNOX2, NOX Controller 3 ENG2, ENG BULKHD 2 B
18U E DCU B+ N0N Disconnectd OR 3.0 GXL CABE2, CAB to ENG2 Bulkhd E SPL TEL, Ultrasonic A
18U F Telematics FSD ND PWR OR 0.8 GXL SPL TEL, Ultrasonic A TEL, Telematics A
18V Heated Mirror PWR OR 1.0 GXL MH, Heated Mirror A ECA, ELECT CNTR A C5
18V A Heated Mirror PWR OR 1.0 GXL SPL2, Ultrasonic A MH-C, Heated Mirror A
18V B Heated Mirror PWR OR 1.0 GXL TRLY, Timer Relay 30 SPL2, Ultrasonic A
18V C Heated Mirror PWR OR 1.0 GXL MHS, Trans Enable SW 2 SPL2, Ultrasonic A
19A Output Speed Sensor Fused Pwr Or 1.0 SXL TRANS, Cab Transmission 29 OSS, Out Speed Sensor 3
19A A Brake Declutch Sw Fused Pwr Or 1.0 SXL Trans, Transmission-Cab 24 PBD, Dec. Pressure Switch A
19A B FNR Switched Fused Power Or 0.8 GXL 197M, FNR Main Cab 1 SPL-FNR, Ultrasonic A
19A C FNR Switched Fused Power Or 0.8 GXL 197F, Main Cab FNR 1 SPL-TRNS-PWR, Trans Pwr F
19A D Trans Enable Switch Fused Pwr Or 0.8 GXL STE, Trans Enable Switch 2 SPL-D15, Ultrasonic A
19A E AIC Fused PWR Or 0.8 GXL STE, Trans Enable Switch 10 SPL-D15, Ultrasonic A
19A F Trans Enable Switch Fused Pwr Or 0.8 GXL SPL-TRNS-PWR, Trans Pwr B SPL-D15, Ultrasonic A
19A G FNR Sw Fused Power Or 0.8 GXL SPL-FNR, Ultrasonic A SFNR, FNR Switch 8
19A H Trans Shifter Fused Power Or 0.8 GXL TS1, Transmission Shifter A SPL-TRNS-PWR, Trans Pwr M
SPL-TRANS-PWR, Trans
19A K TECM Fused Power Or 0.8 TXL J TECM, Trans 45
Pwr

4002-17

21C Bk - 1.0


Color, Size,
and Material
19A L Park Brake Switched Fused Pwr Or 0.8 GXL SPB, Parking Brake Switch 2 SPL-PBS, Ultrasonic A
19A M Output Speed Sensor Fused Pwr Or 0.8 TXL CAB-T, Cab Transmission 29 SPL-TRNS-PWR, Trans Power K
SPL-TRANS-PWR, Trans
19A N Trans Fused Power Or 1.0 GXL A ECA, Elect Center A A1
Pwr
19A P Backup Alarm Relay OR1_0-GXL ECD, ELEC CNTR D AA10 SPL_TRNS_PWR, TRANS_PWR G
19A Q Trans/Auto Switch Fused Power Or 0.8 GXL STA, Trans Auto Switch 2 SPL-TRANS-PWR, Trans Pwr C
19A R Declutch Switch Fused Power Or 0.8 GXL SDC, Declutch Switch 2 SPL-TRANS-PWR, Trans Pwr H
19A T Brake Declutch Switch Fused Or 0.8 GXL CAB-T, Cab Transmission 24 SPL-TRANS-PWR, Trans Pwr D
Power
19A U Trans Dick Down Switch Fused Or 0.8 GXL SPL-FNR, Ultrasonic A 20M, Trans Kick Down 1
Power
19A V FNR Switch Fused Power Or 0.8 GXL SFNR, FNR Switch 5 SPL-FNR, Ultrasonic A
19A W Diagnostic Conn. Fused Power Or 0.8 GXL 108F, Diagnostic Connector 1 SPL-TRANS-PWR, Trans Pwr E
19B Turn Signal Fused Power Or 0.8 GXL SRHSTLK, RH Stalk Switch 49a ECA, Elect Center A A8
19B A FNR Switch Fused Power W 0.8 GXL FNR_RLY, Relay K2 30 JSS_197M, FNR-Main Cab 1
19B B FNR Switch Fused Power OR 0.8 GXL Cab FNR, Main Cab FNR 1 FNR_RLY, Relay K2 87
19B C FNR Switch Fused Power OR 0.8 GXL Arm FNR, FNR-Main Cab 1 SPL_AJ, Ultrasonic A
19B D FNR Switch Fused Power OR 0.8 GXL 21M, Trans_Kick-Down 1 SPL_AJ, Ultrasonic A
19B E FNR Switch Fused Power OR 0.8 GXL SAJ, FNR Switch 5 SPL_AJ, Ultrasonic A
19B F FNR Switch Fused Power OR 0.8 GXL SAJ, FNR Switch 8 SPL_AJ, Ultrasonic A
19C A Pilot Ctrl Rly Fused Pwr Or 1.0 GXL SPL-D24, Ultrasonic A ECA, Elect Center A A5
19C B Pilot Ctrl Rly Fused Pwr Or 1.0 GXL SPL-D24, Ultrasonic A ECD, Elect Center D B5
19C C Pilot Ctrl Rly Fused Pwr Or 0.8 GXL SPL-D24, Ultrasonic A ECD, Elect Center D D5
19C D Ride Control SW Fused Pwr Or 1.0 GXL SRC, Ride Control Switch 2 SPL-D24, Ultrasonic A
19C E Pilot Control SW Fused Pwr OR 0.8 GXL TEL, Telematics C SPL_D24, Ultrasonic A
19C F Pilot Control SW Fused Pwr OR 0.8 GXL SPC, Pilot Control Switch 2 SPL_D24, Ultrasonic A
19D A Parking Brake Relay Fused Pwr Or 1.0 GXL SPL-PBS, Ultrasonic A ECA, Elect Center A A6
19D B Parking Brake Relay Fused Pwr Or 0.8 GXL SPL-PBS, Ultrasonic A ECB, Elect Center B D9
19D C Parking Brake Relay Fused Pwr Or 1.0 GXL SPL-PBS, Ultrasonic A ECB, Elect Center B B9
19E A AIC Wake Up Ignition Or 0.8 TXL SPL_AP, Ultrasonic A ECA, Elect Center A A3
19H Backup Alarm B+ OR 1.0 GXL ECD, ELEC CNTR D A10 ECA, Elect Center A C4
19J Front Wiper Fused Pwr Or 0.8 GXL SPL-FW, Ultrasonic A ECA, Elect Center A C2

4002-18

21C Bk - 1.0


Color, Size,
and Material
19J A Front Wiper Motor Fused Pwr Or 0.8 GXL SPL-FW, Ultrasonic A 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 K SPL-FW, Ultrasonic A
19J D Front Wiper Relay Fused Power Or 0.8 GXL SPL-PK3, Splice 3-4 Way L ECD, Elect Center D D1
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-PK3, Splice 3-4 Way M ECD, Elect Center D D3
Fused Power
19J G Wiper Cutout Relay Fused Pwr Or 0.8 GXL SPL-FW, Ultrasonic A K-WCO, Wiper Cutout 86
19K Rear Wiper Fused Pwr Or 1.0 GXL SPL-RWW, Ultrasonic A ECA, Elect Center A C3
19K A Rear Wiper Sw Fused Pwr Or 1.0 GXL SRWP, Rear Wiper Sw 3 SPL-RWW, Ultrasonic A
19K B Rear Wip Wash Fused Pwr Or 0.8 GXL SRWP, Rear Wiper Sw 5 SPL-RWW, Ultrasonic A
CAB-RF, Cab to Roof

19K C Rear Wiper Motor Fused Pwr Or 1.0 GXL J SPL-RWW, Ultrasonic A
Connect
19K D Rear Wiper Motor Fused Pwr Or 1.0 SXL ROOF, Roof to Cab Connect J RWM, rear Wiper Motor C
19L Pwr Converter Fused Power Or 3.0 GXL PRM-A1, 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
19L B Pwr Converter Fused Power Or 2.0 GXL CNV, 24V to 12V Pwr Conver 2 SPL-CNV, Ultrasonic A
Sec. Steering Accessory Fused

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

4002-19

21C Bk - 1.0


Color, Size,
and Material
19R C Sec. Steering Ign Fused Pwr Or 1.0 SXL SSM, Sec. Steering Module 1 SS-TR, Sec. Steering Mod Trans B
19R D Alternator Resistor Fused Pwr Or 0.8 GXL SPL-2, Ultrasonic A 216F, Alternator Resistor 1
19R E Sec. Steering Ign Fused Pwr Or 0.8 GXL SPL-2, Ultrasonic A CAB-T, Cab Transmission 4
19S1 Sec. Steering Pwr Or 3.0 GXL PRMB L2, B+ Power 1 SPL, 19S, Ultrasonic A
19S2 Sec. Steering Fused Pwr Or 1.0 GXL SPL, 19S, Ultrasonic A 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-DLY3, Ultrasonic A ECC, Elect Center C A8
19S C AIC Delay Fused Power Or 0.8 TXL SPL-DLY3, Ultrasonic A AIC-2, Advanced Instr Cluster 2 20
19S D AIC Delay Fused Power Or 0.8 TXL SPL-DLY3, Ultrasonic A AIC-2, Advanced Instr Cluster 2 14
19S E AIC Batt B+ OR 0.8 GXL SPL_AP, Ultrasonic A AIC_1, Advanced Instr Cluster 1 1
19S F AIC Batt B+ OR 0.8 GXL SPL_AP, Ultrasonic A AIC-2, Advanced Instr Cluster 2 21
19T A Fused Batt. Power Or 0.8 TXL TECM, Trans 23 SPL_D17, Ultrasonic A
19T B Fused Batt. Power OR 0.8 TXL TECM, Trans 68 SPL_D17, Ultrasonic A
19T C Fused Batt. Power OR 0.8 TXL SPL_D17, Ultrasonic A ECC, Elect Center C A10
19U Horn Relay Fused Power Or 0.8 GXL SPL-HRN, Ultrasonic A ECC, Elect Center C A6
19U A Horn Relay Fused Power Or 0.8 GXL SPL-HRN, Ultrasonic A ECC, Elect Center C B7
19U B Beacon Dome Lt Fused Pwr Or 1.0 GXL SPL-LT, Ultrasonic A ECC, Elect Center C A1
ROOF, Roof to Cab

19U C Dome Lt Fused Pwr Or 0.8 GXL D LDM1, Dome Light B+ 1
Connection
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, Elect Cntr C D7
ROOF, Roof to Cab

19U F Door Sw Fused Power Or 0.8 GXL P DS, Door Switch A
Connection
CAB-RF, Cab to Roof
19U G Door Sw Fused Power Or 0.8 GXL P SPL-LT, Ultrasonic A
Connection
19U H Beacon Switch Fused Power Or 1.0 GXL SBE, Beacon Switch 2 SPL-LT, Ultrasonic A
19W Cigar Lighter Fused Power Or 3.0 GXL CL, Cigar Lighter 1 ECA, Elect Cntr A C8
19Y Hood control Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Elect Cntr C A7
19Y A Hood Up Relay Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Elect Cntr C D2

4002-20

21C Bk - 1.0


Color, Size,
and Material
19Y B Hood Down Relay Fused Power Or 1.0 GXL SPL-HOOD, Ultrasonic A ECC, Elect Cntr C D4
19Y C Hood Switch Fused Power Or 1.0 GXL Cabe2, Cab to ENG2 BULKHD T SPL-HOOD, Ultrasonic A
19Y D Hood Switch Fused Power Or 1.0 GXL ENG2, ENG BULKHD 2 T HD, Hood Switch B
19Z Driving Lights Sw Fused Power Or 1.0 GXL SPL_DR, Ultrasoic A ECC, Elect Cntr C A3
19Z A Driving Lights Sw Fused Power Or 1.0 GXL SDR, Driving Lights Sw 2 SPL_DR, Ultrasoic A
19Z B Driving Lights Sw Fused Power Or 1.0 GXL SDR, Driving Lights Sw 5 SPL_DR, Ultrasoic A
19Z C High Beam Flash Fused Power Or 1.0 GXL SRHSTLK, RH Stalk Switch 56d SPL_DR, Ultrasoic A
1CB Cab CB Protected Power R 19.0 SXL P C3, B+ PWR FRM PRMD 1 CBPW, Cab Power 1
1CB A Cab CB Protected Power R 19.0 SXL P-A3, B+ Power 1 CAB-PW, Cab Power 1
1DM Time Delay/Ign Sw Fused Pwr R 1.0 GXL S_KEY, Ignition Switch 1 ECC, Elect Cntr C A5
1 AA Brake Lt Sw Pwr R 1.0 SXL BTM_C, Cab Bottom BULKHD K PBL, Brake Light Press Switch 1
1B EVGT Relay Power R 1.0 GXL EVGT 3, EVGT Fuse B EVGT 4, EVGT A
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 BE Grid Htr Pwr R 19.0 SXL 115 Grid Htr Pwr 1 GH, Grid Htr 1
1 BF Alternator B+ R 13.0 SXL AB 5, Alternator B+ 1 B6, Starter Power 1
1 BG B+ PWR PRMC R19_0-SXL B5, Starter Pwr Stud 1 P C1, B+ Pwr frm prmd 1
1C ECC Bat Power R 8.0 GXL P-A1, B+ Power 1 L1-ECC, ECC Battery Power 1
1 DR Brake Light Switch Power R 1.0 GXL Cab B, Cab BTM Bulkhead K SPL-FLSHR-PWR, Ultrasonic A
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, Elect Cntr C A4
Ultrasonic
SPL-FLSHR-PWR,
1 DW Brake Lt Relay Bat Pwr R 1.0 GXL A ECD, Elect Cntr D A2
Ultrasonic
1E Grid heater Fuse Bat Power R 19.0 SXL P-C2, B+ Power from PRMD 1 GHF1, Grid Heater Fuse 1
1 GA Filter Htr Pwr R 3.0 SXL PRM-D1, PRM Output C SPL-HTR, Ultrasonic A
1 GB Fuel Filter Htr Pwr R 2.0 SXL SPL-HTR, Ultrasonic A FFH, Fuel Filter Heater A
1 GC Water Sep Htr Pwr R 2.0 SXL SPL-HTR, Ultrasonic A WSH, Water Separator Heater B
1 KA Hazard Switch Pwr R 1.0 GXL SHZ, Hazard Switch 2 SPL-FLSHR-PWR, Ultrasonic A
1 NA Battery Crossover R 62.0 SGR BT3, Starter Battery 1 BT2, Disconnect Battery 1
1 NB Battery Starter R 62.0 SGR BT1, Battery Starter 1 DC1, Disconnect Battery 1

4002-21

21C Bk - 1.0


Color, Size,
and Material
1 NC B+ Power PRMC R 19.0 SXL B1, Starter Power Stud 1 P-C1, B+ Power From PRMD 1
1 ND SSM Power R 62.0 SGR 244F Starter Sec. Strg Mtr 1 B4, Starter Power 1
1 NE Battery Starter R 62.0 SGR B7, Starter Battery 1 BT1, Battery Starter 1
1 NF SSM Pwr R 62.0 SGR B8, Starter Power 1 244F, Starter-Sec Strg Mtr 1
1 NG Power Non Disconnected R 8.0 SXL BT1, Battery Starter 1 PW-B, Cab Power 1
1 NH Power Non Disconnected R 8.0 SXL SPL 1N, Ultrasonic A PW-E, Cab Power 1
1 NJ Power Non Disconnected R 3.0 SXL ENG2, ENG BULKHD 2 G SPL 1N, Ultrasonic A
1 NK Power Non Disconnected R 3.0 SXL ENG2, ENG BULKHD 2 D SPL 1N, Ultrasonic A
CABE2, Cab to ENG2

1 NL Power Non Disconnected R 3.0 GXL G P A2, B+ Power 1
BULKHD
CABE2, Cab to ENG2
1 NM Power Non Disconnected R 3.0 GXL D P A2, B+ Power 1
BULKHD
1T EVGT 3 Pwr R 1.0 SXL P C6, B+ Pwr Frm prmd 1 EVGT 3, EVGT Fuse A
1Y Grid Heater Fused Power R 19.0 SXL GHF3, Grid heater Fuse 1 GHF4, Grid Heater 1
1Z Starter Relay Battery Power R 8.0 SXL P-C4, B+, Power From PRMD 1 195, Starter Relay Power 1
20G A EDC7 ISO-K Interface W 0.8 TXL ENG, Engine Cab 1 31 EDC7, Engine Controller 89
20G B EDC7 ISO-K Interface W 0.8 GXL CAB-E, Cab Engine 31 DIA, Diagnostic E
21C Neutral Start Relay Output W 0.8 GXL SPL-CR, Ultrasonic A ECB, Elect Center B D4
21C A Neutral Start Relay Output W 0.8 GXL SPL-CR, Ultrasonic A ECB, Elect Center B D5
21C B Neutral Start Relay Output W 0.8 GXL SPL-CR, Ultrasonic A ECB, Elect Center D A6
21D Starter Relay Signal W 1.0 SXL SRC-1, Relay 1 ENG, Engine Cab 1 15
21D A Starter Relay Signal W 0.8 GXL Cab E, Cab-Engine 15 ECB, Elect Center D AA5
21E Key Switch Crank W 0.8 GXL ECC, Elect Cntr C B9 ECB, Elect Center B D6
21E A Key Switch Crank W 0.8 TXL ENG, Engine Cab 1 27 EDC7, Engine Controller 32
21E B Key Switch Crank W 0.8 GXL Cab E, Cab-Engine 27 ECC, Elect Cntr C C10
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 1 11 SPL-EDC3, Ultrasonic A
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 ENG_B, Cab Bottom 1 SPL-EDC3, Ultrasonic A
21F D EDC7 Digital Ground W 0.8 TXL RTHP, Throttle Pedal 1 BTM E, Cab Bottom 1
21G EDC7 Crank Control relay W 0.8 GXL CAB-E, Cab Engine 3 ECB, Elect Center D AA6

4002-22

21C Bk - 1.0


Color, Size,
and Material
21G A EDC7 Crank Control relay W 0.8 TXL ENG, Engine Cab 1 3 EDC7, Engine Controller 37
21H Crank control relay LSD W 0.8 GXL CAB-E, Cab Engine 4 ECD, Elect Center D A5
21H A Crank control relay LSD W 0.8 TXL ENG, Engine Cab 1 4 EDC7, Engine Controller 17
21J Restart Prevent W 0.8 GXL ECC, Elect Cntr C D9 TEL, Telematics S
21K Ign Sw Start Signal W 0.8 GXL S-KEY, Ignition Switch 2 SPL-CRK, Ultrasonic A
21K A Ign Sw Start Signal W 0.8 TXL SPL-CRK, Ultrasonic A AIC-2, Adv Instrument Cluster 2 17
21K B Ign Sw Start Signal W 0.8 GXL SPL-CRK, Ultrasonic A ECB, Elect Center B B3
22A Declutch SW DU 0.8 TXL SDC, Declutch Switch 3 TECM, Trans 21
Cab_B, Cab BTM

22B Pedal Sensor +5V K 0.8 TXL B TECM, Trans 37
BULKHEAD
22C Pedal Pos Signal Y 0.8 TXL TECM, Trans 38 Cab B, Cab BTM BULKHEAD C
Cab_B, Cab BTM

22D Pedal Sensor Grnd LU 0.8 TXL A TECM, Trans 24
BULKHEAD
22E Pedal Sensor +5V K 0.8 TXL BTM_C, Cab Bottom BULKHD B BPP, Pedal Position 2
22F Pedal Pos Signal Y 0.8 GXL BTM_C, Cab Bottom BULKHD C BPP, Pedal Position 3
22G Pedal Sensor Grnd LU 0.8 GXL BTM_C, Cab Bottom BULKHD A BPP, Pedal Position 1
23A A DNOX2 Module B+ N 0.8 TXL NOXS, NOX Sensor 1 ENG2, ENG BULKHD 2 C
23B A NOX Sensor B+ OR 0.8 GXL CabE2, Cab to ENG2 BULKHD F ECD, Elec Cntr D A8
23B B NOX Sensor B+ N 0.8 GXL CabE2, Cab to ENG2 BULKHD C ECD, Elec Cntr D AA7
23B C NOX Relay Gnd BK 0.8 GXL ECD, Elec Cntr D A7 GND Cab_SPL, Cab Grnd Splice E
23B D NOX Relay, B+ OR 0.8 GXL CabE2, Cab to ENG2 BULKHD A ECD, Elec cntr D AA8
23B E NOX Sensor B+ OR 1.0 GXL SPL EDC2, Ultrasonic A ENG2, ENG BULKHD 2 F
23B F NOX Relay B+ OR 1.0 SXL SPL EDC4, Ultrasonic A ENG2, ENG BULKHD 2 A
23D D NOX Sensor Gnd BK 0.8 TXL NOXS, NOX Sensor 2 GND ENG2 Dedicated, WIF, EDC 1
23J B DNOX2 K-Line W 0.8 GXL Cab E, Cab-Engine 18 DIA 2, Diagnostic E
23K A Temp/Humd B+ K 0.8 TXL HTS, HMDTY And AMB Temp 1 EDC7, Engine Controller 68
23K B Temp/Humd Temp Y 0.8 GXL HTS, HMDTY And AMB Temp 2 EDC7, Engine Controller 26
23K C Temp/Humd Humd Y 0.8 GXL HTS, HMDTY And AMB Temp 4 EDC7, Engine Controller 27
23K E Temp/Humd Gnd LU 0.8 GXL EDC7, Engine Controller 28 HTS, HMDTY And Amb Temp 3
24B Throttle Signal W 0.8 TXL ENG B, Cab Bottom 3 EDC7, Engine Controller 79
24B A Throttle Signal W 0.8 TXL RTHP, Throttle Pedal 3 BTM E, Cab Bottom 3

4002-23

21C Bk - 1.0


Color, Size,
and Material
24L Low Idle Sw W 0.8 TXL ENG B, Cab Bottom 6 EDC7, Engine Controller 48
24L A Low Idle Switch W 0.8 TXL RTHP, Throttle Pedal 6 BTM_E, Cab Bottom 6
24R Throttle Grnd W 0.8 TXL ENG B, Cab Bottom 4 EDC7, Engine Controller 78
24R A Throttle Grnd W 0.8 TXL RTHP, Throttle Pedal 4 BTM E, Cab Bottom 4
24S Throttle Supply W 0.8 TXL ENG B, Cab Bottom 5 EDC7, Engine Controller 77
24S A Throttle Supply W 0.8 TXL RTHP, Throttle Pedal 5 BTM E, Cab Bottom 5
24T B TC Lockup Sol Gnd LU 1.0 SXL YLS, TC Lockup Valve 2 Trans, Transmission-Cab 25
255E Pedal Sensor +5V K 0.8 TXL BTM-C, Cab Bottom Bulkhd E BPP, Pedal Position 5
LU 0.8 GXL
25A Eng Speed Sig TRANS, Cab Transmission 7 ESS, Engine speed Sensor 1
Twist
25A A Eng Speed Sig LU 0.8 TXL CAB-T, Cab Transmission 7 TECM, Trans 19
LU 0.8 GXL
25B Int Speed Sig TRANS, Cab Transmission 9 ISS, Int Speed Sensor 1
Twist
25B A Int Speed Sig LU 0.8 TXL CAB-T, Cab Transmission 9 TECM, Trans 42
LU 0.8 GXL
25C Turbine Speed Sig TRANS, Cab Transmission 8 TSS, Turbine Speed Sensor 1
Twist
25C A Turbine Speed Sig LU 0.8 TXL CAB-T, Cab Transmission 8 TECM, Trans 41
25D Output Speed Sig LU 1.0 SXL TRANS, Cab Transmission 10 OSS, Output Speed Sensor 2
25D A Output Speed Sig LU 0.8 TXL CAB-T, Cab Transmission 10 TECM, Trans 62
25F Forward Signal LU 0.8 TXL TS1, Transmission Shifter B TECM, Trans 43
25G Brake Declutch Switch Ctrl LU 1.0 SXL Trans, Transmission-Cab 14 PBD, Declutch Pressure Switch B
25G A Brake Declutch Switch Ctrl LU 0.8 GXL Cab T, Cab-Transmission 14 SPL-DC, Ultrasonic A
25G B Brake Declutch Switch Ctrl LU 0.8 GXL SDC, Declutch Switch 1 SPL-DC, Ultrasonic A
25G C Brake Declutch Switch Ctrl LU 0.8 TXL SPL-DC, Ultrasonic A TECM, Trans 66
25H Trans Auto Signal LU 0.8 TXL STA, Trans Auto Switch 3 TECM, Trans 29
25J Trans Sol Valve Y6 LU 0.8 TXL TRANS, Cab Transmission 21 TRC, Trans Control 6
25J A Trans Sol Valve Y6 LU 0.8 TXL CAB-T, Cab Transmission 21 TECM, Trans 51
25K Trans Sol Valve Y1 LU 0.8 TXL TRANS, Cab Transmission 16 TRC, Trans Control 1
25K 9 Trans Sol Valve Y2 LU 0.8 TXL TRANS, Cab Transmission 16 TRC, Trans Control 2
25K A Trans Sol Valve Y1 LU 0.8 TXL CAB-T, Cab Transmission 16 TECM, Trans 56
25L Trans Sol Valve Y2 LU 0.8 TXL TRANS, Cab Transmission 17 TRC, Trans Control 2
25L 9 Trans Sol Valve Y1 LU 0.8 TXL TRANS, Cab Transmission 17 TRC, Trans Control 1

4002-24

21C Bk - 1.0


Color, Size,
and Material
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
25R A TC Lockup Sol Power LU 0.8 TXL TECM, Transmission 50 Cab T, Cab-Transmission 15
25R B TC Lockup Sol Power LU 1.0 SXL YLS, TC Lockup Valve 1 Trans, Transmission-Cab 15
25S Output Sw Power VPS1 LU 0.8 TXL TRANS, Cab Transmission 22 TRC, Transmission Control 7
25S A Output Sw Power VPS1 LU 0.8 TXL CAB-T, Cab Transmission 22 SPL D12, Ultrasonic A
25S B Output Sw Power VPS1 LU 0.8 TXL SPL D12 Ultrasonic A TECM, Trans 12
25S C Output Sw Power VPS1 LU 0.8 TXL SPL D12 Ultrasonic A TECM, Trans 13
25T Neutral Signal LU 0.8 GXL SPL-NEU, Ultrasonic A ECB, Elect Center B D3
25T A TC Lockup Sol Gnd W 0.8 TXL SPL_D19, Ultrasonic A Cab T, Cab-Transmission 25
25T B Neutral Signal LU 0.8 GXL TS1, Transmission Shifter D SPL-NEU, Ultrasonic A
25T C Neutral Signal LU 0.8 TXL SPL-NEU, Ultrasonic A TECM, Trans 67
25W 3rd And 4th Gear Signal LU 0.8 TXL TS2, Transmission Shifter B TECM, Trans 65
25Y Trans Kick Down Signal LU 0.8 GXL TS2, Transmission Shifter D SPL D11, Ultrasonic A
25Y A Trans Kick Down Signal LU 0.8 TXL SPL D11, Ultrasonic A TECM, Trans 22
25Y B Trans Kick Down Signal LU 0.8 GXL 197F, Main Cab FNR 6 SPL D11, Ultrasonic A
25Y C Trans Kick Down Signal LU 0.8 GXL 20M, Trans Kick Down 2 197M, FNR Main Cab 6
25Y D Trans Kick Down Signal LU 0.8 GXL KD_Diode, Diode Assy C JSS 197M, FNR Main Cab 6
25Y E Trans Kick Down Signal LU 0.8 GXL Cab Fnr, Main Cab Fnr 6 KD Diode, Diode Assy B
25Y F Trans Kick Down Signal LU 0.8 GXL KD Diode, Diode Assy A JSS 197F, Main Cab FNR 6
25Y G Trans Kick Down Signal LU 0.8 GXL 21M, Trans Kick-Down 2 Arm FNR, FNR-Main Cab 6
25Z 1st And 4th Gear Signal LU 0.8 TXL TS2, Transmission Shifter C TECM, Trans 63
26E A 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
26F B FNR Forward Signal LU 0.8 TXL 197F, Main Cab FNR 2 TECM, Trans 20

4002-25

21C Bk - 1.0


Color, Size,
and Material
26F C FNR Forward Signal LU 0.8 GXL FWD Diode, Diode Assy C JSS 197M, FNR-Main Cab 2
26F D FNR Forward Signal LU 0.8 GXL JSS 197F, Main Cab FNR 2 FWD Diode, Diode Assy A
26F E FNR Forward Signal LU 0.8 GXL Cab FNR, Main Cab FNR 2 FWD Diode, Diode Assy B
26F F FNR Forward Signal LU 0.8 GXL SAJ, FNR Switch 6 Arm FNR, FNR Main Cab 2
26J FNR Switch Jumper LU 0.8 GXL SFNR, FNR Switch 2 SFNR, FNR Switch 4
26K FNR Switch Jumper LU 0.8 GXL SAJ, FNR Switch 2 SAJ, 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
26N C FNR Neutral Signal LU 0.8 GXL JSS 197M, FNR-Main Cab 3 Ntrl Diode, Diode Assy C
26N D FNR Neutral Signal LU 0.8 GXL JSS 197F, Main Cab FNR 3 Ntrl Diode, Diode Assy A
26N E FNR Neutral Signal LU 0.8 GXL Ntrl Diode, Diode Assy B Cab FNR, Main Cab FNR 3
26N F FNR Neutral Signal LU 0.8 GXL SAJ, FNR Switch 3 Arm FNR, FNR-Main Cab 3
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
26R D FNR Reverse Signal LU 0.8 GXL JSS 197F, Main Cab FNR 4 RVS Diode, Diode Assy A
26R E FNR Reverse Signal LU 0.8 GXL Cab FNR, Main Cab FNR 4 RVS Diode, Diode Assy B
26R F FNR Reverse Signal LU 0.8 GXL SAJ, FNR Switch 1 Arm FNR, FNR-Main Cab 4
28F Fuel Filter Htrs Relay Control W 0.8 TXL PRM-D2,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
31A EVGT Relay B+ OR 0.8 GXL EVGT 4, EVGT E SPL EDC4, Ultrasonic A
31B Filter Heater Control OR 0.8 GXL PRM D2, PRM Signal B SPL EDC4, Ultrasonic A
31F Air Filter Rest Sw Signal Y 1.0 SXL ENG, Engine Cab 1 28 PAF, Air Filter Rest Sw 1
31F A Air Filter Rest Sw Signal Y 0.8 TXL CAB-E, Cab Engine 28 SW-PD, Switch Pad 5
31H Hyd Filter Rest Sw Signal Y 1.0 SXL TRANS, Cab Transmission 23 PHF, Hyd Oil Filter Rest Sw 1
31H9 Hyd Filter Rest Sw 9 Y 1.0 SXL Trans, Transmission Cab 23 PHF9, Hyd Oil Filter Rest Sw 2
31H A Hyd Filter Rest Sw Signal Y 0.8 GXL SW-PD, Switch Pad 4 CAB-T, Cab Transmission 23
31L Pilot Control Switch High Y 0.8 TXL SPC, Pilot Control Switch 3 AIC-2, Advance Instr Cluster 2 18
32F Trans Filter Maint Sw Y 1.0 SXL TRANS, Cab Transmission 31 FM, Filter Maint Sw 1
32F A Trans Filter Maint Sw Y 0.8 TXL CAB-T, Cab Transmission 31 TECM, Trans 17
32J A Trans Enable Indiction Y 0.8 GXL SFNR, FNR Switch 7 197M FNR Main Cab 5
32J C Trans Enable Indiction Y 0.8 GXL STE, Trans Enable Switch 9 SPL-D16, Ultrasonic A

4002-26

21C Bk - 1.0


Color, Size,
and Material
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
32J F Trans Enable Indiction Y 0.8 GXL SPL JSS_21, Ultrasonic A JSS 197M, FNR Main Cab 5
32J G Trans Enable Indiction Y 0.8 GXL JSS 197F, Main Cab FNR 5 SPL JSS_21, Ultrasonic A
32J H Trans Enable Indiction Y 0.8 GXL Cab FNR, Main Cab FNR 5 SPL JSS_21, Ultrasonic A
32J J Trans Enable Indiction Y 0.8 GXL SAJ, FNR Switch 7 Arm FNR, FNR Main Cab 5
33P Brake Warning Press Low Y 1.0 SXL BTM_C, Cab Bottom BULKHD L PBW, Brake Warning Press Sw 1
33P A Brake Warning Press Low Y 0.8 TXL Cab B, Cab BTM BULKHEAD L AIC-2, Advance Instr Cluster 2 5
Redundant Brake Accumulator

33R Y 0.8 TXL CAB-T, Cab Transmission 1 AIC-2, Advance Instr Cluster 2 4
Pressure Low
33R A Redundant Brake Accumulator Y 1.0 SXL TRANS, Cab Transmission 1 SPL-RD, Ultrasonic A
Pressure Low
33R B Redundant Brake Accumulator Y 1.0 SXL SPL-RD, Ultrasonic A PRB2, Redundant Brake Switch A
Pressure Low
33R C Redundant Brake Accumulator Y 1.0 SXL SPL-RD, Ultrasonic A PRB1, Redundant Brake Switch A
Pressure Low
33U Parking Brake Switch Y 0.8 TXL SPB, Parking Brake Switch 3 AIC-2, Advance Instr Cluster 2 6
34A A Diff Lock SW B+ OR 0.8 GXL SDA, Diff Lock Switch 2 SPL PBS, Ultrasonic A
34A B Diff Lock SW SIG B+ OR 0.8 GXL SDM, Diff Lock Switch 2 SPL PBS, Ultrasonic A
34A C Diff Lock Sol B+ W 0.8 TXL SPL D19, Ultrasonic A Cab T, CAB Transmission 2
34A D Diff Lock Sol B+ OR 1.0 SXL Trans, Transmission Cab 27 YDL, Diff Lock Solenoid 1
34A E Diff Lock Sol B+ OR 1.0 SXL YDL 1, Diff Lock Solenoid 1 YDL 2, Diff Lock Solenoid 1
34B Diff Lock SW SIG LU 0.8 TXL SDA, Diff Lock Switch 3 TECM, Trans 35
34C Diff Lock Sol GND LU 0.8 TXL Cab T, Cab Transmission 27 TECM, Trans 11
34C A Diff Lock Sol GND LU 1.0 SXL Trans, Transmission Cab 2 YDL, Diff Lock Solenoid 2
34C D Diff Lock Sol GND LU 1.0 SXL YDL 1, Diff Lock Solenoid 2 YDL 2, Diff Lock Solenoid 2
34D Diff Lock SW SIG LU 0.8 TXL TECM, Trans 59 SDM, Diff Lock Switch 1
35A 9 BKUP ALM RLY OUT BK 1.0 SXL HD-9, Hood to ENG 7 BU2, Backup Alarm 1
35A A Backup Alarm Y 0.8 GXL ECD, Elec Cntr D AA9 SPL 35A, Ultrasonic A
35A B Backup Alarm Disable Switch Y 0.8 GXL SBU, Backup Alarm Dis Sw 2 SPL 35A, Ultrasonic A
35A C Backup Alarm Relay Out Y 0.8 GXL Cabe2, Cab to ENG2 BULKHD L SPL 35A, Ultrasonic A

4002-27

21C Bk - 1.0


Color, Size,
and Material
209M, Backup Alarm Dis
35A D Backup Alarm Relay Out Y 0.8 GXL A SPL 35A, Ultrasonic A
Jump
209F, Backup Alarm Dis
35A E Backup Alarm Relay Out Y 0.8 SXL 1 SPL-D8-C1, Ultrasonic A
Jump
35A F Backup Alarm Relay Out Y 0.8 SXL Cabe2, Cab to ENG2 BULKHD K SPL-D8-C1, Ultrasonic A
35A G Backup Alarm Relay Out Y 1.0 SXL ENG2, ENG BULKHD 2 K E-HD, Trans Hood B
35A
Backup Alarm Relay Out Y 1.0 SXL ENG2, ENG BULKHD 2 K ENG-H, Engine to Hood 7
GN
35A H Backup Alarm Relay Out Y 1.0 SXL HD-E, Hood Trans B BU2, Backup Alarm 1
35A
Backup Alarm Relay Out Y 1.0 SXL HD-N, Hood to Engine 7 BU2, Backup Alarm 1
HN
35A J Revers Light K 1.0 SXL ENG2, ENG BULKHD 2 L 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 Reverse Signal Y 0.8 GXL MON, Camera/Monitor 3 SPL 35A, Ultrasonic A
35A N Revers Light K 1.0 SXL SPL, REV A LLR-9, LH Rear Comb Light 4
35A O Revers Light K 1.0 SXL HD-9, Hood to ENG 8 SPL, REV A
35A P Revers Light K 1.0 SXL SPL, REV A LRR-9, RH Rear Comb Light 4
35A R Backup Alarm Relay Out Y 1.0 SXL ENG2, ENG BULKHD 2 L ENG-H, Engine to Hood 8
35B AIC Buzzer HSD W 0.8 TXL BUZ, AIC Buzzer 1 AIC-1, Advance Instr Cluster 1 13
35C Backup Alarm Relay Control Y 0.8 GXL ECD, Elec Cntr D A9 TECM, Trans 7
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
35X Sec. Str Low Press Sig Y 0.8 TXL CAB-T, Cab Transmission 6 AIC-2, Advance Instr Cluster 2 11
35X A Sec. Str Low Press Sig Y 1.0 SXL SPL-C3, Ultrasonic A PSS, Sec. Steering Press Sw C
35X B Sec. Str Low Press Sig Y 1.0 SXL TRANS, Cab Transmission 6 TR-SS, Sec. Steering Mod Option C
35X C Sec. Str Low Press Sig Y 1.0 SXL SPL-C3, Ultrasonic A SS-TR, SS Module Trans C
35X D Sec. Str Low Press Sig Y 1.0 SXL SSM, Sec. Steering Module 8 SPL-C3, Ultrasonic A
36C Radiator Cool Temp Signal P 1.0 GXL ENG, Engine Cab 1 5 RECT, Engine Coolant Temp A
36C A Radiator Cool Temp Signal P 0.8 TXL CAB-E, Cab Engine 5 AIC-1, Advance Instr Cluster 1 11
36F Fuel Level Analog P 1.0 SXL ENG, Engine Cab 1 1 RFL, Fuel Sender 1
36F A Fuel Level Analog P 0.8 TXL CAB-E, Cab Engine 1 AIC-1, Advance Instr Cluster 1 2

4002-28

21C Bk - 1.0


Color, Size,
and Material
Torque Conv Output Temp
36G P 1.0 SXL TRANS, Cab Transmission 13 TCOT, TCO Sender 1
Signal
36G A Torque Conv Output Temp P 0.8 TXL CAB-T, Cab Transmission 13 TECM, Trans 49
Signal
36H Hydraulic Oil Temp Signal P 1.0 SXL TRANS, Cab Transmission 30 HOT, Hydraulic Oil Temp Sender A
36H A Hydraulic Oil Temp P 0.8 TXL CAB-T, Cab Transmission 30 AIC-1, Advance Instr Cluster 1 9
36J Fuel Level Analog P 1.0 SXL ENG, Engine Cab1 1 RFL 23, Fuel Level Sender A
36R A Trans Temps/Filter Return P 1.0 SXL TRANS, Cab Transmission 12 SPL H1, Ultrasonic A
36R B Trans Filter Maint Sw Return P 1.0 SXL SPL H1, Ultrasonic A FM, Filter Maint Switch 2
36R C Valve Body Temp Return P 0.8 TXL SPL H1, Ultrasonic A TRC, Trans Control 9
36R D TCO Temp Return P 1.0 SXL SPL H1, Ultrasonic A TCOT, TCO Sender 2
36R E Trans Temps/Filter Return P 0.8 TXL CAB-T, Cab Transmission 12 TECM, Trans 46
36T Valve Body Temp Sig P 0.8 TXL TRANS, Cab Transmission 5 TRC, Trans Control 8
36T A Valve Body Temp Sig P 0.8 TXL CAB-T, Cab Transmission 5 TECM, Trans 39
37D A Diagnostic Signal P 0.8 TXL 108F, Diagnostic Connector 2 TECM, Trans 15
37E Diagnostic Signal Switched P 0.8 TXL 108F, Diagnostic Connector 4 TECM, Trans 18
38A Doser Valve GND LU 0.8 GXL DNOX2, NOX Controller 11 DEFDM, Doser Metering Valve 2
38B Def Level Sig Y 0.8 GXL UBJ, Def Level Temp 1 DNOX2, NOX Controller 18
DTLTS, Def Tank Level Temp

38B A Def Level Sig Y 0.8 GXL UBJM, Def Level Temp 1 1
Sensor
38C Tank Heat GND LU 0.8 TXL DNOX2, NOX Controller 23 THV, Tank Heater Control Valve 1
38D Tank Heat B+ OR 0.8 TXL DNOX2, NOX Controller 1 THV, Tank Heater Control Valve 2
38E Exht Temp DWN B+ Y 0.8 GXL DNOX2, NOX Controller 26 DTS, Downstream Temp Sens 1
38F Exht up Signal Y 0.8 GXL UTS, Upstream Temp Sense 1 DNOX2, NOX Controller 28
38G Def Temp Sig Y 0.8 GXL UBJ, Def Level Temp 3 DNOX2, NOX Controller 29
DTLTS, Def Tank Level Temp

38G A Def Temp Sig Y 0.8 GXL UBJM, Def Level Temp 3 3
Sensor
38H DNOX2 K-line W 0.8 TXL DNOX2, NOX Controller 31 ENG, Engine-Cab1 18
401B Pedal Pos Signal Y 0.8 GXL BTM_C, Cab Bottom BULKHD F BPP, Pedal Position 4
41H A High Beam Pwr Or 1.0 GXL SRHSTLK, RH Stalk Switch 56a SPL HB, Ultrasonic A
41H B High Beam LH Pwr Or 0.8 GXL SPL HB, Ultrasonic A ECB, Elect Center B A3
41H C High Beam RH Pwr Or 0.8 GXL SPL HB, Ultrasonic A ECB, Elect Center B A4

4002-29

21C Bk - 1.0


Color, Size,
and Material
41H D High Beam Pwr Or 0.8 TXL SW-PD, Switch Pad 1 SPL HB, Ultrasonic A
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 A
41L B Low Beam RH Power Or 0.8 GXL SPL-LB, Ultrasonic A ECB, Elect Center B A6
41L C Low Beam LH Power Or 0.8 GXL SPL-LB, Ultrasonic A ECB, Elect Center B A5
41T Position Lights Switched Pwr K 1.0 GXL SDR, Driving Lights Switch 3 SPL PR, Ultrasonic A
41T A Position Lights RH Switched Pwr K 1.0 GXL SPL PR, Ultrasonic A ECB, Elect Center B A8
41T B Position Lights LH Switched Pwr K 1.0 GXL SPL PR, Ultrasonic A ECB, Elect Center B A7
41T C Position Lights Switched Pwr K 1.0 GXL D-OR, Diode OR B SPL-PR, Ultrasonic A
42C A Front Work Lights Fused Pwr DU 2.0 GXL CAB-RF, Cab to Roof Conn. H SPL-42C Ultrasonic A
42C C Front Work Lights Fused Pwr DU 2.0 GXL SPL-42C Ultrasonic A SWL, Work lights SW 3
42C D Front Work Lights Fused Pwr DU 1.0 GXL SPL-42C Ultrasonic A D-OR, Diode OR A
42C F Front Work Lights Fused Pwr DU 2.0 GXL ROOF, Roof to Cab Conn. H SPL-WRKF, Ultrasonic A
42C G RH Front Work Lights Fused Pwr DU 1.0 GXL SPL-WRKF, Ultrasonic A LRFW, RH Front Work Light 1
42C H LH Front Work Lights Fused Pwr DU 1.0 GXL SPL-WRKF, Ultrasonic A LLFW, LH Front Work Light 1
42R A RH Front Work LTS Fused Pwr DU 1.0 GXL LRFS, Front Wk LT Opt 1 SPL Wrk1, Ultrasonic A
42R B RH Front Work LTS Fused Pwr DU 1.0 GXL SPL Wrk1, Ultrasonic A LRFR, Front Wk LT Opt 1
42R C Rear Work Lights Fused Pwr DU 2.0 GXL CAB-RF, Cab to Roof Conn. S SWL, Work lights SW 6
42R F Rear Work Lights Fused Pwr DU 2.0 GXL ROOF, Roof to Cab Conn. S SPL-WRKR, Ultrasonic A
42R G RH Rear Work Lt Fused Pwr DU 1.0 GXL SPL-WRKR, Ultrasonic A LRRW, RH Rear Work Light 1
42R H LH Rear Work Lt Fused Pwr DU 1.0 GXL SPL-WRKR, Ultrasonic A LLRW, LH Rear Work Light 1
42R K RH Front Work LTS Fused Pwr DU 1.0 GXL SPL WRK1, Ultrasonic A LRFO, Front Wk LT Opt 1
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 1.0 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 AIC 2, ADV Instr Cluster 2 2
43S B Door Open Signal W 0.8 GXL ROOF, Roof to Cab Conn. R DS, Door Switch B
43 A Dome Light Auto Mode DU 0.8 TXL CAB-RF, Cab to Roof Conn. C AIC-1, Adv Instrument Cluster 1 7
43 B Dome Light Auto Mode DU 0.8 GXL ROOF, Roof to Cab Conn. C LDM2, Dome Light Auto 1
44A A Brake Light Relay Out T 0.8 GXL Cabe2, Cab to ENG2 BULKHD S ECD, Elec Cntr D AA1
44A D Brake Light Relay Out T 1.0 SXL ENG2, ENG BULKHD 2 S SPL-B8, Ultrasonic A

4002-30

21C Bk - 1.0


Color, Size,
and Material
44A
Brake Light Relay Out T 1.0 SXL ENG2, ENG BULKHD 2 S 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, LH Rear Comb Light 2 SPL-J2-N, Ultrasonic A
FN
44A
Brake Light Relay Out T 1.0 SXL LRR, RH Rear Comb Light 2 SPL-J2-N, Ultrasonic A
GN
44A J Brake Light Relay Out T 1.0 SXL HD-9, Hood to Engine 2 SPL, L1 A
44A K Brake Light Relay Out T 1.0 SXL SPL, L1 A LRR-9, RH Rear Comb. LT 1
44A L Brake Light Relay Out T 1.0 SXL SPL, L1 A LRR-9, LH Rear Comb. LT 1
44 A Brake Light Control Power T 0.8 GXL Cab_B, Cab BTM BULKHEAD J ECD, Elec Cntr D AA2
45A A Left Turn Switch Power N 0.8 GXL FLSHR, Flasher Module 9 SRHSTLK, RH Stalk Switch L
45B A Right Turn Switch Power N 0.8 GXL FLSHR, Flasher Module 10 SRHSTLK, RH Stalk Switch R
45H Hazard Switch Power N 0.8 GXL FLSHR, Flasher Module 11 SHZ, Hazard Switch 3
45L Left Turn Signal N 1.0 SXL FRONT, Cab Front Chassis 2 LLF, Lights LH 5
45L A Left Turn Signal N 1.0 SXL ENG2, ENG BULKHD 2 R LLR-E, LH Rear Comb Light 2
45L AN Left Turn Signal N 1.0 SXL ENG2, ENG BULKHD 2 R ENG-H, Engine to Hood 3
45L B Left Turn Signal N 0.8 GXL Cabe2, Cab to ENG2 BULKHD R SPL-PK3, Splice 3-4 Way D
45L BN Left Turn Signal N 1.0 SXL HD-N, Hood to Engine 3 LLR, LH Rear Comb Light 4
45L C Left Turn Signal N 0.8 GXL CAB-F, Cab Front Chassis 2 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
45L N Left Turn Signal N 1.0 SXL HD-9, Hood to Engine 3 LLR-9, LH Rear Comb. LT 2
45N A Flasher OPP Side Control N 0.8 GXL FLSHR, Flasher Module 2 64F, Flasher Connector 1
45N B Flasher OPP Side Control N 0.8 GXL FLSHR, Flasher Module 12 64M, Flasher Connector A
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. LT 2
45R A Right Turn Signal N 1.0 SXL ENG2, ENG BULKHD 2 P LRR-E, RH Rear Comb Light 2

4002-31

21C Bk - 1.0


Color, Size,
and Material
45R
Right Turn Signal N 1.0 SXL ENG2, ENG BULKHD 2 P ENG-H, Engine to Hood 4
AN
45R B Right Turn Signal N 0.8 GXL Cabe2, Cab to ENG2 BULKHD P SPL-PK3, Splice 3-4 Way H
45R
Right Turn Signal N 1.0 SXL HD-N, Hood to Engine 4 LRR, RH Rear Comb Light 4
BN
45R C Right Turn Signal N 0.8 TXL SPL-PK3, Splice 3-4 Way E AIC-2, Adv Instrument Cluster 2 10
45R D Right Turn Signal N 0.8 GXL CAB-F, Cab Front Chassis 3 SPL-PK3, Splice 3-4 Way G
45R E Right Turn Signal N 0.8 GXL FLSHR, Flasher Module 7 SPL-PK3, Splice 3-4 Way F
460 A Y 0.8 TXL CAB-E, CAB-Engine 16 AIC-2, Adv Instrument Cluster 2 24
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
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
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
SPL-PED-BL, Spl Back Lgt Pwr 6

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

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

4002-32

21C Bk - 1.0


Color, Size,
and Material
49 P Back Light Power S 0.8 GXL SDR, Driving Lights Switch 8 SPL-BCK-LGT, Spl Back Lgt Pwr G

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

49 S Back Light Power S 0.8 GXL F M
Pwr 6 Pck Pwr
49Y A Back Light Power S 0.8 TXL MH, Heated Mirror C SPL-BCK-LGT, Spl Back Lgt Pwr B
49Y B Back Light Power S 0.8 GXL MHS, Trans Enable SW 8 MH-C, Heated Mirror C

49 T Back Light Power S 0.8 GXL SFWW, Front Wiper/Washer 8 H
Pwr
49 V Back Light Power S 0.8 GXL SPB, Parking Brake Switch 8 E
Pck
49 W JSS Back Light S 0.8 GXL SJS, Joystick Control SW 8 A
Pck
49 X Back Light AIC S 0.8 TXL SW PD, Switch Pad 3 D
Pck
SPL-BCK-LGT2, SPL_Back
49 Z Back Light PWR S 0.8 GXL J SDA, Diff Lock Switch 8
Lgt Pwr
51B A JSS ACT SW W 0.8 GXL SPL-JSS 2, Ultrasonic A SJS, Joystick Control SW 3
51B B JSS ACT SW W 0.8 GXL SJS, Joystick Control SW 6 SPL-JSS 2, Ultrasonic A
51B C JSS ACT SW W 0.8 GXL JSS Cab, JSS Cab 5 SPL-JSS 2, Ultrasonic A
Cab Arm FRM, Cab to Arm to

51B D JSS ACT SW W 0.8 GXL 5 SPL-JSS 7, Ultrasonic A
FRM
51B E B+, JSS W 0.8 GXL JSS-RLY, Relay K2 86 SPL-JSS 7, Ultrasonic A
51B G B+, JSS W 0.8 GXL SPL-JSS 7, Ultrasonic A JSS RLY, Relay K2 87
51B H JSS ACT SW W 0.8 GXL SPL-JSS 7, Ultrasonic A Cab Arm, Cab to Armrest 6
51B J JSS ACT SW BK 0.8 TXL JSS arm, JSS Armrest to Cab 6 CAN MOD_2, JSS CAN MOD 1
51B K JSS Power W 0.8 GXL FNR Rly, relay K2 86 SPL JSS_4, Ultrasonic A
51C A JSS ACT BTN Y 0.8 GXL JSS Cab, JSS Cab 10 SJS, Joystick Control SW 5

51C B JSS ACT BTN Y 0.8 GXL 10 JSS CNT, JSS Controller 13
FRM
51D A GRND, Relay Ctrl BK 0.8 GXL JSS Cab, JSS Cab 4 AIC 1, ADV Instr Cluster 1 21

51D B GRND, Relay Ctrl BK 0.8 GXL 4 JSS RLY, Relay K2 85
FRM

4002-33

21C Bk - 1.0


Color, Size,
and Material
51E A Armrest Lower OR 0.8 GXL JSS CNT, JSS Controller 6 Cab Arm, Cab to Armrest 3
51E B Armrest Lower OR 0.8 GXL JSS Arm, JSS Armrest to Cab 3 Arm Pos, Arm Position 3
51F A LS Press SW SIG G 1.0 GXL JSS LS, JSS Load Sense B JSS FRM, JSS Frame to Cab A
51F B LS Press SW G 0.8 GXL Cab FRM, Cab to JSS Frame A JSS CNT, JSS Controller 16
51F C LS Press SW SIG G 1.0 GXL JSS FRM, JSS Frame to Cab A JSS LS2, JSS Load Sense A
51H B Joystick Signal Y 0.8 GXL JSS CNT, JSS Controller 4 Cab Arm, Cab to Armrest 10
51H C Joystick Signal Y 0.8 GXL JSS Arm, JSS Armrest to Cab 10 PVRES, JSS Joystick T
51J A Valve Alarm P 0.8 GXL SPL JSS_11, Ultrasonic A Cab FRM, Cab to JSS frame B
51J B Valve Alarm P 0.8 GXL JSS CNT, JSS Controller 12 SPL JSS 11, Ultrasonic A
51J C JSS Alarm P 1.0 GXL JSS Valve, JSS HYD Valve 2 JSS FRM, JSS Frame to Cab B
51J D Valve Alarm P 0.8 GXL SPL JSS 11, Ultrasonic A R1, Resistor CS0
51K B Pilot Press SW G 0.8 GXL Cab FRM, Cab to JSS Frame C JSS CNT, JSS Controller 8
JSS PIL PR, JSS Pilot

51K C Pilot Press SW SIG G 1.0 GXL B JSS FRM, JSS Frame to Cab C
Pressure
51L Joystick Signal Y 1.0 GXL JSS Valve, JSS HYD Valve 1 JSS FRM, JSS Frame to Cab D
51L A Joystick Signal Y 0.8 GXL JSS CNT, JSS Controller 7 CAB FRM, Cab to JSS Frame D
51NC NC Neutral SW BK 0.8 TXL PVRES, JSS Joystick W CAN MOD 2, JSS CAN MOD 3
51NO NC Neutral SW Y 0.8 GXL JSS Arm, JSS Armrest to Cab 11 PVRES, JSS Joystick U
51NO
NC Neutral SW P 0.8 GXL Cab Arm, Cab to Armrest 11 JSS CNT, JSS Controller 14
A
51PW
JSS Power W 1.0 SXL SPL JSS_16, Ultrasonic A JSS FRM, JSS Frame to Cab H
H
51PW
JSS Power W 1.0 SXL JSS LS, JSS Load Sense A SPL JSS 16, Ultrasonic A
J
51PW
JSS Power W 1.0 SXL SPL JSS 16, Ultrasonic A JSS Pil Dump, JSS Pilot Dump 1
K
51 PW
JSS Power W 1.0 GXL SPL JSS 16, Ultrasonic A JSS LS2, JSS Load Sense C
L
51PW Cab Arm FRM, Cab to Arm to
JSS Power W 0.8 GXL SPL JSS 6, Ultrasonic A 9
M FRM
51PW
JSS Power W 0.8 GXL JSS Cab, JSS Cab 9 SJS, Joystick_Control SW 10
N
51PW
JSS Power W 0.8 GXL JSS Rly, Relay K2 30 SPL JSS 4, Ultrasonic A
P

4002-34

21C Bk - 1.0


Color, Size,
and Material
51PW
JSS Power W 0.8 GXL JSS Cnt, JSS Controller 9 SP JSS 4, Ultrasonic A
Q
51PW
JSS Power W 0.8 GXL SPL JSS 6, Ultrasonic A Cab Arm, Cab to Armrest 8
R
51PW
JSS Power W 0.8 GXL SPL JSS 13, Ultrasonic A JSS Arm, JSS Armrest to Cab 8
S
51PW
JSS Power W 0.8 GXL SPL JSS 6, Ultrasonic A Cab Frm, Cab to JSS Frame H
T
51PW
JSS Power BK 0.8 TXL SPL JSS 13, Ultrasonic A Can Mod 2, JSS Can mod 2
U
51PW
JSS Power W 0.8 GXL SPL JSS 13, Ultrasonic A PVRES, JSS Joystick S
V
51PW
JSS Power W 0.8 GXL SPL JSS 6, Ultrasonic A SPL JSS 4, Ultrasonic A
W
51P A Sec. Str High Press W 1.0 SXL SSM, Sec. Steer Module 9 PSS, Sec. Str Pres Switch A
51R Armrest Raise BK 0.8 TXL Arm Pos, Arm Position 2 CAN MOD 2, JSS CAN MOD 5
51S A JSS Okay Pwr W 0.8 GXL JSS Cnt, JSS Controller 5 SPL JSS 5, Ultrasonic A
51S B JSS Okay Pwr W 0.8 GXL Cab Arm, Cab to Armrest 9 SPL JSS 5, Ultrasonic A
51S C JSS Okay Pwr W 0.8 GXL SPL JSS 15, Ultrasonic A JSS Arm, JSS Armrest to Cab 9
51S D JSS Okay Pwr BK 0.8 TXL CAN MOD_2, JSS CAN MOD 4 SPL JSS 15, Ultrasonic A
51S E JSS Okay Pwr W 0.8 GXL PVRES, JSS Joystick R SPL JSS 15, Ultrasonic A
51S F JSS Okay Pwr W 0.8 GXL Cab Frm, Cab to JSS Frame F SPL JSS 5, Ultrasonic A
51S J JSS Okay Pwr W 1.0 SXL JSS Valve, JSS HYD Valve 4 JSS Frm, JSS Frame to Cab F
51 A Sec. Str Motor Control W 1.0 SXL SSM, Sec. Steer Module 2 SPL-SS, Ultrasonic A
51 B Sec. Str Motor Control W 1.0 SXL SPL-SS, Ultrasonic A SSS, SS Mag Switch 1
51 C Sec. Strg Sol Control W 1.0 SXL SPL-SS, Ultrasonic A YSS, Sec. Steering Solenoid 1
51 D Sec. Str Flyback W 1.0 SXL SSS, SS MAG Switch 1 SSD, Sec. Steering Diode C
52AU Fan Reverse Auto W 0.8 TXL SFC, Fan Control Switch 3 AIC-2, Adv Instrument Cluster 2 8
52A A Fan Reverse Relay Out W 1.0 GXL CAB-E, Cab Engine 22 ECB, Elect Center B D8
52A B Fan Reverse Relay Out W 1.0 SXL ENG, Engine Cab 1 22 YFR, Fan Rev Solenoid Option 1
AIC-1, Adv Instrument

52C Parking Brake Solenoid LSD W 0.8 TXL 14 ECB, Elect Center B B10
Cluster 1
52J Fan Control Switch Jumper W 0.8 GXL SFC, Fan Control Switch 4 SFC, Fan Control Switch 2
52M Fan Reverse Manual W 0.8 TXL SFC, Fan Control Switch 6 AIC-2, Adv Instrument Cluster 2 7
4002-35

21C Bk - 1.0


Color, Size,
and Material
52P Parking Brk Relay Out W 1.0 SXL BTM_C, CAB Bottom BULKHD M YPB, Park Brake Solenoid 1
52P A Parking Brk Relay Out W 0.8 GXL Cab_B, Cab BTM BULKHEAD M SPL-PTM, Ultrasonic A
52P B Parking Brk Relay Out W 0.8 GXL SPL-PTM, Ultrasonic A ECB, Elect Center B D10
53A RTD Switch Power W 0.8 GXL SRTD, Detent Switch 3 EM, RTD Height Control RTT 3
53B RTD ControlSignal W 1.0 SXL FRONT, Cab Front Chassis 12 PXF, RTD A
53B A RTD Control Signal W 1.0 SXL PXM, RTD A PXT, RTD A
53B B RTD Control Signal W 0.8 GXL EM, RTD Height Control RTT 4 CAB-F, Cab Front Chassis 12
AIC-1, Adv Instrument

53C A Pilot Control Solenoid LSD W 0.8 TXL 20 ECD, Elect Center D B6
Cluster 1
53P A Pilot Control Relay Out W 0.8 GXL SPL-D25, Ultrasonic A YPP, Pilot Pressure Solenoid A
53P B Pilot Control Relay Out W 0.8 GXL SFL, Return to Travel Switch 2 SPL-D25, Ultrasonic A
53P C Pilot Control Relay Out W 1.0 GXL SPL-D25, Ultrasonic A ECD, Elect Center D D6
53P D Pilot Control Relay Out W 0.8 GXL SHC, Height Control Switch 2 SPL-D25, Ultrasonic A
53P E Pilot Control Relay Out W 0.8 GXL SRTD, Detent Switch 2 SPL-D25, Ultrasonic A
53P F Pilot Control Relay Out W 0.8 GXL CAB-F, Cab Front Chassis 9 SPL-D25, Ultrasonic A
53P G Pilot Control Relay Out W 1.0 SXL FRONT, Cab Front Chassis 9 SPL-A3, Ultrasonic A
53P H Pilot Control Relay Out W 1.0 SXL SPL-A3, Ultrasonic A PXF, RTD C
53P I Pilot Control Relay Out W 1.0 SXL PXM, RTD C PXT, RTD C
53P J Pilot Control Relay Out W 1.0 SXL SPL-A3, Ultrasonic A PXH, Height Control RTT C
54A Height Control Switch Power W 0.8 GXL SHC, Height Control Switch 6 EM, RTD Height Control RTT 2
54B Height RTT Control Signal W 1.0 SXL FRONT, Cab Front Chassis 11 PXH, Height Control RTT A
54B A Height RTT Control Signal W 0.8 GXL CAB-F, Cab Front Chassis 11 SPL-D1, Ultrasonic A
54B B Height RTT Control Signal W 0.8 GXL EM, RTD Height Control RTT 5 SPL-D1, Ultrasonic A
54B C Height RTT Control Signal W 0.8 GXL SFL, Return to Travel Switch 6 SPL-D1, Ultrasonic A
55A A RTT Float Sw Power W 0.8 GXL EM, RTD Height Control RTT 1 SPL-RTT, Ultrasonic A
55A B RTT Float Sw Power W 0.8 GXL SFL, Return to Travel Switch 1 SPL-RTT, Ultrasonic A
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 1 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

4002-36

21C Bk - 1.0


Color, Size,
and Material
57 C Pin Engage Sol Pwr W 0.8 TXL SPL-PINE, Ultrasonic A AIC-2, Adv Instrument Cluster 2 16
57 D Pin Engage Sol Pwr W 1.0 SXL YPE1, Pin Engage Jumper A YPE2, Pin Engage Opt A
58C Ride Control Switch Jumper W 0.8 GXL SRC, Ride Control Switch 5 SRC, Ride Control Switch 3
58H A Pwr VPS2 W 0.8 TXL TECM, Trans 8 SPL D19, Ultrasonic A
58H B Power VPSL W 0.8 TXL SPL D19, Ultrasonic A TECM, Trans 53
58H C Power W 0.8 GXL ECD, Elec Cntr D D7 SPL D19, Ultrasonic A
58L Ride Control Relay LSD Bk 0.8 TXL TECM, Trans 57 ECD, Elect Center D B8
58T Ride Control Relay Sw Pwr W 0.8 GXL SRC, Ride Control Switch 4 ECD, Elect Center D B7
58 A Ride Control Sol Pwr W 1.0 SXL 202M, Rollback Jumper A 202M, Rollback Jumper B
58 B Ride Control Sol Pwr W 1.0 SXL FRONT, Cab Front Chassis 18 PRBF, Rollback Pressure Switch B
58 C Ride Control Sol Pwr W 0.8 GXL CAB-F, Cab Front Chassis 18 SPL-D26, Ultrasonic A
58 D Ride Control Sol Pwr W 0.8 GXL 140M, Diode Module D SPL-D26, Ultrasonic A
58 E Ride Control Sol Pwr W 0.8 GXL SPL-D26, Ultrasonic A ECD, Elect Center D D8
58 F Ride Control Sol Pwr W 0.8 GXL SRC, Ride Control Switch 6 SPL-D26, Ultrasonic A
58 G Ride Control Sol Pwr W 1.0 SXL YRC, Ride Control Opt 1 Front, Frnt Chas-Cab 18
58 H Ride Control Signal W 1.0 SXL YRC J, Ride Control Jumper 1 YRC J2, Ride Control Opt 1
59D Hood Relay Control Down W 1.0 GXL Cabe2, Cab to ENG2 BULKHD V ECC, Elect Cntr C D3
59D A Hood Relay Control Down W 1.0 SXL ENG2, ENG BULKHD 2 V HD, Hood Switch A
59U Hood Relay Control Up W 1.0 GXL Cabe2, Cab to ENG2 BULKHD X ECC, Elect Cntr C D1
59U A Hood Relay Control Up W 1.0 SXL ENG2, ENG BULKHD 2 X HD, Hood Switch C
60D Hood Down Relay Out W 1.0 GXL Cabe2, Cab to ENG2 BULKHD U ECC, Elect Cntr C B3
60D A Hood Down Relay Out W 1.0 SXL ENG2, ENG BULKHD 2 U HDM, Hood Lift Motor 2
60U Hood Up Relay Out W 1.0 GXL Cabe2, Cab to ENG2 BULKHD W ECC, Elect Cntr C B1
60U A Hood Up Relay Out W 1.0 SXL ENG2, ENG BULKHD 2 W HDM, Hood Lift Motor 1
61A AC Press Sw Input W 1.0 SXL ENG, Engine Cab 1 30 SPL ACP, Ultrasonic A
61A B Trinary Press Sw Input W 0.8 GXL CAB-E, Cab Engine 30 SPL AC, Ultrasonic A
61A C AC Switch Input W 1.0 SXL SPL ACP, Ultrasonic A ENG B, Cab Bottom 8
61A D AC Switch Input W 1.0 SXL SPL ACP, Ultrasonic A PRH, AC High Press SW A
61A E AC Switch Input W 1.0 SXL PRL, AC Low Press SW A BTM E, Cab Bottom 8
61A F Trinary Press SW Input W 0.8 GXL HVAC1, HVAC1 1 SPL AC, Ultrasonic A
61A G Trinary Press SW Input W 0.8 GXL SPL AC, Ultrasonic A ECD, Elec Cntr D B9

4002-37

21C Bk - 1.0


Color, Size,
and Material
61B A AC Signal W 0.8 GXL AIC 2, ADV Instr Cluster 2 12 HVAC1, HVAC1 4
61C AC Relay Out Or 0.8 GXL CAB-E, Cab Engine 2 ECD, Elect Center D C10
61C A AC Relay Out Or 1.0 SXL ENG, Engine Cab 1 2 ACT, AC Comp Clutch 1
61H Heat Load Valve Solenoid Or 0.8 TXL CAB-E, Cab Engine 8 AIC-1, ADV Instrument Cluster 1 19
61H A Heat Load Valve Solenoid Or 1.0 SXL YLV, Heated Valve opt. 1 ENG, Engine Cab 1 8
61H B Heat Load Valve Solenoid Or 1.0 SXL YLV2, Heated Valve opt. 1 YLV3, Heated Valve opt. 1
61R AC Relay Control W 1.0 SXL ENG, Engine Cab 1 29 SPL ACS, Ultrasonic A
61R B AC Relay Control W 0.8 GXL CAB-E, Cab Engine 29 ECD, Elect Center D D9
61R C AC Switch Output W 1.0 SXL SPL ACS, Ultrasonic A ENG B, Cab Bottom 7
61R D AC Switch Output W 1.0 SXL SPL ACS, Ultrasonic A PRH, AC High Press SW B
61R E AC Switch Output W 1.0 SXL PRL, AC Low Press SW B BTM_E, Cab Bottom 7
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 C2 ECD, Elect Center D D4
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 ECD, Elec Cntr D B2 SPL HC, Ultrasonic A
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 ECD, Elec Cntr D D2 SPL WHS, Ultrasonic A
63H C Front Wiper High Speed Rly Out W 0.8 GXL 140M, Diode Module A SPL-WHS, Ultrasonic A
63LC Front Wiper Low Speed Rly Ctrl W 0.8 GXL SFWW, Front Wiper/Washer 3 ECD, Elect Center D B4
63L A Front Wiper Low Speed Rly Out W 0.8 GXL FMW, Front Wiper Motor B SPL-WLS, Ultrasonic A
63L B Front Wiper Low Speed Rly Out W 0.8 GXL K-WCO, Wiper Cutout 30 SPL-WLS, Ultrasonic A
63L C Front Wiper Low Speed Rly Out W 0.8 GXL 140M, Diode Module B SPL-WLS, Ultrasonic A
63W Front Washer Pump W 0.8 GXL CAB-E, Cab Engine 25 SFWW, Front Wiper/Washer 7
63W A Front Washer Pump W 1.0 SXL ENG, Engine Cab 1 25 FWW, Front Washer 1
64C Horn Relay Control Or 0.8 GXL SRHSTLK, RH Stalk Switch 31b ECC, Elect Center C B8
64 A Horn Power Or 0.8 GXL CAB-F, Cab Front Chassis 13 ECC, Elect Center C D8
65L Left Speaker Or 0.8 GXL LSPK, Left Speaker A SPK, Speaker 7

4002-38

21C Bk - 1.0


Color, Size,
and Material
65R Right Speaker Or 0.8 GXL RSPK, Right Speaker A SPK, Speaker 1
66A RR Camera Pwr OR 0.8 GXL Mon, Camera/MOnitor 1 ECA, Elect Cntr A C9
67A Park Brake Signl OR 0.8 GXL TEL, Telematics E SPL PTM, Ultrasonic A
67B Start Lockout OR 0.8 GXL ECC, Elect Cntr C 87 SRP, Work Lights SW 8
68C Rear Wiper Park Control Or 1.0 GXL CAB-RF, Cab to Roof Conn. K SRWP, Rear Wiper Switch 1
68C A Rear Wiper Park Control Or 1.0 GXL ROOF, Roof to Cab Conn. K RWM, Rear Wiper Motor D
68L Rear Wiper Switch Power Or 1.0 GXL SRWP, Rear Wiper Switch 2 SPL-3, Ultrasonic A
68L A Rear Wiper Switch Power Or 1.0 GXL ROOF, Roof to Cab Conn. L RWM, Rear Wiper Motor B
68L B Rear Wiper Switch Power Or 1.0 GXL CAB-RF, Cab to Roof Conn. L SPL-3, Ultrasonic A
68L C Rear Wiper Switch Power Or 1.0 GXL 140M, Diode Module F SPL-3, Ultrasonic A
68W Rear Washer Pump W 0.8 GXL CAB-E, Cab Engine 24 SRWP, Rear Wiper Switch 6
68W A Rear Washer Pump W 1.0 SXL ENG, Engine Cab 1 24 RWW, Rear Washer 1
69F Heated Mirror Signal W 1.0 GXL TRLY, Timer Relay 87 MHS, Trans Enable SW 3
69A Heated Mirror Signal W 1.0 GXL SPL3, Ultrasonic A TRLY, Timer Relay 86
69B Heated Mirror Signal W 1.0 GXL SPL3, Ultrasonic A MHS, Trans Enable SW 10
69D Heated Mirror Signal W 1.0 GXL SPL3, Ultrasonic A MH-R, Mirror HTR 1
69E Heated Mirror Signal W 1.0 GXL SPL3, Ultrasonic A MH-R, Mirror HTR 1
CAN1 Y 0.8 TXL
CAN HI EDC7, Engine Controller 35 ENG, Engine-Cab1 14
H TWIST
CAN1 G 0.8 TXL
CAN LO EDC7, Engine Controller 34 ENG, Engine-Cab1 13
L TWIST
CANS Y 0.8 TXL
1 7
HA CAN HI, CAN MOD2 TWIST
JSS Arm, JSS Armrest to Cab CAN MOD 2, JSS CAN MOD
CANS Y 0.8 TXL Cab Arm FRM, Cab to Arm to 12 1

HB CAN HI, CAN MOD2 Cab Arm, Cab to Armrest
TWIST FRM
CANS Y 0.8 TXL Cab Arm FRM, Cab to Arm to 7 1
HD CAN HI, CAN MOD3 JSS CNT, JSS Controller
TWIST FRM
CANS G 0.8 TXL
CAN LO, CAN MOD2 JSS Arm, JSS Armrest to Cab 12 CAN MOD 2, JSS CAN MOD 8
LA TWIST
CANS G 0.8 TXL Cab Arm FRM, Cab to Arm to
CAN LO, CAN MOD2 Cab Arm, Cab to Armrest 12 1
LB TWIST FRM
CANS G 0.8 TXL Cab Arm FRM, Cab to Arm to
CAN HI, CAN MOD3 6 JSS CNT, JSS Controller 2
LD TWIST FRM

4002-39

21C Bk - 1.0


Color, Size,
and Material
Y 0.8 TXL
CAN H CAN HIGH ENG, ENGINE-CAB1 14 SPL CAN DH, Ultrasonic A
TWIST
CAN Y 0.8 GXL TERM CAN 2, CAN Bulk
CAN2 HI, TERM B SPL CAN HV, Ultrasonic A
H2 TWIST Head
CAN Y 0.8 TXL
CAN2 HI, Nox SPL-CAN-HT, Ultrasonic A EDC7, Engine Controller 53
H3 TWIST
CAN Y 0.8 TXL
CAN High SPL CAN_JS_H1, Ultrasonic A SPL CAN GH, Ultrasonic A
HA TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-DIAG, Ultrasonic A DIA, Diagnostic C
HB TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-TRANS, Ultrasonic A SPL-CAN-DIAG, Ultrasonic A
HC TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN-TRANS, Ultrasonic A TECM, Trans 25
HD TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN, Ultrasonic A SPL-CAN-TRANS, Ultrasonic A
HE TWIST
CAN Y 0.8 TXL
CAN High SW-PD, Switch Pad 7 SPL-CAN, Ultrasonic A
HF TWIST
CAN Y 0.8 TXL
CAN High SPL-CAN, Ultrasonic A AIC-1, Adv Instrument Cluster 1 3
HG TWIST
CAN Y 0.8 TXL
CAN High SPL CAN TEL, Ultrasonic A TEL, Telematics L
HH TWIST
CAN Y 0.8 TXL
CAN High SPL CAN TEL, Ultrasonic A SPL CAN JS H2, Ultrasonic A
HJ TWIST
CAN Y 0.8 TXL
CAN HI, EDC SPL CAN DH, Ultrasonic A EDC7, Engine Controller 35
HK TWIST
CAN Y 0.8 TXL
CAN High SPL CAN TEL, Ultrasonic A SPL CAN DIAG, Ultrasonic A
HL TWIST
CAN Y 0.8 GXL
CAN2 HI, EDC Cab E, Cab-Engine 14 SPL-CAN-GH, Ultrasonic A
HM TWIST
CAN Y 0.8 TXL
CAN High SPL CAN JS H1, Ultrasonic A SPL CAN JS H2, Ultrasonic A
HN TWIST
CAN Y 0.8 GXL
CAN2 HI, DIAG2 SPL CAN GH, Ultrasonic A DIA 2, Diagnostic C
HO TWIST
CAN Y 0.8 GXL
CAN HI,CAN MOD2 SPL CAN JS H1, Ultrasonic A JSS Cab, JSS Cab 12
HP TWIST

4002-40

21C Bk - 1.0


Color, Size,
and Material
CAN Y 0.8 GXL
CAN HI, DNOX2 SPL CAN DH, Ultrasonic A DNOX2, NOX Controller 7
HQ TWIST
CAN Y 0.8 GXL
CAN HI,CAN MOD3 SPL CAN JS H2, Ultrasonic A JSS Cab, JSS Cab 7
HR TWIST
CAN Y 0.8 TXL
CAN2 HI, NOX SPL CAN HV, Ultrasonic A EDC7, Engine Controller 53
HS TWIST
CAN Y 0.8 TXL
CAN2 HI, NOX SPL CAN HT, Ultrasonic A NOXS, NOX Sensor 4
HU TWIST
CAN Y 0.8 GXL
CAN2 HI, TERM SPL CAN HT, Ultrasonic A TERM CAN 2, CAN Bulk Head B
HV TWIST
CAN Y 0.8 TXL
CAN 2 HI, EVGT SPL CAN HV, Ultrasonic A Turbo, Eng DASH Turbo 7
HW TWIST
CAN Y 0.8 GXL
CAN 2 HI SPL CAN HV, Ultrasonic A SPL CAN HT, Ultrasonic A
HZ TWIST
G 0.8 TXL
CAN L CAN Low ENG, Engine-Cab1 13 SPL CAN DL, Ultrasonic A
TWIST
CAN Y 0.8 GXL
CAN 2 LO, Term Term CAN 2, CAN Bulk Head 13 SPL CAN LV, Ultrasonic A
L2 TWIST
CAN G 0.8 TXL
CAN L2, Nox SPL-CAN-LT, Ultrasonic A EDC7, Engine Controller 52
L3 TWIST
CAN G 0.8 TXL
CAN Low SPL CAN JS_L1, Ultrasonic A SPL CAN GL, Ultrasonic A
LA TWIST
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 TECM, Trans 26 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
CAN G 0.8 TXL
CAN Low SPL CAN TEL2, Ultrasonic A SPL CAN JS L2, Ultrasonic A
LH TWIST

4002-41

21C Bk - 1.0


Color, Size,
and Material
CAN G 0.8 TXL
CAN Low, EDC EDC7, Engine Controller 34 SPL CAN DL, Ultrasonic A
LJ TWIST
CAN G 0.8 GXL
CAN Low, DNOX2 SPL CAN DL, Ultrasonic A DNOX2, NOX Controller 8
LK TWIST
CAN G 0.8 GXL
CAN2 LO, EDC Cab E, Cab-Engine 13 SPL CAN GL, Ultrasonic A
LL TWIST
CAN G 0.8 TXL
CAN Low SPL CAN TEL2, Ultrasonic A TEL, Telematics M
LM TWIST
CAN G 0.8 GXL
CAN Low,CAN MOD3 SPL CAN JS L1, Ultrasonic A JSS Cab, JSS Cab 1
LP TWIST
CAN G 0.8 TXL
CAN LOW SPL CAN JS L1, Ultrasonic A SPL CAN JS L2, Ultrasonic A
LQ TWIST
CAN G 0.8 GXL
CAN Low, CAN MOD2 SPL CAN JS L2, Ultrasonic A JSS Cab, JSS Cab 6
LR TWIST
CAN G 0.8 TXL
CAN2 LO, NOX SPL CAN LV, Ultrasonic A EDC7, Engine Controller 52
LS TWIST
CAN G 0.8 TXL
CAN2 LO, NOX NOXS, NOX Sensor 3 SPL CAN_LT, Ultrasonic A
LU TWIST
CAN G 0.8 GXL
CAN2 LO, Term Term CAN 2, CAN Bulk Head A SPL CAN LT, Ultrasonic A
LV TWIST
CAN G 0.8 TXL
CAN LO, EVGT SPL CAN LV, Ultrasonic A Turbo, ENG DASH Turbo 1
LW TWIST
CAN G 0.8 GXL
CAN2 LO, DIAG2 SPL CAN GL, Ultrasonic A DIA 2, Diagnostic D
LX TWIST
CAN G 0.8 TXL
CAN Low SP CAN TEL2, Ultrasonic A SPL CAN DIAG L, Ultrasonic A
LY TWIST
CAN G 0.8 GXL
CAN 2 LO SPL CAN LV, Ultrasonic A SPL CAN LT, Ultrasonic A
LZ TWIST
ECC
Beacon/Dome Light L1 ECC BUSS L1-ECC, ECC Batt Power 1 ECC, Elect Cntr C L1-1
L1
J1 Trans ECM Power ECA-BUSS ECA-L1, B+ Power cs01 ECA, Elect Center A L1
J2 Trans ECM Power ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J3 EMG STR AIC Power ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J4 Emergency Steer AIC Power ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J5 Emergency Steer Pltem Dtnts ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J6 Pltem Dtnts Park Brk Sol ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1

4002-42

21C Bk - 1.0


Color, Size,
and Material
J7 Park Brake Solenoid Horn ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J8 Fan Reverse Turn Signal ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J9 Turn Signal Engine Shut Down ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J10 DNOX SW B+ ECA-BUSS ECA, Elect Center A L1 ECA, Elect Center A L1
J11 Blower Motor Power ECA-BUSS PRMB_L1, B+ Power cs01 ECA, Elect Center A L2
Blower Motor Front Wiper

J12 ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
Washer
J13 Front Wiper Rear Wiper Washer ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J14 Rear Wiper Washer Backup ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J15 Backup AC ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J16 Heated Mirrors ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J17 Seat Comp EMG Strtr ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J18 Diagnostic Power ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J19 ECA-BUSS ECA, Elect Center A L2 ECA, Elect Center A L2
J2
Beacon/Dome Lt Work Lights ECC-BUSS ECC, Elect Center C L1-1 ECC, Elect Center C L1-2
ECC
J3
Work Lights Driving Lights ECC-BUSS ECC, Elect Center C L1-2 ECC, Elect Center C L1-3
ECC
J4
Driving Lights Brake Lights ECC-BUSS ECC, Elect Center C L1-3 ECC, Elect Center C L1-4
ECC
J5
Brake Lights Delay Power ECC-BUSS ECC, Elect Center C L1-4 ECC, Elect Center C L1-5
ECC
J6
Delay Power Horn ECC-BUSS ECC, Elect Center C L1-5 ECC, Elect Center C L1-6
ECC
J7
Horn HOD Control ECC-BUSS ECC, Elect Center C L1-6 ECC, Elect Center C L1-7
ECC
J9
ECC-BUSS ECC, Elect Center C L1-8 ECC, Elect Center C L1-9
ECC
J10
BUSS ECC, Elect Center C L1-9 ECC, Elect Center C L1-10
ECC
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

4002-43

21C Bk - 1.0


Color, Size,
and Material
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

4002-44
CONNECTORS
CONNECTOR AB+, ALTERNATOR B+ AIC 1, ADV INSTR CLUSTER 1
CAV WIRE IDENT CIRCUIT
1 1 BA ALTERNATOR B+
CONNECTOR AB5, ALTERNATOR B+

1 1 BF ALTERNATOR B+
1 30 BATTERY SENSING
CONNECTOR ACT - AIR CONDITIONING 87419488

COMPRESSOR CLUTCH
1 19S-E AIC BATT B+
2 36F-A FUEL LEVEL ANALOG
3 CAN-HG CAN HIGH
4 CAN-LG CAN LOW
8602417 6 0-DX AIC SENSOR GND
CAV WIRE IDENT CIRCUIT 7 43-A DOME LT AUTO MODE
1 61C-A AC RELAY OUT 9 36H-A HYDRAULIC OIL TEMP
11 36C-A RADITAOR COOL TEMP SGNL
AD, ALTERNATOR D+ 12 0-DW AIC POWER GND

13 35B AIC BUZZER HSD
14 52C PARK BRAKE SOL LSD
1 14 ALTERNATOR D+
19 61H HEAT LOAD VLV SOL
20 53C-A PILOT CTRL SOL LSD
21 51D-A GRND, RELAY CTRL
22 0-EZ POWER RELAY CONTROL
23 52 FAN REVERSER LSD
25 17P-B SW PAD PWR FR0M AIC PWR
26 56 FAN CONTROL PWM

4002-45
AIC 2, ADV INSTR CLUSTER 2 ARM FNR, FNR-MAIN CAB

1 19B-C FNR SWITCHED PWR
2 26F-F FNR FORWARD SIGNAL
3 26N-F FNR NEUTRAL SIGNAL
4 26R-F FNR REVERSE SIGNAL
5 32J-J FNR LT SIGNAL
6 25Y-G TRANS KICKDOWN SIGNAL
ARM POS, ARM POSITION

87410948
1 0-SG COMMON
2 43S-A DOOR OPEN SGNL
2 51R ARMREST RAISE
4 33R RDNT BRK ACCUM PRESS LOW
3 51E-B ARMREST LOWER
5 33P-A BRK WARN PRESS LOW
6 33U PARK BRK SWITCH
7 52M FAN REVERSE MAN
B1, STARTER PWR STUD
8 52AU FAN REVERSE AUTO CAV WIRE IDENT CIRCUIT
9 45L-E LEFT TURN SGNL 1 1-NC B+ PWR PRMC
10 45R-C RIGHT TURN SGNL
11 35X SEC STR LOW PRESS SGNL
B2, STARTER POWER
12 61B-A AC SIGNAL
14 19S-D AIC DELAY FSD PWR CAV WIRE IDENT CIRCUIT
15 0-DB AIC POWER GND RED 1 1-BA ALTERNATOR B+
16 57-C PIN ENGAGE SOL PWR

17 21K-A IGN SW START SIGNAL B3, STARTER BATTERY
18 31L PILOT CTRL SW HIGH
20 19S-C AIC DELAY FSD PWR
1 0-NB MASTER DISCONNECT GND
21 19S-F AIC BATT B+
22 0-DA AIC CHASSIS GND
B4, STARTER POWER
ALT5, ALTERNATOR D+ CAV WIRE IDENT CIRCUIT

1 1-ND SSM PWR
2 30 BATTERY SENSING
B5, STARTER POWER STUD
3 14-5 ALTERNATOR D+
BT1, BATTERY STARTER 1 1-BG B+ PWR PRMC

B6, STARTER POWER
1 1-NB BATTERY STARTER
1 1-NG PWR NON DISCNT CAV WIRE IDENT CIRCUIT
1 1-NE BATTERY STARTER 1 1-BF ALTERNATOR B+

4002-46
B7, STARTER BATTERY BT4, DISCON-BLCK GRND
CAV WIRE IDENT CIRCUIT CAV WIRE IDENT CIRCUIT

1 1-NE BATTERY STARTER 1 0-NC BATTERY DISCONNECT
B8, STARTER POWER BTM C, CAB BOTTOM BULKHD

1 1-NF SSM PWR
BPP, PEDAL POSITION
W230R397

A 22G PEDAL SENSOR GRND
B 22E PEDAL SENSOR +5V
C 22F PEDAL POS SIGNAL
W230R395
D 016B PEDAL SENSOR SIGNAL
E 255E PEDAL SENSOR +5V
1 22G PEDAL SENSOR GRND
F 401B PEDAL POS SIGNAL
2 22E PEDAL SENSOR +5V
J 44 BRK LT CTRL PWR
3 22F PEDAL POS SIGNAL
K 1-AA BRK LT SW PWR
4 401B PEDAL POS SIGNAL
L 33P BRK WARNING PRESS LOW
5 255E PEDAL SESNOR +5V
M 52P PARK BRK RLY OUT
6 016B PEDAL SENSOR GRND
A 22D PEDAL SENSOR GRND
B 22B PEDAL SENSOR +5V
BT2, DISCONECT BATTERY C 22C PEDAL POS SIGNAL

J 44-A BRK LT CTRL PWR
K 1-DR BRK LT SW PWR
1 1-NA BATTERY CROSSOVER
M 52P-A PARK BRK RLY OUT
BT3, STARTER BATTERY

1 1-NA BATTERY CROSSOVER

4002-47
BTM E, CAB BTTOM CABE2, CAB TO ENG2 BULKHD
225319C1 W230R398

1 21F-D EDC7 DIGITAL GND A 23B-D NOX RELAY, B+
2 0-AK PARK BRAKE/WARNING GND B 18U-C DCU B+ NON DISCONNECTD
3 24B-A THROT SIGNAL C 23B-B NOX SENSOR B+
4 24R-A THROT GND D 1-NM PWR NON DISCONNECTD
5 24S-A THROT SUPPLY E 18U-E DCU B+ NON DISCONNECTD
6 24L-A LOW IDLE SWITCH F 23B-A NOX SENSOR B+
7 61R-E AC SWITCH OUTPUT G 1-NL PWR NON DISCONNECTD
8 61A-E AC SWITCH INPUT H 18T DNOX SW B+
K 35A-F BKUP ALM RLY OUT
L 35A-C BKUP ALM RLY OUT
BU1, BACKUP ALARM GRND
M 18F-A LH POSN/TAIL FUSED PWR
CAV WIRE IDENT CIRCUIT N 18G-F RH POSN/TAIL FUSED PWR
1 0-JB BACKUP ALARM GND P 45R-B RIGHT TURN SGNL
R 45L-B LEFT TURN SGNL
BU2, BACKUP ALARM S 44A-A BRK LT RLY OUT

T 19Y-C HOOD SWITCH FSD PWR
U 60D HOOD DOWN RLY OUT
1 35A-H BKUP ALM RLY OUT
V 59D HOOD DOWN RLY CTRL
1 35A-HN BKUP ALM RLY OUT
W 60U HOOD UP RLY OUT
1 35A-9 BKUP ALM RLY OUT
X 59U HOOD UP RLY CTRL
BUZ, AIC BUZZER

1 35B AIC BUZZER HSD
2 0-B27 BUZZER GND
CAB PW, CAB POWER

1 1CB-A CAB CB PROTECTED PWR

4002-48
CAB ARM, CAB TO ARMREST CAB B, CAB BTM BULKHEAD
225389C1 W230R396

1 CANS-HB CAN HI, CAN MOD2 A 22D PEDAL SENSOR GRND
2 0-SJ GRND, CAN MOD B 22B PEDAL SENSOR +5V
3 51E-A ARMREST LOWER C 22C PEDAL POS SIGNAL
4 17P-D B+, CAN MOD J 44-A BRK LT CTRL PWR
6 51B-H JSS ACT SW K 1-DR BRK LT SW PWR
7 0-SD GRND, JOYSTICK L 33P-A BRK WARN PRESS LOW
8 51PW-R JSS POWER M 52P-A PARK BRK RLY OUT
9 51S-B JSS OKAY PWR
10 51H-B JOYSTICK SIGNAL CAB FNR, MAIN CAB FNR
11 51NO-A NO NEUTRAL SW
12 CANS-LB CAN LO, CAN MOD2
1 19B-B TRANS ENA SW PWR
2 26F-E FNR FORWARD SIGNAL
CAB ARM FRM, CAB TO ARM TO FRM 3 26N-E FNR NEUTRAL SIGNAL
4 26R-E FNR REVERSE SIGNAL
5 32J-H TRANS ENABLE LT SIG
1 CANS-LB CAN LO, CAN MOD2
6 25Y-E NONE
2 17P-G B+, JOYSTICK
4 51D-B GRND, RELAY CNTL
5 51B-D JSS ACT SW
6 CANS-LD CAN LO, CAN MOD3
7 CANS-HD CAN HI, CAN MOD3
8 0-SK GRND, CAN MOD
9 51PW-M JSS POWER
10 51C-B JSS ACT BTN
11 18S-D B+, JSS FUSED
12 CANS-HB CAN HI, CAN MOD2

4002-49
CAB E, CAB-ENGINE CAV WIRE IDENT CIRCUIT
16 18C-A RH HIGH BEAM FUSED PWR
17 57-A PIN ENGAGE SOL PWR
1 36F-A FUEL LEVEL ANALOG
18 58-C RIDE CTRL SOL PWR
2 61C AC RELAY OUT
3 21G EDC7 CRANK CTRL RLY
4 21H CRANK CTRL RLY LSD CAB FRM, CAB TO JSS FRAME
5 36C-A RADITAOR COOL TEMP SGNL
CRANK REQUEST RLY CTRL
6 0-DF A 51F-B LS PRESS SW
GND
B 51J-A VALVE ALARM
7 0-L TELEMATICS GRND
C 51K-B PILOT PRESS SW
8 61H HEAD LOAD VLV SOL
D 51L-A JOYSTICK SIGNAL
11 21F EDC7 DIGITAL GND
F 51S-F JSS OKAY PWR
13 CAN-LL CAN2 LO, EDC
G 0-SF GRND
14 CAN-HM CAN2 HI, EDC
H 51PW-T JSS POWER
15 21D-A STARTER RLY SIGNAL
J 18S-D B+, JSS FUSED
16 460-A
17 0-DX AIC SENSOR GND
18 23J-B DNOX2 K-LINE CAB RF, CAB TO ROOF CONNECTION
19 0-DW AIC POWER GND
20 0-DB AIC POWER GND RED
21 13C-B FUEL SHUTOFF FUSED PWR
22 52A-A FAN REVERSE RLY OUT
23 56 FAN CONTROL PWM
24 68W REAR WSHR PUMP
25 63W FNT WASHER PUMP
26 14-AB ALTERNATOR D+
388710A1
27 21E-B KEY SWITCH CRANK
28 31F-A AIR FLTR REST SW SGNL
A 0-DZ WORK LIGHTS GRND
29 61R-B AC RELAY CONTROL
B 0-DY ROOF SPLICE GNDS
30 61A-B TRINARY PRESS SW INPUT
C 43-A DOME LT AUTO MODE
31 20G-B EDC7 ISO-K INTERFACE
D 19U-D DOME LT FSD PWR
E 46-C BEACON SW PWR
CAB F, CAB FRONT CHAS F 0-DR ROOF SPLICE GNDS
CAV WIRE IDENT CIRCUIT G 0-DS ROOF SPLICE GNDS
2 45L-C LEFT TURN SGNL H 42C-A FNT WRK LTS FUSE PWR
3 45R-D RIGHT TURN SGNL J 19K-C REAR WPR MOTOR FSD PWR
5 18G-G RH POSN/TAIL FUSED PWR K 68C REAR WPR PARK CTRL
6 18B-A LH HIGH BEAM FUSED PWR L 68L-B REAR WPR SW PWR
9 53P-F PILOT CTRL RLY OUT M 0-EM RADIO GND
10 18F-E LH POSN/TAIL FUSED PWR N 12V-B 12V FUSED PWR TO RADIO
11 54B-A HC-RTT CTRL SGNL P 19U-G DOOR SW FSD PWR
12 53B-B RTD CTRL SIGNAL R 43S-A DOOR OPEN SGNL
13 64-A HORN POWER S 42R-C REAR WRK LTS FUSE PWR
14 18D-A LH LOW BEAM FUSED PWR

15 18E-A RH LOW BEAM FUSED PWR

4002-50
CAB T, CAB TRANSMISSION CAN MOD 2, JSS CAN MOD
380839A1

RDNT BRK ACCUM PRESS
1 33R
LOW
2 34A-C DIFF LOCK SOL B+
SEC STR ACCESSORY FSD 87552623
3 19M
PWR
4 19R-E SEC STR IGN FSD PWR
1 51B-J JSS ACT SW
5 36T-A VALVE BODY TEMP SGNL
2 51PW-U JSS POWER
6 35X SEC STR LOW PRESS SGNL
3 51NC NC NEUTRAL SW
7 25A-A ENG SP SIGNAL
4 51S-D JSS OKAY PWR
8 25C-A TURBINE SP SIGNAL
5 51R ARMREST RAISE
9 25B-A INT SP SIGNAL
7 CANS-HA CAN HI, CAN MOD2
10 25D-A OUTPUT SP SIGNAL
8 CANS-LA CAN LO, CAN MOD2
11 0-DM SPEED SENSOR GNDS
9 17P-E B+, CAN MODULE
12 36R-E TRANS TEMPS/FLTR RETURN
10 0-SE GRND
13 36G-A TCO TEMP SIGNAL
14 25G-A BRK DECLUTCH SW CTRL
15 25R-A TC LOCKUP SOL POWER CBPW, CAB POWER
16 25K-A TRANS SOL VALVE Y1
17 25L-A TRANS SOL VALVE Y2
1 1CB CAB CB PROTECTED PWR
18 25M-A TRANS SOL VALVE Y3
19 25N-A TRANS SOL VALVE Y4
20 25P-A TRANS SOL VALVE Y5
CONNECTOR CL - CIGAR LIGHTER
21 25J-A TRANS SOL VALVE Y6
22 25S-A OUTPUT SW PWR VPS1
23 31H-A HYD FLTR REST SW SGNL
24 19A-T BRK DECLUTCH SW FSD PWR
25 25T-A TC LOCKUP SOL GND
26 19S2 SEC STR FSD PWR
27 34C DIFF LOCK SOL GND
OUTPUT SPEED SENSOR
28 0-DN
GND
OUTPUT SP SNSR FUSED 3227856R1
29 19A-M
PWR
30 36H-A HYDRAULIC OIL TEMP
1 19W CIGAR LIGHTER FUSED POW
31 32F-A TRANS FLTR MAINT SW
2 0-DV CIGAR LIGHTER GROUND

4002-51
CONNECTOR CNV - 24V TO 12V POWER CONNECTOR DIA - DIAGNOSTIC
CONVERTER
310057A1
225351C1
CAV WIRE IDENT CIRCUIT DIAGNOSTICS CONNECTOR
A 0-DH
1 19L-A POW CONVER. FUSED POW GND
2 19L-B POW CONVER. FUSED POW B 18K-D DIAGNOSTICS FUSED B+
3 0-EJ POW CONVERTER GROUND C CAN-HB CAN HIGH
4 NOT USED D CAN-LB CAN LOW
5 12V-C 12V SWITCHED POWER E 20G-B EDC7 ISO-K INTERFACE
6 0-ER POW CONVERTER GROUND
DIA 2, DIAGNOSTIC
DC1, DISCONECT BATTERY

1 1-NB BATTERY STARTER
DC2, DISCON BLCK GRND

1 0-NB MASTER DISCONNECT GND
310057A1

DC3, FUEL SOL DISCONNECT
A 0D-C DIAG2 GRND
CAV WIRE IDENT CIRCUIT B 18K-B DIAG FUSED B+
1 13C FUEL SHUTOFF FUSED PWR C CAN-HO CAN2 HI, DIAG2

D CAN-LX CAN2 LO, DIAG2
E 23J-B DNOX2 K-LINE
DC4, FUEL SOL DISCONNECT

1 13M FUEL SHUTOFF FUSED PWR
DEFDM, DOSER METERING VLV

1 38 DOSER VALVE B+
2 38A DOSER VALVE GND

4002-52
CONNECTOR DISC - DISCONNECT ENGINE DNOX2, NOX CONTROLLER

1 38D TANK HEAT B+
3 18U-D DCU B+ NON DISCONNECTD
4 18U-B DCU B+ NON DISCONNECTD
7 CAN-QH CAN HI, DNOX2
8 CAN-LK CAN LO, DNOX2
11 38A DOSER VALVE GND
245482C1 12 38 DOSER VALVE B+
CAV WIRE IDENT CIRCUIT 14 0-LB DNOX2 MODULE GND
A 13C FUEL SHUTOFF FUSED POW 15 0-LC DNOX2 MODULE GND
B 13M FUEL SHUTOFF FUSED POW 17 0E-A EXHT TEMP UP GND
18 38B DEF LEVEL SIG
19 0-T DEF SENSOR GND
CONNECTOR DM - DIODE OR
23 38C TANK HEAT GND
24 18T-A DNOX2 SW B+
25 0-U EXHT TEMP DWN GND
26 38E EXHT TEMP DWN B+
28 38F EXHT UP SIGNAL
29 38G DEF TEMP SIG
31 38H DNOX2 K-LINE
245485C1
CAV WIRE IDENT CIRCUIT CONNECTOR DS - DOOR SWITCH

SEC. STEERING IGNITION
A 19RR
FUSED PWR
B NOT USED
C 19R
FUSED PWR
245482C1

DOOR SWITCH FUSED
A 19U-F
POWER
B 43S-B DOOR OPEN SIGNAL

4002-53
DTLTS, DEF TANK LEVEL TEMP SENSOR
W230R399

1 38B-A DEF LEVEL SIG
2 0-TA DEF SENSOR GND
3 38G-A DEF TEMP SIG
DTS, DOWNSTREAM TEMP SENS

1 38E EXHT TEMP DWN B+
2 0-U EXHT TEMP DWN GND
CONNECTOR D-OR - DIODE OR
245485C1

FRONT WORK LIGHTS FUSED
A 42C-D
POWER
POSITION LIGHTS SWITCHED
B 41T-C
POWER
C 49 BACK LIGHT POWER

4002-54
EDC7, ENGINE CONTROLLER CAV WIRE IDENT CIRCUIT
35 CAN1-H CAN HI
35 CAN-HK CAN HI, EDC
36 28F FUEL FLTR HTR RLY CTRL
37 21G-A EDC7 CRANK CTRL RLY
40 13M-A FUEL SHUTOFF FUSED PWR
42 35W WIF INDICATOR
48 24L LOW IDLE SWITCH
51 13A EVGT RELAY
52 CAN-LS CAN LO, NOX
52 CAN-L3 CAN2 LO, NOX
53 CAN-HS CAN2 HI, NOX
53 CAN-H3 CAN2 HI, NOX
68 23K-A TEMP/HUMD B+
75 0-BV GRID HEATER CTRL GND
77 24S THROT SUPPLY
78 24R THROT GND
79 24B THROT SIGNAL
89 20G-A EDC7 ISO-K INTERFACE
ECA L1, B+ POWER

cs01 J1 TRANS ECM PWR
BOSCH-89-POLE CONNECTOR EM - HEIGHT CONTROL RTD - RTT

2 18J-C EDC7 FSD PWR
3 18J-B EDC7 FSD PWR
5 0-BE EDC7 GND
6 0-BF EDC7 GND
8 18J-D EDC7 FSD PWR
9 18J-E EDC7 FSD PWR
10 0-BD EDC7 GND
225351C1
11 0-BC EDC7 GND
12 28G GRID HTR SOURCE DR
1 55A-A RTT/FLOAT SWITCHED POW.
13 31 EDC RELAY CNTL
HEIGHT CONTROL
17 21H-A CRANK CTRL RLY LSD 2 54A
SWITCHED POWER
26 23K-B TEMP/HUMD TEMP
3 53A RTD SWITCHED POWER
27 23K-C TEMP/HUMD HUMD
4 53B-B RTD CONTROL SIGNAL
28 23K-E TEMP/HUMD GND
5 54B-B HC-RTT CONTROL SIGNAL
29 21F-B EDC7 DIGITAL GND
RTT FLOAT SWITCH
6 55B
32 21E-A KEY SWITCH CRANK CONTROL
34 CAN-LJ CAN LO, EDC
34 CAN1-L CAN LO

4002-55
ENG B, CAB BOTTOM ENG, ENGINE CAB1

1 36F FUEL LEVEL ANALOG
1 36J FUEL LEVEL ANALOG
2 61C-A AC RELAY OUT
3 21G-A EDC7 CRANK CTRL RLY
4 21H-A CRANK CTRL RLY LSD
RADIATOR COOL TEMP
5 36C
SGNL
6 0-BAT CRANK REQUEST GND
7 0-BK TELE GROUND
8 61H-A HEAT LOAD VLV SOL
225320C1
11 21F-A EDC7 DIGITAL GND
13 CAN-L CAN LOW
1 21F-C EDC7 DIGITAL GND
13 CAN1-L CAN LO
2 0-BBR GROUND
14 CAN-H CAN HIGH
3 24B THROT SIGNAL
14 CAN1-H CAN HI
4 24R THROT GND
15 21D STRTR RLY SIGNAL
5 24S THROT SUPPLY
16 460 FAN SPEED SENSOR SIGNAL
6 24L LOW IDLE SWITCH
17 0-BJ AIC SENSOR GND
7 61R-C AC SWITCH OUTPUT
18 38H DNOX2 K-LINE
8 61A-C AC SWITCH INPUT
19 0-BG AIC POWER GND
20 0-BH AIC POWER GND RED
21 13C-A FUEL SHUTOFF FUSED PWR
22 52A-B FAN REVERSE RLY OUT
23 56-A FAN CONTROL PWM
24 68W-A REAR WSHR PUMP
25 63W-A FNT WASHER PUMP
26 14 ALTERNATOR D+
26 14-5 ALTERNATOR D+
27 21E-A KEY SWITCH CRANK
28 31F AIR FLTR REST SW SGNL
29 61R AC RELAY CONTROL
30 61A AC PRESS SW INPUT
31 20G-A EDC7 ISO-K INTERFACE

4002-56
ECA, ELECT CNTR A
87315248

L1 J5 EMG STRG PLT EM DTNTS
A1 19A-N TRANS FUSE PWR
L1 J6 PLTEM DTNTS PRK BRK SOL
A2 18S-A B+, JSS FUSED
L1 J7 PRK BRK SOL HRN
A3 19E-A AIC WAKE UP IGN
L1 J8 FAN RVSR TURN SGNL
A4 19RR SEC STR IGN FSD PWR
L1 J9 TURN SGNL ENG SHTDWN.
A5 19C-A PILOT CTRL RLY FSD PWR
L1 J10 DNOX SW B+
A6 19D-A PARK BRK RLY FSD PWR
L2 J11 BLWR MOTOR PWR
A7 19P PIN ENGAGE/FAN FSD PWR
L2 J12 BLWR MTR FRNT WIPR WASH
A8 19B TURN SIGNAL FSD PWR
L2 J13 FRNT WIPR RER WIPR WSH
A9 13C-B FUEL SHUTOFF FUSED PWR
L2 J14 RER WIPR WSH BACKUP
A10 18T DNOX SW B+
L2 J15 BKUP A/C
C1 18N BLOWER MOTOR FUSED PWR
L2 J16 HEATED MIRRORS
C2 19J FNT WPR FSD PWR
L2 J17 SEAT COMP EMG STRTR
C3 19K REAR WPR FSD PWR
L2 J18 DIAGNOSTIC PWR
C4 19H BACKUP ALARM B+
C6 19N SEAT CPRSR FSD PWR
C7 19M SEC STR ACCESSORY FSD PWR
C8 19W CIGAR LIGHTER FSD PWR
C9 66A RR CAMERA PWR
L1 J1 TRANS ECM PWR
L1 J2 TRANS ECM PWR
L1 J3 EMG STR AIC PWR
L1 J4 EMG STR AIC PWR

4002-57
ECB, ELECT CNTR B
87312843

A1 12V-D PLUG 1 12V SW PWR B4 0-DE NEUT START RLY CTRL GND
A2 12V-E PLUG 2 12V SW PWR B5 21F EDC7 DIGITAL GND
A3 41H-B HIGH BEAM LH PWR CRANK REQUEST RLY CTRL

B6 0-DF
GND
A4 41H-C HIGH BEAM RH PWR
B7 19P-E FAN REV RLY FSD PWR
A5 41L-C LOW BEAM RH PWR
B8 52 FAN REVERSER LSD
A6 41L-B LOW BEAM LH PWR
B9 19D-C PARK BRK RLY FSD PWR
A7 41T-B POSN LIGHTS LH SW PWR
B10 52C PARK BRK SOL LSD
A8 41T-A POSN LIGHTS RH SW PWR
C2 0-EA PWR RELAY GND
A9 12V-F RADIO 12V SW PWR
D1 13K-B IGN PWR LATCH B+
A10 12V-G 2 WAY RADIO 12V SW PWR
D2 0-ET POWER RELAT GND
AA1 12V 12V PWR TO OUTLET 1
D3 25T NEUTRAL SIGNAL
AA2 12V-A 12V PWR TO OUTLET 2
D4 21C NEUTR START RLY OUTPUT
AA3 18B-A LH HIGH BEAM FUSED PWR
D5 21C-A NEUTR START RLY OUTPUT
AA4 18C-A RH HIGH BEAM FUSED PWR
D6 21E KEY SWITCH CRANK
AA5 18E-A RH LOW BEAM FUSED PWR
D7 19P-D FAN REV RLY FSD PWR
AA6 18D-A LH LOW BEAM FUSED PWR
D8 52A-A FAN REVERSE RLY OUT
AA7 18F-C LH POSN/TAIL FUSED PWR
D9 19D-B PARK BRAKE RLY FSD PWR
AA8 18G RH POSN/TAIL FUSED PWR
D10 52P-B PARK BRK RLY OUT
AA9 12V-B 12V FUSED PWR TO RADIO
B1 0-EW POWER RELAY GND
B2 0-EV IGN LATCH GND
B3 21K-B IGN SW START SIGNAL

4002-58
ECD, ELECT CNTR D
87312843

B3 63C3 FNT WPR PARK CTRL
A1 0-EF BRK LTS RLY CTRL GND
B4 63LC FNT WPR LS RLY CTRL
A2 1-DW BRAKE LT RLY BAT PWR
B5 19C-B PILOT CTRL RLY FSD PWR
A3 0-EZ POWER RELAY CONTROL
B6 53C-A PILOT CTRL RLY SOL LSD
A4 0-EY POWER RELAY GND
B7 58T RIDE CTRL RLY SW PWR
A5 21H CRANK CTRL RLY LSD
B8 58L RIDE CTRL RLY LSD
A6 21C-B NEUT START RLY OUTPUT
B9 61A-G TRINARY PRESS SW INPUT
A7 23B-C NOX RELAY GND
B10 0-DJ AC RELAY CONTROL GND
A8 23B-A NOX SENSOR B+
C2 63C2 FNT WPR PARK CTRL
A9 35C BACK UP ALRM CNTL
C4 63C FNT WPR PARK CTRL
A10 19H BACK ALARM B+
C10 61C AC RELAY OUT
AA1 44A-A BRK LT RLY OUT
D1 19J-D FNT WPR RLY FSD PWR
AA2 44A BRK LT CTRL PWR
D2 63H-B FNT WPR RLY HS
AA3 0-KA IGN PWR CONTROL GND
FNT WPR RLY LS CTRL FSD
AA4 13K-A IGN PWR CONTROL B+ D3 19J-F
PWR
AA5 21D-A STRTR RLY SIGNAL
D4 63-C2 FNT WPR PARK CTRL
AA6 21G EDC7 CRANK CTRL RLY
D5 19C-C PILOT CTRL RLY FSD PWR
AA7 23B-B NOX SENSOR B+
D6 53P-C PILOT CTRL RLY OUT
AA8 23B-D NOX RELAY B+
D7 58H-C POWER
AA9 35A-A BACKUP ALARM
D8 58-E RIDE CTRL SOL PWR
AA10 19A-P BACKUP ALARM RELAY
D9 61R-B AC RELAY CONTROL
B1 19J-E FNT WPR RLY FSD PWR
B2 63HC-B FNT WPR RLY HS

4002-59
ECC, ELECT CNTR C
87315249

D2 19Y-A HOOD UP RLY FSD PWR
A1 19U-B BEACON DOME LT FSD PWR
A2 42 WORK LIGHTS SW FSD PWR D3 59D HOOD DOWN RLY CTRL
A3 19Z DRIVING LTS SW FSD PWR D4 19Y-B HOOD DOWN RLY FSD PWR
A4 1-DV BRK LTS/FLASHER BAT PWR D7 19U-E HORN RLY FSD PWR
A5 1DM TIME DELAY/IGN SW FSD PWR D8 64-A HORN POWER
A6 19U HORN RLY FSD PWR D9 21J RESTART PREVENT
A7 19Y HOOD CTRL FSD PWR D10 67B START LOCKOUT
A8 19S-B AIC DELAY FSD PWR L1-1 ECC-L1 BEACON/DOME LT LI ECC
A9 18K-A DIAGNOSTIC FUSED PWR L1-1 J2-ECC BEACON/DOME LT WORK LTS
A10 19T-C FUSED BATT PWR L1-2 J3-ECC WORK LTS DRIVING LTS
B1 60U HOOD UP RLY OUT L1-2 J2-ECC BEACON/DOME LT WORK LTS
B2 0-B25 HOOD UP CONTROL GND L1-3 J4-ECC DRIVING LTS BRK LTS
B3 60D HOOD DOWN RLY OUT L1-3 J3-ECC WORK LTS DRIVING LTS
B4 0-B16 HOOD DOWN CONTROL GND L1-4 J5-ECC BRK LTS DLY PWR
B7 19U-A HORN RLY FSD PWR L1-4 J4-ECC DRIVING LTS BRK LTS
B8 64C HORN RLY CTRL L1-5 J6-ECC DLY PWR HRN
B9 21E KEY SWITCH CRANK L1-5 J5-ECC BRK LTS DLY PWR
B10 0-J START LOCKOUT RLY GND L1-6 J7-ECC HRN HOD CTRL
C2 0-B22 HOOD UP RELAY GND L1-6 J6-ECC DLY PWR HRN
C4 0-B12 HOOD DOWN RELAY GND L1-7 J7-ECC HRN HOD CTRL
C10 21E-B KEY SWITCH CRANK L1-8 J9-ECC
D1 59U HOOD UP RLY CTRL L1-9 J10-ECC

L1-10 J10-ECC

4002-60
ENG2, ENG BULKHD 2 CONNECTOR ENG-D - DISCONECT HARNESS
245483C1

A 13C-A FUEL SHUTOFF FUSED POW
B 13M-B WIF IGN PWR
W230R397

A 23B-F NOX RELAY B+ CONNECTOR ENG-H - ENGINE TO HOOD
B 18U-D DCU B+ NON DISCONNECTD
C 23A-A DNOX2 MODULE B+
D 1-NK PWR NON DISCONNECTD
E 18U-B DCU B+ NON DISCONNECTD
F 23B-E NOX SENSOR B+
G 1-NJ PWR NON DISCONNECTD
H 18T-A DNOX2 SW B+
K 35A-G BKUP ALM RLY OUT
K 35A-GN BKUP ALM RLY OUT
L 35A-J REVERSE LT
L 35A-R BKUP ALM RLY OUT
225320C1
M 18F-AN LH POSN/TAIL FUSED PWR
M 18F-B LH POSN/TAIL FUSED PWR
1 0-BAG-N HOOD GROUND (NA)
N 18G-H RH POSN/TAIL FUSED PWR
2 44A-DN BRAKE LIGHT RELAY OUT
N 18G-HN RH POSN/TAIL FUSED PWR
3 45L-AN LEFT TURN SIGNAL
P 45R-A RIGHT TURN SGNL
4 45R-AN RIGHT TURN SIGNAL
P 45R-AN RIGHT TURN SGNL
RH POSITION/TAIL FUSED
R 45L-A LEFT TURN SGNL 5 18G-HN
PWR
R 45L-AN LEFT TURN SGNL LH POSITION/TAIL FUSED
6 18F-AN
S 44A-D BRK LT RLY OUT PWR
S 44A-DN BRK LT RLY OUT 7 35A-GN BACKUP ALARM RELAY OUT
T 19Y-D HOOD SWITCH FSD PWR 8 35A-R BACKUP ALARM RELAY OUT
U 60D-A HOOD DOWN RLY OUT

V 59D-A HOOD DOWN RLY CTRL
W 60U-A HOOD UP RLY OUT
X 59U-A HOOD UP RLY CTRL

4002-61
CONNECTOR E-HD - TRANSMISSION HOOD CONNECTOR FLSHR - FLASHER MODULE
245485C1

225389C1
A 18G-D LIC PLATE LIGHT FUSED PWR
B 35A-G BACKUP ALARM RELAY OUT
1 1-DU FLASHER MODULE POWER
C 0-BAG HOOD GROUND (EURO)
2 45N-A FLASHER OPT. SIDE CONTR.
3 0-EH FLASHER MODULE GROUND
CONNECTOR ESS - ENGINE SPEED SENSOR 4 0-EG FLASHER MODULE GROUND

5 NOT USED
6 NOT USED
7 45R-E RIGHT TURN SIGNAL
8 45L-D LEFT TURN SIGNAL
9 45A-A LEFT TURN SWITCH POWER
10 45B-A RIGHT TURN SWITCH POWER
11 45H HAZARD SWITCH POWER
12 45N-B FLASHER OPT. SIDE CONT.
291718A1
CONNECTOR FM - FILTER MAINTENANCE
CAV WIRE IDENT CIRCUIT SWITCH
1 25A ENGINE SPEED SIGNAL
ENGINE SPEED SENSOR
2 0-HF
GROUND
CONNECTOR FFH - FULE FILTER HEATER
371614A1

1 32F TRANS FILTER MAINT SW
2 36R-B TRANS FM SWITCH RETURN
182069A1

A 1-GB FUEL FILTER HEATER PWR
FUEL FILTER HEATER
B 0-BX
GROUND

4002-62
FNR RLY, RELAY K2 CONNECTOR FWM - FRONT WIPER MOTOR

30 19B-A FNR SW FUSED PWR
85 0-ST GRND, JOYSTICK
86 51B-K JSS POWER
87 19B-B TRANS ENA SW PWR
87A 0-SS TRANS ENA SW PWR
FRONT, FRNT CHAS-CAB

245715C1
2 45L LEFT TURN SGNL
FRONT WIPER HIGH SPEED
A 63H-A
3 45R RIGHT TURN SGNL RLY OUT
5 18G-A RH POSN/TAIL FUSED PWR FRONT WIPER LOW SPEED
B 63L-A
RLY OUT
6 18B LH HIGH BEAM FUSED PWR
FRONT WIPER MOTOR
9 53P-G PILOT CTRL RLY OUT C 19J-A
FUSED POWER
10 18F LH POSN/TAIL FUSED PWR
FRONT WIPER PARK
D 63C
11 54B HC-RTT CTRL SGNL CONTROL
12 53B RTD CTRL SIGNAL
13 64 HORN POWER
CONNECTOR FWMG - FRONT WIPER MOTOR
14 18D LH LOW BEAM FUSED PWR GROUND
15 18E RH LOW BEAM FUSED PWR
16 18C RH HIGH BEAM FUSED PWR
17 57 PIN ENGAGE SOL PWR
18 58-B RIDE CONTROL SOL PWR
18 58-G RIDE CONTROL SOL PWR
FWD DIODE, DIODE ASSY

245480C1
A 26F-D FNR FORWARD SIGNAL
B 26F-E FNR FORWARD SIGNAL
FRONT WIPER MOTOR
C 26F-C FNR FORWARD SIGNAL A 0-B8
GROUND

4002-63
CONNECTOR FWW - FRONT WASHER GHF3, GRID HEATER FUSE

1 1-Y GRID HTR FSD PWR
GHF4, GRID HEATER

1 1-Y GRID HTR FSD PWR
3227856R1 GND CAB1 , GROUND A

1 63W-A FRONT WASHER PUMP
1 0-DD WORK LIGHTS GRND
2 0-B FRONT WASHER GROUND
1 0-DR ROOF SPLICE GNDS
1 0-DS ROOF SPLICE GNDS
GH, GRID HEATER
CAV WIRE IDENT CIRCUIT GND CAB2 , GROUND A

1 1-BE GRID HTR PWR
1 0-B8 FRONT WIPER MOTOR GND
GH 1, GRID HEATER
1 0-B10 HOOD GND
1 0-B26 BUZZER/SW PAD GND
1 0-ES GRID HTR GND
GND CAB3 , GROUND C

CONNECTOR GHC - GRID HEATER RELAY
1 0-DG CAB SPLICE GNDS
1 0-DV CIGAR LIGHTER GND
GND CAB3D , GROUND A

1 0-DP DIAG TECM GND
1 0-DQ DIAG TECM GND
1 0-DAV TECM DIAGNOSTIC GND
3227856R1

1 28G GRID HTR SOURCE DR GND CAB4 , GROUND C
2 0-BV GRID HTR CONT GND
1 0-ED HVAC GNDS
GHF1, GRID HEATER FUSE 1 0-EJ POWER CONVERTER GND
1 0-ER POWER CONVERTER GND
1 1-E GRID HTR FUSE BAT PWR

4002-64
GND CAB5 , GROUND C GND CAB SPL2, SPL BACK LGHT GD

1 0-EK AUX POWER OUTLET 1 GND
1 0-EL AUX POWER OUTLET 2 GND
GND CAB6, STRT, FFH, WAT SEP HTR

SPLICE PACK GND CAB SPL2
1 0-EQ
GND
87324393
EVGT3, EVGT FUSE
CAV WIRE IDENT CIRCUIT A 0-J START LOCKOUT RLY GND
A 1-T EVGT 3 PWR B 0-KA IGN PWR CONTROL GND
B 1-B EVGT RELAY PWR C 0-K CAMERA GND

E 0-EW POWER RELAY GND
F 0-BBC JOYSTICK GROUND
CONNECTOR GND-CAB-SPL - CAB GROUND
G 0-DE NEUT START RLY CTRL GND
SPLICE
SPLICE PACK GND CAB SPL2
H 0-EQ
GND
K 0-EH FLASHER MODULE GND
L 0-EG FLASHER MODULE GND
M 0-EF BRK LTS RLY CTRL GND
GND ENG1 , STRT, FFH, WAT SEP HTR

1 0-BW WATER SEP HEATER GND
1 0-BX FUEL FILTER HEATER GND
87324393 1 0-GB STARTER RLY CTRL GND

DIODE SUPPRESSION
A 0-EE GND ENG2 , DEDICATED WIF, EDC
GROUNDS
B 0-EM RADIO GROUND
C 0-EP HORN SWITCH GROUND
1 0-BP WIF SENSOR GND
D 0D-C DIAG2 GROUND
1 0-BAT CRANK REQUEST GND
E 23B-C NOX RELAY GROUND
1 0-BAC EDC7 GND
F 0-DG CAB SPLICE GROUNDS
1 0-BAU EVGT_2 GND
G 0-DT FRNT WIP/WASHER SW GND
1 23D-D NOX SENSOR GND
J 0-DK SEAT COMPR MOTOR GND
H 0-VA HEATED MIRRORS GND
K 0-DJ AC RELAY CONTROL GRND
L 0-DU PILOT PRESS SOLEN GND
DIAGNOSTIC CONNECTOR
M 0-DH
GROUND

4002-65
GND ENG3 , SPLC PK, WSHR MTR GND FC , GROUND A

1 0-BM ENGINE SPLICE GNDS 1 0-AG FRONT CHASSIS GND
1 0-BBR GROUND 1 0-AB PROX SW GND
GND ENG4 , REAR LIGHTING GND GH1, STRT, FFH, WAT SEP HTR

1 0-BAG HOOD GROUNDS (EURO) 1 0-ES GRID HTR GND
1 0-BAG-N HOOD GROUNDS (NA)
1 0-BT LH REAR LIGHT GND (EURO)
GND JSS , GROUND A
1 0-BR RH REAR LIGHT GND (EURO)

1 0-AV GRND
EVGT4, EVGT

GND PDST , GROUND A
A 13B EVGT RELAY PWR
B 31A EVGT RELAY B+ CAV WIRE IDENT CIRCUIT
C 13A EVGT RELAY 1 0-BA PEDESTAL GND STRAP
D 1-B EVGT RELAY PWR
GND PDST1 , GROUND A

FSS, FAN SPEED SENS
CAV WIRE IDENT CIRCUIT 1 0-DA AIC CHASSIS GND
1 460 FAN SPEED SENSOR SIGNAL
2 017A FAN SPEED SENSOR GND
GND PDST2 , GROUND A
GND ENG6 , DEDICATED CAV WIRE IDENT CIRCUIT

1 0-BA PEDESTAL GND STRAP
1 0-BG AIC POWER GND
GND S1 , GROUND A
1 0-BH AIC POWER GND RED
1 0-BJ AIC SENSOR GND CAV WIRE IDENT CIRCUIT
1 0-BAR WIF BODY GRND FRONT TO REAR CHASSIS
1 0-AP
GND
GND ENG7 , GRND TRANS CLNT

GND S2 , GROUND A
017A FAN SPEED SENSOR GND CAV WIRE IDENT CIRCUIT
1 0-BAE EDC7 SENDER GND FRONT TO REAR CHASSIS

1 0-AP
GND
1 0-BBF DNOX2 MODULE GND
1 0-BK TELE GROUND
1 0-BU FUEL LEVEL SENDER GND
1 0-BZ FUEL LEVEL SENDER GND

4002-66
GND SSCHAS, SSM GROUND CABLE CONNECTOR HD-E - HOOD HARNESS TO
TRANSMISSION HARNESS
1 0-ND SSM GROUND
GND SSMOD, SEC STR CHASIS GND

SEC STEERING CHASSIS
1 0-CE
GND
1 0-CD SEC STEERING SPLICE GND 245484C1
GND WIF, GRND WIF RING TERM LICENSE PLATE LIGHT

A 18G-E
FUSED PWR
CAV WIRE IDENT CIRCUIT B 35A-H BACKUP ALARM RELAY OUT
1 0-BAR WIF BODY GRND C 0-JA HOOD GROUND (EURO)
GND TRANS, GROUND TRANS HDM, HOOD LIFT MOTOR
1 0-HW HOT GROUND 1 60U-A HOOD UP RLY OUT
1 0-HR HYD FLTR SW GRND 2 60D-A HOOD DOWN RLY OUT
1 0-HL RED BRAKE SW GND

1 0-HM RED BRAKE SW GND
CONNECTOR HD - HOOD SWITCH
245485C1

A 59D-A HOOD RELAY CONT DOWN
B 19Y-D HOOD SWITCH FUSED PWR
C 59U-A HOOD RELAY CONTROL UP

4002-67
CONNECTOR HD-N - HOOD TO ENGINE HTS, HMDTY AND AMB TEMP

1 23K-A TEMP/HUMD B+
2 23K-B TEMP/HUMD TEMP
3 23K-C TEMP/HUMD HUMD
4 23K-E TEMP/HUMD GND
HVAC1, HVAC1

1 61A-F TRINARY PRESS SW INPUT
225319C1 BLOWER MOTOR FUSED
2 18N-A
PWR
3 49A BACK LIGHT POWER
1 0-JA-N HOOD GROUNDS (NA)
4 61B-A AC SIGNAL
2 44A-EN BRAKE LIGHT RELAY OUT
3 45L-BN LEFT TURN SIGNAL
4 45R-BN RIGHT TURN SIGNAL CONNECTOR HVAC2 - HVAC2
5 18G-JN RH POSITION/TAIL FUSED PWR
6 18F-BN LH POSITION/TAIL FUSED PWR
7 35A-HN BACKUP ALARM RELAY OUT
HN1, HORN PWR

1 64 HORN POWER
HN2, HORN GRND
87552622
1 0-AF HORN GND
1 18N-B BLOWER MOTOR FUS PWR
2 0-ED HVAC GROUNDS
CONNECTOR HOT - HYDRAULIC OIL
TEMPERATURE SENDER
194788A1

A 36H HYDR. OIL TEMP SIGNAL
B 0-HW HYDR. OIL TEMP GROUND

4002-68
CONNECTOR ISS - INT-SPEED-SENSOR JSS CAB
291718A1 225389C1
1 25B INT SPEED SIGNAL 1 CANS-LP CAN LOW,CAN MOD3
2 0-HG INT SPEED SENSOR GROUND 2 17P-C B+, CAN MOD

4 51D-A GRND, RELAY CTRL
5 51B-C JSS ACT SW
JSS ARM, JSS ARMREST TO CAB
6 CAN-LR CAN LOW, CAN MOD2
7 CAN-HR CAN HI,CAN MOD3
8 0-BBD JOYSTICK GROUND
9 51PW-N JSS POWER
10 51C-A JSS ACT BTN
11 18S-C B+, JSS FUSED
12 CAN-HP CAN HI,CAN MOD2
JSS CONTROLLER

1 CANS-HD CAN HI, CAN MOD3
2 CANS-LD CAN LO, CAN MOD3
3 17P-F B+, JSS CONTROLLER
4 51H-B JOYSTICK SIGNAL
W230R400
5 51S-A JSS OKAY PWR
CAV WIRE IDENT CIRCUIT 6 51E-A ARMREST LOWER
1 CANS-HA CAN HI, CAN MOD2 7 51L-A JOYSTICK SIGNAL
2 0-SH GRND, CAN MOD 8 51K-B PILOT PRESS SW
3 51E-B ARMREST LOWER 9 51PW-Q JSS POWER
4 17P-E B+, CAN MODULE 10 0-SM GRND, JOYSTICK
6 51B-J JSS ACT SW 11 0-SN GRND, JOYSTICK
7 0-SC GRND, JOYSTICK 12 51J-B VALVE ALARM
8 51PW-S JSS POWER 13 51C-B JSS ACT BTN
9 51S-C JSS OKAY PWR 14 51NO-A NO NEUTRAL SW
10 51H-C JOYSTICK SIGNAL 15 0-SR GRND, JOYSTICK
11 51NO NO NEUTRAL SW 16 51F-B LS PRESS SW
12 CANS-LA CAN LO, CAN MOD2

4002-69
JSS FRAME TO CAB JSS PILOT PRESSURE

A 51F-A LS PRESS SW SIG
A 51F-C LS PRESS SW SIG
B 51J-C JSS ALARM
C 51K-C PILOT PRESS SW SIG
D 51L JOYSTICK SIGNAL
F 51S-J JSS OKAY PWR
G 0-AS GRND, JOYSTICK 245483C1
H 51PW-H JSS POWER CAV WIRE IDENT CIRCUIT

J 18S-E B+, JSS FUSED A 18S-E B+, JSS FUSED
B 51K-C PILOT PRESS SW SIG
JSS LOAD SENSE

RLY, RELAY K2
245483C1

A 51PW-J JSS POWER
245731C1
B 51F-A LS PRESS SW SIG
30 51PW-P JSS POWER
JSS PILOT DUMP 85 51D-B GRND, RELAY CNTL
86 51B-E B+, JSS
87 51B-G B+, JSS
1 51PW-K JSS POWER
87A 0-SL GROUND
2 0-AU GRND, PILOT DUMP

4002-70
JSS 197F, MAIN CAB FNR JSS VALVE, JSS HYD VALVE
225350C1
239451A1
1 0-SS GRND, JOYSTICK
1 51L JOYSTICK SIGNAL
2 26F-D FNR FORWARD SIGNAL
2 51J-C JSS ALARM
3 26N-D FNR NEUT SIGNAL
3 0-AT GRND, JSS VLV
4 26R-D FNR REVERSE SIGNAL
4 51S-J JSS OKAY PWR
5 32J-G TRANS ENABLE INDICTION
6 25Y-F TRANS KICK DOWN SIGNAL
KD DIODE, DIODE ASSY
JSS 197M, FNR-MAIN CAB
245485C1

A 25Y-F TRANS KICK DOWN SIGNAL
225351C1
B 25Y-E TRANS KICK DOWN SIGNAL
C 25Y-D TRANS KICK DOWN SIGNAL
1 19B-A FNR SW FUSED PWR
2 26F-C FNR FORWARD SIGNAL
3 26N-C FNR NEUT SIGNAL KWCO, WIPER CUT OUT
4 16R-C FNR REVERSE SIGNAL
5 32J-F TRANS ENABLE INDICTION
30 63L-B FNT WPR LS RLY OUT
6 25Y-D TRANS KICK DOWN SIGNAL
85 63HC-A WPR CUT OUT RLY CTRL
86 19J-G WPR CUT OUT RLY FSD PWR
87A 63C3 FNT WPR PARK CTRL

4002-71
LLR, LH REAR COMB. LT LDM3, DOME LIGHT GND

1 0BR-N LH REAR LIGHT GND (NA) 1 0-MB DOME LIGHT GND
2 44A-FN BRK LT RLY OUT
3 18F-BN LH POSN/TAIL FUSED PWR
LLF, LIGHTS LH
4 45L-BN LEFT TURN SGNL
LLR, RH REAR COMB. LT

1 0BT-N RH REAR LIGHT GND (NA)
2 44A-GN BRK LT RLY OUT
3 18G-CN RH POSN/TAIL FUSED PWR
4 45R-BN RIGHT TURN SGNL
225351C1

L1 ECC, ECC BATT PWR
1 0-AJ LH FRONT LIGHTS GND
CAV WIRE IDENT CIRCUIT 2 18D LH LOW BEAM FUSED PWR
1 1-C ECC BAT PWR 3 18B LH HIGH BEAM FUSED PWR
1 ECC-L1 BEACON/DOME LT LI ECC 4 18F LH POSN/TAIL FUSED PWR

5 45L LEFT TURN SGNL
LBEGRD, LIGHT BEACON GRND

CONNECTOR LLFW - LH FRONT WORK LAMP
1 0-MC BEACON LIGHT GND
LBEPWR, LIGHT BEACON PWR

1 46-D BEACON SW PWR
245483C1
LDM1, DOME LIGHT B+ CAV WIRE IDENT CIRCUIT

LH FRONT WORK LTS FUSE
1 42C-H
CAV WIRE IDENT CIRCUIT PWR
1 19U-C DOME LT FSD PWR 2 0-MU LH FRONT WORK LIGHT GND
LDM2, DOME LIGHT AUTO

1 43-B DOME LT AUTO MODE

4002-72
CONNECTOR LLRW- LH REAR WORK LAMP CONNECTOR LPL - LICENSE PLATE LAMP
245483C1 245482C1

1 42R-H LH REAR WORK LTS FUS PWR LICENSE PLATE LAMP FUSED
A 18G-E
2 0-ME LH REAR WORK LIGHT GRND PWR
LICENSE PLATE LAMP FUSED
A 18G-EN
PWR
CONNECTOR LLR-E - LH REAR COMBINATION LICENSE PLATE LAMP FUSED
A 18G-L
LAMP PWR
B 0-JC LICENSE PLATE LAMP GRND
CONNECTOR LRF - RH FRONT COMBINATION

LAMP
225351C1

1 44A-E BRAKE LIGHT RELAY OUT
2 45L-A LEFT TURN SIGNAL
LEFT POSN/TAIL FUSED
3 18F-B 225351C1
POWER
4 35A-L REVERSE LT CAV WIRE IDENT CIRCUIT
LH REAR LIGHT GROUND 1 0-AH RH FRONT LIGHTS GROUND

5 0-BT
(EURO) 2 18E RH LOW BEAM FUSED PWR
6 NOT USED 3 18C RH HIGH BEAM FUSED PWR
4 18G-A RH POSIT/TAIL FUSED PWR
5 45R RIGHT TURN SIGNAL
6 NOT USED

4002-73
CONNECTOR LRFO - FRONT WORK LAMP OPT CONNECTOR LRFW - RH FRONT WORK LAMP
245483C1 245483C1

RH FRONT WORK LAMP RH FRONT WORK LAMP
1 42R-K 1 42C-G
FUSED PWR FUSED PWR
2 0-MP RH FRNT WORK LAMP GRND RH FRONT WORK LAMP
2 0-MJ
GRND
CONNECTOR LRFR - FRONT WORK LAMP OPT

CONNECTOR LRRW- RH REAR WORK LAMP
245483C1
245483C1
RH FRONT WORK LAMP
1 42R-B RH REAR WORK LAMP FUSED
FUSED PWR 1 42R-G
PWR
2 0-ML RH FRNT WORK LAMP GRND
2 0-MF RH REAR WORK LAMP GRND
CONNECTOR LRFS- FRONT WORK LAMP OPT
245483C1

RH FRONT WORK LAMP
1 42R-A
FUSED PWR
2 0-MG RH FRONT WORK LAMP GRND

4002-74
CONNECTOR LRR-E - RH REAR COMBINATION NOXS, NOX SENSOR
LAMP
1 23A-A DNOX2 MODULE B+
2 23D-D NOX SENSOR GND
3 CAN-LU CAN2 LO, NOX
4 CAN-HU CAN2 HI, NOX
NTRL DIODE, DIODE ASSY
225351C1

1 44A-F BRAKE LIGHT RELAY OUT
2 45R-A RIGHT TURN SIGNAL
RIGHT POSITION/TAIL FUSED
3 18G-J
PWR
4 35A-K REVERSE LAMP
245485C1
5 0-BR RH REAR LIGHT GND (EURO)
6 NOT USED
A 26N-D FNR NEUT SIGNAL
B 26N-E FNR NEUT SIGNAL
CONNECTOR LSPK - LEFT SPEAKER C 26N-C FNR NEUT SIGNAL
CONNECTOR OSS - OUTPUT SPEED SENSOR
195552A1

A 65L LEFT SPEAKER
B 0-PA LEFT SPEAKER GROUND
MON, CAMERA/MONITOR 291719A1

1 0-HE OUTPUT SPEED GROUND
1 66A RR CAMERA PWR
2 25D OUTPUT SPEED SIGNAL
2 0-K CAMERA GND
OUTPUT SPEED SENSOR
3 35A-M REVERSE SIGNAL 3 19A
FUSED PWR

4002-75
CONNECTOR PAF - AIR FILTER RESTRICTION CONNECTOR PBL - BRAKE LAMP PRESSURE
SWITCH SWITCH
222136A1
291718A1
1 1-AA BRAKE LAMP SWITCH PWR
AIR FILTER RESTRICTION
1 31F
SWITCH SIGNAL 2 44 BRAKE LAMP CONTR PWR
AIR FILTER RESTRICTION

2 0-BY
SWITCH GRND
CONNECTOR PBW - BRAKE PRESSURE
WARNING SWITCH
P A1, B+ POWER

1 1-C ECC BAT PWR
P A3, B+ POWER

1 1CB-A CAB CB PROTECTED PWR
225316C1

CONNECTOR PBD - BRAKE DECLUTCH 1 33P
LOW BRAKE PRESS
PRESSURE SWITCH WARNING
BRAKE PRESS WARN SW
2 0-AL
GROUND
P C1, B+ PWR FRM PRMD

1 1-BG B+ PWR PRMC
1 1-NC B+ PWR PRMC
245482C1

BRAKE DECLUTCH SW
A 19A-A
FUSED PWR
BRAKE DECLUTCH SWITCH
B 25G 1 1-E GRID HTR FUSE BAT PWR
CONTROL

4002-76
P C3, B+ PWR FRM PRMD CONNECTOR PO2 - POWER OUTLET

1 1CB CAB CB PROTECTED PWR

1 1-Z STRTR RLY BAT PWR
CAV WIRE IDENT CIRCUIT 12176446
1 1-T EVGT3 POWER CAV WIRE IDENT CIRCUIT

A 12V-A 12V PWR TO OUTLET 2
B NOT USED
PHF, HYD OIL FILT RES SW
C 0-EL AUX POWER OUTLET 2 GND
1 31H HYD FLTR REST SW SGNL
PRH, AC HIGH PRESS SW
PHF9, HYD FLTR RES SW

1 0-HR HYD FLTR SW GRND
2 31-H9 HYD FLTR RST SW 9
CONNECTOR PO1 - POWER OUTLET 245483C1

A 61A-D AC SWITCH INPUT
B 61R-D AC SWITCH OUTPUT
CONNECTOR PRB1 - REDUNDANT BRAKE

SWITCH
12176446

A 12V 12V PWR TO OUTLET 1
B NOT USED
245483C1
C 0-EK AUX POWER OUTLET 1 GND
RDNT BRAKE ACCUMULATOR
A 33R-C
PRESS LOW
B 0-HM RED BRAKE SW GROUND

4002-77
CONNECTOR PRB2 - REDUNDANT BRAKE PRM A2, PRM SIGNAL
SWITCH
PWR CONVERTER PRM CTRL
A 12ACC-C
PWR
PWR CONVERTER RLY CTRL
B 0-EU
GND
CONNECTOR PRM-B1 - PRM SIGNAL
245483C1

RDNT BRAKE ACCUMULATOR
A 33R-B
PRESS LOW
B 0-HL RED BRAKE SW GROUND
CONNECTOR PRBF - ROLLBACK PRESSURE

SWITCH
256340A1

A 12ACC-B ACC PRM CONTROL POWER
C 0-EC ACC RELAY CONTROL GND
PRM C1, PRM SIGNAL

245483C1
A 58 RIDE CONTR SOLENOID PWR A 13K-C IGNITION SWITCH POWER
B 58-B RIDE CONTR SOLENOID PWR B 0-EB IGNITION RELAY CTRL GND
PRM A1, PRM OUTPUT PRM D1, PRM OUTPUT

A 18J-F EDC7 FSD PWR
C 1-GA FLTR HTR PWR
PRM D2, PRM SIGNAL

409084A1
A 28F FUEL FLTR HTR RLY CTRL
B 31B FILTER HEATER CONTROL
A 18U-A DCU B+ NON DISCONNECTD
C 19L PWR CONVERTER FSD PWR

4002-78
PRMB L1, B+ POWER CONNECTOR PXF - RTD

CS01 J11 BLWR MOTOR PWR
PRMB L2, B+ POWER

1 19S1 SEC STRG PWR
245485C1

PVRES, JSS JOYSTICK A 53B RTD CTRL SIGNAL
B 0-AC PROXIMITY SWITCH GROUND
C 53P-H PILOT CONTROL RELAY OUT
R 51S-E JSS OKAY PWR
S 51PW-V JSS POWER
T 51H-C JOYSTICK SIGNAL CONNECTOR PXH - HEIGHT CONTROL RTT
U 51NO NO NEUTRAL SW
V 0-SC GRND, JOYSTICK
W 51NC NC NEUTRAL SW
CONNECTOR PSS - SECONDARY STEERING

PRESSURE SWITCH
245485C1

A 54B HC-RTT CTRL SIGNAL
B 0-AA PROXIMITY SWITCH GROUND
C 53P-J PILOT CONTROL RELAY OUT
245485C1
CONNECTOR PXM - RTD
SECONDARY STEER HIGH
A 51P-A
PRESSURE
SEC. STEER PRESS SWITCH
B 0-CC
GROUND
SECONDARY STEER LOW
C 35X-A
PRESS SIG
245485C1

A 53B-A RTD CONTROL SIGNAL
B 0-AM RTD GROUND
C 53P-I PILOT CONTROL RELAY OUT

4002-79
CONNECTOR PXT - RTD CONNECTOR RAD-J1 - RADIO POWER
245485C1

A 53B-A RTD CONTROL SIGNAL 292497A1
B 0-AM RTD GROUND CAV WIRE IDENT CIRCUIT
C 53P-I PILOT CONTROL RELAY OUT 1 NOT USED
2 NOT USED
R1, RESISTOR 3 NOT USED

4 RAD3 12V FUSED PWR TO RADIO
CAV WIRE IDENT CIRCUIT 5 NOT USED
CS0 0-SP GRND, JOYSTICK 6 NOT USED
CS0 51J-D VALVE ALARM 7 RAD2 12V FUSED PWR TO RADIO
8 RAD1 RADIO GROUND
CONNECTOR RAD - RADIO POWER

CONNECTOR RAD-J2 - SPEAKER
292495A1
CAV WIRE IDENT CIRCUIT 292501A1
1 NOT USED CAV WIRE IDENT CIRCUIT

2 NOT USED 1 RAD11 RIGHT SPEAKER
3 NOT USED 2 RAD10 RIGHT SPEAKER GROUND
4 12V-HB 12V FUSED PWR TO RADIO 3 RAD9 NOT USED
5 NOT USED 4 RAD8 NOT USED
6 NOT USED 5 RAD7 NOT USED
7 12V-HA 12V FUSED PWR TO RADIO 6 RAD6 NOT USED
8 0-EN RADIO GROUND 7 RAD5 LEFT SPEAKER
8 RAD4 LEFT SPEAKER GROUND

4002-80
CONNECTOR RAD-J3 - RADIO JUMPER RFLG, FUEL SEND GRND

1 0-BU FUEL LEVEL SENDER GND
RFL.23, FUEL LEVEL SEND
411311A1 CAV WIRE IDENT CIRCUIT

CAV WIRE IDENT CIRCUIT A 36J FUEL LEVEL ANALOG
1 RAD10 RIGHT SPEAKER GROUND B 0-BZ FUEL LEVEL SENDER GND
2 RAD8 NOT USED
3 RAD4 LEFT SPEAKER GROUND
ROOF, ROOF TO CAB CONNECTION
4 RAD6 NOT USED
5 RAD1 RADIO GROUND
6 NOT USED
7 RAD3 12V FUSED PWR TO RADIO
8 RAD11 RIGHT SPEAKER
9 RAD9 NOT USED
10 RAD5 LEFT SPEAKER
11 RAD7 NOT USED 388708A1
12V FUSED POWER TO CAV WIRE IDENT CIRCUIT

12 RAD2
RADIO A 0-MV RH FRONT WORK LIGHT GND
13 NOT USED B 0-MH REAR WORK LIGHT GND
14 NOT USED C 43-B DOME LT AUTO MODE
D 19U-C DOME LT FSD PWR
CONNECTOR RECT - ENGINE COOLANT E 46-D BEACON SW PWR

TEMPERATURE F 0-MN ROOF GROUNDS
G 0-MK ROOF GROUNDS
H 42C-F FNT WRK LTS FUSE PWR
J 19K-D REAR WPR MOTOR FSD PWR
K 68C-A REAR WPR PARK CTRL
L 68L-A REAR WPR SW PWR
M 0-EN RADIO GND
N 12V-H 12V FUSED PWR TO RADIO
194788A1
P 19U-F DOOR SW FSD PWR
R 43S-B DOOR OPEN SGNL
RADIATOR COOLANT TEMP
A 36C S 42R-F REAR WRK LTS FUSE PWR
SIGNAL
B 0-BAE EDC7 SENDER GROUND
RFL, FUEL SENDER

1 36F FUEL LEVEL ANALOG

4002-81
CONNECTOR RSPK - RIGHT SPEAKER CONNECTOR RWM - REAR WIPER MOTOR
195552A1

A 65R RIGHT SPEAKER 245715C1
B 0-PB RIGHT SPEAKER GROUND CAV WIRE IDENT CIRCUIT

A NOT USED
CONNECTOR RTHP - THROTTLE PEDAL B 68L-A REAR WIPER SWITCH PWR

C 19K-D REAR WIPER MOTR FUS PWR
D 68C-A REAR WIPER PARK CONTROL
CONNECTOR RWMG - REAR WIPER MOTOR

GROUND
225351C1

1 21F-D EDC7 DIGITAL GROUND
2 NOT USED
3 NOT USED
3 24B-A THROTTLE SIGNAL 245480C1

4 24R-A THROTTLE POS. SENS GND 1 0-MA REAR WIPER MOTOR GRND
5 NOT USED
5 24S-A THROTTLE SUPPLY
CONNECTOR RWW - REAR WASHER
6 24L-A LOW IDLE SWITCH
RVS DIODE, DIODE ASSY

A 26R-D FNR REVERSE SIGNAL
B 26R-E FNR REVERSE SIGNAL
C 16R-C FNR REVERSE SIGNAL
3227856R1

1 68W-A REAR WASHER PUMP
2 0-BL REAR WASHER GROUND

4002-82
SAJ, FNR SWITCH CONNECTOR SBU - BACKUP ALARM DISABLE
SWITCH
1 26R-F FNR REVERSE SIGNAL
2 26K FNR SWITCH JUMPER
3 26N-F FNR NEUT SIGNAL
5 19B-E FNR SW FUSED PWR
6 26F-F FNR FORWARD SIGNAL
7 32J-J TRANS ENABLE INDICTION
8 19B-F FNR SW FUSED PWR
A 25Y-F
382391A1

CONNECTOR SBE - BEACON SWITCH 1 35R-C BACKUP ALARM SWITCH
2 35A-B BACKUP ALARM DISABLE SW
3 NOT USED
4 NOT USED
5 NOT USED
6 NOT USED
7 0-B21 BACK LIGHT GROUND
8 49-L BACK LIGHT POWER
9 NOT USED
10 NOT USED
382391A1

1 NOT USED CONNECTOR SC - SEAT COMPRESSOR MOTOR
2 19U-H BEACON SWITCH FUS PWR
3 46-C BEACON SWITCHED POWER
4 NOT USED
5 NOT USED
6 NOT USED
8 49-B BACK LIGHT POWER
9 NOT USED
245482C1
10 NOT USED
SEAT COMPRESSOR FUSED
A 19N
PWR
SEAT COMPRESSOR MOTOR
B 0-DK
GROUND
SDA, DIFF LOCK SWITCH

2 34A-A DIFF LOCK SW B+
3 34B DIFF LOCK SW SIG
7 0-B31 SDA GND
8 49-Z BACK LIGHT PWR

4002-83
CONNECTOR SDC - DECLUTCH SWITCH CONNECTOR SDR - DRIVING LIGHTS SWITCH
382391A1 382391A1

BRAKE DECLUTCH SWITCH 1 NOT USED
1 25G-B
CONTROL
DRIVING LIGHTS SW FUSED
2 19A-R DECLUTCH SW FUSED PWR 2 19Z-A
PWR
3 22A DECLUTCH SW 3 41T POSITION LIGHTS SW PWR
4 NOT USED 4 NOT USED
5 NOT USED DRIVING LIGHTS SWITCH
5 19Z-B
6 NOT USED FUSED POWER
7 0-B18 BACK LIGHT GROUND 6 41J DRIVING LIGHTS POWER
8 49-R BACK LIGHT POWER 7 0-B19 BACK LIGHT GROUND
9 NOT USED 8 49-P BACK LIGHT POWER

10 NOT USED
SDM, DIFF LOCK SWITCH

1 34D DIFF LOCK SW SIG
2 34A-B DIFF LOCK SW SIG B+

4002-84
CONNECTOR SFC - FAN CONTROL SWITCH CONNECTOR SFNR - FNR SWITCH
382391A1 382391A1

1 NOT USED 1 26R-A FNR REVERSE SIGNAL
2 52J FAN CONTROL SW JUMPER 2 26J FNR SWITCH JUMPER
3 52-AU FAN REVERSE AUTO 3 26N-A FNR NEUTRAL SIGNAL
4 52J FAN CONTROL SW JUMPER 4 26J FNR SWITCH JUMPER
FAN REVERSE SWITCH 5 19A-V FNR SWITCH FUSED POWER
5 19P-C
FUSED PWR
6 26F-A FNR FORWARD SIGNAL
6 52M FAN REVERSE MANUAL
7 32J-A TRANS ENABLE INDICATION
8 19A-G FNR SWITCH FUSED POWER
8 49-Q BACK LIGHT POWER
9 NOT USED
9 NOT USED
10 NOT USED
10 NOT USED
CONNECTOR SFWW - FRONT WIPER AND

CONNECTOR SFL - RETURN-TO-TRAVEL WASHER SWITCH
SWITCH
87345132

382391A1
1 NOT USED
FRONT WIPER/WASHER SW
1 55A-B RTT/FLOAT SWITCH POWER 2 0-DT
GND
2 53P-B PILOT CONTROL RELAY OUT
3 63LC FRNT WIP LS RELAY CONTR
3 55A-C RTT/FLOAT SWITCH POWER
4 NOT USED
4 0-29 RTT/FLOAT GROUND
5 19J-B INT WIP/WAS SW FUSED PWR
5 55B RTT FLOAT SW CONTROL
6 NOT USED
6 54B-C HC-RTT CONTROL SIGNAL
7 63W FRONT WASHER PUMP
8 49-T BACK LIGHT POWER
8 49-K BACK LIGHT POWER
FRONT WIPER HS RELAY
9 63HC
9 NOT USED CONTROL

4002-85
CONNECTOR SHC - HEIGHT CONTROL SWITCH SJS, JOYSTICK CONTROL SW

2 18S-B B+, JSS FUSED
3 51B-A JSS ACT SW
4 0-BBA JOYSTICK GROUND
5 51C-A JSS ACT BTN
6 51B-B JSS ACT SW
7 0-BBB JOYSTICK GROUND
8 49-W JSS BACKLIGHT
382391A1 9 0-BBE JOYSTICK GROUND
CAV WIRE IDENT CIRCUIT 10 51PW-N JSS POWER
1 NOT USED
2 53P-D PILOT CONTROL RELAY OUT
S KEY, IGNITION SWITCH
3 NOT USED
4 NOT USED
5 NOT USED
TIME DELAY/IGN SW FSD
1 1DM
6 54A HC CONTROL SW PWR PWR
7 0-B3 BACK LIGHT GROUND 2 21K IGN SW START SIGNAL
8 49-M BACK LIGHT POWER 3 13K IGNITION SWITCH POWER
9 NOT USED 4 12ACC IGNITION SW ACC POWER
10 NOT USED
CONNECTOR SPB - PARKING BRAKE SWITCH

CONNECTOR SHZ - HAZARD SWITCH
382391A1
1 NOT USED 2 19A-L PARK BRK SW FUSED PWR
2 1-KA HAZARD SWITCH POWER 3 33U PARK BRAKE SWITCH
3 45H HAZARD SWITCH POWER 4 NOT USED
6 NOT USED 7 0-B29 RTT/FLOAT GROUND
7 0-B24 BACK LIGHT GROUND 8 49-V BACK LIGHT POWER
8 49-D BACK LIGHT POWER 9 NOT USED
10 NOT USED

4002-86
CONNECTOR SPC - PILOT CONTROL SWITCH CONNECTOR SPK - SPEAKER
382391A1
292494A1
PILOT CONTROL SW FUSED 1 65R RIGHT SPEAKER

2 19C-F
PWR 2 0-PB RIGHT SPEAKER GROUND
3 31L PILOT CONTROL SW HIGH 3 NOT USED
7 0-B1 BACK LIGHT GROUND 7 65L LEFT SPEAKER
8 49-N BACK LIGHT POWER 8 0-PA LEFT SPEAKER GROUND
9 NOT USED
10 NOT USED
SPL ACP, ULTRASONIC
CONNECTOR SPE - PIN ENGAGE SWITCH CAV WIRE IDENT CIRCUIT

A 61A-C AC SWITCH INPUT
A 61A-D AC SWITCH INPUT
A 61A AC PRESS SW INPUT
SPL ACS, ULTRASONIC

A 61R-C AC SWITCH OUTPUT
A 61R-D AC SWITCH OUTPUT
382391A1
A 61R AC RELAY CONTROL
1 57-B PIN ENGAGE SOL PWR
SPL AJ, ULTRASONIC
2 19P-A PIN ENGAGE SW FUS PWR
3 NOT USED
4 NOT USED
A 19B-C FNR SW FUSED PWR
5 NOT USED
A 19B-D FNR SW FUSED PWR
6 NOT USED
A 19B-E FNR SW FUSED PWR
7 NOT USED
A 19B-F FNR SW FUSED PWR
8 NOT USED
10 49-F BACK LIGHT POWER

4002-87
CONNECTOR SPL-BCK-LGT - SPLICE BACK CAV WIRE IDENT CIRCUIT
LIGHT GRND
D 0-B4 BACK LIGHT GND
E 0-B5 BACK LIGHT GND
F 0-B6 CAB 2 GND
G NOT USED
H NOT USED
J 0-B20 BACK LIGHT GND
K 0-B29 RTT/FLOAT GND
L 0-B11 BACK LIGHT GND
M 0-B7 BACK LIGHT GND
SPL BCK LGT, SPLICE BACK LGHT PWR

87324393

A 0-B13 BACK LIGHT GND
B 0-B14 BACK LIGHT GND
C 0-B15 BACK LIGHT GND
D 0-B6 CAB 2 GND
E 0-B17 BACK LIGHT GND
F 0-B18 BACK LIGHT GND
G 0-B19 BACK LIGHT GND
H NOT USED
J 0-B21 BACK LIGHT GND
87324393
K 0-DAP BACK LIGHT GND
L 0-B23 BACK LIGHT GND CAV WIRE IDENT CIRCUIT
M 0-B32 BACK LIGHT GND A 49 BACK LIGHT POWER

C 49-C BACK LIGHT POWER
D 49-H BACK LIGHT POWER
CONNECTOR SPL-BCK-LGT2 - SPLICE BACK
E 49-L BACK LIGHT POWER
LIGHT GRND
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
L 49-B BACK LIGHT POWER
M 49-A BACK LIGHT POWER
87324393

A 0-B31 SDA GROUND
B 0-B2 BACK LIGHT GND
C 0-B3 BACK LIGHT GND

4002-88
SPL PED BL, SPL BACK LGT PWR 6 PCK CONNECTOR SPL-PED-BL-GD - SPL BACK
LIGHT POWER 6 PACK
87324391
87324391
A 49-W JSS BACKLIGHT CAV WIRE IDENT CIRCUIT
B 49-N BACK LIGHT POWER A 0-B9 NOT USED
C 49-D BACK LIGHT POWER B 0-B1 BACK LIGHT GROUND
D 49-X BACK LIGHT AIC C 0-B24 BACK LIGHT GROUND
E 49-V BACK LIGHT POWER D 0-B30 NOT USED
F 49-S BACK LIGHT POWER E 0-B29 RTT/FLOAT GROUND

F 0-B11 BACK LIGHT GROUND
CONNECTOR SPL-HOOD-GND - HOOD GROUND

6 PACK CONNECTOR SPL-PIN - SPL BACK LIGHT
POWER 6 PACK
87324391
87324391
A 0-B12 HOOD DOWN RELAY GRND CAV WIRE IDENT CIRCUIT
B 0-B16 HOOD DOWN CONTR GRND A 19P-A PIN ENGAGE SW FUSED PWR
C 0-B22 HOOD UP RELAY GROUND B 19P PIN ENGAGE/FAN FUS PWR
D 0-B25 HOOD UP CONTR GRND C 19P-C RAN REVERSE SW FUS PWR
E 0-B10 HOOD GROUND D NOT USED
F NOT USED E 19P-D FAN REV RELAY FUS PWR

F 19P-E FAN REV RELAY FUS PWR

4002-89
SPL PK1, SPLICE 3-4 WAY CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY
87324462 87324462

J 18K-D DIAG FUSED B+ A 45L-E LEFT TURN SIGNAL
K 18K-A DIAGNOSTIC FUSED PWR B 45L-D LEFT TURN SIGNAL
L 18K-B DIAG FUSED B+ C 45L-C LEFT TURN SIGNAL
D 45L-B LEFT TURN SIGNAL
E 45R-C RIGHT TURN SIGNAL
SPL BCK LGT2, SPL BACK LGT PWR
F 45R-E RIGHT TURN SIGNAL
G 45R-D RIGHT TURN SIGNAL
H 45R-B RIGHT TURN SIGNAL
FRONT WIPER/WASHER SW
J 19J-B
FUSED PWR
FRONT WIPER RLY FUSED
K 19J-C
POWER
FRONT WIPER RELAY FUSED
L 19J-D
POWER
FRONT WIPER RLY LS CTRL
M 19J-F
FUSED POWER
87324462
SPL ROOF, SPLICE ROOF GROUND
A 49-E BACK LIGHT POWER CAV WIRE IDENT CIRCUIT
B 49Y-A BACK LIGHT POWER A 0-MC BEACON LIGHT GND
C 49-J BACK LIGHT POWER B 0-MB DOME LIGHT GND
D 49-M BACK LIGHT POWER C 0-MA REAR WIPER MOTOR GND
E 49-K BACK LIGHT POWER D 0-MN ROOF GROUNDS
F 49-F BACK LIGHT POWER E 0-MK ROOF GROUNDS
G 49-Q BACK LIGHT POWER
J 49-Z BACK LIGHT POWER
H 49-T BACK LIGHT POWER
K 49-G BACK LIGHT POWER
M 49-S BACK LIGHT POWER

4002-90
CONNECTOR SPL-TRNS-PWR - TRANSMISSION CONNECTOR SRC - RIDE CONTROL SWITCH
POWER
382391A1

1 NOT USED
87324393
2 19C-D RIDE CTRL SW FUSED PWR
3 58C RIDE CTRL SWITCH JUMPER
A 19A-N TRANS FUSED POWER
4 58T RIDE CTRL RELAY SW PWR
TRANS ENABLE SWITCH
B 19A-F 5 58C RIDE CTRL SWITCH JUMPER
FUSED PWR
TRANS/AUTO SWITCH FUSED 6 58-F RIDE CTRL SOLENOID PWR
C 19A-Q
PWR 7 0-B20 BACK LIGHT GROUND
BRAKE DECLUTCH SW 8 49-G BACK LIGHT POWER
D 19A-T
FUSED PWR
9 NOT USED
E 19A-W DIAGN CONN. FUSED PWR
10 NOT USED
F 19A-C FNR SWITCH FUSED PWR
G 19A-P BACKUP ALARM RLY
H 19A-R DECLUTCH SW FUSED PWR CONNECTOR SRC-1 - STARTER RELAY
J 19A-K TECM FUSED PWR
OUTPUT SPEED SENSOR
K 19A-M
FUSED PWR
L NOT USED
M 19A-H TRANS SHIFTER FUSED PWR
225316C1

1 21D STARTER RELAY SIGNAL
STARTER RELAY CONTROL
2 0-GB
GROUND

4002-91
CONNECTOR SRHSTLK - RH STALK SWITCH CONNECTOR SRWP - REAR WIPER SWITCH
382391A1

1 68C REAR WIPER PARK CONTROL
87318288
2 68L REAR WIPER SW PWR
3 19K-A REAR WIPER SW FUSED PWR
31b 64C HORN RELAY CONTROL
4 NOT USED
49a 19B TURN SIGNAL FUSED POWER
5 19K-B REAR WIPER SW FUSED PWR
56a 41H-A HIGH BEAM POWER
6 68W REAR WASHER PUMP
56b 41L-A LOW BEAM POWER
56d 19Z-C HIGH BEAM FLASH FUS PWR
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
SSD, SEC STR DIODE
CONNECTOR SRTD - DETENT SWITCH
245485C1

A 0-CH SEC STR FLYBACK GND
382391A1
B 0-CG SEC STR FLYBACK GND
C 51-D SEC STR FLYBACK
1 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

4002-92
CONNECTOR SSM - SECONDARY STEERING CONNECTOR SS-TR - SS-MOD-TRANS
MODULE
245489C1

A 19M-C SEC. STR ACCESS FUS PWR
B 19R-C SEC. STR IGNIT FUS PWR
225389C1 SEC. STR LOW PRESS

C 35X-C
SIGNAL
D NOT USED
1 19R-C E 19S1-X SEC. STR FUSED POWER
FUSED PWR
SECOND STEER MOTOR F NOT USED
2 51-A
CONTR
3 19S1-X SECONDY STEER FUS PWR
CONNECTOR STA - TRANSMISSION AUTO
SECONDY STEER CHASSIS
4 0-CE
GRND
SWITCH
5 NOT USED
6 NOT USED
SECONDARY STEER ACC
7 19M-C
FUSED PWR
SECOND STEER LOW PRESS
8 35X-D
SIG
SECONDARY STEER HIGH
9 51P-A
PRESS
10 NOT USED
SECONDARY STEER SIGNAL
11 0-CA 382391A1
GRND
SECONDARY STEER SIGNAL CAV WIRE IDENT CIRCUIT
12 0-CB
GRND 1 NOT USED
2 19A-Q TRANS AUTO SW FUS PWR
SSS, SS MAG SWITCH 3 25H TRANS AUTO SIGNAL

4 NOT USED
1 51-D SEC STR FLYBACK 6 NOT USED
1 51-B SEC STR MOTOR CTRL 7 0-B17 BACK LIGHT GROUND
8 49S BACK LIGHT POWER
9 NOT USED
10 NOT USED

4002-93
CONNECTOR STE - TRANSMISSION ENABLE CONNECTOR SWL - WORK LIGHTS SWITCH
SWITCH
382391A1

1 NOT USED 2 42-A WORK LIGHTS FUSED PWR
TRANS ENABLE SW FUSED 3 42C-C FR WORK LIGHTS FUSE PWR
2 19A-D
POWER
4 NOT USED
3 26E-A TRANS ENABLE SIGNAL
5 42-B WORK LIGHTS FUS PWR
4 NOT USED
6 42RC RE WORK LIGHTS FUSE PWR
5 NOT USED
6 NOT USED
8 49-A BACK LIGHT POWER
7 0-DAP BACK LIGHT GROUND
9 NOT USED
8 49-H BACK LIGHT POWER
10 NOT USED
9 32J-C TRANS ENABLE INDICTION
10 19A-E AIC FUSED PWR
STTR GRN, GRID HTR FUSE

1 0-NC BATTERY DISCONNECT

4002-94
CONNECTOR SW-PD - SWITCH PAD CONNECTOR TCOT - TORQUE CONVERTER
OUTPUT SENDER
291718A1
87552623
1 36G TCO TEMPERATURE SIGNAL
1 41H-D HIGH BEAM POWER
2 36R-D TCO TEMPERATURE RETURN
2 NOT USED
3 49-X BACK LIGHT AIC
HYDRAULIC FILTER REST SW
4 31H-A
SIGNAL
AIR FILTER REST SWITCH
5 31F-A
SIGNAL
6 NOT USED
7 CAN-HF CAN HIGH
8 CAN-LF CAN LOW
SWITCH PAD PWR FROM AIC
9 17P-A
PWR
10 0-B28 SWITCH PAD GROUND

4002-95
TECM, TRANS CAV WIRE IDENT CIRCUIT
20 26F-B FNR FORWARD SIGNAL
21 22A DECLUTCH SW
22 25Y-A TRANS KICK DOWN SIGNAL
23 19T-A FUSED BATT PWR
24 22D PEDAL SENSOR GRND
25 CAN-HD CAN HIGH
26 CAN-LD CAN LOW
29 25H TRANS AUTO SIGNAL
30 26R-B FNR REVERSE SIGNAL
31 26E-A TRANS ENABLE SIGNAL
32 25M-A TRANS SOL VALVE Y3
35 34B DIFF LOCK SW SIG
37 22B PEDAL SENSOR +5V
38 22C PEDAL POS SIGNAL
39 36T-A VALVE BODY TEMP SGNL
41 25C-A TURBINE SP SIGNAL
42 25B-A INT SP SIGNAL
43 25F FORWARD SIGNAL
44 26N-B FNR NEUT SIGNAL
45 19A-K TECM FUSED PWR
46 36R-E TRANS TEMPS/FLTR RETURN
49 36G-A TCO TEMP SIGNAL
50 25R-A TC LOCKUP SOL POWER
51 25J-A TRANS SOL VALVE Y6
53 58H-B POWER VPSL
55 25N-A TRANS SOL VALVE Y4
411398A1
56 25K-A TRANS SOL VALVE Y1
57 58L RIDE CTRL RLY LSD
1 0-DP DIAG TECM GND
59 34D DIFF LOCK SW SIG
2 0-DQ DIAG TECM GND
62 25D-A OUTPUT SP SIGNAL
3 0-DM SPEED SENSOR GNDS
63 25Z 1ST AND 4TH GEAR SIGNAL
OUTPUT SPEED SENSOR
4 0-DN
GND 64 25R REVERSE SIGNAL
5 32J-D TRANS ENABLE INDICTION 65 25W 3RD AND 4TH GEAR SIGNAL
7 35C BACK UP ALRM CNTL 66 25G-C BRK DECLUTCH SW CTRL
8 58H-A POWER VPS2 67 25T-C NEUTRAL SIGNAL
9 25P-A TRANS SOL VALVE Y5 68 19T-B FUSED BATT PWR
10 25L-A TRANS SOL VALVE Y2
11 34C DIFF LOCK SOL GND
12 25S-B OUTPUT SW PWR VPS1
13 25S-C OUTPUT SW PWR VPS1
15 37D-A DIAGNOSTIC SGNL
17 32F-A TRANS FLTR MAINT SW
18 37E DIAGN SGNL SWITCHED
19 25A-A ENG SP SIGNAL

4002-96
TERM CAN 2, CAN BULK HEAD TRANS, TRANSMISSION-CAB
380838A1

1 33R-A RDNT BRK ACC PRESS LOW
2 34C-A DIFF LOCK SOL GND
3 19M-A SEC STR ACCESS FSD PWR
87315267
4 19R-A SEC STR IGN FSD PWR
CAV WIRE IDENT CIRCUIT 5 36T VALVE BODY TEMP SGNL
A CAN-L2 CAN 2 LO, TERM 6 35X-B SEC STR LOW PRESS SGNL
A CAN-LV CAN2 LO, TERM 7 25A ENG SP SIGNAL
B CAN-H2 CAN2 HI, TERM 8 25C TURBINE SP SIGNAL
B CAN-HV CAN2 HI, TERM 9 25B INT SP SIGNAL
10 25D OUTPUT SP SIGNAL
THV, TANK HEATER CONTROL VALVE 11 0-HD SPEED SENSOR GNDS

12 36R-A TRANS TEMPS/FLTR RETURN
13 36G TCO TEMP SIGNAL
14 25G BRK DECLUTCH SW CTRL
15 25R-B TC LOCKUP SOL POWER
16 25K TRANS SOL VALVE Y1
16 25K-9 TRANS SOL VALVE Y2
17 25L-9 TRANS SOL VALVE Y1
17 25L TRANS SOL VALVE Y2
18 25M TRANS SOL VALVE Y3
19 25N TRANS SOL VALVE Y4
371614A1
20 25P TRANS SOL VALVE Y5
21 25J TRANS SOL VALVE Y6
1 38C TANK HEAT GND
22 25S OUTPUT SW PWR VPS1
2 38D TANK HEAT B+
23 31H HYD FLTR REST SW SGNL
23 31H9 HYD FLTR REST SW9
BRAKE DECLUTCH SW FSD
24 19A-A
PWR
25 24T-B TC LOCKUP SOL GND
26 19S1-E SEC STR FSD PWR
27 34A-D DIFF LOCK SOL B+
28 0-HE OUTPUT SPEED SENS GND
29 19A OUTPUT SP SENS FSD PWR
30 36H HYDRAULIC OIL TEMP
31 32F TRANS FLTR MAINT SW

4002-97
CONNECTOR TRC - TRANSMISSION CONTROL CONNECTOR TR-SS - SEC-STR-MOD-OPT
245488C1
371566A1
CAV WIRE IDENT CIRCUIT A 19M-A SEC. STEER ACC FUS PWR
1 25K TRANS SOLENOID VALVE Y1 SEC. STEERING IGNITION
B 19R-A
1 25L-9 TRANS SOLENOID VALVE Y1 FUSED PWR
2 25K-9 TRANS SOLENOID VALVE Y2 C 35X-B SEC STR LOW PRESS SGNL
2 25L TRANS SOLENOID VALVE Y2 D NOT USED
3 25M TRANS SOLENOID VALVE Y3 E 19S1-E SEC. STEER FUSED PWR
4 25N TRANS SOLENOID VALVE Y4 F NOT USED
5 25P TRANS SOLENOID VALVE Y5

6 25J TRANS SOLENOID VALVE Y6
CONNECTOR TS1 - TRANSMISSION SHIFTER
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
13 NOT USED
14 NOT USED
15 NOT USED
16 NOT USED 245486C1

A 19A-H TRANS SHIFTER FUSED PWR
B 25F FORWARD SIGNAL
C 25R REVERSE SIGNAL
D 25T-B NEUTRAL SIGNAL

4002-98
CONNECTOR TS2 - TRANSMISSION SHIFTER UBJ, DEF LEVEL TEMP
245487C1 W230R399

A NOT USED 1 38B DEF LEVEL SIG
B 25W 3RD AND 4TH GEAR SIGNAL 2 0-T DEF SENSOR GND
C 25Z 1ST AND 4TH GEAR SIGNAL 3 38G DEF TEMP SIG
TRANSMISSION KICK DOWN
D 25Y
SIGNAL
UBJM, DEF LEVEL TEMP
CONNECTOR TSS - TURBINE SPEED SENSOR CAV WIRE IDENT CIRCUIT

1 38B-A DEF LEVEL SIG
2 0-TA DEF SENSOR GND
3 38G-A DEF TEMP SIG
UTS, UPSTREAM TEMP SENSE

1 38F EXHT UP SIGNAL
2 0E-A EXHT TEMP UP GND
291718A1

CONNECTOR WIF - WATER IN FUEL SENSOR
1 25C TURBINE SPEED SIGNAL
2 0-HH TURBINE SPEED SENS GRND
8602416

1 35W WIF INDICATOR
2 0-BP WIF SENSOR GROUND
3 13M-C WIF SENSOR FUSED PWR

4002-99
CONNECTOR WSH - WATER SEPARATOR CONNECTOR YFN - FNA PWM SOLENOID
HEATER
256340A1
182069A1
A 56-A FAN CONTROL PWM
WATER SEPARATOR HEATER
A 0-BW
GROUND B 0-BQ FAN SPEED PWM SOLEN GND
WATER SEPARATOR HEATER
B 1-GC
POWER
CONNECTOR YFR - FAN REVERSING SOLENOID
OPT
YDL, DIFF LOCK SOLENOID

1 34A-D DIFF LOCK SOL B+
2 34C-A DIFF LOCK SOL GND
YDL 1, DIFF LOCK SOLENOID
225316C1

1 52A-B FAN REVERSING RELAY OUT
2 0-BB FAN REVERSING SOLEN GND
YLS, TC LOCKUP VALVE

225315C1
1 25R-B TC LOCKUP SOL POWER
1 34A-E DIFF LOCK SOL B+
2 24T-B TC LOCKUP SOL GND
2 34C-D DIFF LOCK SOL GND
YDL 2, DIFF LOCK SOLENOID

1 34A-E DIFF LOCK SOL B+
2 34C-D DIFF LOCK SOL GND

4002-100
CONNECTOR YPB - PARKING BRAKE YPE2, PIN ENGAGE OPT
SOLENOID
245482C1

A 57-D PIN ENGAGE SOL PWR
291718A1
B 0-AW PIN ENGAGE GND
1 52P PARKING BRAKE RELAY OUT
2 0-AN PARK BRAKE SOLEN GND CONNECTOR YPP - PILOT PRESSURE
SOLENOID
CONNECTOR YPE - PIN ENGAGE OPT
245482C1

245482C1
A 53P-A PILOT CONTROL RELAY OUT
B 0-DU PILOT PRESS SOLEN GND
A 57 PIN ENGAGE SOLENOID PWR
B 0-AE PIN ENGAGE GROUND
CONNECTOR YRC - RIDE CONTROL OPT
YPE1, PIN ENGAGE JUMPER

A 57-D PIN ENGAGE SOLENOID PWR
B 0-AW PIN ENGAGE GROUND
291718A1

1 58-G RIDE CONTR SOLEN PWR
1 58 RIDE CONTR SOLEN PWR
2 0-AD RIDE CONTROL GROUND

4002-101
YRC J, RIDE CNTRL JUMPER 21M, TRANS KICK-DOWN

1 58-H RIDE CONTROL SIGNAL
2 0-RD RIDE CONTROL GND
YRC J2, RIDE CONTROL OPT

1 58-H RIDE CONTROL SIGNAL 225316C1
2 0-RD RIDE CONTROL GND CAV WIRE IDENT CIRCUIT

1 19B-D FNR SW FUSED PWR
2 25Y-G TRANS KICK DOWN SIGNAL
CONNECTOR YSS - SECONDARY STEERING
SOLENOID
CONNECTOR 64F - FLASHER CONNECTOR
225316C1

245481C1
SEC. STEERING SOLENOID
1 51-C CAV WIRE IDENT CIRCUIT
CONTROL
1 45N-A FLASHER OPT SIDE CONTR
SEC. STEERING SOLENOID
2 0-CF
GROUND
CONNECTOR 64M - FLASHER CONNECTOR

CONNECTOR 20M - TRANSMISSION KICK-DOWN
SWITCH
245480C1

225316C1
A 45N-B FLASHER OPT SIDE CONTR
TRANS KICK DOWN SW FSD
1 19A-U
PWR
2 25Y-C TRANS KICK DOWN SIGNAL

4002-102
CONNECTOR 108F - DIAGNOSTIC CONNECTOR 193, STARTER RELAY

1 1-BB STRTR SOL PWR
194, STARTER SIGNAL

1 1-BB STRTR SOL PWR
291663A1
195, STARTER RELAY POWER
1 19A-W DIAGN CONN. FUSED PWR CAV WIRE IDENT CIRCUIT
2 37D-A DIAGNOSTIC SIGNAL 1 1-Z STRTR RLY BAT PWR
3 0-DAV DIAGNOSTIC TECM GROUND
DIAGNOSTIC SIGNAL
4 37E
SWITCHED CONNECTOR 197F - MAIN CAB FNR
5 NOT USED
6 NOT USED
115, GRID HTR PWR

1 1-BE GRID HTR PWR
CONNECTOR 140M - DIODE MODULE 225350C1

1 19A-C FNR SWITCH FUSED POWER
2 26F-B FNR FORWARD SIGNAL
3 26N-B FNR NEUTRAL SIGNAL
4 26R-B FNR REVERSE SIGNAL
5 32J-E TRANS ENABLE INDIC LAMP
6 25Y-B TRANS KICK DOWN SIGNAL
245488C1

A 63H-C FRONT WIPER HIGH RYL OUT
B 63L-C FRONT WIPER LOW RYL OUT
C 0-EE DIODE SUPPRESSION GNDS
RIDE CONTROL SOLENOID
D 58-D
PWR
E NOT USED
F 68L-C REAR WIPER SWITCH PWR

4002-103
CONNECTOR 197M - FNR MAIN CAB CONNECTOR 209F - BACKUP ALARM DISABLE
JUMPER
225351C1
245481C1
FNR SWITCHED FUSED
1 19A-B
POWER 1 35A-E BACKUP ALARM RELAY OUT
2 26F-A FNR FORWARD SIGNAL
3 26N-A FNR NEUTRAL SIGNAL
CONNECTOR 209M - BACKUP ALARM DISABLE
4 26R-A FNR REVERSE SIGNAL JUMPER
5 32J-A TRANS ENABLE INDIC LAMP
6 25Y-C TRANS KICK DOWN SIGNAL
CONNECTOR 202M - ROLLBACK JUMPER
245480C1

A 35A-D BACKUP ALARM RELAY OUT
B NOT USED
245482C1

A 58-A RIDE CONTR SOLENOID PWR
CONNECTOR 215F - ALTERNATOR RESISTOR
B 58-A RIDE CONTR SOLENOID PWR
199436A1

1 14-A ALTERNATOR D+

4002-104
CONNECTOR 216F - ALTERNATOR RESISTOR
199436A1

ALTERNATOR RESISTOR
1 19R-D
FUSED PWR
242F, CHAS GRD SEC STRG MTR

1 0-ND SSM GROUND
244F STARTER SEC STRG MTR

1 1-ND SSM PWR
1 1-NF SSM PWR
245F, SEC STR FLYBACK

1 0-CG SEC STR FLYBACK GND
1 0-CH SEC STR FLYBACK GND

Section
4003
4003
BATTERIES

Via Plava, 80
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
WARNING: Never try to charge the battery if WARNING: Battery acid causes severe
the electrolyte in the battery is frozen. burns. Batteries contain sulfuric acid. Avoid
47-83A contact with skin, eyes, or clothing. Antidote:
EXTERNAL-Flush with water.
WARNING: Never cause sparks to occur or
INTERNAL-Drink large quantities of water or
smoke near batteries that are charging or
milk. Follow with milk of magnesia, beaten
have been recently charged.
egg, or vegetable oil. Call physician
13-8A
immediately. Eyes: Flush with water for 15
WARNING: Disconnect the ground cable minutes and get prompt medical attention.
first when the battery cables are Batteries produce explosive gases. Keep
disconnected from the battery. sparks, flame, and cigarettes away. Ventilate
Connect the ground cable last when the when charging or using in enclosed area.
battery cables are connected to the battery. Always shield eyes when working near
47-55A batteries.
WARNING: Some batteries have a Keep out of reach of children.

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

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

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

4003-4
MAINTENANCE
Electrolyte Level Inspecting and Cleaning a Battery

If the battery is a maintenance free battery, check the If damage causes an electrolyte leak, replace the
level of the electrolyte every 1000 hours of operation battery.
or six months, whichever occurs first. For all other
Inspect the battery at regular intervals for dirt,
batteries, check the level of the electrolyte every 250
corrosion, and damage. Electrolyte and dirt on the
hours of operation.
top of the battery can cause the battery to discharge
NOTE: A maintenance free battery will have the words by making a passage for the current to flow.
Maintenance Free on the decal on the top of the battery. If
If the battery must be cleaned, remove the battery
the center part of the decal has been removed for access to
from the battery carrier and clean the battery, cable
the battery caps, it is possible that the words Maintenance
terminals, and the battery carrier. When available,
Free have been removed from the decal.
use New Holland Battery Saver and Cleaner
Check the level of the electrolyte more often during according to the instructions on the container. New
hot weather. The use of a large amount of water by Holland Battery Saver and Cleaner also helps
the battery can be caused by high battery prevent corrosion. If New Holland Battery Saver and
temperature or a voltage regulator setting that is too Cleaner is not available, use baking soda and water
high. Keep the electrolyte level above the top of the as a cleaner. DO NOT permit any type of cleaner to
plates in the battery at all times to prevent damage to enter the cells of the battery.
the battery.
Install the battery in the machine and make sure the
NOTE: On maintenance free batteries it is necessary to fasteners are tight. Apply New Holland Battery Saver
remove the center part of the decal for access to the battery and Cleaner or Urethane Seal Coat to the cable
caps. Do not discard the center part of the decal. Install the terminals to prevent corrosion. See the Parts
center part of the decal after the battery caps have been Counter Catalog. DO NOT apply grease.
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. 1 2
Visual Checks
1. Make sure the cable connections are clean and
tight. Clean foreign material from the top of the
battery.
2. Inspect the battery case, battery posts, and
cables for damage.
3. Check the electrolyte level. See Page 4.
4. If you added water to the battery, the battery
must be charged for 15 minutes at 15 to 25
amperes to mix the water with the electrolyte.
Specific Gravity Check B790863
A hydrometer is used to check the specific gravity 1. TEMPERATURE IN F 2. TEMPERATURE IN C

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

4003-6
Capacity (Load) Test NOTE: Never apply a load for longer than 15 seconds.
After each 15 seconds, turn the load control knob to OFF for
This test can be done using a variable load tester at least one minute.
such as the Sun Electric VAT -33. Other test
equipment can be used. Connect the test equipment 4. Apply a 15 ampere load to the battery for 15
according to the instructions of the manufacturer of seconds. Wait at least three minutes before
the equipment. applying the load again.
1. The level of charge of the battery must be at 5. Check and make a record of the temperature of
least 75%. Do the Specific Gravity Check in this the electrolyte.
section. 6. Find the correct load for this test in Specifications
2. Prepare the tester (Sun Electric VAT-33 shown) in Section 4001.
for the test. NOTE: The correct load is half of the cold cranking
A. Select the voltmeter range that will measure 1 amperes at -17°C (0°F).
to 18 volts. 7. Turn the load control knob until the ammeter
B. Make sure the load control knob is in the OFF indicates the specified load. Keep the load for 15
position. seconds and read the voltmeter. Turn the load
control knob to OFF.
C. Select the ammeter range that will measure 0
to 1000 amperes. 8. Compare the test reading and the temperature of
the electrolyte to the chart below.
D. Move the volt lead switch to the NT. position. Temperature of . . . . . . . . . . . . . . . Minimum Voltage
3. Connect the tester to the battery as shown. electrolyte
21°C (70°F) and above . . . . . . . . . . . . . . . . . . . . 9.6
16°C (60°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
10°C (50°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
2
4°C (40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9.3
-1°C (30°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
-7°C (20°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
-12°C (10°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7
1 -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
A. If the test result is equal to or more than the
voltage shown, the battery is in good
condition.
B. If the test result is less than the voltage
shown, discard the battery.
B790499
1. LOAD CONTROL KNOB 2. AMMETER CLAMP (TIP OF

ARROW AWAY FROM
BATTERY)

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

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

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

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

Above 80 to 125 Minutes 7.5 Hours at 10 Amperes 1.5 Hours at 50 Amperes
20 Hours at 5 Amperes 5 Hours at 20 Amperes

Above 125 to 170 Minutes

Above 170 to 250 Minutes 15 Hours at 10 Amperes 3 Hours at 50 Amperes
*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 5 Hours at 10 Amperes 1.5 Hours at 30 Amperes

Above 80 to 125 Minutes 7.5 Hours at 10 Amperes 1.5 Hours at 50 Amperes


6 Hours at 40 Amperes
Above 250 Minutes 24 Hours at 10 Amperes
4 Hours at 60 Amperes
*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 an d the
2. Fill each cell to the top of the separators with
temperature of the electrolyte is at least 15.5°C
electrolyte. This will permit the volume of
(60°F).
electrolyte to increase when heated by charging
the battery. 6. If necessary, fill each cell with electrolyte until the
electrolyte is just below split ring at the bottom of
3. Install the caps on the battery.
the cell opening.
4. Connect a battery charger to the battery.

Section
4003a
4003a
JUMP POST OPTION

Via Plava, 80
4003-2
TABLE OF CONTENTS
Jump Post Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4003-3
JUMP POST OPTION

STEP 1 5. Connect the other end of the negative (-) cable to
the negative (-) terminal of the jump post (black).
Do not connect it to sheet metal or any rotating
part, as damage can result. Do not connect to
the negative (-) terminal on the battery.
6. Start the engine.
7. Remove the booster battery negative (-) cable
from the jump post and then from the machine
being used for starting. Remove the positive (+)
cable from the jump post terminal and then from
the booster battery.
8. Install the terminal covers.
W270R458
The Jump Post option can be used to provide power

to star t the machine if i ts batter ies become
discharged.
The option can be used to provide power to the
machine for the purpose of raising the hood if its
batteries have become discharged.
The option can be used to start other disabled
equipment without accessing the main battery
terminals.
NOTE: Make sure that the voltage of the booster batteries
is the same as that of the machine system (24 volts). The
jump post is located on the left hand side of the machine
inside the main electrical disconnect compartment.
1. Turn off the ignition and all accessories on the
machine(s). Use the jump post to connect the
auxiliary battery.
2. Remove the terminal covers and connect one
end of the positive (+) cable to the positive (+)
terminal on the booster battery.
3. Connect the other end of the positive (+) cable to
the positive (+) terminal of the jump post (red).
4. Connect the negative (-) cable to the negative (-)
terminal on the booster battery.

4003-4
NOTES

Section
4005
INSTRUMENT CLUSTER
4005

Via Plava, 80
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Language Screen, Measurement Units, and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fan Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MPH/KPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
RETRIEVING FAULT CODES AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4005-3
INSTRUMENT CLUSTER
5
4 6
1 2 3 7 8 9 10
15 11
14 12
13
BS06H240
1. LOW BRAKE PRESSURE INDICATOR 9. LACK OF AUX STEER PRESSURE (OPTIONAL)
2. HIGH BEAM INDICATOR 10. PARKING BRAKE INDICATOR
3. TRANSMISSION OIL TEMPERATURE GAUGE 11. RIGHT TURN INDICATOR
4. CAUTION MASTER INDICATOR 12. FUEL LEVEL GAUGE
5. MULTI FUNCTION LCD DISPLAY 13. FUEL LEVEL AT MINIMUM
6. STOP MASTER INDICATOR 14. ENGINE COOLANT TEMPERATURE GAUGE
7. HYDRAULIC OIL TEMPERATURE GAUGE 15. LEFT TURN INDICATOR
8. WAIT TO START ENGINE PREHEAT
The instrument cluster monitors a number of functions and can be tailored to fit the operator’s preferences The
instrument cluster not only monitors machine functions, it warns the operator when caution is needed due to a
possible malfunction and when immediate action is needed due to a possible critical malfunction. When the
machine is started, the instrument cluster will perform the following self-test:

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 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, if default settings were not changed
by the operator.
2. This example, shows that the Transmission
Control Lever is in Neutral. The display will show
W230M139
Forward, Neutral, or Reverse, depending on
where the Directional Control Lever is
The LCD Multi-Function Display is located at the
positioned.
center of the modular dashboard. On start up the
cluster will flash the instructional lamps. NOTE: Forward and Reverse will blink if the transmission
clutches are disconnected.
3. This zone shows the gear numerically (3th).
7.0 H 1 4. This example shows the current transmission
F mode that has been selected.
A. If the Transmission is operating normally it will
2 N display either
● A - Automatic
R
A 5 ● M - Manual operation.
A 11 22 4
3 12 3 4 B. If the Transmission is not operating normally
the display will show
6 ● C - Substitute Clutch.
● L - Limp Home.
● S - Transmission Shutdown.
W230R477
LCD MULTI-FUNCTION DISPLAY 4 SPEED ● U - TCU Shutdown.
5. This example shows the Power Boost Status.
● MAX - Maximum Power.
7.0 H 1 ● STD - Normal/Standard mode of Operation.

F ● AUTO - Switches automatically between
Maximum and Standard Power.
2 N ● ECO - Limited Power for fuel efficiency.
6. This example will show the Time in either 12
R
A 5 hour or 24 hour.
A 11 22 4
3 12 3 D
6
W230R476
LCD MULTI-FUNCTION DISPLAY 5 SPEED

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
A C may be reached by pressing the up or down key. The
following sequence is using the down key only.
to the normal driving screen.
B D
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.
W230R435
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 Urea level.

4005-7
W230R436 W230R438
Info 2 will be displayed next. The Info 2 screen will Press the down button again and the Trip 1 screen
display coolant temperature, turbocharger air will display. The LCD provides two trip computers.
temperature, engine oil temperature in either These will display since last reset the total time in
Fahrenheit or Celsius, and the Urea level. hours, the total fuel, and the average fuel
consumption per hour.
W230R437
W230R439
Push the down button again and the Info 3 screen.
By continuing to scroll down, the fifth screen will
This screen displays the temperature in Fahrenheit
display the Trip 2 screen. Trip 1 and Trip 2 screens
or Celsius of the transmission oil, hydraulic oil, sump
can be reset independently. The previous screen can
oil, and the Urea level.
be accessed by using the up arrow key.
Info 4
Voltage V 24.2
Air Turbo °C 42
DefTemp °C 32
DefLvl % 24
W230M171
Push the down key again to display the info 4 screen.

This screen display the voltage level, turbocharger
air temperature, Urea temperature and Urea level.

4005-8
Reset The Trip Information
Trip 2
04May2008, 17:42
Time Hrs 102.9

Fuel L 1000.6
Fuel/hr L/h 9.1
BD06F172
W230M137 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.
Trip 2
04May2008, 17:42
Time Hrs 102.9

Fuel L 1000.6
BD06F187
Fuel/hr L/h 9.1
Press the confirm button to reset the trip selection to
zero.
W230M137
Press the escape key to return to the main driving
screen and lock settings into memory. The screen
will begin to record time and fuel usage immediately.

4005-9
Entering The Service Screens

After the machine has been started or the key switch has been turned to on the operator or service technican may
use this service menu to adjust machine configurations to working conditions, test components, view faults that
may have occurred, 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.
W230M141 / BD06F188
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: 4. Service
1. Setting Menu ● Calibration (Clutch Calib, Pedal Calib, Park
● Engine (Auto Idle, Power Mode, Eng Options, Brake, Fan Test)
Factory Set, Auto Shutdown, Fan Gain) ● Change Model
● Transmission (Max Gear, Min Gear, ICCO ● Slot Tires
ENABLE) For other submenu see next page.
● Joystick Steering (Option) * The tests in the configuration menu should be
2. Display Menu performed only by a qualified operator or technician,
● Options (Engine Snd, Ground Snd) as some tests require the engine to be running at
high RPM’s.
● Language (English, Deutsch, Francais, Italiano,
Espagnol, Portuguese)
● Units (Metric, English, Imperial)
● Clock (24 or 12 Hour Increments)
● Backlight (Day Disp., Day Led, Night Disp.,
Night Led)
● Factory Set (Reset, Display Setting, Confirm
Please)
3. Diagnostics
● Show Errors (Red, Yellow, White, Memory) -
Memory 1/2
● Reset Errors (Reset, Confirm Please)
● Cluster S/W (Software Part Number, Software
Serial Number, Software ID, Software Version)
● Transmission (SW, HW, VER, SER)

4005-10
84547255A
Main Menu
Settings
Display
Diagnostics
Service
Settings Display Diagnostics Service
Engine OPT Options ! Show Errors Calibration

Transm. Language
Cluster
Slct_Tires
Units
Joyst. Steer Transm.
Clock
Backlight
Factory Set
Engine Transm. Transm. Joyst Steer OPT Options Clock Backlight Factory Set Calibration Select Tires
Language Units
Engine Spd ON Format 12 Hr Day Disp. 20 Reset TireSize 20.5 Rad
Auto Idle Max Gear 4 Max Gear 5 JSS_Spd 2 English Metric ClutchCalib
Ground Spd ON Hour 12 Day LED 20
Power Mode Min Gear 1 Min Gear 1 Deutsch English Minute 30 Display Settings PedalCalib
Night Disp. 5
Francais Imperial Day 1
EngOptions POWERINCH ON Night LED 5 ParkBrake
Italiano Month 1
Year 2011 Confirm Please Fan Test
Factory Set Espagnol
(4 Speed) (5 Speed) (Option) Portugue
Auto Idle Power Mode EngOptions Factory Set Auto Shtdwn ! Show Errors Cluster Transm. ClutchCalib PedalCalib ParkBrake Fan Test
MAX Fan Auto ON Reset RED 0 HW P/N 87372814 SW 6057 018 121 Test Park Brake Switch to Fixed
Off Economy OFF
YELLOW 0 SW P/N 84340740 HW 6009 365 007 Fan Speed Mode
Low STANDARD WorkIdle Deflt Engine Settings Interval 30 min
AUTO WHITE 0 Ldr 1.8.0.0 VER 932___tdz_Luc Confirm Please Confirm Please Confirm Please
Accelerated Protection OFF
ECO MEMORY 2 Ver 3.0.2.8 SER 4506JCWFw Confirm Please
Confirm Please
(Option)
MEMORY 1/2 PedalCalib ParkBrake Fixed 70%

19605 Warning
Push Pedal Full Test Park Brake Test at fixed
SCR Control
CAN Msg Engine Engage 3rdManual Fan Speed
Timeout Press Esc Press Esc
17NOV10,Hr 1067 To Exit To Exit
1 0.00
Issued 11-11
PedalCalib AdjustSpeed
Change OK 70% Speed 735

Now, Reset *****
Turn Key OFF

Actual PWM 420
..
Printed in E.C.
W230R478
4005-11
SELECT SCREEN The "Diagnostic" selection screen allows the
software screens which cannot be modified to be
The "Display" selection screen allows time settings to
viewed by highlighting "cluster S/W" and pressing the
be entered. Highlight "clock" and press the select
confirmation button.
button. This will allow the time settings to be
changed.
W230M145 Figure 4
W230M142 Figure 1
W230M146 Figure 5
W230M143 Figure 2
W230M147 Figure 6
W230M144 Figure 3
to the normal driving screen. In order to lock the changes
into memory, the operator must press the confirm key, then
use the escape key to page back to the main screen.
Turning the machine off will also lock the settings into
memory.

4005-12
SELECTING POWER MODES
The power mode allows the operator to choose the
most effective machine power for the current job
conditions. Idling can be changed from automatic to
a fixed rate.
Most commonly Auto is chosen, as the power will
automatically increase or decrease between
maximum power and standard power while 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.
W230M149 Figure 9
Press and hold the confirm key for two seconds to At the screen shown above, highlight the power
arrive at the service screen. mode, and press the confirm key to move to the
Power Mode Selection Menu.
W230M141 Figure 7
W230M150 Figure 10
At the Power Mode Menu press the confirm key
again to activate the selections. The highlighted
section will flash to indicate a new selection can be
made.
Press the up or down key to select the Power Mode,
and then press the confirm key. Use the escape key
to return to the main driving screen and to lock the
mode selection into memory.
Confirming the Selected Mode
The selected mode will display in zone 3 (bottom) of
the Multi-Function Display when power mode is
W230M148 Figure 8 correctly selected.

4005-13
OPTIONS AND PREFERENCE SCREENS
LANGUAGE SCREEN, MEASUREMENT UNITS,
AND CLOCK
The LCD screen can be set with language,
measurements, and/or clock preferences. Use the
arrow keys to scroll to the display menu. Press the
confirm key on the correct selection. Press the
escape key to return to the main driving screen and
lock the selection into memory.
Choose the preferences desired: language in
English, Spanish, Portuguese, Italian, German,
French; measurement units in metric, English, or
Imperial; and clock units in 12 or 24 hour cycles.
Highlight the preference you wish to change and
press the confirm key. The preference will flash and W230M156 Figure 13
allow you to scroll through the choices. When the
correct preference is chosen, press the confirm key,
then use the escape key to return to the main driving
screen in order to lock the preference into memory.
W230M157 Figure 14
W230M142 Figure 11
W230M158 Figure 15
W230M155 Figure 12

4005-14
CLOCK DISPLAY MENU
Setting The Hour and Date The display menu can be used to change the
background and brightness of the screen. Use the
From the display screen, choose the clock
arrow keys to make your selection from the display
designation and press the confirm key. Use the arrow
menu and press the confirm key until the screen
keys to show field for time and date by pressing the
reverts to the main driving screen to lock the
arrow key. When the correct time and date have
selection into memory. The screen display can be
been entered by using the up and down arrow keys
changed to suit working conditions. The screen will
(up increases the numbers - down decreases the
change to night function illumination when the head
numbers), press the confirm key to lock in correct
lamps are turned on.
time. Press the escape key to return to the main
driving screen and lock selections into memory.
W230M159 Figure 19
W230M142 Figure 16
W230M160 Figure 20
W230M143 Figure 17
W230M144 Figure 18

4005-15
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 Service.
W230M175
If, conditions are not correct, an error message will
appear and guide the operator or technican.
There are six, if conditions not met, screens:
● Not in neutral
● Park Brake OFF
● Machine moving
● Oil temp too low
● Oil temp too high
W230M173
● Engine RPM low
Use the confirm and arrow button to scroll to the
● Engine RPM high
screen shown above. At this screen push the confirm
button again. If conditions are correct the operator or technican will
see six calibration screens pass. They will display in
this order:
● Adjust K1
● Adjust K2
● Adjust K3
● Adjust K4
● Adjust KV
● Adjust KR
Once the process is completed this screen will direct
the operator or technican to shut the engine OFF and
then re-start.
W230M174
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.

4005-16
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.
RPM
Engine speed in RPM will show on the display if the
engine speed is running up to 550 RPM’s, and will
disappear if the engine speed is lower than 300
RPM.
W230M141
Options Menu MPH/KPH

Use the arrow keys to choose the menu. Press the Vehicle speed will show on the display if it is up to 1.0
confirm key, and the options sub-menu will appear. MPH / 1.5 KPH and will disappear if the vehicle
The options menu will allow the operator to choose speed is less than 0.6 MPH / 1.0 KPH.
options for the fan, idle.
Fan Auto
The fan can be set to run at automatic or the fan will
run at maximum speed. Automatic is the more
common or preferred setting. It will switch between
high speed, low speed, or reverse as conditions
require depending on actual temperature of the
coolant, turbocharger air, transmission oil, and
hydraulic oil.
The operator can choose fan speed or reversing
capabilities. Highlight the fan auto selection by using
the arrow keys, then press confirm. When you have
chosen the selection, lock the selection into memory
by pressing the confirm key.

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Section
4006
REAR VIEW CAMERA AND MONITOR
4006

Via Plava, 80
4006-2
TABLE OF CONTENTS
REAR VIEW CAMERA AND MONITOR (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Components of the rear view camera and monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation the rear view camera and monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4006-3
REAR VIEW CAMERA AND MONITOR (OPTIONAL)
The rear view back-up camera reduces vehicle
blind spots during reversing operations. It assists
operators when backing for loading operations and
offers a view of other equipment, obstacles, and/or
personnel in the work area.
Refer to the camera manufacture's instructions for
correct operation of the camera monitor.
The camera monitor is mounted in the operator's
compartment and the camera eye is located
behind the rear grille. The camera eye has built in
moisture resistance for equipment that operates in
harsh environments. The camera is available for
yourauthorized dealer.
W230M181
W230M182

4006-4
COMPONENTS OF THE REAR VIEW CAMERA AND MONITOR
1. Bar mounting
2. Monitor arm mount
3. Plate access monitor adaptor
4. Monitor
5. Mounting bracket rear camera
6. Rear camera
7. Washer
8. Bolt
9. Washer
10. Nut
11. Washer
12. Screw
13. Washer
14. Screw
15. Nut
16. Cab right hand console
17. Washer
18. Screw
19. Latch
20. Rivet
21. Nut
22. Grommet
23. Strap cable

4006-5
5 7
7
8 10
15
6
13
9
14 13
4
12
11
1 18 17 21
22
20
23 16
19 3
W230R490
INSTALLATION THE REAR VIEW CAMERA AND MONITOR

Printed in E.C. Issued 11-11 84547255A
4006-6

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 (JSS) (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5009

Via Plava, 80
5001
Section
5001
REMOVAL AND INSTALLATION OF STEERING

COMPONENTS

Via Plava, 80
5001-2
TABLE OF CONTENTS
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AUXILIARY STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
AUXILIARY STEERING PUMP AND MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5001-3
STEERING CONTROL VALVE
Removal STEP 7
STEP 1
Remove the cab skirts from the cab or canopy.
STEP 2
Remove all dirt and grease from steering control
valve.
STEP 3
Remove hydraulic reservoir fill cap, attach a vacuum
pump to the reservoir, start the pump.
W230R595
STEP 4 Remove the mounting nut and washers from the
Tag hoses connected to steering control valve. steering shaft.
STEP 5 STEP 8
BD06G262 W230R596
Disconnect hoses from steering control valve, cap or Remove the steering wheel from the shaft.
plug the fittings and hoses, turn off the vacuum
pump.
STEP 9
STEP 6
W230R597
Remove the six mounting screws from the instrument

W230R594
cover.
Remove the center cap from the steering wheel.

5001-4
STEP 10 STEP 13
BD06G248 BD06G258
Remove the five mounting screws for the left and Remove the two mounting screws from the lower
right hand trim. trim.
STEP 11 STEP 14
BD06G249 BD06G259
Disconnect the ignition switch, remove the right and Pull floor mat away from the column and remove the
left hand trim pieces from the column. lower trim from the column.
STEP 12 STEP 15
BD06G257 BD06G260
Remove the screw from the brace. Remove the two lower mounting screws from the
front vent.

5001-5
STEP 18
BD06G261
Remove the three vents from the front trim, remove

the three mounting bolts inside of the vent holes, BD06G264
remove the vent. Put the rubber bushing on the spacer with the
tapered end towards the steering valve.
STEP 17
STEP 19
Have an assistant push the valve into place while
turning the steering shaft, this will engage the
splines.
STEP 20
BD06G263
Remove the four mounting bolts for the steering

control valve.
IMPORTANT: Have an assistant support and remove the
valve while removing the mounting bolts.
BD06G263
Install and tighten the four mounting bolts for the

steering control valve.

5001-6
STEP 21 STEP 24
BD06G261 BD06G257
Install the front trim, install and tighten the three Install the screw into the brace.
mounting bolts inside of the vent holes, install three
vents into the front trim. STEP 25
STEP 22
BD06G249
Connect the ignition switch, install the right and left

BD06G260 hand trim pieces onto the column.
Install the two lower mounting screws that mount the
front vent to the cab. STEP 26
STEP 23
BD06G248
Install and tighten the five mounting screws for the

BD06G258 left and right hand trim.
Install the lower trim onto the column, instal and
tighten the two mounting screws mounting the lower
trim, place the floor mat into position.

5001-7
STEP 27 STEP 30
W230R597 BD06G262
Install and tighten the six mounting screws for the Start the vacuum pump, remove the caps and plugs
instrument cover. the fittings and hoses. Connect hoses to steering
control valve according to the tags installed during
STEP 28 removal, remove and discard the tags.
STEP 31
Remove the vacuum pump from the reservoir, install
and tighten the reservoir fill cap.
STEP 32
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.
STEP 33
W230R595
Install the skirts onto the cab or canopy.
Install the steering wheel, install and tighten the
mounting nut and washers, tighten the nut to 50 Nm STEP 34
(37 lbf-ft). Check fluid level in hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
STEP 29
W230R594
Install the center cap on the steering wheel.

5001-8
AUXILIARY STEERING PRIORITY VALVE

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

5001-9
11 1
10
12
7 8
4
3
2
13
9
W270R012
1. HOSE HYDRAULIC ACCUMULATOR 8. STEERING SOLENOID

2. HOSE ORBITROL 9. HOSE STEERING VALVE
3. PRESSURE SWITCH 10. HOSE TANK RETURN
4. HOSE HYDRAULIC TANK 11. REAR CHASSIS
5. TUBE RELIEF RETURN 12. AUXILIARY STEERING PRIORITY VALVE
6. BOLT + WASHER 13. AUXILIARY STEERING PUMP
7. HOSE ORBITROL
AUXILIARY STEERING PRIORITY VALVE ILLUSTRATION

5001-10
STEERING PRIORITY VALVE

1. Park loader on level ground and lower bucket to 1. Install bolts with washers (8) through priority
ground. Put transmission in NEUTRAL, apply valve. Install new O-ring (9) on top of priority
parking brake, and shut down engine, valve. Install priority valve (7) onto low pressure
pump, tighten bolts to 84.7 to 101.7 Nm
2. Put master disconnect switch in OFF position.
(750 to 900 lbf-in).
3. Remove all dirt and grease from steering priority 2. Install new O-rings (6) onto high pressure pump
valve (7) and adjacent area. See illustration on discharge tube (5).
page 11.
3. Place tube into position and intsall two split
4. Remove hydraulic reservoir fill cap. flanges (3) and eight bolts (4) with washers,
5. Connect a vacuum pump to hydraulic reservoir. tighten bolts to 84.7 to 101.7 Nm
(750 to 900 lbf-in).
6. Start vacuum pump.
4. Connect all hoses as tagged to the steering
7. Tag and disconnect all hoses connected to the priority valve (7).
steering priority valve (7).
5. Stop vacuum pump.
8. Loosen and remove eight bolts (4) and two spit
6. Disconnect vacuum pump from hydraulic
flanges (3).
reservoir.
9. Remove the high pressure pump discharge tube
7. Install fill cap on hydraulic reservoir.
(5), discard O-rings (6).
8. Put battery disconnect switch in ON position.
10. Support the steering priority valve (7), remove
Start engine and run at low idle for 30 seconds.
mounting bolts (8).
Stop engine and check for leaks.
11. Remove steering priority valve (7).
9. Check to make sure steering priority valve
12. Discard O-ring (9). operates correctly. See Section 5002.

5001-11
9
6
5 6
7
4
3
W270R017
1. LOW PRESSURE PUMP (LOADER PUMP) 6. O-RINGS

2. HIGH PRESSURE PUMP (STEERING PUMP) 7. STEERING PRIORITY VALVE
3. SPLIT FLANGE 8. BOLT
4. BOLT 9. O-RING
5. STEERING PUMP OUTPUT LINE
STEERING PRIORITY VALVE ILLUSTRATION

5001-12
AUXILIARY STEERING PUMP AND MOTOR
Removal 7. Connect ground cable (1) to ground stud of

auxiliary steering pump and motor (7) following
1. Park loader on level ground and lower bucket to tag installed during removal.
ground. Put transmission in NEUTRAL, apply
parking brake, and shut down engine, 8. Connect positive cable (2) to B+ stud of auxiliary
steering pump and motor (7) following tag
2. Put master disconnect switch in OFF position. installed during removal.
3. Tag and disconnect two wiring harness (8) from 9. Connect wiring harness wires (8) to auxiliary
auxiliary steering pump and motor (7) solenoid. steering pump and motor (7) following tags
See illustration on page 13. installed during removal.
4. Tag and disconnect positive cable (2) from B+ 10. Put master disconnect switch in ON position.
stud of auxiliary steering pump and motor (7).
11. Start and run engine at low idle and raise bucket
5. Tag and disconnect ground cable (1) from 500 mm (20 inches) above ground. Check that
ground stud of auxiliary steering pump and motor auxiliary steering light on information center is
(7). OFF.
6. Remove hydraulic reservoir fill cap. IMPORTANT: In following Step, do not run auxiliary
7. Connect a vacuum pump to hydraulic reservoir. steering pump and motor continuously for more than 20
seconds at a time without a two minute cool down.
12. With engine at low idle and machine steering
9. Disconnect suction hose (4) from auxiliary straight ahead, turn key switch to OFF position to
steering pump and motor (7). Install a plug in stop engine and then immediately back to ON
suction hose and cap on fitting. position (not START position). Auxiliary steering
10. Stop vacuum pump. pump and motor should start operating
immediately. Check that auxiliary steering light
11. Loosen fittings on pressure tube (5). on information center is ON and auxiliary
12. Support auxiliary steering pump and motor (7). steering pump and motor is operating.
Remove nuts (3), cap screws, and washers 13. Turn steering wheel all the way to left and right to
securing auxiliary steering pump and motor (7). make sure that auxiliary steering pump and
13. Remove pressure tube (5) and auxiliary steering motor operates correctly.
pump and motor (7). 14. Restart engine. Check that auxiliary steering light
on information center stays ON and auxiliary
steering pump and motor is operating. After
about three seconds motor should stop operating
Installation and auxiliary steering light should go out.
1. Position auxiliary steering pump and motor (7) on 15. Let engine run and allow batteries to recharge for
its mounting plate while connecting and hand a minimum of 10 minutes.
tightening pressure tube (5) to auxiliary steering
priority valve (6). See illustration on page 13.
2. While supporting auxiliary steering pump and
motor (7) have an assistant install cap screws,
washers, and nuts (3) to secure auxiliary steering
pump and motor (7), tighten the nuts.
3. Tighten pressure tube (5) fittings securely.
5. Remove plug from suction hose (4) and cap from
elbow. Connect suction hose to elbow installed in
auxiliary steering pump and motor (7).
6. Stop and disconnect vacuum pump. Install fill
cap in hydraulic reservoir.

5001-13
10
8
9
10
3
4
7
2 1
5
6
7 4
W270R018
1. GROUND CABLE 6. AUXILIARY STEERING PRIORITY VALVE

2. POSITIVE CABLE 7. AUXILIARY STEERING PUMP AND MOTOR
3. NUT (4) 8. WIRING HARNESS
4. SUCTION HOSE 9. REAR CHASSIS
5. PRESSURE TUBE 10. HYDRAULIC ACCUMULATOR
AUXILIARY STEERING PUMP AND MOTOR ILLUSTRATION

5001-14
STEERING CYLINDER
1. Loosen the fill cap for the hydraulic reservoir to 1. Put steering cylinders (4-11) in position in
release pressure in the reservoir, then tighten the machine.
fill cap.
2. Make sure washers (14) are installed between
2. Disconnect grease hoses (1) from steering steering cylinders (4-11) and front frame of
cylinders (4-11). See illustration on page 15. machine.
3. Disconnect hydraulic hoses (2, 3, 9, 10, 16 and 3. Install the pivot pin (5) to secure rear of steering
17) from steering cylinders (4-11). cylinders (4-11) to machine frame (15). Install
spacer (6), washer (7), and cap screw (8) to
4. Install a plug in each hose (2, 3, 9, and 10) to
secure pivot pin (5).
prevent entry of foreign matter.
4. Tighten cap screw (8).
5. Remove cap screw (13).
5. Install pin (12) in front of steering cylinders
6. Remove pin (12).
(4-11). Make sure that washers (14) are installed
7. Remove washers (14). in correct position.
8. Remove cap screw (8), washer (7), and spacer 6. Install cap screw (13) in steering cylinders (4-11)
(6) securing pivot pin (5) at rear of steering rod end and pin (12). Tighten cap screw (13).
cylinders (4-11).
7. Connect hose assemblies 2, 3, 9, 10, 16 and 17)
9. Use a suitable driver and drive pivot pin (5) out of to steering cylinders (4-11).
steering cylinder (11).
8. Connect grease hoses (1) to steering cylinders
10. Remove steering cylinders (4-11). (4-11).
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.

5001-15
8
7
6
5
15
2 4
9
10
3
17
11
16 12 13
1 14
W270R023
1. GREASE HOSE 6. SPACER 11. STEERING CYLINDER 16. HOSE ASSEMBLY

2. HOSE ASSEMBLY 7. WASHER 12. PIN 17. HOSE ASSEMBLY
3. HOSE ASSEMBLY 8. CAP SCREW 13. CAP SCREW
4. STEERING CYLINDER 9. HOSE ASSEMBLY 14. WASHER
5. PIVOT PIN 10. HOSE ASSEMBLY 15. REAR CHASSIS
STEERING CYLINDER ILLUSTRATION

5001-16
STEERING BACK PRESSURE VALVE
1. Remove the fill cap for the hydraulic reservoir to 1. Install the valve (4), bolts (11), washer (12) and
release pressure in the reservoir, attach a nuts (10) onto the machine, tighten the bolts.
vacuum pump to the reservoir, start the pump.
2. Install new O-rings (8) onto the fittings of the
2. Disconnect hoses 2 and 5 from the pressure hoses, install and tighten the hoses.
valve (4).
3. Stop the vacuum pump, install and tighten the
3. Remove the nuts (10), bolts (11) and washer reservoir filler cap.
(12) from the pressure valve, remove the valve
4. Start and run the machine at low idle, turn the
from 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.

5001-17
A 10
12 7
11 4
8 13
12
9
6 5
W270R022
1. STEERING CONTROL VALVE 8. O-RING

2. RETURN HOSE 9. CONNECTOR
3. CONNECTOR 10. NUTS
4. RELIEF VALVE 11. BOLTS
5. RETURN HOSE TO FILTERS 12. WASHER
6. RETURN MANIFOLD 13. CONNECTOR
7. REAR CHASSIS
STEERING BACK PRESSURE VALVE ILLUSTRATION

5001-18
NOTES

5002
Section
5002
STEERING SPECIFICATIONS, PRESSURE CHECKS,

AND TROUBLESHOOTING

Via Plava, 80
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STEERING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Setting Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Setting Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STEERING CYLINDER LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING BACK PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5002-3
SPECIAL TOOLS
B785789 B009638
380001731 FLOWMETER 380001739 PRESSURE TEST FITTING KIT
B797157
380001740 FLOWMETER FITTING KIT
TROUBLESHOOTING THE STEERING SYSTEM

NOTE: The steering hydraulic schematic is included in the 4. Do the main hydraulic pump test. See Section
hydraulic schematic. Refer to the rear pocket of this 8002. If the main pump is bad, repair or replace
manual. the main hydraulic pump.
1. Make sure the oil level in the hydraulic reservoir 5. Test the steering cylinders for leakage, refer to
is correct. Visually inspect the steering system instructions on page 8. If a steering cylinder is
for leakage and damage. leaking, repair or replace the steering cylinder.
2. The loader/steering pump differential pressure 6. If the steering system is noisy test the back
must be properly adjusted. Refer to Section 8002 pressure relief valve, refer to instructions on
Testing and Adjusting the Loader/Steering Pump page 9.
differential Pressure.
3. Do the steering limit valve pressure test. Refer to
page 6. If the pressure is above or below
specifications, adjust the steering limit valve.

5002-4
AUXILIARY STEERING SYSTEM PUMP TEST
Equipment Required
6. Connect the ammeter clamp (1) to the cable as
1. 380001731 Flowmeter in illustration.
2. 380001740 Flowmeter fitting kit
Test Procedure
1. Install articulation lock.
BB830300
1. AMMETER CLAMP
1 7. Make sure that the parking brake is applied and

the bucket is on the floor.
W230R407
8. Make sure that the oil is at operating
temperature.
1. ARTICULATION LOCK
NOTE: When performing this pressure check, always be 9. Make sure that the load valve for the flowmeter is
sure the articulation lock is in place, especially when open (zero pressure).
working in the articulation joint areas. 10. Start and run the engine.
2. Loosen and remove the outlet hose to the 11. Stop the engine and turn the key back to the On
Auxiliary Steering Pump from the Auxiliary position.
Steering Priority Valve.
12. Turn the steering wheel, this will activate the
3. Install a plug into the Auxiliary Steering Priority auxiliary steering pump.
Valve.
13. Turn the load valve on the flowmeter towards
4. Connect the inlet of the flowmeter to the outlet CLOSED until the pressure is 104 bar (1500 psi).
line of the Auxiliary Steering Pump.
14. Read the flowmeter and ammeter gauges and
5. Install the outlet hose of the flowmeter in the record the readings.
hydraulic reservoir and hold in place with wire.
15. The flowmeter reading must not be less than
24.6 L/min, (6.5 U.S. gpm). The ammeter
reading must be 315 amps.
16. Turn the key switch to the OFF position. If the
flow was less than the specification, or if the
amperage was more than 315 amperes, remove
the auxiliary steering motor and pump. Test the
auxiliary steering motor. If the motor is good,
make repairs to the pump.

5002-5
AUXILIARY STEERING SYSTEM MOTOR TEST
Test Equipment 5. Push the button on the remote starter switch (1)
and look at the voltmeter in the tester.
1. A 24 volt battery that is fully charged.
6. Turn the load control (8) until the voltmeter (7)
NOTE: A 24 volt battery system (two 12 volt batteries in a indicates 24 volts. Look at the ammeter (6) in the
series) is used for this test. A 12 volt battery system will tester. Make a record of the ammeter indication.
cause damage to the auxiliary steering motor.
2. A remote starter switch.
6 7
3. A tachometer to check the armature speed.
4. A Sun Electric VAT-33 Starting and Charging
System Tester.
Test Procedure 8
1. Remove the connector that is between the
terminals on the magnetic switch and the
auxiliary steering motor.
2. Remove the auxiliary steering motor from the
B795328
auxiliary steering pump.
6. AMMETER
3. Remove the drive coupling from the auxiliary 7. VOLTMETER
steering motor (3). 8. LOAD CONTROL
4. Connect the auxiliary steering motor (3), remote 7. Hold the tachometer against the armature shaft.
starter switch (1) and tester (2) to the 24 volt Look at the tachometer. Make a record of the
battery system (5) as illustrated. indication.
8. Release the button on the remote starter
switch (1).
2
1
Understanding The Results Of The
4
Test
3 1. If the ammeter indication in step 6 was 30
amperes or less and the tachometer indication in
step 7 was 6950 r/min (rpm) or more, the
auxiliary steering motor is good.
2. If the armature speed was less than 6950 r/min
5 (rpm) and the ammeter indication was higher
than 30 amperes, replace the motor.
B790852
1. REMOTE STARTER SWITCH

2. TESTER
3. AUXILIARY STEERING MOTOR
4. AMMETER CLAMP
5. 24 VOLT BATTERY SYSTEM

5002-6
STEERING PRIORITY VALVE

NOTE: The loader/steering pump differential pressure must be properly adjusted before doing this test. Refer to Section 8002
Testing and Adjusting the Loader/Steering Pump Differential Pressure.
Pressure Setting Test 4. Make sure that the temperature of the hydraulic
oil is at least 54° C (129° F).
1. Install articulation lock (1). 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.
6. Apply the parking brake.
7. Start and run the engine at full throttle.
8. Lower the lift arms and hold the control lever in
the FLOAT position.
1 9. Hold the bucket control lever in the rollback
position.
W230R407 10. Continue holding until the specified temperature
1. ARTICULATION LOCK of the oil is reached.
IMPORTANT: When performing the following pressure
check and adjustment, the articulation lock must be 12. Start the engine and operate the machine at full
installed. Use caution when working in or near the throttle.
articulation area. 13. With the articulation lock still in place, turn and
2. Remove the dust cap from the test port (1-2). hold the steering wheel for a hard right turn.
14. Continue holding the steering wheel, and read
the pressure gauge.
15. The pressure gauge must indicate 239 to 243
bar (3465 to 3525 psi). If the pressure is not
correct, adjust the steering relief valve.
2
1
W270R019
1. G1 TEST PORT
2. G2 TEST PORT
3. Connect a 345 bar (5000 psi) pressure gauge to
the test port (2).
NOTE: Make sure when you connect the pressure gauge
that you do so in a manner that you can read the pressure
gauge while sitting in the operators seat.

5002-7
Pressure Setting Adjustment

1. Turn the adjusting screw clockwise to increase 1
the pressure setting. Turn the adjusting screw
counterclockwise to decrease the pressure
setting.
2. Repeat pressure test procedure.
3. If necessary, adjust the limit valve again until
within the specified range.
4. Stop the engine before removing the pressure
gauge.
2
W270R020
1. STEERING PRIORITY VALVE

2. LIMIT VALVE

5002-8
STEERING CYLINDER LEAK TEST

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

5002-9
STEERING BACK PRESSURE VALVE
W270R021
1. STEERING CONTROL VALVE 3. CONNECTOR M27 ORB

2. RETURN HOSE 4. RELIEF VALVE

5002-10
Pressure Test 4. Turn the steering wheel and observe the

pressure.
1. Disconnect the return hose (2) from the
connector (3). 5. The pressure should be 8 to 10 bar (115 to 145
psi).
2. Install a “T” fitting and connect a pressure gauge
capable of reading 35 bar (500 psi). 6. If pressure is not as specified, replace the relief
valve.
3. Start and run the machine at high idle.
NOTE: The relief valve is not adjustable.

Section
5005
STEERING CYLINDERS
5005

Via Plava, 80
5005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5005-3
SPECIFICATIONS
Torque for piston cap screw ...............................................................1600 to 1830 Nm (1180 to 1349.7 pound feet)
Torque for gland ..................................................................................................407 ± 68 Nm (300 ± 50 pound feet)
STEERING CYLINDER
Disassembly Inspection
1. Fasten tube (18) 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 (14) is straight.
2. Remove gland (1) from tube (18). If piston rod is bent, install a new piston rod.
3. Pull piston rod (14) and piston (9) straight out of 3. Inspect inside of tube (18) for deep grooves and
tube (18). other damage. If there is any damage to tube, a
new tube must be used.
4. Fasten piston rod (14) yoke in vise and put a
support below piston rod near piston (9). Put a 4. Remove small scratches on piston rod (14) or
shop cloth between support and piston rod to inside tube (18) 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 (8) that hold 5. Inspect bushing (17). If bushing requires
piston (9). replacement, remove grease fitting (15) and
retaining rings (16) then press bushing from tube
6. Remove piston (9) from piston rod (14).
end.
7. Remove and discard seal (13), loader ring (12),
wear ring (11), cast iron ring (10) and seal (20)
from piston (9).
8. Remove gland (1) from piston rod (14).
9. Remove and discard O-ring (7), backup ring (6),
rod wiper (2), rod seal (3), buffer seal (4), and
bearing (5) from gland (1).

5005-4
16
17
15
16
18
8
9
11
19 13
12
20
7
10
6
4
5 3
1 14
2
W270R024
1. GLAND 6. BACKUP RING 11. WEAR RING 16. RETAINING RING

2. ROD WIPER 7. O-RING 12. RING LOADER 17. BUSHING
3. ROD SEAL 8. BOLT AND WASHER 13. SEAL 18. TUBE
4. BUFFER SEAL 9. PISTON 14. PISTON ROD 19. SCREW
5. BEARING 10. RING CAST IRON 15. GREASE FITTING 20. SEAL
STEERING CYLINDER ILLUSTRATION

5005-5
Assembly 16. Install bolt and hardened washer (8) in piston (9).
1. Install bearing (5) in gland (1). 17. Install piston (9) on piston rod (14) and start bolt
(8) into piston rod.
2. Install buffer seal (4) in gland (1) so that lips of
seal are toward small end of gland. 18. Tighten bolt (8) to a torque of 1600 to 1830 Nm
(1180 to 1349.7 pound feet).
3. Install rod seal (3) in gland (1). Rod seal must be
installed so that lips of seal are toward small end 19. Fasten tube (18) in vise. Be careful not to
of gland. Seal can be difficult to install. Use tools damage tube.
that will not damage seal. See illustration on 20. Apply petroleum jelly to O-rings (7) and backup
page 4. ring (6) on gland (1) and to sealing surface in
4. Install rod wiper (2) in gland (1) with wiper lips tube (18).
toward large end of gland. 21. Lubricate piston (9) and inside of tube (18) with
5. Install O-ring (7) on gland (1). clean hydraulic oil.
6. Install backup ring (6) on gland (1). The backup 22. Push the piston (9) straight into tube (18). Be
ring must be toward large end of gland. If backup careful not to damage cast iron ring (10), wear
ring is not flat on both sides, the side that is not ring (11), and seal (13) on piston (9).
flat must be toward O-ring (7). 23. When piston (9) is in smooth part of tube (18),
7. Fasten piston rod (14) yoke in vise. start gland (1) into tube (18).
8. Lubricate piston rod (15) and bore in gland (1) 24. If the original parts are being assembled:
with clean hydraulic oil. A. Tighten gland to a torque of 407 ± 68 Nm (300
NOTE: If a new gland (1) is being installed, write part ± 50 pound-feet).
number of cylinder on gland. B. Install and tighten self-tapping screw (19) to a
9. Push gland (1) onto piston rod (14) large end torque of 2.3 Nm (20 inch-pounds).
first. If necessary, use a soft hammer to drive the C. If, after tightening gland, the self-tapping
gland onto piston rod. screw (19) holes are not aligned, a new hole
10. Put a support below and near the end of piston for self-tapping screw must be drilled. See
rod (14). Put a cloth between support and piston Step 25.
rod to prevent damaging piston rod. 25. If a new gland (1) or a new tube (18) are being
11. Install new cast iron ring (10) on piston (9). assembled:
12. Install new wear ring (11) on piston (9). A. Tighten gland (1) to a torque of 407 ± 68 Nm
(300 ± 50 pound-feet).
13. Install a new loader ring (12) on piston (9).
B. Use a No. 27 drill bit and drill a hole half in
14. Install a new seal (13-20) over loader ring (12). gland (1) and half in tube (18). Drill to a depth
15. Clean the threads on the end of piston rod (14) of 11 mm (7/16 inch). Do not drill within 13 mm
and threads of bolt (8) using Loctite cleaning (1/2 inch) of a hole for gland wrench.
solvent. Allow to dry. Apply Loctite 243 to piston C. Install and tighten self-tapping screw (19) to a
rod threads 6.4 mm (1/4 inch) from open end of torque of 2.3 Nm (20 inch-pounds).
piston rod so that there is 12.7 mm (1/2 inch) of
Loctite 243 on piston rod threads. DO NOT apply 26. If hoses were removed with cylinder, install new
Loctite to first 6.4 mm (1/4/inch) of piston rod O-rings, if equipped, on hose fittings. Lubricate
threads. O-rings with clean oil. Install hoses.

5005-6
NOTES

Section
5006
CENTER PIVOT
5006

Via Plava, 80
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.......................................................................404 to 448 Nm (298 to 331 pound-feet)
M12 bolts for bearing retainers and lower pivot pin ..................................603 to 752 Nm (445 to 555 pound-feet)
M12 bolts for lower pin plate .....................................................................404 to 448 Nm (298 to 331 pound-feet)
Ferry head screws for the drive shaft ................................................................61 to 81 Nm (45 to 60 pound-feet)
LUBRICANT
Pivot bearings and seals ........................................................................................................ Molydisulfide grease
Steering cylinder rod eyes...................................................................................................... Molydisulfide grease
SPECIAL TOOLS
380001730....................................................................................................................... Hand pump (hydraulic ram)
380001734....................................................................................................................................... 10 ton ram (long)
380001735........................................................................................................... Puller set, includes 24827 leg ends
380001736................................................................................Bearing cup and seal puller, includes 24850 adapter
380001729..............................................................................................................................Vacuum pump (12 volt)
380001744................................................................................ *Top bearing driver, bottom bearing driver and plate

* (Requires screw, two nuts, and two washers from 380001735)
BC06A173 BC06A174
380001744 DRIVER SET CAS2029 DRIVER SET
NOTE: The upper bearing can be installed using 380001744 Driver Set and the lower bearing can be installed using CAS2029
Driver Set.

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

5006-5
1
2
3
4
16
1
6
2
7
8
9
6
16
5
10
16
11
6 A
12
16
8
13
6 8
2 15
14
1
2
2
1
A 1
W270R002
1. BOLT 5. REAR CHASSIS 9. UPPER PIVOT BEARING 13. BEARING RETAINER

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

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

24. SPCAER 26. BEARING CUP

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

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

bearing cup (28) is seated in the bore in the
BC06A121 bottom pivot (29).
17. Fill the other seal (6) for the top pivot with
27. Remove the bearing driver (17) and plate (21)
grease.
from the bottom pivot (29).
28. Install a bearing cone (25), spacer (24), the other
bearing cone (23), and the remaining bearing
cup (26) in the bottom pivot (29).
29. Install the bearing driver (17) and plate (21).

5006-8
40. Install the seal (6) in the bearing retainer (13).
21 18 19 The bottom of the seal (6) must be even with the
25 bearing retainer (13).
24
29
23 26
17
BC06A124

bottom bearing cup (26) is seated against the
spacer (24). BC06A126
41. Install the other seal (6) in the bottom pivot. The
31. Remove the bearing driver (17) and plate (21)
top of the seal (6) must be even with the top of
from the bottom pivot (29).
the bottom pivot.
32. Put the bearing retainer (13) in place on the
lower pivot bearing (12).
33. Install the bearing driver and plate.
21 18 19
29
12 30
BC06A121
13 42. Install the lower bearing spacer (11) and the

17 bottom spacer (14).
BC06A125 43. Apply grease to the lower pivot pin (10).
44. Install the lower pivot pin (10) in the bottom pivot.
bearing retainer (13) is tight against the lower
pivot bearing assembly (12). 45. Hold the bottom spacer (14) in place and
lubricate the bottom pivot until grease is forced
35. Measure the gap (30) between the bearing
out of the seal (6).
retainer (13) and the bottom pivot (29). Make a
record of the measurement. Subtract 0.0762 to 46. Rotate the lower pivot pin (10) to check the
0.1016 mm (0.003 to 0.004 inch) from the bearing assembly. The lower pivot pin (10) must
measurement. Select shims (8) equal to that rotate smoothly, but not easily.
value.
47. Remove the lower pivot pin (10) and the upper
36. Remove the bearing driver (17), plate (21) and pivot pin (4).
bearing retainer (13) from the bottom pivot.
48. Remove the bottom spacer (14).
37. Install the shims (8), the bearing retainer (13),
washers (2) and bolts (1).
38. Tighten the bolts (1) to 124 Nm (91 pound-feet).
39. Fill the seal (6) for the bearing retainer (13) with
grease.

5006-9
CONNECTING THE FRONT FRAME TO THE REAR FRAME

1. Release the parking brake. 26. Align the hole in the pivot pin with the holes in the
2. Move the rear frame into alignment with the front steering cylinder rod eye, and install the pivot
frame. pin.
3. Move the steering cylinders as required to move 27. Install the bolt and self-locking nut that hold the
the rear frame into alignment with the front pivot pin.
frame. 28. Repeat steps 25, 26 and 27 for the other steering
4. Apply the parking brake. cylinder.
5. Apply grease to the upper pivot pin (4). 29. Start the vacuum pump.
6. Install the upper pivot pin (4), spacer (3), washer 30. Connect the return hose.
(2) and bolt (1). Be careful not to damage the 31. Connect the supply hose.
seal (6). 32. Put the bracket for the hoses in position on the
7. Tighten the bolt (1) to 404 to 448 Nm (298 to 331 rear frame. Install the bolts, flat washers, and
pound-feet). self-locking nuts that fasten the bracket to the
8. Apply grease to the lower pivot pin (10). rear frame.
9. Install the lower pivot pin (10) in the frames. Be 33. Put the bracket for the hoses in position on the
careful not to damage the seal (6). front frame.
10. Use the ram and hand pump to install the bottom 34. Install the bolts, flat washers, and self-locking
spacer (14). See Special Tools in this section. nuts that fasten the bracket to the front frame.
11. Install the lower pin plate (15), three inner bolts 35. Connect the hoses for the steering cylinders.
(1), and washers (2) that fasten the lower pin 36. Connect the brake hose for the front brakes at
plate (15) to the lower pivot pin (10). the front bracket.
12. Tighten the bolts (1) to 69 Nm (51 pound-feet). 37. Stop the vacuum pump.
13. Measure the gap between the lower pin plate 38. Connect the front wiring harness to the rear
(15) and the bottom pivot. Make a record of the wiring harness.
measurement. Subtract 0.0762 to 0.1016 mm 39. Put the clamp on the wiring harness in position
(0.003 to 0.004 inch) from the measurement. on the bracket. Install the bolt, lock washer, and
Select shims equal to that value. nut that fasten the clamp on the wiring harness to
14. Loosen the bolts (1) that fasten the lower pin the bracket.
plate (15) to the lower pivot pin (10). 40. Put the ground wire in position on the stud. Install
15. Start the six outer bolts (1) into the lower pin the washer and nut that fasten the ground wire to
plate (15) and the bottom pivot. the stud.
16. Install the shims (8). 41. Install a tie strap to fasten the wiring harness to
17. Tighten the six outer bolts (1) to 404 to 448 Nm the tube.
(298 to 331 pound-feet). 42. Disconnect the vacuum pump from the hydraulic
18. Tighten the three inner bolts (1) to 603 to 752 reservoir.
Nm (445 to 555 pound-feet). 43. Check the fluid level in the hydraulic reservoir.
19. Remove the jacks from the rear frame. Add oil as required.
20. Remove the blocks from the rear axle. 44. Install the fill cap in the hydraulic reservoir.
21. Remove the stands from the front frame. 45. Bleed air from the front axle bleed screws. Refer
to Section 7002 for complete brake bleeding
22. Put the drive shaft in position on the front yoke. instructions.
23. Install new Ferry head screws that fasten the 46. Lubricate the pivot pins for the steering cylinder
drive shaft to the front yoke. rod eyes.
24. Tighten the Ferry head screws to 53 to 62 Nm 47. Install the covers on both sides of the machine.
25. Put the steering cylinder rod eye in position in the
frame. Install the washer between the steering
cylinder rod eye and the rear frame.

5006-10
NOTES

Section
5008
AUXILIARY STEERING MOTOR AND PUMP
5008

Via Plava, 80
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 L/min 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 installation 1. Lubricate all parts with clean hydraulic oil before
of the auxiliary steering motor and pump. assembly.
NOTE: The pump is the only component that is 2. Lubricate and install a new seal (4) and retaining
disassembled. The switch (8) and motor (1) are replaced as ring (3) on the plate (17). Refer to the illustration
units and are not serviced. Refer to the illustration on page on page 5.
5.
3. Lubricate and install a new backup ring (5) and a
1. Make an alignment mark on the pump assembly new seal (6) on the plate (17).
and motor (1).
4. Lubricate and install new O-rings (7) on the body
2. Loosen and remove the two screws (15) and lock (18).
washers (14) that hold the pump assembly to the
5. Lubricate and install the pins (22), drive gear
motor (1).
(20), driven gear (19) and wear plates (23) on the
3. Remove and discard the mounting gasket (13), body (18).
retaining ring (3) and seal (4) from the pump
6. Lubricate and install a new backup ring (5) and a
assembly.
new seal (6) on the end plate (21).
4. Loosen and remove the four bolts (2) that hold
7. Align the marks, made during disassembly, on
the pump assembly together.
the end plate (21), body (18) and plate (17) and
5. Remove the end plate (21) from the body (18). install the four bolts (2). Tighten the four bolts (2).
6. Remove and discard the seal (6) and backup 8. Install a new gasket (13) on the pump assembly.
ring (5) from the end plate (21).
9. Align the marks, made during disassembly, on
7. Remove the wear plate (23), drive gear (20) and the pump assembly and the motor (1).
driven gear (19) from the body (18).
10. Install the lock washer (14) and screw (15).
8. Remove the body (18) from the plate (17). Torque the screw (15) to 35 to 39 Nm (312 to
348 pound-inches).
9. Remove and discard the O-rings (7) from the
body (18).
10. Remove the pins (22) and wear plate (23) from
the body (18).
11. Remove and discard the seal (6) and backup
ring (5) from the plate (17).
NOTE: The only serviceable items on the pump assembly
are the seals (6), backup rings (5), O-rings (7), seal (4),
retaining ring (3) and gasket (13). If any of the other items
are damaged, replace the pump assembly.
Inspection
1. Inspect the wear plates (23) for grooves, scoring
and pitting. If damage is found replace the pump
assembly. Refer to the illustration on page 5.
2. Inspect the drive gear (20) and driven gear (19).
If the shafts are worn or damaged, replace the
pump assembly.
3. Clean all parts in cleaning solvent and air dry.
4. Inspect the plate (17), end plate (21) and body
(18). Replace the pump assembly as necessary.

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

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

5008-6
NOTES

5009
Section
5009
JOYSTICK STEERING SYSTEM

(JSS)
(optional)

Via Plava, 80
10135 Torino Printed at E.C.
Italy 84547255A Issued November, 2011
5009-2
TABLE OF CONTENTS
SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
JOYSTICK STEERING SYSTEM (JSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description of the JSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Activation logic of the software and joystick steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preliminary check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
System efficiency check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3rd F-N-R SWITCH ON THE ARMREST (left-hand side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PROCEDURES FOR TURNING ON / OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Main F-N-R lever activation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Activation procedure for auxiliary JSS F-N-R (left-hand side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Turning JSS ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Turning JSS OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Turning on auxiliary F-N-R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Turning off auxiliary F-N-R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
KICK-DOWN BUTTON TO SELECT A LOWER GEAR (left-hand side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
JSS Related Error Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WORKING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ELECTRICAL SYSTEM FOR JOYSTICK STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
STEERING VALVES PVG32 AND PVFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
JOYSTICK STEERING SYSTEM ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
JSS HYDRAULIC PRESSURE ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
STEERING CALIBRATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

5009-3
SAFETY STANDARDS
For all the safety measures, refer to the use and maintenance book supplied together with this manual.
WARNING: this symbol is used to draw attention to the safety instructions given in the manual. When found in the
text, carefully read the accompanying message and pay attention to the risk of serious or deadly accidents.
M171C
WARNING: when the machine is running and the Joystick Steering control has been activated, to avoid serious or
deadly accidents pay particular attention to sudden movements in the cab.
WARNING: make sure that the Joystick Steering control has been turned off during the operations of raising and
lowering the machine from the trailer loading deck. The machine could fall off the ramp or off the trailer and cause serious
or deadly accidents. It is absolutely forbidden to use the Joystick Steering control for these operations.
WARNING: when the Joystick Steering system is active and the operator presses the implement locking switch, the
Joystick Steering function will be active.
WARNING: the function of the Joystick steering control is forbidden when driving on roads.
WARNING: the emergency steering system always comes into operation via the main steering system.
WARNING: the main steering system is always active and is considered the normal steering system. Regular use of
the Joystick Steering is allowed within 20 km/h and this limit depends on the actual conditions of the ground being
worked on.
WARNING: before starting to drive on the public highway, lock the LH arm in the vertical position with the special pin.

5009-4
JOYSTICK STEERING SYSTEM (JSS)
Description of the JSS

The JSS is mounted in parallel with the standard The JSS must be disconnected for driving on
steering system, that always has priority, increasing roads
the comfort and the functionality of the machine. For safely turning on and off, there is a specific
procedure to avoid accidental turning on/off and
The main components of the JSS are: steering (as indicated in the Use and Maintenance
Manual).
- proportional valve PVG32 with pilot solenoid valve
incorporated;
- compensation valve PVFC for the pressures from 3
the proportional valve PVG32 and from the power
steering valve;
- pressure switch LS connected to the line from the
power steering to detect use of the standard
steering: normally closed (N/C) switch, it opens at
60 bar;
- pilot pressure switch connected to the proportional
valve PVG32 to detect whether the pilot solenoid
valve is working/defective: normally closed (N/C)
switch, it opens at 8 bar;
- joystick (1) controlling the proportional valve
incorporated in the left armrest (2); 4 1
- position switch incorporated in the left armrest
with double contact: 5
1. at the top N/C (normally closed);
2. at the bottom N/O (normally open);
- three-position switch (3) to control the JSS:
1. Off - retained with mechanical lock; 2
2. On - retained;
3. activation - transitory position (clicks);
- relay K2 for JSS power supply;
- set of diodes to combine the JSS control button
521E-4R001
and the AUX F-N-R enabling button in safety;
- Can Module that incorporates the JSS activation
procedure and the software for monitoring the
system;
- modulation controller of the electric signal
between the joystick and proportional valve;
- left-hand F-N-R switch (4) on the armrest (2);
- Kick-Down left-hand button (5) on the armrest (2).
The joystick steering gear is available only on

request.
The speed with which it is possible to work with this
system depends on the type of terrain.

5009-5
Activation logic of the software and Joystick steering is turned off as soon as:
joystick steering - the left armrest is raised;
To enable the joystick steering system it is necessary - the gearbox / main lever control is moved from
first of all to put the machine in a safe condition and neutral to forward or reverse drive;
then activate the JSS with the control button.
On sending the JSS activation signal the software - the steering wheel is operated;
runs a preliminary test to verify whether the machine - the proportional valve suffers trouble;
is in a condition of safety. Secondarily it checks the
efficiency of the system. - system errors occur;
- the JSS switch is disconnected;
Preliminary check
- ignition turned off.
The condition of the machine being made safe is
given by: A slight audible warning and a message on the
display warn that the JSS has been disconnected.
- left armrest completely lowered; To switch the JSS back on after disconnection, follow
- gear lever in neutral; the system activation procedure.
- implement locking switch disenabled; The errors related to the JSS are only displayed with
the JSS switch in the ON position and they can be
- pilot pressure switch on; reset by moving the JSS switch onto OFF.
- joystick steering switch in neutral;
- machine stationary.
System efficiency check

- with the JSS off, the pilot pressure must be less
than or equal to 8 bar;
- the software monitors the armrest position switch.
When the JSS is turned on and during the whole
time it stays on, the switching of the N/O-N/C
switch is checked. Any trouble is detected with an
error message and the system is switched off;
When all the prerequisites have been satisfied the

JSS will be powered via closure of PIN 1:21 of the
output AIC LSD1 that switches over the relay K2
enabling the electric supply of the JSS with
consequent activation of the system under safety
conditions.
Once the supply is made, the system verifies that the
alarm signal of the valve of the JSS is = 0 and that on
the joystick supply PIN the signal is = 1.
After activation the system stays in operation for the
whole time in which:
- 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;

5009-6
3rd F-N-R SWITCH ON THE ARMREST - in order to enable the auxiliary JSS switch, it is
(left-hand side) necessary to check the position of the switch;
- if the auxiliary JSS F-N-R switch is in neutral,
For the joystick steering system it is necessary to enabling will take place directly;
integrate a third F-N-R switch in the current operating - if the auxiliary JSS F-N-R switch is not in
logic of the gearbox. For this purpose the software of neutral, enabling will not take place directly, the
the control unit of the transmission (TCU) is able to software will check the status of the JSS F-N-R
turn the F-N-R switch on the armrest on/off when the switch; Indeed, only at the moment when the
JSS is activated. JSS F-N-R switch is in the neutral position will
It is therefore necessary for the TCU control unit to its enabling be confirmed (without pressing the
generate a new CAN message stating JSS F-N-R JSS activation switch again);
enabled/disenabled. - during activation of the JSS a message is sent via
The software in the transmission control unit (TCU) CAN stating "JSS ON";
has to be compatible with systems with and without - the auxiliary JSS F-N-R switch is disenabled when
the joystick steering system. This means that all the the JSS is disenabled;
current TCU functions will remain unchanged. - when turning off the JSS a message is sent via
CAN stating "JSS OFF".
Position of the F-N-R switches in the cab
Turning JSS ON
1. F-N-R (current) main located on the gear lever of
the steering column; - Press the JSS ON button:
2. F-N-R (current) AUX incorporated on the a. armrest on left-hand side lowered;
implement control joystick (or console on b. implement locking switch disenabled;
right-hand side); c. low JSS piloting pressure;
3. JSS F-N-R (new) AUX incorporated on the d. JSS joystick in neutral;
armrest on the left-hand side. e. no error in the JSS;
f. main F-N-R gear control lever in neutral;
g. vehicle stationary (speed less than or equal to
PROCEDURES FOR TURNING ON / OFF 1.5 km/h).
Among the three F-N-R activation devices, the one
Turning JSS OFF
on the gear lever of the steering column has priority
over the other two auxiliary ones, which must be 1. Using the steering wheel;
enabled, each one with a specific enabling signal and 2. gear lever on the steering column / main F-N-R
according to a specific activation procedure. If switch not in neutral;
enabled, the JSS F-N-R auxiliary switch located on 3. armrest on left-hand side raised;
the left-hand side armrest has priority over the F-N-R 4. JSS enabling button OFF;
auxiliary switch on the right. 5. errors in the JSS;
6. engine OFF.
Main F-N-R lever activation procedure
- The main F-N-R lever on the steering column is
always active;
- the main F-N-R switch has priority over all the
other auxiliary F-N-R switches;
- one of the auxiliary F-N-R switches can be
enabled only if the main switch is in neutral.
Activation procedure for auxiliary JSS F-N-R
(left-hand side)
The auxiliary JSS F-N-R switch is incorporated in the
armrest on the left-hand side that is an integral part
of the JSS:
- the auxiliary 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 gearbox control unit;
- this will cause activation of the auxiliary JSS
switch as well as starting the JSS F-N-R enabling
procedure;

5009-7
Turning on auxiliary F-N-R
The auxiliary F-N-R switch is on the console on the
right-hand side. If the machine is provided with an
implement control joystick, the auxiliary F-N-R switch
is incorporated on the joystick:
- if the JSS is ON, JSS F-N-R is enabled and
auxiliary F-N-R cannot be enabled;
- if the JSS is OFF, the activation procedure
remains unchanged, and that is:
● press the auxiliary F-N-R momentary enabling
switch;
a. main F-N-R on the steering column in
neutral;
b. auxiliary F-N-R switch in neutral;
c. machine stationary;
d. engine ON;
● auxiliary F-N-R provides enabling signal for 8
seconds;
a. within 8 seconds:
1. press the parking brake release button;
2. engage forward or reverse drive;
3. permanent enabling signal for auxiliary
F-N-R;
b. after 8 seconds:
1. auxiliary F-N-R is disenabled.
Turning off auxiliary F-N-R

- gear lever on the steering column / main F-N-R
switch not in neutral;
- parking brake engaged;
- engine off.
KICK-DOWN BUTTON TO SELECT A

LOWER GEAR (left-hand side)
Besides the current button to select a lower gear on
the implement control joystick (or on the console on
the right-hand side according to the option), a second
button will be available to select a lower gear
incorporated in the left armrest with the joystick
steering system. This button will be activated
together with the JSS and it will disenable the button
on the right-hand side to select a lower gear.

5009-8
Summary table of the ON/OFF statuses
The following table illustrates the states of activation of the JSS, JSS F-N-R and auxiliary F-N-R:
Starting JSS Off JSS Off JSS Off JSS On

status
JSS / AUX F-N-R (JSS) AUX F-N-R JSS / AUX F-N-R JSS (AUX) F-N-R
disenabled enabled disenabled enabled
Activation JSS activation signal JSS activation signal Auxiliary F-N-R F-N-R enabling
signal enabling signal signal or JSS
enabling signal
JSS safety Implement locking Implement locking

conditions switch disenabled; switch disenabled;
to be Armrest on Armrest on
respected left-hand side left-hand side
lowered; lowered;
Vehicle stationary; Vehicle stationary;
Main F-N-R gear Main F-N-R gear
lever = neutral; lever = neutral;
JSS pilot pressure JSS pilot pressure
less than 8 bar; less than 8 bar;
JSS Joystick = JSS Joystick =
neutral; neutral;
No error JSS No error JSS
system. system.
Resulting JSS On JSS On JSS Off JSS On

JSS
status
F-N-R JSS On JSS On Vehicle Vehicle stationary

conditions JSS F-N-R = JSS F-N-R = stationary; Main F-N-R gear
neutral. neutral. Main F-N-R gear lever = neutral;
lever = neutral; AUX F-N-R =
AUX F-N-R = neutral.
neutral.
Resulting JSS F-N-R JSS F-N-R AUX F-N-R JSS F-N-R

F-N-R Enabled Enabled Enabled Enabled
status Stays enabled. Stays enabled. within 8 seconds
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
conditions neutral. neutral. in neutral.
not
respected
Alternative JSS / AUX F-N-R JSS / AUX F-N-R JSS / AUX F-N-R
F-N-R disenabled. disenabled. disenabled.
status

5009-9
JSS Related Error Handling
All JSS related errors will be displayed only while the JSS activation switch is in ON position except for the red
error “Short to power on power supply” and the failure of the activation switch which will be always displayed when
present.
All JSS related errors will be reset by switching the JSS activation switch to the OFF position.
While ignition is ON and JSS is deactivated the software will check if the JSS Power Supply is off. Check JSS
Output Control is low/open if not a red error will be displayed “Short on JSS power supply JSS active”
Table of error codes

Location
Error
of Error Message
Item
Detection
1812y JSC Open Circuit, Short to Battery or Short to Ground at JSS armrest switch.
1816y JSC Open Circuit / JSS activation switch mechanical defect.
1820y JSC Check JSS Relay, JSS Valve, JSS Joystick power supply connections.
Short to ground on JSS Relay 85/AIC1.21 or short to Power on Relay 86/87a. Or
1821r JSC
Activation Switch failure.
JSS RELAY, GROUND CONNECT., BAD ELEC. CONNCT. Permanent ground at JSS
1823y JSC
Relay (87) open circuit or short to power.
1824y JSC Short to battery at activation button. Aactivation switch failure.
1829y JSC Joystiok Steering is not calibrated.
1830y JSC Open circuit between activation switch Pin 3 and C5.E Pin 1.
1831y JSC JSC CONTROLLER, WRONG OPERATION. JSC controller internal fault.
JSC CONTROLLER, JSC SIGNAL IN, OUT OF LIMITS. Input signal from JSS joystick
1832y JSC to JSC controller out of limits. (Joystick Neutral: USignal>40%UBat + <60%Ubat;
Joystick Actuated: USignal>20%UBat + <80%UBat)
Output signal from JSC controller to valve out of limits. Check connector of JSS valve
1833y JSC
and JSC controller.
JSS CONTROLLER, JSC OUTPUT, SC to BAT Power is applied to one of the JSC
1834y JSC controller outputs. Check electrical connection for short to power. Or JSC internal Relay
is defect.
1835y AIC JSS-valve/Pin4 JSC/Pin5 short to power, short to ground or open circuit.
JSS CONTROLLER, BOARD TEMPERATURE, OUT OF LIMITS Temperature on the
1836y JSC JSC board is <-40°C or >+85°C; Check ambient temperature or short circuit at JSC
power outputs.
JSS CONTROLLER, SWITCHED POWER, OUT OF LIMITS Switched power supply at
1837y JSC
JSC Pin3 is out of limit; Check elect connection for electrical transients, burst or drifts.
1838y JSC Neutral Sw out of range.
1841y JSC JSS valve internal error, spool position not accurate or signal voltage out of range.
1842y JSC JSS valve Pin2 (alarm signal) open circuit.
Pilot pressure switch open when JSS is deactivated. High pilot pressure on JSS valve
1843y JSC even when JSS is not active. Pilot Dump valve stuck close or short to power on valve
power supply. Or open circuit on JSS pilot pressure switch lines or JSC/Pin8.
1844y JSC Pilot pressure switch short to ground.
Pilot pressure switch stays closed (Input JSC8 =1) allthough JSS is activated. With low
pilot pressure on JSS valve no steering with JSS possible. Error is displayed when JSS
1845y JSC active and Pilot pressure stays low. Pilot Dump valve stuck open or open circuit or short
to ground on JSS valve power supply (Valve Connector Pin4). Or short to power on JSS
pilot pressure switch lines or input JSC/Pin8.

5009-10
Location
Error
of Error Message
Item
Detection
Standard steering orbitro tank pressure transducer switch short to power or short to
1846y JSC
ground.
JSC Model type not available, no model type information available in JSC, probably
1847y JSC
missing information from AIC.
JSS joystick Pins2, 4 or 6 short to ground, short to battery or open circuit. Or JSS
1850y JSC
joystick internal failure.
1852y JSC JSS joystick Pins5 open circuit. Or JSS joystick internal failure.
1860y JSC CAN timeout of C5.E detected by JSC.
1861y JSC CAN timeout of AIC detected by JSC Controller.
Internal malfunction transmission controller. TCU message JSS F-N-R dissabled or
1863y AIC
JSS F-N-R not activated.
9128y AIC CAN timed out during operation
9134y AIC CAN timed out during operation C5.E detected by AIC
9135y AIC CAN timed out during operation JSC detected by AIC

5009-11
WORKING PRINCIPLE If, when using the JSS, a manoeuvre is made with
the steering wheel, the pressure switch LS (11),
The main components of the JOYSTICK STEERING located on the LS line of the power steering valve (4)
SYSTEM are: receives enough pressure to switch over and
- hydraulic valves therefore to turn off the JSS.
● proportional steering valve PVG32 (1) for IT IS IMPORTANT to remember that, for reasons of
activating the steering cylinders with an safety, the joystick (10) must be turned off for driving
incorporated pilot solenoid valve (2); on roads.
● valve PVFC (3) that controls the LS signals Use of the joystick can be disenabled at any time by
from the proportional valve PVG32 (1) and from the operator with the steering wheel, which has
the power steering valve (4) and transmits priority over the joystick.
them to the pump (5) to allow correct operation; In addition, it is absolutely prohibited to use the JSS
- two-way PVRES control joystick that sends the during the operations of loading and unloading the
signal to the pilot solenoid valve (2) located inside machine on and off a truck for transport.
the proportional valve PVG32 (1); For signalling any JSS malfunctioning, there are
- modulation controller (7) of the electric signal some warning lights on the control panel
between the joystick (10) and proportional valve accompanied by audible warnings of two different
(1); lengths depending on the trouble that has occurred.
- F-N-R switch (12) on the armrest on the left-hand
side;
- Kick-Down button (13) on the left-hand armrest;
- F-N-R switch (14) on console on right-hand side;
- Kick-Down button (15) on implement control
Joystick on right-hand side.
The JSS is controlled by a switch (8) located on the
control panel, which, via software loaded on a
component (9) installed inside the armrest, checks
that there are all the necessary safety conditions for
correct operation of the system.
These conditions must be:
a. left armrest completely lowered;
b. gear lever in neutral;
c. implement locking switch disenabled;
d. pilot pressure sensor closed;
e. JSS switch (8) in neutral;
f. machine stationary.
If not even one of these conditions occurs, the
software will not allow activation of the system. Only
after the software receives all the information and
confirms that the general situation is correct will it
allow operation of the joystick that, via an electric
signal, activates the pilot solenoid valve (2) located
inside the proportional valve PVG32 (1).
The actuator inside the electric module (6) of the
proportional valve of the steering gear (1) sets the
directional shuttle in operation that allows the oil to
flow to the line of the steering cylinder. Through the
pilot pressure switch of the valve PVG32 (1), the
software verifies that the oil pressure is correct for
the operation of the joystick (10).

5009-12
212 bar
3
212 bar
1
212 bar
2
W230R057
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
Illustration of the valve PVFC
5009-13
LX
TO
T2
PP
B
A
P
M
T LS
T
TO
PP
LX
T2
B
P
A
LS
W190-4R092
Connections
ports A and B. to the steering cylinder on the stem port PP. pilot pressure switch 8 bar
side and bottom side 350 bar, port T. outlet 25/40 bar
100 l/min port T2. not used
LS port. to port 3 of the valve PVFC port TO, LX. not used
port P. to the steering priority valve 350 bar,
150-230 l/min
Illustration of the valve PVG32
5009-14
2
6
9
11
4
3
8
10
1
5
W190-4R099
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. Valve PVSI
Exploded view of the valve PVG32

5009-15
10 10
20 20
5.7 Nm 1.7 Nm 1.7 Nm 5.7 Nm
Signal
SW1
SW2
Vbat
+/-
+/-
2 1
PVE
E
- +
W190-4R093
Illustration of the Joystick Steering PVRES

5009-16
ELECTRICAL SYSTEM FOR JOYSTICK STEERING SYSTEM
Removal STEP 2
STEP 1 1
Park loader on level ground and lower bucket to
ground. Put transmission in NEUTRAL, apply parking
brake, and shut down engine. Put the master 8
disconnect switch in the OFF position.
3
Remove all dirt and grease from the steering system 2
valves and adjacent area.
5
IMPORTANT: MARK and LABEL all the various parts
(electric connections, hydraulic connections, etc..) so
as to facilitate all the various operations of
INSTALLATION.
4
6
W270R050
Disconnect the chassis frame cable (1) from the

valve PVG32 (2), the connection (3) from the pilot
pressure switch at 8 bar, the four-way "DEUTSCH"
connection (4) of the electric actuator of the
proportional valve, the two-way "DEUTSCH"
connection (5) of the solenoid valve.
From the valve PVFC (6) disconnect the connection
(7) from the 60 bar pressure switch and release the
connection by removing the strap (8).

5009-17
STEP 3 STEP 4
11 2
9
10
1
W190-4R072
Release the chassis frame cable (1) from the stud

pin (9) positioned on the rear chassis frame (10) of
the machine by removing the nut (11). W190-4R073
From the right-hand side of the machine, under the

cab, open the door to access the fuse and relay
compartment and disconnect the ten-position
"PACKARD" interface connector of the chassis frame
cable (1) with the connector of the cab/joystick cable
(2). Remove the chassis frame cable (1).

5009-18
STEP 5 STEP 6
3 1
3
2
2 W190-4R075
Disconnect the twelve-position "DEUTSCH" interface

connector (1) of the cab/joystick cable (2) with the
W190-4R074
armrest cable (3) and the six-position connector (4).
Disconnect the cab/joystick cable (2) from the cab
wiring (3) by disconnecting the twelve-position
"DEUTSCH" connector (4).

5009-19
STEP 7 STEP 8
5
2
7
10
8 9
5
12
11
W190-4R076
W190-4R077
Disconnect the cab/joystick cable (2) from the Remove the steering control device (5) from the
steering control device (5) by detaching the supporting plate (9) by removing the nut (10, qty. 3),
sixteen-position connector (6), the six-position and the screw (11) complete with washer (12).
"DEUTSCH" connector (7) of the transmission switch
and the cab cable connector (8).
STEP 9
6 2
3
4
W190-4R078
Staccare il cavo cabina/joystick (1) dai punti di

fissaggio situati sul pannello fusibili e relè (2)
mediante la rimozione dei due connettori a cinque
posizioni (3), svitando i dadi (4, q.tà totale 2), le
rondelle (5) e le viti (6).
Remove the cab / joystick cable (1).
5009-20
STEP 10 ELECTRICAL COMPONENTS OF THE
JOYSTICK STEERING SYSTEM
7 1. Plate
2. Steering control device
3. Cab/joystick cable
4. Chassis frame cable
5. Washer
6. Screw
7. Nut
8. Joystick Steering System switch
9. Nylon strap
8 7
10. Screw
11. Washer
12. Nut
13. 10A fuse in position ECA-F2
14. Cab
15. Stud pin on rear chassis frame
8 16. Cable terminal with eyelet
17. Metal cable clamp
18. Armrest cable
19. Control joystick
20. CAN module
1
21. Relay
22. Diode
W190-4R079
23. Pressure switch 8 bar
Disconnect the two 24-volt relays (7) and the four 24. Pressure switch 60 bar
diodes (8) from the respective connectors of the cab / 25. Steering valve PVFC
joystick cable (1). 26. Steering valve PVG32
27. Armrest position switch
28. F-N-R switch
STEP 11
29. Kick-Down switch
30. Solenoid Valve
W190-4R080
To remove the armrest cable (9), refer to the chapter

titled "JOYSTICK STEERING ARMREST."

5009-21
8
14
C 20
12 11 10 19
27
28
15 29
E
E
C 16
13
1 18
21 A
2 9
22
23 17
3 26
7 6 5
30 A
4
24
25
721E-4R001
ELECTRICAL COMPONENTS OF THE JOYSTICK STEERING SYSTEM

5009-22
20
21
27
19
22 22
29
8
22 22
28
21
26
13
24
25
16
23
2
W190-4R097
WIRING DIAGRAM OF THE JOYSTICK STEERING SYSTEM

5009-23
Installation STEP 13
STEP 12
1 1
8
3
2 11
5
9
10
W190-4R088
Fasten the chassis frame cable (1) to the stud pin (9)
positioned on the rear chassis frame (10) of the
4 machine by installing the nut (11).
6
STEP 14
7
W270R050
Connect the chassis frame cable (1) to the valve

PVG32 (2), the connection (3) of the pilot pressure
switch at 8 bar, the four-way “DEUTSCH” connection
(4) of the electric actuator of the proportional valve,
the two-way “DEUTSCH” connection (5) of the
solenoid valve.
Connect the connection (7) of the 60 bar pressure
switch to the valve PVFC (6) and secure the 12
connection by inserting the strap (8) on one of the
14
two fixing screws of the valve.
13
16
15
W190-4R083
On the right-hand side of the machine, under the

cab, open the door providing access to the fuse and
relay compartment and fit the steering control device
(12) on the supporting plate (13) by installing the nut
(14, qty. 3), and the screw (15) complete with washer
(16).

5009-24
STEP 15 STEP 17
2
12 9
8 10
3
2 11
1 W190-4R085
Fasten the cab/joystick cable (1) via the connectors

W190-4R100
(8) to the fixing points on the fuse and relay panel (9)
Connect the two 24-volt relays (2) and the four by installing the nuts (10, qty. 2), washers (11) and
diodes (3) to the respective connectors of the cab / screws (12).
joystick cable (1).
STEP 16 STEP 18
4
1
5 14
6
13
1
7
W190-4R086
Connect the cab/joystick cable (1) to the cab cable

(13) via the twelve-position “DEUTSCH” connector
(14).
W190-4R084
Connect the cab/joystick cable (1) to the steering

control device (4) via the sixteen-position connector
(5). Connect the six-position “DEUTSCH” connector
(6) of the transmission button and the cab cable
connector (7).
5009-25
STEP 19 STEP 21
3 4
1
2
W190-4R073 W190-4R087
Connect the ten-position “PACKARD” interface Connect the twelve-position “DEUTSCH” interface
connector of the chassis frame cable (1) with the connector (4) of the cab/joystick cable (2) with the
connector of the cab/joystick cable (2). armrest cable (3) and the six-position connector (5).
STEP 20
W190-4R082
To install the armrest cable (3), refer to the chapter

titled “JOYSTICK STEERING ARMREST.”

5009-26
STEERING VALVES PVG32 AND PVFC
Removal STEP 3
STEP 1
Remove all dirt and grease from the steering valves
and adjacent area.
5
STEP 2
6
2
1
3 W270R053
Disconnect the connection hose (5) from the valve

PVFC (2), with the auxiliary steering valve and the
hose (6) coming from the steering priority valve.
W270R052 Plug the hoses in order to avoid oil spillage and the
Detach the rigid steering pipe LS (3) from the valve fittings to prevent debris getting inside.
PVG32 (1) and from the valve PVFC (2).
Disconnect hose (4) from the accumulator hydraulic. STEP 4
W270R054
Disconnect the suction hose (7) of the auxiliary

steering valve from the valve PVG32.

5009-27
STEP 5 STEP 7
W270R057
Disconnect the stem side steering cylinder line

W270R055 supply hose (3).
Disconnect the hose to return manifold (1).
STEP 8
STEP 6
5 4
2
7
6
W270R056
Disconnect the bottom side steering cylinder line

supply hose (2).
W270R058
Remove the steering valve PVG32 (4) from the

support (5) by taking out the fixing screws (6, qty. 4)
complete with washers (7).

5009-28
STEP 9 STEP 12
1 11
11
6
3 4
2 5 11
W270R059
Remove the support (1) from the rear chassis frame W270R062
by removing the nuts (2, qty. 4) complete with Unscrew the couplings (11) for connection to the
washers (3) that lock the screws (4) and spacers (5). hydraulic pipes from the steering valve PVFC (6).
STEP 10 STEP 13
1
1
6
2
W270R060
W190-4R014
Remove the support (1) with valve PVFC (6). Remove the 15 bar pilot pressure switch (1) complete
with seal (2) from the steering valve PVG32.
STEP 11
STEP 14
1
8 6 9
7
3
10
W270R061
Remove the steering valve PVFC (6) from the W190-4R015

support (1) by removing the nuts (7, qty. 2) and the Remove the reduction unit (3).
washers (8) that secure the screws (9) complete with
washers (10).

5009-29
STEP 15 STEP 17
1
W190-4R016 W270R063
Unscrew the coupling (1) from the “LS” port of the Unscrew the coupling (3) from the port “P”.
steering valve PVG32.
STEP 18
STEP 16
W190-4R017
Remove the two couplings (2) from the ports “A” and
“B” supplying the steering cylinder line. W270R064
Remove the coupling (4) from the port “T”.

5009-30
LEGEND OF JSS HYDRAULIC COMPONENTS WITH AUXILIARY STEERING SYSTEM
1. Bracket valve steering 61. Hydraulic tank
2. Spacer 62. Auxiliary steering valve
3. Bracket accumulator 63. Return manifold
4. Proportional valve PVG32 64. Reliefe valve steering
5. Valve PVFC
6. Clamp
7. Hydraulic accumulator
9. Connector
10. Connector
11. Elbow
12. Elbow
13. Tee with orifice
14. Elbow
15. Hose accumulator to PVFC valve
16. Connector
17. Tube steering LS
18. Connector
19. Hose PVFC valve to Auxiliary steering valve
20. Clamp
23. Hose auxiliary valve to Joystick Steering valve
PVG32
25. Hose Joystick to priority valve
26. Hose to return manifold
27. Connector
28. Pressure trasmitter
29. Connector
31. Elbow
32. Connector
33. Hose orbitrol to reliefe valve
34. Hose reliefe valve to tank
35. Reduction
36. Switch pilot pressure
37. Washer
38. Bolt
39. Nut
40. Washer
41. Nut
42. Tube Joystick Steering left
43. Tube Joystick Steering right
44. Washer
45. Bolt
46. Elbow
47. Washer
48. Nut
49. Plate
50. Bolt
51. Washer
52. O-ring
53. Elbow
54. Block tube mounting
55. Connector
56. Connector
57. Seal
58. Priority valve
59. Chassis rear
60. Standard orbitrol
5009-31
57 35
53 36
42
D
33 10
M 46
19
43 2
M F 59
46
B 20 9 4 41 40
C 55 10 B
B 26 1
4 23
K
58
E 12
19
C 25
A E
J 44 12
H F 45
L
C 11
25 38 16
34 60 15
37
H 5
L 39 37 17
32
J
A
33 13
G
D
W270R065
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERING SYSTEM- Table 1
5009-32
E F
64 G
59 28
53 43
47
41 27
3
7 48
6 31
58
44
45
17
14
L 63
K 52
25
26
61
M
62
18
56 49 50
29 H
34
23 19 54
J 41 51
W270R066
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITH AUXILIARY STEERING SYSTEM - Table 2
5009-33
NOTES

5009-34
LEGEND OF JSS HYDRAULIC COMPONENTS WITHOUT AUXILIARY STEERING SYSTEM
1. Bracket valve steering 60. Standard orbitrol
2. Spacer 61. Hydraulic tank
3. Bracket accumulator 63. Return manifold
4. Proportional valve PVG32 64. Reliefe valve steering
5. Valve PVFC
6. Clamp
7. Hydraulic accumulator
8. Elbow
9. Connector
10. Connector
11. Elbow
12. Elbow
13. Tee with orifice
14. Elbow
15. Hose accumulator to PVFC valve
16. Connector
17. Tube steering LS
18. Connector
19. Hose PVFC valve to standard orbitrol
20. Clamp
23. Hose priority valve to Joystick Steering valve
PVG32
25. Hose Joystick steering valve PVFC to priority valve
26. Hose to return manifold
27. Connector
28. Pressure trasmitter
29. Connector
31. Elbow
32. Connector
33. Hose orbitrol to reliefe valve
34. Hose reliefe valve to tank
35. Reduction
36. Switch pilot pressure
37. Washer
38. Bolt
39. Nut
40. Washer
41. Nut
42. Tube Joystick Steering left
43. Tube Joystick Steering right
44. Washer
45. Bolt
46. Elbow
47. Washer
48. Nut
49. Plate
50. Bolt
51. Washer
52. O-ring
53. Elbow
54. Block tube mounting
55. Connector
56. Connector
57. Seal
58. Priority valve
59. Chassis rear
5009-35
57 35
33
53 36
42
10
M D 46
19 43
M 2
F
59 4
46
B 10
9 41
C 55 40
26 B
1
G B
23
K 58
12
19
20 25
C
A E
H 12
J 44
45
L
F
11
C 25 16
38
39
34 37 15
H 5
17
L 37
J 60
13 A
G 32
33 19 D
W270R067
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITHOUT AUXILIARY STEERING SYSTEM- Table 1
5009-36
E F
64 G
59 28
53 43
47
41 27
3
7 48
58
6 31
44
45 17
14
K L 63
25
52
26
61
58
M
49 50
29 H
34
54
23
41 51
W270R068
HYDRAULIC COMPONENTS OF THE JOYSTICK STEERING SYSTEM WITHOUT AUXILIARY STEERING SYSTEM - Table 2
5009-37
Before refitting the steering valves, clean all the
disassembled parts thoroughly using a specific wash
solvent and dry them using a jet of air.
Carry out the procedure for installation following the
phases described here:
1. Check each part to verify that they there are no
dents, scoring or other defects. 2
2. Replace all damaged or deformed parts with new
ones.
STEP 19
W270R070
Fit the coupling (2) for connection with the suction

hose of the steering priority valve on the port “P”.
Tighten the coupling to a torque of 170 Nm.
STEP 21
1
3
W270R069
Fit the coupling (1) for connection with the hydraulic

outlet hose on the port “T” of the steering valve
PVG32. Tighten the couplings to a torque of 310 Nm. W190-4R022
Fit the two couplings (3) for connection with the

steering cylinder line supply hoses on the ports “A”
and “B”. Tighten the couplings to a torque of 100 Nm.

5009-38
STEP 22 STEP 25
8 6
7
1
W190-4R023
Fit the coupling (1) on the port “LS”. Tighten the W270R071
coupling to a torque of 45 Nm. Fit the coupling (6) on the port “1” of the steering
valve PVFC (5), the “T” coupling (7) on the port “2”
STEP 23 and the coupling (8) on the port “3”. Tighten all the
couplings to a torque of 45 Nm.
W190-4R024
Fit the reduction unit (2) of the pilot pressure switch

on the port “Pp”. Tighten the reduction unit to a
torque of 45 Nm.
STEP 24
4 2
W190-4R025
Install the pilot pressure switch (3) complete with seal

(4) on the reduction unit (2).

5009-39
STEP 26 STEP 28
1
1
6 2 3
5
10 7
9 8
4
W270R072 W270R074
Fit the steering valve PVFC (2) on the support (1) by Install the screws (7, qty. 3) and the washers (8) for
inserting the screws (3, qty. 2) complete with assembling the support (1) complete with valve
washers (4), the nuts (5) and washers (6). PVFC and lock them with the nuts (9) and the
washers (10). Tighten the nuts to a torque of
STEP 27 110 Nm.
STEP 29
1
1 11
2
13
W270R073
Position the support (1) with valve PVFC (2) on the

LH side wall of the rear chassis frame of the
machine.
12
W270R075
Fit the steering valve PVG32 (11) on the support (1)

using the screws (12, qty. 4) and washers (13).
Tighten the screws to a torque of 30 Nm.

5009-40
STEP 30 STEP 32
W270R076
Connect the stem side steering cylinder line supply

hose (1) on the coupling fitted on the valve PVG32. W270R077
Tighten the pipe to a torque of 60 Nm. Connect and tighten the hose to return manifold (3)
to a torque of 125 Nm.
STEP 31
STEP 33
W270R078
Connect the suction hose (4) of the auxiliary steering

W270R056
valve. Tighten the pipe to a torque of 60 Nm.
Connect the bottom side steering cylinder line supply
hose (2). Tighten to a torque of 60 Nm.

5009-41
STEP 34 STEP 35
2
1
4
6
3
1
W270R080
Connect the rigid pipe of the device “LS” (5) on the

valve PVG32 (4) and on the valve PVFC (1). Tighten
W270R079
the pipe to a torque of 14 Nm.
Connect the connection hose (2) on the valve PVFC Connect and tighten the hose (6) from the
(1), with the auxiliary steering valve and the hose (3) accumulator hydraulic.
coming from the steering priority valve. Tighten the
pipes to a torque of 14 Nm.

5009-42
JOYSTICK STEERING SYSTEM ARMREST
REMOVAL STEP 3
STEP 1
3
1 6
4
W190-4R037
Remove the locking screws (6, qty. 4) of the cover of

W190-4R036 the armrest (3) from the support (4). Remove the
Unscrew and remove the knob (1) and the washer cover (3).
(2) for longitudinal armrest adjustment.
STEP 4
STEP 2
8
4 7
9
5
W190-4R101
W190-4R035
Remove the cover (3) complete with support (4) from Disconnect the two-position “DEUTSCH” connector
the armrest adjustment device (5). (7) of the “Kick-Down” button (8) with the armrest
cable connector (9).

5009-43
STEP 5 STEP 7
3
8 7 12
1
9 10
W190-4R102 11
From the inside and bottom of the armrest cover (1)
unscrew the threaded washer (2) and extract the W190-4R038
“Kick-Down” button (3) complete with cable and Remove the nuts (8, qty. 2), washers (9), screws (10)
connector from the top of the armrest cover. and washers (11) from the valve PVRES (7) of the
Joystick. Disconnect the six-position connector (12)
STEP 6 from the valve (7).
W190-4R103
Disconnect the ten-position connector (4) of the

“F-N-R” switch (5) with the armrest cable (6).
Remove the switch (5) from the armrest cover (1).

5009-44
STEP 8 STEP 11
1
7
W230R049
Disconnect the ten-position connector (2) from the

CAN module (1).
8
STEP 9 6
W230R052
1 Unscrew and remove the knob (5) for height

adjustment of the armrest and spacer (6). Raise and
extract the armrest device (7) from the support fixed
to the seat (8).
3
W230R050
Detach the CAN module (1) from the support (3).
STEP 10
W230R051
Disconnect the three-position “DEUTSCH” connector

(4) from the armrest positioning switch. Remove the
armrest cable.

5009-45
STEP 12 STEP 13
1 10 8
7 11
3 5
4 4
2 6
W190-4R043
With the armrest lowered remove the armrest height /

angle adjustment device (2) from the support
assembly (1) by removing the nut (3) and the
washers (4), screws (5) and nylon bushings (6, 9
qty. 2).
2
W190-4R104
Remove the locking bracket (7) of the pin (8) from the
armrest height/angle adjustment device (2) by
unscrewing the nuts (9, qty. 2), removing the screws
(10) and the washers (11).
Remove the pin (8) from inside the seat of the
bracket (7).

5009-46
STEP 14 STEP 16
2
13 12
3 10 11
1 W190-4R046
Remove the support for fastening the safety belt by

removing the nut (10) complete with washer (11), the
screw (12) and washer (13).
4
STEP 17
7
5 6
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
14
removing the screws (5, qty. 4) complete with
washers. Remove the armrest position switch (6)
from the inside of the support (1) by removing the
W190-4R047
screws (7, qty. 2) and the washers.
Remove the four fixing screws (14, qty. 4) complete
STEP 15 with washers from the seat cushion.
8 9
W190-4R045
Disconnect the wiring harness from the operator’s

seat (if equipped with air seat option). Remove the
screws (8, qty. 4) and washers (9) from the base of
the seat.
Remove the seat inside the cab by using a hoist
provided with straps. Pay particular attention when
carrying out this operation so as not to cause any
damage to the inside or outside of the machine.

5009-47
STEP 18 STEP 20
1
1
3
2
W190-4R048 W190-4R050
Pressing down on the seat cushion support plate (1), Unhook the metal rod (4) from the locking support (3)
slightly tilt the aluminium tongue (2) to allow release and remove the seat cushion support plate (1).
of the support (1) and allow raising/rotating the front.
In this phase, take great care since the aluminium STEP 21
tongue (2) has greatly reduced thickness and so
therefore avoid breaking it.
3
STEP 19
7
6
W190-4R051
Turn the knob of the locking support (3) clockwise

and move the plate (5) forward in such a way as to
1 allow the sliding blocks (6, qty. 4) to slide inside the
W190-4R049 guides and get positioned in their respective seats
Raise, slowly rotating, the seat cushion support plate (7).
(1). Remove the plate (5).

5009-48
STEP 22 STEP 23
2 3
4 5 8
W190-4R052
Remove the plate (1) of the seat by removing the

retaining bolts (2, qty. 4) and washers (3). To perform W190-4R053
this operation it is necessary to slide the plate (1) Remove the armrest support plate (8).
forwards to have access to the two front nuts (4)
complete with washers (5) positioned inside the INSTALLATION
guides (6, qty. 2) underlying the plate (1) of the seat.
Repeat the disassembly operation of the two rear
screws (7) making the plate (1) slide back.
STEP 24
8
W190-4R054
Position the armrest support plate (8) on the seat

runners (6).

5009-49
STEP 25 STEP 27
10
9
2
1
W190-4R055 W190-4R057
Position the previously removed seat plate (1) on the Install the seat plate (9).
seat support plate (2). Turn the locking support (10) clockwise and at the
same time push the plate (9) toward the rear of the
STEP 26 seat to allow locking it.
STEP 28
8 13
11
9
3 4
12
W190-4R058
Insert the two lugs for positioning the seat cushion

support plate (11) inside the two special openings
shown in the figure on the seat plate (9) and hook the
metal rod (13) to the catch (12).
5 6 Slowly lower the seat cushion support plate (11).
W190-4R056
Push the seat plate (1) forwards. From the top, insert
the two front screws (3) complete with washers (4)
and lock them at the bottom, from the seat runners
(7), using the nuts (5) and the washers (6).
Tighten the nuts to a torque of 32 Nm.
Repeat the assembly operation of the two rear
screws (8) making the seat plate (1) slide back.

5009-50
STEP 29 STEP 31
6 5
1 7 8
W190-4R048 W190-4R060
Lock the seat cushion support plate (1) by restoring Fit the support for fastening to the safety belt by
the correct bend in the aluminium tongue (2). In this inserting the screw (5) and the washer (6), the nut (7)
phase, take great care since the aluminium tongue and the washer (8). Tighten the nut to a torque of
(2) has greatly reduced thickness and so therefore between 47 and 68 Nm.
avoid breaking it so as not to jeopardize seat Carefully check that the seat belt mounting hardware
operation. is tight and the seat belt is not cut or frayed.
STEP 30 STEP 32
4
3
1
9 10
W190-4R059 W190-4R061
Install the seat cushion (3) on the support plate (1) Using a hoist equipped with lifting straps, sling the
and secure it with the screws (4, qty. 4) complete seat and position it inside the cab.
with washers. 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 screws (9) complete
with washers (10). Tighten the screws to a torque of
between 73 and 87 Nm.
Carefully check that the tightening torque of the
screws fastening the operator’s seat is as prescribed
and that the parts are not worn or damaged.

5009-51
STEP 33 STEP 34
5 11 8
9 12
4
6
13
3 10
7 2
W190-4R105
W190-4R062
Fit the armrest position switch (2) on the support (1) Insert the armrest locking pin (8) inside the seat of
using the screws (3, qty. 2) complete with washers. the bracket (9) and fit it all on the armrest
Insert the adjuster pin (4) inside the support (1) and height/angle adjustment device (10) using the screws
screw the knob (5) on it. Install the closing plate (6) (11, qty. 2), washers (12) and nuts (13).
on the support (1) and secure it with the screws (7, Tighten the nuts to a torque of 7 Nm.
qty. 4) complete with washers.
STEP 35
W190-4R106
Insert, rotate and secure the armrest locking pin (8)

as shown in the figure.

5009-52
STEP 36 STEP 38
1
11
6 4
5 5
2 3 W190-4R065
Install the armrest cable connecting it to the

W190-4R063
positioning switch via the three-position “DEUTSCH”
Fit the armrest height / angle adjustment device (2) connector (11).
on the support assembly (1) by inserting the nylon
bushings (3, qty. 2), screw (4) with the washers (5)
and nut (6).
STEP 37
8
10
W190-4R064
Insert the armrest device (7) inside the support (8)

fixed to the seat and screw on the knob (9) for
armrest height adjustment complete with spacer (10).

5009-53
STEP 39 STEP 41
9 4 5
2
W190-4R066 6
Install the CAN module (1) inside the special seat (2)
situated on the armrest device. 8
STEP 40 W230R054
Connect the “PHOENIX” connector (5) to the valve

PVRES (4) of the Joystick and fit the valve on the
1 support (6) by inserting the screws (7, qty. 2) with the
washers (8, qty. 4) and the nuts (9, qty. 2).
Pay attention to the correct positioning of the valve
(4) so that the letter “A” stamped on it is on the
left-hand side in relation to the direction of travel of
the machine.
3 STEP 42
W230R053
11
Connect the ten-position connector (3) to the CAN
module (1). 10
12
W230R055
Insert the “Kick-Down” button (11) on the armrest

cover (10) and lock it from the bottom with the
threaded washer (12).

5009-54
STEP 43 STEP 44
2 5
4
1
3 7
W190-4R108 W190-4R109
Connect the two-position “DEUTSCH” connector (1) Insert the “F-N-R” switch (5) in the related assembly
of the “Kick-Down” button (2) with the armrest cable seat of the armrest cover (4) and connect it to the
connector (3). ten-position connector (6) of the armrest cable (7).
STEP 45
9
8
W190-4R069
Put the armrest cover (4) on the support (8) and

secure it with the screws (9, qty. 4).

5009-55
STEP 46
2
4
W190-4R070
Position the cover (1) complete with support (2) on

the armrest adjustment device (3) and screw on the
knob (4) complete with washer (5).
STEP 47
Put the battery disconnecting switch in the ON
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.

5009-56
JSS HYDRAULIC PRESSURE ADJUSTMENTS

IMPORTANT: in making the following checks and 1. with the engine OFF and bucket on the ground,
pressure adjustments, the machine articulation must connect a quick coupling pressure gauge to the
be locked. Great attention must be paid to following pressure point G1 (1) of the priority valve (2,
all the procedures for making the machine safe, figure 1), to the LS pressure point (3) of the
particularly when operating on the articulation joint hydraulic pump 1 (5, figure 2) and to the LS
and near the arm of the loader. pressure point (4) of the hydraulic pump 2 (6,
figure 2);
A. Main hydraulic pressure setting of the 2. with the engine at idle speed, with all the controls
pump in neutral, JSS NOT active, the difference
This setting is given by the difference between the between the pressure P and LS must be equal to
pressure of the hydraulic pump and the LS signal, that specified 26±1 bar (377±14.5 psi);
which must be between 26±1 bar (377±14.5 psi): 3. with the engine at idle speed, with all the controls in
neutral, JSS ON and joystick in neutral, the
difference between the pressure P and LS must be
equal to that specified 26±1 bar (377±14.5 psi);
W270R081
Figure 1
1. Pressure point G1
2. Priority valve

5009-57
4. with the engine at idle speed, with all the controls 5. if the setting is not correct, verify that all the
in neutral, JSS ON and joystick NOT in neutral, hydraulic connections are exact, particularly the
the difference between the pressure P and LS connections on the hydraulic steering valve
must be equal to that specified 26 ±1 bar PVFC that manages the LS signals.
(377±14.5 psi);
3 4
W270R082
Figure 2
3. Pressure point LS hydraulic pump 1
4. Pressure point LS hydraulic pump 2
5. Hydraulic pump 1
6. Hydraulic pump 2
7. Pressure regulator hydraulic pump 1
8. Pressure regulator hydraulic pump 2

5009-58
B. Steering pressure limit setting 3. move the joystick completely to the right and at
the same tim e, with a chronometer, start
With the engine at high revs, the pressure of the port
measuring the time. Stop the chronometer when
G1 must be between 239 and 243 bar (3465-3525 psi):
the machine is completely steered on the
- make sure that the pressure value stated in right-hand side. Take the time to compare it with
paragraph A is as specified 26±1 bar (377±14.5 psi); the time specified in the table of speed levels.
- with the engine OFF and bucket on the ground, 4. move the joystick completely to the left and at the
connect a quick coupling pressure gauge on the same time, with a chronometer, start measuring
pressure point G1 of the front and bottom of the the time. Stop the ch ronometer when the
priority valve (figure 1); machine is completely steered on the left-hand
side. Take the time to compare it with the time
- with the articulation locked, engine at high revs
specified in the table of speed levels. If the value
and JSS ON begin steering with the joystick in
is not in the range shown in the table, follow the
both directions to its limit stop. Keep this condition
system calibration procedure;
and read the pressure value on the pressure
gauge, which must be equal to that specified 5. repeat what is specified in point 1, 2, 3 and 4
above 239 and 243 bar (3465-3525 psi); with the difference that the engine has to have
high revs;
- if the pressure gauge records a pressure above or
below the specified one, check that all the 6. if the adjustments are not exact, verify the
hydraulic connections have been made correctly. specifications given in paragraphs A and B.
C. Steering times
IMPORTANT: when carrying out the following
procedure check that the articulation of the machine
is NOT locked. Great attention must be paid to
following all the procedures for making the machine
safe, particularly when operating on the articulation
joint and near the arm of the loader.
The speed of steering is not constant but depends on
the speed reached by the vehicle. On reaching 20
km/h the steering sensitivity is reduced by 80%
compared to the normal speed of steering.
The JSS can be set on three different levels of
steering speed.
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 machine from all right to all left).
The purpose of this setting is to make steering the
machine equipped with the JSS similar to the
standard steering system:
1. with the engine at idle speed, with all the controls
in neutral and JSS ON, steer the machine
completely to the left;
2. set a speed level (e.g. 1, 2 or 3);

5009-59
STEERING CALIBRATION PROCEDURE

ATTENTION: The views in the following steps may STEP 4
be different than the machine.
STEP 1
Before running the machine calibration procedure,
the operator must carry out the following operations:
- Start the engine;
- Set the machine in a straight position;
- Activate the Joystick Steering System;
- Slightly lift the bucket off the ground;
- Release the parking brake.
STEP 2
W190-4R112
Press the confirm/send button (2) within two seconds

to confirm access to the calibration procedure. If you
do not press any buttons after two seconds the
1 screen will show "Calibration", "Timeout"
"Cancelled". In this case to be able to re-access the
calibration procedure repeat Step 2.
STEP 5
2
W230R605
At the same time press the Joystick Steering

activation switch (1) and the confirm/send button (2).
STEP 3
W190-4R113
If it is kept pressed longer than expected, the main

menu screen appears.
W190-4R111
Keep pressed until the screen shows "Calibration?".

5009-60
STEP 6 STEP 8
W190-4R114 W190-4R116
If you want to run calibration, press (within two After this operation the display will show a screen
seconds) the confirm/send button (2, see figure on with the wording "O. K." The display will
preceding page). automatically show the screen with the wording
The display will show a screen with the wording "Joyst Full Left" "Release when WL starts
"Steer Straight?" that asks the operator whether the moving", the operator must then repeat Step 7
machine is positioned straight. twice.
Press the confirm / send button (2, see figure on
preceding page) to confirm the operation. STEP 9
STEP 7
W190-4R117
Afterwards the display will automatically show the

W190-4R115 screen with the wording "Joyst Full Right" "Release
The display will show a screen with the wording when WL starts moving".
"Joyst Full Left" "Release when WL starts At this moment the operator must move the Joystick
moving". At this moment the operator must move lever c ompletely to the right. As soon as he
the Joystick lever completely to the left. As soon as perceives a small movement of the machine he must
he perceives a small movement of the machine he release the lever.
must release the lever.

5009-61
STEP 10
W190-4R116
After this operation the display will show a screen

with the wording "O. K.". The display will
automatically show the screen with the wording
"Joyst Full Right" "Release when WL starts
moving", the operator must then repeat Step 9
twice.
STEP 11
W190-4R118
The display will show a screen with the wording

"Calibration Successful" indicating the success of
the calibration procedure.

5009-62
NOTES

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

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

Via Plava, 80
6001
Section
6001
REMOVAL AND INSTALLATION OF POWER TRAIN

COMPONENTS

Via Plava, 80
6001-2
TABLE OF CONTENTS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Front Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Rear Axle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6001-3
TRANSMISSION
Removal
NOTE: The transmission must be removed with the
engine. Do the procedure for engine removal in Section
2000 but DO NOT disconnect the engine from the
transmission remove both from the machine as a single
unit.
1. Remove the filler cap for the hydraulic reservoir.
2. Drain the hydraulic reservoir.
3. Tag and disconnect all hydraulic hoses and
electrical connections from the hydraulic tank
and from the radiator fluid tank.
4. Fasten acceptable lifting equipment to the
hydraulic reservoir.
5. Remove the nuts, hardened washers, and bolts
that mount the hydraulic reservoir to the frame.
6. Carefully raise the reservoir and remove the
reservoir.
7. Remove the cap screws (1) from the center drive
shaft (2) at the transmission, refer to illustration
on page 4.
8. Remove the cap screws (3) from the rear drive
shaft (4) at the transmission.

6001-4
1
2
W270R580
1. CAP SCREW 3. CAP SCREW

2. CENTER DRIVE SHAFT 4. REAR DRIVE SHAFT
DRIVE SHAFTS

6001-5
9. Loosen the clamp and remove the sight gauge 15. Tag and disconnect the hose transmission to
upper hose (1), refer to illustration on page 6. thermal valve by pass (1) “INLET” port. Refer to
10. Loosen the clamp and remove the sight gauge
lower hose (2) from the fill tube (3). 16. Tag and disconnect the hose transmission to
thermal valve by pass (2) “TANK” port.
11. Remove the filler tube (3) from the transmission.
17. Tag and disconnect the parking brake hose (1),
12. Tag and remove the filters bypass hose (1), refer
refer to illustration on page 9.
to illustration on page 7.
18. Tag and disconnect the differential lock axle
13. Tag and remove the filters inlet hose (2).
pressure hose (2).
14. Tag and remove the filters return hose (3).

6001-6
2
4
W270R581
1. SIGHT GAUGE UPPER HOSE 3. FILLER TUBE

2. SIGHT GAUGE LOWER HOSE 4. SIGHT GAUGE BRACKET
TRANSMISSION LINES

6001-7
2
1
3 4
W270R582
1. FILTER BYPASS HOSE 3. FILTER RETURN HOSE

2. FILTER INLET HOSE 4. FILTERS
TRANSMISSION LINES

6001-8
W270R583
1. HOSE TRANSMISSION TO THERMAL VALVE 2. HOSE TRANSMISSION TO THERMAL VALVE

BYPASS “INLET” PORT BYPASS “TANK” PORT
TRANSMISSION LINES

6001-9
2
1
W270R584
1. PARKING BRAKE HOSE 2. DIFFERENTIAL LOCK AXLE PRESSURE HOSE
TRANSMISSION LINES

6001-10
19. Tag and disconnect hydraulic oil temperature 29. Tag and disconnect the turbine speed sensor
sender (1), refer to illustration on page 11 and (11).
12.
30. Tag and disconnect the engine speed sensor
20. Tag and disconnect the transmission filter (12).
clogged switch (2).
31. Tag and disconnect the PRB2 redundant brake
21. Tag and disconnect the hydraulic filter clogged switch (13).
switch (3).
32. Tag and disconnect the PRB1 redundant brake
22. Remove the harness retaining clamp (4). switch (14).
23. Tag and disconnect the transmission controller 33. Tag and disconnect the output speed sensor
(5). (15).
24. Tag and disconnect the torque converter output 34. Tag and disconnect the transmission to cab
sender (6). connector (16).
25. If equipped, tag and disconnect the secondary 35. Tag and disconnect the parking brake declutch
steering harness (7). pressure switch (17).
26. Tag and disconnect the transmission ground (8). 36. Tag and disconnect the differential lock solenoid
(18).
27. Remove the harness retaining clamp (9).
37. Move the wiring harness out and away from the
28. Tag and disconnect the intermediate speed
transmission.
sensor (10).

6001-11
8
14
17
2
13
A
A
12
18
11 10
W270R585
2. TRANSMISSION FILTER CLOGGED SWITCH 12. ENGINE SPEED SENSOR

4. CLAMP 13. PRB2 BRAKE SWITCH
7. SECONDARY STEERING (OPT) 14. PRB1 BRAKE SWITCH
8. TRANSMISSION GROUND 17. PARKING BRAKE DECLUTCH PRESSURE SWITCH
10. INTERMEDIATE SPEED SENSOR 18. DIFFERENTIAL LOCK SOLENOID
11. TURBINE SPEED SENSOR
TRANSMISSION WIRING HARNESS

6001-12
9 5
6
16
B
3 15
W270R586
1. HYDRAULIC OIL TEMPERATURE SENDER 9. CLAMP

3. HYDRAULIC FILTER CLOGGED SWITCH 15. OUTPUT SPEED SENSOR
5. TRANSMISSION CONTROLLER 16. TRANSMISSION TO CAB CONNECTOR
6. TORQUE CONVERTER OUTPUT SENDER

6001-13
38. Remove the self-locking nuts (4), hardened 42. Remove the engine and transmission from the
washers (5), bolts (2), and washers (3), refer to machine. Put the engine and transmission on an
illustration on page 14. acceptable support.
39. Loosen the nuts on the front ROPS cab or 43. Remove the starter from the engine.
canopy mounting bolts and remove the rear
44. Fasten acceptable lifting equipment to the
mounting bolts. Raise the rear of the ROPS cab
transmission.
or canopy approximately 152 MM. (6 inches).
45. Using the engine turning tool, turn the flywheel
40. Install a block on each side.
for access to the flex plate bolts (10).
41. Raise the engine and transmission, move the
46. Remove the twelve hardened washers (11) and
engine and transmission to the rear of the
bolts (10) from the flex plate.
machine. Do this as required until the
transmission is free of the ROPS cab or canopy. 47. Remove the cap screws (13) that hold the
transmission to the flywheel housing.
48. Remove the transmission.

6001-14
Transmission Mounting Bracket
13 12
11 10
2 9
8
7 5
4
W270R572
1. ISOLATOR 8. WASHER
2. BOLT 9. TRANSMISSION 4 SPEED
3. WASHER 10. BOLT - Torque 33 to 41 Nm (24 to 30 lbf-ft)
4. NUT - Torque 929 to 1044 Nm (685 to 770 lbf-ft) 11. WASHER
5. WASHER 12. BOLT - Torque 54 to 60 Nm (40 to 44 lbf-ft)
6. BRACKET 13. WASHER
7. BOLT - Torque 1125 to 1274 Nm (830 to 940 lbf-ft)

6001-15
Installation
NOTE: The transmission must be installed with the 9. Connect the differential lock solenoid (18).
engine. See Section 2000 for engine installation.
10. Connect the parking brake declutch pressure
1. Fasten acceptable lifting equipment to the switch (17).
transmission.
11. Connect the transmission to cab connector (16).
2. Install bracket (6), bolts (7) and washer (8),
12. Connect the output speed sensor (15).
torque bolts to 1125 to 1274 Nm (830 to 940
pound-feet), refer to illustration on page 14. 13. Connect the PRB1 redundant brake switch (14).
3. Replace the cap screws (13) that hold the 14. Connect the PRB2 redundant brake switch (13).
transmission to the flywheel housing. Tighten the
15. Connect the engine speed sensor (12).
cap screws to 54 to 60 Nm (40 to 44 pound-feet).
16. Connect the turbine speed sensor (11).
4. Turn the flywheel to access, install and tighten
the twelve bolts (10) and hardened washers (11) 17. Connect the intermediate speed sensor (10).
for the flex plate to 33 to 41 Nm (24 to 30
18. Install the harness retaining clamp (9).
pound-feet).
19. Connect the transmission ground (8).
5. Place the engine and transmission in the
machine. 20. If equipped, connect the secondary steering
harness (7).
6. Install the self-locking nuts (4), hardened
washers (5), isolators (1), washers (3), and bolts 21. Connect the torque converter output sender (6).
(2) that hold the transmission mounting brackets
22. Connect the transmission controller (5).
(6) to the machine. Tighten the self-locking bolts
to 929 to 1044 Nm (685 to 770 pound-feet). 23. Install the harness retaining clamp (4).
7. Lower the ROPS cab or canopy and tighten the 24. Connect the hydraulic filter clogged switch (3).
front mounting bolt nuts to 773 to 854 Nm (570 to
25. Connect the transmission filter clogged switch
630 pound-feet).
(2).
8. Place the wiring harness into position over the
26. Connect hydraulic oil temperature sender (1).
transmission, refer to illustration on page 11 and
12.

6001-16
8
14
17
2
13
A
A
12
18
11 10
W270R585
2. TRANSMISSION FILTER CLOGGED SWITCH 12. ENGINE SPEED SENSOR

4. CLAMP 13. PRB2 BRAKE SWITCH
7. SECONDARY STEERING (OPT) 14. PRB1 BRAKE SWITCH
8. TRANSMISSION GROUND 17. PARKING BRAKE DECLUTCH PRESSURE SWITCH
10. INTERMEDIATE SPEED SENSOR 18. DIFFERENTIAL LOCK SOLENOID
11. TURBINE SPEED SENSOR

6001-17
9 5
6
16
B
3 15
W270R586
1. HYDRAULIC OIL TEMPERATURE SENDER 9. CLAMP

3. HYDRAULIC FILTER CLOGGED SWITCH 15. OUTPUT SPEED SENSOR
5. TRANSMISSION CONTROLLER 16. TRANSMISSION TO CAB CONNECTOR
6. TORQUE CONVERTER OUTPUT SENDER

6001-18
27. Install the differential lock axle pressure hose (2), 32. Install the filters bypass hose (1), refer to
refer to illustration on page 22. illustration on page 20.
28. Install the parking brake hose (1). 33. Install the filters inlet hose (2).
29. Install the sight gauge upper hose (1) and tighten 34. Install the filters return hose (3).
th clamp., rfer to illustration on page 19.
35. Install the transmission to thermal valve bypass
30. Install the filler tube (3) on the transmission. hose (1) “INLET” port, refer to illustration on
page 21.
31. Install the sight gauge lower hose (2) to the fill
tube (3) and tighten the clamp. 36. Install the transmission to thermal valve bypass
(2) “TANK” port.

6001-19
2
4
W270R581
1. SIGHT GAUGE UPPER HOSE 3. FILLER TUBE

2. SIGHT GAUGE LOWER HOSE 4. SIGHT GAUGE BRACKET
TRANSMISSION LINES

6001-20
2
1
3 4
W270R582
1. FILTER BYPASS HOSE 3. FILTER RETURN HOSE

2. FILTER INLET HOSE 4. FILTERS
TRANSMISSION LINES

6001-21
W270R583
1. HOSE TRANSMISSION TO THERMAL VALVE 2. HOSE TRANSMISSION TO THERMAL VALVE

BYPASS “INLET” PORT BYPASS “TANK” PORT
TRANSMISSION LINES

6001-22
2
1
W270R584
1. PARKING BRAKE HOSE 2. DIFFERENTIAL LOCK AXLE PRESSURE HOSE
TRANSMISSION LINES

6001-23
37. Install the cap screws (1) to fasten the center 39. Replace the cap screws to the rear drive shaft (4)
drive shaft (2) to the transmission. Tighten the at the rear axle. Tighten the cap screws to 136 to
cap screws to 136 to 149 Nm (100 to 110 149 Nm (100 to 110 pound-feet).
pound-feet). refer to illustration on page 24.
40. Install the cap screws (3) to the rear drive shaft
38. Put the rear drive shaft (4) into position on the (4) to the transmission. Tighten the cap screws
machine. to 136 to 149 Nm (100 to 110 pound-feet).

6001-24
1
2
W270R580
1. CAP SCREW 3. CAP SCREW

2. CENTER DRIVE SHAFT 4. REAR DRIVE SHAFT
DRIVE SHAFTS

6001-25
41. Carefully place the reservoir into position onto 45. Replace the filler cap for the hydraulic reservoir.
the machine.
46. Fill the transmission with proper lubricant, refer
42. Install the nuts, hardened washers, and bolts that to section 1002.
mount the hydraulic reservoir to the frame,
47. Refer to section 2000 and complete the engine
tighten the bolts.
installation procedures.
43. Connect to the hydraulic tank and fluid reservoir
48. Start and run the machine until all systems are at
all the hydraulic hoses and electrical
operating temperature, check for leaks and
connections.
repair as needed.
44. Fill the hydraulic reservoir.

6001-26
FRONT AXLE
Removal STEP 4
STEP 1
W270R573
Remove eight bolts securing front drive shaft to front

W230R406
axle.
Park machine on level surface. Have assistant put
articulation lock in LOCKED position. STEP 5
IMPORTANT: If machine is equipped with quick-attached
components, disconnect them from machine prior to
2
proceeding.
3
2
STEP 2
W270R574
Remove clamp securing lubrication hose (1) to

machine and nut securing opposite end of hose.
Remove eight bolts (2) 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 (3) and bolts and
Raise bucket and have assistant install safety link. washers. Lower center bearing and front drive shaft
Lower loade r arm s slowly until sa fe ty link is from mounting plate and remove from machine.
supporting loader arms.
STEP 3
Stop engine. Actuate brake pedal several times to
discharge brake accumulators. Put key switch in ON
position and move loader control lever back and forth
at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.

6001-27
STEP 6 STEP 9
W270R575 BD01F297
Disconnect brake hose (1), differential lock axle Use an acceptable jack to hold front axle.
pressure hose (2) and accumulator brake damping
(3). Remove and discard O-ring face seal from elbow. STEP 10
STEP 7
BD01F295
Remove bolts and washers from front wheels.

BD01F298 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 BD01F296
under machine. Remove eight nuts bolts, and washers securing front
axle to machine.
STEP 8
Repeat Step 7 to raise other front axle tire from STEP 12
ground. Carefully lower front axle and remove from under
machine.

6001-28
Front Axle Mounting
W230R008
1. BOLT 4. NUT
2. WASHER 5. FRONT AXLE
3. WASHER

6001-29
STEP 13
Carefully move front axle under machine and raise
against mounting pads on machine.
STEP 14
BD01F295
16 1
8 9
20 17
12 5
BD01F296
4 13
Apply one drop of engine oil to threads prior to
assembly. Install eight washers, bolts, washers, and 22 21
nuts to secure front axle to machine. Tighten bolts to 14 3
a torque of 1520 to 1712 Nm (1121 to 1263 pound
feet). 6 11
18 19
10 7
2 23 15
W270R576
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.
STEP 16
BD01F297
Remove jack from front axle.

6001-30
STEP 17 STEP 20
2
3
2
BD01F298 W270R574
Position and support center bearing and front drive

shaft and install washers and four bolts and nuts (3).
Tighten bolts to a torque of 150 to 164 Nm (110 to
120 pound feet). Install eight bolts (2). Tighten bolts
to a torque of 136 to 149 Nm (100 to 110 pound feet).
Secure lubrication hose (1) to machine using clamp;
secure opposite end of hose using nut.
STEP 21
BD01D392
Using an acceptable hydraulic jack, raise axle and

remove jack stand from under machine.
STEP 18
Repeat Step 17 to remove other jack stand from
under machine.
STEP 19
W270R573
3 Secure drive shaft to front axle using eight bolts.

Tighten bolts to a torque of 136 to 149 Nm (100 to
110 pound feet).
2
STEP 22
If necessary, fill axle with gear lubricant specified in
Section 1002.
1 STEP 23
Refer to Section 7002 and bleed brakes.
W270R575
STEP 24
Install a new O-ring face seal and connect
Start engine and raise bucket. Have assistant
accumulator brake damping (3), brake hose (1) and
remove safety link. Lower bucket to ground and stop
differential lock axle pressure hose (2).
engine.
STEP 25

6001-31
REAR AXLE
Removal STEP 5
STEP 1
Park machine on a level surface; be sure to allow
adequate space at side of machine for removal of
rear axle. Stop engine. Actuate brake pedal several
times to discharge brake accumulators. Put key
switch in ON position and move loader control lever
back and forth at least 30 times to release any
pressure from hydraulic circuit.
STEP 2
W270R578
Disconnect brake hose. Remove and discard O-ring

face seal from elbow.
STEP 6
W230R406
Put articulation lock in LOCKED position.
STEP 3
Install wood blocks between rear axle and chassis to
prevent rear axle from pivoting. BD01F299
Using an acceptable hydraulic jack, raise one tire

STEP 4 from ground and install an acceptable jack stand
under machine. Repeat this step for other tire.
STEP 7
W270R577
Remove eight bolts. Use a pry bar to disconnect rear

drive shaft from rear axle.
BD01F302
Use an acceptable jack to hold rear axle, front and

rear of trunnion.

6001-32
STEP 8 STEP 18
Only W300C, refer to illustration on page 34, remove
the screw (13) and washer (14). Remove the bearing
trunnion (15) rear axle.
STEP 19
Remove the rear trunnion (3) from the rear axle (1).
NOTE: Replace the seals and bushings in the trunnions as
required.
BD01F295
Remove bolts and washers from rear wheels.

Remove both wheels from rear axle.
STEP 9
Remove the grease hoses (12) from the rear axle
trunnions (2 and 3), refer to illustration on page 33.
STEP 10
Remove the self-locking nuts (11) from the bolts (10).
STEP 11
Remove the rear axle (1) and trunnions (2 and 3)
from the machine. Place the rear axle (1) and
trunnions (2 and 3) onto blocks or suitable work
bench.
STEP 12
Remove the front trunnion (2) from the rear axle (1).
STEP 13
Remove the cap screws (8) and washers (9) from the
rear cover (7) on the rear trunnion (3).
STEP 14
Remove the rear cover (7) from the rear trunnion (3).
STEP 15
Remove the thrust washer (5).
STEP 16
Remove the cap screws (8) and washers (9) that
fasten the spacer (6) to the rear axle (1).
STEP 17
Remove the spacer (6) and thrust washer (5).

6001-33
Rear Axle Mounting W270C
8
9 5 8
12
9 10 1
6
5
7
9
10
9
9
11 4
3
12
9
4 11
2
4
W270R579
1. REAR AXLE 5. THRUST WASHER 9. WASHER

2. FRONT TRUNNION 6. TRUNNION SPACER 10. BOLT
3. REAR TRUNNION 7. COVER 11. SELF-LOCKING NUT
4. OIL SEAL 8. CAP SCREW 12. GREASE HOSES

6001-34
Rear Axle Mounting W300C
8
9
8
12 9
10
5 13
14 9 10
5
1
7
6
4
3 9
11
15 12
2
9
4
11
W300R002
1. REAR AXLE 6. TRUNNION SPACER 11. SELF-LOCKING NUT

2. FRONT TRUNNION 7. COVER 12. GREASE HOSES
3. REAR TRUNNION 8. CAP SCREW 13. SCREW
4. OIL SEAL 9. WASHER 14. WASHER
5. THRUST WASHER 10. BOLT 15. BEARING TRUNNION

6001-35
Installation
STEP 20
Put the rear axle (1) on blocks.
STEP 21
Install the rear trunnion (3) to the rear axle (1).
Ensure bushing is properly positioned.
STEP 22
Only W300C, refer to illustration on page 34, install
the bearing trunnion (15) rear axle, the washers (14)
and screws (13). Tighten the screws to a torque of
575 to 600 Nm (420 to 440 pound-feet).
STEP 23
Install a thrust washer (5) and the spacer (6). Use
eight cap screws (8) and hardened washers (9) to
fasten the spacer (6) to the rear axle (1).
STEP 24
Tighten the cap screws (8) to a torque of 285 to 320
Nm (210 to 235 pound-feet).
STEP 25
Install the other thrust washer (5). Fasten the rear
cover (7) to the rear trunnion (3) using six washers
(9) and cap screws (8).
STEP 26
Tighten the cap screws (8) to a torque of 105 to 115
Nm (75 to 85 pound-feet).
STEP 27
Install the front trunnion (2) to the rear axle (1).
Ensure trunnion is properly positioned, see
STEP 28
Using acceptable lifting equipment, slowly move the
rear axle (1) and trunnions (2 and 3) into position
under the rear chassis.
STEP 29
Install the bolts (10), hardened washers (9), and nuts
(11) to fasten the trunnions (2 and 3) to the rear
chassis.
STEP 30
Tighten the nuts (11) to a torque of 651 to 732 Nm

6001-36
STEP 31 STEP 33
BD01F295 W270R578
Install a new O-ring face seal. Connect brake hose.
STEP 34
16 1
8 9
20 17
12 5
4 13
22 21
14 3
6 11
18 19
10 7
2 23 15
W270R577
W270R576
Connect rear drive shaft to rear axle. Install eight
Install both wheels on front axle and secure. Tighten bolts. Tighten bolts to a torque of 136 to 149 Nm (100
bolts to a preliminary torque of 298 Nm (220 pound to 110 pound feet).
feet) in sequence indicated; then tighten to a torque
of 640 to 720 Nm (475 to 530 pound feet) in same STEP 35
sequence. If necessary, fill axle with gear lubricant specified in
Section 1002.
STEP 32
Remove hydraulic jack supporting rear axle and jack STEP 36
stands supporting loader. Refer to Section 7002 and bleed brakes.
STEP 37

6002
Section
6002
TRANSMISSION SPECIFICATIONS, PRESSURE

CHECKS, AND TROUBLESHOOTING

Via Plava, 80
6002-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Shift Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission ECM Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission Sensor Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Automatic Problem Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clutch Modulation Substitute Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Limp-Home Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission/Transmission ECM Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission Clutch Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PRESSURE TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
All or Most Pressures Low and/or Flow Test Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Some Pressures Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Not Enough Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Machine Stops or Hesitates While Shifting - Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CONVERTER OUT PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Test Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LUBRICATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FLOWMETER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Flowmeter Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONSUMPTION TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TRANSMISSION OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TRANSMISSION SHIFTER LOGIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES . . . . . . . . . . . . . . . . . . . . . . 18

6002-3
SPECIAL TOOLS
380001743 Transmission supplemental fitting kit. 380001740 Flowmeter kit
Includes: 380000509 special 90 degree adapter and
380001750 Flowmeter adapter
380001749 plug and cap set.
380001745 Flow test kit
380001739 Master pressure test kit
SPECIFICATIONS
Main pressure and clutch pressure ................................................................................16 to 18 bar (232 to 261 psi)
Converter in pressure .......................................................................................................8 to 10 bar (116 to 145 psi)
Pressure reduction for solenoids ........................................................................................7 to 9 bar (102 to 131 psi)
Converter out pressure.....................................................................................................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 L/min (21 U.S. gpm)
Transmission oil operating temperature .........................................................................80 to 120 °C (176 to 248 °F)
Clutch KV........................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch KR .......................................................................................................................16 to 18 bar (232 to 261 psi)
Clutch K1 ........................................................................................................................16 to 18 bar (232 to 261 psi)
Ratio W270C 1st 2nd 3rd 4th

Forward 3.731 2.207 1.421 0.625
Reverse 3.731 2.207 1.421 -
Ratio W300C 1st 2nd 3rd 4th

Forward 3.731 2.207 1.421 0.625
Reverse 3.731 2.207 0.970 -

6002-4
4
1
2
2
2 2
3
5
6
W270R592
1. TRANSPORATION EYE 5. OIL FILLER MOUNTING PROVISION
2. GEARBOX MOUNTING PADS 6. OIL DRAIN PLUG
3. COARSE FILTER 7. CONNECTION TO HEAT EXCHANGER
4. PLUG CONNECTION 8. OUTPUT FLANGE
COMPONENT LOCATIONS 4 SPEED FRONT VIEW

6002-5
12
1
2 9
11
3
5 10
8 4
8 13
W270R593
1. CONNECTION TO ENGINE 8. GEARBOX MOUNTING PADS
2. BREATHER 9. CONNECTION SYSTEM PRESSURE
3. PTO, COAXIAL, ENGINE DEPENDENT 10. INDUCTIVE SENSOR FOR INTERMEDIATE GEAR TRAIN SPEED
4. PARKING BRAKE (DISC BRAKE) 11. INDUCTIVE SENSOR FOR ENGINE SPEED
5. INDUCTIVE SENSOR FOR TURBINE SPEED 12. TRANSPORTATION EYE
6. ASSEMBLY APERTURE 13. OUTPUT FLANGE REAR SIDE
7. CONNECTION RETURN PIPE FROM
DIFFERENTIAL LOCK
COMPONENT LOCATIONS 4 SPEED SIDE VIEW

6002-6
11
1
1
9
8
10
5
4
W270R594
1. TRANSPORTATION EYE 7. INDUCTIVE SENSOR FOR ENGINE SPEED

2. HALL-SENSOR OUTPUT SPEED 8. CONNECTION TO FILTER
3. CONNECTION FROM HEAT EXCHANGER 9. CONNECTION FROM FILTER
4. OIL FILLER MOUNTING PROVISION 10. PRESSURE CONNECTION
5. TYPE PLATE 11. ELECTRICAL HYDRAULIC TRANSMISSION CONTROL
6. BREATHER
COMPONENT LOCATIONS 4 SPEED REAR VIEW

6002-7
3
9 11
12 7
8 10
2
5 13
6
W270R595
1. OIL FILLER PLUG 8. MEASURING POINT FOR PRESSURE OIL CLUTCH KR

2. CONNECTION FROM FILTER BYPASS 9. MEASURING POINT FOR PRESSURE OIL CLUTCH K1
3. BREATHER 10. MEASURING POINT FOR PRESSURE OIL CLUTCH K2
4. TRANSPORTATION EYE 11. MEASURING POINT FOR PRESSURE OIL CLUTCH K3
5. PLUG CONNECTION 12. MEASURING POINT FOR PRESSURE OIL CLUTCH K4
6. MEASURING POINT FOR PRESSURE BEFORE CONVERTER 13. MEASURING POINT FOR SYSTEM PRESSURE
7. MEASURING POINT FOR PRESSURE OIL CLUTCH KV
COMPONENT LOCATIONS 4 SPEED TOP VIEW

6002-8
TRANSMISSION OPERATION
General Transmission ECM Tasks

The transmission is equipped with a Transmission The Transmission ECM performs a variety of tasks in
ECM (Electronic Control Module). This module the overall system. The Transmission ECM:
controls modulation and shifting that were normally
A. Determines which clutches to engage in the
associated with hydraulically modulated
transmission.
transmissions, providing smoother shifts and
enhanced clutch life. B. Protects the engine and transmission turbine
from overspeed conditions during
The Transmission ECM relies on signals from
downloading.
several sensors that are incorporated into the design.
These sensors measure the speed of several C. Receives speed information from the engine
components, as well as other sensors that measure speed sensor, the turbine speed sensor, the
temperature. These solenoids and sensors are intermediate shaft speed sensor and the
further defined in the following paragraphs. transmission output shaft speed sensor.
These speed sensors are checked to
I n ad d i t i on , t h e t ra n s m i s s i o n i n c o rp o r a t es a
determine if normal sensor operation is
two-piece transmission case for ease of transmission
present. The data is also used to control
maintenance, helical cut gears that help reduce
modulation during shifting and to determine
noise, and all external hoses have been eliminated
the appropriate shift patterns.
(all oil passages are internal).
D. Detects system failures and determines the
Transmission ECM appropriate alternative actions.
Modulation and shifting are controlled by the E. Provides various diagnostic messages to the
Transmission Electronic Control Module Information Center.
(Transmission ECM). This module replaces the oil F. Provides other information to the information
and springs that are found in hydraulically modulated center, which in turn displays engine speed,
transmissions. wheel speed, gear shift selection, and actual
The Transmission ECM controls the clutch gear selection.
engagement, providing smoother shifts and G. Provides a method to calibrate the
enhanced clutch life, whether the transmission is set transmission clutch control.
to the automatic or manual shift mode.
H. Establishes clutch modulation pressure during
The Transmission ECM also informs the Information transmission shifts.
Center, by the use of diagnostic codes, of any
transmission error and the hours of operation that the
error occurred.
Electrical Shift Solenoids

Electrical Shift Solenoids control the modulation of
the clutches, eliminating the need for a modulation
valve, and providing a smooth shift while maintaining
constant control over clutch engagement as follows:
A. A temperature sensor relays the oil
temperature to the Transmission ECM.
B. The Transmission ECM times the rate the
solenoid energizes and de-energizes.
C. As the transmission changes gears, there is
reduced hesitation from one gear to the next.

6002-9
Transmission Sensor Data Clutch Modulation Substitute Mode

Collection In this mode, the transmission clutch modulation is
The Transmission ECM collects and uses time dependant rather than load dependant. The
information from four sensors to accurately shift the transmission will go into the Clutch Modulation
transmission and determine if any clutches are Substitute Mode if any of the four speed sensors fail.
slipping. These sensors are: If the output speed sensor is working and the
Engine (Speed) Sensor - monitors engine speed to transmission is in gear, the shift points in Automatic
determine the load on the engine for shift points and mode will be speed dependant but the modulation
sends the engine rpm to the Transmission ECM, will be a predetermined amount of time.
which sends the information to the tachometer in the If the output speed sensor is not working and the
Information Center. transmission is in gear, the shift points will be load
Turbine (Speed) Sensor - assists the engine speed d e p e n d a n t b u t t h e m o d u l a t i o n w i ll s t i l l b e a
sensor in determining the load going into the predetermined amount of time.
transmission and helps determine shift points. If the transmission is shifted from neutral into a
Intermediate (Shaft Speed) Sensor - determines direction in the Clutch Modulation Substitute Mode in
differential gear speed in the transmission to check automatic, the transmission will shift into 4th gear
for clutch slippage. and shift down until it gets the correct output speed
from the turbine.
Output (Speed) Sensor - monitors transmission
output shaft speed to help determine the load on the Limp-Home Mode
transmission and to assist in determining shift points.
Sends output shaft speed to Transmission ECM In this mode, the transmission will go into second
which sends the information to the speedometer in gear, forward or reverse, no matter what gear is
the Information Center. selected. If second gear is not obtainable, the
Transmission ECM selects a series of prioritized
The transmission E CM 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, the
wrench over the service manual icon will be
displayed on the Information Center.

6002-10
Transmission Clutch Calibration

The Transmission ECM has the capability to find the
optimal adjustment of the clutch filling parameters for
each individual transmission, providing the ability to
individually adjust the optimum fill time for the
individual transmission in the machine. Clutch Filling
Parameter Calibration is performed on each machine
at the plant and should be repeated at the first 250
hours of use and every 1000 hours thereafter.
Before doing the following transmission clutch
calibration procedures make sure of the following:
1. The machine is running and the transmission oil
W230M173
is warm.
Highlight Calibration, and press the confirm key.
2. Engine low idle speed is correct. Always follow the prompts on the screen. Should an
error occur, use the escape key to start over again.
3. The transmission is in neutral.
4. The park brake is applied.
5. If steps 1 through 4 have been accomplished,
calibrate the transmission clutches as follows:
With the engine running at idle, enter the service
screen menu and scroll to Service screen. Press the
confirm key.
W230M174
W230M139
W230M175
The screen will show a confirm prompt. If you doubt

your ability to perform this operation, press the
escape key and call your dealer.
W230M172

6002-11
If machine conditions are incorrect, an error Gear Selections
message will appear. The calibration procedure will
not complete. Follow the prompts to aid in correcting The transmission provides 4 forward and 3 reverse
any machine conditions. gear selections. The transmission ratios were
designed to give optimized speed and torque for
The screen may display the following prompts to
each gear selection. The torque converter is a single
guide the user to correct machine conditions:
stage torque converter (one locking unit in the torque
❷ Not in neutral converter).
❷ Parking Brake OFF
❷ Machine moving Automatic/Manual Modes
❷ Oil temp too low
The automatic/manual switch is located on the right
❷ Oil temp too high
control panel. The transmission is in automatic mode
❷ Engine RPM low
when the top of the automatic/manual switch is
❷ Engine RPM high
depressed. The Transmission Display Center
indicates when the machine is in the automatic
If conditions are correct, the user will see six
mode.
calibration screens displayed. They will appear in the
following order:
❷ Adjust K1 Upshifting in Automatic Mode
❷ Adjust K2
Upshifting is determined by machine speed and the
❷ Adjust K3
torque on the transmission.
❷ Adjust K4
❷ Adjust KV The transmission will shift from first or second gear
❷ Adjust KR up to the highest gear selected as the accelerator is
depressed, machine speed increases, and required
Once the calibration process is complete, the user
torque is reduced.
will be prompted to turn the engine Off and restart the
machine. If the machine speed is increasing, but the operator
If the process is not completed, the screen will is not depressing the accelerator (such as when
prompt the user to escape. going down a hill), the transmission will not upshift.
As the operator depresses the accelerator and the
torque on the transmission is lowered, the
transmission will upshift.
Downshifting in Automatic Mode

Downshifting is determined directly by machine
speed and transmission torque. The transmission will
downshift to first or second gear as machine speed
decreases and transmission torque increases. For
example, if the unit begins to climb a hill in forth gear
and the machine speed decreases, as the torque
requirement increases, the transmission will
downshift into third, then second, and down to first
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
machines with a three lever configuration. into 1st gear. When the operator shuttles the shifter,
the transmission upshifts back into 2nd gear.
With the number of different ways the downshift
button functions, the operator can tailor the use of Cold Start Protection System
the machine to the application at hand.
The transmission has a cold start protection system.
Automatic Mode When the transmission sump temperature is minus
10° C (14° F), the Transmission ECM will keep the
In the Automatic Mode, the downshift button only transmission in neutral.
shifts down. The downshift button allows the operator
to downshift through the entire range of gears. This is When the transmission sump temperature warms up
useful in long haul applications or roading. to minus 10° C (14°F) (within approximately one
minute), the machine will operate in all gears.
Each time the button is pushed the transmission will
instantly downshift one gear from 4th to 3rd, then Brake Pedal Transmission
from 3rd to 2nd, and then from 2nd to 1st.
Declutch
The transmission will automatically downshift and
then upshift, as needed, to the last gear that was A transmission declutch feature concentrates more
selected with the downshift button. engine power on the loader when digging in heavy or
tough conditions, providing smoother stops and
Example: If the downshift button was used to shift from starts. Total disconnection of the transmission from
4th to 3rd gear, the transmission will automatically shift the engine is prevented. This feature will function in
from 3rd down and then back up to 3rd again. It will not 1st, 2nd, or 3rd gear only. It will not function in 4th
shift into 4th until the transmission has been returned to the gear.
full range automatic mode.
When the transmission declutch switch is in the on
The transmission will return to the full range position and the brake pedal is pushed, the
automatic mode when: Transmission ECM reduces the pressure to the
A. Another gear is selected. transmission forward or reverse clutch.
B. The shifter is moved into neutral and then into The Transmission ECM will not completely
forward or reverse. disconnect the clutch from the engine, but gradually
reduces the forward or reverse clutch pressure down
C. The autoshift switch is recycled. to a lower level.
When the brake pedal is released, the Transmission
ECM gradually increases the forward or reverse
clutch back up to system clutch pressure.
If the direction is changed while the transmission is
declutched, the selected forward or reverse clutch
will be filled and maintain a low pressure until the
brake pedal is released. Then the selected forward or
reverse clutch pressure will gradually increase up to
system clutch pressure.

6002-13
TRANSMISSION PRESSURE TEST POINTS DIAGRAM

DESIGNATION
No. IDENTIFICATION/LOCATION CONNECTION ON VALVE
BLOCK
Measuring Points for Pressure Oil and Temperature
1 Before the Converter - Opening Pressure 11+2 bar (159.5 + 29 psi) M10x1 H
2 Behind the Converter - Opening Pressure 4.3+3 bar (62 + 43.5 psi) M10x1
3 Clutch Forward 16+2 bar (232 + 29 psi) KV M10x1 B
4 Clutch Reverse 16+2 bar (232 + 29 psi) KR M10x1 E
5 Clutch 16+2 bar (232 + 29 psi) K1 M10x1 D
6 Clutch 16+2 bar (232 + 29 psi) K2 M10x1 A
7 Clutch 16+2 bar (232 + 29 psi) K3 M10x1 C
8 Clutch 16+2 bar (232 + 29 psi) K4 M10x1 F
9 System Pressure 16+2 bar (232 + 29 psi) M10x1 K
6 9
8
3
7 1
W270R596

6002-14
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 9 3 4 5 6 7 8 1 2
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

6002-15
PRESSURE TEST RESULTS
All or Most Pressures Low and/or Not Enough Power

Flow Test Low Possible causes include:
Possible causes include: 1. Check Electrical Troubleshooting in this Section
1. Oil level not correct. to verify actual gear selected.
2. Oil type and grade not correct. 2. Engine RPM below Stall Test specified RPM.
(Refer to Section 2002 for specifications.)
3. Oil operating temperature high.
A. Check engine and fuel system for problem.
4. Screen for suction tube plugged.
B. Check that torque converter installation is
5. Suction tube or gaskets leak. correct.
6. Main pressure valve, springs, or valve bore. 3. Engine RPM above Stall Test specified RPM.
7. Reduction valve, springs, or valve bore. (Refer to Section 2002 for specifications.)
8. Charge pump seals or gaskets leak. A. Check converter pressures and flow.
9. Charge pump worn. B. Check that torque converter installation is

correct.
10. Oil supply flange not sealing correctly.
Machine Stops or Hesitates While
Some Pressures Low Shifting - Intermittent
Possible causes include:
Possible causes include:
1. Circuit isolation does not correct low pressure.
1. Check orifice and O-ring. (See Section 6007 for
A. Control valve or gasket. replacing.)
B. Channel plate or gasket. 2. Check for foreign material plugging orifices or
sticking valves.
2. Circuit isolation corrects low pressure.
3. Check for reduced pressure at test pressure
A. Clutch shaft or seals.
points.
B. Clutch drum or piston.
4. See Electrical Troubleshooting in this Section for
electrical system problem.

6002-16
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 380000509 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 (100 psi) gauge.
4. Heat the oil to an operating temperature of 80 to
100° C (176 to 212 ° F).
Test Procedure
5. While in the cab, run the engine at full throttle.
1. Block the machine tires. Put the transmission in each gear and record the
2. Apply the parking brakes. reading in the chart on page 16. Pressure must
be 0.2 to 1.2 bar (3 to 18 psi).
FLOWMETER TEST
Test Equipment Required 3. Heat the oil to an operating temperature of 80 to
100° C (176 to 212° F).
380001740 Flowmeter Kit; 380001750 Flowmeter
Adapter. 4. Remove the filter and install the 380001750
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 L/min
(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.
L/min (2 U.S. gpm).
3. Heat the oil to an operating temperature of 80 to
7. Repeat the procedure with the transmission in
100° C (176 to 212 ° F).
REVERSE in third gear. The flow must be 9.1
4. Install the flowmeter to converter outlet line (line L/min (2 U.S. gpm).
to cooler) in series.
Put the transmission in NEUTRAL and record the
flow measurement. The flow must be 9.1 L/min
(2 U.S. gpm).

6002-17
TRANSMISSION OVERHEATING
1. Operate machine in normal operating conditions and observe:
A. Verify actual oil temperature at test point. Normal operating temperature can be 56°C (100°F) above the
ambient temperatures.
B. Use a stop watch to establish the exact length of time required to reach the overheating condition.
C. Observe engine temperature, does the engine overheat? Which overheats first - engine or transmission?
2. When the transmission reaches overheated condition, shift to Neutral and maintain engine RPM at a fast idle
(1250 to 1450 RPM).
A. Oil temperature returns to Normal - establish length of time.
1. Check oil level, type and grade is correct (See Section 1002).
2. Check operator’s gear selection is correct for conditions.
3. Make sure brakes are fully released.
4. Check the engine full throttle and stall speeds are correct as specified (See Section 2002).
B. Oil temperature remains overheated.
1. Check for dirty radiator - airflow restricted.
2. Check for engine overheating problem.
3. Check for faulty oil temperature gauge and sender or switch (See Section 4002).
3. Perform all the pressure and flow tests.
4. Compare the pressure and flow test results to the specifications in this section to determine if any circuits are
not within specifications.
5. Refer to Pressure Test Results to determine possible cause of any test results not within specifications.

6002-18
ERROR CODES
In case of possible errors in the system, an amber or red warning appears on the instrument panel, combined with
a recorded error number. See section 4005 for error code retrieval procedures and definitions.
TRANSMISSION SHIFTER LOGIC INFORMATION

Shifter Wire Shifter Tower Shifter Shroud Harness Harness
Function Shifter Trans. ECM #
Color Connector Connector Wire # ped/cab #
power B+ black/red A A 19A_H 43 45
forward V yellow - B 25F 44 43
reverse R pink - C 25R 45 64
neutral N gray - D 25T_B 46 67
gear2(3-4) B2 green B - 25W 48 65
gear1(1-2) B1 blue C - 25Z 49 63
downshift DS purple D - 25Y 50 22
NOTE: Power is supplied through the fuse A to the transmission shifter via 19A wire. This is 24 Volt. Within the shifter are limit
switches to transfer the signal voltages to the outputs. In forward V is high. In reverse R is high. In neutral N is high. In first gear,
B1 is high and B2 is low. In second gear, B1 and B2 are low. In third gear, B1 is low and B2 is high. In fourth gear, B1 and B2 are
high. Downshift, DS, is activated when the end of the shifter is engaged.
RELATIONSHIP BETWEEN TRANSMISSION ECM, VALVES, AND CLUTCHES

Transmission ECM Transmission Transmission Transmission Trans/Cab
Clutch # Wire #
Function ECM Pin # Valve Valve Pin # Pin #
A1P1 56 Y1 K4 1 25K 16
A1P2 10 Y2 KR 2 25L 17
A1P3 32 Y3 K1 3 25M 18
A1P4 55 Y4 K3 4 25N 19
A1P5 9 Y5 KV 5 25P 20
A1P6 51 Y6 K2 6 25J 21
VPSI 12,13 all Y all K 7 25S 22
TEMP 39 TEMP none 8 36T 5
TEMP 46 TEMP none 9 36R 12

Section
6003
6003
TRANSMISSION

Via Plava, 80
6003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6003-3
SPECIAL TOOLS
Adjusting screws M6
1 380001558
Handle
2 380001557
Rolling tool
3 380001285
Assembly
4
380001556
Rolling tool
5
380001286
Rolling tool
6 380001287

6003-4
Driver tool
7
380001560
Assembly fixture
(Inner installer and driver)
8
380001559

6003-5
TRANSMISSION
DISASSEMBLY STEP 3
STEP 1
W270R139
Remove all oil pipes, the complete gear shift

W270R137
system and the duct plate.
Fasten the complete transmission to the assembly
truck. Converter Drive
STEP 2 STEP 4
W270R138 W270R140
Remove the plug (arrow) and drain the oil. By means of the lifting tackle separate the torque
Then remove the oil cylinder. converter from the transmission.

6003-6
STEP 5 STEP 8
W270R141 W270R144
Loosen the bolt connection and by means of the Loosen the bolt connection and by means of lifting
forcing screws (3x) separate the cover from the tackle and pry bar set separate the converter bell
converter bell. from the transmission housing.
STEP 6 STEP 9
W270R142 W270R145
By means of the extractor pull the oil supply flange Remove the rectangular ring (arrow).
out of the converter bell.
STEP 10
STEP 7
W270R146
W270R143 Press the input shaft out of the spur gear bearing.
Remove the converter safety valve (arrow 1), if Remove the released bearing inner ring and the
required. spur gear.
NOTE: Converter safety valve is fixed by means of slotted
pin (arrow 2).
6003-7
STEP 11
W270R147
Press off the bearing inner ring from the spur gear.
STEP 12
W270R148
Remove the converter pressure back-up valve.
STEP 13
W270R149
Remove the inductive transmitter (9).

6003-8
Input Shaft STEP 17
STEP 14
W270R153
S n a p o ut t he r e c t an g u l ar r i n g ( ar ro w 1 ) an d
W270R150
remove both shims (arrow 2).
Loosen the cap screw.
Transmission Pump
STEP 15
STEP 18
W270R151
Remove the cap screw and clamping plate. W270R154
Loosen the cap and hexagon screws (depending

STEP 16 on the version) respectively and separate the
pump flange from the housing.
W270R152
Press the input shaft out of the bearing.

NOTE: Pay attention to released input shaft as well as
shims.

6003-9
STEP 19 STEP 21
W270R155 W270R157
Loosen the cap screws. Position the extractor on Press out the driver with ball bearing from the
the transmission pump and fasten it by means of bearing bore. Then separate the ball bearing from
screws to the transmission pump. the driver.
Then pull out the pump from the housing bore.
STEP 22
NOTE: Extracting is supported by slightly tapping onto
the transmission housing.
Remove the ball bearing and the driver

(Step 20 ... 21)
STEP 20
W270R158
Loosen the cap screws, take off the pump cover

and remove the rotor set.
NOTE: If marks due to running-in are found on the pump
housing or housing cover, the complete pump is to be
replaced.
W270R156
Then assemble the rotor set with the chamfer on
Snap out the retaining ring.
the tooth tip showing downwards and install the
housing cover again.

6003-10
Layshaft Removal of Inductive and Speed
transmitter
STEP 23
STEP 25
W270R159
Remove the sealing cover and loosen the hexagon

screw.
STEP 24
W270R161
14 = n – Turbine
5 = n – internal speed input
13 = n – Output (Speed transmitter)
W270R160
Expel the idler shaft by means of the striker from

the housing bore and layshaft bearing respectively.

6003-11
Output STEP 28
Version with Parking Brake
STEP 26
W270R164
Loosen the cap screws and separate the complete

brake from the transmission housing.
W270R162
Remove the lock p late. Loosen th e hexagon
screws and separate the output flange/brake disc
Transmission rearside:
from the output shaft.
ATTENTION: For working on the brake system observe
the instructions and specifications of the brake Removal of the Clutches and Layshaft
manufacturer.
STEP 29
Unscrew the screw cap.
STEP 27
W270R165
Loosen the hexagon screws and expel the bearing

W270R163
cover KV/K1 by means of the striker from the
housing bore. Remove the bearing cover KR/K2
Loosen the counternut and unscrew the adjusting
(arrow) analogously.
screw in counterclockwise direction until the brake
disc is released. NOTE: Mark the installation location of the bearing cover.

6003-12
STEP 30 STEP 33
W270R166 W270R169
Pull out the bearing cover K4/K3 by means of the Expel the output shaft from the output gear.
forcing screws from the housing bore.
STEP 34
STEP 31
W270R170
W270R167 Loosen the hexagon screws and remove the oil

Separate the bearing inner ring from bearing cover baffle. Lift the output gear out of the transmission
K4/K3. housing.
STEP 32 STEP 35
2 1
3
W270R168 W270R171
Loosen the bolt connection. Remove the bearing inner ring from the output
Separate the housing cover from the housing by gear.
equally tightening both forcing screws (arrow 1 and
2) as well as the threaded spindle (arrow 3).

6003-13
STEP 36 STEP 38
W270R172 W270R174
Take the roller bearing out of the housing bore and Opposite figure shows the clutches when removed.
remove the oil baffle (arrow).
STEP 39
Remove the multi-disc clutches
STEP 37
W270R175
Remove the layshaft gear.
W270R173
NOTE: For removal of the single clutches observe the

following sequence:
K4/K3 --> KR/K2 --> KV/K1.
For removal of clutch K4/K3, lift the clutch KR/K2 slightly
and move it in direction of the arrow, see figure.

6003-14
Removal of the 2nd Power Take-Off STEP 43
STEP 40
W270R179
Pull the bearing outer ring out of the housing bore.

W270R176
Snap out the retaining ring and remove the shims. STEP 44
STEP 41
W270R180
Pull off the bearing inner ring from the shaft.

W270R177
Press off the opposite bearing inner ring from the
Lift the output shaft by means of the pry bar set shaft.
until the bearing outer ring is released.
NOTE: Shaft and gear cannot be separated (shrink fit).
STEP 42
W270R178
Take the output shaft out of the housing.

6003-15
Dismantling of the Multi-Disc Clutch STEP 48
K3/K4
STEP 45
W270R184
Pull off the bearing inner ring from the disc carrier.
W270R181 STEP 49
By means of clamping ring fasten the clutch to the
assembly truck.
STEP 46
W270R185
Squeeze out the snap ring.

Remove the end shim and disc set K3.
W270R182 STEP 50
Pull off the roller bearing from the disc carrier.
STEP 47
W270R186
Rotate disc carrier by 90°.

Loosen the slotted nut.
W270R183
Separate spur gear K3 from the disc carrier.

6003-16
STEP 51 STEP 54
W270R187 W270R190
Rotate disc carrier by 90°. Pull off the taper roller bearing.
Pull off the taper roller bearing.
STEP 55
STEP 52
W270R191
W270R188 Squeeze out the snap ring.

Pull off the spur gear K4 from the disc carrier. Remove the end shim and the disc set K4.
STEP 53 STEP 56
W270R189 W270R192
Remove the ring. Preload the compression spring by means of

fixture. Squeeze out the snap ring and the
released single components. Remove the opposite
single components (K3 side) analogously.

6003-17
STEP 57 STEP 60
W270R193 W270R196
Separate both pistons by means of compressed air Pull off the taper roller bearing from the disc
from the disc carrier. carrier.
Dismantling of the Multi-Disc Clutch STEP 61

KR/K2
STEP 58
W270R197
Press off the spur gear K2 from the disc carrier.
W270R194
ATTENTION: Pay attention to released disc carrier.
Fasten the clutch by means of clamping ring STEP 62
(arrow) on the assembly truck.
STEP 59
W270R198
Fasten the disc carrier by means of clamping ring.

W270R195
Pull off the taper roller bearing from the disc
carrier.

6003-18
STEP 63 STEP 66
W270R199 W270R202
Squeeze out the snap ring. Fasten spur gear KR by means of clamping ring
Remove the end shim and disc set K2. (arrow) and pull it from the disc carrier.
STEP 64 NOTE: Collar of the clamping ring must show upwards

(to the spur gear).
STEP 67
W270R200

Loosen the slotted nut. W270R203
STEP 65 Remove the ring.
STEP 68
W270R201
Pull off the taper roller bearing from the disc W270R204
carrier.
Remove end shim and disc set KR.

6003-19
STEP 69 STEP 71
W270R205 W270R207
Pull off the taper roller bearing from the disc Pull off the taper roller bearing from the disc
carrier. Remove both pistons (like described in carrier.
Step 56 and 57).
STEP 72
Dismantling of the Multi-Disc Clutch
KV/K1
STEP 70
W270R208
Remove the shim.
STEP 73
W270R206
Fasten clutch by means of clamping ring to the

assembly truck. Loosen the slotted nut.
W270R209
Pull off spur gear K1 from the disc carrier.

6003-20
STEP 74 STEP 76
W270R210
Opposite figure shows the spur gear bearing K1.

Bearing (1) can only be obtained as complete part.
ATTENTION: If it is necessary to remove the
clutch-pack-sided ball bearing (arrow or Step 76), the
complete bearing (1) has to be removed.
STEP 75
W270R212
Pull off the ball bearing from the disc carrier.

NOTE: Pay attention to released balls.
STEP 77
W270R211
Take off the bush.
W270R213

Remove end shim and disc set K1.

6003-21
STEP 78 STEP 81
W270R214 W270R217
Rotate disc carrier by 90°. Remove the ring.

STEP 82
STEP 79
W270R218
W270R215 Pull off the taper roller bearing from the disc
Pull off the taper roller bearing from the disc carrier. Squeeze out the snap ring. Remove end
carrier. shim and disc set KV. Remove both pistons (like
described in Step. 56 and 57).
STEP 80
W270R216
Pull off spur gear KV from the disc carrier.

6003-22
REASSEMBLY STEP 4
2nd Power Take-Off
STEP 1
W270R222
Position the preassembled power take-off shaft in the

housing and insert the bearing outer ring until
contact.
W270R219
Undercool the shaft (ca. - 80° C), heat the gear STEP 5
(approx. + 120° C) and install or press it until contact.
STEP 2
W270R223
Axial play – power take-off bearing max. 0.0039 in

(0.10 mm), to be adjusted by means of shim(s) and
W270R220 retaining ring.
Press the bearing inner ring until contact.
Press the opposite bearing inner ring until contact.
STEP 3
W270R221
Insert the bearing outer ring (arrow) into the housing

bore until contact.
6003-23
STEP 6
W270R224
Rotate the transmission housing by 180°.

Insert the sealing disc (arrow) with the concave side
showing downwards into the housing bore until
contact.
NOTE: Wet contact face with Loctite (Type No. 262).
ATTENTION: Do not damage the centric orifice bore ø
0.031 in (0.80 mm) when installing the sealing disc.

6003-24
Assembly of the Multi-Disc Clutch K4/K3
The following sketch shows the clutch sectioning
1
3
2
K4 K3
5 4 4 5
W270R225
1 = Disc carrier (assy)

2 = Spur gear K4
3 = Spur gear K3
K4 = Multi-disc clutch K4
4 = Piston
5 = Compression spring
6 = Plug 2x
7 = Plug 1x
NOTE: Observe the installation position of the single components for the following assembly.

6003-25
STEP 7 STEP 9
W270R228
Put both O-Rings scroll-free into the annular grooves

of the piston, see arrows.
STEP 10
W270R226
Lift the disc carrier with the K4-side showing

downwards into the clamping ring and fasten it.
ATTENTION: To install new disc carriers the finished
W270R229
bores have to be sealed with plugs.
Installation position, see arrow. Oil the O-Rings and the piston contact surface.
Install K3 piston equally until contact.
STEP 8 NOTE: Observe the installation position of the piston.
STEP 11
W270R227
Flush-mount the drain valve (arrow) with the chamfer

showing downwards. W270R230
Install spacer and compression spring.

6003-26
STEP 12
W270R231
Place guide ring, with the chamfer (arrow) showing

upwards, over the compression spring and install the
snap ring.
STEP 13
W270R232
Lift the disc carrier out of the clamping ring.

Preload the compression spring by means of fixture
and engage the snap ring into the annular groove of
the disc carrier (arrow).
Install the drain valve, piston and compression
spring on the opposite side (Clutch K4)
analogously ( Step 8...13).
Then lift the disc carrier with the K4-side showing

6003-27
Disc Components K4
K4 K3
3 4 3 2 1
6 6 5
7 7
W270R233
Pos. Description Quantity s (mm) Remarks

1= Disc carrier 1
2= Piston 1
3= Outer clutch disc 2 0.072 in (1.85 mm) Coated on one side
4= Outer clutch disc 4 0.098 in (2.5 mm) Coated on both sides
5= Inner clutch disc 2 0.15 in (4.0 mm)
7= Inner clutch disc 2 0.098 ... 0.15 in (2.5 ... 4.0 mm) Optional
8= Snap ring 1 0.082 ... 0.12 in (2.10 ... 3.10 mm) Optional
9= End shim 1
Number of friction surfaces: 10
Disc clearance: 0.086 ... 0.094 in (2.2 ... 2.4 mm)
NOTE: Install the outer clutch discs Pos. 3 with uncoated side showing to the piston and end shim respectively.
The respective clutch side can be seen on the length of the disc carrier, see sketch.
K4 = Dimension X (short disc carrier side)
K3 = Dimension Y (long disc carrier side).

6003-28
Check disc clearance K4 = 0.086 ... 0.094 in STEP 16
(2.2 ... 2.4 mm) (Step 14 ... 16)
STEP 14
W270R236
Press on end shim with approx. 100 N (10 kg) and

set dial indicator to „Zero“.
W270R234 Then press end shim against snap ring (upwards)
NOTE: In order to ensure a perfect measuring result, the and read disc clearance on the dial indicator.
disc set is first of all to be installed without oil. NOTE: If the required disc clearance differs, it has to be
Install disc set according to sketch or table (Page 27). corrected with the adequate inner clutch disc or/and snap
ring, see table / Pos. 7 and Pos. 8. (Page 27).
STEP 15
Preassemble and install spur gear K4
(Step 17 ... 21)
STEP 17
W270R235
Install the end shim and fasten it by means of the

snap ring.
W270R237
Opposite figure shows the single components of spur

gear K4.
1 = Bearing inner ring
2 = Bearing outer ring
3 = Ring
4 = Spur gear
Locate both bearing outer rings (2) until contact.

6003-29
STEP 18 STEP 21
W270R238 W270R241
Heat the bearing inner ring and install it until contact. Heat the bearing inner ring (spur gear bearing) and
locate it until contact.
STEP 19 ATTENTION: Use safety gloves.
STEP 22
W270R239
Install the ring (3).

W270R242
STEP 20 Heat the bearing inner ring (clutch bearing) and
install it until contact.
ATTENTION: Use safety gloves.
W270R240
Assemble the spur gear until all inner clutch discs are
located.

6003-30
Clutch Components K3
K4 K3
X Y
1 2 3 4 3
5 6 6
7 7
W270R243

1= Disc carrier 1
2= Piston 1
9= End shim 1
K3 = Dimension Y (long disc carrier side)
K4 = Dimension X (short disc carrier side).

6003-31
(2.2 ... 2.4 mm) (Step 23 ... 25)
STEP 23
W270R246

Install disc set according to sketch or table (Page corrected with the adequate inner clutch disc or/and snap
30). ring, see table / Pos. 7 and Pos. 8. (Page 30).
STEP 24 STEP 26
W270R245 W270R247
Install the end shim and fasten it by means of the Heat the bearing inner ring and install it until contact.
snap ring. ATTENTION: Use safety gloves.

6003-32
STEP 27 STEP 29
W270R248 W270R250
Lift the disc carrier out of the clamping ring. To Install the bearing outer ring into spur gear K3 until
ensure the exact locating of the single components, contact.
preload the bearing with 100 000 N (10 t).
ATTENTION: Support on the lower as well as upper STEP 30
bearing inner ring. Use pressure pieces.
STEP 28
W270R251
located.
W270R249
Lift the disc carrier with the K4-side showing STEP 31

Install the slotted nut.
NOTE: Observe installation position of the slotted nut!
Collar ø 2.36 in (ø 60 mm) must show to the bearing inner
ring, also see sketch/page 24. Oil the thread.
Tightening torque .......= 550 Nm (4867.9 pound in)
W270R252
Heat the roller bearing and locate it until contact.


6003-33
STEP 32
W270R253
Install the bearing inner ring.
STEP 33
W270R254
Check function of the clutches K3 and K4 by means

of compressed air.
NOTE: Closing or opening of the clutches is clearly
audible when the single parts have been installed
adequately.
STEP 34
W270R255
Snap-in and lock the rectangular rings (3, see

arrows).

6003-34
Assembly of the Multi-Disc Clutch KR/K2
The following sketch shows the clutch sectioning.
2 1 3
KR K2
5 4 4 5
W270R256
1 = Disc carrier
2 = Spur gear KR
3 = Spur gear K2
K4 = Multi-disc clutch KR
4 = Piston
6 = Plug
7 = Plug

6003-35
STEP 35 STEP 37
W270R259
Put both O-Rings scroll-free into the annular

grooves of the piston, see arrows.
STEP 38
W270R257
Lift the disc carrier with the KR-side showing

Then rotate disc carrier by 180°.
W270R260
Installation position, see arrow, Step 35... 36. Oil the O-Rings and the piston contact surfaces.
STEP 36 NOTE: Observe the installation position of the piston, see
figure.
STEP 39
W270R258

showing downwards.
W270R261

6003-36
STEP 40
W270R262

snap ring.
STEP 41
W270R263

Preload the compression spring by means of fixture
and engage the snap ring into the annular groove of
the disc carrier (arrow).
Install the drain valve, piston and compression spring
on the opposite side (Clutch KR) analogously (like
Step 36 ... 41).
Then lift the disc carrier with the KR-side showing

6003-37
Disc Components KR
KR K2
.
W270R264

1= Disc carrier 1
2= Piston 1
9= End shim 1
KR = Dimension Y (long disc carrier side)
K2 = Dimension X (short disc carrier side).

6003-38
Check disc clearance KR = 0.110 ... 0.118 in STEP 44
(2.8 ... 3.0 mm) (Step 42 ... 44)
STEP 42
W270R267

STEP 43 Preassemble and install spur gear KR

(Step 45... 49)
STEP 45
W270R266

snap ring.
W270R268

gear KR.
1 = Bearing inner ring 2.9 x 1.4 in (75 x 37 mm)
2 = Ring
3 = Spur gear
4 = Bearing inner ring 2.9 x 1.6 in (75 x 41 mm)

6003-39
STEP 46 STEP 49
W270R269 W270R272
Heat the bearing inner ring 2.9 x 1.4 in (75 x 37 mm) Heat the bearing inner ring 2.9 x 1.6 in (75 x 41 mm)
and install it until contact. and locate it until contact.
ATTENTION: Use safety gloves. ATTENTION: Use safety gloves.
STEP 47 STEP 50
W270R270 W270R273
Assemble the spur gear until all inner clutch discs are Heat the bearing inner ring (clutch bearing) and
located. locate it until contact.
STEP 48
W270R271
Install the ring.

6003-40
Disc Components K2
KR K2
W270R274

1= Disc carrier 1
2= Piston 1
9= End shim 1
K2 = Dimension X (short disc carrier side)
KR = Dimension Y (long disc carrier side).

6003-41
(2.2 ... 2.4 mm) (Step 51 ... 53)
STEP 51
W270R277

40). ring, see table / Pos. 7 and Pos. 8. (Page 40),
STEP 52
W270R276

snap ring.

6003-42
Preassemble and install spur gear K2 STEP 56
(Step 54 ... 58)
STEP 54
W270R280
Heat the bearing inner ring and install it until contact.

W270R278
Undercool gear 1 (approx. – 80° C) and heat gear 2

STEP 57
(approx. 120° C).
Engage the snap ring (arrow), preload it and join both
components by means of hydr. press until the snap
ring engages into the annular groove of gear 2.
STEP 55
W270R281
located.
STEP 58
W270R279
Opposite figure shows the single components of the

spur gear bearing.
2 = Spur gear assy
W270R282
Heat the bearing inner ring (spur gear bearing) and

install it until contact.

6003-43
STEP 59 STEP 61
W270R283 W270R285
Heat the bearing inner ring (clutch bearing) and Lift the disc carrier into the clamping ring and fasten
locate it until contact. it. Rotate disc carrier by 90°.
K2-side:
STEP 60 NOTE: Observe installation position of the slotted nut!
Chamfer must show to the bearing inner ring, also see
sketch/page 34. Oil the thread.
STEP 62
W270R284

To ensure the exact locating of the single components,
W270R286
ATTENTION: Support on the lower as well as upper
KR-side:
bearing inner ring. Use pressure pieces.
NOTE: Observe installation position of the slotted nut!
Collar ø 2.9 in (ø 76 mm) must show to the bearing inner
ring, also see sketch/page 34. Oil the thread.
Tightening torque ...= 800 Nm (7080.6 pound inch)

6003-44
STEP 63
W270R287
Check function of the clutches K3 and K4 by means

of compressed air.
audible when the single parts have been installed
adequately.
Snap-in and lock the rectangular rings (see arrows).

6003-45
Assembly of the Multi-Disc Clutch KV/K1
The following sketch shows the clutch sectioning
2 1
KV K1
7
5 4 4 5
W270R288
1 = Disc carrier
2 = Spur gear KV
3 = Spur gear K1
K4 = Multi-disc clutch KV
4 = Piston
6 = Plug 2x
7 = Plug 1x

6003-46
STEP 64 STEP 66
W270R290
Put both O-Rings scroll-free into the annular

grooves of the piston, see arrows.
STEP 67
W270R289
Lift the disc carrier with the KV-side showing

Then rotate disc carrier by 180°.
W270R291
bores have to be sealed with plugs . Installation position,
see arrow. Oil the O-Rings and the piston contact surfaces.
STEP 65 NOTE: Observe the installation position of the piston, see
figure.
STEP 68
W270R258

showing downwards.
W270R292

6003-47
STEP 69
W270R293

snap ring.
STEP 70
W270R294
Lift the disc carrier out of the clamping ring. Preload

the compression spring by means of fixture and
engage the snap ring into the annular groove of the
disc carrier (arrow).
Install the drain valve, piston and compression spring
on the opposite side (Clutch KV) analogously.
Then lift the disc carrier with the KV-side showing

6003-48
Disc Components KV
KV K1
Y X
3 4 3 2 1
7 5 6 5
W270R295

1= Disc carrier 1
2= Piston 1
9= End shim 1
The respective clutch side can be seen on the length and ø of the disc carrier respectively, see sketch.
KV = Dimension Y (short disc carrier side and large ø respectively)
K1 = Dimension X (short disc carrier side and small ø respectively).

6003-49
Check disc clearance KV = 0.110 ... 0.118 in STEP 73
(2.8 ... 3.0 mm) (Step 71 ... 73)
STEP 71
W270R298

STEP 72 Preassemble and install spur gear KV

(Step 74 ... 78)
STEP 74
W270R297

snap ring.
W270R299

gear KV.
2 = Bearing outer ring
3 = Ring
4 = Spur gear
Install both bearing outer rings (2) until contact.

6003-50
STEP 75 STEP 78
W270R300 W270R303
Heat the bearing inner ring and install it until contact. Heat the bearing inner ring (spur gear bearing) and
locate it until contact.
STEP 76
STEP 79
W270R301
Install the ring. W270R304
Heat the bearing inner ring (clutch bearing) and

STEP 77 locate it until contact.
W270R302
located.

6003-51
Disc Components K1
KV K1
Y X
1 2 3 4 3
5 6 5 7
W270R305

1= Disc carrier 1
2= Piston 1
9= End shim 1
The respective clutch side can be seen on the length and ø of the disc carrier respectively, see sketch.
K1 = Dimension X (short disc carrier side and small ø respectively)
KV = Dimension Y (short disc carrier side and large ø respectively).

6003-52
(2.2 ... 2.4 mm) (Step 80 ... 82)
STEP 80
W270R308

STEP 81
W270R307

snap ring.

6003-53
Preassemble and install spur gear K1 STEP 85
(Step 83 ... 89)
STEP 83
W270R311
Install the bush with collar (arrow) on face end

showing to the snap ring.
STEP 86
W270R309

W270R312
gear K1.
Press in the ball bearing until contact.
1 = Ball bearing (assy)
2 = Snap ring NOTE: Install the ball bearing with the lubricating groove
3 = Spur gear (arrow) showing downwards. Put the press-in tool only to
the bearing outer ring.
NOTE: Prior to installation of the single components,
align the disc set by means of the spur gear radially and
center it.
STEP 84
W270R310
Install the snap ring.

6003-54
STEP 87 STEP 90
W270R313 W270R316
Heat the second ball bearing and install it until Install shim s = 0.04 in (1.20 mm).
contact.
NOTE: Lubricating groove (arrow), must show upwards. STEP 91
STEP 88
W270R317

W270R314
Assemble the bush.
STEP 89
W270R315
Heat the spur gear to approx. 120° C and assemble it

until all inner clutch discs are located.

6003-55
STEP 92 STEP 94
W270R318 W270R320
Lift the disc carrier out of the clamping ring. Check function of the clutches KV and K1 by means of
To ensure the exact locating of the single components, compressed air.
ATTENTION: Support on the lower as well as upper audible when the single parts have been installed
bearing inner ring. Use pressure pieces. adequately.
STEP 93 STEP 95
W270R319 W270R321
Lift the disc carrier into the clamping ring. Snap-in and lock the rectangular rings (see arrows).
Rotate disc carrier by 90°. Install the slotted nut.
NOTE: Observe installation position of the slotted nut.
Collar ø 2.3 in (ø 60 mm) must show to the taper roller
bearing, also see sketch/page 45.
Oil the thread.
Tightening torque ... = 550 Nm (4867.9 pound inch)

6003-56
Installation of Layshaft Gear, Multi-Disc STEP 98
Clutches and Output Gear
STEP 96
W270R324
Insert the bearing outer rings KV/K1, KR/K2 and K3/K4

into the housing bores until contact, see arrows.
W270R322
Opposite figure shows the single components of the STEP 99

layshaft gear bearing.
2 = Ring
3 = Layshaft gear
STEP 97
W270R325
Position clutch KV/K1 by means of lifting tackle.
STEP 100
W270R323
Position layshaft gear (assy) in the housing.

NOTE: Only when the clutches are installed, the idler
shaft can be mounted.
W270R326
Position clutch KR/K2.

6003-57
STEP 101 STEP 104
W270R327 W270R330
Check the installation position of the layshaft gear Insert the bearing outer ring into the housing bore until
(arrow) once again and correct it, if required. contact.
STEP 102 STEP 105
W270R328 W270R331
Fasten the spur gear K3 by means of fixture and Heat the bearing inner ring and install it until contact.
eyebolt (arrow) axially.
NOTE: Spur gear fixing prevents the clutch discs from
NOTE: Observe installation position – collar (arrow)
dislocating when the clutch is lifted in.
shows to the spur gear. Install the bearing inner ring after
cooling down subsequently (press).
STEP 103
STEP 106
W270R329
Lift the clutch KR/K2 slightly, move it in direction of the W270R332

arrow and position clutch K3/K4.
Position the oil baffle.
Then remove the fixture (Step 102) again.

6003-58
STEP 107
W270R333
Install the output gear by means of lifting tackle.
STEP 108
W270R334
Position upper oil baffle and fasten both plates by

means of hexagon screws.
NOTE: Install washers.
Secure hexagon screws with Loctite (Type No. 243).
Tightening torque .......= 23 Nm (203.5 pound inch)

6003-59
Preassembly and Mounting of the STEP 111
Housing Cover
STEP 109
W270R337
Wet the mounting face with sealing compound (Loctite,

Type No. 574).
W270R335 By means of the lifting tackle place the housing cover
Note to Step 109 and 110: on the transmission housing until contact.
Depending on the transmission version, differences as
regards the single components and their installation STEP 112
position are possible.
Obligatory is the respective spare parts list. 2
NOTE: Install the sealing cover (arrow).
Wet the sealing surface with Loctite (Type No. 262).
STEP 110
3 1
W270R338
Install both cylindrical pins (arrow 1 and 2) and the

slotted pin (arrow 3).
Then fasten the housing cover by means of hexagon
and cap screws.
Tightening torque ......... = 46 Nm (407 pound inch)
W270R336
Insert the O-Ring into the annular groove of the cover

and fasten the cover by means of hexagon screws.
NOTE: Wet the thread of the hexagon screws with Loctite
(Type No. 574). Observe the installation position of the
cover, see Figure.
Tightening torque ....... = 23 Nm (203.5 pound inch)

6003-60
Adjust the bearing preload of clutch STEP 114
K4/K3 = 0.0 ... 0.0019 in (0.0 ... 0.05 mm)
(Step 114 ... 116)
STEP 113
W270R340
Housing dimension:
P re ss o n e q u a l l y t h e b e a r i n g i n n e r r i n g a n d
determine Dim. I, from the mounting face to the
bearing inner ring.
1
Dim. I e.g.............................. = 1.71 in (43.65 mm)
NOTE: Take several measuring points and determine the
mean value.
Then remove the bearing inner ring again.
2
STEP 115
W270R339
NOTE: For installation of a new bearing cover, both

finished bores have to be sealed by means of a plug.
Finished bores are located opposite (180°) to each other,
also see arrow.
1 = Bearing cover-K4/K3
2 = Plug
W270R341
Cover dimension:
Determine Dim. II, from the mounting face until
contact/bearing inner ring.
Dim. I e.g.............................. = 1.65 in (42.12 mm)

6003-61
STEP 116 STEP 118
W270R342 W270R344
Example: Grease the rectangular rings (arrows) and centrally

align them.
Dim. I ................................... = 1.71 in (43.65 mm)
Dim. II ................................... = 1.65 in (42.12 mm)
Difference ............................. = 0.060 in (1.53 mm) STEP 119
Bearing preload................... = 0.0007 in (0.02 mm)
Resulting shim(s) ............... = 0.061 in (1.55 mm)
Put on the shim.
STEP 117
W270R345
Install the O-Ring (arrow) and grease it.

Heat the inner diameter of the bearing cover (bearing
seat).
W270R343
Heat the bearing inner ring and place it until contact.

NOTE: Install the bearing inner ring after cooling down
subsequently (press).

6003-62
STEP 120
W270R346
Install two adjusting screws.

Assemble the bearing cover and tighten it equally until
contact by means of hexagon screws.
Tightening torque ............= 46 Nm (47 pound inch)
NOTE: Observe the radial installation position.
STEP 121
W270R347
Check the function of both clutches by means of

compressed air.
NOTE: In case of a decisive pressure loss, the possible
cause might be the breakage of one or several rectangular
rings (see arrow, Step 118).
Replace the rectangular rings, if required.

6003-63
Adjust the bearing preload of clutch STEP 123
KR/K2 = 0.0 ... 0.0019 in (0.0 ... 0.05 mm)
(Step 123 ... 127)
STEP 122
1
W270R349
Install both studs (arrows).

NOTE: Wet the thread with Loctite (Type No. 243).
1
STEP 124
W270R348

Finished bores are located opposite (180°) to each other, W270R350
also see arrow. Install the bearing outer ring until contact.
1 = Bearing cover-KR/K2 NOTE: Pay attention to exact contact.
2 = Plug

6003-64
STEP 125 STEP 127
W270R351 W270R353
Housing dimension: Example:

Determine Dim. I, from the bearing outer ring to the Dim. I ................................... = 0.69 in (17.75 mm)
mounting face. Dim. II................................... = 0.63 in (16.13 mm)
Dim. I e.g. .............................= 0.63 in (16.13 mm) Difference ............................. = 0.063 in (1.62 mm)
Bearing preload ............e.g. + 0.0011 in (0.03 mm)
STEP 126 Resulting shim(s) ...............= 0.065 in (1.65 mm)
Fix the shim with assembly grease into the cover.
Install the O-Ring (arrow).
STEP 128
W270R352
Cover dimension:
Determine Dim. II, from the contact/bearing outer
ring to the mounting face.
W270R354
Dim. II e.g. ............................= 0.69 in (17.75 mm)
Grease the rectangular rings (arrows) and centrally
align them.

6003-65
STEP 129 Adjust the bearing preload of clutch
KV/K1 = 0.0 ... 0.0019 in (0.0 ... 0.05 mm)
(Step 132 ... 135)
STEP 131
2
W270R355
Pull the bearing cover equally until contact.

Tightening torque ..........= 46 Nm (407 pound inch)
W270R357
STEP 130
Installation position, see arrows.
1 = Bearing cover-KV/K1
2 = Plug
STEP 132
W270R356
Check the function of both clutches by means of

compressed air.
cause might be the breakage of one or several rectangular
rings (see STEP 128).
Replace the rectangular rings, if required.
W270R358
Put the bearing outer ring over the bearing inner ring.
Housing dimension:
Press on equally the bearing outer ring and determine
Dim. I, from the mounting face to the bearing outer ring.
Dim. I e.g.............................. = 2.07 in (52.67 mm)
NOTE: Take several measuring points and determine the
mean value.

6003-66
STEP 133 STEP 135
W270R359 W270R361
Put the ring with the chamfer showing downwards into Example:
the bearing cover.
Dim. I ................................... = 2.07 in (52.67 mm)
Dim. II................................... = 1.99 in (50.75 mm)
STEP 134 Difference ..........................e.g. 0.075 in (1.92 mm)
Bearing preload .................... = 0.001 in (0.03 mm)
Resulting shim(s) ...............= 0.076 in (1.95 mm)
Put in the shim.
STEP 136
W270R360
Cover dimension:
Determine Dim. II, from the mounting face to the ring.
Dim. II e.g. ............................= 1.99 in (50.75 mm)
W270R362
Install the bearing outer ring until contact.

Assemble the O-Ring (arrow).

6003-67
STEP 137 STEP 140
W270R363 W270R366
Grease the rectangular rings (arrows) and centrally Check the function of both clutches by means of
align them. compressed air.
STEP 138 cause might be the breakage of one or several rectangular
rings (see arrow, STEP 137).
Replace the rectangular ring, if required.
W270R364
Heat the bearing bore.
STEP 139
W270R365
Install two adjusting screws.

Place the bearing cover until contact and fasten it by
NOTE: Observe the radial installation position, see figure.

6003-68
Output STEP 143
Installation of the Output Shaft
STEP 141
W270R367
Heat the inner diameter of the output gear.
STEP 142
W270R369
Rotate the transmission housing into the vertical

position (90°).
By means of the mounting tool the output shaft has
preliminarily to be fixed axially at the converter side.
Then rotate the transmission housing back again (90°).
W270R368
Assemble the output shaft with the long gearing

showing downwards until contact.

6003-69
Adjust the axial play of the output STEP 146
bearing = 0.011 ... 0.019 in (0.3 ... 0.5 mm)
(Step 144 ... 146)
STEP 144
W270R372
Install the shim.
STEP 147
W270R370
Determine Dim. I, from plane face/housing to end

face/output shaft.
Dim. I e.g. ...............................= 2.6 in (66.90 mm)
STEP 145
W270R371
Measure Dim. II, from plane face/housing to contact

face/ball bearing.
Dim. II e.g. .............................. = 2.5 in (64.20 mm)
Example:
W270R373
Dim. I ........................................ 2.6 in (66.90 mm)
Dim. II ......................................- 2.5 in (64.20 mm) Install the ball bearing and pull it until contact by means
Difference ...............................= 0.10 in (2.70 mm) of the output flange.
required axial play 0.011 ... 0.019 in Then remove the output flange again.
(0.3 ... 0.5 mm) e.g.................- 0.015 in (0.40 mm)
Resulting shim e.g. ........... s = 0.09 in (2.30 mm)

6003-70
STEP 148 Output Flange – Version with Parking
Brake
STEP 150
W270R374
Fasten the ball bearing by means of retaining ring.
STEP 149 W270R376
Press on the screen sheet (arrow) until contact.
STEP 151
W270R375
Remove the converter-side mounting tool again.

Install the shaft seal, (arrow) with the sealing lip
showing to the oil sump. W270R377
NOTE: Using of the specified mounting tool, results in the Install the output flange-brake disk until contact.
exact installation position (without retaining ring = 0.78 in
(20 mm)).
Grease the sealing lip.
ATTENTION: Depending on the version different shaft
seals can be used: Outer diameter rubber-coated – wet it
with spirit.
Outer diameter metallic – wet it with sealing compound
(Loctite, Type No. 574).

6003-71
Adjust gap size X = 0.011 ... 0.031 in STEP 154
(0.3 ... 0.8 mm) (Step 152 ... 155)
STEP 152
W270R380
Measure Dim. II, from the plane face to the collar of the
output flange.
Dim. II z.B. ........................... = 1.41 in (36.00 mm)
Example:
Dim. I .................................... 1.45 in (37.00 mm)
X Dim. II ..................................... 1.41 in (36.00 mm)
Difference............................. = 0.039 in (1.00 mm)
W270R378
Gap size X 0.011 ... 0.031 in (0.3 ... 0.8 mm)
e.g. ........................................ - 0.019 in (0.50 mm)
X = Gap size Resulting shim................. s = 0.019 in (0.50 mm)
1 = Shim
2 = O-Ring
STEP 155
STEP 153
W270R381
W270R379
Place the O-Ring (arrow) into the space between
output flange and shaft (see also Step. 152) and put on
Install the output flange until contact. the shim.
Measure Dim. I, from the plane face of the output
flange to the end face of the output shaft.
Dim. I e.g. ............................. = 1.45 in (37.00 mm)

6003-72
STEP 156 Mount the brake (Step 158 ... 162)
STEP 158
>13
W270R382
Put on the washer and fasten the output flange by

means of hexagon screws. W270R384
ATTENTION: For working on the brake system, the

Tightening torque ..........= 46 Nm (407 pound inch)
instructions and specifications of the brake manufacturer
are mandatory.
STEP 157
Remove the screw cap and loosen the locking nut.
Unscrew the adjusting screw in counterclockwise
direction until a Dim. > 0.51 in (13.0 mm) (brake disc
shim) results.
STEP 159
W270R383
Fasten the hexagon screws by means of the lock plate.
W270R385
Position the brake and fasten it with cap screws.

Tightening torque ..... = 125 Nm (1106 pound inch)

6003-73
Adjust the nominal clearance = 0.078 in STEP 162
(2.0 mm) (Step 160 ... 162)
STEP 160
W270R388
Put new O-Ring into the screw cap and grease it.
Install the screw cap.
W270R386
Make the pressure connection and apply the required

release pressure = 2175.5 psi (150 bar) to the brake
(cup spring set preloaded). Fasten the adjusting screw
in clockwise direction until both brake lining carriers
contact the brake disc (turning of the adjusting screw is
then not possible or admissible any more without a
higher application of force).
Then turn back the adjusting screw by 4/5 turns in
counterclockwise direction. 4/5 turns is equal to a
nominal clearance of 0.078 in (2.0 mm).
STEP 161
W270R387
Keep the adjusting screw positioned and fix it by means

of a lock nut.

6003-74
Output Flange (Converter Side) STEP 165
STEP 163 1
W270R391
1 = Screen sheet
W270R389 2 = Output flange
Install the shaft seal (arrow) with the sealing lip
showing to the oil sump. STEP 166
NOTE: Using of the specified mounting tool, results in the
exact installation position (with retaining ring
= 0.27 in (7.0 mm)). Grease the sealing lip.
ATTENTION: Depending on the version different shaft
seals can be used: Outer diameter rubber-coated – wet it
with spirit. Outer diameter metallic – wet it with sealing
compound (Loctite, Type No. 574).
STEP 164
W270R392
Install the output flange until contact.

NOTE: Setting of the gap size as well as fixing of the
output flange is identical with the installation of the output
flange at the transmission rearside.
W270R390
Press the screen sheet (arrow) over the collar of the

output flange until contact.
NOTE: Observe the installation position, see Step 165.

6003-75
Installation of the Idler shaft STEP 170
STEP 167
W270R396
Remove the adjusting screw and fasten the axle by

W270R393 means of hexagon screw.
Align the layshaft gear and the single components
NOTE: Wet the thread of the hexagon screw with Loctite
centrically.
(Type No. 243).
Heat the layshaft gearing.
STEP 168
STEP 171
W270R394
W270R397
Install the adjusting screw.
Insert the sealing covers (arrow), with the concave side
STEP 169 showing downwards, flush to the housing surface.
NOTE: Wet contact face with Loctite (Type No. 262).
W270R395
Install the idler shaft until contact.

6003-76
Transmission Pump STEP 175
STEP 172
W270R401
Install the ball bearing and driver respectively and

W270R398 press it until contact.
Press the needle sleeve (arrow), with the reinforced
NOTE: Pay attention to align the key to the keyway.
coating towards the press-in tool until contact.
STEP 176
STEP 173
W270R402
W270R399
Fasten the ball bearing by means of retaining ring.
Snap the V-Rings into the recess of the driver (internal
gearing). Install the key (arrow).
STEP 177
STEP 174
W270R403
W270R400
Install the O-Ring (arrow) and grease it.
Press the ball bearing over the collar of the driver until
contact.

6003-77
STEP 178 STEP 180
W270R404 W270R406
Heat the housing bore. Put the O-Ring (arrow) into the annular groove of the
pump flange.
STEP 179 NOTE: Depending on the transmission version,
differences as regards the version and fastening of the
pump flange are possible.
Obligatory is the respective spare parts list.
STEP 181
W270R405
Install two adjusting screws and assemble the pump

until contact.
W270R407
Fasten the pump flange and the pump respectively by

NOTE: Wet thread of both hexagon screws (position, see
arrows) with Loctite, Type No. 574 (through holes).
Then rotate the transmission housing by 90°.

6003-78
STEP 182 STEP 185
W270R408 W270R411
Snap-in and lock the rectangular ring (arrow). Install the input shaft until contact.
STEP 183 STEP 186
W270R409 W270R412
Install both shims (each 0.078 in (2.0 mm) thick). Fasten the input shaft by means of clamping plate and
cap screw (arrow).
NOTE: Use assembly grease.
STEP 184 NOTE: Wet thread of the cap screw with Loctite (Type No.
243).
W270R410
Heat the bevel bearing inner ring.

6003-79
Input – Converter Bell STEP 190
STEP 187
W270R416
Heat the spur gear bore (arrow).

W270R413
ATTENTION: To install a new converter bell the finished STEP 191

Installation position, see arrow.
STEP 188
W270R417
Install the input shaft until contact.
STEP 192
W270R414
Locate the bearing outer ring into the housing bore until
contact and install the bearing inner ring, see arrow.
STEP 189
W270R418

W270R415
Install the spur gear (arrow) with the long collar

showing upwards and position it.

6003-80
STEP 193 STEP 196
W270R419 W270R422
Install the bearing outer ring until contact. Press the needle bearing (arrow), with the reinforced
coating towards the press-in tool into the bore of the
STEP 194 bearing cover until contact.
STEP 197
W270R420
Snap in the rectangular ring (arrow) into the annular

groove of the input shaft and lock it. W270R423
Then grease the rectangular ring and centrally align it. Flush-mount the shaft seal (arrow) with the sealing lip
showing (downwards) to the oil sump.
STEP 195 NOTE: Wet the outer diameter with spirit. Grease the
sealing lip.
3 2
W270R421
Install the converter safety valve (arrow 1) and fasten it

by means of slotted pin (arrow 2).
NOTE: Flush-mount slotted pin to recess.
Put the O-Ring (arrow 3) into the annular groove.

6003-81
STEP 198 STEP 201
W270R424 W270R427
NOTE: Make the following steps (Step 198...201) in direct Put on the bearing cover and fasten it by means of
time sequence to secure the precise contact of the oil hexagon screws.
supply flange.
Heat the housing bore.
STEP 202
STEP 199
1 2
W270R428
W270R425 Install the single components according to the opposite

Install two adjusting screws and put in the oil supply figure.
flange until contact.
1 = Screw plug ......... = 150 Nm (1327.6 pound inches)
2 = Screw plug .............. = 25 Nm (221.2 pound inches)
STEP 200 3 = Temperature sensor = 25 Nm (221.2 pound inches)
and screw plug respectively (depending on
the version) ....... = 35 Nm (309.7 pound inches)
NOTE: Always install new O-Rings.
W270R426
Place the O-Ring (arrow) with assembly grease into the

annular groove of the bearing cover.
6003-82
Converter pressure back-up valve STEP 205
(Step 203 ... 204)
STEP 203
W270R431
Fasten the gasket and cover plate by means of

hexagon screws (install the washers).
W270R429
Tightening torque .......... = 9.5 Nm (84 pound inch)
Install the slotted pin 0.23 x 1.96 in (6 x 50 mm) until
contact.
STEP 206
STEP 204
W270R432
Install two adjusting screws and put on the gasket

W270R430
(arrow 1).
Assemble piston and compression spring. Put the O-Ring (arrow 2) into the annular groove.
Provide screw plug with a new O-Ring and install it.
Tightening torque ... = 130 Nm (1150.5 pound inch)

6003-83
STEP 207 STEP 209
W270R433 W270R435
Install the converter bell by means of lifting tackle until Fasten flexible plates by means of hexagon screws
contact. (install the washers).
NOTE: Slight rotary motions of the input shaft facilitate NOTE: Wet thread of the hexagon screws with Loctite
the installation (protect teeth from damage). (Type No. 243).
Observe the radial installation position.
STEP 208 STEP 210
W270R434
W270R436
Fasten the converter bell by means of hexagon screws.
Install the rectangular ring (arrow) into the annular
Tightening torque (M8/10.9) ..................... = 34 Nm groove and lock it.
................................................ (300.9 pound inch) Then grease the rectangular ring and centrally align it.
Tightening torque (M12/10.9) ................. = 115 Nm
.............................................. (1017.8 pound inch)

6003-84
STEP 211 Coarse Filter
STEP 213
W270R439
Install filter (assy) into the housing bore.

ATTENTION: Oil the sealing (arrow).
STEP 214
W270R437
Assemble converter by means of lifting tackle until

contact.
NOTE: At a control dimension < 1.69 in (43 mm), the
exact installation position of the converter is ensured.
STEP 212
W270R440
Fasten the cover by means of hexagon screws (install

the washers).
NOTE: Install the new O-Ring (arrow).
Tightening torque ...... = 23 Nm (203.5 pound inch)
W270R438
ATTENTION: Until installation of the transmission, fix

the converter axially.

6003-85
Inductive and Speed Transmitters STEP 216
STEP 215
5 13
14
W270R442
13 = Speed transmitter n – Output

W270R441
Following sketches show the installation position of the STEP 217

single inductive and speed transmitters.
14 = Inductive transmitter n – Turbine
9 = Inductive transmitter n – Engine
5 = Inductive transmitter n – int. speed input
"S"
"A"
I
X
W270R443
NOTE: The following figures describe the installation and

setting respectively of the inductive transmitter n – Engine
(9). Installation of the inductive transmitter n – Turbine (14)
and n – internal speed input (5) is to be made analogously.
Observe the different setting dimensions “X”:
ATTENTION:
Inductive transmitter n – Engine (9) X = 0.019 + 0.011 in
(0.5 + 0.3 mm)
Inductive transmitter n – Turbine (14) X = 0.019 + 0.011 in
(0.5 + 0.3 mm)
Induct. transmitter n – int. speed input (5) X = 0.011 ±
0.0039 in (0.3 ± 0.1 mm).

6003-86
Adjust Dim. „X" by means of shim ring STEP 220
(Step 218 ... 222)
STEP 218
W270R447
Turn out the plug gauge and determine Dim. II (also

see Step 219).
W270R444
Dim. II e.g........................... = 1.185 in (30.10 mm)
Measure Dim. I on the inductive transmitter, from
contact face to screw-in face. Example “A1”:
Dim. I e.g. .............................= 1.18 in (30.00 mm) Dim. II.................................... 1.185 in (30.10 mm)
Dim. X 0.019 + 0.011 in
STEP 219 (0.5 + 0.3 mm) ....................... - 0.023 in (0.60 mm)
results in installation
dimension A ......................... = 1.16 in (29.50 mm)
Example “A2”:
Dim. I.................................... 1.181 in (30.00 mm)
Installation dimension A......... - 1.16 in (29.50 mm)
results in shim ring .........s = 0.019 in (0.50 mm)
STEP 221
II
W270R448
Install the adequate shim ring and wet the thread

(arrow) with Loctite (Type No. 574).
W270R445
Turn in the counting disc radially until one tooth tip is

centrally to the inductive transmitter bore. Turn the plug
gauge until contact. Locate anvil at the tooth tip and
lock it by means of threaded pin.

6003-87
STEP 222 STEP 224
W270R449 W270R451
Install the inductive transmitter n – Engine (9), see Opposite figure shows the speed transmitter (Hall
arrow. sensor).
Tightening torque ....... = 30 Nm (265.5 pound inch)
STEP 225
Set and install the inductive transmitter n – Turbine (14)
and n-internal speed input (5) analogously.
NOTE: Observe the different setting dimensions.
Installation position of the single inductive transmitters,
also see Step 215 and 216.
Install speed transmitter n –

Output/Speedo (13) (Step 223... 228)
STEP 223
X
W270R452
2 Determine Dim. I, from the housing face to spur gear
13
K3.
1
Dim. I e.g.............................. = 1.56 in (39.70 mm)
3
STEP 226
W270R450
1 = Housing
2 = Spur gear K3
3 = Disc carrier
13 = Speed transmitter (Hall sensor)
X = Setting dimension “X” = 0.039 + 0.019 in (1.0 +
0.5 mm)
W270R453
Measure Dim. II, from the contact face to the mounting

face.
Dim. II e.g............................. = 1.57 in (40.00 mm)

6003-88
STEP 227 STEP 229
W270R454 W270R456
Example “B1”: Flush-mount cup (arrow) to the housing face and install
the breather.
Dim. I ....................................... 1.56 in (39.70 mm)
Dim. X 0.039 + 0.019 in Tightening torque
(1.0 + 0.5 mm) ........................ - 0.04 in (1.20 mm) (breather) .................. = 12 Nm (106.2 pound inch)
results in installation dimension.. = 1.51 in (38.50 mm) NOTE: Wet the sealing surface of the cup with Loctite
Example “B2”: (Type No. 262).
Dim. II ..................................... 1.57 in (40.00 mm)

STEP 230
Installation dimension A .........- 1.51 in (38.50 mm)
results in shim................. s = 0.059 in (1.50 mm) 1
Install shims (3x, s = 0.019 in (0.50 mm)) and grease
the O-Ring (arrow).
STEP 228 2
W270R457
Provide both screw plugs (arrow 1 and 2) with a new

O-Ring and install them.
Tightening torque ....... = 100 Nm (885 pound inch)
Tightening torque ..... = 145 Nm (1283 pound inch)
W270R455
Provide the adapter (arrow 3) with a new O-Ring and
Fasten the speed transmitter by means of cap screw. install it.
Tightening torque .......= 23 Nm (203.5 pound inch)
NOTE: Installation position of the speed transmitter, also
see Step 215 and 216.

Section
6004
6004
FRONT AXLE

Via Plava, 80
6004-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
LEAKAGE TEST OF THE BRAKE HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6004-3
SPECIAL TOOLS
Planetary bearing puller collet set .............................................................................................................380001757
Brake housing seal installer.......................................................................................................................380001574
Differential bearing cone puller collet set...................................................................................................380001569
Differential bearing preload wrench...........................................................................................................380001565
Brake housing inner bearing cup installer .................................................................................................380001572
Brake housing outer bearing cup installer .................................................................................................380001573
Wear ring installer adapter ........................................................................................................................380001754
Wear ring installer adapter .......................................................................................................................380001755
Pinion depth gauge set..............................................................................................................................380001570
Pinion depth gauge block ..........................................................................................................................380001753
Puller body and screw ...............................................................................................................................380001575
Support bracket .........................................................................................................................................380001576
Slide hammer puller adapter .....................................................................................................................380001545
Slide hammer ............................................................................................................................................380001582
Replacer ....................................................................................................................................................380001552
Magnetic base with indicator .....................................................................................................................380001725
Heat gun ....................................................................................................................................................380001544
Lifting sling.................................................................................................................................................380001579
Engine stand..............................................................................................................................................380001580
Snap ring pliers..........................................................................................................................................380001584
Snap ring pliers..........................................................................................................................................380001583
Snap ring pliers..........................................................................................................................................380001585
Step plate set (includes 380001539, 380001541, and 380001542) ............................................................OEM4288
Step plate ..................................................................................................................................................380001539
Step plate ..................................................................................................................................................380001541
Step plate ..................................................................................................................................................380001542
Hexagonal wrench 4.1 in (105 mm)...........................................................................................................380003004
Lifting devise..............................................................................................................................................380002303
Clamping devise ........................................................................................................................................380001564
Assembly fixture ........................................................................................................................................380100001

6004-4
SPECIFICATIONS
Axle supplied with hydraulic avtivated locking differentials
Overall width ................................................................................................................................. 2493 mm (98 inch)
Track........................................................................................................................................... 2550 mm (88.5 inch)
Distance flange to flange ............................................................................................................... 2314 mm (91 inch)
Mounting pad center to center.................................................................................................... 1041 mm (40.9 inch)
Mounting pad height .......................................................................................................................112 mm (4.4 inch)
Wheel mounting bolt circle Dia. .................................................................................................... 500 mm (19.6 inch)
Wheel mounting studs 23
Hub pilot Dia. ................................................................................................................................ 448 mm (17.6 inch)
Input flange joint centerline to be.................................................................................................. 399 mm (15.7 inch)
Axle filled with 20W-40 Oil
SPECIAL TORQUES
Bolts Securing Wheel End to Axle Housing......................................................................... 560 Nm (413 pound feet)
Nut Securing Input Flange (Apply Loctite 262 to Threads)................................................1200 Nm (885 pound feet)
Bolts Securing Differential Ring Gear.................................................................................. 560 Nm (413 pound feet)
Bolts Securing Axle Housing to Center Section .................................................................. 560 Nm (413 pound feet)
Locknut Securing Planetary Carrier.................................................................................. 500 Nm (368.7 pound feet)

6004-5
GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased
BS01D011 BS01D009
COAST SIDE (CONCAVE)
BS01D013
BS01D012
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)

6004-6
Pinion Distance Must Be Decreased
BS01D016
BS01D010 DRIVE SIDE (CONVEX)
BS01D015

6004-7
LUBRICATION
3
5
2
4
1 1
2
W230R550
1. OIL DRAIN HOLE (AXLE HOUSING) 3. OIL FILL HOLE 5. BLEEDER

2. OIL DRAIN HOLE (OUTPUTS) 4. BRAKE BLEEDER
WEAR MEASUREMENT ON MULTI-DISC BRAKE
BD00M234 BS00M071
NOTE: A wear measurement on the multi-disc brake has to be made at least once a year, especially in case of a changed braking
behavior.
A wear measurement has to be made on both wheels ends.
Remove crew plug, actuate brake and determine dimension “X” using a feeler guage.
If dimension “X” is less than or equal to 4.0 mm (0.16 in) the lined discs on both output sides have to be replaced.
Replace O-ring when installing the level plug. Tighten plug to 70 Nm (52 pond-feet).

6004-8
DISASSEMBLY
Output and brake STEP 3
STEP 1
W230R445
Remove the breather valve (see arrow).

W230R551
Fix axle to assembly truck. STEP 4

ATTENTION: Before clamping the axle fully turn in the
support. Position axle first onto the two fixtures, secure
with clamping brackets and then unbolt the support until
contact with the axle is obtained.
STEP 2
W230R553
Secure the output with the lifting device 380002303

and loosen hexagon screws.
Then separate the output assy from the axle housing.
STEP 5
W230R447
W230R552
Pull stub shaft and sun gear shaft.
Loosen screw plugs and drain oil from the axle.
NOTE: Pay attention to potentially releasing shim.

6004-9
STEP 6 STEP 9
W230R448 W230R451
Fix output to assembly truck. Press planetary carrier with a two-armed puller out of
the profile of the output shaft.
STEP 7
STEP 10
W270R459
Use a lever to remove the cover from the output W230R452
shaft. Lift the planetary carrier out of the brake housing by

means of the lifting device 380001578.
STEP 8
STEP 11
W270R460
Loosen locking screws and remove the releasing W230R453
cover. Pull the tapered roller bearing from the planetary

carrier.

6004-10
STEP 12 STEP 15
W230R454 W230R457
Disengage retaining ring. Lift the disk package out of the brake housing.
STEP 13 STEP 16
W230R455 W230R458
Pull off planetary gear. Loosen hexagon screws, remove releasing cover
and cup spring.
STEP 14
STEP 17
W230R456
Lift the end plate out of the brake housing. W230R459
Mount breather valve and press piston out of the

brake housing by means of compressed air.

6004-11
STEP 18 STEP 19
W230R460
If necessary, remove guide ring, back-up rings and

grooved rings out of the annular grooves of the brake
housing (see arrows).
NOTE: For the installation position of the single parts
please also refer to the following sketch.
W270R461
Legend to sketch:
1 = Brake housing
2 = Guide ring
3 = Back-up ring
4 = Grooved ring
5 = Grooved ring
6 = Back-up ring
7 = Slide ring seal
8 = Output shaft
STEP 20
W230R462
Lift the brake housing from the output shaft by means

of the lifting device.

6004-12
STEP 21
W230R463
Use a lever to remove the slide ring seal from the

brake housing.
STEP 22
W230R464

output shaft.
STEP 23
W230R465
Pull the tapered roller bearing from the output shaft.

6004-13
Axle Housing STEP 26
STEP 24
W230R468
Loosen screw neck.

W230R554
Secure axle housing with the lifting device and

loosen the hexagon screws.
Then separate the axle housing from the axle drive
housing.
NOTE: Pay attention to releasing differential.
STEP 25
W230R467
Loosen the threaded connections and remove the

releasing brake tube.

6004-14
Disassembly axle drive housing STEP 30
STEP 27
W270R465
Pull the bearing outer ring (see arrow) out of the

W270R462 bearing hole and remove the shim behind.
Secure axle drive housing with the lifting device (S)
and loosen the hexagon screws. STEP 31
Then separate the axle drive housing from the axle
housing.
STEP 28
W270R466
Press the piston out of the bearing housing by means

of compressed air.
W270R463 STEP 32
Fix axle drive housing to the assembly truck.
STEP 29
W270R467
Lift differential out of the axle drive housing with the

lifting device.
W270R464
Loosen cylindrical screws and lift the releasing

bearing housing with the lifting device.

6004-15
STEP 33 STEP 36
W270R468 W270R471
Pull the bearing outer ring (see arrow) out of the Pull input flange from the input pinion and use a lever
bearing hole and remove the shim behind. to lift the shaft seal ring behind out of the axle drive
housing.
STEP 34
STEP 37
W270R469
Heat slotted nut by means of hot-air blower. W270R472
Use a two-armed puller to press the input pinion out

NOTE: Slotted nut is secured with Loctite (Type no.: 262).
of the axle drive housing and remove the releasing
tapered roller bearing.
STEP 35
STEP 38
W270R470
Loosen the slotted nut and remove the shim behind.

W270R473
Remove the spacer and pull the tapered roller

bearing from the input pinion.

6004-16
STEP 39
W270R474
Loosen the threaded connection and remove the

releasing oil tube.
STEP 40
W270R475
If necessary pull the internal bearing outer ring out of

the axle drive housing and remove the shim behind.
STEP 41
W270R476
If necessary pull the external bearing ring out of the

axle drive housing.

6004-17
Disassembly differentials STEP 45
Disassembly multi-disk differential lock
STEP 42
W270R480
Lift the differential cover from the differential housing

by means of the lifting device.
W270R477 STEP 46
Remove axial roller cage (arrow).
STEP 43
W270R481
Preload the compression spring by means of the

press and disengage the retaining ring.
W270R478
Then pull the sliding sleeve out of the differential
Pull both tapered roller bearings from the differential.
cover and remove the releasing compression
springs.
STEP 44
W270R479
Preload the differential by means of the press and

loosen the locking screws.

6004-18
STEP 47 STEP 49
W270R482 W270R484
Remove single parts. Remove thrust washer and axle bevel gear from the
differential housing.
1 = Disk
2 = Pressure piece
3 = Cage STEP 50
4 = Lever
5 = Disk carrier
6 = Disk package
STEP 48
W270R485
Force out slotted pins.
STEP 51
W270R483
Loosen hexagon screws and remove the releasing

disk.
W270R486
Pull spider shafts and remove the releasing spider

gears with the thrust washers from the differential
housing.

6004-19
STEP 52
W270R487
Remove the axle bevel gears and the shims behind.
STEP 53
W270R488
Support the crown wheel and force out the


6004-20
REASSEMBLY
Reassembly differentials STEP 3
Reassembly multi-disk differential lock
STEP 1
W270R487
Insert axle bevel gear.
STEP 4
W270R489
Mount two adjusting screws and press the heated

crown wheel onto the differential housing until
contact is obtained.
STEP 2
W270R491
Insert spider gears with thrust washers into the

differential housing and fix them with the spider shaft.
NOTE: Thrust washers must be positioned with the tabs
(see arrow 1) in the recesses of the differential housing.
W270R490 NOTE: Pay attention to radial installation position of the
Insert disk and thrust washer into the differential spider shafts (fixing holes, arrow 2).
housing.

6004-21
STEP 5 Setting of disk package
STEP 8
8
7
6
5
4
3
2
1
W270R485
Fix spider shafts with slotted pins (2 pieces / hole).

W270R493
NOTE: Press the slotted pins with 180° offset openings
into flush position. Premount single parts according to the adjacent
sketch.
STEP 6 1 = Differential cover
2 = Pressure piece
3 = Disk
4 = Cage
5 = Lever
6 = End plate
7 = Outer disks (optional)
8 = Inner disks
STEP 9
W270R484
Mount second axle bevel gear and thrust washer.
STEP 7
W270R494
Preload disk package with an axial force of F = 7 t.

Then check the setting dimension “A” = 0.61-0.0078 in
(15.5 -0.2 mm) from the mounting face of the
differential cover to the plane face of the outer disk
(see also below sketch).
W270R492
Mount disk and fix it with hexagon screws.

Tightening torque.................50 Nm (36.8 pound feet)

6004-22
STEP 10 STEP 13
W270R495 W270R498
A = Setting dimension = 0.61-0.0078 in (15.5 -0.2 mm). Mount outer and inner disks.
NOTE: For the number of disks and disk arrangement
STEP 11 please refer to the relating spare parts list.
ATTENTION: Pay attention to the radial installation
position of the disk package, as shown on the adjacent
figure.
STEP 14
W270R496
Engage the snap ring (see arrow) into the annular

groove of the disk carrier.
STEP 12
W270R499
Insert end plate.
STEP 15
W270R497
Insert the premounted disk carrier onto the axle bevel

gear.
W270R500
Mount cage and lever.

6004-23
STEP 16 STEP 19
W270R501 W270R481
Insert pressure piece (see arrow) and install disk. Preload the compression springs by means of the
press and engage the retaining ring into the annular
STEP 17 groove of the sliding sleeve.
STEP 20
W270R502
Insert compression springs into the differential cover.

W270R480
STEP 18 Mount two adjusting screws and insert the differential

cover by means of the lifting device.
STEP 21
W270R503
Insert sliding sleeve.
W270R504

bolt with new locking screws.
Tightening torque ............= 400 Nm (295 pound feet)

6004-24
STEP 22 Determination of shim thickness
to obtain a correct contact pattern
STEP 25
The following measuring procedures must be carried
out with utmost accuracy. Inaccurate measurements
lead to an incorrect contact pattern requiring an
additional disassembly and reassembly of input
pinion and differential.
STEP 26
W270R505
Heat both tapered roller bearings and insert until

NOTE: Adjust tapered roller bearing after cooling down.
STEP 23
W270R506
Read dimension I from the axle drive housing.

Dimension I e.g. ............................13 in (331.25 mm)
STEP 27
W270R477
Insert axial roller cage (see arrow).
Reassembly axle drive housing
STEP 24
If crown wheel or input pinion are damaged, both
parts must be jointly replaced.
In case of a new installation of a complete bevel gear W270R507
set pay attention to an identical mating number of Read dimension II (pinion dimension).
input pinion and crown wheel.
Dimension II e.g. ........................10.4 in (265.00 mm)

6004-25
STEP 28 STEP 30
W270R508 W270R510
Determine dimension III (bearing width). Insert the determined shim e.g. s = 0.10 in (2.60 mm)
into the housing hole.
Dimension III e.g............................ 2.5 in (63.60 mm)
CALCULATION EXAMPLE “A”: STEP 31
Dimension I................................... 13 in (331.25 mm)
Dimension II............................... - 10.4 in (265.0 mm)
Dimension III................................ - 2.5 in (63.60 mm)
Difference = shim...................s = 0.10 in (2.60 mm)
Reassembly of input pinion
STEP 29
W270R511
Undercool the internal bearing outer ring and bring it

into contact position in the housing hole by using the
assembly fixture.
STEP 32
W270R509
Undercool the external bearing outer ring and insert it

into the axle drive housing until contact is obtained.
W270R512
Heat the tapered roller bearing and insert it into the

input pinion until contact is obtained.

6004-26
STEP 33 STEP 35
W270R513 W270R515
Setting of rolling torque of input pinion Press the protection plate onto the input flange (see
bearing 1.0 ... 5.0 Nm (0.7...3.6 pound feet) arrow) until contact is obtained.
(without shaft seal ring) NOTE: Do not fit the shaft seal ring until the contact
pattern has been checked (page 31).
Insert spacer e.g. s = 0.28 in (7.13 mm).
NOTE: According to our experience the necessary rolling STEP 36
torque is obtained when reusing the spacer which has been
removed during disassembly e.g. s = 0.28 in (7.13 mm). A
later check of the rolling torque, however, is absolutely
necessary.
STEP 34
W270R516
Insert input flange and fix it by means of disk and

slotted nut.
Tightening torque ..........= 1200 Nm (885 pound feet)
NOTE: Preliminarily mount slotted nut without Loctite.
W270R514
ATTENTION: While tightening rotate the input pinion
Insert the preassembled input pinion into the axle several times in both directions.
drive housing and insert the heated tapered roller
bearing until contact is obtained.

6004-27
STEP 37 STEP 39
W270R517 W270R519
Check rolling torque (1.5 ... 5.0 Nm (1.1 ... 3.6 pound Mount oil tube.
feet) without shaft seal ring).
Tightening torque ...........= 100 Nm (73.7 pound feet)
NOTE: When installing new bearings try to achieve the
upper value of the rolling torque. STEP 40
ATTENTION: In case of deviations from the necessary
rolling torque correct with a corresponding spacer (STEP
33) as specified below.
Insufficient rolling torque - install thinner spacer ring.
Excessive rolling torque - install thicker spacer ring.
STEP 38
W270R520
Grease O-rings (see arrows) and insert them into the

annular grooves of the piston.
STEP 41
W270R518
Mount threaded connection.

Tightening torque............= 100 Nm (73.7 pound feet)
W270R465
Insert piston (see arrow) into the bearing housing

until contact is obtained.

6004-28
Setting Backlash and Bearing

Preload
Crow wheel marking -30 -20 -10 0 10 20
Deviation -0.3 -0.2 -0.1 0 0.1 0.2
Shim
Diff. cage side 1.1 1.2 1.3 1.4 1.5 1.6
Shim thickness
Shim
Crown wheel side 1.7 1.6 1.5 1.4 1.3 1.2
Shim thickness
STEP 42 STEP 43
1 3
2 4
W270R521 W270R522
Deviation see crown wheel rear side. Legend to sketch:

The test dimension “108” is stamped into the crown 1 = Bearing housing
wheel rear side. If no + or – deviation is indicated, 2 = Shim (crown wheel side)
this value corresponds to the actual value ”O” in the 3 = Shim (diff. carrier side)
table below. 4 = Axle housing
According to this value, the required shims are
allocated in the table below. STEP 44
Any + or – deviation of the test dimension caused by
production is also marked on the crown wheel rear
side (e.g. - 20 or - 10 or 10 or 20) . In accordance
with this deviation, the required shims are allocated
in the table below.
W270R523
Insert the determined shim e.g. s = 0.055 in (1.4 mm)

into the hole of the axle drive housing and reset until
contact with the bearing outer ring is obtained.

6004-29
STEP 45 STEP 47
W270R467 W270R525
Cover some drive and coast flanks of the crown Place the premounted bearing housing onto the axle
wheel with marking ink. drive housing by means of the lifting device.
Then insert the premounted differential into the axle
NOTE: Preliminarily mount the bearing housing without
drive housing.
O-ring.
STEP 46 STEP 48
W270R524
W270R526
Insert the determined shim e.g. s = 0.055 in (1.4 mm)
Fix the bearing housing by means of cylindrical
into the bearing housing and reset the bearing outer
screws.
ring until contact is obtained.
Tightening torque .............= 50 Nm (36.8 pound feet)

6004-30
Leakage test of lock STEP 51
STEP 49
W270R467
After the contact pattern check insert the differential

W270R527 again into the axle drive housing.
Pressurize the lock = 1 bar (14.5 psi), close shut-off
valve and remove air line.
ATTENTION: No noticeable pressure loss is allowed to
occur within 10 sec.
STEP 50
W270R464
By rotating the input flange, roll crown wheel over the

input pinion in both directions several times.
Then remove the bearing housing again and lift the
differential out of the axle drive housing.
ATTENTION: In case of any contact pattern deviation, a
measuring error was made when determining the shim
(STEP 30), which must be corrected by all means.

6004-31
Reassembly of shaft seal ring STEP 54
(STEP 52 … 54)
STEP 52
W270R529
Insert input flange and finally tighten by means of

disk and slotted nut.
W270R470 Tightening torque ..........= 1200 Nm (885 pound feet)
Loosen slotted nut and pull the input flange from the
input pinion. ATTENTION: Cover the thread of the slotted nut with
Loctite (Type no.: 262).
STEP 53
STEP 55
W270R528
W270R530
Mount the shaft seal ring with the seal lip showing to
the oil chamber. Grease O-ring (see arrow) and insert it into the
annular groove of the bearing housing.
NOTE: The exact installation position of the shaft seal ring
is obtained when using the specified driver tool.
ATTENTION: Wet the outer diameter of the shaft seal
ring with spirit directly before installation and fill the space
between seal and dust lip with grease.

6004-32
STEP 56 STEP 58
W270R531 W270R533
Insert the bearing housing by means of the lifting Mount two adjusting screws and bring axle drive
device and finally tighten it with cylindrical screws. housing in contact position with the axle housing by
using the lifting device.
Tightening torque..............= 50 Nm (36.8 pound feet)
Then fix the axle drive housing with hexagon screws.
STEP 57 Tightening torque ............= 560 Nm (413 pound feet)
ATTENTION: After mounting the axle drive housing
unbolt the support until contact is obtained.
W270R532
Grease O-rings (see arrows) and insert them on both

sides of the axle drive housing.

6004-33
Reassembly axle housing STEP 61
STEP 59
W270R536
Mount two adjusting screws and bring the axle

W270R534 housing into contact position with the axle drive
Mount both fittings. housing by using the lifting device.
Then fix the axle housing by means of hexagon
Tightening torque..............= 36 Nm (26.5 pound feet) screws.
STEP 60 Tightening torque ............= 560 Nm (413 pound feet)

ATTENTION: After assembling the axle housing secure
the axle with clamping brackets.
W270R535
Mount brake tube.


6004-34
Output and Brake STEP 64
STEP 62
W230R524
Wet O-ring of slide ring seal and locating hole with

W230R522 spirit.
Pull in wheel stud into the output shaft until contact is Snap new slide ring seal into the output shaft.
obtained. Then mount new slide ring seal accordingly into the
brake housing.
STEP 63 NOTE: For the installation position of the seal please also
refer to sketch STEP 70.
STEP 65
W230R523
Heat tapered roller bearing and insert it into the

output shaft until contact is obtained.
W230R525
ATTENTION: The surface of the slide ring seal may not

have any grooves, scratches or other types of damage.
Take care that the sealing surface is parallel to the housing
face.
The O-rings must be mounted evenly into the locating hole
and must not bulge out of the hole.
Risk of injury - Metal rings have extremely sharp edges.
Wear protective gloves.

6004-35
STEP 66 STEP 68
W230R526 W230R460
Insert both bearing outer rings (see arrows) into the Insert back-up rings and grooved rings into the
brake housing until contact is obtained. annular grooves of the brake housing (see arrows).
NOTE: Pay attention to the installation position; please
STEP 67 also refer to sketch STEP 70.
STEP 69
W230R462
Insert the premounted brake housing by means of

the lifting device over the output shaft until contact is
W230R527
obtained.
Clean the annular groove of the brake housing with
ATTENTION: Before clamping the seal rings (slide ring spirit.
seal) to installation dimension, clean the sliding surfaces Then insert the guide ring into the annular groove
and apply an oil film. We recommend to use a leather cloth (see also the following sketch) and fix it with Loctite
soaked with oil. (type no.: 415) at its extremities (see arrows).
NOTE: The full circumference of the guide ring must be in
an exact contact position.
ATTENTION: Upon installation the orifice of the guide
ring must show upwards (12 o’clock).

6004-36
STEP 70 STEP 72
W270R546
Insert disk and cup spring with the convex side

showing upwards into the piston.
STEP 73
W270R461
Legend to sketch:
1 = Brake housing
2 = Guide ring
3 = Back-up ring
4 = Grooved ring
5 = Grooved ring W230R531
6 = Back-up ring Insert cover and fix it by means of hexagon screws.
7 = Slide ring seal
8 = Output shaft Tightening torque ................= 34 Nm (25 pound feet)
STEP 71 STEP 74
W230R529 W230R457
Insert the piston into the brake housing and carefully Mount outer and inner disks.
install with the fixing device until contact is obtained. NOTE: For the number of disks and the disk arrangement
please refer to the relating spare part list.

6004-37
STEP 75 STEP 77
1
2
W230R456 W270R551
Insert end plate. Press stop bolt into the planetary carrier until contact
is obtained.
STEP 76 Legend to sketch:
1 = Stop bolt
2 = Cover
3 = Planetary carrier
STEP 78
1 2
W270R550 4
Setting of installation dimension 2.25 … 2.27 in
(57.25 … 57.79 mm)
Measure installation dimension from the mounting
face of the brake housing to the front face of the end
plate. W230R533
Insert the cylindrical roller bearing into the planetary

Installation dimension e.g. ........... 2.26 in (57.50 mm)
gear – for this purpose press the cylindrical roller
NOTE: Any deviation from the necessary installation bearing through the packaging sleeve until the snap
dimension must be corrected with an approppriate outer ring engages into the annular groove of the planetary
disk (see spare parts list). gear.
1 = Cylindrical roller bearing
2 = Packaging sleeve
3 = Snap ring
4 = Planetary gear

6004-38
STEP 79 STEP 81
1
2
W230R454 W230R535
Heat bearing inner rings and insert the premounted Wet front face (contact face bearing inner ring, arrow
planetary gears with large radius facing the planetary 1) and profile (teeth, arrow 2) in the output shaft with
carrier (downwards) until contact is obtained. anti-corrosive agent.
NOTE: Adjust bearing inner rings after cooling down.
STEP 82
Then fix planetary gears by means of retaining rings.
STEP 80
W230R452
Align disk package centrally and radially.

Then insert the planetary carrier by means of the
W230R534 lifting device into the teeth of the output shaft.
Heat tapered roller bearing and install it to the
planetary carrier until contact is obtained.

6004-39
STEP 83 STEP 85
W230R537 W230R539
Pivot output 90°. Insert the cover into the output shaft until contact is
Insert disk and fix planetary carrier with new locking obtained.
screws.
ATTENTION: Tighten locking screws successively with a STEP 86
tightening torque of 200 Nm (147.5 pound feet).
Then retighten the locking screws successively with a
STEP 84
2
W230R540
Determine dimension I, from the mounting face of the

brake housing to the front face of the stop bolt.
1
Dimension I ....................................2.3 in (58.60 mm)
W230R538
Install O-ring (see arrow 1) to the cover (2).

NOTE: Use new cover and O-ring.

6004-40
STEP 87 STEP 89
W230R541 W230R543
Insert stub shaft into the teeth of the axle bevel gear Measure dimension II, from the front face of the sun
until contact is obtained. gear shaft to the mounting surface of the axle
housing.
ATTENTION: Pay attention to the installation position;
mount the stub shaft with the long teeth showing to the Dimension II ...................................2.2 in (56.60 mm)
differential.
CALCULATION EXAMPLE:
STEP 88 Dimension I ...................................2.3 in (58.60 mm)
Dimension II ................................ - 2.2 in (56.60 mm)
Difference .........................................0.1 in (2.00 mm)
Required axial play........................ - 0.4 in (1.00 mm)
Difference = shim e.g. ................s = 0.4 in (1.00 mm)
STEP 90
W230R542
Insert the sun gear shaft until contact is obtained.
W230R544
Insert sun gear shaft into the planetary carrier.

6004-41
STEP 91 STEP 94
W230R545 W230R588
Fix determined shim(s) e.g. s = 0.4 in (1.00 mm) with Mount two adjusting screws and use the lifting device
grease into the sun gear shaft. to 380002303 bring the output into contact position
with the axle housing.
STEP 92 Then fix the output by means of hexagon screws.
STEP 95
W230R546
Fix O-ring (see arrow) with grease into the

countersink of the brake housing.
STEP 93 W230R548
Mount breather (see arrow).
W230R547
Grease O-ring (see arrow) and install it to the axle

housing.

6004-42
BRAKE HYDRAULICS LEAKAGE TEST

IMPORTANT: DO NOT EXCEED 100 BAR (1450 PSI) High Pressure Test
PRESSURE IN THE FOLLOWING STEPS.
STEP 97
STEP 96
Operate the hand pump to increase pressure to 100
bar (1450 psi) maximum. Close connection to hand
pump using the shutoff valve. During a 5 minute
period, pressure shall not drop more than 2 bar (29
psi).
Low Pressure Test

STEP 98
Reduce pressure to 5 bar (72.5 psi) and close the
shutoff valve. During a 5 minute period pressure shall
not drop.
W230R589
STEP 99
Connect a hand pump with pressure gauge to the
Check operability of DHL
brake port as shown above. 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.
W230R590
Build up pressure p = 20 bar max. (290 psi) and

close connection to HP pump via shut-off valve.
Lock on:
When rotating the input flange, both outputs must
have the same direction of rotation.
Lock off:
When rotating the input flange one side has no
movement or has the opposite direction of rotation.

Section
6004
6004
REAR AXLE

Via Plava, 80
6004-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GEAR TOOTH CONTACT PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WEAR MEASUREMENT ON MULTI-DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
BRAKE HYDRAULICS LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6004-3
SPECIFICATIONS
Axle supplied with open differentials
Overall width ..............................................................................................................................2476 mm (97.4 inch)
Track...........................................................................................................................................2250 mm (88.5 inch)
Distance flange to flange ...............................................................................................................2314 mm (91 inch)
Wheel mounting bolt circle Dia. ....................................................................................................500 mm (19.6 inch)
Wheel mounting studs 23
Hub pilot Dia. ................................................................................................................................448 mm (17.6 inch)
Input flange joint centerline to be..................................................................................................399 mm (15.7 inch)
Axle filled with 20W-40 Oil
SPECIAL TORQUES
Bolts Securing Wheel End to Axle Housing......................................................................390 Nm (287.6 pound feet)
Nut Securing Input Flange (Apply Loctite 262 to Threads)................................................1200 Nm (885 pound feet)
Bolts Securing Differential Ring Gear..................................................................................560 Nm (413 pound feet)
Bolts Securing Axle Housing to Center Section ..................................................................560 Nm (413 pound feet)
Locknut Securing Planetary Carrier..................................................................................500 Nm (368.7 pound feet)
SPECIAL TOOLS
Planetary bearing puller collet set .............................................................................................................380001757
Brake housing seal installer.......................................................................................................................380001574
Differential bearing cone puller collet set...................................................................................................380001569
Differential bearing preload wrench...........................................................................................................380001565
Brake housing outer bearing cup installer .................................................................................................380001573
Wear ring installer adapter ........................................................................................................................380001754
Wear ring installer adapter .......................................................................................................................380001755
Pinion depth gauge set..............................................................................................................................380001570
Pinion depth gauge block ..........................................................................................................................380001753
Puller body and screw ...............................................................................................................................380001575
Support bracket .........................................................................................................................................380001576
Slide hammer puller adapter .....................................................................................................................380001545
Slide hammer ............................................................................................................................................380001582
Replacer ....................................................................................................................................................380001552
Magnetic base with indicator .....................................................................................................................380001725
Heat gun ....................................................................................................................................................380001544
Lifting sling.................................................................................................................................................380001579
Engine stand..............................................................................................................................................380001580
Snap ring pliers..........................................................................................................................................380001584
Snap ring pliers..........................................................................................................................................380001583
Snap ring pliers..........................................................................................................................................380001585
Step plate set (includes 380001539, 380001541, and 380001542) ............................................................OEM4288
Step plate ..................................................................................................................................................380001539
Step plate ..................................................................................................................................................380001541
Step plate ..................................................................................................................................................380001542
Hexagonal wrench 4.1 in (105 mm)...........................................................................................................380003004
Lifting devise..............................................................................................................................................380002303
Clamping devise ........................................................................................................................................380001564
Assembly fixture ........................................................................................................................................380100001

6004-4
GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased
BS01D011 BS01D009
BS01D013
BS01D012
DRIVE SIDE (CONVEX)
BS01D014
DRIVE SIDE (CONVEX)

6004-5
Pinion Distance Must Be Decreased
BS01D016
BS01D010 DRIVE SIDE (CONVEX)
BS01D015

6004-6
LUBRICATION
7
4
6
5
6
7 2
3
W270R084
1. OIL DRAIN HOLE (AXLE HOUSING) 4. BRAKE BLEEDER 7. WEAR CHECK FOR MULTIPLE DISK BRAKE
2. OIL DRAIN HOLE (OUTPUTS) 5. BREATHER
3. OIL FILLING AND OIL LEVEL CHECK 6. BRAKE INLET
NOTE: Refer to section 1002 of this service manual for proper lubricant.
WEAR MEASUREMENT ON MULTI-DISC BRAKE
BD00M234 BS00M071
NOTE: A wear measurement on the multi-disc brake must be made at least once a year. Wear measurement should also be
made if brake noise is heard, if braking power is reduced, or anytime it is suspected that braking function is impaired.
Wear measurement must be made on both wheel end sides.
Remove plug, actuate brake and determine dimension (A) using a thickness gauge. If dimension (A) is less than or
equal to 4.0 mm (0.16 inch) the lined discs on both output sides must be replaced. Replace O-ring when installing
the plug. Tighten plug to a torque of 50 Nm (40 pound feet).

6004-7
DISASSEMBLY
ATTENTION: The views in the following steps may be STEP 3
different than the machine.
Output and Brake
STEP 1
W230R445
Remove the breather valve (see arrow).
STEP 4
W230R551
Fix axle to assembly truck.

ATTENTION: Before clamping the axle fully turn in the
support. Position axle first onto the two fixtures, secure
with clamping brackets and then unbolt the support until
contact with the axle is obtained.
STEP 2
BD06G004
Secure the output with the lifting device 380002303

and loosen hexagon screws.
Then separate the output assy from the axle housing.
STEP 5
W230R447
Pull stub shaft and sun gear shaft.

NOTE: Pay attention to potentially releasing shim.
W230R444
Loosen screw plugs and drain oil from the axle.

6004-8
STEP 6 STEP 9
W230R448 W230R451
Fix output to assembly truck. Press planetary carrier with a two-armed puller out of
the profile of the output shaft.
STEP 7
STEP 10
W230R449
Use a lever to remove the cover from the output W230R452
shaft. Lift the planetary carrier out of the brake housing by

means of the lifting device 380001578.
STEP 8
STEP 11
W230R450
Loosen locking screws and remove the releasing W230R453
cover. Pull the tapered roller bearing from the planetary

carrier.

6004-9
STEP 12 STEP 15
W230R454 W230R457
Disengage retaining ring. Lift the disk package out of the brake housing.
STEP 13 STEP 16
W230R455 W230R458
Pull off planetary gear. Loosen hexagon screws, remove releasing cover
and cup spring.
STEP 14
STEP 17
W230R456
Lift the end plate out of the brake housing. W230R459
Mount breather valve and press piston out of the

brake housing by means of compressed air.

6004-10
STEP 18 STEP 19
W230R460
If necessary, remove guide ring, back-up rings and

grooved rings out of the annular grooves of the brake
housing (see arrows).
NOTE: For the installation position of the single parts
please also refer to the following sketch.
W230R461
Legend to sketch:
1 = Brake housing
2 = Guide ring
3 = Back-up ring
4 = Grooved ring
5 = Grooved ring
6 = Back-up ring
7 = Slide ring seal
8 = Output shaft
STEP 20
W230R462
Lift the brake housing from the output shaft by means

of the lifting device.

6004-11
STEP 21
W230R463

brake housing.
STEP 22
W230R464

output shaft.
STEP 23
W230R465
Pull the tapered roller bearing from the output shaft.

6004-12
STEP 24
W230R468
Loosen screw neck.

W230R554
Secure axle housing with the lifting device and STEP 27

loosen the hexagon screws.
Then separate the axle housing from the axle drive
housing.
NOTE: Pay attention to releasing differential.
STEP 25
W230R469
Pull the bearing outer ring out of the bearing hole and
remove the shim behind.
Then remove the O-ring (see arrow).
W230R467
Loosen the threaded connections and remove the

releasing brake tube.

6004-13
Input STEP 31
STEP 28
W230R558
Install holding wrench on input flange. Hold flange

W230R555 using holding wrench, 380001546, and remove lock
Use the lifting device to lift the differential out of the nut and washer. Remove holding tool from flange.
axle drive housing.
STEP 32
STEP 29 Remove the input flange from the drive pinion.
STEP 33
W230R556
Pull the bearing outer ring out of the housing hole

and remove the shim behind. W230R559
Remove the shaft seal from the axle drive housing.

STEP 30
Heat lock nut securing flange with a hot air blower to STEP 34
loosen Loctite, approximately 120° C (248° F).
W230R560
Press the input pinion out of the housing.

6004-14
STEP 35
W230R489
Remove spacer ring and pull the tapered roller

bearing from the input pinion.
STEP 36
W230R484
If necessary, force both bearing outer rings out of the

axle drive housing.

6004-15
Differential “Open” STEP 40
STEP 37
W230R507
Remove axle bevel gear with thrust washers from the

W230R504 differential housing.
Pull both tapered roller bearings from the differential.
STEP 41
STEP 38
W230R508
W230R505 Force out both slotted pins.

Preload the differential by means of the press, loosen
the hexagon screws and remove the releasing STEP 42
housing cover.
STEP 39
W230R519
Force out both differential axles and remove the

releasing spider gears with thrust washers from the
W230R506 differential housing.
Preload the differential by means of the press, loosen
locking screws and housing cover.

6004-16
STEP 43
W230R509
Remove the axle bevel gear and the shim behind.
STEP 44
W230R510
Press crown wheel from the differential carrier.

6004-17
REASSEMBLY
Differential “Open” STEP 48
STEP 45
W230R520
Insert spider gears with thrust washers into the

W230R511 differential housing and fix them with the two spider
Mount two locating pins and press the heated crown shafts.
wheel onto the differential housing until contact is NOTE: Thrust washers must be positioned with the tabs
obtained. (see arrow 1) being located in the recesses of the
STEP 46 Pay attention to radial installation position of the spider
shafts (fixing holes, arrow 2).
STEP 49
W230R512
Insert thrust washer into the differential housing.
STEP 47 W230R521
Fix spider shafts (short) with slotted pins.

NOTE: Flush mount slotted pins.
W230R513
Insert axle bevel gear.

6004-18
STEP 50 STEP 53
W230R507 W230R517
Mount second axle bevel gear. Attach the housing cover and preload the differential
with the press.
STEP 51 Then fix the housing cover with hexagon screws.
Tightening torque .........= 185 Nm (136.5 pound feet)
STEP 54
W230R515
Fix the thrust washers into the housing cover by

means of grease.
STEP 52 W230R518
Heat both tapered roller bearings and insert until

NOTE: Adjust tapered roller bearing after cooling down.
W230R516
Mount two adjusting screws and insert the housing

cover until contact with the differential housing is
obtained.
bolt with new locking screws.
Tightening torque.............= 400 Nm (295 pound feet)
6004-19
Input STEP 57
STEP 55
2
BD06G139
1. MATING NUMBER (MARKED MANUALLY)
2. PINION BASIC DIMENSION (STAMPED)
W230R572
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 56 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 58
Calculation example A:
36.13 mm
Dimension I
-------(1.422 inch)
167.95 mm
Dimension II
-------(6.612 inch)
204.08 mm
Results in dimension Y
------(8.034 inch)
BD06G138
Measure the thickness of the inner bearing and Calculation example B:

record its measurement, dimension “I”. 205.30 mm
Dimension I (Example) . . . . . 36.13 mm (1.422 inch) Dimension X
-------(8.080 inch)
NOTE: Deduct the thickness of the gauge blocks being 204.08 mm
Dimension Y
used to support the bearing from the overall measurement, -------(8.034 inch)
IE: overall measurement 106.13 mm (4.178 inch) Difference = shim 1.22 mm
minus gauge block thickness 70 mm (2.756 inch) will equal thickness ------(0.046 inch)
dimension I.
NOTE: Shims are available in 0.10 mm (0.004 inch),

round up or down to the next available shim thickness, s =
1.20 (0.044 inch)

6004-20
STEP 59 STEP 62
W230R573 BD06G143
Heat the bearing hole to approximately 120° C (248° Press the inner bearing on the drive pinion shaft.
F) and install the outer bearing until contact is made
using the outer bearing cup installer. Drive Pinion Bearing Rolling
STEP 60
Torque Adjustment
STEP 63
W230R574
Install the shim set determined in Step 58 in the

BD06G144
bearing bore on the differential carrier.
Install an 8.18 mm (0.32 inch) thick spacer on the
pinion shaft.
STEP 61
W230R575
Undercool the internal bearing outer ring and bring it

into contact position in the housing hole by using
380100001 the assembly fixture.

6004-21
STEP 64 STEP 66
WARNING: Always wear heat protective
gloves to prevent burning your hand when
handling heated parts.
SM121A
W230R577
Install the input flange on the pinion shaft.
STEP 67
Put the washer in place on the pinion shaft.
W230R576
Heat the pinion shaft outer bearing to 120° C (248°

F) in a bearing oven. Wearing heat resistance gloves STEP 68
or mittens, install the bearing on the pinion shaft until Install holding wrench, 380001546, on input flange.
contact. Hold flange using holding tool and tighten nut to a
torque of 1200 Nm (885 pound feet). Remove
NOTE: Prior to mounting the input flange and tightening holding wrench.
the nut, allow the bearing to cool to ambient temperature.
NOTE: When tightening rotate the pinion shaft in both
STEP 65 directions several times.
STEP 69
BD06G146
Press the dust shield on the input flange.

W230R578
Check the rolling torque of the drive pinion bearing.

The rolling torque should be 1.5 to 4.0 Nm (13.3 to
35.4 lb-inch). If rolling torque is too low, install a
thinner spacer (Step 63); if rolling torque is too high,
install a thicker spacer (Step 63).

6004-22
Setting Backlash and Bearing

Preload
Deviation Value -0.2 -0.1 0 0.1
Shim 2 0.8 0.9 1.0 1.1
Shim 3 1.2 1.1 1.0 0.9
STEP 70 STEP 71
1 3
2
4
W270R085
Deviation see crown wheel rear side.

The test dimension „106“ is stamped into the crown
W230R501
wheel rear side. If no + or – deviation is indicated,
this value corresponds to the actual value ”O” in the Legend to sketch:
table below. 1 = Axle housing
According to this value, the required shims are 2 = Shim (crown wheel side)
allocated in the table below. 3 = Shim (diff. carrier side)
4 = Axle housing
Any + or – deviation of the test dimension caused by
production is also marked on the crown wheel rear
side (e.g. - 20 or - 10 or 10 or 20) . In accordance
STEP 72
with this deviation, the required shims are allocated
in the table below.
W230R495
Insert the determined shim (e.g. s = 1.0 mm) (0.039

inch) into the hole of the axle housing and adjust the
bearing outer ring (see arrow) until contact is
obtained.

6004-23
STEP 73 STEP 75
W230R579 W230R580
Cover some drive and coast flanks of the crown Mount two locating pins and bring the axle housing
wheel with marking ink. into contact position with the axle drive housing by
Then insert the premounted differential into the axle means of the lifting device.
drive housing.
Then preliminarily fix the axle housing with 4
hexagon screws.
STEP 74
NOTE: Preliminarily mount the axle housing without
O-ring.
STEP 76
W230R496
Insert the determined shim (e.g. s = 1.0 mm) (0.039

inch) into the hole of the axle housing and adjust the
bearing outer ring until contact is obtained.
W230R584
Loosen the slotted nut and input flange.
STEP 77 W230R573
Install the shaft seal with the sealing lip towards oil
sump using pinion shaft seal.
NOTE: Wet the outer diameter of the seal with a solution
of 50% water and 50% mineral spirits. Fill the space
between the sealing and dust lip with grease.

6004-24
STEP 78
W230R577
Install the input flange. Install holding wrench,

380001546, 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 1200 Nm (885 pound feet).
NOTE: Rotate the input pinion several times in both
directions when tightening.

6004-25
STEP 79
W230R498
Mount fitting.
W230R497
Tightening torque .............= 36 Nm (26.5 pound feet)
Grease O-ring (see arrow) and insert it into the axle
housing.
STEP 82
STEP 80
W230R499
Grease O-ring and insert it into the annular groove of

W230R585
the brake tube (see arrow).
Mount two locating pins and bring the axle housing
into contact position with the axle drive housing by
using the lifting device.
Then fix the axle housing by means of hexagon
screws.
Tightening torque.............= 560 Nm (413 pound feet)

6004-26
STEP 83
W270R086
Mount brake tube with threaded connection and

hexagon nut (1).
STEP 84
2
W270R087
Provide screw plug with a new O-ring and fit it (2).

Tightening torque..............= 50 Nm (36.8 pound feet)

6004-27
Output and Brake STEP 87
STEP 85
W230R524
Wet O-ring of slide ring seal and locating hole with

W230R522 spirit.
Pull in wheel stud into the output shaft until contact is Snap new slide ring seal into the output shaft.
obtained. Then mount new slide ring seal accordingly into the
brake housing.
STEP 86 NOTE: For the installation position of the seal please also
refer to sketch page 29.
STEP 88
W230R523
Heat tapered roller bearing and insert it into the

output shaft until contact is obtained.
W230R525
ATTENTION: The surface of the slide ring seal may not

have any grooves, scratches or other types of damage.
Take care that the sealing surface is parallel to the housing
face.
The O-rings must be mounted evenly into the locating hole
and must not bulge out of the hole.
Risk of injury - Metal rings have extremely sharp edges.
Wear protective gloves.

6004-28
STEP 89 STEP 91
W230R526 W230R460
Insert both bearing outer rings (see arrows) into the Insert back-up rings and grooved rings into the
brake housing until contact is obtained. annular grooves of the brake housing (see arrows).
NOTE: Pay attention to the installation position; please
STEP 90 also refer to sketch page 29.
STEP 92
W230R462
Insert the premounted brake housing by means of

the lifting device over the output shaft until contact is
W230R527
obtained.
Clean the annular groove of the brake housing with
ATTENTION: Before clamping the seal rings (slide ring spirit.
seal) to installation dimension, clean the sliding surfaces Then insert the guide ring into the annular groove
and apply an oil film. We recommend to use a leather cloth (see also the following sketch) and fix it with Loctite
soaked with oil. (type no.: 415) at its extremities (see arrows).
NOTE: The full circumference of the guide ring must be in
an exact contact position.
ATTENTION: Upon installation the orifice of the guide
ring must show upwards (12 o’clock).

6004-29
STEP 93 STEP 95
W230R529
Insert the piston into the brake housing and carefully

install with the fixing device until contact is obtained.
STEP 96
W230R461
Legend to sketch:
1 = Brake housing
2 = Guide ring
3 = Back-up ring
4 = Grooved ring
5 = Grooved ring W230R530
6 = Back-up ring Insert disk and cup spring with the convex side
7 = Slide ring seal showing upwards into the piston.
8 = Output shaft
STEP 97
STEP 94
W230R531
W230R528
Insert cover and fix it by means of hexagon screws.
Flush-mount the slotted pins (6x) into the holes of the
piston. Tightening torque ................= 34 Nm (25 pound feet)

6004-30
STEP 98 STEP 100
W230R457 W230R532
Mount outer and inner disks. Press stop bolt into the planetary carrier until contact
is obtained.
NOTE: For the number of disks and the disk arrangement
please refer to the relating spare part list. Legend to sketch:
1 = Stop bolt
STEP 99 2 = Planetary carrier
STEP 101
1 2
W230R456
Insert end plate.

W230R533
Insert the cylindrical roller bearing into the planetary

gear – for this purpose press the cylindrical roller
bearing through the packaging sleeve until the snap
ring engages into the annular groove of the planetary
gear.
1 = Cylindrical roller bearing
2 = Packaging sleeve
3 = Snap ring
4 = Planetary gear

6004-31
STEP 102 STEP 104
1
2
W230R454 W230R535
Heat bearing inner rings and insert the premounted Wet front face (contact face bearing inner ring, arrow
planetary gears with large radius facing the planetary 1) and profile (teeth, arrow 2) in the output shaft with
carrier (downwards) until contact is obtained. anti-corrosive agent.
NOTE: Adjust bearing inner rings after cooling down.
STEP 105
Then fix planetary gears by means of retaining rings.
STEP 103
W230R452
Align disk package centrally and radially. Then insert

the planetary carrier by means of the lifting device
W230R534 380001578 into the teeth of the output shaft.
Heat tapered roller bearing and install it to the
planetary carrier until contact is obtained. STEP 106
W230R536
Bring planetary carrier into contact position with the

cover and the old locking screws which were
removed during disassembly.
Then remove the locking screws again.
6004-32
STEP 107 STEP 109
W230R537 W230R539
Pivot output 90°. Insert the cover into the output shaft until contact is
Insert disk and fix planetary carrier with new locking obtained.
screws.
ATTENTION: Tighten locking screws successively with a STEP 110
Then retighten the locking screws successively with a
STEP 108
2
W230R540
Determine dimension I, from the mounting face of the

brake housing to the front face of the stop bolt.
1
Dimension I ................................40.80 mm (1.6 inch)
W230R538
Install O-ring (see arrow 1) to the cover (2).

NOTE: Use new cover and O-ring.

6004-33
STEP 111 STEP 113
W230R541 W230R543
Insert stub shaft into the teeth of the axle bevel gear Measure dimension II, from the front face of the sun
until contact is obtained. gear shaft to the mounting surface of the axle
housing.
ATTENTION: Pay attention to the installation position;
mount the stub shaft with the long teeth showing to the Dimension II ...............................38.20 mm (1.5 inch)
differential.
CALCULATION EXAMPLE:
STEP 112 Dimension I ...............................40.80 mm (1.6 inch)
Dimension II .............................- 38.20 mm (1.5 inch)
Difference ...................................2.60 mm (0.10 inch)
Required axial play.....................- 1.00 mm (0.4 inch)
Difference = shim e.g. ........... s = 1.60 mm(0.06 inch)
STEP 114
W230R542
Insert the sun gear shaft until contact is obtained.
W230R544
Insert sun gear shaft into the planetary carrier.

6004-34
STEP 115 STEP 118
W230R545 BD06G004
Fix determined shim(s) e.g. s = 1.60 mm (0.06 inch) Mount two adjusting screws and use the lifting device
with grease into the sun gear shaft. to 380002303 bring the output into contact position
with the axle housing.
STEP 116 Then fix the output by means of hexagon screws.
STEP 119
W230R546
Fix O-ring (see arrow) with grease into the

countersink of the brake housing.
STEP 117 W230R548
Mount breather (see arrow).
W230R547
Grease O-ring (see arrow) and install it to the axle

housing.

6004-35
BRAKE HYDRAULICS LEAKAGE TEST

IMPORTANT: DO NOT EXCEED 100 BAR (1450 PSI) High Pressure Test
PRESSURE IN THE FOLLOWING STEPS.
STEP 121
STEP 120
Operate the hand pump to increase pressure to 100
bar (1450 psi) maximum. Close connection to hand
pump using the shutoff valve. During a 5 minute
period, pressure shall not drop more than 2 bar (29
psi).
Low Pressure Test

STEP 122
Reduce pressure to 5 bar (72.5 psi) and close the
shutoff valve. During a 5 minute period pressure shall
not drop.
W230R549
Connect a hand pump with pressure gauge to the

brake port as shown above. 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.

6004-36
NOTES

Section
6005
DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL

JOINTS
6005

Via Plava, 80
6005-2
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CENTER DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SLIDING YOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6005-3
SPECIAL TORQUES
Center, Rear and Front Drive Shaft Bolts......................................................136 to 149 Nm (100 to 110 pound-feet)
Lock Nut for Yoke on Front Drive Shaft.........................................................339 to 373 Nm (250 to 275 pound-feet)

6005-4
FRONT DRIVE SHAFT
1. Remove the cap screws that fasten the center 1. Apply antiseize compound to the bearing area of
drive shaft to the yoke (16) at the rear of the front the front drive shaft (1), refer to Figure 1.
drive shaft. Use a prybar to disengage the
2. Put the front drive shaft (1) into position on the
universal joint from the yoke (16) and move the
machine.
center drive shaft out of the way.
3. Fasten the front drive shaft (1) to the universal
2. Loosen the lock nut (9) and set screw (8) in the
joint (3) with cap screws (2). Tighten the cap
center bearing (10) of the housing (7).
screws (2) to 136 to 149 Nm (100 to 110
3. Remove the self-locking nut (15) and flat washer pound-feet).
(14) that fasten the yoke (16) to the rear of the
4. Apply antiseize compound to the splines on the
front drive shaft (1).
4. Make an alignment mark on the yoke (15) and
5. Install the yoke (16) so that the alignment marks
the end of the front drive shaft (1) to make sure
are aligned. If a new front drive shaft has been
that the yoke is installed correctly.
installed, make sure this yoke is parallel with
5. Use an acceptable puller and remove the yoke yoke at the other end of the front drive shaft.
(16) from the end of the front drive shaft (1).
6. Install the self-locking nut (15) and flat washer
6. Remove paint or rust from the rear of the front (14) that fasten the yoke to the front drive shaft.
drive shaft (1) and apply penetrating oil to loosen Tighten the self-locking nut to 339 to 373 Nm
any rust between the inner race and the front (250 to 275 pound-feet).
drive shaft (1).
7. Align the set screw (8) with the slot in the front
7. Remove the cap screws (2) that fasten the drive shaft (1).
universal joint (3) to the front drive shaft (1).
8. Tighten the set screw (8) until it bottoms out in
8. Use a prybar to disengage the front drive shaft the slot, loosen the set screw (8) one full turn.
(1) from the universal joint (3) and remove the
9. Hold the set screw (8) so it will not turn, tighten
front drive shaft (1). If necessary, use a brass
the jam nut (9).
hammer to drive the front drive shaft (1) out of
the center bearing. 10. Engage the universal joint of the center drive
shaft with the yoke (16).
11. Install the cap screws that fasten the center drive
shaft to the yoke (16). Tighten the cap screws to

6005-5
2
2
5
4 7
16
10
11
12
9
14
15
14
8 13
15
14
9
BS07B229
1. FRONT- DRIVE SHAFT 7. HOUSING 13. CLAMP

2. CAP SCREW 8. SET SCREW 14. FLAT WASHER
3. UNIVERSAL JOINT 9. JAM NUT 15. SELF-LOCKING NUT
4. NUT 10. CENTER BEARING 16. YOKE
5. LOCK WASHER 11. ELBOW
6. BOLT 12. HOSE

6005-6
CENTER BEARING
1. Remove the hardware (14 and 15) that holds the NOTE: The center bearing (10) and housing (7) are not
clamp (13) for the lubrication hose (12). serviced separately. If the center bearing (10) is worn or
damaged or if the housing (7) has cracks, a new housing
2. Remove the lock nut (9) from the end of the
(7) and center bearing (10) must be used.
lubrication hose (12).
1. Apply antiseize compound to the bearing area of
3. Remove the lubrication hose (12).
the front drive shaft (1).
4. Remove the cap screws that fastens the center
2. Install the housing (7) so that the lubrication
drive shaft to the yoke (16) at the rear of the front
fitting is to the right.
drive shaft (1). Use a prybar to disengage the
universal joint from the yoke. Move the center 3. Install the bolts (6), lock washers (5), and nuts
drive shaft out of the way. (4) that hold the housing (7). Tighten the nuts (4)
to 150 to 164 Nm (110 to 120 pound-feet).
5. Loosen the lock nut (9) and set screw (8) in the
center bearing (10). 4. Apply antiseize compound to the splines on the
6. Remove the self-locking nut (15) and flat washer
(14) that fasten the yoke (16) to the rear of the 5. Install the yoke (16) so that the alignment marks
front drive shaft (1). are aligned. If a new front drive shaft (1) has
been installed.
7. Make an alignment mark on the yoke (16) and
the end of the front drive shaft (1) to make sure 6. Install the self-locking nut (15) and flat washer
that the yoke (16) is installed correctly. (14) that fasten the yoke (16) to the front drive
shaft (1). Tighten the self-locking nut (15) to 339
8. Use an acceptable puller and remove the yoke
to 373 Nm (250 to 275 pound-feet).
(16) from the end of the front drive shaft (1).
7. Align the set screw (8) with the slot in the front
9. Remove paint or rust from the rear of the front
drive shaft (1).
drive shaft (1) and apply penetrating oil to loosen
any rust between the inner race and the front 8. Tighten the set screw (8) until it bottoms out in
drive shaft. the slot, loosen the set screw (8) one full turn.
10. Remove the nuts (4), lock washers (5), and bolts 9. Hold the set screw (8) so it will not turn, tighten
(6) that hold the housing (7). the lock nut (9).
11. Install two longer bolts, approximately 3 inches 10. Engage the universal joint at the front of the
(75 mm) longer to hold the housing (7) during center drive shaft with the yoke (16).
removal. Use an acceptable puller to remove the
11. Install the cap screws that fasten the center drive
housing (7).
shaft to the yoke (16). Tighten the cap screws to
12. Install the lubrication hose (12).
13. Install the jam nut (9) to end of the lubrication
hose (12).
14. Install the hardware (14 and 15) that holds the
clamp (12) for the lubrication hose (12).
15. Lubricate the center bearing (10).

6005-7
2
1
3
4
5
7
3
2
9 2
2
6
3
BS07B230 BS07B231
CENTER DRIVE SHAFT (TOP ILLUSTRATION) REAR DRIVE SHAFT- (BOTTOM ILLUSTRATION)
1. DRIVE SHAFT 4. YOKE 7. SEAL

2. CAP SCREW 5. RETAINER 8. BREATHER
3. UNIVERSAL JOINT 6. SLIDING YOKE 9. PLUG

6005-8
CENTER OR REAR DRIVE SHAFT
1. Remove the cap screws (2) that hold both 1. Lubricate the rear drive shaft (1) with the grease.
universal joints (3).
2. Engage the front universal joint (3) with the yoke
2. Use a prybar to disengage the rear universal (4) and install the cap screws (2). Tighten the
joint (3) from the yoke (4). cap screws (2) to 136 to 149 Nm (100 to 110
pound-feet).
3. Hold the drive shaft (1) and disengage the front
universal joint (3) from the yoke (4) and remove 3. Engage the rear universal joint (3) with the yoke
the drive shaft. (4) and install the cap screws (2). Tighten the
cap screws to 136 to 149 Nm (100 to 110
pound-feet).
SLIDING YOKE
1. Make an alignment mark on the sliding yoke (6) 1. Install the retainer (5) and seal (7) on the drive
and the drive shaft (1) so that the par ts are shaft (1).
assembled correctly.
2. Install the sliding yoke (6) so that the alignment
2. Remove the retainer (5) and seal (7) from the marks are aligned. If a new par t is being
sliding yoke (6). installed, the yokes must be parallel.
3. Remove the sliding yoke (6). 3. Turn the retainer (5) and seal (7) onto the sliding
yoke (6) and tighten the retainer (5).
4. Clean the parts in cleaning solvent. Inspect the
splines for damage and wear. 4. Lubricate the sliding yoke.
UNIVERSAL JOINT
1. Remove the cap screws (2) that fasten the NOTE: The bearing race and journal that make up the
universal joint (3) to the drive shaft (1) or the universal joint are not serviced separately. If the bearing
yoke (4). race or the journal is worn or damaged, a new universal
joint (3) must be used.
2. Remove the universal joint (3).
1. Clean the slots in the yoke (4) or the drive sliding
yoke (7). Clean the tabs on the universal joint (3).
2. Install the universal joint (3) and install the cap
screws (2). Tighten the cap screws (2) to 136 to
149 Nm (100 to 110 pound-feet).
3. Lubricate universal joints.

Section
6006
WHEELS AND TIRES
6006

Via Plava, 80
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
Wheel Bolt Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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. Then a final torque
of 640 to 720 Nm (475 to 530 pound-feet) in the
A. If the machine is new.
same sequence.
B. If a wheel has been removed and installed.
TIRE PRESSURES
W270C Service Specifications - Normal Work Tire Inflations

Tire Type Front Pressure Rear Pressure
26.5 X 25 Bias Ply 3.5 bar (50.0 psi) 2.8 bar (40.0 psi)
26.5 X 25 Radial 4.5 bar (65.0 psi) 3.2 bar (47.0 psi)
W300C Service Specifications - Normal Work Tire Inflations

Tire Type Front Pressure Rear Pressure
26.5 X 25 Bias Ply 4.5 bar (50.0 psi) 3.2 bar (47.0 psi)
26.5 X 25 Radial 5.0 bar (73 psi) 3.5 bar (50.0 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, lubricate
retaining ring and rim can come off with the tire with a tire mounting lubricant and inflate the tire to
enough force to result in death to a person 551 kPa, 5.5 bar (80 psi) to make sure that the tire is seated
in front of the rim. on the rim. Then decrease the pressure to the specified
48-44 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 b olts to pu ll the wheel against the
planetary housing. DO NOT use an impact
wrench to tighten the wheel bolts.

6006-5
16 1
8 9
20 17
12 5
4 13
22 21
14 3
6 11
18 19
10 7
2 15
23
W270R011
WHEEL BOLT TORQUE SEQUENCE

6006-6
NOTES

Section
6007
TRANSMISSION CONTROL VALVE
6007

Via Plava, 80
6007-2
TABLE OF CONTENTS
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6007-3
CONTROL VALVE
Disassembly STEP 4
STEP 1
BD06A010
Loosen and remove the cap screws, remove the

BD06A007
cover. Remove the opposite cover.
Mark the installation position of the wiring harness to
the valve block. STEP 5
STEP 2
BD06A011
Remove the wiring harness.

BD06A008
Loosen and remove the cap screws that secure the STEP 6
distribution plate and intermediate plate to the valve
body, remove the intermediate plate and distribution
plate.
STEP 3
BD06A012
Loosen and remove the retaining plate cap screws,

remove the retaining plates and solenoids.
BD06A009
Remove the wiring harness retaining clamp.

6007-4
STEP 7 STEP 9
BD06A013 BD06A015
Loosen and remove two cap screws, install two Remove the components.
adjusting screws. Loosen and remove the remaining
cap screws. STEP 10
STEP 8
BD06A016
Remove the opposite solenoids, housing, and

BD06A014 components.
Separate the housing from the valve body by equally
loosening the adjusting screws.

6007-5
Inspection Assembly
1. Clean all metal parts in cleaning solvent. NOTE: Apply clean engine oil (15W-40) to pistons and
springs, orifices, new O-rings, and filter screens before
2. Immerse end housings, valve housing, valve
assembly.
plate, and distribution plate in cleaning solvent
and agitate cleaning solvent. WEAR EYE
PROTECTION WHEN USING COMPRESSED STEP 11
AIR. Use compressed air to remove foreign
matter from interior of housings and plates and to
ensure that all bores are clear of foreign matter.
3. WEAR EYE PROTECTION WHEN USING
COMPRESSED AIR. Use compressed air to
ensure that orifices are clear of foreign matter.
4. Check filter screens for blockage, rips, or tears.
Replace if any of these conditions are seen.
5. Inspect the plates, housings and covers for
corrosion, cracks, breaks, chipping or other
damage. Check bores in housings for deep BD06A017
scratches, gouges, and other damage. Replace Place the valve body on the bench with the orifices
a housing or cover if any of the above conditions up.
are seen.
6. Check pressure regulators for cracks, breaks, or STEP 12
other damage. Check connector contacts for
looseness or signs of corrosion. Replace a
pressure regulator if any of these conditions are
seen. Check resistance of pressure regulators
using a multimeter. Replace a pressure regulator
if resistance is not 17 to 21 ohms.
7. Check wiring harness connectors for signs of 3
breaks, cracks, or other damage. Check contacts
for foreign matter or corrosion. Check harness
wiring for signs of broken or cracked insulation 1 1
and broken or frayed wiring at connection to 2 2
connectors. Replace wiring harness if any of BD06A018
these conditions are seen.
1. VIBRATION DAMPER 3. PRESSURE REDUCING
8. Check springs for cracks, breaks, distortion, or 2. PISTONS VALVE
signs of permanent set. Replace a spring if any Install components in positions shown.
of these conditions are seen.
9. Inspect pistons for cracks, breaks, chipping, STEP 13
grooves, or other damage. Replace if any of
these conditions are seen.
BD06A019
Preload the compression springs of the pistons,

install a roll pin of a diameter of 5.0 mm (0.20 inch).
6007-6
STEP 14 STEP 17
BD06A020 BD06A023
Install the adjusting screws, gasket, and housing Install the cap screws and torque in a criss cross
cover. pattern to 7.5 Nm (66.3 pound-inch).
STEP 15 STEP 18
BD06A021 BD06A024
Tighten the adjusting screws equally until the cover is Install the solenoids and secure them with the
flush on the valve body. retaining plates and cap screws. Torque the cap
screws to 5.5 Nm (48.5 pound-inch).
STEP 16 NOTE: Install the retaining plate with the neck towards
valve body, install controllers with connectors as shown.
STEP 19
BD06A022
1 3
Push the pistons down through the pressure
controller wholes and remove the roll pins.
1
2 2
BD06A025
1. VIBRATION DAMPER 3. MAIN PRESSURE VALVE

2. PISTONS
Install components in positions shown.

6007-7
STEP 20 STEP 23
BD06A026 BD06A028
Preload the compression springs of the pistons, Install the wiring harness with connector on side of
install a roll pin of a diameter of 5.0 mm (0.20 inch). valve body marking made during disassembly.
Install the adjusting screws, gasket, and housing Connect wiring harness to the solenoids.
cover.
STEP 24
STEP 21
BD06A029
BD06A023 Install the gasket, install the wiring harness plug in

Install the cap screws and torque in a criss cross the cover. Install the cap screws and torque in a criss
pattern to 7.5 Nm (66.3 pound-inch). cross pattern to 7.5 Nm (66.3 pound-inch).
STEP 22 STEP 25
BD06A027 BD06A030
Install the solenoids and secure them with the Install the wiring harness retaining clamp.
retaining plates and cap screws. Torque the cap
screws to 5.5 Nm (48.5 pound-inch).
NOTE: Install the retaining plate with the neck towards
valve body, install controllers with connectors as shown.

6007-8
STEP 26 STEP 28
BD06A031 BD06A033
Install the screens into the bores of the intermediate Install the distribution plate, install the cap screws
plate towards the distribution plate. and torque in a criss cross pattern to 9.5 Nm (84
pound-inch).
STEP 27
STEP 29
BD06A032
Install two adjusting screws. Place the intermediate BD06A034
plate with the screens facing up. Install new o-rings on the plugs, install and torque
plugs to 6 Nm (53 pound-inch).

SECTION INDEX
BRAKES
Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001

Hydraulic Brake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7002
Brake Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7003
Brake Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7004
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7008

Via Plava, 80
7001
Section
7001
REMOVAL AND INSTALLATION OF BRAKE

COMPONENTS

Via Plava, 80
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
4 7
W270R003
1. FRONT AXLE 5. FRONT ACCUMULATOR

2. REAR AXLE 6. REAR ACCUMULATOR
3. BRAKE VALVE 7. BRAKE PUMP
4. PARKING BRAKE ACCUMULATOR
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
4
2
3
5
8
10
1 6 7
W270R005
1. BRAKE VALVE 6. FRONT BRAKE LINE

2. REAR ACCUMULATOR LINE 7. REAR BRAKE LINE
3. PARKING BRAKE LINE 8. FRONT ACCUMULATOR
4. BRAKE PUMP INPUT 9. RETURN TO TANK
5. BRAKE VALVE DISCHARGE 10. HOSE 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 (1) in the accumulators
the loader bucket to the floor. Stop the engine. clamps (7), 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
(1) and tighten.
3. Make sure the service brake accumulators (1)
and the parking brake accumulator (2) are 3. Tighten accumulator clamp studs (7) to 17Nm
completely discharged. Refer to illustration on (13 pound feet).
page 7. Push down and release the brake pedal
4. Install the parking brake accumulator (2) into the
at least 30.
bracket.
4. Turn the master disconnect switch to the OFF
5. Install the nut (3) and tighten.
position.
6. Connect the line to the parking brake
5. Remove the left cab skirt located under the cab
accumulator (2).
or canopy to gain access to accumulators.
7. Stop the vacuum pump and remove.
6. To release the pressure on the parking brake
accumulator, the line at the accumulator must be 8. Install the left cab skirt.
SLOWLY cracked open. A pan will be needed to
catch the hydraulic oil.
position.
7. Connect a drain hose to the quick disconnect
couplings in each brake circuit to release any
pressure in the brake circuit. 11. Refer to Section 7008 and perform the Parking
Brake Test Procedure.
8. Clean the brake accumulators (1), parking brake
accumulator (2) and lines. 12. Check the hydraulic reservoir oil level and add oil
as required. See Section 1002 for the correct oil.
9. Put identification tags on the line that is
connected to the parking brake accumulator (2).
reservoir. Start the vacuum pump.
11. Disconnect the tubes from both brake
accumulators (1).
12. Loosen the clamp stud (8) on the accumulator
clamp (7).
13. Remove the accumulators (1) from the
accumulator clamps (7).
14. Install plugs in the tubes.
15. Disconnect the hose from parking brake
accumulator (2).
16. Remove the nut (3), remove the parking brake
accumulator (2).
17. Install a plug in the hose.

7001-7
5 7
W270R004
1. BRAKE ACCUMULATORS 5. TUBE FRONT BRAKE ACCUMULATOR

2. PARKING BRAKE ACCUMULATOR 6. TUBE REAR BRAKE ACCUMULATOR
3. MOUNTING NUT 7. CLAMP ACCUMULATOR
4. HOSE PARKING BRAKE ACCUMULATOR 8. CLAMP STUD
BRAKE AND PARKING BRAKE ACCUMULATORS ILLUSTRATION

7001-8
BRAKE PUMP
1. Park the machine on a level surface and lower 1. Install the brake pump (1), mounting bolts (2)
the loader bucket to the floor. Stop the engine. and washers (3).
2. Put blocks on both sides of each tire to prevent 2. Torque mounting bolts (2) to 149.14 to 169.48
machine movement. Nm (110 to 125 pound feet).
3. Turn the master disconnect switch to the OFF 3. Remove the plugs or caps and connect the lines
position. to the brake pump (1).
4. Clean the brake pump (1) and lines, refer to the 4. Stop the vacuum pump and remove.
5. Put identification tags the lines that are position.
connected to the brake pump (1).
7. Check the hydraulic reservoir oil level and add oil
reservoir. Start the vacuum pump.
as required. See Section 1002 for the correct oil.
7. Disconnect the lines from the brake pump (1)
and put plugs in each line.
8. Remove the mounting bolts (2) and washers (3)
from the brake pump (1) and remove the brake
pump (1).

7001-9
12
4
5
6 8
7 11
3
2
1
10
9
W270R006
1. BRAKE PUMP 5. BOLT 9. HOSE BRAKE PUMP TO BRAKE VALVE

2. MOUNTING BOLT 6. WASHER 10. PRESSURE HOSE
3. WASHER 7. FLANGE 11. TRANSMISSION
4. SUCTION HOSE 8. O-RING 12. HYDRAULIC TANK
BRAKE PUMP ILLUSTRATION

7001-10
NOTES

7002
Section
7002
HYDRAULIC BRAKE TROUBLESHOOTING

Via Plava, 80
7002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BLEEDING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BRAKE MODULATION PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the Brake Modulation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BRAKE PUMP OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake Valve Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7002-3
SPECIFICATIONS
Brake pump output ..............................................................................................................42 to 45 L/min 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..................................................................80 to 87 bar (1160 to 1260 psi)
Modulation pressure rear brake cylinders ..................................................................78 to 85 bar (1130 to 1230 psi)
SPECIAL TOOLS
G
94L95
380001737 NITROGEN CHARGING KIT USED TO CHECK AND
CHARGE THE ACCUMULATOR WITH NITROGEN.
BC04A001
380001168 ACCUMULATOR CHARGING ADAPTER

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. As the lowest pressure
2. Push and release the brake pedal many times reaches 106 to 115 bar (1530 to 1670 psi) the
with the engine stopped to remove all hydraulic brake warning lamp and alarm buzzer must
pressure from the brake system until there is no actuate. If the warning lamp and alarm buzzer
pressure on the pedal. fail to work, test the low brake pressure warning
switches and electrical circuit. If the warning
3. Install two 207 bar (3000 psi) pressure gauges to
lamp and alarm buzzer actuate at a higher or
front and rear hydraulic brake accumulator test
lower pressure than specified, test the low brake
ports, refer to page 7 for the locations of the test
pressure warning switches and replace as
ports.
needed.
4. Make sure that the pressure gauge hoses are
9. As the lowest pressure reaches 106 to 115 bar
long enough so the gauges can be read while
(1530 to 1670 psi) the brake warning lamp and
sitting in the operators seat.
alarm buzzer must actuate. If the warning lamp
NOTE: The gauges can not be connected to the test and alarm buzzer fail to work, test the low brake
ports if hydraulic pressure remains in the system. pressure warning switches and electrical circuit.
If the warning lamp and alarm buzzer actuate at
5. Start the engine. Run the engine at low idle while
a higher or lower pressure than specified, test
reading the pressure gauges. The alarms
the low brake pressure warning switches and
(buzzer, master warning light and brake pressure
replace as needed.
warning light) should shut off when the
accumulator with the lowest pressure reaches 10. After the low brake pressure light activates,
106 to 115 bar (1530 to 1670 psi), approximately press the brake pedal eight more times.
40 seconds at any engine speed. 11. Record the readings on the pressure gauges.
6. After the alarms stop, run the machine at high The pressure gauges should read at or above
idle to finish charging the accumulators. The 48 to 59 bar (700 to 850 psi).
pressure must increase on both gauges until 190 12. If the pressures are at or above 48 to 59 bar (700
to 196 bar (2757 to 2843 psi) is reached. This is to 850 psi), the test is complete.
the accumulator valve cut-out pressure. It is 13. If the pressures are not within the required
normal for the pressure to drop slightly once the specifications, then the brake system must be
cut-out pressure is reached. bled.
7. With the engine running at high idle, push and 14. After bleeding the brake system, perform the
release the brake pedal rapidly while reading the brake system check again.
drop in pressure on the gauges. The pressure
drops may not be equal, but as the lowest 15. Continue to slowly push and release the brake
pressure reaches 157 to 167 bar (2280 to 2420 pedal several times until the gauge pressure
psi), the system pressure must start to increase. suddenly drops to zero. The last pressure
This is the valve cut in pressure. reading before the drop to zero is the nitrogen
charge pressure in the accumulator. Test the
NOTE: The brake cut-in and cut-out pressures of the pressure in both accumulators. If the pressure is
brake system charge valve are factory preset and are below 48 to 59 bar (700 to 850 psi), charge or
not adjustable. replace the accumulator(s) (see page 5).
NOTE: If the pressure on one of the pressure NOTE: Nominal temperature of 20° C (68° F), colder
gauges is lower than specified, the problem can be a temperature will reduce pressure, hotter temperature
bad accumulator valve. will increase pressure.

7002-5
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

1. Make sure that the oil side of the accumulator is
completely discharged by doing the following: E
C
A. Stop the engine.
B. Push down and release the brake pedal many
times to release the pressure.
F
2. Connect a drain hose to the test connector in
each brake circuit to release any pressure in the
brake circuit.
3. Close valves B and C on the nitrogen charging
kit, refer to the illustration.
D B A
4. Turn the stem out of valve F until the stem stops.
94L95
5. Remove the cap screws and guard from the NITROGEN CHARGING KIT
accumulator.
8. Make sure that valve D is open.
6. Remove the cap from the accumulator valve
9. Turn the stem into valve F and read the pressure
stem.
gauge E.
7. Connect valve F to the accumulator valve stem.
10. The pressure must be 48 to 59 bar (700 to 850
psi). If the pressure is too low, charge the
accumulator with dry nitrogen.
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

NOTE: Check the pressure in the accumulator 5. If the pressure increases above 59 bar
according to the instructions in Checking the (850 psi), quickly open and close valve D and
Nitrogen Charge in the Accumulator. Keep the read gauge E. If the pressure is still too high,
nitrogen charging kit connected to the accumulator. close valve A (turn counterclockwise) a small
amount and quickly open and close valve D. The
1. Close (turn counterclockwise) valve A and open
pressure shown on gauge E is the charge
valve B. Close valves C and D.
pressure.
2. Turn the stem out of valve F until the stem stops
6. Connect valve F to the accumulator valve stem.
moving. Disconnect valve F from the
Turn the stem into valve F until the stem stops
accumulator valve stem.
moving and open valve D to charge the
3. Connect the nitrogen charging kit to a dry accumulator.
nitrogen tank.
7. After the accumulator stops charging, turn the
4. Slowly turn valve A clockwise and read gauge E stem out of valve F until the stem stops moving.
until the pressure is 48 to 59 bar (700 to 850 psi).
8. Close valve B and disconnect the nitrogen
Stop turning valve A.
charging kit from the accumulator valve stem.
9. Install the cap on the accumulator valve stem.
Install the guard and cap screws on the
accumulator.

7002-6
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.
quick-attached components, disconnect them from
10. Close all four wheel end bleed screws.
machine prior to proceeding.
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.
1 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.

7002-7
BRAKE MODULATION PRESSURE CHECK
3
1 2
W270R008
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 80 to 87
brake test ports. bar (1160 to 1260 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 78 to 85 bar
test port (2). (1130 to 1230 psi). This is the modulation
pressure for the rear axle
to the front brake accumulator test port (4) and 12. If the pressures are not within the specified
the rear brake accumulator test port (3). range, it will be necessary to adjust the
modulation pressures.

7002-8
Adjusting the Brake Modulation 1. Remove the tamper evident cover (1).
Pressure NOTE: This is a tamper evident cover and it will be
necessary to install a new cover after the modulation
NOTE: The adjusting bolt to adjust the modulation pressure is adjusted.
pressure is located in the cab, under the brake pedal.
2. Remove the locking bolt (2).
3. Turn the adjusting screw (3) to adjust the
modulation pressure.
NOTE: The rear brake modulation pressure cannot
be adjusted separately from the front brake
modulation pressure.
4. Repeat steps 5 through 10 in the Testing the
Brake Modulation Pressure procedure.
5. Repeat these steps until the brake modulation
pressure is within the specified range.
1
W270R015
1. TAMPER RESISTANT COVER

2. LOCKING BOLT
3. ADJUSTING SCREW

7002-9
SERVICE BRAKE SYSTEM PERFORMANCE (STORED ENERGY)
3
1 2
W270R008
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.
1
10. Record the readings on the pressure gauges.
W230R407 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.
to the test ports 3 and 4.
7002-10
BRAKE PUMP OUTPUT TEST

1. Connect the flowmeter to the brake pump as 3. Measure the flow at 0 bar (0 psi). Record the flow
shown, refer to the illustration 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.
1
6
2
4
W270R009
1. BRAKE PUMP 3. FLOWMETER INLET HOSE 5. FILTER INLET MANIFOLD

2. PUMP OUTPUT ELBOW 4. FLOWMETER OUTLET HOSE 6. TRANSMISSION
*: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION

7002-11
NOTES

7002-12
BRAKE VALVE CONNECTIONS
T1-T2. Brake
F1-F2. Brake pressure switch (F1 plugged)
R1-R2-R4. Accumulators
F. Accumulators pressure switch
P. Inlet oil
N. Tank
B. Other services or tank
X. Parking brake
X’. Parking pressure switch (plugged)
BRAKE VALVE COMPONENTS

- Seal kit
1. Complete pedal support
2. Dust rubber
3. Pedal rubber cover
4. Solenoid 24V Deutsch connector
5. Solenoid + Cartridge valve
6. Brake pressure adjustment
7. Accumulator pressure adjustment
8. Pedal position adjustment

7002-13
F2
R1 F P B N X1
7 F1
R
4 F1 F2 T2
R4 X T1
5
8
1 8 2
P
B
X1
N
R1
F T1
R2 T2
W270R014
BRAKE VALVE ASSEMBLY

7002-14
40 Nm
30 Nm
1
15 Nm 50 Nm
1
1
1 1
25 Nm
9 Nm
1
1
1
9 Nm
1
2 2
1
10 Nm 2 1
2
2.4 10 Nm
2 2 2
2
55 Nm
2 2 1 44-50 Nm
2
2 2
9 Nm
2 1
10 Nm 2
1
2 5.6 9-11 Nm
6
2
25 Nm 2
2
2
2.3
1.2
45 Nm
2
1.2 3 Nm
2
70 Nm
2 9 Nm 1
1
2
1
2 22 Nm
1 22 Nm
25 Nm
1
1
1
9 Nm
1 1 45 Nm
45 Nm
1
W270R016
BRAKE VALVE EXPLODED VIEW

7002-15
SPARE PARTS LIST
1. Seal kit
2. Complete pedal support
3. Dust rubber
4. Pedal rubber cover
5. Solenoid 24V Deutsch connector
6. Solenoid + Cartridge valve

7002-16
NOTES

Section
7003
7003
BRAKE PUMP

Via Plava, 80
7003-2
TABLE OF CONTENTS
BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7003-3
BRAKE PUMP
Remove STEP 9
STEP 1
loader bucket to the floor. Stop the engine.
STEP 2
Put blocks on both sides of each tire to prevent
machine movement.
STEP 3
Turn the master disconnect switch to the OFF
position.
STEP 4 W270R653
Clean the brake pump and lines. Remove the brake pump-to-brake valve hose (1).
Remove the valve tube (2).
STEP 5
Put identification tags on all lines that are connected STEP 10
to the brake pump.
STEP 6
Connect a vacuum pump to the hydraulic reservoir.
Start the vacuum pump.
NOTE: Hydraulic pump suction hose removed for picture
clarity.
STEP 7
Drain the hydraulic tank.
STEP 8
Remove the hydraulic pump suction hose (not
shown). W270R654
Attach lifting equipment to the brake pump. Remove

the brake pump mounting bolts (1). Remove brake
pump.

7003-4
W270R657
BRAKE PUMP ILLUSTRATION

1. BRAKE PUMP 6. ELBOW
2. MOUNTING BOLT (2) 7. CONNECTOR STRAIGHT
3. LOCK WASHER (2) 8. SUCTION HOSE
4. GEAR 9. PRESSURE HOSE
5. GASKET

7003-5
Install STEP 13
STEP 11
W270R656
Install the brake pump-to-brake valve hose (3).

W270R655 Install the valve tube (2).
Lubricate and install the pump O-ring. Install the hydraulic pump suction hose (not shown).
Tighten the split, flange clamp bolts (1) to a torque of
NOTE: Hydraulic pump suction hose removed for picture 73 - 90 N·m (54 - 66 lb ft).
clarity.
STEP 14
STEP 12 Stop the vacuum pump and remove.
STEP 15
Turn the master disconnect switch to the ON position.
STEP 16
Bleed the brake system.
STEP 17
Check the hydraulic reservoir oil level and add oil as
required.
W270R654
Attach lifting equipment to the brake pump. Install the

brake pump. Tighten the brake pump mounting bolts
(1) to a torque of 149 - 170 N·m (110 - 125 lb ft).

7003-6
NOTES

Section
7004
7004
BRAKE ACCUMULATORS

Via Plava, 80
7004-2
TABLE OF CONTENTS
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Temperature/Charge Pressure Brake Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7004-3
SPECIAL TOOL
C E
G
D B A
94L95 BC04A001
380001737 NITROGEN CHARGING KIT 380001168 ACCUMULATOR CHARGING ADAPTER
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR

1. Remove cover from accumulator charge port. 6. Connect valve F to the valve stem on the
Loosen the Allen screw in the charge port. adapter.
NOTE: Do not turn the Allen screw more than 1/8 of a 7. Turn the T-handle inward on valve F to engage
turn or gas will escape uncontrolled. the pin in the valve stem, open valve G.
2. Install adapter on accumulator, use the 8. Open valve D and check the charge pressure on
380001737 nitrogen charging kit to discharge the gauge E.
accumulator, refer to illustrations above. The tool
9. To discharge the accumulator, partially open
must be disconnected from the nitrogen tank.
valve B. The accumulator charge will bleed down
3. Close valves B, C and D. through the regulator.
4. Adjust the regulator A to the minimum pressure 10. Once the accumulator is fully discharged,
setting by turning the knob counterclockwise. disconnect valve F from the valve stem and
remove adapter.
5. Turn the T-handle on valve F fully out.
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

1. Make sure that the oil side of the accumulator is 5. Remove the cap from the accumulator. Loosen
completely discharged by doing the following: the Allen screw in the charge port.
A. Stop the engine. NOTE: Do not turn the Allen screw more than 1/8 of a
turn or gas will escape uncontrolled.
B. Push down and release the brake pedal 21
times to release the pressure. 6. Connect adapter to accumulator.
2. Connect a drain hose to the test connector in 7. Connect valve F to the adapter valve stem.
each brake circuit to release any pressure in the
8. Make sure that valve D and G are open.
brake circuit.
9. Turn the stem into valve F and read the pressure
3. Close valves B and C on the nitrogen charging
gauge E.
kit, refer to the illustration.
NOTE: See chart below for pressure readings.
4. Turn the stem out of valve F until the stem stops.
10. If the pressure is too low, charge the
accumulator with dry nitrogen.

7004-4
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

NOTE: Check the pressure in the accumulator according 6. Connect valve F to the adapter valve stem. Turn
to the instructions in Checking the Nitrogen Charge in the the stem into valve F until the stem stops moving
Accumulator. Keep the nitrogen charging kit connected to and open valve G and D to charge the
the accumulator. accumulator.
1. Close (turn counterclockwise) valve A and open 7. After the accumulator stops charging, turn the
valve B. Close valves C, D, and G. stem out of valve F until the stem stops moving
and close valve G.
2. Turn the stem out of valve F until the stem stops
moving. Disconnect valve F from the adapter 8. Close valve B and disconnect the nitrogen
valve stem. charging kit from the adapter valve stem, remove
the adapter.
3. Connect the nitrogen charging kit to a dry
nitrogen tank. 9. Torque the Allen screw to 20 Nm (15 lb-ft), install
the cover on the accumulator valve stem.
4. Slowly turn valve A clockwise and read gauge E
until the pressure is equal to charge pressure
required for accumulator being charged. Stop
TEMPERATURE CHARGE PRESSURE
turning valve A.
10° C 50° F 67.4 BAR 977 PSI
5. If the pressure increases above required 13° C 55° F 68.1 BAR 987 PSI
pressure, quickly open and close valve D and 16° C 60° F 68.8 BAR 998 PSI
read gauge E. If the pressure is still too high, 18° C 65° F 69.3 BAR 1005 PSI
close valve A (turn counterclockwise) a small 21° C 70° F 70.0 BAR 1015 PSI
amount and quickly open and close valve D. The 24° C 75° F 70.7 BAR 1025 PSI
pressure shown on gauge E is the charge 27° C 80° F 71.4 BAR 1036 PSI
pressure. 29° C 85° F 71.9 BAR 1043 PSI
32° C 90° F 72.6 BAR 1053 PSI
35° C 95° F 73.3 BAR 1063 PSI
38° C 100° F 74.0 BAR 1074 PSI
TEMPERATURE/CHARGE PRESSURE BRAKE

ACCUMULATOR

Section
7008
PARKING BRAKE
7008

Via Plava, 80
7008-2
TABLE OF CONTENTS
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PARKING BRAKE TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7008-3
PARKING BRAKE
Disassembly STEP 7
STEP 1
Park the machine on a hard level surface and lower
the loader bucket to the ground.
STEP 2
Place wheel chocks on each wheel to prevent
machine movement.
STEP 3
BD03A185
Loosen the jam nut, turn adjusting bolt

counterclockwise until the brake pads are loose.
STEP 8
W230R406
Install the articulation lock.
STEP 4
position.
STEP 5 BD03A186
Remove the retainer pin and brake pin.
Pump the brake pedal at least 30 times to discharge
the accumulators.
STEP 9
STEP 6
BD03A187
Remove the two brake pads from the parking brake
BD03A184 assembly.
Loosen and remove the cover from the parking
brake.

7008-4
Inspection STEP 14
Disengage the parking brake.
STEP 10 NOTE: Hydraulic pressure will not be applied to the
Clean and inspect all parts for wear and damage. parking brake until the parking brake rocker switch is
Inspect the brake disc for wear and damage. turned off, the service brakes applied and the transmission
is put into gear.
Replace all parts that are worn or damaged.
A. Place the parking brake rocker switch in the
OFF position.
Assembly
B. Apply the service brake and put the machine
STEP 11 into gear.
C. The parking brake light on the cluster will turn
off at this time.
Place the transmission back into neutral before
proceeding.
STEP 15
BD03A187
Install the two brake pads in the parking brake

assembly.
STEP 12
BD0CA185
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.
STEP 16
Install the cover on the parking brake.
STEP 17
Perform the Parking Brake Test Procedure as
BD03A186
described in this section.
Install the brake pins and retainer pins.
STEP 18
STEP 13
Remove the articulation lock.
Start the machine and run the engine at low idle with
the bucket resting on the ground.
STEP 19
IMPORTANT: It will be necessary to have an assistant Place the master disconnect switch to the ON
help for this procedure. An operator must be present in the position.
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.
WARNING: Always know the location of all

workers in your area. Warn them before you
start working the machine. Always keep all
other persons away from your area. Serious
injury or death can result if you do not follow
these instructions.
SA015
STEP 21
Start the machine and run the engine at low idle in W230R430
third gear neutral. Use up or down arrow and highlight Service, 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
W230R431
Press the up or down arrow and high light

Calibration, press the enter key.
STEP 27
BD06F141
Press and hold the enter key for 2 to 3 seconds until

the instrument cluster monitor display changes to the
select screen.
W230R432
Press the up or down arrow and high light Park

Brake, press the enter key.

7008-6
STEP 28 STEP 34
Shift the gear selector to third gear reverse and
slowly increase the engine speed to wide open
throttle.
STEP 35
Verify that the machine does not move.
STEP 36
Reduce the engine speed to low idle and return the
transmission to neutral.
W230R433 STEP 37
Press the up or down arrow and high light brake test,
press the enter key.
STEP 29
BD06F141
Press the escape switch on the key pad to exit the

test mode.
W230R434 STEP 38
Monitor will display Test Park Brake if all conditions If any machine movement was detected, the parking
are met to test the brake, press the enter key. brake must be adjusted, see procedures this section.
NOTE: If all conditions are not met to test the brake the
monitor will display the condition that needs corrected prior
to proceeding.
STEP 30
Monitor will display Test Park Brake Ready.
STEP 31
Shift the gear selector into third gear forward and
slowly increase the engine speed to wide open
throttle.
STEP 32
Verify that the machine does not move.
STEP 33
Reduce the engine speed to low idle and return the
transmission neutral.

SECTION INDEX
HYDRAULICS
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
Ride Control Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013
Ride Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8014

Via Plava, 80
8001
Section
8001
REMOVAL AND INSTALLATION OF HYDRAULIC

COMPONENTS

Via Plava, 80
8001-2
TABLE OF CONTENTS
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Valve Pilot Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Loader Control Valve Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
JOYSTICK CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Joystick and 1 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Lever Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Joystick Hose Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
RIDE CONTROL ACCUMULATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FAN REVERSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
THERMAL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

8001-3
LOADER CONTROL VALVE
Removal STEP 5
STEP 1
Park the machine on a level surface.
IMPORTANT: If machine is equipped with quick-attached
components, disconnect them from machine prior to
proceeding.
STEP 2
BD06H198
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.
STEP 6
Loosen the filler cap on the reservoir to release the
air pressure in the reservoir.
BD03A092
STEP 7
Raise the lift arms and install the safety link on the lift
arm cylinder. Drain the hydraulic reservoir.
STEP 3 STEP 8
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.
STEP 4
position.
BD03A093
Loosen and remove the bolts and washers that

fasten the access cover plate for the loader control
valve. Remove the cover plate.

8001-4
W270R025
1. GREEN-BLACK-BLACK 3. YELLOW-BLACK-BLACK 5. HOSE PILOT ACCUMULATOR

2. RED-BLACK-BLACK 4. ORANGE-BLACK-BLACK 6. RED-WHITE-BLACK
HYDRAULIC VALVE PILOT LINE CONNECTIONS

8001-5
1 2
5 7
3
3
6
4
W270R026
1. TUBE TILT LEFT BASE 4. TUBE LIFT RIGHT ROD 7. TUBE LIFT RIGHT BASE
2. TUBE TILT RIGHT BASE 5. TUBE LIFT LEFT ROD 8. LOADER VALVE
3. HOSE LIFT CYLINDER 6. TUBE LIFT LEFT BASE
LOADER CONTROL VALVE LINE CONNECTIONS

8001-6
STEP 9 STEP 15
Disconnect the hoses from the remote control
valve(s) at the loader control valve. Refer to the
illustration on page 4 for color coding. Install a plug in
each hose and a cap on each fitting.
STEP 10
Loosen and remove tilt cylinder lines (1 and 2). Install
a plug in each line and a cap on each fitting.
STEP 11
Loosen and remove lines (4 and 5). Install a plug in
each line and a cap on each fitting.
STEP 12
Loosen and remove lines (6 and 7). Install a plug in
each line and a cap on each fitting.
STEP 13
Loosen and remove supply and return lines. Install a
plug in each line and a cap on each fitting.
STEP 14 W270R027
Loosen and remove the three bolts, washers and
Attach proper lifting equipment to lift loader control spacer that hold the loader control valve to the valve
valve. mounting plate. Remove the loader control valve.

8001-7
Fill the hydraulic reservoir with oil. Refer to Section
IMPORTANT: Before installing the fittings or connecting
1002 for the correct oil.
the tubes to the fittings, install new O-rings on the fittings.
STEP 24
STEP 16
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 25
position.
STEP 26
W270R027
BD03A092
Install and align the loader control valve with the
valve mounting plate. Raise the loader arms and remove the safety link.
STEP 17 STEP 27
Install the bolts, washers and spacer that fasten the Run engine at half throttle.
loader control valve to the valve mounting plate.
Tighten the bolts. STEP 28
Slowly and completely extend and retract all
STEP 18 cylinders at least 10 times to remove any air from the
Tighten the left lift cylinder lines (5 and 6). circuits.
STEP 19 STEP 29
Install and tighten the supply and return lines. Stop the engine and check for leaks.
STEP 20 STEP 30
Install and tighten right lift cylinder lines (4 and 7). Install the access cover on the front of the machine.
STEP 21 STEP 31
Install and tighten tilt cylinder lines (1 and 2). Check the level of the hydraulic oil and add hydraulic
oil as required.
STEP 22
Connect the hoses to the remote control valve(s) at
the loader control valve. Refer to the illustration on
page 4 for color coding.

8001-8
JOYSTICK CONTROL VALVE
Removal STEP 37
STEP 32
parking brake.
BD06F208
STEP 33 Open and remove the access panel.

position. STEP 38
STEP 34
Unlatch and open the right hand side access door.
STEP 35
Lift the access door up and remove the access door
from the pins.
STEP 36
BD06F209
Remove the front access panel.
STEP 39
BD06F207
Unlatch and open the window on the right hand side.
BD06F210
Disconnect the electrical connectors for the joystick

control valve.
STEP 40
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.

8001-9
Put identification tags on each hose and disconnect
one at a time from the joystick control valve. Install STEP 45
plugs in the hoses and caps on the fittings. Install new O-rings on the adapters for the joystick
control valve.
STEP 42
Loosen and remove the screws and washers holding STEP 46
the hydraulic control tower cover. Remove the cover. Install the joystick control valve and screws in the
hydraulic control tower and tighten the screws.
STEP 43
Loosen and remove the screws that fasten the STEP 47
joystick control valve to the hydraulic control tower. Install the cover over the joystick control valve and
install the screws and washers.
STEP 44
Remove the joystick control valve from the hydraulic STEP 48
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 11 and 12 as necessary.
STEP 49
Turn off the vacuum pump and disconnect from the
STEP 50
BD06F210
Connect the electrical connectors for the joystick

control valve.
STEP 51
position.
STEP 52
Start the engine and run the engine at low idle.
STEP 53
Check to see that the joystick control valve works
correctly.

8001-10
STEP 54 STEP 57
Check for hydraulic oil leakage at the joystick control
valve.
STEP 55
Check the level of hydraulic oil in the reservoir and
add as required.
STEP 56
BD06F208
Install and close the access panel.
STEP 58
BD06F209
Position the access panel on the ROPS cab or the

ROPS canopy and install and tighten the screw.
BD06F207
Close the right hand window.

8001-11
7 1
7
4 6
5 7
4 2 1
6 3
3 2
5
7 7 7 7
2 1 2 1
3 6 3 6
4 5 4 5
W230R021 W230R022
1. PILOT TANK HOSE 1. PILOT TANK HOSE

2. PILOT PRESSURE HOSE 2. PILOT PRESSURE HOSE
3. RED BLACK GREEN 3. RED BLACK GREEN
4. ORANGE BLACK GREEN 4. ORANGE BLACK GREEN
5. YELLOW BLACK GREEN 5. YELLOW BLACK GREEN
6. GREEN BLACK GREEN 6. GREEN BLACK GREEN
7. RED WHITE GREEN 7. RED WHITE GREEN
3 LEVER HOSE COLOR CODING JOYSTICK AND 1 LEVER HOSE COLOR CODING

8001-12
1
4
5
6
3 4 5
6
3
2 1
2 1 2 1
6 6
3 3
4 5 4 5
W230R023 W230R020

2 LEVER HOSE COLOR CODING JOYSTICK HOSE COLOR CODING

8001-13
HYDRAULIC PUMP
17
4
10
5 4
7
5
17 6 6
8
11 1
16
12
14 18
13
2 3
15
W270R028
1. PUMP MAIN HYDRAULIC 6. TUBE 11. TRANSMISSION 16. STEERING PRIORITY MANIFOLD
2. MOUNT BOLTS 7. HOSE SUCTION 12. LOADER LOAD SENSE HOSE 17. CLAMPS
3. DRAIN HOSE 8. HOSE CASE DRAIN 13. BOLT 18. LOADER VALVE
4. BOLT 9. HYDRAULIC TANK 14. SPLIT FLANGE
5. SPLIT FLANGE 10. CLAMPS 15. LOADER HIGH PRESSURE

8001-14
Removal STEP 69
Connect lifting equipment to hydraulic pump (1).
NOTE: When disconnecting hydraulic fittings, plug hoses
Take up all slack in lifting equipment. Remove four
and cap fittings to prevent entry of foreign matter into
mounting bolts (2) and washers securing pump to
hydraulic system.
transmission. Pull hydraulic pump from transmission
and remove from loader. Remove and discard O-ring
STEP 59 from pump.
bucket to the floor. Stop the engine and apply the Installation
parking brake.
NOTE: Install new O-rings where required.
STEP 60
Place the master disconnect switch in the OFF STEP 70
position. Install new O-ring on hydraulic pump flange. Move
pump into position and install in transmission. Install
STEP 61 four washers and bolts (2) to secure pump (1) to
Loosen the filler cap on the reservoir to release any transmission, tighten the bolts. Disconnect lifting
air in the reservoir. Connect a vacuum pump to the equipment from pump.
hydraulic reservoir, turn on the pump.
STEP 71
STEP 62 Connect pump pressure hose (15) to steering priority
Refer to Section 9007 and remove the ROPS cab or manifold (16).
ROPS canopy. Install two split flanges (14). Install four bolts (13).
Apply tightening and torquing bolts to 198 to 242 Nm
(1752-2142 pound feet).
STEP 63
Remove eight bolts (4) and washers. Remove four
STEP 72
split flanges (5). Disconnect tubes (6) with suction
hoses (7) from hydraulic pump. Remove and discard Connect drain hose (3).
O-ring face seals from flange heads of tubes.
STEP 73
STEP 64 Connect load sense hose (12).
Loosen clamps (10). Tag and disconnect suction
hoses (7) from hydraulic reservoir and remove from STEP 74
machine. Install and connect case drain hose (8).
STEP 65 STEP 75
Tag and disconnect case drain hose (8); remove Install suction hoses (7), tighten clamps (10) to 10 to
hose (8). Remove and discard O-ring face seal from 11 Nm (90 to 100 pound inches).
fitting.
STEP 76
STEP 66 Install four split flanges (5). Install eight bolts (4) and
Tag and disconnect load sense hose (12). Remove washers, tighten bolts (4) to 73.4 to 90.4 Nm (650 to
and discard O-ring face seal from fitting. 800 pound inches).
STEP 67 STEP 77
Tag and disconnect drain hose (3). Remove and Refer to Section 9007 and install the ROPS cab or
discard O-ring face seal from fitting. ROPS canopy.
STEP 68 STEP 78
Remove four bolts (13) and washers. Remove two Turn off the vacuum pump and disconnect from the
split flanges (14). Tag and disconnect pump pressure hydraulic reservoir.
hose (15) from steering priority manifold (16).
Remove and discard O-ring face seal from flange
heads of hose.

8001-15
STEP 79 STEP 81
Place the master disconnect switch in the ON Stop the engine and check for hydraulic oil leakage
position. at the hydraulic pump.
STEP 80 STEP 82
Start the engine and run the engine at low idle for two Check the level of the hydraulic oil in the reservoir
minutes. and add hydraulic oil as required.
NOTE: If any unusual vibration is heard coming from the
pump, stop the machine immediately and check for
obstructions in the pump suction line.

8001-16
LIFT CYLINDERS
Removal STEP 87
STEP 83
parking brake.
STEP 84 BD01D709
Relieve the pressure in the ride control accumulator Loosen and remove the bolt, washer and spacer that
with the manual bleeder valve located at the rear of hold the pivot pin for the yoke.
the front chassis.
STEP 88
STEP 85
Loosen the filler cap on the hydraulic reservoir to
release any pressure.
STEP 86
BD01D711
Use a proper lifting device and secure a strap around

the lift cylinder.
STEP 89
W230R479
Tag and disconnect the hoses on each side of the lift

cylinder. Install plugs in the hoses and caps on the
fittings.
BD01D712
Remove the pivot pin from the yoke end of the lift
cylinder.

8001-17
STEP 93
Apply antiseize compound to the bores in the front
frame and the yoke on the piston rod.
STEP 94
BD01D710
Loosen and remove the bolt, washer and spacer that

hold the pivot pin at the closed end of the lift cylinder.
STEP 91
BD01D714
Use a proper lifting device and position the lift

cylinder on the machine.
STEP 95
BD01D713
Remove the pivot pin from the closed end of the lift
cylinder.
STEP 92
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.

8001-18
STEP 96 STEP 99
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 100
STEP 97
BD01D709
W230R479 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 101
STEP 98 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 102
SLOWLY move the yoke into alignment with the Lubricate the pivot pins with molydisulfide grease.
loader frame.
STEP 103
Check the level of hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the

8001-19
BUCKET CYLINDER
Removal STEP 108
STEP 104
parking brake.
STEP 105
With the engine stopped, move the bucket control
lever to release pressure in the bucket circuit.
STEP 106
BD01D695
Loosen and remove the two bolts that fasten the

mounting bracket to the machine. Remove the
mounting bracket.
STEP 109
W230R480
Disconnect the proximity switch connector from the

wiring harness connector.
STEP 107
W230R483

mounting bracket for the proximity switch to the
bucket cylinder. Remove the mounting bracket and
switch.
W230R481

target bar to the mounting bracket. Remove the
target bar.

8001-20
STEP 110 STEP 113
W230R482 BD01D701
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 114
STEP 111
BD01D704
BD01D700 Remove the pivot pin from the head end of the
Use acceptable equipment to hold the bucket bucket cylinder.
cylinder.
NOTE: It is not necessary to remove the grease line from
the pivot pin unless the pivot pin is to be replaced.
STEP 112
STEP 115
BD01D698
Loosen and remove the bolt, washer and spacer that

BD01D706
fasten the pivot pin from both ends of the bucket
Raise the bucket cylinder and remove the cylinder
cylinder.
from the machine.

8001-21
STEP 116
Apply antisieze compound to the bores in the front
frame and the bores in the loader arm for the bucket
cylinder.
STEP 117
W230R482
Connect the hoses to each side of the bucket

cylinder.
STEP 121
If the rod end of the bucket cylinder is not aligned
with the bellcrank, have another person start the
BD01D706
engine and run the engine at low idle and use the
Use acceptable lifting equipment to lower the bucket bucket control lever to SLOWLY move the piston rod
cylinder into position. eye into alignment with the bellcrank.
STEP 118 STEP 122

Install the pivot pin and stop the engine.
STEP 123
BD01D704
Install the pivot pin to the head end of the bucket

cylinder.
BD01D698
STEP 119 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.

8001-22
STEP 124 STEP 127
W230R483 W230R480
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 125 STEP 128

See Section 9006 for the adjustment procedure for
adjusting the proximity switch.
STEP 129
Start and run the engine at low idle.
STEP 130
SLOWLY extend and retract the piston rod three
times to remove any air from the bucket cylinder.
STEP 131
Lubricate the pivot pins with molydisulfide grease.
BD01D695
Install the two bolts for the mounting bracket for the STEP 132
target bar.
Check the level of the hydraulic oil in the reservoir
and add as required. Tighten the filler cap on the
STEP 126 hydraulic reservoir.
W230R481
Install the two bolts that fasten the target bar to the
mounting bracket.

8001-23
OIL COOLER
Removal STEP 138
STEP 133
bucket to the ground. Stop the engine and apply the
parking brake.
STEP 134
Raise the engine hood.
STEP 135
position.
W270R609
Disconnect the top hose and install a plug in the hose
STEP 136
and a cap on the fitting.
STEP 139
W270R610
Disconnect the hose from the bottom of the oil
cooler. Install a plug in the hose and a cap on the
1 fitting.
STEP 140
W270R118
Open the frame (1) of the engine cooling system. 2

1
STEP 137
release the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.
W270R611
Loosen and remove the bolt (1) and washer (2) that
fasten the oil cooler to the cooling frame. Remove
the oil cooler from the machine.

8001-24

STEP 145
2 position.
1
STEP 146
Start the engine and run the engine at low idle for two
minutes. Stop the engine and check for hydraulic oil
leakage at the ports on the oil cooler.
STEP 147
W270R611
Place the oil cooler in position in the cooling frame. and add hydraulic oil as required.
Install and tighten the mounting washers (2) and
bolts (1).
STEP 142
W270R610
Connect the lower hose to the oil cooler to the

cooling frame
STEP 143
W270R609
Connect the hose to the top of the oil cooler.

8001-25
RIDE CONTROL ACCUMULATORS
Removal STEP 151
STEP 148
parking brake. 3
W270R030
STEP 149 Disconnect the hoses (3) from the elbow at the top of
the ride control accumulators. Install a plug in the
hoses and a cap on the fittings.
STEP 152
5
4
2
6
1
W270R031
Loosen and remove the nuts (4) and washers (5)
from the U-bolt (6). Remove the U-bolt.
STEP 153
Loosen and remove the eight bolts that fasten the
W270R029 accumulators bracket to the front frame. Remove the
Relieve the pressure in the ride control accumulators ride control accumulators from the machine.
with the manual bleeder valve (1) located on the top
of the ride control valve (2). Remove the plug and
turn the valve two turns counter-clockwise.
STEP 150
release the air pressure in the reservoir. Connect a
pump.

8001-26
STEP 154
Place the ride control accumulators in position on the
front frame.
4
STEP 155
Install the eight bolts that fasten the accumulators
bracket to the front frame. Tighten the bolts.
STEP 156
W270R033
2 Remove the caps and plugs and install the hoses (4) on
the elbow at the top of the ride control accumulators.
3
STEP 158
Turn off and disconnect the vacuum pump from the
1
STEP 159
Tighten the accumulator manual bleeder valve
located on the top of the ride control valve to a torque
W270R032
of 3.5 Nm (31 lb-in). Install the plug and torque to
Install the U-bolt (1), washers (2) and nuts (3).
5 Nm (44 lb-in).
Tighten the nuts.
STEP 160
Refer to Section 8002 Testing the Ride Control for
the proper charging of the accumulator to check for
leaks.
STEP 161

8001-27
RIDE CONTROL VALVE
Removal STEP 164

STEP 162 release the air pressure in the reservoir. Connect a
Park the machine on a level surface and lower the vacuum pump to the hydraulic reservoir, turn on the
bucket to the floor. Stop the engine and apply the pump.
parking brake.
STEP 165
position.
several times to release any hydraulic pressure in the pilot STEP 166
control circuit, turn ignition switch OFF. Disconnect the electrical connector the ride control
valve.
STEP 163
STEP 167
Tag and disconnect the hoses from the ride control
valve. Install a plug in the hoses and caps on fittings.
STEP 168
3
4
2
W270R034
Loosen and remove the three bolts (3) and washers

(4) that fasten the ride control valve to the frame.
STEP 169
W270R029
Remove the ride control valve from the machine.
Relieve the pressure in the ride control accumulators
with the manual bleeder valve (1) located on the top
of the ride control valve (2). Remove the plug and
STEP 170
turn the valve two turns counter-clockwise. Remove and discard all O-rings.

8001-28

Connect the hoses to the ride control valve.
STEP 171
Install the ride control valve in position on the front STEP 176
frame. Connect the electrical connector to the ride control
valve.
STEP 172
STEP 177
2 3 Turn off the vacuum pump and disconnect from the
1
STEP 178
position.
STEP 179
Start and run the engine at low idle for two minutes.
W270R036 STEP 180

Install the washers (1) and bolts (2) through the plate Stop the engine and check for hydraulic oil leakage
(3) into the ride control valve. Tighten the bolts. at the ride control valve.
STEP 173 STEP 181

STEP 182
Refer to Section 8002 and perform the Ride Control
Test Procedure.
W270R036
Tighten the accumulator manual bleeder valve (4)

located on the top of the ride control valve (5) to a
torque of 3.5 Nm (31 lb-in). Install the plug and
torque to 5 Nm (44 lb-in).
STEP 174
Lubricate and install new O-rings.

8001-29
FAN REVERSING VALVE
Removal STEP 186
STEP 183 1
2
bucket to the ground. Stop the engine and apply the
parking brake.
STEP 184 W270R038
Loosen the filler cap on the hydraulic reservoir to Tag and disconnect the fan forward hose (1) from the
release the air pressure in the reservoir. Connect a fan reversing valve. Install a plug in the hose and a
vacuum pump to the hydraulic reservoir, turn on the cap on the fitting. Tag and disconnect the fan reverse
pump. hose (2) from the fan reversing valve. Install a plug in
the hose and a cap on the fitting.
STEP 185
STEP 187
3 4
3
W270R039
W270R037
Disconnect the electrical connector (1-2) for the fan Tag and disconnect the fan valve return hose (3)
reversing valve (3). from the fan reversing valve. Install a plug in the hose
and 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 188
Loosen and remove the nuts, washers and bolts.
STEP 189
Remove the fan reversing valve from the machine.
STEP 190
Remove and discard all O-rings from the fittings.

8001-30
STEP 191
Place the fan reversing valve into position on the 1
machine.
STEP 192 3
Lubricate and install new O-rings in the fittings.
STEP 193 2
Install the bolts, washers and nuts. Tighten the nuts.
STEP 194
W270R037
Connect the electrical connector for the fan reversing

valve.
STEP 197
4 Turn off the vacuum pump and disconnect from the
STEP 198
Check the level of the hydraulic oil in the reservoir.
3
STEP 199
W270R039
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 200
STEP 195 Stop the engine and check for hydraulic oil leakage
at the fan reversing valve.
1
2 STEP 201
reservoir.
W270R038
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.

8001-31
THERMAL VALVE
STEP 202 STEP 206
Park the machine on a level surface and lower the Place the thermal valve (5) into position on the
bucket to the ground. Stop the engine and apply the machine.
parking brake.
IMPORTANT: With the engine NOT running, pump the STEP 207
brake repeatedly to be sure the brake accumulators have no Lubricate and install new O-rings in the fittings.
position then move the loader control valve back and forth STEP 208
several times to release any hydraulic pressure in the pilot Install the bolts (8), washers (7) and nuts (6). Tighten
control circuit, turn ignition switch OFF. the nuts.
STEP 203 STEP 209

Loosen the filler cap on the hydraulic reservoir to Connect the hoses (1-2-3-4) to the thermal valve,
release the air pressure in the reservoir. Connect a remove and discard tags.
pump. STEP 210
8
STEP 211
Check the level of the hydraulic oil in the reservoir.
1
2 STEP 212
Start the engine and run the engine at low idle for two
minutes.
STEP 213
5 Stop the engine and check for hydraulic oil leakage
at the thermal valve.
3
7 STEP 214
6 Check the level of the hydraulic oil in the reservoir
4
reservoir.
W270R040
Tag and disconnect the hoses (1-2-3-4) from the

thermal valve (5). Install a plug in the hose and a cap
on the fitting.
STEP 205
Remove the nuts (6), washer (7) and mounting bolts
(8) from the thermal valve, remove the valve from the
machine.

8001-32
NOTES

8002
Section
8002
HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING,

AND PRESSURE CHECKS

Via Plava, 80
8002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problems 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 HIGH PRESSURE
PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjusting the High Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TESTING AND ADJUSTING THE LOW PRESSURE
PUMP DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjusting the Low Pressure Pump Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjusting the Loader Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjusting the Steering Limit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adjusting the Loader Pump Cutoff Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
HIGH PRESSURE PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TESTING THE RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

8002-3
SPECIFICATIONS
Manufacturer ....................................................................................................................................... Bosch-Rexroth
High pressure pump (closest to transmission) .............................................................................220 L/min (58 gpm)
Differential pressure ......................................................................................................... 26 ± 1 bar (377 ± 14.5 psi)
Nominal displacement .............................................................................................................100 cm3 (6 cubie inch)
Implement Limit Pressure.................................................................................248 to 255 bar (3596.9 to 3698.4 psi)
Low pressure pump (furthest from transmission) ......................................................................187 L/min (49.5 gpm)
Differential pressure ......................................................................................................... 22 ± 1 bar (319 ± 14.5 psi)
Nominal displacement ...............................................................................................................85 cm3 (5 cubie inch)
Implement Limit Pressure.................................................................................239 to 243 bar (3466.4 to 3524.4 psi)
Circuit relief valve pressure setting

Auxiliary A and B port.................................................................................................................280 bar (4061 psi)
Bucket A port..............................................................................................................................280 bar (4061 psi)
Bucket B port..............................................................................................................................280 bar (4061 psi)
Hydraulic Controller Pilot supply Pressure ..................................................................29 to 40 bar (420.6 to 580 psi)
Steering relief valve pressure setting ............................................................................................ See Section 5002
Accumulator pressure .................................................................................................................... See Section 7002
NOTE: Both pump sections provide flow for both the steering and loader functions.

8002-4
SPECIAL TOOLS
633L95 B877168V
380001741 PRESSURE FITTING KIT 380001740 FLOWMETER FITTING KIT
632L95 B877895M
380001742 PRESSURE FITTING KIT 380001726 HAND PUMP
B785789M B877558M
380001731 FLOWMETER 380001739 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 specified in Section 1002.
the oil level correct?.
Yes
Heat the oil in the hydraulic system to

operating temperature. Operate the
machine to find which circuits have
problems.
Problems in All Circuits

Replace the return line hydraulic filter.
See Section 2002. Do the stall test to see if
the engine is good.
See Section 8003 and check for contaminated See Page 18. Do the flow meter test of the
No hydraulic pump.
oil. Is the oil contaminated?
Yes
See Section 8003 and clean or replace the

oil.
Problem in All Loader Circuits

See Page 11 and check the pressure setting
Adjust the limit pressure. See page 11 in this
of the limit pressure in the loader control No 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 See Section 8006 and repair the cylinder.
No
packing good?
Yes
See Page 20. Check and adjust the circuit See Section 8005. Disassemble the loader
relief valves. Then check the operation of control valve and check for worn or
No
the circuit again. Does the circuit work damaged parts.
correctly?
Yes
The problem is repaired.
Problem in the Steering Circuit

See Section 5002 and check the steering
No Repair the component as necessary.
circuit. Is the steering circuit good?
Yes
See Page 13. Do the Steering Pump Limit

Pressure Test and Adjustment
Problem in the Ride Control

Lift arms rapidly and continuously sink See the Ride Control Test Procedure page
towards the ground. No 21 in this section.
Yes
Check the manual bleed valve for the ride

control accumulator to be sure that it is
closed.

8002-7
TESTING AND ADJUSTING THE HIGH PRESSURE

PUMP DIFFERENTIAL PRESSURE
Pressure Check STEP 3
STEP 1
1
W230R407
2 3
W270R041
Install articulation lock (1).
2. TEST PORT G1 (PUMP PRESSURE)
STEP 2 4. TEST PORT (LOAD SENSE)
Make sure that the temperature of the hydraulic oil is
at least 54°C to 57°C (129°F to 135°F). The following Connect two 69 bar (1000 psi) test gauges, one to
is the procedure for heating the hydraulic oil. the test port G1 (2) located on the priority valve (3),
and one on the pump load-sense pressure tap (4
A. Start the engine and run at full throttle.
closest to transmission).
B. Lower the loader bucket to the ground and
IMPORTANT: Do not steer or operate loader controls
hold the lift control lever in the FLOAT
while the gauges are connected, gauges could be damaged.
position.
C. Roll the bucket back against the stops and STEP 4
hold. Start the engine and run at low idle.
D. View the oil temperature by pressing the down
arrow on the key pad to display hydraulic oil STEP 5
temperature. Make sure all of the controls are in the neutral
After heating oil to operating temperature, lower position and record the readings on the test gauges
bucket to the ground, turn off the engine, and relieve (2) and (4).
all pressure in the hydraulic system.
STEP 6
Subtract the reading of the test port (4) from the
reading of the test port (2).

8002-8
STEP 7 Adjusting the High Pressure Pump
The difference between the two readings should be Differential Pressure
25 to 27 bar (363 to 392 psi).
STEP 9
STEP 8
The load-sense adjusting screw is directly under the
If this reading is more or less than specified, it will be priority valve. Turn the screw clockwise to increase
necessary to adjust the pump load-sense pressure. the load-sense pressure. Turning the screw
counterclockwise will decrease the load-sense
pressure.
NOTE: One turn of the adjustment screw will change the
pressure approximately 16 bar (230 psi).

8002-9
TESTING AND ADJUSTING THE LOW PRESSURE

PUMP DIFFERENTIAL PRESSURE
STEP 1
1
W230R407
2 3
Install articulation lock (1). W270R042

STEP 2 4. TEST PORT (LOAD SENSE)
at least 54°C to 57°C (129°F to 135°F). The following Connect two 69 bar (1000 psi) test gauges, one to
is the procedure for heating the hydraulic oil. the test port G2 (2) located on the priority valve (3),
and one on the pump load-sense pressure tap (4
furthest from the transmission).
IMPORTANT: Do not steer of operate loader controls
while the gauges are connected, gauges could be damaged.
position.
C. Roll the bucket back against the stops and STEP 4
hold. Start the engine and run at low idle.
● To measure the oil temperature with the
instrument cluster: STEP 5
A. Press the up or down arrow key. Make sure all of the controls are in the neutral
position and record the readings on the test gauges
B. Stop at the info screen with the temperatures (2) and (4).
that need to be monitored are on.
After heating oil to operating temperature, lower STEP 6
bucket to the ground, turn off the engine, and relieve Subtract the reading of the test port (4) from the
all pressure in the hydraulic system. reading of the test port (2).

8002-10
STEP 7 Adjusting the Low Pressure Pump
The difference between the two readings should be Differential Pressure
21 to 23 bar (305 to 333 psi).
STEP 9
STEP 8
The differential adjusting screw is directly under the
If this reading is more or less than specified, it will be priority valve. Turn the screw clockwise to increase
necessary to adjust the pump differential pressure. the load-sense pressure. Turning the screw
counterclockwise will decrease the differential
pressure.
NOTE: One turn of the adjustment screw will change the

8002-11
TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE

STEP 1 at least 54°C to 57°C (129°F to 135°F). The following
is the procedure for heating the hydraulic oil.
position.
C. Roll the bucket back against the stops and
hold.
instrument cluster:
1 A. Press the up or down arrow key.
W230R407 B. Stop at the info screen with the temperatures
1. ARTICULATION LOCK that need to be monitored are on.
After heating oil to operating temperature, lower
Install articulation lock (1). bucket to the ground, turn off the engine, and relieve
STEP 2
STEP 4
Run the engine at full throttle.
STEP 5
Roll the loader bucket back against the stops.
STEP 6
Record the reading on the test gauge.
STEP 7
Reading should be 248 to 255 bar (3597 to 3700 psi).
STEP 8
If this reading is more or less than specified, it will be
necessary to adjust the pump limit pressure.
2
1
W270R043
1. TEST PORT G1 (LOAD LIMIT)
Connect a 345 bar (5000 psi) test gauge to the test

port G1 (1), located on the priority valve (2).

8002-12
Adjusting the Loader Limit STEP 9

Pressure The limit adjusting screw (1) is located on the left
side of the loader valve (2). Turn the screw clockwise
to increase the limit pressure. Turning the screw
counterclockwise will decrease the limit pressure.
2 NOTE: One turn of the adjustment screw will change the
W270R044

8002-13
TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE

position.
hold.
instrument cluster:
STEP 2
STEP 4
Start the engine and run at full throttle.
STEP 5
Steer hard in either direction over relief pressure.
STEP 6
STEP 7
STEP 8
necessary to adjust the steering limit pressure.
2
1
W270R043
1. TEST PORT G1 (LOAD LIMIT)
Connect a 345 bar (5000 psi) test gauge to the test

port G1 (1), located on the priority valve (2).

8002-14
Adjusting the Steering Limit STEP 9

Pressure The steering priority valve is located on the hydraulic
pump, the adjusting valve (1) is located on the
transmission side of the priority valve. Turning the
screw clockwise to increase the limit pressure.
Turning the screw counterclockwise will decrease the
limit pressure.
W270R045
1. STEERING LIMIT VALVE

8002-15
TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE

position.
hold.
instrument cluster:
STEP 2
STEP 4
Start the engine and run at full throttle.
STEP 5
Roll the loader bucket back against the stops.
STEP 6
STEP 7
STEP 8
necessary to adjust the pump cutoff pressure.
2
1
W270R046
Connect two 345 bar (5000 psi) test gauge to the test
port G2 (1) located on the priority valve (2).

8002-16
Adjusting the Loader Pump Cutoff

Pressure
STEP 9
W270R047
The unloading adjuster (1) is the longer of the two

adjusters on the loader pump. Turn the screw
clockwise to increase the cutoff pressure. Turning
the screw counterclockwise will decrease the cutoff
pressure.
NOTE: The adjusting screw is located just above the
steering priority valve on the pump furthest from the
transmission.

8002-17
TESTING THE HYDAULIC CONTROLLER PILOT SUPPLY PRESSURE

NOTE: This pressure is factory preset and is not STEP 2
adjustable. Raise lift arms to the top and turn off the engine. Turn
the ignition switch to the “RUN” position and
Pressure Check disengage the controller lock-out switch.
STEP 1 STEP 3
Make sure that the temperature of the hydraulic oil is Wait for the buzzer to stop then repeatedly put the
at least 54°C to 57°C (129°F to 135°F). The following loader control lever into “FLOAT” position and back
is the procedure for heating the hydraulic oil. to neutral.
STEP 4
B. Lower the loader bucket to the ground and The system should allow a minimum of 10 actuations
hold the lift control lever in the FLOAT into float and still cause the lift arms to come down.
position.
NOTE: If 10 full actuations cannot be made, an internal
C. Roll the bucket back against the stops and hydraulic leak exists.
hold.
instrument cluster:
A. Press the up or down arrow key.
B. Stop at the info screen with the temperatures
that need to be monitored are on.

8002-18
HIGH PRESSURE PUMP FLOW TEST

NOTE: The pump differential pressure must be set before STEP 6
attempting any other tests. Refer to page 3 of this section. Using the temperature gauge on the flow meter,
continue to run the engine at high idle until the
STEP 1 temperature of the hydraulic oil is at least 52°C to
Connect the flow meter (3) by disconnecting the 60°C (125°F to 140°F).
articulation pressure hose (6) to the valve supply
tube (12), installing a cap on the fitting at the valve STEP 7
supply tube (12). Refer to illustration on page 19. Run the engine at low idle, fully open the flow meter
valve.
STEP 2
Disconnect the load sense hose (7) and install a cap STEP 8
the fitting at the loader valve (13). Open the needle valve (8) and operate the engine at
NOTE: This is the line that returns to the pump 2000 rpm. At 0 bar (0 psi) the flow should be 250 to
compensator valve. 255 L/min (66 to 67.4 gpm).
STEP 3 STEP 9
Connect a “T” fitting (10) into the loader control valve Close the flow meter valve slowly and read the flow
inlet hose (6) and to the flow meter inlet hose (11). at 34.5 bar (500 psi) the flow should be 249 to 255
L/min (65.8 to 66.8 gpm).
STEP 4
Use a union (9) and connect an in line needle valve STEP 10
(8) to the open port in the “T” fitting (10), connect the Close the flow meter valve slowly and read the flow
load sense hose (7) to the needle valve (8). at 2000 psi @ 2000 rpm. The flow should read 244.5
to 247.5 L/min (64.6 to 65.4 gpm).
STEP 5
Make sure that the flow meter valve and the installed STEP 11
needle valve are in the open position. Start and run Continue to close the flow meter valve slowly, at
the engine at high idle, slowly close the flow meter approximately 2900 psi the flow should drop
valve until a pressure reading of 103 bar (1500 psi) is significantly, this will be the low pressure pump
obtained. destroking.
STEP 12
Continue slowly closing the flow meter valve until
3500 psi is reached. The flow should read between
120 to 122 L/min (31.6 and 32.1 gpm).
STEP 13
If any of the pump flow readings are not within
specifications, the pump may be out of calibration
and Technical Support Services should be
contacted.

8002-19
1
4
7
2
3
11
6
10
9
8
12
13
W270R049
1. HYDRAULIC RETURN MANIFOLD 6. HOSE ARTICULATION PRESSURE 11. FLOW METER INLET HOSE
2. FLOW METER RETURN HOSE 7. LOAD SENSE HOSE M14 ORB 12. VALVE TUBE SUPPLY
3. FLOW METER 8. NEEDLE VALVE 13. LOADER VALVE
4. PUMPS 9. UNION
5. PRIORITY VALVE 10. T FITTING
NOTE: IF UNIT IS EQUIPPED WITH AUXILIARY STEERING A TEE FITTING WILL HAVE TO BE USED IN THIS LOCATION

8002-20
TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES

Remove the safety strut and lower the bucket to the
STEP 1 floor. Shut off the engine. Find an easy place to
Circuit relief valves are located as shown below. disconnect the line for the circuit to be tested.
STEP 5
6 2 Connect the hand pump to the disconnected line that
goes to the loader control valve.
4
STEP 6
Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
21°C (70°F).
3
STEP 7
5 Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
be sure of the reading.
STEP 8
Compare the reading to the specifications on Page 3.
STEP 9
1 If the pressure is not correct, adjust the circuit relief
valve.
Adjustment
STEP 1
W270R048
Loosen the lock nut. Turn the adjustment screw
1. CIRCUIT RELIEF VALVES clockwise to increase the pressure or
2. PUMP LIMIT PRESSURE ADJUSTMENT
counterclockwise to decrease the pressure.
3. BUCKET SPOOL
4. LIFT SPOOL NOTE: One turn of the adjusting screw will change the
5. AUXILIARY SPOOL pressure approximately 138 bar (2000 psi).
6. LOADER CONTROL VALVE
STEP 2
STEP 2
Check the pressure again. Repeat the adjustment as
Raise the lift arms and install the safety link on the lift
necessary.
arm cylinder.
STEP 3
Loosen and remove the bolts and washers that
fasten the access cover plate for the loader control
valve. Remove the cover plate.

8002-21
TESTING THE RIDE CONTROL

STEP 1 STEP 6
Move the machine to a clear level surface with Dump the bucket until it hits the dump stops. Hold the
clearance for full lift arm and bucket movement. bucket in the dump position for 5 to 10 seconds.
NOTE: This will charge the ride control accumulator.
STEP 2
Install the articulation lock, start the machine, STEP 7
activate the parking brake.
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
STEP 3 their stops, place the pilot control lever in the neutral
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 STEP 8
should illuminate.
Set the ride control rocker switch to the “Always On”
position. The lift arms should rise 15 to 30 cm (6 to
STEP 4 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 illuminate STEP 9
see section 4002 and troubleshoot the electrical system for
If there is little or no lift arm raise, the test may have
the ride control.
been done too slowly. The elapsed time between
step 6 and step 8 should not exceed six seconds.
STEP 5
Raise the lift arms to the top of their travel and dump NOTE: If test was done to slowly repeat in the allotted
the bucket. time.
STEP 10
If test was completed in the allotted time and the lift
arms still do not rise, test the nitrogen charge in the
accumulator, see section 8013.

8002-22
NOTES

Section
8003
8003
CLEANING THE HYDRAULIC SYSTEM

Via Plava, 80
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
806128
380001733, fitting kit.
806127
380001727, filter unit, portable.
TR98H032
380001728, 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
hydraulic system permits efficient operation with a the hydraulic oil for contamination. See types of
small amount of contamination. An increase in this contamination below. If you find contamination, use
amount of contamination can cause problems in the the Portable Filter to clean the hydraulic system.
hydraulic system. The following list includes some of
these problems.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic 3. Visible contamination is foreign material that can
and visible. be found by sight, touch, or odor. Visible
contamination can cause a sudden failure of
1. Microscopic contamination occurs when very fine
components. Examples of visible contamination:
particles of foreign material are in suspension in
the hydraulic oil. A. Particles of metal or dirt in the oil.
2. These particles are too small to see or feel. B. Air in the oil
Microscopic contamination can be found by
C. The oil is dark and thick.
identification of the following problems or by
testing in a laboratory. Examples of the D. The oil has an odor of burned oil.
problems:
E. Water in the oil. See page 7.
A. Cylinder rod seal leak.
B. Control valve spools do not return to
NEUTRAL.
C. The hydraulic system has a high operating
temperature.

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,
19. Decrease the engine speed to low idle.
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.
WARNING: If retracting the cylinder rods
causes the attachments to be raised, block 16. Connect a suitable drain line to the OPEN end of
the attachments in place before proceeding each cylinder and place the other end in an
to the next step! acceptable container for contaminated oil.
39-4
NOTE: Any attachment or part of an attachment that is 18. Slowly and completely extend all cylinders. As
raised must be supported with acceptable equipment to the piston rod comes in/out of the cylinder, oil will
prevent the attachment from falling. be pushed out of the OPEN end of the cylinders.
3. Move each control lever in both directions to NOTE: Any attachment or part of an attachment that is
release pressure in the hydraulic circuits. raised must be supported with acceptable equipment to
4. Loosen and remove the filler cap from the prevent the attachment from falling.
reservoir. 19. Support any attachments that will be in the
5. Drain the hydraulic oil from the reservoir. RAISED position.
A. See Section 1002 for capacity specifications. 20. Stop the engine.
B. Have available acceptable equipment to drain 21. Disconnect the drain lines and connect the
the hydraulic oil. system lines to the cylinders.
C. Remove the drain plug from the bottom of the 22. Check the oil level in the hydraulic reservoir. Add
reservoir. oil as required. See Section 1002 for
specifications.
6. Remove the hydraulic filter elements from the
machine. 23. Install the filler cap on the reservoir.
7. Install new hydraulic filter elements on the 24. Remove the hydraulic filter elements from the
machine. machine.
8. Install the drain plug in the bottom of the 25. Install new hydraulic filter elements on the
reservoir. machine.
9. Fill the hydraulic reservoir with hydraulic fluid. 26. Start and run the engine at 1500 rpm (r/min),
See Section 1002 for specifications. operate each hydraulic circuit to completely
extend and retract the cylinders.
10. Disconnect the line from the OPEN end and
CLOSED end of each cylinder. 27. Stop the engine and check for leaks. Check the
oil level in the hydraulic reservoir. Add oil as
11. Be sure all control levers are in the NEUTRAL required. See Section 1002 for specifications.
position.
12. Start and run the engine at low idle.
IMPORTANT: Check the oil level in the hydraulic
reservoir frequently while doing step 13. Have another
person hold a container under the hydraulic lines while you
do step 13.

8003-8
NOTES

Section
8004
8004
HYDRAULIC PUMP

Via Plava, 80
8004-2
TABLE OF CONTENTS
PUMP SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PREPARING THE EQUIPMENT PUMP FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EQUIPMENT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

8004-3
PUMP SPECIFICATIONS
W270C
Manufacturer .................................................................................................................................................. Rexroth
High pressure pump (steering pump next to transmission) ..........................................................220 L/min (58 gpm)
Nominal displacement ............................................................................................................. 100 cm3 (6 cubic inch)
Low pressure pump (loader pump farthermost from transmission) ...........................................187 L/min (49.5 gpm)
Nominal displacement ............................................................................................................... 85 cm3 (5 cubic inch)
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)
W300C
High pressure pump (steering pump next to transmission) ..........................................................220 L/min (58 gpm)
Low pressure pump (loader pump farthermost from transmission) ..............................................220 L/min (58 gpm)
Rotation ................................................................................................. Clockwise as seen from the end of the shaft
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
7 8 9
6 5
5 4
4
3
10
2 11
1
12 24
13 23
22
21
20
19
18
17
15
14 16
30
29
15 28
27
26
25
BC06F550
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. O-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 STEP 3
STEP 1
Remove all dirt, oil, and grease from the exterior of
the equipment pump.
STEP 2
BC06F552
Remove the control valve.
STEP 4
BC06F551
Put alignment marks on the end cover and housing.
BC06F553
Remove the four bolts.

8004-6
STEP 5 STEP 6
BC06F555
BC06F554
Remove the end cover. Use a suitable bearing race puller and pull the
bearing race from the end cover.
NOTE: Watch for the flow plate, it can be stuck to either
the end cover or pump body. NOTE: Do not damage the sealing surfaces.

8004-7
STEP 7 STEP 9
BC06F558
Remove plug, pull control piston using a suitable tool

as shown.
NOTE: Do not use a magnet to pull the piston.
STEP 10
BC06F556
Remove the bearing and shim.
STEP 8
BC06F559
Remove the piston rod and swash plate. Turn the

swash plate slightly to break it free from the bearings.
BC06F557
Remove the rotary group from the housing in a

horizontal position.

8004-8
STEP 11 STEP 14
BC06F560
Remove the bearing and spring.
STEP 12
BC06F563
Use a suitable bearing race puller and pull the

bearing race from the housing.
STEP 15
BC06F561
Remove the shaft and bearing.
STEP 13
BC06F564
Remove the shim and plug.
BC06F562
Remove the retaining ring an seal.

8004-9
Inspection STEP 19
STEP 16
Clean all parts in cleaning solvent. Be careful not to
remove the alignment marks made during
disassembly.
STEP 17
BC06F567
Check the bearing surface.
STEP 20
BC06F565
Check for wear on the splines, seal areas for

grooves, bearing areas for scaring, and key set.
STEP 18
BC06F568
Check that the retaining plate is free of grooves and

that there is no sign of wear.
STEP 21
BC06F566
Check the surface that the pistons contact for

grooves and scaring.
BC06F569
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.

8004-10
STEP 22 STEP 24
BC06F572
BC06F570
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
BC06F573
Check ball for grooves and wear.
Check mounting surface for the flow plate for
damage.

8004-11
Assembly STEP 27
STEP 26
BC06F574 BC06F575
Install the plug in the housing and tighten to 127 Nm Put the shaft and bearing in the housing.
(93.5 pound-feet). Install shim and press in the
bearing race. STEP 28
BC06F576
Press in a new race into the end cover.

8004-12
STEP 29 STEP 31
BC06F579
Install the seal and retaining ring.
STEP 32
BC06F577
Install the end cover, 4 bolts and hand tighten.
STEP 30
BC06F578
A bearing pre load of 0.05 mm (0.002 inch) must be

obtained, add remove shims from bearing as
required.
BC06F580
Put new bearings in the housing. Install the reaction

spring.

8004-13
STEP 33 STEP 34
BC06F582
Install the piston into the housing with flat surface

out. Lubricate the O-ring and install the plug, tighten
the plug to 90 Nm (66 pound-feet).
STEP 35
BC06F581
Install the swash plate into the housing, work the

swash plate from side to side to seat it in the
bearings and spring. Install the piston rod.
BC06F583
Use grease to hold the pressure pins into position,

install the spacer, spring and snap ring.

8004-14
STEP 36 STEP 39
BC06F584
Use a suitable compressor, compress the spring and

install the snap ring.
STEP 37
BC06F585 BC06F587
Place the ball onto the pressure pins, install the Hold the pistons in the rotating housing using an
pistons into the retaining plate. O-ring, install the rotating group into the housing,
remove the O-ring.
STEP 38
BC06F586
Lubricate the piston and retaining plate with clean oil,

install the piston into the rotating housing.

8004-15
STEP 40 STEP 41
BC06F588
Use the shim that was required for the bearing pre
load in step 30. Install the shim and bearing onto the
shaft.
BC06F589
Install a new O-ring on the end cover, place the flow

plate onto the rotating group with aligning notch up.
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.

8004-16
STEP 42 STEP 43
BC06F591
Use new O-rings, install and tighten the control valve.
BC06F590
Instal and tighten the four bolts to 165 Nm

(121.5 pound-feet).

Section
8005
LOADER CONTROL VALVE
8005

Via Plava, 80
8005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Spool Valve Housing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Spool Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Spool Valve Spool Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DISSASEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Circuit Relief Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Circuit Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

8005-3
SPECIFICATIONS
Special Torques
End plate mounting bolts.....................................................................................................68 Nm (50 pound feet)
Pressure relief, flow limit, and pilot pressure reducing valves.................. 20 to 25 Nm (177 to 221 pound inches)
Allen head plugs...........................................................................................................200 Nm (147.5 pound feet)
Allen head locking screw................................................................................................100 Nm (73.7 pound feet)
Allen head cover screws (short) ................................................................................. 8.3 Nm (73.4 pound inches)
Allen head cover screws (long) .................................................................................. 8.3 Nm (73.4 pound inches)
Anticavitation valves.......................................................................................................100 Nm (73.7 pound feet)
Combination anticavitation and circuit relief .....................................................................60 Nm (44.2 pound feet)
Main relief valve pressure settings (Long Reach and Z-Bar) ............................. 248 to 255 bar (3597 to 3698.5 psi)
Circuit relief valve pressure setting
Auxiliary A and B port (Long Reach and Z-Bar) ........................................................................290 bar (4206 psi)
Bucket A port (Long Reach and Z-Bar) .....................................................................................290 bar (4206 psi)
Bucket B port (Long Reach and Z-Bar) .....................................................................................290 bar (4206 psi)

8005-4
3
2
1
8
21
9
10
6
8
12
14
5
16 7
20 13
19
14
15 11 13 10
5 18
17
W270R089
1. STUD 8. ANTICAVITATION AND CIRCUIT RELIEF 15. ANTI-CAVITATION VALVE

2. WASHER 9. HOUSING 1M6-22 16. CHECK VALVE
3. HEXAGON NUT 10. FLOW COMPENSATOR SPOOL 17. LOCKING PLATE
4. PLATE 11. HOUSING 2M-22 18. CYLINDER SCREW
5. ANTI-CAVITATION VALVE 12. INTERMEDIATE PLATE 19. PRESSURE RELIEFE VALVE
6. O-RINGS 13. O-RINGS 20. FLOW LIMIT VALVE
7. THROTTLE CHECK VALVE 14. PLUG 21. PRESSURE REDUCING VALVE
3 SPOOL VALVE HOUSING CONFIGURATION

8005-5
36 6
22
24
23
6
32
26
35 22
6 31 37
23
22 24 6
27
36
28
29 6 25
24
34 33 23
30 32
W270R090
6. O-RINGS 27. BOLT 33. COVER

22. THREADED STEEL PIPE FITTING 28. COVER 34. ADJUSTING ROD
23. SPRING RETAINER 29. CAP NUT 35. SPOOL
24. SPRING 30. JAM NUT 36. LOCKING SCREW
25. SPRING 31. SPOOL 37. SPOOL
26. COVER 32. BOLT
3 SPOOL VALVE SPOOL CONFIGURATION

8005-6
38 39
40
39
W270R091
38. HOUSING 39. ANTICAVITATION AND CIRCUIT RELIEF 40. FLOW COMPENSATOR SPOOL
4 SPOOL MOUNTING CONFIGURATION

8005-7
36 6
22
24
23
6 32
26
35 22
6 31 37
23
22 24 6
27
36
28
29 6 25
24
34 33 23
30 32
W270R092
6. O-RINGS 27. BOLT 33. COVER

22. THREADED STEEL PIPE FITTING 28. COVER 34. ADJUSTING ROD
23. SPRING RETAINER 29. CAP NUT 35. SPOOL
24. SPRING 30. JAM NUT 36. LOCKING SCREW
25. SPRING 31. SPOOL 37. SPOOL
26. COVER 32. BOLT
4 SPOOL VALVE SPOOL CONFIGURATION

8005-8
DISSASEMBLY
STEP 1 STEP 7
Remove valve from machine, see section 8001. Remove pressure relief valve (19).
STEP 2 STEP 8
Remove bolts (27), cover (28), springs (24 and 25), Remove flow limit valve (20).
and spring retainer (23).
STEP 9
STEP 3 Remove the check valve (16).
Remove bolts (32), covers (33 and 26), spring (24),
and spring retainer (23). STEP 10
Remove locking screw (14).
STEP 4
Use wooden dowel or brass drift and push spools STEP 11
(31, 35 and 37) from housing (11). Remove load sense shuttle check valve (7).
IMPORTANT: Do not force spools from housing, if spool
binds work back and forth until spool comes out freely. STEP 12
NOTE: Repeat steps 3 and 4 for a spool valve Remove pilot pressure reducing valve (21).
configuration.
STEP 13
STEP 5 Remove the cylinder screw (18) and the locking plate
Remove anticavitation valves (5, 8 and 15). (17).
NOTE: Repeat step for a 4 spool anticavitation valves STEP 14

(39).
Remove the hexagon nut (3) and washers (2) from
stud (1), remove plate (4) and intermediate plate (12)
STEP 6 from housing (11).
Remove the flow compensator spool (10).
NOTE: For 4 spool configuration remove housing (38)
NOTE: Repeat step for a 4 spool for the flow compensator from housing (11).
spool (40).

8005-9
STEP 15 STEP 17
2
1
2
1
1
1
BS03C025 BS03C027
1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RING

Remove and discard O-rings and thrust rings from Remove and discard O-rings and thrust ring from
pilot pressure reducing valve (21). locking screw (14).
STEP 16
2 STEP 18
1
2
1
1
3
1 1
BS03C026 2
1. O-RINGS 2. THRUST RINGS BS03C028
Remove and discard O-rings and thrust rings from 1. O-RINGS 2. THRUST RING 3. SPOOL SEAL
flow limit valve (20).
Remove and discard O-rings, thrust ring, and spool
seal from anticavitation valve (5).

8005-10
STEP 19
1
1
2
BS03C029
1. O-RINGS 2. THRUST RINGS

Remove and discard O-rings and thrust rings from pressure relief valve (19).

8005-11
STEP 20
3
4
2 1
1
1
BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Remove and discard O-rings and thrust rings from anticavitation and circuit relief valves (8 and 39).

8005-12
INSPECTION
1. Discard all O-rings, thrust rings, and spool seals. 4. Check the parts of the pressure relief valve,
anticavitation valves, and the anticavitation and
2. Clean all parts in cleaning solvent.
circuit relief valves. Use new parts as necessary.
3. Check the spools and the spool bores for
Inspect the other parts of the control valve. If any of
damage and wear.
the parts are damaged, install new parts.
ASSEMBLY
STEP 1
3
4
A
2 1
1 See Note
1
BS03C032
1. O-RINGS 2. THRUST RING 3. SPOOL SEAL 4. LOCK NUT

Install new O-rings and thrust rings on anticavitation and circuit relief valves (8 and 39). Torque relief valve (A) into
anticavitation valve to 20 Nm (14.7 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
STEP 2
1
1
2
BS03C029
1. O-RINGS 2. THRUST RINGS

Install new O-rings and thrust rings on pressure relief valve (19).

8005-14
STEP 3 STEP 6
2 1
1
1
3
1 1
2
BS03C025 BS03C028
1. O-RINGS 2. THRUST RINGS 1. O-RINGS 2. THRUST RING 3. SPOOL SEAL

Install new O-rings and thrust rings on pilot pressure Install new O-rings, thrust ring, and spool seal on
reducing valve (21). anticavitation valve (5).
STEP 4 STEP 7
Install and torque locking screw (14) to 100 Nm
2
(73.7 pound feet).
STEP 8
Install and tighten load sense shuttle check valve (7).
2
1 STEP 9
1 Install and torque pilot pressure reducing valve (21)
to 60 Nm (44 pound feet).
STEP 10
BS03C026 Install new O-rings on housing (11). Install plate (4)
1. O-RINGS 2. THRUST RINGS and intermediate plate (12), stud (1), washers (2) and
Install new O-rings and thrust rings on flow limit valve hexagon nut (3) onto housing (11). Torque nut to 68
(20). Nm (50 pound feet).
STEP 5 STEP 11
Install the locking plate (17) and the cylinder screw
(18). Torque screw to 68 Nm (50 pound feet).
1 NOTE: Repeat step for a 4 spool configuration for the
housing (38).
2
1 STEP 12
Install anticavitation valves (5 and 8) and torque to
100 Nm (73.7 pound feet).
NOTE: Repeat step for a 4 spool anticavitation valves
(39).
BS03C027
STEP 13
1. O-RINGS 2. THRUST RING
Install anticavitation valves (15) and torque to 60 Nm
Install new O-rings and thrust ring on locking screw (44.2 pound feet).
(14).

8005-15
STEP 14 Circuit Relief Pressure Test
Install and torque flow limit valve (20) to 20 to 25 Nm
(177 to 221 pound inches). STEP 1
Connect the hand pump to the port for anticavitation
STEP 15 and circuit relief valves (19).
Install the check valve (16). Torque locking screw to
NOTE: Repeat steps for machines that are configured
100 Nm (73.7 pound feet).
with a 3 or 4 spool valve.
STEP 16 STEP 2
Lubricate spools with hydraulic oil and push spools
Make sure that the hand pump is full of hydraulic oil
(31, 35 and 37) into housing (11).
and that the temperature of the oil is approximately
IMPORTANT: Do not force spools into housing. 21°C (70°F).
STEP 17 STEP 3
Install spring retainers (23), springs (24), covers (33 Operate the handle of the hand pump and read the
and 26), and bolts (32). Torque bolts to 8.3 Nm (73.4 highest pressure. Repeat this step several times to
pound inches). be sure of the reading.
STEP 18 STEP 4
Install spring retainers (23), spring (24 and 25), cover Compare the reading to the specifications on Page 3.
(28), and bolts (27). Torque bolts to 8.3 Nm (73.4
pound inches). STEP 5
NOTE: Prior to installation in the machine, circuit reliefs If the pressure is not correct, adjust the circuit relief
can be tested. valve.
STEP 19 Circuit Relief Adjustment

Install valve in machine, see section 8001.
STEP 1
STEP 20 Loosen the lock nut. Turn the adjustment screw
Check loader limit pressure, see section 8002. clockwise to increase the pressure or
counterclockwise to decrease the pressure.
NOTE: One turn of the adjusting screw will change the
STEP 2
Check the pressure again. Repeat the adjustment as
necessary.

8005-16
NOTES

Section
8006
CYLINDERS
8006

Via Plava, 80
8006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REPLACING BUSHINGS FOR THE BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

8006-3
SPECIFICATIONS
W270C Approximate weight
Lift Cylinder..............................................................................................................................279 kg (616.6 pounds)
Bucket Cylinder ....................................................................................................................289.3 kg (637.7 pounds)
W300C Approximate weight

Lift Cylinder..............................................................................................................................294.4 kg (649 pounds)
Bucket Cylinder ....................................................................................................................304.1 kg (670.4 pounds)
SPECIAL TORQUES
W270C
Gland Bolts Bucket Cylinder....................................................................535 to 660 Nm (394.5 to 486.7 pound-feet)
Screw in Gland for Lift Cylinders ................................................................420 to 500 Nm (310 to 368.8 pound-feet)
W300C
Gland Bolts Bucket Cylinder....................................................................535 to 660 Nm (394.5 to 486.7 pound-feet)
Screw in Gland for Lift Cylinders ................................................................420 to 500 Nm (310 to 368.8 pound-feet)
SPECIAL TOOLS
Torque Multiplier........................................................................................................................................380001732

8006-4
LIFT CYLINDER
1. Clean exterior of cylinder. If hoses were removed 1. Clean all parts in cleaning solvent. Use only lint
with cylinder, remove hoses from cylinder. free cloths for cleaning and drying.
2. Fasten tube (1) in an acceptable repair stand or 2. Check to be sure that piston rod (13) is straight.
other holding equipment. Do not damage tube If piston rod is not straight, replace it with a new
(1). piston rod.
3. Use a spanner wrench to loosen and remove the 3. Shine a light inside tube (1) and check for deep
bolt (7, q.ty 8) of gland (4) from tube (1). grooves and other damage. If there is any
damage to tube, replace with a new tube.
4. Pull piston rod (13) straight out of tube (1) to
prevent damage to tube. 4. Remove any small scratches on piston rod (13)
or inside tube (1) with emery cloth of medium
5. Fasten piston rod eye or yoke in a vise and put a
grit. Use emery cloth with a rotary motion.
support under piston rod (13) near piston (15).
Put a shop cloth between support and piston rod 5. Inspect bushings (2) in tube eye. Replace as
to prevent damage to piston rod. required.
6. Remove the lock pin (14). 6. Inspect gland (4) for rust. Clean and remove rust
as necessary.
7. Remove piston (15) from piston rod (13).
7. Inspect gland end of tube (4) for sharp edges
8. Remove and discard seal (16), ring (17), and
that may cut gland O-ring (11) and remove as
wear ring (18) and O-ring (10) from piston (15).
necessary.
9. Remove and discard O-ring (11), backup ring (9),
8. Inspect piston (15) for damage and wear. If
O-ring (12), wiper (5), rod seal (6), and bushing
piston is damaged or worn, replace with a new
(8) from gland (4).
piston.

8006-5
13
14
5
12
6
9
8 11
16
7
19
18
4 17
10
15
2
3
W230R591
1. TUBE 6. ROD SEAL 11. O-RING 16. SEAL

2. BUSHING 7. BOLT 12. O-RING 17. RING
3. WIPER 8. BUSHING 13. ROD 18. WEAR RING
4. GLAND 9. BACKUP RING 14. BOLT 19. WASHER
5. WIPER 10. O-RING 15. PISTON
LIFT CYLINDER

8006-6
Assembly 21. Turn the bolt (7, q.ty 8) on gland (4) into tube (1).
Tighten gland to a torque of 535 to 660 Nm
NOTE: If a new gland is being used, put part number of (394.5 to 486.7 pound-feet).
cylinder on new gland.
22. If hoses were removed with cylinder, install new
1. Install bushing (8) in gland (4). O-rings, if equipped, on hose fittings. Lubricate
2. Install rod seal (6) in gland (4). Rod seal is to be O-rings with clean oil. Install hoses.
installed so that lips of seal are toward bushing
(8). Rod seal (6) can be difficult to install.
3. Install a new wiper (5) in gland (4). Lips of wiper
must be toward outside end of gland (4).
4. Install a new O-ring (12) in groove on OD of
gland (4).
5. Install a new backup ring (9) in groove on OD of
gland (4). If both sides of backup ring are not flat,
side that is not flat must be toward small end of
gland (4).
6. Install a new O-ring (11) next to backup ring (9)
in groove on outside of gland (4). O-ring must be
toward small end of gland.
7. Fasten piston rod (13) eye or yoke in vise.
8. Remove any marks and sharp edges on chamfer
at end of piston rod (13). Make sure that piston
rod is clean.
9. Lubricate bore of gland (4) and piston rod (13)
with clean oil.
10. Push gland (4) onto piston rod (13). If necessary,
use a soft hammer to drive gland onto piston rod.
11. Put a support below and near end of piston rod
(13). Use a shop cloth between support and the
piston rod to prevent damage to piston rod.
12. Start piston (15) onto piston rod (13) and install
the lock pin (14) on piston (15).
13. Install a new wear ring (18) in wide groove on
outside of piston (15).
14. Install a new ring (17) in the other groove on the
outside of the piston (15).
15. Install a new seal (16) on top of ring (17).
16. Fasten tube (1) in an acceptable repair stand or
other holding equipment. Be careful to prevent
damage to tube.
17. Lubricate inside of the tube (1) and piston (15)
with clean oil.
18. Push piston (15) straight into tube (1).
19. When the piston (15) is in smooth part of tube
(1), start gland (4) into tube.
20. Lubricate O-rings (11 and 12) on gland (4) with
clean oil.

8006-7
BUCKET CYLINDERS
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. Do not damage the 3. Check to be sure that the piston rod is straight. If
tube (1). the piston rod is not straight, replace it with a
3. Loosen and remove the cap screws (2) and new piston rod.
hardened washers (18) from the gland (3) and 4. Illuminate the inside of the tube for deep grooves
the tube (1). and other damage. If there is any damage to the
4. Pull the piston rod (4) straight out of the tube (1) tube, replace it with a new tube.
to prevent damage to the tube (1). 5. Remove any small scratches on the piston rod or
5. Fasten the piston rod eye or yoke in a vise and inside the tube with emery cloth of medium grit.
put a support under the piston rod (4) near the Use the emery cloth with a rotary motion.
piston (7). Put a shop cloth between the support 6. Inspect the bushings in the piston rod eye or
and the piston rod (4) to prevent damage to the yoke and the tube. Replace as required.
piston rod (4).
7. Inspect the gland for rust and clean and remove
6. Remove the retaining ring (10) that fastens the rust as necessary.
pin (11) in the piston (7) and piston rod (4).
8. Inspect the gland end of the tube for sharp edges
7. Remove the pin (11) from the piston (7) and the that will cut the gland O-ring and remove as
piston rod (4). necessary.
8. Turn the piston (7) off the piston rod (4) and 9. Inspect the piston for damage and wear. If the
remove the piston (7). piston is damaged or worn, replace it with a new
9. Remove the gland (3) from the piston rod (4). piston.
10. Remove the seal (6) from the OD of the piston
(7).
11. Remove the wear ring (5) from the OD of the
piston (7).
12. Remove the backup rings (8) and the O-ring (9)
from the ID of the piston (7).
13. Remove the seal (16), backup ring (15), wiper
(12), wide seal (13), narrow seal (14), and
bushing (17) from the gland (3).

8006-8
20 19
20
19 11
12 13
14 17
8 15 16
9 6
2 5
18 10
3 7
19
20
19 20
W230R592
1. TUBE 7. PISTON 12. WIPER 17. BUSHING

2. CAP SCREW 8. BACKUP RING 13. WIDE SEAL 18. HARDENED WASHER
3. GLAND 9. O-RING 14. NARROW SEAL 19. SEAL
4. PISTON ROD 10. RETAINING RING 15. BACKUP RING 20. BUSHING
5. WEAR RING 11. PIN 16. SEAL
6. SEAL
BUCKET CYLINDER

8006-9
Assembly 11. Install a new backup ring (8) in the groove in the
ID of the piston (7). If both sides of the backup
NOTE: If a new gland is being used, put the part number ring (8) are not flat, the side that is not flat must
of the cylinder on the new gland. be toward the O-ring (9).
1. Install the bushing (17) in the gland (3), refer to 12. Install a new O-ring (9) in the groove in the ID of
illustration on page 8. the piston (7) next to the backup ring (8).
2. Install the wide seal (13) in the gland (3). The 13. Install the other new backup ring (8) in the
wide seal (13) is to be installed so that the lips of groove in the ID of the piston (7) next to the
the wide seal (13) are toward the bushing (17). O-ring (9). If both sides of the backup ring (8) are
The wide seal (13) can be difficult to install. not flat, the side that is not flat must be toward
3. Install a new wiper (12) in the gland (3). The lips the O-ring (9).
of the wiper (12) must be toward the outside end 14. Lubricate the ID of the piston (7) with clean oil.
of the gland (3).
15. Start the piston (7) onto the piston rod (4). Turn
4. Install the narrow seal (14) in the gland (3). The the piston (7) onto the piston rod (4) until the
side of the narrow seal (14) with the groove must piston (7) is seated against the shoulder of the
be toward the bushing (17). piston rod (4).
5. Install a new backup ring (15) in the groove on 16. If none of the holes in the piston (7) align with the
the outside of the gland (3). If both sides of the holes in the piston rod (4), turn the piston (7)
backup ring (15) are not flat, the side that is not counterclockwise until one of the holes in the
flat must be toward the small end of the gland piston (7) aligns with one of holes in the piston
(3). rod (4). Do not turn the piston (7) more than 90
6. Install the seal (16) next to the backup ring (15) degrees.
in the groove on the outside of the gland (3). The
seal (16) must be toward the small end of the 7 11
gland (3).
7. Remove any marks and sharp edges on the
chamfer at the end of the piston rod (4). Make 10
sure that the piston rod (4) is clean.
8. Lubricate the bore of the gland (3) and the piston
rod (4) with clean oil.
9. Push the gland (3) onto the piston rod (4). If
necessary, use a soft hammer to drive the gland
(3) onto the piston rod (4). 4
10. Put a support below and near the end of the
GS98J804
piston rod (4). Use a shop cloth between the
support and the piston rod (4) to prevent damage PISTON AND PISTON ROD HOLE ALIGNMENT
to the piston rod (4). 17. Install the pin (11) in the piston (7) and the piston
rod (4).
18. Install the retaining ring (10) in the pin (11).

8006-10
19. Install a new wear ring (5) in the wide groove on 27. Tighten the cap screws (2). Torque to 535 to 660
the OD of the piston (7). Nm (394.5 to 486.7 pound-feet).
20. Install a new seal (6) in the groove on the OD of
the piston (7).
21. Fasten the tube (1) in an acceptable repair stand
or other holding equipment. Be careful to prevent
damage to the tube (1).
22. Lubricate the inside of the tube (1) and the
outside of the piston (7) with clean oil.
23. Push the piston (7) straight into the tube (1).
24. Lubricate the O-ring (16) on the gland (3) with
clean oil.
25. Push the gland into the tube (1) and align the
holes in the tube (1).
26. Install the cap screws (2) and hardened washers
(18).

8006-11
REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS
Removal
1. Put piston tube (4) in a press.
2. Use an acceptable driver to press wipers (1) and
bushings (2) out of piston tube (4) eye.
3
3. Clean bore for bushings (2) in tube (4) eye.
1
Installation
4
1. Use an acceptable driver to press new bushings
(2) into tube (4) eye. Bushings shall be recessed
8 mm (0.315 inch) in tube eye.
2
2. Use an acceptable driver to install wipers (1) until
flush with tube (4) eye. The lips of wipers must 1
be toward outside of bore. 2
BS01C003
1. WIPER 3. PISTON ROD YOKE

2. BUSHING 4. TUBE
BUSHING AND WIPER REMOVAL AND REPLACEMENT
LIFT CYLINDERS

8006-12
REPLACING BUSHINGS FOR THE BUCKET CYLINDER
Removal
3
1. Put piston rod eye (3) in a press.
2. Use an acceptable driver to press wipers (1) and
bushing (2) out of piston rod eye (3). 2
3. Put tube (4) in a press. 1 1
4. Use an acceptable driver to press bushings (2) 2
out of tube (4) eye.
5. Clean bore for bushings (2) in piston rod eye (3)
and tube (4) eye.
4
1
Installation 2
(2) into piston rod eye (3) until recessed 8 mm
(0.315 inch).
2. Use an acceptable driver to install wipers (1) until
flush with piston rod eye (3). The lips of the 2
wipers (1) must be towards outside of bore.
(2) into tube (4) eye until recessed 8 mm (0.315
inch).
1
4. Use an acceptable driver to install wipers (1) until BS03B201
flush with tube (4) eye. The lips of wipers (1)
1. WIPER 3. PISTON ROD EYE
must be towards outside of bore. 2. BUSHING 4. TUBE
BUSHING AND WIPER REMOVAL AND REPLACEMENT
BUCKET CYLINDERS

Section
8013
8013
RIDE CONTROL ACCUMULATOR

Via Plava, 80
8013-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ACCUMULATOR SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHARGING THE ACCUMULATOR WITH NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

8013-3
SPECIFICATIONS
Ride Control Accumulator Dry Nitrogen Pressure ...................................................................... See chart on page 7
Ride Control Accumulator Fluid Capacity............................................................................. 3.78 liters (230 cu. inch)
Ride Control Accumulator Maximum Operating Pressure..............................................................280 bar (4061 psi)
SPECIAL TOOLS
94L95 B786441M
380001737 NITROGEN ACCUMULATOR CHARGING KIT 380001738 GLAND WRENCH

8013-4
DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR
C E
D B A
94L95
380001737 NITROGEN CHARGING KIT
1. Use the 380001737 Nitrogen Charging Kit to 7. Turn the T-handle inward on valve F to engage
discharge the accumulator, refer to the the pin in the valve stem.
illustration above. The tool must be disconnected
8. Open valve D and check the charge pressure on
from the nitrogen tank.
gauge E.
2. Close valves B, C and D.
9. To discharge the accumulator, partially open
3. Adjust the regulator A to the minimum pressure valve B. The accumulator charge will bleed down
setting by turning the knob counterclockwise. through the regulator.
4. Turn the T-handle on valve F fully out. 10. Once the accumulator is fully discharged,
disconnect valve F from the valve stem.
5. Remove the guard and valve assembly cap from
the accumulator. 11. The accumulator can now be disassembled.
6. Connect valve F to the valve stem on the
accumulator.

8013-5
4 2 1 4 3
W230R026
1. CYLINDER 3. GAS VALVE 5. FLUID CONNECTION

2. PISTON 4. END CAP
RIDE CONTROL ACCUMULATOR ILLUSTRATION

8013-6
CHARGING THE ACCUMULATOR WITH NITROGEN
6 5
4 3
GS98N801
1. VALVE C 4. VALVE B
2. TO NITROGEN TANK 5. VALVE D
3. VALVE A 6. TO ACCUMULATOR
NITROGEN CHARGING KIT 380001737
WARNING: Use only nitrogen when charging the accumulator. Do not use air or oxygen that will cause an
explosion.
M253A
WARNING: Do not drop the accumulator. A charged accumulator contains nitrogen compressed to 31 bar
(450 psi). If the charging valve breaks away from the accumulator, the escaping nitrogen will propel the
accumulator at a dangerous rate of speed.
M406
WARNING: Do not expose the accumulator to temperatures above 49° C (120° F). A charged accumulator
contains nitrogen compressed to 31 bar (450 psi). High heat will cause the safety plug to blow out of the
accumulator and the escaping nitrogen will propel the accumulator at a dangerous rate of speed.
M407
IMPORTANT: The four valves must be in the positions noted in the procedure before connecting the Nitrogen Accumulator
Charging Kit to the machine or nitrogen, refer to the above illustration.
IMPORTANT: To help prevent equipment damage, the low pressure gauge valve C MUST BE SHUT OFF during high pressure
(10 bar/150 psi and above) applications.

8013-7
1. Close the shutoff valve A by turning it all the way 11. Open the shutoff valve A on the nitrogen supply
to the left (counterclockwise), refer to the tank. While observing the pressure on the gauge,
illustration on page 6. slightly open the needle valve on the
accumulator charge hose. By regulating the
2. Open valve B by turning it out all the way to the
needle valve, fill the accumulator to pressure
left (counterclockwise).
according to temperature chart below. Close the
3. Close valve C by turning it all the way to the right needle valve. Close the shutoff valve A on the
(clockwise). nitrogen supply tank.
4. Close the gauge valve D by turning it all the way TEMPERATURE CHARGE PRESSURE
to the right (clockwise). 10° C 50° F 1636 KPA 237 PSI
13° C 55° F 1655 KPA 240 PSI
5. Connect the charging hose to the nitrogen supply
16° C 60° F 1674 KPA 243 PSI
tank.
18° C 65° F 1687 KPA 245 PSI
6. SLOWLY turn valve A clockwise while watching 21° C 70° F 1706 KPA 248 PSI
the high pressure gauge. Stop turning valve A 24° C 75° F 1726 KPA 250 PSI
when the needle on the gauge reaches 31 bar 27° C 80° F 1745 KPA 253 PSI
(450 psi). 29° C 85° F 1758 KPA 255 PSI
32° C 90° F 1777 KPA 258 PSI
NOTE: If the needle goes over the needed pressure,
35° C 95° F 1796 KPA 261 PSI
quickly open and close valve D and check the pressure
38° C 100° F 1815 KPA 263 PSI
setting again.
The charging kit is now ready to be installed on the TEMPERATURE/CHARGE PRESSURE RIDE CONTROL
accumulator. ACCUMULATOR
12. Close valve B by turning to the right (clockwise).
7. Remove the valve cap from the pressure valve
After a few minutes, check the accumulator for
on the accumulator.
leakage.
8. Back off the needle valve on the accumulator
13. Back off the needle valve on the accumulator
end of the charging hose by turning it
end of the charging hose by turning it
counterclockwise to the maximum amount. This
counterclockwise the maximum amount. This will
prevents nitrogen from escaping from the
p re ve n t n itro g e n fro m esca p ing from th e
accumulator when the charging hose is attached
accumulator as the hose is removed. Remove
to the accumulator gas charging valve.
the charging hose from the accumulator
9. Install the charging hose fitting onto the pressure valve.
accumulator pressure valve.
14. Install the valve cap onto the pressure valve on
10. Tighten the needle valve by turning it clockwise. the accumulator.
Slowly open the gauge valve D and observe the
15. Remove the charging hose from the nitrogen
reading on the gauge. This reading is the
supply tank.
nitrogen pressure level inside the accumulator.

8013-8
NOTES

Section
8014
8014
RIDE CONTROL VALVE

Via Plava, 80
8014-2
TABLE OF CONTENTS
RIDE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dissasembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8014-3
RIDE CONTROL VALVE
5 6 7
8
2
9
12
10 11
BC06A224
1. PLUG 5. SPRING 9. SOLENOID

2. CAP SCREW 6. SPRING 10. ORFICE
3. BUSHING 7. SPOOL 11. POPPET
4. SPRING CARRIER 8. PLUG 12. ORFICE
Issued 11-11 Printed in E.C. 84547255A

8014-4
Dissasembly Assembly
STEP 1 STEP 1
Remove ride control valve, refer to section 8001. Install new O-rings.
STEP 2 STEP 2
Remove plugs (1 and 8). Install and torque pressure relief valve to 50 Nm
(37 lb-ft).
STEP 3
Remove the solenoid (9). STEP 3
Install and torque accumulator drain screw to 20 Nm
STEP 4 (177 lb-in).
Remove the spool (7) from the valve block.
STEP 4
STEP 5 Install and torque orifice (12) to 15 Nm (11 lb-ft),
Remove cap screw (2), bushing (3), spring carrier install poppet (11), install and torque orifice (10) to 15
(4), springs (5 & 6) from spool (7). Nm (11 lb-ft).
STEP 6 STEP 5
Remove orifice (10), poppet (11), and orifice (12). Install and torque solenoid valve (9) to 12 Nm
(106 lb-in).
STEP 7
STEP 6
Remove accumulator drain screw.
Install springs (5 &6), spring carrier (4), bushing (3),
cap screw (2) onto spool (7) and torque cap screw
STEP 8
(2) to 23 Nm (203.5 lb-in).
Remove the pressure relief valve.
STEP 7
Inspection Install spool (7) into valve block.
1. Discard all O-rings.
STEP 8
2. Clean all parts in cleaning solvent.
Install and torque plug (1) to 420 Nm (309.7 lb-ft).
3. Check the spools and the spool bores for
damage and wear. STEP 9
4. Check the parts of the pressure relief valve. Install plug (8) and torque to 330 Nm (243.3 lb-ft).
If any of the parts are damaged, install new parts.
STEP 10
Install the ride control valve in the machine, see
section 8001.
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
Rollover Protective Structure (ROPS) Cab Structural Frame (CSF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007
Cab Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010

Via Plava, 80
9002
Section
9002
AIR CONDITIONING TROUBLESHOOTING AND SYSTEM

CHECKS FOR SYSTEMS WITH HFC-134A
REFRIGERANT

Via Plava, 80
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 by an 3. Keep refrigerant containers in the correct upright
approved training and certification organization may service position. Always keep refrigerant containers
or repair motor vehicle or mobile air conditioning systems. away from heat and sunlight. The pressure in a
It is mandatory that all refrigerant must be RECOVERED and container will increase with heat.
RECYCLED when removed from a system during servicing.
4. Always reclaim refrigerant from the system, if
Refrigerant HFC-134a is the most stable, and easiest you are going to weld or steam clean near the air
to work with of the refrigerants now used in air conditioner system.
conditioner systems. Refrigerant HFC-134a does not
5. Always check the temperature and pressure of
contain any chlorofluorocarbons (CFC’s) which are
the air conditioner system before reclaiming
harmful to the earth’s ozone layer.
refrigerant and when you test the system.
Safety procedures must be followed when working
6. Dangerous gas can form when refrigerant comes
with Refrigerant HFC-134a to prevent possible
in contact with an open flame. Never permit
personal injury.
fumes to be inhaled.
1. Always wear safety goggles when doing any
7. Never leak test with compressed air or flame
service work near an air conditioner system.
testers. Tests have indicated that compressed
Liquid refrigerant getting into the eyes can cause
mixtures of HFC-134a and air can form a
serious injury. Do the following if you get
combustible gas.
refrigerant near or in your eyes:
8. Always reclaim refrigerant from the system
A. Flush your eyes with water for 15 minutes.
before removing any air conditioning component.
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 A22094
BELT TENSION TOOL 380001325 REFRIGERANT RECOVERY, RECYCLING AND CHARGING
STATION, 380001326
A22090
109L7
ELECTRONIC LEAK DETECTOR 380001327
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
pressure gas. The compressor then compresses the flowing through the evaporator fins. The combination
refrigerant and sends it in the form of a high pressure of increased heat and decreased pressure causes
gas to the condenser. The air flow through the the air flow through the evaporator fins to become
condenser then removes the heat from the very cool and the liquid refrigerant to become a low
refrigerant. As the heat is removed the refrigerant pressure gas. The cooled air then passes from the
changes to a high pressure liquid. evaporator to the cab for the operator’s comfort.
The high pressure refrigerant liquid then flows from The electrical circuit of the air conditioning system
the condenser to the receiver-drier. The consists of a fan speed control, temperature control,
receiver-drier is a container filled with moisture one (1) relay, a blower motor, blower resistor, A.C.
removing material, which removes any moisture that compressor clutch, A.C. low pressure switch, A.C.
may have entered the air conditioner system in order high pressure switch, and A.C. warning light.
to prevent corrosion of the internal components of
the air conditioner system.
3
5
4
208L95
1. EXPANSION VALVE 3. COMPRESSOR 5. RECEIVER-DRIER

2. EVAPORATOR 4. CONDENSER

9002-6
TROUBLESHOOTING
Perform a visual inspection of the machine. Check 5. - Are there heavy accumulations of oil, or oily
the following and correct as necessary: dust around the fittings, indicating refrigerant
leakage?
1. - Obtain service history if possible.
6. - Are air ducts undamaged, sealed properly and
2. - Is compressor drive belt in place and tensioned?
in position?
3. - Are grille screens, fan blades, condenser, air filter, and
7. - Condensate drain hoses and check valves
evaporator unobstructed?
present and unobstructed?
4. - Are there any sharp bends or kinks in the
hoses?
Problem: No Cooling
Mechanical - See Mechanical Compressor
Check Page 8
Compressor Runs No
Electrical - See Blower and Compressor
Clutch Check Page 9
Yes
Internal System Problem

See Pressure Testing, Page 13

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 (10 amp) 1. Check for damaged blower fuse.
1. Check switch operation. Switch must give

four different blower speeds: OFF, Low,
High, and Purge.
Blower Fan Switch 2. Check for loose connections or broken
wires. Repair or replace as necessary.
3. Check resistor board.
1. Check the wiring to the blower motor.

Make repairs or replace items as
necessary.
Blower Motor 2. Check motor ground wire. Make sure
motor ground wire is making good contact
with mounting bracket.
1. With key in ON position, turn switch to

maximum cold. Compressor clutch must
engage.
NOTE: Blower must be operating, since
electrical power to temperature control switch
is received from blower switch.
Temperature Control Switch 2. Turn the blower off. Disconnect the wires
from the temperature control. Using an
ohmmeter, check the continuity between
switch terminals. If continuity is not
present when switch is on maximum cold,
replace switch.

9002-10
Cab Temperature Check

1. Make sure louvers and recirculation vents are fully open
for most efficient air conditioning operation. Defrost
Air Louvers louvers must be closed.
2. Check blower; blower must be running.
ATTENTION: Use caution when feeling hoses. Hoses

become very hot. Check temperature by slowly reaching for
hose and touching briefly several times with finger tips,
increasing the duration with each touch.
Air Conditioning 1. Feel the air conditioning hoses. The high pressure hoses
(small line) must be warmer than the low pressure hose
(large line).
2. If no temperature difference, the system is low on
refrigerant, or compressor is not working correctly.
1. Put a thermometer in the air duct behind the seat and

run the compressor for five minutes to make
temperature stable. Refer to page 12.
2. Duct temperature must be below 25° C (72° F) if the
system is operating at maximum efficiency.
Duct Temperature NOTE: Ambient temperature must be 27 to 43° C (80 to
110° F).
3. If temperature is above 25° C (72° F), system is low on
refrigerant, there is a restriction in the system,
compressor is not working correctly, or air ducts are not
sealed correctly.
1. Turn the engine OFF, key switch ON, blower switch ON

and temperature control switch turned fully clockwise.
2. Remove the temperature sensing probe from the
evaporator. Refer to Section 9004.
3. Put the end of the temperature sensing probe in a
container with ice and water.
Temperature Sensing Probe Check 4. When the sensing tube has cooled to the temperature of
the ice and water mixture, the temperature control switch
should interrupt the current flow to the compressor.
Check for current at the control switch terminals as on
previous page. If current is not interrupted then replace
the control switch.

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 380001327 to
inspect all connections. Use instructions
from manufacturer of leak finding tool.
Leak Finding Check
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 optimize bar) after the system has run 10 to 15 minutes.
an existing charge of HFC-134a. The best use of the gauge
set is to determine whether undercharge or overcharge HIGH PRESSURE GAUGE - The high pressure
exists, and then evacuate, reclaim and recharge system gauge is used to indicate pressures in the high side
with the recommended quantity (charge) of HFC-134a. of the system. The gauge must indicate from 0 to 400
psi (0 to 27.6 bar) minimum.
The manifold gauge set is the most important tool
used to service the air conditioning system. The During normal operation, the high pressure gauge
manifold gauge set is used to measure the high and will normally indicate from 120 to 310 psi (8.3 to 21.4
low pressures of the system, as a tool to troubleshoot bar). See pressure-temperature chart on page 14.
for correct refrigerant charge quantity, system
diagnosis, and operating efficiency. The manifold Pressure Test Connection
gauge set can read both the high (discharge) and low
Connect the manifold gauge set into the air
(suction) sides at the same time, since pressure must
conditioning system as shown. Make sure that both
be compared in order to make a diagnosis of system
valves in the manifold gauge set are closed.
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 AIR LOUVER (BEHIND

NORMAL HIGH
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION SEAT) MAXIMUM TEMP.
°F (°C) psi (bar) psi (bar) °F (°C)
80 (27) 9 to 12 145 to 165 55 (14)

(0.62 to 0.83) (10 to 11.53)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.10 to 14.48)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.48 to 15.86)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.58)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.93 to 19.31)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.37)
The pressure-temperature chart is based on the 2. All panels and access doors installed and closed.
following conditions:
3. Cab filters clean and installed.
NOTE: High humidity will cause higher air louver
4. Heater valve at engine closed.
temperatures and dramatic increase in suction pressure.
The table shown represents readings taken in low relative 5. Measurements taken 15 minutes after startup.
humidity. Adjust the chart according to local conditions.
1. Engine at 1500 RPM, no load, fan speed &
temperature control at max setting, A/C switch
ON, all louvers and doors open
QUICK REFERENCE TROUBLESHOOTING CHART
PROBLEM LOW PRESSURE HIGH PRESSURE SEE

GAUGE GAUGE PAGE
NO COOLING VERY LOW VERY LOW 16
NO COOLING HIGH HIGH 17
NOT ENOUGH COOLING NORMAL TO HIGH NORMAL 19
NOT ENOUGH COOLING LOW LOW 20
NOT ENOUGH COOLING HIGH LOW 22
NOT ENOUGH COOLING HIGH HIGH 23
INTERMITTENT COOLING NORMAL NORMAL 24
NOISE IN SYSTEM NORMAL TO HIGH HIGH 25

9002-15
A/C RECOVERY AND CHARGING STATION CONNECTIONS

STEP 1 STEP 4
Clean the external surfaces of the compressor and Connect the hose from the high pressure gauge to
hoses. Remove the caps from the service ports on the port on the discharge hose.
the suction and pressure hoses.
WARNING: Always wear safety goggles
WARNING: Do not steam clean any air when working with liquid refrigerant. Liquid
conditioning system parts while the system is refrigerant in your eyes could cause
charged. The heat will cause the refrigerant blindness. SM105A
to rise to a pressure that could cause the
system to explode. SM104A
STEP 5
Make sure the charging station manifold gauge
STEP 2 valves are in the closed position.
Connect the hoses from the test gauges to the
service ports by turning the knurled knobs on the STEP 6
depressors. Start the engine and run at 1500 RPM maximum
speed. Operate the air conditioner system at
STEP 3 maximum cooling setting and blower speed for 15
Connect the hose from the low pressure gauge to the minutes with the cab door open. Observe the test
port on the suction hose. gauges and check the chart on page 13 against the
gauge readings.

9002-16
PROBLEM: NO COOLING
VERY LOW VERY LOW
476L7
SEE PRESSURE - TEMPERATURE CHART ON PAGE 14
Indication of No Refrigerant or Low Refrigerant Charge:

1. Leak test the system, see Page 11. It may
be necessary to add refrigerant. See
Section 9003.
2. Evacuate and reclaim remaining

refrigerant from system. See Section
9003.
3. Repair system leaks as needed. Follow

the given repair procedure.
A. Discharge air from evaporator warm.
B. Compressor does not run, or cycles off 4. Check level of oil in compressor - possible
Yes
rapidly after start-up. (A/C warning light for compressor to have an oil loss.
in cab should illuminate).
5. Remove air and moisture from the
system. Replace Receiver-Drier. See
Section 9004.
6. Charge system with new refrigerant. See

Section 9003.
7. Continue performance test for other

possible problems.

9002-17
HIGH HIGH
476L7
Indication of Large Quantity of Air in System:

1. Evacuate and reclaim refrigerant from
system. See Section 9003.
2. Replace receiver-drier.
Discharge air from evaporator warm Yes 3. Remove air and moisture from the
Section 9003.
Condenser Malfunctioning - Indications:

1. Check for loose or worn compressor or engine fan
belt and proper condenser fan operation.
2. Check to see that condenser is clean and

unobstructed and that the fins are straight.
3. Check system for too much refrigerant. Evacuate,
reclaim and recharge refrigerant until gauge
pressure is normal. See Section 9003.
4. Remove and check condenser for restrictions

A. Liquid line (between evaporator and
caused by oil or reduced heat transfer.
condenser) is very hot.
A. Remove refrigerant from the system. See
B. Discharge air from evaporator warm.
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9003.
5. Continue the performance test for other possible

problems.

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 qF (q C) Pressure PSIG (Bar)
50 (10) 45 (3.1)
55 (13) 51 (3.5)
60 (16) 57 (3.9)
65 (18) 64 (4.4)
70 (21) 71 (4.9)
75 (24) 78 (5.4)
80 (27) 88 (6.1)
85 (29) 95 (6.6)
90 (32) 104 (7.2)
95 (35) 114 (7.9)
100 (38) 124 (8.6)
102 (39) 129 (8.9)
104 (40) 133 (9.2)
106 (41) 138 (9.5)
108 (42) 142 (9.8)
110 (43) 147 (10.1)
112 (44) 152 (10.5)
114 (46) 157 (10.8)
116 (47) 162 (11.2)
118 (48) 167 (11.5)
120 (49) 172 (11.9)

9002-19
PROBLEM: NOT ENOUGH COOLING
NORMAL TO
SLIGHTLY HIGH NORMAL
476L7
Air in the System - Indications:

1. Test system for leaks. See page 11. Possible
leak has let air enter; check compressor seal
carefully.
2. Discharge system of refrigerant. See Section
9003.
A. Suction line warm to your hand. 3. Repair system leak as necessary.
B. Discharge air from heater/evaporator 4. Replace receiver-drier.
only a little cool.
5. Check compressor oil level.
6. Remove air and moisture from the system.
See Section 9003.
Section 9003.

9002-20
LOW LO W
476L7
Not Enough Refrigerant - Indications:

1. Leak test system - system has a loss of refrigerant.
NOTE: Normally, the system will lose 1/2 to 1 ounce (14.7
to 29.5 grams) of refrigerant between seasons.
A. If leak is found, go to Step 2.
B. If no leak is found, go to Step 6.
2. Discharge refrigerant from system. See Section 9003.
A. Discharge air from evaporator 3. Repair system leaks as needed.

cool or warm - not cold.
4. Check oil level in compressor - It is possible for
compressor to lose oil.
5. Remove air and moisture from the system. Replace

Receiver-Drier. See Section 9004.
6. Charge system with new refrigerant. See Section

9003.
High Side Restriction - Indications:

A. Discharge air from heater/evaporator
1. Discharge refrigerant from system-restriction in
only a little cool.
receiver-drier or liquid line must be removed.
B. Condensation or frost on
2. Remove and replace part with restriction.
receiver-drier.
3. Remove air and moisture from the system. See
C. Liquid line to receiver-drier cool, with
Section 9003.
frost or condensation.
4. Charge system with new refrigerant. See Section
NOTE: The frost will form downstream from
9003.
or at the point of the restriction

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
HIGH LOW
476L7
SEE THE PRESSURE - TEMPERATURE CHART ON PAGE 14
Compressor Turning But Not Pumping Properly - Indications:

1. Discharge refrigerant from system. See Section
9003.
2. Remove the compressor from the machine. See
Section 9004.
3. Remove and replace compressor because there is
indication of internal leak in compressor.
A. System is fully charged. 4. Replace compressor.
B. Cool discharge air from evaporator. 5. Replace receiver-drier if:
A. System has been opened before.
B. Receiver-drier has been used two or more
years. See Section 9004 for receiver-drier
replacement.
6. Charge the system with refrigerant. See Section
9003.
Expansion Valve Stuck Open

Expansion Valve Stuck Open 1. Replace expansion valve. See Section 9004.

9002-23
HIGH HIGH
476L7
Condenser Not Operating - Indications:

1. Check for loose or worn compressor belt and
proper condenser fan operation.
2. Check to see that condenser is clean and that
the fins are straight.
3. Check system for too much refrigerant.
A. Remove refrigerant from system until gauge
pressure is below normal. See Section 9003.
B. Add refrigerant until gauge pressures are
A. Liquid line very hot.
normal. See Section 9003.
B. Discharge air from evaporator warm.
C. If there is still a problem, do step 4.
4. Remove and inspect condenser for restrictions
caused by oil or reduced heat transfer.
A. Discharge refrigerant from system. See
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier. See Section 9004.
Air in the System - Indications:

1. Discharge refrigerant from system. See
Section 9003.
2. Replace receiver-drier.
Warm discharge air from evaporator. 3. Remove air and moisture from the
Section 9003.

9002-24
PROBLEM: INTERMITTENT COOLING
NORMAL NORMAL
476L7
Moisture in the System - Indications:

1. Discharge system of refrigerant. If too
much moisture enters the orifice of the
expansion valve, the freezing of this
moisture can stop refrigerant flow. See
Section 9003.
2. Replace receiver-drier. The moisture

removing material could be full to capacity
with moisture. See Section 9004.
Cooling is acceptable during cool part of day
but not acceptable during hot part of day. 3. Remove air and moisture from the
NOTE: The time needed to remove a large
amount of moisture will be two to three hours
minimum.

Section 9003.

9002-25
PROBLEM: NOISE IN SYSTEM
NORMAL
HIGH
TO HIGH
476L7
Too Much Refrigerant in System - Indications:

1. Remove refrigerant from system until gauge
readings are below normal. See Section
A. Cool discharge air from heater/evaporator.
9003.
B. Compressor makes noise.
2. Add new refrigerant until gauge readings are
normal. See Section 9003.

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
9003
AIR CONDITIONER SYSTEM SERVICE

Via Plava, 80
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 380001326

9003-4
SAFETY PROCEDURES

ATTENTION: Only authorized technicians certified by an 3. Keep refrigerant containers in the correct upright
approved training and certification organization may service position. Always keep refrigerant containers
or repair motor vehicle or mobile air conditioning systems. away from heat and sunlight. The pressure in a
It is mandatory that all refrigerant must be RECOVERED and container will increase with heat.
RECYCLED when removed from a system during servicing.
4. Always reclaim refrigerant from the system, if
Refrigerant HFC-134a is the most stable and easiest you are going to weld or steam clean near the air
to work with of the refrigerants now used in air 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.
refrigerant near or in your eyes:
8. Always reclaim refrigerant from the system

9003-5
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

Recovered refrigerant passes through an oil STEP 3
separator and a filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system off before proceeding.
STEP 1
A22114
Open the high and low valves.
STEP 4
BD03A213
Clean the external surfaces of the compressor and

hoses. Remove the caps from the service ports on
the suction and pressure hoses.
STEP 2
A22107
Make certain the refrigerant tank gas and liquid

valves are open.
BD03B001
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
STEP 5 STEP 7
A22112 A22110
Connect the main power plug to a 115 volt AC outlet. Slowly open the oil drain valve and drain the oil into
Move the main power switch to the ON position and the reservoir. When the oil stops draining, close the
depress the recovery start switch. oil drain valve completely.
The compressor will shut OFF automatically when
recovery is complete. Wait for 5 minutes and observe STEP 8
the manifold pressure gauges for a pressure rise. If
pressure rises above 0 psi (0 bar), depress the
hold/cont switch. Then wait for the compressor to
automatically shut OFF.
STEP 6
A22111
Fill the A/C compressor with fresh SP-20 PAG oil

equal to the amount in the reservoir.
STEP 9
A22108
Drain the oil separator of the A/C system oil. Open

the air purge valve long enough to let some of the
compressor discharge pressure back into the
separator.
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 more of Air and moisture are removed from the system by a
the following conditions occurs before you remove the air vacuum pump. A vacuum pump is the only
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 user
B. Receiver-drier has operated two or more
manual for additional information.
years.
C. Disassembly of compressor shows small STEP 11
particles of moisture removing material (gold
or brown particles).
D. Large system leak (broken hose, break in
line).
E. Too much air or moisture in system.
F. Removal of compressor caused the system to
be open (uncapped) longer than 5 minutes.
STEP 10
A22113
Connect the main power plug to a 115 volt AC outlet.

Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum
of 45 minutes and press the Enter key. The display
will flash once indicating the programmed data has
been accepted.
STEP 12
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.
A22115
Removal of air and moisture from the system is
necessary after the refrigerant has been removed Press the Charge key. “Program” and “Charge” will
after the system has been opened for maintenance. appear on the display.
Air enters the system when the system is opened. Air
has moisture that must be removed to prevent
damage to the system components.
NOTE: The pump on the reclamation unit will not pull a
sufficient vacuum to remove air and moisture.

9003-8
STEP 13 STEP 16
A22113 A22123
Program 3.5 lbs and press the enter key. The display Press the Vacuum key. “Automatic” will appear on
will flash once indicating the programmed data has the display. Vacuum will appear on the display and
been accepted. after a slight delay, the vacuum pump will start. The
display will show the amount of time programmed
STEP 14 and begin a countdown to zero.
When the programmed time has elapsed, an
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 10 minutes. A previously charged,
leak-free system will leach refrigerant from
compressor oil and raise system pressure under
vacuum. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See Section 9002 in the manual for a leak
test.
A22114
Fully open the low and high pressure valves.

STEP 17
STEP 15
A22113
Press the charge key to begin refrigerant charging.

A22107
“Automatic” and “Charge” will appear on the display.
Open the red (vapor) and blue (liquid) valves on the The display shows the programmed amount and
tank. counts down to zero as charging proceeds. When
charging is completed, the display shows “CPL”.

9003-9
STEP 18 STEP 21
A22114 BD03B001
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 recovery unit. STEP 22
The pressure reading should be obtainable with valves
closed. Damage may occur if the machine is started with
the valves accidently open or if either or both valves are
opened while the A/C system is operating.
STEP 19
Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting
and blower speed with the doors and windows open.
NOTE: The compressor will not operate if the system
pressure is too low or too high. The pressure indicator lamp
will illuminate when the relay is actuated by a low or high BD03B213
pressure and the compressor clutch will disengage. To Install the caps on the service ports on the suction
restart the compressor, the air conditioner control or and discharge hoses.
blower switch must be turned to the OFF position and then
to the ON position.
STEP 20
A22117
Observe the pressure gauge readings to determine

that the correct amount of refrigerant has entered the
system. See chart on Page 9002-9 for temperature
and pressure variations.

9003-10
PRESSURE - TEMPERATURE CHART
AMBIENT NORMAL LOW NORMAL HIGH AIR LOUVER

TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION MAXIMUM TEMP.
°F (°C) psi (bar) psi (bar) °F (°C)
80 (27) 9 to 12 145 to 165 55 (14)
(0.62 to 0.83) (10 to 11.5)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.1 to 14.5)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.5 to 15.8)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.6)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.9 to 19.3)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.4)
The pressure-temperature chart is based on the 5. Both cab doors open

following conditions:
6. All panels and access doors installed and closed.
1. Engine operating at 1500 RPM
7. Cab filters clean and installed.
2. No engine load
8. Heater valve at engine closed.
3. Fan speed control in maximum position and all
9. Measurements taken 15 minutes after start-up.
louvers open.
4. Cab temperature control set to maximum
cooling.

Section
9004
9004
REMOVAL AND INSTALLATION OF AIR CONDITIONING
AND HEATER COMPONENTS

Via Plava, 80
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

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
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.
refrigerant near or in your eyes: 8. Always reclaim refrigerant from the system

9004-4
SPECIAL TOOLS
A22094 BS03H012
REFRIGERANT RECOVERY, RECYCLING AND CHARGING SAFETY GOGGLES CAS-10073-3
STATION 380001326

9004-5
COMPRESSOR
Removal STEP 4
STEP 1
position.
STEP 2
Discharge the air conditioning system according to
the instructions in Section 9003.
STEP 3
BD06F117
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.
W270R591
Remove the fan belt.

9004-6
STEP 5 Installation
STEP 8
Place the compressor into position on the machine.
STEP 9
BD06F117
Disconnect the compressor clutch wire from the

engine harness assembly.
STEP 6
BD06F117
Install the three bolts to mount the compressor.
STEP 10
BD06F117
Loosen and remove the three compressor mounting

bolts.
STEP 7 BD06F117
Remove the compressor from the machine. Connect the compressor clutch wire to the engine
harness assembly.

9004-7
STEP 11 STEP 12
Carefully remove the protective cap, install a new
O-ring, and connect the low pressure line to the
suction port on the compressor.
STEP 13
Install the belt.
STEP 14
Install the protective shield.
STEP 15
Charge the air conditioning system according to the
BD06F117 instructions in Section 9003.
Slowly remove the protective cap, install a new
O-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
3 6
5
7
8
9
18 10
17
12 11
14
13
16
15
BS06G118
1. EVAPORATOR 7. WASHER 13. LOWER BOX PPE

2. UPPER BOX PPE 8. GROMMET 14. EXPANSION VALVE
3. COVER PPE 9. HEATER CORE 15. BLOWER
4. SOLENOID DRIVER 10. HEATER VALVE 24V 16. RECIRCULATING VAIN
5. UPPER BOX 11. THERMOSTAT 17. RECIRCULATING MOTOR
6. BOLT 12. LOWER BOX 18. RESISTOR BLOWER MOTOR

9004-9
Removal STEP 21
STEP 16
bucket to the floor.
STEP 17
If changing any air conditioning components,
discharge the air conditioning system according to
STEP 18
BD06G202
Remove the four bolts that fasten the operator’s seat

to the upper box, remove the seat from the machine.
STEP 22
W270R571
BD06G212
If changing the heater core, put a 37 liter (10 gallon)
container below radiator drain. Remove radiator cap. Open the cover on the cooler.
Remove cap and drain coolant into container. Install
cap after coolant has drained. Install radiator cap. STEP 23
STEP 19
Place the master disconnect in the OFF position.
STEP 20
Disconnect the wiring harness from the operator’s
seat (if equipped with air seat option).
BD06G213
Remove the four screws securing the air vent,

remove the vent cover.

9004-10
STEP 24 STEP 28
Place the air selector on the control panel to outside air.
NOTE: In step 29 and 32 the upper box is shown
removed for clarity only, these steps must be done
prior to removing the upper box.
STEP 29
BD06G214
Remove the three screws securing the cooler to the

cab, remove the cooler.
STEP 25
Fold the rubber mat over to gain access to the upper
box mounting bolts.
BD06G217
G o i n g t h r o u g h t h e i n s i d e f i l t er a re a f e e l t he
STEP 26 recirculating vain to make sure is is in the outside air,
“closed”, position.
STEP 30
BD06G215
Remove the six bolts securing the upper box.
STEP 27 BD06G218
The above photo shows that the recirculating vain is

not in the outside air “closed” position.
STEP 31
BD06G216
Remove two screws, one on each side of the upper

box, securing the upper box to the lower box.
BD06G240
Use a screw driver and disconnect the linkage.

9004-11
STEP 32 STEP 35
BD06G219
Close the vain so the upper cover can be removed. BD06G203
Disconnect the solenoid driver.

STEP 33
Remove the upper box up and rest it against the STEP 36
console.
NOTE: The wiring harness for the HVAC system
goes through the upper cover, by resting the cover
against the console the wiring harness will not need
to be removed.
STEP 34
BD06G236
Remove the upper PPE from the heater and air

conditioning cores.
NOTE: If testing on the electrical components are
required the solenoid driver can be reconnected
once the upper PPE is removed.
BD06G220
Pull the wiring harness loose from the upper PPE.

9004-12
NOTE: If replacing the heater control valve, heater STEP 39
core, air conditioning expansion valve, air
conditioning evaporator core do steps 37 through 46,
if replacing electrical components go to step 47.
STEP 37
BD06G206
Remove the thermostat probe and clamp from the

evaporator core.
STEP 40
BD06G204
Remove the right side cab skirt.
STEP 38
2 3
1 BD06G237
Disconnect the electrical connectors from the

thermostat control.
STEP 41
BD06G205
1. TRANSMISSION FILTER
2. AIR CONDITIONING HOSES
3. HEATER HOSES
Fasten identification tags on the hoses. Disconnect

the hoses for the heater core and evaporator core,
install plugs in the hoses and caps on the fittings.
BD06G236
Disconnect the electrical connectors from the heater

control valve.

9004-13
STEP 42 STEP 48
Pull the heater core and evaporator core from the
lower box PPE.
STEP 43
Remove the expansion valve from the evaporator
core.
STEP 44
Remove and discard the O-rings from the openings
in the expansion valve.
STEP 45
Remove the screws from the heater core and remove BD06G208
the control valve. Disconnect the electrical connector for the

recirculating vain motor, disconnect the linkage from
STEP 46 the vain. Remove the mounting screws and remove
the motor.
Remove and discard the O-rings from the heater
control valve.
STEP 49
STEP 47
1 2
3
BD06G209
1. FAN SPEED AND A/C SWITCH
BD06G207 2. INSIDE/OUTSIDE AIR SELECTOR SWITCH
1. RESISTORS
3. THERMOSTAT
2. RESISTOR CONNECTOR
3. BLOWER MOTOR CONNECTOR Remove the switch panel from the console.
Disconnect the electrical connectors and remove
Remove the fans from the lower PPE, disconnect the
switches as required.
electrical connectors. Remove the two mounting
screws for the resistor, remove the resistor.

9004-14
STEP 50
1
1 2
3
BD06G207
1. RESISTORS
2. RESISTOR CONNECTOR
BD06G209 3. BLOWER MOTOR CONNECTOR
1. FAN SPEED SWITCH
2. INSIDE/OUTSIDE AIR SELECTOR SWITCH Install the resistor, install the two mounting screws
3. THERMOSTAT and tighten. Install the fans in the lower PPE,
Replace switches and connect the electrical connect the electrical connectors.
connectors as required. Install the switch panel in the
console. STEP 53
Install new O-rings on the heater control valve.
STEP 51
STEP 54
Install the control valve, install and tighten the screws
to the heater core.
STEP 55
Install new O-rings on the openings of the expansion
valve.
STEP 56
Install the heater core and evaporator core into the
lower box PPE.
BD06G208 STEP 57
Install the motor and install the mounting screws and
tighten. Connect the electrical connector for the
recirculating vain motor, connect the linkage to the
vain.
BD06G236
Connect the electrical connectors to the heater

control valve.

9004-15
STEP 58 STEP 60
2 3
BD06G237
Connect the electrical connectors to the thermostat BD06G205

control.
3. HEATER HOSES
STEP 59
Remove the plugs from the hoses and the caps from
the fittings. Install new O-rings in the evaporator
fittings, connect the heater and evaporator hoses.
Remove and discard identification tags that were
used during disassemble.
STEP 61
BD06G206
Install the thermostat probe coil and clamp to the

evaporator core “cold” tube.
BD06G204
Install the right side cab skirt.
STEP 62
BD06G238
Install the upper PPE on the heater and air

conditioning cores.
9004-16
STEP 63 STEP 66
BD06G210.
BD06G203 Make sure that the recirculating vain is in the closed

Connect the solenoid driver. position.
IMPORTANT: This photo shows it in the open
STEP 64 position and the upper box will not go back into
position without damaging the recirculating vain.
STEP 67
BD06G239
Push the wiring harness into the preformed notches

in the upper PPE.
BD06G241
Set the upper box into position on the heater and

STEP 65 evaporator cores.
Place the air selector on the control panel to outside
air. STEP 68
BD06G216
Install two screws, one on each side of the upper box

securing the upper box to the lower box.

9004-17
STEP 69 STEP 73
BD06G242 BD06G214
Install the insolation panel in the center of the upper Install and tighten the three screws securing the
box. cooler to the cab.
STEP 70 STEP 74
BD06G215 BD06G213
Install and tighten the six bolts securing the upper Install the vent cover, install and tighten the four
box. screws securing the air vent.
STEP 71 STEP 75
BD06G243
Install the right rear floor mat into the cab, if machine BD06G202
is equipped with air ride seat make sure to pull the Install and torque the four bolts to 73 to 87 Nm (55 to
wiring up above the mat for the seat. 65 pound-feet).
STEP 72
Install the remainder of the floor mat.

9004-18
STEP 76 STEP 78
Connect the wiring connector to the operator’s seat Charge the air conditioning system according to the
(if equipped with air seat option). instructions in Section 9003.
STEP 77
Ethylene Glycol and 50% water. Install the radiator
cap. Fill the coolant reservoir up to the FULL mark on
the reservoir.

9004-19
CONDENSER AND RECIEVER DRIER
Removal STEP 83
STEP 79
bucket to the ground.
STEP 80
W270R597
Fasten identification tags on the hoses and

1
disconnect the hoses from the condenser.
STEP 84
Install plugs in the hoses and caps on the fittings.
W270R118
STEP 85
access cover. Open the frame (1) of the engine 1
cooling system.
2
STEP 81
position.
STEP 82 3
Discharge the air conditioning system according to
W270R598
Loosen the bolts that fasten the condenser to the

frame cooling (1) and remove the bolts (2), washers
(3) and condenser.

9004-20
STEP 89
Put the condenser in position on the bracket.
STEP 90
W270R598
Install the washer (3) and bolts (2) that fasten the
condenser to the frame cooling (1) and tighten the
bolts.
W270R599
STEP 91
Fasten identification tags on the hoses and
disconnect the hoses from the receiver drier.
STEP 87
Install plugs in the hoses and caps on the fittings.
STEP 88
W270R597
Remove the plugs from the hoses and the caps from
the fittings. Install new O-rings and connect the
hoses to the fittings. Remove and discard
identification tags that were used during
W270R600 disassemble.
Disconnect the trinary switch, remove the mounting
bolt, remove the receiver drier and bracket.
9004-21
STEP 92 STEP 94
Pivot the condenser down and close the cover.
STEP 93
W270R599
W270R600
Remove plugs from the hoses and caps from the
Mount the receiver drier and bracket, install and fittings, install new O-rings and connect the hoses to
tighten the mounting bolt. the fittings, connect the trinary switch. Remove and
discard identification tags that were used during
disassemble.
STEP 95
Charge the air conditioning system according to the
instructions in Section 9003.
STEP 96
position.

9004-22
NOTES

Section
9006
LOADER
9006

Via Plava, 80
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVING THE LOADER FRAME (Z-BAR AND LONG REACH MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLING THE LOADER FRAME (Z-BAR AND LONG REACH MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . 10

9006-3
SPECIFICATIONS
Special Torques
Bolts for the Bucket Teeth .......................................................................1315 to 1480 Nm (970 to 1090 pound-feet)
BUCKET TEETH
Replacement of the Tooth Points

1. Use a hammer and punch to drive the retaining 3 5
pin (1) for the tooth point (2) out of the tooth
4
shank (3), refer to the illustration on this page. 2 1
2. Remove the tooth point (2).
3. Install a new tooth point (2) on the tooth shank
(3).
4. Install the retaining pin (1) into the tooth point (2)
7
and tooth shank (3). Make sure the shoulder on
the retaining pin is toward the cutting edge. Use
6
8 10
a hammer to hit the retaining pin (1) until the 3
retaining pin (1) is even with the outside of the
tooth shank (3).
2 1
Replacement of the Bucket Teeth
1. Loosen and remove the nuts (4), hardened
washers (5), and bolts (6) from the bucket teeth. 9
NOTE: If wear of the bolt or nut makes removal difficult, 7
the bolt or nut can be cut off.
2. Remove the tooth.
B0740A88J
3. Install the new tooth on the bucket cutting edge 1. RETAINING RING 6. BOLT
(7). 2. TOOTH POINT 7. CUTTING EDGE
3. TOOTH SHANK 8. PLOW BOLT
4. Use new nuts (4), hardened washers (5), and
4. NUT 9. NUT
bolts (6) for the tooth being installed.
5. HARDENED WASHER 10. CORNER TOOTH
5. Tighten the nuts (4) to 1315 to 1480 Nm (970 to
1090 pound-feet). BUCKET TEETH ILLUSTRATION
Replacement of the Bucket Corner

Teeth
1. Loosen and remove the nuts (9) and bolts (8)
from the bucket corner teeth (10).
NOTE: If wear of the bolt or nut makes removal difficult,
the bolt or nut can be cut off.
2. Remove the corner tooth (10).
3. Install the new corner tooth (10) on the bucket
cutting edge (7).
4. Use new nuts (9) and bolts (8) for the corner
tooth being installed.
5. Tighten the nuts (9) to 1315 to 1480 Nm (970 to
1090 pound-feet).
9006-4
RETURN TO DIG ADJUSTMENT
6
1
3
4
5
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
IMPORTANT: Before adjusting the return-to-dig, make 7. Loosen the bolts holding the target bar (3) to the
sure that the target bar on the bucket linkage is not target mounting bracket (1). Slide the target bar
damaged. Slowly roll back and dump the bucket and make (3) towards the proximity switch (5) until the face
sure that the target bar stays the same distance from the of the proximity switch (5) is completely covered.
switch. The switch mounting bracket protects the switch. 8. Align the target bar (3) parallel to the tilt cylinder
Make sure the target bar cannot touch the switch when the (2) and tighten the bolts.
bucket is dumped.
9. Turn the ignition switch to the ON position. Do
1. Park the machine on a level surface. Raise the NOT start the engine.
lift 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
target bar (3), until an air gap of 3.2 to 5.0 mm the TRAVEL position.
(1/8 to 3/16 inch) is obtained. Torque the jam nut 16. Raise the lift arms approximately horizontal, and
to 6.7 ± 0.6 Nm (5 ± 0.5 pound-feet). put the bucket in the fully dumped position.
NOTE: The proximity switch (5) must not protrude past 17. Place the loader control lever in the ROLLBACK
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
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT
5
6
3
2
1
BS01C081
1. TARGET MOUNTING PLATE 3. PROXIMITY SWITCH 5. RETURN TO TRAVEL TARGET

2. HEIGHT CONTROL TARGET 4. LIFT ARM 6. FRONT CHASSIS (TOP LEFT HAND SIDE)
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION
1. Park the machine on a level surface. 6. Adjust the proximity switch (3) out towards the
return to travel target (5) until an air gap of 3.2 to
2. Start the engine and apply the parking brake.
5.0 mm (1/8 to 3/16 inch) is obtained.
3. Lower the lift arms and place the bucket flat on
7. Lock the proximity switch (3) in this position with
the ground.
the jam nut. Torque the jam nut to 6.7 ± 0.6 Nm
4. Stop the engine. (5 ± 0.5 pound-feet).
NOTE: To avoid damage to the proximity switch (3), it
must be adjusted back to clear everything on the lift arm as
it passes. Refer to the illustration on this page.
WARNING: Raised equipment on the machine

without an operator can cause injury or death.
Before you leave the operators compartment,
always support or lower the equipment
(backhoe, blade, boom, bucket, etc.) to the
ground and stop the engine.
CSM105
5. Position the return to travel target (5) opposite

the proximity switch (3) and tighten it to the target
mounting plate (1).

9006-6
2
A
B
1
BS01C082
1. HEIGHT CONTROL TARGET 2. RETURN TO TRAVEL TARGET 3. TARGET MOUNTING PLATE
APPROXIMATE APPROXIMATE
RESULTING RETURN TO RESULTING HEIGHT
MACHINE A B
TRAVEL HINGE PIN CONTROL HINGE PIN
HEIGHT HEIGHT
W270C Z-Bar 67.0 mm (2.6 in) 540.0 mm (21.3 in) 75.0 mm (3.0 in) 4140.0 mm (163.0 in)
W270C Long Reach 50.0 mm (2.0 in) 693.0 mm (27.3 in) 60.0 mm (2.4 in) 4140.0 mm (163.0 in)
W300C Z-Bar 59.0 mm (2.3 in) 653.5 mm (25.7 in) 76.0 mm (3.0 in) 4220.0 mm (166.0 in)
W300C Long Reach 46.0 mm (1.8 in) 694.0 mm (27.3 in) 65.0 mm (2.6 in) 4220.0 mm (166.0 in)
HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT ILLUSTRATION
8. Refer to the table and the illustration on this NOTE: The higher the return to travel target (2) is
page. Position the height control target (1) on the positioned in its slot in the target mounting plate (3), the
target mounting plate (3) using the table above. lower the lift arms will stop as they are lowered.
NOTE: The higher the height control target (1) is 11. Check to make sure the proximity switch (3) and
positioned in its slot in the target mounting plate (3), the all of the mounting bolts are tight. Refer to the
lower the lift arms will stop as they are raised. illustration on page 5.
9. Tighten the height control target (1). 12. Start the engine.
10. Position the return to travel target (2) using the 13. Place the detent switch in the ON position, and
table above. set the return to travel/float detent switch to the
return to travel position.

9006-7
14. Place the loader control lever in the raise
position and verify that the electromagnet holds it
in that position until the height control target (2)
passes in front of the proximity switch (3). Refer
to the illustration on page 5.
15. With the lift arms still raised, place the loader
control lever in the lower position and verify that
the electromagnet holds it in that position until
the return to travel target (5) passes in front of
the proximity switch (3). Refer to the illustration
on page 5.
16. Repeat steps 8 through 15 until the desired
heights are reached.
17. Lower the bucket to the ground and stop the
engine.

9006-8
REMOVING THE LOADER FRAME (Z-BAR AND LONG REACH MODELS)

1. Park the machine on a level surface and apply 17. Remove from pivot pin (9) the hoses grease (26
the parking brake. Roll the bucket all the way and 27). Loosen and remove the bolt (19), flat
forward and lower the bucket to the floor. Stop washer (20) and spacer (21) that fasten the pivot
the engine. pin (9) to the front frame.
2. Loosen the filler plug in the reservoir to release 18. Raise the loader frame slightly. Use an
the air in the reservoir. acceptable driver and drive the pivot pin (9) out
of the front frame. Do not lose the washers (18)
3. Fasten a chain hoist to the cross member (1) of
and wipers (22) between the front frame and the
the loader frame (2), refer to the illustration on
loader frame (2).
page 9.
19. Remove the proximity switch cover (30).
4. Loosen and remove the bolt (12), flat washer
Left-hand side of the machine only.
(13), and spacer (14) that fasten the pivot pin (3)
to the piston rod yoke of the right lift cylinder (4).
5. Use an acceptable driver and drive the pivot pin 30
(3) out of the piston rod yoke of the right lift
cylinder (4). Do not remove the driver.
32
6. Repeat Steps 4 and 5 for the left lift cylinder (8).
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 (4 or 8).
8. Raise the lift cylinder (4 or 8) slightly and remove
the driver. 31
9. Repeat steps 7 and 8 for the other lift cylinder (4
or 8).
10. Connect the chain hoist to the bucket cylinder
(8).
11. Loosen and remove the bolt (15), flat washer
(16), and spacer (17) that fasten the pivot pin (7) W230R083
for the piston rod eye of the bucket cylinder (8) to 20. Disconnect the electrical connector (31), remove
the bell crank (11). the lock nut from the proximity switch (32) and
12. Use an acceptable driver and drive the pivot pin remove the proximity switch (32) from the
(7) out of the piston rod eye of the bucket machine. Left-hand side of the machine only.
cylinder (8). 21. Repeat Steps 17 and 18 for the other pivot pin
13. Raise the bucket cylinder (8) and use a chain or (9).
other acceptable holding equipment to hold the 22. Raise the loader frame (2) out of the front frame.
bucket cylinder (8) in place. Carefully move the machine out of the loader
14. If the machine is equipped with auxiliary frame (2).
hydraulics, disconnect the two hoses from the
tubes at the bracket on the right side of the
loader frame (2). Install caps on the hoses and
plugs in the tube fittings.
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 (2).

9006-9
28
29
26
6
27 8
9
18 22 5
9
21 29
20 1 17
19 5 7
22 25
10
16
3 15
4
12 13 14
2
11
24
23
W270R001
1. CROSS MEMBER 9. PIVOT PIN 12.9 in (329 mm) 17. SPACER 25. TUBE GREASE
2. LOADER FRAME 10. PIVOT PIN 18.5 in (472 mm) 18. WASHER 26. HOSE GREASE
3. PIVOT PIN 10.8 in (276 mm) 11. BELL CRANK 19. BOLT 27. HOSE GREASE
4. LIFT CYLINDER 12. BOLT 20. WASHER 28. HOSE GREASE
5. PIVOT PIN 13.5 in (343 mm) 13. WASHER 21. SPACER 29. PIVOT PIN 10.4 in (266 mm)
6. BUCKET CYLINDER 14. SPACER 22. WIPER
7. PIVOT PIN 11.6 in (295 mm) 15. BOLT 23. DUMP LINK
8. LIFT CYLINDER 16. WASHER 24. PIVOT PIN 11.6 in (295 mm)
LOADER FRAME ILLUSTRATION

9006-10
INSTALLING THE LOADER FRAME (Z-BAR AND LONG REACH MODELS)

1. Apply antiseize compound to the inner bores and 17. Disconnect the chain hoist from the bucket
outer bores for the pivot pins of the front frame, cylinder (6).
refer to the illustration on page 9.
18. Fasten the chain hoist to one of the lift cylinders
2. Move the machine into alignment with the loader (4 or 8).
frame (2).
19. Raise the piston rod yoke of the lift cylinder (4 or
3. Lower the loader frame (2) into alignment with 8) so the piston rod yoke is aligned with the
the front frame. loader frame (2).
4. Apply antiseize compound to the pivot pins (9) 20. Install a driver in the piston rod yoke and the
that fasten the loader frame (2) to the front loader frame (2).
frame.
21. Repeat Steps 18, 19, and 20 for the other lift
5. Start the pivot pins (9) into the front frame. Install cylinder (4 or 8).
the washers (18) and new wipers (22) between
22. Disconnect the chain hoist from the lift cylinder (4
the loader frame (2) and the front frame.
or 8).
6. Install the pivot pins (9) all the way.
23. Start the engine. Raise the loader frame and roll
7. Install the bolt (19), washer (20) and spacer (21) the bucket all the way forward. Lower the bucket
that fasten the pivot pins (9). Tighten the bolt. to the floor. Stop the engine.
Install on the pivot pin (9) the hoses grease (26
24. Fasten the chain hoist to the cross member (1) of
and 27).
the loader frame (2).
8. Install the proximity switch and cover. Left-hand
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
(2).
rod yoke of one of the lift cylinders (4 or 8) with
10. If the machine is equipped with front lamps, hold the loader frame (2).
the front lamps in place and install the cap
screws and lock washers that fasten the front IMPORTANT: D o n o t u s e y o u r f i n g e r s t o
lamps to the front frame. Tighten the cap screws. check the alignment of the cylinder rod.
11. If the machine is equipped with auxiliary Personal injury can be the result.
48-88
hydraulics, remove the plugs from the tube
fittings and the caps from the hoses. Connect the 27. Remove the driver and install the pivot pin (3).
hoses to the tubes.
28. Install the bolt (12), washer (13), and spacer(14)
12. Connect the chain hoist to the bucket cylinder (6) that fasten the pivot pin (3). Tighten the bolt.
and lower the bucket cylinder (6).
29. Repeat Steps 26, 27, and 28 for the other lift
13. Start the engine and run the engine at low idle. cylinder (4 or 8). 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 (6) with the
bell crank (11). Stop the engine. 31. Disconnect the chain hoist from the cross
member (1) of the loader frame (2).
IMPORTANT: D o n o t u s e y o u r f i n g e r s t o 32. Tighten the filler plug in the reservoir.
check the alignment of the cylinder rod.
33. If the machine is equipped with auxiliary
Personal injury can be the result.
48-88
hydraulics, start the engine and run the engine at
low idle.
15. Install the pivot pin (7) in the bell crank (11) and
34. Slowly extend and retract the clam cylinders four
the piston rod eye of the bucket cylinder (6).
times to remove air from the auxiliary circuit.
16. Install the bolt (15), washer (16), and spacer (17)
35. Stop the engine, check the level of the oil in the
that fasten the pivot pin (7). Tighten the bolt.
reservoir, and check for leaks. Add oil to the
reservoir as required.

Section
9007
ROLLOVER PROTECTIVE STRUCTURE (ROPS)

CAB STRUCTURAL FRAME (CSF)
9007

Via Plava, 80
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

CAB STRUCTURAL FRAME (CSF)
After an accident, fire or rollover, the following MUST
be performed before returning the machine to field or
Attention
job site operation:
● The ROPS or CSF structure MUST be replaced.
The Rollover Protective Structure (ROPS) or Cab ● The ROPS or CSF mounting or suspension,
Structural Frame (CSF) is a special safety operator seat and suspension, seat belts and
component of your machine. mounting components and wiring within the
DO NOT attach any device to the ROPS or CSF for operator’s protective system MUST be carefully
pulling purposes. inspected for damage.
● All damaged parts MUST be replaced.
The ROPS or CSF is a certified structural support
and any damage, fire, corrosion or modification will DO NOT WELD, ATTEMPT TO STRAIGHTEN OR
weaken the structure and reduce your protection. If REPAIR THE ROPS OR CAB STRUCTURAL
this occurs, the ROPS or CSF MUST be replaced so FRAME.
that it will provide the same protection as a new
ROPS or CSF.
MAINTENANCE AND INSPECTION OF THE (CSF) CAB OR (ROPS) CANOPY

After every 500 hours of operation or every six
months, whichever comes first, do the following: WARNING: Do not install attachments that
will make the total weight of the machine
1. Check the torque on the CSF cab or ROPS more than the weight shown in the maximum
canopy mounting bolts; torque should be 773 to gross vehicle weight section of the ROPS
854 Nm (570 to 630 lb-ft). If necessary, tighten serial number plate. 47-26
the bolts to the correct torque.
2. Check that seat belt mounting hardware is tight WARNING: Do not change the ROPS in any
and seat belt is not cut or frayed. Check the way. Changes made to the ROPS which are
torque on operators seat mounting bolts; torque not authorized, such as welding, drilling or
should be 73 to 87 Nm (54 to 64 lb-ft). If cutting will make the ROPS weaker and
necessary, tighten the bolts to the correct torque. decrease your protection. Replace the
Replace parts that are worn or damaged. ROPS if it becomes damaged in any way.
DO NOT TRY TO MAKE REPAIRS TO THE
WARNING: Grade 8 hardware is used to ROPS. 47-25
mount and anchor the ROPS. Parts used for
replacement must be those shown in the
parts catalog. 47-27A

9007-4
CSF CAB AND ROPS CANOPY
Removal STEP 4
NOTE: Procedures and photos in following steps cover in
detail removal and installation of CSF structure. Removal
and installation of ROPS is similar to removal and
installation of CSF structure.
STEP 1
floor. Stop engine. Actuate brake pedal several times
to discharge brake accumulators. Put key switch in
ON position and move loader control lever back and
forth at least 30 times to release any pressure from
hydraulic circuit. Put key switch in OFF position.
STEP 2
W270R571
If machine is equipped with a heater, put a 40 liters

(10 Gallons) container below radiator drain. Remove
cap and drain coolant into container. Install cap after
coolant has drained.
STEP 5
W230R406
Put articulation lock in LOCKED position.
STEP 3
Put battery disconnect switch in OFF position.
BD06G191
Remove skirting under each side and front of cab.

9007-5
STEP 6 STEP 9
2 3
BD06G186 BD06G205
Remove the ducts from the machine.
3. HEATER HOSES
STEP 7
If machine is equipped with a heater disconnect
heater hoses (3), if machine is equipped with air
conditioning discharge the air conditioning system,
see section 9003, and disconnect the air conditioning
hoses (2), cap and plug lines and fittings.
STEP 10
BD06G189
At RH rear, bottom of cab, disconnect ground strap

from rear chassis.
STEP 8
BD06G193
Disconnect throttle connector and the air duct.
BD06G194
If machine is equipped with windshield washers,

identify, tag, and disconnect front and rear
windshield washer nozzle hoses from supply hoses.

9007-6
STEP 11 STEP 14
BD06F209
BD06G192
Identify, tag, and disconnect hoses from steering Remove the front access panel.
control valve. Plug hoses and cap steering control
valve fittings to prevent entry of foreign matter into STEP 15
hydraulic system.
STEP 12
BD06F210
Disconnect the electrical connectors for the remote

control valve.
BD06F207 STEP 16
Unlatch and open the window on the right hand side. Loosen the filler cap on the reservoir to release any
air in the reservoir. Connect a vacuum pump to the
STEP 13 hydraulic reservoir, turn on the pump.
STEP 17
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install
plugs in the hoses and caps on the fittings to prevent
entry of foreign matter into hydraulic system.
STEP 18
Push the hoses out of the bottom of the cab with the
rubber gromment.
BD06F208
Open and remove the access panel.

9007-7
STEP 19 STEP 22
BD06G187 BD06G184
Disconnect the electrical connectors, push Install lifting eyes in threaded holes at top of the cab.
connectors out of the bottom of the cab with the
rubber gromment STEP 23
Connect lifting equipment to cab at lifting eyes. Take
STEP 20 up all slack in lifting equipment.
STEP 24
Remove nuts, bolts, and washers securing cab to
rear chassis.
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
BD06G188
machine. Lower ROPS or CSF onto wooden blocks
to prevent damaging cab or canopy.
Raise floor mat up and away from brake pedal to
gain access to mounting hardware.
STEP 21
BD06G185
Remove hardware securing brake valve to cab floor.

Let brake valve rest on the frame.

9007-8
2 1
4
4
5
5
6
6
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 BD06G192
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
BD06G193
Connect throttle connector and mount air duct.
BD06G185
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 37
BD06G186 BD06G194
Install the ducts on the machine. If machine is equipped with windshield washers,
connect front and rear windshield washer nozzle
STEP 36 hoses following tags installed during removal.
Remove and discard tags.
STEP 38
2 3
1
BD06G189
At RH rear, bottom of cab, connect ground strap to

rear chassis.
BD06G205
3. HEATER HOSES
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 and 12.

9007-11
7 1
7
4 6
5 7
4 2 1
6 3
3 2
5
7 7 7 7
2 1 2 1
3 6 3 6
4 5 4 5
W230R021 W230R022

7. RED WHITE GREEN 7. RED WHITE GREEN
3 LEVER HOSE COLOR CODING JOYSTICK AND 1 LEVER HOSE COLOR CODING

9007-12
1
4
5
6
3 4 5
6
3
2 1
2 1 2 1
6 6
3 3
4 5 4 5
W230R023 W230R020

2 LEVER HOSE COLOR CODING JOYSTICK HOSE COLOR CODING

9007-13
STEP 40 STEP 43
BD06F210 BD06F208
Connect the electrical connectors for the remote Install and close the access panel.
control valve.
STEP 44
STEP 41
BD06F209 BD06F207
Place the access panel into position, install and Close the right hand window.
tighten the screw.
STEP 42 STEP 45
BD06G187
BD06G191
Connect wiring harness connectors.
Install skirting under each side and front of cab.

9007-14
STEP 46 STEP 49
Start engine and run engine at low idle. Run engine
at operating temperature for approximately five
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.
WARNING: Hot coolant can spray out if radiator cap is
removed. To remove radiator cap: let system cool, turn to
first notch, then wait until all pressure is released. Scalding
can result from fast removal of radiator cap.
STEP 50
W270R571
If machine is equipped with a heater and coolant was

drained, check that coolant drain cap is tight.
STEP 47
Ethylene Glycol and 50% water. Cooling system
capacity is 56.8 liters (15 U.S. Gallons). Install
radiator cap. Fill coolant reservoir up to FULL mark
on reservoir.
STEP 48
Put battery disconnect switch in ON position.

Section
9010
CAB GLASS INSTALLATION
9010

Via Plava, 80
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 (349-110) to the
black ceramic painted edges of the window.
2. Remove all the adhesive from the window frame.
6. When replacing a front window section, a
3. The window frame recesses must be free of oil
silicone forming tool is needed, refer to Figure 2.
and dust. Clean the frame with rubbing alcohol
Use the template and instructions provided to
with a clean rag. Do not reuse the rag.
make the tool.
4. Apply a 25 mm (1 inch) wide band of metal
primer (349-108) to the window recesses.
GLASS INSTALLATION
NOTE: Once the adhesive is applied, the glass must be 3. For front glass installations install a glass spacer
installed within 5 minutes. If the glass is not installed within 12 mm (1/2 inch) from each corner on bottom
the 5 minute period, the adhesive must be removed and edge of each glass section, refer to Figure 3.
applied again.
4. Install the glass. The glass edges must not
1. Apply a 10 mm (3/8 inch) diameter bead of contact the metal frame at any point.
adhesive (345-135) to the primed surface
5. For front glass installations position the glass to
approximately 12 mm (1/2 inch) from edge.
maintain a uniform 3 mm (1/8 inch) gap between
2. The adhesive may be applied either to the front and front side glass sections.
primed glass or to the primed metal frame. DO
NOT apply the adhesive to both the glass and
the frame.
NOTE: When replacing two or more sections of the front
glass apply extra adhesive in corners, refer to Figure 3.
SILICONE SEALANT APPLICATION - FRONT WINDOWS

1. Clean the edges of the front center and front side 6. Fill the joint with the clear silicone sealant
windows. Use glass cleaning primer. (114328A1), refer to Figure 1. The silicone must
completely penetrate and fill the gap between the
2. Apply masking tape to the inside edge of each
glass sections. The sealant must extend at least
glass section next to the gap.
1.5 mm (1/16 inch) above the outside surface of
3. Apply the polyester tape on top of the masking the glass section for the length of the gap. Be
tape across the inside side gap. Do not push the sure the sealant fills against the adhesive at
tape into the gap. each end of the joint.
4. Apply masking tape to the outside edge of each 7. Remove the polyester tape from the inside joint.
glass section. Align the edge of the tape with
8. Remove the extra silicone from the outside joint
edge of glass on both sections.
by carefully sliding the forming tool down the
5. The tape must be smooth to get the best result length of the joint. The tool must remain in
when using the silicone forming tool. contact with the glass sections during this
process. Refer to Figure 2 for forming tool
template.

9010-4
9. Remove all the silicone from the forming tool
1 2 immediately after use.
10. Remove the outside tape from the glass
sections.
11. Remove the extra silicone sealant from the
inside joint by carefully sliding the forming tool
down the length of the joint.
12. Remove all the silicone from the forming tool
immediately after use.
3 13. Remove the inside joint masking tape.
4 14. If two or more glass sections are being replaced,

498L93
use the procedure on the second joint.
1. FRONT RH SIDE GLASS 3. SILICONE BEFORE 15. Apply the gray silicone sealant above the front
SMOOTHING center, front side or rear windows for additional
2. FRONT CENTER GLASS 4. SILICONE AFTER leak protection.
SMOOTHING
FIGURE 1. SILICONE APPLICATION 16. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top on
NOTE: Make the forming tool from 10 mm (3/8 inch)
each front side window replaced, refer to Figure
plexiglass, or wood. Sand all radius and edges smooth.
3.
17. Apply the gray silicone sealant (345-174) down
approximately 50 mm (2 inches) from the top
edge of the rear glass, if replaced.
6 MM 120°
(1/2 INCH) R
120°
4 MM
(3/16 INCH) R
496L93
FIGURE 2. SILICONE FORMING TOOL TEMPLATE

9010-5
2
1
3
4
2
1
497L93
1. SIDE GLASS ADHESIVE 4. RIGHT HAND SIDE GLASS SPACER LOCATIONS

2. CENTER GLASS ADHESIVE 5. APPLY GRAY SILICONE SEALANT DOWN 50 MM (2 INCHES)
FROM TOP OF FRONT SIDE GLASS
3. APPLY EXTRA ADHESIVE HERE WHEN REPLACING BOTH 6. APPLY GRAY SILICONE SEALANT ALONG BOTTOM EDGE OF
CENTER AND SIDE PANELS CENTER GLASS
FIGURE 3 SILICONE APPLICATION
NOTE: After completing the installation, DO NOT slam the cab door. The increased air pressure may break the seal on newly
installed glass. DO NOT operate the machine for a period of 12 hours, allowing the adhesive and silicone to properly set.

9010-6
NOTES

INDEX OF FUNCTIONS DIAGRAM SYMBOL DESCRIPTIONS
FUNCTIONS SHT SPLICE SYMBOL

AIR SEAT 12
SPLICE NAME
CAN COMMUNICATION 12
WIRE NAME
COLD START 4
WIRE COLOR
ENGINE CONTROL 5
WIRE SIZE (mm 2)
HOOD LIFT 11 MALE CONNECTOR
HVAC 12
FEMALE CONNECTOR
IGNITION SWITCH 4
INSTRUMENT CLUSTER 9
HOOD LIFT 11
CONNECTOR REFERENCE DESIGNATOR
LIGHTING 1 (combos...) 6
LIGHTING 2 (work lights) 7
MACHINE CONTROLS 10
RADIO/POWER CONVERTER 12 CONNECTOR INTERFACE
POWER DISTRIBUTION 4 (ONE HARNESS CONNECTS TO ANOTHER HARNESS)
TRANSMISSION CONTROL 8 INDICATES WIRES CROSSING (NOT CONNECTED)
SCR EXHAUST TREATMENT 6
SECONDARY STEERING 11
WIPER/WASHER SYSTEM 11
JOYSTICK STEERING 13 INDICATES PARTIAL CONNECTOR
(NOT ALL ENTRY PORTS SHOWN)
REF DES NAMING CONVENTION

S... ROCKER SWITCHES INDICATES THAT THE WIRE CONNECTS TO CONNECTOR
L... LIGHTS TECM (TRANSMISSION ELECTRONIC CONTROL MODULE) COLOR ABBREVIATIONS
P... PRESSURE SENSOR/SWITCHES ON SHEET 6. TECM CAN BE LOCATED ON SHEET 6 USING
Y... SOLENOIDS ZONE (GRID) LOCATIONS GIVEN IN TABLES ON SHEET 2. ABBREVIATION COLOR
R... RESISTANCE MEASURE Bk BLACK
ABOVE LETTER FOLLOWED BY THE FIRST LETTER DU DARK BLUE
OF THE FIRST TWO WORDS OF THE SYMBOL LABEL. INDICATES INTERNALLY GROUNDED COMPONENT G GREEN
SPL... SPLICE K PINK
LG LIGHT GREEN
LARGE CONNECTOR LIST LU LIGHT BLUE
NAME DESCRIPTION SHT
N BROWN
Or ORANGE
P PURPLE OR VIOLET
R RED
S GREY
T TAN
U BLUE
W WHITE
Y YELLOW
INDEX / WIRE INFORMATION 1

CONNECTOR LIST CONNECTOR LIST CONNECTOR LIST CONNECTOR LIST

NAME DESCRIPTION SHT NAME DESCRIPTION SHT NAME DESCRIPTION SHT NAME DESCRIPTION SHT
CONNECTOR LIST 2
CONNECTOR LIST CONNECTOR LIST CONNECTOR LIST PIN NAME LOCATION PIN NAME LOCATION PIN NAME LOCATION
NAME DESCRIPTION SHT NAME DESCRIPTION SHT NAME DESCRIPTION SHT
PIN LOCATION
PIN NAME LOCATION
PIN LOCATION PIN LOCATION
PIN LOCATION PIN LOCATION PIN LOCATION PIN LOCATION
CONNECTOR LIST 3
3 18
15
21
13
14
20
2
8
11
10
1
158
16
6 159
17
160
COLD START POWER DISTRIBUTION IGNITION SWITCH 4

22
24
162
161
163
23
PL23
ONLY
169
164
168
165
166
167
ENGINE CONTROL 5
95 92
90
78
93
91
94
79
101 100
101 100
103
96 97
102
LIGHTING 1 BACKUP ALARM 6

89
81
88
87
80
86
84
85
170
83
82
LIGHTING 2 7
172
54
173
171
JOYSTICK ONLY 57
55
SINGLE AXIS CONTROLLER ONLY 59
56
174
46
47
45
61 58
48
49
50
51
52
53
60
TRANSMISSION CONTROLS 8
64
74
68
72
67
65 75
69
73
76
66
INSTRUMENT CLUSTER 9
25
35
36
26
32
29
33
31
37
98
27
39
99
28
40
34
38
44 30
41
42
43
MACHINE CONTROLS 10
113
155
154
105 104
108
114
106 107
156 109
115
117 111
112
113
116
157
110
118
SECONDARY STEERING HOOD LIFT WIPER/WASHER SYSTEM 11

121
127
122
129 126
128
130
125
123
124
119
CAN COMMUNICATION HVAC AIR SEAT RADIO POWER/CONVERTER 12

184
177
175
185
176
179
178
181
182
180
183
186
JOYSTICK STEERING 13
145
144
146
143
147
148
149 153
150
151
152
STANDARD HVAC 14
COMPONENT NUMBERS
# SHT COMPONENT # SHT COMPONENT # SHT COMPONENT # SHT COMPONENT
1 4 STARTING RELAY 61 8 DIAGNOSTIC CONNECTOR 119 12 DIAGNOSTIC CONNECTOR 177 13 ARM POS
2 4 RESISTOR - 75 OHM 62 1 INSTRUMENT CLUSTER CONNECTOR 1 121 12 POWER CONVERTER - 24 TO 12 VOLT 178 13 FNR SWITCH (OPTION)
3 4 ALTERNATOR 63 9 WARNING BUZZER 122 12 12 VOLT POWER OUTLETS (OPTION) 179 13 FNR RELAY
4 4 CRANK CONTROL RELAY 64 9 PARKING BRAKE RELAY 123 12 RADIO 180 13 PILOT DUMP VALVE
5 4 BATTERIES 65 9 FUEL LEVEL SENDER 124 12 RIGHT SPEAKER 181 13 JSS VALVE
6 4 CRANK REQUEST RELAY 66 9 AIR FILTER RESTRICTION SWITCH 125 12 LEFT SPEAKER 182 13 LOAD SENSE PRESSURE SENSOR
8 4 MASTER DISCONNECT SWITCH 67 9 PARKING BRAKE SOLENOID 126 12 AIR SEAT 183 13 PILOT PRESSURE SWITCH
9 4 STARTER 68 9 RADIATOR COOLANT TEMPERATURE SENDER 127 12 CIGAR LIGHTER 184 13 JSS RELAY
10 4 IGNITION SWITCH 69 9 BRAKE PRESSURE WARNING SWITCH 128 12 AIR CONDITIONING CLUTCH RELAY 185 13 JOYSTICK STR SWITCH (OPTION)
11 4 NEUTRAL START RELAY 70 1 SWITCH PAD 129 12 AIR CONDITIONING HIGH-LOW PRESSURE SWITCH 186 13 JSS CONTROLLER
13 4 POWER RELAY MODULE A 71 1 INSTRUMENT CLUSTER CONNECTOR 2 130 12 AIR CONDITIONING COMPRESSOR CLUTCH
14 4 POWER RELAY MODULE B 72 9 HYDRAULIC FILTER RESTRICTION SWITCH 131 NA ELECTRONIC PANEL
15 4 POWER RELAY MODULE C 73 9 HYDRAULIC OIL TEMPERATURE SENDER 132 NA EXTERNAL AIR TEMPERATURE SENSOR
16 4 GRID HEATER RELAY 74 9 PARK BRAKE SWITCH 133 NA INTERNAL AIR TEMPERATURE SENSOR
17 4 GRID HEATER 75 9 REDUNDANT BRAKE PRESSURE SWITCH 1 134 NA SUN SENSOR
18 4 POWER RELAY MODULE D 76 9 REDUNDANT BRAKE PRESSURE SWITCH 2 135 NA BLOWER FAN RESISTOR
20 4 WATER SEPARATOR HEATER 78 6 BACKUP ALARM RELAY 136 NA BLOWER MOTORS
21 4 FUEL FILTER HEATER 79 6 BACKUP ALARM DISABLE SWITCH 137 NA THERMOCOUPLE SENSOR
22 5 WATER IN FUEL SENSOR 80 7 WORK LAMPS SWITCH 138 NA MIXED AIR SENSOR
23 5 THROTTLE POTENTIOMETER 81 7 DOOR SWITCH 139 NA COMPRESSOR RELAY
24 5 ENGINE CONTROLLER 82 7 ROTATING BEACON (OPTIONAL) 140 NA RECYCLING MOTOR
25 10 RETURN TO TRAVEL FLOAT SWITCH 83 7 DOME LAMP 141 NA ELECTRONIC WATER VALVE
26 10 HEIGHT CONTROL SWITCH 84 7 ROTATING BEACON SWITCH (OPTIONAL) 142 NA 24 TO 12 VOLT CONVERTER
27 10 ELECTROMAGNETIC DETENTS 85 7 LEFT HAND FRONT WORK LAMP 143 14 ACTUATOR
28 10 RETURN TO DIG PROXIMITY SWITCH 86 7 RIGHT HAND FRONT WORK LAMP 144 14 DRIVER
29 10 PILOT CONTROL RELAY ECD-K3 87 7 LEFT HAND REAR WORK LAMP 145 14 ELECTRONIC WATER VALVE
30 10 HEIGHT CONTROL AND RETURN TO TRAVEL PROXIMITY SW 88 7 RIGHT HAND REAR WORK LAMP 146 14 BLOWER FAN RESISTOR
31 10 RETURN TO DIG SWITCH 89 7 DIODES 147 14 BLOWER MOTOR
32 10 PIN ENGAGE SWITCH (OPTION) 90 6 BRAKE LAMP SWITCH 148 14 THERMOSTAT
33 10 PILOT PRESSURE SOLENOID 91 6 BRAKE LAMP RELAY 149 14 FAN SPEED SWITCH
34 10 PIN ENGAGE SOLENOID (OPTION) 92 6 FLASHER MODULE 150 14 AIR CONDITIONING SWITCH
35 10 RIDE CONTROL SWITCH (OPTION) 93 6 HAZARD SWITCH 151 14 CONTROL PANEL LAMPS
36 10 RIDE CONTROL RELAY (OPTION) 94 6 TURN SIGNAL, HIGH-LOW BEAM, AND HORN SWITCH 152 14 WATER VALVE POTENTIOMETER
37 10 FAN CONTROL SWITCH (OPTION) 95 6 DRIVING LAMPS SWITCH 153 14 AIR RECIRCULATING SWITCH
38 10 FAN REVERSE RELAY (OPTION) 96 6 LEFT HAND FRONT COMBINATION LAMPS 154 11 HOOD UP RELAY
39 10 PILOT CONTROL SWITCH 97 6 RIGHT HAND FRONT COMBINATION LAMPS 155 11 HOOD DOWN RELAY
40 10 RIDE CONTROL SOLENOID (OPTION) 98 10 HORN RELAY 156 11 HOOD SWITCH
41 10 ROLLBACK PRESSURE SW (XT WITH RIDE CONTROL ONLY) 99 10 HORN RELAY 157 11 HOOD MOTOR
42 10 ROLLBACK JUMPER 100 6 RIGHT HAND REAR COMBINATION LAMPS 158 4 IGNITION POWER LATCH
43 10 FAN PWM SOLENOID 101 6 LEFT HAND REAR COMBINATION LAMPS 159 4 IGNITION POWER CONTROL
44 10 FAN REVERSE SOLENOID (OPTION) 102 6 LICENSE PLATE LAMP 160 4 START LOCKOUT
45 8 OUTPUT SPEED SENSOR 103 6 BACKUP ALARM 161 5 NOX SENSOR
46 8 TRANSMISSION SOLENOID VALVE AND TEMP SENDER 104 11 FRONT WIPER HIGH SPEED RELAY 162 5 HUMIDITY AND AMBIENT TEMPERATURE SENSOR
47 8 FILTER MAINTENANCE SWITCH 105 11 WIPER CUTOUT RELAY 163 5 NOX SENSOR (NOXS)
48 8 TORQUE CONVERTER OUTPUT TEMPERATURE SENDER 106 11 FRONT WIPER LOW SPEED RELAY 164 5 TANK HEATER CONTROL VALVE
49 8 ENGINE SPEED SENSOR 107 11 REAR WIPER AND WASHER SWITCH 165 5 DEF LEVEL AND TANK TEMPERATURE
50 8 INTERMEDIATE SPEED SENSOR 108 11 FRONT WIPER AND WASHER SWITCH 166 5 UPSTREAM TEMPERATURE SENSOR
51 8 TURBINE SPEED SENSOR 109 11 FRONT WIPER MOTOR 167 5 DOWNSTREAM TEMPERATURE SENSOR
52 8 TRANSMISSION SHIFTER 110 11 REAR WIPER MOTOR 168 5 DOSER METERING VALVE
53 8 TRANSMISSION ELECTRONIC CONTROL MODULE 111 11 REAR WASHER MOTOR 169 5 DNOX CONTROLLER
54 8 TRANSMISSION ENABLE SWITCH 112 11 FRONT WASHER MOTOR 170 7 REAR VIEW CAMERA/MONITOR
55 8 FNR SWITCH FOR JOYSTICK CONTROLS 113 11 DIODES 171 8 DIFFERENTIAL LOCK SWITCH (MANUAL)
56 8 TRANSMISSION KICK DOWN SWITCH 114 11 SECONDARY STEERING DIODES 172 8 DIFFERENTIAL LOCK SWITCH
57 8 FNR SWITCH FOR SINGLE AXIS CONTROLS 115 11 SECONDARY STEERING SOLENOID 173 8 DIFFERENTIAL LOCK SOLENOID
58 8 TRANSMISSION AUTO SWITCH 116 11 SECONDARY STEERING MODULE 174 8 LOCKUP SOLENOID
59 8 BRAKE DECLUTCH PRESSURE SWITCH 117 11 SECONDARY STEERING MOTOR 175 13 JOYSTICK PVRES
60 8 DECLUTCH SWITCH 118 11 SECONDARY STEERING PRESSURE SWITCH 176 13 TRANSMISSION KICK DOWN SWITCH
COMPONENT NUMBERING INFORMATION 15

COMPONENTS
1. Rear Axle Brakes 8. Low Brake Pressure Warning Switch 18. Lift Cylinders 25. Auxiliary Steering Pressure Switch 33. Reservoir 41. Steering Control Valve PVG 32
2. Front axle Brakes 9. Brake Declutch 19. Ride Control 26. Auxiliary Steering Control Valve 34. Reservoir Vent 42. LS Joystick Steering Valve
3. Parking Brake 10. Brake Light Pressure Switch 20. Ride Control Accumulator 27. Auxiliary Steering Pump 35. Filter 10 Micron Media
4. Brake Valve 11. Front Brake Accumulator 3.78 Liter (4 Quart) 28. Low Pressure Pump Bypass 3.4 BAR (49.3 PSI)
5. Parking Brake Accumulator 3.5 Liter (3.69 Quart) 10 BAR (145 PSI) Precharge Cut Off 280 BAR (4061 PSI) Warning Switch 2.7 BAR (39 PSI)
0.16 Liter (0.17 Quart) 70 BAR (1015 PSI) Precharge 21. Pilot Control Accumulator Delta 25 BAR (362 PSI) 36. Oil Cooler Thermal Valve
97 BAR (1392 PSI) Precharge 12. Redundant Accumulator Brake 0.75 Liter (0.79 Quart) 29. Priority Valve 37. Oil Cooler
6. Rear Brake Accumulator Pressure Switch 13.8 BAR (200 PSI) Precharge 30. High Pressure Pump 38. Oil Cooler Fan
3.5 Liter (3.69 Quart) 13. Brake Damping Accumulator 22. Loader Valve Cut Off 280 BAR (4060 PSI) 39. Fan Reversing and Variable Valve
70 BAR (1015 PSI) Precharge 14. Axle Cooler 23. Steering Cylinders Delta 29 BAR (420.6 PSI) 40. Steering Back Pressure Valve
7. Redundant Accumulator Brake 15. Pilot Control Valve 24. Steering Control Valve 31. Brake Pump 10 BAR (145 PSI)
Pressure Switch 16. Bucket Cylinder Z BAR 32. 100 MSH Strainers
17. Not Used
CIRCUIT DIAGRAM LEGEND CONVERSION INFORMATION

CIRCUIT
COMPONENT
1 bar = 14.5 pounds per square inch (PSI)
1 liter per minute = 264 gallons per minute
HYDRAULIC SCHEMATIC
#
SHOWS CIRCUIT LOAD SENSE
W270C WHEEL LOADER
CROSSING SHOWS CIRCUIT COMPONENT
NOT CONNECTED CONNECTED NUMBER CHECK VALVE RESTRICTOR FILTER OR SCREEN OIL COOLER
LINE TYPES
COMPONENTS
1. Rear Axle Brakes 8. Low Brake Pressure Warning Switch 18. Lift Cylinders 25. Auxiliary Steering Pressure Switch 33. Reservoir 41. Steering Control Valve PVG 32
2. Front axle Brakes 9. Brake Declutch 19. Ride Control 26. Auxiliary Steering Control Valve 34. Reservoir Vent 42. LS Joystick Steering Valve
3. Parking Brake 10. Brake Light Pressure Switch 20. Ride Control Accumulator 27. Auxiliary Steering Pump 35. Filter 10 Micron Media
4. Brake Valve 11. Front Brake Accumulator 3.78 Liter (4 Quart) 28. Low Pressure Pump Bypass 3.4 BAR (49.3 PSI)
5. Parking Brake Accumulator 3.5 Liter (3.69 Quart) 10 BAR (145 PSI) Precharge Cut Off 280 BAR (4061 PSI) Warning Switch 2.7 BAR (39 PSI)
0.16 Liter (0.17 Quart) 70 BAR (1015 PSI) Precharge 21. Pilot Control Accumulator Delta 25 BAR (362 PSI) 36. Oil Cooler Thermal Valve
97 BAR (1392 PSI) Precharge 12. Redundant Accumulator Brake 0.75 Liter (0.79 Quart) 29. Priority Valve 37. Oil Cooler
6. Rear Brake Accumulator Pressure Switch 13.8 BAR (200 PSI) Precharge 30. High Pressure Pump 38. Oil Cooler Fan
3.5 Liter (3.69 Quart) 13. Brake Damping Accumulator 22. Loader Valve Cut Off 280 BAR (4060 PSI) 39. Fan Reversing and Variable Valve
70 BAR (1015 PSI) Precharge 14. Axle Cooler 23. Steering Cylinders Delta 29 BAR (420.6 PSI) 40. Steering Back Pressure Valve
7. Redundant Accumulator Brake 15. Pilot Control Valve 24. Steering Control Valve 31. Brake Pump 10 BAR (145 PSI)
Pressure Switch 16. Bucket Cylinder Z BAR 32. 100 MSH Strainers
17. Not Used
CIRCUIT DIAGRAM LEGEND CONVERSION INFORMATION

CIRCUIT
COMPONENT
1 bar = 14.5 pounds per square inch (PSI)
1 liter per minute = 264 gallons per minute
HYDRAULIC SCHEMATIC
#
SHOWS CIRCUIT LOAD SENSE
W300C WHEEL LOADER
CROSSING SHOWS CIRCUIT COMPONENT
NOT CONNECTED CONNECTED NUMBER CHECK VALVE RESTRICTOR FILTER OR SCREEN OIL COOLER
LINE TYPES

Service Manual: W W270C Wheel Loader W300C

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Service Manual: W W270C Wheel Loader W300C

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SERVICE MANUAL

Print No. 84547255A

Print No. 84547255A

Use for Service Manual

W270C - W300C Wheel Loader

Fuel System Tab 3

Copyright © 2011 CNH Italia S.p.A.

W270C - W300C Wheel Loader

Power Train Tab 6

W270C - W300C Wheel Loader

Electrical Schematic Foldouts and Hydraulic Schematic Foldout In Rear Pocket

Copyright © 2011 CNH Italia S.p.A.

Section Title Section Number

Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001

Copyright © 2011 CNH Italia S.p.A.

GENERAL TORQUE SPECIFICATIONS

Copyright © 2011 CNH Italia S.p.A.

84547255A Issued 11-11 Printed in E.C.

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Pound- Newton Pound- Newton

84547255A Issued 11-11 Printed in E.C.

TORQUE SPECIFICATIONS - METRIC HARDWARE

M6 96 to 108 11 to 12 M12 93 to 112 125 to 150

M8 228 to 276 26 to 31 M14 149 to 179 200 to 245

M10 456 to 540 52 to 61 M16 230 to 280 310 to 380

Pound- Newton M24 780 to 940 1050 to 1275

84547255A Issued 11-11 Printed in E.C.

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

37 Degree Flare Fitting Straight Threads with O-ring

Split Flange Mounting Bolts

84547255A Issued 11-11 Printed in E.C.

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

O-ring Boss End

Thread Pound- Newton

Nom. 1-1/16-12 85 to 90 115 to 122

84547255A Issued 11-11 Printed in E.C.

FLUIDS AND LUBRICANTS

Copyright © 2011 CNH Italia S.p.A.

84547255A Issued 11-11 Printed in E.C.

CAPACITIES AND LUBRICANTS

84547255A Issued 11-11 Printed in E.C.

84547255A Issued 11-11 Printed in E.C.

HYDRAULIC OIL TEMPERATURE CHART

TRANSMISSION OIL TEMPERATURE CHART

ENGINE OIL TEMPERATURE CHART

84547255A Issued 11-11 Printed in E.C.

84547255A Issued 11-11 Printed in E.C.

Copyright © 2011 CNH Italia S.p.A.

84547255A Issued 11-11 Printed in E.C.

Area: sq. meter 10.763 91 square foot

Force: newton 3.596 942 ounce force

Length: millimeter 0.039 370 inch

Mass: kilogram 2.204 622 pound

Mass/Area: kilogram/hectare 0.000 466 ton/acre

Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.

Power: kilowatt 1.341 02 horsepower

Pressure: kilopascal 0.145 038 lb/sq. inch

Temperature: degree C 1.8 x C +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)

84547255A Issued 11-11 Printed in E.C.