Workshop Manual: Wheel Loader

Copyright © New Holland
W170/W170TC
WHEEL LOADER
Workshop Manual
Print N° 604.13.497.00 English
II - 2005
THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.
Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid
potential risks and to safeguard your health and your safety.
You will find this symbol in the text of this Manual referred to the following key words:
WARNING - Cautions directed to avoid improper repair interventions involving potential consequences
for the operator’s safety.
DANGER - These warnings qualify specifically potential dangers for the safety of the operator or other
persons directly or indirectly involved.
IMPORTANT NOTICE
All maintenance and repair interventions explained in this Manual must be performed exclusively by the
Service Organization of the Manufacturer, observing strictly the instructions explained using, whenever
necessary, the recommended specific tools.
Whoever performs the operations reported without following exactly the precautions is responsible on his own,
for the damages that may result.
Neither the Factory nor any Organizations in its Distribution Network, including but not limited to national,
regional or local distributors, are responsible for any liability arising from any damage resulting from defects
caused by parts and/or components not approved by the Factory for use in maintaining and/or repairing products
manufactured or merchandized by the Factory.
In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or
merchandized by the Factory, when failures are caused by the use of parts and/or components not approved
by the Factory.
AVOID ACCIDENTS
Most accidents and injuries occurring in industry, on the

farm, at home or on the road, are caused by the failure
of some individual to follow simple and fundamental
safety rules or precautions. For this reason, MOST
ACCIDENTS CAN BE PREVENTED by recognizing
the real cause and taking the necessary precautions,
before the accident occurs.
Regardless of the care used in design and construction
of any type of equipment, there may be conditions that
cannot be completely safeguarded against without in-
terfering with reasonable accessibility and efficient op-
eration.
A careful operator is the best insurance against acci-
dents. The complete observance of one simple rule
would prevent many thousands serious injuries each
year.
This rule is: Never attempt to clean, lubricate or adjust
a machine while it is in motion.
WARNING
On machines having hydraulically, mechanically

and/or cable controlled equipment (such as
showels, loaders, dozers, scrapers etc.) be certain
the equipment is lowered to the ground before
servicing, adjusting and/or repairing.
If it is necessary to have the equipment partially or
fully raised to gain access to certain items, be sure
the equipment is suitably supported by means
other than the hydraulic lift cylinders, cable and/or
mechanical device used for controlling the equip-
ment.
SUMMARY
GENERALITIES ................................................... Section 0

ENGINE ................................................................ Section 1
TRANSMISSION .................................................. Section 2
BRAKE SYSTEM ................................................. Section 3
STEERING SYSTEM ........................................... Section 4
BUCKET BOOMS AND FRAME ........................ Section 5
EQUIPMENT HYDRAULIC SYSTEM ................. Section 6
ELECTRICAL SYSTEM ...................................... Section 7
CAB ...................................................................... Section 8
SECTION 0
GENERALITIES
INDEX
SUBJECT PAGE
SAFETY RULES ........................................................................................................................................... 0-1
SPECIFICATIONS - WHEEL LOADER W170 ............................................................................................... 0-8
DIMENSIONS AND WEIGHT ....................................................................................................................... 0-15
TABLE OF FLUID CAPACITIES ...................................................................................................................0-16
UNITS OF MEASURE ................................................................................................................................. 0-17
TORQUE SPECIFICATIONS ........................................................................................................................ 0-18
LOCTITE PRODUCT CHART ....................................................................................................................... 0-22

W170/W170TC GENERALITIES 0-1
SAFETY RULES
GENERALITIES Ensure that nobody is in the machine operating range
before moving off or operating the attachment. WALK
Read this Manual carefully before starting, operating,
COMPLETELY AROUND the machine before mounting.
maintaining, fuelling or servicing the machine.
Sound the horn.
Read and comply with all safety precautions before any
Before starting machine, check, adjust and lock the driver's
intervention.
seat for maximum comfort and control of the machine.
Do not allow unauthorised personnel to operate or serv-
Fasten your seat belts (when fitted).
ice this machine.
Obey all flag signals and signs.
Do not wear rings, wrist watches, jewellery, loose or hang-
ing garments, such as ties, torn clothing, scarves, unbut- Due to the presence of flammable fluids on the machine,
toned or unzipped jackets that can get caught in moving never check or fill fuel tanks or accumulator batteries near
parts. Wear certified safety clothes such as: hard hat, no- fires, open flames, or sparks.
slip footwear, heavy gloves, ear protection, safety glasses, REMEMBER THAT SPECIAL STARTING FLUIDS ARE
reflector vests, respirators. Ask your employer about spe- FLAMMABLE. Scrupolously follow recommendations
cific safety equipment requirements. printed on the containers and in this Manual.
Keep the operator’s compartment, step plates, grab-rails DO NOT PUNCTURE OR BURN CONTAINERS.
and handles clean and clear of foreign objects, oil, grease,
mud or snow to minimize the danger of slipping or stum- Containers must be stored in fresh, well ventilated places
bling. Remove mud or grease from your shoes before and out of the reach of unauthorised persons. Strictly
attempting to mount or operate the machine. follow the instructions provided by the Manufacturer.
Do not jump on or off the machine. Always keep both hands Never use these products near fires, open flames, or
and one foot, or both feet and one hand in contact with sparks.
steps and grab rails.
Do not use controls or hoses as hand holds when climbing
on or off the machine. Hoses and controls are movable
parts and do not provide solid support. Besides, controls
OPERATING
may be inadvertently moved and cause unexpected
movement of the machine or its attachments. Check wheel and rim retainers before each working shift.
If necessary, tighten to the torque specified.
Never operate the machine or its attachments from any
position other than sitting in the driver’s seat. Do not run the engine of this machine in closed buildings
without proper ventilation capable to remove harmful
Keep head, body, limbs, hands and feet inside the opera-
exhaust gases.
tor’s compartment at all times to reduce exposure to
external hazards. Roll Over Protective Structures (ROPS) are required on
wheel or crawler loaders, dozers, or graders. NEVER
Be careful of possible slippery conditions of the steps and
OPERATE the machine if such protective structure is
hand rails as well as of the ground around the machine.
removed.
Do not leave the machine until it is has come to a complete
Keep the operator’s compartment free of foreign objects,
stop.
especially if not firmly secured. Never use the machine to
Check the seat safety belt at least twice per year and transport objects, unless proper securing points are pro-
replace it if it shows signs of wear, fraying or other vided.
weakness that could lead to failure.
DO NOT CARRY RIDERS ON THE MACHINE
Study and familiarize with escape routes alternate to
normal exit routes.
According to law provisions, seat belts must be fitted with
STARTING Roll Over Protection Structures or cabs. Keep safety belts
NEVER START OR OPERATE A FAILED MACHINE. Be- fastened during operation.
fore operating the machine, always ensure that any unsafe For your personal safety, do not climb on or off the machine
condition has been satisfactorily corrected. while it is in motion.
Check brakes, steering and attachment controls before Make sure that bystanders are clear of the machine oper-
moving off. Report any malfuctioning part or system to the ating range before starting the engine and operating the
maintenance managers for proper action. attachment. Sound the horn. Obey all indications provided
Ensure all protective guards and panels as well as all by flags, signs and signals.
safety devices provided are in place and in good operating DO NOT COAST OR FREEWHEEL down hills. Engage the
condition. most suitable gear speed to keep the machine under control.
Carefully read personal and machine SAFETY PRECAUTIONS (at the beginning of this manual)
0-2 GENERALITIES W170/W170TC
SAFETY RULES
Do not operate the machine if you are extremely tired or feel When working on slopes or near sudden level drops in the
ill. Be especially careful towards the end of the working shift. terrain, avoid areas where ground is loose or soft since
Do not operate a machine with misadjusted brakes. overturn or loss of machine control could result.
Operate the machine at low speed which can ensure If noise level is high and continuosly exceeds 90 dBA over
complete control at all times. 8 hours at the operator's ear, wear approved ear protection
in compliance with local regulations.
Travel slowly over very rough terrain, slopes or near drop-
offs, in congested areas or on frozen or slippery surfaces. Where counterweights are provided, do not operate the
machine if they have been removed.
When backing, always look to where the machine is to be
moved. Be alert of the position of bystanders. Should When transporting a loaded bucket, keept it as rolled-back
someone enter the work area, STOP THE MACHINE. and low as possible for maximum visibility, stability and
safety of there machine. Ground speed should be ad-
Maintain a safe distance from other machines or obstacles equate to the load and ground conditions.
to ensure required visibility conditions. Give way to loaded
machines. The load must always be properly arranged in the bucket;
move with extreme care when transporting oversize loads.
Maintain a clear vision of the surroundings of the travel or
work area at all times. Keep cab windows clean and Use only the type of bucket recommended for the machine
repaired. and the materials to be handled. Follow the recommenda-
tions concerning loading capacity, arrangement of the
When machines are operating in tandem, the pusher (rear) materials, characteristics of the ground and job to be
must be equipped with the appropriate deflectors to protect performed.
the front unit driver against the air stream coming from the
blower fan. Do not lift and move loads overhead where persons are
standing or working, nor downhill when working crosswise
When pulling or towing through a cable or chain, do not on slopes. In this case, the bucket should be unloaded on
start suddenly at full throttle. Take-up slack carefully. the uphill side, whenever possible.
Carefuly inspect the towing items for flaws or problems
Start and stop the machine carefully when the bucket is full.
before proceedig. Do not move off without first reducing engine speed.
Avoid kinking or twisting chains or cables. Do not pull
Overtaking manoeuvres should be performed only when
through a kinked chain or cable as the high stresses
absolutely necessary and unavoidable. Beware possible
existing in this condition may induce failures. Always wear
uneven terrains, poor visibility, presence of other machin-
heavy gloves when handling chains or cables.
ery or persons out of sight.
Chains and cables should be securely anchored. Anchor
Operate the machine at a speed adequate to the working
points should be strong enough to withstand the expected
site conditions and in any case slow enough to ensure
load. Keep anyone clear of anchor points and cables or
complete control at all times.
chains.
Check instruments at start-up and frequently during
DO NOT PULL UNLESS THE OPERATOR’S COMPART-
operation. Stop the machine immediately should any
MENTS OF THE MACHINES INVOLVED ARE PROP-
malfunction be signalled.
ERLY PROTECTED AGAINST POSSIBLE BACKLAS IN
CASE OF CABLE OR CHAIN FAILURE OR DETACH- Never use the bucket as a man lift or to carry riders.
MENT. Never use the machine as a work platform or scaffolding,
Be alert of soft ground conditions close to newly con- nor for other improper use (such as pushing railway cars,
structed walls. The fill material and machine weight may trucks or other machines).
cause the wall to collapse.
Pay attetion to people within the machine operating range.
In darkness, check area of operation carefully before Load trucks from the driver’s side whenever possible.
moving in with the machine. Use all lights provided. Do not
Prior to operating the machine, check which obstacles
move into low visibility areas.
and/or difficulties you will encounter, such as narrow
If the engine tends to stall for whatever reason under load streets, overhead doors, cables, piping, as well as ground,
or at idle, immediately report this problem to the mainte- bridges, paving and ramps bearing load limitations.
nance managers for proper action. Do not operate the
In case of road transfers, find out beforehand what condi-
machine until this condition has been corrected.
tions are likely to be encountered, such as size restrictions,
On machines fitted with suction radiator fans, regularly heavy traffic, paving type, etc.. Beware fog, smoke or dust
check the engine exhaust system for leaks, as exhaust that obscure visibility.
fumes expelled towards the operator are toxic.
When crossing gullies or ditches, move at an angle with
Operators must know thoroughly the performances of the reduced speed after ensuring ground conditions will per-
machine they are driving. mit a safe traverse.
SAFETY RULES
Always inspect the working area to identify potential risks Always remember to move the gearshift lever to the neutral
such as: inclines, overhangs, trees, demolition rubble, position and engage the control lever lock for safety
fires, ravines, steep slopes, rough terrain, ditches, crowns, purposes.
ridge trenches, heavy traffic, crowded parking and service Apply the parking brake (if fitted).
areas, closed ambients. In such conditions, proceed with
extreme care. NEVER LEAVE THE MACHINE UNATTENDED with the
engine running.
Whenever possible, avoid going over obstacles such as
very rough terrain, rocks, logs, steps, ditches, railroad Prior to leaving the operator’s seat,and after making sure
tracks. When obstructions must be crossed, do so with that all people are clear of the machine, always slowly
extreme care and at an angle, if possible. Slow down and lower the attachment until resting it safely to the ground
select a lower gear. Ease up to the break-over point, pass Park the machine in a non-operating and no-traffic area.
the balance point slowly and ease down the other side. Park on firm level ground. If this is not possible, position the
In steep down-hill operation, do not allow the engine to machine at a right angle to the slope, making sure there is
over-speed. Select the proper gear before starting down no danger of uncontrolled sliding. Apply the parking brake.
grade. If parking in traffic lanes cannot be avoided, provide
Avoid crosswise hill travel, whenever possible. Drive up appropriate flags, barriers, flares and signals as required
and down the slope. Should the machine start slipping to adequately warn the oncoming drivers.
sideways when going uphill, steer and turn machine front Keep head, body, limbs, hands and feet clear of the dozer,
immediately downhill. arms, bucket or ripper when raised.
The gradient you may attempt to overcome is limited by Always switch off the battery isolator switch before serv-
factors such as ground conditions, load being handled, icing the machine in whatever manner (i.e., cleaning,
machine type and speed, and visibility. repairing, maintaining, etc.). Do the same when the
There is no substitute for good judgement and experience machine is to remain parked for prolonged periods of time
when working on slopes. to avoid accidental or unauthorized starting.
Avoid operating the attachment too close to an overhang Never lower the attachments other than sitting in the
or high wall, either above or below the machine. Beware operator’s seat. Sound the horn. Make sure that nobody is
of caving edges, falling objects and landslips. Remember within the machine operating range. Lower the attachment
that such hazards are likely to be concealed by bushes, slowly. DO NOT USE FLOAT POSITION in case of hydrau-
undergrowth and such. lic controls.
When pushing-over trees, the machine must be equipped Securely block the machine and lock it every time you
with proper overhead guards. Never drive a machine up leave it unattended. Return keys to authorized security.
the roots, particularly while the tree is being felled. Use Perform all necessary operations as detailed in the Opera-
extreme care when pushing over any tree with dead tion and Maintenance Instruction Manual. Apply the park-
branches. ing brake (if fitted) every time you leave the machine.
Avoid faggots, bushes, logs and rocks.
NEVER DRIVE OVER THEM, nor over any other surface
irregularities that discontinue adherence or traction with MAINTENANCE
the ground, especially near slopes or drop-offs.
Be alert to avoid changes in traction conditions that could GENERALITIES
cause loss of control. AVOID driving on ice or frozen Before operating or performing any intervention on the
ground when working on steep slopes or near drop-offs. machine:
Working in virgin rough terrains is characterized by the - carefully read all the norms contained in this Manual;
presence of all the perils and risks listed above. In these
- read and observe all safety plates and instructions
conditions, it is emphasised the danger represented by
located on the machine.
large tree limbs (possibly falling on the machine), large
roots (which may act as a leverage under the machine Do not allow unauthorized personnel to service the ma-
when up-rooted and cause the unit to overturn), etc. chine. Do not carry out any maintenance work without prior
authorization. Follow all recommended maintenance and
service procedures.
Keep the operator’s compartment free of loose objects that
STOPPING are not properly secured.
When the machine is to be stopped for whatever reason, Do not wear rings, wrist watches, jewellery, loose or
do so following the instructions given in chapters “Stop- hanging garments, such as ties, torn clothing,
ping the machine” and “Shutting off the engine" in the scarves,unbuttoned or unzipped jackets that can get
Operation and Maintenance Instruction Manual. caught in moving parts.
SAFETY RULES
Wear certified safety clothes such as: hard hat, no-slip The fuel filler pipe nozzle must be constantly kept in contact
footwear, heavy gloves, ear protection, safety glasses, with the filler neck. Keep this contact from the beginning to
reflector vests, respirators. Ask your employer about spe- the end of the fuelling operation to avoid possible genera-
cific safety equipment requirements. tion of sparks due to static electricity.
Never service the machine with someone sitting in the Tow the machine only from the attaching points provided.
driver's seat, unless this person is an authorized operator Use care in making connections and ensure pins and/or
assisting in the maintenance being carried out. bolt are firmly secured before pulling. Stay clear of draw-
bars, cables or chains under load.
Keep the operator’s compartment, step plates, grab rails
and handles clear of foreign objects, oil, grease, mud or To move a failed machine, use a trailer or a low platform
snow to minimize the danger of slipping or stumbling. truck, if available. In case towing is needed, use all neces-
sary signals required by local regulations, and follow
Clean mud or grease from your shoes before climbing on
directions provided in this Manual.
the machine or driving it.
Load/unload the machine from transporter on firm level
Never attempt to operate the machine or its attachments
ground providing safe support to the wheels of the truck or
from any position other than sitting in the operator’s seat.
trailer. Use strong access ramps, with adequate height and
Never stand under the boom. angle. Keep the loading platform free of mud, oil or slippery
Should it be necessary to move the attachment through the materials.
hydraulic controls for maintenance purposes, remember Tie the machine securely to the platform of the truck or
that this should be done while sitting in the operator’s seat. trailer and opportunely wedge machine wheels or tracks
Before starting the machine or moving its attachment, as required.
apply the brakes, sound the horn and call that you are
about to manoeuvre. Raise the attachment slowly. Never align holes or slots using your fingers; always use
appropriate aligning tools.
Always lock machine arms or any other parts that must be
lifted for maintenance purposes using adequate external Remove all sharp edges and burrs from re-worked parts.
means. Do not allow anyone to pass near or even below Use only approved and effectively grounded auxiliary
a raised yet unlocked attachment. If you are not absolutely power sources for heaters, battery chargers, pumps and
sure about your safety, do not stay under a raised attach- similar equipment to reduce electrical shock hazard.
ment, even if it is locked.
Lift and handle heavy components using hoisting devices
Do not place body, limbs, or fingers near articulated cutting of appropriate capacity. Ensure the sling has been cor-
edges of uncontrolled machine parts or deprived of the rectly applied. Use lifting eyes if provided. Pay attention to
necessary guards, unless they are suitably and safely bystanders.
locked.
Never pour gasoline or diesel fuel into open, wide and low
Never perform any work on the machine with the engine containers. Never use gasoline, solvents or other flamma-
running, except when this is specifically required. Do not ble fluids to clean parts. Use proprietary certified non-
wear loose clothing, jewellery or such near moving parts. flammable, non-toxic solvents only.
When service or maintenance require access to areas that When using compressed air to clean parts, wear safety
cannot be reached from the ground, use a ladder or step glasses with side shields. Limit pressure to max 2 bars, in
platform conforming to regulations in force. If such means accordance with local safety regulations in force.
are not available, use machine grab rails and steps.
Always perform all service or maintenance work with the Do not run the engine in closed buildings without proper
greatest care and attention. ventilation capable to remove lethal fumes.
Shop and/or field service platforms or ladders should be Do not smoke, use open flames or produce sparks nearby
manufactured in accordance with safety regulations in while refuelling the unit or handling highly flammable
force. materials.
Disconnect batteries and label all controls to warn that Do not use any flame as a light source during maintenance
service work is in progress. Block the machine and all work or to look for leaks anywhere on the machine.
attachments to be raised.
Make sure that all tools provided are in good condition at
Do not check or fill fuel tanks, batteries and accumulators, all times. NEVER USE tools with mushroomed or dam-
nor use the starting liquid if you are smoking or near open aged heads. Always wear eye protections.
flames. These fluids are flammable!
Move with extreme care when working under the machine,
BRAKES ARE INOPERATIVE when manually released for its attachments, and even on or near them. Always wear
servicing. Provisions must be made to maintain control of protective safety equipment as required, such as hard hat,
the machine using suitable blocks or other means. goggles, safety shoes, and ear plugs.
SAFETY RULES
In case tests during which the engine should be kept Metal cables get frayed after prolonged use. Always wear
runinng, a qualified operator must sit in the driver’s seat appropriate protections (heavy gloves, goggles, etc.)
with the mechanic in sight at all times. Place the transmis- while handling them.
sion in neutral, apply and lock the brakes. KEEP HANDS
Handle all parts carefully. Keep hands and fingers away
OFF MOVING PARTS.
from gaps, gears, and similar. Always use and wear the
In case of field service, move machine to level ground, if appropriate protections.
possible, and block it. If work on an incline cannot be
Water can build up in pneumatic systems from condensate
advised, block the machine and its attachments securely.
moisture due to changes in atmospheric conditions. If
Move damaged to level ground as soon as possible.
necessary, drain such deposits following instructions.
Do not trust worn and/or kinked chains and cables. Never
Before carrying out any maintenance work or service, lock
use them for lifting or pulling. Always wear heavy gloves
the machine articulated frame modules using the appro-
to handle chains or cables.
priate safety device. Remember to remove and store it
Be sure chains and cables are firmly fastened and that properly at the end of work.
anchor points are strong enough to withstand the expected If the machine is equipped with hydraulic brakes, make
load. Nobody should stay near the anchor points, cables sure that the reservoir is always filled up to the correct level.
or chains. DO NOT PULL OR TOW UNLESS THE OPERA-
TOR’S COMPARTMENTS OF THE MACHINES IN- Always block all wheels, front and rear, before bleeding
VOLVED ARE FITTED WITH THE PROPER GUARDS the braking system or disconnecting control hoses and/or
AGAINST BACKLASH IN CASE OF CABLE OR CHAIN cylinders.
FAILURE OR DETACHMENT.
Keep the area where maintenance is carried out CLEAN
and DRY at all times. Clean immediately all water and oil
spillages. STARTING
Do not pile up oily or greasy rags as they represent a major Do not run the engine in closed buildings without proper
fire hazard. Always store them in closed metal containers. ventilation capable to remove lethal exhaust fumes.
Before starting the machine or its attachment, check, adjust Do not place head, body, limbs, feet, hands or fingers near
and lock the operator’s seat. Also ensure that nobody is rotating fans or belts.
within the machine operating range. Sound the horn.
Be especially careful near blower fans.
Rust inhibitors are volatile and flammable. Use them only
in well ventilated areas. Keep open flames away - DO NOT REMEMBER THAT THE STARTING FLUID IS HIGHLY
SMOKE - Store containers in a cool well ventilatedplace FLAMMABLE. Follow recommendations provided in this
where they could not be reached by unauthorised people. Manual and printed on the containers. Containers must be
stored in a cool, well ventilated place out of the reach of
Do not carry loose objects in your pockets that might fall unauthorised persons.
unnoticed into open compartments. DO NOT PUNCTURE OR BURN CONTAINERS.
Wear safety glasses with side shields, hard hat, safety
shoes, heavy gloves when metal particles or similar may
be ejected and hit you.
Wear appropriate protective equipment such as dark ENGINE
safety glasses, hard hat, protective clothing, special
Loosen the radiator cap very slowly to relieve system
gloves and footwear while welding. Nearby persons
should also wear dark safety glasses even if they are not pressure before removing it. Always top-up coolant level
with the engine off.
welding. DO NOT LOOK THE WELDING ARC WITHOUT
PROPER EYE PROTECTION. Avoid that flammable materials could touch exhaust parts.
If not possible, provide necessary protections.
Become acquainted with all your jacking equipment and
its capacity. Remember that the jacking point on the Do not refuel with the engine running, especially if hot, as
machine should be appropriate for the load applied. Also, this increases fire hazard.
be sure the support area of the jack at the machine and on
Never attempt to check or adjust fan belt tensions when the
the ground is appropriate and stable.
engine is running.
Any load supported by a jack represents a possible haz-
Do not adjust the fuel pump when the machine is motion.
ard. Always transfer the load onto appropriate support
means according to local or national safety requirements Do not lubricate the machine with the engine running.
before proceeding with service or maintenance work.
Do not run the engine with air intakes, door or guards open.
SAFETY RULES
ELECTRICAL SYSTEM Do not use the machine to transport loose objects, unless
proper devices to this purpose are provided.
Always disconnect the batteries prior to any intervention
on the machine or its electrical system (cleaning, repair, Clutches and brakes of this machine as well as auxiliary
maintenance). devices and attachments (such as drive cylinder or winch
control valves) should always be properly adjusted in
Should booster batteries be used, remember to connect
accordance with the instructions provided by the Manufac-
ends of the booster cables in the proper manner: (+) to (+)
turer. Never perform adjustments with the engine running,
and (-) to (-). Do not short-circuit terminals. Thoroughly
except when this is specifically required by the relevant
follow instructions given in this Manual.
procedures.
Before any intervention, make sure that the battery isolator
switch is off.
BATTERY GAS IS HIGHLY FLAMMABLE. Leave the bat-
tery compartment open during recharging to improve
ventilation. Never check battery charge by placing metal
TYRES AND WHEELS
objects across the posts. Keep sparks or open flames away
from batteries. Do not smoke near the battery to prevent Make sure that the tyre inflation pressure corresponds to
explosion hazard. specifications issued by the Manufacturer. Regularly
check inflation pressure.
Before any intervention, make sure that there are no fuel
or electrolyte leakages. If any, correct prior to proceeding Should pressure be changed, do this while staying on the
with further work. Do not recharge batteries in confined tyre side and at a safe distance.
spaces. Ensure proper ventilation is provided to avoid Pressure checks should always be carried out with the
accidental explosions due to build-up of gas released machine unloaded and cold tyres.
during charging.
Never use reconditioned tyre rims, since possible
weldings, incorrect heat-treatments or repairs can
weaken the wheels and cause damages or failures.
Do not cut, nor weld rims with inflated tyres installed.
The spare tyre should be inflated only enough to keep the
HYDRAULIC SYSTEM
rim components assembled. Remember that when not
Pressure fluid escaping from a very small hole can be installed on the disc, a tyre inflated to maximum pressure
almost invisible and still have sufficient force to penetrate can explode.
the skin. Always check any suspected pressure leaks Therefore, maximum care must be taken when handling a
using a piece of cardboard or wood. DO NOT USE HANDS. fully inflated tyre.
If injured by escaping fluid, obtain medical attention imme-
diately or serious infection or reaction may develop. Before servicing tyres, block all wheels, front and rear. After
jacking up the machine, block it in the raised position using
Stop the engine and relieve all system pressure before suitable stands conforming to current safety regulations.
removing panels, housings, caps, plugs or covers.
Deflate the tyre before removing objects from the tyre tread.
Always use gauges of adequate capacity (end-of-scale
reading) and follow recommended procedures. Never inflate tyres with flammable gas: explosions and
severe bodily injuries may result.
When starting your work shift, check for loose wheel or rim
bolts and brackets and retighten to correct torque as
necessary.
TOOLS
Always keep head, body, limbs, feet, or hands away from
bucket, blade, or ripper when in the raised position. Prior
to any intervention, install all safety devices according to
current regulations. In case the attachment is to be oper-
ated through the machine hydraulic system for mainte-
nance purposes, remember to do so only while sitting in the
driver's seat. Make sure that nobody is within the machine
operating range. Before operating the attachment, alert
people by sounding the horn and by voice. Raise the
attachment slowly.
SAFETY RULES
DECOMMISSIONING THE MACHINE
For the decommissioning of the machine, the availability WARNING
of particular tooling (hoists, hydraulic presses. contain- • The decommissioning of the machine must be
ers for liquids etc.) is required as well as specific tools performed exclusively by personnel trained,
listed in the Repair Manuals, available from FIAT qualified and authorised to perform such op-
KOBELCO Dealers. eration.
This has the purpose of avoiding that during disassem-
bly operations, dangerous situations may arise both for • Start the disassembly of hydraulic components
the personnel involved and the environment. only after the same, the hydraulic oil and lubri-
cants have fully cooled-off and after all residual
In the machine are present: pressures have been released, as described by
• Fluids under pressure (hydraulic system, cooling the Repair Instruction Manual.
system etc.)
• Gases (air conditioning system and accumulator, if • Prior to proceeding with disassembly opera-
installed) tions, comply with the GENERAL SAFETY
• Mechanical devices mounted under pressure (track RULES and drain each components of the ma-
tensioner etc.) chine filled with fluids, both in the reservoirs
• Heavy machine components (frames, blades, buck- and the relevant systems.
ets etc.)
WARNING
Ensure that the attachment is safely resting on to the ground before repairing,adjusting, or servicing
machines fitted with hydraulically, mechanically or cable controlled attachments (such as excavators,
loaders, dozers, scrapers, etc.). Should it be necessary to partially or fully raise the hydraulically, me-
chanically, or cable controlled attachment to gain access to certain items, make sure the attachment is
adequately retained in the raised position by means other than the hydraulic lift cylinders, cable and/or
mechanical devices used for controlling it.
SPECIFICATIONS - WHEEL LOADER W170
ENGINE - EMISSION
Make CNH
Model 6TAA-6.8L-4V
Fuel #2 Diesel (#1 & 2 Mixture Permitted For Cold

Temperature)
Number of Cylinders 6
Bore and Stroke 4.09" (104 mm) x 5.20" (132 mm)
Displacement 411 cu. in. (6.8 Liters)
Electrical System 24 Volts
Batteries (2) 12 Volt
Alternator 70 Amp
Compression Ratio 17:1
Fuel Pump Bosch CP 3.3
Air Cleaner Dry Type Elements With Warning Restriction

Indicator
Oil Filter Full Flow Replaceable Cartridge
Lubrication Positive Pressure
Cooling System Air/Water with Lube Oil Cooler
Rated Power
Standard:
- Peak Gross (per SAE J1995) 181 hp (135 kW) @ 2000 RPM
- Peak Net (per SAE J1349) 170 hp (127 kW) @ 2000 RPM
Boosted Power
- Peak Gross (per SAE J1995) 195 hp (146 kW) @ 2000 RPM
- Peak Net (per SAE J1349) 184 hp (138 kW) @ 2000 RPM
Torque, Max.
Standard:
- Peak Gross (per SAE J1995) 590 lb-ft (800 Nm) @ 1300 RPM
- Peak Net (per SAE J1349) 767 lb-ft (566 Nm) @ 1300 RPM
Boosted:
- Peak Gross (per SAE J1995) 627 lb-ft (850 Nm) @ 1400 RPM
- Peak Net (per SAE J1349) 599 lb-ft (812 Nm) @ 1400 RPM
Governor Electronic Control
0 - 10 GENERALITIES W170/W170TC
POWER TRAIN
TRANSMISSION
Make ZF
Model 4WG190
Radio 1st 2nd 3rd 4th
Forward 3.745 2.089 1.072 0.636

Reverse 3.551 1.981 1.017 -
TORQUE CONVERTER
Make ZF
Model VNR 118/428
Stall Ratio 2.81:1
SPEEDS: mph (km/h)

1st 2nd 3rd 4th
(20.5 x 25 L3 Tires)
- Forward 4.7 (7.6) 8.3 (13.4) 15.3 (24.6) 23.5 (37.8)
AXLES Front Rear

- Differential Ratio 3.364 3.182
- Planetary Ratio 6.000 6.400
- Final Axle Ratio 20.18 20.36
- Limited Slip Differential, Front (up to 72.5% of available axle torque to wheel with traction)
- Limited Slip Differential, Rear (up to 72.5% of available axle torque to wheel with traction)
Make ZF
Model Front – MT-L3085
Rear – MT-L3075
W170/W170TC GENERALITIES 0 - 11
BRAKES
Hydraulic, wet four-wheel disc. Two brake pedals, both pedals apply brakes and electrically neutralize power flow
to wheels with transmission disconnect switch activated. Both pedals apply brakes only when transmission
disconnect switch is not activated. Hydraulic brake valve for front and rear split system. Spring applied/hydraulic
released disc parking brake on transmission output shaft neutralizes power flow to wheels when engaged.
Brake Area of Service Brakes 480 in² (0.31m²)/Hub
Brake Area of Parking Brake 12.6 in² (81.6 cm²)
Brake Pressure Front: 1300 psi (8963 Kpa)
Rear: 1250 psi (8618 kPa)
ACCUMULATOR DATA
Cut In 2350 psi (16200 kPa)
Cut Out 2799 psi (19300 kPa)
Low Pressure Warning 1494 psi (10300 kPa)
Transmission Declutch 348 psi (2400 kPa)
Charge Pressure (N2) 798 psi (5500 kPa)
TIRES
600/65 R 25 x LD
600/65 R 25 GP - 3D
20.5 R 25 GP - 2B
20.5 R 25 RT - 3B
20.5 R 25 x HAT 1
20.5 R 25 x LD - D2
20.5 R 25 x RD - D1
20.5 R 25 x MINE D2
20.5 R 25 RL - 5K
HYDRAULICS AND STEERING
Reservoir: Filtered vent with relief on hydraulic reservoir main-

tains 3-5 psi (20-34 kPa) on reservoir. Full time 10
micron return filters furnish only clean oil to all com-
ponents of the system.
Valves: Closed-center, load sensing circuit, positive low pres-

sure regeneration for bucket dump. Remote control
hydraulic power assist with electromagnetic detents.
Loader Valve Inlet section relief valve provides maximum loader

pressure of 3625 psi (25000 kPa).
Loader control valve section contains float circuitry.
Steering Priority Valve Senses steering demand to control oil flow to loader
valve or steering valve as required by steering de-
mand. Relief valve allows maximum steering pres-
sure of 3500 psi (24132 kPa).
System: A tandem variable displacement piston pump is used

to supply oil to the integrated loader and steering hy-
draulic system.
Steering/Loader pump displacement 3.84 in3/rev (63

cc/rev).
31.6 GPM @ 2000 RPM @ 3600 psi
(119.7 l/min @ 2000 RPM @ 24822 kPa)
Loader pump displacement 2.75 in3/rev (45 cc/rev).

22.6 GPM @ 2000 RPM @ 2800 psi
(85.6 l/min @ 2000 RPM @ 19305 kPa)
Loader/Steering Section:
Section displacement 3.84 in 3 /rev.
31.6 GPM @ 2000 RPM @ 3575 psi
(120 l/min @ 2000 RPM @ 24649 kPa)
Loader Section:
Section displacement: 2.75 in3/rev.
22.6 GPM @ 2000 RPM @ 3575 psi.
(85.6 l/min @ 2000 RPM @ 24649 kPa)
Steering Section:
Center pivot articulated steering - front and rear wheels
always track. Two hydraulic cylinders controlled by a
hydrostatic steering gear and a priority valve.
The steering Orbitrol is flow amplified to provide a

constant ratio with 3.6 turns lock-to-lock. Lock-to-lock
time at high idle is 3.25 sec.
Hydraulic Cylinder:
Dump:
Z-Bar, XR 5.75 dia x 24.78 stroke x 3.00 rod
(146.0 mm dia x 629.4 mm stroke x 76.2 mm rod)
TC 4.25 dia x 40.02 stroke x 2.25 rod

Lift: 4.75 dia x 32.59 stroke x 3.00 rod

Steer: 3.00 dia x 19.09 stroke x 1.75 rod

(76.2 mm dia x 484.9 mm stroke x 44 mm rod)
Clam: 4.00 dia x 10.00 stroke x 2.00 rod

Diameter of Hydraulic Inlet and Outlet Ports:
One Inlet – Implement & Steering 2" Split Flange (50.8 mm)
One Inlet – Implement Only 1.5" Split Flange (38.1 mm)
Two Outlets – Implement & Steering 1.0" Split Flange (25.4 mm)
Two Outlets – Implement Only 1.0" Split Flange (25.4 mm)
CAPACITIES
Cooling System:
6.75 Gallon (25.6 liters) to fill system
Gallons Ethylene Glycol (Prestone) required:

2.25 gal. (8.5 liters) for 0°F
3.0 gal. (11.4 liters) for -20°F
3.5 gal. (13.3 liters) for -40°F
Fuel Tank:
65.0 U.S. gallons (246 liters) Usable Fuel
66.9 U.S. gallons (253 liters) Total
Engine:
Crankcase Only 14 quarts (13.25 liters)
Crankcase and Filter 15 quarts (14.2 liters)
Total in System 16 quarts (15.1 liters)
Transmission: 6.0 gallons (22.7 liters) initial capacity
3.25 gallons (12.3 liters) service (w/filter)
Axles: Front Rear
Total/Axle 32 quarts 29 quarts

(30.3 liters) (27.4 liters)
Hydraulic Reservoir:
Reservoir, oil only 27.9 gal. (105.7 liters)
Total System 51.0 gal. (193.1 liters)
SOUND LEVEL DATA
Emission Engine Sound Level (Arithmetic Average) dBA

with Standard Muffler
Cab Closed Cab Open Canopy
Exterior Sound Level @ 15 meters

per SAE J88 SEP80
Stationary - Rated Speed 76.9 - -

Stationary - High Idle 78.1 - -
Moving 78.8 - -
IMI 77.3 - -
Component Cycling 79.2 - -
Operator's Station Sound Level

per SAE J919 JUN86
Stationary - Rated Speed 73.6 84.2 -

Stationary - High Idle 74.3 87.3 -
Moving 74.5 86.4 -
IMI 75.1 87.1 -
Component Cycling 75.8 86.8 -
Time Weighted Average Sound Level (Leq) dBA
Operator's Station Work Cycle - - -

per SAE J1166 MAR85
(no blowers)
Note – Rated speed of engine is 2200 rpm and High - Idle is 2300-2380 rpm.
Emission Engine Sound Level (Arithmetic Average) dBA

with Spark Arrestor Muffler
Exterior Sound Level @ 15 meters

per SAE J88 SEP80
Stationary - Rated Speed - - -

Stationary - High Idle - - -
Moving - - -
IMI - - -
Component Cycling - - -
Operator's Station Sound Level

per SAE J919 JUN86
Stationary - Rated Speed - - -

Stationary - High Idle - - -
Moving - - -
IMI - - -
Component Cycling - - -
Time Weighted Average Sound Level (Leq) dBA
Operator's Station Work Cycle - - -

per SAE J1166 MAR85
(no blowers)
Note – Rated speed of engine is 2200 rpm and High - Idle is 2300-2380 rpm.
DIMENSIONS AND WEIGHT
1626.5
W170-0R001
Dimensions in mm
Operating weight: 14 053 kg (30981.56 lbs)
Note – Machine equipped with tyres 20.5R25XHAT1, fluids and operator.
* Please refer to the table
Type of bucket
With teeth and segments With suppl. cutting edge

Bucket capacity cu cm 2.6 2.8 2.6 2.8
Bucket weight kg (lbs) 1178 (2597.04) 1197 (2638.93) 1132 (2495.63) 1147 (2528.70)
Bucket width mm (in) 2535 (99.80) 2750 (108.26) 2495 (99.22) 2710 (106.69)
Dumping height at 45° mm (in) 2741 (107.91) 2741 (107.91) 2826 (111.25) 2826 (111.25)
Dumping reach at 45° mm (in) 1084 (42.67) 1084 (42.67) 1008 (39.68) 1008 (39.68)
Max. length
(w/ bucket on ground) mm (in) 7856 (309.29) 7856 (309.29) 7742 (304.80) 7742 (304.80)
Max. height
(w/ bucket raised) mm (in) 5242 (206.37) 5242 (206.37) 5242 (206.37) 5242 (206.37)
Turning radius
(in transportation position) m (ft) 6.2 (20.34) 6.3 (20.66) 6.2 (20.34) 6.3 (20.66)
TABLE OF FLUID CAPACITIES 0 - 18
ITEM QUANTITY FLUIDS OR LUBRICANT CLASSIFICATION VISCOSITY OUT DOOR TEMPERAT.

LITRES (USG) SPECIFICATIONS (SAE) OF REFERENCE (°C)
API CF-4/SG
15 (4) Super Gold MIL-L-2104E 15W-40 –10 to 50 °C (14 to 122 °F)
15 W 40 ACEA E2 –30 to 20 °C (-22 to 68 °F)
ENGINE + OIL FILTER
API CH-4
Mastergold HSP* 15W-40 –10 to 50 °C (14 to 122 °F)
ACEA E3
RADIATOR 26 (6.9) Agriflu ASTM D-5345 – –35 to 50 °C (-31 to 122 °F)
API CF-4/SG
TRANSMISSION + FILTER 22 (5.8) Super Gold MIL-L-2104E 10W-30 –30 to 20 °C (-22 to 68 °F)
15 W 40 ACEA E2
109 (28.8) ISO VG 46, DIN 51524

HYDRAULIC SYSTEM 193 tot. (51) HITECH 46 Item 1 and 2, QFH583/HD – –20 to 50 °C (-4 to 122 °F)
GENERALITIES
front 32 (8.4)
AXLES rear 27 (7.1) HS 1317 API GL4 SAE 80W-140 –20 to 50 °C (-4 to 122 °F)
FUEL TANK 246 (65) – – – Diesel fuel ASTM no. 2D
Grade 251H-EP
GREASE FITTINGS – MG-2 – Spec. B-27 –40 to 50 °C (-40 to 122 °F)
AIR CONDITIONER
COMPRESSOR 0.2 (0.05) L BAR 134 – – –
WINDSHIELD WASHER
FLUID 4.7 (1.2) SC 35 – – –
Oil quantities indicated are those required for periodical changes following the draining and filling procedures indicated in detail for each group.
* In the event engine oil with "CH4" classification is used, the change interval can be prolonged to 500 hours providing that the outer temperature of operation
does not exceed 38 °C (100 °F) and that the percentage of sulphur in the fuel does not exceed 0.5 %.
In the event of really heavy duty conditions, reduce the greasing intervals.
W170/W170TC
UNITS OF MEASURE
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: g/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)
TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special torques
are not given. These torques apply to fasteners with
both UNC and UNF threads as received from suppli-
ers dry, or when lubricated with engine oil. Not appli-
cable if special graphitiesm Molydisulfide greases, or
other extreme pressure lubricants are used.
Grade 5 Bolts, Nuts, and Studs Grade 8 Bolts, Nuts, and Studs
Pound- Newton Pound- Newton

Size Size
Inches metres Inches metres
1/4 inch 108 to 132 12 to 15 1/4 inch 144 to 180 16 to 20
5/16 204 to 252 23 to 28 5/16 288 to 348 33 to 39

Size Size
Feet metres Feet metres
1.0 inch 580 to 696 787 to 944 1.0 inch 900 to 1080 1220 to 1465
1-1/8 inch 800 to 880 1085 to 1193 1-1/8 inch 1280 to 1440 1736 to 1953
Note – Use thick nuts with Grade 8 bolts.
TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following torques when specifications are not
given.
These values apply to fasteners with coarse threads

as received from supplier, plated or unplated, or when
lubricated with engine oil. These values do not apply
if graphite or Molydisulfide grease or oil is used.
Grade 8.8 Bolts, Nuts, and Studs Grade 10.9 Bolts, Nuts, and Studs
8.8 10.9

Size Size
Inches metres Inches metres
M4 24 to 36 3 to 4 M4 36 to 48 4 to 5
M5 60 to 72 7 to 8 M5 84 to 96 9 to 11
M6 96 to 108 11 to 12 M6 132 to 156 15 to 18
M8 228 to 276 26 to 31 M8 324 to 384 37 to 43
M10 456 to 540 52 to 61
Pound- Newton
Size
Feet metres
Pound- Newton
Size M10 54 to 64 73 to 87
Feet metres
M12 66 to 79 90 to 107 M12 93 to 112 125 to 150
M14 106 to 127 144 to 172 M14 149 to 179 200 to 245
M16 160 to 200 217 to 271 M16 230 to 280 310 to 380
M20 320 to 380 434 to 515 M20 450 to 540 610 to 730
M24 500 to 600 675 to 815 M24 780 to 940 1050 to 1275
M30 920 to 1100 1250 to 1500 M30 1470 to 1770 2000 to 2400
M36 1600 to 1950 2175 to 2600 M36 2580 to 3090 3500 to 4200
Grade 12.9 Bolts, Nuts, and Studs
12.9
Usually the torque values specified for grade 10.9 fas-

ten can be used satisfactorily on grade 12.9 fasten-
ers.
TORQUE SPECIFICATIONS - STEEL HYDRAULIC

Tube OD Thread Pound- Newton
FITTINGS
Hose ID Size Inches metres
Tube OD Thread Pound- Newton Straight Threads with O-ring
Hose ID Size Inches metres
1/4 inch 7/16-20 144 to 228 16 to 26
37 Degree Flare Fitting 6.4 mm
1/4 inch 7/16-20 72 to 144 8 to 16 5/16 inch 1/2-20 192 to 300 22 to 34
6.4 mm 7.9 mm
7.9 mm 9.5 mm
9.5 mm 12.7 mm
1/2 inch 3/4-16 180 to 504 20 to 57
12.7 mm
Tube OD Thread Pound- Newton
5/8 inch 7/8-14 300 to 696 34 to 79 Hose ID Size Inches metres
15.9 mm
5/8 inch 7/8-14 58 to 92 79 to 124
15.9 mm
Tube OD Thread Pound- Newton 3/4 inch 1-1/16-12 80 to 128 108 to 174
Hose ID Size Inches metres 19.0 mm
3/4 inch 1-1/16-12 40 to 80 54 to 108 7/8 inch 1-3/16-12 100 to 160 136 to 216
19.0 mm 22.2 mm
7/8 inch 1-3/16-12 60 to 100 81 to 135 1.0 inch 1-5/16-12 117 to 187 159 to 253
22.2 mm 25.4 mm
1.0 inch 1-5/16-12 75 to 117 102 to 158 1-1/4 inch 1-5/8-12 165 to 264 224 to 357
25.4 mm 31.8 mm
1-1/4 inch 1-5/8-12 125 to 165 169 to 223 1-1/2 inch 1-7/8-12 250 to 400 339 to 542
31.8 mm 38.1 mm
1-1/2 inch 1-7/8-12 210 to 250 285 to 338
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
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
Nom
SAE Thread Pound- Newton Thread Pound- Newton
Tube OD
Dash Size Inches metres Size Inches metres
Size
O-ring Boss End
O-ring Face Seal End
Fitting or Lock Nut
-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 Inches 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 Thread Pound- Newton
Tube OD
Dash Size Inches metres 1-3/16-12 95 to 100 129 to 136
Size
-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 1-5/18-12 150 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
Working
0 - 24
Similar Gap Strength Fixture/Full Cure
Product Color Temperature Primer Description
Products (In Inches) (Steel/Steel) (Steel/Steel) Time
Range-Farenheit
Form a Gasket (works with oil,
#3 Dark Brown 24 hr N/A
fuel or grease) Pliable
80 Yellow Fast N/A Weatherstrip Adhesive
123 Clear N/A N/A Parts Cleaner Fluid
220 Blue 290 0.003 57/143 in lbs -65 to +250 6 min/24 hrs 747 Wicking Threadlocker
221 Purple 222 0.005 75/44 in lbs -65 to +300 2 min/24 hrs 747 Low Strength Threadlocker
Low Strength Threadlocker
222 Purple 0.005 53/30 in lbs -65 to +300 20 min/24 hrs 764
(Small Screws)
225 Brown 222 0.010 45/25 in lbs -65 to +300 7 min/24 hrs 747 Low Strength Threadlocker
242 Blue 0.005 80/50 in lbs -65 to +300 10 min/24 hrs 764 Medium Strength Threadlocker
262 Red 271 0.005 160/190 in lbs -65 to +300 5 min/24 hrs 747 High Strength Threadlocker
270 Green 271 0.007 160/320 in lbs -65 to +300 3 min/24 hrs 747 High Strength Threadlocker
271 Red 262 0.007 160/320 in lbs -65 to +300 10 min/24 hrs 764 High Strength Threadlocker
272 Red 620 0.007 180/220 in lbs -65 to +450 30 min/24 hrs 764 High Temperature, High Strength
275 Green 277 0.010 210/300 in lbs -65 to +300 3 min/24 hrs 747 High Strength Threadlocker
277 Red 0.010 225/300 in lbs -65 to +300 60 min/24 hrs 764 High Strength Threadlocker
290 Green 0.003 85/350 in lbs -65 to +300 6 min/24 hrs 764 Wicking Threadlocker
*404 Clear 495 0.006 3200 psi -65 to +180 30 sec/24 hrs NA Instant Adhesive
*406 Clear 0.004 3200 psi -65 to +180 15 sec/24 hrs N/A Surface Insensitive Adhesive
*409 Clear 454 0.008 2500 psi -65 to +180 50 sec/24 hrs N/A Gap Instant Adhesive
GENERALITIES
*414 Clear 0.006 2500 psi -65 to +180 30 sec/24 hrs N/A Instant Adhesive
*415 Clear 454 0.010 2500 psi -65 to +180 50 sec/24 hrs N/A Gap Filling Instant Adhesive (Metals)
*416 Clear 454 0.010 2500 psi -65 to +180 50 sec/24 hrs N/A Gap Filling Instant Adhesive (Plastics)
LOCTITE PRODUCT CHART
*420 Clear 0.002 2500 psi -65 to +180 15 sec/24 hrs N/A Wicking Instant Adhesive
*422 Clear 454 0.020 2800 psi -65 to +180 60 sec/24 hrs N/A Gap Filling Instant Adhesive
*430 Clear 0.005 2500 psi -65 to +180 20 sec/24 hrs N/A Metal Bonding Adhesive
*445 White/Black 0.250 2000 psi -65 to +180 5 min/24 hrs N/A Fast Setting 2 Part Epoxy
Surface Insensitive Gen
*454 Clear 0.010 3200 psi -65 to +180 15 sec/24 hrs N/A
Instant Adhesive
*495 Clear 0.004 2500 psi -65 to +180 20 sec/24 hrs N/A General Purpose Instant Adhesive
*496 Clear 0.005 2500 psi -65 to +180 20 sec/24 hrs N/A Metal Bonding Adhesive
504 Brt Orange 515 0.030 750 psi -65 to +300 90 min/24 hrs None Rigid Gasket Eliminator
509 Light Blue 0.020 750 psi -65 to +320 6 hr/72 hrs 764 Flange Sealant
510 Red 0.020 1000 psi -65 to +400 30 min/24 hrs 764 High Temperature, Gasket Eliminator
515 Purple 0.010 750 psi -65 to +300 1 hr/24 hrs 764 Gasket Eliminator 515
* Products 404-496 (except for #445) are all instant adhesives (super glues) they differ mostly in viscosity
W170/W170TC
Working
Similar Gap Strength Fixture/Full Cure
Product Color Temperature Primer Description
Products (In Inches) (Steel/Steel) (Steel/Steel) Time
W170/W170TC
Range-Farenheit
518 Red 515 0.030 500 psi -65 to +300 1 hr/24 hrs 764 Gasket Eliminator 518 for Aluminum
542 Brown 569 N/A 132/92 in lbs -65 to +300 2 hrs/24 hrs 747 Hydraulic Sealant
Low Strength Pneumatic/Hydraulic
545 Purple N/A 25/20 in lbs -65 to +300 4 hrs/24 hrs 747
Sealant
549 Orange 504 0.020 2500 psi -65 to +300 2 hrs/24 hrs 747 Instant Seal Plastic Gasket
554 Red 277 0.015 240/240 in lbs -65 to +300 2 to 4 hrs/24 hrs 764 Refrigerant Sealant
567 White 592 N/A 500 psi -65 to +400 4 hrs/24 hrs 764 Pipe Sealant for Stainless Steel
568 Orange 277 0.015 2500 psi -65 to +300 12 hrs/24 hrs 764 Plastic Gasket
569 Brown 545 0.010 40/25 in lbs -65 to +300 1 hr/24 hrs 764 Hydraulic Sealant
570 Brown 592 N/A 25/40 in lbs -65 to +300 6 hrs/72 hrs 764 Steam Sealant
571 Brown 592 0.015 40/20 in lbs -65 to +300 2 to 4 hrs/24 hrs 764 Pipe Sealant
572 White 578.575 N/A 80/27 in lbs -65 to +300 24 hrs/72 hrs None Gasketing
592 White 0.020 500 psi -65 to +400 4 hrs/72 hrs 736 Pipe Sealant with Teflon
593 Black 0.250 400 psi -95 to +400 30 min/24 hrs N/A RTV Silicone
601 Green 609 0.005 3000 psi -65 to +300 10 min/24 hrs 764 Current PIN #609
609 Green 0.005 3000 psi -65 to +300 10 min/24 hrs 764 General Purpose Retaining Compound
High Temperature Retaining
620 Green 640 0.015 3000 psi -65 to +450 30 min/24 hrs 747
Compound
GENERALITIES
635 Green 680 0.010 4000 psi -65 to +300 1 hr/24 hrs 747 High Strength Retaining Compound
638 Green 680 0.015 4100 psi -65 to +300 10 min/24 hrs 747 High Strength Retaining Compound
640 Green 620 0.007 3000 psi -65 to +400 1 hr/24 hrs 747 High Temperature Retaining Compound
660 Silver 0.020 3000 psi -65 to +300 20 min/24 hrs 764 Quick Metal
675 Green 609 0.005 3000 psi -65 to +300 20 min/24 hrs 747 General Purpose Retaining Compound
680 Green 635 0.015 4000 psi -65 to +300 10 min/24 hrs 747 High Strength Retaining Compound
706 Clear 755 N/A N/A N/A N/A N/A Cleaning Solvent
707 Amber N/A N/A N/A N/A N/A Activator for Structural Adhesives
736 Amber N/A N/A N/A N/A N/A Primer NF
738 Amber N/A N/A N/A N/A N/A Depend Activator
747 Yellow N/A N/A N/A N/A N/A N/A Primer T
751 Clear N/A N/A N/A N/A N/A Activator for Structural Adhesives
755 Clear N/A N/A N/A N/A N/A Cleaning Solvent
764 Green N/A N/A N/A N/A N/A Primer N
767 Silver N/A N/A -65 to +1600 N/A N/A Anti-Seize Lubricant
0 - 25
NOTES:
W170/W170TC ENGINE 1-1
SECTION 1
ENGINE
INDEX
PARAGRAPH SUBJECT PAGE
1.1 ENGINE IDENTIFICATION ..................................................................................... 1-1
1.2 ENGINE DIAGRAM ................................................................................................ 1-2
1.3 GENERAL FEATURES ........................................................................................... 1-3
1.4 DESCRIPTION OF MAIN GROUPS ....................................................................... 1-11

1.4.1 Lubrication .............................................................................................................. 1-11
1.4.2 Cooling .................................................................................................................... 1-12
1.4.3 High pressure electronic fuel injection system (Common Rail) ................................ 1-14
1.5 TROUBLESHOOTING GUIDE ................................................................................ 1-26

1.5.1 Troubleshooting with PT-01 instrument ................................................................... 1-27
1.5.2 Troubleshooting with blink code .............................................................................. 1-28
1.5.3 Diagnosis of main malfunctions .............................................................................. 1-30
1.6 ENGINE SUPPORTS ............................................................................................. 1-43
1.7 ENGINE OVERHAUL .............................................................................................. 1-44

Repair interventions cylinder group .......................................................................... 1-53
Bushes .............................................................................................................. 1-53
Timing system ................................................................................................... 1-55
Crankshaft ......................................................................................................... 1-57
Conrod-Piston assembly .................................................................................... 1-60
Pistons .............................................................................................................. 1-61
Engine flywheel .................................................................................................. 1-69
Cylinder head ..................................................................................................... 1-73
Valves ............................................................................................................... 1-75
Valve guide ........................................................................................................ 1-75
Valve seats ........................................................................................................ 1-76
Valve seats in cylinder head .............................................................................. 1-76
Valve springs ..................................................................................................... 1-77
Assembly of the cylinder head ........................................................................... 1-78
Rods .................................................................................................................. 1-80
Tightening torques .................................................................................................. 1-87
1.8 TOOLS ................................................................................................................... 1-88
1-2 ENGINE W170/W170TC
1.1 ENGINE IDENTIFICATION
Engine data plate

The engine data plant provides specific information
about your engine.
Note – The engine plate must not be replaced without

the authorisation by the manufacturer.
TYPE - SERIAL NUMBER - APPROVAL
IVECO N. V.
ENGINE
TYPE
F4HE0684J* D100
ENGINE SERIAL
FAMILY F4HE43B00A NUMBER 000000
EEC
APPR. N e3*97/68EA*2001/63*1004
85R-021050
E3
24R-031048
W170-2R001
ENGINE DATA
IVECO N. V. IMPORTANT ENGINE INFORMATION

EPA family 2VEXLO6. 7DCR F4HE068AJ*D Date of MFG (mo-yr) 12 02
Dsplac. 411 cu. in. Adv. H. P. 194@2000 r. p. m. idle speed 800 r. p. m.
Fuel rate @ adv. pow. 109 mm3/str. Initial in ]. timing BTDC Valve lash: Intake Exhaust
This engine conforms to 2002 U. S. EPA & CARB regulations for large 0.010" 0.020"
non-road compression ignition engines This engine is certified to operate on diesel fuel
When making adjustments, set parking brake and block wheel. EMISSION CONTROL SYSTEM: ECU TCI
504038585 EZ
W17011002
W170-2R002
1.2 ENGINE DIAGRAM
The illustrations here below provide information about The illustrations and the configuration of components
the components of the engine, the location of filters, described in these diagrams are of a general nature.
draining points and the access location for the instru- the locations of some components can change, de-
mentation and controls of the engine. pending upon the arrangement.
ENGINE F4HE0684J
W170-2R003
1. Turboblower - 2. Conditioner compressor - 3. Alternator - 4. Fixed guide pulley - 5. Automatic take-up unit - 6. Water pump
- 7. Fixed guide pulley - 8. Damper flywheel - 9. Electronic control unit - 10. Oil sump - 11. Fuel oil filter - 12. High pressure
pump with fuel pump - 13. Common rail.
1.3 GENERAL FEATURES
F4HE0684J
Type
*D100
Cycle 4-stroke diesel engine
Feeding Boosted by intercooler
Injection Direct
Number of cylinders In-line, 6-cylinder
Bore mm 11042
Stroke mm 132
Total displacement cm3 6728 cm3
Compression ratio
Max. rating kW 145

min–1 2000
Max. torque Nm (kgm) 850

min–1 1400
No-load idle rpm min–1 700
No-load peak rpm min–1 –
BOOSTING With intercooler

Type of turbocompressor: HOLSET HX35W
LUBRICATION Forced by means of gear pump,

pressure relief valve, oil filter
Oil pressure with hot engine:
at idle rpm bar 1.2
at peak rpm bar 3.8
F4HE0684J
Type
*D100
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
start of opening: °C 81± 2
REFUELLING
Ambra Super Gold
15W40 Full filling capacity 1° litres –
10W30 kg
- engine sump litres –
kg
- engine sump + filter litres
kg
FEEDING High pressure

Bosch-type injection Common Rail
Pump setting
Start of delivery mm
Type of nozzle Electro-injectors
Injection sequence 1-5-3-6-2-4
Injection pressure bar 250 - 1450 bar
ASSEMBLING PLAY - SPECIFICATIONS
F4HE0684J
Type
*D100
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Cylinder liners Ø1 104
Pistons: supplied with standard

spares
Measurement dimension X 61
Outer diameter Ø1 103.730 to 103.748
Pin seat Ø2 38.016 to 38.010
Piston - cylinder liners –
Piston diameter Ø1 0.5
Position of pistons
from crankcase X –
Gudgeon pin Ø3 37.994 to 38.000
Gudgeon pin-Pin seat 0.01 to 0.022
Type of piston X1 2.705 to 2.735

Piston ring slots X2 2.440 to 2.460
X3 4.03 to 4.05
S1 2.560 to 2.605
Piston rings S2 2.350 to 2.380
S3 3.977 to 3.990
1 0.100 to 0.175
Piston rings-Slots 2 0.010 to 0.11
3 0.040 to 0.083
Piston rings 0.5
F4HE0684J
Type
*D100
Piston ring end opening in cylinder
liner:
X1 0.3 to 0.4
X2 0.6 to 0.8
X3 0.3 to 0.55
Connecting rod small-end

bushing seat Ø1 41.2797 to 41.553
Connecting rod bearing seat Ø2 72.987 to 73.013
Connecting rod small-end bushing

diameter
Outer Ø4 40.987 to 41.013
Inner Ø3 38.019 to 38.033
Connecting rod small-end bushing -

seat 0.266 to 0.566
Gudgeon pin . Bushing 0.019 to 0.039
Measurement dimension X
Max. error on connecting rod axis

parallelism =
Journals Ø1 82.99 to 83.01

Crankpins Ø2 68.987 to 69.013
Main half bearings S1* 2.456 to 2.464
Connecting rod half bearings S2* 1.955 to 1.968
* supplied with spares
Bed supports no.:

n. 1-5 Ø3 87.982 to 88.008
n. 2-3-4 87.977 to 88.013
F4HE0684J
Type
*D100
Half bearings – journals:
n. 1-7 0.041 to 0.119
n. 2-3-4-5-6 0.041 to 0.103
Half bearings – crankpins 0.033 to 0.041
Main half bearings

Connecting rod half bearings + 0.250; + 0.500
Shoulder journal X1 37.475 to 37.545
Shoulder bed support X2 25.98 to 26.48
Shoulder half rings X3 37.28 to 37.38
Drive shaft shoulder 0.068 to 0.410
F4HE0684J
Type
*D100
VALVE GEAR CYLINDER ASSEMBLY mm
Valve guide seats on

cylinder head Ø1 7.042 to 7.062
Valves:
Ø4 6.970 to 6.999
α 60 ÷ 0.25°
Ø4 6.970 to 6.999
α 45 ÷ 0.25°
Valve stem and respective guide 0.043 to 0.092

Seat on head for valve seat:
Ø1 34.837 to 34.863
Ø1 34.837 to 34.863
Valve seat outer diameter;

inclination of valve seats
on cylinder head:
Ø2 34.917 to 34.931
α 60°
Ø2 34.917 to 34.931
α 45°
Hollow X 0.59 to 1.11
X 0.96 to 1.48
Between the valve 0.054 to 0.094

seat and the head
0.054 to 0.094
Valve seats –
F4HE0684J
Type
*D100
VALVE GEAR . CYLINDER ASSEMBLY mm
Valve spring height:
free spring H 47.75
under a load of:
329 N (l) – 339.8 N (n) H1 35.33 (n)
641 N (l) – 741 N (n) H2 25.2 (n)
Injector protrusion X not adjustable
Seats for distributing shaft

bushings no. 1-7 –
Distributing shaft seats no.
2-3-4-5-6 –
Distributing shaft support pins:

1 þ 7 Ø 53.995 to 54.045
Bushing inner diameter Ø 54.083 to 54.147
Bushings and seats in crankcase –

Bushings and support pins 0.038 to 0.162
Eccentric working lift:

6.45
7.582
1 - 10 ENGINE W170/W170TC
F4HE0684J
Type
*D100
VALVE GEAR – CYLINDER ASSEMBLY mm
Seat for tappet
Ø1 collar
in the crankcase Ø1 16.000 to 16.030
Ø2
Outer diameter of
Ø3
tappet collar:
Ø2 Ø2 15.924 to 15.954
Ø3 15.960 to 15.970
Between the tappets and the seats 0.025 to 0.070
Tappets –
Ø1
Rocker arm shaft Ø1 21.965 to 21.977
Rocker arms Ø2 22.001 to 22.0027
Ø2
Between the rocker arm and the
shaft 0.024 to 0.377
W170/W170TC ENGINE 1 - 11
1.4 DESCRIPTION OF MAIN GROUPS
1.4.1 LUBRICATION - water/oil heat exchanger (3), housed in the engine

block, with oil filter support;
- oil pressure regulation valve (1 incorporated in the
Forced circulation lubrication is afforded by the filter support;
following components: - by-pass valve (4) to bypass the clogged oil filter,
- vane type oil pump (5), housed in the front part of incorporated in the filter support;
the engine block, controlled by the straight-toothed - cartridge type oil filter (2).
gear splined on the tail of the crankshaft;
Pressure oil path

Oil return drop-type path
Introduction oil
W170-2R004
1.4.2 COOLING
The forced circulation, closed loop engine cooling - a centrifugal type water pump housed in the front
system comprises the following components: part of the engine block;
- a heat exchanger to cool the lubrication oil (see - a thermostat that regulates circulation of the cooling
lubrication); fluid.
Water in output from the thermostat Water supplied to the pump
Water recirculating in the engine

W170-2R005
Water pump
Thewater pump is housed in a seat obtained fromthe clamps eliminates many connections, thus reducing
crankcase and is controlled by means of a poly-V possible leak points.
belt. The engine temperature is controlled by a thermostat.
The nearly total absence of outer pipes, sleeves and The coolant flows also in the oil heat exchanger.
W170-2R006
W170-2R007
1.4.3 HIGH PRESSURE ELECTRONIC

FUEL INJECTION SYSTEM
(COMMON RAIL)
DESCRIPTION OF SYSTEM Electrical system
The system is composed of the electrical system and The controller directs the operation of the engine
the hydraulic system. through the sensors installed on it.
W170-2R008
1. Connections for injectors - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil pressure and
temperature sensor - 5. Engine shaft sensor - 6. Injector - 7. Temperature-air pressure sensor - 8. Timing phase sensor -
9. Fuel temperature sensor and fuel heater - 10. Pressure adjuster - 11. Control unit EDC7.
INJECTION SYSTEM ASSEMBLY
REF. DESCRIPTION
1 Position sensor on accelerator pedal
2 Key switch
3 Parking brake engaged switch
4 Gearshift in neutral switch
5 EDC main fuse (20 Amp)
6 Diagnostic connector
7 Blink-Code button
8 Engine oil pressure
9 Coolant temperature
10 Revolution counter
11 Pre-heater ON indicator
12 Starter motor
13 Crankshaft sensor
14 Pre-heater activation solenoid switch
15 Fuel temperature sensor
16 Fuel heater resistor
17 Timing sensor
18 Pressure regulator solenoid valve
19 Coolant temperature sensor
20 Pre-heater resistor
21 Electric injectors
22 Air temperature/pressure sensor
23 Fuel pressure sensor
24 Oil temperature/pressure sensor
INJECTION SYSTEM ASSEMBLY
21 22
19 20 23
18
16
17
15
24
14
12 13
7
6
8 9 10 5
MEGA
FUSE
w …\
w …\ E H@ w …\ E H@
w …\
w… w… w… P N
3 4
11 2 CAN LINE
OFF
ACC.
ON
ACCELERAT. PEDAL
START
PEDAL PROXIMITY SENSOR
POTENTIOMETER
W170-2R009
DESCRIPTION OF INJECTION SYSTEM
Control of engine pre-heater resistor Limitation of maximum speed

The pre-heater is activated every time even just one At 2300 rpm, the controller limits the delivery of fuel
of the coolant, air or fuel sensors measures a tem- by reducing the opening time of the electric injectors.
perature < 5 °C (41 °F).
Cut-off
Timing recognition
The cutting-off of fuel during the engine slow down or
Through the signals of the sensor on the camshaft
when used to brake is managed by the controller by
and the one on the crankshaft, the starting cylinder
performing these logics:
where the fuel must be injected is identified.
– it cuts-off supply to the electric injectors;
Control of injection – it reactivates the electric injectors just before reach-
The controller, in accordance with the information pro- ing low idle speed;
vided by the sensors, controls the pressure regulator,
– it controls the fuel pressure regulator.
changing the modes of the pre-injection and the main
injection.
On tector engines, the pre-injection is activated at all Control of smoke emission during accelerations
engine speeds. When high loads are required, the controller, depend-
ing upon the signals provided by the air intake meas-
Closed circuit control of the injection pressure uring device and the crankshaft speed sensor, con-
Depending upon the engine load, determined by the trols the pressure regulator and changes the actua-
processing of the signals provided by the various sen- tion time of the electric injectors, to prevent the en-
sors, the controller controls the regulator to provide gine from smoking.
constantly an optimised pressure.
After Run
Control of pilot and main injection advance
When cutting-off the engine, the microprocessor of
The controller, depending upon the signals provided the controller memorises some data in the EPROM
by the various sensors, defines the optimised injec- including a trouble memory, so that the data are avail-
tion point in accordance with an internal mapping. able when a new starting occurs.
Control of low idle speed
The controller processes the signals provided by the
various sensors and regulates the quantity of fuel in-
jected. It controls the pressure regulator and changes
the injection timing of the electric injectors.
Within certain thresholds, it considers also the volt-
age of the batteries.
Overheating protection
In the event the coolant temperature reaches 110 °C
(230 °F) the controller decreases the performance of
the engine.
Once the temperature drops below 100 °C (212 °F)
the engine resumes normal operations.
Hydraulic system
The Common Rail system features a special pump This means that fuel at the injection pressure calcu-
that maintains the fuel constantly at high pressure lated by the electronic control unit is always available
regardless of the phase and of the cylinder to be in- at the infeed to the electro-injectors.
jected and accumulates it in a duct common to all the
When the solenoid valve of an electro-injector is en-
electro-injectors.
ergized by the electronic control unit, fuel tapped di-
rectly from the rail is injected in the related cylinder.
High pressure
Low pressure
Fuel drainage
W170-2R010
1. Electric injector - 2. Common rail - 3. Pressure limit device for fuel return - 4. Common rail pressure relief valve -
5. Pre-filter installed on the frame - 6. High pressure pump - 7. Rotor type mechanical pump - 8. Fuel filter.
The hydraulic system consists of a low pressure cir- The low pressure circuit comprises the following pipes:
cuit and a high pressure circuit.
- suction pipe of the fuel from the tank to the prefilter;
The high pressure circuit comprises the following
- pipes that supply the mechanical fuel pump through
pipes:
the heat exchanger of the control unit, the manual
- pipe connecting the outlet of the high pressure pump priming pump and the prefilter;
to the Common Rail;
- pipes that supply the high pressure pump through
- pipes that supply the electro-injectors from the the fuel filter.
Common Rail.
The supply system also includes the fuel drainage
system from the Common Rail, from the injectors and
the cooling circuit of the high pressure pump.
Hydraulic diagram
Exhaust
Intake (low pressure)
High pressure pump supply (low pressure)
High pressure
Intake (low pressure)
W170-2R011
1. High pressure pump - 2. Limiting valve on the high pressure pump, 5 bar - 3. Regulating valve fitted on the fuel return
from the electro-injectors, 1.3 ÷ 2 bar - 4. Common Rail overpressure valve - 5. Common Rail - 6. Pressure sensor -
7. Electro-injector - 8. Return pipe - 9. Heat exchanger of the control unit - 10. Mechanical priming pump - 11. Prefilter fitted
on chassis - 12. Fuel tank - 13. Mechanical fuel pump - 14. Fuel filter - 15. Pressure regulator - 16. Return pipe from high
pressure pump - 17. By-pass valve - 18. By-pass valve.
The pressure regulator located ahead of the high pres- The limiting valve (3) housed on the cylinder head,
sure pump regulates the flow of fuel required on the fitted on the return of the electro-injectors, regulates
low pressure system. Subsequently, the high pres- return flow of the fuel from the electro-injectors to a
sure pump supplies the Common Rail correctly. pressure of 1.3 ÷ 2 bar.
This solution, which pressurizes only the fuel required, Two by-pass valves are installed in parallel with the
improves energy efficiency and restricts heating of mechanical fuel pump.
the fuel in the system.
By-pass valve 18 permits return of the fuel from the
The limiting valve (2), fitted on the high pressure pump, outlet of the mechanical pump to its infeed when the
maintains a constant pressure of 5 bar (72.52 psi) at pressure at the entrance to the fuel filter exceeds the
the infeed to the pressure regulator. permitted limit. By pass valve 17 makes it possible to
fill the fuel system through the manual priming pump
(10).
FUEL MECHANICAL PUMP HIGH PRESSURE PUMP CP3
Sect. A-A A W170-2R012
Pressure regulator on inlet A

Located on the inlet of the high-pressure pump, 1 B
on the low-pressure system, it modulates the quan-
tity of fuel supplied to the high-pressure pump in ac- C
cordance with the commands received from the con- 3
troller.
2
It is mainly composed of the following components: D
– trapezoidal section plunger;
– valve control pin; E
– pre-load spring;
– solenoids.
When no command signal is received, the pressure W170-2R013
regulator is normally open, thus the high-pressure
pump is in maximum flow condition. A. Connection for fuel discharge outlet to filter support. -
B. Connection for fuel inlet from controller heat exchanger -
The controller modulates a PWM command to control C. Connection for fuel inlet from fuel filter - D. Connection
in a larger or smaller manner the fuel passage section for fuel outlet from fuel pump to filter - E. Fuel outlet con-
toward the high-pressure pump. nection to rail - 1. High pressure pump - 2. Fuel pump -
3. Pressure regulator (solenoid valve NA modulated by
The component cannot be replaced individually; thus controller with PWM signal).
it must not be removed.
3-radial piston pump driven timing gear, without need
for timing setting, with fuel rotor pump mounted on
the rear side.
Internal structure of the high pressure pump
Sect. B-B B C
7
B C
6 2
Sect. C-C
3 4
W170-2R014
1. Cylinder - 2. Three lobe element - 3. Plate type inlet valve - 4. Ball delivery valve - 5. Piston - 6. Pump shaft - 7. Low-
pressure fuel inlet - 8. Fuel ducts for pumping element supply.
Each pumping group is composed of:

– piston (5) actuated by a three-lobe element floating Note – The high pressure-fuel pump group cannot be
on pump shaft (6). Element (2), floating on a out-of- overhauled, thus the securing screws must not be
line part of shaft (6) during the rotation of the shaft tempered with nor it must be removed. The only inter-
does not rotate with it but it is only moved circularly vention allowed is replacing the drive gear and replac-
on a larger radius, with the result that it actuates, ing pressure regulator (3).
alternatively, the three pumping elements;
– a plate type suction valve (3);
– a ball delivery valve (4).
Operation Rail
The cylinder is filled through the plate intake valve
only when the supply pressure is capable of opening
the delivery valves located on the pumping elements
(about 2 bar) (29 psi). 2
The quantity of fuel supplying the high-pressure valve 4
is dosed by the pressure regulator, located on the
low-pressure system; the pressure regulator is con-
trolled by the EDC7 controller through a PWM signal.
When fuel is forwarded to the pumping element, the 5 3 1
relevant piston is moving downward (suction stroke). W170-2R015
Once the stroke of the piston is inverted, the intake

1. Rail - 2. Flow limiters - 3. Fuel inlet from high pressure
valve closes and the fuel in the pumping element
pump - 4. Pressure sensor - 5. Pressure relief valve.
chamber, being prevented from getting-out, is com-
pressed over the value of the supply pressure in the
rail. The volume of the rail has reduced dimensions to pro-
The pressure generated in this manner causes the vide a fast pressurisation when starting, at low idle
opening of the discharge valve and compressed fuel and in case of large flows.
reaches the high-pressure circuit. It has anyway, a volume sufficient to minimise the
The pumping element compresses the fuel until it fluctuations caused by the opening and the closing of
reaches the TDC (delivery stroke). Then, the pres- the injectors and the operation of the high-pressure
sure decreases until the discharge valve closes. pump. This function is further eased by a calibrated
orifice located after the high-pressure pump.
The piston of the pumping element returns toward the
BDC and the residual fuel decompresses. A fuel pressure sensor (4) is screwed on the rail. The
signal forwarded by this sensor to the controller pro-
Once the pressure in the pumping element chamber
vides a feedback information, on which the pressure
becomes lower than the supply pressure, the intake
value in the rail is measured and corrected, if required.
valve opens again and the cycle is repeated.
Delivery valves must always be free in their move-
ment, free from impurities and oxidation.
The delivery pressure to the rail is modulated between
250 and 1350 bar (3625 to 19580 psi) by the control-
ler, through the solenoid valve of the pressure regula-
tor.
The pump is lubricated and cooled by the fuel itself.
The cut-off/reactivation time of the radialjet pump on
the engine is greatly reduced compared with traditional
injection pumps, since it does not require timing set-
ting.
In case of removal-reinstallation of the piping between
fuel filter and high-pressure pump, keep your hands
and components perfectly clean.
Pressure relief valve

The pressure relief valve (1750 bar) (25381 psi) on system in the event a flow limiter intervenes.
the common rail protects the components of the
4 4
4
B
A
5 3 1 2
6 5 3 1 2 6
W170-2R016 W170-2R017
1. Body - 2. Piston - 3. Stop - 4. Spring - 5. Discharged directed to tank - 6. Seat on rail.
A. Normally, the tapered end of the piston keeps the B. In case the fuel pressure of 1750 bar (25381 psi)
discharge toward the tank closed. in the rail is exceeded, the piston moves and the
pressure excess is discharged into the tank.
Flow limiters WARNING

They are located on the rail fuel outlet connections. After the intervention to block the leakage of fuel
Their function is to protect the integrity of the engine from the rail, the flow limiter is automatically re-
or the vehicle in the event of internal spills (example set under the action of the spring. However, f the
injector stuck open) or external (example: damaged cause of its intervention is not eliminated, at the
high-pressure pipes). next starting tentative the engine could operate
If this occurs, the operation of the system is provided, only at low idle or at low speed or to be cut-off
within certain limits, by the components of the other again, depending upon the entity of the leakage.
cylinders in operational conditions.
1
1
A B
3
5 2 4 3 5 2 4
W170-2R018 W170-2R019
1. Body - 2. Piston - 3. Fuel inlet - 4. Spring - 5. Securing thread on rail.
A. The passage of fuel from the rail to the electric B. In the event of a large pressure drop after the
injectors occurs through holes drilled on the small limiter, the inlet pressure prevails and moves the
diameter of the piston. piston toward the opposite side, cutting-off the
Under normal conditions, the fuel pressure is on outflow of fuel.
both sides of the piston, kept by the spring in open
position.
Electric injector
The injector has a design similar to traditional ones. The solenoid valve controls the lifting of the injector
The electric injector can be considered composed of needle.
two parts:
– actuator-nozzle composed of pressure rod (1), nee-
dle (2) nozzle (3);
– control solenoid valve composed of coil (4) and pi-
lot valve (5).
Injector in rest condition
12
4 6
9
5
11 1
10
13
2
8
3
W170-2R020
1. Pressure rod - 2. Needle - 3. Nozzle - 4. Coil - 5. Pilot valve - 6. Ball plunger - 7. Control area - 8. Pressure chamber -
9. Control volume - 10. Supply-control duct - 11. Outlet of control fuel - 12. Electric connector - 13. Spring.
Beginning of injection
When solenoid (4) is energised it moves ball plunger At the same time the fuel pressure in pressure cham-
(6) upward. The fuel of control volume (9) flows to- ber (8) causes the lifting of needle (2) with the subse-
ward re-flow duct (12) causing a pressure drop in con- quent injection of the fuel into the cylinder.
trol volume (9).
12
4 6
9
5
11 1
10
13
2
8
W170-2R021
1. Pressure rod - 2. Needle - 3. Nozzle - 4. Solenoid - 5. Pilot valve - 6. Ball plunger - 7. Control area - 8. Pressure chamber -
9. Control volume - 10. Supply-control duct - 11. Outlet of control fuel - 12. Electric connector - 13. Spring.
End of injection
Once solenoid (4) is de-energised, plunger (6) returns returning needle (2) into closed position, terminating
into position closed, re-creating equilibrium of forces the injection.
1.5 TROUBLESHOOTING GUIDE
FOREWORD
Experience is the factor facilitating the solution of trou- controller. These troubles are of are mostly of an
bles. electric- electronic nature;
To partially overcome the lack of experience by the
repair engineer on this new electronic device, since – the second, organised by symptom, describes pos-
no previous systems to which refer existed, we list in sible troubles not directly identifiable by the control-
the pages to follow a TROUBLESHOOTING GUIDE. ler. These troubles are mostly of a mechanical-hy-
The troubleshooting guided is composed of two sec- draulic nature.
tions, neatly defined:
The troubleshooting guides do not replace the diag-
– the first one, organised by Blink Code, refers to nosis with electronic diagnostic equipment, but should
troubles that can be directly identified by the EDC7 be considered as integration to the same.
1.5.1 TROUBLESHOOTING WITH PT-01

INSTRUMENT
illustration is supplied with a set of connecting cables
The 380001218 diagnostic instrument shown in the as well as an Operation Manual.
1. outer power connection

2. diagnostic connecting cable
1. HW failure
2. transm. K line comun.
3. transm. line K reception
4. transmission L line communication
P T- 0 1 5. line bus CAN
1. serial port
2. porta USB
! K K L CAN
6. power
7. navigation buttons
8. communication status
indicators
1 2 3
4 5 6 9. numerical buttons
7 8 9
10. CANCEL button
0 X
1010
11. USB port indicator
12. OK button
13. serial port indicator
Controller-instrument
connecting cable
Connection point
P T- 0 1
! K K L CAN
W170-2R022
1.5.2 TROUBLESHOOTING WITH BLINK

CODE
Performance of the EDC indicator lights

The panel with the trouble indicator light is located in
the cab and can be reached after removing the plas-
tic cover behind the operator's seat.
ON
ENGINE
DIAGNOSTIC
W170-2R023
1-26
ACTIVATION/READING THE BLINK CODE
By actuating the "ENGINE DIAGNOSTIC" switch it The code is composed of two digits divided by a dot
is possible to monitor the operational condition of the (Ex. "2.3") and it is shown by slow flashes followed
controller and to identify the presence of the error by fast flashes.
codes activated. If no troubles are identified in the system, the EDC
indicator light does not provide any information and
Method: Engine inoperative comes ON once only. If, as an example, the first ac-
Key on second click (ON) tive code is "2.3" we have:
"Diagnostic" switch ON a. 2 slow flashes;
b. pause;
c. 3 fast flashes.
Important – The connection and disconnection op-

erations of the controller must be performed with the
positive terminal of the battery disconnected.
TROUBLE CODES
FLASH SAE TYPE OF POWER

CODE DESCRIPTION OF TROUBLE CODE CODE FLASH REDUCTION
VEHICLE
1.4 Accelerator Pedal Signal APP1 0120 1 0
ENGINE 1
2.1 Coolant Temp. Signal CTS 0115 1 0
2.2 Boost Temp. Signal BTS 0239 0 0
2.3 Fuel Temp. Signal FTS 0180 0 0
2.4 Boost Pressure Signal BPS 0235 1 0
2.5 Atmospheric Pressure Signal APS 0105 0 0
2.6 Oil Pressure Signal OPS 0520 1 0
2.7 Oil Temp. Signal OTS 0195 1 0
2.8 Power stage Fuel filter heater HP7 1686 0 0
ENGINE 2
3.7 Battery voltage signal BAT 0560 1 0
3.8 LS Power stage cold start lamp LP1 1670 0 0
3.9 HS power stage Cold start heater relay TGHV 1875 0 0
INJECTORS
5.1 Injector solenoid valve Cyl.1 SV1 0201 1 0
5.7 Injector Booster Voltage C1 C1 1606 1 0
5.8 Injector Booster Voltage C2 C2 1607 1 0
ENGINE SPEED
6.1 Increment speed signal CRK 0335 1 2
6.2 Segment speed signal CAM 0340 1 2
6.3 Engine speed sensing ESS 0320 1 0
6.4 Engine overspeed CMOL 0219 2 0
6.5 HS power stage 8 for Starter control HP8 1687 0 0
FUEL PRESSURE
8.1 Fuel pressure monitoring CP3 MPROP 0233 2 3
8.2 Fuel pressure signal FPS 0190 2 3
8.3 CC HS Power stage 1 fuel press. Control HPC1 1690 2 3
8.4 Monitoring of rail pressure relief valve MPRV 0231 2 3
8.5 Fuel pressure monitoring CP3 (high) DRV 0233 2 4
CONTROLLER
9.4 Main relay defect MOMR 1625 1 0
9.6 ECU: Self Test Shutoff Paths STSP 1285 1 0
9.7 Power supply for sensors PSS 0561 1 0
BLINK TYPES: 2 = Blinking light 1 = Continous light 0 = No light

SYSTEM DEGRADATION: 0 = 0% derate 1 = slight derate 2 = moderate derate 3 = significant derate
4 = engine stop
1.5.3 DIAGNOSIS OF MAIN

MALFUNCTIONS
Main engine operating anomalies:

1 – Engine won’t start; 7 – Engine knocks irregularly;
2 – Engine overheats; 8 – Engine stops;
3 – Engine lacks power and works erratically; 9 – Engine exceeds max. revs number;
4 – Engine exhaust smoke black or dark grey; 10 – Excessive or insufficient oil pressure;
5 – Engine exhaust smoke grey (verging on white); 11 – Excessive fuel consumption;
6 – Engine exhaust smoke light blue; 12 – Engine won’t stop.
1 ENGINE WON’T START
Connections to battery terminals are in working NO

Clean, check, tighten or replace clamp nuts.
order.
YES
NO Carry out the checks described in the “Electric

Batteries in working order.
system” repair manual.
YES
NO Carry out the checks described in the “Electric

Starter motor in working order.
system” repair manual.
YES
NO
Thermal starter in working order. Replace.
YES
NO Verify correct timing as described in the relevant

Injection pump timed.
chapter.
NO
Injectors in working order. Check operation and adjust.
YES
The feeding circuit or injection pump does not NO Check and blow off.
show air penetration.
YES
The feeding circuit or pump does not show NO Check and clean the feeding circuit (including
traces of water. the tank).
YES
Prescribed compression ratio. NO Overhaul the engine or make repairs only on

concerned parts (valves, piston rings, etc.).
YES
Fuel filters in working order. NO Replace.
YES
Automatic advance variator and electric STOP NO

device both in working order. Check and replace the concerned parts.
YES
NO Check and replace (if necessary) the fuel

Fuel pump fed correctly.
pump.
YES
Fuel tank supplied correctly. NO

Refuel.
2 ENGINE OVERHEATS
NO
Coolant level correct. Check for leaks and restore the level.
YES
Fan and water pump drive belts in working NO

order. Check for leaks and restore the level.
YES
NO
Water pump in working order. Overhaul or replace the unit.
YES
NO Replace.
Thermostat in working order.
YES
Radiator in working order. NO Wash down thoroughly, check for fluid leaks,
replace (if necessary) the part.
YES
NO
Air filter and circuit piping both in working order. Clean or replace faulty parts.
YES
Openings for coolant flow to the head in working NO Wash down thoroughly.
order.
Valve timing correct. NO Check and perform correct timing.
YES
Injection pump timed. NO Check correct timing as described in the

relevant paragraph.
YES
Cylinder head gasket in working order. NO Replace.
YES
Fan in working order. NO

Replace.
3 ENGINE LACKS POWER AND WORKS

ERRATICALLY
NO Clean the unit and replace (if necessary) the

Air filter in working order.
filter element.
YES
NO Replace by following the instructions given in

Fuel filters in working order.
the “Owner Handbook”.
YES
NO Check and make (if necessary) the required

Feeding circuit in working order.
repairs.
Take off the pipes and injection pump, clean

The feeling circuit does not show impurities NO them thoroughly, then clean (if necessary) and
and/or traces of water.
dry the fuel tank.
YES
Thermostat in working order. NO Replace.
YES
Fuel pump in working order. NO

Replace.
YES
Injectors in working order. NO Check operation and adjust them.
YES
NO Check correct timing as described in the

relevant paragraph.
YES
Automatic advance variator (in injection pump) NO Check and bench-adjust the injection pump.
in working order.
YES
Distributing plunger (in injection pump) in NO Check and bench-adjust the injection pump.
working order.
NO
Injection pump rate correct. Check and bench-adjust the injection pump.
YES
Speed governor (in injection pump) in working NO Check and bench-adjust the injection pump.
order at all speeds.
YES
Circuit and L.D.A. device both in working order. NO Check.
YES
Injection pump with peak adjusting-screw fine- NO Fine-tune the peak adjusting-screw.
tuned.
YES
Correct play between the valves and rocker NO Adjust the play between the valves and rocker
arms. arms.
YES
Prescribed compression ratio. NO

Check and bench-adjust the injection pump.
YES
Turbocharger in working order. NO Repair or replace the unit.
YES
Correct tie rod length between the accelerator NO

and injection pump. Adjust the tie rod length.
ENGINE EXHAUST SMOKE BLACK

4
OR DARK GREY
NO
Air filter in working order. Replace.
YES
NO Replace.
Thermal starter in working order.
YES
Automatic addition device comes into operation. NO

Check and replace (if necessary).
YES
Injectors in working order. NO Check operation and adjust them as described.
YES
NO Check correct timing as described in the

relevant paragraph.
YES
L.D.A. device in working order. NO Ad just the L.D.A. device.
YES
Injection pump adjusted as prescribed. NO

Check and bench--adjust the injection pump.
NO Check the condition of pipes and replace them

Injection pipes intact.
(if necessary).
YES
NO Check by means of a Motometer tool and carry

Prescribed compression ratio.
out the necessary operations.
YES
High-quality diesel fuel. NO Clean the tank and replace the diesel oil filter.
ENGINE EXHAUST SMOKE GREY

5
(VERGING ON WHITE)
NO
The thermostat comes into operation correctly. Replace.
YES
NO Check operation and adjust as described in S.I.

Injectors in working order.
1094.
YES
Injection pump timed. NO Check correct timing as described in the

relevant paragraph.
YES
Possible flow of coolant into the combustion

Coolant level correct. NO chamber; replace the cylinder head gasket or
overhaul the engine.
High-quality diesel oil. NO

Clean the tank and replace the diesel oil filters.
6 ENGINE EXHAUST SMOKE LIGHT BLUE
YES Check the oil vapour vent and cylinder

Excessive oil consumption. compression. Overhaul, if necessary, the
cylinder head or engine.
7 ENGINE KNOCKS IRREGULARLY
YES Perform correct timing of injection pump on the

Knock detected in the injection pump.
engine.
NO
Check the following items: journal play and out-

YES of-roundness; screw fastening for bed caps and
Knock detected in the drive shaft.
engine flywheel; oil pressure. Replace the parts
or overhaul the engine.
NO
Check the following items: crankpin play and

YES out-of-roundness; screw fastening for connecting
Knock detected in the connecting rods. rod caps; connecting rod squaring. Replace the
parts or overhaul the engine.
NO
Check the following items: play between the

YES pistons and the cylinder liners; integrity of piston
Knock detected in pistons.
rings; play between the pins and the piston
hubs. Replace the parts or overhaul the engine.
Check the following items: operation play

Knock detected in the cylinder head. YES
between the rocker arms and the valves;
injection pump timing; valve timing. Adjust.
NO
Check and replace (if necessary) the gears; moreover,

Knock detected in the valve gear. YES check for broken springs, for excessive play between
the stems and guides, the tappets and seats. Adjust the
play between the valves and rocker arms.
NO
YES Check and adjust as described in S.I. 1094,

Knock detected in injectors.
then replace.
NO
YES Replace loose screws and tighten all screws

Knock detected in the engine flywheel.
to the specified torque and angles.
NO
Clean the pipes and replace the pipes that

Knock detected in the fuel piping. YES show evident dents; clean (if necessary) the
injection pump.
8 ENGINE STOPS
NO
Fuel tank filled. Refuel and drain (if necessary).
YES
NO
Fuel filters in working order. Replace.
NO Check the circuit and drain.

Feeling circuit in working order.
YES
Regular idle speed. NO

Adjust.
YES
Regular injection pump rates. NO Bench-check the flow rates.
YES
Injection pump controls in working order. NO Replace worn parts and adjust.
YES
Correct play between the valves and rocker NO Ad just the play between the valves and rocker
arms. arms.
YES
Intact valves. NO Replace the valves.
ENGINE EXCEEDS MAX. REVS

9
NUMBER
NO
Speed governor in working order. Check and replace (if necessary) the worn
parts.
EXCESSIVE OR INSUFFICIENT
10 OIL PRESSURE
NO
Pressure control valve in working order. Check and replace (if necessary).
YES
Oil pump and delivery pipes both in working NO

Check and replace (if necessary).
order.
YES
Main bearings and connecting rod bearings NO Replace the bearings and reface (if necessary)
both in working order. the drive shaft.
YES
Engine oil SAE viscosity conforming to NO Replace the engine oil with equivalent of
standards. adequate viscosity.
11 EXCESSIVE FUEL CONSUMPTION
NO Eliminate leaks (if any) and replace the worn

Fuel tank and pipes in working order.
parts.
YES
NO
Air filter in working order. Replace.
NO
Correct injector adjustment. Check operation and adjust them.
YES
NO
Correct injection pump adjustment. Check and bench-adjust.
YES
L.D.A. device in working order. NO Adjust the L.D.A. device.
YES
Injection pump timed. NO

Check static force-fit of the injection pump.
12 ENGINE WON’T STOP
NO
Cut-off electromagnet in working order. Replace the electromagnet.
YES
NO Overhaul the injection pump and bench-adjust

Speed governor in working order at all speeds.
it according to the relevant adjustment table.
1.6 ENGINE SUPPORTS
The engine is secured to the rear module of the frame Frontally by the torque converter-transmission group
in four points by brackets. and rearward by the engine itself. All the brackets, in
turn, rest on elastic pads.
W170-2R024
Engine supports
1. Engine mount bolt - 2. Washer - 3. Insolator upper - 4. Insolator lower - 5. Washer - 6. Washer - 7. Nut - 8. Remote oil drain
hose.
1.7 ENGINE OVERHAUL
Disassembly of the engine

– Drain the engine oil removing the cap from the sump.
W170-2R027
W170-2R025
Disconnect the fuel hose (1) from the rail and from
the high pressure pump (5) and detach it removing
In order to apply to the engine block the engine fixing the lock screws (2).
brackets to the stand for the overhaul, operating on
the engine left side, it is necessary: Important – When unlocking the pipe (3) union (1), it
– to remove the fuel filter (5) from the support (1) by is necessary to prevent the union (4) rotation of the
means of tool 380000670; high-pressure pump (5), by using the proper wrench.
– to remove the low pressure fuel pipe (2-3-4) from
the support (1);
– to remove the support (1) bracket from the block.
On the right side
A B
W170-2R026 W170-2R028
Important – In order to remove the low-pressure fuel Remove the screws (2) and remove the oil pipe (3)
pipe (2-3-4) from the relevant connection unions, it is from the supercharger pipe (1) and from the engine
necessary to press the fastener (1) as shown in fig- block.
ure B. After removing the pipe, position the fastener Remove the starting engine (5) from the flywheel cover
(1) into its lock position, figure A, in order to avoid (4).
possible deformations. Apply to the block the bracket 380000661 and fix by
means of these latter the engine to the revolving stand
380000301.
W170-2R029
1. Connections for injectors - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil pressure and
temperature sensor - 5. Engine shaft sensor - 6. Injector - 7. Temperature-air pressure sensor - 8. Timing phase sensor -
9. Fuel temperature sensor and fuel heater - 10. Pressure adjuster - 11. Control unit EDC7.
Disconnect the engine wire by disconnecting the con-

nectors: (1) from the injector harness (6); (7) air tem-
perature /pressure sensor: (3) fuel pressure sensor;
(11) control unit; (10) high pressure pump sensor; (8)
timing phase sensor; (2) engine coolant temperature
sensor on thermostat (5) rpm sensor.
W170-2R030
Remove from the rail: the fuel pipe (7) according to

the procedures described in Figure. Remove the fuel
pipe (5) from the rail (2) and from the manifolds (6) for
injectors.
Important – During the unlocking operation of the pipe

(6) fixing unions (4) from the rail (2), it is necessary to
prevent the possible flow limiting device rotation (3)
by means of a proper wrench.
Remove the screws (1) and the rail (2).
W170-2R031 W170-2R033
Remove from the fuel return pressure limiting device Loosen the tappet adjuster fixing nuts (1) and unscrew
(1), the pipe (2) as described in Figure. Remove the the adjuster.
pipe (4) from the air supercharger (3) and from the
union (5). Remove the nut (10) Loosen the elastic hose Remove the screws (2), remove the equalizer unit (3)
clamp (6) and remove the oil vapor pipe (9).Remove composed by the support (6), equalizers (4), shafts
the unions (13-11) and remove the pipe (12). Remove (5) and remove the bonds (7) from the valves. Re-
the nuts (7) and remove the tappet (8) cover com- move the rods (8).
plete of gasket.
W170-2R032 W170-2R034
Remove the nuts (7) and disconnect the electric wires Remove the injector fixing scrcews and by means of
from the injectors (8). Remove the screws (1) and re- tool 380001099 (1) withdraw the injectors (2) from the
move the injector harness support (2) complete of cylinder head.
gasket. Remove the screws (5) and remove the air
pressure/temperature sensor (6). Remove the nuts (3)
and withdraw the fuel manifolds (4).
Important – The removed fuel manifold (4) shall not
be used again and they must be replaced by new
ones.
W170-2R035 W170-2R036
Detach the conveyor (5) from the turboblower (1). Remove the lock screws (1) and detach the exhaust
Disconnect the oil hose from the heat exchange/oil manifold in two parts (2-3) with the related gaskets.
filter support.
Remove the nuts (2) and detach the turboblower (1)
from the exhaust manifold (3).
W170-2R037
– Remove the automatic take-up device (5); – remove the damper flywheel (6) with the pulley un-
– remove the Poly-V belt (4); derneath (7);
– remove the conditioner compressor (1), the alterna- – remove the phonic wheel (8).
tor (3) and the fixed guide pulley (2);
– remove the fitting of the engine cooling system from
the engine block;
W170-2R038 W170-2R041
Remove the screws (1) and detach the air conveyor Using tool 380000670, remove the oil filter (1).
(2) c/w heater. Remove the screws (4), remove the
cover (3) and the thermostat below. Remove the cyl-
inder head (6) lock screws (5).
Important – The outside screws highlighted are

shorter.
W170-2R042
Remove the screws (4) and disassemble the oil tem-

perature pressure sensor (3).
Remove the screws (1) and disassemble the support
W170-2R039 (2) oil filter heat exchanger, intermediate plate (6) and
related gaskets.
Remove the oil level sensor (5).
Attach the brackets (1) using metal ropes and using
the lifting device detach the cylinders head (2) from
the engine block.
W170-2R043
W170-2R040
Remove the screws (1) and detach the electronic con-
Remove the cylinder head gasket (1). trol unit (2) c/w heat exchanger.
W170-2R044 W170-2R047
Remove the nut (1) and disassemble the phase sen- Remove the screws (1) and detach the front cover (2).
sor (2).
Remove the nuts (3) and detach the high pressure Important – Note the assembly position of the screws
pump (4) c/w fuel pump (5). (1) as they are of different length.
W170-2R045 W170-2R048
Apply tool 380000144 (2) to the flywheel cover box Remove the screws (1) and detach the oil pump (2).
(1) in order to block rotation of the flywheel (3). Loosen
the screws (4). Important – The oil pump (2) cannot be serviced.
W170-2R046 W170-2R049
Remove the screws (1) and detach the water pump (2). Remove tool 380000144 (2).
Remove the screw (3) and disassemble the roller (4). Remove the screws (1) that fasten the engine flywheel
Remove the screw (5) and detach the engine speed (3) to the crankshaft (4).
sensor (6).
W170-2R050 W170-2R053
Screw two pins (2) of suitable length in the holes of Remove the screws (1) and (4) and disassemble the
the crankshaft (3). Slide out the engine flywheel (1) oil suction rose (5).
so that it can be rigged using the lifting device and Remove the screws (2) and disassemble the reinforce-
place it in the container. ment plate (3).
W170-2R054
W170-2R051
Remove the screws (1) and detach the rear cover (2). Remove the screws (1) and disassemble the gear (3)
from the camshaft (2).
Important – Note the assembly position of the screws
(1) as they are of different size.
W170-2R055
Remove the screws (2) and detach the timing gear

box (1).
W170-2R052
Turn the engine over, remove the screws (2) and de- Important – Note the assembly position of the screws
tach the oil sump (1) with the gasket underneath. (2) as they are of different size.
W170-2R056 W170-2R058
Remove the screws (1) that fasten the con-rod caps The last but one main bearing cap (1) and the related
(2) and disassemble these. support have the bearing halves (2) with shoulder.
Slide out the pistons c/w con-rods from the upper part
of the engine block. Important – Note the assembly position of the lower
and upper bearing halves as, if these are re-used,
Important – Leave the bearing halves in their respec- they must be fitted in the position found during disas-
tive housings as, if these are re-used, they must be sembly.
fitted in the position found during disassembly.
W170-2R057 W170-2R059
Remove the screws (1) and disassemble the main Using tool 380000362 (1) and lifting device, remove
bearing caps (2). the crankshaft (2) from the engine block.
W170-2R060 W170-2R062
Disassemble the main bearing halves (1). Remove the camshaft (1) carefully from the engine
Remove the screws (2) and disassemble the oil block.
sprayers (3).
W170-2R061 W170-2R063
Remove the screws (1) and disassemble the camshaft Remove the tappets (1) from the engine block.
(3) retention plate (2).
Important – Note the assembly position of the plate

(2).
REPAIR INTERVENTIONS CYLINDER GROUP oversized of 0.5 mm in respect of the nominal value and
Controls and measurements prescribed assembling clearance.
Cam lift check and pin alignment check

Position the shaft on counterpoints and, by means of a
centesimal gauge, located on the central support, check
that the alignment error is not higher than 0.04 mm: on
the contrary, replace the shaft. Then, check the cam lif-
ting: it must result of 6.045 mm (0.238 in) for the exhaust
ones and of 7.582 mm (0.277 in) for the suction ones; if
s
you detect different values, replace the shaft.
W170-2R064
Carefully clean the cylinder-block group, when performed

the engine disassembly.Use the proper rings to transfer
the cylinder group. Carefully check that the block does
not present any cracks. Check the working plug conditions.
Replace them if they are rusty or in case of doubt about
their conditions. Examine the cylinder barrel surfaces;
they must not present any seizing, scoring, ovalization,
taper, and excessive wearing traces. The internal diameter
check of the cylinder barrels, to verify the ovalization,
taper and wearing entity, is performed by means of bore W170-2R066
meter (1) equipped with comparator previously set to zero
on the ring gauge (2) of the cylinder barrel diameter. Check the camshaft (2) support pin diameter by means
of a micrometer (1) on two perpendicular surfaces.
Important – If you do not have at your disposal the ring
gauge, use a micrometer for the zero setting operation. BUSHES
W170-2R065
W170-2R067
The measurements must be performed for each individual The camshaft bushes (2) must result forced in their
cylinder at three different heights from the barrel and on relevant seats.
two perpendicular surfaces: one parallel to the longitudinal The inner surfaces must result without seizing and wearing
engine axis (A) and the other one perpendicular (B); traces.
usually the max wear is detected on this latter surface By means of a bore meter (3), measure the diameter of
and in correspondence with the first measurement.If you the rear and front bushes (2) and intermediate seats (1)
detect any ovalization, taper or wear, ream and grind the for camshaft.
cylinder barrels. The cylinder barrel regrinding must be The measurements must be performed on two
performed in relation to the diameter of the spare pistons perpendicular axes.
sez. A-A
Sect. A-A
W170-2R068
MAIN DATA OF THE CAMSHAFT BUSHES AND RELEVANT SEATS

* Dimensions to be obtained after the bush driving
Head face check on the cylinder group
W170-2R070
Check that the head face, on the cylinder group, does

not present deformations. This check can be carried
out, after a previous grains (4) extraction by means of
a calibrated ruler (2) and feeler gauge (3). After verified
the deformation areas, perform the flattening of the
W170-2R069
face by means of grinding machine. The flatness error
must not be higher than 0.075 mm (0.003 in).
Important – In the event of grinding operation, all the
barrels must result of the same oversize (0.5 mm). Important – The block flattening could be performed
only after you have checked that, at finished work,
Check the bench bearing seats, proceeding as follows: the piston projection from the cylinder barrel is not
– mount the bench caps on the supports without higher than the value prescribed.
bearings;
– screw the fixing screws to the torque prescribed; Check the conditions of the working plugs (1) of the
– by means of an adequate gauge, verify that the cylinder groups; replace them if rusty or in case of
internal diameter of the seats correspond to the value doubt about their conditions.
prescribed. When flattening is finished, restore the cylinder barrel
If you detect a higher value, replace its block. bevel.
TIMING SYSTEM
Camshaft
W170-2R071
CAMSHAFT MAIN DATA

The data listed are refereed to the standard pin diameter.
The surfaces of the camshaft support pins and cams if they present seizing and scoring traces, it is better
must be very smooth; to replace the shaft and relevant bushes.
Bush replacement Fitting tappets – camshaft
W170-2R072 W170-2R074
To replace front and rear bushes (1), use for their Lubricate the tappets (1) and fit them into the relevant
removal and refitting the tool 380000667 (2) and housings on the engine block.
handgrip 380000999 (3).
Important – When refitting bushes (1) direct them so

that lubrication holes coincide with engine block
housing holes.
W170-2R075
Lubricate the camshaft bushes and fit the camshaft (1)

Tappets taking care not to damage the bushes or the housings.
W170-2R076
W170-2R073
Set camshaft (3) retaining plate (1) with the slot facing
MAIN DATA CONCERNING THE TAPPETS AND the top of the engine block and the marking facing the
THE RELEVANT HOUSINGS ON THE ENGINE operator, then tighten the screws (2) to the specified
BLOCK torque.
CRANK SHAFT
Measuring journals and crankpins
W170-2R077
Check camshaft end float (1).

It shall be 0.23 ± 0.13 mm (0.009 ± 0.005 in).
W170-2R079
Grind journals and crankpins if seizing, scoring or

excessive ovalisation are found. Before grinding the
pins (2) measure them with a micrometer (1) to deci-
de the final diameter to which the pins are to be ground.
Important – It is recommended to insert the found

values in the proper table.
Undersize classes are: 0.250 - 0.500 mm (0.010 - 0.020 in)
Important – Journals and crankpins shall always be

ground to the same undersize class. Journals and
crankpins undersize shall be marked on the side of
W170-2R078
the crank arm No.1.
For undersized crankpins: letter M
Fit nozzles (2) and tighten the fastening screws (1) to For undersized journals: letter B
the specified torque. For undersized crankpins and journals: letters MB
W170-2R080
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
W170-2R081
MAIN TOLERANCES OF DRIVE SHAFT

TOLERANCES
TOLERANCE-RELATED FEATURE GRAPHIC SYMBOL
CONCERNING:
Roundness O
SHAPE
Cylindricality /O/
Parallelism //
ORIENTATION Perpendicularity ⊥
Straightness —
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION Total oscillation
Taper
CLASS OF IMPORTANCE ASSIGNED TO PRODUCT FEATURES GRAPHIC SYMBOL

CRITICAL ©
IMPORTANT ⊕
SECONDARY c–
45° 2x45° 45°

BEARINGS ON TIMING INTERMEDIATE FIRST
SIDE BEARINGS BEARING ON
UPPER SIDE
W170-2R082
Replacing oil pump control gear Finding journal clearance
W170-2R085
Mount drive shaft (1).

W170-2R083 Check the play between the drive shaft journals and their
Check that gear toothing (1) is not damaged or worn, respective bearings by following the procedure below:
otherwise remove it using the proper puller (3).
When fitting the new gear, heat it to 180 °C for 10

minutes in an oven and then key it to the output shaft.
Fitting main bearings
W170-2R086
– clean accurately the parts and remove any trace of oil;

– position a piece of calibrated wire (3) on the output shaft
pins (4) so that it is parallel to the longitudinal axis;
– fit caps (1), including the half bearings (2) on the relevant
supports.
W170-2R084
Important – Refit the main bearings that have not

been replaced, in the same position found at removal.
Main bearings (1) are supplied spare with 0.250 - 0.500

mm (0.010 - 0.020 in) undersize on the internal diameter.
W170-2R087
Important – Do not try to adapt the bearings.
Tighten the pre-lubricated screws (1) in the following
Clean accurately the main half bearings (1) having three successive stages:
the lubricating hole and fit them into their housings. – 1st stage, with dynamometric wrench to 50 ± 6 Nm
(36.88 ± 4.42 lb.ft.).
The second last main half bearing (1) is fitted with – 2nd stage, with dynamometric wrench to 80 ± 6 Nm
shoulder half rings. (59 ± 4.42 lb.ft.).
Checking output shaft shoulder clearance
W170-2R088 W170-2R090
– 3rd stage, with tool 380000304 (1) set as shown in This check is performed by setting a magnetic-base
the figure, tighten the screws (2) with 90° ± 5° angle. dial gauge (2) on the output shaft (3) as shown in the
figure, standard value is 0.068 - 0.41.
If higher value is found, replace main thrust half
bearings of the second last rear support (1) and repeat
the clearance check between output shaft pins and
main half bearings.
CONROD - PISTON ASSEMBLY
W170-2R089 W170-2R091
– Remove caps from supports. CONNECTING ROD - PISTON ASSEMBLY

COMPONENTS
The backlash between the main bearings and the pins
is found by comparing the width of the calibrated wire 1. Stop rings - 2. Pin - 3. Piston - 4. Split rings -
(2) at the narrowest point with the scale on the envelope 5. Screws - 6. Half bearings - 7. Connecting rod -
(1) containing the calibrated wire. 8. Bush.
The numbers on the scale indicate the backlash in
mm. Important – Pistons are supplied spare with 0.5 mm
Replace the half bearings and repeat the check if a (0.20 in) oversize.
different backlash value is found. Once the specified
backlash is obtained, lubricate the main bearings and
fit the supports by tightening the fastening screws as
previously described.
PISTONS
Measuring piston diameter
W170-2R092 W170-2R094
Remove split rings (1) from piston (2) using pliers Using a micrometer (2), measure the diameter of the
380000221 (3). piston (1) to determine the assembly clearance.
Important – The diameter shall be measured at

12 mm (0.47 in) from the piston skirt.
W170-2R093 W170-2R095
Piston pin (1) split rings (2) are removed using a scriber The clearance between the piston and the cylinder
(3). barrel can be checked also with a feeler gauge (1) as
shown in the figure.
W170-2R096
MAIN DATA CONCERNING PISTON, PINS AND SPLIT RINGS

* Value measured on 99 mm diameter
Gudgeon pins
W170-2R097 W170-2R100
To measure the piston pin (1) diameter use the Check the clearance between the sealing rings (3) of
micrometer (2). the 2nd and 3rd slot and the relevant housings on the
piston (2), using a feeler gauge (1).
Conditions for proper pin-piston coupling
W170-2R098
W170-2R101
Lubricate the pin (1) and its seat on piston hubs with
DIAGRAM FOR MEASURING THE CLEARANCE
engine oil; the pin shall be fitted into the piston with a
X BETWEEN THE FIRST PISTON SLOT AND
slight finger pressure and shall not be withdrawn by
THE TRAPEZOIDAL RING
gravity.
Since the first sealing ring section is trapezoidal, the
Split rings
clearance between the slot and the ring shall be
measured as follows: make the piston (1) protrude
from the engine block so that the ring (2) protrudes
half-way from the cylinder barrel (3).
In this position, use a feeler gauge to check the

clearance (X) between ring and slot: found value shall
be the specified one.
W170-2R099
Use a micrometer (1) to check split ring (2) thickness.
W170-2R102
Use feeler gauge (1) to measure the clearance between

the ends of the split rings (2) fitted into the cylinder
barrel (3).
Connecting rods W170-2R104
Important – Every connecting rod is marked as

follows:
- On body and cap with a number showing their

coupling and the corresponding cylinder.
In case of replacement it is therefore necessary to
mark the new connecting rod with the same numbers
of the replaced one.
- On body with a letter showing the weight of the
connecting rod assembled at production:
• V, 1600 ÷ 1640 (yellow marking);

• W, 1641 ÷ 1680 (green marking);
• X, 1681 ÷ 1720 (blue marking);
Spare connecting rods are of the W class with green

marking*.
Material removal is not allowed.
Bushes
W170-2R103
Check that the bush in the connecting rod small end
MAIN DATA FOR CONNECTING ROD, BUSH, is free from scoring or seizing and that it is not loosen.
PISTON PIN AND HALF BEARINGS Otherwise replace.
Removal and refitting shall be performed using the
* Value for inside diameter to be obtained after driving proper beater.
in connecting rod small end and grinding When refitting take care to make coincide the oil holes
** Value not measurable in released condition set on the bush with those set on the connecting rod
small end. Grind the bush to obtain the specified
Important – To obtain best coupling the connecting diameter.
rod-cap coupling surfaces are knurled.
It is therefore recommended to not remove knurling.
Checking connecting rods Checking bending
W170-2R105 W170-2R107
Check that the axes of the connecting rods (1) are Check connecting rod (5) bending by comparing two
parallel using tool 380001003 (5) as follows: points C and D of the pin (3) on the vertical plane of
– fit the connecting rod (1) on tool 380001003 (5) the connecting rod axis.
spindle and lock it with screw (4); Position the vertical support (1) of the dial gauge (2)
– set the spindle (3) on V-blocks by resting the to rest the latter on pin (3), point C.
connecting rod (1) on the stop bar (2). Move the connecting rod forwards and backwards to
find pin top position, then in this condition reset the
Checking torsion dial gauge (2).
Move the spindle with the connecting rod (5) and repeat
the check of the top point on the opposite side D of
the pin (3). The difference between point C and point
D shall not exceed 0.08 mm (0.003 in).
Fitting connecting rod-piston assembly

Connecting rod-piston coupling
W170-2R106
Check connecting rod (5) torsion by comparing two W170-2R108

points (A and B) of pin (3) on the horizontal plane of
the connecting rod axis. Position the dial gauge (2) The piston crown is marked as follows:
support (1) to obtain a preload of approx. 0.5 mm on 1. Part number and design modification number;
the pin (3) in point A and then set the dial gauge (2) to 2. Arrow showing piston assembling direction into
zero. Move the spindle (4) with the connecting rod (5) cylinder barrel, this arrow shall face the front key
and compare any deviation on the opposite side (B) of the engine block;
of the pin (3): the difference between A and B shall 3. Manufacturing date.
not exceed 0.08 mm. 4. Marking showing 1st slot insert testing;
Important – Split rings are supplied spare with the

following sizes:
– standard, yellow marking;
– 0.5 mm (0.20 in) oversize, yellow/green marking;
W170-2R109
Connect piston (2) to connecting rod (4) with pin (3) so

that the reference arrow (1) for fitting the piston (2) into
the cylinder barrel and the numbers marked on the
connecting rod (5) are read as shown in the figure.
W170-2R112
Fit half bearings (1) on connecting rod and cap.
Important – Refit the main bearings that have not

been replaced, in the same position found at removal.
Do not try to adapt the half bearings.
Fitting connecting rod-piston assembly into

cylinder barrels
W170-2R110
Fit pin (1) split rings (2).
Fitting split rings
W170-2R113
Lubricate accurately the pistons, including the split rings

W170-2R111
and the cylinder barrel inside.
Use pliers 380000221 (3) to fit the split rings (1) on the Use band 380000220 (2) to fit the connecting rod-piston
piston (2). assembly (1) into the cylinder barrels and check the
Split rings shall be fitted with the marking "TOP" facing following:
upwards and their openings shall be displaced with each – the number of each connecting rod shall correspond
other by 120°. to the cap coupling number.
W170-2R116
W170-2R114
– lubricate the screws (1) with engine oil and then

DIAGRAM FOR CONNECTING ROD-PISTON tighten them to the specified torque using the
ASSEMBLY FITTING INTO BARREL dynamometric wrench (2).
– split ring openings shall be displaced with each other

by 120°;
– connecting rod-piston assemblies shall have the
same weight;
– the arrow marked on the piston crown shall be facing
the front side of the engine block or the slot obtained
on the piston skirt shall be corresponding to the oil
nozzle position.
Finding crankpin clearance

W170-2R117
– apply tool 380000304 (1) to the socket wrench and

tighten screws (2) of 60°.
W170-2R115
To measure the clearance proceed as follows:

– clean the parts accurately and remove any trace of
oil; W170-2R118
– set a piece of calibrated wire (2) on the output shaft
pins (1); – remove the cap and find the existing clearance by
– fit the connecting rod caps (3) with the relevant half comparing the calibrated wire width (1) with the sca-
bearings (4). le on the wire envelope (2).
Timing gear case
W170-2R119
If a different clearance value is found, replace the W170-2R121

half bearings and repeat the check. Once the specified
clearance has been obtained, lubricate the main half SEALANT APPLICATION AREAS
bearings and fit them by tightening the connecting
rod cap fastening screws to the specified torque. Clean accurately the timing gear case (1) and the
engine block. Perfect seal is only obtained by cleaning
Important – Before the final fitting of the connecting accurately the surface to seal. Smear the case with
rod cap fastening screws, check that their diameter sealant to obtain a bead of few mm diameter. It shall
measured at the centre of the thread length is not be uniform (no clots), without air bubbles, thin areas
< 0.1 mm than the diameter measured at approx. 10 or discontinuities. Any imperfection shall be corrected
mm from screw end. as soon as possible. Avoid to use excess material to
seal the joint. Excessive sealant could come out from
Check manually that the connecting rods (1) are sliding joint sides and cause lubricant passage clogging. After
axially on the output shaft pins and that their end float, applying the sealant, the joint shall be assembled
measured with feeler gauge (2) is 0.10 ÷ 0.33 mm immediately (10 - 20 minutes).
(0.004 ÷ 0.13 in).
Checking piston protrusion
W170-2R122
DIAGRAM FOR TIGHTENING THE REAR TIMING

GEAR CASE FASTENING SCREWS
W170-2R120 Refit the case (1) to the engine block. Screw the
fastening screws in the same position found at removal
Once connecting rod-piston assemblies refitting is and tighten them to the following torque values in the
over, use dial gauge 380000228 (1) fitted with base sequence shown in the figure:
380000364 (2) to check piston (3) protrusion at T.D.C. Screws M12 65 ÷ 89 Nm (47.94 ÷ 65.64 lb.ft.)
with respect to the top of the engine block. Screws M8 20 ÷ 28 Nm (14.75 ÷ 20.65 lb.ft.)
Protrusion shall be 0.28 ÷ 0.52 mm (0.11 ÷ 0.20 in). Screws M10 42 ÷ 52 Nm (30.98 ÷ 38.35 lb.ft.)
Timing Flywheel housing
W170-2R126
W170-2R123
SEALANT APPLICATION AREAS

Use a felt pen to mark the driving gear (1) tooth fitted
on the output shaft (2) having the mark (→) for timing Clean accurately the flywheel housing (1) and timing
on the side surface. gear case coupling surfaces. Perfect seal is only
obtained by cleaning accurately the surface to seal.
Smear housing (1) with sealant to obtain a bead of
few mm diameter. It shall be uniform (no clots), without
air bubbles, thin areas or discontinuities. Any
imperfection shall be corrected as soon as possible.
Avoid to use excess material to seal the joint.
Excessive sealant could come out from joint sides
and cause lubricant passage clogging. After applying
the sealant, the joint shall be assembled immediately
(10 - 20 minutes).
W170-2R124
Direct the output shaft (4) and the camshaft (2) so

that when fitting the driven gear (1) on the camshaft
the marks on the gears (1 and 3) are coinciding.
W170-2R127
SEQUENCE FOR TIGHTENING THE FLYWHEEL

HOUSING FASTENING SCREWS
Refit the housing (1) to the engine block and screw

the fastening screws in the same position found at
W170-2R125 removal and tighten them to the following torque values
in the sequence shown in the figure:
Tighten the screws (1) fastening gear (2) to camshaft Screws M12 75 ÷ 95 Nm (55.32 ÷ 70.07 lb.ft.)
(3) to the specified torque. Screws M10 44 ÷ 53 Nm (32.45 ÷ 39.10 lb.ft.)
W170-2R130
Screw two pins (2) having suitable length into shaft

holes (3) and remove the engine flywheel (1) using
W170-2R128
proper sling and hoister.
Apply tool 380000666 part (5) to the rear output shaft
tang (6), secure it by screws (4) and fit the new sealing
ring (3).
Position part (1) on part (5), screw nut (2) until
completing sealing ring (3) fitting into flywheel housing
(7).
ENGINE FLYWHEEL
W170-2R131
Tighten the screws (4) fastening the engine flywheel (3)

to the output shaft. Apply tool 380000144 (2) to the
flywheel housing (1) to stop engine flywheel (3) rotation.
W170-2R129
Check clutch plate supporting surface and turn it if

scored.
W170-2R132
Important – Engine flywheel rated thickness is 70,5 mm.
Tighten engine flywheel (2) fastening screws (1) in
Replacing engine flywheel ring gear two stages:
Check ring gear teeth (2), if breakage or excessive – 1st stage, tightening to 30 ÷ 4 Nm (22.13 ÷ 2.95 lb.ft.)
wear is found remove the ring gear from the engine torque with dynamometric wrench;
flywheel (1) using a generic beater and fit the new – 2nd stage, tightening to 60° ± 5° angle.
one, previously heated to 150 °C for 15 ÷ 20 minutes.
Chamfering on ring gear inside diameter shall be facing Important – Tightening to angle is performed using
the engine flywheel. tool 380000304.
W170-2R136
Remove the sealing ring (2) from the front cover (1),
W170-2R133
clean accurately the coupling surfaces and smear them
Fit the oil pump (1). with sealant.
Tighten the fastening screws (2) to the specified torque.
W170-2R137
W170-2R134 Clean accurately the front cover (2) surface and refit
it. Tighten the screws (1) to the specified torque.
Apply a new sealing ring (2) to the water pump (1).
W170-2R138
Apply tool 380000666 part (5) to the front output shaft

W170-2R135
tang (6), secure it by screws (4) and fit the new sealing
Fit the water pump (1). ring (3). Position part (1) on part (5), screw nut (2) until
Tighten the screws (2) to the specified torque. completing sealing ring (3) fitting into front cover (7).
W170-2R139 W170-2R141
Fit the plate (3), the rose pipe (5) and tighten the Fit the phonic wheel (1) and the hub (2) on the output
fastening screws (1 - 2 and 4) to the specified torque. shaft.
Tighten the fastening screws (3) in two stages:
– 1st stage, tightening to 50 ± 5 Nm (36.88 ± 3.69 lb.ft.)
torque with dynamometric wrench;
– 2nd stage, tightening to 90° angle.
Important – Tightening to angle is performed using

tool 380000304 (4).
Fit the damper flywheel (5) and the pulley (6).

Tighten the fastening screws (7) to 68 ± 7 Nm
(50.15 ± 5.16 lb.ft.) torque.
W170-2R140 W170-2R142
Fit the oil sump (1) and apply the plate (3) to the gasket Fit a new sealing ring on the speed sensor (3).
underneath. Fit the speed sensor (3) on the front cover (1) and
Tighten the screws (2) to the specified torque. tighten the screw (2) to the specified torque.
W170-2R143 W170-2R145
Fit on the engine block: a new gasket (1), the heat exchanger Position the alternator support (1) so that pins (3 and
(2) a new gasket (3) and the oil filter support (4). 4) are set against the engine block.
Tighten the screws (5) to the specified torque. Tighten the screws (2) to the specified torque.
W170-2R144
W170-2R146
Lubricate the sealing ring (2) with engine oil and set it
Re-attach the conditioner (1)
on the oil filter (3).
Refit the alternator (2).
Screw manually to seat the oil filter (3) on the support
connection (1) and then screw again the oil filter (3)
by 3/4 turn.
Apply a new sealing ring on the oil temperature/

pressure sensor (4) and fit it on the support (1).
Tighten the screws (5) to the specified torque.

Fit a new sealing ring (6) in the engine block seat.
W170-2R147
Refit the automatic belt tensioner (2).

Tighten the screw (3) to the specified torque using
the proper wrench, turn the automatic belt tensioner
(2) to fit the belt (1) on pulleys and guide rollers.
CYLINDER HEAD
Removing the valves
W170-2R148
Refit the high pressure pump (5) including the feed W170-2R150
pump (6) and tighten the nuts (3) to the specified

torque. Fit the support (4) with a new sealing ring, the Intake (1) and exhaust (2) valves have heads with the
timing sensor (2) with a new sealing ring and tighten same diameter.
the relevant fastening nut (1) to the specified torque.
The central notch (→) of the exhaust valve (2) head
distinguishes it from the intake valve.
Important – Should cylinder head valves be not

replaced, number them before removing in order to
refit them in the same position.
A = intake side – S = exhaust side
W170-2R149 W170-2R151
Refit the ECU (3) including the heat exchanger to the Valve removal shall be performed using tool 380000302
engine block and tighten the screws (2) to the specified (1) and pressing the cap (3) so that when compressing
torque. the springs (4) the cotters (2) can be removed. Then
remove the cap (3) and the springs (4).
Important – Replace support elastic elements (1).
Repeat this operation for all the valves.
Overturn the cylinder head and withdraw the valves
(5).
Checking cylinder head supporting surface
W170-2R152
Remove the sealing rings (1 and 2) from the relevant

valve guides. W170-2R154
Important – Sealing rings (1) for intake valves are Use a rule (2) and a feeler gauge (3) to check the
yellow. cylinder head (1) supporting surface.
Sealing rings (2) for exhaust valves are green.
Distortion found along the whole cylinder head shall
not exceed 0.20 mm (0.008 in).
If higher values are found grind the cylinder head

according to values and indications shown in the
following figure.
Checking cylinder head wet seal
W170-2R153 W170-2R155
This check shall be performed using the proper tools. The rated thickness A for the cylinder head is 105
± 0.25 mm, max. metal removal shall not exceed
Use a pump to fill with water heated to approx. 90 °C thickness B by 0.13 mm (0.005 in).
(194 °F) and 2 ÷ 3 bar (29 ÷ 43.51 psi) pressure.
Important – After grinding, check valve sinking.
Replace the cup plugs (1) if leaks are found, use the Regrind the valve seats, if required, to obtain the
proper beater for their removal/refitting. specified value.
Important – Before refitting, smear the plug surfaces

with water-repellent sealant.
Replace the cylinder head if leaks are found.
VALVES Checking clearance between valve stem

and valve guide and valve centering
EXHAUST INTAKE
VALVE VALVE
6.970 6.970
6.990 6.990
44.75° 59.75°
45.25° 60.25°
32.87 32.87
33.13 33.13
W170-2R156
W170-2R159
INTAKE AND EXHAUST VALVE MAIN DATA

Use a magnetic base dial gauge (1) set as shown
Removing carbon deposits, checking in the figure, the assembling clearance shall be
and grinding valves 0.052 ± 0.092 mm (0.002 ± 0.003 in).
Turn the valve (2) and check that the centering error
is not exceeding 0.03 mm (0.001 in).
VALVE GUIDE
7.051
7.053
W170-2R157
Remove carbon deposits from valves using the proper

metal brush.
Check that the valves show no signs of seizing,
scoring or cracking.
Regrind the valve seats, if required, using tool
380000828 and removing as less material as possible.
INTAKE EXHAUST
W170-2R160
Use a bore dial gauge to measure the inside diameter

of the valve guides, the read value shall comply with
the value shown in the figure.
W170-2R158
Check the valve stem (1) using a micrometer (2), it

shall be 6.970 ± 6.999.
VALVE SEATS
Regrinding - replacing the valve seats
W170-2R161
Check the valve seats (2). If slight scoring or burnout

is found, regrind seats using tool 380000975 (1)
according to the angle values shown in Figure.
VALVE SEATS IN CYLINDER HEAD
1.1
1.5
27.25 27.25
27.75 39.5 27.75
40.5
34.837 34.837
34.863 34.863
36.78 36.78
INTAKE EXHAUST
W170-2R162
VALVE SEAT MAIN DATA
1.1
1.5
EXHAUST INTAKE
27.25 27.25
27.75 39.5 27.75
40.5
34.837 34.837
34.863 34.863
36.78 36.78
W170-2R163
MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD
Should valve seats be not reset just by regrinding, Heat the cylinder head to 80° ÷ 100 °C (176 ÷ 212 °F)
replace them with the spare ones. Use tool 380000975 and using the proper beater, fit the new valve seats,
to remove as much material as possible from the val- previously cooled, into the cylinder head.
ve seats (take care not to damage the cylinder head) Use tool 380000828 to regrind the valve seats
until they can be extracted from the cylinder head according to the values shown in Figure.
using a punch.
VALVE SPRINGS
W170-2R165
MAIN DATA TO CHECK INTAKE AND EXHAUST

VALVE SPRINGS
W170-2R164
Before refitting use tool 380000976 to check spring flexibility.
After regrinding, check that valve (3) sinking value is Compare load and elastic deformation data with those of
the specified one by using the base 380000364 (2) the new springs shown in the following table.
and the dial gauge 380000228 (1).
Height Under a load of
mm N
H 47.75 Free
H1 35.33 P 339.8 + 9 N
H2 25.2 P1 741 + 39 N
ASSEMBLY OF THE CYLINDER HEAD Refitting the cylinder head
W170-2R168
W170-2R166
Check cleanness of cylinder head and engine block

Lubricate the valve stems (1) and fit them into the coupling surface.
relevant valve guides according to the position marked Take care not to foul the cylinder head gasket.
at removal. Set the cylinder head gasket (1) with the marking "TOP"
Fit the sealing rings (2 and 3) on the valve guide. (1) facing the head.
The arrow shows the point where the gasket thickness
Important – Sealing rings (2) for intake valves are is given.
yellow and sealing rings (3) for exhaust valves are
green. Important – Before reusing the cylinder head
fastening screws check whether they are free from
damages or distortions, otherwise replace.
W170-2R167 W170-2R169
Position on the cylinder head: the spring (4), the upper Refit the cylinder head (1), tighten the screws (2) in
cap (3); use tool 380000302 (1) to compress the spring three successive stages according to the sequence
(4) and lock the parts to the valve (5) by the cotters and procedure shown in the following figure.
(2).
Important – Use tool 380000304 (3) to tighten to angle.
W170-2R170
Cylinder head fastening screw tightening sequence:

– 1st stage pre-tightening, with dynamometric wrench:
· Screw 12 x 1.75 x 130 ( ) 35 ± 5 Nm
(25.81 ± 3.69 lb.ft.)
· Screw 12 x 1.75 x 150 ( ) 55 ± 5 Nm
(40.56 ± 3.69 lb.ft.)
– 2nd stage, tightening to 90° ± 5° angle W170-2R172
– 3rd stage, tightening to 90° ± 5° angle

Fit injectors (1) on the cylinder head seats, directed
so that the fuel inlet hole (2) is facing the fuel manifold
A = front side
seat (3) side.
Fitting injectors
W170-2R171
Fit a new sealing ring (2) lubricated with vaseline and

a new sealing washer (3) on injector (1).
W170-2R173
Use tool 380001099 (1) to fit the injector (2) into its
seat.
Screw injector fastening screws without tightening them.
RODS
W170-2R176
Rocker control rods shall not be distorted; the ball seats

W170-2R174
in touch with the rocker adjusting screw and with tappets
Fit a new sealing ring (3) lubricated with vaseline on (arrows) shall not show seizing or wear; otherwise replace
the fuel manifold (2) and fit it into the cylinder head them. Intake and exhaust valve control rods are identical
seat so that the positioning ball (5) is coinciding with and are therefore interchangeable.
the relevant housing (4).
Rocker assembly
Important – Removed fuel manifolds (2) shall not be
reused but replaced with new ones.
Screw the fastening nuts (2) without locking them.
Important – During this operation, the injector (1) shall

be moved so that the manifold (2) is properly inserted
into the fuel inlet hole (2).
W170-2R177
ROCKER ASSEMBLY COMPONENTS:

1. Screws - 2. Bracket - 3. Shafts - 4. Rockers.
W170-2R175
W170-2R178
Use the dynamometric wrench to tighten gradually and
alternately the injector fastening screws (1) to 8.5 ± SHAFT-ROCKER MAIN DATA
0.8 Nm (6.27 ± 0.59 lb.ft.) torque.
Tighten the fuel manifold (3) fastening nuts (2) to 50 Check that shaft/rocker coupling surfaces are not
Nm torque. showing excessive wear or damages.
Tappet clearance adjustment
W170-2R179
Fit the rods (2). W170-2R181
Position jumpers (1) on valves with marks (→) facing

the exhaust manifold. Adjust clearance between rockers and valves using
setscrew wrench (1), box wrench (3) and feeler gauge
(2).
Working clearance shall be as follows:
– intake valves 0.25 ± 0.05 mm (0.010 ± 0.002 in)
– exhaust valves 0.51 ± 0.05 mm (0.020 ± 0.002 in)
Important – In order to more quickly perform the

operating clearance adjustment for rocker arms -
valves, proceed as follows:
rotate the drive shaft, balance cylinder 1 valves and
adjust the valves marked by the asterisk as shown in
the table:
cylinder n. 1 2 3 4 5 6
intake - - * - * *
exhaust - * - * - *
W170-2R180
Rotate he drive shaft, balance cylinder 6 valves and
Check that tappet adjusters (1) are loosen to prevent adjust the valves marked by the asterisk as shown in
their balking on the rods (2) when refitting the rocker the table:
assembly.
Then refit the rocker assembly consisting of: bracket cylinder n. 1 2 3 4 5 6
(5), rockers (3), shafts (4) and secure them to the
cylinder head by tightening the fastening screws (2) intake * * - * - -
to 36 Nm torque. exhaust * - * - * -
W170-2R182 W170-2R184
Fit the rail (2) and tighten the screws (1) to the specified Important – Pipe (7) connections shall be tightened
torque, connect the ground cable (3) to the intake to 20 Nm (14.75 lb.ft.) torque, using the proper wrench
manifold (4) and tighten the fastening nut (5) to the (5) and the dynamometric wrench 380000158 (4).
specified torque. Connections (6) shall be tightened by holding the flow
limiting valve hexagon (1) with the proper wrench.
Connect the fuel pipe (3) to the rail (2) following the
procedure shown in the following figure.
W170-2R183 W170-2R185
Connect new fuel pipes (1) to rail (3) and injector Press the clamp (1) in arrow direction (Figure B) and
manifolds (2). connect the pipe to the rail (2), reset the clamp to the
initial locking position "A".
Important – When removed, pipes (1) shall always
be replaced. Important – Check proper fuel pipe connection.
Harness support
W170-2R189
W170-2R186
Fit a new gasket (2) on the tappet cover (1).
Check the condition of the electric cables (5), if they
are damaged, replace by cutting the clips that fasten
them to the support (2) and removing the screws (4)
that fasten the connectors (3) to this.
Fit a new gasket (1) on the support (2).
W170-2R190
Fit the tappet cover (1), draw up the nuts (2) and
tighten them to the prescribed torque.
W170-2R187
Fit the harness support (2), draw up the screws (1)

and tighten them to the prescribed torque.
W170-2R191
Re-attach the exhaust manifold (3) with new gaskets.

Draw up the lock screws (6) and tighten them to the
prescribed torque.
Re-attach the turbo-blower (1) with a new gasket to
W170-2R188
the exhaust manifold (3) and tighten the lock nuts (2)
to the prescribed torque.
Connect the electric cables (1) to the electro-injectors Connect the oil hose (5) to the heat exchanger support
(3) and using torque wrench 380000158 (4) tighten (7) and to the turbocompressor (1). Attach the oil duct
the lock nuts (2) to the prescribed torque. (4) to the heat exchanger support.
W170-2R192
W170-2R194
Connect the air conveyor (2) to the turbo-blower (3)
and secure it to this with the clip (1). Press the clip (1) in the direction of the arrow (fig. B)
and connect the pipe.
Return the clip to the initial clamping position A.
Important – Make sure the fuel hose is connected

correctly.
W170-2R193
With the fittings (13-15) and new copper washers,

connect the pipe (14) to the tappet cover (10) and to
the timing case (6).
Connect the pipe (7) to the fitting located on the timing

box (6) and secure it with a clamp (8).
Fit the new snap ring on the fitting of the pipe (11) and
assemble it in the tappet cover (10).
Fasten the pipe (11) to the tappet cover (10) with the
bracket and nut (12), connect the pipe (4) to the fitting
(5) and to the air compressor (3).
Connect the pipe (2) to the pressure limiting device

(1) as shown in the figure below.
W170-2R195
1. Injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil tempera-
ture and pressure sensor - 5. Output shaft sensor - 6. Injector - 7. Air temperature/pressure sensor - 8. Timing
sensor - 9. Fuel heater and fuel temperature sensor - 10. Pressure regulator - 11. Control unit
Reconnect the engine cable by connecting injector Apply to engine lifting hooks the lifting rig 380000216,
wiring (6) connectors (1); (7) air pressure/temperature hook the latter to the hoister and remove the engine
sensor; (3) rail pressure sensor; (11) control unit; (10) from the revolving stand. Remove the brackets
high pressure pump sensor; (8) timing sensor; (2) engine 3800000661.
coolant temperature sensor on thermostat; (5) engine
speed sensor.
W170-2R196 W170-2R198
Complete engine refitting as follows: Screw manually the fuel filter to the support (1), screw
Form the right side: the filter by ¾ turn, connect the pipes (2-3-4) to the
relevant support connections (1) as shown in the
Refit the starter (5) to the flywheel housing (4) and following figure.
tighten the fastening nuts to the specified torque.
Fit the oil pipe (3) with a new sealing ring into the
engine block and secure it to the turbosupercharger
(1) by the screws (2) tightened to the specified torque.
W170-2R197 W170-2R199
Refit the bracket (2) including the fuel filter support Press the clamp (1) as shown in figure B.
(1) to the engine block, tighten the screws (3) to the
specified torque. After disconnecting the pipe, reset the clamp (1) to
the initial locking position A, to prevent deformations.
When refitting is over, fill engine with the prescribed

lubricating oil in the specified quantity.
TIGHTENING TORQUE
PART COUPLE
Nm (kgm)
Cylinder head fastening screw 1st phase: screws M12x1.75x70 50 ± 5 (5 ± 0.5)
screws M12x1.75x140 40 ± 5 (4 ± 0.5)
screws M12x1.75x180 s 70 ± 5 (7 ± 0.5)
2nd phase: 90°
3rd phase: (only for screw 140 and 180 mm lomg) 90°
Bed cap fastening screws 1st phase 50 ± 6 (5 ± 0.6)
2nd phase s 80 ± 6 (8 ± 0.6)
3rd phase 90° ± 5°
Connecting rod cap fastening 1st phase 30 ± 5 (3 ± 0.5)
2nd phase s 50 ± 5 (5 ± 0.5)
3rd phase 60° ± 5°
Engine flywheel fastening screws pre-tighten s 30 ± 5 (3 ± 0.5)
Angle 60° ± 5°
Injector fastening 60 ± 5 (6 ± 0.5)
Sump oil drain plug 60 ± 5 (6 ± 0.5)
Fuel filter contact + 3/4 turn
Injection pump gear cover fastening screw 25 ± 5 (2.5 ± 0.5)
Valve gear cover and case fastening screw 25 ± 5 (2.5 ± 0.5)
Container fastening screw 25 ± 5 (2.5 ± 0.5)
Intake manifold fastening screw 25 ± 5 (2.5 ± 0.5)
Fuel pump fastening screw 25 ± 5 (2.5 ± 0.5)
Exhaust manifold fastening screw 53 ± 5 (5.3 ± 0.5)
Tappet cover fastening nut 25 ± 5 (2.5 ± 0.5)
Rocker arm support fastening screw 48 ± 8 (4.8 ± 0.5)
Nut for rocker arm adjusting screw 25 ± 5 (2.5 ± 0.5)
Screw fastening the pulley on drive shaft pre-tighten 50 ± 5 (5 ± 0.5)
Angle 90° ± 5°
Distributing shaft shoulder plate fastening screw 25 ± 5 (2.5 ± 0.5)
Fan support fastening screw 25 ± 5 (2.5 ± 0.5)
Injection pump fastening screw 12 ± 5 (1.2 ± 0.5)
Fan pulley fastening screw 45 ± 5 (4.5 ± 0.5)
Turbocompressor fastening screw 25 ± 5 (2.5 ± 0.5)
Heat exchanger fastening screw 25 ± 5 (2.5 ± 0.5)
Oil pump and front cover fastening screw 25 ± 5 (2.5 ± 0.5)
Starter motor fastening screw 55 ± 5 (5.5 ± 0.5)
Alternator fastening screw 45 ± 5 (4.5 ± 0.5)
Water pump fastening screw 25 ± 5 (2.5 ± 0.5)
Oil filter contact + 3/4 turn
Belt stretcher fastening screw 45 ± 5 (4.5 ± 0.5)
s - Lubrication with oil
1.8 TOOLS
380000158 1-6 Nm torque wrench for calibration of the injector solenoid valve connector lock nut
380000216 Engine detachment and re-attachment device
380000975 Box with equipment complete with tools for valve seat reconditioning
380000976 Unit for spring load check.
380000977 Tool for checking the top dead centre (to be used with 380001005)
380000301 Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)
380000322 Extractor for the gear linking the injection pump to the engine
380000665 Tool for removing the drive shaft front gasket
380000663 Tool for removing the drive shaft rear gasket
380000671 Injector extracting tool
380000666 Coupler for mounting the drive shaft front gasket
380000664 Coupler for mounting the drive shaft rear gasket
380000670 Cartridge filter removing tool
380000221 Pliers for removing and reassembling the piston rings (65-110 mm, 2.56-4.33 in)
380000302 Tool for removing and reassembling the engine valves
380000988 Tool for rotating the engine flywheel
380000150 Adapter for compressor check in cylinders (380001006)
380000144 Engine flywheel retaining tool
380000667 Beater for removing and reassembling the distributing shaft bushings (to be used with 380000999)
380000362 Drive shaft lifting tool
380000993 Swing bar for engine detachment and reattachment
380000220 Band for inserting the piston into the cylinder liner (60-125 mm, 2.36-4.92 in)
380000661 Brackets for fastening the engine to the rotary stand 380000301
380000669 Gasket extracting tool
380000997 Comparator holder tool for rotary injection pump timing (to be used with 380001005)
380000998 Manual pump for pressure and vacuum measurements
380000999 Handle for interchangeable beaters
380000364 Comparator holder base for miscellaneous measurements (to be used with 380000228)
380000304 Set of 2 gauges for angular tightening with 1/2" and 3/4" square mount
380001002 All-purpose inclinometer/Goniometer
380001003 Full square for connecting rod squaring check
380000228 Comparator (0-5 mm)
380001005 Comparator (0-10 mm)
380001006 Device for checking diesel engine cylinder compression
380001099 Electro-injector extraction tool (Common Rail engines)
SECTION 2
TRANSMISSION
INDEX
2.1 REMOVAL AND INSTALLATION OF POWER TRAIN COMPONENTS .................. 2-1

2.1.1 TRANSMISSION .................................................................................................. 2-1
Removal ........................................................................................................... 2-1
Transmission Mounting ..................................................................................... 2-7
Installation ........................................................................................................ 2-8
2.1.2 FRONT AXLE ....................................................................................................... 2-13
Removal ........................................................................................................... 2-13
Front Axle Mounting .......................................................................................... 2-15
Installation ........................................................................................................ 2-16
2.1.3 REAR AXLE ......................................................................................................... 2-18
Removal ........................................................................................................... 2-18
Rear Axle Mounting .......................................................................................... 2-20
Installation ........................................................................................................ 2-21
2.2 TRANSMISSION SPECIFICATIONS, PRESSURE CHECKS, ..............................

AND TROUBLESHOOTING .................................................................................. 2-23
2.2.1 SPECIAL TOOLS ................................................................................................. 2-23
2.2.2 SPECIFICATIONS ................................................................................................ 2-23
2.2.3 TRANSMISSION OPERATION ............................................................................. 2-29
General ............................................................................................................. 2-29
Transmission ECM............................................................................................ 2-29
Transmission Clutch Calibration ........................................................................ 2-30
Gear Selections ................................................................................................ 2-30
Automatic/Manual Modes ................................................................................. 2-30
Downshift Button .............................................................................................. 2-31
Brake Pedal Transmission Declutch .................................................................. 2-32
2.2.4 TRANSMISSION PRESSURE TEST POINTS DIAGRAM .................................... 2-33
2.2.5 CHART FOR RECORDING PRESSURE READINGS ........................................... 2-35
2.2.6 PRESSURE TEST RESULTS ............................................................................... 2-36
All or Most Pressures Low and/or Flow Test Low .............................................. 2-36
Some Pressures Low ........................................................................................ 2-36
Not Enough Power ............................................................................................ 2-36
Machine Stops or Hesitates While Shifting - Intermittent................................... 2-36
2.2.7 CONVERTER OUT PRESSURE CHECK ............................................................. 2-37
Test Equipment Required .................................................................................. 2-37
Test Procedure ................................................................................................. 2-37
2.2.8 LUBRICATION PRESSURE CHECK ..................................................................... 2-37
Test Procedure ................................................................................................. 2-37
2.2.9 FLOWMETER TEST ............................................................................................. 2-37
Flowmeter Test Procedure ................................................................................. 2-37
2.2.10 CONSUMPTION TEST PROCEDURE .................................................................. 2-37

2.2.11 TRANSMISSION OVERHEATING ........................................................................ 2-38
2.2.12 TROUBLESHOOTING GUIDE .............................................................................. 2-39
2.3 TRANSMISSION .................................................................................................. 2-61

2.3.1 SPECIAL TOOLS ................................................................................................. 2-61
2.3.2 SPECIAL TORQUES ............................................................................................ 2-62
2.3.3 SPECIFICATIONS ................................................................................................ 2-62
2.3.4 DISASSEMBLY .................................................................................................... 2-63
2.3.5 ASSEMBLY .......................................................................................................... 2-74
2.4 FRONT AXLE ....................................................................................................... 2-97

2.4.1 SPECIAL TOOLS ................................................................................................. 2-97
2.4.2 GEAR TOOTH CONTACT PATTERNS ................................................................... 2-98
Ideal Tooth Contact Pattern ............................................................................... 2-98
Pinion Distance Must Be Increased .................................................................. 2-98
Pinion Distance Must Be Decreased ................................................................. 2-99
2.4.3 LUBRICATION ...................................................................................................... 2-100
2.4.4 WEAR MEASUREMENT ON MULTI-DISC BRAKE .............................................. 2-100
2.4.5 WHEEL END AND BRAKE ................................................................................... 2-101
Disassembly ..................................................................................................... 2-101
Assembly ......................................................................................................... 2-107
2.4.6 BRAKE HYDRAULICS LEAKAGE TEST .............................................................. 2-116
High Pressure Test ............................................................................................ 2-116
Low Pressure Test ............................................................................................ 2-116
2.4.7 DISASSEMBLY OF DIFFERENTIAL CARRIER AND BRAKE TUBES .................. 2-117
2.4.8 DISASSEMBLY OF LIMITED SLIP DIFFERENTIAL ............................................ 2-120
2.4.9 DRIVE PINION DISASSEMBLY ........................................................................... 2-121
2.4.10 DISASSEMBLY OF THE BRAKE TUBES ............................................................. 2-122
2.4.11 ASSEMBLY OF BRAKE TUBES AND DIFFERENTIAL CARRIER ........................ 2-123
2.4.12 DIFFERENTIAL CARRIER ASSEMBLY ............................................................... 2-125
Determine Shim Thickness for Correct Tooth Contact Pattern ........................... 2-125
Install the drive pinion ....................................................................................... 2-126
Adjust Rolling Moment of Drive Pinion Bearing ................................................. 2-127
2.4.13 LIMITED SLIP DIFFERENTIAL ASSEMBLY ........................................................ 2-129
Determine the Disc Clearance .......................................................................... 2-130
Adjust Backlash and Bearing Preload ............................................................... 2-132
2.5 REAR AXLE ......................................................................................................... 2-137

2.5.1 SPECIFICATIONS ................................................................................................ 2-137
2.5.2 SPECIAL TORQUES ............................................................................................ 2-137
2.5.3 SPECIAL TOOLS ................................................................................................. 2.137
2.5.4 GEAR TOOTH CONTACT PATTERNS ................................................................... 2-138
Ideal Tooth Contact Pattern ............................................................................... 2-138
Pinion Distance Must Be Increased .................................................................. 2-138
Pinion Distance Must Be Decreased ................................................................. 2-139
2.5.5 LUBRICATION ...................................................................................................... 2-140
2.5.6 WEAR MEASUREMENT ON MULTI-DISC BRAKE .............................................. 2-140
2.5.7 WHEEL END AND BRAKE ................................................................................... 2-141
Disassembly ..................................................................................................... 2-141
Cleaning and Inspection .................................................................................... 2-147
Assembly ......................................................................................................... 2-147
2.5.8 BRAKE HYDRAULICS LEAKAGE TEST .............................................................. 2-157
High Pressure Test ............................................................................................ 2-157
Low Pressure Test ............................................................................................ 2-157

2.5.9 DIFFERENTIAL CARRIER DISASSEMBLY .......................................................... 2-158
2.5.10 DIFFERENTIAL DISASSEMBLY .......................................................................... 2-161
2.5.11 DRIVE PINION DISASSEMBLY ........................................................................... 2-162
2.5.12 BRAKE TUBES REMOVAL .................................................................................. 2-163
2.5.13 BRAKE TUBES INSTALLATION ........................................................................... 2-164
2.5.14 DIFFERENTIAL CARRIER ASSEMBLY ............................................................... 2-166
Determine Shim Thickness for Correct Tooth Contact Pattern ........................... 2-166
Install Drive Pinion............................................................................................ 2-167
Drive Pinion Bearing Rolling Torque Adjustment ................................................ 2-168
2.5.15 DIFFERENTIAL ASSEMBLY ................................................................................ 2-170
Limited Slip Differential ..................................................................................... 2-171
Open Differential ............................................................................................... 2-171
Limited Slip Differential ..................................................................................... 2-172
Open Differential ............................................................................................... 2-172
Determine Disc Clearance ................................................................................ 2-172
Adjust Blacklash and Bearing Preload .............................................................. 2-175
2.6 DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL JOINTS ...................... 2-177
2.6.1 SPECIAL TORQUES ............................................................................................ 2-177
2.6.2 FRONT DRIVE SHAFT ......................................................................................... 2-177
Removal ........................................................................................................... 2-177
2.6.3 FRONT DRIVE SHAFT ......................................................................................... 2-178
Installation ........................................................................................................ 2-178
2.6.4 CENTER BEARING .............................................................................................. 2-179
Removal ........................................................................................................... 2-179
2.6.5 CENTER BEARING .............................................................................................. 2-180
Installation ........................................................................................................ 2-180
2.6.6 CENTER DRIVE SHAFT ...................................................................................... 2-181
Removal ........................................................................................................... 2-181
Installation ........................................................................................................ 2-181
2.6.7 REAR DRIVE SHAFT ........................................................................................... 2-182
Removal ........................................................................................................... 2-182
Installation ........................................................................................................ 2-182
2.6.8 ENGINE DRIVE SHAFT ....................................................................................... 2-183
Removal ........................................................................................................... 2-183
Installation ........................................................................................................ 2-183
2.6.9 UNIVERSAL JOINTS ........................................................................................... 2-184
Removal ........................................................................................................... 2-184
Installation ........................................................................................................ 2-184
2.7 WHEELS AND TIRES ........................................................................................... 2-185

2.7.1 WHEELS AND BOLTS ......................................................................................... 2-185
General Information .......................................................................................... 2-185
Torque Specification ......................................................................................... 2-185
2.7.2 TIRE PRESSURE ................................................................................................ 2-185
2.7.3 CHANGING TIRES ............................................................................................... 2-186
2.7.4 INSTALLING A WHEEL ........................................................................................ 2-186
2.8 TRANSMISSION CONTROL VALVE ..................................................................... 2-187

2.8.1 DISASSEMBLY .................................................................................................... 2-187
2.8.2 INSPECTION ....................................................................................................... 2-191
2.8.3 ASSEMBLY .......................................................................................................... 2-193
W170/W170TC TRANSMISSION 2-1
2.1 REMOVAL AND INSTALLATION OF POWER TRAIN COMPONENTS
2.1.1 TRANSMISSION STEP 2

Removal Put a 25.5 liter (27 quarts) container under transmis-
sion drain plug. Remove drain plug and drain trans-
STEP 1
mission oil. Install drain plug after oil has drained.
Refer to Section 8 and remove ROPS cab or ROPS
canopy.
11
10
7
8
2
1
4
6
3
10
5
13
7
4
6 9
12
5
14
14 13
12
BS03B154
1. Shuttle valve bracket - 2. Load sense tubes - 3. Connector - 4. Bolt - 5. Split flange - 6. Tube -
7. Hose suction - 8. Hose case drain - 9. Fitting - 10. Clamp - 11. Connector - 12. Bolt - 13. Split flange - 14. Hose high
pressure.
2-2 TRANSMISSION W170/W170TC
STEP 3 STEP 8
Identify, tag, and disconnect pump load sensing tubes 17 15
(2). Remove and discard O-ring face seals from fit-
tings (3). Plug tubes and cap fittings to prevent entry
of foreign matter into hydraulic system. Remove shut-
tle valve and bracket (1) from transmission.
STEP 4 18
Remove eight bolts (4) and washers. Remove four

split flanges (5). Disconnect tubes (6) with suction
hoses (7) from hydraulic pump. Remove and discard 16
O-ring face seals from flange heads of tubes. Tag and BD01D306
disconnect case drain hoses (8) from fittings (9). Re-
move and discard O-ring face seals from fittings. Plug Identify, tag, and disconnect brake pump pressure
hoses, tubes, and pump por ts to prevent intrusion of hose (15) and brake to hydraulic reservoir hose (16).
foreign matter into hydraulic system. Position hoses away from transmission. Remove and
discard O-ring face seals from fittings (17 and 18).
STEP 5 Plug hoses and cap fittings to prevent entry of foreign
matter into hydraulic system.
Loosen clamps (10). Disconnect suction hoses (7)
from hydraulic reservoir and remove from machine. STEP 9
Disconnect case drain hoses (8) from fittings (11);
remove hoses (8). Remove and discard O-ring face
seals from fittings. Plug hoses and cap fittings to pre-
vent entry of foreign matter into hydraulic system.
STEP 6
19
split flanges (13). Disconnect pump pressure hoses 20
(14) from hydraulic pump. Remove and discard O-ring
face seals from flange heads of hoses (14). Plug
hoses and pump ports.
BD01D315
STEP 7
Disconnect transmission wiring harness connector (19)
Connect lifting equipment to hydraulic pump. Take up from control valve connector. Remove socket head
all slack in lifting equipment. Remove four mounting bolt securing wiring harness clamp (20). Move wiring
bolts and washers securing pump to transmission. Pull harness away from transmission.
hydraulic pump from transmission and remove from
loader. Remove and discard O-ring from pump.
STEP 10 STEP 13
21
27
BD01D317 BD01D316
Just above where clamp (20) was installed, tag and Remove socket head bolt securing wiring harness
disconnect transmission wiring harness connector (21) clamp (27). Move wiring harness away from transmis-
from torque converter output sender. Move wiring har- sion.
ness away from transmission.
STEP 14
STEP 11
28
22 29
23
BD01D314
BD01D310
Identify, tag, and disconnect transmission wiring har-
Remove two socket head bolts securing transmission ness connectors from filter maintenance switch (28)
wiring harness clamps (22 and 23). and output speed sensor (29). Move transmission wir-
ing harness away from transmission.
STEP 12
STEP 15
24
25
26
31 30
BD01D312
BD01F281
Identify, tag, and disconnect transmission wiring har-
ness connectors from engine speed sensor (24), in- Remove two bolts (30) and washers securing hose
termediate speed sensor (25), and turbine speed sen- retainer (31) to front of rear chassis. Move hose re-
sor (26). Move transmission wiring harness away from tainer towards front of machine.
transmission.
STEP 16 STEP 18
34
46
37 35
36
45
38
BD03A165 BD03A160
At front of transmission, identify, tag, and disconnect Remove two bolts (45). Remove fill tube (46), with
parking brake hose (34) from parking brake (35). Plug cap and oil gauge assembled, two seals, and metal
hose and cap fitting to prevent entry of foreign matter strainer. Discard seals.
into hydraulic system. Move hose away from trans-
mission. Remove four bolts (36) and two straps (37) STEP 19
securing center drive shaft (38) to transmission out-
put flange. Disconnect center drive shaft from trans- 48
mission.
47
STEP 17
41
BD01D318
39 Identify, tag, and disconnect cooler hose (47) from

40 fitting (48) installed in LH side of transmission. Install
a plug in hose. Remove and discard O-ring face seal
from fitting (48).
BD03A161
Remove four bolts (39) and two straps (40) securing STEP 20
rear drive shaft (41) to transmission output flange.
Disconnect rear drive shaft from transmission.
48
BD01D339
Remove fitting (48). Remove and discard O-ring from

fitting. Install a plug in transmission port.
STEP 21 STEP 23
58 57
49
59
60
50 60
61
BD01D340 BD01D342
Repeat Steps 20 and 21 to disconnect cooler hose In area between rear of transmission and front of en-
(49) and remove fitting (50). gine, remove four bolts (57) and two straps (58). Dis-
card bolts (57) and straps (58). Use pry bar to discon-
STEP 22 nect engine drive shaft (59) from transmission. Using
3/4 inch drive socket, extensions, and impact wrench,
remove four bolts (60) and washers securing trans-
mission to top mounting bracket (61).
STEP 24
56
56
64
63
65
BD01D343
Connect lifting equipment to transmission lifting eyes

(56). Take up all slack in lifting equipment.
BD03A163
Remove bolts (64) and washers (65) securing RH and

LH mounting brackets (63) to rear chassis.
STEP 25 STEP 27
67 66
63
62
61
BD01D326 BD01D361
Raise transmission just enough to enable removal of If top mounting bracket (61) requires removal, remove
RH and LH mounting brackets (63). Remove two bolts bolt (66) and washer (67) then remove bracket.
(62) and washers securing RH and LH mounting brack-
ets (63) to transmission. Remove RH and LH mount-
ing brackets.
STEP 26
BD01D345
Slowly and carefully raise transmission from loader

while checking that all hoses, electrical connectors,
and wires have been disconnected and nothing inter-
feres with transmission removal. Remove transmis-
sion from loader.
Transmission Mounting
64,66
65
C 68
B
68
64
66 65
67
65
68
68 62
62
60
61
67
60
68 63
68
65
BS03B153
A. Rear chassis trunnion - B. bracket (61 or 63) - C. Smaller piece on top - 60. Bolt - 61. Top mounting bracket - 62. Bolt -
63. Mounting bracket - 64. Bolt - 65. Washer - 66. Bolt - 67. Washer - 68. Isolator.
Installation STEP 31
STEP 28
Check isolators (68) for deterioration, tears, deforma-
tion, or other damage. Replace as necessary.
STEP 29
63
62
67 66
BD01D326
Install RH and LH mounting brackets (63) on trans-
mission using two washers and bolts (62). Do not
61 tighten bolts.
STEP 32
BD01D361
If top mounting bracket (61) was removed, put bracket

on rear chassis trunnion and secure using washer (67) 64
and bolt (66). Do not tighten bolt. 63
65
STEP 30
BD03A163
Loosely install washers (65) and bolts (64) to secure

RH and LH mounting brackets (63) to rear chassis.
Tighten bolts (62) securing RH and LH mounting brack-
ets to transmission to a torque of 481 to 590 Nm (355
to 435 lb-ft).
BD01D345
Move transmission into position above loader. Slowly

lower transmission into loader.
STEP 33 STEP 35
Note – In this step, new straps (58) and bolts (57)
must be installed whenever these parts are removed.
Bolts have a nylon patch to maintain torque which
requires new bolts.
56
58 57
56
59 66
60 BD01D343
60 Disconnect lifting equipment from transmission lifting

61 eyes (56).
STEP 36
BD01D342
Using 3/4 inch drive socket, extensions, and impact

wrench, install four washers and bolts (60) to secure
top mounting bracket (61) to transmission. Then tighten
bolts (60) to a torque of 251 to 319 Nm (185 to 49
235 lb-ft). If bracket (61) had been removed, tighten
bolt (66) to a torque of 890 to 1000 Nm (655 to
735 lb-ft). Connect engine drive shaft (59) to trans-
mission. Install two new straps (58) and four new bolts 50
(57). Tighten bolts (57) to a torque of 61 to 81 Nm (45
to 60 lb-ft).
BD01D340
STEP 34
Install new O-ring on fitting (50) and install fitting in
transmission. Install new O-ring face seal in fitting
then connect cooler hose (49) to fitting following tag
64 installed during removal. Remove and discard tag.
STEP 37
48
47
BD03A163
Tighten bolts (64) securing RH and LH mounting brack-

ets to a torque of 890 to 1000 Nm (655 to 735 lb-ft).
BD01D318
Install new O-ring on fitting (48) and install fitting in

transmission. Install new O-ring face seal in fitting
then connect cooler hose (47) to fitting following tag
installed during removal. Remove and discard tag.
2 - 10 TRANSMISSION W170/W170TC
STEP 38 STEP 40
34
46
37 35
36
45
38
BD03A160 BD03A165
Position fill tube (46), two new seals, and metal strainer Connect center drive shaft (38) to transmission and
on transmission; metal strainer is installed between install two straps (37) and four bolts (36). Tighten bolts
seals. Secure using two bolts (45). Tighten bolts to a to a torque of 61 to 81 Nm (45 to 60 lb-ft). Connect
torque of 17 to 33 Nm (12 to 24 lb-ft). parking brake hose (34) to parking brake (35) follow-
ing tag installed during removal. Remove and discard
STEP 39 tag.
STEP 41
41
39
40
30
31
BD03A161
Connect rear drive shaft (41) to transmission then in-

BD01F281
stall two straps (40) and four bolts (39). Tighten bolts
to a torque of 61 to 81 Nm (45 to 60 lb-ft). Position hose retainer (31) on front of rear chassis
and secure using two washers and bolts (30).
STEP 42
28
29
BD01D314
Connect transmission wiring harness connectors to

output speed sensor (29) and filter maintenance switch
(28) following tags installed during removal. Remove
and discard tags.
W170/W170TC TRANSMISSION 2 - 11
STEP 43 STEP 46
21
27
BD01D316 BD01D317
Install socket head bolt to secure wiring harness clamp Connect transmission wiring harness connector (21)
(27). to torque converter output sender following tag installed
during removal. Remove and discard tag.
STEP 44
STEP 47
24
25 19
26 20
BD01D312
BD01D315
Connect transmission wiring harness connectors to
turbine speed sensor (26), intermediate speed sensor Install socket head bolt to secure wiring harness clamp
(25), and engine speed sensor (24) following tags in- (20). Connect transmission wiring harness connector
stalled during removal. Remove and discard tags. (19) to control valve connector.
STEP 45 STEP 48
17 15
22
18
23
16
BD01D310 BD01D306
Install two socket head bolts to secure transmission At brake valve, install new O-ring face seals in fit-
wiring harness clamps (23 and 22). tings (18 and 17). Connect brake to hydraulic reser-
voir hose (16) and brake pump pressure hose (15)
following tags installed during removal. Remove and
discard tags.
Note – Refer to art on page 1 for pump and hose STEP 54

components.
STEP 49
Install new O-ring on hydraulic pump flange. Move
pump into position and install in transmission. Install
four washers and bolts to secure pump to transmis-
sion. Disconnect lifting equipment from pump.
STEP 50
At hydraulic pump, remove plugs from pump and high
pressure hoses (14). Install a new O-ring face seals BD01D314
in flange head of hoses (14). Position pump pressure
hoses (14) on pump ports and secure using four split Check that transmission drain plug is tight.
flanges (13) and eight washers and bolts (12).
STEP 55
STEP 51 Fill transmission with oil until oil level is up to the
Remove plugs from hoses and caps from fittings. In- arrow.
stall new O-ring face seals in fitting (11). Connect
hydraulic pump case drain hoses (8) to fittings (11). STEP 56
Position suction hoses (7) between reservoir port and Refer to Section 8 and install ROPS cab or ROPS
hydraulic pump inlet ports. Connect suction hose (7) canopy.
to hydraulic reservoir. Tighten clamp (10).
STEP 57
STEP 52
Start and run engine at idle speed with transmission
At hydraulic pump, remove plugs from hoses (8), in neutral. If transmission oil level is at or below bot-
tubes (6), pump ports, and caps from fittings (9). In- tom of crosshatch region, put articulation lock in
stall new O-ring face seals in fittings (9). Connect LOCKED position and add oil until oil level is up to
pump case drain hoses (8) to fittings (9) following tags crosshatch region. Shut down engine and put articu-
installed during removal. Install new O-ring face seals lation lock in OPERATING position.
in flange head of tubes (6). Position tubes (6) with
hoses (7) on hydraulic pump port. Install four split
flanges (5) and secure using eight washers and bolts
(4).
STEP 53
Remove caps from fittings (3) and plugs from hoses
(2). Instal a new O-ring face seals on fittings (3). Con-
nect hose to fitting following tags installed during re-
moval. Remove and discard tag from hose. Mount
shuttle valve and bracket to transmission.
2.1.2 FRONT AXLE STEP 4

Removal
STEP 1
2
1
3
BD03A167
Remove four bolts (1) and two straps (2) securing front
drive shaft (3) to front axle.
BD03A040
Park machine on level surface. Have assistant put STEP 5

articulation lock in LOCKED position.
4
STEP 2
7
8
5
6
3
9
BD03A166
Remove clamp securing lubrication hose (4) to ma-

chine and nut securing opposite end of hose (4). Re-
BD03A092
move four bolts (5) and two straps (6) securing center
Raise bucket and have assistant install safety link. drive shaft (7) to front drive shaft (3). Use a pry bar to
Lower loader arms slowly until safety link is support- separate drive shafts. While supporting center bear-
ing loader arms. ing (9) and front drive shaft (3), remove four nuts and
bolts (8) and eight washers. Lower center bearing and
STEP 3 front drive shaft from mounting plate and remove from
machine.
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 hy-
draulic circuit. Put key switch in OFF position.
STEP 6 STEP 9
10
11
BD03A168 BD01F297
Disconnect brake hose (10) from elbow (11). Remove Use an acceptable jack to hold front axle.
and discard O-ring face seal from elbow.
STEP 10
STEP 7
12
13
BD01F295
BD01F298
Remove 12 bolts (12) and washers from front wheels
(13). Remove both wheels from front axle.
STEP 11
14
BD01D392
Using an acceptable hydraulic jack, raise one tire from

ground and install an acceptable jack stand under
machine. BD01F296
STEP 8 Remove eight nuts (17) bolts (14), and 16 washers

(15 and 16) securing front axle to machine.
Repeat Step 68 to raise other front axle tire from
ground. STEP 12
Carefully lower front axle and remove from under
machine.
Front Axle Mounting
14
15
18
16
17
BS03B151
14. Bolt - 15. Washer - 16. Washer - 17. Nut - 18. Front axle.
STEP 13
Carefully move front axle under machine and raise
against mounting pads on machine.
STEP 14
14
BD01F297
Remove jack from front axle.
STEP 17
BD01F296
Install eight washers (15), bolts (14), washers (16),

and nuts (17) to secure front axle to machine. Tighten
bolts to a torque of 955 to 1075 Nm (705 to 790 lb-ft).
STEP 15
12
13
BD01F298
BD01F295
BD01D392
Using an acceptable hydraulic jack, raise axle and

remove jack stand from under machine.
STEP 18
B0987A88
Repeat Step 78 to remove other jack stand from un-
der machine.
Install both wheels (13) on front axle and secure us-
ing 10 washers and bolts (12). Tighten bolts to a pre-
liminary torque of 298 Nm (230 lb-ft) in sequence indi-
cated; then tighten to a torque of 640 to 720 Nm (475
to 530 lb-ft) in same sequence.
STEP 19 STEP 21
10
11
1
3
BD03A168 BD03A167
Install a new O-ring face seal in elbow (11). Connect Secure drive shaft (3) to front axle using two straps
brake hose (10) to elbow. (2) and four bolts (1). Tighten bolts (1) to a torque of
61 to 81 Nm (45 to 60 lb-ft).
STEP 20
STEP 22
4 If necessary, fill axle with gear lubricant.
7
8 STEP 23
Bleed brakes.
5
6 STEP 24
3
9
BD03A166
Position and support center bearing (9) and front drive

shaft (3) and install eight washers and four bolts (8)
and nuts. Tighten bolts (8) to a torque of 99 to 128 Nm
(73 to 94 lb-ft). Install two straps (6) and four bolts (5).
Tighten bolts (5) to a torque of 61 to 81 Nm (45 to
60 lb-ft). Secure lubrication hose (4) to machine using
clamp; secure opposite end of hose using nut.
BD03A092
Start engine and raise bucket. Have assistant remove
safety link. Lower bucket to ground and stop engine.
STEP 25
Put articulation lock in OPERATING position.
2.1.3 REAR AXLE STEP 5

Removal
STEP 1
Park machine on a level surface; be sure to allow ad-
equate 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 5
hydraulic circuit.
4
STEP 2 BD03A169
Disconnect brake hose (4) from elbow (5). Remove

and discard O-ring face seal from elbow.
STEP 6
BD03A040
Put articulation lock in LOCKED position.
STEP 3
BD01F299
Install wood blocks between rear axle and chassis to
prevent rear axle from pivoting. Using an acceptable hydraulic jack, raise one tire from
ground and install an acceptable jack stand under
STEP 4 machine. Repeat this step for other tire.
STEP 7
1 2
BD03A162
Remove four bolts (1) and two straps (2). Use a pry BD01F302
bar to disconnect rear drive shaft (3) from rear axle.
Use an acceptable jack to hold rear axle.
STEP 8 STEP 9
8 10
6
A
A
10
9 12
BD01F295 BD03A170
Remove 12 bolts (6) and washers (7) from rear wheels At front of trunnion (9), remove two Allen head bolts
(8). Remove both wheels from rear axle. (10) and washers (11). Remove front cap (12): if nec-
essary use two M12 by 32 mm (1.25 inches) bolts in
puller holes (A); tighten bolts evenly to pull cap from
axle and trunnion. Remove and discard O-ring (15)
from cap. Repeat this step at rear of trunnion except
remove and retain shim(s) (14) after removal of rear
cap (13). Remove pivot shaft (16) using acceptable
sleeve or rod if necessary.
STEP 10
Carefully lower rear axle and remove through side of
machine.
STEP 11
Remove and discard two seals (17) from rear axle
pivot point.
Rear Axle Mounting
10
9 11
12
17
10
15
11
14 7
16
15 18
11
10 17
13 6
11
10
BS01D132
6. Bolt - 7. Washer - 9. Trunnion - 10. Bolt - 11. Washer - 12. Front cap - 13. Rear cap - 14. Shim(s) - 15. O-ring - 16. Pivot
pin - 17. Seal - 18. Rear axle.
Note – If shim(s) (14) have been lost or pivot pin (16)
A
has been replaced, do Step 12 to determine required
shim(s) otherwise go to Step 13.
STEP 12
10 10
9 9
13 16 12
BD01D482A
A B
BS01E091A
Install pivot pin (16) and caps (12 and 13) in trunnion
(9) without rear axle or shim(s). Install washers (11)
and bolts (10). Tighten bolts securely. Push assem-
bled pivot pin and caps to rear of machine as far as
possible. Measure and record gap (A) between rear
cap (13) and trunnion. Select shims from the follow-
BD01D499
ing:
Clean front (A) and rear (B) pivot area of rear axle
Note – Shims are available in following sizes: where seals (17) will be installed.
0.50 mm (0.020 inch), 1.0 mm (0.039 inch), and
1.50 mm (0.059 inch). STEP 14
MEASURED GAP SHIM(S) REQUIRED

A
(mm) (mm)
0.07 to 0.55 None
17
0.56 to 1.09 0.50 12
13
1.10 to 1.59 1.0
1.60 to 2.09 1.50
2.10 to 2.59 0.50 plus 1.50 15 BS01E092
2.60 to 3.02 1.0 plus 1.50

Lubricate two new seals (17) and new O-rings (15).
Install seals, smooth side out, into front and rear of
axle housing (A) until flush with housing or recessed
2.0 mm (0.079 inch). Install an O-ring in each cap (12
and 13).
STEP 15
Carefully move rear axle under machine. Raise axle
into position in trunnion and align pivot holes in trun-
nion with pivot holes in axle.
STEP 16 STEP 18
Remove hydraulic jack supporting rear axle and jack
14 A 12 10 stands supporting loader.
10 13
STEP 19
9 16 9
BS01E091
Lubricate pivot pin (16). At rear of trunnion (9), install 5

pivot pin into trunnion and axle (A). Install shim pack
(14), rear cap (13) with O-ring installed, and two wash- 4
ers and bolts (10). At front of trunnion install front cap BD03A169
(12) with O-ring installed, and two washers and bolts
Install a new O-ring face seal in elbow (5). Connect
(10). Tighten bolts (10) to a torque of 490 to 550 Nm
brake hose (4) to elbow.
(360 to 405 lb-ft).
STEP 20
STEP 17
8
6 3
1 2
BD03A162
BD01F295
Connect rear drive shaft (3) to rear axle. Install two
straps (2) and four bolts (1). Tighten bolts to a torque
of 61 to 81 Nm (45 to 60 lb-ft).
STEP 21
If necessary, fill axle with gear lubricant.
STEP 22
Bleed brakes.
B0987A88 STEP 23
Install both wheels (8) on front axle and secure using Put articulation lock in OPERATING position.
12 washers and bolts (6). Tighten bolts to a prelimi-
nary torque of 298 Nm (220 lb-ft) in sequence indi-
cated; then tighten to a torque of 640 to 720 Nm
(475 to 530 lb-ft) in same sequence.
2.2 TRANSMISSION SPECIFICATIONS, PRESSURE CHECKS,

AND TROUBLESHOOTING
2.2.1 SPECIAL TOOLS

380001743 Transmission supplemental fitting kit.
Includes: 380000509 special 90 degree adapter and 380001749 plug and cap set.
380001739 Master pressure test kit
380001740 Flowmeter kit
380001750 Flowmeter adapter
380001745 Flow test kit
2.2.2 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)
W170 ......................................................................................................................... 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)
1
4
3 2
12
5
9
6
11
14
13
7
10
BS01A190
Component locations systems
1. Transmission electronic control module - 2. Downshift button - 3. Declutch rocker switch - 4. Manual/automatic rocker
switch - 5. Shifter - 6. Supply system connections B+ and return - 7. Transmission - 8. Inductive transmitter - Intermediate
speed sensor - 9. Inductive transmitter - Turbine speed sensor - 10. Inductive transmitter - Engine speed sensor - 11. Hall
sensor - Output speed sensor - 12. Transmission control valve cable - 13. Declutch limit switch - 14. Plug.
12
11
1
2
10
3
10
9
4
15
5
14 6
14
8
7
13
BS03A262
Component locations transmission layout
1. Clutch shaft KR - 2. Power take OFF - 3. Clutch shaft KV - 4. Clutch shaft K2 - 5. Clutch shaft K3 - 6. Output flange rear -
7. Output flange converter side - 8. Output shaft - 9. Transmission pump - 10. Input flange - 11. Converter - 12. Inductive
transmitter for engine speed - 13. Clutch shaft K4 - 14. Converter relief valve - 15. Clutch shaft K1.
2 2
2 2
1
3
4
BS01A191
Component locations front view
1. Attachment for oil filler pipe with oil dipstick - 2. Transmission suspension bores - 3. Output flange converter side - 4. Oil
drain plug.
1
2
3
10
BS01A192
Component locations side view
1. Converter bell housing - 2. Breather - 3. Transmission case cover - 4. Filter head - 5. Filter - 6. Output flange rear - 7. Oil drain
plug - 8. Output flange converter side - 9. Transmission case - 10. Parking brake.
2
1 1
3
7
4 4
BS01B048
Component locations rear view
1. Lifting lugs - 2. Power take off - 3. Transmission control valve - 4. Transmission suspension bores - 5. Output flange rear -
6. Filter - 7. Filter head.
2.2.3 TRANSMISSION OPERATION A. Determines which clutches to engage in the trans-

mission.
General
B. Protects the engine and transmission turbine from
The transmissions for the D series equipment is
overspeed conditions during downloading.
equipped with a Transmission ECM (Electronic Con-
trol Module). This module controls modulation and C. Receives speed information from the engine
shifting that were normally associated with hydrauli- speed sensor, the turbine speed sensor, the in-
cally modulated transmissions, providing smoother termediate clutch speed sensor and the trans-
shifts and enhanced clutch life. mission output speed sensor. These speed sen-
sors are checked to determine if normal sensor
The Transmission ECM relies on signals from sev-
operation is present. The data is also used to
eral solenoids that are incorporated into the design.
control modulation during shifting and to deter-
These solenoids measure the speed of several com-
mine the appropriate shift patterns.
ponents, as well as other sensors that measure tem-
perature. These solenoids and sensors are further D. Detects system failures and determines the ap-
defined in the following paragraphs. propriate alternative actions.
In addition, the transmission incorporates a two-piece E. Provides various diagnostic messages to the In-
transmission case for ease of transmission mainte- formation Center.
nance, helical cut gears that help reduce noise, and
all external hoses have been eliminated (all oil pas- F. Provides other information to the information
sages are internal). center, which in turn displays engine speed, wheel
speed, gear shift selection, and actual gear se-
Transmission ECM lection.
Modulation and shifting are controlled by the Trans- G. Provides a method to calibrate the transmission
mission Electronic Control Module (Transmission clutch control.
ECM). This module replaces the oil and springs that
H. Establishes clutch modulation pressure during
are found in hydraulically modulated transmissions.
transmission shifts.
The Transmission ECM controls the clutch engage-
ment, providing smoother shifts and enhanced clutch Transmission Sensor Data Collection
life, whether the transmission is set to the automatic The Transmission ECM collects and uses informa-
or manual shift mode. tion from four sensors to accurately shift the trans-
The Transmission ECM also informs the Information mission and determine if any clutches are slipping.
Center, by the use of diagnostic codes, of any trans- These sensors are:
mission error and the hours of operation that the er- Engine (Speed) Sensor - monitors engine speed to
ror occurred. determine the load on the engine for shift points and
sends the engine rpm to the Transmission ECM, which
Electrical Shift Solenoids sends the information to the tachometer in the Infor-
Electrical Shift Solenoids control the modulation of mation Center.
the clutches, eliminating the need for a modulation
Turbine (Speed) Sensor - assists the engine speed
valve, and providing a smooth shift while maintaining
sensor in determining the load going into the trans-
constant control over clutch engagement as follows:
mission and helps determine shift points.
A. A temperature sensor relays the oil temperature
Intermediate (Shaft Speed) Sensor - determines dif-
to the Transmission ECM.
ferential gear speed in the transmission to check for
B. The Transmission ECM times the rate the sole- clutch slippage.
noid energizes and de-energizes.
Output (Speed) Sensor - monitors transmission out-
C. As the transmission changes gears, there is re- put shaft speed to help determine the load on the
duced hesitation from one gear to the next. transmission and to assist in determining shift points.
Sends output shaft speed to Transmission ECM which
Transmission ECM Tasks sends the information to the speedometer in the In-
formation Center.
The Transmission ECM performs a variety of tasks in
the overall system. The Transmission ECM:
The transmission ECM also reviews voltage informa- If the Transmission ECM generates a code, the
tion from the shifter and transmission solenoids to wrench over the service manual icon will be displayed
determine if there are any short circuits or open cir- on the Information Center.
cuits in the system.
Transmission Clutch Calibration
Automatic Problem Modes
The Transmission ECM has the capability to find the
If the Transmission ECM detects an error condition in optimal adjustment of the clutch filling parameters for
the transmission system, it will generate a service each individual transmission, providing the ability to
code in the Information Center and will enter one of individually adjust the optimum fill time for the indi-
three modes: vidual transmission in the machine. Clutch Filling
Parameter Calibration is performed on each machine
A. Clutch Modulation Substitute Mode at the plant and should be repeated at the first 250
B. Limp-Home Mode hours of use and every 1000 hours thereafter.
C. Transmission/Transmission ECM Shutdown Mode
Gear Selections
Clutch Modulation Substitute Mode
The transmission in all D Series models provides 4
In this mode, the transmission clutch modulation is forward and 3 reverse gear selections. The transmis-
time dependant rather than load dependant. The sion ratios were designed to give optimized speed
transmission will go into the Clutch Modulation Sub- and torque for each gear selection. The torque con-
stitute Mode if any of the four speed sensors fail. verter is a single stage torque converter (one locking
If the output speed sensor is working and the trans- unit in the torque converter).
mission is in gear, the shift points in Automatic mode
will be speed dependant but the modulation will be a Automatic/Manual Modes
predetermined amount of time. The automatic/manual switch is located on the right
If the output speed sensor is not working and the control panel. The transmission is in automatic mode
transmission is in gear, the shift points will be load when the top of the automatic/manual switch is de-
dependant but the modulation will still be a predeter- pressed. The Transmission Display Center indicates
mined amount of time. when the machine is in the automatic mode.
If the transmission is shifted from neutral into a direc-

tion in the Clutch Modulation Substitute Mode in au-
tomatic, the transmission will shift into 4th gear and
shift down until it gets the correct output speed from
the turbine.
Limp-Home Mode
In this mode, the transmission will go into second gear,
forward or reverse, no matter what gear is selected.
If second gear is not obtainable, the Transmission
ECM selects a series of prioritized gears until an op- W17012001
erable gear is found. The transmission will go into the

Auto/Manual transmission switch
Limp Home Mode if there is a fault on one clutch, a
fault on one clutch valve, or a fault on more than one
Upshifting in Automatic Mode
speed sensor.
Upshifting is determined by machine speed and the
Transmission/Transmission ECM Shutdown Mode torque on the transmission.
In this mode, the Transmission ECM has detected a The transmission will shift from first or second gear
severe failure that disables control of the transmis- up to the highest gear selected as the accelerator is
sion. The transmission will go into Shutdown Mode if depressed, machine speed increases, and required
there is a fault on more than one clutch, a fault on the torque is reduced.
solenoid power supply, or invalid voltage. In this mode,
the Transmission ECM will shut off all solenoid valves
and the power supply and the transmission shifts into
and stays in neutral.
If the machine speed is increasing, but the operator

is not depressing the accelerator (such as when go-
ing down a hill), the transmission will not upshift.
As the operator depresses the accelerator and the
torque on the transmission is lowered, the transmis-
sion 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 W110R0334
decreases and transmission torque increases. For 1. Downshift button.

example, if the unit begins to climb a hill in forth gear
and the machine speed decreases, as the torque re- Automatic Mode
quirement increases, the transmission will downshift
into third, then second, and down to first gear, if nec- In the Automatic Mode, the downshift button only shifts
essary. down. The downshift button allows the operator to
downshift through the entire range of gears. This is
Upshifting in Manual Mode useful in long haul applications or roading.
In the manual mode, the transmission starts out in Each time the button is pushed the transmission will
the selected gear and stays in that gear until the op- instantly downshift one gear from 4th to 3rd, then from
erator selects another gear or direction. The trans- 3rd to 2nd, and then from 2nd to 1st.
mission can be upshifted without reducing engine
The transmission will automatically downshift and then
speed or machine speed.
upshift, as needed, to the last gear that was selected
If the gear selected is two or more gears higher than with the downshift button.
the present gear, the transmission will shift up through
the gears at 2.5 second intervals until the selected Example – If the downshift button was used to shift
gear has been reached. from 4th to 3rd gear, the transmission will automati-
cally shift from 3rd down and then back up to 3rd again.
Downshifting in Manual Mode It will not shift into 4th until the transmission has been
returned to the full range automatic mode.
The transmission can be downshifted in the manual
mode without reducing engine speed or machine
speed.
If 1st gear is selected from 3rd or 4th gear, the transmis-
sion will downshift into 2nd gear for 1.2 seconds and
then will shift into 1st gear.
Downshift Button
The downshift button is located on front of the joy-
stick control lever in machines with a single lever con-
figuration, and on top of the control tower in machines
with a two lever configuration.
With the number of different ways the downshift but-
ton functions, the operator can tailor the use of the
machine to the application at hand.
The transmission will return to the full range automatic Brake Pedal Transmission Declutch
mode when:
A transmission declutch feature concentrates more
A. Another gear is selected. engine power on the loader when digging in heavy or
tough conditions, providing smoother stops and starts.
B. The shifter is moved into neutral and then into Total disconnection of the transmission from the en-
forward or reverse. gine is prevented. This feature will function in 1st, 2nd,
C. The autoshift switch is recycled. or 3rd gear only. It will not function in 4th gear.
Manual Mode
In the manual mode, the downshift button toggles
between 1st and 2nd gear. The manual mode is useful
in short haul operations. In this mode, the downshift
button functions in two ways in 1st and 2nd gear.
When the operator is in 2nd gear and pushes the
downshift button, the transmission instantly shifts into
1st gear. When the operator pushes the downshift but-
ton again, the transmission upshifts into 2nd gear.
W17012003
If the machine is in 2nd gear and the downshift button
is pushed, the transmission instantly shifts into 1st Transmission declutch switch
gear. When the operator shuttles the shifter, the trans-
mission upshifts back into 2nd gear. When the transmission declutch switch is in the on
position and the brake pedal is pushed, the Trans-
Cold Start Protection System mission ECM reduces the pressure to the transmis-
sion forward or reverse clutch.
The transmission has a cold start protection system.
When the transmission sump temperature is minus The Transmission ECM will not completely discon-
10 °C (14 °F), the Transmission ECM will keep the nect the clutch from the engine, but gradually reduces
transmission in neutral. the forward or reverse clutch pressure down to a lower
level.
When the transmission sump temperature warms up
to minus 10 °C (14 °F) (within approximately one When the brake pedal is released, the Transmission
minute), the machine will operate in all gears. 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 re-
verse clutch pressure will gradually increase up to
system clutch pressure.
2.2.4 TRANSMISSION PRESSURE TEST POINTS DIAGRAM
DESIGNATION ON
No. IDENTIFICATION/LOCATION CONNECTION
VALVE BLOCK
Measuring Points for Pressure Oil and Temperature
51 Before the Converter - Opening Pressure 8 bar (116 psi) M10x1 H
52 Behind the Converter - Opening Pressure 2.5 bar (36 psi) M14x1.5
53 Clutch Forward 16+2 bar (232 + 29 psi) KV M10x1 B
55 Clutch Reverse 16+2 bar (232 + 29 psi) KR M10x1 E
56 Clutch 16+2 bar (232 + 29 psi) K1 M10x1 D
57 Clutch 16+2 bar (232 + 29 psi) K2 M10x1 A
58 Clutch 16+2 bar (232 + 29 psi) K3 M10x1 C
60 Clutch 16+2 bar (232 + 29 psi) K4 M10x1 F
63 Behind the Converter Temperature 100 °C, Short Time 120 °C M14x1/5
65 System Pressure 16+2 bar (232 + 29 psi) M10x1 K
Measuring Points for Delivery Rates
15 Connection to the Heat Exchanger 1 5/16” - 12 UNF-2B
16 Connection from the Heat Exchanger 1 5/16” - 12 UNF-2B
Inductive Transmitter and Speed Sensor
21 Inductive Transmitter for Turbine Speed M18x1.5
34 Output Speed Sensor
47 Inductive Transmitter for Central Gear Train Speed M18x1.5
48 Inductive Transmitter for Engine Speed M18x1.5
Connections
49 Plug Connection on the Hydraulic Control Unit
68 System Pressure M16x1.5 G
69 Pilot Pressure M16x1.5 J
Note – See next page for Measuring Point, Transmitter, Sensor and Connection locations.
65 51 68
69 49
57
60
53 55
VIEW X
58 56
VIEW X
48
47 21
16
16 15
15
VIEW Y
52
52
63 63
VIEW Y
34
• PRESSURE REGULATOR UNDER VOLTAGE
FORWARD REVERSE NEUTRAL
CLUTCH PRESSURE REGULATOR 1 2 3 4 1 2 3
KV Y5 • • •
KR Y2 • • •
K1 Y3 • •
K2 Y6 • •
K3 Y4 • • •
K4 Y1 •
BC01B047
Measuring points and connections
2.2.5 CHART FOR RECORDING PRESSURE READINGS

Use this chart to record the pressure readings.
P.I.N. Number: Date:

TEST POINTS
Shift P V R 1 2 3 4 5 6 LP
Speed 65 53 55 56 57 58 60 51 52
1st F
2nd F
3rd F
4th F
1st R
2nd R
3rd R
Neut
LP. Lube pressure - P. Main pressure - R. Reverse clutch - V. Forward clutch - 1. First gear clutch - 2. Second gear clutch -
3. Third gear clutch - 4. Fourth gear clutch - 5. Converter in - 6. Converter out.
2.2.6 PRESSURE TEST RESULTS Not Enough Power

All or Most Pressures Low and/or Flow Test Possible causes include:
Low 1. Check Electrical Troubleshooting in this Section to
Possible causes include: verify actual gear selected.
1. Oil level not correct. 2. Engine RPM below Stall Test specified RPM.
2. Oil type and grade not correct. A. Check engine and fuel system for problem.
3. Oil operating temperature high. B. Check that torque converter installation is cor-
rect.
4. Screen for suction tube plugged.
3. Engine RPM above Stall Test specified RPM.
5. Suction tube or gaskets leak.
A. Check converter pressures and flow.
6. Main pressure valve, springs, or valve bore.
B. Check that torque converter installation is cor-
7. Reduction valve, springs, or valve bore.
rect.
8. Charge pump seals or gaskets leak.
Machine Stops or Hesitates While Shifting -
9. Charge pump worn.
Intermittent
10. Oil supply flange not sealing correctly.
Possible causes include:
Some Pressures Low 1. Check orifice and O-ring.
Possible causes include: 2. Check for foreign material plugging orifices or stick-
ing valves.
1. Circuit isolation does not correct low pressure.
3. Check for reduced pressure at test pressure points.
A. Control valve or gasket.
4. See Electrical Troubleshooting in this Section for
B. Channel plate or gasket.
electrical system problem.
2. Circuit isolation corrects low pressure.
A. Clutch shaft or seals.
B. Clutch drum or piston.
2.2.7 CONVERTER OUT PRESSURE 2.2.9 FLOWMETER TEST

CHECK Test Equipment Required
Test Equipment Required 380001740 Flowmeter Kit; 380001750 Flowmeter
0 to 28 bar (406 psi) gauge with hose long enough to Adapter.
take readings in the cab and 380000509 Special
Adapter. Flowmeter Test Procedure
1. Block the machine tires.
Test Procedure
2. Apply the parking brakes.
1. Block the machine tires.
3. Heat the oil to an operating temperature of 80 to
2. Apply the parking brakes. 100 °C (176 to 212 °F).
3. Install the pressure gauge. 4. Remove the filter and install the 380001750 adapter.
4. Heat the oil to an operating temperature of 80 to 5. Install the flowmeter between the adapter and the
100 °C (176 to 212 °F). filter.
5. While in the cab, put the transmission in NEUTRAL. 6. While in the cab, run the engine at full throttle. Put
Run the engine at full throttle. Record the reading the transmission in NEUTRAL and record the flow
in the chart on page 35. Pressure must be a mini- measurement. The correct flow is 80 L/min (21 U.S.
mum of 3.5 to 6.5 bar (51 to 94 psi). gpm) at 2000 rpm.
2.2.8 LUBRICATION PRESSURE CHECK 2.2.10 CONSUMPTION TEST PROCEDURE

Test Equipment Required 1. Block the machine tires.
0 to 7 bar (101 psi) gauge. 2. Apply the parking brakes.
Test Procedure 100 °C (176 to 212 °F).
1. Block the machine tires. 4. Install the flowmeter to converter outlet line (line to
2. Apply the parking brakes. cooler) in series.
3. Install the pressure gauge in the cooler return line 5. While in the cab, run the engine at full throttle. Put
at the transmission. the transmission in NEUTRAL and record the flow
measurement. The flow must be 9.1 L/min (2 U.S.
gpm).
100 °C (176 to 212 °F).
6. Repeat the procedure with the transmission in
5. While in the cab, run the engine at full throttle. Put
FORWARD in third gear. The flow must be
the transmission in each gear and record the read-
9.1 L/min (2 U.S. gpm).
ing in the chart on page 35. Pressure must be 0.2
to 1.2 bar (2.9 to 17.4 psi). 7. Repeat the procedure with the transmission in RE-
VERSE in third gear. The flow must be 9.1 L/min
(2 U.S. gpm).
2.2.11 TRANSMISSION OVERHEATING

1. Operate machine in normal operating conditions and
observe:
A. Verify actual oil temperature at test point. Nor-
mal operating temperature can be 56 °C (133 °F)
above the ambient temperatures.
B. Use a stop watch to establish the exact length
of time required to reach the overheating condi-
tion.
C. Observe engine temperature, does the engine
overheat? Which overheats first - engine or
transmission?
2. When the transmission reaches overheated con-
dition, 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.
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.
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.
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 pos-
sible cause of any test results not within specifica-
tions.
2.2.12 TROUBLESHOOTING GUIDE
The diagnosis of possible operating malfunctions on The error codes are composed of two decimal digits.
the transmission group can be performed using the The first one indicates the type of signal, the second
display indicated here below tool 380001297. Under the signal and the type of error
engine operating conditions and gearshift selector in
neutral position, the troubles are displayed by symbol
"g" and the showing of an alpha-numerical code iden-
tifying the type of failure. Definition of error codes
First digit Meaning of digit
1 hex Input digital signal
2 hex Input analogical signal
h f ed left right
3 hex Speed signal
digit digit
4 hex CAN error signal
7 hex Output current analogical signal
8 hex Output current analogical signal
9 hex Output analogical signal
A hex Output analogical signal
a bc g B hex Transmission error. Clutch error
C hex Logic error
D hex Power supply
E hex High speed signal
F hex General error
The display must be connected through harness Please find here below some symbols relative to dif-
380001297 provided to the socket indicated located ferent operating conditions of the machine and the
behind the plastic panel in the cab, behind the opera- list of trouble codes with their meaning and the possi-
tor's seat. ble repair intervention.
"EST-37A" ELECTRONIC CONTROLLER
The transmission control unit consists of a control A continuous regulation of the parameters constantly
electronic unit EST-37A and a hydraulic control unit. ensures a high quality of the gearshifting.
The EST-37A electronic control unit, connected to a
32-bit microprocessor, controls the gearshifting se- Also, the software includes extended functions to en-
quence of the transmission. The optimised modulat- sure the line of command and to support the diagnos-
ing pressure is calculated for each gearshifting as a tic system. The control electronic unit has a CAN in-
function of the load and the speed for the clutch interface for the exchange of data with the vehicle and
volved. engine electronic system.
Technical specifications:
Nominal voltage: 24 Volt
Max. current absorbed: 10 Amp
Operating temperature: -40 °C (- 40 °F)
through + 70 °C (158 °F)
Protection class: IP54
Weight: 0.9 kg
Identification
plate
Protections:
The controller is protected against
s
Connection
- short-circuits
- voltage jumps
- wrong connections
START-UP PROCEDURE OF TRANSMISSION

ELECTRONIC CONTROLLER
In order to optimise the operational parameters of the The determination of the filling parameters, in fact, pro-
transmission it is necessary to start-up the controller vides the optimisation of the tolerances, the disc play,
every time one of the following conditions occur: the pressure level inside the clutches and the filling
- disassembly/assembly of the transmission; speed of the clutches during the gearshifting.
- replacement of an electronic component or a trans- The start-up of the controller is possible using the fol-
mission component. lowing tooling:
The same procedure should be performed when the
modulation of the gearshifting is insufficient. AEB Starter (tool No. 380000818)
In fact, the clutch packs, after a certain use, have dif- DISPLAY (tool No. 380001297)
ferent plays from the original values.
DISPLAY
380001297
AEB-STARTER
380000818
W190-2R001
Connection of the transmission start-up tooling.
The display and the AEB must be connected to the sockets indicated, located behind the plastic panel of
the cab, behind the operator's seat.
Introduction
Abbreviations
o.c. open circuit
s.c. short circuit
OP-Mode operating mode
TCU transmission control unit
EEC electronic engine controller
PTO power take off
ZF - Display:
If a fault is detected, the display shows a spanner symbol (g) for a fault. The display shows the fault code, if the
gear selector is on neutral position.
If more than one fault is detected, each fault code is shown for about 1 second.
left right
h f e d character character
S
T
O
P
a b c g
(special symbols a-h)
Display during operation
Symbol meaning remarks

1F, 1R actual gear and direction
2F, 2R left digit shows actual gear
3F, 3R right digit shows actual direction
4F
5F
6F
LF, LR limp home gear
F or R, no gear Clutch Cutoff
F or R flashing direction F or R selected while turbine CAUTION gear will engage if turbine speed
speed is too high drops
NN not neutral, waiting for neutral after to engage a gear, first move shift selector to
power up or a severe fault neutral position and again to F or R position
** oil temperature too low, no gear warm up engine / transmission
available
*N oil temperature low, only one gear warm up engine / transmission
available
Symbol Meaning Remarks

st
1 bar (special symbol) Manual mode 1 gear
2 bars Manual mode 2nd gear
3 bars Manual mode 3rd gear
4 bars Manual mode 4th gear and also 5th
and 6th gear in 6WG
4 bars and 2 arrows Automatic mode
Bars flashing 6 WG: converter lockup clutch open Difference of engine and turbine speed above a
4 WG: Downshift mode activ certain limit and lockup clutch not activated
Spanner At least one fault activ Select neutral to get fault code displayed
Fault code See faultcode list
WS Warning sump temperature Changes between actual gear/direction
while driving, in neutral only displayed if no
fault is detected (spanner)
WR Warning retarder temperature Changes between actual gear/direction
WT Warning torque converter temperature Changes between actual gear/direction
WE Warning high engine speed Changes between actual gear/direction
PN Direction F or R selected while Transmission in neutral until parking brake
parking brake engaged is releasedCAUTION: vehicle starts to move
after release of parking brake
EE flashing No communication with display Checked wiring from TCU to display
Display during AEB-Mode
Symbol Meaning Remarks

PL AEB - Starter is plugged at the
diagnostic plug
ST AEB-Starter-button is pressed
K1..K4,KV,KR Calibrating clutch K1..K4, KV or KR
resp.
_ and Kx Wait for start, initialization of clutch
Kx, x: 1, 2, 3, 4, V, R
≡ and Kx Fast fill time determination of clutch Kx
= and Kx Compensating pressure determination
of clutch Kx
OK Calibration for all clutches finished Transmissions stays in neutral, you have
to restart the TCU (ignition off/on) after
removing AEB-Starter
STOP AEB canceled (activation stopped) Transmissions stays in neutral, you have
to restart the TCU (ignition off/on)
STOP and Kx AEB stopped, clutch Kx can't be Transmissions stays in neutral, you have
calibrated to restart the TCU (ignition off/on)
Spanner and Kx Kx couldn't be calibrated, AEB Transmissions stays in neutral, you have
finished to restart the TCU (ignition off/on)
∆E Engine speed too low,
ï raise engine speed
∇E Engine speed too high,
ï lower engine speed
∆T Transmission oil temperature too low,
ï heat up transmission
∇T Transmission oil temperature too high
ï cool down transmission
FT Transmission temperature not in Transmissions stays in neutral, you have
defined range during calibration to restart the TCU (ignition off/on)
FB Operating mode not NORMAL or Transmissions stays in neutral, you have
transmission temperature sensor to restart the TCU (ignition off/on)
defective or storing of Calibrated
values to EEPROM-has failed.
FO Outputspeed_not_zero Transmissions stays in neutral, you have
FN Shift lever not in Neutral position Transmissions stays in neutral, you have
FP Parkbrake_not_applied Transmissions stays in neutral, you have
STOP AEB - Starter was used incorrect Transmissions stays in neutral, you have
or is defective. Wrong device or to restart the TCU (ignition off/on)
wrong cable used
DEFINITION OF OPERATING MODES

NORMAL:
There's no failure detected in the transmission-system or the failure has no or slight effects on transmission
control. TCU will work without or in special cases with little limitations. (see following table)
SUBSTITUTE CLUTCH CONTROL:

TCU can't change the gears or the direction under the control of the normal clutch modulation. TCU uses the
substitute strategy for clutch control. All modulations are only time controlled. (Comparable with EST 25)
LIMP-HOME:
The detected failure in the system has strong limitations to transmission control. TCU can engage only one
gear in each direction. In some cases only one direction will be possible.
TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator must shift
the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into forward
or reverse, the TCU will select the limp-home gear .
If output speed is less than a threshold for reversal speed and TCU has changed into the limp-home gear and
the operator selects a shuttle shift, TCU will shift immediately into the limp-home gear of the selected direc-
tion.
If output speed is greater than the threshold, TCU will shift the transmission into neutral. The operator has to
slow down the vehicle and must shift the gear selector into neutral position.
TRANSMISSION-SHUTDOWN:
TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1). Transmis-
sion shifts to Neutral. The park brake will operate normally, also the other functions which use ADM 1 to ADM
8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
TCU-SHUTDOWN:
TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The park brake will
engage, also all functions are disabled which use ADM 1 to ADM 8.
The transmission will stay in neutral.
TABLE OF FAULT CODES 2 - 46
Fault
MEANING OF THE FAULT CODE
Code SPN FMI reaction of the TCU possible steps to repair remarks
possible reason for fault detection
(hex)
11 5000 12 LOGICAL ERROR AT GEAR RANGE TCU shifts transmission to • check the cables from TCU to shift lever failure cannot be
SIGNAL TCU detected a wrong neutral • check signal combinations of shift lever detected in systems with
signal combination for the gear range OP-Mode: transmission • positions for gear range DW2/DW3 shift lever
• cable from shift lever to TCU is broken shutdown
• cable is defective and is contacted to fault is taken back if TCU
• battery voltage or vehicle ground detects a valid signal for
• shift lever is defective the position
12 5010 12 LOGICAL ERROR AT DIRECTION TCU shifts transmission to • check the cables from TCU to shift lever fault is taken back if TCU
SELECT SIGNAL neutral • check signal combinations of shift lever detects a valid signal for
TCU detected a wrong signal combination OP-Mode: transmission • positions F-N-R the direction at the shift
for the direction shutdown lever
• cable from shift lever to TCU is broken
• cable is defective and is contacted to
• battery voltage or vehicle ground
• shift lever is defective
13 5020 12 LOGICAL ERROR AT ENGINE after selecting neutral, TCU • check engine derating device This fault is reset after
DERATING DEVICE changes to OP-Mode limp power up of TCU
TCU detected no reaction of engine home
while derating device activ
TRANSMISSION
15 5040 12 LOGICAL ERROR AT DIRECTION TCU shifts transmission to • check the cables from TCU to shift fault is taken back if TCU
SELECT SIGNAL 2. SHIFT LEVER neutral if selector activ • lever 2 detects a valid neutral
TCU detected a wrong signal combination OP-Mode: transmission • check signal combinations of shift lever signal for the direction
for the direction shutdown if selector activ • positions F-N-R at the shift lever
• cable from shift lever 2 to TCU is broken
• battery voltage or vehicle ground
• shift lever is defective
16 5050 12 LOGICAL ERROR AT AXLE OP-Mode: normal • check the cables from TCU to
CONNECTION feedback axle connection • feedback axle connection switch
measured by TCU and output signal axle • check signals of the feedback axle
connection don't fit • connection switch
• axle can't be connected or
• disconnected due to mechanical
• problem
• one of the cables from feedback
• axle connection -switch to TCU is
• broken
W170/W170TC
Fault
(hex)
17 5060 4 S.C. TO GROUND AT SPEED SIGNAL customer specific • check the cable from TCU to speed
7 KM/HTCU detected a wrong voltage at • signal 7 km/h device
W170/W170TC
the output pin, that looks like a s.c. • check the connectors from speed
to vehicle ground: • signal 7 km/h to TCU
• cable is defective and is contacted to • check the resistance of speed signal
• vehicle ground • 7 km/h device
• speed signal 7 km/h device has an
• internal defect
• connector pin is contacted to vehicle
• ground
18 5060 3 S.C. TO BATTERY VOLTAGE AT SPEED customer specific • check the cable from TCU to speed
SIGNAL 7 KM/H • signal 7 km/h device
TCU detected a wrong voltage at the • check the connectors from speed signal
output pin, that looks like a s.c. to • 7 km/h to TCU
battery voltage: • check the resistance of speed signal
• cable is defective and is contacted to • 7 km/h device
• battery voltage
• speed signal 7 km/h device has
• an internal defect
• connector pin is contacted to battery
• voltage
TRANSMISSION
19 5060 5 O.C. AT SPEED SIGNAL 7KM/HTCU customer specific • check the cable from TCU to speed
detected a wrong voltage at the output • signal 7 km/h device
pin, that looks like a o.c. for this output pin: • check the connectors from speed signal
• cable is defective and has no • 7 km/h device to TCU
• connection to TCU • check the resistance of speed signal
• speed signal 7 km/h device has an • 7 km/h device
• internal defect
• connector has no connection to TCU
25 5110 3 S.C. TO BATTERY VOLTAGE OR O.C. no reaction, • check the cable from TCU to the sensor
AT TRANSMISSION SUMP TCU uses default • check the connectors
TEMPERATURE SENSOR INPUT temperature • check the temperature sensor
the measured voltage is too high: OP-Mode: normal
• cable is defective and is contacted
• to battery voltage
• cable has no connection to TCU
• temperature sensor has an internal
• defect
2 - 47
• voltage or is broken
Fault
2 - 48
(hex)
26 5110 4 S.C. TO GROUND AT TRANSMISSION no reaction, • check the cable from TCU to the sensor
SUMP TEMPERATURE SENSOR INPUT TCU uses default • check the connectors
the measured voltage is too low: temperature • check the temperature sensor
• cable is defective and is contacted to OP-Mode: normal
• vehicle ground
• temperature sensor has an internal
• defect
• ground
29 5130 3 S.C. TO BATTERY VOLTAGE OR O.C. TCU uses default value • check the cable from TCU to the sensor
AT PARKING BRAKE SENSOR INPUT OP-Mode: normal • check the connectors
the measured voltage is too high: • check the parking brake sensor
• battery voltage
• sensor has an internal defect
• voltage or is broken
2A 5130 4 S.C. TO GROUND PARKING BRAKE TCU uses default value • check the cable from TCU to the sensor
SENSOR INPUT OP-Mode: normal • check the connectors
the measured voltage is too low: • check the parking brake sensor
TRANSMISSION
• vehicle ground
• sensor has an internal defect
• ground
2B 5313 12 INCHSENSOR-SIGNAL MISMATCH During inching mode: TCU • check the cable from TCU to the sensor
the measured voltage from CCO and shifts to neutral • check the cable from TCU to the sensor
CCO2 signal don't match: While not inching: • check the connectors
• cable is defective no change • check sensor
• sensor has an internal defect OP-Mode: normal
31 5140 3 S.C. TO BATTERY VOLTAGE OR O.C. OP-Mode: substitute clutch • check the cable from TCU to the sensor
AT ENGINE SPEED INPUT control • check the connectors
TCU measures a voltage higher than • check the speed sensor
7.00 V at speed input pin
• battery voltage
• speed sensor has an internal defect
W170/W170TC
• voltage or has no contact

Fault
(hex)
32 5140 4 S.C. TO GROUND AT ENGINE SPEED OP-Mode: substitute clutch • check the cable from TCU to the sensor
INPUT control • check the connectors
W170/W170TC
TCU measures a voltage less than 0.45V • check the speed sensor
at speed input pin
• cable / connector is defective and is
• contacted to vehicle ground
33 5140 12 LOGICAL ERROR AT ENGINE SPEED OP-Mode: substitute clutch • check the cable from TCU to the sensor This fault is reset after
INPUT control • check the connectors power up of TCU
TCU measures a engine speed over • check the speed sensor
a threshold and the next moment the • check the sensor gap
measured speed is zero
• cable / connector is defective and has
• bad contact
• sensor gap has the wrong size
AT TURBINE SPEED INPUT control • check the connectors
TCU measures a voltage higher than if a failure is existing at • check the connectors
7.00 V at speed input pin output speed,TCU shifts to • check the speed sensor
• cable is defective and is contacted to neutral
TRANSMISSION
• battery voltage OP-Mode: limp home

35 5150 4 S.C. TO GROUND AT TURBINE SPEED OP-Mode: substitute clutch • check the cable from TCU to the sensor
INPUT control • check the connectors
TCU measures a voltage less than 0.45V if a failure is existing at • check the speed sensor
at speed input pin output speed,
• cable / connector is defective and is TCU shifts to neutral
• contacted to vehicle ground OP-Mode: limp home
36 5150 12 LOGICAL ERROR AT TURBINE SPEED OP-Mode: substitute clutch • check the cable from TCU to the sensor This fault is reset after
INPUT control • check the connectors power up of TCU
TCU measures a turbine speed over a if a failure is existing at • check the speed sensor
threshold and at the next moment the output speed, • check the sensor gap
measured speed is zero TCU shifts to neutral
• cable / connector is defective and has OP-Mode: limp home
2 - 49
• bad contact
Fault
2 - 50
(hex)
AT INTERNAL SPEED INPUT control • check the connectors
TCU measures a voltage higher than • check the speed sensor
7.00 V at speed input pin
• battery voltage
38 5160 4 S.C. TO GROUND AT INTERNAL OP-Mode: substitute clutch • check the cable from TCU to the sensor
SPEED INPUT control • check the connectors
TCU measures a voltage less than 0.45V • check the speed sensor
at speed input pin
• cable / connector is defective and is
39 5160 12 LOGICAL ERROR AT INTERNAL OP-Mode: substitute clutch • check the cable from TCU to the sensor This fault is reset after
TRANSMISSION
SPEED INPUT control • check the connectors power up of TCU

TCU measures a internal speed over • check the speed sensor
a threshold and at the next moment the • check the sensor gap
measured speed is zero
• cable / connector is defective and has
• bad contact
3A 5170 3 S.C. TO BATTERY VOLTAGE OR O.C. special mode for gear • check the cable from TCU to the sensor
AT OUTPUT SPEED INPUT selection • check the connectors
TCU measures a voltage higher than OP-Mode: substitute clutch • check the speed sensor
12.5 V at speed input pin control
• cable is defective and is contacted to if a failure is existing at
• battery voltage turbine speed,
• cable has no connection to TCU TCU shifts to neutral
• speed sensor has an internal defect OP-Mode: limp home
W170/W170TC
Fault
(hex)
3B 5170 4 S.C. TO GROUND AT OUTPUT SPEED special mode for gear • check the cable from TCU to the sensor
INPUT selection • check the connectors
W170/W170TC
TCU measures a voltage less than 1.00V OP-Mode: substitute clutch • check the speed sensor
at speed input pin control
• cable / connector is defective and is if a failure is existing at
• contacted to vehicle ground turbine speed,
• speed sensor has an internal defect TCU shifts to neutral
OP-Mode: limp home
3C 5170 12 LOGICAL ERROR AT OUTPUT SPEED special mode for gear • check the cable from TCU to the sensor This fault is reset after
INPUT selection • check the connectors power up of TCU
TCU measures a output speed over OP-Mode: substitute clutch • check the speed sensor
a threshold and at the next moment the control • check the sensor gap
measured speed is zero if a failure is existing at
• cable / connector is defective and has turbine speed,
• bad contact TCU shifts to neutral
3E 5180 2 OUTPUT SPEED ZERO DOESN'T FIT special mode for gear • check the sensor signal of output This fault is reset after
TO OTHER SPEED SIGNALS selection • speed sensor power up of TCU
if transmission is not neutral and the OP-Mode: substitute clutch • check the sensor gap of output speed
shifting has finished, control • sensor
TRANSMISSION
TCU measures outputspeed zero and if a failure is existing at • check the cable from TCU to the sensor
turbine speed or internal speed not turbine speed,
equal to zero. TCU shifts to neutral
54 5260 9 DCT1 TIMEOUT OP-Mode: normal • check display computer
Timeout of CAN-message DCT1 from • check wire of CAN-Bus
display computer • check cable to display computer
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and
• has contact to vehicle ground or
• battery voltage
71 5480 3 S.C. TO BATTERY VOLTAGE AT TCU shifts to neutral • check the cable from TCU to the
CLUTCH K1 OP-Mode: limp home • gearbox
the measured resistance value of the if failure at another clutch • check the connectors from TCU to the
valve is out of limit, the voltage at K1 is pending • gearbox
valve is too high. TCU shifts to neutral • check the regulator resistance
2 - 51
Fault
2 - 52
(hex)
• cable / connector is defective and has OP-Mode: TCU shutdown • check internal wire harness of the
• contact to battery voltage • gearbox
• regulator has an internal defect
72 5480 4 S.C. TO GROUND AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the
the measured resistance value of the OP-Mode: limp home • gearbox
valve is out of limit, the voltage at K1 if failure at another clutch • check the connectors from gearbox
valve is too low. is pendingTCU shifts to • to TCU
• cable / connector is defective and has neutral • check the regulator resistance
• contact to vehicle ground OP-Mode: TCU shutdown • check internal wire harness of the
• cable / connector is defective and has • gearbox
• contact to another regulator output
• of the TCU
73 5480 5 O.C. AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the
valve is out of limit. if failure at another clutch • check the connectors from gearbox
• cable / connector is defective and has is pending • to TCU
• no contact to TCU TCU shifts to neutral • check the regulator resistance
• regulator has an internal defect OP-Mode: TCU shutdown • check internal wire harness of the
• gearbox
TRANSMISSION
the measured resistance value of the if failure at another clutch • check the connectors from gearbox
valve is out of limit, the voltage at K2 is pending • to TCU
valve is too low. is pending • to TCU
• cable / connector is defective and has TCU shifts to neutral • check the regulator resistance
• contact to another regulator output of
• the TCU
W170/W170TC
Fault
(hex)
W170/W170TC
• gearbox
valve is out of limit, the voltage at K3 is pendingTCU shifts to • to TCU
valve is too high. neutral • check the regulator resistance
TRANSMISSION

• contact to another regulator output
• of the TCU
• no contact to TCU is pending • check the regulator resistance
• regulator has an internal defect TCU shifts to neutral • check internal wire harness of the
OP-Mode: TCU shutdown • gearbox
valve is out of limit, the voltage at K4 is pending • to TCU
2 - 53

Fault
2 - 54
(hex)
• the TCU
83 5510 5 O.C. AT CLUTCH K4the measured TCU shifts to neutral • check the cable from TCU to the
resistance value of the valve is out OP-Mode: limp home • gearbox
of limit. if failure at another clutch • check the connectors from gearbox
• gearbox
CLUTCH KV OP-Mode: limp home • gearbox
valve is out of limit, the voltage at KV is pending • to TCU
TRANSMISSION
85 5520 4 S.C. TO GROUND AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the
valve is out of limit, the voltage at KV if failure at another clutch • check the connectors from gearbox
• the TCU
86 5520 5 O.C. AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the
W170/W170TC

Fault
(hex)
• gearbox
W170/W170TC
CLUTCH KR OP-Mode: limp home • gearbox
valve is out of limit, the voltage at KR is pending • to TCU
88 5530 4 S.C. TO GROUND AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the
valve is out of limit, the voltage at KR if failure at another clutch • check the connectors from gearbox
• the TCU
TRANSMISSION
89 5530 5 O.C. AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the
• gearbox
91 5560 4 S.C. TO GROUND AT RELAY REVERSE backup alarm will be on • check the cable from TCU to the
WARNING ALARM until TCU power down • backup alarm device
TCU detected a wrong voltage at the even if fault vanishes • check the connectors from backup
output pin, that looks like a s.c. to vehicle (loose connection) • alarm device to TCU
ground OP-Mode: normal • check the resistance of backup
• cable is defective and is contacted • alarm device
• to vehicle ground
• backup alarm device has an internal
• defect
• ground
2 - 55
Fault
2 - 56
(hex)
92 5560 3 S.C. TO BATTERY VOLTAGE AT RELAY no reaction • check the cable from TCU to the
REVERSE WARNING ALARM OP-Mode: normal • backup alarm device
TCU detected a wrong voltage at the • check the connectors from backup
output pin, that looks like a s.c. to battery • alarm device to TCU
voltage • check the resistance of backup
• cable is defective and is contacted to • alarm device
• battery voltage
• defect
• voltage
93 5560 5 O.C. AT RELAY REVERSE WARNING no reaction • check the cable from TCU to the
ALARM TCU detected a wrong voltage OP-Mode: normal • backup alarm device
at the output pin, that looks like a o.c. for • check the connectors from backup
this output pin • alarm device to TCU
• cable is defective and has no • check the resistance of backup
• connection to TCU • alarm device
• defect
• connector has no connection to TCU
B1 5660 2 SLIPPAGE AT CLUTCH K1 TCU shifts to neutral • check pressure at clutch K1
TCU calculates a differential speed at OP-Mode: limp home • check main pressure in the system
TRANSMISSION
closed clutch K1. If this calculated value if failure at another clutch • check sensor gap at internal speed
is out of range, TCU interprets this as is pending • sensor
slipping clutch. TCU shifts to neutral • check sensor gap at output speed
• low pressure at clutch K1 OP-Mode: TCU shutdown • sensor
• low main pressure • check signal at internal speed sensor
• wrong signal at internal speed sensor • check signal at output speed sensor
• wrong signal at output speed sensor • replace clutch
• wrong size of the sensor gap
• clutch is defective
W170/W170TC
Fault
(hex)
W170/W170TC
TCU calculated a difference speed at OP-Mode: limp home • check main pressure in the system
TCU calculates a differential speed if failure at another clutch • check sensor gap at internal speed
at closed clutch K4. If this calculated is pending • sensor
value is out of range, TCU interprets this TCU shifts to neutral • check sensor gap at turbine speed
as slipping clutch. OP-Mode: TCU shutdown • sensor
• low pressure at clutch K4 • check signal at internal speed sensor
• low main pressure • check signal at turbine speed sensor
• wrong signal at internal speed sensor • replace clutch
• wrong signal at turbine speed sensor
TRANSMISSION

B5 5680 2 SLIPPAGE AT CLUTCH KV TCU shifts to neutral • check pressure at clutch KV
closed clutch KV. If this calculated value if failure at another clutch • check sensor gap at internal speed
slipping clutch. TCU shifts to neutral • check sensor gap at turbine speed
• low pressure at clutch KV OP-Mode: TCU shutdown • sensor
• wrong signal at internal speed sensor • check signal at turbine speed sensor
• wrong signal at turbine speed sensor • replace clutch
B6 5685 2 SLIPPAGE AT CLUTCH KR TCU shifts to neutral • check pressure at clutch KR
closed clutch KR. If this calculated value if failure at another clutch • check sensor gap at internal speed
slipping clutch. TCU shifts to neutral • check sensor gap at turbine speed
2 - 57
• low pressure at clutch KR OP-Mode: TCU shutdown • sensor

Fault
2 - 58
(hex)
• wrong signal at internal speed sensor • check signal at turbine speed sensor
• wrong signal at turbine speed sensor • replace clutch
B7 5700 0 OVERTEMP SUMP no reaction • cool down machine
TCU measured a temperature in the oil OP-Mode: normal • check oil level
sump that is over the allowed threshold. • check temperature sensor
BA 5730 0 DIFFERENTIAL PRESSURE OIL FILTER no reaction • check oil filter
TCU measured a voltage at differential OP-Mode: normal • check wiring from TCU to differential
pressure switch out of the allowed range • pressure switch
• oil filter is polluted • check differential pressure switch
• cable/connector is broken or cable/ • (measure resitance)
• connector is contacted to battery
• voltage or vehicle ground
• differential pressure switch is defective
C3 5760 0 OVERTEMP CONVERTER OUTPUT no reaction • cool down machine
TCU measured a oil temperature at the OP-Mode: normal • check oil level
converter ouput that is over the allowed • check temperature sensor
TRANSMISSION
threshold.
D1 5810 3 S.C. TO BATTERY VOLTAGE AT POWER see fault codes no. 21 to 2C • check cables and connectors to fault codes no. 21 to no.
SUPPLY FOR SENSORS • sensors, which are supplied from AU1 2C may be a reaction of
TCU measures more than 6V at the pin • check the power supply at the pin AU1 this fault
AU1 (5V sensor supply) • (should be appx. 5V)
D2 5810 4 S.C. TO GROUND AT POWER SUPPLY see fault codes no. 21 to 2C • check cables and connectors to fault codes no. 21 to no. 2C
FOR SENSORS • sensors, which are supplied from AU1 may be a reaction of this
TCU measures less than 4V at the pin • check the power supply at the pin AU1 fault
AU1 (5V sensor supply) • (should be appx. 5V)
D3 5820 4 LOW VOLTAGE AT BATTERY shift to neutral • check power supply battery
measured voltage at power supply is OP-Mode: TCU shutdown • check cables from batteries to TCU
lower than 10 V (12V device) • check connectors from batteries to TCU
lower than 18 V (24V device)
D4 5820 3 HIGH VOLTAGE AT BATTERY shift to neutral • check power supply battery
measured voltage at power supply is OP-Mode: TCU shutdown • check cables from batteries to TCU
higher than 18 V (12V device) • check connectors from batteries to TCU
W170/W170TC
higher than 32.5 V (24V device)

Fault
(hex)
D5 5830 2 ERROR AT VALVE POWER SUPPLY VPS1 shift to neutral • check fuse
TCU switched on VPS1 and measured OP-Mode: TCU shutdown • check cables from gearbox to TCU
W170/W170TC
VPS1 is off or TCU switched off VPS1 • check connectors from gearbox to TCU
and measured VPS1 is still on • replace TCU
• cable or connectors are defect and are
• contacted to battery voltage
• permanent power supply KL30 missing
• TCU has an internal defect
D6 5840 2 ERROR VALVE POWER SUPPLY VPS2 shift to neutral • check fuse
TCU switched on VPS2 and measured OP-Mode: TCU shutdown • check cables from gearbox to TCU
VPS2 is off or TCU switched off VPS2 • check connectors from gearbox to TCU
and measured VPS2 is still on • replace TCU
• contacted to battery voltage
• permanent power supply KL30 missing
TRANSMISSION
• TCU has an internal defect

E3 5860 3 S.C. TO BATTERY VOLTAGE AT no reaction • check the cable from TCU to the display
DISPLAY OUTPUT OP-Mode: normal • check the connectors at the display
TCU sends data to the display and • change display
measures allways a high voltage level
on the connector
• cable or connectors are defective and
• are contacted to battery voltage
• display has an internal defect
E4 5860 4 S.C. TO GROUND AT DISPLAY OUTPUT no reaction • check the cable from TCU to the display
TCU sends data to the display and OP-Mode: normal • check the connectors at the display
measures allways a high voltage level • change display
on the connector
• cable or connectors are defective and
• are contacted to vehicle ground
• display has an internal defect
2 - 59
Fault
2 - 60
(hex)
E5 5270 9 DISPID1_TIMEOUT TCU select parameter set • check display controller
Timeout of CAN-message DISPID1 from with ID0 • check wire of CAN-Bus
display controller OP-Mode: Limp Home • check cable to display controller
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and
• has contact to vehicle ground or
• battery voltage
E6 5880 2 ILLEGAL ID REQUEST VIA CAN transmission stay neutral
OP-Mode: TCU shutdown
F1 5890 2 GENERAL EEPROM FAULT no reaction • replace TCU often shown together
TCU can't read non volantile memoy OP-Mode: normal with fault code F2
• TCU is defective
F2 5900 13 CONFIGURATION LOST transmission stay neutral • Reprogramm the correct configuration
TCU has lost the correct configuration OP-Mode: TCU shutdown • for the vehicle (e.g. with cluster
and can't control the transmission. • controller,...)
• interference during saving data on
• non volatile memory
• TCU is brand new or from another
TRANSMISSION
• vehicle
F3 5910 13 APPLICATION ERROR transmission stay neutral • replace TCU !! This fault occurs only if
something of this application is wrong OP-Mode: TCU shutdown an test engineer did
something wrong in the
application of the vehicle
F5 5930 7 CLUTCH FAILURE transmission stay neutral • check clutch TCU shows also the
AEB was not able to adjust clutch filling OP-Mode: TCU shutdown affected clutch on the
parameters Display
• One of the AEB-Values is out of limit
F6 5930 13 CLUTCH ADJUSTMENT DATA LOST default values = 0 for AEB • execute AEB
OR INCHPEDAL CALIBRATION DATA offsets used
LOST OP-Mode: normal
TCU was not able to read correct clutch no Inchmode available
adjustment parameters
• interference during saving data on non
• volatile memory
• TCU is brand new
W170/W170TC
2.3 TRANSMISSION
2.3.1 SPECIAL TOOLS
380001559 380001560 380001577 380001568

Transmission Torque Transmission Input/ Transmission valve Transmission output
Converter Seal Output shaft seal adjustment tool set shaft seal installation
Installation Tool installation tool tool
BS02C093 THRU 096
380001554 380001556 380001558

Nesting plate Clutch pack holder and Alignment dowel set
spring compressor tools
380001555 380001557 380001567

Gear puller collet set Clutch assembly Clutch spring
holding knob set compressor
BS02C097 THRU 104
2.3.2 SPECIAL TORQUES

Oil pipes
Studs ..................................................................................................................................... 9 Nm (80 lb-in)
Socket head screw ............................................................................................................. 23 Nm (204 lb-in)
Screw plug ............................................................................................................................ 51 Nm (38 lb-ft)
Clutch K1, K2, K3, K4 Stud .................................................................................................... 17 Nm (150 lb-in)
Plugs ....................................................................................................................................... 25 Nm (221 lb-in)
Output shaft
Output shaft screws (apply Loctite 243 to threads) ............................................................. 23 Nm (204 lb-in)
Housing cover screws (apply Loctite 574 to threads) .......................................................... 46 Nm (407 lb-in)
Output flange screws .......................................................................................................... 34 Nm (301 lb-in)
Oil feed housing and transmission pump
Transmission pump screws ................................................................................................. 46 Nm (407 lb-in)
Oil feed housing screws ...................................................................................................... 25 Nm (221 lb-in)
Engine connection and converter
Input shaft screws .............................................................................................................. 115 Nm (85 lb-ft)
Converter housing screws ..................................................................................................... 68 Nm (50 lb-ft)
Cover ................................................................................................................................... 23 Nm (204 lb-in)
Converter cover .................................................................................................................. 46 Nm (407 lb-in)
Input flange .......................................................................................................................... 34 Nm (301 lb-in)
Duct plate
Screws ................................................................................................................................ 25 Nm (221 lb-in)
Screw plug .......................................................................................................................... 30 Nm (265 lb-in)
Hydraulic control unit .............................................................................................................. 9.5 Nm (84 lb-in)
Filter
Filter head screws ............................................................................................................... 25 Nm (221 lb-in)
Oil distribution cover screws ............................................................................................... 25 Nm (221 lb-in)
Speed sensor and inductive transmitter
Speed sensor screw ........................................................................................................... 23 Nm (204 lb-in)
Inductive transmitter ........................................................................................................... 30 Nm (265 lb-in)
Cover plate ......................................................................................................................... 23 Nm (204 lb-in)
Screw plug ........................................................................................................................ 140 Nm (103 lb-ft)
Clutch KV and KR plate clearance ................................................................. 2.7 to 2.9 mm (0.106 to 0.114 in)
Clutch K1plate clearance ............................................................................... 2.4 to 2.6 mm (0.094 to 0.102 in)
Clutch K2 and K3 plate clearance .................................................................. 1.8 to 2.0 mm (0.071 to 0.079 in)
Clutch K4 plate clearance .............................................................................. 1.2 to 1.4 mm (0.047 to 0.055 in)
Note – The manufactured reserves the right to make improvements in design or changes in specifications at any
time without incurring any obligation to install them on units previously sold.
2.3.4 DISASSEMBLY STEP 4

STEP 1
GD98M837
GD98M833 Remove two socket head screws and install

380001577 transmission valve adjustment tool set.
Fasten transmission on an assembly stand using
Remove remaining 21 socket head screws securing
transmission mounting brackets.
control valve. Loosen and remove hex rods (part of
STEP 2 380001577) from studs then remove control valve.
STEP 5
GD98M835
Remove and discard oil filter. GD98M838
STEP 3 Remove both gaskets and the intermediate plate.
STEP 6
GD98M836
Remove hex head screws securing filter head. Re- GD98M839

move filter head from transmission.
Remove socket head screws and hex nuts. Remove
duct plate. Remove flat gasket.
STEP 7 STEP 10
GD98M844 GD98M847
Bend lock plate away from hex head screws. Remove Using proper size rod, press input shaft and converter
two hex head screws, lock plate, and washer. Remove from cover.
input flange from shaft.
STEP 11
STEP 8
GD98M848
GD98M845
Remove retaining ring then remove bearing.
Put alignment marks on converter cover and housing
to aid in assembly. Remove 12 nuts and hex head STEP 12
screws.
STEP 9
GD98M849
Remove four hex head screws and remove diaphragm

and input shaft.
GD98M846
Connect suitable lifting equipment to shaft. Remove

cover, shaft, and converter from transmission and
place in hydraulic press.
STEP 13 STEP 16
GD98M850 GD98M853
Put input shaft and diaphragm in vise as shown. Re- Remove the socket head screws for removal of the
move 12 hex head screws to separate diaphragm and transmission pump.
input shaft.
STEP 17
STEP 14
GD98M854
GD98M851
Apply a bearing separator on the splines shoulder of
Remove the inductive transmitter. the stator shaft and pull the pump out of the housing
bores, using two-leg puller.
STEP 15
Note – If traces of wear should be encountered in the
pump housing or the cam disk, the complete pump
has to be replaced.
STEP 18
GD98M852
Remove the hex head screws and remove the con-

verter housing.
GD98M855
Separate the transmission pump from stator. Sepa-

rate the cam plate from pump.
STEP 19 STEP 23
Turn the transmission 180 degrees and remove the
rear output flange.
STEP 24
GD98M856
Remove the hex head screws and remove the oil feed
housing. Remove the flat gasket.
STEP 20 GD98M862
Remove the speed sensor and both inductive trans-

mitters.
STEP 25
GD98M860
Remove the hex head screws, cover, and flat gasket.
STEP 21
GD98M863
Remove the hex nuts and the two covers.
STEP 26
GD98M861
Remove the lock plate, hex head screws, and pry the
converter side output flange from the shaft.
STEP 22 GD98M864
Pry the shaft seal out of the housing bore. Install 380001558 alignment dowel set.
Note – The following steps describe the common re-

moval of all clutches.
STEP 27 STEP 30
Remove 380001557 clutch assembly holding knob set
and lift cover free.
STEP 31
BK00D029
Install 380001557 clutch assembly holding knob set.

With knobs installed on all clutches in housing cover,
install lifting eyebolt set and lifting device to trans-
mission cover. GD98M867
Remove the socket head screws and remove the out-

STEP 28
put shaft and both oil baffle plates.
STEP 32
BK00D028
Separate the cover along with clutches from the trans-

mission housing, using lifting device. GD98M872
Remove clutch K2.

STEP 29
STEP 33
BK00D026
Place clutch disc carriers onto 380001554 nesting GD98M873
plate.
Remove clutch K1 while lifting clutch K4.
STEP 34 STEP 37
GD98M874 GD98M877
Remove clutch K3. Remove the bearing outer race and pull output shaft
out of the housing bore.
STEP 35
STEP 38
GD98M875
Remove clutch K4 while lifting input shaft slightly.

GD98M878
STEP 36 Remove the rectangular ring and separate ball bear-

ing from the shaft.
Note – The following steps are for the disassembly of

the clutch KV. The disassembly of the clutch KR is
similar.
STEP 39
GD98M876
Remove clutches KV and KR together with input shaft.
GD98M879
Remove the sealing ring. Pull the tapered roller bear-

ing from the shaft. Remove the opposite tapered roller
bearing.
STEP 40 STEP 43
GD98M881 BK00D020
Separate the clutch disc carrier from the shaft. Remove snap ring.
STEP 41 STEP 44
GD98M882 BK00D019
Remove the snap ring and remove the clutch disc Remove the compression spring.
pack.
STEP 45
STEP 42
GD98M885
BK00D018
Preload compression spring using 380001556 clutch Remove piston from clutch pack holder. Remove and
pack holder and spring compressor tool. discard the O-rings from piston.
STEP 46 STEP 48
GD98M886 GD98M889
Remove the snap ring. Remove the snap ring and remove the ball bearing.
STEP 47 Note – The following steps are for disassembly of

clutch K3. Disassembly of clutches K1 and K2 is simi-
lar.
STEP 49
GD98M887
GD98M890
Remove the rectangular ring. Pull the tapered roller

bearing from the shaft.
STEP 50
GD98M888
Press the idler gear from the shaft using a bearing

separator. Remove released needle bearing.
GD98M892
Remove the thrust washer, thrust bearing, and thrust

washer.
STEP 51 STEP 54
GD98M893 BK00D018
Remove the idler gear. Preload compression spring using 380001556 clutch
pack holder and spring compressor tool.
STEP 52
STEP 55
GD98M894
BK00D020
Remove the needle bearings and thrust bearing.
Remove the snap ring.
STEP 53
STEP 56
GD98M895
BK00D019
Remove the snap ring and remove the clutch disc
pack. Remove the compression spring.
STEP 57 STEP 59
BS00G001 GD98M800
Remove the sealing ring. Remove bearing using bear- Remove and discard two sealing rings. Pull two bear-
ing puller. Tap assembly until piston drops out of the ings from shaft using bearing puller. Remove the snap
clutch pack carrier. Then, remove and discard O-rings ring and separate the clutch disc carrier from the shaft.
from piston.
STEP 60
STEP 58
GD98M801
BK00D022
Remove the snap ring and remove the clutch disc
Remove the clutch disc carrier from the shaft. pack.
Note – The following steps are for the disassembly of STEP 61

the clutch K4.
BK00D018
Preload compression spring using 380001556 clutch

pack holder and spring compressor tool.
STEP 62 STEP 64
BK00D020 GD98M803
Remove the snap ring. If turbine shaft is to be removed from input shaft, use
proper size diameter sleeve or rod and press turbine
STEP 63 shaft out of input shaft.
STEP 65
Remove bearings from input shaft using a bearing
puller.
BK00D019
Remove the compression spring.
Note – The following two steps are for disassembly of

the input shaft.
Note – A snap ring is used to lock turbine shaft in

input shaft. Snap ring will be destroyed when turbine
shaft is pressed from input shaft.
2.3.5 ASSEMBLY STEP 69

Note – The following steps are for the reassembly of
the oil pipes.
STEP 66
20
GD98M607
Install a new O-ring on plug. Tighten the plug to a

3 torque of 51 Nm (37.6 lb-ft).
STEP 70
GD98M603
Install suction tube (1), pressure pipes (2), and lubri-

cation pressure pipe (3) in housing.
STEP 67
Secure suction tube (1) and pressure pipes (2) with GD98M608
socket head screw and hex nuts. Tighten to a torque
of 23 Nm (204 lb-in). Install all bearing outer races in housing bores.
STEP 68 STEP 71
GD98M609
GD98M605
Tilt the cover 180 degrees. Install the suction tubes Install both oil pipes into the housing cover. Tilt the
and pressure pipes into the housing bores using a cover 180 degrees and install pipes into the housing
rolling tool. bores using a rolling tool.
Note – Pipe end of the pressure pipes must be slightly Note – The pipe end must be slightly below the hous-
below the housing plane face. ing plane face.
STEP 72 STEP 75
GD98M610 BK00D019
Install the studs. Tighten the studs to a torque of

9 Nm (80 lb-in).
Note – The following steps are for the assembly of

clutches KV and KR, starting with assembly of the
clutch disc carrier.
STEP 73
BK00D018
Install compression spring and two spring cups in

clutch disc carrier. Preload compression spring using
380001556 clutch pack holder and spring compres-
sor tool.
STEP 76
GD98M612
Check that drain hole is clear and free of foreign mat-

ter. Install both O-rings in recesses of the piston and
apply oil.
STEP 74
BK00D020
Install the snap ring.
Note – The following steps are for the KV and KR

clutch disc packs. The disc stacking of clutches KV
and KR is identical.
GD98M613
Install piston in clutch disc carrier.
STEP 77 STEP 79
A 5
3 3
6
2 7
GD98M617
Install end shim and snap ring.

4 225B
STEP 80
A. Running clearance 2.7 to 2.9 mm (0.106 to 0.114 in) -
1. Plate carrier - 2. Piston - 3. Outer plate - one-sided
coated - 4. Inner plates - 5. Outer plates - coated on both
sides - 6. Snap ring - 7. End shim.
Install clutch disc plates in KV and KR clutch disc

carriers in position and sequence shown above. In-
stall outer plates (3) with steel faced side facing pis-
ton and end shim (7).
Note – Snap rings of different thickness are available

for adjustment of the running clearance. To ensure cor-
rect adjustment, do not apply oil to clutch discs until GD98M618
after adjustment is completed.
Adjust running clearance to 2.7 to 2.9 mm (0.106 to
STEP 78 0.114 in). Press down on the end shim with approxi-
mately 10 kg (20 lb). Measure and record dimension
(A) from carrier face to end shim using depth gauge
as shown.
Example
Dimension A ................................ 7.25 mm (0.29 in)
GD98M616
Install the clutch disc pack.
STEP 81 STEP 84
GD98M619 GD98M621
Use tools to lift the end shim against snap ring (up- Apply Loctite 243 to stud. Tighten stud to a torque of
ward) until contact is obtained. Measure and record 17 Nm (150 lb-in).
dimension (B) from carrier face to end shim using
depth gauge as shown. Subtract this measurement STEP 85
from the measurement of Step 80. The difference is
the running clearance.
Example
Dimension A ................................ 7.25 mm (0.29 in)
Dimension B ................................ 4.45 mm (0.18 in)
Difference = Running ................... 2.80 mm (0.11 in)
Clearance
Required running clearance is 2.7 to 2.9 mm (0.106 to

0.114 in). Use snap ring(s) of different thickness as
necessary to obtain correct running clearance. GD98M622
Install ball bearing until contact is obtained. Secure

STEP 82 using snap ring.
Remove clutch disc pack, apply oil to discs, and in-
stall clutch disc pack, end shim, and snap ring as STEP 86
determined in Step 81.
STEP 83
GD98M623
Install needle bearing.

GD98M620
Install idler gear to align and engage all inner discs,

then remove idler gear.
STEP 87 STEP 90
GD98M624 BP00G020
Support the idler gear on the bearing inner race. Press Install gear and shaft into heated bore.
the idler gear against the shoulder.
STEP 91
STEP 88
BK00D024
GD98M625
Heat bearing.
Secure idler gear using snap ring.
STEP 92
STEP 89
WARNING
Always wear heat protective gloves to prevent
burning your hand when handling heated parts.
BK00D023
Use heat gun to heat assembled clutch disc carrier

inner bore.
BK00D025
Install heated bearing on shaft against shaft shoul-

der.
STEP 93 STEP 96
Check operation of the clutch using compressed air.
Note – The following steps are for assembly of clutch

K1, K2, and K3.
STEP 94
GD98M632

ter. Install both O-rings in recesses of piston and ap-
ply oil.
STEP 97
GD98M630
Press bearing against shoulder of shaft. Apply Loctite

243 to the stud and install the stud. Tighten the stud
to a torque of 17 Nm (150 lb-in).
STEP 95
GD98M633
Install piston in clutch disc carrier.
STEP 98
GD98M631
Install the clutch disc carrier until contact is obtained.
GD98M634
Install the compression spring and spring cup.
STEP 99 STEP 101
A 5
3
6
2
7
1
BK00D018
4
232A
A. Clutch K1 running clearance 2.4 to 2.6 mm (0.094 to

0.102 in); clutches K2 and K3 running clearance 1.8 to
2.0 mm (0.071 to 0.079 in) - 1. Plate carrier - 2. Piston -
3. Outer plate - one-sided coated - 4. Inner plates -
5. Outer plates - coated on both sides - 6. Snap ring -
7. End shim.
Install clutch disc plates in K1, K2, and K3 clutch

disc carriers in position and sequence shown above.
BK00D018 Install outer plate (3) with steel faced side facing pis-
ton.
Install compression spring and two spring cups in
clutch disc carrier. Preload compression spring using
380001556 clutch pack holder and spring compres-
for adjustment of the running clearance. To ensure cor-
sor tool.
rect adjustment, do not apply oil to clutch discs until
after adjustment is completed.
STEP 100
STEP 102
BK00D020
Install the snap ring. GD98M636
Install the clutch disc pack.

Note – The following steps are for K1, K2 and K3
clutches. The assembly of clutches K1, K2, and K3
is identical except for running clearance dimensions.
STEP 103 STEP 105
GD98M637 GD98M639
Install the end shim and snap ring. Use tools to lift the end shim against snap ring (up-
ward) until contact is obtained. Measure and record
STEP 104 dimension (B) from carrier face to end shim using
depth gauge as shown. Subtract this measurement
Example
Dimension A .................................. 8.2 mm (0.32 in)
Dimension B .................................. 6.1 mm (0.24 in)
Difference = Running Clearance ..... 2.1 mm (0.08 in)
Required running clearance for K1 is 2.4 to 2.6 mm

(0.094 to 0.102 in); for K2 and K3 required running
GD98M638 clearance is 1.8 to 2.0 mm (0.071 to 0.079 in). Use
Adjust running clearance for K1 to 2.4 to 2.6 mm (0.094 snap ring(s) of different thickness as necessary to
to 0.102 in); adjust running clearance for K2 and K3 to obtain correct running clearance.
1.8 to 2.0 mm (0.071 to 0.079 in). Press down on the
end shim with approximately 10 kg (20 lb). Measure STEP 106
and record dimension (A) from carrier face to end shim Remove clutch disc pack, apply oil to discs, and in-
using depth gauge as shown. stall clutch disc pack, end shim, and snap ring as
Example
Dimension A .................................. 8.2 mm (0.32 in) STEP 107
3
2
1
GD98M640
Install the thrust washer (1), thrust bearing (2), and

thrust washer (3).
Note – Install the thrust washer (1) with the chamfer

facing the thrust bearing.
STEP 108 STEP 111
GD98M641 BK00D024
Install both needle bearings. Heat bearing.
STEP 109 STEP 112
WARNING
GD98M642
Install idler gear until all inner discs are engaged.
STEP 110
BK00D025
1
2 Place heated bearing on the shaft.
3 STEP 113
GD98M643
Install the thrust washer (3), thrust bearing (2), and

thrust washer (1). Install the thrust washer (1) with the
chamfer facing the thrust bearing.
Note – Ensure the thrust washer (1) is overlapping

with the chaff collar to accommodate all the inner
discs.
Note – The following steps are for assembly of clutch STEP 116
K4.
STEP 114
WARNING
GD98M649
Apply Loctite 243 to the stud and install the stud.

Tighten the stud to a torque of 17 Nm (150 lb-in).
STEP 117
GD98M647
Heat the gear to about 120 °C (248 °F) and install until
seated in position.
STEP 115
GD98M650

ter. Install both O-rings in recesses of the piston and
apply oil.
STEP 118
GD98M648
Install retaining ring to secure gear.
GD98M651
Install piston in clutch disc carrier. Be sure piston

bottoms out.
STEP 119 STEP 121
A 5
6
3
2
7
1
BK00D019
4
BS02C131
A. Running clearance 1.2 to 1.4 mm (0.047 to 0.055 in) -

1. Plate carrier - 2. Piston - 3. Outer plate - one-sided
coated - 4. Inner plates - 5. Outer plates - coated on both
sides - 6. Snap ring - 7. End shim.
Install clutch disc plates in K4 clutch disc carrier in

position and sequence shown above. Install outer plate
(3) with steel faced side facing piston.
BK00D018
Install compression spring and two spring cups in for adjustment of the running clearance. To ensure cor-
clutch disc carrier. Preload compression spring using rect adjustment, do not apply oil to clutch discs until
380001556 clutch pack holder and spring compres- after adjustment is completed.
sor tool.
STEP 122
STEP 120
GD98M653
BK00D020
Install clutch disc pack.
Install snap ring.
Note – The following steps are for installing the clutch

disc pack in clutch K4.
STEP 123 STEP 125
GD98M654 GD98M656
Install end shim and snap ring. Use tools to lift the end shim against snap ring (up-
ward) until contact is obtained. Measure and record
STEP 124 dimension (B) from carrier face to end shim using
depth gauge as shown. Subtract this measurement
Example
Dimension A .................................. 7.2 mm (0.28 in)
Dimension B .................................. 6.0 mm (0.24 in)
Difference = Running ..................... 1.2 mm (0.04 in)
Clearance
Required running clearance is 1.2 to 1.4 mm (0.047 to

GD98M655 0.055 in). Use snap ring(s) of different thickness as
Adjust running clearance to 1.2 to 1.4 mm (0.047 to necessary to obtain correct running clearance.
0.055 in). Press down on the end shim with approxi-
mately 10 kg (20 lb). Measure and record dimension STEP 126
(A) from carrier face to end shim using depth gauge Remove clutch disc pack, apply oil to discs, and in-
as shown. stall clutch disc pack, end shim, and snap ring as
Example
Dimension A .................................. 7.2 mm (0.28 in) STEP 127
GD98M657
Install the idler gear until all inner discs are engaged,
then remove idler gear.
STEP 128 STEP 131

1
2
3
GD98M658 GD98M661
Assemble two thrust washers and thrust bearing. Assemble thrust washer (3), thrust bearing (2), and
thrust washer (1). Install the thrust washer (1) with the
Note – Upper and lower thrust washers are the same chamfer facing the thrust bearing.
thickness.
STEP 132
STEP 129
GD98M662
GD98M659 Install the assembled clutch disc carrier until all the
Install both needle bearings. inner discs are engaged.
STEP 130 STEP 133
GD98M660 GD98M663
Install the idler gear. Install snap ring to secure clutch disc carrier.
STEP 134 STEP 138
WARNING
BK00D024
Heat bearing.
STEP 135
GD98M666
WARNING
Heat gear to about 120 °C (248 °F) and install on input
Always wear heat protective gloves to prevent shaft until contact is obtained.
STEP 139
BK00D025
GD98M667
Install heated bearing on the shaft shoulder.
Secure gear with snap ring.
STEP 136
STEP 140
Repeat Steps 134 and 135 to install bearing on oppo-
site end of shaft.
STEP 137

the input shaft.
GD98M668
Install snap ring into recess of turbine shaft.
STEP 141 STEP 144
GD98M669 GD98M672
Install the turbine shaft until the snap ring snaps into Install output shaft into housing bore until contact is
the recess of the input shaft. made.
STEP 142 Note – The following steps are for the installation of
the output shaft and clutches. All clutches have a
common installation.
WARNING
Always wear heat protective gloves to prevent STEP 145
K4 KR
K1 AN
AB
K3 K2
KV
GD98M673
BK00D024
Install bearing outer races into housing cover until
Heat bearings and install on turbine shaft until bear- contact is obtained.
ings are against shoulder.
STEP 146
STEP 143
BK00F003
GD98M671
Install the clutches onto 380001554 nesting plate.
Install bearing then install rectangular ring.
STEP 147 STEP 150
BK00D029 GD98M681
Using lifting eye bolt set and acceptable lifting equip- Install the sealing rings and insert rings in their re-
ment, install housing cover onto clutches. Install spective grooves. Apply grease to the sealing rings
380001557 clutch assembly holding knob set to se- and align the rings centrally.
cure clutch shafts to cover.
STEP 151
STEP 148
KR
KV
K4
K2
K1 K3
GD98M692
GD98M679
Install both the O-rings into the annular groove of the
The above photo shows the position of the single oil pipes and apply grease.
clutches in the housing cover.
STEP 152
STEP 149
Tilt the housing cover 180 degrees.
KV AN KR
K2 K4
K1
K3
AB
GD98M866
The above shows the position of the single clutches

and the input and output clutches.
STEP 153 STEP 156
BK00d028 GD98M686
Install output gear and shaft in transmission housing. Install screen sheet on output shaft. Press front and
Install alignment screws. Carefully lower the cover and rear bearings on output shaft until contact with shoul-
clutches into the gear box housing. der of output shaft is made.
STEP 154 STEP 157

Remove 380001557 clutch assembly holding knob set.
STEP 155
GD98M688
Install the screening plate.
GD98M685 STEP 158

Separate the housing cover from the gearbox, using
a lifting device.

the output shaft.
GD98M689
Install the output shaft.
STEP 159 STEP 162
GD98M690 GD98M697
Apply Loctite 243 to the socket head screws and Heat the output flange to about 90 °C (194 °F). Apply
install the screws. Tighten the screws to a torque of Loctite 574 to the contact area and assemble the flange
23 Nm (204 lb-in). with the washers and hex head screws. Tighten the
screws to a torque of 34 Nm (301 lb-in). Bend corner
STEP 160 of lock plate over hex head screws.
STEP 163
Repeat Steps 161 and 162 to install shaft seal and
output flange on converter side.
Note – The following steps are for the assembly of

the oil feed housing and transmission pump.
STEP 164
GD98M691
Install rectangular rings in grooves of clutch shafts.

Apply grease to rings and align rings.
STEP 161
GD98M702
Install two alignment studs and install the gasket.
GD98M696
Position shaft seal with sealing lip facing oil chamber.

Apply grease to sealing lip. Use 380001560 transmis-
sion output shaft seal installation tool to install seal.
STEP 165 STEP 168
GD98M703 GD98M706
Install the oil feed housing with washers and hex head Install transmission pump.
screws. Screw the hex head screws in only until con-
tact is obtained, do not tighten. STEP 169
STEP 166
GD98M707
Apply grease to new O-rings. Install the O-rings on

GD98M704
the socket head screws.
Install the two alignment screws and install the stator
shaft. STEP 170
STEP 167
GD98M708
Secure the transmission pump with the socket head

GD98M705
screws. Tighten screws to a torque of 46 Nm (407 lb-
Apply oil and install the O-ring. in).
STEP 171 STEP 173
GD98M709 GD98M712
Install the oil feed housing with the hex head screws Position converter housing. Secure with hex head
and flat washers. Tighten the screws to a torque of 25 screws. Tighten the screws to a torque of 68 Nm
Nm (221 lb-in). (50 lb-ft).
STEP 172 STEP 174
GD98M711 GD98M713
Position the gasket and cover. Secure the cover with Put input shaft in a vise as shown. Position diaphragm
the hex head screws. Tighten the screws to a torque on input shaft and secure using 12 hex head screws.
of 23 Nm (204 lb-in). Tighten screws to a torque of 115 Nm (85 lb-ft).
Note – The following steps are for the assembly of STEP 175
the engine connection and converter.
GD98M714
Position diaphragm and input shaft on converter. Ap-

ply Loctite 262 to threads of hex head screws. Install
screws and tighten to a torque of 115 Nm (85 lb-ft).
STEP 176 STEP 178
GD98M715 GD98M718
Position converter cover on converter housing. Make

sure alignment marks made during removal of cover
are aligned. Install input flange, two hex head screws,
lock plate, and washer. Pull cover against housing by
tightening two hex head bolts evenly.
STEP 179
GD98M716
Position converter. Check and ensure that impulse

disk of converter is centered on the bore for the in-
ductive transmitter.
STEP 177
GD98M719
Secure converter cover using 12 hex head screws

and nuts. Tighten screws to a torque of 46 Nm
(407 lb-in).
GD98M717
Position converter cover as shown. Install bearing

against shoulder in cover. Secure using retaining ring.
STEP 180 STEP 183
GD98M720
Tighten input flange hex head screws to a torque of

34 Nm (301 lb-in). Lock screws by bending corners of 258
lock plate over screws.

Install 380001577 transmission valve adjustment tool
STEP 181 set. Be sure hex rods (part of tool set) are not in-
stalled on studs. Mount the gasket (1), intermediate
plate (2), and gasket (3).
STEP 184
Install the screw plug with new O-ring. Tighten the
plug to a torque of 30 Nm (265 lb-in).
STEP 185
GD98M724
Install new sealing rings and both plugs in duct plate.
STEP 182
GD98M727
Install control valve on duct plate and 380001577

studs. Install hex rods on studs and tighten against
control valve. Install 21 socket head screws. Tighten
screws to a torque of 9.5 Nm (84 lb-in). Remove
380001577 transmission valve adjustment tool set.
Install remaining two socket head screws. Tighten
GD98M725 screws to a torque of 9.5 Nm (84 lb-in).
Install the gasket and place the duct plate against
Note – The following steps are for the installation of
shoulder. Install socket head screws and hex nuts.
the filter.
Tighten to a torque of 25 Nm (221 lb-in).
Note – The following steps are for installation of trans-

mission control valve.
STEP 186 STEP 189
GD98M729 GD98M735
Install new O-rings in recesses of oil filter head. Posi- Apply grease to the new O-ring and install the speed
tion filter head on transmission and secure using two sensor with the socket head screw. Tighten the screw
socket head screws. Tighten screws to a torque of 25 to a torque of 23 Nm (204 lb-in).
Nm (221 lb-in).
STEP 190
STEP 187
GD98M736
GD98M730
With new O-rings, install the inductive transmitters.
Install a new transmission filter. Tighten to a torque of 30 Nm (265 lb-in).
STEP 188 STEP 191

Install the breather.
STEP 192
GD98M733
Install new O-rings in oil distribution covers. Install

the two oil distribution covers on the housing with hex
nuts and flat washers. Tighten to a torque of 25 Nm GD98M737
(221 lb-in).
Install the gasket and the cover plate. Tighten to a
torque of 23 Nm (204 lb-in). With a new O-ring, install
the screw plug. Tighten to a torque of 140 Nm (103 lb-
ft).
2.4 FRONT AXLE
2.4.1 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
Brake housing inner bearing cup installer .......................................................................................... 380001756
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 ............................................................................................................. 380001543
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)
Step plate ......................................................................................................................................... 380001539
Step plate ......................................................................................................................................... 380001541
Step plate ......................................................................................................................................... 380001542
2.4.2 GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased
BS01D009
BS01D011
Coast Side (concave)
BS01D013
BS01D012
Drive side (convex)
BS01D014
Drive side (convex)
Pinion Distance Must Be Decreased
BS01D010
BS01D016
Drive side (convex)
BS01D015
Coast side (concave)
2.4.3 LUBRICATION 2.4.4 WEAR MEASUREMENT ON

MULTI-DISC BRAKE
4
5
4
1 2
2
BS00M069
BD00M234
4
5
4
3 2
1
2
BS00M070
BS00M071
1. Oil drain hole (Axle casing) - 2. Oil drain hole (Outputs) -
3. Oil filler hole - 4. Brake bleeder - 5. Bleeder.
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 wheel

ends.
Remove screw plug, actuate brake and determine di-
mension “X” using a feeler gauge.
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 pound-feet).
2.4.5 WHEEL END AND BRAKE

Disassembly
STEP 1 STEP 3
BD00M235 BD00M238
Fasten axle on a stand. Pry the cover off the wheel end.
STEP 2 STEP 4
BD00M236 BD03B008
Use 380001582 slide hammer and 380001545 adapter,

remove the slotted pin from wheel end lock nut.
STEP 5
BD00M237
Loosen the screw plugs and drain the oil from the
axle casting.
BD03B009
Using 380001571 locknut socket and 380001576 sup-

port bracket, loosen and remove the locknut.
STEP 6 STEP 9
BD00M241 BD00M244
Use acceptable lifting equipment and hold the wheel Remove the shim(s) from the sun gear shaft.
end in place. Loosen and remove the bolts.
STEP 10
STEP 7
BD00M245
BD03B010
Pull the sun gear shaft out of the planet gears.
Separate the wheel end from the axle casing.
STEP 11
STEP 8
BD03B011
BD00M243
Lift planet carrier out of the brake housing using
Pull the stub shaft out of the sun gear shaft. 380001578 pulling attachment.
Note – Watch for released shim(s).
STEP 12 STEP 15
BD03B012 BD03B015
Remove the snap rings from the planet gear shaft Using suitable puller, remove planetary ring gear from
using 380001585 snap ring pliers. brake housing.
STEP 13 STEP 16
BD03B013 BD03B016
Remove the planet gear using 380001563 gear puller Remove O-rings from the annular grooves of the ring
and 380001539 step plate. gear.
STEP 14 STEP 17
BD03B014 BD03B017
Remove the bearing from the planetary using Remove O-ring from recess of the brake housing.
380001757 collet set, 380001575 puller body and
screw, and 380001539 step plate.
STEP 18 STEP 21
BD00M253 BD03B021
Remove the brake disc pack from the brake housing. Use compressed air to raise piston out of the brake
housing.
STEP 19
STEP 22
BD03B019
BD00M257
Drive slotted pins in the support shim until they are
flush with the top of the support shim. Remove the support shim out of the piston.
STEP 20 STEP 23
BD03B020 BD03B022
Remove the circlip using 380001584 external pliers. Drive slotted pins out of the support shim.
STEP 24 STEP 27
BD00M259 BD00M262
Preload the cup springs using a press and remove Lift the piston out of the brake housing.
the retaining ring.
STEP 28
STEP 25
BD00M263
BD00M260
Remove and discard the guide ring, support rings and
Pull the pin out of the support shim and remove the O-rings from the grooves of the brake housing.
released cup springs.
Note – If replacing brakes only, go to step 44.
STEP 26
STEP 29
BD00M261
Press the gripping rings off of the pins. BD03B023
Using 380001564 puller bridge and 380001542 step

plate, remove the brake housing from the wheel end
shaft.
STEP 30 STEP 32
BD03B024 BD00M267
Use acceptable lifting equipment and lift the brake Remove the shaft seal from the brake housing.
housing from the wheel end shaft.
STEP 33
STEP 31
If the wheel end pressure ring or bearing needs to be
replaced, remove the bearing from the wheel end shaft.
STEP 34
BD00M266
If necessary drive both bearing outer rings out of the

brake housing.
BD00M269
If the wheel end pressure ring needs to be replaced,

remove the pressure ring from the wheel end shaft.
Assembly
WARNING
STEP 35
STEP 38
BD00M271
Install a new pressure ring on the wheel end shaft.
STEP 36
BD00M273
Heat the bearing inner ring and install it onto the wheel
end shaft.
STEP 39
BD01F107
Install the 380001754 pressure ring installer adapter

on the wheel end shaft.
STEP 37
BD03B026
Freeze the bearing outer ring. Press the bearing outer

ring into the brake housing using 380001756.
STEP 40
Freeze the bearing outer ring. Press the bearing outer
ring into the brake housing using 380001751.
BD01F105
Press the pressure ring over the collar of the wheel

end shaft using 380001566 pressure ring installer.
STEP 41 STEP 42
BD03B027 BD03B024
Use a solution of 50% water and 50% mineral spirits Use acceptable lifting equipment and install the brake
to wet the outer diameter of the shaft seal. Using housing over the wheel end shaft until contact.
380001574 install the shaft seal with the sealing lip
showing to the oil chamber. See illustration below.
WARNING
1 burning your hand when handling heated parts.
2 STEP 43
BS00M073
Shaft seal
1. Brake housing - 2. Shaft seal - * Grease filling.
BD00M277
Heat the bearing inner ring and install it into the brake
housing until contact.
STEP 44 STEP 45
BD00M263 BD00M279
Clean the groove of the brake housing with solvent.

Install the guide ring into the groove and fix it with
Loctite 415.
Note – Upon installation the guide ring must have

contact on the whole circumference and the orifice
must show upwards (12 o’clock).
STEP 46
BS00M072
1. Brake housing - 2. Guide ring - 3. Support ring - 4. O-ring -

5. O-ring - 6. Support ring - 7. Wheel end shaft.
BD00M280
Install the guide ring, support rings and O-rings in the Apply oil on the sliding surface of the piston. Care
grooves of the brake housing. fully insert the piston into the brake housing.
STEP 47
5 4
2
BD00M281
Insert the pins into the assembly fixture until contact.

1
STEP 48
BS00M074
X. 10.5 mm +0.3 (0.41 inch +0.02) - 1. Pin - 2. Gripping rings -

3. Cup springs - 4. Support shim - 5. Retaining ring.
STEP 50
BD00M282
1. Gripping rings.
Press the gripping rings onto the pins until contact on

the assembly fixture.
BD00M284
Attention – Observe the installation position, install
the gripping rings with the orifices offset by 180° to Insert the assembled pins into the support shim and
each other. install the snap ring.
STEP 49 STEP 51
BD00M283 BD00M285
Install the cup springs onto the pins. See illustration Insert the assembled support shim into the piston.
below.
STEP 52 STEP 54
1
BD00M286 BD00M288
Install the circlip into the brake housing. 1. Spline.
STEP 53 Drive the stop bolt into the planet carrier. Then coat
the spline with anti-corrosive antiseize.
STEP 55
BD03B028
1 2 3 4 5
"X"
BD00M289
Insert the planet carrier into the spline of the wheel

end shaft until contact.
STEP 56
BD03B034
X. Installation dimension 5.0 mm ± 0.5 mm - 1. Brake hous-

ing - 2. Circlip - 3. Slotted pin - 4. Support shim - 5. Piston.
Drive slotted pins into the bores of the support shim

to lock the circlip.
BD00M253
Install the outer and inner clutch discs alternately

starting with an outer clutch disc. Lubricate the clutch
disc with transmission oil.
STEP 57 STEP 60
BD03B029 BD01C009
Insert O-ring into the recess of the brake housing. Heat the bearing inner rings with a hot air gun.
STEP 58
WARNING
STEP 61
BD03B016
Grease both O-rings.
STEP 59
BD00M292
Install the bearings with the big radius showing to the

planet carrier (downwards).
STEP 62
BD03B030
Install two aligning dowels in the brake housing, in-

stall ring gear onto the brake housing.
Note – Make sure alignment is correct on ring gear.

BD00M293
Put the planet gears onto the bearing inner rings.
Adjust end play of sun gear shaft 0.5 to 2.0 mm

WARNING (0.02 to 0.08 inch)
Always wear heat protective gloves to prevent STEP 65
STEP 63
BD00M296
Determine dimension I, from the mounting face of the

brake housing up to the face of the stop bolt.
BD00M294
Dimension I e.g. .................... 46.20 mm (1.82 inch)
Heat the bearing inner rings and install into the planet
gears.
STEP 66
STEP 64
BD00M297
BD03B031 Insert the stub shaft into the spline of the axle bevel
gear until contact.
Install the snap rings on the planet gear shafts using
380001585 snap ring pliers.
STEP 67 STEP 69
BD00M298 BD00M245
Insert the sun gear shaft onto the stub shaft until con- Insert the sun gear shaft into the planet carrier.
tact.
STEP 70
STEP 68
BD00M244
BD00M299
Install the determined shim(s), e.g. S. = 2.20 mm
Determine dimension II from the face of the sun gear (0.09 inch) into the sun gear shaft with grease.
shaft up to the mounting face of the axle casing.
Dimension II e.g. ................... 43.00 mm (1.69 inch) STEP 71
Example:
Dimension I + 46.20 mm (1.82 inch)
Dimension II - 43.00 mm (1.69 inch)
Difference 3.20 mm (0.13 inch)
Required end play e.g. - 1.00 mm (0.04 inch)
Difference = shim size e.g. s= 2.20 mm (0.09 inch)
BD03B032
Install O-ring and hold into place with grease, install

output housing onto axle.
STEP 72 STEP 75
BD00M300 BD00M303
Install the washers and bolts by hand. 1. O-ring.
Tightening torque ............. 390 Nm (288 pound-feet) Install an O-ring on the cover.
STEP 73 STEP 76
BD03B033
BD00M304
Install the locknut by hand and tighten it using Insert the cover into the wheel end.
380001571 locknut socket and 380001576 support
bracket.
Tighten torque ......... 700 +300 Nm (516 +221 pound-feet)
STEP 74
BD00M302
Secure the locknut with the slotted pin.
2.4.6 BRAKE HYDRAULICS LEAKAGE Low Pressure Test

TEST Reduce test pressure to p = 5 bar (72.5 psi) and close
Note – Prior to start the test, ventilate the brake hy- the shutoff valve again.
draulics and then actuate it several times. During a 5 minute testing time a pressure drop is not
allowed.
High Pressure Test
STEP 77
BD00M305
Increase test pressure up to p =100 bar (1450 psi)

maximum and close connection to HD pump by means
of shutoff valve. During a 5 minute testing time, a
pressure drop of maximum 2 bar (29 psi) is allowed.
Attention – If the maximum pressure of 100 bar (1450

psi) is exceeded, there will be an excessive piston
adjustment and a repeated disassembly of the brake
or the adjusting is required to reset the gripping rings
to the adjusting dimension.
2.4.7 DISASSEMBLY OF DIFFERENTIAL STEP 3

CARRIER AND BRAKE TUBES
STEP 1
BD00M241
Use acceptable lifting equipment to hold the wheel

BD00M235 end in place. Loosen and remove the bolts.
Fasten the axle to a stand. STEP 4
STEP 2
BD03B032
BD00M236 Separate the wheel end from the axle housing. Re-
move O-ring.
STEP 5
BD00M237
Loosen the screw plugs and drain the oil from the
axle casing. BD00M243
Pull the stub shaft out of the sun gear shaft. Repeat
steps 3 through 5 for the other wheel end.
Note – Pay attention to the released shim(s).
STEP 6 STEP 9
BD00M395 BD00M398
Remove the bolts from the differential carrier. Drive out the slotted pins from the differential carrier.
Note – Mark the location of the differential carrier to STEP 10

the axle casing.
STEP 7
BD01F072
Loosen and remove both adjusting nuts using

380001565 wrench.
BD03B035
Use suitable lifting equipment and lift the differential STEP 11

carrier out of the axle casing.
STEP 8
BD00M400
Heat the axle drive housing with a hot air gun.

BD03B036
Note – Bolts are installed with Loctite.
Fasten the differential carrier on 380001580 engine
stand using 380001562 mounting bracket.
STEP 12 STEP 14
BD00M401 BD00M403
Loosen the bolts and take off both bearing brackets. Use acceptable lifting equipment and lift the differen-
tial out of the differential carrier.
Note – Make an alignment mark between the bearing
bracket and the housing.
Attention – Loosen the bolts by hand only.
STEP 13
BD00M402
Remove both bearing outer rings from the differential

carrier.
2.4.8 DISASSEMBLY OF LIMITED SLIP STEP 18

DIFFERENTIAL
STEP 15
BD00M407
Remove all the single parts from the differential hous-

BD01F089 ing.
Using 380001551 cone puller and 380001540 step STEP 19
plate, remove the bearing inner ring from the differen-
tial housing.
STEP 16
BD00M408
Press off the ring gear from the differential housing.
BD01F096
Remove the bearing inner ring from the housing cover

using 380001551 cone puller and 380001540 step
plate.
STEP 17
BD00M406
Place the differential in a press to prevent it from turn-

ing. Remove the bolts and the released housing cover.
2.4.9 DRIVE PINION DISASSEMBLY STEP 23

STEP 20
BD00M412
BD00M409 Remove the shaft seal from the differential carrier.

Heat the pinion shaft locknut with a hot air gun.
STEP 24
Note – Locknut is held with Loctite Type No. 262. Use a rubber hammer to remove the drive pinion out
of the differential carrier.
STEP 21
STEP 25
Take off the spacer ring and pull the bearing inner ring
from the drive pinion shaft.
STEP 26
BD01F091
Using 380001546 yoke holding wrench, loosen the

locknut and remove the washer behind it.
STEP 22
BD00M414
If necessary drive out both bearing outer rings from

the differential carrier.
BD00M411
Pull the input yoke from the drive pinion shaft.
2.4.10 DISASSEMBLY OF THE BRAKE STEP 30

TUBES
STEP 27
BD00M337
Disconnect the pipe union and remove the released

BD00M334 brake tube from the axle casing.
Remove the screw plug with the vent valve from the STEP 31
axle casing.
STEP 28
BD00M338
Remove the vent valve from the connection part.

BD00M335
STEP 32
Loosen and remove the hexagon screw from the axle.
STEP 29
BD00M339
Loosen the connection part and remove it from the

BD00M336 axle. Repeat steps 28 to 32 for the other wheel end.
Loosen and remove the union screw from the axle.
2.4.11 ASSEMBLY OF BRAKE TUBES STEP 36

AND DIFFERENTIAL CARRIER
STEP 33
1 2
3
1
4
BD00M343
1. O-ring.
BD00M340
Install an O-ring into the groove of the brake tube.
1. Vent Valve - 2. Connection part - 3. O-ring - 4. Rectangu-
lar ring.
STEP 37
Assemble the part as shown in the photo above.
STEP 34
1
2
2
BD00M344
1. Brake tube - 2. Union screw.

BD00M341
Insert the brake tube into the axle casing, assem-
Install the connection part on the axle casing.
bling the connection part through the union screw.
Tightening torque ................ 130 Nm (96 pound-feet)
STEP 35
BD00M342
Install the union screw with a new O-ring on the axle.

Tightening torque .............. 190 Nm (140 pound-feet)
STEP 38 STEP 40
1
2
BD00M345 BD00M347
Fasten the brake tube with the hexagon nut and union 1. O-ring - 2. Screw plug - 3. Vent valve.
nut.
Assemble the screw plug as shown in the above photo.
Tightening torque .................. 70 Nm (52 pound-feet)
STEP 41
STEP 39
MD00M348
BD00M346
Install the screw plug on the axle casing.
Note – Repeat steps 33 to 39 for the other wheel end.
2.4.12 DIFFERENTIAL CARRIER STEP 44

ASSEMBLY
Note – If the ring gear or drive pinion are damaged,
both parts have to be replaced together. For new in-
stallation of a complete bevel gear set pay attention
to the same pair number of drive pinion and ring gear.
Determine Shim Thickness for Correct Tooth

Contact Pattern
Note – Make the following measuring steps at maxi-
mum accuracy. In exact measurements result in a
faulty tooth contact pattern and require a repeated BD00M350
disassembly and assembly of the drive pinion as well
Determine Dimension I (bearing width).
as of the differential.
Dimension I e.g. ................... 36.00 mm (1.417 inch)
STEP 42
Install the 380001753 pinion depth gauge block and STEP 45
380001548 gauge tube on the differential carrier.
STEP 43 1
BD00M351
+0.05
1. 168.00 .
BD01F106 Read Dimension II (dimension for pinion).

Determine the gap between the measuring shaft and Dimension II e.g. .................. 168.05 mm (6.62 inch)
the measuring pin with a feeler gauge.
Example B:
Dim. B e.g. ............................ 1.00 mm (0.039 inch)
Dimension I 36.00 mm (1.417 inch)
Example A:
Dimension II + 168.05 mm (6.616 inch)
Dimension A (tool constant) 204.25 mm (8.041 inch) Results in Dimension Y s= 204.05 mm (8.04 inch)
Dimension B (gap) + 1.00 mm (0.039 inch)
Results in Dimension X s= 205.25 mm (8.08 inch)
Example C:
Dimension X 205.25 mm (8.081 inch)

Dimension Y - 204.05 mm (8.033 inch)
Difference = Shim e.g. s= 1.20 mm (0.048 inch)
Install the Drive Pinion STEP 48

STEP 46
BD01F087
BD00M416 Freeze the bearing outer ring on the input side and
install using 380001550 and 380001542 step plate.
Place the determined shim e.g. S. = 1.20 mm
(0.05 inch) into the bearing bore in the differential car-
STEP 49
rier.
STEP 47
BD01F065
BD01F063 Press the bearing inner ring on the drive pinion shaft
using 380001552 and 380001542 step plate.
Freeze the bearing outer ring and insert into the differ-
ential carrier using 380001549, 380001550, and
380001542 step plate.
Adjust Rolling Moment of Drive Pinion Bearing STEP 52

STEP 50
BD01F101
BD00M356 Press the dust shield onto the input yoke using
380001575 puller tube.
Install the spacer ring on the pinion shaft.
STEP 53
Note – As per experience the required rolling move-
ment is obtained by use of the spacer ring [e.g. s=8.70
mm (0.34 inch)] available at disassembly.
However, a later checking of the rolling movement
must be done.
WARNING
STEP 51
BD00M422
Install the input yoke on the pinion shaft.
STEP 54
BD00M357
Insert the assembled drive pinion into the differential

carrier and install the heated bearing inner ring.
BD00M423
Install the washer on the pinion shaft.
STEP 55 STEP 58
BD01F091 BD01F098
Install the locknut by hand. Using 380001546 yoke Using 380001747 and 380001748, install the shaft seal
holding wrench tighten the locknut. with the sealing lip showing to the oil chamber (down-
wards).
Tightening torque ............. 700 Nm (516 pound-feet)
Attention – Just before the installation wet the outer
Note – When tightening rotate the drive pinion in both
diameter of the shaft seal with a solution of 50% wa-
directions several times.
ter and 50% mineral spirits. Fill the space between
the sealing and dust lip with grease.
STEP 56
STEP 59
BDM00425
Check rolling movement. Rolling movement should BD01F091

be 1.5 to 3.0 Nm (1.10 to 2.21 pound-feet).
Put the input yoke in place and install the washer and
locknut. Using 380001546 yoke holding wrench tighten
Note – For new bearings it should be tried to achieve
the locknut.
the maximum value of the rolling movement.
Tighten torque ................... 700 Nm (516 pound-feet)
Attention – If the required rolling movement is not
obtained, correct it with an adequate spacer ring, ac- Attention – Apply Loctite, Type No. 262, onto the thread
cording to the following indications: of the locknut.
Rolling movement too low - install a thinner spacer
ring.
Rolling movement too high - install a thicker spacer
ring.
STEP 57
Remove the locknut again and pull off the input yoke
from the drive pinion shaft.
2.4.13 LIMITED SLIP DIFFERENTIAL STEP 63

ASSEMBLY
STEP 60
BD00M430
Insert the axle bevel gear and slide the splined shaft
BD00M427 into the clutch discs.
Place both thrust washers into the differential hous- STEP 64
ing.
STEP 61
BD00M431
Assemble the differential spider and insert it into the

BD00M428 differential housing.
Starting with an outer clutch disc install alternately STEP 65
the outer and inner clutch discs.
Attention – Thickness of the disc pack must be iden-
tical on both sides.
STEP 62
BD00M432
Insert the second axle bevel gear.
BD00M429
Insert the pressure ring into the differential housing.
STEP 66 Determine the Disc Clearance

STEP 68
BD00M433
Insert the second pressure ring into the differential BD00M435

housing.
Determine dimension I, from the mounting face of the
differential housing to the plane face of the outer clutch
STEP 67
disc.
Dimension I e.g. .................... 38.05 mm (1.50 inch)
STEP 69
BD00M434
Starting with an inner clutch disc install alternately

the inner and outer clutch disc.
BD00M436
Attention – The thickness of the clutch disc pack
must be identical on both sides. Determine dimension II, from the contact surface of
the outer clutch disc to the mounting face of the hous-
Example B: ing cover.
Dimension II e.g. ................... 37.75 mm (1.48 inch)
Dimension I 38.05 mm (1.50 inch)
Dimension II + 37.75 mm (1.49 inch)
Difference = Disc clearance = 0.30 mm (0.01 inch)
Note – If the required disc clearance is not obtained,

correct it with the adequate outer clutch discs [s=2.1,
s=2.2, s=2.3, s=2.4 or s=2.5 mm (0.083, 0.087, 0.091,
0.094, 0.098 inch)], taking care that the difference in
thickness between the left and the right disc pack
must only be 0.1 mm (0.004 inch) at a maximum.
STEP 70 STEP 73
BD00M437 BD00M440
Fix the thrust washer with grease into the recess of Press both bearing inner rings onto the differential
the differential housing cover. housing.
STEP 71 STEP 74
BD00M438 BD00M441
Put the housing cover in place on the differential hous- Use acceptable lifting equipment and insert the dif-
ing. Heat the ring gear and install onto the differential ferential into the differential carrier.
housing.
STEP 75
STEP 72
BD00M442
BD00M439
Place the bearing outer ring into the differential car-
Put the differential in a press to prevent it from turn- rier.
ing and install the bolts on the ring gear.
Tightening torque ............. 410 Nm (302 pound-feet)
Attention – Use new locking bolts.
STEP 76 STEP 79
BD00M443 BD00M446
Install the adjusting nut by hand on the differential Install both bearing brackets and install the bolts and
carrier. washers.
Tighten torque .................. 280 Nm (207 pound-feet)
STEP 77
Attention – Apply Loctite Type No. 262 onto threads
of the bolts.
Adjust Backlash and Bearing Preload

STEP 80
BD00M444
Install the ring gear sided bearing outer ring.
STEP 78
BD00M447
Place a dial indicator right-angled at the outer diam-

eter of the tooth flank (ring gear).
Adjust the pinion to ring gear backlash to the low side
of specifications (see value etched on the outer di-
ameter of the ring gear) by alternately turning each of
the adjusting nuts to move the ring gear closer to or
further away from the pinion. Backlash is checked
BD00M445 using a dial indicator against a tooth on the ring gear.
Install the adjusting nut by hand on the differential
carrier. Note – Rotate the differential several times and
recheck the backlash.
STEP 81 STEP 85
BD01F072 BD00M449
Go to the adjusting nut opposite the ring gear and Coat several teeth on the ring gear with marking ink
loosen the nut approximately one turn to release pres- and roll the ring gear in both directions over the drive
sure on the bearing. It should be very noticeable that pinion.
pressure is released on the bearing, as the adjusting
Compare the obtained tooth contact pattern with the
nut will turn much easier.
examples on page 98 and 99.
STEP 82
Attention – If the tooth contact pattern differs, there
Tighten the adjusting nut slowly until firm contact is has been a measuring error at determination of the
made with the bearing. shim. This must be corrected.
Note – As the adjusting nut makes firm contact with STEP 86

the bearing, the adjusting nut will immediately begin
to turn much harder.
STEP 83
To adjust the bearing preload, note the position of the
adjusting nut. Now tighten the nut two additional
notches.
STEP 84
As the bearing preload is adjusted as described in
steps 81, 82 and 83, pinion to ring gear backlash may BD00M450
increase slightly. Check pinion backlash to confirm
that it is within specifications. If backlash is outside Install both adjusting nuts with the slotted pins on the
of specified range, repeat step 80 through 84 again. differential carrier.
STEP 87
BD00M453
BD03B035 Insert the stub shaft into the spline of the axle bevel
Use suitable lifting equipment and insert the differen- gear.
tial carrier into the axle casing.
STEP 89
Note – Align the two alignment marks together.
Attention – Apply sealing compound on the mount-

ing surface.
STEP 88
BD00M454
Install the thrust washer removed at disassembly in

the sun gear shaft with grease.
BD00M452
Install new bolts on the differential carrier.

Tighten torque ................... 250 Nm (185 pound-feet)
STEP 90 STEP 91
BD03B032 BD00M456
Install O-ring and hold into place with grease. Use Install the bolts and washers on the wheel end.
acceptable lifting equipment and place the wheel end
Tightening torque .............. 390 Nm (288 pound-feet)
on the axle housing.
Note – Repeat steps 1 to 91 for the other wheel end.
Note – Prior to putting into operation of the axle, fill

with oil.
NOTES:
2.5 REAR AXLE

Lubricant Capacity ................................................................................................ 22.1 Liters (23.5 U.S. Quarts)
Distance Between Gripping Rings and Shoulder of Pin ................................. 10.5 to 10.8 mm (0.41 to 0.43 inch)
Top of Pins to Top of Support Shim ................................................................. 4.5 to 5.0 mm (0.18 to 0.20 inch)
Sun Gear Shaft End Play .................................................................................................... 1.00 mm (0.04 inch)
Drive Pinion Rolling Torque ............................................................................. 1.1 to 2.3 Nm (9.7 to 20.3 lb-inch)
Seal Caps Depth in Differential Housing .......................................................... 1.5 to 2.5 mm (0.06 to 0.10 inch)
Differential Carrier Disc Clearance ....................................................................................... 0.40 mm (0.02 inch)

Bolts Securing Wheel End to Axle Housing ............................................................................ 390 Nm (288 lb-ft)
Locknut Securing Planetary Carrier ................................................................. 700 to 1000 Nm (516 to 737 lb-ft)
Vent Valve and Fitting .............................................................................................................. 130 Nm (96 lb-ft)
Axle Housing Connector for Brake Tube ................................................................................. 190 Nm (140 lb-ft)
Nut Securing Brake Tube to Connector ....................................................................................... 70 Nm (52 lb-ft)
Brake Tube Fitting to Wheel End Fitting ...................................................................................... 80 Nm (60 lb-ft)
Breather Plug ............................................................................................................................. 70 Nm (52 lb-ft)
Nut Securing Input Flange (Apply Loctite 262 to Threads) ...................................................... 700 Nm (516 lb-ft)
Bolts Securing Differential Ring Gear ..................................................................................... 250 Nm (185 lb-ft)
Bolts Securing Differential Bearing Caps (Apply Loctite 262 to Threads) ................................ 280 Nm (207 lb-ft)
Differential Carrier Mounting Bolts .......................................................................................... 250 Nm (185 lb-ft)
2.5.3 SPECIAL TOOLS

Brake housing seal installer ................... 380001574 Alignment Studs .................................... 380001752
Differential bearing cone puller Step plate set (includes 380001539,
collet set ................................................ 380001569 380001541, and 380001542)
Differential bearing preload wrench ......... 380001565 Step plate .............................................. 380001539
Brake housing inner bearing cup Step plate .............................................. 380001541
installer .................................................. 380001572 Step plate .............................................. 380001542
Brake housing outer bearing cup Socket ................................................... 380001571
installer .................................................. 380001573 Planetary Gear Puller ............................. 380001563
Wear ring installer adapter ...................... 380001755 Brake Housing Puller Bridge .................. 380001564
Pinion depth gauge set........................... 380001570 Pressure Ring Installer ........................... 380001566
Puller body and screw ............................ 380001575 Holding Bracket .................................... 380001562
Support bracket ..................................... 380001576 Puller ..................................................... 380001563
Slide hammer puller adapter ................... 380001545 Pulling Attachment ................................. 380001581
Slide hammer ......................................... 380001582 Puller Legs ............................................. 380001538
Replacer ................................................ 380001552 Step Plate .............................................. 380001540
Dial indicator with magnetic base ........... 380001543 Holding Wrench ...................................... 380001546
Heat gun ................................................ 380001544 Pinion Inner Bearing Cup Installer .......... 380001549
Engine stand .......................................... 380001580 Pinion Outer Bearing Cup Installer ......... 380001550
Snap ring pliers ...................................... 380001584 Pinion Seal Installer ............................... 380001747
Snap ring pliers ...................................... 380001583 Pinion Seal Installer ............................... 380001748
Snap ring pliers ...................................... 380001585 Pulling Attachment ................................. 380001578
2.5.4 GEAR TOOTH CONTACT PATTERNS

Ideal Tooth Contact Pattern Pinion Distance Must Be Increased
BS01D011
BS01D009
BS01D012
Drive side (convex)
BS01D013
BS01D014
Drive side (convex)
Pinion Distance Must Be Decreased
BS01D016
Drive side (convex)
BS01D010
BS01D015
Coast side (concave)
2.5.5 LUBRICATION
5
4
3 2
1
2
BS02D084
1. Oil drain hole (Axle housing) - 2. Oil drain hole (Outputs) - 3. Oil fill plug - 4. Brake bleeder - 5. Breather - 6. Dipstick.
2.5.6. WEAR MEASUREMENT Note – A wear measurement on the multi-disc brake

ON MULTI-DISC BRAKE must be made at least once a year. Wear measure-
ment 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 dimen-

sion (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
BD00M234
of 70 Nm (52 lb-ft).
BS00M071
2.5.7 WHEEL END AND BRAKE STEP 3

Disassembly
Note – Tools and axle shown in the following photo-
graphs may appear slightly different than the tools
and axle you may have. The use of the tools and dis-
assembly/assembly of axle is the same regardless
of appearance.
STEP 1
BD00M238
Using two pry bars, remove cover from output shaft.

Remove and discard O-ring from cover.
STEP 4
BD00M235
Fasten axle on a stand.
STEP 2
BD00M239
Remove pin from lock nut using 380001582 slide ham-

mer and 380001545 adapter.
STEP 5
BD00M236
BD00M240
Remove lock nut using 380001576 support bracket

and 380001571 socket and nuts.
BD00M237
Remove drain plugs and drain oil from axle housing.
STEP 6 STEP 9
BD00M241 BD00M244
Use acceptable lifting equipment to hold wheel end in Remove the shim(s) from the sun gear shaft.
place. Loosen and remove the bolts and washers.
STEP 10
STEP 7
BD00M245
BD00M242
Pull the sun gear shaft out of the planetary gears and
Carefully pull the wheel end from the axle housing. remove.
Remove and discard O-ring from axle housing wheel
end. STEP 11
STEP 8
BD00M246
Using 380001578 pulling attachment, remove the plan-

BD00M243
etary carrier.
Pull the stub shaft out of the sun gear shaft. Be care-
ful not to lose shim(s) that may be installed in sun
gear shaft.
STEP 12 STEP 15
BD00M247 BD00M250
Remove retaining ring. Put alignment marks on planetary ring gear and brake
housing to aid in assembly. Using suitable puller, re-
STEP 13 move planetary ring gear from brake housing.
STEP 16
BD00M248
Using 380001563 planetary gear puller and step plate

BD00M251
380001541, remove planetary gear and outer bearing
from planetary carrier shaft. Using a suitable puller, Remove and discard two O-rings from planetary ring
remove the inner bearing from carrier shaft. gear.
STEP 14 STEP 17
Repeat Steps 12 and 13 to remove the remaining three
retaining rings, planetary gears, and six bearings.
BD00M252
Remove and discard O-ring from brake housing port.
STEP 18 STEP 21
BD00M253 BD00M256
Remove the brake disc pack from brake housing. WEAR FACE PROTECTION WHEN USING COM-
PRESSED AIR. Apply compressed air to brake hous-
STEP 19 ing port to push brake piston from brake housing.
STEP 22
BD00M254
Using suitable tool, push the three pins down until BD00M257
pins are even with top surface of shim.
Remove the support shim from the brake piston.
STEP 20
STEP 23
BD00M255
BD00M258
Remove the snap ring.
Remove three pins from support shim.
STEP 24 STEP 27
BD00M259 BD00M262
Put support shim in a press and compress Belleville Lift and remove the piston from the brake housing.
washers. Remove retaining ring and pull pin with
Belleville washers and rings installed from support STEP 28
shim. Repeat this step to remove the remaining five
retaining rings and pins from support shim.
STEP 25
BD00M263
BD00M260
Remove seven Belleville washers from each pin.
STEP 26
BD00M261 BS00M072
Using a press, remove four gripping rings from each 1. Brake housing - 2. Guide ring - 3. Support ring -
pin. 4. O-ring - 5. O-ring - 6. Support ring - 7. Wheel end shaft.
Remove the guide ring (2), support rings (3 and 6),

and O-rings (4 and 5) from the grooves of the brake
housing.
STEP 29 STEP 32
BD01F102A BD00M267
Using the 380001564 brake housing puller bridge and Remove the face seal from the brake housing.
380001542 step plate, pull the brake housing from
the wheel end shaft and remove the inner bearing. STEP 33
Using a puller, remove the outer bearing from the wheel
STEP 30
end shaft.
STEP 34
BD00M265
Use acceptable lifting equipment and lift the brake

housing from the wheel end shaft. BD00M269
Remove and discard the face seal metal ring from the
STEP 31
wheel end shaft.
BD00M266
If replacement of bearing cups is necessary, drive

both bearing cups out of the brake housing.
Cleaning and Inspection Assembly

Important – Do not use compressed air to dry bear- STEP 40
ings. Allow bearings to air dry.
STEP 35
Clean all parts except friction plates in brake disc
pack using cleaning solvent. WEAR FACE PROTEC-
TION WHEN USING COMPRESSED AIR. Use com-
pressed air to clear passages in planetary ring gear
and brake housing.
STEP 36
Inspect bearing rollers for pitting, scoring, deforma- BD00M271
tion, or other damage. Check inner face and bearing
cage for deformation, dents, and other damage. Check Install a new face seal metal ring on the wheel end
associated bearing cups for scratches, grooves, or shaft.
cracks. Check bearings for rough spots or binding by
holding bearing and rotating. If bearing binds or action STEP 41
is not smooth, replace the bearing.
STEP 37
Inspect bearing cups for pitting, scoring, cracks, or
other damage. Replace if any of these conditions are
seen.
Note – If a bearing or bearing cup requires replace-

ment, the associated part must also be replaced.
STEP 38
BD01F107
Check planetary ring gear, planetary gears, and plan-
etary carrier gear teeth for cracks, breaks, chipping,
or other damage. Replace the part if any of these con-
ditions are seen. Check planetary carrier shaft splines
for broken, cracked, or twisted condition. Replace if
necessary.
STEP 39
Check wheel end shaft for cracked, broken, or twisted
splines. Replace if any of these conditions are seen.
BD01F105
Install 380001755 pressure ring installer adapter on

wheel end shaft. Press the face seal metal ring over
the collar of the wheel end shaft using 380001566
pressure ring installer.
STEP 42 STEP 45
WARNING
BD00M275
A A
BD00M273 1
A
Heat the wheel end shaft outer bearing to 100 °C
(212 °F) in a bearing oven. Wearing heat resistant
2
gloves or mittens, install the bearing on the wheel
end shaft until the bearing is against the shoulder on
the wheel end shaft.
STEP 43
BS00M073
A. Fill with grease - 1. Face seal - 2. Brake housing.
Wet the outer diameter of the face seal with a solu-

tion of 50% water and 50% mineral spirits. Use
380001574 seal installer to install the face seal with
the seal lip positioned as shown. Apply grease to seal
as indicated by (A) above.
BD00M274
STEP 46
Using 380001572 inner bearing cup installer, press

the inner bearing cup into the brake housing until
seated against the shoulder in the brake housing.
STEP 44
Using 380001573 outer bearing cup installer press the
outer bearing cup into the brake housing until seated
against the shoulder in the brake housing.
BD00M276
Use acceptable lifting equipment and install the brake

housing on the wheel end shaft.
STEP 47 STEP 48
WARNING
BD00M278
BD00M277
Heat the wheel end shaft inner bearing to 100 °C

(212 °F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearing on the wheel
end shaft until the bearing is against the bearing cup
in the brake housing.
BS00M072
Guide Ring, Support rings and O-rings location
1. Brake housing - 2. Guide ring - 3. Support ring - 4. U-ring -

5. U-ring - 6. Support ring - 7. Wheel end shaft.
Install the support rings and U-rings in the grooves of

the brake housing.
STEP 49 STEP 52
A
B
BD00M279 BD00M283
Clean the groove of the brake housing with cleaning

solvent. Install the guide ring in the groove. Make sure 5 4
the ends (A) of the guide ring are facing up towards
the top (B) of the brake housing and the guide ring is
installed completely in its groove in the brake hous-
ing. Apply Loctite 415 to ID of guide ring to secure 3
guide ring in its groove.
STEP 50
A
1
BS00M074
A. 10.5 to 10.8 mm (0.41 to 0.43 inch) - 1. Pin - 2. Gripping

rings - 3. Belleville springs - 4. Support shim - 5. Retaining
BD00M280
ring.
Apply oil on the sliding surface of the piston, support
rings, U-rings and guide ring. Carefully install piston Install the Belleville springs on the pins. Make sure
in the brake housing. dimension (A) is 10.5 to 10.8 mm (0.41 to 0.43 inch).
STEP 51
BD00M282
1. Gripping rings.
Press the gripping rings on the pins. Ends of gripping

rings must be 180° opposite from each other.
STEP 53 STEP 56
BD00M284 BD00M287
Put the assembled pins into the support shim and

install the snap ring. 1 2 3 4 A 5
STEP 54
BS00M075
A. 4.5 to 5.0 mm (0.18 to 0.20 inch) - 1. Brake housing -

BD00M285 2. Snap ring - 3. Pin - 4. Support shim - 5. Piston.
Put the assembled support shim in the piston.

Install the three pins (3) in the support shim (4) to
lock the snap ring (2). Dimension (A) between top of
STEP 55
pins (3) and top of support shim (4) must be 4.5 to
5.0 mm (0.18 to 0.20 inch).
STEP 57
BD00M286
Install the snap ring to secure the support shim. 1
BD00M288
1. Spline.
If removed, drive the stop bolt into the planetary car-

rier until contact. Then coat the spline with Loctite
No. 767 antiseize lubricant.
STEP 58 STEP 61
BD00M289 BD00M251
Install the planet carrier into the spline of the wheel Apply grease to new O-rings and install on planetary
end shaft. ring gear.
STEP 59 STEP 62
BD00M253 BD00M291
Apply oil to the clutch discs. Install the outer and in- Install two alignment studs in the brake housing. Po-
ner clutch discs alternately starting with an outer clutch sition the planetary ring gear on the brake housing.
disc. Make sure alignment marks made during disassem-
bly are aligned. Press planetary ring gear into brake
STEP 60 housing.
BD00M290
Install a new O-ring in the brake housing port.
STEP 63 STEP 65
WARNING WARNING
Always wear heat protective gloves to prevent Always wear heat protective gloves to prevent
burning your hand when handling heated parts. burning your hand when handling heated parts.
BD00M292 BD00M294
Heat the planetary gears inner bearings to 100 °C Heat the planetary gears outer bearings to 100 °C
(212 °F) in a bearing oven. Wearing heat resistant (212 °F) in a bearing oven. Wearing heat resistant
gloves or mittens, install the bearings on the shafts gloves or mittens, install the bearings on the shafts
until the bearing is against the bottom of the shaft. until the bearing is against the gear.
STEP 64 STEP 66
BD00M293 BD00M295
Install the planetary gears on the bearings. Install the retaining rings on the planetary gear shafts.
Sun Gear Shaft End Play Adjustment

STEP 67 STEP 69
BD00M296 BD00M298
Using two M18 bolts of suitable length, secure plan- Install the sun gear shaft in the stub shaft. Make sure
etary ring gear to brake housing. Then, determine di- the stub shaft is installed all the way into the sun gear
mension A, from the face of the planetary carrier stop shaft.
bolt to the mounting face of the planetary ring gear.
STEP 70
Example
Dimension A ......................... 36.00 mm (1.42 inch)
STEP 68
BD00M299
Determine dimension B from the face of the sun gear

shaft to the mounting face of the axle housing.
BD00M297
Example
Install the stub shaft in the spline of the axle bevel Dimension B ......................... 32.80 mm (1.29 inch)
gear. Make sure the stub shaft is installed all the way
into the axle bevel gear. STEP 71
Subtract dimension B from dimension A. Then sub-
tract 1 mm (0.04 inch) from the difference. The differ-
ence is the required shim size.
Example
Dimension A + 36.00 mm (1.42 inch)
Dimension B - 32.80 mm (1.29 inch)
Difference 3.20 mm (0.13 inch)
Required end play - 1.00 mm (0.04 inch)
Difference = shim size 2.20 mm (0.09 inch)
STEP 72 STEP 75
BD00M245 BD00M300
Install the sun gear shaft in the planet carrier. Install the washers and bolts to secure the wheel end
to the axle housing. Tighten the bolts to a torque of
STEP 73 390 Nm (288 lb-ft).
STEP 76
BD00M244
Install the shim set (size as determined in Step 71

BD00M301
above) into the sun gear shaft with grease.
Install the lock nut by hand and tighten using
STEP 74 380001576 support bracket and 380001571 locknut
socket and nuts. Tighten the lock nut to a torque of
700 to 1000 Nm (516 to 737 lb-ft).
STEP 77
BD00M242
Apply grease to a new O-ring and install O-ring in brake

port. Use acceptable lifting equipment and install the
assembled wheel end onto the axle housing.
BD00M302
Install the slotted pin into the wheel end lock nut.
STEP 78 STEP 79
BD00M303 BD00M304
1. O-ring. Install the cover into the wheel end.

Install a new O-ring on the wheel end cover.
2.5.8 BRAKE HYDRAULICS LEAKAGE High Pressure Test

TEST STEP 81
Important – DO NOT EXCEED 100 BAR (1450 PSI) Operate the hand pump to increase pressure
PRESSURE IN THE FOLLOWING STEPS. If the to 100 bar (1450 psi) maximum. Close connection
maximum pressure of 100 bar (1450 psi) is exceeded, to hand pump using the shutoff valve. During a 5
the piston will move too much changing the gripping minute period, pressure shall not drop more than 2
rings adjustment. If the gripping rings adjustment bar (29 psi).
changes, the wheel end must be removed and disas-
sembled and the gripping rings adjusted to the cor- Low Pressure Test
rect dimension (Step 52).
STEP 82
STEP 80 Reduce pressure to 5 bar (72.5 psi) and close the
shutoff valve. During a 5 minute period pressure shall
not drop.
BD00M305
Connect a hand pump with pressure gauge to the brake

port as shown above. Build up pressure in the axle
internal brake lines then bleed air from the lines. After
air is bled, actuate the brakes a minimum of 10 times
by operating the hand pump.
2.5.9 DIFFERENTIAL CARRIER

DISASSEMBLY
STEP 83 STEP 85
BD00M306 BD00M241
Fasten the axle to a stand. Use acceptable lifting equipment to hold wheel end in
place. Remove the bolts and washers.
STEP 84
STEP 86
BD00M307
BD00M242
Carefully pull the wheel end from the axle housing.

Remove and discard O-ring from axle housing wheel
end.
BD00M308
Remove drain plugs and drain oil from axle.
STEP 87 STEP 91
BD00M243 BD00M314
Pull the stub shaft out of the sun gear shaft. Be care- Mount differential carrier in 380001580 engine stand
ful not to lose shim(s) that may be installed in sun using one 380001562 holding bracket.
gear shaft.
STEP 92
STEP 88
Do Steps 85 to 87 to remove the other wheel end.
STEP 89
BD00M315
Drive out the roll pins from the bearing caps.
STEP 93
BD00M312
Put alignment marks on the differential carrier and

axle housing. Remove 15 bolts securing differential
carrier.
STEP 90
Connect lifting equipment to flange and remove the
differential carrier from axle housing.
BD01F072
Remove both adjusting nuts using 380001565 wrench.
STEP 94 STEP 96
BD00M317 BD00M319
Heat the differential carrier using a hot air blower. Remove both bearing cups.
Note – Bolts are installed with Loctite. STEP 97
STEP 95
Important – Do not use an air ratchet or wrench to
remove bolts.
1
BD00M320
Use acceptable lifting equipment and remove the dif-

ferential from the differential carrier.
BD00M318
1. Alignment mark.
Make alignment marks on bearing caps and differen-

tial housing to aid in assembly. Remove four bolts
then remove both bearing caps.
2.5.10 DIFFERENTIAL DISASSEMBLY

STEP 98 STEP 101
BD01F059 BD00M324
Remove the bearing from the differential housing us- Remove the housing cover from the differential hous-
ing 380001563 puller, 380001581 pulling attachment, ing.
380001538 puller legs, and 380001540 step plate.
STEP 102
STEP 99
BD00M325
BD01F075
Remove all parts from the differential housing.
Remove the bearing from the housing cover using
380001569 collet set, 380001575 puller body, and STEP 103
380001541 step plate.
STEP 100
BD00M326
Press the ring gear from the differential housing.

BD00M323

ing. Remove the bolts.
2.5.11 DRIVE PINION DISASSEMBLY

STEP 104
Heat lock nut securing flange with a hot air blower to
loosen Loctite.
STEP 105 STEP 107
BD01F091 BD00M330
Install 380001546 holding wrench on input flange. Hold Remove the shaft seal from the axle drive housing.
flange using holding wrench and remove lock nut and
washer. Remove holding tool from flange. STEP 108
Using a rubber hammer remove the drive pinion from
STEP 106 the axle drive housing. Remove the pinion outer bear-
ing.
STEP 109
Remove the spacer ring and inner bearing from the
drive pinion.
STEP 110
BD00M329
Remove the input flange from the drive pinion.
BD00M333
If necessary drive out both bearing cups from the dif-

ferential carrier.
2.5.12 BRAKE TUBES REMOVAL

STEP 111 STEP 114
BD00M334 BD00M337
Remove the plug with the breather installed from the Loosen the fitting on the opposite end of the brake
axle housing. tube then remove the brake tube from the axle hous-
ing.
STEP 112
STEP 115
BD00M335
BD00M338
Remove the nut securing the brake tube to the axle
housing. Remove the vent valve from the fitting.
STEP 113 STEP 116
BD00M336 BD00M339
Loosen and remove the connector from the axle. Remove the fitting. Remove and discard O-ring and
rectangular ring from fitting.
Note – Do Steps 112 to 116 on other wheel end.
2.5.13 BRAKE TUBES INSTALLATION

STEP 117 STEP 119
1 2
3
4
BD00M340 BD00M342
1. Vent Valve - 2. Fitting - 3. O-ring - 4. Rectangular ring. Install a new O-ring on the connector. Install the con-
nector in the axle and tighten to a torque of 190 Nm
Install new O-ring and rectangular ring on fitting. In- (140 lb-ft).
stall and tighten vent valve in fitting.
STEP 120
STEP 118
BD00M343
BD00M341
1. O-ring.
Install the assembled vent valve and fitting in the axle.
Tighten the fitting to a torque of 130 Nm (96 lb-ft). Install a new O-ring in the groove of the brake tube
fitting.
STEP 121 STEP 124

1
2
1
3
3
2
BD00M344 BD00M347
1. Brake tube - 2. Fitting - 3. Connector. 1. O-ring - 2. Plug - 3. Breather.
Install the brake tube (1) in the axle housing, insert- Remove and discard O-ring (1) from plug (2) and in-
ing the fitting (2) through the connector (3). stall a new O-ring. Install breather (3) in plug.
STEP 122 STEP 125
BD00M345 BD00M348
Install the nut to secure the brake tube fitting. Tighten Install the plug in axle housing. Tighten plug to a torque
the nut to a torque of 70 Nm (52 lb-ft). of 70 Nm (52 lb-ft).
STEP 123
BD00M346
Connect fitting on opposite end of brake tube to fitting

installed in wheel end. Tightening brake tube fitting to
a torque of 80 Nm (60 lb-ft).
Note – Do Steps 117 to 123 on other wheel end.
2.5.14 DIFFERENTIAL CARRIER STEP 128

ASSEMBLY
Note – The ring gear and the drive pinion are a matched
gear set and cannot be serviced separately.
Determine Shim Thickness for Correct Tooth

Contact Pattern
Note – Make the following measurements at maxi-
mum accuracy. Inaccurate measurements will result
in a faulty tooth contact pattern causing disassembly
of the drive pinion and differential.
BD00M350
STEP 126
Determine dimension C (bearing width).
Install the 380001570 pinion depth gauge set on the
differential carrier. Dimension C (Example) ...... 33.50 mm (1.319 inch)
STEP 127 STEP 129
BD00M351
BD00M349
1. 148.00 mm (+0.05 mm).
Determine dimension B (gap between the measuring
shaft and the measuring pin) using a thickness gauge. Read dimension D (dimension for pinion).
Dimension B (Example) ........ 1.00 mm (0.039 inch) Dimension D (Example) ...... 148.05 mm (5.83 inch)
Example A: Example B:
Dimension A (tool constant) 181.75 mm (7.155 inch) Dimension C 33.50 mm (1.319 inch)
Dimension B (gap) + 1.00 mm (0.039 inch) Dimension D + 148.05 mm (5.829 inch)
Results in Dimension X 182.75 mm (7.195 inch) Results in Dimension Y 181.55 mm (7.148 inch)
STEP 130
Subtract dimension Y from dimension X. The differ-
ence is the required shim thickness.
Example C:
Dimension X 182.75 mm (7.195 inch)

Dimension Y - 181.55 mm (7.148 inch)
Difference = Shim 1.20 mm (0.047 inch)
Install Drive Pinion STEP 133

STEP 131
WARNING
Always wear insulated gloves or mittens when
handling frozen parts.
BD00M352
Install the shim set determined in Step 130 in the

bearing bore on the differential carrier.
BD01F062
STEP 132
Freeze new outer bearing cup in dry ice for several
hours. Install bearing cup in differential carrier using
WARNING 380001550.
Always wear insulated gloves or mittens when
handling frozen parts. STEP 134
BD01F065
BD01F064
Press the inner bearing on the drive pinion shaft us-
Freeze new inner bearing cup in dry ice for several
ing 380001552.
hours. Install bearing cup in differential carrier using
380001549.
Drive Pinion Bearing Rolling Torque Adjustment

STEP 135 STEP 137
BD00M356 BD01F101
Install an 8.90 mm (0.35 inch) thick spacer on the Using 380001575 puller tube, press the dust shield
pinion shaft. on the input flange.
STEP 136 STEP 138
WARNING
BD00M359
Install the input flange on the pinion shaft.
STEP 139
BD00M357
Heat the pinion shaft outer bearing to 100 °C (212 °F)

in a bearing oven. Wearing heat resistance gloves or
mittens, install the bearing on the pinion shaft until
contact.
BD00M360
Put the washer in place on the pinion shaft.
STEP 140 STEP 143
BD01F091 BD01F066
Install 380001546 holding wrench on input flange. Hold Using the 380001747 and 380001748 pinion seal in-
flange using holding tool and tighten nut to a torque of stallers, install the shaft seal with the seal lip down.
700 Nm (516 lb-ft). Remove 380001546.
Note – Just before installation, wet the outer diam-
Note – When tightening rotate the pinion shaft in both eter of the shaft seal with a solution of 50% water and
directions several times. 50% mineral spirits. Fill the space between the seal-
ing and dust lip with grease.
STEP 141
STEP 144
BD00M362
BD01F091
Check the rolling torque of the drive pinion bearing.
The rolling torque should be 1.1 to 2.3 Nm (9.7 to 20.3 Install the input flange. Install 380001546 holding
lb-inch). If rolling torque is too low, install a thinner wrench on input flange. Apply Loctite No. 262, on the
spacer (Step 135); if rolling torque is too high, install a threads of the locknut. Install the washer and locknut
thicker spacer (Step 135). by hand. Hold flange using holding tool and tighten
nut to a torque of 700 Nm (516 lb-ft). Remove
STEP 142 380001546.
Remove the nut and input yoke from the drive pinion
shaft.
2.5.15 DIFFERENTIAL ASSEMBLY

STEP 145 STEP 146
BD00M365 BD00M366
1. Groove.
1
Install the retaining ring in the groove in the bottom of
the differential housing.
2
STEP 147
BS00M077 1
A. 1.5 to 2.5 mm (0.06 to 0.10 inch) - 1. Differential hous-

ing - 2. Seal caps.
Install the seal caps. Seal caps must be installed to

depth A.
BD00M367
Note – Be sure to apply oil to all parts before assembly.
1. Grooves.
Install the driving pins in the grooves of the differen-

tial housing.
STEP 148 STEP 152
BD00M368 BD00M371
Install both thrust washers in the differential housing. Install the axle bevel gear. Make sure axle bevel gear
splines mate with splines of all inner clutch discs.
Limited Slip Differential
STEP 153
STEP 149
BD00M372
BD00M369
Assemble the differential spider and install into the
Starting with an outer clutch disc install alternately
differential housing.
the outer and inner clutch discs. Thickness of disc
pack must be the same on both sides.
STEP 154
Open Differential
STEP 150
Install four outer clutch discs in differential housing.
Thickness of disc pack must be the same on both
sides.
STEP 151
BD00M373
Install the second axle bevel gear.
BD00M370
Install the pressure ring in the differential housing.
STEP 155 Determine Disc Clearance

STEP 159
BD00M374
Install the second pressure ring in the differential hous- BD00M377

ing.
Determine dimension A, from mounting face of the
differential housing to face of the outer clutch disc.
Limited Slip Differential
Dimension A (Example) ......... 15.60 mm (0.61 inch)
STEP 156
STEP 160
BD00M375
Starting with an inner clutch disc, install alternately BD00M378
the inner and outer clutch disc. Thickness of disc pack

Determine dimension B, from contact surface of the
must be the same on both sides.
outer clutch disc to mounting face of the housing
cover.
Open Differential
Dimension B (Example) ......... 15.20 mm (0.60 inch)
STEP 157
Install four outer clutch discs. Thickness of disc pack Example B:
must be the same on both sides.
Dimension A 15.60 mm (0.62 inch)
STEP 158 Dimension B - 15.20 mm (0.60 inch)
Difference = Disc clearance 0.40 mm (0.02 inch)
Note – If required disc clearance of 0.40 mm

(0.02 inch) is not obtained, install new outer clutch
discs of thickness necessary to obtain 0.40 mm
(0.02 inch) disc clearance. Difference in thickness
between left and right disc pack must not exceed
0.1 mm (0.04 inch). Outer clutch discs are available
in following thicknesses: 2.1 mm (0.083 inch), 2.2 mm
(0.087 inch), 2.3 mm (0.090 inch), 2.4 mm (0.094 inch),
and 2.5 mm (0.098 inch).
BD00M376
Install the driving pin in the differential housing.
STEP 161 STEP 163
WARNING
BD00M379
Install the thrust washer with grease in the recess of

the housing cover.
STEP 162
BD00M381
Heat the ring gear to 100 °C (212 °F) in a bearing

oven. Wearing heat resistance gloves or mittens, in-
stall the ring gear on the differential.
STEP 164
BD00M380
Put the housing cover on the differential housing.
BD00M382

ing. Install new bolts and tighten bolts to a torque of
250 Nm (185 lb-ft).
STEP 165 STEP 168
BD00M383 BD00M385
Press both bearings on the differential. Install both bearing caps. Apply Loctite No. 262 to
threads of bolts. Install the bolts and washers. Tighten
STEP 166 the bolts to a torque of 280 Nm (207 lb-ft).
STEP 169
BD00M320
Use acceptable lifting equipment and install the dif-

BD01F072
ferential into the differential carrier.
Use 380001565 wrench to tighten the two adjusting
STEP 167 nuts evenly until there is light pressure against the
bearings on each side of the differential.
BD00M384
Install both bearing cups and install adjusting nuts.
Adjust Backlash and Bearing Preload

STEP 170 STEP 175
BD01F061 BD00M388
Place 380001725 dial indicator right-angled at the outer Apply marking ink on several teeth of the ring gear
diameter of the tooth flank (ring gear). Adjust the pin- and rotate it in both directions. Compare the obtained
ion to ring gear backlash to the low side of specifica- tooth contact pattern with the examples on pages 138
tions (see numbers etched on the outer diameter of and 139.
the ring gear) by alternately turning each of the ad-
justing nuts to move the ring gear closer to or further Note – If the tooth contact pattern differs, the wrong
away from the pinion. shim size was selected in Step 130. Remove differ-
ential and repeat Steps 126 though 130.
STEP 171
STEP 176
Go to the adjusting nut opposite the ring gear and
loosen the nut approximately one turn to release pres-
sure on the bearing. It should be very noticeable that
pressure is released on the bearing, as the adjusting
nut will turn much easier.
STEP 172
Tighten the bearing adjusting nut slowly until firm con-
tact is made with the bearing.
Note – As the adjusting nut makes firm contact with

the bearing, the adjusting nut will immediately begin BD00M389
to turn with more effort.
Install pins to secure both adjusting nuts.
STEP 173
STEP 177
To adjust the differential bearing preload, note the
position of the adjusting nut. Now tighten the nut two Apply sealing compound (Three Bond Type 1215) to
additional notches. differential mounting surface on axle housing. Install
two 380001752 alignment studs in axle housing to aid
STEP 174 installation of differential carrier. Using suitable lifting
equipment, install the differential carrier in the axle
When the bearing preload is adjusted the backlash housing then remove alignment studs.
may increase slightly. Check pinion backlash to con-
firm that it is within specifications. If within specifica-
tions, install the adjusting nut locking roll pins. If back-
lash is outside of specified range, repeat Step 170
through 174 again.
STEP 178 STEP 181
BD00M391 BD00M242
Using new bolts, secure the differential carrier to the Apply grease to a new O-ring and install O-ring in brake
axle housing. Tighten bolts to a torque of 250 Nm port. Position the wheel end on the axle housing.
(185 lb-ft).
STEP 182
STEP 179
BD00M394
BD00M392
Install the washers and bolts on the wheel end. Tighten
Install the stub shaft into the spline of the differential the bolts to a torque of 390 Nm (288 lb-ft).
bevel gear.
Note – Repeat Steps 179 through 182 for the other
STEP 180 wheel end.
BD00M393
Install the thrust washer removed at disassembly. Use

grease to keep it in the sun gear.
2.6 DRIVE SHAFTS, CENTER BEARING, AND UNIVERSAL JOINTS

Coupler to Flywheel Bolts ........................................................................................ 53 to 62 Nm (39 to 46 lb-ft)
Engine Drive Shaft to Coupler Bolts ......................................................................... 53 to 62 Nm (39 to 46 lb-ft)
Engine Drive Shaft to Transmission Bolts ................................................................. 34 to 41 Nm (25 to 30 lb-ft)
Center, Rear and Front Drive Shaft Bolts .................................................................. 61 to 81 Nm (45 to 60 lb-ft)
Carrier Bearing Bolts ............................................................................................... 99 to 128 Nm (73 to 94 lb-ft)
Lock Nut for Yoke on Front Drive Shaft .............................................................. 339 to 375 Nm (250 to 275 lb-ft)
2.6.2 FRONT DRIVE SHAFT STEP 4

Removal Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
STEP 1
STEP 5
Loosen the set screws that secure the center bearing
to the front drive shaft.
STEP 6
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
STEP 7
BD03A166
Loosen and remove the bolts and straps that fasten the
center drive shaft to the yoke of the front drive shaft.
STEP 2
BD03A167
Loosen and remove the bolts and straps that fasten

the front drive shaft to the front axle.
STEP 8
BD03A183 Use a prybar to disengage the front drive shaft from
Remove the lock nut that fastens the yoke to the front the front axle and remove the front drive shaft from
drive shaft. the machine.
STEP 3 Note – If necessary, use a brass hammer to drive the

front drive shaft out of the center bearing.
Make an alignment mark on the yoke and the end of
the front drive shaft to make sure that the yoke is
installed correctly.
2.6.3 FRONT DRIVE SHAFT STEP 14

Installation
STEP 9
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 10
Place the front drive shaft into position in the center
bearing of the machine.
STEP 11
BD03A183
Install the lock nut that fastens the yoke to the front
drive shaft. Tighten the lock nut to a torque of 339
to 375 Nm (250 to 275 lb-ft).
STEP 15
Tighten the set screws, that secures the center bear-
ing to the front drive shaft, alternately until they stop
turning and the hex head socket wrench starts to
spring.
BD03A167 STEP 16
Install the bolts and straps that fasten the front drive
shaft to the front axle. Tighten the bolts to a torque of
61 to 81 Nm (45 to 60 lb-ft).
STEP 12
Apply antiseize compound to the splines on the front
drive shaft.
STEP 13
Install the yoke to the front drive shaft, making sure
the alignment marks made during removal are aligned.
BD03A166
Note – If a new front drive shaft has been installed,
make sure the yoke being installed is 90° to the yoke Install the bolts and straps that fasten the front drive
on the other end of the front drive shaft. shaft to the center drive shaft. Tighten the bolts to a
torque of 61 to 81 Nm (45 to 60 lb-ft).
2.6.4 CENTER BEARING STEP 20

Removal Make an alignment mark on the yoke and the front
drive shaft to be sure that the yoke is installed cor-
STEP 17
rectly.
STEP 21
Use an acceptable puller and remove the yoke from
the end of the front drive shaft.
STEP 22
Remove any paint or rust from the rear of the front
drive shaft and apply WD40 or similar oil to loosen
any rust between the inner race and the front drive
shaft.
BD03A166 STEP 23
Loosen and remove the bolts and straps that fasten Loosen the set screws that secure the center bearing
the center drive shaft to the front drive shaft. to the front drive shaft.
STEP 18 STEP 24
BD03A183 BD03A183
Loosen and remove the lubrication hose from the Loosen and remove the bolts, washers and nuts that
center bearing. fasten the bearing housing to the front frame.
STEP 19 STEP 25
Install two longer bolts, at least 3 inches, to hold the
bearing housing during removal. Use an acceptable
puller to remove the bearing housing from the front
drive shaft.
BD03A183
Loosen and remove the lock nut that fastens the yoke
to the front drive shaft.
2.6.5 CENTER BEARING STEP 31

Installation
Note – The center bearing and the bearing housing
are not serviced separately. If the center bearing is
worn or damaged or if the bearing housing is cracked,
a new center bearing and bearing housing must be
used.
STEP 26
Apply antiseize compound to the bearing area of the
front drive shaft.
STEP 27 BD03A183
Install the bearing housing so that the lubrication fit- Install the washer and lock nut that fasten the yoke to
ting is at the top. the front drive shaft. Tighten the lock nut to a torque
of 339 to 375 Nm (250 to 275 lb-ft).
STEP 28
STEP 32
BD03A183
Install the bolts, washers and nuts that fasten the BD03A166
bearing housing to the front frame. Tighten the bolts Install the straps and bolts that fasten the center drive
to a torque of 99 to 128 Nm (73 to 94 lb-ft). shaft to the yoke on the front drive shaft. Tighten the
bolts to a torque of 61 to 81 Nm (45 to 60 lb-ft).
STEP 29
Apply antiseize compound to the splines on the front STEP 33
drive shaft. Install the lubrication hose into the fitting on the bear-
ing housing.
STEP 30
Install the yoke to the front drive shaft, making sure STEP 34
the alignment marks made during removal are aligned. Lubricate the center bearing with the grease.
2.6.6 CENTER DRIVE SHAFT

Removal Installation
STEP 35 STEP 39
BD03A166 BD03A165
Loosen and remove the bolts and straps that fasten Hold the center drive shaft in position and install the
the center drive shaft to the yoke of the front drive bolts and straps that fasten the center drive shaft to
shaft. the transmission. Tighten the bolts to a torque of 61
to 81 Nm (45 to 60 lb-ft).
STEP 36
Use a prybar to disengage the center drive shaft from STEP 40
the yoke of the front drive shaft.
STEP 37
BD03A166
Install the bolts and straps that fasten the center drive
shaft to the yoke of the front drive shaft. Tighten the
BD03A165 bolts to a torque of 61 to 81 Nm (45 to 60 lb-ft).
the center drive shaft to the transmission.
STEP 38
Hold the center drive shaft and remove from the ma-
chine.
2.6.7 REAR DRIVE SHAFT

STEP 41 STEP 45
BD01D323

the rear drive shaft to the transmission.
BD01F304
STEP 42 Hold the rear drive shaft into position and install the
Use a prybar to disengage the rear drive shaft from bolts and straps that fasten the rear drive shaft to the
the transmission. rear axle. Tighten the bolts to a torque of 61 to 81 Nm
(45 to 60 lb-ft).
STEP 43
STEP 46
BD01D323
Install the bolts and straps that fasten the rear drive
BD01F304 shaft to the transmission. Tighten the bolts to a torque
Loosen and remove the bolts and straps that fasten of 61 to 81 Nm (45 to 60 lb-ft).
the rear drive shaft to the rear axle.
STEP 44
Hold the rear drive shaft and remove from the ma-
chine.
2.6.8 ENGINE DRIVE SHAFT

STEP 47 STEP 50
BD01D342 BD01D342
Remove and discard the bolts and straps that fasten Place the engine drive shaft into position on the trans-
the engine drive shaft to the transmission. mission and install new straps and bolts. Tighten the
bolts to a torque of 61 to 81 Nm (45 to 60 lb ft).
Important – The bolts and straps that fasten the en-
gine drive shaft to the transmission must be replaced STEP 51
when removed.
STEP 48
BD03A172
Install the six bolts that fasten the engine drive shaft
to the engine. Tighten the bolts to a torque of 53 to
BD03A172 62 Nm (39 to 46 lb ft).
Loosen and remove the six bolts that fasten the en-
gine drive shaft to the engine.
STEP 49
Remove the engine drive shaft from the machine.
2.6.9 UNIVERSAL JOINTS Installation

Removal Note – The bearing race and journal that make up the
universal joint are not serviced separately. If the bear-
STEP 52
ing race or journal is worn or damaged, a new univer-
Remove the drive shaft from the machine. sal joint must be use.
STEP 53 STEP 55
Clean the slots in the yoke of the drive shaft.
STEP 56
Install the universal joint and install the bearings (2)
and the rings (1). Refer to the photo in Step 53.
STEP 57
Install the drive shaft.
BD01F304
1. Ring - 2. Bearing.
Remove the ring (1) and the bearing (2) from the drive
shaft.
Note – The above photo shows the drive shaft on the

machine and is for reference of the ring and bearing
only.
STEP 54
Remove the universal joint from the drive shaft.
2.7 WHEELS AND TIRES
2.7.1 WHEELS AND BOLTS Torque Specification

General Information Tighten the wheel nuts to 298 Nm (220 pound-feet) in
the sequence shown in Figure page 186. Then a final
The wheel nuts must be tightened after every 20 hours torque of 640 to 720 Nm (475 to 530 pound-feet) in
of operation until the wheel nuts stay tight: the same sequence.
A. If the machine is new.
B. If a wheel has been removed and installed.
2.7.2 TIRE PRESSURE

20.5 x 25 L2 ................................................................................ Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
20.5R x 25 XTLA TL.................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
20.5R x 25 XHA TL ..................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
20.5 x 25 GP2B .......................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
20.5 x 25 RT3B ........................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
20.5R x 25 VUT .......................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
20.5R x 25 VMT .......................................................................... Front, 3.45 bar (50 psi), Rear, 2.75 bar (40 psi)
2.7.3 CHANGING TIRES 2.7.4 INSTALLING A WHEEL

1. Make sure the mounting surfaces of the rim and
WARNING axle flange are clean and free of dirt and grease.
The split rim wheels used on this machine can be 2. Install the wheel, hardened washers and wheel nuts.
dangerous. When inflating a tire on the machine,
3. Use a hand wrench (not an impact) to tighten the
use a self-locking nozzle and stand at the front or
wheel nuts to pull the wheel against the planetary
rear of the tire.
housing. DO NOT use an impact wrench to tighten
the wheel nuts.
When inflating a tire off the machine, put the wheel
in a tire inflation cage. The retaining ring and rim 4. Tighten the wheel nuts to 298 Nm (220 pound-feet)
can come off with enough force to result in death in the sequence shown in Figure. Then tighten the
to a person in front of the rim. wheel nuts in the same sequence to 640
to 720 Nm (475 to 530 pound-feet).
1. Have a qualified tire mechanic service the split rim
wheels used on this machine.
2. The correct tire equipment, especially a tire infla- 1
tion cage, is required. Using the wrong procedure 10 8
for a split rim wheel can result in death.
3 6
Important – When installing a Michelin tire, lubricate
the tire with a tire mounting lubricant and inflate the
tire to 551 kPa, 5.5 bar (80 psi) to make sure that the 5 4
tire is seated on the rim. Then decrease the pressure
to the specified pressure. 7 9
2 BS00J104
Wheel bolt torque sequence
2.8 TRANSMISSION CONTROL VALVE

2.8.1 DISASSEMBLY STEP 3
STEP 1 Remove distribution plate (2), housing gasket (3),
valve plate (4), and housing gasket (5). Discard hous-
To aid in assembly, put alignment marks on transmis-
ing gaskets (3 and 5).
sion control valve (7, figure 1), distribution plate (2),
and valve plate (4).
STEP 4
STEP 2 Remove six filter screens (6) from valve plate (4).
Remove 18 screws (1) securing distribution plate (2)
to transmission control valve (7).
5
4
3
2
6
BS98J157
Figure 1 – Transmission control valve plates and gaskets
1. Screw - 2. Distribution plate - 3. Housing gasket - 4. Valve plate - 5. Housing gasket - 6. Filter screen - 7. Transmission
control valve.
STEP 5 STEP 13
To aid in assembly, put alignment marks on covers (3 Remove two screws (13) from opposite corners of end
and 6, figure 2), end housings (14), and valve housing housing (14).
(27). Put alignment marks on wiring harness (8) con-
nector and cover (3). STEP 14
STEP 6
Remove clamp (1) securing wiring harness (8) con-
nector to cover (3).
STEP 7
Remove 14 screws (2) securing cover (3) to end hous-
ing (14).
STEP 8
Remove cover (3) and gasket (4). Discard gasket (4). BS02C114
Install 380001577 transmission valve adjustment tool

STEP 9 set in holes where screws (13) were removed. Tighten
Remove 14 screws (5) securing cover (6) to end hous- hex rods of 380001577 down against end housing.
ing (14). Remove remaining 16 screws from end housing (14).
Loosen 380001577 hex rods uniformly to release spring
STEP 10 tension. Remove end housing and gasket (15). Dis-
card gasket. Remove 380001577 studs.
Remove cover (6) and gasket (7). Discard gasket (7).
STEP 15
STEP 11
BS02C113
Disconnect wiring harness (8) connectors from six BS02C115

pressure regulators (11). Remove wiring harness from
housings (14 and 27) by carefully routing harness and Remove three pistons (16 and 18), springs (17 and
connectors through openings in housings. 19), spring (20), and piston (21) from valve housing
(27).
STEP 12
STEP 16
Remove three screws (9) and locating plates (10) se-
curing three pressure regulators (11) to end housing Repeat Steps 12 through 14 for other side of valve
(14). Remove pressure regulators (11). Remove and housing (27).
discard O-ring (12) from pressure regulators.
Note – End housings (14) are under spring pressure.

Use 380001577 transmission valve adjustment tool
set to hold springs down.
8
1
4
3
21
20
18
19
9
23
25 22
11,12 26
10
18
19
15
13 14
14
15 9 7
10
16 5
17 27
13 11,12
24
17
16
6
BS01B099
Figure 2 – Transmission control valve
1. Clamp - 2. Screw - 3. Cover - 4. Gasket - 5. Screw - 6. Cover - 7. Gasket - 8. Wiring harness - 9. Screw - 10. Locating plate -
11. Pressure regulator - 12. O-ring - 13. Screw - 14. End housing - 15. Gasket - 16. Piston - 17. Spring - 18. Piston -
19. Spring - 20. Spring - 21. Piston - 22. Piston - 23. Spring - 24. Orifice - 25. Plug - 26. O-ring - 27. Valve housing.
STEP 17 STEP 18
BS02C116 BS02C117
Remove three pistons (16 and 18), springs (17 and Remove six orifices (24) from valve housing (27).
19), piston (22), and spring (23) from valve housing
(27). STEP 19
Remove eight plugs (25). Remove and discard
O-ring (26) from plugs.
2.8.2 INSPECTION STEP 25

STEP 20 Check pressure regulators (11) for cracks, breaks, or
other damage. Check connector contacts for loose-
Clean all metal parts in cleaning solvent.
ness or signs of corrosion. Replace a pressure regu-
lator if any of these conditions are seen. Check re-
STEP 21
sistance of pressure regulators using a multimeter.
Immerse end housings (14, figure 2), valve housing Replace a pressure regulator if resistance is not 17 to
(27), valve plate (4, Figure 1), and distribution plate 21 ohms.
(2) in cleaning solvent and agitate cleaning solvent.
WEAR EYE PROTECTION WHEN USING COM- STEP 26
PRESSED AIR. Use compressed air to remove for-
Check wiring harness (8) connectors for signs of
eign matter from interior of housings and plates and
breaks, cracks, or other damage. Check contacts for
to ensure that all bores are clear of foreign matter.
foreign matter or corrosion. Check harness wiring for
signs of broken or cracked insulation and broken or
STEP 22
frayed wiring at connection to connectors. Replace
WEAR EYE PROTECTION WHEN USING COM- wiring harness if any of these conditions are seen.
PRESSED AIR. Use compressed air to ensure that
orifices (24, figure 2) are clear of foreign matter. STEP 27
Check springs (17, 19, 20, and 23, figure 2) for cracks,
STEP 23
breaks, distortion, or signs of permanent set. Replace
Check filter screens (6, figure 1) for blockage, rips, or a spring if any of these conditions are seen.
tears. Replace if any of these conditions are seen.
STEP 28
STEP 24
Inspect pistons (16, 18, 21 and 22, figure 2) for cracks,
Inspect the plates (2 and 4, figure 1), housings (14 breaks, chipping, grooves, or other damage. Replace
and 27, figure 2) and covers (3 and 6) for corrosion, if any of these conditions are seen.
cracks, breaks, chipping or other damage. Check
bores in housings for deep scratches, gouges, and
other damage. Replace a housing or cover if any of
the above conditions are seen.
8
1
4
3
21
20
18
19
9
23
25 22
11,12 26
10
18
19
15
13 14
14
15 9 7
10
16 5
17 27
13 11,12
24
17
16
6
BS01B099
Figure 3 – Transmission control valve
1. Clamp - 2. Screw - 3. Cover - 4. Gasket - 5. Screw - 6. Cover - 7. Gasket - 8. Wiring harness - 9. Screw - 10. Locating plate
- 11. Pressure regulator - 12. O-ring - 13. Screw - 14. End housing - 15. Gasket - 16. Piston - 17. Spring - 18. Piston -
19. Spring - 20. Spring - 21. Piston - 22. Piston - 23. Spring - 24. Orifice - 25. Plug - 26. O-ring - 27. Valve housing.
2.8.3 ASSEMBLY STEP 31

STEP 29
BS02C118
BS02C117 Push down on pistons (16) to compress springs (17)

and use 5.0 mm (0.197 inch) diameter pins to hold
Install six orifices (24, figure 3) with concave side
pistons in position. Install pins in locations shown
facing up. Install orifices until contact with shoulder in
above.
valve housing (27) is made.
STEP 32
STEP 30
15
A
BS02C119
BS02C115
Install springs (17 and 19) and piston (21) in valve

housing (27) bores then install pistons (16 and 18)
and spring (20).
BS02C120
Install gasket (15) and end housing (14) on valve hous-

ing (27). Make sure 15 mm (0.6 inch) diameter recess
(A) in end housing is facing spring (20). Install
380001577 transmission valve adjustment tool set to
secure end housing. Remove three pins installed in
Step 31 above. Install 16 screws (13) then remove ad-
justment tool set and install remaining two screws (13).
Tighten screws (13) to a torque of 5.5 Nm (48 lb-in).
STEP 33 STEP 36
BS02C121 BS02C123
Install a new O-ring (12) lubricated. Install pres- Do Step 33 to install remaining pressure regulators
sure regulators and locating plates (10). Make sure (11) except make sure pressure regulators are posi-
pressure regulators are positioned as shown above. tioned as shown above.
Locating plates (10) are installed with the nose
(bump) down. Install screws (9) and tighten to a STEP 37
torque of 5.5 Nm (48 lb-in).
STEP 34 4
BS02C125
Install wiring harness (8) by routing harness and con-

nectors through openings in housings (14 and 27).
BS02C116
Connect harness connectors to pressure regulators
At opposite side of valve housing (27), install springs (11). Install gasket (4). Insert wiring harness multi-pin
(17, 19, and 23) and pistons (16, 18, and 22) in valve circular connector in its hole in cover (3) making sure
housing (27) bores. marks made in Step 5 are aligned. Secure connector
to cover using clamp (1).
STEP 35
STEP 38
Install 14 screws (2) to secure cover (3) to end hous-
ing (14). Tighten screws to a torque of 5.5 Nm
(48 lb-in).
A
STEP 39
Install gasket (7) and cover (6).
STEP 40
Install 14 screws (5) to secure cover (6). Tighten
BS02C122 screws to a torque of 5.5 Nm (48 lb-in).
Repeat Steps 31 and 32 except when installing end
housing (14), make sure 19 mm (0.75 inch) diameter
recess (A) faces large piston as shown above.
STEP 41 STEP 42
BS02C127 BS02C128
Install a new O-ring (26) on eight plugs (25). Install Install two studs in transmission control valve (7, Fig-
eight plugs and tighten to a torque of 6 Nm (53 lb-in). ure 4) then install housing gasket (5).
5
4
3
2
6
BS98J157
Figure 4 – Transmission control valve plates and gaskets
1. Screw - 2. Distribution plate - 3. Housing gasket - 4. Valve plate - 5. Housing gasket - 6. Filter screen - 7. Transmission
control valve.
STEP 43 STEP 44
BS02C129 BS02C130
Install six filter screens (6) flush in bores of valve Install housing gasket (3) then distribution plate (2).
plate (4). Screens must be facing upward toward dis- Make sure marks made in Step 1 are aligned. Install
tribution plate (2). Make sure marks made in Step 1 18 screws (1) and tighten evenly to a torque
are aligned. of 9.5 Nm (84 lb-in).
SECTION 3
BRAKE SYSTEM
INDEX
3.1 REMOVAL AND INSTALLATION OF BRAKE COMPONENTS .............................. 3-1

3.1.1 BRAKE VALVE ..................................................................................................... 3-1
Removal ........................................................................................................... 3-1
Installation ........................................................................................................ 3-1
3.1.2 SERVICE BRAKE AND PARKING BRAKE ACCUMULATORS ............................. 3-3
Removal ........................................................................................................... 3-3
Installation ........................................................................................................ 3-3
3.1.3 BRAKE PUMP ...................................................................................................... 3-5
Removal ........................................................................................................... 3-5
Installation ........................................................................................................ 3-5
3.2 HYDRAULIC BRAKE TROUBLESHOOTING ......................................................... 3-7

3.2.1 SPECIFICATIONS ................................................................................................ 3-7
3.2.2 SPECIAL TOOL .................................................................................................... 3-7
3.2.3 TROUBLESHOOTING THE HYDRAULIC BRAKE SYSTEM ................................. 3-8
3.2.4 CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR ......................... 3-9
3.2.5 CHARGING THE ACCUMULATOR WITH DRY NITROGEN ................................... 3-9
3.2.6 BLEEDING THE BRAKE SYSTEM ...................................................................... 3-10
3.2.7 BRAKE MODULATION PRESSURE CHECK ........................................................ 3-11
Testing the Brake Modulation Pressure ............................................................. 3-11
Adjusting the Brake Modulation Pressure ......................................................... 3-12
3.2.8 CHECKING THE BRAKE SYSTEM ...................................................................... 3-13
3.2.9 BRAKE PUMP OUTPUT TEST ............................................................................ 3-14
3.3 DISASSEMBLY AND ASSEMBLY OF BRAKE ACCUMULATORS ........................ 3-15

3.3.1 SPECIAL TOOL .................................................................................................... 3-15
3.3.2 DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR ................... 3-15
3.3.3 CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR ......................... 3-15
3.3.4 CHARGING THE ACCUMULATOR WITH DRY NITROGEN ................................... 3-16
Temperature/Charge Pressure Parking Brake Accumulator ............................... 3-16
Temperature/Charge Pressure Brake Accumulator ............................................ 3-16
3.3.5 PARKING BRAKE ................................................................................................ 3-17
Disassembly ..................................................................................................... 3-17
Inspection ......................................................................................................... 3-18
Assembly ......................................................................................................... 3-18
W170/W170TC BRAKE SYSTEM 3-1
3.1 REMOVAL AND INSTALLATION OF BRAKE COMPONENTS
3.1.1 BRAKE VALVE Installation

Removal 1. Install the brake valve (1), washers, mounting bolts
and hoses. Refer to the illustration below.
1. Park the machine on a level surface and lower
the loader bucket to the floor. Stop the engine. 2. Remove the plugs from the hydraulic lines and con-
nect the hydraulic lines to the brake valve (1).
2. Put blocks on both sides of each tire to prevent
machine movement. 3. Stop the vacuum pump and remove.
3. Make sure the brake accumulators are completely 4. Connect all of the electrical connections.
discharged. Push down and release the brake ped- 5. Turn the master disconnect switch to the ON posi-
als at least 30 times. tion.
4. Turn the master disconnect switch to the OFF po- 6. Bleed the brake system.
sition.
7. Install the cab skirts.
5. Remove the cab skirts located under the cab or
canopy. 8. Check the hydraulic reservoir oil level and add oil
as required.
6. To release the pressure on the parking brake ac-
cumulator, the line at the accumulator must be
SLOWLY cracked open. A pan will be needed to
catch the hydraulic oil.
7. Connect a drain hose to the quick disconnect cou-
plings in each brake circuit to release any pres-
sure in the brake circuit.
8. Clean the brake valve (1) and lines, refer to the
illustration below.
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 reser-
voir. Start the vacuum pump
11. Disconnect the lines from the brake valve (1) and
put plugs in each line.
12. Remove the mounting bolts, washers, hoses (5,
6, 7, 8, 9) and the brake valve (1).
3-2 BRAKE SYSTEM W170/W170TC
3 3
3 4 5
7
8
9
1 3
W170-3R001
Brake accumulator charging valve illustration
1. Brake accumulator charging valve - 2. Brake pedal - 3. Connector - 4. Hose/A. Brake discharge – 5. Hose/A. Front
accumulator - 6. Hose/A. Rear accumulator - 7. Hose/A. Brake valve discharge - 8. Hose/A. Front axle brake - 9. Hose/A.
Rear axle brake.
3.1.2 SERVICE BRAKE AND PARKING Installation

BRAKE ACCUMULATORS 1. Mount the accumulators (1) in the accumulators
Removal clamps (7), do not tighten clamps at this time.
1. Park the machine on a level surface and lower 2. Connect the lines for both brake accumulators (1).
the loader bucket to the floor. Stop the engine. 3. Install the spacers (8), bolts (6), washers (4) and
2. Put blocks on both sides of each tire to prevent nuts (5). Tighten the bolts (6).
machine movement. 4. Tighten accumulator clamps (7).
3. Make sure the service brake accumulators (1) and 5. Install the parking brake accumulator (2) to the
the parking brake accumulator (2) are completely bracket.
discharged. Push down and release the brake
pedal at least 30. 6. Install the nut (3) and tighten.
4. Remove the left cab skirt located under the cab 7. Connect the line to the parking brake accumula-
or canopy to gain access to parking brake accu- tor (2).
mulator. 8. Stop the vacuum pump and remove.
5. To release the pressure on the parking brake ac- 9. Install the left cab skirt.
cumulator, the line at the accumulator must be
SLOWLY cracked open. A pan will be needed to 10. Turn the master disconnect switch to the ON po-
catch the hydraulic oil. sition.
6. Connect a drain hose to the quick disconnect cou- 11. Bleed the brake system.
plings in each brake circuit to release any pres- 12. Check the hydraulic reservoir oil level and add oil
sure in the brake circuit. as required.
7. Turn the master disconnect switch to the OFF po-
sition.
8. Clean the brake accumulators (1), parking brake
accumulator (2) and lines.
9. Put identification tags on all lines that are con-
nected to the brake accumulators (1) and parking
brake accumulator (2).
voir. Start the vacuum pump.
11. Disconnect the lines from both brake accumula-
tors (1) and parking brake accumulator (2).
12. Install plugs or caps on each line.
13. Remove the nut (3), remove the parking brake
accumulator (2).
14. Loosen and remove the bolts (6), washers (4),
accumulators (1), accumulator clamps (7) and
spacers (8).
15. Remove the accumulator clamps (7) from the ac-
cumulators (1).
3
2
4 5
6
1
1
BS03B169
Brake and parking brake accumulators illustration
1. Brake accumulator - 2. Parking brake accumulator - 3. Mounting nut - 4. Washer (8) - 5. Nut (4) - 6. Bolt (4) - 7. Clamp
accumulator - 8. Spacer.
3.1.3 BRAKE PUMP Installation

Removal 1. Install the brake pump (1), mounting bolts (2) and
lock washers (3). Refer to the illustration below.
1. Park the machine on a level surface and lower the
loader bucket to the floor. Stop the engine. 2. Tighten the mounting bolts (2).
2. Put blocks on both sides of each tire to prevent 3. Remove the plugs or caps and connect the lines to
machine movement. the brake pump (1).
3. Turn the master disconnect switch to the OFF po- 4. Stop the vacuum pump and remove.
sition. 5. Turn the master disconnect switch to the ON posi-
4. Clean the brake pump (1) and lines, refer to the tion.
illustration below. 6. Bleed the brake system.
5. Put identification tags on all lines that are connected 7. Check the hydraulic reservoir oil level and add oil
to the brake pump (1). as required.
6. Connect a vacuum pump to the hydraulic reservoir.
Start the vacuum pump.
7. Disconnect the lines from the brake pump (1) and
put plugs or caps on each line.
8. Remove the mounting bolts (2) and lock washers
(3) from the brake pump (1) and remove the brake
pump (1).
1
3
2
6
4
BS03B170
Brake pump illustration
1. Brake pump - 2. Mounting bolt (2) - 3. Lock washer (2) - 4. Gear - 5. Gasket - 6. Elbow - 7. Connector straight - 8. Suction
hose - 9. Pressure hose
NOTES:
3.2 HYDRAULIC BRAKE TROUBLESHOOTING
Brake pump output ................................................................................................... 41.5 to 43 L/min at 172 bar
........................................................................................................ (10.9 to 11.3 gpm at 2500 psi at 2000 rpm)
Accumulator nitrogen charge pressure ................................................................. 53.5 to 57 bar (775 to 825 psi)
Accumulator valve cut in pressure ................................................................. 147 to 167 bar (2130 to 2420 psi)
Accumulator valve cut out pressure ............................................................... 190 to 196 bar (2755 to 2842 psi)
Brake warning pressure switch ..................................................................................... 112 bar (1625 psi) falling
..................................................................................................................................... 126 bar (1825 psi) rising
Brake redundant pressure switch ............................................................................................... 62 bar (900 psi)
Brake light pressure switch ......................................................................................................... 4.1 bar (60 psi)
Modulation pressure front brake cylinders ........................................................... 76 to 83 bar (1100 to 1200 psi)
Modulation pressure rear brake cylinders ............................................................ 74 to 81 bar (1070 to 1170 psi)
3.2.2 SPECIAL TOOL
94L95
380001737 Nitrogen charging kit used to check and

charge the accumulator with nitrogen.
3.2.3 TROUBLESHOOTING THE 6. With the engine running at high idle, push and re-
HYDRAULIC BRAKE SYSTEM lease the brake pedal rapidly while reading the drop
in pressure on the gauges. The pressure drops may
Note – The hydraulic brake schematic is included in not be equal, but as the lowest pressure reaches
the hydraulic schematic. 147 to 167 bar (2132 to 2422 psi), the system pres-
sure must start to increase. This is the valve cut in
1. Check the oil level in the hydraulic reservoir; add pressure.
oil as necessary. Push and release the brake pedal
many times with the engine stopped to remove all Note – The brake cut-in and cut-out pressures of the
hydraulic pressure from the brake system until there brake system charge valve are factory preset and are
is no pressure on the pedal. not adjustable.
2. Install two 207 bar (3000 psi) pressure gauges to
front and rear hydraulic brake accumulator test Note – If the pressure on one of the pressure gauges
ports. The test ports are located behind the left is lower than specified, the problem can be a bad ac-
cab skirt across from the transmission mounted cumulator valve.
on the diagnostic panel. If your loader does not have
a diagnostic panel, refer to page 8 for the locations 7. Stop the engine. Push and release the brake sev-
of the test ports. eral times while reading the pressure on the gauges.
Each push and release of the pedal will result in a
3. Make sure that the pressure gauge hoses are long slight drop in pressure, but not necessarily equal
enough so the gauges can be read while sitting in on the two gauges. As the lowest pressure reaches
the operators seat. 112 to 126 bar (1624 to 1827 psi) the brake warning
lamp and alarm buzzer must actuate. If the warn-
Note – The gauges can not be connected to the test ing lamp and alarm buzzer fail to work, test the low
ports if hydraulic pressure remains in the system. brake pressure warning switches and electrical cir-
cuit. If the warning lamp and alarm buzzer actuate
4. Start the engine. Run the engine at low idle while at a higher or lower pressure than specified, test
reading the pressure gauges. The alarms (buzzer, the low brake pressure warning switches and re-
master warning light and brake pressure warning place as needed.
light) should shut off when the accumulator with
the lowest pressure reaches 112 to 126 bar 8. Continue to slowly push and release the brake pedal
(1624 to 1827 psi). several times until the gauge pressure suddenly drops
to zero. The last pressure reading before the drop to
5. After the alarms stop, run the machine at high idle zero is the nitrogen charge pressure in the accumu-
to finish charging the accumulators. The pressure lator. Test the pressure in both accumulators. If the
must increase on both gauges until 190 to 196 bar pressure is below 95 to 98 bar (1378 to 1421 psi),
(2756 to 2843 psi) is reached. This is the accumu- charge or replace the accumulator(s).
lator valve cut-out pressure. It is normal for the pres-
sure to drop slightly once the cut-out pressure is Note – Nominal temperature of 20 °C (68 °F), cold
reached. temperature can cause a drop in pressure.
3.2.4 CHECKING THE NITROGEN 3.2.5 CHARGING THE ACCUMULATOR

CHARGE IN THE ACCUMULATOR WITH DRY NITROGEN
1. Make sure that the oil side of the accumulator is Note – Check the pressure in the accumulator ac-
completely discharged by doing the following: cording to the instructions in Checking the Nitrogen
Charge in the Accumulator. Keep the nitrogen charg-
A. Stop the engine.
ing kit connected to the accumulator.
B. Push down and release the brake pedal many
times to release the pressure. 1. Close (turn counterclockwise) valve (A) and open
valve (B). Close valves (C) and (D).
2. Connect a drain hose to the test connector in each
brake circuit to release any pressure in the brake 2. Turn the stem out of valve (F) until the stem stops
circuit. moving. Disconnect valve (F) from the accumula-
tor valve stem.
3. Close valves (B) and (C) on the nitrogen charging
kit, refer to the illustration. 3. Connect the nitrogen charging kit to a dry nitrogen
tank.
4. Turn the stem out of valve (F) until the stem stops.
5. Remove the cap screws and guard from the ac- 4. Slowly turn valve (A) clockwise and read gauge (E)
cumulator. until the pressure is 95 to 98 bar (1378 to 1421 psi).
Stop turning valve (A).
6. Remove the cap from the accumulator valve stem.
5. If the pressure increases above 98 bar
7. Connect valve (F) to the accumulator valve stem. (1421 psi), quickly open and close valve (D) and
8. Make sure that valve (D) is open. read gauge (E). If the pressure is still too high, close
valve (A) (turn counterclockwise) a small amount
9. Turn the stem into valve (F) and read the pres- and quickly open and close valve (D). The pres-
sure gauge (E). sure shown on gauge (E) is the charge pressure.
10. The pressure must be 95 to 98 bar (1378 to 6. Connect valve (F) to the accumulator valve stem.
1421 psi). If the pressure is too low, charge the Turn the stem into valve (F) until the stem stops
accumulator with dry nitrogen. moving and open valve (D) to charge the accumu-
lator.
C E
7. After the accumulator stops charging, turn the stem
out of valve (F) until the stem stops moving.
8. Close valve (B) and disconnect the nitrogen charg-
F ing kit from the accumulator valve stem.
9. Install the cap on the accumulator valve stem. In-
stall the guard and cap screws on the accumulator.
A
D B 94L95
Nitrogen charging kit
3 - 10 BRAKE SYSTEM W170/W170TC
3.2.6 BLEEDING THE BRAKE SYSTEM 8. Start the engine and run at low idle.
1. Check the level of hydraulic fluid in the reservoir. 9. Push the brake pedal all the way down and slowly
Add fluid to the reservoir if necessary. release for one cycle.
10. Close all four wheel end bleed screws.
11. Fully depress the brake pedal three times in 5
second cycles.
12. With the brake pedal partially depressed, open
the bleed screw on the left front axle. Hold the
brake pedal in position until the oil is clear (no
1 bubbles). Close the bleed screw.
13. Open the bleed screw on the right front axle. Re-
peat step 18.
BD03A092 14. Open the bleed screw on the left rear axle. Re-
peat step 18.
2. Raise loader arms and install the safety link (1) for
safe access to the front axle bleed screws. 15. Open the bleed screw on the right rear axle. Re-
peat step 18.
3. Apply the parking brake.
16. Replace all bleed screws, caps and plugs.
4. Keep the engine speed at low idle until both brake
accumulators are fully charged. 17. Check the hydraulic fluid and add as necessary.
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.
W170/W170TC BRAKE SYSTEM 3 - 11
3.2.7 BRAKE MODULATION PRESSURE 4. Connect two 207 bar (3002 psi) pressure gauges
CHECK to the front axle test port (1) and the rear axle test
port (2).
Testing the Brake Modulation Pressure
5. Start the engine.
1. Make sure the hydraulic accumulator cut-in and cut- 6. Operate the machine at low idle and watch the
out pressures are correct. Refer to page 5 of this pressure gauges on the brake accumulators until
section. the gauges rise above 170 bar (2466 psi).
2. Stop the engine. Pump the brake pedal until there 7. Apply and hold the brakes for 10 to 15 seconds.
is no pressure in the brake system.
8. Make a note of the pressure on the gauges for
the front and rear axles.
9. The front axle brake pressure should read 76 to
83 bar (1102 to 1204 psi). This is the modulation
pressure for the front axle.
10. The rear axle brake pressure should read 74
to 81 bar (1073 to 1175 psi).
11. If the pressures are not within the specified range,
it will be necessary to adjust the modulation pres-
sures.
BD03A089
3. Remove the left side transmission access plate to

gain access to the brake test ports.
2 1
BD03A099
1. Front axle test port - 2. Rear axle test port.
Adjusting the Brake Modulation Pressure

Note – The adjusting bolt to adjust the modulation pressure is located in the cab, under the brake pedal.
Angle adjustment with pedal

released 40° to 60°
3°
Min. angle from released position
to start sending pressure oil to
the brakes
Max working angle 16°
Pedal angle adjust

screw
Backlash
take-up screw Brake oil delivery
spools
Brake feed ports
Brake pressure adjustment stop

screw = Pf Max. W110R0348
Section view of oil delivery spools to users
3.2.8 CHECKING THE BRAKE SYSTEM

1. Check the level of the hydraulic fluid in the reser-
voir, add as needed.
3
1 2
BD03A103
5. Connect two 207 bar (3000 psi) pressure gauges

to the test ports 1 and 2.
1
BD00M030 6. Start the engine and let idle until both the front
1. Articulation lock and rear accumulators 3 and 4 are fully charged.
The accumulators are fully charged at 190 to 196
2. Install the articulation lock (1) before doing this test. 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 pres-
sure reaches 96.5 to 110 bar (1400 to 1595 psi).
After the low brake pressure light activates, press
BD03A089 the brake pedal eight more times.
3. Remove the left side transmission access plate to 10. Record the readings on the pressure gauges. The
gain access to the brake accumulator test ports. pressure gauges should read at or above
4. Pump the brake pedal until there is no hydraulic 52 to 58 bar (754 to 841 psi).
pressure in the brake system (approximately 20 11. If the pressures are at or above 52 to 58 bar
pumps). (754 to 841 psi), the test is complete.
12. If the pressures are not within the required speci-
fications, then the brake system must be bled.
13. After bleeding the brake system, perform the brake
system check again.
3.2.9 BRAKE PUMP OUTPUT TEST 3. Measure the flow at 0 bar (0 psi). Record the flow
reading. Slowly close the load valve on the flowm-
1. Connect the flowmeter to the brake pump as shown,
eter and read the flow at 170 bar (2466 psi). Record
refer to the illustration below.
the flow reading.
2. Make sure the load control of the flowmeter is open.
4. Divide the flow reading at 170 bar (2466 psi) by the
Start the engine. Run the engine at full throttle.
reading at 0 bar (0 psi). Multiply the result by 100.
Make sure the oil is at operating temperature.
This is the percent efficiency of the pump. If the
efficiency of the pump is less than 85%, repair or
replace the pump.
NOTE
3
2
BS03B021
1. Brake pump - 2. Pump output elbow - 3. Flowmeter inlet hose - 4. Flowmeter outlet hose - 5. Filter inlet manifold -
6. Filters.
Note – If unit is equipped with auxiliary steering a tee fitting will have to be used in this location
3.3 DISASSEMBLY AND ASSEMBLY OF BRAKE ACCUMULATORS
3.3.1 SPECIAL TOOL
E
C
D A
B
94L95
380001737 Nitrogen charging kit
3.3.2 DISCHARGING THE NITROGEN 3.3.3 CHECKING THE NITROGEN

CHARGE ON AN ACCUMULATOR CHARGE IN THE ACCUMULATOR
1. Use the 380001737 nitrogen charging kit to dis- 1. Make sure that the oil side of the accumulator is
charge the accumulator, refer to illustration above. completely discharged by doing the following:
The tool must be disconnected from the nitrogen
A. Stop the engine.
tank.
B. Push down and release the brake pedal many
2. Close valves (B), (C) and (D).
times to release the pressure.
3. Adjust the regulator A to the minimum pressure
2. Connect a drain hose to the test connector in each
setting by turning the knob counterclockwise.
brake circuit to release any pressure in the brake
4. Turn the T-handle on valve (F) fully out. circuit.
5. Remove the guard and valve assembly cap from 3. Close valves (B) and (C) on the nitrogen charging
the accumulator. kit, refer to the illustration.
6. Connect valve (F) to the valve stem on the accu- 4. Turn the stem out of valve (F) until the stem stops.
mulator.
5. Remove the cap screws and guard from the ac-
7. Turn the T-handle inward on valve (F) to engage cumulator.
the pin in the valve stem.
6. Remove the cap from the accumulator valve stem.
8. Open valve (D) and check the charge pressure
7. Connect valve (F) to the accumulator valve stem.
on gauge (E).
8. Make sure that valve (D) is open.
9. To discharge the accumulator, partially open valve
(B). The accumulator charge will bleed down 9. Turn the stem into valve (F) and read the pres-
through the regulator. sure gauge (E).
10. Once the accumulator is fully discharged, discon-
Note – See chart below for pressure readings.
nect valve (F) from the valve stem.
10. If the pressure is too low, charge the accumulator
with dry nitrogen.
3.3.4 CHARGING THE ACCUMULATOR

WITH DRY NITROGEN
Note – Check the pressure in the accumulator ac- 5. If the pressure increases above required pressure,
cording to the instructions in Checking the Nitrogen quickly open and close valve (D) and read gauge
Charge in the Accumulator. Keep the nitrogen charg- (E). If the pressure is still too high, close valve (A)
ing kit connected to the accumulator. (turn counterclockwise) a small amount and quickly
open and close valve (D). The pressure shown on
1. Close (turn counterclockwise) valve (A) and open gauge (E) is the charge pressure.
valve (B). Close valves (C) and (D).
6. Connect valve (F) to the accumulator valve stem.
2. Turn the stem out of valve (F) until the stem stops Turn the stem into valve (F) until the stem stops
moving. Disconnect valve (F) from the accumula- moving and open valve (D) to charge the accumu-
tor valve stem. lator.
3. Connect the nitrogen charging kit to a dry nitrogen 7. After the accumulator stops charging, turn the stem
tank. out of valve (F) until the stem stops moving.
4. Slowly turn valve (A) clockwise and read gauge (E) 8. Close valve (B) and disconnect the nitrogen charg-
until the pressure is equal to charge pressure re- ing kit from the accumulator valve stem.
quired for accumulator being charged. Stop turning
9. Install the cap on the accumulator valve stem. In-
valve (A).
stall the guard and cap screws on the accumulator.
TEMPERATURE CHARGE PRESSURE TEMPERATURE CHARGE PRESSURE

0° C 32° F 89.4 BAR 1297 PSI 0° C 32° F 51.2 BAR 743 PSI
Temperature/Charge Pressure Parking Brake Ac- Temperature/Charge Pressure Brake Accumulator

cumulator
3.3.5 PARKING BRAKE STEP 7

Disassembly
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 ma-
chine movement.
STEP 3 W170-3R003
Loosen the jam nut, turn adjusting bolt

counterclockwise until the brake pads are loose.
STEP 8
BD01F143
Install the articulation lock.
STEP 4
Place the master disconnect switch in the OFF posi- W170-3R004
tion. Remove the retainer pin and brake pin.
STEP 5 STEP 9
Pump the brake pedal at least 30 times to discharge
the accumulators.
STEP 6
W170-3R005
Remove the two brake pads from the parking brake

assembly.
W170-3R002
Loosen and remove the cover from the parking brake.
Inspection STEP 13
STEP 10
Clean and inspect all parts for wear and damage.
Inspect the brake disc for wear and damage.
Replace all parts that are worn or damaged.
Assembly
STEP 11
W170-3R003
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 se-
cure the adjusting bolt.
STEP 14
W170-3R005
Install the two brake pads in the parking brake as-

sembly.
STEP 12
W170-3R002
Install the cover on the parking brake.
STEP 15
Perform the Parking Brake Test Procedure as described
W170-3R004 in this section.
Install the brake pins and retainer pins. STEP 16

Remove the articulation lock.
STEP 17
Place the master disconnect switch to the ON posi-
tion.
W170/W170TC STEERING SYSTEM 4-1
SECTION 4
STEERING SYSTEM
INDEX
4.1 REMOVAL AND INSTALLATION OF STEERING COMPONENTS ...................... 4-1

4.1.1 STEERING CONTROL VALVE ............................................................................. 4-1
Removal ........................................................................................................... 4-1
Installation ........................................................................................................ 4-1
4.1.2 AUXILIARY STEERING PRIORITY VALVE ......................................................... 4-3
Removal ........................................................................................................... 4-3
Installation ........................................................................................................ 4-3
4.1.3 STEERING PRIORITY VALVE ............................................................................. 4-5
Removal ........................................................................................................... 4-5
Installation ........................................................................................................ 4-5
4.1.4 AUXILIARY STEERING PUMP AND MOTOR ...................................................... 4-7
Removal ........................................................................................................... 4-7
Installation ........................................................................................................ 4-7
4.1.5 STEERING CYLIDNER ........................................................................................ 4-9
Removal ........................................................................................................... 4-9
Installation ........................................................................................................ 4-9
4.2 STEERING SPECIFICATIONS, PRESSURE CHECKS

AND TROUBLESHOOTING .................................................................................. 4-11
4.2.1 SPECIAL TOOLS ................................................................................................. 4-11
4.2.2 TROUBLESHOOTING THE STEERING SYSTEM ............................................... 4-11
4.2.3 AUXILIARY STEERING SYSTEM PUMP TEST .................................................. 4-12
Equipment Required ......................................................................................... 4-12
Test Procedure ................................................................................................. 4-12
4.2.4 AUXILIARY STEERING SYSTEM MOTOR TEST ............................................... 4-13
Test Equipment ................................................................................................ 4-13
Test Procedure ................................................................................................. 4-13
4.2.5 UNDERSTANDING THE RESULTS OF THE TEST .............................................. 4-14
4.2.6 STEERING RELIEF VALVE ................................................................................. 4-15
Pressure Setting Test ....................................................................................... 4-15
Pressure Setting Adjustment ............................................................................ 4-16
4.2.7 STEERING CYLINDER LEAK TEST .................................................................... 4-17
4.3 STEERING CONTROL VALVE ............................................................................. 4-18

4.3.1 SPECIFICATIONS ............................................................................................... 4-18
4.3.2 SPECIAL TOOLS ................................................................................................. 4-18
4.3.3 STEERING CONTROL VALVE ............................................................................. 4-18
Disassembly ..................................................................................................... 4-18
Inspection ......................................................................................................... 4-20
Assembly ......................................................................................................... 4-21
4-2 STEERING SYSTEM W170/W170TC
4.4 STEERING PRIORITY VALVE ............................................................................. 4-24

Disassembly ..................................................................................................... 4-24
Cleaning and Inspection .................................................................................... 4-25
Assembly ......................................................................................................... 4-25
4.5 STEERING CYLINDER ........................................................................................ 4-26

4.5.1 SPECIFICATIONS ............................................................................................... 4-26
4.5.2 STEERING CYLINDER ........................................................................................ 4-26
Disassembly ..................................................................................................... 4-26
Inspection ......................................................................................................... 4-26
Assembly ......................................................................................................... 4-28
4.6 CENTER PIVOT ................................................................................................... 4-29

4.6.1 SPECIFICATIONS ............................................................................................... 4-29
4.6.2 SPECIAL TOOLS ................................................................................................. 4-29
4.6.3 CENTER PIVOT ................................................................................................... 4-30
Disassembly ..................................................................................................... 4-30
Assembly ......................................................................................................... 4-32
4.6.4 CONNECTING THE FRONT FRAME TO THE REAR FRAM ................................ 4-35
4.7 AUXILIARY STEERING MOTOR AND PUMP ...................................................... 4-37

4.7.1 SPECIFICATIONS ............................................................................................... 4-37
4.7.2 AUXILIARY STEERING MOTOR AND PUMP ...................................................... 4-38
Disassembly ..................................................................................................... 4-38
Inspection ......................................................................................................... 4-38
Assembly ......................................................................................................... 4-38
4.1 REMOVAL AND INSTALLATION OF STEERING COMPONENTS
4.1.1 STEERING CONTROL VALVE Installation

Removal 1. Connect hose assemblies to steering control valve
(1) following tags installed in Step 4 of Removal.
1. Remove left, right, and front cab skirts, located
under the cab or canopy. 2. Install hydraulic reservoir fill cap.
2. Remove all dirt and grease from steering control 3. Start engine and turn machine all the way to the
valve (1) and area around steering control valve left and right several times to remove any air in
(1), see illustration on page 4-2. hydraulic circuits.
3. Remove hydraulic reservoir fill cap. 4. Stop engine and check for leaks.
4. Tag and identify hose assemblies connected to 5. Check the fluid level in hydraulic reservoir. Add oil
steering control valve (1). as required.
5. Disconnect hose assemblies from steering control
valve (1).
6. Cap or plug the fittings and hoses.
2
2
1
4 3
W170-4R001
Steering control valve illustration
1. Steering control valve - 2. Elbow - 3. Connector - 4. Hose/A. steering return - 5. Hose/A. steering supply - 6. Hose/A. load
sense - 7. Hose/A. steering cylinder.
4.1.2 AUXILIARY STEERING PRIORITY Installation

VALVE 1. Connect and hand tighten pressure tube (10) to aux-
Removal iliary steering priority valve (13).
1. Park loader on level ground and lower bucket to 2. Install two bolts (11) and washers in auxiliary steer-
ground. Put transmission in NEUTRAL, apply parking priority valve (13). Install two spacers (12) on
ing brake, and shut down engine. bolts. Refer to illustration on page 4-4.
2. Put master disconnect switch in OFF position. 3. Position priority valve (13) on mounting plate while
hand tightening pressure tube (10) to auxiliary steer-
3. Remove all dirt and grease from auxiliary steering ing pump and motor (A).
priority valve (13) and adjacent area. See illustra-
tion on page 4-4. 4. Support priority valve (13) and install two washers
and nuts to secure priority valve.
4. Remove hydraulic reservoir fill cap.
5. Tighten pressure tube (5) fittings securely.
5. Connect a vacuum pump to hydraulic reservoir.
6. Remove caps from tees (9). Connect auxiliary steer-
6. Start vacuum pump. ing supply tube (8) between tees (9).
7. Tag and disconnect suction hose (1) from auxiliary 7. Tighten fitting (7) connected to elbow installed in
steering pump and motor (A). Install a plug in suc- steering priority valve.
tion hose.
8. Connect and tighten fitting on auxiliary steering tank
8. Stop the vacuum pump. return tube (6) to priority valve (13).
9. Tag and disconnect load sensing hose (2) from aux- 9. Remove cap from fitting installed in auxiliary steer-
iliary steering priority valve (13). ing solenoid valve port T.
10. Install plug in hose (2). 10. Connect tank return tube (5) to fitting installed in
11. Tag and disconnect tank return tube (3) from elbow port T of auxiliary steering solenoid valve (B) and
installed in priority valve (13) and fitting installed in fitting installed in auxiliary steering tank return tube
auxiliary steering tank return tube (6). (6).
12. Tag and disconnect load sensing tube (4) from tee 11. Remove cap from elbow. Connect load sensing tube
installed in priority valve (13) and elbow installed in (4) to tee installed in priority valve (13) and elbow
port LS of auxiliary steering solenoid valve (B). In- installed in port LS of auxiliary steering solenoid
stall a cap on elbow. valve (B).
13. Tag and disconnect tank return tube (5) from fitting 12. Connect tank return tube (3) to elbow installed in
installed in port T of auxiliary steering solenoid valve priority valve (13) and fitting installed in auxiliary
(B) and fitting installed in auxiliary steering tank re- steering tank return tube (6).
turn tube (6). 13. Remove plug from load sensing hose (2). Connect
14. Install a cap on fitting installed in auxiliary steering hose to priority valve (13).
solenoid valve port T. 14. Start vacuum pump.
15. Loosen and disconnect fitting on auxiliary steering 15. Remove plug from suction hose (1); connect hose
tank return tube (6) connected to priority valve (13). to auxiliary steering pump and motor (A).
16. Loosen fitting (7) connected to elbow installed in 16. Stop vacuum pump. Disconnect vacuum pump from
steering priority valve. This will provide some play hydraulic reservoir.
to allow removal of tube (8) in following step.
17. Install fill cap on hydraulic reservoir.
17. Tag and disconnect auxiliary steering supply tube
(8) from tees (9). Install caps on tees. 18. Put battery disconnect switch in ON position. Start
engine and run at low idle for 30 seconds. Stop
18. Loosen fittings on pressure tube (10). engine and check for leaks.
19. Support auxiliary steering priority valve (13). Re- 19. Check to make sure priority valve operates cor-
move two nuts, bolts (11), and spacers (12) and rectly.
four washers.
20. Check fluid level in hydraulic reservoir. Add oil as
20. Remove pressure tube (10) and auxiliary steering required.
priority valve (13).
2
A
9 3
8 5
11
6
C
D 7
1
B
12 11 13 10
BS03B140
Auxiliary Steering priority valve illustration
1. Suction hose - 2. Load sensing hose - 3. Tank return hose - 4. Load sensing tube - 5. Tank return tube - 6. Auxiliary
steering tank return tube - 7. Fitting - 8. Auxiliary steering supply tube - 9. Tee - 10. Pressure tube - 11. Bolts - 12. Spacers
- 13. Auxiliary steering priority valve - A. Auxiliary steering pump and motor - B. Auxiliary steering solenoid valve -
C. Auxiliary steering check valve - D. Auxiliary steering pressure switch.
4.1.3 STEERING PRIORITY VALVE Installation

Removal 1. Install two bolts with washers (7) through mount-
ing holes in rear chassis. Install spacers (8) on
1. Park loader on level ground and lower bucket to
bolts. Install steering priority valve (9) on bolts.
ground. Put transmission in NEUTRAL, apply
Install two washers and nuts (6) to secure steer-
parking brake, and shut down engine.
ing priority valve.
2. Put master disconnect switch in OFF position.
2. Start vacuum pump.
3. Remove all dirt and grease from steering priority
3. Remove plug from excess flow tube (4). Connect
valve (15) and adjacent area. See illustration on
excess flow tube to elbow (2). Tighten elbow and
page 4-6.
excess flow tube.
4. Remove plug from steering pump pressure tube
5. Connect a vacuum pump to hydraulic reservoir. (3). Connect steering pump pressure tube to pri-
ority valve (9).
5. Remove plug from tank return tube (1). Connect
7. If equiped, tag and disconnect load sensing tube
tank return tube to priority valve (9).
from elbows installed in auxiliary steering sole-
noid valve and steering priority valve (9). 6. If equiped, connect fitting to elbow installed in
steering priority valve (9). Tighten tee, auxiliary
8. If equiped, loosen fitting, auxiliary steering sup-
steering supply tube, and fitting.
ply tube, and tee. Disconnect fitting from elbow
installed in steering priority valve. 7. If equiped, connect load sensing tube to elbows
installed in auxiliary steering solenoid valve and
9. Disconnect tank return tube (1) from steering pri-
steering priority valve (9).
ority valve (9). Install plug in tube.
8. Stop vacuum pump.
10. Disconnect steering pump pressure tube (3) from
priority valve (9). Install plug in tube. 9. Disconnect vacuum pump from hydraulic reser-
voir.
11. Loosen elbow (2) then disconnect excess flow
tube (4) from elbow. Install plug in tube. 10. Install fill cap on hydraulic reservoir.
12. Stop vacuum pump. 11. Put battery disconnect switch in ON position. Start
engine and run at low idle for 30 seconds. Stop
13. Support steering priority valve (9). Remove two
engine and check for leaks.
nuts and washers (6), bolts and washers (7), and
spacers (8). 12. Check to make sure steering priority valve oper-
ates correctly.
14. Remove steering priority valve (9).
13. Check fluid level in hydraulic reservoir. Add oil as
required.
9
4
2
3
6 7
8
BS03B143
Steering priority valve illustration
1. Tank return tube - 2. Elbow - 3. Steering pump pressure tube - 4. Excess flow tube - 5. Fitting - 6. Nut - 7. Bolt - 8. Spacer
- 9. Steering priority valve.
4.1.4 AUXILIARY STEERING PUMP AND 4. Tighten pressure tube (5) fittings securely.
MOTOR 5. Start vacuum pump.
6. Remove plug from suction hose (4) and cap from
Removal elbow. Connect suction hose to elbow installed in
1. Park loader on level ground and lower bucket to auxiliary steering pump and motor (7).
ground. Put transmission in NEUTRAL, apply 7. Stop and disconnect vacuum pump. Install fill cap
parking brake, and shut down engine. in hydraulic reservoir.
8. Connect ground cable (3) to ground stud of auxil-
2. Put master disconnect switch in OFF position. iary steering pump and motor (7) following tag in-
3. Tag and disconnect two wiring harness wires (1) stalled during removal.
from auxiliary steering pump and motor (7) sole- 9. Connect positive cable (2) to B+ stud of auxiliary
noid. See illustration on page 4-8. steering pump and motor (7) following tag installed
during removal.
4. Tag and disconnect positive cable (2) from B+
10. Connect wiring harness wires (1) to auxiliary steer-
stud of auxiliary steering pump and motor (7).
ing pump and motor (7) following tags installed
5. Tag and disconnect ground cable (3) from ground during removal.
stud of auxiliary steering pump and motor (7). 11. Remove and discard tags installed during remov-
al.
12. Put master disconnect switch in ON position.
7. Connect a vacuum pump to hydraulic reservoir. 13. Start and run engine at low idle and raise bucket
500 mm (20 inches) above ground. Check that
auxiliary steering light on information center is
9. Disconnect suction hose (4) from elbow installed OFF.
in auxiliary steering pump and motor (7). Install a
plug in suction hose and cap on elbow. Important – In following Step, do not run auxiliary
10. Stop vacuum pump. steering pump and motor continuously for more than
20 seconds at a time without a two minute cool down.
11. Loosen fittings on pressure tube (5).
12. Support auxiliary steering pump and motor (7). 14. With engine at low idle and machine steering
Remove nuts (6), bolts, and washers securing aux- straight ahead, turn key switch to OFF position to
iliary steering pump and motor (7). stop engine and then immediately back to ON
position (not START position). Auxiliary steering
13. Remove pressure tube (5) and auxiliary steering pump and motor should start operating immedi-
pump and motor (7). ately. Check that auxiliary steering light on infor-
mation center is ON and auxiliary steering pump
Installation and motor is operating.
1. Connect and hand tighten pressure tube (5) to 15. Turn steering wheel all the way to left and right to
auxiliary steering pump and motor (7). See illus- make sure that auxiliary steering pump and mo-
tration on page 4-8. tor operates correctly.
2. Position auxiliary steering pump and motor (7) on 16. Restart engine. Check that auxiliary steering light
its mounting plate while connecting and hand tight- on information center stays ON and auxiliary
ening pressure tube (5) to auxiliary steering prior- steering pump and motor is operating. After about
ity valve (8). three seconds motor should stop operating and
3. While supporting auxiliary steering pump and auxiliary steering light should go out.
motor (7) have an assistant install bolts, wash-
ers, and nuts (6) to secure auxiliary steering pump 17. Let engine run and allow batteries to recharge for
and motor (7). a minimum of 10 minutes.
3
2
7
8 1
6
4
BS03B140
Auxiliary steering pump and motor illustration
1. Wiring harness wires - 2. Positive cable - 3. Ground cable - 4. Suction hose - 5. Pressure tube - 6. Nut - 7. Auxiliary steering
pump and motor - 8. Auxiliary steering priority valve.
4.1.5 STEERING CYLINDER Installation

Removal 1. Put steering cylinder (16) in position in machine.
Make sure that washers (15) are installed between
1. Loosen the fill cap for the hydraulic reservoir to
steering cylinder (16) and rear frame. See illustra-
release pressure in the reservoir, then tighten the
tion on page 4-10.
fill cap.
2. Disconnect grease hoses (1 and 2) from steering Note – Install a washer (15) on top and bottom of
cylinder (16). See illustration on page 4-10. steering cylinder (16) if possible. If only one washer
(15) can be installed, place washer (15) at bottom of
3. Disconnect hydraulic hoses (3, 4, 5, and 6) from
steering cylinder (16).
steering cylinder (16).
4. Install a plug in each hose (3, 4, 5, and 6) to pre- 2. Make sure washers (10) are installed between
vent entry of foreign matter. steering cylinder (16) and front frame of machine.
5. Remove locknut (7). 3. Install the pivot pin (14) to secure rear of steering
cylinder (16) to machine frame. Install spacer (13),
6. Remove bolt (8).
washer (12), and bolt (11) to secure pivot pin (14).
7. Remove pin (9).
4. Tighten bolt (11).
8. Remove washers (10).
5. Install pin (9) in front of steering cylinder (16).
9. Remove bolt (11), washer (12), and spacer (13) Make sure that washers (10) are installed in cor-
securing pivot pin (14) at rear of steering cylinder rect position.
(16).
6. Install bolt (8) and new locknut (7) in steering cyl-
10. Use a suitable driver and drive pivot pin (14) out inder (16) rod end and pin (9). Tighten locknut (7).
of steering cylinder (16).
11. Remove washer(s) (15) from between steering cyl- Note – Bolt (8) should turn freely in hole after tighten-
inder (16) and rear frame of machine. ing.
12. Remove steering cylinder (16). 7. Connect hose assemblies (6, 5, 4, and 3) to steer-
ing cylinders (16).
8. Connect grease hoses (2 and 1) to steering cylin-
der (16).
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 engine. Check the hydraulic oil level.
4 - 10 STEERING SYSTEM W170/W170TC
4
3
11
12
13
14
15
9
6
2
8
5 10
16
2 1
7
16
BS03B141
Steering cylinder illustration
1. Grease hose - 2. Grease hose - 3. Hose assembly - 4. Hose assembly - 5. Hose assembly - 6. Hose assembly - 7. Locknut
- 8. Bolt - 9. Pin - 10. Washer - 11. Bolt - 12. Washer - 13. Spacer - 14. Pivot pin - 15. Washer - 16. Steering cylinder.
W170/W170TC STEERING SYSTEM 4 - 11
4.2 STEERING SPECIFICATIONS, PRESSURE CHECKS AND TROUBLESHOOTING
4.2.1 SPECIAL TOOLS 4.2.2 TROUBLESHOOTING THE

STEERING SYSTEM
Note – The steering hydraulic schematic is included
in the hydraulic schematic.
1. Make sure the oil level in the hydraulic reservoir is

correct. Visually inspect the steering system for
leakage and damage.
2. Do the steering limit valve pressure test. Refer to
page 4-15. If the pressure is above or below speci-
fications, adjust the steering limit valve.
3. Do the main hydraulic pump test. If the main pump
is bad, repair or replace the main hydraulic pump.
B785789
4. Test the steering cylinders for leakage, refer to in-
380001731 Flowmeter structions on page 4-17. If a steering cylinder is
leaking, repair or replace the steering cylinder.
B797157
380001740 Flowmeter fitting kit
B009638
380001739 Pressure test fitting kit
4.2.3 AUXILIARY STEERING SYSTEM

PUMP TEST
Equipment Required
1. 380001731 Flowmeter
2. 380001740 Flowmeter fitting kit
Test Procedure
1 BB830300
BD03A040
1. Install articulation lock. 1. Ammeter clamp.
11. Stop the engine and turn the key back to the On
1. Install articulation lock. position.
Note – When performing this pressure check, always 12. Turn the steering wheel, this will activate the aux-
be sure the articulation lock is in place, especially iliary steering pump.
when working in the articulation joint areas.
13. Turn the load valve on the flowmeter towards
CLOSED until the pressure is 104 bar (1508 psi).
2. Loosen and remove the outlet hose of the Auxiliary
Steering Pump from the Steering Priority Valve. 14. Read the flowmeter and ammeter gauges and
record the readings.
3. Install a plug into the hose.
15. The flowmeter reading must not be less than
4. Connect the inlet of the flowmeter to the outlet fit-
24.6 L/min, (6.5 U.S. gpm). The ammeter reading
ting on the Steering Priority Valve.
must be 315 amps.
5. Install the outlet hose of the flowmeter in the hy-
16. Turn the key switch to the OFF position. If the
draulic reservoir and hold in place with wire.
flow was less than the specification, or if the
6. Connect the ammeter clamp (1) to the cable as in amperage was more than 315 amperes, remove
illustration above. the auxiliary steering motor and pump. Test the
7. Make sure that the parking brake is applied and auxiliary steering motor. If the motor is good, make
the bucket is on the floor. repairs to the pump.
8. Make sure that the oil is at operating temperature.

9. Make sure that the load valve for the flowmeter is
open (zero pressure).
10. Start and run the engine.
4.2.4 AUXILIARY STEERING SYSTEM

MOTOR TEST
2
Test Equipment 1
1. A 24 volt battery that is fully charged.
Note – A 24 volt battery system (two 12 volt batter-

ies in a series) is used for this test. A 12 volt battery
system will cause damage to the auxiliary steering 4
motor.
2. A remote starter switch. 3

3. A tachometer to check the armature speed.
4. A Sun Electric VAT-33 Starting and Charging Sys-
tem Tester.
5
Test Procedure
1. Remove the connector that is between the termi- B790852
nals on the magnetic switch and the auxiliary steer-
ing motor. 1. Remote starter switch - 2. Tester - 3. Auxiliary steering
motor - 4. Ammeter clamp - 5. 24 volt battery system.
2. Remove the auxiliary steering motor from the aux-
iliary steering pump.
3. Remove the drive coupling from the auxiliary steer-
ing motor (3).
4. Connect the auxiliary steering motor (3), remote
starter switch (1) and tester (2) to the 24 volt bat-
tery system (5) as illustrated.
5. Push the button on the remote starter switch (1) 8
6 7
and look at the voltmeter in the tester.
6. Turn the load control (8) until the voltmeter (7) indi-
cates 24 volts. Look at the ammeter (6) in the tester.
Make a record of the ammeter indication.
7. Hold the tachometer against the armature shaft.
Look at the tachometer. Make a record of the indi-
B795328
cation.
8. Release the button on the remote starter switch (1). 1. Ammeter - 2. Voltmeter - 3. Load control.
4.2.5 UNDERSTANDING THE RESULTS 4. If the armature did not turn, and the ammeter indi-
OF THE TEST cation was zero amperes, possible causes include
the following:
1. If the ammeter indication in step 6 was 30 amperes
or less and the tachometer indication in step 7 was A. An open field coil.
6950 r/min (rpm) or more, the auxiliary steering B. An open armature coil. After the motor is dis-
motor is good. assembled, look at the commutator on the ar-
2. If the armature speed was less than 6950 r/min mature. If the commutator is badly burned, the
(rpm) and the ammeter indication was higher than armature coil is probably open.
30 amperes, possible causes include the follow- C. Broken brush springs or worn brush springs.
ing:
5. If the armature speed was less than 6950 r/min
A. Damaged bearings. (rpm) and the ammeter indication was less than 30
B. Loose pole shoes. amperes, possible causes include the following:
C. A short circuit in the armature coil. The arma- A. Bad connections between the brushes and the
ture coil must be checked on an armature tester field coil.
after the motor is disassembled. B. Dirty commutator.
D. A ground connection in the field coil. 6. If the armature speed was 6950 r/min (rpm) or more
3. If the armature did not turn and the ammeter indi- and the ammeter indication was more than 30 am-
cation was higher than 30 amperes, possible peres, there is probably a short circuit in the field
causes include the following: coil. A short circuit in the field coil is difficult to
find. It is recommended that a new field frame as-
A. The motor terminal is in contact with the field sembly be installed.
frame.
B. A damaged bearing that will not let the arma-
ture turn.
4.2.6 STEERING PRIORITY VALVE 3. Make sure that the temperature of the hydraulic
oil is at least 54 °C (129 °F).
Note – The loader/steering pump load-sense pressure
must be properly adjusted before doing this test. 4. To measure the temperature of the oil using the
instrument panel:
Pressure Setting Test A. Press the program switch (left side of the pro-
gram/reset switch).
B. Press the up count switch to function 008.
C. Return the program switch to the OFF (center)
position.
6. Start and run the engine at full throttle.
7. Lower the lift arms and hold the control lever in
the FLOAT position.
1 8. Hold the bucket control lever in the rollback posi-
tion.
BD03A085
1. Cover plate. 9. Continue holding until the specified temperature
of the oil is reached.
1. Remove the cover plate (1) to gain access to the 10. Stop the engine.
quick disconnect test port (port 5 on optional diag-
nostic panel) and steering priority valve. 11. Remove the cap on the hydraulic reservoir to re-
lease any pressure in the hydraulic system.
1
2 1
BD03A040
BD03A086
2. Articulation lock.
1. Steering priority valve - 2. Pump pressure test port.
2. Install articulation lock (1).
12. Remove the dust cap from the test port (2).
Important – When performing the following pressure 13. Connect a 345 bar (5000 psi) pressure gauge to
check and adjustment, the articulation lock must be the test port (2).
installed. Use caution when working in or near the ar-
ticulation area. 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.
14. Start the engine and operate the machine at full Pressure Setting Adjustment
throttle.
15. With the articulation lock still in place, turn and
hold the steering wheel for a hard right turn.
16. Continue holding the steering wheel, and read the
pressure gauge.
17. The pressure gauge must indicate 239 to 243 bar
(3466 to 3524 psi). If the pressure is not correct,
adjust the steering relief valve.
2
1
BD03A086
1. Steering priority valve - 2. "T" port.
18. The adjusting screw is located inside the “T” port

on the steering priority valve.
19. Turn the adjusting screw clockwise to increase
the pressure setting. Turn the adjusting screw
counterclockwise to decrease the pressure set-
ting.
20. Repeat pressure test procedure.
21. If necessary, adjust the limit valve again until
within the specified range.
22. Stop the engine before removing the pressure
gauge.
4.2.7 STEERING CYLINDER LEAK TEST 9. Connect the tube to the rod end of the left-hand
steering cylinder.
Note – Make sure all persons are clear of the area of
the center pivot. Make sure the center pivot is free of 10. Turn the machine all the way to the left.
any obstructions. 11. Stop the engine.
1. Park the machine on a level surface. 12. Find the tube that is connected to the rod end of
the right-hand steering cylinder. Disconnect the
2. Turn the machine all the way to the right. tube from the right-hand steering cylinder.
3. Stop the engine and apply the parking brake. 13. Install a plug in the tube.
4. Find the tube that is connected to the rod end of 14. Start and run the engine at full throttle.
the left-hand steering cylinder. Disconnect the tube
from the left-hand cylinder. 15. Turn the steering wheel to the left. Hold the steer-
ing wheel for a full left turn. Have another person
5. Install a plug in the tube. check for leakage at the opening of the rod end of
6. Start and run the engine at full throttle. the right-hand steering cylinder.
7. Turn the steering wheel to the right. Hold the steer- 16. If there is constant leakage from the rod end, the
ing wheel for a full right turn. Have another person piston packing in the right-hand steering cylinder
check for leakage from the opening of the rod end is damaged. Repairs must be made.
of the left-hand steering cylinder. 17. Connect the tube to the rod end of the right-hand
8. If there is constant leakage from the rod end, the steering cylinder.
piston packing in the left-hand steering cylinder is
damaged. Repairs must be made.
4.3 STEERING CONTROL VALVE
Manufacturer ............................................................................................................................................. Eaton
Special Torques
Cap screws for end cap ...................................................................................... 33.9 Nm (300 pound-inches)
4.3.2 SPECIAL TOOLS

Retaining ring pliers ................................................................................................... Eaton part number 600610
Splined shaft end tool, #600604 .................................................................................... Eaton part number 8063
Order Special Tools from:

Eaton Corporation, Hydraulics Division, 15151 Highway 5, Eden Prairie, MN 55344
4.3.3 STEERING CONTROL VALVE

Disassembly 8. Turn the tool clockwise or counter-clockwise to
compress the centering spring (12).
1. Clean the port area of the steering control valve
housing before disconnecting the hydraulic lines. 9. Hold the drive shaft (6) stationary.
2. Drain the oil, and plug the ports. Clean the exterior 10. Remove the centering spring (12), spool (9) and
of the steering control valve housing. Protect the sleeve (8), ball checks (10), pin (11), drive shaft
machines surfaces during repair. (6), bearing race (14), retaining ring (18) and nee-
dle thrust bearing (13). Use retaining ring pliers.
3. Put the steering control valve in a vise so that the
(See Special Tools).
end cap (2) is up, refer to Figure 1.
11. Remove the back-up washer (15), seal ring (16),
3 and O-ring (17).
12. Carefully pry the dust seal (19) from the steering
2 control valve housing (7), using a small blade
screwdriver. Do not damage the dust seal (19).
Note – If the steering control valve housing (7) has

anti-cavitation valves, find the anti-cavitation valves
in the steering control valve housing (7).
1
GS98K501
13. To disassemble these valves, insert soda straws
(3) in each end of the threaded holes, refer to Fig-
Figure 1 – Steering control valve-end cap up
ure 3. Remove the steering control valve housing
1. Vise - 2. End cap - 3. Anti-cavitation valves. from the vise and tilt it until the port face (4) is
upward. Continue turning until the roll pins (2) and
4. Remove the seven cap screws (1), end cap (2), O- ball checks (1) slide through the straws (3).
ring (3), gerotor (4), O-ring (3), spacer plate (5), and
O-ring (3), refer to Figure 2.
5. Remove the gerotor star from gerotor (4).
6. Using a splined shaft end no. 8063 tool (refer to
Special Tools), start the tool on the splined end of
the spool (9).
7. Hold the gerotor star and drive shaft (6), with your
hand. Protect both the gerotor star and hand with a
shop towel while turning.
14 18 13
14
17 7
16
15
19
8 10
11
1
9
2 10
12
3
4
3
21
5
3
20
GS98K502
Figure 2 – Steering control valve - exploded view
1. Cap screw - 2. End cap - 3. O-ring - 4. Gerotor - 5. Spacer plate - 6. Drive shaft - 7. Steering control housing - 8. Sleeve -
9. Spool - 10. Ball check - 11. Pin - 12. Centering spring - 13. Needle thrust bearing - 14. Bearing race -
15. Backup washer - 16. Seal ring - 17. O-ring - 18. Retaining ring - 19. Dust seal - 20. Ball check - 21. Roll pin.
3
4
5 2
GS98K503
Figure 3 – Anti-cavitation valve - disassembly
1. Ball check - 2. Roll pin - 3. Soda straw - 4. Port face - 5. Anti-cavitation valvese.
Inspection 3. If the spool (9) and sleeve (8) or the bore in the
housing of the steering control valve (7) is dam-
1. Clean all parts in cleaning solvent and air dry on
aged or worn, use a new steering control valve.
paper towels. Do not use cloths to wipe parts dry,
as it may leave lint on the parts. 4. Inspect the cap screws (1), pin (11), ball check
(10), backup washer (15), seal ring (16), O-ring (17),
2. Check all machined surfaces for wear or damage.
needle thrust bearing (13) and bearing race (14).
If there are rough places on the ends of the gerotor
Use new parts as required.
star or gerotor (4), steering control valve housing
(7), end cap (2), or spacer plate (5), use 600 grit 5. If your steering control valve has anti-cavitation
emery cloth to smooth the surfaces, refer to Figure valves, inspect the ball checks (20) and roll pins
2. Place the emery cloth on a flat surface. If the (21) for damage or wear. Use new parts as required.
emery cloth is new, rub a piece of steel across the
emery cloth six times to remove the sharp pieces
of grit. Make sure that the part is held flat on the
emery cloth. Rub each part across the cloth six
times. Check to see if the rough places are re-
moved. Use this method until all rough places are
removed. Clean the parts in cleaning solvent to
remove any grit.
Assembly 3. Lubricate the spool (3) with clean hydraulic fluid

and slide it into the sleeve (2), along with the ball
Note – Use new seals (3), (16), and (19) when reas-
check (5), refer to Figure 5.
sembling the steering control valve.
4. Install the drive shaft (1) and pin (4).
Important – Lubricate the new seals with a petro-
5. Install the centering spring (6). Position one end of
leum jelly. Lubricate machined surfaces with clean
the centering spring (6) in slotted end of spool (3)
hydraulic fluid.
and sleeve (2). Compress the centering spring (6)
by turning it counter-clockwise to engage the free
1. Use a soda straw (3) as a guide tool, refer to Figure
end of the spring.
4. Drop the straw (3) into the anti-cavitation valve
(5) to the bottom of the bore. Drop the ball check 6. Install the bearing race (8) and retaining ring (7),
(2) through the straw (3). Pull the straw (3) out and onto the spool (3), using retaining ring pliers.
use the same procedure in the second ball seat.
7. Lubricate, using petroleum jelly, the ID of the dust
seal (19) that is mounted in the steering control
2 valve housing (7), refer to Figure 2.
8. Lubricate, using petroleum jelly, the needle thrust
3 1
bearing (13), second bearing race (14), backup
washer (15), seal ring (16) and O-ring (17). Position
4 each part onto the spool (9). The needle thrust bear-
ing (13) goes between the two bearing races (14),
and must be centered around the retaining ring (18).
9. Lubricate, using clean hydraulic fluid, the spool (9)
and sleeve (8) assembly and slide it into the steer-
ing control valve housing (7), as follows:
Important – Do not damage the dust or shaft seals.

5
GS98K504
A. Protecting the gerotor star and hand with shop
towels, hold the gerotor star and splined end of
Figure 4 – Optional anti-cavitation valves assembly drive shaft (6) to keep it from turning.
1. Roll pin - 2. Ball check - 3. Soda straw - 4. Port face - B. Insert the splined shaft end No. 8063 (see Spe-
5. Anti-cavitation valves. cial Tools this section), into the steering control
valve housing (7), and start it onto the splined
2. Use a small light and check each bore to make end of the spool (9). Turn the tool clockwise or
sure each ball check (2) is in the correct place. counter-clockwise to compress the centering
Add the roll pin (1) in each. spring (12).
Note – If the unit is positioned horizontally, keep the

pin horizontal. If the tension on the pin is released
before the assembly is fully engaged, the pin can drop
and lockup can occur if the pin is not horizontal.
1 5
2
4
5 3
2
1
6 6
2
6 8
1 7
4 3
5
GS98K505
Figure 5 – Spool and sleeve assembly
1. Drive shaft - 2. Sleeve - 3. Spool - 4. Pin - 5. Ball check - 6. Centering spring - 7. Retaining ring - 8. Bearing race.
10. Compressing the centering spring (12), carefully 16. Lubricate a new O-ring (3) and install into the
insert the assembled bearing races (14), retain- groove of the spacer plate (5).
ing ring (18), needle thrust bearing (13), backup
17. Install the gerotor (4) and align the screw holes.
washer (15), seal ring (16) and O-ring (17).
18. Lubricate a new O-ring (3) and install into the
11. Release the centering spring (12) tension.
groove in the gerotor ring (4).
12. Remove the gerotor star.
19. Install the end cap (2) and seven cap screws (1).
13. Remove the splined shaft end No. 8063 tool. Pre-tighten the cap screws in a criss-cross pat-
tern to 17 Nm (150 pound-inch), and finally, in a
14. Lubricate new O-rings (3) and install in the groove
criss-cross pattern, tighten cap screws (1) to 33.9
of the steering control valve housing (7).
Nm (300 pound-inch). See SPECIAL TORQUES
15. Install the spacer plate (5), O-ring (3), and align in this section.
the holes in the spacer plate (5) with the threaded
holes in the housing (7).
4.4 STEERING PRIORITY VALVE

Disassembly STEP 4
STEP 1 Remove plug (5). Remove and discard O-ring (6) from
plug.
Put the steering priority valve in a soft jawed vise.
STEP 5
STEP 2
Remove spring (7).
Remove adapter (1). Remove and discard O-ring (2)
from adapter.
STEP 6
STEP 3 Remove spool (8).
Remove relief valve (3). Remove and discard O-ring
STEP 7
(4) from relief valve.
Remove plug (9). Remove and discard O-ring (10) from
plug.
1 2 3 4 11
10
9
7 8
BS01E129
1. Adapter - 2. O-ring - 3. Relief valve - 4. O-ring - 5. Plug - 6. O-ring - 7. Spring - 8. Spool - 9. Plug - 10. O-ring - 11. Housing.
Cleaning and Inspection Assembly

STEP 8 STEP 12
Clean all parts in cleaning solvent. Immerse housing Install new O-ring (10) on plug (9). Install plug and O-
(11) in cleaning solvent and agitate cleaning solvent. ring. Tighten plug to a torque of 33.9 to 54.2 Nm (25 to
WEAR EYE PROTECTION WHEN USING COM- 40 lb-ft).
PRESSED AIR. Use compressed air to remove for-
eign matter from interior of valve housing and to en- STEP 13
sure that all orifices and bores are clear.
Install spool (8) and spring (7).
STEP 9 STEP 14
Inspect spool (8) and housing bores for deep scratches, Install new O-ring (6) on plug (5). Install plug and O-
gouges, and other damage. Replace steering priority ring. Tighten plug to a torque of 33.9 to 54.2 Nm (25 to
valve if any of these conditions are seen. 40 lb-ft).
STEP 10 STEP 15
Check that orifice screws in each end of spool (8) are Install new O-ring (4) on relief valve (3). Install relief
free and clear of foreign matter. WEAR EYE PRO- valve and O-ring. Tighten relief valve to a torque of
TECTION WHEN USING COMPRESSED AIR. If nec- 33.9 to 54.2 Nm (25 to 40 lb-ft).
essary, remove orifice screws and use compressed
air to remove foreign matter from interior of spool (8) STEP 16
and orifice screws. Install orifice screws in spool (8) Install new O-ring (2) on adapter (1). Install adapter
ends. Tighten screws to a torque of 7.3 to 9.6 Nm (65 and O-ring. Tighten adapter to a torque of 8.1 to 9.5
to 85 lb-inch). Nm (72 to 84 lb-inch).
STEP 11
Check spring (7) for cracks, breaks, or signs of per-
manent set. Replace if any of these conditions are
seen.
3 1 11
1 2
10 9
7 8
BS01E129
1. Adapter - 2. O-ring - 3. Relief valve - 4. O-ring - 5. Plug - 6. O-ring - 7. Spring - 8. Spool - 9. Plug - 10. O-ring - 11. Housing.
4.5 STEERING CYLINDERS
Torque for piston cap screw............................................................................. 895 to 1110 Nm (660 to 819 lb-ft)
Torque for gland ................................................................................................ 339 to 475 Nm (250 to 350 lb-ft)
4.5.2 STEERING CYLINDER

Disassembly Inspection
1. Fasten tube (19) in a vise. Be careful not to dam- 1. Clean all parts in cleaning solvent.
age the tube. See illustration on page 4-27.
2. Check to be sure that piston rod (15) is straight. If
2. Remove gland (1) from tube (19). piston rod is bent, install a new piston rod.
3. Pull piston rod (15) and piston (10) straight out of 3. Inspect inside of tube (19) for deep grooves and
tube (19). other damage. If there is any damage to tube, a
new tube must be used.
4. Fasten piston rod (15) yoke in vise and put a sup-
port below piston rod near piston (10). Put a shop 4. Remove small scratches on piston rod (15) or in-
cloth between support and piston rod to prevent side tube (19) with emery cloth of medium grit. Use
damage to piston rod. emery cloth with a rotary motion.
5. Loosen and remove bolt and washer (9) that hold 5. Inspect bushing (18). If bushing requires replace-
piston (10). ment, remove grease fitting (16) and retaining rings
(17) then press bushing from tube end.
6. Remove piston (10) from piston rod (15).
7. Remove and discard seal (11), loader ring (12), wear
ring (13), and cast iron ring (14) from piston (10).
8. Remove gland (1) from piston rod (15).
9. Remove and discard O-ring (6), backup ring (7), O-
ring (8), rod wiper (2), rod seal (3), buffer seal (4),
and bearing (5) from gland (1).
17 16
18
17
19
9
10
14
12
13
11
5
4
3
7
6
8
15
2
BS03B156
Steering cylinder illustration
1. Gland - 2. Rod wiper - 3. Rod seal - 4. Buffer seal - 5. Bearing - 6. O-ring - 7. Backup ring - 8. O-ring - 9. Bolt and washer
- 10. Piston - 11. Seal - 12. Ring loader - 13. Wear ring - 14. Ring cast iron - 15. Piston rod - 16. Grease fitting - 17. Retaining
ring - 18. Bushing - 19. Tube.
Assembly 14. Install a new loader ring (12) on piston (10).

1. Install bearing (5) in gland (1). 15. Install a new seal (11) over loader ring (12).
2. Install buffer seal (4) in gland (1) so that lips of 16. Clean the threads on the end of piston rod (15)
seal are toward small end of gland. and threads of bolt (9) using Loctite cleaning sol-
vent. Allow to dry. Apply Loctite 243 to piston rod
3. Install rod seal (3) in gland (1). Rod seal must be
threads 6.4 mm (1/4 inch) from open end of pis-
installed so that lips of seal are toward small end
ton rod so that there is 12.7 mm (1/2 inch) of
of gland. Seal can be difficult to install. Use tools
Loctite 243 on piston rod threads. DO NOT apply
that will not damage seal. See illustration on page
Loctite to first 6.4 mm (1/4/inch) of piston rod
4-27.
threads.
4. Install rod wiper (2) in gland (1) with wiper lips
17. Install bolt and hardened washer (9) in piston (10).
toward large end of gland.
18. Install piston (10) on piston rod (15) and start bolt
5. Install O-ring (8) in groove at large end of gland
(9) into piston rod.
(1).
19. Tighten bolt (9) to a torque of 895 to 1110 Nm
6. Install O-ring (6) on gland (1). The O-ring (6) must
(660 to 819 lb-ft).
be toward small end of gland.
20. Fasten tube (19) in vise. Be careful not to dam-
7. Install backup ring (7) on gland (1). The backup
age tube.
ring must be toward large end of gland. If backup
ring is not flat on both sides, the side that is not 21. Apply petroleum jelly to O-rings (6 and 8) and
flat must be toward O-ring (6). backup ring (7) on gland (1) and to sealing sur-
face in tube (19).
8. Fasten piston rod (15) yoke in vise.
22. Lubricate piston (10) and inside of tube (19) with
9. Lubricate piston rod (15) and bore in gland (1) with clean hydraulic oil.
clean hydraulic oil.
23. Push the piston (10) straight into tube (19). Be
Note – If a new gland (1) is being installed, write part careful not to damage cast iron ring (14), wear
number of cylinder on gland. ring (13), and seal (11) on piston (10).
10. Push gland (1) onto piston rod (15) large end first. 24. When piston (10) is in smooth part of tube (19),
If necessary, use a soft hammer to drive the gland start gland (1) into tube (19).
onto piston rod.
25. Tighten gland (1) to 339 to 475 Nm (250 to
11. Put a support below and near the end of piston 350 lb-ft).
rod (15). Put a cloth between support and piston
rod to prevent damaging piston rod.
12. Install new cast iron ring (14) on piston (10).
13. Install new wear ring (13) on piston (10).
4.6 CENTER PIVOT
Special Torques
M16 bolt for upper pivot pin .................................................................220 to 250 Nm (162 to 184 pound-feet)
M12 bolts for bearing retainers and lower pivot pin ..................................................... 124 Nm (91 pound-feet)
M12 bolts for lower pin plate ................................................................ 128 to 136 Nm (94 to 100 pound-feet)
Ferry head screws for the drive shaft ......................................................... 61 to 81 Nm (45 to 60 pound-feet)
Lubricant
Pivot bearings and seals ............................................................................................................ MG-2 grease
Steering cylinder rod eyes .......................................................................................................... MG-2 grease
Fluids
Hydraulic system reservoir ............................................................................................................ HITECH 46
4.6.2 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)
4.6.3 CENTER PIVOT 19. Disconnect the supply hose.

Disassembly 20. Install a cap on the hose and a plug in the fitting.
1. Remove all dirt and grease from the area of the 21. Stop the vacuum pump.
center pivot. Park the machine on a level 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 rod
floor. eye.
3. Stop the engine and apply the parking brake. 23. Remove the pivot pin from the rear frame and the
steering cylinder rod eye.
4. Remove the covers from both sides of the ma-
chine. 24. Remove the washer from the rear frame. Move
the steering cylinder out of the way.
5. Disconnect the front wiring harness from the cab
floor. 25. Repeat steps 22, 23 and 24 for the other steering
cylinder.
6. Remove any tie straps that fasten the front wiring
harness to the chassis near the center pivot. 26. Loosen and remove the Ferry head screws and
retainers that fasten the drive shaft to the front
7. Loosen and remove the nut and washer that fas-
yoke. Move the drive shaft out of the way.
ten the chassis ground wire and cab ground wire
to the studs. 27. Place two stands below and in contact with the
front frame.
8. Loosen and remove the bolt, lock washer, and
nut that fasten the clamp on the front wiring har- 28. Install blocks between the rear axle and the rear
ness to the bracket on the rear frame. Move the frame on both sides of the machine to prevent
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 jack
at the rear of the machine to prevent the rear frame
from tipping.
voir. Start the vacuum pump.
30. Loosen and remove the bolt (1), washer (2), and
11. Disconnect the brake hose from the backside of
spacer (3) that fasten the upper pivot pin (4) to
front brake line bracket.
the rear chassis (5), refer to Figure.
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 (2)
14. Install caps on the fittings and plugs in the hoses. that fasten the lower pin plate (15) to the lower
pivot pin (10).
15. Loosen and remove the bolts, lock washers, and
self-locking nuts that fasten the mounting bracket 33. Loosen and remove the bolts (1) and washers (2)
for the hoses to the bracket on the front frame. that fasten the lower pin plate (15) to the bottom
of the rear chassis (5).
16. Loosen and remove the bolts, flat washers, and
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
Special Tools in this section.
18. Install the cap on the hose and a plug in the fit-
ting.
1 2
3
4
5
1
6 2
7
5
8
10
6 9
11
16 12
6
8
13
6
2
14
1
8
15
2
2
1 1
BS03B152
Figure 1 – Center pivot assembly
1. Bolt - 2. Washer - 3. Spacer - 4. Upper pivot pin - 5. Rear chassis - 6. Seal - 7. Bearing retainer - 8. Shim - 9. Upper pivot
bearing - 10. Lower pivot pin - 11. Lower bearing spacer- 12. Lower pivot bearing - 13. Bearing retainer - 14. Bottom spacer
- 15. Lower pin plate - 16. Front chassis.
36. Remove the bottom spacer (14). Assembly

37. Release the parking brake. 1. Pack the bearing cones with grease. See Specifi-
cations in this section. Be careful not to mix the
38. Use prybars to turn the left rear wheel backwards
bearing cones.
and the right rear wheel forward to move the front
of the rear frame to the left for access to the bear- 2. Lubricate the bore in the top pivot with grease. See
ings. Install blocks under the wheels to prevent Specifications in this section for the correct grease.
the rear frame from moving.
3. Install a bearing cup in the top pivot, refer to Figure 2.
4. Install the bearing driver and plate.
40. Hold the bearing retainer (13) in place and loosen
and remove the bolts (1) and washers (2) that fas-
ten the bearing retainer (13) and shims (8) to the NUT
TOP PIVOT
bottom of the rear pivot. WASHER
TOP BEARING
41. Remove the bearing retainer (13) and shims (8). DRIVER
42. Remove the lower bearing spacer (11) from the

top of the lower pivot.
43. Loosen and remove the bolts (1) and washers (2)
that fasten the bearing retainer (7) and shims (8)
to the top of the top pivot. BEARING
CUP PLATE
44. Remove the bearing retainer (7) and shims (8). WASHER
TOP
45. Use the puller to remove the seal (6) from the top PIVOT
SCREW NUT
of the bottom pivot.
B1423A88J
46. Use the puller to remove the seal (6) from the
bottom of the top pivot. Figure 2
47. Use an acceptable driver, the hydraulic ram, and 5. Tighten a nut on the screw until the bearing cup is
the hand pump to remove the upper pivot bearing seated in the bore of the top pivot. Remove the
(9) from the top pivot. See Special Tools in this bearing driver and plate from the top pivot.
section. 6. Install a bearing cone, spacer, the other bearing
cone, and the remaining bearing cup in the top pivot,
Note – The spacers are matched to the bearing sets. refer to Figure 3.
Do not mix the spacers. Do not use the old spacers if
new bearing sets are being installed. 7. Install the bearing driver and plate.
8. Tighten a nut on the screw until the bearing cup is
48. Use an acceptable driver, the hydraulic ram, and seated against the spacer. Remove the bearing
the hand pump to remove the lower pivot bearing driver and plate from the top pivot.
(12) from the bottom pivot. See Special Tools in
this section. SCREW
TOP BEARING
DRIVER NUT
Note – The spacers are matched to the bearing sets.
WASHER
Do not mix the spacers. Do not use the old spacers if BEARING
new bearing sets are being installed. CUP BEARING
CONE
49. Use an acceptable driver to press the seal (6) out

of each bearing retainer (7 and 13).
SPACER
BEARING
TOP PIVOT
CONE
BEARING
PLATE
CUP WASHER
NUT B1424A88J
Figure 3
9. Put the bearing retainer (7) in place on the upper 18. Use an acceptable driver to install the seal (6) in
pivot bearing (9), refer to Figure 1. the bottom of the top pivot, refer to Figure 6.
10. Install the bearing driver and plate, refer to Figure 4. 19. The bottom of the seal (6) must be even with the
bottom of the top pivot.
11. Tighten a nut on the screw until the bearing retain-
er (7) is tight against the upper pivot bearing (9). 20. Apply grease to the upper pivot pin (4).
21. Install the upper pivot pin (4) in the top pivot.
BEARING RETAINER UP
GAP
TOP PIVOT
B1425A88J
B1430A88J
Figure 4
Figure 6
12. Measure the gap between the bearing retainer (7)
and the top pivot. Make a record of the measure- 22. Lubricate the top pivot until grease is forced out
ment. Subtract 0.0762 to 0.1016 mm (0.003 to of the seal (6). See Specifications in this section.
0.004 inch) from the measurement, refer to Fig- 23. Rotate the upper pivot pin (4) to check the bear-
ure 4. Select shims (8) equal to that value. ing assembly. The upper pivot pin (4) must rotate
13. Remove the bearing driver, plate, and bearing re- smoothly, but not easily. Leave the upper pivot
tainer (7) from the top pivot. pin (4) in place to keep dirt out of the upper pivot
bearing (9).
14. Install the shims (8) and the bearing retainer (7).
24. Lubricate the bore for the bottom pivot with grease.
15. Install the washers (2) and bolts (1). Tighten the Install a bearing cup in the bottom pivot.
bolts (1) to 124 Nm (91 pound-feet).
25. Install the bearing driver and plate, refer to
16. Install the seal (6) in the bearing retainer (7). The Figure 7.
top of the seal (6) must be even with the top of
the bearing retainer (7), refer to Figure 5. SCREW
UP
NUT
WASHER
BEARING CUP PLATE
B1426A88J
Figure 5 BOTTOM
BOTTOM WASHER BEARING
PIVOT NUT DRIVER
17. Fill the other seal (6) for the top pivot with grease. B1427A88J
See Specifications in this section for the correct
grease. Figure 7
26. Tighten a nut on the screw until the bearing cup is 35. Measure the gap between the bearing retainer (13)
seated in the bore in the bottom pivot. and the bottom pivot. Make a record of the meas-
urement. Subtract 0.0762 to 0.1016 mm (0.003 to
27. Remove the bearing driver and plate from the bot-
0.004 inch) from the measurement. Select shims
tom pivot.
(8) equal to that value.
28. Install a bearing cone, spacer, the other bearing
36. Remove the bearing driver, plate and bearing re-
cone, and the remaining bearing cup in the bot-
tainer (13) from the bottom pivot.
tom pivot.
37. Install the shims (8), the bearing retainer (13),
29. Install the bearing driver and plate, refer to Figure 8.
washers (2) and bolts (1).
SCREW
38. Tighten the bolts (1) to 124 Nm (91 pound-feet).
NUT 39. Fill the seal (6) for the bearing retainer (13) with
WASHER
grease. See Specifications in this section for the
BEARING PLATE
CUP BEARING correct grease.
CONE
40. Install the seal (6) in the bearing retainer (13). The
bottom of the seal (6) must be even with the bot-
tom of the bearing retainer (13). Be careful not to
damage seal (6), refer to Figure 10.
UP
SPACER
BEARING
CUP BEARING
BOTTOM CONE
BOTTOM WASHER BEARING
PIVOT NUT DRIVER B1428A88J
Figure 8
30. Tighten a nut on the screw until the bottom bear-
ing cup is seated against the spacer.
31. Remove the bearing driver and plate from the bot-
tom pivot.
B1430A88J
32. Put the bearing retainer (13) in place on the lower
Figure 10
pivot bearing (12).
33. Install the bearing driver and plate, refer to Figure 9. 41. Install the other seal (6) in the bottom pivot, refer
to Figure 11. The top of the seal (6) must be even
with the top of the bottom pivot.
BOTTOM
PIVOT
UP
GAP
BEARING
RETAINER
B1429A88J B1426A88J
Figure 9 Figure 11
34. Tighten a nut on the screw until the bearing retainer 42. Install the lower bearing spacer (11) and the bot-
(13) is tight against the lower pivot bearing (12). tom spacer (14).
43. Apply grease to the lower pivot pin (10). See 16. Install the shims (8).
Specifications in this section.
17. Tighten the six outer bolts (1) to 128 to 136 Nm
44. Install the lower pivot pin (10) in the bottom pivot. (94 to 100 pound-feet).
45. Hold the bottom spacer (14) in place and lubri- 18. Tighten the three inner bolts (1) to 124 Nm (91
cate the bottom pivot until grease is forced out of pound-feet).
the seal (6).
19. Remove the jacks from the rear frame.
46. Rotate the lower pivot pin (10) to check the bear-
20. Remove the blocks from the rear axle.
ing assembly. The lower pivot pin (10) must rotate
smoothly, but not easily. 21. Remove the stands from the front frame.
47. Remove the lower pivot pin (10) and the upper 22. Put the drive shaft in position on the front yoke.
pivot pin (4). 23. Install new Ferry head screws that fasten the drive
48. Remove the bottom spacer (14). shaft to the front yoke.
24. Tighten the Ferry head screws to 61 to 81 Nm (45
to 60 pound-feet).
4.6.4 CONNECTING THE FRONT FRAME
TO THE REAR FRAME 25. Put the steering cylinder rod eye in position in the
frame. Install the washer between the steering
1. Release the parking brake. cylinder rod eye and the rear frame.
2. Move the rear frame into alignment with the front 26. Align the hole in the pivot pin with the holes in the
frame. steering cylinder rod eye, and install the pivot 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 frame. pivot pin.
4. Apply the parking brake. 28. Repeat steps 25, 26 and 27 for the other steering
5. Apply grease to the upper pivot pin (4), refer to cylinder.
Figure 1. 29. Start the vacuum pump.
6. Install the upper pivot pin (4), spacer (3), washer (2) 30. Connect the return hose.
and bolt (1). Be careful not to damage the seal (6).
31. Connect the supply hose.
7. Tighten the bolt (1) to 220 to 250 Nm (162 to 184
pound-feet). 32. Put the bracket for the hoses in position on the
rear frame. Install the bolts, flat washers, and self-
8. Apply grease to the lower pivot pin (10). locking nuts that fasten the bracket to the rear
9. Install the lower pivot pin (10) in the frames. Be frame.
careful not to damage the seal (6). 33. Put the bracket for the hoses in position on the
10. Use the ram and hand pump to install the bottom front frame.
spacer (14). See Special Tools in this section. 34. Install the bolts, flat washers, and self-locking nuts
11. Install the lower pin plate (15), three inner bolts that fasten the bracket to the front frame.
(1), and washers (2) that fasten the lower pin plate 35. Connect the hoses for the steering cylinders.
(15) to the lower pivot pin (10).
36. Connect the brake hose for the front brakes at
12. Tighten the bolts (1) to 69 Nm (51 pound-feet). the front bracket.
13. Measure the gap between the lower pin plate (15) 37. Stop the vacuum pump.
and the bottom pivot. Make a record of the meas-
urement. Subtract 0.0762 to 0.1016 mm (0.003 to 38. Connect the front wiring harness to the rear wiring
0.004 inch) from the measurement. Select shims harness.
equal to that value. 39. Put the clamp on the wiring harness in position
14. Loosen the bolts (1) that fasten the lower pin plate on the bracket. Install the bolt, lock washer, and
(15) to the lower pivot pin (10). nut that fasten the clamp on the wiring harness to
the bracket.
15. Start the six outer bolts (1) into the lower pin plate
(15) and the bottom pivot.
40. Put the ground wire in position on the stud. Install 44. Install the fill cap in the hydraulic reservoir.
the washer and nut that fasten the ground wire to
45. Bleed air from the front axle bleed screws.
the stud.
46. Lubricate the pivot pins for the steering cylinder
41. Install a tie strap to fasten the wiring harness to
rod eyes.
the tube.
47. Install the covers on both sides of the machine.
42. Disconnect the vacuum pump from the hydraulic
reservoir.
43. Check the fluid level in the hydraulic reservoir.
Add oil as required. See Specifications in this
section.
4.7 AUXILIARY STEERING MOTOR AND PUMP
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)
4.7.2 AUXILIARY STEERING MOTOR AND Assembly

PUMP 1. Lubricate all parts with clean hydraulic oil before
Disassembly assembly.
Note – Refer to Section 4-1 for removal and installation 2. Lubricate and install a new seal (4) and retaining
of the auxiliary steering motor and pump. ring (3) on the plate (17). Refer to the illustration
on page 4-39.
Note – The pump is the only component that is disas-
sembled. The switch (8) and motor (1) are replaced as 3. Lubricate and install a new backup ring (5) and a
units and are not serviced. Refer to the illustration on new seal (6) on the plate (17).
page 4-42. 4. Lubricate and install new O-rings (7) on the body
(18).
1. Make an alignment mark on the pump assembly
5. Lubricate and install the pins (22), drive gear (20),
and motor (1).
driven gear (19) and wear plates (23) on the body
2. Loosen and remove the two screws (15) and lock (18).
washers (14) that hold the pump assembly to the
motor (1). 6. Lubricate and install a new backup ring (5) and a
new seal (6) on the end plate (21).
3. Remove and discard the mounting gasket (13),
retaining ring (3) and seal (4) from the pump as- 7. Align the marks, made during disassembly, on
sembly. the end plate (21), body (18) and plate (17) and
install the four bolts (2). Tighten the four bolts (2).
4. Loosen and remove the four bolts (2) that hold
the pump assembly together. 8. Install a new gasket (13) on the pump assembly.
5. Remove the end plate (21) from the body (18). 9. Align the marks, made during disassembly, on
the pump assembly and the motor (1).
6. Remove and discard the seal (6) and backup ring
(5) from the end plate (21). 10. Install the lock washer (14) and screw (15). Torque
7. Remove the wear plate (23), drive gear (20) and the screw (15) to 35 to 39 Nm (312 to 348 pound-
driven gear (19) from the body (18). inches).
8. Remove the body (18) from the plate (17).
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 as-

sembly 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 4-42.
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.
8
10 9
11
12 16
1
13
3 17
4 14
15
5
6
23
19
7
22
18
22
7
20
23
6
5
21
2
BS01C121
Auxiliary steering pump and motor illustration
1. Motor - 2. Bolt - 3. Retaining ring - 4. Seal - 5. Backup ring - 6. Seal - 7. O-ring - 8. Switch - 9. Cable - 10. Screw - 11. Lock
washer - 12. Washer - 13. Gasket - 14. Lock washer - 15. Screw - 16. Wire - 17. Plate - 18. Body - 19. Driven gear - 20. Driven
gear - 21. End Plate - 22. Pins - 23. Wear Plate.
NOTES:
SECTION 5
BUCKET BOOMS AND FRAME

INDEX
5.1 LOADER ............................................................................................................... 5-1

5.1.1 GENERAL DESCRIPTION ................................................................................... 5-1
5.1.2 SPECIFICATIONS ............................................................................................... 5-2
5.1.3 BUCKET TEETH .................................................................................................. 5-2
Replacement of the Tooth Points ...................................................................... 5-2
Replacement of the Bucket Teeth ..................................................................... 5-2
Replacement of the Bucket Corner Teeth ......................................................... 5-2
5.1.4 RETURN TO DIG ADJUSTMENT (Z-BAR AND XR MODELS) ............................. 5-3
5.1.5 HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT
(Z-BAR, XR AND TC MODELS) ............................................................................ 5-4
5.1.6 RETURN TO DIG ADJUSTMENT (TC MODELS) ................................................. 5-6
5.1.7 REMOVING THE LOADER FRAME (Z-BAR AND XR MODELS) ......................... 5-7
5.1.8 INSTALLING THE LOADER FRAME (Z-BAR AND XR MODELS) ........................ 5-9
5.1.9 REMOVING THE LOADER FRAME (TC MODELS) .............................................. 5-10
5.1.10 INSTALLING THE LOADER FRAME (TC MODELS) ............................................ 5-12
W170/W170TC BUCKET BOOMS AND FRAME 5-1
5.1 LOADER
5.1.1 GENERAL DESCRIPTION The bucket positioner device and the boom kick-out
ensure an optimised efficiency of the equipment.
The load handling system is composed of:
All pivot pins of the handling system have dust seals
- booms
to prevent the entry of debris.
- strut
The three bucket pivot pins and the lower strut hing-
- link
ing pin are equipped with O-rings. All pivot pins are
- bucket
mounted with securing screws.
- bucket cylinder
For the part relative to bucket and boom cylinders,
- boom cylinders
please refer to Section 6 (Hydraulic system).
- pins
3 4
2
6
5
8 9
11
7
7 12
8
12
11
9
10
10
Detail of typical pin Bucket pins
W170-5R001
Booms, strut and bucket
Note – Apply grease to the inner surfaces of the bushings and dust seals, prior to inserting the pins. Apply rust
preventing oil to the inner surfaces of the bosses.
1. Bucket - 2. Strut - 3. Boom - 4. Bucket cylinder - 5. Link - 6. Boom cylinder - 7. Locking screw - 8. Dust seal - 9. Bushing - 10.
Pin - 11. Grease fitting - 12. O-Ring.
5-2 BUCKET BOOMS AND FRAME W170/W170TC
Special Torques
Bolts for the Bucket Teeth ....................................................................... 515 to 618 Nm (380 to 456 pound-feet)
5.1.3 BUCKET TEETH

Replacement of the Tooth Points
1. Use a hammer and punch to drive the retaining pin 3
4 5
(1) for the tooth point (2) out of the tooth 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 6
the retaining pin is toward the cutting edge. Use 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).
1
2
Replacement of the Bucket Teeth
1. Loosen and remove the nuts (4), hardened wash-
9
ers (5), and bolts (6) from the bucket teeth. 7
Note – If wear of the bolt or nut makes removal diffi-
cult, the bolt or nut can be cut off.
B0740A88J
2. Remove the tooth.

Bucket teeth illustration
3. Install the new tooth on the bucket cutting edge
(7). 1. Retaining ring - 2. Tooth point - 3. Tooth shank - 4. Nut -
5. Hardened washer - 6. Bolt - 7. Cutting edge - 8. Plow
4. Use new nuts (4), hardened washers (5), and bolts bolt - 9. Nut - 10. Corner tooth.
(6) for the tooth being installed.
5. Tighten the nuts (4) to 515 to 618 Nm (380 to
456 lb ft).
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 diffi-

cult, the bolt or nut can be cut off.
2. Remove the corner tooth (10).

3. Install the new corner tooth (10) on the bucket cut-
ting edge (7).
4. Use new nuts (9) and bolts (8) for the corner tooth
being installed.
5. Tighten the nuts (9) to 515 to 618 Nm (380 to
456 lb ft).
5.1.4 RETURN TO DIG ADJUSTMENT (Z-BAR AND XR MODELS)
2
6
1
3
4
5 BS01C083
Return to dig adjustment illustration
1. Target mounting bracket - 2. Bucket cylinder - 3. Target bar - 4. Proximity switch mounting bracket - 5. Proximity switch -
6. Proximity switch guard.
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 (3) towards the proximity switch (5) until the face
make sure that the target bar stays the same dis- of the proximity switch (5) is completely covered.
tance from the switch. The switch mounting bracket 8. Align the target bar (3) parallel to the tilt cylinder
protects the switch. Make sure the target bar cannot (2) and tighten the bolts.
touch the switch when the bucket is dumped. 9. Turn the ignition switch to the ON position. Do
NOT start the engine.
1. Park the machine on a level surface. Raise the lift
arms until they are approximately horizontal and 10. Place the bucket control lever in the ROLLBACK
dump the bucket. Lower the bucket until the bucket position.
edge is on the ground. 11. Loosen the bolts holding the target bar (3) to the
2. Apply the parking brake and stop the engine. target mounting bracket (1).
12. Slide the target bar (3) slowly away from the prox-
3. Loosen the bolts holding the target mounting
imity switch (5), until the control lever returns to
bracket (1) to the tilt cylinder eye. Align the target
the center position. Tighten the bolts holding the
mounting bracket (1) parallel to the tilt cylinder (2).
target bar (3).
Tighten the bolts, refer to the illustration on this
page. 13. Check to make sure that the 3.2 to 5.0 mm (1/8
to 3/16 inch) gap is still maintained.
4. Loosen the bolts holding the proximity switch mount-
ing bracket (4) to the tilt cylinder (2). Position the 14. Start the engine.
proximity switch (5) parallel to the target bar (3) 15. Place the detent switch in the ON position and
and tighten the bolts. place the return to travel/float detent switch to
5. Adjust the proximity switch (5) out towards the tar- the TRAVEL position.
get bar (3), until an air gap of 3.2 to 5.0 mm (1/8 to 16. Raise the lift arms approximately horizontal, and
3/16 inch) is obtained. Torque the jam nut to 6 to put the bucket in the fully dumped position.
7.5 Nm (4.5 to 5.5 pound-feet).
17. Place the loader control lever in the ROLLBACK
Note – The proximity switch (5) must not protrude position, and verify that the electromagnet holds
past the proximity switch guard (6). it in that position until the end of the target bar (3)
passes in front of the proximity switch (5).
6. Start the engine, position the bucket to the cor- 18. Lower the lift arms and verify that the bucket is at
rect digging angle and stop the engine. the correct digging angle.
5.1.5 HEIGHT CONTROL AND RETURN TO TRAVEL ADJUSTMENT

(Z-BAR, XR AND TC MODELS)
5
6
2
1
BS01C081
Height control and return to travel adjustment illustration Z-BAR, XR and TC models
1. Target mounting plate - 2. Height control target - 3. Proximity switch - 4. Lift arm - 5. Return to travel target - 6. Front
chassis (top left hand side).
1. Park the machine on a level surface. 5. Position the return to travel target (5) opposite the
proximity switch (3) and tighten it to the target
2. Start the engine and apply the parking brake.
mounting plate (1).
3. Lower the lift arms and place the bucket flat on the
6. Adjust the proximity switch (3) out towards the re-
ground.
turn to travel target (5) until an air gap of 3.2
4. Stop the engine. to 5.0 mm (1/8 to 3/16 inch) is obtained.
7. Lock the proximity switch (3) in this position with
Note – To avoid damge to the proximity switch (3), it
the jam nut. Torque the jam nut to 6 to 7.5 Nm
must be adjusted back to clear everything on the lift
(4.5 to 5.5 pound-feet).
arm as it passes. Refer to the illustration on this page.
WARNING
Raised equipment on the machine without an op-
erator 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.
2
A
B
1
BS01C082
Height control and return to travel adjustment illustration Z-BAR, XR and TC models
1. Height control target - 2. Return to travel target - 3. Target mounting plate.
APPROXIMATE
RESULTING APPROXIMATE
MACHINE A RETURN TO B RESULTING
TRAVEL HINGE HEIGHT CONTROL
PIN HEIGHT HINGE PIN HEIGHT
54 mm 380 mm 48 mm 3302 mm
W170 Z-BAR
(2.1 inches) (15 inches) (1.9 inches) (130 inches)
78 mm 459 mm 54 mm 3302 mm
W170 XR
(3 inches) (18 inches) (2.1 inches) (130 inches)
51 mm 403 mm 43 mm 3302 mm
W170 TC
(2 inches) (15.9 inches) (1.7 inches) (130 inches)
8. Refer to the table and the illustration on this page. 13. Place the detent switch in the ON position, and
Position the height control target (1) on the target set the return to travel/float detent switch to the
mounting plate (3) using the table above. return to travel position.
Note – The higher the height control target (1) is posi- 14. Place the loader control lever in the raise position
tioned in its slot in the target mounting plate (3), the and verify that the electromagnet holds it in that
lower the lift arms will stop as they are raised. position until the height control target (2) passes
in front of the proximity switch (3). Refer to the
9. Tighten the height control target (1). illustration on page 5-4.
10. Position the return to travel target (2) using the 15. With the lift arms still raised, place the loader
table above. control lever in the lower position and verify that
the electromagnet holds it in that position until
Note – The higher the return to travel target (2) is the return to travel target (5) passes in front of the
positioned in its slot in the target mounting plate (3), proximity switch (3). Refer to the illustration on
the lower the lift arms will stop as they are lowered. page 5-4.
11. Check to make sure the proximity switch (3) and 16. Repeat steps 8 through 15 until the desired heights
all of the mounting bolts are tight. Refer to the are reached.
illustration on page 5-4. 17. Lower the bucket to the ground and stop the en-
12. Start the engine. gine.
5.1.6 RETURN TO DIG ADJUSTMENT (TC MODELS)
2
3
1 5
6 BS01C084
Return to dig adjustment illustration tc models

1. Bucket cylinder (left hand side) - 3. Target mounting bracket - 5. Proximity switch - 2. Proximity switch mounting bracket
- 4. Proximity switch guard - 6. Target bar
IMPORTANT – Before adjusting the return-to-dig, 8. Loosen the bolts holding the target bar (6) to the
make sure that the target bar on the bucket linkage is target mounting bracket (3). Slide the target bar
not damaged. Slowly roll back and dump the bucket (6) away from the proximity switch (5) until the
and make sure that the target bar stays the same face of the proximity switch (5) is completely un-
distance from the switch. The switch mounting bracket covered.
protects the switch. Make sure the target bar cannot 9. Align the target bar (6) parallel to the bucket cyl-
touch the switch when the bucket is dumped. inder (1) and tighten the bolts.
1. Park the machine on a level surface. Raise the lift 10. Turn the ignition switch to the ON position. Do
arms until they are approximately horizontal and NOT start the engine.
dump the bucket. Lower the bucket until the bucket 11. Place the bucket control lever in the ROLLBACK
edge is on the ground. position.
2. Apply the parking brake and stop the engine.
12. Loosen the bolts holding the target bar (6) to the
3. Loosen the bolts holding the target mounting target mounting bracket (3).
bracket (3) to the bucket cylinder clevis. Align the
target mounting bracket (3) parallel to the bucket 13. Slide the target bar (6) slowly towards the proxim-
cylinder (1) and tighten the bolts. Refer to the il- ity switch (5), until the bucket control lever re-
lustration on this page. turns to the center position. Tighten the bolts hold-
ing the targe bar (6).
4. Loosen the bolts holding the target bar (6) to the
target mounting bracket (3). Align the target bar 14. Check to make sure that the 3.2 to 5.0 mm (1/8
(6) parallel to the bucket cylinder (1) and tighten to 3/16 inch) gap is still maintained.
the bolts. 15. Start the engine.
5. Loosen the bolts holding the proximity switch 16. Place the detent switch in the ON position and
mounting bracket (2) to the bucket cylinder (1). set the return to travel/float detent switch to the
Position the proximity switch (5) face parallel to return to travel position.
the target bar (6) and tighten the bolts.
17. Raise the lift arms to approximately the horizon-
6. Adjust the proximity switch (5) out towards the
tal position and put the bucket in the fully dumped
target bar (6) until an air gap of 3.2 to 5.0 mm
position.
(1/8 to 3/16 inch) is obtained. Torque the jam nut
to 6 to 7.5 Nm (4.5 to 5.5 pound-feet). 18. Place the loader control lever in the ROLLBACK
position and verify that the electromagnet holds it
NOTE – The proximity switch (5) must not protrude in that position until the end of the target bar (6)
past the proximity switch guard (4). passes in front of the proximity switch (5).
7. Start the engine, position the bucket to the cor- 19. Lower the lift arms to the ground and verify that
rect digging angle and stop the engine. the bucket is at the correct digging angle.
5.1.7 REMOVING THE LOADER FRAME 17. Loosen and remove the bolt (19), flat washer (20)
(Z-BAR AND XR MODELS) and spacer (21) that fasten the pivot pin (9 or 10)
to the front frame.
1. Park the machine on a level surface and apply
the parking brake. Roll the bucket all the way for- 18. Raise the loader frame slightly. Use an accept-
ward and lower the bucket to the floor. Stop the able driver and drive the pivot pin (9 or 10) out of
engine. the front frame. Do not lose the washers (18) and
wipers (22) between the front frame and the loader
2. Loosen the filler plug in the reservoir to release frame (2).
the air in the reservoir.
3. Fasten a chain hoist to the crossmember (1) of
the loader frame (2), refer to the illustration on
page 5-8.
4. Loosen and remove the bolt (12), flat washer (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
(3) out of the piston rod yoke of the right lift cylin-
der (4). Do not remove the driver.
6. Repeat Steps 4 and 5 for the left lift cylinder (6).
7. Start the engine. Roll the bucket back and lower
the bucket so that the bucket is flat on the floor
and fasten the chain hoist to a lift cylinder (4 or BD01G009
6).
19. Remove the proximity switch cover. Left-hand side
8. Raise the lift cylinder (4 or 6) slightly and remove of the machine only.
the driver.
9. Repeat steps 7 and 8 for the other lift cylinder (4
or 6).
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) for 1
the piston rod eye of the bucket cylinder (8) to the
bellcrank (11).
12. Use an acceptable driver and drive the pivot pin 2
(7) out of the piston rod eye of the bucket cylinder
(8).
13. Raise the bucket cylinder (8) and use a chain or
other acceptable holding equipment to hold the BD01G010
bucket cylinder (8) in place.
1. Electrical connection - 2. proximity switch.
14. If the machine is equipped with auxiliary hydrau-
lics, disconnect the two hoses from the tubes at 20. Disconnect the electrical connector (1), remove
the bracket on the right side of the loader frame the lock nut from the proximity switch (2) and re-
(2). Install caps on the hoses and plugs in the move the proximity switch (2) from the machine.
tube fittings. Left-hand side of the machine only.
15. If the machine is equipped with front lamps, 21. Repeat Steps 17 and 18 for the other pivot pin (9
loosen and remove the cap screws and lock wash- or 10).
ers that fasten the lamp brackets to the front frame.
22. Raise the loader frame (2) out of the front frame.
Put the lamp brackets on the fenders.
Carefully move the machine out of the loader frame
16. Connect the chain hoist to the loader frame (2). (2).
10
18 18 8 16
22 17 15
20
19 9 7
6
2
11
1
21
5
4
5
14
12 5
13 3
23
BS01G022
Loader frame - z-bar and xr models illustration
1. Crossmember - 2. Loader frame - 3. Pivot pin - 4. Lift cylinder - 5. Pivot pin - 6. Lift cylinder - 7. Pivot pin - 8. Bucket cylinder
- 9. Pivot pin - 10. Pivot pin - 11. Bellcrank - 12. Bolt - 13. Washer - 14. Spacer - 15. Bolt - 16. Washer - 17. Spacer -
18. Washer - 19. Bolt - 20. Washer - 21. Spacer - 22. Wiper - 23. Dump link.
5.1.8 INSTALLING THE LOADER FRAME 17. Disconnect the chain hoist from the bucket cylin-
(Z-BAR AND XR MODELS) der (8).
1. Apply antiseize compound to the inner bores and 18. Fasten the chain hoist to one of the lift cylinders
outer bores for the pivot pins of the front frame , (4 or 6).
refer to the illustration on page 5-8. 19. Raise the piston rod yoke of the lift cylinder (4 or
2. Move the machine into alignment with the loader 6) so the piston rod yoke is aligned with the loader
frame (2). frame (2).
3. Lower the loader frame (2) into alignment with the 20. Install a driver in the piston rod yoke and the loader
front frame. frame (2).
4. Apply antiseize compound to the pivot pins (9 and 21. Repeat Steps 18, 19, and 20 for the other lift cyl-
10) that fasten the loader frame (2) to the front inder (4 or 6).
frame. 22. Disconnect the chain hoist from the lift cylinder
5. Start the pivot pins (9 and 10) into the front frame. (4 or 6).
Install the washers (18) and new wipers (22) be- 23. Start the engine. Raise the loader frame and roll
tween the loader frame (2) and the front frame. the bucket all the way forward. Lower the bucket
6. Install the pivot pins (9 and 10) all the way. to the floor. Stop the engine.
7. Install the bolt (19), washer (20) and spacer (21) 24. Fasten the chain hoist to the crossmember (1) of
that fasten the pivot pins (9 and 10). Tighten the the loader frame (2).
bolt. 25. Start the engine and run the engine at low idle.
8. Install the proximity switch and cover. Left-hand 26. Have another person help you at this time. Move
side of the machine only. the lift control lever as required to align the piston
9. Disconnect the chain hoist from the loader frame rod yoke of one of the lift cylinders (4 or 6) with
(2). the loader frame (2).
10. If the machine is equipped with front lamps, hold Important – Do not use your fingers to check the
the front lamps in place and install the cap screws alignment of the cylinder rod. Personal injury can be
and lock washers that fasten the front lamps to the result.
the front frame. Tighten the cap screws.
11. If the machine is equipped with auxiliary hydrau- 27. Remove the driver and install the pivot pin (3).
lics, remove the plugs from the tube fittings and 28. Install the bolt (12), washer (13), and spacer(14)
the caps from the hoses. Connect the hoses to that fasten the pivot pin (3). Tighten the bolt.
the tubes.
29. Repeat Steps 26, 27, and 28 for the other lift cyl-
12. Connect the chain hoist to the bucket cylinder (8) inder (4 or 6). Stop the engine.
and lower the bucket cylinder (8).
30. Lubricate the pivot pins with molydisulfide grease.
13. Start the engine and run the engine at low idle.
31. Disconnect the chain hoist from the crossmember
14. Have another person help you at this time. Move (1) of the loader frame (2).
the bucket control lever as required to align the
piston rod eye of the bucket cylinder (8) with the 32. Tighten the filler plug in the reservoir.
bellcrank (11). Stop the engine. 33. If the machine is equipped with auxiliary hydrau-
lics, start the engine and run the engine at low
Important – Do not use your fingers to check the idle.
alignment of the cylinder rod. Personal injury can be
the result. 34. Slowly extend and retract the clam cylinders four
times to remove air from the auxiliary circuit.
15. Install the pivot pin (7) in the bellcrank (11) and 35. Stop the engine, check the level of the oil in the
the piston rod eye of the bucket cylinder (8). reservoir, and check for leaks. Add oil to the res-
16. Install the bolt (15), washer (16), and spacer (17) ervoir as required.
that fasten the pivot pin (7). Tighten the bolt.
5 - 10 BUCKET BOOMS AND FRAME W170/W170TC
5.1.9 REMOVING THE LOADER FRAME 13. Disconnect the hoses to the bucket cylinders.
(TC MODELS) Disconnect the hoses from the tubes at the bucket
cylinders.
1. Remove all dirt and grease from the hose and
tube connections for the bucket cylinders and clam 14. Install a cap on each hose and a plug in each
cylinder, if equipped. tube.
2. With the engine running at low idle, roll the bucket 15. If equipped, disconnect the clam hydraulic con-
all the way forward and lower the loader frame nections, the auxiliary hydraulic connections, and
until the bucket is on the floor. the coupler connections as necessary. Plug and
cap lines as needed.
3. Stop the engine and apply the parking brake.
16. Disconnect the wiring harnesses.
4. Loosen the filler plug in the reservoir to release
the air in the reservoir. 17. Connect the chain hoist to the loader frame (3).
5. Loosen and remove the bolt (7), washer (8), and 18. Loosen and remove the bolt (11), washer (12),
spacer (9) that fasten the pivot pin (1) to the pis- and spacer (13) that fasten the loader frame (3),
ton rod yoke of the lift cylinder (2 or 10), refer to pivot pin (4) and anchor link pivot pin (5) to the
the illustration on page 5-11. machine frame.
6. Use an acceptable driver and drive the pivot pin 19. Raise the loader frame (3) slightly. Use an accept-
(1) out of the piston rod yoke of the lift cylinder (2 able driver and drive both the pivot pins (4 and 5)
or 10). Do not remove the driver. from the loader frame (3) and anchor link (6).
7. Repeat Steps 5 and 6 for the other lift cylinder (2 20. Do not lose the washers (14) between the front
or 10). frame and the loader frame (3).
8. Start the engine. Roll the bucket back and lower 21. If equipped, remove the proximity switch cover
the bucket so that the bucket is flat on the floor. and the proximity switch from the left-hand side
Fasten the chain hoist to a lift cylinder (2 or 10). of the machine.
9. Raise the lift cylinder (2 or 10) slightly and re- 22. Repeat Steps 18 and 19 on the opposite side of
move the driver. the machine.
10. Repeat Steps 8 and 9 for the other lift cylinder (2 23. Raise the loader frame from the machine. Be sure
or 10). all the necessary hydraulic lines, wiring etc. are
properly disconnected.
11. Stop the engine.
24. Carefully move the machine out of the loader
12. Move the bucket control lever to the ROLLBACK frame.
position and the lift control lever to the LOWER
position to relieve any pressure in the circuits.
W170/W170TC BUCKET BOOMS AND FRAME 5 - 11
14
15
12
11 4 14
13 3
5
7
9
1
BS01G021
Loader frame - TC models illustration
1. Pivot pin - 2. Lift cylinder - 3. Loader frame - 4. Pivot pin - 5. Pivot pin - 6. Anchor link - 7. Bolt - 8. Washer - 9. Spacer - 10.
Lift cylinder (not shown) - 11. Bolt - 12. Washer - 13. Spacer - 14. Washer - 15. Wiper.
5 - 12 BUCKET BOOMS AND FRAME W170/W170TC
5.1.10 INSTALLING THE LOADER FRAME 15. Repeat Steps 12, 13, and 14 for the other lift cyl-
(TC MODELS) inder (2 or 10).
16. Disconnect the chain hoist from the lift cylinder
1. Apply antiseize compound to the inner bores and (2 or 10).
outer bores of the front frame. 17. Start the engine. Raise the loader frame (3) and
2. Move the machine into alignment with the loader roll the bucket all the way forward. Lower the
frame (3), refer to the illustration on page 12. bucket to the floor. Stop the engine.
3. Lower the loader frame (3) into alignment with the 18. Fasten the chain hoist to the crossmember of the
machine frame. loader frame (3).
4. Apply antiseize compound to the pivot pins (4) 19. Start the engine and run the engine at low idle.
and (5) that fasten the loader frame (3) to the
machine frame.
5. Start the loader frame pivot pin (4), washer (14) IMPORTANT
and wiper (15). Do not use your fingers to check the alignment of
the cylinderrod. Personal injury can be the result.
6. Install the loader frame pivot pin (4) and anchor
link pivot pin (5) on one side of the machine.
7. Repeat Steps 5 and 6 for the opposite side of the 20. Have another person help you at this time. Move
machine. the lift control lever as required to align the piston
rod yoke of one of the lift cylinders (2 or 10) with
8. Install the bolt (11), washer (12) and spacer (13) the loader frame (3).
that secure the pivot pins (4 and 5) to the ma-
chine on each side of the machine. Tighten the 21. Remove the driver and install the pivot pin (1).
bolt. 22. Install the bolt (7), washer (8), and spacer (9) that
9. Disconnect the chain hoist from the loader frame fasten the pivot pin (1). Tighten the cap bolt.
(3). 23. Repeat Steps 20, 21, and 22 for the other lift cyl-
10. If the machine is equipped with auxiliary hydraul inder (2 or 10). Stop the engine.
ics, clam hydraul ics, or coupler hydraulics, re- 24. Lubricate the pivot pins with molydisulfide grease.
move the plugs from the tube fittings and the caps
from the hoses and make the necessary connec- 25. Disconnect the chain hoist from the crossmember
tions. of the loader frame (3).
11. Connect the hoses and tubing to the bucket cyl- 26. Start the engine and run the engine at low idle.
inders. 27. Slowly extend and retract the cylinders four times
12. Fasten the chain hoist to one of the lift cylinders to remove air from the hydraulic circuit.
(2 or 10). 28. If equipped with auxiliary hydraulics, slowly ex-
13. Raise the piston rod yoke of the lift cylinder (2 or tend and retract the clam cylinders four times to
10) so the piston rod yoke is aligned with the loader remove air from the auxiliary circuit.
frame (3). 29. Stop the engine, check the level of the oil in the
14. Install a driver in the piston rod yoke and the loader reservoir, and check for oil leaks. Add oil to the
frame (3). reservoir as required.
SECTION 6
EQUIPMENT HYDRAULIC SYSTEM

INDEX
6.1 REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS ...................... 6-1

6.1.1 REMOVAL AND INSTALLATION OF THE LOADER CONTROL VALVE ................. 6-1
Removal ........................................................................................................... 6-1
Installation ........................................................................................................ 6-4
6.1.2 REMOVAL AND INSTALLATION OF THE REMOTE CONTROL VALVE ................ 6-6
Removal ........................................................................................................... 6-6
Installation ........................................................................................................ 6-7
6.1.3 REMOVAL AND INSTALLATION OF THE HYDRAULIC PUMP ............................. 6-9
Removal ........................................................................................................... 6-9
Installation ........................................................................................................ 6-10
6.1.4 REMOVAL AND INSTALLATION OF THE LIFT CYLINDERS ................................ 6-12
Removal ........................................................................................................... 6-12
Installation ........................................................................................................ 6-13
6.1.5 REMOVAL AND INSTALLATION OF THE BUCKET CYLINDER - Z-BAR LOADER .. 6-15
Removal ........................................................................................................... 6-15
Installation ........................................................................................................ 6-17
6.1.6 REMOVAL AND INSTALLATION OF THE BUCKET CYLINDERS - TC LOADER 6-19
Removal ........................................................................................................... 6-19
TC Loader Bucket Cylinder Removal And Installation Illustration .................. 6-20
Installation ........................................................................................................ 6-21
6.1.7 REMOVAL AND INSTALLATION OF THE OIL COOLER ....................................... 6-22
Removal ........................................................................................................... 6-22
Installation ........................................................................................................ 6-23
6.1.8 REMOVAL AND INSTALLATION OF THE RIDE CONTROL ACCUMULATOR ....... 6-25
Removal ........................................................................................................... 6-25
Installation ........................................................................................................ 6-26
6.1.9 REMOVAL AND INSTALLATION OF THE RIDE CONTROL VALVE ...................... 6-27
Removal ........................................................................................................... 6-27
Installation ........................................................................................................ 6-28
6.1.10 REMOVAL AND INSTALLATION OF THE FAN REVERSING VALVE .................... 6-30
Removal ........................................................................................................... 6-30
Installation ........................................................................................................ 6-31
6.2 HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING

AND PRESSURE CHECKS .................................................................................. 6-32
6.2.1 SPECIFICATIONS ................................................................................................ 6-32
6.2.2 SPECIAL TOOLS ................................................................................................. 6-33
6.2.3 TROUBLESHOOTING PROCEDURE ................................................................... 6-34
Problems in All Circuits .................................................................................... 6-34
Problem in All Loader Circuits ........................................................................... 6-34
Problem in the Braking Circuit .......................................................................... 6-34
Problem in a Single Loader Circuit .................................................................... 6-35
Problem in the Steering Circuit ......................................................................... 6-35
Problem in the Ride Control .............................................................................. 6-35
6.2.4 TESTING AND ADJUSTING THE LOADER/STEERING

PUMP DIFFERENTIAL PRESSURE .................................................................... 6-36
Pressure Check ................................................................................................ 6-36
Adjusting the Loader/Steering Pump Differential Pressure ................................ 6-37
6.2.5 TESTING AND ADJUSTING THE LOADER/UNLOADING
PUMP DIFFERENTIAL PRESSURE .................................................................... 6-37
Pressure Check ................................................................................................ 6-37
Adjusting the Loader/Unloading Pump Differential Pressure .............................. 6-38
6.2.6 TESTING AND ADJUSTING THE LOADER LIMIT PRESSURE ........................... 6-39
Pressure Check ................................................................................................ 6-39
Adjusting the Loader Limit Pressure ................................................................. 6-40
6.2.7 TESTING AND ADJUSTING THE STEERING LIMIT PRESSURE ....................... 6-40
Pressure Check ................................................................................................ 6-40
Adjusting the Steering Limit Pressure ............................................................... 6-41
6.2.8 TESTING AND ADJUSTING THE LOADER PUMP CUTOFF PRESSURE ........... 6-42
Pressure Check ................................................................................................ 6-42
Adjusting the Loader Pump Cutoff Pressure ..................................................... 6-43
6.2.9 TESTING THE HYDRAULIC CONTROLLER PILOT SUPPLY PRESSURE ........... 6-43
Pressure Check ................................................................................................ 6-43
6.2.10 LOADER/STEERING PUMP FLOW TEST ........................................................... 6-44
6.2.11 TESTING AND ADJUSTING THE CIRCUIT RELIEF VALVES .............................. 6-45
Pressure Check ................................................................................................ 6-45
Adjustment ....................................................................................................... 6-45
6.2.12 TESTING THE RIDE CONTROL ........................................................................... 6-46
6.3 CLEANING THE HYDRAULIC SYSTEM ............................................................... 6-47

6.3.1 SPECIAL TOOLS ................................................................................................. 6-47
6.3.2 GENERAL INFORMATION ................................................................................... 6-48
6.3.3 TYPES OF CONTAMINATION .............................................................................. 6-48
6.3.4 CLEANING THE HYDRAULIC SYSTEM ............................................................... 6-49
6.3.5 FLUSHING WATER FROM THE HYDRAULIC SYSTEM ....................................... 6-51
6.4 LOADER CONTROL VALVE ................................................................................. 6-52

6.4.1 SPECIFICATIONS ................................................................................................ 6-52
2 Spool Valve Housing Configuration ................................................................. 6-53
2 Spool Valve Spool Configuration .................................................................... 6-54
3 Spool Mounting Configuration ........................................................................ 6-55
4 Spool Mounting Configuration ........................................................................ 6-56
3 and 4 Spool Valve Spool Configuration ........................................................... 6-57
6.4.2 DISASSEMBLY .................................................................................................... 6-58
6.4.3 INSPECTION ....................................................................................................... 6-63
6.4.4 ASSEMBLY .......................................................................................................... 6-63
Circuit Relief Pressure Test ............................................................................... 6-67
Circuit Relief Adjustment .................................................................................. 6-67
6.5 CYLINDERS ......................................................................................................... 6-68

6.5.1 SPECIFICATIONS ................................................................................................ 6-68
6.5.2 SPECIAL TORQUES ............................................................................................ 6-68
6.5.3 SPECIAL TOOLS ................................................................................................. 6-68
6.5.4 LIFT CYLINDER ................................................................................................... 6-69
Disassembly ..................................................................................................... 6-69
Inspection ......................................................................................................... 6-69
Assembly ......................................................................................................... 6-71
6.5.5 BUCKET CYLINDERS Z-BAR MODELS .............................................................. 6-72

Disassembly ..................................................................................................... 6-72
Inspection ......................................................................................................... 6-72
Assembly ......................................................................................................... 6-74
6.5.6 BUCKET CYLINDERS FOR TC MODELS ............................................................ 6-75
Disassembly ..................................................................................................... 6-75
Inspection ......................................................................................................... 6-75
Assembly ......................................................................................................... 6-77
6.5.7 REPLACING THE BUSHINGS FOR THE LIFT CYLINDERS Z-BAR - TC MODELS ... 6-78
Removal ........................................................................................................... 6-78
Installation ........................................................................................................ 6-78
6.5.8 REPLACING BUSHINGS FOR THE BUCKET CYLINDERS TC MODELS............ 6-78
Removal ........................................................................................................... 6-78
Installation ........................................................................................................ 6-78
6.5.9 REPLACING BUSHINGS FOR THE BUCKET CYLINDER Z-BAR MODELS ........ 6-79
Removal ........................................................................................................... 6-79
Installation ........................................................................................................ 6-79
6.6 PILOT PRESSURE ACCUMULATOR AND RIDE CONTROL ACCUMULATOR ...... 6-80
6.6.1 SPECIFICATIONS ................................................................................................ 6-80
6.6.2 RIDE CONTROL ACCUMULATOR SPECIAL TORQUES ...................................... 6-80
6.6.3 SPECIAL TOOLS ................................................................................................. 6-80
6.6.4 DISCHARGING THE NITROGEN CHARGE ON AN ACCUMULATOR ................... 6-81
6.6.5 RIDE CONTROL ACCUMULATOR ........................................................................ 6-82
Disassembly ..................................................................................................... 6-82
Inspection ......................................................................................................... 6-82
Assembly ......................................................................................................... 6-82
6.6.6 CHARGING THE ACCUMULATOR WITH NITROGEN ........................................... 6-84
6.7 RIDE CONTROL VALVE CONFIGURATION .......................................................... 6-86

Ride Control Valve Configuration ....................................................................... 6-86
6.7.1 DISASSEMBLY .................................................................................................... 6-87
6.7.2 INSPECTION ....................................................................................................... 6-87
6.7.3 ASSEMBLY .......................................................................................................... 6-87
Insert Valve ...................................................................................................... 6-87
Logic Cover ...................................................................................................... 6-88
Directional Valve ............................................................................................... 6-88
Pressure Relief Valve ........................................................................................ 6-89
HYDRAULIC SCHEMATIC W170/W170TC WHEEL LOADERS ............................ 6-91

W170/W170TC EQUIPMENT HYDRAULIC SYSTEM 6-1
6.1 REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS
6.1.1 REMOVAL AND INSTALLATION STEP 5

OF THE LOADER CONTROL VALVE Release the pressure in the ride control accumulator
Removal with the manual bleeder valve at the rear of the front
chassis.
STEP 1
Park the machine on a level surface. STEP 6
Loosen the filler cap on the reservoir to release the air
STEP 2 pressure in the reservoir.
STEP 7
Drain the hydraulic reservoir.
STEP 8
BD03A092
Raise the lift arms and install the safety link on the lift
arm cylinder.
STEP 3
BD03A093
Stop the engine and apply the parking brake.
Loosen and remove the bolts and washers that fas-
Important – Pump the brake repeatedly to be sure ten the access cover plate for the loader control valve.
the brake accumulators have no hydraulic pressure, Remove the cover plate.
then move the loader control valve back and forth
several times to release any hydraulic pressure in the
pilot control circuit.
STEP 4
Place the master disconnect switch in the OFF posi-
tion.
W110R0004
6-2 EQUIPMENT HYDRAULIC SYSTEM W170/W170TC
REAR OF MACHINE
2
7 4 3
8 1
6
5
10
11
BS03B182
Hydraulic Valve Pilot Line Connections
1. 2 spool valve - 2. Red black red - 3. Green black green - 4. Orange black orange - 5. Yellow black yellow -
6. 3 spool valve - 7. Red white green - 8. Red white green - 9. 4 spool valve - 10. Green white green - 11. Green white green.
1
2
9
3
4
7
5 8
BS03B187
Loader Control Valve Line Connections
1. Rollback line - 2. Dump line - 3. Return line - 4. Supply line - 5. Lower line right - 6. Raise line right - 7. Raise line left -
8. Lower line left - 9. Control valve.
STEP 9 Installation
Disconnect the hoses (2, 3, 4, 5, if equipped 7, 8, 10, Important – Before installing the fittings or connect-
and 11) from the remote control valve(s) at the loader ing the tubes to the fittings, install new O-rings on the
control valve (1, 6, or 9). Refer to the illustration on fittings.
page 6-2 for color coding. Install a plug in each hose
and a cap on each fitting. STEP 16
Note – Line 7, 8, 10, and 11 will need to be tagged as

top or bottom of valve.
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 right lift cylinder lines (5 and 6).
Install a plug in each line and a cap on each fitting.
BS03B183
STEP 12
Note – Before installing loader control valve, remove
Loosen and remove the supply and return lines (3 and
caps and plugs for the left lift cylinder.
4). Install a plug in each line and a cap on each fitting.
Install and align the loader control valve with the valve
STEP 13
mounting plate.
Loosen the left lift cylinder lines (7 and 8).
STEP 17
Note – After removing control valve plug the lines
Install the bolts and washers that fasten the loader
and cap the fittings.
control valve to the valve mounting plate. Tighten the
bolts.
STEP 14
Attach proper lifting equipment to lift loader control STEP 18
valve.
Tighten the left lift cylinder lines (7 and 8).
STEP 15
STEP 19
Install and tighten the supply and return lines (3 and
4).
STEP 20
Install and tighten right lift cylinder lines (5 and 6).
STEP 21
Install and tighten tilt cylinder lines (1 and 2).
STEP 22
BS03B183 Fill the hydraulic reservoir with oil. Refer to Section 0
for the correct oil.
Loosen and remove the three bolts and washers that
hold the loader control valve to the valve mounting
STEP 23
plate. Remove the loader control valve.
Place the master disconnect switch in the ON posi-
tion.
STEP 24 STEP 25
Run engine at half throttle.
STEP 26
Slowly and completely extend and retract all cylin-
ders at least 10 times to remove any air from the
circuits.
STEP 27
Stop the engine and check for leaks.
STEP 28
BD03A092
Install the access cover on the front of the machine.
Raise the loader arms and remove the safety link. STEP 29
Check the level of the hydraulic oil and add hydraulic
oil as required.

OF THE REMOTE CONTROL VALVE
Removal
STEP 30
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the park-
ing brake.
Important – Pump the brake repeatedly to be sure

the brake accumulators have no hydraulic pressure,
then move the loader control lever back and forth
W110R0333
several times to release any hydraulic pressure in the
pilot control circuit. Open the access panel.
STEP 37
Lock the access panel.
STEP 38
Disconnect the electric cables.
STEP 39
Put identification tags on each hose and disconnect
one at a time from the remote control valve. Install
W110R0004
plugs in the hoses and caps on the fittings.
Place the master disconnect switch in the OFF posi- STEP 40

tion.
Tag and disconnect the electrical connectors for the
STEP 31 remote control valve.
Loosen and remove the bolts and washers that fas-

ten the right skirt panel under the right side of the
ROPS cab or ROPS canopy. Remove the right skirt
panel.
STEP 32
Loosen the filler cap on the reservoir to release any
air in the reservoir.
STEP 33
Drain the hydraulic reservoir.
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 41 Installation
STEP 44
Install new O-rings on the adapters for the remote
control valve.
STEP 45
W110R0334
Loosen the three knobs of the valves indicated in the

figure.
1
STEP 42
W110R0335
Install the valves with securing nuts (2) and connect

hydraulic hoses (1).
STEP 46
Connect the electrical connectors for the remote con-
trol valve.
STEP 47
W110R0333
Open the panel located on the right side of the ma-

chine.
STEP 43
Remove hydraulic pipes (1) connected to the valves
loosening securing nuts (2) as indicated in the figure.
W110R0334
2 Install the three valve knobs.
STEP 48
Remove the plugs from the hoses and the caps from
the fittings and connect the hydraulic hoses to the
1
fittings according to the identification tags.
W110R0335 STEP 49
Fill the hydraulic reservoir.
STEP 50 STEP 55
W110R0004 W110R0333
Place the master disconnect switch in the ON posi- Unlock the access door.
tion.
STEP 56
STEP 51
Close the access door.
Start the engine and run the engine at low idle.
STEP 57
STEP 52
Install the right skirt panel under the ROPS cab or the
Check to see that the remote control valve works ROPS canopy and tighten the bolts.
correctly.
STEP 53
Check for hydraulic oil leakage at the remote control
valve.
STEP 54
Check the level of hydraulic oil in the reservoir and
add as required.

OF THE HYDRAULIC PUMP Loosen the filler cap on the reservoir to release any
Removal air in the reservoir. Connect a vacuum pump to the
hydraulic reservoir, turn on the pump.
STEP 58
ing brake.
STEP 59
tion.
11
10
2
1 4
6
3
13
10 5
4 6
9
7
12
5
14
14 13
12 BS03B154
1. Shuttle valve bracket - 2. Load sense tubes - 3. Connector - 4. Bolt - 5. Split flange - 6. Tube - 7. Hose suction - 8. Hose case
drain - 9. Fitting - 10. Clamp - 11. Connector - 12. Bolt - 13. Split flange - 14. Hose high pressure.
6 - 10 EQUIPMENT HYDRAULIC SYSTEM W170/W170TC
Identify, tag, and disconnect pump load sensing tubes STEP 66
(2). Remove and discard O-ring face seals from fit-
Install new O-ring on hydraulic pump flange. Move
tings (3). Plug tubes and cap fittings to prevent entry
pump into position and install in transmission. Install
of foreign matter into hydraulic system. Remove shut-
four washers and bolts to secure pump to transmis-
tle valve and bracket (1) from transmission.
sion. Disconnect lifting equipment from pump.
STEP 62
STEP 67
At hydraulic pump, remove plugs from pump and high
split flanges (5). Disconnect tubes (6) with suction
pressure hoses (14). Install a new O-ring face seals
hoses (7) from hydraulic pump. Remove and discard
in flange head of hoses (14). Position pump pressure
O-ring face seals from flange heads of tubes. Tag and
hoses (14) on pump ports and secure using four split
disconnect case drain hoses (8) from fittings (9). Re-
flanges (13) and eight washers and bolts (12).
move and discard O-ring face seals from fittings. Plug
hoses, tubes, and pump ports to prevent intrusion of
STEP 68
foreign matter into hydraulic system.
Remove plugs from hoses and caps from fittings. In-
STEP 63 stall new O-ring face seals in fitting (11). Connect
hydraulic pump case drain hoses (8) to fittings (11).
Loosen clamps (10). Disconnect suction hoses (7)
Position suction hoses (7) between reservoir port and
from hydraulic reservoir and remove from machine.
hydraulic pump inlet ports. Connect suction hose (7)
Disconnect case drain hoses (8) from fittings (11);
to hydraulic reservoir. Tighten clamp (10).
remove hoses (8). Remove and discard O-ring face
seals from fittings. Plug hoses and cap fittings to pre-
STEP 69
vent entry of foreign matter into hydraulic system.
At hydraulic pump, remove plugs from hoses (8), tubes
STEP 64 (6), pump ports, and caps from fittings (9). Install new
O-ring face seals in fittings (9). Connect pump case
drain hoses (8) to fittings (9) following tags installed
split flanges (13). Disconnect pump pressure hoses
during removal. Install new O-ring face seals in flange
(14) from hydraulic pump. Remove and discard O-ring
head of tubes (6). Position tubes (6) with hoses (7) on
face seals from flange heads of hoses (14). Plug
hydraulic pump port. Install four split flanges (5) and
hoses and pump ports.
secure using eight washers and bolts (4).
STEP 65
STEP 70
Connect lifting equipment to hydraulic pump. Take up
Remove caps from fittings (3) and plugs from hoses
all slack in lifting equipment. Remove four mounting
(2). Instal a new O-ring face seals on fittings (3). Con-
bolts and washers securing pump to transmission. Pull
nect hose to fitting following tags installed during re-
hydraulic pump from transmission and remove from
moval. Remove and discard tag from hose. Mount
loader. Remove and discard O-ring from pump.
shuttle valve and bracket (1) to transmission.
STEP 71
Turn off the vacuum pump and disconnect from the
hydraulic reservoir.
STEP 72
tion.
W170/W170TC EQUIPMENT HYDRAULIC SYSTEM 6 - 11
STEP 73 STEP 74
Start the engine and run the engine at low idle for two Stop the engine and check for hydraulic oil leakage at
minutes. the hydraulic pump.
Note – If any unusual vibration is heard coming from STEP 75

the pump, stop the machine immediately and check
Check the level of the hydraulic oil in the reservoir
for obstructions in the pump suction line.
and add hydraulic oil as required.

OF THE LIFT CYLINDERS
Removal
STEP 76
ing brake.
STEP 77
Pump the brake repeatedly to be sure the brake ac-
cumulators have no hydraulic pressure, then move
the loader control lever back and forth several times
to release any hydraulic pressure in the pilot control BD01D709
circuit.
Loosen and remove the bolt, washer and spacer that
hold the pivot pin for the yoke.
STEP 78
Relieve the pressure in the ride control accumulator STEP 82
with the manual bleeder valve located at the rear of
the front chassis.
STEP 79
Loosen the filler cap on the hydraulic reservoir to re-
lease any pressure.
STEP 80
BD01D711
Use a proper lifting device and secure a strap around

the lift cylinder.
STEP 83
BD01D708
Tag and disconnect the hoses on each side of the lift

cylinder. Install plugs in the hoses and caps on the
fittings.
BD01D712
Remove the pivot pin from the yoke end of the lift
cylinder.
STEP 87
Apply antiseize compound to the bores in the front
frame and the yoke on the piston rod.
STEP 88
BD01D710

hold the pivot pin at the closed end of the lift cylinder.
STEP 85
BD01D714
Use a proper lifting device and position the lift cylin-

der on the machine.
STEP 89
BD01D713
Remove the pivot pin from the closed end of the lift
cylinder.
STEP 86
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.
STEP 90 STEP 93
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 94
STEP 91
BD01D709
BD01D708
Align the pivot pin with the yoke and install the spacer,
Remove the caps and plugs and connect the hoses washer and bolt. Tighten the bolt.
to the lift cylinder.
STEP 95
STEP 92
SLOWLY extend and retract the piston rod three times
If the yoke of the lift cylinder is not aligned with the 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 96
SLOWLY move the yoke into alignment with the loader Lubricate the pivot pins with molydisulfide grease.
frame.
STEP 97
Check the level of hydraulic oil in the reservoir and
add as required. Tighten the filler cap on the hydraulic
reservoir.

OF THE BUCKET CYLINDER -
Z-BAR LOADER
Removal
STEP 98
ing brake.
STEP 99
With the engine stopped, move the bucket control le-
ver to release pressure in the bucket circuit.
BD01D695
STEP 100 Loosen and remove the two bolts that fasten the
mounting bracket to the machine. Remove the mount-
ing bracket.
STEP 103
BD01D694
Disconnect the proximity switch connector from the

wiring harness connector.
BD01D697
STEP 101
Loosen and remove the two bolts that fasten the
mounting bracket for the proximity switch to the bucket
cylinder. Remove the mounting bracket and switch.
BD01D696
Loosen and remove the two bolts that fasten the tar-
get bar to the mounting bracket. Remove the target
bar.
STEP 104 STEP 107

BD01D701
BD01D701
BD01D699
Remove the pivot pin from the rod end of the bucket
Disconnect the hoses from each side of the bucket cylinder.
cylinder. Install plugs in the hoses and caps on the
fittings. STEP 108
STEP 105
W170-6R002
Remove the pivot pin from the head end of the bucket
BD01D700 cylinder.
Use acceptable equipment to hold the bucket cylinder.
Note – It is not necessary to remove the grease line
STEP 106 from the pivot pin unless the pivot pin is to be re-
placed.
STEP 109
BD01D698
W170-6R003
fasten the pivot pin from both ends of the bucket cyl- Raise the bucket cylinder and remove the cylinder
inder. from the machine.

STEP 110
Apply antisieze compound to the bores in the front
frame and the bores in the loader arm for the bucket
cylinder.
STEP 111
BD01D699
Connect the hoses to each side of the bucket cylin-

der.
STEP 115
If the rod end of the bucket cylinder is not aligned
W170-6R003 with the bellcrank, have another person start the en-
Use acceptable lifting equipment to lower the bucket gine and run the engine at low idle and use the bucket
cylinder into position. control lever to SLOWLY move the piston rod eye into
alignment with the bellcrank.
STEP 112
STEP 116
Install the pivot pin and stop the engine.
STEP 117
W170-6R002
Install the pivot pin to the head end of the bucket

cylinder.
STEP 113 BD01D698
Install the spacer, washer and bolt that fasten the pivot Install the spacer, washer and bolt that fasten the pivot
pin to the front frame. Tighten the bolt. pin to the bellcrank. Tighten the bolt.
Note – If a new pivot pin is being installed, connect

the grease line to the pivot pin.
STEP 118 STEP 121
BD01D697 BD01D694
Install the two bolts that fasten the mounting bracket Connect the proximity switch connector to the wiring
for the switch to the bucket cylinder. harness connector.
STEP 119 STEP 122

See Section 5 for the adjustment procedure for ad-
justing the proximity switch.
STEP 123
Start and run the engine at low idle.
STEP 124
SLOWLY extend and retract the piston rod three times
to remove any air from the bucket cylinder.
STEP 125
BD01D695 Lubricate the pivot pins with molydisulfide grease.
Install the two bolts for the mounting bracket for the
STEP 126
target bar.
STEP 120 and add as required. Tighten the filler cap on the hy-
draulic reservoir.
BD01D696
Install the two bolts that fasten the target bar to the
mounting bracket.
6.1.6 REMOVAL AND INSTALLATION OF

THE BUCKET CYLINDERS - TC
LOADER
Removal STEP 130
STEP 127 Disconnect the hoses from the elbows at both ports
of the bucket cylinders. Install a plug in the tube and
Lower the bucket to the floor. With the engine stopped,
a cap on the elbow.
move the bucket control lever to release any pres-
sure in the bucket circuit.
STEP 131
Note – The following two steps apply only to the left Remove the roll pin (1) from the yoke (2). Remove the
hand bucket cylinder. pivot pin (3).
STEP 128 STEP 132

Loosen and remove the nuts (4) and washers (5) at
the top and bottom of the cylinder bellcrank.
2
3 STEP 133
Remove the inner bellcrank (6) from the pivot pins
5 (7).
1 STEP 134
4 Remove the nut (8) and the grease line (9) from the
6 bucket cylinder (10).
BS01C084
STEP 135
1. Bucket cylinder (left hand side) - 2. Proximity switch
mounting bracket - 3. Target mounting bracket - 4. Proxim- Fasten acceptable lifting equipment to the bucket
ity switch guard - 5. Proximity switch - 6. Target bar cylinder (10) and remove the bucket cylinder (10) from
the machine.
Disconnect the Return-to-Dig proximity switch (5) and
remove with the mounting bracket (2) as an assem-
bly.
STEP 129
Remove the Return-to Dig target bar (6) with the mount-
ing bracket (3) from the yoke of the bucket cylinder
(1).
10 9
3
5 10 1
7
4
2
7
5
4
BS01C086
TC loader bucket cylinder removal and installation illustration
1. Roll pin - 2. Yoke - 3. Pivot pin - 4. Nut - 5. Washer - 6. Inner bellcrank - 7. Pivot pin - 8. Nut - 9. Grease line - 10. Bucket
cylinder

STEP 136 Install the Return-to Dig target bar and proximity switch
assembly. Connect the proximity switch connector to
Use acceptable lifting equipment to install the bucket
the wiring harness connector. This step applies only
cylinder (10) closed end on the pivot pins (7).
to the left hand bucket cylinder.
STEP 137
STEP 143
Install the grease line (9) and the nut (8) on the bucket
Remove the plugs and caps and connect the hoses
cylinder (10).
to the elbows at the cylinder ports.
STEP 138
STEP 144
Install the inner bellcrank (6) on the pivot pins (7).
Start the engine and run the engine at low idle.
STEP 139
STEP 145
Install the washers (5) and nuts (4) on the retaining
SLOWLY, extend and retract the piston rod three times
bolts. Tighten the nuts (4).
to remove any air from the bucket cylinder (10).
STEP 140
STEP 146
Align and install the pivot pin (3) in the yoke (2).
Lubricate the pivot pins with molydisulfide grease.
STEP 141
STEP 147
Install the roll pin (1) in the yoke (2) and pivot pin (3).
Check the level of the hydraulic oil in the hydraulic
reservoir and add as required.

OF THE OIL COOLER
Removal
STEP 148
bucket to the ground. Stop the engine and apply the
parking brake.
STEP 149
tion.
STEP 150 BD03A154
Raise the engine hood and remove the shield on the Disconnect the top hose and install a plug in the hose
right side of the machine between the tire and the oil and a cap on the fitting.
cooler.
STEP 154
STEP 151
BD03A179
BD03A120
Loosen and remove the bolt and washer that fasten
Have assistant hold side panel in raised position, re- the oil cooler to the cooling frame.
move two mounting screws, remove side panel.
STEP 152
lease the air pressure in the reservoir. Connect a
vacuum pump to the hydraulic reservoir, turn on the
pump.

STEP 156
BD03A217 BD03A217
Raise oil cooler and disconnect the hose from the Place the oil cooler in position in the cooling frame.
bottom of the oil cooler. Install a plug in the hose and Connect the lower hose to the oil cooler.
a cap on the fitting. Remove oil cooler from the ma-
chine. Note – Make sure that the oil cooler slides into retain-
ing bracket on frame.
STEP 157
BD03A179
Install the bolt and washer that fasten the oil cooler to
the cooling frame.
STEP 158
BD03A154
Connect the hose to the top of the oil cooler.
STEP 159 STEP 161

tion.
STEP 162
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 163
Install the shield between the right rear tire and the oil
cooler and tighten the two bolts holding the shield.
BD03A120
STEP 164
Have assistant hold side panel in raised position, in- Check the level of the hydraulic oil in the reservoir
stall and tighten two mounting screws. and add hydraulic oil as required.
STEP 160

OF THE RIDE CONTROL
ACCUMULATOR
Removal
STEP 165
ing brake.
STEP 166
With the engine NOT running, pump the brake repeat-
edly to be sure the brake accumulators have no hy-
BD03A195
draulic pressure, move the loader control lever back
and forth several times to release any hydraulic pres- Loosen and remove the nuts and washers from the U-
sure in the pilot control circuit. bolt. Remove the U-bolt.
STEP 167
STEP 171
Relieve the pressure in the ride control accumulator
the front chassis.
STEP 168
lease the air pressure in the reservoir. Connect a
pump.
STEP 169
BD03A196
Loosen and remove the two bolts that fasten the ac-
cumulator bracket to the front frame.
STEP 172
Remove the ride control accumulator from the ma-
chine.
BD03A196
Disconnect the hose from the elbow at the bottom of

the ride control accumulator. Install a plug in the hose
and a cap on the fitting.

STEP 173
Place the ride control accumulator in position on the
front frame.
STEP 174
BD03A196
Remove the caps and plugs and install the hose on

the elbow at the bottom of the ride control accumula-
tor.
BD03A196 STEP 177

Install the two bolts that fasten the accumulator Turn off and disconnect the vacuum pump from the
bracket to the front frame. Tighten the bolts. hydraulic reservoir.
STEP 175 STEP 178

Refer to section "Testing the Ride Control" for the
proper charging of the accumulator to check for leaks.
STEP 179
and add as required. Tighten the filler cap on the hy-
draulic reservoir.
BD03A195
Install the U-bolt, washers and nuts. Tighten the nuts.

OF THE RIDE CONTROL VALVE Loosen the filler cap on the hydraulic reservoir to re-
Removal lease the air pressure in the reservoir. Connect a
STEP 180 pump.
Park the machine on a level surface and apply the
parking brake. STEP 186
STEP 181 tion.
STEP 187
BD03A092
Raise the loader arms and install the safety link.
STEP 182 BD03A094
Disconnect the electrical connector on top of the ride

control valve.
STEP 188
BD03A093
Remove the access cover.
STEP 183 BD03A094
With the engine NOT running, pump the brake repeat- Tag and disconnect the hoses from the ride control
edly to be sure the brake accumulators have no hy- valve. Install a plug in the hoses and caps on fittings.
draulic pressure, then move the loader control lever
back and forth several times to release any hydraulic
pressure in the pilot control circuit.
STEP 184
Relieve the pressure in the ride control accumulator
the front chassis.

STEP 192
Install the ride control valve in position on the front
frame.
STEP 193
BD03A197
Loosen and remove the four bolts and washers that

fasten the ride control valve to the ride control bracket.
STEP 190
BD03A197
Remove the ride control valve from the machine.
Install the washers and bolts through the ride control
STEP 191 bracket and into the ride control valve. Tighten the
bolts.
Remove and discard all O-rings.
STEP 194
Lubricate and install new O-rings.
STEP 195
BD03A094
Connect the hoses to the ride control valve.
STEP 196 STEP 202
BD03A094 BD03A092
Connect the electrical connector to the ride control Raise the loader arms and remove the safety link.
valve.
STEP 203
STEP 197
Turn off the vacuum pump and disconnect from the and add as required. Tighten the filler cap on the hy-
hydraulic reservoir. draulic reservoir.
STEP 198 STEP 204

Place the master disconnect switch in the ON posi- Refer to section and perform the "Ride Control Test
tion. Procedure".
STEP 199
Start and run the engine at low idle for two minutes.
STEP 200
Stop the engine and check for hydraulic oil leakage at
the ride control valve.
STEP 201
BD03A093
Install the access cover.

OF THE FAN REVERSING VALVE
Removal
STEP 205
bucket to the ground. Stop the engine and apply the
parking brake. 2
STEP 206
1
With the engine NOT running, pump the brake repeat-
edly to be sure the brake accumulators have no hy-
draulic pressure, then move the loader control lever
back and forth several times to release any hydraulic BD03A174
pressure in the pilot control circuit. Tag and disconnect the fan forward hose (1) from the
fan reversing valve. Install a plug in the hose and a
STEP 207 cap on the fitting. Tag and disconnect the fan reverse
Loosen the filler cap on the hydraulic reservoir to re- hose (2) from the fan reversing valve. Install a plug in
lease the air pressure in the reservoir. Connect a the hose and a cap on the fitting.
pump. STEP 210
STEP 208
3 4
BD03A173
Tag and disconnect the fan valve return hose (3) from
the fan reversing valve. Install a plug in the hose and
BD03A174
a cap on the fitting. Tag and disconnect the fan valve
Disconnect the electrical connector for the fan revers- supply hose (4) from the fan reversing valve. Install a
ing valve. plug in the hose and a cap on the fitting.
STEP 211
Loosen and remove the nuts, washers and bolts.
STEP 212
Remove the fan reversing valve from the machine.
STEP 213
Remove and discard all O-rings from the fittings.

STEP 214
Place the fan reversing valve into position on the
machine.
STEP 215
Lubricate and install new O-rings in the fittings.
STEP 216
Install the bolts, washers and nuts. Tighten the nuts.
STEP 217 BD03A174
Connect the electrical connector for the fan reversing

valve.
STEP 220
STEP 221
3 4
Check the level of the hydraulic oil in the reservoir.
STEP 222
BD03A173 Start the engine and run the engine at low idle for two
minutes.
Connect the fan valve supply hose (4) to the fitting on
the fan reversing valve. Connect the fan valve return
STEP 223
hose (3) to the elbow on the fan reversing valve.
Stop the engine and check for hydraulic oil leakage at
STEP 218 the fan reversing valve.
STEP 224
and add as required. Tighten the filler cap on the res-
ervoir.
BD03A174
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.
6.2 HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING

AND PRESSURE CHECKS
Pump Output
Steering Pump (Front) ...................................................................... 117 to 125 L/min at 2000 rpm at 138 bar
(31 to 33 gpm at 2000 rpm at 2001 psi)
Loader Pump (Rear) ............................................................................. 85 to 90 L/min at 2000 rpm at 138 bar
(23 to 24 gpm at 2000 rpm at 2001 psi)
Main relief valve pressure settings

W170 (Z-Bar - TC) ....................................................................................... 248 to 252 bar (3597 to 3655 psi)
Circuit relief valve pressure setting

Auxiliary A and B port (Z-Bar) ............................................................................................ 290 bar (4206 psi)
Bucket A and B port (TC and Z-Bar) .................................................................................. 290 bar (4206 psi)
Bucket A port (TC) ............................................................................................................. 183 bar (2654 psi)
Bucket B port (TC) ............................................................................................................. 290 bar (4206 psi)
Steering relief valve pressure setting ........................................................................................... See Section 4
Accumulator pressure .................................................................................................................. See Section 3
6.2.2 SPECIAL TOOLS
633L95
B877168V
380001741 Pressure Fitting Kit
380001740 Flowmeter Fitting Kit
632L95

B877895M
380001726 Hand Pump
B785789M
B877558M
380001731 Flowmeter
6.2.3 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 reser- Fill the hydraulic reservoir with the hydrau-
No
voir. Is the oil level correct? lic oil specified in Section 0.
Yes
Heat the oil in the hydraulic system to op-

erating temperature. Operate the machine
to find which circuits have problems.
Problems in All Circuits
Replace the return line hydraulic filter.

See Section 1. Do the stall test to see if
the engine is good.
Do the flow meter test of the hydraulic
See section and check for contaminated No pump.
oil. Is the oil contaminated?
Yes
See section and clean or replace the oil.
Problem in All Loader Circuits
See Page 10 and check the pressure set-

ting of the limit pressure in the loader con- No Adjust the limit pressure.
trol valve. Is the pressure setting correct?
Problem in the Braking Circuit
Check the braking circuit.
Problem in a Single Loader Circuit
Start and run the engine at full throttle.

Operate the control for the bad circuit. The loader control valve is damaged. Re-
Does the cylinder move in both direc- No
pair the loader control valve.
tions?
Yes
Check the cylinder piston packing. Is the

No See section and repair the cylinder.
packing good?
Yes
Check and adjust the circuit relief valves.

Then check the operation of the circuit No Disassemble the loader control valve and
again. Does the circuit work correctly? check for worn or damaged parts.
Yes
The problem is repaired.
Problem in the Steering Circuit
Check the steering circuit. Is the steering

No Repair the component as necessary.
circuit good?
Yes
Do the Steering Pump Limit Pressure Test

and Adjustment.
Problem in the Ride Control

Lift arms rapidly and continuously sink to-
No See the Ride Control Test Procedure.
wards the ground.
Yes
Check the manual bleed valve for the ride

control accumulator to be sure that it is
closed.
6.2.4 TESTING AND ADJUSTING STEP 3

THE LOADER/STEERING PUMP
DIFFERENTIAL PRESSURE
Pressure Check
STEP 1
Make sure that the temperature of the hydraulic oil is
at least 54 °C to 57 °C (129 °F to 135 °F). The follow-
ing is the procedure for heating the hydraulic oil.
A. Start the engine and run at full throttle. 1
B. Lower the loader bucket to the ground and hold

the lift control lever in the FLOAT position.
C. Roll the bucket back against the stops and hold. BD03A101
D. View the oil temperature by pressing the program

switch, then press the up count switch to func-
tion 008. Return the program switch to the center
(OFF) position.
STEP 2
2
BD03A086
1. Test port (load sense) - 2. Test port (pump pressure).
Connect two 69 bar (1000 psi) test gauges, one to the

1 test port (2) located on the large hydraulic tube near
the right side rear frame opening (port 5 optional diag-
BD00M041 nostic panel), and one on the pump load-sense pres-
1. Articulation lock. sure tap (1 closest to transmission) (port 3 optional
diagnostic panel).
Install articulation lock (1).
Important – Do not steer of operate loader controls
while the gauges are connected, gauges could be
damaged.
STEP 4
Start the engine and run at low idle.
STEP 5
Make sure all of the controls are in the neutral posi-
tion and record the readings on the test gauges (1)
and (2).
STEP 6 6.2.5 TESTING AND ADJUSTING

Subtract the reading of the test port (1) from the read- THE LOADER/UNLOADING PUMP
ing of the test port (2). DIFFERENTIAL PRESSURE
Pressure Check
STEP 7
STEP 10
The difference between the two readings should be
30 to 33 bar (435 to 477 psi). Make sure that the temperature of the hydraulic oil is
STEP 8 ing is the procedure for heating the hydraulic oil.
If this reading is more or less than specified, it will be A. Start the engine and run at full throttle.
necessary to adjust the pump load-sense pressure. B. Lower the loader bucket to the ground and hold
Adjusting the Loader/Steering
Pump Differential Pressure C. Roll the bucket back against the stops and hold.
STEP 9 D. View the oil temperature by pressing the pro-

gram switch, then press the up count switch to func-
The load-sense adjusting screw is directly above the tion 008. Return the program switch to the center
load-sense pressure tap. Turn the screw clockwise to (OFF) position.
increase the load-sense pressure. Turning the screw
counterclockwise will decrease the load-sense pres- After heating oil to operating temperature, lower bucket
sure. to the ground, turn off the engine, and relieve all pres-
sure in the hydraulic system.
Note – One turn of the adjustment screw will change
the pressure approximately 16 bar (232 psi). STEP 11
BD00M041
STEP 12 STEP 15
Subtract the reading of the test port (1) from the read-
ing of the test port (2).
STEP 16
The difference between the two readings should be
22 to 25 bar (319 to 362 psi).
STEP 17
1
If this reading is more or less than specified, it will be
necessary to adjust the pump differential pressure.
Adjusting the Loader/Unloading

BD03A190
Pump Differential Pressure
STEP 18
The differential adjusting screw is directly above the
load-sense pressure tap. Turn the screw clockwise to
increase the load-sense pressure. Turning the screw
2 counterclockwise will decrease the differential pres-
sure.
Note – One turn of the adjustment screw will change

the pressure approximately 16 bar (232 psi).
BD03A091
1. Test port (load sense) - 2. Test port (pump pressure).
Connect two 69 bar (1000 psi) test gauges, one to the

test port (2) located on the large hydraulic tube on the
bottom of the pump (port 1 optional diagnostic panel),
and one on the pump load-sense pressure tap (1 fur-
thest from the transmission) (port 2 optional diagnos-
tic panel).
Important – Do not steer of operate loader controls

while the gauges are connected, gauges could be
damaged.
STEP 13
Start the engine and run at low idle.
STEP 14
Make sure all of the controls are in the neutral posi-
tion and record the readings on the test gauges (1)
and (2).

THE LOADER LIMIT PRESSURE
Pressure Check
STEP 19
A. Start the engine and run at full throttle.
1
C. Roll the bucket back against the stops and hold.
BD03A086
switch, then press the up count switch to func- 1. Test port (load limit).
Connect a 345 bar (5004 psi) test gauge to the test
(OFF) position.
port (1), located on the large hydraulic tube near the
After heating oil to operating temperature, lower bucket right side rear frame opening (port 5 optional diagnos-
to the ground, turn off the engine, and relieve all pres- tic panel).
STEP 22
STEP 20
Start the engine and run at full throttle.
STEP 23
Roll the loader bucket back against the stops.
STEP 24
Record the reading on the test gauge.
STEP 25
1 Reading should be 248 to 252 bar (3596 to 3654 psi).
BD00M041
STEP 26
1. Articulation lock. If this reading is more or less than specified, it will be

necessary to adjust the pump limit pressure.
Adjusting the Loader Limit Pressure STEP 29
BD03B005 BD00M041
STEP 27 1. Articulation lock.
The limit adjusting screw is located on the loader valve. Install articulation lock (1).
Turn the screw clockwise to increase the limit pres-
sure. Turning the screw counterclockwise will decrease
the limit pressure.
6.2.7 TESTING AND ADJUSTING

THE STEERING LIMIT PRESSURE
Pressure Check
STEP 28
(OFF) position.
After heating oil to operating temperature, lower bucket
to the ground, turn off the engine, and relieve all pres-
STEP 30 Adjusting the Steering Limit Pressure
2
1 1
BD03A086 BD03A086
1. Test port (load limit). 1. Test port (load limit) - 2. “T” port.
Connect a 345 bar (5000 psi) test gauge to the test STEP 36
port (1), located on the large hydraulic tube near the
The steering priority valve is located in the center of
right side rear frame opening (port 5 optional diagnos-
the right side frame opening, the adjusting valve is
tic panel).
located inside the “T” port of the valve. Turn the screw
clockwise to increase the limit pressure. Turning the
STEP 31
screw counterclockwise will decrease the limit pres-
Start the engine and run at full throttle. sure.
STEP 32
Steer hard in either direction over relief pressure.
STEP 33
STEP 34
Reading should be 239 to 243 bar (3466 to 3524 psi).
STEP 35
necessary to adjust the steering limit pressure.

THE LOADER PUMP CUTOFF
PRESSURE
Pressure Check
STEP 37
1
C. Roll the bucket back against the stops and hold. BD03A091
D. View the oil temperature by pressing the program 1. Test port (pump pressure).
Connect two 345 bar (5004 psi) test gauge to the test
port (1) located on the large hydraulic tube on the
(OFF) position.
bottom of the pump (port 1 optional diagnostic panel).
After heating oil to operating temperature, lower bucket
to the ground, turn off the engine, and relieve all pres- STEP 40
Start the engine and run at full throttle.
STEP 38
STEP 41
Roll the loader bucket back against the stops.
STEP 42
STEP 43
Reading should be 198 to 202 bar (2872 to 2930 psi).
1 STEP 44
BD00M041 necessary to adjust the pump cutoff pressure.
Adjusting the Loader Pump Cutoff Pressure STEP 47

Raise lift arms to the top and turn off the engine. Turn
the ignition switch to the “RUN” position and disen-
gage the controller lockout switch.
STEP 48
Wait for the buzzer to stop then repeatedly put the
loader control lever into “FLOAT” position and back to
neutral.
STEP 49
The system should allow a minimum of 10 actuations
into float and still cause the lift arms to come down.
BD03B007
STEP 45 Note – If 10 full actuations cannot be made, and in-

ternal hydraulic leak exists.
The unloading adjuster is the longer of the two adjust-
ers on the loader pump. Turn the screw clockwise to
increase the cutoff pressure. Turning the screw
counterclockwise will decrease the cutoff pressure.
6.2.9 TESTING THE HYDAULIC

CONTROLLER PILOT SUPPLY
PRESSURE
Note – This pressure is factory preset and is not ad-

justable.
Pressure Check
STEP 46
View the oil temperature by pressing the program
switch, then press the up count switch to function
008. Return the program switch to the center (OFF)
position.
6.2.10 LOADER/STEERING PUMP FLOW STEP 52

TEST Measure the flow at 0 bar (0 psi). Record the flow
reading. Slowly close the load valve on the flow meter
STEP 50 and read the flow at 170 bar (2466 psi). Record the
flow reading.
Connect the flow meter to the loader/steering pump
as shown, refer to the illustration below. STEP 53
STEP 51 Divide the flow reading at 170 bar (2466 psi) by the
reading at 0 bar (0 psi). Multiply the result by 100.
Make sure the load control of the flow meter is open. This is the percent efficiency of the pump. If the effi-
Start the engine. Run the engine at full throttle. Make ciency of the pump is less than 85%, repair or re-
sure the oil is at operating temperature. place the pump.
NOTE
5 4
2
1
BS03B163
1. Tee - 2. Loader control valve - 3. Flowmeter inlet hose - 4. Loader control valve inlet hose - 5. 380001731 flowmeter -
6. Flowmeter outlet hose - 7. Filter inlet manifold - 8. Filters.
Note – If unit is equipped with auxiliary steering a tee fitting will have to be used in this location.

THE CIRCUIT RELIEF VALVES Connect the hand pump to the disconnected line that
Pressure Check goes to the loader control valve.
STEP 54 STEP 57
Circuit relief valves are located as shown below. Make sure that the hand pump is full of hydraulic oil
and that the temperature of the oil is approximately
3 4 1 5 21°C (70°F).
1
2 STEP 58
Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
be sure of the reading.
STEP 59
Compare the reading to the specifications on Page 6-32.
STEP 60
If the pressure is not correct, adjust the circuit relief
valve.
Adjustment
1 STEP 61
1 Loosen the lock nut. Turn the adjustment screw clock-
5
3 wise to increase the pressure or counterclockwise to
4 decrease the pressure.
BS03B022
1. Circuit relief valves - 2. Pump limit pressure adjustment STEP 62

- 3. Bucket spool - 4. Lift spool - 5. Auxiliary spool -
6. Loader control valve. Check the pressure again. Repeat the adjustment as
necessary.
Remove the cover at the front of the machine.
STEP 55
Lower the bucket to the floor. Shut off the engine. Find
an easy place to disconnect the line for the circuit to
be tested.
6.2.12 TESTING THE RIDE CONTROL STEP 70

STEP 63 Accelerate the machine to at least 5 km/hr (3 mph).
At 5 km/hr (3 mph) the lift arms should raise a visible
Verify that the manual ride control accumulator bleeder
amount, 102 mm to 635 mm (4 to 25 inches) depend-
valve is closed.
ing on bucket and coupler weight. This is an indica-
tion that the ride control is functioning. As the ma-
Note – The bleeder valve is located on the right rear
chine continues to travel there should be visible cyl-
inside wall of the front chassis. If this valve is left
inder movement in response to the road conditions.
open, the lift arms will rapidly and continuously sink.
Ride control will not function in this state because the
Note – With an empty bucket, cylinder travel will not
ride control accumulator cannot charge.
exceed 25 mm (1 inch).
STEP 64
STEP 71
Move the machine to a clear level area with sufficient
With the machine traveling over 5 km/hr (3 mph) check
space to accelerate the machine to 5 km/hr (3 mph)
the indicator light on the ride control rocker switch, it
for 30 seconds and stop.
should be illuminated.
STEP 65
STEP 72
Start the engine.
Slow the machine down and observe the indicator light.
The indicator light should go out when the machine
STEP 66
slows below 5 km/hr (3 mph).
Activate the ride control. Press down on the symbol
side of the switch to activate. The indicator light WILL STEP 73
NOT illuminate at this time.
Stop the machine.
Note – The ride control switch is located in the bank
STEP 74
of rocker switches to the right of the operator’s seat.
It is in the center row, second switch from the front. De-activate the ride control with the rocker switch.
Repeat steps 67, 68 and 69.
STEP 67
STEP 75
Raise the lift arms to near the top of their travel.
Accelerate the machine to at least 5 km/hr (3 mph).
STEP 68 This time there should be no visible raising of the lift
arms and the light should remain off. The quality of
Rapidly dump the bucket until it hits the dump stops.
the ride should be noticeably worse with the ride con-
This will create a down force on the lift arms and they
trol de-activated.
should drop visibly. Repeat this process 2 or 3 times
if necessary.
STEP 76
Note – The oil displaced from the lift cylinders is used Stop the machine.
to charge the ride control accumulator.
STEP 69
Lower the lift arms and roll the bucket back to a carry
position. Do not leave the lift arms or the bucket on
their stops.
6.3 CLEANING THE HYDRAULIC SYSTEM
6.3.1 SPECIAL TOOL
806128
380001733, fitting kit.
806127
380001727, filter unit, portable.
TR98H032
380001728, vacuum pump.
6.3.2 GENERAL INFORMATION 6.3.3 TYPES OF CONTAMINATION

Contamination in the hydraulic system is a major There are two types of contamination, microscopic
cause of the malfunction of hydraulic components. and visible.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in 1. Microscopic contamination occurs when very fine
several ways. particles of foreign material are in suspension in
the hydraulic oil.
1. When you drain the oil or disconnect any line.
2. These particles are too small to see or feel. Micro-
2. When you disassemble a component. scopic contamination can be found by identifica-
tion of the following problems or by testing in a
3. From normal wear of the hydraulic components.
laboratory. Examples of the problems:
4. From damaged or worn seals.
A. Cylinder rod seal leak.
5. From a damaged component in the hydraulic sys-
B. Control valve spools do not return to NEUTRAL.
tem.
C. The hydraulic system has a high operating
All hydraulic systems operate with some contamina- temperatur.
tion. The design of the components in this hydraulic
3. Visible contamination is foreign material that can
system permits efficient operation with a small amount
be found by sight, touch, or odor. Visible contami-
of contamination. An increase in this amount of con-
nation can cause a sudden failure of components.
tamination can cause problems in the hydraulic sys-
Examples of visible contamination:
tem. The following list includes some of these prob-
lems. A. Particles of metal or dirt in the oil.
B. Air in the oil.
1. Cylinder rod seals leak.
C. The oil is dark and thick.
2. Control valve spools do not return to neutral.
D. The oil has an odor of burned oil.
3. Movement of control valve spools is difficult.
E. Water in the oil. See page 6-51.
4. Hydraulic oil becomes too hot.
5. Pump gears, housing, and other parts wear rap-
idly.
6. Relief valves or check valves held open by dirt.
7. Quick failure of components that have been re-
paired.
8. Cycle times are slow; machine does not have
enough power.
If your machine has any of these problems, check

the hydraulic oil for contamination. See types of con-
tamination below. If you find contamination, use the
Portable Filter to clean the hydraulic system.
6.3.4 CLEANING THE HYDRAULIC 8. Using the fitting kit shown on page 6-47, install
SYSTEM the valve in the hole for the drain plug. Make sure
that the valve is closed.
1. Prepare the portable filter on page 6-47 by doing
the following steps: 9. Stop the vacuum pump.
A. Remove all the hydraulic oil from the inlet and 10. Connect the inlet hose for the portable filter to the
outlet hoses for the portable filter. valve that is installed in the hole for the drain plug.
B. Remove the filter element from the portable fil- 11. Disconnect the vacuum pump from the hydraulic
ter. reservoir air breather hose. Remove the filler cap.
C. Remove all hydraulic oil from the portable fil- 12. Install the outlet hose for the portable filter in the
ter. hydraulic reservoir filler neck.
D. Clean the inside of the housing for the filter 13. Open the valve that is installed in the hole for the
element. drain plug.
2. You must know whether the contamination is mi- 14. Move the switch for the portable filter to the ON
croscopic or visible. See types of contamination position. Start and run the engine at 1500 rpm (r/
on page 6-48. min).
3. If the contamination is microscopic: 15. Run the portable filter for 10 minutes.
A. Check the maintenance schedule for the ma- 16. Continue to run the portable filter. Increase the
chine to learn if the hydraulic oil must be engine speed to full throttle. Heat the oil to oper-
changed. If needed, change the hydraulic oil. ating temperature by doing the following steps:
See Section 0 for specifications. Change the A. Hold the blade control lever in the TILT posi-
hydraulic filter. tion for five seconds.
B. Do steps 6 through 35. B. Return the blade control lever in the NEUTRAL
4. If the contamination is visible: position for five seconds.
A. Change the hydraulic oil and hydraulic filter. See C. Repeat steps A and B until the oil in the hy-
Section 0 for specifications. draulic system is at operating temperature.
B. Do steps 5 through 35. 17. Continue to run the engine at full throttle. Con-
tinue to run the portable filter.
5. Check the amount of contamination in the hydrau-
lic system by doing the following steps: 18. Operate each hydraulic circuit to completely ex-
tend and retract the cylinders. Continue to oper-
A. Disassemble one cylinder in two different cir- ate each hydraulic circuit two times, one after the
cuits. Check for damage to seals, scoring of other for 45 minutes.
the cylinder wall, etc. Repair the cylinders as
necessary. 19. Decrease the engine speed to low idle.
B. If, in your judgment, the damage to the cylin- 20. Continue to run the portable filter for 10 minutes.
ders was caused by sever contamination and 21. Stop the portable filter.
is not the result of normal wear, it is necessary
to remove, clean and repair valves, pump, lines, 22. Stop the engine.
cylinders, hydraulic reservoir, etc. in the hydrau- 23. Remove the hose from the hydraulic reservoir.
lic system.
24. Close the valve that is installed in the hole for the
6. Remove the breather from the reservoir and con- drain plug.
nect the vacuum pump to the opening. Start the
vacuum pump. 25. Disconnect the inlet hose for the portable filter
from the valve. Remove the outlet hose from the
7. Loosen and remove the drain plug from the reser- reservoir filler neck and replace filler cap.
voir.
26. Connect a vacuum pump to the breather hose of

the hydraulic reservoir.
27. Start the vacuum pump.
28. Remove the valve from the hole for the drain plug.
29. Install the drain plug.
30. Stop the vacuum pump. Disconnect the vacuum
pump from the opening in the reservoir and install
the breather.
31. Remove the hydraulic filter elements from the
machine.
32. Install new hydraulic filter elements on the ma-
chine.
33. Start the engine. Check for oil leakage around the
new hydraulic filters.
34. Stop the engine.
35. Check the oil level in the hydraulic reservoir. Add
oil as required. See Section 0 for specifications.
6.3.5 FLUSHING WATER FROM THE Important – Check the oil level in the hydraulic reser-
HYDRAULIC SYSTEM voir frequently while doing step 13. Have another per-
son hold a container under the hydraulic lines while
1. Start and run the engine at 1500 rpm (r/min). you do step 13.
2. Completely retract the cylinders of all attachments
on the machine. Angle the blade to the right, the 13. Slowly move each control lever in both directions
right cylinder will be fully retracted and the left will until oil begins to flow from the open line. Hold the
be fully extended. Stop the engine. control lever in place until clean oil flows from the
open line.
WARNING 14. Stop the engine.
If retracting the cylinder rods causes the attach- 15. Connect the system line to the CLOSED end of
ments to be raised, block the attachments in place each cylinder.
before proceeding to the next step! 16. Connect a suitable drain line to the OPEN end of
each cylinder and place the other end in an ac-
Note – Any attachment or part of an attachment that ceptable container for contaminated oil.
is raised must be supported with acceptable equip-
ment to prevent the attachment from falling. 17. Start the engine and run the engine at low idle.
18. Slowly and completely extend all cylinders. As
3. Move each control lever in both directions to re- the piston rod comes in/out of the cylinder, oil will
lease pressure in the hydraulic circuits. be pushed out of the OPEN end of the cylinders.
4. Loosen and remove the filler cap from the reser-
voir. Note – Any attachment or part of an attachment that
is raised must be supported with acceptable equip-
5. Drain the hydraulic oil from the reservoir. ment to prevent the attachment from falling.
A. The reservoir holds approximately 20 U.S. gal-
lons (75.7 litres) of hydraulic oil. 19. Support any attachments that will be in the
RAISED position.
B. Have available acceptable equipment to drain
the hydraulic oil. 20. Stop the engine.
C. Remove the drain plug from the bottom of the 21. Disconnect the drain lines and connect the sys-
reservoir. tem lines to the cylinders.
6. Remove the hydraulic filter elements from the ma- 22. Check the oil level in the hydraulic reservoir. Add
chine. oil as required. See Section 0 for specifications.
7. Install new hydraulic filter elements on the ma- 23. Install the filler cap on the reservoir.
chine. 24. Remove the hydraulic filter elements from the
8. Install the drain plug in the bottom of the reser- machine.
voir. 25. Install new hydraulic filter elements on the ma-
9. Fill the hydraulic reservoir with 20 U.S. gallons chine.
(75.7 litres) of FIAT KOBELCO Fluid AMBRA 26. Start and run the engine at 1500 rpm (r/min), op-
HITECH 46. erate each hydraulic circuit to completely extend
10. Disconnect the line from the OPEN end and and retract the cylinders.
CLOSED end of each cylinder. 27. Stop the engine and check for leaks. Check the
11. Be sure all control levers are in the NEUTRAL oil level in the hydraulic reservoir. Add oil as re-
position. quired. See Section 0 for specifications.
12. Start and run the engine at low idle.
6.4 LOADER CONTROL VALVE
Special Torques
End plate mounting bolts..................................................................................................... 70 Nm (51.6 lb-ft)
Pressure relief, flow limit, and pilot pressure reducing valves ........................... 20 to 25 Nm (177 to 221 lb-in)
Allen head plugs ................................................................................................................ 240 Nm (177 lb-ft)
Allen head locking screw................................................................................................... 100 Nm (73.7 lb-ft)
Allen head cover screws (short) .......................................................................................... 10.4 Nm (92 lb-in)
Allen head cover screws (long) ............................................................................................... 6 Nm (53 lb-in)
Anticavitation valves ......................................................................................................... 100 Nm (73.7 lb-ft)
Combination anticavitation and circuit relief .................................................................... 200 Nm (147.5 lb-ft)
Main relief valve pressure settings

W170 (Z-Bar/TC) ......................................................................................... 248 to 252 bar (3596 to 3654 psi)
Circuit relief valve pressure setting (TC and Z-Bar)

Auxiliary A and B port (TC and Z-Bar) ................................................................................ 290 bar (4206 psi)
Bucket A and B port (Z-Bar) ............................................................................................... 290 bar (4206 psi)
Bucket A port (TC) ............................................................................................................. 183 bar (2654 psi)
Bucket B port (TC) .............................................................................................................. 290bar (4206 psi)
22
6 10
10
16
7 10
9
21
13
12 20
10
11 19
10
15
14
21
17 18 17
BS03C033
2 - Spool valve housing configuration
1. Housing - 2. Plate - 3. Bolt - 4. Washer - 5. Locking screws - 6. Locking screw - 7. Cone - 8. Pressure relief valve - 9. Flow
limit valve - 10. O-rings - 11. Locking screw - 12. Spring - 13. Cone - 14. Regeneration check valve - 15. Locking screw -
16. Load sense shuttle check - 17. Locking screw - 18. Anticavitation valve - 19. Anticavitation and circuit relief - 20. Pilot
pressure reducing valve - 21. Anticavitation and circuit relief - 22. Anticavitation valve.
10
10
10
23
23
24
25
23 27
26
10
10
29 28
30
31
32
31
33
29
31
25 10
32
10
30
27
26 28
BS03C034
2 - Spool valve spool configuration
23. Cover - 24. Bolt - 25. Piston - 26. Jam nut - 27. Cap nut - 28. Bolt - 29. Cover - 30. Adjusting rod - 31. Spring retainer -
32. Spring - 33. Spool.
35
10
10
34
35
BS03C036
3 - Spool mounting configuration
34. Housing - 35. Anticavitation and circuit relief.
36
4
37
34 35
35
BS03C035
4 - Spool mounting configuration
36. Nut - 37. Stud.
25 27
26
29
30
10
31
10
32
31
28
33
29
25
10 31
32
27 30 10
28
26
BS03C037
3 and 4 - Spool valve spool configuration
6.4.2 DISSASEMBLY STEP 7

STEP 1 Remove pressure relief valve (8).
Remove valve from machine.
STEP 8
STEP 2 Remove flow limit valve (9).
Remove bolts (24), cover (23), spring retainers (31),
and spring (32). STEP 9
Remove locking screw (11), spring (12), and cone (13).
STEP 3
Remove bolts (28), covers (29), spring retainers (31), STEP 10
and springs (32). Remove regeneration check valve (14).
STEP 4 STEP 11
Use wooden dowel or brass drift and push spools (33) Remove locking screw (15).
from housing (1).
STEP 12
Important – Do not force spools from housing, if spool
binds work back and forth until spool comes out freely. Remove load sense shuttle check valve (16).
Note – Repeat steps 3 and 4 for 3 and 4 spool valve STEP 13

configuration. Remove locking screws (17).
STEP 5 STEP 14
Remove anticavitation valves (18, 19, 21, and 22). Remove pilot pressure reducing valve (20).
Note – Repeat step for 3 and 4 spool anticavitation STEP 15

valves (35).
Remove bolts (3) and washers (4), remove plate (2)
STEP 6 from housing (1).
Remove locking screw (6) and cone (7). Note – For 4 spool configuration remove nut (36) from
stud (37), remove housings (34) from housing (1).
STEP 16 STEP 18
2
1
2
1
1
BS03C027
BS03C025 1. O-rings - 2. Thrust ring.
1. O-rings - 2. Thrust rings. Remove and discard O-rings and thrust ring from lock-
ing screw (15).
Remove and discard O-rings and thrust rings from
pilot pressure reducing valve (20). STEP 19
STEP 17
1
2
1
2
1
1 3
1
2
BS03C028
BS03C026
1. O-rings - 2. Thrust rings. 1. O-rings - 2. Thrust ring - 3. Spool seal.
Remove and discard O-rings and thrust rings from Remove and discard O-rings, thrust ring, and spool
flow limit valve (9). seal from anticavitation valve (22).
STEP 20
1
1
2 BS03C029
1. O-rings - 2. Thrust rings.
Remove and discard O-rings and thrust rings from pressure relief valve (8).
STEP 21
1
2
1
2
BS03C030
Remove and discard O-rings and thrust rings from anticavitation and pressure relief valves (19).
STEP 22
BS03C031
1. O-rings - 2. Coil.
Remove and discard O-rings and thrust rings from anticavitation valve (18).
STEP 23
1
See Note
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 (21 and 35).
6.4.3 INSPECTION 4. Check the parts of the pressure relief valve,

anticavitation valves, and the anticavitation and
1. Discard all O-rings, thrust rings, and spool seals.
circuit relief valves. Use new parts as necessary.
2. Clean all parts in cleaning solvent.
Inspect the other parts of the control valve. If any of
3. Check the spools and the spool bores for damage the parts are damaged, install new parts.
and wear.
6.4.4 ASSEMBLY
STEP 24
2
A
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 (21 and 35). Torque relief valve (A)
into anticavitation valve to 200 Nm (147.5 lb-ft).
Note – Spool seal mounting position is critical, seal must be mounted with lip facing as shown above, pressure is
in direction of arrow.
STEP 25
1
A
BS03C031
1. O-rings - 2. Coil.
Install new O-rings and thrust rings on anticavitation valve (18). Hand tighten coil nut (A).
STEP 26
1
2
1
2
BS03C030
Install new O-rings and thrust rings on anticavitation and pressure relief valves (19). Torque cap (A) to 100 Nm
(73.7 lb-ft).
STEP 27
1
1
2 BS03C029
Install new O-rings and thrust rings on pressure relief valve (8).
STEP 28 STEP 31
2
1
1 1
1 3
2
BS03C028
BS03C025
1. O-rings - 2. Thrust ring - 3. Spool seal.

Install new O-rings, thrust ring, and spool seal on
Install new O-rings and thrust rings on pilot pressure anticavitation valve (22).
reducing valve (20).
STEP 32
STEP 29
Install and torque regeneration check valve (14) to
100 Nm (73.7 lb-ft).
2
STEP 33
2 Install and torque locking screw (15) to 100 Nm
(73.7 lb-ft).
1
STEP 34
1 Install and tighten load sense chuttle check valve (16).
BS03C026 STEP 35
1. O-rings - 2. Thrust rings. Install and torque locking screws (17) to 240 Nm (177 lb-ft).
Install new O-rings and thrust rings on flow limit valve STEP 36
(9). Install and torque pilot pressure reducing valve (20)
to 60 Nm (44 lb-ft).
STEP 30
STEP 37
1 Install new O-rings on housing (1). Install plate (2),
2 bolts (3) and washers (4), onto housing (1). Torque
bolts to 70 Nm (52 lb-ft).
1
Note – For 4 spool configuration install new O-rings
between housings (34) and housing (1), install nuts
(36) on studs (37). Torque nuts to 70 Nm (52 lb-ft).
STEP 38
BS03C027 Install anticavitation valves (18, 21, and 22) and
1. O-rings - 2. Thrust rings. torque to 100 Nm (73.7 lb-ft).
Install new O-rings and thrust ring on locking screw Note – Repeat step for 3 and 4 spool anticavitation
(15). valves (35).
STEP 39 Circuit Relief Pressure Test

Install anticavitation valves (19) and torque to STEP 48
200 Nm (147.5 lb-ft).
Connect the hand pump to the port for anticavitation
and circuit relief valves (21).
STEP 40
Install and torque flow limit valve (9) to 20 to 25 Nm Note – Repeat steps for machines that are configured
(177 to 221 lb-in). with a 3 or 4 spool valve.
STEP 41 STEP 49
Install cone (13), spring (12), locking screw (11). Make sure that the hand pump is full of hydraulic oil
Torque locking screw to 100 Nm (73.7 lb-ft). and that the temperature of the oil is approximately
21°C (70°F).
STEP 42
STEP 50
Install cone (7) and locking screw (6). Torque locking
screw to 40 Nm (29.5 lb-ft). Operate the handle of the hand pump and read the
highest pressure. Repeat this step several times to
STEP 43 be sure of the reading.
Lubricate spools with hydraulic oil and push spools
STEP 51
(33) into housing (1).
Compare the reading to the specifications on
Important – Do not force spools into housing. Page 6-52.
STEP 44 STEP 52
Install spring retainers (31), springs (32), covers (29), If the pressure is not correct, adjust the circuit relief
and bolts (28). Torque bolts to 10.4 Nm (92 lb-in). valve.
Note – Repeat steps 41 and 42 for 3 and 4 spool Circuit Relief Adjustment
valve configuration.
STEP 53
STEP 45 Loosen the lock nut. Turn the adjustment screw clock-
wise to increase the pressure or counterclockwise to
Install spring retainers (31), spring (32), cover (23),
decrease the pressure.
and bolts (24). Torque bolts to 6 Nm (53 lb-in).
STEP 54
Note – Prior to installation in the machine, circuit re-
liefs can be tested. Check the pressure again. Repeat the adjustment as
necessary.
STEP 46
Install valve in machine.
STEP 47
Check loader limit pressure.
6.5 CYLINDERS
Approximate weight
Lift Cylinder - TC and Z-Bar Models .................................................................................... 119 kg (262 pounds)
Bucket Cylinder - Z-Bar Models ....................................................................................... 128.7 kg (284 pounds)
Bucket Cylinders - TC Models............................................................................................ 85.9 kg (189 pounds)

Screw in Gland Z-Bar Bucket Cylinder .............................................. 135 to 542 Nm (99.6 to 399.77 pound-feet)
Screw in Gland TC Bucket Cylinder ........................................................ 135 to 541 Nm (100 to 400 pound-feet)
Screw in Gland for Lift Cylinders TC and Z-Bar Models ..................... 135 to 542 Nm (99.6 to 399.77 pound-feet)
Piston Bolt for Lift Cylinders TC and Z-Bar Models ......................... 3310 to 3850 Nm (2441 to 2840 pound-feet)
Piston Bolt for TC Bucket Cylinder .................................................. 1780 to 2180 Nm (1312 to 1607 pound-feet)
Lock Screw for all Cylinders ....................................................................................... 2.3 Nm (20 pound-inches)
6.5.3 SPECIAL TOOLS

Torque Multiplier ................................................................................................................................ 380001732
6.5.4 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. If
other holding equipment, refer to Figure page piston rod is not straight, replace it with a new pis-
6-70. Do not damage tube (1). ton rod.
3. Loosen and remove self-tapping screw (12). 3. Shine a light inside tube (1) and check for deep
grooves and other damage. If there is any damage
4. Use a spanner wrench to loosen and remove gland
to tube, replace with a new tube.
(4) from tube (1).
4. Remove any small scratches on piston rod (13) or
5. Pull piston rod (13) straight out of tube (1) to pre-
inside tube (1) with emery cloth of medium grit. Use
vent damage to tube.
emery cloth with a rotary motion.
6. Fasten piston rod eye or yoke in a vise and put a
5. Inspect bushings (2) in tube eye. Replace as re-
support under piston rod (13) near piston (15). Put
quired.
a shop cloth between support and piston rod to
prevent damage to piston rod. 6. Inspect gland (4) for rust. Clean and remove rust
as necessary.
7. Use a torque multiplier, 380001732, to loosen and
remove bolt (14) that fastens piston (15) to piston 7. Inspect gland end of tube (1) for sharp edges that
rod (13). may cut gland O-ring (11) and remove as neces-
sary.
8. Inspect piston (15) for damage and wear. If piston
is damaged or worn, replace with a new piston.
10. Remove and discard seal (16), ring (17), and wear
ring (18) from piston (15).
11. Remove and discard O-ring (10), backup ring (9),
O-ring (11), wiper (5), rod seal (6), buffer seal (7),
and bushing (8) from gland (4).
13
5
6
7
4
8
11
9
10
15
17
16
18
14 1
3
2
2
3
BS03B200
Lift cylinder
1. Tube - 2. Bushing - 3. Wiper - 4. Gland - 5. Wiper - 6. Rod seal - 7. Buffer seal - 8. Bushing - 9. Backup ring - 10. O-ring -
11. O-ring - 12. Screw (not shown) - 13. Rod - 14. Bolt - 15. Piston - 16. Seal - 17. Ring - 18. Wear ring.
Assembly 17. Install a new ring (17) in the other groove on the
outside of the piston (15).
Note – If a new gland is being used, put part number
of cylinder on new gland. 18. Install a new seal (16) on top of ring (17).
19. Fasten tube (1) in an acceptable repair stand or
1. Install bushing (8) in gland (4); refer to Figure page
other holding equipment. Be careful to prevent
6-70.
damage to tube.
2. Install rod seal (6) in gland (4). Rod seal is to be
20. Lubricate inside of the tube (1) and piston (15)
installed so that lips of seal are toward bushing
with clean oil.
(8). Rod seal (6) can be difficult to install.
21. Push piston (15) straight into tube (1).
3. Install buffer seal (7) in gland (4). The side of buffer
seal with groove must be toward bushing (8). 22. When the piston (15) is in smooth part of tube (1),
start gland (4) into tube.
4. Install a new wiper (5) in gland (4). Lips of wiper
must be toward outside end of gland (4). 23. Lubricate O-rings (10 and 11) on gland (4) with
clean oil.
5. Install a new O-ring (11) in groove on OD of gland
(4). 24. Turn gland (4) into tube (1). Tighten gland to a
torque of 135 to 542 Nm (99.6 to 399.7 pound-
6. Install a new backup ring (9) in groove on OD of
feet).
gland (4). If both sides of backup ring are not flat,
side that is not flat must be toward small end of 25. If the original parts are being assembled:
gland (4). A. Tighten gland to a torque of 135 to 542 Nm
7. Install a new O-ring (10) next to backup ring (9) in (99.6 to 399.7 pound-feet).
groove on outside of gland (4). O-ring must be
B. Install and tighten self-tapping screw (12) to a
toward small end of gland.
torque of 2.3 Nm (20 inch-pounds).
8. Fasten piston rod (13) eye or yoke in vise.
C. If, after tightening gland, the self-tapping screw
9. Remove any marks and sharp edges on chamfer (12) holes are not aligned, a new hole for self-
at end of piston rod (13). Make sure that piston tapping screw must be drilled. See Step 26.
rod is clean.
26. If a new gland (4) or a new tube (1) are being
10. Lubricate bore of gland (4) and piston rod (13) with assembled:
clean oil.
A. Tighten gland (4) to 135 to 542 Nm (100 to
11. Push gland (4) onto piston rod (13). If necessary, 400 pound-feet).
use a soft hammer to drive gland onto piston rod. B. Use a No. 27 drill bit and drill a hole half in
12. Put a support below and near end of piston rod gland (4) and half in tube (1). Drill to a depth of
(13). Use a shop cloth between support and the 11 mm (7/16 inch). Do not drill within 13 mm
piston rod to prevent damage to piston rod. (1/2 inch) of a hole for gland wrench.
13. Start piston (15) onto piston rod (13). C. Install and tighten self-tapping screw (12) to a
14. Clean the threads on the end of the piston rod
(13) and the threads of the bolt (14) using Loctite 27. If hoses were removed with cylinder, install new
cleaning solvent. Allow to dry. Apply Loctite 242 O-rings, if equipped, on hose fittings. Lubricate
to piston rod threads 6.3 mm (1/4 inch) from open O-rings with clean oil. Install hoses.
end of piston rod so that there is 13 mm (1/2 inch)
of Loctite 242 on piston rod threads. DO NOT ap-
ply Loctite to first 6.3 mm (1/4 inch) of piston rod
threads.
15. Install bolt (14) into piston rod (13). Tighten bolt to
a torque of 3310 to 3850 Nm (2440 to 2838 pound-
feet). A torque multiplier can be used to help torque
the bolt.
16. Install a new wear ring (18) in wide groove on out-
side of piston (15), refer to Figure page 6-67.
6.5.5 BUCKET CYLINDERS Z-BAR MODELS

1. Clean outside 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. If
other holding equipment, see Figure page 6-73. piston rod is not straight, replace it with a new pis-
Do not damage tube. ton rod.
3. Loosen and remove self-tapping screw (4) from 3. Shine a light inside tube (1) and check for deep
gland (5) and tube (1). grooves and other damage. If there is any damage
to tube, replace it with a new tube.
4. Use a spanner wrench to loosen and remove gland
(5) from tube (1). 4. Remove any small scratches on piston rod (13) or
tube (1) interior with emery cloth of medium grit.
5. Pull piston rod (13) straight out of tube (1) to pre-
Use emery cloth with a rotary motion.
5. Inspect bushings (3 or 14) in piston rod eye or yoke
6. Fasten piston rod eye or yoke in a vise and put a
and tube. Replace as required.
support under piston rod (13) near piston (16). Put
a shop cloth between support and piston rod to 6. Inspect gland (5) for rust and clean and remove
prevent damage to piston rod. rust as necessary.
7. Remove wear ring (17) from piston (16) to gain 7. Inspect gland end of tube (1) for sharp edges that
access to dowel pin (18). Discard wear ring (17). will cut gland O-ring (10) and remove as neces-
sary.
8. Remove dowel pin (18) securing piston (16) to pis-
ton rod (13). Loosen and remove piston from pis- 8. Inspect piston (16) for damage and wear. If piston
ton rod. is damaged or worn, replace it with a new piston.
10. Remove and discard seal (19), ring (20), backup
rings (21 and 23), and O-ring (22) from piston (16).
11. Remove and discard wiper (6), rod seal (7), buffer
seal (8), bushing (9), O-rings (10 and 12), and
backup ring (11) from gland (5).
15
14 14
6
15
7
8
5
13
9
10
11
12
18
21
22
23
16
20
19
17
2
3 2
BS03B203
Bucket cylinder for Z-bar models
1. Tube - 2. Wiper - 3. Bushing - 4. Screw (not shown) - 5. Gland - 6. Wiper - 7. Rod seal - 8. Buffer seal - 9. Bushing - 10. O-ring -
11. Backup ring - 12. O-ring - 13. Piston rod - 14. Bushing - 15. Wiper - 16. Piston - 17. Wear ring - 18. Dowel pin - 19. Seal
- 20. Ring - 21. Backup ring - 22. O-ring - 23. Backup ring.
Assembly 19. Install a new ring (20) in groove on OD of piston

(16).
Note – If a new gland is being used, put part number
of cylinder on new gland. 20. Install a new seal (19) on top of ring (20).
21. Install a new wear ring (17) in wide groove on OD
1. Install bushing (9) in gland (5); see Figure page 6-73.
of piston (16) over dowel pin installed in Step 18
2. Install rod seal (7) in gland (5). Rod seal is in- above.
stalled so that lips of seal are toward bushing (9).
22. Fasten tube (1) in an acceptable repair stand or
Rod seal can be difficult to install.
other holding equipment. Be careful to prevent
3. Install buffer seal (8) in gland (5). Side of buffer damage to tube.
seal with groove must be toward bushing (9).
23. Lubricate inside of tube (1) and piston (16) with
4. Install a new wiper (6) in gland (5). Lips of wiper clean oil.
(6) must be toward outside end of gland (5).
5. Install a new O-ring (10) in groove on gland (5).
25. When piston (16) is in smooth part of tube (1),
6. Install a new backup ring (11) in groove on OD of start gland (5) into tube.
gland (5). If both sides of backup ring (11) are not
26. Lubricate O-rings (10 and 12) on gland (5) with
flat, the side that is not flat must be toward small
clean oil.
end of gland (5).
27. Turn gland (5) into tube (1). Tighten gland (5) to a
7. Install a new O-ring (12) next to backup ring (11)
torque of 339 to 475 Nm (250 to 350 pound-feet).
in groove on outside of gland (5). O-ring (12) must
be toward small end of gland. 28. If original parts are being assembled:
8. Fasten piston rod (13) eye or yoke in vise. A. Tighten gland to a torque of 135 to 542 Nm
(99.6 to 399.7 pound-feet).
9. Remove any marks and sharp edges on chamfer
behind threaded end of piston rod (13). Make sure B. Install and tighten self-tapping screw (4) to a
that piston rod is clean. torque of 2.3 Nm (20 inch-pounds).
10. Lubricate bore of gland (5) and piston rod (13) with C. If, after tightening gland, self-tapping screw
clean oil. (4) holes are not aligned, a new hole for self-
tapping screw must be drilled. See Step 29.
11. Push gland (5) onto piston rod (13). If necessary,
use a soft hammer to drive gland (5) onto piston 29. If a new gland (5) or a new tube (1) are being
rod (13). assembled:
12. Install backup ring (23) in groove in ID of piston A. Tighten gland (5) to a torque of 135 to 542 Nm
(16). (99.6 to 399.7 pound-feet).
13. Install O-ring (22) in groove in ID of piston (16) B. Use a No. 27 drill bit and drill a hole half in
next to backup ring (23). gland (5) and half in tube (1). Drill to a depth of
11 mm (7/16 inch). Do not drill within 13 mm
14. Install backup ring (21) in groove in ID of piston
(1/2 inch) of a hole for gland wrench.
(16) next to O-ring (22). O-ring must be between
backup rings (21 and 23). C. Install and tighten self-tapping screw (4) to a
15. Put a support below and near end of piston rod
(13). Use a shop cloth between support and pis- 30. If hoses were removed with cylinder, install new
ton rod to prevent damage to piston rod. O-rings, if equipped, on hose fittings. Lubricate
O-rings with clean oil. Install hoses.
16. Lubricate bore of piston (16) and chamfer area of
piston rod (13) with clean oil.
17. Thread piston (16) on piston rod (13) until piston
seats against piston rod hand tight.
18. If no holes in piston (16) and piston rod (13) are
aligned, back off piston (less than 90°) until first
set of holes are aligned. Install dowel pin (18).
6.5.6 BUCKET CYLINDERS FOR TC Inspection

MODELS 1. Clean all parts in cleaning solvent. Use only lint
Disassembly free cloths for cleaning and drying.
1. Clean exterior of cylinder. If hoses were removed 2. Check to be sure that piston rod (12) is straight. If
with cylinder, remove hoses from cylinder. piston rod is not straight, replace it with a new
piston rod.
2. Fasten cylinder in a vise or other holding equip-
ment. Be careful to prevent damage to tube (1); 3. Illuminate inside of tube (1) for deep grooves and
see Figure page 6-76. other damage. If there is any damage to tube,
replace it with a new tube.
3. Loosen and remove self-tapping screw (3) from
gland (4) and tube (1). 4. Remove any small scratches on piston rod (12)
or inside tube (1) with emery cloth of medium grit.
4. Use a spanner wrench to loosen and remove gland Use emery cloth with a rotary motion.
(4) from tube (1).
5. Inspect bushings (2) in tube eye. Replace as re-
5. Pull piston rod (12) straight out of tube (1) to pre- quired.
6. Inspect gland (4) for rust and clean and remove
6. Fasten rod yoke in a vise and put a support below rust as necessary.
piston rod (12) near piston (13). Use a shop cloth
between support and piston rod to prevent dam- 7. Inspect gland end of tube (1) for sharp edges that
age to piston rod. will cut gland O-ring (9) and remove as neces-
sary.
7. Use a torque multiplier, 380001732, to loosen and
remove bolt (17) securing piston (13). 8. Inspect piston (13) for damage and wear. If piston
is damaged or worn, replace with new piston.
10. Remove and discard backup ring (14), piston seal
(15), and wear ring (16) from piston (13).
11. Remove and discard wiper (5), rod seal (7), buffer
seal (8), and bushing (6) from gland (4).
NOTE – Use care not to scratch ID of gland when

removing seals.
12. Remove and discard O-rings (9 and 10) and backup

ring (11) from OD of gland (4).
12
7
8
4
13
9
11
10 14
15
16
17
6
19
2 1
2
19
18
BS03B202
Bucket cylinder for TC models
1. Tube - 2. Bushing - 3. Screw - 4. Gland - 5. Wiper - 6. Bushing - 7. Rod seal - 8. Buffer seal - 9. O-ring - 10. O-ring - 11.
Backup ring - 12. Piston rod - 13. Piston - 14. Backup ring - 15. Seal - 16. Wear ring - 17. Bolt - 18. Grease fitting - 19. Wiper
Assembly 19. Fasten tube (1) in a vise or other holding equip-

ment. Be careful to prevent damage to tube.
NOTE – If a new gland (4) is being installed, put part
number of cylinder on new gland (4). 20. Lubricate inside of tube (1) and piston (13) with
clean oil.
1. Install bushing (6) in gland (4); see page 6-76.
2. Install rod seal (7). Rod seal must be installed
22. When piston (13) is in smooth part of tube (1),
with seal lips toward bushing (6). Rod seal can be
start gland (4) into tube.
difficult to install.
23. Lubricate O-rings (9 and 10) on gland (4) with
3. Install buffer seal (8). Buffer seal must be installed
clean oil.
with lips toward bushing (6).
24. Tighten gland (4) into tube (1). Tighten gland to a
4. Install a new wiper (5) in gland (4). Lips of wiper
torque of 135 to 542 Nm (100 to 400 pound-feet).
(5) must be toward large end of gland (4).
25. If the original parts are being assembled:
5. Install a new O-ring (9) in groove of gland (4).
A. Tighten gland to a torque of 135 to 542 Nm
6. Install a new backup ring (11) in groove on OD of
(100 to 400 pound-feet).
the gland (4). If both sides of backup ring (11) are
not flat, side that is not flat must be toward small B. Install and tighten self-tapping screw (3) to a
end of gland (4). torque of 2.3 Nm (20 inch-pounds).
7. Install O-ring (10) on gland (4). O-ring (10) must C. If, after tightening gland, self-tapping screw (3)
be toward small end of gland (4). holes are not aligned, a new hole for lock screw
(3) must be drilled. See Step 27.
8. Fasten piston rod (12) yoke in vise.
26. If a new gland (4) or a new tube (1) are being
9. Remove any marks and sharp edges on chamfer
assembled:
at end of piston rod (12).
A. Tighten gland (4) to 135 to 542 Nm (100 to 400
10. Lubricate bore of gland (4) and piston rod (12) with
pound-feet).
clean oil.
B. Use a No. 27 drill bit and drill a hole half in
11. Push gland (4) on piston rod (12). If necessary,
gland (4) and half in tube (1). Drill to a depth of
use a soft hammer to drive gland on piston rod.
11 mm (7/16 inch). Do not drill within 13 mm (1/
12. Put a support below and near end of piston rod 2 inch) of a hole for gland wrench.
(12). Use a shop cloth between support and pis-
C. Install and tighten lock screw (3) to a torque of
ton rod to prevent damage to rod.
2.3 Nm (20 inch-pounds).
13. Put piston (13) on end of piston rod (12).
27. If hoses were removed with cylinder, install new
14. Clean threads on end of piston rod (12) and threads O-rings, if equipped, on hose fittings. Lubricate
of bolt (17) using Loctite cleaning solvent. Allow O-rings with clean oil. Install hoses.
to dry. Apply Loctite 242 to piston rod threads 6.3
mm (1/4 inch) from open end of piston rod so that
there is 13 mm (1/2 inch) of Loctite 242 on piston
rod threads. DO NOT apply Loctite to first 6.3 mm
(1/4 inch) of piston rod threads.
15. Install bolt (17). Tighten bolt to a torque of 1780 to
2180 Nm (1312 to 1607 pound-feet). A torque
multiplier can be used to help tighten bolt.
16. Install a new wear ring (16) in groove on outer end
of piston (13).
17. Install piston backup ring (14) into remaining
groove in piston (13).
18. Install a new piston seal (15) on top of backup
ring (14).
6.5.7 REPLACING THE BUSHINGS

FOR THE LIFT CYLINDERS
3
Z-BAR AND TC MODELS
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. 1
4
3. Clean bore for bushings (2) in tube (4) eye.
Installation
1. Use an acceptable driver to press new bushings 2
(2) into tube (4) eye. Bushings shall be recessed 8 2
mm (0.315 inch) in tube eye.
1
2. Use an acceptable driver to install wipers (1) until
flush with tube (4) eye. The lips of wipers must be
toward outside of bore.
BS01C003
Bushing and wiper removal and replacement lift

cylinders
1. Wiper - 2. Bushing - 3. Piston rod yoke - 4. Tube.
6.5.8 REPLACING BUSHINGS FOR THE

BUCKET CYLINDERS TC MODELS
3
Removal
1. Put piston tube (4) in a press.
bushing (2) out of piston tube (4) eye.
3. Clean bore for bushings (2) in tube (4) eye.
1 4
Installation
1. Use an acceptable driver to press new bushings 2
(2) into tube (4) eye. Bushings shall be recessed 8
mm (0.315 inch) in tube eye.
2
flush with tube (4) eye. The lips of wipers (1) must
be toward outside of bore. 1
BS01C002
Bushing and wiper removal and replacement TC

bucket cylinders
1. Wiper - 2. Bushing - 3. Piston rod yoke - 4. Tube
6.5.9. REPLACING BUSHINGS FOR 1

THE BUCKET CYLINDER 2
3
Z-BAR MODELS
Removal
2
1. Put piston rod eye (3) in a press.
1
bushing (2) out of piston rod eye (3).
3. Put tube (4) in a press.
4. Use an acceptable driver to press bushings (2) out
of tube (4) eye. 1 4
2
5. Clean bore for bushings (2) in piston rod eye (3)
and tube (4) eye.
Installation
1. Use an acceptable driver to press new bushings
2
(2) into piston rod eye (3) until recessed 8 mm (0.315
inch).
flush with piston rod eye (3). The lips of the wipers
(1) must be towards outside of bore. 1
BS03B201
3. Use an acceptable driver to press new bushings
(2) into tube (4) eye until recessed 8 mm Bushing and wiper removal and replacement
(0.315 inch). Z-bar bucket cylinder
4. Use an acceptable driver to install wipers (1) until 1. Wiper - 2. Bushing - 3. Piston rod eye - 4. Tube.
flush with tube (4) eye. The lips of wipers (1) must
be towards outside of bore.
6.6 PILOT PRESSURE ACCUMULATOR AND RIDE CONTROL ACCUMULATOR
Ride Control Accumulator Dry Nitrogen Pressure ..................... 17.2 ± 1.7 bar (249.5 ± 24.6 psi) at 21° C (70°F)
Ride Control Accumulator Fluid Capacity ...................................................................... 3.79 liters (231 cu. inch)
Ride Control Accumulator Maximum Operating Pressure .................................................. 248.4 bar (3602.7 psi)
Pilot Pressure Accumulator Dry Nitrogen Pressure ............................. 14 ± 1 bar (203 ± 15 psi) at 20° C (68° F)
Pilot Pressure Accumulator Fluid Capacity .................................................................... 0.75 liters (45 cu. inch)
Pilot Pressure Accumulator Maximum operating Pressure .................................................. 210 bar (3045.8 psi)
6.6.2 RIDE CONTROL ACCUMULATOR SPECIAL TORQUES

Accumulator Gas Charging Valve Cap ........................................................................... 13.6 Nm (10 pound-feet)
Gas Charging Valve ...................................................................................... 88 to 102 Nm (65 to 75 pound-feet)
Cap screws for the protection bracket .................................................... 54 to 61 Nm (480 to 540 pound-inches)
Gland ...................................................................................................... 163 to 176 Nm (120 to 130 pound-feet)
6.6.3 SPECIAL TOOLS
94L95
B786441M
380001737 Nitrogen accumulator charging kit 380001738 Gland wrench
6.6.4 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 dis- 7. Turn the T-handle inward on valve F to engage the
charge the accumulator, refer to the illustration pin in the valve stem.
above. The tool must be disconnected from the ni-
8. Open valve D and check the charge pressure on
trogen tank.
gauge E.
2. Close valves B, C and D.
9. To discharge the accumulator, partially open valve
3. Adjust the regulator A to the minimum pressure B. The accumulator charge will bleed down through
setting by turning the knob counterclockwise. the regulator.
4. Turn the T-handle on valve F fully out. 10. Once the accumulator is fully discharged, discon-
nect 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 accumu-
lator.
6.6.5 RIDE CONTROL ACCUMULATOR

Disassembly Assembly
Note – Refer to section for the proper procedure for 1. Fasten the body (1) in a vise. Be careful not to
the removal of the ride control accumulator. damage the body (1). Refer to the illustration on
page 6-83.
WARNING 2. Install a new wear ring (8), O-ring (10) and backup
ring (9) on the piston (5).
DO NOT attempt to disassemble any accumulator
until the nitrogen charge is properly discharged. 3. Lubricate the bore of the body (1) and the piston
(5) with clean oil.
1. Fasten the body (1) in a vise. Be careful not to 4. Start the piston (5) into the body (1), round sur-
damage the body (1), refer to the illustration on face first. Then push the piston (5) farther into the
page 6-83. body (1).
2. Remove the screws (3) and guard (2) from the body
(1). Note – The piston (5) must be installed squarely and
slowly into the body (1). Once the piston (5) is started
3. Remove the pressure valve (4) from the body (1).
straight into the bore of the body (1), use a hammer
4. Remove and discard the O-ring (7) from the pres- and wood block to gently tap the piston into the pol-
sure valve (4). ished area of the bore. Keep force on the piston (5)
while tapping into the bore or damage may occur to
5. Loosen and remove the cap (12) from the body (1).
the O-ring.
6. Loosen and remove the gland (6) from the body
(1).
5. Install and tighten the cap (12) into the body (1).
7. Remove the piston (5) from the body (1).
6. Install new seals (11) on the gland (6).
8. Remove and discard the wear ring (8), O-ring (10)
7. Lubricate the seals (11) with clean oil and start
and the backup ring (9) from the piston (5).
the gland (6) into the body (1).
9. Remove the seals (11) from the gland (6).
8. Tighten the gland (6).
Inspection
9. Install a new O-ring (7) on the pressure valve (4).
1. Clean body (1), gland (6), cap (12) and piston (5)
10. Install the pressure valve (4) in the body (1).
in cleaning solvent, refer to the illustration on page
6-83. 11. Install the guard (2), screws (3) in the body (1).
2. Inspect the piston (5) for cracks, burrs or other 12. Charge the accumulator with dry nitrogen accord-
damage. ing to instructions on page 6-84.
3. Inspect the bore of the body (1) for scratches or
scoring using a light. WARNING
Use only nitrogen when charging the accumula-
Note – Minor scratches or scoring in the bore of the
tor. DO NOT use air or oxygen that will cause an
body (1) can be removed using crocus clot.
explosion.
4. Inspect the pressure valve (4) and replace as
needed.
11 6 5 8 9 10 12 3
7
2
1 3
BS01B224
Ride control accumulator illustration
1. Body - 2. Guard- 3. Screw - 4. Pressure valve - 5. Piston - 6. Gland - 7. O-ring - 8. Wear ring - 9. Backup ring - 10. O-ring
- 11. Seals (2) - 12. Cap.
6.6.6 CHARGING THE ACCUMULATOR WITH NITROGEN
5 4 3 2
GS98N801
Nitrogen charging kit 380001737
1. To nitrogen tank - 2. Valve A - 3. Valve B - 4. Valve D - 5. To accumulator - 6. Valve C.
WARNING WARNING
Use only nitrogen when charging the accumula- Do not expose the accumulator to temperatures
tor. Do not use air or oxygen that will cause an above 49° C (120° F). A charged accumulator con-
explosion. tains 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 pro-
WARNING pel the accumulator at a dangerous rate of speed.
Do not drop the accumulator. A charged accumu-
lator contains nitrogen compressed to 31 bar Important – The four valves must be in the positions
(450 psi). If the charging valve breaks away from noted in the procedure before connecting the Nitro-
the accumulator, the escaping nitrogen will pro- gen Accumulator Charging Kit to the machine or ni-
pel the accumulator at a dangerous rate of speed. trogen, 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/145 psi and above) appli-
cations.
1. Close the shutoff valve A by turning it all the way 10. Install the charging hose fitting onto the accumu-
to the left (counterclockwise), refer to the illustra- lator pressure valve (4), refer to the illustration on
tion on page 6-84. page 6-83.
2. Open valve B by turning it out all the way to the left 11. Tighten the needle valve by turning it clockwise.
(counterclockwise). Slowly open the gauge valve D and observe the
reading on the gauge. This reading is the nitrogen
3. Close valve C by turning it all the way to the right
pressure level inside the accumulator, refer to il-
(clockwise).
lustration on page 6-84.
4. Close the gauge valve D by turning it all the way to
12. Open the shutoff valve A on the nitrogen supply
the right (clockwise).
tank. While observing the pressure on the gauge,
5. Connect the charging hose to the nitrogen supply slightly open the needle valve on the accumula-
tank. tor charge hose. By regulating the needle valve,
6. SLOWLY turn valve A clockwise while watching the fill the accumulator to 31 bar (450 psi). Close the
high pressure gauge. Stop turning valve A when needle valve. Close the shutoff valve A on the
the needle on the gauge reaches 31 bar (450 psi). nitrogen supply tank.
13. Close valve B by turning to the right (clockwise).
Note – If the needle goes over the needed pressure, After a few minutes, check the accumulator for
quickly open and close valve D and check the pres- leakage.
sure setting again.
14. Back off the needle valve on the accumulator end
of the charging hose by turning it counterclockwise
The charging kit is now ready to be installed on the
the maximum amount. This will prevent nitrogen
accumulator.
from escaping from the accumulator as the hose
is removed. Remove the charging hose from the
7. Remove the two cap screws (3) and the protection
accumulator pressure valve (4), refer to the illus-
bracket (2) from the body (1) on the accumulator,
tration on page 6-83.
refer to the illustration on page 6-77.
15. Install the valve cap onto the pressure valve (4)
8. Remove the valve cap from the pressure valve (4)
on the accumulator.
on the accumulator.
16. Install the protection bracket (2) over the pres-
9. Back off the needle valve on the accumulator end
sure valve (4) and secure it with cap screws (3).
of the charging hose by turning it counterclockwise
to the maximum amount. This prevents nitrogen 17. Remove the charging hose from the nitrogen sup-
from escaping from the accumulator when the charg- ply tank, refer to the illustration on page 6-84.
ing hose is attached to the accumulator gas charg-
ing valve, refer to the illustration on page 6-84.
6.7 RIDE CONTROL VALVE CONFIGURATION
10
3
5
1
6
3
5
BS03C055
Ride control valve configuration
1. Housing - 2. Insert valve - 3. Locking screw - 4. Locking screw - 5. Locking screw - 6. Relief valve - 7. Logic cover -
8. Directional valve - 9. Mounting screw - 10. Mounting screw.
6.7.1. DISASSEMBLY STEP 5

STEP 1 Remove the pressure relief valve (6) from the hous-
ing (1).
Remove ride control valve.
6.7.2. INSPECTION
STEP 2
1. Discard all O-rings, thrust rings, R-rings, and
Remove the four mounting screws (9), remove the
bonded seal.
directional valve (8).
2. Clean all parts in cleaning solvent.
STEP 3
3. Check the spools and the spool bores for damage
Remove the four mounting screws (10), remove the and wear.
logic cover (7).
4. Check the parts of the pressure relief valve, direc-
tional valve, insert valve, and the logic cover valve.
STEP 4
Use new parts as necessary.
Remove the insert valve (2) from the housing (1).
Inspect the other parts of the control valve. If any of
the parts are damaged, install new parts.
6.7.3. ASSEMBLY
STEP 6
3
3
1 1
BS03C056
Insert valve
1. O-rings - 2. R-rings - 3. Thrust rings.
Replace O-rings (1) and thrust rings (3) on the insert valve (2).
STEP 7
1
2
3
3
BS03C057
Logic cover
1. O-ring - 2. Backup ring - 3. R-rings.
Replace O-rings (1), thrust rings (2), and R-rings on the logic cover.
STEP 8
1
2
3 3
BS03C058
Directional valve
1. O-rings - 2. Coil - 3. R-ring.
Replace O-rings (1) and R-rings (3) on the directional valve.
STEP 9
2
2
1
1
3
BS03C059
Pressure Relief Valve
1. O-rings - 2. Thrust rings - 3. Bonded seal.
Replace O-rings (1), thrust rings (2), and bonded seal (3) on the pressure relief valve. Assembly pressure relief
valve as shown above.
STEP 10 STEP 13
Install the pressure relief valve (6) into the housing Place the directional valve (8) into position on the logic
(1) and tighten. cover (7). Secure the directional valve (8) with four
mounting screws (9) and tighten screws.
STEP 11
Note – Make sure R-rings remain in place and oil ports
Install the insert valve (2) into the housing (1).
are properly aligned.
STEP 12
STEP 14
Place the logic cover (7) into position on the housing
Install new O-rings on the locking screws (3, 4,
(1). Secure the logic cover (7) with four mounting
and 5), install and tighten locking screws.
screws (10) and tighten screws.
STEP 15
Note – Make sure R-rings remain in place and oil ports
are properly aligned. Install the ride control valve in the machine.
STEP 16
Test the ride control system.
W170/W170TC HYDRAULIC SCHEMATIC W170 Z-BAR, XR AND TC MODELS 6 - 91
12 HYDRAULIC
SYMBOLS
6
14
Pressure
R R1 R2 P
P
L
13
LS
7
17 18
Component
T2
R
T
P
M
15
T1
11 32
Return
25
N
36
MT1 T MP
39
26
TC MODELS
8-11 BAR
Load sense
116-159 PSI
P
19 PST
Z-BAR and
41 (OPT.) XR MODELS 5
XY
TP11
B1 A1 XZ Pilot pressure
TP10
TP6 TC MODELS
NOTE 2
TP7
TP3 A1 A1
37 XY XY
TP2 B1 XZ XZ 5
B1
TP5
TP1
Z-BAR and XR MODELS
Crossing lines
290 BAR
TP9
B2 4206 PSI A2
M2 IN
NOTE 1
21 A2 A2
31 98.3 BAR
Line connection
1425 PSI
M2 IN
35 B2 B2
98.3 BAR
22
1425 PSI
M1 TANK A1 30 BAR
193 NOTE 3
435 PSI
BAR
34 4
2800 PSI
23 LS
P
M1 TANK
220 BAR
3190 PSI
B1
T
Check valve
A2
B3 A3
290 BAR
4206 PSI
20
A3
B2 1
20.7 BAR
24
B X3 X1
27
B X4 X2
300 PSI
10 293 BAR
4250 PSI
B3 SOLENOID
VALVE
Restrictor
A3 A B
38
LS EF CF S2 S1 P T
FR1 FR1 33
2
SEQ UENCE
B3 Y
VALVE
28 FR2 FR2
218 BAR
3162 PSI
X1 X Z1 Y X2
Filter or screen
T P
LOGIC
VALVE
STEERING PUMP LO ADER PUMP MA MX 3
FRONT REAR RELIEF
30 VALVE
S L2 L1 S L4 L3
LS EF CF
9 A T
PP
8 240.3 BAR Oil cooler

3481 PSI
M
29 40 40 40 T P
W170-6R004
COMPONENTS: 1. Ride control valve (option) – 2. Ride control accumulator (option) - Precharge: 14.5 bar (210 psi) - Capacity: 3.78 litres (231 cu in.) – 3. Ride control accumulator bleeder valve – 4. Lift cylinders - Bore: 120.5 mm (4.74 in) - Rod: 76.2 mm (3.0 in) - Stroke: 828.1 mm
(32.6 in) – 5. Bucket cylinder (Z-Bar Models) - Bore: 146 mm (5.75 in) - Rod: 76.20 mm (3.00 in) - Stroke: 629.40 mm (24.7 in) – 5. Bucket cylinder (TC Models) - Bore: 108.00 mm (4.25 in) - Rod: 57.20 mm (2.25 in) - Additional copies of this hydraulic and electrical schematic can be ordered
through - Stroke: 1016.40 mm (40.0 in) – 6. Steering control valve - Displacement: 985 cc/rev (60 cu in./rev) – 7. Steering cylinders (2) - Bore: 76.2 mm (3.00 in) - Rod: 44.5 mm (1.75 in) - Stroke: 484.9 mm (19.10 in) – 8. Auxiliary steering motor and pump (option - north american models) -
Displacement: 11 cc/rev (0.671 cu in./rev) – 9. Auxiliary steering VLC priority valve (option - north american models) relief pressure: 240.3 bar (3485 psi) – 10. Auxiliary steering pressure switch - 2.4 bar (34.8 psi) closing setpoint – 11. Brake declutch pressure switch - Opens at 24 3.5
± bar (348 ± 50.8 psi) – 12. Brake accumulators (2) - Precharge: 55 +2 -1 bar (826.7 + 30 15 psi) - Capacity: 3.5 litre (214 cu in.) – 13. Brake valve and accumulator charging valve - Cut-in: 157 +10 bar (2277 + 145 psi) - Cut-out: 193 ± 3 bar (2799 ± 43 psi) – 14. Brake warning pressure switch -
128 bar (1856 psi) rising - 103 bar (1494 psi) falling – 15. Brake light pressure switch - 4.1 bar (59.5 psi) – 16. Not used – 17. Rear brake cylinders - Modulation pressure: 79.5 bar (1153 1 psi) ± 3.5 ± 5 – 18. Front brake cylinders - Modulation pressure: 79.5 ± 3.5 bar (1153 ± 51 psi) –
19. Parking brake cylinder – 20. Load sense shuttle valve – 21. Fan drive motor - Displacement: 23 cc/rev (1.40 cu in./rev) – 22. Fan reversing valve (option) - Relief setting: 98.3 bar (1426 psi) – 23. Fan relief valve (standard) - Relief setting: 98.3 bar (1426 psi) – 24. Brake hydraulic pump -
Displacement: 23 cc/rev (1.4 cu in./rev) – 25. Parking brake pressure switch – 26. Parking brake solenoid valve – 27. Hydraulic pump - Consists of steering pump and loader pump steering pump (front) (closest to transmission) - Displacement: 63 cc/rev (3.84 cu in./rev) - Cutoff: 280
bar (4061 psi) - Delta: 35 bar (507.6 psi) - Loader pump (rear) - Displacement: 45 cc/rev (2.75 cu in./rev) - Cutoff: 200 bar (2900 psi) - Delta: 22 bar (319 psi) – 28. Hydraulic filter assembly - Bypass valve: 3.4 bar (49.31 psi) - Warning switch: 2.7 bar (39.2 psi) – 29. Hydraulic reservoir
- Total volume: 192.8 litres (51 u.s. Gallons) - Oil capacity: 68.5 litres (18 u.s. Gallons) – 30. Hydraulic reservoir breather - 20 micron breather – 31. Hydraulic cooler (option) – 32. Pilot pressure accumulator - Precharge: 13.8 bar (200 psi) - Capacity: 0.75 litre (45.8 cu in.) – 33. Steering
vle priority valve - Relief pressure: 218 bar (3162 psi) – 34. Ride control disable switch - Closes at 24 ± 3.5 bar (348 ± 50.1 psi) – 35. Controller with two spool loader valve - Two lever or joystick controller – 35. Controller with three spool loader valve - Three lever or joystick with one
lever controller – 35. Controller with four spool loader valve - Joystick with two lever controller – 36. Loader control valve - Two spool (standard) - Three spool (option) - Four spool (option) – 37. Pilot supply cut-off valve – 38. (Option auxiliary steering load sense solenoid valve - North
american models) – 39. Parking brake accumulator - Precharge: 97 bar (1407 psi) - Capacity: 0.16 litre (9.8 cu in.) – 40. 100 mesh strainer (3) – 41. Diagnostic panel consists of: TP1 loader pressure - TP2 loader pump load sense pressure - TP3 steering pump load sense pressure -
TP4 not used - TP5 steering pump pressure - TP6 front brakes accumulator pressure - TP7 rear brakes accumulator pressure - TP8 not used - TP9 pilot pressure - TP10 front axle brake pressure - TP11 rear axle brake pressure - TP12 not used.
NOTES: 1. Check and relief valves not used with fan reverser – 2. TC Models - 183 bar (2654 psi) - Z-BAR Models - 290 bar (4206 psi) – 3.TC Models only.
SECTION 7
ELECTRICAL SYSTEM
INDEX
SAFETY RULES .................................................................................................. 7-1
7.1 GENERAL LAYOUT OF THE ELECTRICAL SYSTEM ......................................... 7-3
7.2 MAIN CONNECTORS ........................................................................................... 7-4
7.3 CAB MAIN COMPONENTS .................................................................................. 7-13

7.3.1 OPERATOR COMPARTMENT REAR PANEL ....................................................... 7-13
7.3.2 CAB FUSE BOARD DESCRIPTION ..................................................................... 7-14
7.3.3 CAB RELAY DESCRIPTION ................................................................................ 7-16
7.3.4 TRANSMISSION CONTROLLER ZF EST 37 ....................................................... 7-16
7.3.5 "BROWN BOX" CAN INTERFACE ........................................................................ 7-18
7.3.6 INSTRUMENT CLUSTER AND MONITOR ............................................................ 7-20
7.3.7 SWITCH PANEL ................................................................................................... 7-23
7.3.8 AUTOMATIC TRANSMISSION .............................................................................. 7-24
7.3.9 CONTROLS .......................................................................................................... 7-25
7.4 MACHINE COMPONENTS ................................................................................... 7-28

7.4.1 ENGINE COMPARTMENT FUSES AND RELAY BOXES ..................................... 7-28
7.4.2 FRONT CHASSIS RELAY BOX ............................................................................ 7-29
7.4.3 EMERGENCY STEERING ................................................................................... 7-30
7.4.4 RIDE CONTROL SYSTEM (LTS) .......................................................................... 7-31
7.4.5 TRANSMISSION COMPONENTS ........................................................................ 7-32
7.4.6 BRAKE SYSTEM COMPONENTS ....................................................................... 7-34
7.4.7 HYDRAULIC SYSTEM COMPONENTS ............................................................... 7-35
7.4.8 ENGINE COMPONENTS ..................................................................................... 7-36
7.5 FUNCTIONS OF DIGITAL DISPLAY ..................................................................... 7-37

7.5.1 DESCRIPTION OF HOME PAGE (DEFAULT PAGE) ............................................ 7-37
7.5.2 PARKING BRAKE EFFICIENCY TEST ................................................................. 7-38
7.5.3 EMERGENCY STEERING SYSTEM EFFICIENCY TEST .................................... 7-41
7.5.4 CALIBRATION OF TRANSMISSION GEARSHIFTS ............................................. 7-44
7.5.5 DISPLAY OF TRANSMISSION FAULT CODES .................................................... 7-47
7.5.6 INITIAL SET-UP OF THE "BROWN BOX" CONTROLLER .................................... 7-49
7.5.7 READING OF THE ENGINE OPERATION PARAMETERS ................................... 7-52
7.5.8 READING OF THE TRANSMISSION OPERATION PARAMETERS ...................... 7-53
7.5.9 READING OF THE BRAKE SYSTEM OPERATION PARAMETERS .................... 7-54
7.5.10 READING OF THE ELECTRICAL SYSTEM OPERATION PARAMETERS ........... 7-55
7.6 ELECTRICAL SYSTEM FOLDING DIAGRAMS ................................................... 7-57

W170/W170TC ELECTRICAL SYSTEM 7-1
SAFETY RULES
WARNING
When working on the electrical system always
wear protective gloves and remove rings, wrist
watches and any other metallic jewel.
W110R0337
DISCONNECT
WARNING
Prior to proceeding with inspection or repair in- A C
terventions of electrical components DISCON- B
NECT GROUND CABLE "A" from negative termi-
nal "B" of the battery. DISCONNECT THE CABLE
from positive terminal "D".
BATTERY 12 Volt x 2
GROUND W110R0338
WARNING
NEVER REST METALLIC ITEMS on the battery
to prevent the danger of short circuits.
W110R0339
WARNING
BATTERY GASES ARE FLAMMABLE.
Never place open flames or generate sparks near batteries. During the recharging, the emission of
gases is higher.
WARNING
BATTERY GASES ARE DANGEROUS if in contact with the skin or materials.
7-2 ELECTRICAL SYSTEM W170/W170TC
NOTES:
7.1 GENERAL LAYOUT OF THE ELECTRICAL SYSTEM
A 1
2
Left side
W170-7R013
Left side
A. Cab/Machine lh connector group - 1. Cab wiring harness - 2. Transmission wiring harness - 3. Engine wiring harness.
1 B
4 5
Right side
W170-7R014
Right side
B. Cab/Machine rh connector group - 1. Cab wiring harness - 4. Rear frame wiring harness - 5. Front frame wiring harness.
7.2 MAIN CONNECTORS
Left side
Left side
1. Connector X21 (Transmission
harness) - 2. Connector A (En-
W170-7R015
gine harness). W170-7R017
5
Right side
3. Connector X20 (Front frame
6 harness) - 4. Connector X22
(Rear frame harness) - 5. Con-
nector X23 (Rear frame har-
W170-7R016
ness). W170-7R018
Engine compartment
Right side:
1. Connector XD (Rear frame harness) - 2. Connector F
(Engine controller harness).
2 2
1
W170-7R019
W170-7R020
CONNECTOR X21 DETAIL

(Transmission harness)
23 pins
Left side
W170-7R021
W170-7R071
CONNECTOR X21
WIRE NUMBER WIRE NUMBER
CAVITY USER
(Cab side) (Machine side)
A Proportional solenoid Y1 ZF56 430
B Proportional solenoid Y2 ZF10 434
C Proportional solenoid Y3 ZF32 438
D Proportional solenoid Y4 ZF55 442
E Proportional solenoid Y5 ZF9 446
F Proportional solenoid Y6 ZF51 450
G Common power supply to prop. solen. ZF12 454
J Valve oil temp. sensor power supply ZF39 458
K Conv. oil temp sensor power supply ZF49 574
L Valve oil temp. sensor return ZF46 462
M Engine speed sensor signal ZF19 GE2
N Engine speed sensor return ZF3 BL2
O Turbine speed sensor signal ZF41 GN3
P Turbine speed sensor return ZF3A SW3
Q Intermediate speed sensor signal ZF42 RT4
R Intermediate speed sensor return ZF3B BL4
S Output speed sensor ground ZF4 500
T Output speed sensor signal ZF62 504
U Output speed sensor power supply ZF45_A 508
V Oil filter pressure switch power supp. ZF17 480
W Oil filter pressure switch return ZF46B 484
X Conv. oil temp sensor return ZF46A 570
CONNECTOR A DETAIL
(Engine harness)
31 pins
Left side
W170-7R022
W170-7R072
CONNECTOR A
CAVITY CIRCUIT
1 Empty - -
2 Empty - -
3 Empty - -
4 Empty - -
5 Accelerator idle validation switch signal EDC72 EDC72
6 Diagnostic panel enabling signal EDC60 EDC60
7 Accelerator idle validation switch negative EDC19 EDC19
8 Accelerator pedal position sensor negative EDC81 EDC81
9 Accelerator pedal position sensor signal EDC83 EDC83
10 Accelerator pedal position sensor positive EDC55 EDC55
11 EDC lamp positive EDC28 EDC28
12 Bridge provision EDC43 EDC43
13 EDC lamp negative EDC64 EDC64
14 Low oil pressure warning light control relay (86) EDC08 EDC08
15 Empty - -
16 Empty - -
17 Empty - -
18 Empty - -
19 Positive from EDC diagnostic switch EDC27 EDC28
20 Empty - -
21 Diagnostic connector provision EDC49 EDC50
22 Empty - -
23 Low oil pressure warning light control relay (87) EDC23 EDC24
24 Empty - -
25 Heater indicator light negative EDC46 EDC46
26 Not used EDC59 EDC59
27 Empty - -
28 Empty - -
29 Water in fuel signal 836 836
30 Ground EDC19 EDC19
31 K31 diagnostic plug connector EDC31 EDC31

(Front chassis harness)
31 pins
Right side
W170-7R023
W170-7R073
CONNECTOR X20
CAVITY USER
1 LTS relay power 169_FB 169_D
2 Not connected 553_B 553_D
3 Brake low pressure signal 613_A 613_B
4 Horn pedal signal 116 116_E
5 Horn signal 138 138_E
6 Turning light power (front-right) 103 103_E
7 Turning light power (front-left) 109 109_E
8 TUV light power 124 (OPT)
9 TUV light power 126 (OPT)
10 Position light power (front-right) 330_FA 330_E
11 Position light power (front-left) 339_FA 339_E
12 Fused power 835 835_D
13 Fused power 895_M 895_L
14 Low beam light power (front-left) 231_A 231_E
15 Low beam light power (front-right) 223_A 223_E
16 Hi-beam light power (front-left) 219_A 219_E
17 Hi-beam light power (front-right) 221_A 221_E
18 Parking brake solenoid power supply 945_A 945_E
19 Clutch cut-off press. switch power 975 975_E
20 Clutch cut-off press. switch signal ZF66 974_E
21 Boom proximity switch power supply 995_F 995_G
22 Boom proximity switch signal 980_C 980_H
23 Bucket proximity switch power supply 994_H 994_G
24 Bucket proximity switch signal 981_E 981_H
25 LTS solenoid power supply 952_B 952_D
26 Pilot cut-off solenoid power supply 859_B 859_A
27 LTS switch signal 956_B 956_D
28 LTS switch power supply ZF5 954_D
29 Boom proximity switch return 994_L 994_M
31 Emergency steering pressure switch 844 844_D

(Rear chassis harness 1)
21 pins
Right side
W170-7R024
W170-7R074
CONNECTOR X22
CAVITY USER
A Parking brake switch ground N_RCC
C Parking brake press. switch signal 996_A 996_B
F Tail light (rear - right) 331_FA 331
H Tail light (rear - left) 332_FA 332_L
J Turning light (rear-left) 120 120_E
K Turning light (rear-right) 125 125_E
L Starting relay 802_RA 802_T
M Back-up alarm relay (coil ground) ZF7 556
N Back-up alarm relay (coil power) ZF45_FB 558
P Fan drive inverter solenoid power 876_B 876_C
R From ignition key ("M" position) 895_F 895_E
S From ignition key ("ACC" position) 801_F 801_T
U Coolant hi-temp sender signal 552 552_B
W Coolant temp sensor signal 528 528_B
X Engine oil low pressure signal 503 503_B
7 - 10 ELECTRICAL SYSTEM W170/W170TC

(Rear chassis harness 2)
18 pins
Right side
W170-7R025
W170-7R075
CONNECTOR X23
CAVITY USER
1 B+ power from batteries R_B 772_A
2 Grid heater signal 965_D 965_B
3 Coolant temperature sender signal 827_C 827_T
6 Ground N_RCG N_CHA
7 Ground N_RCH N_CHB
8 Rear working light power supply 225_E 225_D
10 Alternator signal 637 637_A
11 Alternator "W" --- 552_A
12 Air cleaner pressure switch 663 663_B
13 Fuel level sensor signal 557 557_B
15 Coolant temperature switch signal 824_C 824_A
16 Rear washer power supply 886_F 886_RR
17 Front washer power supply 885_F 885_RF
W170/W170TC ELECTRICAL SYSTEM 7 - 11
CONNECTOR F DETAIL
(Engine harness - rear frame harness link)
21 pins
Rear frame
W170-7R026
W170-7R076
CONNECTOR F
CAVITY CIRCUIT
(EDC7 side) (Machine side)
A Empty - -
B Fuel filter heater resistor power supply 309 309
C Empty - -
D EDC7 power supply from fuse LF5 (direct) 774 774
E EDC7 power supply from fuse LF5 (direct) 774 774
F Empty - -
G Empty - -
H Oil low pressure warning light ground 000 000
J Water in fuel sensor power supply 808 808
K Positive fron EDC7 to starting relay 888 888
L Start signal through neutral safety relay 802 802
M Positive to fuel pre-heater relay coil EDC36 EDC36
N Negative to fuel pre-heater relay coil EDC02 EDC02
P Positive from ignition key switch EDC39 EDC39
R Oil low pressure warning light control relay ground EDC08 EDC08
S Oil low pressure warning light control relay pos. EDC16 EDC16
T Grid heater relay negative EDC04 EDC04
U Empty - -
V Oil low pressure warning light control relay ground EDC63 EDC63
W Oil low pressure signal from Brown Box EDC23 EDC23
X Empty - -
CONNECTOR XD DETAIL
(Various connections rear frame cable)
18 pins
Right side
W170-7R027
W170-7R077
CONNECTOR XD
CAVITY CIRCUIT
1 B+ from battery R_B 772_A
2 Empty - -
3 Engine coolant transmitter signal 827_C 827_T
4 Empty - -
5 Empty - -
6 Ground N_RCG N_CHA
7 Ground N_RCH N_CHB
8 Rear working light power supply 225_E 225_D
9 Empty - -
10 Alternator "L" signal to Brown Box 637 637_A
11 "W" alternator --- 552_A
12 Clogging air filter pressure switch signal 663 663_B
13 Fuel level sensor signal 557 557_B
14 Empty - -
15 A/C clutch solenoid power supply 824_C 824_A
16 Rear washer power supply 886_F 886_RR
17 Front washer power supply 885_F 885_RF
18 Empty - -
7.3 CAB MAIN COMPONENTS
7.3.1 OPERATOR COMPARTMENT REAR PANEL
1 2
W170-7R028 W170-7R029
1. Transmission controller ZF EST37 - 2. CAN interface “Brown Box” - 3. Diagnostic plugs - 4. Accessory relay 90 A -
5. Flasher unit - 6. 7.5 A Relay board - 7. “F” Fuses board.
7.3.2 OPERATOR COMPARTMENT

REAR PANEL
F1 F2
A B C A B C
X1
F3 F4
A B C A B C
F5 F6
X2
A B C A B C
F7 F8
A B C A B C
X3
F9 F10
A B C A B C
F11 F12
X4
A B C A B C
X5 ACC +B
W170-7R030
Pos. Amp Circuit under protection Connect.

A 7.5 Dome light X4
F1 B 7.5 Hazard light X4
C 7.5 Hi-beam, low beam and turning light switch X1
A 7.5 Rotating beacon X1
F2 B 7.5 Not connected X1
C 7.5 Front wiper motor X1
A 15 Air conditioner unit X5
F3 B 5 General lighting switch X1
C 5 Bucket detent solenoid / boom and bucket proximity switch/ float solenoid X1
A 5 Flasher unit X1
F4 B 7.5 Power reducer 24V-12V X1
C 7.5 Seat heater X1
A 15 +ACC engine compartment relay box X5
F5 B 10 Rear working light X1
C 10 Front working light X1
A 7.5 Air conditioner control unit X1
F6 B 5 Rear wiper motor X1
C 5 LTS solenoid valve X1
A 15 Engine stop solenoid / Fuse EF2 + EF5 (engine comp. fuse box) X5
Front lh and rear rh position light / licence plate light / lh overall light/ dasboard
F7 B 3
backlight / cigarette lighter backlight X3
C 3 Front rh and rear lh position light / rh overall light X3
A 5 Seat air compressor X2
B 5 Parking brake solenoid X2
F8 Back-up alarm relay / +24V output speed sensor / aut-man selector switch, clutch
C 7.5 cut-off and FNR aux switch / Transmission controller switched power / display plug X2
power / transmission shifter / Parking brake relay
A 3 Not connected X2
F9 B 3 Not connected X3
C 7.5 Alarm buzzer / dashboard / digital monitor X2
A 7.5 Cigarette lighter X4
F10 B 7.5 B+ transmission controller ZF EST 37 X4
C 10 Hi-beam relay X4
A 7.5 Horn relay X4
F11 B 20 Ignition key switch X5
C 3 Transmission diagnostic plug X4
A 3 +30 Brown box X3
F12 B 7.5 B+ general lighting switch X4
C 10 Low-beam relay X4
7.3.3 CAB RELAY DESCRIPTION 7.3.4 TRANSMISSION CONTROLLER

ZF EST 37
W170-7R031 W170-7R033
Components
K1. Hi -beam relay - K2. LTS Relay (Speed = 0 km/h) -

K3. Flasher unit - K4. Low beam relay - K5. Neutral start-
ing safety relay - K6. Horn relay (controlled by hand switch
on the shifter) - K7. Horn relay (controlled by foot switch
on cab floor) - K8. Parking brake relay - SERV. Accessory
main relay 90 A.
K3
K1 K2 SERV
X C
K 4 K 5 K 6 K 7 K 8 X25A
X33 X34 X25_2 X D

X25_1
B+ Cab
W170-7R032 W170-7R034
Connections
X33. Relay K1, K2, K4, K5 - X34. Relay K6, K7, K8; Acces-
sory relay coil; Flasher unit K3 - XC. Accessory relay 90 A
input power (+30) - XD. Delivery from batteries to +30
accessory relay 90 A - X25_A. Output connection (G) ac-
cessory relay 90 A (to ACC connection cab fuse board) -
X25_1. Power supply from batteries (from engine com-
partment B+ box) - X25_2. Delivery from batteries to +B
connection on cab fuse board.
CONNECTOR X19
CAVITY CONTROLLER FUNCTION NOTES
1 Ground
2 Ground
3 Ground (inductive speed sensors)
4 Ground (output speed sensor)
5 LTS signal
7 Back-up alarm relay coil ground
9 Proportional solenoid Y5 negative signal
12 +24 V (common) to proportional solenoids
13 +24 V (common) to proportional solenoids
14 External display plug signal
15 Diagnostic plug signal
16 Diagnostic plug signal
17 Oil filter differential pressure switch signal
19 Engine speed sensor signal
20 Forward signal from aux FNR
21 Parking brake relay signal
22 Kick down signal
23 Unswitched power from batteries under fuse F10B
25 Can Bus (H)
26 Can Bus (L)
27 Can Bus (L)
29 AUT / MAN selector switch signal
30 Aux FNR enabling signal
31 Reverse signal from aux FNR
39 Valve oil temperature sensor signal
41 Converter turbine speed sensor signal
42 Intermadiate gear speed sensor signal
43 Forward signal from shifter
44 Neutral signal from aux FNR
45 Switched power (ignition key pos. "ON") under fuse F8C
46 Valve oil temperature sensor return
49 Torque converter oil temperature sensor signal
62 Output speed sensor signal
63 1st and 4th gear signal from shifter
64 Reverse signal from shifter
65 3rd and 4th gear signal from shifter
66 Transmission cut-off signal from press. Switch
67 Neutral signal from shifter
68 Unswitched power from batteries under fuse F10B
W170-7R070
7.3.5 “BROWN BOX” CAN INTERFACE
CN2 CN1
Detail "A"
W170-7R035
CAN_ SPL
CAN_SPL joint
XA. CAN line from ZF EST 37

X72 XA - X72. CAN line from Brown
Detail "B"
Box.
W170-7R036
BROWN BOX – CONNECTION CN1 (INPUT)

CAVITY CONTROLLER FUNCTION
2 Can Bus (H) - to CAN_SPL joint - connection X72 pin B
3 Brake accumulators low pressure signal (from pressure switch)
4 Can Bus (L) - to CAN_SPL joint - connection X72 pin A
5 Alternator "L" signal
9 Coolant temperature switch signal
11 Air cleaner pressure switch signal
14 Ground
15 Unswitched power from batteries (under fuse F9C)
16 Variable coolant temperature sensor signal
17 Steering low pressure signal
19 Steering high pressure signal
21 Engine oil low pressure signal
22 Fuel level sensor signal
23 LTS enabled signal
25 Transmission cut-off selected signal
28 Ground
29 Switched power (ignition key pos. "ON" - under fuse F12A)
42 Ground
BROWN BOX – CONNECTOR CN2 (OUTPUT)

CAVITY CONTROLLER FUNCTION
1 Battery charge indicator light signal
3 Emergency steering warning light signal
5 General warning buzzer signal
9 Clogged air cleaner warning light signal
10 Low engine oil pressure warning light signal
11 Transmission oil temperature warning light signal
12 Transmission oil temperature gauge signal
13 Fuel level warning light signal
16 Coolant temperature warning light signal
17 Brake oil low pressure warning light signal
18 1st gear indicator light signal
19 2nd gear indicator light signal
20 3rd gear indicator light signal
21 4th gear indicator light signal
22 Fuel level gauge signal
23 Coolant temperature gauge signal
24 Vehicle speed signal
26 Emergency steering relay coil ground
27 Digital monitor
30 Digital monitor
31 Digital monitor
32 Digital monitor
33 Digital monitor
34 Digital monitor
35 Serial interface shield (external link)
36 Serial interface RX_B (receiving data) - (external link)
37 Serial interface RX_V (receiving data) - (external link)
38 Serial interface TX_R (sending data) - (external link)
39 Serial interface TX_G (sending data) - (external link)
40 Serial interface power supply 12 V (external link)
42 serial interface ground (external link)
7.3.6 INSTRUMENT CLUSTER AND MONITOR
6 2 16 4 11
7
12
8
13
9
14
10
15
3 1 3
W170-7R102
Instrument cluster
1. Speedmeter - 2. Coolant temperature gauge - 3. Fuel level gauge - 4. Transmission oil temperature gauge - 5. Hourmeter -
6. Coolant temperature warning light - 7. Low engine oil pressure warning light - 8. Battery charge warning light -
9. Clogged air cleaner warning light - 10. Fuel level warning light - 11. Transmission oil temperature warning
light - 12. Brake oil low pressure warning light - 13. Emergency steering warning light - 14. Parking brake
indicator light - 15. General warning light (+ buzzer) - 16. Engaged gear indicator lights.
CN2
CN3 CN1
W170-7R038
Connector CN1
1. Brake oil low pressure warning light - 2. Coolant temperature warning light - 3. Coolant temperature gauge - 4. Dash-
board backlight - 5. Left turning light - 6. Dashboard backlight - 7. Hi - beam indicator light - 8. Dashboard backlight - 9.
Ground - 10. Fuel level gauge - 11. Parking brake indicator light - 12. Battery charge warning light - 13. Fuel level warning
light - 14. Not connected - 15. Dashboard backlight - 16. Right turning light - 17. Speedmeter - 18. Buzzer - 19. General
warning light - 20. Dashboard backlight.
Connector CN2
21. Transmission oil temperature gauge - 22. Clogged air cleaner warning light - 23. Emergency steering warning light -
24. Batteries - 25. Low engine oil pressure warning light - 26. Coolant temperature warning light.
Connector CN3
27. Hourmeter (ground) - 28. Hourmeter (power).
On-board instrumentation
2 3 4 5
6 7 8
9 10 11
W170-7R069
Digital monitor
1. Multi-function digital display - 2. Button P0 (Set-up) - 3.

Button P1 (Home/Service) - 4. Button P2 (Selection/Entry)
- 5. Button p3 (Menu).
Switch panel
6. Rotary beacon switch (optional) - 7. Rear washer switch

- 8. Rear wiper switch - 9. Rear work lights switch - 10.
Front work lights switch - 11. Main light switch.
7.3.7 SWITCH PANEL
2 3 4 5 6
11
1
8 10 9
W170-7R101
Right side console
1. Starter switch - 2. Cigarette lighter - 3. LTS control switch - 4. Switch, transmission cut-off selection - 5. Switch, transmis-
sion aut/man selection - 6. Switch, boom kick-out engagement - 7. Indicator light, engine pre-post heater - 8. Switch, fan
rotation reverser - 9. Auxiliary reversing switch consent button (optional) - 10. Inhibiting valves cut-off switch (optional) - 11.
Water presence in the fuel filter indicator light.
7.3.8 AUTOMATIC TRANSMISSION

Gearshift selector (ZF DW3)
X7
X6
W110R0035
X6 – Transmission pilot valve
A. Not connected - B. Signal 3 rd and 4 th speed -

C. Signal 1st and 4th speed - D. Horn.
X7 – Transmission pilot valve
A. Pilot valve power - B. Forward speed signal -

C. Reverse signal - D. Signal in neutral position.
Transmission gearshift pilot valve
BLACK
GREEN
To controller EST 37 – Signal 3rd and 4th gear
BLUE
To controller EST 37 – Signal 1st and 4th gear
VIOLET
To horn relay (K6)
RED
Power
YELLOW
To controller EST 37 – Signal forward gear
PINK
To controller EST 37 – Signal reverse
GREY
To controller EST 37 – Signal in neutral
W110R0340
7.3.9 CONTROLS To select the auxiliary FNR function:

Auxiliary FNR control • Start the engine.
(Hydraulic manipulator joystick version) • Disengage the parking brake.
• Keep the gear selector in neutral position.
• Press the push buttons 3 (N).
• Press the push button 2 (KD) and, simoltaneously,
1 3 move the sliding switch 1 to F or R.
ed
t us
No The machine will start move in the selected direction.
To invert the direction, move the sliding switch 1. The
function will be disabled by pressing the push button
F R
3 (N), or by using again the gear selector on the steer-
ing column. To enable the function again, repeat the
2 above procedure.
d
se
tu
No
W170-7R039
Note – At machine stop, turning the ignition key in
1. Sliding switch forward (F) - reverse (R) - 2. Kick-down “off” position, the priority is given back to the gear
push button - 3. Neutral push button. selector on the steering column at the next starting.
BROWN
GREY
WHITE
YELLOW
BLUE
GREEN
X11 W170-7R040
CONNECTOR X11
CAVITY DESCRIPTION WIRE NUMBER
1 Forward signal ZF20
2 Neutral signal ZF44
3 Reverse signal ZF31
4 Power supply (from fuse F8C - key "on") ZF45
5 Kick Down signal ZF22
6 Control enabling signal ZF30
Auxiliary FNR control

(2/3 levers on hydraulic manipulator)
3 1
W170-7R041
2
1. Auxiliary FNR control switch - 2. Auxiliary FNR function

enabling push button - 3. Kick down push button. W170-7R042
To select the auxiliary FNR

KICK-DOWN PUSH BUTTON function:
• Start the engine.
• Disengage the parking brake.
• Keep the gear selector in neutral.
KICK-DOWN signal
• Press once the push button 2 (Aux
FNR function enabling).
Joystick version
provision
• Select the travel direction by acting
on the rocket switch 1(Aux FNR
control).
The machine will start to move in the
FNR control switch
selected direction. To invert the travel
Reverse signal direction, activate the rocket switch 1.
The function will be disabled by using
Neutral signal
Forward signal again the gear selector on the steer-
ing column. To select the function
again, repeat the above procedure.
AUX FNR enabling (Ground bridge with centr. lube switch)

(Ground bridge with centr. lube switch)
(Ground bridge with seat. heat switch)
(Ground bridge with seat. lube switch)
Enabling and control signal
+24V from fuse F8C

W170-7R043
Parking brake
ON OFF
CAB GROUND – CONN. GND FCAB
FROM FUSE F8B (Key “ON”)
FROM FUSE F3B (Key “ACC”)
PARKING
BRAKE
SWITCH Ground bridge with
general lighting switch
PARKING
CHASSIS GROUND – CONN. GND
BRAKE
SOLENOID
W170-7R044
7.4 MACHINE COMPONENTS
7.4.1 ENGINE COMPARTMENT FUSES AND RELAY BOXES
Rear view
4 3 11
1
13
12
10 9 8 7 6 5
A) Engine box
W170-7R045
16 17
15
A
18 19
14
B) Cold staring box

W110R0041
W170-7R047
W170-7R046
A) ENGINE BOX
Relays
1. Staring relay - 2. Air cond. Compressor clutch relay (optional - NOT SHOWN) - 3. Reverse alarm relay - 4. Diode module.
Fuses - Group ‘‘E’’
5. Fuse EF1 (4 A) - Stop lights - 6. Fuse EF2 (4 A) - Fuel filter pre-heater - 7. Fuse EF3 (7.5 A) - +30 reverse alarm relay - 8. Fuse
EF4 (4 A) - Not connected (spare) - 9. Fuse EF5 (4 A) - 15 Alternator - 10. Fuse EF6 (7.5 A) - EDC 7 controller switched power.
Other components
11. Fuse “Link” 50 A - 12. “B+” stud (engine box supply from battery - conn- TB6) - 13. “B+” stud (+24V distribution
to cab fuse board and accessory main relay 90 A).
B) COLD STARTING BOX

14. Grid heater relay - 15. Fuse “Mega” 150 A - 16. Low engine oil pressure warning light control relay - 17. Fuel filter pre-
heater relay - 18. Fuse LF5 20 A (EDC7 engine controller unswitched power) - 19. Fuse LF2 20 A (+30 grid heater relay).
7.4.2 FRONT CHASSIS RELAY BOX
1
2
W170-7R050
W170-7R048
W170-7R049
LEGEND
Relays
1. LTS relay (speed >7 km/h in forward and >5 km/h in reverse - 2. Emergency steering pump motor start relay.
Connectors
3. Connector LTSF.
7.4.3 EMERGENCY STEERING 7 - 30
1
5
CN2 CN1
BP Signal
GROUND
2 RELAY COIL AP Signal
ELECTRICAL SYSTEM
Legend
1. Emergency steering pump motor - 2. Steering pressure switch
(switching pressure: 2.4 bar) - 3. Steering LS excluding solenoid
valve - 4. Emergency steering pump motor start relay - 5. “Brown
KEY "ON" Box” CAN controller.
W170-7R051
W170/W170TC
7.4.4 RIDE CONTROL SYSTEM (LTS)
2 1st STEP 2nd STEP 4
= 0 Km/h
5 >7 Km/h 3
6
>7 Km/h Signal LTS ON on

digital monitor
W170-7R052
Legend
1. LTS control swith (3 positions) - 2. LTS relay (front chassis speed > 7 km/h) - 3. LTS solenoid valve - 4. LTS relay (K2 into
the cab - speed = 0 km/h) - 5. Transmission controller ZF EST37 - 6. Brown box CAN interface.
7.4.5 TRANSMISSION COMPONENTS
1 2 3
W170-7R055 4
3
2
W170-7R056
W170-7R054
Legend
1. Engine speed sensor - 2. Intermediate gear speed sen-
sor - 3. Converter turbine speed sensor - 4. Output speed
sensor (Vehicle speed) - 5. Transmission oil filter differen-
5 tial pressure switch.
Notes – Sensors 1, 2, 3 are the same and interchange-

able to each other. They are inductive speed sensor,
in which the output signal is given by a variable volt-
4 age depending on the detected speed. The sensor 4
is “Hall effect” type, that means that the output signal
is given by a constant voltage and a variable frquency.
W170-7R053
W170-7R057 W170-7R059
Legend
1. Connector X12 (link between transmission harness and
control valve harness) - 2. Proportional solenoid valves
Y1, Y2, Y3, Y4, Y5, Y6 - 3. Control valve oil temperature
sensor - 4. Converter output oil temperature sensor.
W170-7R058
7.4.6 BRAKE SYSTEM COMPONENTS
3
1
W170-7R060
Legend
1. Accumulators oil low pressure switch (Nor-
mally closed - open at 115 +/-5 bar) - 2.
Transmission cut-off pressure switch (Nor-
mally open - closed at 25 +/-1 bar) - 3. Stop
light pressure switch (Normally open -
closed at 1.8 +/-0.5 bar) - 4. Parking brake
solenoid valve (Off = brake engaged / On =
brake released) - 5. Parking brake pressure
switch (Normally closed - open at 82 +/- 2
bar).
W170-7R061
7.4.7 HYDRAULIC SYSTEM COMPONENTS
W170-7R062
Legend
1. LTS anticavitation solenoid valve (Pow-
ered in parallel with the LTS block sole-
noid valve) - 2. Fan drive motor inverter
solenoid valve (Powerd by a push-button
in the cab).
W170-7R063
7.4.8 ENGINE COMPONENTS
2
5
3 4
W170-7R064 W170-7R065
7
8
W170-7R066 W170-7R067
Legend
1. Alternator - 2. Alternator B+ stud (battery charge) - 3. Alternator “ALT” connector - 4. Starter motor - 5. Starter motor “CMS”
connector - 6. Starter motor “B+” studs (power from battery) - 7. EDC7 engine controller (for details see chapter 3) - 8. Air
filter clogging pressure switch (normally open - closed at 62 mbar).
7.5 FUNCTIONS OF DIGITAL DISPLAY

(Display of output signals from Brown Box)
7.5.1 DESCRIPTION OF HOME PAGE

(Default page)
After the initial check subsequent to the switching-on
of the machine, the digital monitor in the cab shows
the initial default page shown on the right.
1 2
1. Current date
It is set-up by entering the menu “SET” through
button 10.
2. Current hour
It is set-up by entering the menu “SET” through 3 6
button 10.
3. LTS indicator engaged
It is shown when the system is activated by the 4 7
operator through the appropriate switch.
4. Transmission cut-off engaged indicator
It shows when the function is selected by the op-
erator through the appropriate switch.
5. Transmission use mode indicator (aut./man.) 5 8
It shows when the automatic mode is selected by
the appropriate switch.
6. Parameter visible on the initial page
In the setting-up at 1 parameter the engine rpm is
always shown. 9
7. Value of the parameter shown
8. Unit of measure of the parameter shown 10 11 12
W110R0061
9. Button P0 (machine configuration)
To be used simultaneously with button 11 to per-
form the initial set-up of the machine.
10. Button P1 entering the “SERVICE” menu
To be used to perform the efficiency tests on the
parking brake and emergency steering and the
calibration of the clutch packs of the transmis-
sion.
11. Button P2 entering the “SET” menu
Used individually to enter the setting utilities proper
to the monitor.
12. Button P3 entering the “MACHINE” menu
It provides the entry to the under menus readings
for the parameters relative to engine, transmis-
sion, brake system and electrical system.
7.5.2 PARKING BRAKE EFFICIENCY TEST 7 - 38
Test conditions: ENGINE IN OPERATION, PARKING BRAKE ENGAGED, 3RD GEAR FORWARD OR REVERSE ENGAGED, TRANSMISSION IN
MANUAL MODE, TRANSMISSION CUT-OFF DISENGAGED.
ELECTRICAL SYSTEM
W110R0062
1. From the initial page enter the 2. The “SERVICE PAGE” is normally 3. Confirm the selection through but-
“SERVICE” menu through button set on “CLUTCH CALIBRATION” ton P3.
P1. (clutch calibration). Select “TEST”
W170/W170TC
through button P2.

Test conditions: ENGINE IN OPERATION, PARKING BRAKE ENGAGED, 3RD GEAR FORWARD OR REVERSE ENGAGED, TRANSMISSION IN
W170/W170TC
ELECTRICAL SYSTEM
W110R0063
4. The display “TEST” is already set 5. The system asks the operator to 6. The test is started. The system per-
on “PARKING BRAKE TEST”. If confirm the start of the test. Con- forms automatically an engage-
not, select the option by using the firm through button P3. ment and disengagement manoeu-
central button, then confirm the vre of the parking brake, deacti-
selection through button P3. vating, when the brake is en-
gaged, the transmission cut-off.
During the test, verify that the
machine does not move. Wait for
7 - 39
the complete execution of the test.

Test conditions: ENGINE IN OPERATION, PARKING BRAKE ENGAGED, 3RD GEAR FORWARD OR REVERSE ENGAGED, TRANSMISSION IN 7 - 40
ELECTRICAL SYSTEM
W110R0064
7. Once the test is completed, the 8. The display positions itself auto- 9. The monitor is positioned again on
operator is warned by the display matically in the tests selection the home page.
W170/W170TC
indicated in the figure. mode. Press button P1 to exit.

7.5.3 EMERGENCY STEERING SYSTEM EFFICIENCY TEST
Test conditions: ENGINE INOPERATIVE AND STARTER SWITCH IN POSITION ON (2ND STEP)
W170/W170TC
ELECTRICAL SYSTEM
W110R0065
1. From the home page enter the 2. The “SERVICE PAGE” is normally 3. Confirm the selection through but-
menu “SERVICE” through button set on “CLUTCH CALIBRATION”. ton p3.
7 - 41
P1. Select “TEST” through button P2.

7 - 42
ELECTRICAL SYSTEM
W110R0066
4. The display “TEST” is set on 5. The system asks the operator to 6. The test is started. the system ac-
“PARKING BRAKE SET”. Select confirm the start of the test. Con- tivates automatically for 20 sec.s
option “SEC. STEERING TEST” firm through button P3. the electric motor driving the emer-
through button P2, then confirm the gency steering pump. During this
selection through button P3. interval actuate the steering wheel
in the two directions to check that
the machine is operating the steer-
W170/W170TC
ing with engine inoperative.

W170/W170TC
ELECTRICAL SYSTEM
W110R0067
7. Once the test is completed, the 8. The display is automatically posi- 9. The monitor is positioned again on
operator is informed by the display tioned on test selection. Press the home page.
7 - 43
indicated in the figure. button P1 to exit.

7.5.4 CALIBRATION OF TRANSMISSION GEARSHIFTS 7 - 44
Test conditions: ENGINE IN OPERATION, PARKING BRAKE ENGAGED, GEARSHIFT IN NEUTRAL, TRANSMISSION IN MANUAL MODE,
TRANSMISSION CUT-OFF DISENGAGED, TRANSMISSION OIL TEMPERATURE AT 80 °C (176 °F), ENGINE SPEED AT LOW IDLE.
ELECTRICAL SYSTEM
W110R0068
1. From the home page enter the 2. The “SERVICE PAGE” is normally 3. The system ask for the confirma-
menu “SERVICE” through button set on “CLUTCH CALIBRATION”. tion to start the calibration. Con-
P1. Confirm the selection through but- firm through button P3.
W170/W170TC
ton P3.
Test conditions: ENGINE IN OPERATION, PARKING BRAKE ENGAGED, GEARSHIFT IN NEUTRAL,

TRANSMISSION IN MANUAL MODE, TRANSMISSION CUT-OFF DISENGAGED, TRANSMISSION OIL
TEMPERATURE AT 80 °C (176 °F), ENGINE SPEED AT LOW IDLE.
4. At this stage the system, after verifying that the

test conditions of the machine are complied with,
starts automatically the procedure on all the 6
clutch packs of the transmission in the following
sequence.
• K1 for the engagement of 1st speed;
• K2 for the engagement of 2nd speed;
• K3 for the engagement of 3rd speed;
• K4 for the engagement of 4th speed;
• KV for the engagement of forward direction;
• KR for the engagement of reverse direction.
For each engagement the calibration phases are moni-

tored on a horizontal filling bar located in the lower
side of the monitor.
The system moves forward automatically at the sub-
sequent engagement after finding the optimised modu-
lation on the current engagement.
If the system finds a trouble on a determined engage-
ment, the calibration is suspended and the monitor
indicates the clutch on which the procedure has been
interrupted.
On the other hand, if the system is able to calibrate
without any problem all 6 engagements, the message
W110R0069
“CALIBRATION COMPLETED” is shown. At this stage
it is necessary TO CUT-OFF THE ENGINE for about
10 seconds.
Thus, the procedure is completed.
Test conditions: ENGINE IN OPERATION, PARKING BRAKE ENGAGED, GEARSHIFT IN NEUTRAL,

TRANSMISSION IN MANUAL MODE, TRANSMISSION CUT-OFF DISENGAGED, TRANSMISSION OIL
TEMPERATURE AT 80 °C (176 °F), ENGINE SPEED AT LOW IDLE.
5. In the event even just one of the test conditions is

not complied with, the procedure does not start and
the system displays the reason for the failed start-
ing. Under these conditions, it is necessary to
exit the program through button P1 and to cut-
off the engine. Then, reinstate the test conditions
and restart the procedure.
In the example in the figure, the system warns the
operator that the oil temperature is too low (< 80 °C
– 176 °F).
Other fault messages could appear depending upon
which one of the conditions is not complied with:
• Oil temperature too high
(temperature oil too high)
• Engine speed too low
(engine speed too low)
• Engine speed too high
(engine speed too high)
• Output speed is not 0
(the machine is moving)
• Parking brake not engaged
(the parking brake is not engaged)
• Gearshift lever not in neutral
(the selector is not in neutral)
W110R0070
7.5.5 DISPLAY OF TRANSMISSION FAULT CODES

In the event, during the operation of the machine, the
transmission controller should monitor a malfunction,
the fault messages are transferred through line CAN
Bus from ZF EST37 controller to the Brown Box con-
troller, that transforms them into output digital signals
the monitor, that shows the numerical code corre-
sponding to the ZF coding (See list of fault codes in
the chapter “Transmission”).
If the machine stops (while the engine is still in opera-
tion) it means that the failure generated is such that
the transmission is set into “recovery” mode (Op mode:
Limp-Home). Under this condition it is necessary to
move the gearshift selector into neutral, then re-shift
into forward or reverse. The speed gearshifting is in-
hibited and the machine would travel, generally, in 2nd
gear only. Also the direction reversing is inhibited. To
reverse direction it is necessary to stop, then reverse
the travel direction.
In the event the malfunction is not particularly seri-
ous, the machine continues to perform normally (Op
Mode: NORMAL).
A medium level malfunction would result, when work-
ing in automatic mode, abnormal gearshifting, not cor-
responding to the load conditions of the machine (Op
Mode: SUBSTITUTION) although it maintains all the
gears available when working in manual mode.
A malfunction due to the transmission controller sets
W110R0071 the system under the condition where the machine
cannot move unless it is towed (Op Mode: TCU SHUT-
DOWN).
CODE DESCRIPTION OPERATING MODE

11 Logical error at direction range signal t/m shutdown
12 Logical error at direction signal t/m shutdown
15 Logical error at direction signal; auxiliary selector selector active
31 Short circuit or open circuit at engine speed input subs clutch ctrl
32 Short circuit to ground at engine speed input subs clutch ctrl
33 Logical error at engine speed input subs clutch ctrl
34 Short circuit or open circuit at turbine speed input subs clutch ctrl
35 Short circuit to ground at turbine speed input subs clutch ctrl
36 Logical error at turbine speed input subs clutch ctrl
37 Short circuit or open circuit at internal speed input subs clutch ctrl
38 Short circuit to ground at internal speed input subs clutch ctrl
39 Logical error at internal speed input subs clutch ctrl
3A Short circuit or open circuit at output speed input subs clutch ctrl
3B Short circuit to ground at output speed input subs clutch ctrl
3C Logical error at output speed input subs clutch ctrl
3E Logical error between speed input subs clutch ctrl
71 Short circuit to at clutch K1 limp home
72 Short circuit to ground at clutch K1 limp home
73 Open circuit at clutch K1 limp home
84 Short circuit to at clutch KV limp home
85 Short circuit to ground at clutch KV limp home
86 Open circuit at clutch KV limp home
87 Short circuit to at clutch KR limp home
88 Short circuit to ground at clutch KR limp home
89 Open circuit at clutch KR limp home
B1 Slippage at K1 limp home
B5 Slippage at KV limp home
B6 Slippage at KR limp home
D3 Low voltage at battery TCU shutdown
D4 High voltage at battery TCU shutdown
D5 Error at valve power supply VPS1 TCU shutdown
D6 Error at valve power supply VPS2 TCU shutdown
F3 Application error TCU shutdown
F5 Clutch failure TCU shutdown
F6 Execute AEB (Calibration clutch) NORMAL
7.5.6 INITIAL SET-UP OF THE “BROWN BOX” CONTROLLER
1. Prior to proceeding with the initial setting-up of the con-

troller, disconnect connection XA from the 3-way joint CAN-
SPL (cab rear panel) to cut-off the CAN bus line, then turn
the starter key onto “ON” (second step).
W110R0072
2. From the initial page, enter the menu SET-UP press- 3. Keep buttons P0 and P2 pressed until the monitor
ing buttons P0 and P2 simultaneously. displays the picture illustrated above (about 3
sec.s).
In the event the Brown Box controller is replaced, it is necessary to perform the setting-up procedure to provide
the controller with the following information:
MODEL ON WHICH THE CONTROLLER IS GOING TO BE INSTALLED
This information is required to choose the set of parameters to be used by the transmission controller (the ZF
controller contains 3 sets of parameters relative to models W110, W130 and W190).
CONFIGURATION OF HYDRAULIC CONTROLS
This information identifies whether the model is equipped with the 2/3 lever optional or the joystick control. This
identification is important, since the function of the hydraulic control type changes the operational logic of the
auxiliary direction control (FNR by a switch instead of the gearshift selector).
7 - 50
W170-7R068
ELECTRICAL SYSTEM
4. After a few seconds, selection 5. After the confirmation of the pre- 6. Select the type of hydraulic con-
page “Brand” is displayed, after ceding step, the model choice trol installed on the machine with
performing the procedure, during page is entered. Select the model button P2, then confirm the selec-
the initial check when the machine with button P2 (pressing n times tion with button P3. Warning: this
is turned ON. Select “FK” with but- until the desired model is dis- selection is important, since it
ton P2, then confirm with button played) then confirm the selection defines the operation logic of the
W170/W170TC
P3. with button P3. FNR auxiliary control.

STAR
ON T
C
W170/W170TC
AC
OFF
9. Cut-off the starter switch

ELECTRICAL SYSTEM
7. The setting up on the monitor is 8. The monitor returns to home page.

now over. Exit the program by se-
lecting “exit set-up” with button p2
and confirm the selection with but-
ton P3.
10. Reconnect line CAN rein-sert-
END OF PROCEDURE ing connector XA into joint
CAN_SPL.
7 - 51
W110R0074
7.5.7 READING OF THE ENGINE OPERATION PARAMETERS 7 - 52
W170-7R100
ELECTRICAL SYSTEM
1. From the home page, enter menu “MACHINE” 2. Select the under menu “ENGINE” with but- 3. The display shows in sequence:
through button P3. ton P2 to enter the reading of the operation
- Oil pressure: value of the engine oil relative
parameters of the engine, then confirm the
pressure (bar or psi)
selection with button P3.
- Boost press: value of boost relative pres-
sure (bar or psi)
- Engine speed: value of engine speed (rpm)
- Coolant temp: coolant temperature (°C or °F)
- Air inlet temp: air inlet temperature (°C or °F)
- Throttle: position of throttle (in percentage
0-100%)
To return to home page, press button P1
(HOME). To return to the previous menu, press
button P3 (MACHINE).
W170/W170TC
7.5.8 READING OF THE TRANSMISSION OPERATION PARAMETERS
W170/W170TC
W110R0076
ELECTRICAL SYSTEM
1. From the home page, enter menu 2. Select the under menu TRANS- 3. The display shows in sequence:
“MACHINE” through button P3. MISSION” with button P2 to enter
- Oil temperature
the reading of the operation param-
Value in °C
eters of the transmission, then
- Trasm, cut-off selection
confirm the selection with button
OFF or ON
P3.
- Automatic mode select.
OFF or ON
- Gear engaged
1, 2, 3 or 4
- Vehicle travel speed
Value in km/h
To return to home page, press button
P1 (HOME). To return to the previous
7 - 53
menu, press button P3 (MACHINE).

7.5.9 READING OF THE BRAKE SYSTEM OPERATION PARAMETERS 7 - 54
W110R0077
ELECTRICAL SYSTEM
1. From the home page, enter menu 2. Select the under menu BRAKES” 3. The display shows in sequence:
“MACHINE” through button P3. with button P2 to enter the read-
- State of parking brake
ing of the operation parameters of
OFF or ON
the transmission, then confirm the
- State of accumul. press.
OK or LOW
W170/W170TC
7.5.10 READING OF THE ELECTRICAL SYSTEM OPERATION PARAMETERS
W170/W170TC
W110R0078
ELECTRICAL SYSTEM
1. From the home page, enter menu 2. Select the under menu ELECTRIC” 3. The display shows in sequence:
“MACHINE” through button P3. with button P2 to enter the read-
- Alternator output voltage;
ing of the operation parameters of
- Voltage of batteries prior to start-
the transmission, then confirm the
ing
- Charge condition of batteries (OK
or LOW)
7 - 55

NOTES:
7.6 ELECTRICAL SYSTEM
FOLDING DIAGRAMS
INDEX
Sheet 1 POWER CONTROL AND DISTRIBUTION (FROM BATTERY) .............................. 7-59
Sheet 2 POWER CONTROL AND DISTRIBUTION (KEY “ACC”) ....................................... 7-60
Sheet 3 POWER CONTROL AND DISTRIBUTION (KEY “ON”) ......................................... 7-61
Sheet 4 ENGINE STARTING ............................................................................................. 7-62
Sheet 5A AUTOMATIC TRANSMISSION (1) ........................................................................ 7-63
Sheet 5B AUTOMATIC TRANSMISSION (2) ........................................................................ 7-64
Sheet 6 INSTRUMENT CLUSTER AND MONITOR ............................................................ 7-65
Sheet 7 HYDRAULIC LEVER DETENTS AND COOLING FAN REVERSER ...................... 7-66
Sheet 8 LTS (RIDE CONTROL) AND EMERGENCY STEERING ....................................... 7-67
Sheet 9 FRONT AND REAR WINDSHIELD WIPER AND WASHER ................................... 7-68
Sheet 10 PARKING BRAKE AND HOR CONTROLS ........................................................... 7-69
Sheet 11 LIGHTING DEVICES ............................................................................................ 7-70

Sheet 1 - POWER CONTROL AND DISTRIBUTION (FROM BATTERY)
“LINK” FUSE 50 A FB R - 6 724_f B - 2.5

701_N R - 10 772_B R - 10 772_A R - 10 R_B R - 10
Cab B+
Connector “XD” Studs
777_N R -16 To “M ega” fuse 150 A IGNITION KEY SWITCH
Connector “X23”
30_BAT_B R - 35
BOX B+
Engine
To fuse “Link” 20/30 A 772_FA R - 6
compartment 30_BAT R - 70 To starter m otor
RH (3 A) +30 B row n Box

(7.5 A) C ab dom e light
(7.5 A) +B H azard light
(7.5 A) H orn relay

LH. N_BAT R - 70
(7.5 A) +B G eneral lighting sw itch
BATTERIES
(7.5 A) C igarette lighter
N_MS BD - 70
(7.5 A) Transm ission controller Z F E S T37 unsw itched pow er

MAIN SW ITCH
(3 A) +30 E D C 7 D iagnostic plug connector
(10 A) Low beam relay
(10 A) H i-beam relay

R ear chassis fram e
CAB FUSE BOARD
W170-7R001
Sheet 2 - POWER CONTROL AND DISTRIBUTION (KEY “ACC”)
Connector “X13” Connector “S16”
Frrom fuse F11B 724_F B - 2.5 724_K B - 2.5
ACCESSORY RELAY 90 A 804_K B - 1.0
Connector “X34”
FM R - 10 IGNITION KEY SWITCH
804_K B - 1.0
FA R - 10
(10 A) Front working light CAB GROUND

Cab B+
studs (10 A) Rear w orking light
R_B R - 10
(5 A) LTS solenoid valve
(5 A) B ucket lever detent solenoid

(5 A) B oom and bucket proxim ity switches
(5 A) B oom lever float position detent solenoid
(5 A) Flasher unit
(7.5 A) Front wiper m otor

TO C HASS IS G RO U N D conn. “G N D_RC ”
From connector “X23” (see sheet 1)
(7.5 A) Dim m er sw itch 000 B - D 50 N_RCM B - 1.0

(7.5 A) Turning light switch
(7.5 A) Autom atic loading control
(7.5 A) Clim a control panel
(5 A) Rear w iper m otor
(5 A) Dashboard backlight switch Connector “GND_RCAB”

(5 A) G eneral lighting switch
(7.5 A) Power reducer
(5 A) S eat heater
(7.5 A) Roatating beacon
(7.5 A) Not connected
(15 A) +ACC engine com partm ent relay box
(15 A) A ir conditioner
CAB FUSE BOARD W170-7R002
Sheet 3 - POWER CONTROL AND DISTRIBUTION (KEY “ON”)
Connector “X13” Connector “S16”
From fuse F11B (sheet 1) 724_F B - 2.5 724_K B - 2.5
To accessory relay 90A (sheet 2) 804_K B - 1.0 804_K B - 1.0

949_K B - 2.5
IG NITIO N KEY SW ITCH
N ot connected (Battery charge w arning light)

949_K B - 2.5
(15 A)
To brow n box controller

895_F B - 1.5 895_E H - 1.0
(5 A) Parking brake solenoid valve Connector “X22”
(5 A) Seat air com pressor
707_F H - 1.0 707_A H - 1.0

(7.5 A) Back-up alarm relay coil 875_F H - 1.0 875_A H - 1.0
(7.5 A) +24 V transm ission output speed sensor
(7.5 A) Aut/M an, clutch cut-off & FN R sw itches
(7.5 A) Transm ission controller ZF E ST 37 sw itched pow er
(7.5 A) Transm ission diagnostic plugs pow er supply
(7.5 A) Transm ission gear selector 895_H H - 1.0
(7.5 A) Parking brake relay
(5 A) Alarm buzzer
(5 A) Instrum ent cluster
(5 A) D igital m onitor
Connector “XD” ALTERNATO R
(7.5 A) N ot connected
To batteries throught
773 R - 16 connector “C M 2”
on cranking m otor
(5 A) Brow n Box sw itched pow er “B+” studs
4A
(3 A) N ot connected Stop lights
4A Fuel pre-heater relay
895_H A - 1.0 (opt)
CAB FUSE BO ARD 7.5 A
Back-up alarm
4A N ot connected
4A
875_F H - 1.0
7.5 A Engine controller E DC 7
895_H B - 1.0 EDC39 B - 0.5 key sw itched pow er - pin 39
“B+”STUDS (ENG INE COM PARTM ENT BO X)
30_BAT_B R - 35
“E” FUSES (ENG INE CO M PARTM ENT BO X)
From batteries (sheet 1) W170-7R009
Sheet 4 - ENGINE STARTING
From fuse F11B (sheet 1) 7 2 4 B - 2 .5 Starting relay

(engine com partment box)
To Accessory R elay 90 A (sheet 2) 8 0 4 B - 1 .0 From B + stud
To connection “X F 5” cab fuse board (sheet 3) 9 4 9 B - 2 .5 30 7 7 7 H - 2 .5 Engine com p. box XD
(C onnection T B 3)
X13 87 8 8 8 / A B - 0 .5 10 10 8 8 8 / A B - 0 .5
12 12 7 2 4 B - 2 .5
C AB FUSE BO ARD 85 0 0 0 H - 1 .0 B B 0 0 0 H - 1 .0 08 08 0 0 0 H - 1 .0 R ear chassis ground - conn. GND_F
N eutral safety starting relay A A
86 8 8 8 B - 0 .5 SSTP R - 50
11 11 8 0 4 B - 1 .0 To secondary steering motor (sheet 7)
C ND
30 30 11 11 8 0 2 B - 1 .0 13 13 9 4 9 B - 2 .5 From alternator - connection B + (sheet 3) 773 R - 16
87 87 10 10 9 0 7 B - 1 .0 10 10 9 0 7 B - 1 .0
87a 87a 15 15 Z F 6 7 B - 1 .0 STARTING KEY SW ITC H “M ega” fuse - 150 A
85 85
(cold start box) From B + stud
9 9 6 B - 1 .0
TO T R A N S M IS S IO N C O N T R O L LE R
86 86 12 12 To h orn relay
Engine com p. box From batteries (sheet 1)
K5 X33 Transm ission gear selector 786 R - 16 777 R - 16 (C onnection T B 6 ) 3 0 R - 70
X16 X6
B la ck C ranking
Parking brake relay 12 12 A A Fuse L F 2 - 20 A
G reen motor
11 11 13 13 ZF65 B B (engine com p. Box)
From B + stud
12 12 14 14 ZF63 C C 7 7 7 H - 2 .5 Engine com p. box From fuse F11C (sheet 3)
30 30 13 13
11 11 595 D D Violet (C onnection T B 8 ) key “ON ”
87 87 14 14
87a 87a 16 16
X7 Fuel filter Low oil pressure Water in fuel C old start A ccelerator pedal Engine diagnostic
85 85 17 17 R ed heater relay warning light relay warning light indicator light potentiom eter lamp and switch
86 86 18 18 ZF45 A A
(cold start box) (engine com p. box) (under cab floor) (rear cab panel)
19 19 9 9 6 B - 1 .0 15 15 Z F 43 B B Yellow (cab rh consolle) (cab rh consolle)
K8 20 20 9 9 6 B - 1 .0 16 16 Z F 64 C C P in k
21 21 17 17 ZF67 D D G rey
7 7 7 R - 2 .5
tra nsm issio n d ia gn o stic plu g

X34 X15
From B + stud
Engine com partm ent box From fuse F8C (sheet 3)
07 07 Z F 4 5 B - 1 .0
(Connection TB8) key “ON ”
N e g ative b rid ge w ith

C ab ground
E D C + 30 B - 1 .0
N B - 1 .0
8 7a 8 7a
87a 87 a
87 87
85 85
86 86
30 30
1 2 1 2
87 87
85 85
86 86
30 30
conn. ì GND _RC ABî
K 03 K 04 L2 L1
Parking brake 1 2 1 2
L C A pressure switch
X22
7 7 7 R - 4.0
L C A
E D C 0 8 B - 1 .0
E D C 4 6 B - 1 .0
0 0 0 B - 1 .0
8 3 6 B - 1 .0
B rown
Yellow
W hite
G rey
P ink
9 7 8 H - 1 .0
9 9 6 H - 1 .0 1 2 3 4 5
3-w ay conn ector CA N_ SPL

To ì Brow n Boxî through
1 2 3 4 5
From fuse E F 6
(engine com partm ent box)
E D C 3 9 B - 0 .5
8 0 2 B - 1 .0
(sheet 3) - key “ON”

Fuse L F5 - 20 A
8 8 8 B - 0 .5
E D C 0 8 B - 1 .0
(rear cab p anel)

From fuse E F1
0 00 B - 1 .0
E D C 2 3 B - 1 .0
E D C 6 3 B - 0 .5
E D C 0 8 B - 1 .0
E D C 0 2 B - 1 .0
E D C 3 6 B - 0 .5
30 9 B - 2.5
8 0 8 B - 1 .0 (sheet 3) - key “ON”
30 786 R - 16 9 8 10
B rown box - connector C N 1 - pin 21

X12
C ab ground- conn. GND _SCF

Engine block 9 8 10
87 787 R - 16 ground stud
2 3 4 1
XE 85
2 3 4 1 ì W .I.F.î Service tool plug
Sensor 86 (R ear cab panel)
(W ater in A
C A N H B - 0 .3 5
Engine
E D C 1 6 B - 1.0
E D C 0 4 B - 1.0
C A N L V - 0 .3 5
E D C 3 9 B - 0.5
E D C 2 3 B - 0 .5
E D C 0 8 B - 1 .0
E D C 4 6 B - 1 .0
E D C 7 2 B - 0 .5
E D C 1 9 B - 0 .5
E D C 8 1 B - 0 .5
E D C 8 3 B - 0 .5
E D C 5 5 B - 0 .5
E D C 6 0 B - 0 .5
E D C 2 8 B - 0 .5
E D C 6 4 B - 0 .5
E D C 4 3 B - 0 .5
E D C 2 7 B - 0 .5
E D C 1 9 B - 0 .5
E D C 3 1 B - 0 .5
fuel)
7 7 4 R - 2 .5
7 7 4 R - 2 .5
C old starting relay Grid

8 0 8 B - 1 .0
(cold start box)

8 02 B - 1 .0
88 8 B - 0.5
B H eater
83 6 B - 1.0
3 2 1
XW M G RH P
3 2 1
Massa telaio - conn. GND _E
0 0 0 B - 1.0
80 8 B - 1.0
83 6 B - 1.0
D E L P K S T H W V R 23 29 14 25 05 07 08 09 10 0 6 11 1 3 1 2 1 9 3 0 31
XF XF A XB
D E L P K J S T B N M H W V R 23 29 14 25 05 07 08 09 10 0 6 11 1 3 1 2 1 9 3 0 31
E D C 2 3 B - 1 .0
8 0 8 B - 1 .0
7 74 R - 2.5
7 74 R - 2.5
R ear chassis ground

conn. GN D_E
8 3 6 B - 1 .0
0 0 0 B - 2 .5 conn. GN D_E

conn. GN D_E
A A Fuel filter
C A N H B - 0 .35
C A N L V - 0.3 5
E D C 03 B - 1 .0
E D C 09 B - 1 .0
E D C 14 B - 1 .0
E D C 15 B - 1 .0
E D C 39 B - 0 .5
E D C 1 6 B - 1 .0
E D C 0 4 B - 1 .0
E D C 0 2 B - 1 .0
E D C 3 6 B - 0 .5
E D C 6 3 B - 0 .5
E D C 0 8 B - 2 .5
E D C 4 6 B - 1 .0
E D C 7 3 B - 0 .5
E D C 7 2 B - 0 .5
E D C 1 9 B - 0 .5
E D C 8 1 B - 0 .5
E D C 8 3 B - 0 .5
E D C 5 5 B - 0 .5
E D C 6 0 B - 0 .5
E D C 2 8 B - 0 .5
E D C 6 4 B - 0 .5
E D C 4 3 B - 0 .5
E D C 2 7 B - 0 .5
E D C 3 1 B - 0 .5
heater
7 7 4 R - 1 .0
7 7 4 R - 1 .0
7 7 4 R - 1 .0
7 7 4 R - 1 .0
8 0 2 B - 1 .0
8 8 8 B - 0 .5
B B resistor
XPM
3 0 9 B - 2 .5
03 09 14 15 01 07 12 13 20 39 37 16 04 02 36 63 08 46 73 72 19 81 83 55 60 28 64 43 27 31 53 52
redondant input signal
Throttle idle sw itch input signal
Throttle potentiom eter output signal

Key sw itch cranking positive (in)
Key sw itched pow er (in)
Starting relay control pow er (out)
G rid heater relay pow er (out)
Fuel filter relay control pow er (out)
Sw itched battery output
Cruise control sw itch input (bridged)

Diagnostic lam p pow er supply (out)
Diagnostic lam p return (out)
Transm . neutral positive sig. (Bridged)
Diagnostic request sw itch (in)
Fused battery pow er
Throttle potentiom eter pow er supply
J9141 IS O interface
G round
G round
G round
G round
G rid heater relay ground
Fuel filter heater relay ground
C old starting indicator light ground
Throttle idle sw itch
Throttle idle sw itch ground

Trottle potentiom eter return
CA N BUS - channel L
CAN BUS - channel H
W170-7R010
Sheet 5A - AUTOMATIC TRANSMISSION (1)
TRANSMISSION GEAR SHIFT SELECTOR
ZF65 B - 1.0
ZF63 B - 1.0
595_A B - 1.0 To horn relay
ZF43 B - 1.0
ZF64 B - 1.0
ZF67 B - 1.0
X16 ZF67_A B - 1.0 To neutral safety start relay (sheet 4)
3R D A N D 4T H S PE E D S IG N AL
63 1S T AN D 4T H SP EE D S IG N AL
43 FO RW A R D S IG N AL
ZF45_FE B - 1.0
X15 64 R E VE R S E S IG N A L
TRANSMISSION CONTROL VALVE 67 N E U TR AL S IG NA L
430 W S - 1.0 ZF56 B - 1.0 56 P R O PO RT IO N A L S O LEN O ID . Y 1

446 W S - 1.0 ZF09 B - 1.0 09 P R O PO RT IO N A L S O LEN O ID Y 5
454 W S - 1.0 ZF12 B - 1.0 12 +24 V SO LE N O IDS (KE Y O N )
ZF12_A B - 1.0 13 +24 V SO LE N O IDS (KE Y O N )
458 W S - 1.0 ZF39 B - 1.0 39 C TR L VALV E T EM P. S E NS O R SIG N A L
TRANSMISSION CONTROLLER ZF EST37

462 W S - 1.0 ZF46 B - 1.0 46 C TR L VALV E T EM P. S E NS O R R ETU R N
ENGINE SPEED GE2 GE - 1.0 ZF19 B - 1.0 19 E N G IN E SP EE D S EN S O R S IG N AL

INDUCTIVE SENSOR BL2 BL - 1.0 ZF03 B - 1.0 03 IN D U C T IVE S PE ED SE N S O R S G R O U N D
ZF41 B - 1.0 41 TU R B IN E S P E ED S E N SO R SIG N A L
ZF3A B - 1.0
CONVERTER TURBINE SPEED GN3 GN - 1.0 ZF42 B - 1.0 42 IN T ER M ED IATE SP E ED SE N SO R S IG N A L
INDUCTIVE SENSOR SW 3 SW - 1.0 ZF3B B - 1.0
ZF04 B - 1.0 4 O U T PU T SP E ED S EN S O R G R O UN D
ZF62 B - 1.0 62 O U T PU T SP E ED S EN S O R S IG N AL
INTERM EDIATE GEAR SPEED RT4 RT - 1.0 ZF45_A B - 1.0
INDUCTIVE SENSOR BL4 BL - 1.0
ZF49 B - 1.0 49 C O N V ERT ER O IL TE M P. SE N SO R
ZF4A B - 1.0
OUTPUT SPEED 500 W S - 1.0 ZF17 B - 1.0 17 FILTER R ES TR ICT IO N S E NS O R SIG N A L
“HALL EFFECT” SENSOR 504 W S - 1.0 ZF46B B - 1.0
508 W S - 1.0 X21
05 L.T.S.
XF2 07 B AC K -U P A LA R M R ELAY C O IL G R O UN D
7.5 A E XT ER N AL D IS P LAY PLU G
CONVERTER OUTPUT OIL 574 W S - 1.0 14
TEMPERATURE SENSOR Back-up alarm relay 15 D IS G N O STIC PLU G SIG N A L
570 W S - 1.0
16 D IA G N O STIC PLU G SIG N A L
Aut/M an, clutch cut-off and FN R sw itches 20 FO RW A R D S IG N AL FR O M A U X FN R
21 PA R KIN G BR A K E R E LAY S IG N A L
D iagnostic plugs pow er supply 22 S KICK D O W N S IG N AL
OIL FILTER DIFFERENTIAL 480 W S - 1.0 25 C A N B U S (H )
PRESSURE SW ITCH 484 W S - 1.0 Parking brake relay 26 C A N B U S (L)
27 C A N B U S (L)
29 A U T / M A N S E LE C TO R SW ITC H SIG N A L
CAB FUSE BOARD 30 A U X F N R E N AB LING S IG N A L
31 R E VE R S E S IG N A L FR O M A U X F NR
FROM IGNITION KEY - “ON” POSITION XF4 44 N E U TR AL S IG NA L F R O M A UX FN R
7.5 A 66 C LU TC H CU T -O FF SIG N A L
ZF68 B - 1.0 68 U N S W IT CH E D P O W E R (FR O M BATT E RY )
ZF23 B - 1.0 23 U N S W IT CH E D P O W E R (FR O M BATT E RY )
ZF45_A B - 1.0 45 S W ITC H ED P O W E R (K EY ìO N î)
FROM BATTERIES (B+ STUDS O N CAB FUSE BOARD) N_RCN B - 1.0 2 GROUND
N_RCL B - 1.0 1 GROUND
Cab ground - connector G N D_R CAB W170-7R003
Sheet 5B - AUTOMATIC TRANSMISSION (2)

R EV ER SE S I G N A L FR O M A U X FN R 31 ZF31 B - 1.0 ZF31_S B - 1.0 (REVERSE)
N EU TR AL S IG NA L F RO M AU X FN R 44 ZF44 B - 1.0 ZF44_S B - 1.0 (NEUTRAL)
FO RW A RD S IG NA L F RO M AU X FN R 20 ZF20 B - 1.0 ZF20_S B - 1.0 (FORWARD)
KIC K -D O W N S IG N A L 22 ZF22 B - 1.0 ZF22_K B - 1.0 (KICK-DO WNI)
AU T / M AN SE LEC TO R S W IT CH SIG NAL 29 ZF29 B - 1.0 ZF45_H B - 1.0
PA R KIN G BR A KE R E LAY SIG NA L 21 ZF21 B - 1.0 ZF45_FC B - 1.0 ZF45_F B - 1.0
BA C K-U P ALAR M R ELAY C O IL GR OU N D 07 ZF7 B - 1.0 ZF29_A B - 1.0 (SEL. AUT-MAN)
C LUTC H CU T-O FF S IG N A L 66 ZF66 B - 1.0
AU X FN R E NA BLING SIG N AL 30 ZF30 B - 1.0
L.T.S. 05 ZF5 B - 1.0 EXTERNAL DISPLAY PLUG KICK-DOWN PUSH BUTTON
EX TER N A L D ISPL AY P LU G S IGN AL 14 ZF14 B - 1.0

D IAG N O S TIC P LUG SIG N AL 15 ZF15 B - 1.0
D IAG N O S TIC P LUG SIG N AL 18 ZF18 B - 1.0
C AN BU S (H ) 25
C AN BU S (L ) 26
C AN BU S (L ) 27
To 3-w ay connector C AN _SP L CANH_B B - 0.35

cab rear panel CANL_B V - 0.35
DIAGNOSTIC PLUG ZF22_J B - 1.0
ZF31_J B - 1.0
ZF45_E B - 1.0
From LTS relay ZF30_J B - 1.0
XF2 ZF44_J B - 1.0
7.5 A
ZF45_F B - 1.0
ZF20_J B - 1.0
ZF45_D B - 1.0
IGNITIO N KEY “ON” ZF45_FB B - 1.0
O utput speed sensor pow er AUX FNR CONTROL (JOYSTICK)
ZF45_FC B - 1.0
C ontroller sw itched pow er
(G rou nd bridge w ith E ngine d iagnostic p lug)

ZF45_FF B - 1.0
G ear selector pow er AUX FNR CONTROL (2/3 LEVERS)
ZF45_AB B - 1.0
ZF45_B B - 1.0
CAB FUSE BOARD ZF31_S B - 1.0
C ab ground - connector. G N D_R C AB

ZF44_S B - 1.0
ZF20_S B - 1.0
ZF45_B B - 1.0
AUX FNR ENABLING (G round brid ge w ith centralized lube sw.)

N _J B - 1.0
ZF45_AA B - 1.0 PARKING BRAKE N _F B - 1.0 (G round brid ge w ith seat heater sw.)
PRESSURE SWITCH 921 _A B - 1.0 (P ositive bridge with seat heater sw.)
ZF21 B - 1.0 (n.c. - open at 82 +/-2 bar) 921 _G B - 1.0 (P ositive bridge with centr. lube sw.)
996 B - 1.0 978_B H - 1.0

996_A B - 1.0 996_B H - 1.0
PARKING BRAKE RELAY 567_A B - 1.0
(CAB RELAY BOARD) ZF45_G B - 1.0
ZF45_FB B - 1.0 558 H - 1.0
From parking brake indicator light (dashboard) ZF7 B - 1.0 556 H - 1.0 ZF30_J B - 1.0
From neutral safety start rela y
SEL. AUT-MAN N _G M B - 1.0 (G round brid ge w ith cut-off sw.)

3R D A N D 4TH SP EE D S IGN AL From batteries (B + studs engine com p. B ox - conn. T B 3) N _E B - 1.0
1ST A ND 4T H SP EED S IG NA L 63 921 _B B - 1.0
To fuse E F 3 (engine com p. Box) 921 _G M B - 1.0
FO RW A RD S IG NA L 43 (P ositive bridge with cut-off sw.)
R EV ER SE S IG N A L 64
N EU TR AL S IG NA L 67
56 197_BA H - 2.5
PR O P O RTIO N A L S O LEN O ID. Y1
PR O P O RTIO N A L S O LEN O ID. Y2 10 772_FC H - 2.5
PR O P O RTIO N A L S O LEN O ID. Y3 32
PR O P O RTIO N A L S O LEN O ID. Y4 55 556_C H - 1.0 ZF29_A B - 1.0
PR O P O RTIO N A L S O LEN O ID. Y5 09 558_C H - 1.0 ZF45_H B - 1.0
PR O P O RTIO N A L S O LEN O ID. Y6 51 ZF45_F B - 1.0
+24 V S O LE NO ID S (K EY O N ) 12 BACK-UP ALARM RELAY
+24 V S O LE NO ID S (K EY O N ) 13 (ENGINE COMPARTMENT BOX) CLUTCH CUT-OFF.
N _G B - 1.0 (G round brid ge w ith fan reverser switch)
C TR L VALVE O IL TE M P. SE N SO R SIG NA L 39
C TR L VALVE O IL TE M P. SE N SO R R ETU R N 46 CLUTCH CUT-OFF
EN G IN E S PE ED SE NS O R S IG NA L 19 PRESSURE SWITCH 921 _D B - 1.0 (P ositive bridge with fan rev. S w.))
IN D UC TIV E SPE E D S EN S OR S G R O U N D 03 (n.o. - closed at 25 +/-1 bar) N _JB B - 1.0 (C ab ground -conn. G N D_S CF))
TU R BIN E S PE ED SE NS O R S IG N AL 41
IN TER M ED IATE S PE ED SE NS O R S IG N A L 42
O U TP UT SP E ED SEN SO R G R O U ND 4 ZF66 B - 1.0 975_A B - 1.0 943 B - 1.0
O U TP UT SP E ED SEN SO R SIG N AL 62 975 B - 1.0 975_A B - 1.0
C O N VE RT ER O IL TE M P. SEN SO R SIG N AL 49
FILTER R ES TRIC TIO N SE NS O R SIG NAL 17 975_A B - 1.0
U N SW ITC H ED P OW E R (F RO M BAT TERY ) 68
U N SW ITC H ED P OW E R (F RO M BAT TERY ) 23 ZF45_L B - 1.0
SW ITC HED P O W E R (K EY “O N ”) 45
GROUND 2 975_A B - 1.0
GROUND 1
To B row n B ox controller - connect. C N 1 pin 25 943_A B - 0.5 943 B - 1.0

ZF30 B - 1.0 ZF30_J B - 1.0
W170-7R004
Sheet 6 - INSTRUMENT CLUSTER AND MONITOR
TO CONN. X34F (relay board)

(G round connection through
parkin g brake p ressure switch)
C ab ground conn. G ND _FC AB
FRO M FUSE F9C (KEY “ON”)
To em ergency steering pressure sw itch through conn. X 20 & LT S
To em ergency steering pressure sw itch through conn. X 20 & LT S HO U RMETER
To connector ALT (“L”) through conn. X 23
X14F
BROW N BOX (INPUT) BROW N BOX (OUTPUT) 858_FA B - 1.0 3 19 858 B - 1.0
CONNECTOR C N 1 ( L ) CONNECTOR C N2 ( R ) X4F DA SHBO ARD
BAC KLIG HT
637_B B - 0.5 “L” S IG N A L F R O M A LT E R N ATO R B AT T E R Y C H A R G E W A R N IN G LIG H T 568_A B - 1.0 3 3 568_B B - 1.0 3 3 EMERG . STEERIN G
E M E R G E N C Y S T E E R IN G W A R N IN G LIG H T 11 575_A B - 1.0 14 14 575_B B - 1.0 14 14
844 B - 0.5 17 S T E E R IN G LO W P R E S S U R E S IG N A L
Air cleaner restriction press. Sw. G ENERAL W ARN.
N . O . - C lo se d at 6 2 m illiba r 835 B - 0.5 19 S T E E R IN G H IG H P R E S S U R E S IG N A L A LA R M B U Z Z E R S IG N A L 1 104_A B - 1.0 18 18 104_B B - 1.0 18 18
0.38 H - 1.0 Chassis ground. - conn. G ND _E A IR C LE A N E R R E S TR IC T IO N W A R N IN G LIG H T 574_A B - 1.0 13 13 574_B B - 1.0 13 13
AIR C LE ANER RE STR.
ENG IN E O IL PRESS.
E N G IN E O IL P R E S S U R E W A R N IN G LIG H T 576_A B - 1.0 15 15 576_B B - 1.0 15 15
TRANSM . O IL TEMP.
663_B H - 1.0 12 12 663 B - 0.5 A IR C LE A N E R R E S TR IC T IO N S E N S O R S IG N A L T R A N S M IS S IO N O IL T E M P. W A R N IN G L IG H T 26 577_A B - 1.0 16 16 577_B B - 1.0 16 16
16 578 A B-10 17 17 578_B B - 1.0 17 17
FROM FUSE F7C (IGENERAL LIGHTING SW ITCH

T R A N S M IS S IO N O IL T E M P. G A U G E S IG N A L
557_B H - 1.0 13 13 557 B - 0.5 22 F U E L L E V E L S E N S O R S IG N A L
X23M X23F 570_A B - 1.0 4 4 570_B B - 1.0 4 4
FUEL LEVEL
Fuel level sensor F U E L L E V E L W A R N IN G L IG H T S IG N A L 24 CO O LANT TEM P.
C O O LA N T T E M P. W A R N IN G LIG H T S IG N A L 572_A B - 1.0 11 11 572_B B - 1.0 11 11
3 3 - 2 4 0 o hm 10 10 10 10
BRAKE O IL PRESS.
B R A K E O IL P R E S S U R E W A R N IN G LIG H T 3 571_A B - 1.0 571_B B - 1.0 PAR KING BRAKE
0.41 H - 1.0 Chassis ground - conn. G ND_E 567_A B - 1.0 2 2 567_B B - 1.0 2 2
ALTER NATO R
FROM FUSE F9C (KEY “O N”)

TUR NING , RH
Brake accumulator pressure switch TUR NING , LH
N . C . - O p en a t 11 5 + /- 5 b ar HI-B EAM
1ST GE AR
Chassis ground - conn. G ND_A 1 S T S P E E D IN D IC ATO R L IG H T S IG N A L 17 583_A B - 1.0 8 8 583_B B - 1.0 8 8
0.43 H - 1.0 584_A B - 1.0 7 7 584_B B - 1.0 7 7
2ND G EAR
3 B A K E A C C U M U LATO R P R E S S . S W IT C H S IG N A L 2N D S P E E D IN D IC AT O R LIG H T S IG N A L 19 3RD G EAR
613_B H - 1.0 3 3 613_A B - 0.5 21 585_A B - 1.0 6 6 585_B B - 1.0 6 6
3R D S P E E D IN D IC AT O R LIG H T S IG N A L 4T H G EAR
X20M X20F 4T H S P E E D IN D IC ATO R LIG H T S IG N A L 586_A B - 1.0 5 5 586_B B - 1.0 5 5

FUEL LEVEL GAU GE S IG N A L 18 562_A B - 1.0 1 1 562_B B - 1.0 1 1 FUEL LEV. INDIC ATOR
C O O LA N T T E M P. G A U G E S IG N A L 10 573_A B - 1.0 12 12 573_B B - 1.0 12 12 CO O LANT TEM P. G AU GE

TRSM . O IL TEMP G AUG E
V E H IC L E S P E E D S IG N A L 12 579_A B - 1.0 9 9 579_B B - 1.0 9 9 SPEEDM ETER
To low oil pressure

warning light relay EDC23 B - 0.5 X X X14M X4M
503 B - 0.5 E N G IN E O IL LO W P R E S S U R E S IG N A L
(sheet 4)
E M E R G E N C Y S T E E R IN G R E LAY G R O U N D 5 579_A B - 1.0 To em ergency steering relay (through conn. X20 e LTS) To hi-beam relay (tthrough conn. X5) INSTRUM ENT CLUSTER
To hazard switch
X22M X22F To hazard switch
T1 N - 0.5 1
CONNECTOR CN7
DIGITAL MONITOR
(PUSH-BUTTONS)
M ONITOR KEYS
R1 N - 0.5 2 K E Y P 1 (G R O U N D )
CANL_A V - 0.35 T0 N - 0.5 3 K E Y P 0 (S IG N A L)
C A N B U S (H ) R0 N - 0.5 KEY P0 (G R O U N D )
CANH_A B - 0.35 T3 N - 0.5 5 KEY P3 (S IG N A L)
pin 52-53 through “X B ”(sheet 4)
R3 N - 0.5 6 KEY P3 (G R O U N D )
T2 N - 0.5 7 KEY P2 (S IG N A L)
To Engine controller E DC 7
R2 N - 0.5 8 KEY P2 (G R O U N D )
D IS P LAY TXA_B V - 0.22 TXA_A V - 0.22 1 S P I T x (S E R IA L IN T E R FA C E S E N D IN G D ATA )

D IS P LAY 33 RXDA_B R - 0.22 2 2 RXDA_A R - 0.22 2 S P I R x (S E R IA L IN T E R FA C E R E C E IV IN G D ATA )
35 RXDB_B G - 0.22 3 3 RXDB_A G - 0.22 3 S P I R x (S E R IA L IN T E R FA C E R E C E IV IN G D ATA )
DIGITAL MONITOR
CONNECTOR CN6
D IS P LAY
(INTERFACES)
D IS P LAY RXCA_B N - 0.22 RXCA_A N - 0.22 S P I R x C H E C K (R E C E IV IN G D ATA C H E C K )
D IS P LAY 39 RXCB_B L - 0.22 7 7 RXCB_A L - 0.22 5 S P I R x C H E C K (R E C E IV IN G D ATA C H E C K )
D IS P LAY 27 TXB_A B - 0.22 4 4 TXB_A B - 0.22 12 S P I T x (S E R IA L IN T E R FA C E S E N D IN G D ATA )
953 B - 0.5 23 LT S O N S IG N A L 8 8 7 P O W E R S U P P LY + 1 2 V (N O T U S E D )
943_A B - 0.5 25 C LU T C H C U T -O F F O N S IG N A L 9 9 8 N ot u sed
CN3M
CN3F
S E R IA L IN T E R FA C E S H IE L D 10 10 9 N ot u sed
B B 30 R 1.0 U N S W IT C H E D P O W E R (F R O M B AT T E R Y )
S E R IA L IN T E R FA C E R X _ B (R E C .) 32 11 11 10 N ot u sed
S E R IA L IN T E R FA C E R X _ V (R E C .) 12 12 11 N ot u sed
B B 15 B 1.0 29 S W IT C H E D P O W E R (K E Y “O N ”) S E R IA L IN T E R FA C E T X _R (S E N D .) 1 1 6 G R O U N D (not used)
N_RCT B - 1.0 G RO UND S E R IA L IN T E R FA C E T X _G (S E N D .) 38
S E R IA L IN T E R FA C E P O W E R 1 2 V 40
N_RCA B - 1.0 42 G R O U N D 42 1 N ot u sed
IN T E R FA C E G R O U N D
2 N ot u sed
N_RCT U - 1.0 14 G R O U N D N_AA B - 1.0 3 G RO UND
N_AB B - 1.0
N_AC B - 1.0 5
DIGITAL MONITOR
CONNECTOR CN5
To LTS switch - conn. X12
To clutch cut-off selector switch - conn. X32
To transm ission controller ZF ES T 37
N_AD B - 1.0 6 G RO UND
(POWERING)
7 GRND_C N - 0.22
6 SUPP_C M - 0.22 N_AE B - 1.0 7 G RO UND
TXG_C G - 0.22 N_AF B - 1.0 8 G RO UND
CN4F R_AA B - 1.0 9 P O W E R S U P P LY +24 V
TXT_C R - 0.22 R_AB B - 1.0
5 10 P O W E R S U P P LY + 2 4V
RXV_C V - 0.22 R_AC B - 1.0 11 P O W E R S U P P LY + 2 4V
4 RXB_C B - 0.22
1 S_1 SH - 0.22 R_AD B - 1.0 12 P O W E R S U P P LY + 2 4V
C ab ground - conn. G ND _R CA B 13 N ot u sed
14 N ot u sed
From fuse F9C (see sheet 3) 15 N ot u sed
From fuse F12A (see sheet 1) 16 N ot u sed
R B - 1.0 951_B B - 1.0 951_A B - 1.0 951_F B - 1.0

N B - 1.0 N_CK B - 1.0 N_FCE B - 1.0 Cab ground conn. G N D_FCA B
W170-7R005
Sheet 7 - HYDRAULIC LEVER DETENTS AND COOLING FAN REVERSER
Ground bridge with switch S9 (LTS)

Ground bridge with switch S11 (Cut-off)
Positive bridge with switch S9 (LTS)
Positive bridge with switch S11 (Cut-off)
From fuse F3C (Key "ACC")
BOOM MAX HEIGHT

OUT PROXIMITY SWITCH
PROXIM. (NPN - N.C)
SWITCH
HYD. LEVER DETENTS ENABLING SWITCH
OUT BUCKET LEVELER

PROXIM. PROXIMITY SWITCH
SWITCH (NPN - N.O)
FLOAT PRESSURE
SWITCH
(N.O Closed at 19 bar)
COOLING FAN REVERSER CONTROL SWITCH

FLOAT SOLENOID
(ON LOADER VALVE)
DIODE CONNECTOR (39.7 ohm a 20°C)
BOOM
MAX HEIGHT
Chassis ground. - conn. GND_D

Chassis ground. - conn. GND_A
Chassis ground. - conn. GND_A
From fuse F3C (ACC)
From fuse F3C (ACC)
BUCKET
LEVELER
FLOAT
POSITION
HYDRAULIC LEVER DETENT SOLENOIDS

Cab ground
Conn. GND_SCF
ground bridge with seat heater switch

ground bridge with clutch cut-off selector switch (sheet 5B)
positive bridge with seat heater switch
positive bridge with clutch cut-off selector switch (sheet 5B)
DIODE MODULE
(engine compartment box) Chassis ground - conn. GND_G
FAN REVERSER
SOLENOID VALVE W170-7R006
Sheet 8 - LTS (RIDE CONTROL) AND EMERGENCY STEERING
F rom fu se F 3B (ig nitio n key sw itch in “A C C “ p osition ) - she et 2 9 21 B - 1 .0 1 1

STEERING LS SEC . STEERIN G M OTO R F rom fu se F 6C (ig nition key sw itch in “A C C “ p ositio n) - sh ee t 2 1 69 B - 1 .0
CU T-O FF SO LEN O ID
SSTG
S S T N B D - 50
M 1 69 B - 1 .0
9 52 B - 1 .0
3 3
X13
2 1 N B - 1 .0
SSS
2 1 9 55 B - 1 .0 5 5
C h a ssis grou n d
co nn . G N D _S S T SST SSTP LTS RELAY (2) X32
(Cab relay board) PIN ENG AG E
00 0 H - 1 .0
CO N TRO L SW ITC H
9 58 H - 1 .0 (Cab r.h. consolle)
S ta rte r m otor B + stu ds
SSTP R - 50
co nn . T B 7 ( she et 4)
N B - 1 .0 10 10
C h a ssis grou n d B ro w n B ox - co nn . C N 2 p in 5 (em e rge ncy ste erin g rela y gn d) - she et 6 9 21 B - 1 .0 9 9
co nn . G N D _S S S F rom fu se F 6C (ig nition key sw itch in “A C C “ p ositio n) - sh ee t 2
B ro w n B ox - co nn . C N 1 p in 17 (lo w p ressure sig na l) - she et 6
B ro w n B ox - co nn . C N 1 p in 19 (h igh pre ssure sig na l) - sh ee t 6 8
SEC . STEERIN G - 3
C ab grou nd
co nn . G N D _ R C A B
0 .5
0 .5
1 .0
1 .0
SSB _G 6
PRESSURE SW ITCH 2
-
-
-
-
(Loader valve inlet)
B
B
B
B
83 5
84 4
89 5
55 3
X20 4
7
A A 8 35 H - 1 .0 C C 8 35 H - 1 .0 12 12
8 59 B - 1 .0 1 1
B B 0 00 H - 1 .0
1 69 B - 1 .0 5 5
C C 8 44 H - 1 .0 B B 8 44 H - 1 .0 31 31
A A 9 58 H - 1 .0
LTS
SEC . STEERIN G RELAY N B - 1 .0 10 10
0 00 H - 1 .0 5 5 0 00 H - 1 .0
con n. G N D _S C F
(Front fram e - LTS relay box) 9 21 B - 1 .0 9 9
C a b grou nd
8 95 H - 1 .0 8 8 8 95 H - 1 .0 13 13
30 30
9 53 B - 0 .5 3 3
87 87 9 58 H - 1 .0 10 10 9 58 H - 1 .0
87a 87a N B - 1 .0 1 1
85 85 5 53 H - 1 .0 9 9 5 53 H - 1 .0 2 2 5 5
86 86 8 95 H - 1 .0 N B - 1 .0 7 7
SSTR 8 59 H - 1 .0 26 26 8 59 B - 1 .0 4 4 1 69 B - 1 .0 4 4
1 69 B - 1 .0 2 2
2 2 6 6
9 61 H - 1 .0 12 12 9 61 H - 1 .0 9 55 B - 1 .0
8 8
30 30 9 56 H - 1 .0 3 3 9 56 H - 1 .0 27 27 9 56 B - 1 .0 1 1 9 56 B - 1 .0
87 87 9 52 H - 1 .0 2 2 9 52 H - 1 .0 25 25 9 52 B - 1 .0
X12 LTS CO N TRO L SW ITCH
87a 87a 9 52 H - 1 .0
(Cab r.h. consolle)
85 85 9 54 H - 1 .0 4 4 9 54 H - 1 .0 28 28 Z F 5 B - 1 .0
86 86 1 69 H - 1 .0 1 1 1 69 H - 1 .0 1 1 9 52 B - 1 .0
B ro w n bo x - con n. C N 1 pin 2 3
9 53 B - 0 .5
LTS1 (LTS O N sig na l) sh ee t 6
0 00 H - 1 .0
C h assis gro un d
LTS RELAY (1)
con n. G N D _D
(Front fram e - LTS relay box) Z F E S T 37 con trolle r - p in 5
0 00 H - 1 .0 (LTS relay g nd ) she et 5B
0 00 H - 1 .0
F rom fu se F 6C (ig nition key sw itch
1 2 1 2 A B in “A C C ” po sition ) - sh ee t 2
LTS_V1 FL_SO L STY_V
1 2 1 2 A B
LTS SO LENO ID FLO AT SO LENO ID PIN ENG AG E SO LEN O ID W170-7R011
Sheet 9 - FRONT AND REAR WINDSHIELD WIPER AND WASHER
FRONT WIPER AND WASHER CONTROL

Cab ground - conn. GND_FCAB
WASH
SIGNAL "53" FRONT TIMER
FRONT
FRONT WIPER - HIGH SPEED
WIPER
FRONT WIPER - LOW SPEED
MOTOR
SIGNAL "J" FRONT TIMER
FRONT WIPER POWER SUPPLY
FRONT TIMER SIGNAL - WASHER
PIN 4 E 6 ARE INTERNALLY CONNECTED
PULSE
Cab ground - conn. GND_FCAB
FRONT WIPER TIMER
FRONT TIMER GROUND

TIMER SIGNAL - FRONT WASHER
REAR WIPER FROM FUSE F2C (key "ACC" -sheet 2)
SIGNAL "J" FRONT TIMER
SWITCH Ground bridge with FROM FUSE F6B (key "ACC" -sheet 2)
SIGNAL "53" FRONT TIMER
general lighting switch
FRONT TIMER POWER SUPPLY
TIMER SIGNAL - FRONT WIPER
CHASSIS GROUND - conn. GND_G
FRONT
WASHER
MOTOR
CHASSIS GROUND - conn. GND_G
REAR
WASHER
MOTOR
Ground bridge with

rotating beacon switch
CAB GROUND - conn. GND_FCAB
REAR WASHER FRONT WIPER TIMER

SWITCH
REAR TIMER GROUND
TIMER SIGNAL - REAR WASHER
SIGNAL "J" REAR TIMER
REAR
SIGNAL 1ST SPEED REAR WIPER
WIPER
REAR TIMER POWER SUPPLY
MOTOR
TIMER SIGNAL - REAR WIPER W170-7R007
Sheet 10 - PARKING BRAKE AND HOR CONTROLS
PARKING BRAKE CIRCUIT

CAB GROUND - CONN. GND_FCAB
X5F X5M X15F X15M
587_C B - 1.0 4 4 587 B - 1.0 8 8 587 _F B - 1.0 FROM FUSE F8B (KEY “ON”)
N_CA B - 1.0 11 11 N_FCA B - 1.0
945_C B - 1.0 3 3 945_B B - 1.0
921_C B - 1.0 14 14 921_K B - 1.0 18 18 921 _F B - 1.0 FROM FUSE F3B (KEY “ACC”)
N_CB B - 1.0 12 12 N_FCB B - 1.0

N_CD B - 1.0
PARKING BRAKE X16F X16M X20F X20M

CONTROL SW ITCH
G round bridge with 8 8 945_A B - 1.0 18 18 945_E H - 1.0

hazard light sw itch 000_CBA H 1.0
PARKING BRAKE
SOLW NOID VALVE
CHASSIS GROUND - CONN. GND_B
HORN CIRCUIT
FROM FUSE F11A (direct from the battery - see sheet 1)

HORN RELAY (1)
HORN
HORN RELAY (2)
FROM HORN SW ITCH ON GEAR SELECTOR

(THR O U G H C O NN EC TO R X 16)
HORN FOOTSW ITCH

ACCESSORY RELAY
90 A (see sheet 2)
CHASSIS GROUND - CONN. GND_B
N_RCM B - 1.0 CAB GROUND - CONN. GND_RCAB
CAB RELAY BOARD

W170-7R008
Sheet 11 - LIGHTING DEVICES
X20F X20M
124 B - 1.0 8
103 B - 1.0 6 103_E H - 1.0
TO DASHBOARD - sh. 8 G round bridge with
590_D B - 1.0 126 B - 1.0 9
connector X1C / Cn1 parking brake sw itch 109_E H - 1.0
588_D B - 1.0 109 B - 1.0 7
221_A B - 1.0 17 221_E H - 1.0
879_D B - 1.0 219_A B - 1.0 16 16 219_E H - 1.0
N_CD B - 1.0 223_A B - 1.0 15 15 223_E H - 1.0
X5F X5M X16F X16M
231_A B - 1.0 14 14 231_E H - 1.0
11 11 339_E H - 1.0
190_C B - 1.0 10 10 190_B B - 1.0 9 9 190_A B - 1.0
10 10 330_E H - 1.0
103_A B - 1.0
7 7 588_B B - 1.0 6 6 125 B - 1.0
588_C B - 1.0 120 B - 1.0
590_C B - 1.0 8 8 590_B B - 1.0 7 7 109_A B - 1.0
102_C B - 1.0 6 6 102_B B - 1.0 5 5 102_A B - 1.0
879_C B - 1.0 5 5
From fuse F12 C (Dir. Battery - sh. 1)
708_C B - 1.0 9 9 From fuse F10 C (Dir. Battery - sh. 1)
102_D B - 1.0 115_C B - 1.0 15 15 From fuse F1 C (key “ACC” - sh. 2)
879_G B - 1.0
R708 B - 1.0
From fuse F1 B (Dir. Battery - sh. 1)
115_D B - 1.0
HAZARD LIGHT SWITCH
From fuse F4 A (key “ACC” - sh. 2)
R923 B - 1.5
R924 B - 1.5
000_CCA H - 1.0
000_CCB H - 1.0
X15F X15M
109_E H - 1.0
339_E H - 1.0
219_E H - 1.0
231_E H - 1.0
103_E H - 1.0
221_E H - 1.0
221_E H - 1.0
223_E H - 1.0
590_E B - 1.0 4 4 879_F B - 1.0
3 3 708_FA B - 1.0
588_E B - 1.0 16 16 115_E B - 1.0
190_D B - 1.0 112_F B - 1.0
6 6
6 5 4 3 2 1 6 5 4 3 2 1
112_D B - 1.0 X16F X16M H1 6 5 4 3 2 1 H2 6 5 4 3 2 1
593_A B - 1.0 19 19 593_B B - 1.0
18 18 594_B B - 1.0
594_A B - 1.0
118_B B - 1.0
Low beam
Low beam
H i beam
H i beam
Position
Position
Turning
Turning
DIMMER AND TURNING
conn. “GND_B”
conn. “GND_D”
Chassis ground
Chassis ground
LIGHT SWITCH X8F X8M
N_EA B - 1.0 16 16 N_FCD B - 1.0 Cab ground - conn. “G ND_FCAB”
From fuse F5 B (key “ACC” - Fg. 2) ROAD LIGHT, FRONT LEFT ROAD LIGHT, FRONT RIGHT
X15F X15M
K3 K1 K4
168_B B - 1.5 12 12 168_C B - 1.5 15 15 168_F B - 1.5
225_A B - 1.5 225_B B - 1.5 225_C B - 1.5 FLASHER UNIT HI-BEAM RELAY LOW BEAM RELAY
13 13
REAR W ORKING LIGHT SWITCH
163_B H - 1.0
CAB RELAY BOARD BACK-UP ALARM
X16F X16M
000_CGD H - 1.0
N_ED B - 1.0
4 4 225_E B - 1.5 From fuse EF3 (engine comp.box-back-up alarm relay closed)
229_G B - 1.5 From fuse EF1 (engine comp.box-key "ACC")
3 3
XDF XDM
6 6 163_C H - 2.5 175_A H - 1.0 STOP LIGHT

X15F X15M
ITALIAN ROAD REGULATION - OVERALL LIGHT

RIGHT 2 2 117_B H - 1.0 PRESSURE SWITCH
336_TR H - 1.0 N.O . - C LO SE D AT 1.8 +/- 0.5 BAR
167_A B - 1.5 8 8 167_C B - 1.5 16 16 167_F B - 1.5
229_B B - 1.5 229_C B - 1.5 X23F X23M
229_A B - 1.5 9 9
N_XC H 1.0 8 8 225_D H - 2.5
FRONT WORKING LIGHT SWITCH
From fuse F5 C (key “ACC” - Fg. 2)
X22M X22F
N_ED B - 1.0 Rear wiper sw. (Sheet 11)
N_EC B - 1.0 F F
334_TL H - 1.0
X15F X15M H H
166_D B - 1.5 Conn. “LCD” pin 3 (sheet 8) J J
N_XE H 1.0 K K
R153 B - 1.5 7 7 R153_C B - 1.5 13 13 153_FA B - 1.5
166_B B - 1.5 LEFT
166_A B - 1.5 11 11 166_C B - 1.5 12 12 166_FA B - 1.5
000_CFA H - 1.0
000_CFC H - 1.0
000_CFB H - 1.0
301_A H - 1.0
225_R H - 1.0
331_R H - 1.0
302_A H - 1.0
120_E H - 1.0
125_E H - 1.0
226_L H - 1.0
332_L H - 1.0
177 H - 1.0
337 H - 1.0
172 H - 1.0
X11F X11M
118_A B - 1.0 2 2
149_A B - 1.0 21 21 149_C B - 1.0 11 11 149_F B - 1.0 1 1
Clim a control panel backlight
339_FA B - 1.0
330_FA B - 1.0
331_FA B - 1.0
332_FA B - 1.0
2 2 RIGHT
From fuse F1 C (key “ACC” - sh. 2) 3 3 229_D B - 1.0 XPLM B A
XLT1 XPLF B A CHASSIS GROUND CHASSIS GROUND XLT2
XF3 From fuse F12 B (direct from battery - sh. 1) conn. “GND_G” conn. “GND_F”
FRONT W ORKING LIGHT
2_PL H - 1.0
1_PL H - 1.0
N_XF H 1.0
3 Am p
332_FA B 1.0 A Rear lh position light. (Through conn. X 22)
334_FB B 1.0 B O verall light, rh.
330_FA B 1.0 C Front rh position light. (Through conn. X 20) 229_E B - 1.0
From fuse F7C
From fuse F7B
From fuse F7B
From fuse F7C
XPLB B A XPLA
3 Am p N_XD H 1.0
331_FA B 1.0 D Rear rh position light. + licence plate light (through conn. X22)
LEFT
339_FA B 1.0 E Front lh position light (through conn. X 20) work stop turning position reverse work stop turning position reverse
336_FA B 1.0 F O verall light, lh.
E C D A
REAR LEFT LIGHT GROUP LICENCE PLATE LIGHT REAR RIGHT LIGHT GROUP
450_F B 1.0 G Dashboard backlight (through conn. X15 and X5 - sheet 8)
CAB GROUND (ROOF)
450_FB B 1.0 H Cigarette lighter backlight (through conn. X8)
connector “X2_GND”
CAB FUSE BOARD W170-7R012
SECTION 8
CAB
INDEX
8.1 GENERAL DESCRIPTION ................................................................................... 8-1
8.2 REPAIR ................................................................................................................ 8-2

8.2.1 CAB ..................................................................................................................... 8-2
Removal ........................................................................................................... 8-2
Reinstallation .................................................................................................... 8-3
8.3 WINDSCREEN WIPERS AND WASHERS ........................................................... 8-4
8.4 HEATER ............................................................................................................... 8-5

8.4.1 GENERALITIES ................................................................................................... 8-5
8.4.2 MAIN COMPONENTS AND SPECIFICATIONS ................................................... 8-5
8.5 CAB GLAZING ..................................................................................................... 8-6

8.5.1 DISASSEMBLY AND ASSEMBLY ........................................................................ 8-7
8.6 AIR CONDITIONING UNIT .................................................................................. 8-10

8.6.1 OPERATING INSTRUCTIONS ............................................................................. 8-10
8.6.2 TECHNICAL DATA ............................................................................................... 8-11
8.6.3 SERVICE PRECAUTIONS ................................................................................... 8-12
8.6.4 TOOL CONNECTIONS ........................................................................................ 8-14
8.6.5 DISCHARGING .................................................................................................... 8-15
8.6.6 REFRIGERANT CHARGING ............................................................................... 8-15
8.6.7 LEAK INSPECTION ............................................................................................. 8-16
8.7 TROUBLESHOOTING ......................................................................................... 8-18

W170/W170TC CAB 8-1
8.1 GENERAL DESCRIPTION
W170-8R001
The cab is a tested protection structure against roll-

over hazard (ROPS).
The cab is complete with the driver’s seat, steering
column, controls and instruments to drive and oper-
ate the machine.
Other standard features are the heating system, de-
mister, front and rear windscreen washer-wipers, ceil-
ing light, clock/thermometer, loud-speakers, safety
glasses, rear-view mirrors, sun visor, and emergency
exit.
Access inside the cab is through the left-hand door.
The right-hand door is used to gain access to the
heater/air conditioning system compartment. Doors
can be locked wide open and are fitted with a key
lock. W170-8R002
The main components such as the hydraulic reser-
voir, hydraulic pump and control valve, steering con-
trol valves and cylinders, and drive shafts can be re- The cab serial number is etched on a plate located on
moved or repaired without disassembling the cab. the lower side of the seat.
8-2 CAB W170/W170TC
8.2 REPAIR
8.2.1 CAB Loosen the four safety screws and the four screws
securing the cab to the frame.
Removal
Install an appropriate lifting device over the cab hook-
Park the machine on level ground and block wheels ing the 4 lifting eyes previously tightened (weight of
securely to prevent motion. the cab about 700 kg - 1543 lbs) and set a slight ten-
Disconnect the battery isolator switch. sion on the lifting chain.
WARNING
WARNING
Always disconnect the battery isolator switch
Always use hoists or similar devices of suitable
before cleaning, repairing, overhauling or park-
capacity to lift or move heavy components. En-
ing the machine.
sure that the sling is perfectly made.
Use the lifting eyes.
W110R004
Remove the guards around the bottom of the cab from

both sides.
Disconnect the ground plait and the electric connec-
tions between cab and frame.
W110R0299
Lifting cab
Slightly raise the cab taking care not to tension any

electrical cables or hoses.
Lifting height should be such to allow detachment of
all lines and cables from machine assemblies.
W170-8R003
W170/W170TC CAB 8-3
Disconnect the sensor and potentiometer wires from Disconnect the two heater hoses located in the rear
the accelerator pedal. right side of the cab.
Loosen the screws securing the brake pedal valve Make sure that all connections on the machine are
and remove the pedal assembly without sisconnecting disconnected, then lift the cab, moving it sideways.
the pipes.
Open the panel on the right side of the machine and Reinstallation
label the hoses of equipment control levers (3) and
The installation is the reversal of the removal.
three-way valve (4). Disconnect the pipes of the
Tighten the cab screws to the frame to the specified
windshield washer from the washer liquid tank.
torque.
Close the heater feeding valves.
5
4
3
9
10
1 6 2 10 1
7 1
W170-8R005
Note – 1 Screw M16 - Tightening torque 23 daNm
1. Safety screw M30 - 2. Safety screw M24 - 3. Equipment control lever pipes - 4. Three-way valve pipes - 5. Throttle ball
joint - 6. Cab and frame front securing nut M16 - 7. Cab and frame rear securing nut m16 - 8. Accelerator pedal - 9. Steering
column - 10. Elastic pads.
8-4 CAB W170/W170TC
8.3 WINDSCREEN WIPERS AND WASHERS
The front windscreen wiper motor (1) is located at the Note 1 – Before setting the wiper blades in motion,
front of the steering column. The front windscreen wiper operate the windscreen washer to minimise the risk
has two intermittent working speeds: 35 strokes per of scratching the glass.
min (slow) and 55 strokes per min (fast).
A dog-leg mechanism transforms the motor shaft ro- Note 2 – Use the cleaning fluid DP1 diluted with water
tary motion into 45° strokes of the wiping arm. dependent upon working temperature. A 50% deter-
The rear windscreen wiper motor (2) is located un- gent/water solution does not freeze down
der the cab trim behind the driver’s seat, on the right- to -10 °C (14 °F). Below this temperature, use clean-
hand side. The rear windscreen motor has but one ing fluid only.
speed (approx. 54 strokes per min).
Internal gears provide an 80° oscillation of the wiping Pump hoses are connected to the nozzles located at
arm. the sides of the wiping arms.
5 4
W170-8R004 W110R0302
In case of motor or arm assembly replacement, it will

The windscreen washer fluid bottle (3) is located in- be necessary to reassemble the arm assembly to the
side the engine compartment, on the left-hand side. drive part correctly to centre the wiping action over
The bottle is fitted with two pumps (4) and (5) for the the glass width.
front and rear windscreens, respectively. To this aim, select the most suitable position for the
arm on the knurled drive part shown by the arrow in
Specifications the figure.
Bottle capacity ............................... 2.5 lt. (0.87 gal)
Rated voltage ................................................... 24V
Absorbed current ............................................. ≤ 2A
Max. flow ........................ ≥ 3 lt./min (0.6 USG/min)
W170/W170TC CAB 8-5
8.4 HEATER
8.4.1 GENERALITIES
The cab heater is placed in a special compartment,
on the cab right-hand side. 6
The associated switches are located on the control
2
console and are used to: 1
- adjust air temperature; 3

9
- control air flow intensity;
- admit air from the outside or recirculate the air in-
side the cab.
In case of air intake from the outside, air is drawn in

through the filter (A). If air is being recirculated, inter-
nal cab air is driven through the filtering panel (B). 4
Both filter (A) and filtering panel (B) should be re-
placed periodically.
7
A
5
W110R0304
8.4.2 MAIN COMPONENTS

AND SPECIFICATIONS
B The heater main components are:
W110R0303 1. Electrical fan

2. Outside air filter
3. Filtering panel
4. Heat exchanger
5. Shroud
6. Housing
7. Water lines
8. Air ducting
9. Feed valve
Specifications
Heat value .........................................10 000 Kcal/h
Air flow ........................................... 575 ± 10% m3/h
Absorbed power .......................................... 400 W
Working temperature range ....................................
......................................... –15 + 50 °C (5 + 122 °F)
8-6 CAB W170/W170TC
8.5 CAB GLAZING
All cab glasses are differential hardening type.

Glasses should be ordered on the manufactured.
4
They should be kept clean at all times to guarantee
good visibility. When cleaning the glasses, pre-wash
6
them with a water and detergent solution or other pro-
prietary product using a squeegee to reduce abrasion
2
and make cleaning easier.
Notice – Never use hot water over cold glasses.
All glasses fitted to the cab have been subjected to

differential hardening and have a 5 ± 0.2 mm
(0.20 ± 0.008 in) thickness. They are firmly bonded to
their seats by means of a polyurethane sealant. 5
1
5 ± 0.2 mm
7 3
0.20 ± 0.008 in
W110R0305 W110R0306
1. Front windscreen - 2. Rear windscreen - 3. Door glass

- 4. RH side glass (emergency exit) - 5. LH rear glass -
6. RH rear glass - 7. Bonding kit.
W170/W170TC CAB 8-7
8.5.1 DISASSEMBLY AND ASSEMBLY Preparing the replacement glass

Disassembly 1. Place the glass momentarily in position and mark
with adhesive tape to position it correctly during
1. Push a pointed object through the adhesive from
final bonding.
inside the cab and insert the wire.
2. Using the wire, cut the adhesive all around the glass.
Lift out the glass using two suction cups.
3. To leave a smooth bevel of approximately 1 or
2 mm, which should be kept clean as it will be the
bonding base for the polyurethane adhesive.
Should the paint be partially damaged, apply some
glass primer as a protection against corrosion.
Note – Work only in well ventilated premises. The

polyurethane adhesive does not contain low molecu-
lar weight (monomolecular) volatile isocyanates.
Therefore, there is no danger of irritation for the res-
piratory tract. However, all precautions required when
using chemicals should be observed. Avoid contact
with the eyes and skin.
W110R0308
2. Thoroughly clean the glass edge using the special

cloth moistened in the degreaser supplied.
Important – After degreasing, wipe the degreased part

using a clean dry cloth.
W110R0307
WARNING
Always wear gloves and use special suction cups
with handles when replacing the glasses.
Do not strike the glasses to remove.
W110R0309
8-8 CAB W170/W170TC
3. Shake well the glass activator bottle before use (at 5. Punch the membrane in the threaded connection.
least 1 minute after ball separation from the sedi-
ment). Apply an even continuous bead of activator
along the black stencil using the applicator sup-
plied.
Important – Once applied, allow the activator to dry

for at least 10 minutes keeping the surface clean.
W110R0312
6. Cut off the nozzle and apply a smooth continuous

bead of BETASEAL sealant-adhesive along the
edge of the body or windscreen keeping the gun
vertical.
W110R0310
4. Remove the sealant cartridge bottom cover and

salts therein.
W110R0313
W110R0311
W170/W170TC CAB 8-9
Glass assembly Note – Work only in well ventilated premises. The

polyurethane adhesive does not contain low molecu-
1. Position the glass in its seat slightly pressing it.
lar weight (monomolecular) volatile isocyanates. There-
fore, there is no danger of irritation for the respiratory
tract. However, all precautions required when using
chemicals should be observed. Avoid contact with
the eyes and skin.
Note – The BETASEAL sealant-adhesive hardens

with air moisture. Hardening depends upon ambient
humidity and relative penetration degree. Therefore,
machine downtime ranges from 2 to 3 hours at a
temperature of 23 °C (73.4 °F). During this period the
machine should not be submitted to any stress what-
ever.
WARNING
Any variation to instructions specified, such as
use of materials after expire date or improper work
W110R0314
procedures, may negatively affect the results of
the operation. The manufacturer does not assume
Note – The glass must be fitted to the machine within any responsibility for damages which may derive
maximum 15 minutes after applying the BETASEAL to persons and/or things.
sealant-adhesive.
8 - 10 CAB W170/W170TC
8.6 AIR CONDITIONING UNIT
8.6.1 OPERATING INSTRUCTIONS erant itself. Then, the Freon reaches the expansion
thermostatic valve, which has the purpose of regulat-
The principle of operation can be summarised as fol-
ing the refrigerant flow into the evaporator at a pres-
lows: the refrigerant, Freon R134a, in its gaseous state,
sure of 1-5 (14.5 to 72.5 psi) bar, causing its passage
is sucked by the compressor at a pressure of 1-5 bar
from liquid to gaseous state. At the same time, the air
(14.5 to 72.5 psi) and taken to a final compression at a
flowing through the evaporator, under the action of
pressure of 10-20 bar (145 to 290 psi). The gas, heated
the fan, having a temperature which is higher than the
by the compression to 89-100 °C (192 to 212 °F), flows,
refrigerator contained by the evaporator itself, caus-
still in a gaseous state, into the condenser where, un-
ing its boiling and full evaporation, releasing heat.
der the effect of the cooling provided by the air flowing
The air, being cooled, deposits on the fins of the
through it by the action created by the fan, reaches the
evaporator parts of its moisture content, under the
condensation point, passing into a liquid state at high
form of little drops, which drop into the tanks and are
pressure.
discharged outside the cab.
Subsequently, the refrigerant, at liquid state, reaches
Air cooled and dehumidified, is sent into the cab. The
a dehydration filter, which has the function of captur-
refrigerant, at the outlet of evaporator, is sucked again
ing impurities, absorb moisture trapped into the sys-
by the compressor, beginning a new cycle.
tem and operate as a reserve reservoir for the refrig-
Compressor
Fan unit Evaporator
Condenser
Expansion valve
High
pressure
Intake
Low
pressure
Pressure switch Filter
W110R0315
W170/W170TC CAB 8 - 11
8.6.2 TECHNICAL DATA

Fan
Voltage ........................................................................................................................................................ 24 V
Electrical input ............................................................................................................................................ 17 A
Air flow ................................................................................................................................................ 1190 m3/h
Speed .............................................................................................................................................................. 3
Heater
Power ................................................................................................................................................... 11,7 KW
Rate of flow .............................................................................................................................................. 500 l/h
Air flow ................................................................................................................................................. 575 m3/h
Input air temperature ..................................................................................................................... -15 °C (5 °F)
Evaporator
Power ................................................................................................................................................... 8,17 KW
Rate of flow .............................................................................................................................................. 500 l/h
Air flow ................................................................................................................................................. 575 m3/h
Input air temperature ................................................................................................................. 43 °C (109.4 °F)
Relative humidity ........................................................................................................................................ 30%
Vaporisation temperature .................................................................................................................. 5 °C (41 °F)
Condensation temperature ........................................................................................................... 60 °C (140 °F)
Expansion valve
Type .................................................................................................................................... TGK TEV 216 PO-2
Gas ............................................................................................................................................... Freon R134A
Superheat ..................................................................................................................................... 4 °C (39.2 °F)
Compressor
Type ......................................................................................................... SANDEN SD7H15 md 7948 for 134A
Displacement ........................................................................................................................................ 154.9 cc
Pulley .............................................................................................................................................. ø 135.6 mm
Lubricant oil q.ty ...................................................................................................................................... 200 cc
Filter
Type ................................................................................................................................................ SKG CC164
Dimension .................................................................................................................................. 141 x ø 76 mm
Capacity .................................................................................................................................................. 415 cc
Dehydrating ............................................................................................................................................. 140 gr
Pipe fitting ..................................................................................................................................... 5/8'' - 18 UNF
Pressure switch
Type ................................................................................................................................... 3L-F LMH-971-641
Interruption: Low pressure ........... OFF 2.45 bar (35.5 psi)
ON 2.6 bar (37.7 psi)
High pressure ........... OFF 28 bar (406 psi)
ON 25 bar (362.6 psi)
(Fan) ........................ OFF 12 bar (174 psi)
ON 17 bar (246.6 psi)
Thermostat
Type ................................................................................................................................... RANKO K50-L9421
Setting Cold ......................... OUT 0 °C (32 °F)
IN 5 °C (41 °F)
8 - 12 CAB W170/W170TC
Conditioning Performance
IN ACCORDING WITH ISO 10263
8.6.3 SERVICE PRECAUTIONS Piping precautions

It is known that CFC refrigerants (including R 12) are - Position the O-ring against the bulge in the pipe
among those substancens that destroy the ozone layer when connecting hoses and pipes.
producing an increase of ultra violet radiation result- - Coat the piping connections and the O-rings with
ing from the destruction of the ozone layer. PAG oil.
They stay in the atmosphere for over 100 years, with
a potential increment of cataract and skin cancer. As - Fit the nuts and unions tightly against the base of
a result of the global evaluation of the environmental the companion pieces then hand tighten the nut as
impact, a new refrigerant R134a has been used. This much as possible. Then, tighten to the specific
refrigerant has a potential destruction of the ozone torque.
(ODP) equal to 0 and a low global warming potential
(GWP). Note – Always use oil specified for R134a system to
coat the O-rings.
WARNING
Piping connection procedure
Direct contact with refrigerant can cause frostbite
or blindness. Union Nut
Always wear safety glasses and protective gloves.
Do not work with refrigerant colse to the face.
CORRECT INCORRECT
CAUTION
PAG oil, in the R134a systems, absorbs moisture
quickly when exposed to the atmosphere. Damage
Handle the air conditioner componenets carefully. Do

not knock or drop them.
Gnawing at pipe end
W110R0316
W170/W170TC CAB 8 - 13
Do not mistakes refrigerants

Before charging an air conditioning system be sure CAUTION
that refrigerant is correct. Confirm before charging that Cap the oil container after use and the air condi-
the type of air conditioner system is in fact an R134a tioner system parts, when servicing.
system. Never mix compressor oil with other types of oil.
Do not exchange the A/C refrigerants
R 12 R 134 a
OIL
CFC12 HFC134a
W110R0317
Do not release refrigerant into the air

Although R134a is not subject to CFC regulations, it
can have an effect on global warming, and so should Cap all container and components
not be released into the air. W110R0319
The oil must be replaced or replenished in the follow-

WARNING ing cases:
When removing refrigerant from the air conditioner - when refrigerant or oil leaks from the system;
system, always use a refrigerant recovery unit - when refrigerant is suddenly discharged from the
made especially for R134a. system;
- when system components are replaced.
Do not release the refrigerants
into the atmosphere Note – The oil plug O-ring must be replaced with a
new one.
Refrigerant charge inspection

As shown in the left hand figure, R134a compressor
oil will not blend with refrigerant (R134a) at certain
R 134 a temperatures. At these temperatures, the refrigerant
may appear 'cloudy' when checked using the
sightglass, and the charge may be mistakenly judged
as insufficient.
Temperature
Recovery unit
Oil-refrigen
W110R0318 Condensation separation
temperature
Blending range
Compressor oil range
Use compressor oil made specifically for use with

Vaporization
R134a. temperature
R134a system compressor oil has an extremely high range
moisture absorption capacity.
Oil-refrigerant blending rate W110R0320
8 - 14 CAB W170/W170TC
8.6.4 TOOL CONNECTIONS 1. Fully close both manifold gauge valves.

2. Connect the three hoses securely to the manifold
WARNING gauge.
Do not connect hoses to the air conditioner sys- 3. Connect the utility hose to the vacuum pump or
tem when the manifold gauge valves are open. refrigerant source.
4. Connect the couplers to the high and low pressure
hoses. Turn the knob on the fitting to depress the
CAUTION
core if so equipped.
If there is any refrigerant in the air conditioner Before disconnecting hoses, close both manifold
system, connect the hoses only after the service gauge valves.
hoses and the manifold gauge have been evacu-
ated.
Manifold gauge
Low pressure High pressure
Charging hose
Charging hose
Coupler
Vacuum pump
Refrigerant container
W110R0321
W170/W170TC CAB 8 - 15
8.6.5 DISCHARGING
CAUTION
WARNING If the pointer moves toward 0 (zero) the system is
not sealed. Inspect the system to identify the leak-
Do not release the refrigerant into the air.
ages and repair them.
Discharge refrigerant only into the refrigerant re-
covery unit.
CAUTION
- 101.3 kPa
Never use a refrigerant recovery unit for CFC12 on
{ - 760 mmHg,
an HFC134a system. - 29.92 inHg
The recovered refrigerant must be recycled trough a

refrigerant recovery unit to ensure that it is clean and
free of moisture.
Refer to the user's instruction manual for refrigerant Check for leaks and
repair if gauge needle
recovery unit handling and operations.
moves towards 0 W110R0322
Evacuation
8.6.6 REFRIGERANT CHARGING
1. Operate the vacuum pump.
There are various methods of charging refrigerant into
the air conditioner system. These include using refrig- 2. Open both manifold gauge valves
erant recovery units and direct charging using a scale. 3. Evacuate the system for at least 20 minutes.
4. Close both manifold gauge valves.
Note – Change refrigerant in the system of wheel
loader every 2 years. Initial charge
Initial evacuation 1. Put the refrigerant container on the scale.
1. Close both manifold gauge valves.

2. Connect the high and low pressure hoses to the
system.
3. Connect the utility hose to the vacuum pump.
4. Open the manifold gauge's high and low pressure R 134 a
valves.
5. Operate the vacuum pump.
6. Evacuate the system for at least 5 minutes to sta-
bilize the vacuum inside the system.
7. Close both valves and stop the vacuum pump.
Scale W110R0323
Checking air tightness
2. Disconnect the utility hose from the vacuum pump
1. Leave the system as it is for 5 to 10 minutes.
and connect it to the refrigerant container.
Ensure the low pressure gauge needle does not
move towards the atmospheric pressure side 3. Purge air from the utility hose.
(gauge pressure 0). 4. Record the refrigerant weight.
5. Open the refrigerant container valve.
6. Slowly open the manifold gauge's low pressure side
valve to charge refrigerant from the low pressure
side valve to charge refrigerant from the low pres-
sure side.
8 - 16 CAB W170/W170TC
7. Charge with refrigerant until the low pressure gauge

reaches 0.2 MPa (2 bar, 29 psi). Pressure in high
pressure line
The optimal refrigerant's weight is approximally
1100 gr.
8. Close the manifold gauge's low pressure valve.
Pressure
CAUTION
Do not overcharge the system.
Pressure in low
Initial Leak check pressure line
Using the leak detector, check the system connec- Time

tion for leaks. Compressor stops
W110R0325
Note – As the system pressure is not yet high, only

large leaks can be detected at this time.
Inspection procedure
Evacuation
Refrigerant
charging
Leak detector
Operate compressor
for at last 5 min Repair
W110R0324
8.6.7 LEAK INSPECTION

To facilitate refrigerant leak detection, operate the air Check for refrigerant
conditioner at the full cooling setting with the fan run- leaks from high
ning at maximum speed for at least 5 minutes. pressure side parts
Stop the engine and, using a leak detector, check for
refrigerant leaks on the high pressure side.
This must be done immediately because when the
refrigerant stops circulating, the high pressure de-
creases gradually, as shown in the graph, while the Operation test
low pressure side pressure increases gradually.
W170/W170TC CAB 8 - 17
Inspection sequence
High pressure side
Compressor Condenser Cooling unit Receiver drier inlet

discharge port inlet and outlet inlet and outlet
Low pressure side
Compressor Cooling unit

suction port outlet
CAUTION
Clean all inspection points.
Check all connections carefully.
To prevent incorrect diagnoses, ensure there is
no refrigerant or cigarette smoke in the vicinity of
the vehicle.
Inspection points
W110R0315
8 - 18 CAB W170/W170TC
8.7 TROUBLESHOOTING
Air conditioner switch ON
Lights Does not light
Air conditioner fuse inspection
Normal Fuse blown

Air outlet flow rate check
Replace
No air flow Air flow
Blower motor inspection
Does not operate Operates, but low flow rate Compressor operation
inspection
A (a) A (b)
Magnetic clutch rotates Magnetic clutch does not rotate
A (d)
Sightglass inspection
CAUTION
Refer to REFRIGERANT CHARGE

INSPECTION on page 13
Air bubbles (no cooling) Air bubbles (no cooling)
A (c)
Refrigerant pressure
inspection
Connect the manifold gauge to the service

valves and check the gauge reading
Refer to page 21
W170/W170TC CAB 8 - 19
Troubleshooting chart
(a) Fan motor does not operate
Possible cause Inspection Remedy
1. Blown fuse. Inspect the air conditioner fuse. Replace.
2. Broken wiring Check the fan motor earth and connectors. Repair the wiring or
or bad connection. connect correctly.
3. Fan motor Check the two lead wires from the motor with a circuit tester. Replace.
malfunction. If there is no conductance, the motor is malfunctioning.
4. Broken resistor wiring. Check resistor conductance using a circuit tester. If there is Replace.
no conductance, the wiring is broken.
5. Fan motor switch Operate the fan switches in sequence and check whether Replace.
failure. the fan operates.
(b) Fan motor operates normally, but air flow is insufficient
1. Evaporator iniet Check the iniet. Remove the

obstruction. obstruction and clean.
2. Air leak. Check the cooling unit case fittings. Repair of adjust.
3. Defective thermo Check whether the evaporator is frozen. Check the switch Replace.
switch. using a circuit tester.
(c) Insufficient cooling although air flow and compressor operation are normal
1. Insufficient There will be little temperature difference between the low- Repair any leaks and
refrigerant. and high-pressure sides. Air bubbles or a "cloudy" flow will recharge the refrigerant
be visible in the sightglass. to the correct level.
2. Excessive refrigerant. The high-pressure side pressure will be high and even if the Drain small quantity of
condenser is cooled using water, air bubbles will not ap- refrigerant until air bub-
pear in the sightglass. bles appear periodically
through the window.
8 - 20 CAB W170/W170TC
(d) The compressor does not operate at all, or operates improperly
1. Loose V-belt. The belt oscillates considerably. Adjust the tension.
2. Internal compressor The V-belt slips. Repair or replace.

malfunction.
3. Magnetic clutch related.
• Low battery voltage. Clutch slips. Recharge the battery.
• Faulty coil. Same as above. Replace the magnetic

clutch.
• Oil on the clutch The magnetic clutch face is dirty, causing it to slip. Replace, or clean the
surface. clutch surface.
• Excessive clearance Adjust the clearance, or

between the clutch replace.
plate and clutch disk.
The clutch plate clings
when pushed.
• Open coil. Clutch does not engage and there is no reading when a Replace.
circuit tester is connected between the coil terminals.
• Broken wiring or poor Clutch will not engage at all. Inspect the earth and connec- Repair.
earth. tions.
• Wiring harness Test the conductance of the pressure switch, thermoswitch, Check operation, refer-
components. relay, etc. ring to the wiring dia-
gram, and replace de-
fective parts.
W170/W170TC CAB 8 - 21
Normal compressor suction and discharge pressures at an atmospheric temperature of 30 ~ 35 °C (86 ~ 95 °F)
and engine speed of approx. 1500 rpm are:
High pressure side pressure : 1.47 ~ 1.67 MPa (15 ~ 17 kg/cm2, 213 ~ 242 psi)
Low pressure side pressure: 0.13 ~ 0.2 MPa (1.3 ~ 2.0 kg/cm2, 18 ~ 28 psi)
Low -pressure side pres- The pressure in the low-pressure side becomes, normally, too high
sure too high. when the pressure on the high-pressure side is excessive. As
explained here below, the check that follows is performed only
when the pressure on the low-pressure side is too high.
1. Defective The magnetic clutch switch turns off before the outlet air tempera- Adjust or replace.
thermoswitch. ture is sufficiently low.
2. Defective compressor The high- and low-pressure side gauge pressures equalize when Repair or replace the com-
gasket or valve. the magnetic clutch is turned off. pressor.
3. Poor expansion valve Frost has adhered to the compressor connector so that the tem- Install the temperature sen-
temperature sensor con- perature is lower than that of the evaporator outlet side piping. sor against the low-pres-
tact. sure pipe.
4. The expansion valve Same as above, or there is little pressure fluctuation when the Replace.
opens too far. temperature sensor is places against the pipe and then removed.
5. Clogged compressor The compressor connector is cool but the low-pressure hose is not. Remove and clean the filter.
suction filter.
Low-pressure side
pressure too low.
1. Insufficient refrigerant. Refer to "Insufficient refrigerant" on previous page. Same as at left.
2. Clogged receiver drier. Considerable temperature difference between the inlet and outlet Replace the receiver drier.
sides, or the tank is frosted.
3. Clogged expansion The expansion valve's inlet side is frosted. Clean the filter or replace
valve. the expansion valve.
4. Expansion valve The expansion valve's outlet side is chilled, and low pressure gauge Clean or replace the piping.
temperature sensor indicates a vacuum.
gas leak (damaged
capillary tube, etc.)
5. Clogged or blocked When the piping is clogged or blocked, the low-pressure gauge Clean or replace piping.
piping. reading will decrease, or a negative reading may be shown.
6. Defective The evaporator is frozen. Adjust or replace.

thermoswitch.
High-pressure side
pressure too high.
1. Poor condenser Dirty or clogged condenser. Cooling fan does not operate correctly. Clean, and repair the fan.
cooling. Blown fuse, broken wiring or poor contact. Fan motor malfunction. Repair the wiring or replace
the fuses.
2. Excessive refrigerant. Refer to "Excessive refrigerant" on previous page.
3. Air in the system. Evacuate and recharge

with refrigerant.
High-pressure side
pressure too low.
1. Insufficient refrigerant. Refer to "Insufficient refrigerant" on previous page. Same as at left.
8 - 22 CAB W170/W170TC
Gauge pressure diagnosis • Problems in the system can be diagnosed using a

manifold gauge by reading the system's low and
high pressures.
Low pressure side High pressure side
0.13 - 0.2 MPa 1.47 - 1.67 MPa
Normal pressures
{1.3 - 2.0 kg/cm2, {15 - 17 kg/cm2, Low-pressure side: 0.13 ~ 0.2 MPa
18 - 28 psig} 213 - 242 psig} {1.3 ~ 2.0 kgf/cm2, 18 ~ 28 psig}
High-pressure side: 1.47 ~ 1.67 MPa
6 7 8 1.5
4
5 9
10
1.0 15
2.0
20 2.5
{15 ~ 17 kgf/cm2, 213 ~ 242 psig}
5
10 10 25
11
3 0.5 5 3.0
30
2 12
0 35
1
0
0 15
14
13 0
3.5
Conditions
15
Atmospheric temperature ........................ 30 ~ 35 °C

............................................................. (86 ~ 95 °F)
Engine speed ......................................... 1 500 r/min
Blower speed ................................... HI (high-speed)
Temperature switch ............................... Full cooling
W110R0326
Insufficient refrigerant
Low pressure side High pressure side Indications: • Low pressures on both the low pres-
98 MPa 0.78 - 0.98 MPa sure and high-pressure sides.
{1.0 kg/cm2, {8 - 10 kg/cm2, • Discharge temperature will not de-
18 psig} 114 - 142 psig} crease.
Cause: Refrigerant leakage.
5
6 7 8
9
1.5 2.0 Remedy: Inspect using a gas leak detector, repair
1.0 15 20 2.5
3
4 5
10
10
11
0.5 5
10 25
3.0
the leak, and replenish the refrigerant.
30
2 12
0 35
0 15 13
1 0
3.5
0 14
15
W110R0327
W170/W170TC CAB 8 - 23
Excessive refrigerant
(poor condenser radiation)
Indication: Both the low and high pressures are too
0.25 - 0.29 MPa 2.26 MPa
high.
{2.5 - 3.0 kg/cm2, {23 kg/cm2, Causes: Pressure increment due to excessive
36 - 43 psig} 327 psig} refrigerant.
Insufficient condenser cooling.
7
5
6 8
9
1.0
1.5
15 20
2.0
2.5
Remedy: Clean the condenser.
4 5 10
3
10
11
0.5 5
10 25
30 3.0
Inspect and adjust the fan belt and con-
2 12
1
0 15 13 0
0 35
3.5
denser motor.
0 14
15
Check the refrigerant level.
W110R0328
Air in cooling system

(insufficient suction)
Low pressure side High pressure side Indications: Both the low and high pressures are too
0.25 - 0.34 MPa 1.96 - 2.45 MPa high.
{2.5 - 3.5 kg/cm2, {20 - 25 kg/cm2, The low-pressure side piping is not cold.
36 - 50 psig} 284 - 356 psig} Cause: Air entered the cooling system. When the
suction is not applied, the reading of the
5
6 7 8
9
1.0
1.5 2.0 instruments are indicated in the illustra-
10 15 20 2.5
4
3
5
10
11
0.5 5
10 25
30 3.0
tion on the left.
12
2
1
0 15 13 0
0 35
Remedy: Evacuate the system, replenish the re-
3.5
14
0
15
frigerant and check the gauge readings.
After prolonged operation with air in the
system, the receiver drier must be re-
placed.
W110R0328
8 - 24 CAB W170/W170TC
Defective expansion valve

Indication: Both the low and high pressures are too
high.
0.25 MPa 2.16 - 2.26 MPa
Causes: Improper refrigerant charge.
{2.5 kg/cm2, {22 - 23 kg/cm2, Defective expansion valve.
36 psig} 313 - 327 psig} Improper temperature sensor installation.
Remedy: Check temperature sensor installation,
7
5
6 8
9
1.0
1.5
15 20
2.0
2.5
and insulation.
4 5 10
3
10
11
0.5 5
10 25
30 3.0
If normal, replace the expansion valve.
2 12
0 35
0 15 13
1 0
3.5
0 14
15
W110R0328
Insufficient compressor compression

Indications: High pressure on the low-pressure side,
Low pressure side High pressure side pressure too low on the high pressure
0.39 - 0.59 MPa 0.69 - 1.08 MPa side.
{4 - 6 kg/cm2, {7 - 11 kg/cm2, The high and low pressures are already
18 psig} 99 - 156 psig} equal when operation is stopped.
Causes: Insufficient compression due to a defec-
5
6 7 8
9
1.0
1.5 2.0
tive compressor gasket or damaged suc-
10 15 20 2.5
4
3
5
10
11
0.5 5
10 25
30 3.0
tion valve.
12
2
1
0 15 13 0
0 35
Remedy: Disassemble and repair the compressor.
3.5
0 14
15
W110R0329
W170/W170TC CAB 8 - 25
Infiltration of moisture
Indication: The low-pressure side pressure alter-
nates between a vacuum and normal
Vide - 0.13 MPa 0.59 - 1.77 MPa
pressure.
{Vide - 1.3 kg/cm2, {6 - 18 kg/cm2, Causes: Moisture has frozen in the air conditioner
Vide - 18 psig} 85 - 256 psig} system, clogging the expansion valve,
which then blocks the air conditioner sys-
6 7 8 1.5
4
5 9
10
1.0 15
2.0
20 2.5
tem. When the ice melts, normal opera-
5
10
3
10
11
12
0.5 5
25
30 3.0 tion resumes.
2 0 35
1
0 15
14
13 0
3.5
Remedy: Replace the receiver drier.
0
15
Evacuate the system.
Recharge with refrigerant to the proper
level
W110R0330
Refrigerant does not circulate

Indications: The low pressure side pressure becomes
Low pressure side High pressure side a vacuum and the high pressure side
- 101.3 MPa 0.49 - 0.59 MPa pressure reads 0.49 ~ 0.59 MPa
{- 760 mm Hg, {5 - 6 kg/cm2, {5 ~ 6 kgf/cm2, 71 ~ 85 psi}.
- 29.92 in Hg} 71 - 85 psig} Ice or condensation are forming on the
piping connections of the drier receiver
5
6 7 8
9
1.0
1.5 2.0 or the expansion valve.
10 15 20 2.5
4
3
5
10
11
0.5 5
10 25
30 3.0
Causes: The air conditioner system is blocked
2
1
0 15
12
13 0
0 35
by ice or dirt.
3.5
0
15
14
The air conditioner system is shut off
by a defective expansion valve tempera-
ture sensor.
Remedy: Stop operation and check for ice or con-
tamination.
If the problem is moisture, evacuate the
system.
Replace the expansion valve tempera-
ture sensor if defective.
W110R0331 Replace the receiver drier.
Recharge with refrigerant to the proper
level.
8 - 26 CAB W170/W170TC

Workshop Manual: Wheel Loader

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THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY.

Most accidents and injuries occurring in industry, on the

On machines having hydraulically, mechanically

GENERALITIES ................................................... Section 0

SAFETY RULES ........................................................................................................................................... 0-1

SPECIFICATIONS - WHEEL LOADER W170 ............................................................................................... 0-8

DIMENSIONS AND WEIGHT ....................................................................................................................... 0-15

TABLE OF FLUID CAPACITIES ...................................................................................................................0-16

UNITS OF MEASURE ................................................................................................................................. 0-17

TORQUE SPECIFICATIONS ........................................................................................................................ 0-18

LOCTITE PRODUCT CHART ....................................................................................................................... 0-22

W170/W170TC GENERALITIES 0-1

0-2 GENERALITIES W170/W170TC

W170/W170TC GENERALITIES 0-3

0-4 GENERALITIES W170/W170TC

W170/W170TC GENERALITIES 0-5

0-6 GENERALITIES W170/W170TC

W170/W170TC GENERALITIES 0-7

0-8 GENERALITIES W170/W170TC

SPECIFICATIONS - WHEEL LOADER W170

Fuel #2 Diesel (#1 & 2 Mixture Permitted For Cold

Bore and Stroke 4.09" (104 mm) x 5.20" (132 mm)

Displacement 411 cu. in. (6.8 Liters)

Electrical System 24 Volts

Batteries (2) 12 Volt

Compression Ratio 17:1

Fuel Pump Bosch CP 3.3

Air Cleaner Dry Type Elements With Warning Restriction

Oil Filter Full Flow Replaceable Cartridge

Lubrication Positive Pressure

Cooling System Air/Water with Lube Oil Cooler

W170/W170TC GENERALITIES 0-9

Governor Electronic Control

Radio 1st 2nd 3rd 4th

Forward 3.745 2.089 1.072 0.636

Stall Ratio 2.81:1

SPEEDS: mph (km/h)

AXLES Front Rear

Brake Area of Service Brakes 480 in² (0.31m²)/Hub

Brake Area of Parking Brake 12.6 in² (81.6 cm²)

Brake Pressure Front: 1300 psi (8963 Kpa)

Rear: 1250 psi (8618 kPa)

Cut Out 2799 psi (19300 kPa)

Low Pressure Warning 1494 psi (10300 kPa)

Transmission Declutch 348 psi (2400 kPa)

Charge Pressure (N2) 798 psi (5500 kPa)

HYDRAULICS AND STEERING

Reservoir: Filtered vent with relief on hydraulic reservoir main-

Valves: Closed-center, load sensing circuit, positive low pres-

Loader Valve Inlet section relief valve provides maximum loader

Loader control valve section contains float circuitry.

System: A tandem variable displacement piston pump is used

Steering/Loader pump displacement 3.84 in3/rev (63

Loader pump displacement 2.75 in3/rev (45 cc/rev).

The steering Orbitrol is flow amplified to provide a

TC 4.25 dia x 40.02 stroke x 2.25 rod

Lift: 4.75 dia x 32.59 stroke x 3.00 rod

Steer: 3.00 dia x 19.09 stroke x 1.75 rod

Clam: 4.00 dia x 10.00 stroke x 2.00 rod

Diameter of Hydraulic Inlet and Outlet Ports:

6.75 Gallon (25.6 liters) to fill system

Gallons Ethylene Glycol (Prestone) required: